Yamaha Outboard F115 Service Repair Manual

F115C
LF115C
SERVICE MANUAL
*LIT186160271*
LIT-18616-02-71 68V-28197-1F-11
E
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 equip-
ment. It has been written to suit the needs of persons who have a basic understanding of the
mechanical and electrical concepts and procedures inherent in the work, for without such
knowledge attempted repairs or service to the equipment could render it unsafe or unfit for
use.
Because Yamaha has a policy of continuously improving its products, models may differ in
detail from the descriptions and illustrations given in this publication. Use only the latest edi-
tion of this manual. Authorized Yamaha dealers are notified periodically of modifications and
significant changes in specifications and procedures, and these are incorporated in succes-
sive editions of this manual.
F115C, LF115C
SERVICE MANUAL
©2003 by Yamaha Motor Corporation, USA
1st Edition, October 2003
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Corporation, USA
is expressly prohibited.
Printed in USA
LIT-18616-02-71
E
HOW TO USE THIS MANUAL

MANUAL FORMAT
All of the procedures in this manual are organized in a sequential, step-by-step format. The
information has been compiled to provide the mechanic with an easy to read, handy refer-
ence that contains comprehensive explanations of all disassembly, repair, assembly, and
inspection operations.
For instance, the condition of a faulty component will precede an arrow symbol and the
course of action required will follow the symbol.
• Bearings
Pitting/scratches → Replace.
To assist you in finding your way through this manual, the section title and major heading is
given at the top of every page.
MODEL INDICATION
Multiple models are mentioned in this manual and their model indications are noted as fol-
lows.
Model name F115AET FL115AET
USA and
F115TR LF115TR
Canada name
Indication F115AET FL115AET
ILLUSTRATIONS
The illustrations within this service manual represent all of the designated models.
CROSS REFERENCES
The cross references have been kept to a minimum. Cross references will direct you to the
appropriate section or chapter.
E
IMPORTANT INFORMATION
In this Service Manual particularly important information is distinguished in the following
ways.
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS
INVOLVED!
WARNING
Failure to follow WARNING instructions could result in severe injury or death to the machine
operator, a bystander, or a person inspecting or repairing the outboard motor.
CAUTION:
A CAUTION indicates special precautions that must be taken to avoid damage to the out-
board motor.
NOTE:
A NOTE provides key information to make procedures easier or clearer.
E
HOW TO USE THIS MANUAL

1 The main points regarding removing/installing and disassembling/assembling procedures
are shown in the exploded views.
2 The numbers in the exploded views indicate the required sequence of the procedure and
should be observed accordingly.
3 Symbols are used in the exploded views to indicate important aspects of the procedure.
A list of meanings for these symbols is provided on the following page.
4 It is important to refer to the job instruction charts at the same time as the exploded views.
These charts list the sequence that the procedures should be carried out in, as well as pro-
viding explanations on part names, quantities, dimensions and important points relating
to each relevant task.
Example:
O-ring size 39.5 × 2.5 mm: inside diameter (D) × ring diameter (d)
5 In addition to tightening torques, the dimensions of the bolts and screws are also men-
tioned.
Example:
Bolt and screw size 10 × 25 mm : bolt and screw diameter (D) × length (L)
D
6 In addition to the exploded views and job instruction charts, this manual provides individ-
ual illustrations when further explanations are required to explain the relevant procedure.
E
1 2 SYMBOLS
Symbols 1 to 9 are designed as thumb-
GEN tabs to indicate the content of a chapter.
INFO SPEC
1 General information
3 4 2 Specifications
3 Periodic inspections and adjustments
INSP FUEL 4 Fuel system
ADJ 5
6
Power unit
Lower unit
5 6 7 Bracket unit
8 Electrical systems
9 Trouble analysis
POWR LOWR
7 8
– +
BRKT ELEC
9 0 Symbols 0 to E indicate specific data.
0 Special tool
TRBL A Specified liquid
ANLS B Specified engine speed
C Specified torque
A B D Specified measurement
E Specified electrical value
[Resistance (Ω), Voltage (V), Electric current
(A)]
C D
T.
R.
E F Symbol F to H in an exploded diagram

indicate the grade of lubricant and the loca-
tion of the lubrication point.
E
F Apply Yamaha 4-stroke outboard motor oil
G H (TC-W3)
G Apply water resistant grease
A M (Yamaha grease A, Yamaha marine grease)
H Apply molybdenum disulfide oil
I J Symbols I to N in an exploded diagram

indicate the grade of the sealing or locking
GM 4 agent and the location of the application
point.
K L I Apply Gasket Maker®
J Apply Yamabond #4
LT LT (Yamaha bond number 4)
271 242
K Apply LOCTITE® No. 271 (Red LOCTITE)
L Apply LOCTITE® No. 242 (Blue LOCTITE)
M N M Apply LOCTITE® No. 572
N Apply silicon sealant
LT SS
LT
572
E
CONTENTS
GENERAL INFORMATION GEN
INFO
1
SPECIFICATIONS
SPEC 2
PERIODIC INSPECTIONS AND
ADJUSTMENTS INSP
ADJ
3
FUEL SYSTEM
FUEL 4
POWER UNIT
POWR 5
LOWER UNIT
LOWR 6
BRACKET UNIT
BRKT 7
– +
ELECTRICAL SYSTEMS
ELEC 8
TROUBLE ANALYSIS TRBL
ANLS
9
GEN
E
INFO
CHAPTER 1
GENERAL INFORMATION
IDENTIFICATION ............................................................................................ 1-1

SERIAL NUMBER ..................................................................................... 1-1
STARTING SERIAL NUMBERS ............................................................... 1-1
1
SAFETY WHILE WORKING ............................................................................ 1-2
FIRE PREVENTION ................................................................................... 1-2
VENTILATION........................................................................................... 1-2
SELF-PROTECTION.................................................................................. 1-2
OILS, GREASES AND SEALING FLUIDS................................................ 1-2
2
GOOD WORKING PRACTICES ................................................................ 1-3
DISASSEMBLY AND ASSEMBLY ........................................................... 1-4
SPECIAL TOOLS ............................................................................................. 1-5

MEASURING ............................................................................................ 1-5
REMOVING AND INSTALLING ............................................................... 1-7
3
4
5
6
7
8
9
GEN
INFO IDENTIFICATION E
IDENTIFICATION 1
SERIAL NUMBER
The outboard motor serial number is
stamped on a label attached to the port
clamp bracket.
S68V1010
1 Model name
2 Approved model code
3 Transom height
4 Serial number
1020
STARTING SERIAL NUMBERS

The starting serial number blocks are as fol-
lows:
Approved Starting
Model name
model code serial number
L: 1016859 -
F115TR 68V
X: 1016859 -
LF115TR 68W X: 1000743 -
1-1
GEN
INFO SAFETY WHILE WORKING E
SAFETY WHILE WORKING 1
The procedures given in this manual are

those recommended by Yamaha to be fol-
lowed by Yamaha dealers and their
mechanics.
FIRE PREVENTION
Gasoline (petrol) is highly flammable.
Petroleum vapor is explosive if ignited.
Do not smoke while handling gasoline and
keep it away from heat, sparks and open
flames.
1030
VENTILATION
Petroleum vapor is heavier than air and is
deadly if inhaled in large quantities. Engine
exhaust gases are harmful to breathe.
When test-running an engine indoors,
maintain good ventilation.
1040
SELF-PROTECTION
Protect your eyes with suitable safety
glasses or safety goggles, when grinding or
when doing any operation which may
cause particles to fly off. Protect hands and
feet by wearing safety gloves or protective
shoes if appropriate to the work you are
doing.
1050
OILS, GREASES AND SEALING

FLUIDS
Use only genuine Yamaha oils, greases and
sealing fluids or those recommended by
Yamaha.
1060
1-2
GEN
Under normal conditions of use, there

should be no hazards from the use of the
lubricants mentioned in this manual, but
safety is all-important, and by adopting
good safety practices, any risk is minimized.
A summary of the most important precau-
tions is as follows:
1. While working, maintain good stan-
dards of personal and industrial
hygiene.
2. Clothing which has become contami-
nated with lubricants should be
changed as soon as practicable, and
laundered before further use.
3. Avoid skin contact with lubricants; do
not, for example, place a soiled wiping-
rag in your pocket.
4. Hands and any other part of the body
which have been in contact with lubri-
cants or lubricant-contaminated cloth-
ing, should be thoroughly washed with
hot water and soap as soon as practica-
ble.
5. To protect the skin, the application of a
suitable barrier cream to the hands
before working, is recommended.
6. A supply of clean lint-free cloths should
be available for wiping purposes.
GOOD WORKING PRACTICES

1. The right tools
Use the recommended special tools to
protect parts from damage. Use the
right tool in the right manner – do not
improvise.
2. Tightening torque
Follow the tightening torque instruc-
1070 tions. When tightening bolts, nuts and
screws, tighten the large sizes first, and
tighten inner-positioned fixings before
outer-positioned ones.
1-3
GEN
3. Non-reusable items
Always use new gaskets, packings, O-
rings, split-pins, circlips, etc., on reas-
sembly.
1080
DISASSEMBLY AND ASSEMBLY

1. Clean parts with compressed air when
disassembling.
2. Oil the contact surfaces of moving parts
before assembly.
1090
3. After assembly, check that moving parts

operate normally.
1100
4. Install bearings with the manufacturer’s

markings on the side exposed to view,
and liberally oil the bearings.
5. When installing oil seals, apply a light
coating of water-resistant grease to the
outside diameter.
1-4
GEN
INFO SPECIAL TOOLS E
SPECIAL TOOLS 1
Using the correct special tools recom-

mended by Yamaha, will aid the work and
enable accurate assembly and tune-up.
Improvising and using improper tools can
damage the equipment.
NOTE:
• For U.S.A. and Canada, use part numbers
that start with “J-”, “YB-”, “YM-”, “YU-”
or “YW-”.
• For others countries, use part numbers
1 2 that start with “90890-”.
MEASURING
1 Pressure tester
P/N. YB-35956
90890-06762
3 4 2 Mity vac
P/N. YB-35956
90890-06756
3 Pinion height gauge
P/N. YB-34432-6, YB-34432-11,
YB-34432-97
90890-06702
4 Dial gauge set
5 6 P/N. YU-03097
90890-01252
5 Magnetic base
P/N. YU-34481
90890-06705
6 Digital caliper
P/N. 90890-06704
7 Backlash indicator
7 8 P/N. YB-06265
90890-06706
8 Magnetic base attaching plate
P/N. YB-07003
90890-07003
9 Fuel pressure gauge
P/N. YB-06766
9 0 90890-06786
0 Hydraulic pressure gauge
P/N. 90890-06776
1-5
GEN
A Up-relief valve attachment

A B P/N. 90890-06773
Down-relief valve attachment
P/N. 90890-06774
B Digital tester
P/N. J-39299
90890-06752
C C Peak voltage adapter
a b P/N. YU-39991 ................................ a
90890-03169 ........................... b
D Spark gap tester
P/N. YM-34487 ............................... a
90890-06754 ........................... b
E Shimming gauge
P/N. YB-34446-1, YB-34446-3,
D YB-34446-5, YB-34446-7
a b F Shimming gauge
P/N. YB-34468-2
G Shimming plate
P/N. 90890-06701
H Shift rod wrench
P/N. YB-06052
90890-06052
I Test harness
E F P/N. 90890-06790, 90890-06791,
90890-06792, 90890-06793
G H
1-6
GEN
REMOVING AND INSTALLING

1 1 Flywheel magnet assembly holder
a b
P/N. YB-06139 ................................ a
90890-06522 ........................... b
2 Universal puller
P/N. YB-06117 ................................ a
90890-06521 ........................... b
2 3 Bearing/oil seal attachment
a b
P/N. YB-06196 ................................ a
90890-06653 ........................... b
4 Driver rod
P/N. YB-06071
90890-06602, 90890-06604,
90890-06605, 90890-06606,
3 90890-06652
a b 5 Bearing/oil seal attachment
P/N. YB-06377
90890-06630
6 Bearing/oil seal attachment
P/N. YB-06199
4 5
90890-06620
7 Piston ring compressor
P/N. YU-33294 ................................ a
90890-06530 ........................... b
8 Bearing separator
6 P/N. YB-06219 ................................ a
90890-06534 ........................... b
9 Guide plate stand
P/N. 90890-06538
0 Guide plate
7 P/N. 90890-06501
a b
8
a b
9 0
1-7
GEN
A Bearing puller
A B P/N. 90890-06535
B Bearing/oil seal attachment
P/N. 90890-06661, 90890-06640
C Ring nut wrench
P/N. YB-34447, YB-06578
90890-06511, 90890-06578
C D D Ring nut wrench extension
P/N. 90890-06513
E Propeller shaft housing puller
P/N. YB-06207 ................................ a
90890-06502 ........................... b
E F Center bolt
a b
P/N. 90890-06504
G Slide hammer
P/N. YB-06096
90890-06531
H Small universal claws
F G P/N. 90890-06536
I Bearing/oil seal depth plate
P/N. YB-06213, YB-34474 .............. a
90890-06603 ........................... b
J Drive shaft holder
H P/N. YB-06151
90890-06519
K Pinion nut holder
P/N. 90890-06505
L Pinion nut holder attachment
I P/N. 90890-06507
a b
M Bearing/oil seal attachment
P/N. YB-06194, YB-06195,
YB-06200, YB-06376
90890-06607, 90890-06610,
90890-06612, 90890-06633,
J K
90890-06636
N Bearing puller
P/N. 90890-06523
O Large universal claws
P/N. 90890-06532
L M
N O
1-8
GEN
P Slide hammer attachment

P Q P/N. YB-06335
90890-06514
Q Oil filter wrench
P/N. YU-38411
90890-01426
R End screw wrench
R S P/N. YB-06175-1A
S End screw wrench
P/N. YB-06548
90890-06548
T Valve spring compressor
P/N. YM-01253
90890-04019
T U U Valve spring compressor adapter
(ø22 mm)
P/N. YB-06554
90890-06554
V Valve seat cutter set
P/N. YM-91043-C............................ a
90890-06803 ........................... b
V W Valve seat cutter holder (ø6 mm)
a b P/N. YB-06553
90890-06553
X Valve seat cutter
P/N. YB-06555 (45˚ - 30 mm)
YB-06556 (90˚ - 30 mm)
90890-06555 (45˚ - 30 mm)
90890-06556 (90˚ - 30 mm)
Y Valve guide remover (ø5.9 mm)
P/N. YM-4064-A
90890-04064
Z Valve guide reamer (ø6 mm)
W X P/N. YM-04066
90890-04066
[ Crankshaft holder
P/N. YB-06552
90890-06552
Y Z
1-9
GEN
\ Bearing installer
\ ] P/N. YB-41446
] Bearing cup installer
P/N. YB-06167
_ Roller bearing installer/remover
P/N. YB-06432-1A
1-10
SPEC E
CHAPTER 2
SPECIFICATIONS
GENERAL SPECIFICATIONS.......................................................................... 2-1
MAINTENANCE SPECIFICATIONS................................................................ 2-3

1
POWER UNIT............................................................................................ 2-3
LOWER UNIT............................................................................................ 2-7
ELECTRICAL ............................................................................................. 2-7
DIMENSIONS ......................................................................................... 2-10
TIGHTENING TORQUES .............................................................................. 2-13

2
SPECIFIED TORQUES ............................................................................ 2-13
GENERAL TORQUES ............................................................................. 2-15
3
4
5
6
7
8
9
SPEC GENERAL SPECIFICATIONS E
GENERAL SPECIFICATIONS 2
Model
Item Unit
F115TR LF115TR
DIMENSION
Overall length mm (in) 825 (32.5)
Overall width mm (in) 498 (19.6)
Overall height
(L) mm (in) 1,609 (63.3) —
(X) mm (in) 1,736 (68.3)
Boat transom height
(L) mm (in) 508 (20.0) —
(X) mm (in) 635 (25.0)
WEIGHT
(without propeller)
(L) kg (lb) 183 (403) —
(X) kg (lb) 188 (414)
PERFORMANCE
Maximum output kW (hp) 84.6 (115)
@ 5,500 r/min
Full throttle operating range r/min 5,000 - 6,000
Maximum fuel consumption L (US gal, 38 (10.0, 8.4)
lmp gal)/hr
@ 6,000 r/min
POWER UNIT
Type In-line, 4 stroke, DOHC, 16 valves
Number of cylinders 4
Displacement cm3 (cu. in) 1,741 (106.2)
Bore × stroke mm (in) 79.0 × 88.8 (3.11 × 3.50)
Compression ratio 9.7
Minimum compression kPa 950 (9.5, 135)
pressure(*1) (kgf/cm2, psi)
Fuel system Electronic fuel injection
Fuel injection system Fuel injection
Starting system Electric
Ignition control system TCI
Alternator output V, A 12, 25
Spark plugs (NGK) LFR6A-11
Cooling system Water
Exhaust system Through propeller boss
Lubrication system Wet sump
(*1) Measuring conditions:
Ambient temperature 20 °C (68 °F), wide open throttle, with spark plugs removed from all
cylinders.
The figures are reference only.
2-1
SPEC GENERAL SPECIFICATIONS E
Model
Item Unit
F115TR LF115TR
Lubrication oil pressure(*1) kPa 350 (3.5, 49.8)
at 55˚C (131˚F) (kgf/cm2, psi)
@ idling
FUEL AND OIL
Fuel type Unleaded regular gasoline
Fuel rating PON(*2) 86
RON 91
Engine oil type 4-stroke motor oil
Engine oil grade API SE, SF, SG, SH, or SJ
SAE 10W-30 or 10W-40
Engine oil capacity
(with oil filter) L (US qt, 4.5 (4.76, 3.96)
lmp qt)
(without oil filter) L (US qt, 4.3 (4.55, 3.78)
lmp qt)
Gear oil type GEAR CASE LUBE
Gear oil grade SAE 90
Gear oil total quantity cm3 (US oz, 760 (25.7, 26.8) 715 (24.2, 25.2)
lmp oz)
BRACKET
Trim angle Degree –4 - 16
(at 12˚ boat transom)
Tilt-up angle Degree 70
Steering angle Degree 30 + 30
DRIVE UNIT
Gear shift positions F-N-R
Gear ratio 2.15 (28/13)
Reduction gear type Spiral bevel gear
Clutch type Dog clutch
Propeller shaft type Spline
Propeller direction Clockwise Counterclockwise
(rear view)
Propeller mark K KL
ELECTRICAL
Battery minimum capacity(*3)
CCA/SAE A 380
MCA/ABYC A 502
RC/SAE Minute 124
(*1) The figures are reference only. (*3) CCA: Cold Cranking Ampere
(*2) PON: Pump Octane Number = MCA: Marine Cranking Ampere
(RON + Motor Octane Number)/2 ABYC: American Boat and Yacht Council
RON: Research Octane Number SAE: Society of Automotive Engineers
RC: Reserve Capacity
2-2
SPEC MAINTENANCE SPECIFICATIONS E
MAINTENANCE SPECIFICATIONS 2
POWER UNIT
Model
Item Unit
F115TR LF115TR
CYLINDER HEADS
Warpage limit mm (in) 0.1 (0.004)
(lines indicate straightedge

position)
Camshaft journal inside mm (in) 25.000 - 25.021 (0.984 - 0.985)
diameter
CYLINDERS
Bore size mm (in) 79.000 - 79.020 (3.110 - 3.111)
Taper limit mm (in) 0.08 (0.003)
Out-of-round limit mm (in) 0.05 (0.002)
PISTONS
Piston diameter (D) mm (in) 78.928 - 78.949 (3.1074 - 3.1082)
Measuring point (H) mm (in) 13 (0.51)
Piston-to-cylinder clearance mm (in) 0.070 - 0.080 (0.0028 - 0.0031)
<Limit> mm (in) 0.13 (0.005)
Oversize piston diameter mm (in) 79.25 (3.120)
PISTON PINS
Outside diameter mm (in) 17.997 - 18.000 (0.7085 - 0.7087)
PISTON RINGS
Top ring
Dimension B B mm (in) 1.17 - 1.19 (0.046 - 0.047)
Dimension T T mm (in) 2.80 - 3.00 (0.110 - 0.118)
End gap mm (in) 0.15 - 0.30 (0.006 - 0.012)
Side clearance mm (in) 0.04 - 0.08 (0.002 - 0.003)
2nd ring
Dimension T T mm (in) 3.00 - 3.20 (0.118 - 0.126)
End gap mm (in) 0.70 - 0.90 (0.028 - 0.035)
Oil ring
Dimension T T mm (in) 2.40 (0.094)
End gap mm (in) 0.20 - 0.70 (0.008 - 0.028)
2-3
Model
Item Unit
F115TR LF115TR
CAMSHAFTS
Intake (A) mm (in) 37.22 - 37.38 (1.465 - 1.472)
A
Exhaust (A) mm (in) 36.90 - 37.06 (1.453 - 1.459)
Intake and mm (in) 29.92 - 30.08 (1.178 - 1.184)
exhaust (B) B
Camshaft journal diameter mm (in) 24.96 - 24.98 (0.9827 - 0.9835)

Camshaft journal oil clearance mm (in) 0.020 - 0.061 (0.0008 - 0.0024)
Maximum camshaft runout mm (in) 0.03 (0.0012)
VALVES
Valve clearance (cold)
Intake mm (in) 0.20 ± 0.03 (0.008 ± 0.001)
Exhaust mm (in) 0.34 ± 0.03 (0.013 ± 0.001)
Head diameter (A)
Intake mm (in) 29.0 - 29.2 (1.14 - 1.15)
Exhaust A mm (in) 24.0 - 24.2 (0.94 - 0.95)
Face width (B)
Intake B
mm (in) 2.00 - 2.43 (0.079 - 0.096)
Exhaust mm (in) 2.28 - 2.71 (0.090 - 0.107)
Seat width (C)
Intake mm (in) 1.2 - 1.6 (0.047 - 0.063)
C
Exhaust mm (in) 1.2 - 1.6 (0.047 - 0.063)
Margin thickness (D)
Intake mm (in) 0.8 - 1.2 (0.031 - 0.047)
D
Exhaust mm (in) 1.0 - 1.4 (0.039 - 0.055)
Stem diameter
Intake mm (in) 5.975 - 5.990 (0.2352 - 0.2358)
Exhaust mm (in) 5.960 - 5.975 (0.2346 - 0.2352)
Guide inside diameter
Intake and exhaust mm (in) 6.000 - 6.018 (0.2362 - 0.2369)
Stem-to-guide clearance
Intake mm (in) 0.015 - 0.043 (0.0006 - 0.0017)
Exhaust mm (in) 0.030 - 0.058 (0.0012 - 0.0023)
Stem runout limit mm (in) 0.01 (0.0004)
2-4
Model
Item Unit
F115TR LF115TR
VALVE SPRINGS
Free length mm (in) 53.20 (2.094)
Minimum free length mm (in) 52.25 (2.057)
Tilt limit mm (in) 2.6 (0.10)
VALVE LIFTERS
Valve lifter outside diameter mm (in) 27.965 - 27.980 (1.1010 - 1.1016)
Valve-lifter-to-cylinder-head mm (in) 0.020 - 0.056 (0.0008 - 0.0022)
clearance
VALVE PADS
Valve pad thickness mm (in) 2.000 - 3.300 (0.0787 - 0.1299)
(in 0.025 mm increments)
CONNECTING RODS
Small-end inside diameter mm (in) 17.965 - 17.985 (0.7073 - 0.7081)
Big-end inside diameter mm (in) 45.025 - 45.045 (1.7726 - 1.7734)
Big-end oil clearance mm (in) 0.025 - 0.031 (0.0010 - 0.0012)
Big-end bearing thickness
Yellow mm (in) 1.502 - 1.508 (0.0591 - 0.0593)
Green mm (in) 1.508 - 1.514 (0.0593 - 0.0596)
Blue mm (in) 1.514 - 1.520 (0.0596 - 0.0598)
Red mm (in) 1.520 - 1.526 (0.0598 - 0.0601)
CRANKSHAFT
Crankshaft journal
Diameter mm (in) 47.984 - 48.000 (1.8891 - 1.8898)
Minimum diameter mm (in) 47.972 (1.8887)
Crankshaft pin
Diameter mm (in) 41.982 - 42.000 (1.6528 - 1.6535)
Runout limit mm (in) 0.03 (0.001)
2-5
Model
Item Unit
F115TR LF115TR
CRANKCASE
Crankcase main journal inside mm (in) 54.023 - 54.042 (2.1269 - 2.1276)
diameter
Crankshaft journal oil mm (in) 0.024 - 0.044 (0.0009 - 0.0017)
clearance
Upper crankcase main journal
bearing thickness
Green mm (in) 2.992 - 2.999 (0.1178 - 0.1181)
Blue mm (in) 2.999 - 3.006 (0.1181 - 0.1183)
Red mm (in) 3.006 - 3.013 (0.1183 - 0.1186)
Lower crankcase main journal
bearing thickness
Yellow mm (in) 3.010 - 3.017 (0.1185 - 0.1188)
Green mm (in) 3.017 - 3.024 (0.1188 - 0.1191)
Blue mm (in) 3.024 - 3.031 (0.1191 - 0.1193)
Red mm (in) 3.031 - 3.038 (0.1193 - 0.1196)
No. 3 main journal bearing
thickness
Green mm (in) 2.992 - 2.999 (0.1178 - 0.1181)
Blue mm (in) 2.999 - 3.006 (0.1181 - 0.1183)
Red mm (in) 3.006 - 3.013 (0.1183 - 0.1186)
OIL PUMP
Discharge
at 100 ˚C (212 ˚F), with L (US gal, 5.9 (1.56, 1.30)
10W-30 engine oil Imp gal)/min
@ 1,000 r/min
Pressure kPa 118 (1.18, 16.78)
(kgf/cm2, psi)
Relief valve opening pressure kPa 490 (4.90, 69.69)
(kgf/cm2, psi)
THERMOSTATS
Opening temperature ˚C (˚F) 48 - 52 (118 - 126)
Full-open temperature ˚C (˚F) 60 (140)
Valve open lower limit mm (in) 4.3 (0.17)

ENGINE SPEED
Idling speed r/min 750 ± 50
2-6
LOWER UNIT
Model
Item Unit
F115TR LF115TR
GEAR BACKLASH
Pinion - forward gear mm (in) 0.19 - 0.53 0.31 - 0.66
(0.007 - 0.021) (0.012 - 0.026)
Pinion - reverse gear mm (in) 0.86 - 1.26 0.86 - 1.21
(0.034 - 0.050) (0.034 - 0.048)
Pinion shims mm 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50
Forward gear shims mm 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50
Reverse gear shims mm 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50
ELECTRICAL
Model
Item Unit
F115TR LF115TR
IGNITION SYSTEM
Ignition timing Degree 4 ATDC - 20 BTDC
ECM unit (B/R, B/W – B)
Output peak voltage lower
limit
@ cranking 1 V 5.0
@ cranking 2 V 122
@ 1,500 r/min V 242
@ 3,500 r/min V 245
Pulser coil (W/R, W/B – B)
limit
@ cranking 1 V 3.5
@ cranking 2 V 3.0
@ 1,500 r/min V 26
@ 3,500 r/min V 44
IGNITION CONTROL SYSTEM
Engine cooling water
temperature sensor
Resistance (B/Y – B)
@ 5˚C (41˚F) kΩ 4.62
@ 20˚C (68˚F) kΩ 2.44
@ 100˚C (212˚F) kΩ 0.19
Throttle position sensor
Output voltage (P – B) V 0.732 ± 0.014
* Cranking 1: Open circuit voltage.
Cranking 2: Loaded circuit voltage.
2-7
Model
Item Unit
F115TR LF115TR
STARTING SYSTEM
Fuse 1 V-A 12-20
Fuse 2 V-A 12-30
STARTER MOTOR
Type Sliding gear
Output kW 1.4
Rating Second 30
Brushes
Standard length mm (in) 15.5 (0.61)
Wear limit mm (in) 9.5 (0.37)
Commutator
Standard diameter mm (in) 29.0 (1.14)
Mica
Standard undercut mm (in) 0.5 - 0.8 (0.02 - 0.03)
CHARGING SYSTEM
Lighting coil (W – W)
limit
@ cranking 1 V 9.3
@ cranking 2 V 7.4
@ 1,500 r/min V 37 (open circuit voltage)
@ 3,500 r/min V 89 (open circuit voltage)
Rectifier/regulator (R – B)
limit
@ cranking 1 V —
@ cranking 2 V 7.5
@ 1,500 r/min V 12.5
@ 3,500 r/min V 13.0
POWER TRIM AND TILT
SYSTEM
Trim sensor
Resistance (P – B) Ω 9 - 378.8
* Cranking 1: Open circuit voltage.
Cranking 2: Loaded circuit voltage.
2-8
Model
Item Unit
F115TR LF115TR
POWER TRIM AND TILT
MOTOR
Fluid type ATF Dexron II
Brushes
Standard length mm (in) 9.8 (0.39)
Commutator
Standard diameter mm (in) 22.0 (0.87)
Mica
Standard undercut mm (in) 1.35 (0.05)
2-9
DIMENSIONS
L7 L6
L2 L1 W5 A1
W1
H9
H2 T
H7 H10
L8
H8
B6
H4
A2
H1 C3
H3 H6
Models
Symbol Unit
L5 F115TR LF115TR
H11
A1 Degree 30
A3 A2 Degree 68.5
L9
L4 A3 Degree 2.5
B6 mm (in) 367 (14.4)
C3 mm (in) 82 (3.2)
L1 mm (in) 662 (26.1)
L2 mm (in) 115 (4.5)
L4 mm (in) 631 (24.8)
L5 (L) mm (in) 81 (3.2) —
(X) mm (in) 104 (4.1)
L6 (L) mm (in) 1,005 (39.6) —
(X) mm (in) 1,122 (44.2)
L7 mm (in) 555 (21.9)
L8 mm (in) 137 (5.4)
L9 (L) mm (in) 12 (0.5) —
(X) mm (in) 16 (0.6)
H1 (L) mm (in) 929 (36.6) —
(X) mm (in) 1,056 (41.6)
H2 mm (in) 681 (26.8)
H3 mm (in) 191 (7.5)
H4 (L) mm (in) 516 (20.3) —
(X) mm (in) 643 (25.3)
H6 (L) mm (in) 773 (30.4) —
(X) mm (in) 850 (33.5)
H7 mm (in) 404 (15.9)
H8 mm (in) 31 (1.2)
H9 mm (in) 879 (34.6)
H10 mm (in) 45 (1.8)
H11 mm (in) 14 (0.6)
W1 mm (in) 246 (9.7)
W5 mm (in) 388 (15.3)
T mm (in) 660 (26.0)
2-10
L3
A1 W5
W2
W1
W6
L7 L6
L2 L1
L10
H9
H5
H2
H7
H10
H8 Models
Symbol Unit
B6 F115TR LF115TR
H4 A1 Degree 30
A2 Degree 68.5
H1 A2
C3 H6 A3 Degree 2.5
H3 B6 mm (in) 367 (14.4)
C3 mm (in) 82 (3.2)
L5
L8 L1 mm (in) 662 (26.1)
H11 L2 mm (in) 316 (12.4)
A3 L3 mm (in) 832 (32.8)
L9 L4 L4 mm (in) 631 (24.8)
L5 (L) mm (in) 81 (3.2) —
(X) mm (in) 104 (4.1)
L6 (L) mm (in) 1,005 (39.6) —
(X) mm (in) 1,122 (44.2)
L7 mm (in) 555 (21.9)
L8 mm (in) 294 (11.6)
L9 (L) mm (in) 12 (0.5) —
(X) mm (in) 16 (0.6)
H1 (L) mm (in) 929 (36.6) —
(X) mm (in) 1,056 (41.6)
H2 mm (in) 681 (26.8)
H3 mm (in) 191 (7.5)
H4 (L) mm (in) 516 (20.3) —
(X) mm (in) 643 (25.3)
H6 (L) mm (in) 773 (30.4) —
(X) mm (in) 850 (33.5)
H7 mm (in) 404 (15.9)
H8 mm (in) 105 (4.1)
H9 mm (in) 879 (34.6)
H10 mm (in) 45 (1.8)
H11 mm (in) 14 (0.6)
W1 mm (in) 246 (9.7)
W2 mm (in) 93 (3.7)
W5 mm (in) 388 (15.3)
W6 mm (in) 574 (22.6)
2-11
Models
Symbol Unit
F115TR LF115TR
B1 mm (in) 125.4 (4.9)
B2 mm (in) 254 (10.0)
B3 mm (in) 163.5 (6.4)
B4 mm (in) 50.8 (2.0)
B5 mm (in) 180 (7.1)
B6 mm (in) 367 (14.4)
B9 mm (in) 18.5 (0.7)
C3 mm (in) 82 (3.2)
D1 mm (in) 13 (0.5)
D2 mm (in) 55.5 (2.2)
2-12
SPEC TIGHTENING TORQUES E
TIGHTENING TORQUES 2
SPECIFIED TORQUES
Tightening torques
Part to be tightened Thread size
Nm m•kgf ft•lb
POWER UNIT
Flywheel magnet assembly M24 186 19 137
Positive battery lead M8 9 0.9 6.5
Power unit mount M8 42 4.2 30
Driven sprocket M10 60 6.0 43
Drive sprocket M40 265 27 192
Timing belt tensioner M10 40 4.0 29
Spark plug M14 25 2.5 18
Cylinder head cover M6 8 0.8 5.8
Breather cover M4 2 0.2 1.4
Fuel pump bracket assembly M7 17 1.7 12
1st 8 0.8 5.8
Camshaft cap M7
2nd 17 1.7 12
1st 14 1.4 10
Cylinder head assembly M8
2nd 28 2.8 20
1st 15 1.5 11
Cylinder head assembly
2nd M10 30 3.0 22
(1.5 mm thread pitch)
3rd Turn 90˚
1st 6 0.6 4.3
Exhaust cover M6
2nd 12 1.2 8.7
Oil filter — 18 1.8 13
Oil pressure switch — 8 0.8 5.8
1st 14 1.4 10
Crankcase M8
2nd 28 2.8 20
Crankcase 1st 19 1.9 14
M10
(1.5 mm thread pitch) 2nd Turn 60˚
1st 15 1.5 11
Connecting rod cap M8
2nd Turn 60˚
LOWER UNIT
Propeller M18 55 5.5 40
Trim tab M10 43 4.3 31
Lower unit M10 37 3.7 27
Impeller housing M8 18 1.8 13
Shift rod assembly M6 8 0.8 5.8
Ring nut M101.5 105 10.5 76
Drive shaft housing assembly M8 18 1.8 13
Pinion nut M16 93 9.3 67
Gear oil drain screw — 7 0.7 5.1
Gear oil level check screw — 7 0.7 5.1
2-13
Tightening torques
Part to be tightened Thread size
Nm m•kgf ft•lb
BRACKET UNIT
Friction piece — 13 1.3 9.4
Steering handle assembly — 38 3.8 27.5
Main switch assembly — 5 0.5 3.7
Engine stop lanyard switch — 4 0.4 2.9
Shift lever M8 18 1.8 13
Steering handle bracket M10 38 3.8 27.5
Shift rod detent mechanism screw — 18 1.8 13
Oil pump M6 10 1.0 7.2
Upper mount M12 53 5.3 38
Lower mount M14 73 7.3 53
Muffler assembly M8 20 2.0 14
Exhaust manifold M6 11 1.1 8.0
Oil pan M6 11 1.1 8.0
Oil strainer M6 11 1.1 8.0
Clamp bracket M22 15 1.5 11
Cam — 2 0.2 1.4
Trim stopper — 37 3.7 27
POWER TRIM AND TILT UNIT
Power trim and tilt reservoir 1/4” 5 0.5 3.6
Power trim and tilt motor 1/4” 5 0.5 3.6
Manual valve — 4 0.4 2.9
Tilt ram end screw — 130 13 94
Gear pump unit 5/16” 9 0.9 6.5
Gear pump — 6 0.6 4.3
Trim ram end screw — 80 8.0 52
2-14
General torque
GENERAL TORQUES
specifications This chart specifies tightening torques for
Nut (A) Bolt (B)
standard fasteners with a standard ISO
Nm m•kgf ft•lb
thread pitch. Tightening torque specifica-
8 mm M5 5 0.5 3.6 tions for special components or assemblies
10 mm M6 8 0.8 5.8 are provided in applicable sections of this
12 mm M8 18 1.8 13 manual. To avoid warpage, tighten multi-
14 mm M10 36 3.6 25 fastener assemblies in a crisscross fashion
17 mm M12 43 4.3 31 and progressive stages until the specified
tightening torque is reached. Unless other-
wise specified, tightening torque specifica-
tions require clean, dry threads.
Components should be at room tempera-
ture.
2150
2-15
INSP
E
ADJ
CHAPTER 3
PERIODIC INSPECTIONS AND ADJUSTMENTS
MAINTENANCE INTERVAL CHART .............................................................. 3-1
TOP COWLING ............................................................................................... 3-2

CHECKING THE TOP COWLING FIT ....................................................... 3-2
FUEL SYSTEM ................................................................................................ 3-2

CHECKING THE FUEL LINE ..................................................................... 3-2
CHECKING THE FUEL FILTER ................................................................. 3-3
MEASURING THE FUEL PRESSURE
(HIGH-PRESSURE FUEL LINE) ............................................................... 3-3
CONTROL SYSTEM........................................................................................ 3-4

CHECKING AND ADJUSTING THE THROTTLE BODY
PICKUP TIMING ...................................................................................... 3-4
ADJUSTING THE SHIFT CABLE.............................................................. 3-5
ADJUSTING THE THROTTLE CABLE ..................................................... 3-6
ADJUSTING THE THROTTLE POSITION SENSOR................................ 3-7
SYNCHRONIZING THE THROTTLE VALVES.......................................... 3-8
ADJUSTING THE THROTTLE POSITION SENSOR
(WHEN DISASSEMBLING OR REPLACING THE
THROTTLE BODY)................................................................................. 3-10
COOLING SYSTEM ...................................................................................... 3-11

CHECKING THE COOLING WATER DISCHARGE ................................ 3-11
POWER UNIT ................................................................................................ 3-11

CHECKING THE ENGINE OIL LEVEL..................................................... 3-11
REPLACING THE ENGINE OIL/OIL FILTER ........................................... 3-11
CHECKING THE TIMING BELT .............................................................. 3-12
ADJUSTING THE VALVE CLEARANCE ................................................ 3-13
POWER TRIM AND TILT SYSTEM .............................................................. 3-16

CHECKING THE POWER TRIM AND TILT FLUID LEVEL ..................... 3-16
ADJUSTING THE TRIM SENSOR CAM ................................................ 3-17
INSP
E
ADJ
LOWER UNIT ................................................................................................ 3-18
CHECKING THE GEAR OIL LEVEL ........................................................ 3-18
CHANGING AND CHECKING THE GEAR OIL ...................................... 3-18
CHECKING THE LOWER UNIT (FOR AIR LEAKS) ................................ 3-20
GENERAL ...................................................................................................... 3-20

CHECKING THE ANODES...................................................................... 3-20
CHECKING THE BATTERY..................................................................... 3-21
1
CHECKING THE SPARK PLUGS............................................................ 3-22
COMPRESSION PRESSURE MEASUREMENT .................................... 3-23
OIL PRESSURE MEASUREMENT ......................................................... 3-24
LUBRICATION POINTS.......................................................................... 3-25
2
3
4
5
6
7
8
9
INSP
ADJ MAINTENANCE INTERVAL CHART E
MAINTENANCE INTERVAL CHART 3
Use the following chart as a guide to general maintenance intervals.

Dependant on operating conditions, adjust the maintenance intervals accordingly.
Initial Every
Refer to
Item Remarks 10 hours 50 hours 100 hours 200 hours page
(Break-in) (3 months) (6 months) (1 year)
TOP COWLING
Top cowling fit Check 3-2
FUEL SYSTEM
Fuel line Check 3-2
Fuel filter Check/replace 3-3
POWER UNIT
Water leakage Check —
Motor exterior Check —
Engine oil Replace 3-11
Oil filter Replace 3-11
Timing belt (*1) Check/replace 3-12
Valve clearance (*2) Check/adjust Every 400 hours (2 years) 3-13
Thermostat Check 5-25
Exhaust leakage Check —
Cooling water passage (*3) Flush —
CONTROL SYSTEM
Remote control shift cable Check/adjust 3-5
Remote control throttle Check/adjust 3-6
cable
Throttle position sensor Check/adjust 3-7
Power trim and tilt fluid Check 3-16
LOWER UNIT
Gear oil Change 3-18
Lower unit leakage Check 3-20
Propeller(s) Check 6-3, 6-28
GENERAL
Anodes Check/replace 3-20
Battery Check/charge 3-21
Spark plugs Clean/adjust/ 3-22
replace
Wiring and connectors Adjust/reconnect —
Bolts and nuts (*4) Tighten —
Lubrication points Grease 3-25
(*1) Be sure replace the timing belt after every 1,000 hours or 5 years (whichever comes first) of operation.
(*2) If leaded gasoline is usually used, engine valves and related parts should be inspected after every
300 hours of operation in addition to the items on the maintenance chart above.
(*3) The engine should be flushed with fresh water after operating in salt, turbid or muddy water.
(*4) Except for the cylinder head bolts and crankcase journal bolts.
3-1
INSP
ADJ TOP COWLING/FUEL SYSTEM E
TOP COWLING 3
CHECKING THE TOP COWLING FIT 3
1. Check:
• Top cowling fitting
Loose/unlatched → Adjust the top
cowling hook.
3010
2. Adjust:
• Top cowling hook position
2
Adjustment steps
(1) Loosen the bolts 1.
(2) Move the top cowling hook 2 either
up or down slightly (only a few milli-
1 meters).
3020
(3) Secure the bolts.
(4) Check the top cowling fitting and
repeat the adjustment if necessary.
NOTE:
• Moving the latch towards the seal will
loosen the top cowling.
• Moving the latch away from the seal will
tighten the top cowling.
FUEL SYSTEM 3
CHECKING THE FUEL LINE 3
1. Check:
• High-pressure fuel line
Cracks/damage/leaks → Replace.
Refer to “HIGH-PRESSURE FUEL
LINE” on page 4-8.
3030
3-2
INSP
ADJ FUEL SYSTEM E
2. Check:
• Plastic locking tie
Loosen → Retighten or replace.
3. Check:
• Low-pressure fuel line
Refer to “LOW-PRESSURE FUEL
LINE” on page 4-26.
3040
CHECKING THE FUEL FILTER 3
Check:
• Fuel filter element
• Fuel filter cup
Clogs/cracks/leaks → Replace.
Foreign matter → Clean.
Refer to “FUEL FILTER” on page 4-29.
3050
MEASURING THE FUEL PRESSURE

(HIGH-PRESSURE FUEL LINE) 3
Measure:
• Fuel pressure (high-pressure fuel line)
Out of specification → Check the high-
pressure fuel line.
Fuel pressure
(high-pressure fuel line)
300 kPa (3.0 kg/cm2, 44.1 psi)
Measuring steps
(1) Install the fuel pressure gauge onto the
pressure check valve.
Fuel pressure gauge ................. 1

YB-06766 / 90890-06786
(2) Turn the main switch to on, and then

3060 measure the fuel pressure.
3-3
INSP
ADJ CONTROL SYSTEM E
1
CONTROL SYSTEM 3
CHECKING AND ADJUSTING THE

a THROTTLE BODY PICKUP TIMING 3
1. Check:
• Throttle body pickup timing
Incorrect → Adjust.
Checking steps
3100
(1) Turn the throttle control lever to the
full retard position.
(2) Check that the mark a on the throttle
cam aligns with the center of the throt-
tle roller 1 as shown.
2. Adjust:
2 1 • Throttle body pickup timing
5
Adjustment steps
(1) Loosen the nut 1.
(2) Remove the throttle joint link rod 2.
(3) Move the throttle control lever 3 until
b
it contacts the fully-closed stopper 4.
c NOTE:
a
Make sure the throttle is fully-closed.
4
(4) Align the fully-closed mark a on the
3 throttle control lever 3 with the center
of the throttle roller 5 as shown.
(5) Adjust the length of the throttle joint
link rod until b is 0.5 mm.
(6) Tighten the nut and install the throttle
joint link rod onto the throttle control
3110 lever.
(7) Move the throttle control lever to
check that the throttle valve opens and
closes smoothly. Also, make sure the
throttle roller aligns with the fully-
open position c on the accelerator
cam.
(8) Set the throttle to the fully-closed posi-
tion and check that the fully-closed
mark a aligns with the center of the
throttle roller.
3-4
INSP
ADJUSTING THE SHIFT CABLE 3
1. Check:
a
• Shift operation
c Incorrect → Adjust.
2. Adjust:
• Shift cable joint position
Adjustment steps
b 3120 (1) Align the mark a on the bushing with
the mark b on the bracket c.
(2) Loosen the locknut 1 and remove the
clip 2.
(3) Remove shift cable joint 3 from the
set pin.
(4) Position the remote control lever in the
neutral position.
(5) Adjust the position of the shift cable
joint until it aligns with the set pin.
3130
WARNING
The shift cable joint must be screwed in at
least 8 mm (0.31 in).
(6) Install the shift cable joint onto the set

pin.
(7) Install the clip and tighten the locknut.
(8) Move the remote control lever to the
forward, neutral, and reverse positions
and make sure it shifts smoothly and
3140 correctly. If the shifting operation is
unsmooth or incorrect, repeat the
above procedure.
3. Check:
• Shift operation
Unsmooth operation → Repair.
3-5
INSP
ADJUSTING THE THROTTLE CABLE 3
1. Check:
• Fully closed position
Incorrect → Adjust.
Checking steps
(1) Fully close the throttle.
(2) Check that the throttle control lever 1
touches the fully-closed stopper 2.
2
2. Adjust:
1 • Throttle cable joint position
3 4 Adjustment steps
(1) Contact the throttle control lever 1
with the fully-closed stopper 2.
(2) Loosen the locknut 3 and remove the
clip 4.
(3) Remove throttle cable joint 5 from the
3150 set pin a.
(4) Position the remote control lever in the
neutral position.
(5) Adjust the position of the throttle cable
joint until it aligns with the set pin.
WARNING
The throttle cable joint must be screwed in
at least 8 mm (0.31 in).
3160 (6) Install the throttle cable joint onto the

set pin.
(7) Install the clip and tighten the locknut.
(8) Open and close the throttle (at the
remote control) several times and
make sure the throttle valves open and
close smoothly and correctly. If the
throttle operation is unsmooth or
incorrect, repeat the above procedure.
3-6
INSP
ADJUSTING THE THROTTLE

POSITION SENSOR 3
1. Measure:
• Throttle position sensor output
voltage
Out of specification → Adjust.
Throttle position sensor output

voltage (pink (P) – black (B))
0.732 ± 0.014 V
NOTE:
• Be sure to adjust the throttle valve’s open-
ing before measuring the throttle position
sensor output voltage.
• When measuring the throttle position sen-
sor output voltage, set the digital tester to
the manual range.
3170 Measuring steps

(1) Remove the intake silencer. Refer to
“INTAKE ASSEMBLY” on page 4-3.
(2) Disconnect the throttle joint link rod 1
at the throttle body.
(3) Check the throttle valve.
(4) Connect the test harness (3-pin) as
shown.
Test harness (3-pin)

90890-06793
3180
(5) Connect the digital tester probes to the
test harness (3-pin) as shown.
(6) Turn the engine start switch on.
(7) Measure the output voltage.
(8) Install the intake silencer.
(9) Start the engine and measure the out-
put voltage again.
P B
3-7
INSP
2. Adjust:
2 2 • Throttle position sensor
B PO
B
Adjustment steps
P
O
(1) Loosen the screws 2.
(2) Adjust the position of the throttle posi-
1 tion sensor until the specified output
voltage is obtained.
3190
Throttle position sensor output
voltage (pink (P) – black (B))
0.732 ± 0.014 V
General adjusting tool

Torx T-20 (with a concave in the center)
(3) Tighten the screws.

(4) Connect the throttle joint link rod 1.
SYNCHRONIZING THE THROTTLE

VALVES 3
CAUTION:
Do not adjust the throttle valve when it is
operating properly. Excess adjustment may
cause poor engine performance.
Adjustment steps
(1) Remove all of the blind plugs 1.
(2) Connect the adaptors 2 and vacuum
gauge 3 to the intake manifold assem-
bly as shown.
3
Vacuum gauge set
YU-08030 / 90890-03094
(3) Start the engine and allow it to warm

up for several minutes.
(4) Connect the tachometer to the spark
4 2 plug lead of cylinder #1.
1
Tachometer
YU-08036-A / 90890-06760
Engine idling speed

750 ± 50 r/min
3161
3-8
INSP
(5) Check the vacuum pressure of all cylin-

ders.
(6) Turn the synchronizing screw 4 so the
vacuum pressure of cylinder #3 or #4
is within 30 mmHg (40 mbar, 1.18
inHg) based of the vacuum pressure of
cylinder #1 or #2.
Tighten Vacuum pressure increases.
Loosen Vacuum pressure decreases.
General adjusting tool

Torx T-25 (with a concave in the center)
Example 1:
Check results:
Cylinder #1 360 mmHg
(480 mbar,
14.2 inHg)
Cylinder #2 350 mmHg Adjust the differ-
(467 mbar, ence of the vac-
13.8 inHg) uum pressure
between cylin-
ders #1 and #4
Cylinder #3 310 mmHg within 30 mmHg
(413 mbar, (40 mbar, 1.18
12.2 inHg) inHg).
(400 mbar,
11.8 inHg)
Example 2:
Check results:
(480 mbar,
14.2 inHg)
Cylinder #2 350 mmHg Adjust the differ-
(467 mbar, ence of the vac-
13.8 inHg) uum pressure
between cylin-
ders #2 and #4
Cylinder #3 390 mmHg within 30 mmHg
(520 mbar, (40 mbar, 1.18
15.4 inHg) inHg).
(533 mbar,
15.8 inHg)
3-9
INSP
ADJUSTING THE THROTTLE

POSITION SENSOR
(WHEN DISASSEMBLING OR
REPLACING THE THROTTLE BODY) 3
Adjusting steps
(1) Install the intake assembly with the
intake silencer removed.
(2) Disconnect the throttle position sensor
coupler.
(3) Install the test harness to the throttle
position sensor coupler.
Test harness
90890-06793
(4) Connect the digital circuit tester.

1
Digital tester
2 J-39299 / 90890-06752
3162
(5) Turn the main switch to on.

(6) Loosen the synchronizing screw and
d fully open the lower side throttle valve
(#3, 4).
(7) Loosen the idling screw 1 and fully
close the upper side throttle valve (#1,
2).
(8) Adjust the position of the throttle posi-
tion sensor until the output voltage is
0.7 ± 0.01 V and operate the throttle
e valve several times.
(9) Record the value.
(10) Slowly tighten the synchronizing
screw 2 until the recorded value is
changed.
(11) Slowly tighten the idling screw until
0.032 ± 0.004 V increase over the
recorded value.
(12) Operate the throttle valve several
times.
3163 (13) Install the throttle roller d as the mark
e aligns with center of the throttle
roller and check that the output volt-
age is not change.
(14) Install the intake silencer.
(15) Start the engine.
(16) If the output voltage of the throttle
position sensor is not within 0.732 ±
0.014 V, adjust the throttle position
sensor.
(17) Check that the throttle valve is syn-
chronized.
3-10
INSP
ADJ COOLING SYSTEM/POWER UNIT E
COOLING SYSTEM 3
CHECKING THE COOLING WATER

DISCHARGE 3
Check:
• Cooling water discharge
No discharge → Clean and check the
cooling water passage.
3200
Checking steps
(1) Place the lower unit in water.
(3) Check that water flows from the cool-
ing water outlet.
POWER UNIT 3
CHECKING THE ENGINE OIL LEVEL 3
a Check:
• Engine oil level
Above a → Check for fuel in the
b engine oil.
Below b → Add engine oil so that the
level is between a and b.
3210
REPLACING THE ENGINE OIL/OIL

FILTER 3
1. Remove:
• Oil filler cap 1
• Drain plug 2
1
2. Remove:
3 • Oil filter 3
3220 Oil filter wrench

YU-38411 / 90890-01426
3. Install:
• Drain plug 2
Drain plug
28 Nm (2.8 m • kgf, 20 ft • lb)
T.
R.
3230
3-11
INSP
ADJ POWER UNIT E
4. Install:
3 • Oil filter 3
Oil filter
18 Nm (1.8 m • kgf, 13.3 ft • lb)
T.
R.
NOTE:
Lubricate the rubber seal with engine oil
3240 before installation.
5. Add:
• Engine oil
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
3250 4.5 L (4.76 US qt, 3.96 Imp qt)
without oil filter
4.3 L (4.55 US qt, 3.78 Imp qt)
6. Install:
• Oil filler cap
7. Check:
• Engine oil level
Refer to “CHECKING THE ENGINE OIL
LEVEL” on page 3-11.
NOTE:
• Run the engine for several minutes and
then check the engine oil level.
• If the engine oil is still not within the
proper level, add/drain as needed.
CHECKING THE TIMING BELT 3
Check:
• Timing belt
Wear/damage → Replace.
3260
3-12
INSP
ADJ POWER UNIT E
ADJUSTING THE VALVE CLEARANCE 3
NOTE:
1 Valve clearance adjustment should be made
on a cold engine, at room temperature.
3 2
1. Remove:
2 • Flywheel magnet cover
3270 • Spark plug cap cover 1
2. Disconnect:
• Spark plug leads 2
• Fuel hoses 3
• Ventilation hose
• Vacuum hose
3. Loosen:
• Timing belt tensioner
4. Remove:
• Timing belt
• Driven sprockets
• Cylinder head cover
• Spark plugs
5. Install:
• Timing belt
6. Tighten:
7. Measure:
• Intake valve clearance a
• Exhaust valve clearance b
Valve clearance
Intake
0.20 ± 0.03 mm
(0.008 ± 0.001 in)
b a Exhaust
0.34 ± 0.03 mm
(0.013 ± 0.001 in)
NOTE:
If any valve clearance is out of specification,
record its measurement.
3280
3-13
INSP
ADJ POWER UNIT E
Measurement steps
(1) Turn the flywheel magneto clockwise
until cylinder #1’s piston is at TDC.
IN EX (2) Measure the intake valve clearance for
cylinders #1 and #2.
(3) Measure the exhaust valve clearance
for cylinders #1 and #3.
#1
(4) Turn the flywheel magneto 360˚ clock-
wise.
#2 (5) Measure the intake valve clearance for
cylinders #3 and #4.
(6) Measure the exhaust valve clearance
#3 for cylinders #2 and #4.
#4
3290
8. Loosen:
9. Remove:
• Timing belt
• Camshaft caps
• Camshafts
Refer to “POWER UNIT” on page 5-4.
10. Adjust:
• Valve clearance
NOTE:
• Do not mix the valve train parts (i.e., valve
pads, camshaft caps, camshafts). Keep
them organized in their proper groups
(e.g., cylinder #1 parts kept together).
• Install the removed parts in their original
positions. If valve train parts are installed
in the wrong position, proper valve
adjustments are impossible.
3-14
INSP
ADJ POWER UNIT E
Adjustment steps
(1) Insert a thin screwdriver into the notch
in the valve lifter.
(2) Carefully pry up the valve pad and
remove it.
(3) Measure the thickness removed valve
pad with a micrometer.
(4) Select a proper replacement valve pad
by calculating its thickness with the
following formula.
Proper valve pad thickness =
Removed valve pad thickness +
Measured valve clearance –
Specified valve clearance
(5) Install the proper valve pad into the
valve lifter.
NOTE:
• Measure the thickness of the new valve
pad with a micrometer because the thick-
ness number is not indicated on the pad.
• Lubricate the valve pad with molybdenum
disulfide grease.
• Perform the above procedure for all
valves whose clearances are out of speci-
fication.
11. Install:
• Camshafts
• Camshaft caps
• Timing belt
12. Tighten:
Refer to “POWER UNIT” on page 5-4.
13. Recheck:
• Valve clearance
NOTE:
If any valve clearance is still out of specifi-
cation, repeat all of the valve clearance
adjustment steps until the specified clear-
ance is obtained.
3-15
INSP
ADJ POWER UNIT/POWER TRIM AND TILT SYSTEM E
14. Loosen:
15. Remove:
• Timing belt
16. Tighten:
17. Install:
• Cylinder head cover
• Timing belt
• Spark plugs
18. Connect:
• Vacuum hose
• Ventilation hose
• Fuel hoses
• Spark plug leads
19. Install:
• Spark plug cap cover
• Flywheel magneto cover
POWER TRIM AND TILT SYSTEM 3
CHECKING THE POWER TRIM AND

TILT FLUID LEVEL 3
Check:
• Power trim and tilt fluid level
Level is low → Add power trim and tilt
fluid to the proper level.
Recommended power trim and

tilt fluid
ATF Dexron II
WARNING
When removing the power trim and tilt res-
ervoir cap, the power trim and tilt fluid may
spurt out due to internal pressure. There-
fore, fully tilt up the outboard (the tilt ram
assembly fully extended) and then slowly
remove the power trim and tilt reservoir
cap.
3300
3-16
INSP
ADJ POWER TRIM AND TILT SYSTEM E
Checking steps
(1) Tilt the outboard all the way up and
lock it with the tilt stop levers 1.
WARNING
After tilting up the outboard, be sure to
support it with the tilt stop levers.
Otherwise, the outboard could suddenly
3310 lower if the power trim and tilt unit should
lose fluid pressure.
(2) Remove the reservoir cap 2 and check

the fluid level.
NOTE:
The fluid level should be directly below the
check hole as shown.
3320 (3) Add power trim and tilt fluid if needed,

and then install the reservoir cap.
Reservoir cap
8 Nm (0.8 m • kgf, 5.8 ft • lb)
T.
R.
ADJUSTING THE TRIM SENSOR CAM 3
1. Measure:
• Trim sensor setting resistance
Trim sensor setting resistance

Pink (P) – Black (B)
10 ± 1 Ω at 20 ˚C (68 ˚F)
Measuring steps
(1) Fully tilt the outboard down.
(2) Measure the trim sensor resistance.
3323
3-17
INSP
ADJ POWER TRIM AND TILT SYSTEM/LOWER UNIT E
2. Adjust:
2 2 • Trim sensor cam position
Adjusting steps
(1) Fully tilt the outboard down.
(2) Loosen the screw 1.
(3) Adjust the position of the trim sensor
1 1 cam 2 until the specified resistance is
3325
obtained.
Trim sensor resistance

9 – 378.8 Ω at 20 ˚C (68 ˚F)
(4) Tighten the screw.
Trim sensor cam screw

2 Nm (0.2 m • kgf, 1.4 ft • lb)
T.
R.
LOWER UNIT 3
CHECKING THE GEAR OIL LEVEL 3
Check:
• Gear oil level
Level is low → Add gear oil to the
proper level.
CHANGING AND CHECKING THE

GEAR OIL 3
1. Check:
• Gear oil
Milky oil → Replace the oil seal.
Slag oil → Check the gears, bearings,
and clutch dog.
Checking steps
(1) Tilt up the outboard slightly.
(2) Place a container under the gear oil
drain screw 1.
(3) Remove the gear oil drain screw and
gear oil level check screw 2.
3330
3-18
INSP
ADJ LOWER UNIT E
2. Fill:
• Gear oil
(with the specified amount of the rec-
ommend gear oil)
Recommended gear oil

GEAR CASE LUBE
SAE: 90
Total amount
Regular rotation models
760 cm3
(25.7 US oz, 26.8 Imp oz)
Counter rotation models
715 cm3
(24.2 US oz, 25.2 Imp oz)
Filling steps
(1) Place the outboard in an upright posi-
tion.
(2) Insert the gear oil tube into the drain
hole and slowly fill the gear oil until oil
flows out of the check hole and no air
bubbles are visible.
(3) Install the gear oil level check screw
and then quickly install the gear oil
3340
drain screw.
Gear oil level check screw

7 Nm (0.7 m • kgf, 5.1 ft • lb)
T.
R.
Gear oil drain screw

7 Nm (0.7 m • kgf, 5.1 ft • lb)
3-19
INSP
ADJ LOWER UNIT/GENERAL E
CHECKING THE LOWER UNIT

(FOR AIR LEAKS) 3
Check:
• Lower unit holding pressure
Pressure drops → Check the seals and
components.
Lower unit holding pressure

70 kPa (0.7 kg/cm2, 10.0 psi)
Checking steps
CAUTION:
Do not overpressurize the lower unit.
Excessive pressure may damage the oil
seals.
(1) Remove the gear oil level check screw.

3350
(2) Install the pressure tester into the
check hole.
Pressure tester
YB-35956 / 90890-06762
(3) Apply the specified pressure.
NOTE:
The lower unit should hold the specified
pressure for 10 seconds.
GENERAL 3
CHECKING THE ANODES 3
Check:
• Anodes 1
• Trim tab 2
Scales → Clean.
Grease/oil → Clean.
Excessive wear → Replace.
1
CAUTION:
Do not oil, grease or paint the anode, or it
will not operate properly.
2
1
3360
3-20
INSP
ADJ GENERAL E
CHECKING THE BATTERY 3
WARNING
Battery electrolytic fluid is dangerous; it
contains sulfuric acid and therefore is poi-
sonous and highly caustic.
Always follow these preventive measures:
• Avoid bodily contact with electrolytic
fluid as it can cause severe burns or per-
manent eye injury.
• Wear protective eye gear when handling
or working near batteries.
Antidote (EXTERNAL):
• SKIN - Flush with water.
• EYES - Flush with water for 15 minutes
and get immediate medical attention.
Antidote (INTERNAL):
• Drink large quantities of water or milk fol-
lowed by milk of magnesia, beaten egg,
or vegetable oil. Get immediate medical
attention.
Batteries also generate explosive hydrogen
gas; therefore, you should always follow
these preventive measures:
• Charge batteries in a well-ventilated area.
• Keep batteries away from fire, sparks, or
open flames (e.g., welding equipment,
lighted cigarettes, etc.).
• DO NOT SMOKE when charging or han-
dling batteries.
KEEP BATTERIES AND ELECTROLYTIC
FLUID OUT OF REACH OF CHILDREN.
NOTE:
• Batteries vary among manufacturers.
Therefore, the following procedures may
not always apply. Consult your battery
manufacturer’s instructions.
• First, disconnect the negative lead, then
the positive lead.
3-21
INSP
ADJ GENERAL E
Check:
• Electrolyte level
Below the minimum level mark →
Add distilled water to the proper level.
• Electrolyte specific gravity
Less than specification → Recharge
the battery.
Electrolyte specific gravity

1.280 at 20˚C (68˚F)
CHECKING THE SPARK PLUGS 3
1. Check:
• Electrodes 1
Cracks/excessive wear → Replace.
• Insulator color 2
Distinctly different color → Check the
engine condition.
2. Clean:
3370
• Spark plug
(with a spark plug cleaner or wire
brush.)
3. Measure:
• Spark plug gap a
Out of specification → Regap.
Spark plug gap

1.0 - 1.1 mm (0.039 - 0.043 in)
a
3380
3-22
INSP
ADJ GENERAL E
4. Tighten:
• Spark plug
Spark plug
25 Nm (2.5 m • kgf, 18 ft • lb)
T.
R.
NOTE:
• Before installing the spark plug, clean the
3390 gasket surface and spark plug surface.
Also, it is suggested to apply a thin film of
anti-seize compound to the spark plug
threads to prevent thread seizure.
• If a torque wrench is not available, a good
estimate of the correct tightening torque
is to finger tighten a the spark plug and
then tighten it another 1/4 to 1/2 of a
turn b.
COMPRESSION PRESSURE
MEASUREMENT 3
CAUTION:
Before removing a spark plug, use com-
pressed air to blow away dirt accumulated
in the spark plug well to prevent it from
falling into the cylinder that is being tested.
1. Check:
• Valve clearance
Refer to “ADJUSTING THE VALVE
CLEARANCE” on page 3-13.
2. Warm-up:
• Engine
3. Remove:
• Spark plug(-s)
4. Install:
• Compression gauge 1
(into the spark plug hole)
1 NOTE:
Use a compression gauge that is used for
automobiles.
3391
3-23
INSP
ADJ GENERAL E
5. Measure:
• Compression pressure
Below minimum compression pres-
sure → Inspect valve clearance, valve
face, valve seat, piston rings, cylinder
sleeve, piston, cylinder head gasket
and cylinder head.
Compression pressure
(reference data)
Minimum
950 kPa (9.5 kg/cm2, 135 psi)
Measurement steps
(1) Remove the lock plate from the engine
stop lanyard switch on the remote con-
trol box.
(2) With the throttle wide open, crank the
engine setting the main switch in the
START position until the reading on
the compression gauge stabilizes.
6. Remove:
• Compression gauge
7. Install:
• Spark plug(-s)
OIL PRESSURE MEASUREMENT 3
1. Warm-up:
• Engine
2. Remove:
• Oil pressure switch
3. Install:
3392
1 • Oil pressure gauge 1
(into the oil pressure switch hole)
NOTE:
Use a pressure gauge with the range of 0 to
10 kg/cm2 and an adopter with a PT 1/4
thread.
3-24
INSP
ADJ GENERAL E
4. Measure:
• Oil pressure
Out of specification → Check the oil
pump, oil suction pipe and oil strainer.
Oil pressure
(reference data)
At idling (55 ˚C (131 ˚F))
350 kPa (3.5 kg/cm2, 49.8 psi)
or higher
5. Remove:
• Oil pressure gauge
6. Install:
• Oil pressure switch
3400
LUBRICATION POINTS 3
1. Apply:
• Water resistant grease
3410
3420
3-25
INSP
ADJ GENERAL E
3430
3440
3450
2. Apply:
• Corrosion resistant grease
3451
3-26
FUEL E
CHAPTER 4
FUEL SYSTEM
INTAKE SILENCER ......................................................................................... 4-1

REMOVING/INSTALLING THE INTAKE SILENCER................................ 4-1
INTAKE ASSEMBLY ....................................................................................... 4-3

REMOVING/INSTALLING THE INTAKE ASSEMBLY ............................. 4-3
THROTTLE BODY ........................................................................................... 4-5

REMOVING/INSTALLING THE THROTTLE BODY ................................. 4-5
CONTROL UNIT.............................................................................................. 4-6

REMOVING/INSTALLING THE CONTROL UNIT .................................... 4-6
HIGH-PRESSURE FUEL LINE......................................................................... 4-8

REMOVING/INSTALLING THE HIGH-PRESSURE FUEL LINE ............... 4-8
REDUCING THE FUEL PRESSURE (HIGH-PRESSURE FUEL LINE) .... 4-10
CHECKING THE PRESSURE REGULATOR........................................... 4-11
FUEL INJECTORS......................................................................................... 4-12

REMOVING/INSTALLING THE FUEL INJECTORS ............................... 4-12
DISASSEMBLING/ASSEMBLING THE FUEL INJECTORS .................. 4-13
FUEL HOSES................................................................................................. 4-14

REMOVING/INSTALLING THE FUEL HOSES....................................... 4-14
VAPOR SEPARATOR.................................................................................... 4-15

REMOVING/INSTALLING THE VAPOR SEPARATOR .......................... 4-15
DISASSEMBLING/ASSEMBLING THE VAPOR SEPARATOR ............. 4-16
HIGH-PRESSURE FUEL PUMP .................................................................... 4-17

DISASSEMBLING/ASSEMBLING THE HIGH-PRESSURE
FUEL PUMP ........................................................................................... 4-17
PRESSURE REGULATOR............................................................................. 4-18

REMOVING/INSTALLING THE PRESSURE REGULATOR ................... 4-18
FUEL E
IDLE SPEED CONTROL ASSEMBLY ........................................................... 4-19

REMOVING/INSTALLING THE IDLE SPEED CONTROL ASSEMBLY.. 4-19
DISASSEMBLING/ASSEMBLING THE IDLE SPEED CONTROL
ASSEMBLY............................................................................................ 4-21
FUEL RAIL ..................................................................................................... 4-22

DISASSEMBLING/ASSEMBLING THE FUEL RAIL............................... 4-22 1
INTAKE MANIFOLD...................................................................................... 4-23
DISASSEMBLING/ASSEMBLING THE INTAKE MANIFOLD ............... 4-23
THROTTLE POSITION SENSOR .................................................................. 4-24

REMOVING/INSTALLING THE THROTTLE POSITION SENSOR ........ 4-24
2
INSTALLING THE THROTTLE POSITION SENSOR ............................. 4-25
LOW-PRESSURE FUEL LINE ....................................................................... 4-26

REMOVING/INSTALLING THE LOW-PRESSURE FUEL LINE.............. 4-26
DISASSEMBLING/ASSEMBLING THE LOW-PRESSURE
FUEL LINE.............................................................................................. 4-28
3
FUEL FILTER ................................................................................................. 4-29
DISASSEMBLING/ASSEMBLING THE FUEL FILTER........................... 4-29 4
FUEL PUMP .................................................................................................. 4-30
DISASSEMBLING/ASSEMBLING THE FUEL PUMP ............................ 4-30
CHECKING THE FUEL PUMPS .............................................................. 4-31
5
6
7
8
9
FUEL INTAKE SILENCER E
INTAKE SILENCER 4
REMOVING/INSTALLING THE INTAKE SILENCER 4
8 × 20 mm
11
9
2
1 7
12 6 × 105 mm
10
4 5
8
6 × 20 mm
4015
Order Job/Part Q’ty Remarks

Flywheel cover Refer to “FLYWHEEL MAGNET
ASSEMBLY” on page 5-1.
1 Plastic locking tie 1 Not reusable
2 Hose 1 (cylinder head cover-to-intake silencer)
3 Hose 1 (vapor separator-to-intake silencer)
4 Intake air temperature sensor 1
coupler
5 Intake air temperature sensor 1
6 Bolt 2
Continued on next page.
4-1
FUEL INTAKE SILENCER E
8 × 20 mm
11
9
2
1 7
12 6 × 105 mm
10
4 5
8
6 × 20 mm
4010

7 Collar 2
8 Bolt 6
9 Intake silencer 1
10 O-ring 2
11 Bolt 2
12 Bracket 1
For installation, reverse the removal
procedure.
4-2
FUEL INTAKE ASSEMBLY E
INTAKE ASSEMBLY 4
REMOVING/INSTALLING THE INTAKE ASSEMBLY 4
6 × 20 mm
18
3 2
7
16
15
4
8 × 40 mm
8
13
14
1
5 12
6
15
20 17 9
19 8 × 120 mm
11 10
4010

Intake silencer Refer to “INTAKE SILENCER” on page
4-1.
1 Throttle joint link rod 1
2 Throttle position sensor coupler 1
3 Idle speed control valve coupler 1
4 Intake air pressure sensor 1
coupler
5 Fuel injector coupler 4
6 High-pressure fuel pump coupler 1
7 Bolt 4
8 Bolt 4
9 Bolt 1
4-3
FUEL INTAKE ASSEMBLY E
6 × 20 mm
18
3 2
7
16
15
4
8 × 40 mm
8
13
14
1
5 12
6
15
20 17 9
19 8 × 120 mm
11 10
4010

10 Washer 1
11 Collar 1
13 Hose clamp 1
14 Fuel filter assembly 1
15 Hose clamp 2
16 Water hose 1 (fuel cooler-to-water outlet)
17 Water hose 1 (fuel cooler-to-exhaust cover)
18 Hose 1
19 Intake assembly 1
20 Gasket 1 Not reusable
procedure.
4-4
FUEL THROTTLE BODY E
THROTTLE BODY 4
REMOVING/INSTALLING THE THROTTLE BODY 4
3
8 × 70 mm
2
1
5 6 × 20 mm
4030

Intake assembly Refer to “INTAKE ASSEMBLY” on page
4-3.
1 Bolt 4
2 Bracket 2
3 Bolt 6
4 Throttle body #1 1
5 Spring 1
7 Throttle body #2 1
8 O-ring 4 2.46 × 48 mm
procedure.
4-5
FUEL CONTROL UNIT E
CONTROL UNIT 4
REMOVING/INSTALLING THE CONTROL UNIT 4
14
10
SS
LT
9
13
12
11
7
2
6
SS
LT
4
3
1 4020
6 × 30 mm

Intake silencer Refer to “INTAKE SILENCER” on page
4-1.
1 Bolt 1
2 Collar 1
3 Wave washer 1
4 Washer 1
5 Throttle control lever 1
6 Spring 1
7 Washer 1
4-6
FUEL CONTROL UNIT E
14
10
SS
LT
9
13
12
11
7
2
6
SS
LT
4
3
1 4020
6 × 30 mm

9 Nut 1
10 Collar 1
11 Wave washer 1
12 Washer 1
13 Accelerator cam 1
14 Stud bolt 1
procedure.
4-7
FUEL HIGH-PRESSURE FUEL LINE E
HIGH-PRESSURE FUEL LINE 4
REMOVING/INSTALLING THE HIGH-PRESSURE FUEL LINE 4
9 16
13
12 14 2
7 3
6 × 10 mm
4
6 1
5
6 × 30 mm
6 × 25 mm
8
15
11
10
8 × 45 mm
4040

4-3.
1 Bolt 3
2 Washer 3
3 Vapor separator 1
5 Bolt 2
6 Washer 2
7 Fuel cooler 1
8 Collar 2
4-8
9 16
13
12 14 2
7 3
6 × 10 mm
4
6 1
5
6 × 30 mm
6 × 25 mm
8
15
11
10
8 × 45 mm
4040

9 Hose 1 (intake manifold-to-pressure regulator)
10 Bolt 2
11 Washer 2
12 Bolt 1
13 Washer 1
14 Fuel rail 1
15 Collar 2
16 Collar 1
procedure.
4-9
REDUCING THE FUEL PRESSURE

(HIGH-PRESSURE FUEL LINE) 4
WARNING
Always reduce the fuel pressure in the
high-pressure fuel line before servicing the
line or the vapor separator. If the fuel pres-
sure is not released, pressurized fuel may
spray out.
1. Reduce:
• Fuel pressure (high-pressure fuel line)
Reducing steps
(1) Remove the cap 1.
(2) Cover the pressure check valve a of
the fuel rail with a rag, and then press
in the valve using a thin screwdriver 2
to release the fuel pressure.
WARNING
Always reduce the fuel pressure in the
high-pressure fuel line before servicing the
line or the vapor separator. If the fuel pres-
sure is not released, pressurized fuel may
spray out.
(3) Remove the cap 3, and then press in

the valve b using a thin screwdriver
2.
(4) Place a container under the vapor sep-
arator, and then drain the fuel from the
separator by removing the drain screw
4.
4-10
4060
CHECKING THE PRESSURE
1 REGULATOR
Check:
• Pressure regulator
Faulty → Replace the pressure regula-
tor.
Checking steps
(1) Install the fuel pressure gauge onto the
pressure check valve.
Fuel pressure gauge ................. 1

YB-06766 / 90890-06786
(2) Main switch to on.

(3) Check the fuel pressure.
Fuel pressure
Approx.
300 kPa (3.0 kg/cm2, 44.1 psi)

(5) Check the fuel pressure.
Fuel pressure
Approx.
250 kPa (2.5 kg/cm2, 35.6 psi)
4-11
FUEL FUEL INJECTORS E
FUEL INJECTORS 4
REMOVING/INSTALLING THE FUEL INJECTORS
2
1
6
8 × 45 mm
5
4070

High-pressure fuel line Refer to “HIGH-PRESSURE FUEL LINE”
on page 4-8.
Before performing the following
procedure, reduce the fuel pressure
(high-pressure fuel line).
1 Bolt 2
2 Washer 2
3 Fuel cooler 1
4 Collar 2
5 Fuel injector coupler 4
6 Fuel injector 4
procedure.
4-12
FUEL FUEL INJECTORS E
DISASSEMBLING/ASSEMBLING THE FUEL INJECTORS
3 2
2
3
4080

1 Rubber seal 1
2 Rubber damper 1
3 O-ring 1 2.2 × 7.8 mm
For assembly, reverse the disassembly
procedure.
4-13
FUEL FUEL HOSES E
FUEL HOSES 4
REMOVING/INSTALLING THE FUEL HOSES
2
4
1
2
1
5
4100

on page 4-8.
(high-pressure fuel line).
1 Hose clamp 2 Not reusable
2 Hose clamp 4
3 Fuel hose 1 (vapor separator-to-fuel rail)
4 Fuel hose 1 (pressure regulator-to-fuel cooler)
5 Fuel hose 1 (fuel cooler-to-vapor separator)
procedure.
4-14
FUEL VAPOR SEPARATOR E
VAPOR SEPARATOR 4
REMOVING/INSTALLING THE VAPOR SEPARATOR
2
1
6 × 30 mm
4110

Fuel hoses Refer to “FUEL HOSES” on page 4-14.
1 Bolt 3
2 Washer 3
3 Hose 1 (vapor separator-to-intake silencer)
4 Vapor separator 1
procedure.
4-15
FUEL VAPOR SEPARATOR E
DISASSEMBLING/ASSEMBLING THE VAPOR SEPARATOR
4 × 16 mm
4 3
2 6
1
4120

1 Drain screw 1
2 Gasket 1
3 Screw 7
4 O-ring 1
5 Float chamber 1
6 Holder 1
7 High-pressure fuel pump filter 1
8 Vapor separator body 1
procedure.
4-16
FUEL HIGH-PRESSURE FUEL PUMP E
HIGH-PRESSURE FUEL PUMP 4
DISASSEMBLING/ASSEMBLING THE HIGH-PRESSURE FUEL PUMP
7 5
6 10
9
3 × 8 mm 4
4130

1 Float pin 1
2 Float 1
3 Needle valve 1
4 Screw 1
5 Retainer 1
6 Collar 1
7 O-ring 1 1.35 × 7 mm
8 High-pressure fuel pump 1
9 Grommet 1
10 High-pressure fuel pump 1
connector
procedure.
4-17
FUEL PRESSURE REGULATOR E
PRESSURE REGULATOR 4
REMOVING/INSTALLING THE PRESSURE REGULATOR
6 × 12 mm
4140

Fuel rail Refer to “HIGH-PRESSURE FUEL LINE”
on page 4-8.
(high-pressure fuel line)
1 Hose clamp 1
2 Hose 1 (fuel cooler-to-pressure regulator)
3 Hose 1 (intake manifold-to-pressure regulator)
4 Screw 2
5 Pressure regulator 1
6 O-ring 1 1.8 × 8 mm
procedure.
4-18
FUEL IDLE SPEED CONTROL ASSEMBLY E
IDLE SPEED CONTROL ASSEMBLY 4
REMOVING/INSTALLING THE IDLE SPEED CONTROL ASSEMBLY 4
10
6 × 24 mm 3
2
6 6
5 1
9
4
6 × 60 mm 6
8
6 4150

4-3.
1 Hose 1 (idle speed control assembly-to-intake
silencer)
2 Bolt 1
3 Washer 1
4 Bolt 2
5 Washer 2
6 Hose clamp 4
4-19
10
6 × 24 mm 3
2
6 6
5 1
9
4
6 × 60 mm 6
8
6 4150

7 Vacuum hose 1 (idle speed control assembly-to-intake
manifold)
8 Hose 1 (idle speed control assembly-to-throttle
body #2)
9 Hose 1 (idle speed control assembly-to-throttle
body #1)
10 Idle speed control assembly 1
procedure.
4-20
DISASSEMBLING/ASSEMBLING THE IDLE SPEED CONTROL ASSEMBLY 4
1 4
4 × 12 mm
5 × 6 mm
5
2
4160

1 Screw 2
2 Pressure sensor 1
3 O-ring 1 1.9 × 14.8 mm
4 Screw 3
5 Idle speed control 1
6 O-ring 1 2 × 29 mm
7 Filter 1
8 Idle speed control body 1
procedure.
4-21
FUEL FUEL RAIL E
FUEL RAIL 4
DISASSEMBLING/ASSEMBLING THE FUEL RAIL 4
5 × 10 mm 4170

Fuel injectors Refer to “FUEL INJECTORS” on page
4-12.
Fuel hoses Refer to “FUEL HOSES” on page 4-14.
Pressure regulator Refer to “PRESSURE REGULATOR” on
page 4-18.
1 Cap 1
2 Screw 2
3 Fuel rail joint 1
4 O-ring 1 2.4 × 12 mm
5 Fuel rail 1
procedure.
4-22
FUEL INTAKE MANIFOLD E
INTAKE MANIFOLD 4
DISASSEMBLING/ASSEMBLING THE INTAKE MANIFOLD 4
4180

Throttle body Refer to “THROTTLE BODY” on page 4-5.
on page 4-8.
Idle speed control assembly Refer to “IDLE SPEED CONTROL
1 Hose 1 (pressure regulator-to-intake manifold-to-
idle speed control assembly)
2 Collar 6
3 Grommet 3
4 Rubber seal 4
5 Intake manifold 1
procedure.
4-23
FUEL THROTTLE POSITION SENSOR E
THROTTLE POSITION SENSOR 4
REMOVING/INSTALLING THE THROTTLE POSITION SENSOR
2 3
4190

1 Throttle position sensor 1
connector
2 Screw 2
3 Throttle position sensor 1
procedure.
4-24
FUEL THROTTLE POSITION SENSOR E
INSTALLING THE THROTTLE

POSITION SENSOR
NOTE:
During installation, make sure the throttle
position sensor is properly adjusted.
Install:
• Throttle position sensor
Refer to “ADJUSTING THE THROTTLE
POSITION SENSOR” on page 3-7.
4-25
FUEL LOW-PRESSURE FUEL LINE E
LOW-PRESSURE FUEL LINE 4
REMOVING/INSTALLING THE LOW-PRESSURE FUEL LINE 4
6 × 28 mm
1
2 5
6 × 28 mm
16
6 × 20 mm 3 6 × 16 mm
4
6 × 35 mm
10
6 8
15
11
14
12
13 9
6 × 16 mm
4200

1 Bolt 2
2 Grommet retaining plate 1
3 Bolt 1
4 Plate 1
5 Bolt 1
6 Clamp plate 1
7 Bolt 1
8 Screw 5
9 Plug cover 1
4-26
6 × 28 mm
1
2 5
6 × 28 mm
16
6 × 20 mm 3 6 × 16 mm
4
6 × 35 mm
10
6 8
15
11
14
12
13 9
6 × 16 mm
4200

10 Bolt 2
11 O-ring 1 3.1 × 29.4 mm
13 Hose 1
15 Fuel hose joint 1
16 Low-pressure fuel line 1
procedure.
4-27
DISASSEMBLING/ASSEMBLING THE LOW-PRESSURE FUEL LINE
1
3
4210

2 Fuel hose 1 (hose joint-to-fuel filter)
3 Fuel filter 1
4 Fuel hose 1 (fuel pump-to-fuel filter)
5 Fuel pump 1
procedure.
4-28
FUEL FUEL FILTER E
FUEL FILTER 4
DISASSEMBLING/ASSEMBLING THE FUEL FILTER
4220

1 Nut 1
2 Fuel filter bracket 1
3 Fuel filter cup 1
4 O-ring 1 2.0 × 32.2 mm Not reusable
5 Fuel filter element 1
6 O-ring 1 1.5 × 13.5 mm Not reusable
7 Float 1
8 Fuel filter cap 1
procedure.
4-29
FUEL FUEL PUMP E
FUEL PUMP 4
DISASSEMBLING/ASSEMBLING THE FUEL PUMP 4
6 × 35 mm
LT
572
2 4
10
11
8
7
6 4230

1 Screw 3
2 Nut 2
3 Fuel pump cover 1
5 Fuel pump body 1
6 Pin 1
7 Plunger 1
8 Spring 1
9 Diaphragm 1
10 Spring 1
11 Fuel pump cover 1
procedure.
4-30
FUEL FUEL PUMP E
CHECKING THE FUEL PUMPS 4
1. Check:
• Diaphragm
• Fuel pump valves
Damage → Replace.
2. Check:
• Fuel pump
Reverse air flow → Replace.
Checking steps
a
NOTE:
Do not overpressurize the fuel pump.
Excessive pressure may cause air to leak
out.
(1) Install the Mity vac onto the fuel pump

b as shown.
Mity vac
YB-35956 / 90890-06756
a (2) Apply the specified pressure with the

Mity vac.
Fuel pump pressure a

50 kPa (0.5 kg/cm2, 7.1 psi)
Fuel pump negative pressure b
30 kPa (0.3 kg/cm2, 4.3 psi)
4240
NOTE:
• Make sure no air comes out of the oppo-
site side of the fuel pump.
• To eliminate any gaps between the fuel
pump valves and the fuel pump body, and
to ensure a better seal, make sure the
inside of the fuel pump is wet (i.e., with
gas).
4-31
POWR E
CHAPTER 5
POWER UNIT
FLYWHEEL MAGNET ASSEMBLY ................................................................ 5-1

REMOVING/INSTALLING THE FLYWHEEL MAGNET ASSEMBLY ...... 5-1
REMOVING THE FLYWHEEL MAGNET ASSEMBLY ............................. 5-2
INSTALLING THE FLYWHEEL MAGNET ASSEMBLY ........................... 5-3
POWER UNIT .................................................................................................. 5-4

DISCONNECTING/CONNECTING THE CONTROL CABLE .................... 5-4
DISCONNECTING/CONNECTING THE LEADS ...................................... 5-6
REMOVING/INSTALLING THE POWER UNIT ........................................ 5-8
STATOR COIL ASSEMBLY ............................................................................ 5-9

REMOVING/INSTALLING THE STATOR COIL ASSEMBLY................... 5-9
TIMING BELT ................................................................................................ 5-10

REMOVING/INSTALLING THE TIMING BELT ...................................... 5-10
REMOVING THE DRIVEN SPROCKET .................................................. 5-12
REMOVING/INSTALLING THE DRIVE SPROCKET............................... 5-12
INSTALLING THE DRIVEN SPROCKET................................................. 5-13
INSTALLING THE TIMING BELT ........................................................... 5-13
IGNITION COILS AND STARTER MOTOR.................................................. 5-14

REMOVING/INSTALLING THE IGNITION COILS AND
STARTER MOTOR................................................................................. 5-14
ECM AND JUNCTION BOX ASSEMBLY..................................................... 5-15

REMOVING/INSTALLING THE CDI UNIT AND
JUNCTION BOX ASSEMBLY ............................................................... 5-15
DISASSEMBLING/ASSEMBLING THE JUNCTION BOX
ASSEMBLY............................................................................................ 5-18
CYLINDER HEAD COVER............................................................................. 5-20

REMOVING/INSTALLING THE CYLINDER HEAD COVER ................... 5-20
CAMSHAFTS ................................................................................................ 5-21

REMOVING/INSTALLING THE CAMSHAFTS....................................... 5-21
CHECKING THE CAMSHAFT................................................................. 5-22
INSTALLING THE CAMSHAFT.............................................................. 5-22
POWR E
CYLINDER HEAD ASSEMBLY ..................................................................... 5-23

REMOVING/INSTALLING THE CYLINDER HEAD ASSEMBLY............ 5-23
CHECKING THE THERMOSTAT ............................................................ 5-25
VALVES......................................................................................................... 5-26
REMOVING/INSTALLING THE VALVES ............................................... 5-26
CHECKING THE VALVE ......................................................................... 5-28
CHECKING THE VALVE SPRING........................................................... 5-29
1
CHECKING THE CYLINDER HEAD ........................................................ 5-29
CHECKING THE VALVE GUIDE ............................................................. 5-29
CHECKING THE VALVE SEAT ............................................................... 5-30
INSTALLING THE VALVE ...................................................................... 5-31
OIL FILTER AND EXHAUST COVER............................................................ 5-32

2
REMOVING/INSTALLING THE OIL FILTER AND EXHAUST COVER .. 5-32
INSTALLING THE OIL FILTER ............................................................... 5-35
CRANKSHAFT AND PISTON/CONNECTING ROD ASSEMBLY................ 5-36

REMOVING/INSTALLING THE CRANKSHAFT AND PISTON/
3
CONNECTING ROD ASSEMBLY.......................................................... 5-36
4
CHECKING THE CYLINDER BLOCK ...................................................... 5-38
CHECKING THE PISTON........................................................................ 5-38
CALCULATING THE PISTON-TO-CYLINDER CLEARANCE................. 5-39
CHECKING THE PISTON RING.............................................................. 5-39
CHECKING THE CRANKSHAFT............................................................. 5-40
CHECKING THE MAIN-BEARING OIL CLEARANCE ............................ 5-40
5
CHECKING THE CONNECTING ROD BIG-END OIL CLEARANCE....... 5-43
INSTALLING THE PISTON RING........................................................... 5-46
INSTALLING THE PISTON..................................................................... 5-47
6
7
8
9
POWR FLYWHEEL MAGNET ASSEMBLY E
FLYWHEEL MAGNET ASSEMBLY 5
REMOVING/INSTALLING THE FLYWHEEL MAGNET ASSEMBLY 5
8 × 20 mm
1
186 Nm (19 m • kgf, 137 ft • Ib)

2
2 5
3 6
3
2 E
7
2
5010

1 Bolt 2
2 Collar 4
3 Grommet 2
4 Flywheel cover 1
5 Flywheel magnet nut 1
6 Washer 1
7 Flywheel magnet assembly 1
8 Woodruff key 1
procedure.
5-1
Å
CAUTION:
The major load should be applied in the
direction of the arrows. If the load is not
applied as shown, the flywheel holder may
easily slip off.
5020
REMOVING THE FLYWHEEL MAGNET
ASSEMBLY 5
ı 1. Remove:
• Flywheel magnet assembly nut
Flywheel magnet assembly

holder
YB-06139 / 90890-06522
Å For USA and Canada

ı For worldwide
5030
Å 2. Remove:
• Flywheel magnet assembly
Universal puller
YB-06117 / 90890-06521

ı For worldwide
5040 CAUTION:
• Keep the nut side flush with the crank-
ı shaft end until the flywheel magnet
assembly comes off the tapered portion
of the crankshaft.
• To prevent damage to the engine or
tools, screw in the universal-puller set-
bolts evenly and completely so that the
universal-puller plate is parallel to the fly-
wheel magnet assembly.
5050
5-2
Å INSTALLING THE FLYWHEEL

MAGNET ASSEMBLY 5
Install:
• Flywheel magnet assembly nut

holder
YB-06139 / 90890-06522
5060
ı For worldwide
ı
Flywheel magnet assembly nut
186 Nm (19.0 m • kgf, 137 ft • lb)
T.
R.
5070
5-3
POWR POWER UNIT E
POWER UNIT 5
DISCONNECTING/CONNECTING THE CONTROL CABLE 4
6 × 30 mm
1
6 × 20 mm 3
4
8
6 × 20 mm
6
9
7
5
10
5080

Battery leads Disconnect the leads form the battery
terminals.
Low-pressure fuel line Refer to “LOW-PRESSURE FUEL LINE”
on page 4-26.
1 Bolt 2
2 Grommet retaining plate 1
3 Bolt 1
4 Hose locating plate 1
5 Clip 2
5-4
POWR POWER UNIT E
6 × 30 mm
1
6 × 20 mm 3
4
8
6 × 20 mm
6
9
7
5
10
5080

6 Bolt 1
7 Cable clamp 1
8 Grommet 1
9 Throttle control cable 1
10 Shift control cable 1
procedure.
5-5
POWR POWER UNIT E
DISCONNECTING/CONNECTING THE LEADS 4
18 19 6 × 10 mm
8
6 7
9 Nm (0.9 m • kgf, 6.5 ft • Ib)

9
4
5
6 × 20 mm
10
16 2
11
17 3 12
6 × 10 mm
20
19
14
13
17 15 5090

1 Junction box cover 1
2 Wire harness coupler 1 For the remote control box.
3 Warning lamp coupler 1
4 Bolt 1
5 Negative battery lead 1
6 Nut 1
7 Washer 2
8 Positive battery lead 1
9 Bolt 1
10 PTT motor lead (sky blue) 1
11 Bolt 1
5-6
POWR POWER UNIT E
18 19 6 × 10 mm
8
6 7
9 Nm (0.9 m • kgf, 6.5 ft • Ib)

9
4
5
6 × 20 mm
10
16 2
11
17 3 12
6 × 10 mm
20
19
14
13
17 15 5090

12 PTT motor lead (light green) 1
14 Flushing water hose 1 (exhaust cover-to-hose joint)
16 Hose clamp 1
17 Pilot water hose 1 (fuel cooler-to-exhaust cover)
18 Hose clamp 1
19 Pilot water hose 1 (fuel cooler-to-water outlet)
20 Oil level dipstick 1
procedure.
5-7
POWR POWER UNIT E
REMOVING/INSTALLING THE POWER UNIT 4
5 5
7
9
3
6 × 16 mm
LT
572
2
42 Nm (4.2 m • kgf, 30 ft • Ib)
5 10 × 130 mm
4 1
6 6 × 40 mm
LT
8 × 35 mm 5100
572

1 Bolt 2
2 Nut 2
3 Bolt 5
4 Apron 1
5 Bolt 6
6 Bolt 2
7 Power unit 1
9 Dowel pin 2
procedure.
5-8
POWR STATOR COIL ASSEMBLY E
STATOR COIL ASSEMBLY 5
REMOVING/INSTALLING THE STATOR COIL ASSEMBLY 4
4 × 8 mm 6 × 28 mm
5
4
6
8
6 × 28 mm
6 × 16 mm 1 5110

Flywheel magnet assembly Refer to “FLYWHEEL MAGNET
1 Stator coil coupler 1
2 Rectifier/regulator connector 1
3 Bolt 1
4 Screw 1
5 Bolt 3
6 Lighting coil assembly 1
7 Pulser coil connector 1
8 Bolt 4
9 Base 1
procedure.
5-9
POWR TIMING BELT E
TIMING BELT 5
REMOVING/INSTALLING THE TIMING BELT 4
5120

Stator coil assembly Refer to “STATOR COIL ASSEMBLY” on
page 5-9.
1 Bolt 2
2 Flywheel cover bracket 1
4 Hose clamp 1
5 Hose 1
6 Driven sprocket bolt 2
7 Washer 2
8 Driven sprocket 2
5-10
POWR TIMING BELT E
5120

9 Pin 2
10 Drive sprocket nut 1
11 Bolt 1
12 Spring 1
13 Timing belt tensioner 1
14 Timing belt 1
15 Drive sprocket 1
16 Pick-up rotor 1
17 Woodruff key 1
procedure.
5-11
POWR TIMING BELT E
Å ı REMOVING THE DRIVEN SPROCKET 5
CAUTION:
Make sure cylinder #1’s position is at TDC
before removal.
Remove:
• Bolt
5130

holder
YB-06139 / 90890-06522

ı For worldwide
REMOVING/INSTALLING THE DRIVE

SPROCKET 5
1. Remove:
• Nut
Crankshaft holder
YB-06552 / 90890-06552
5140
NOTE:
A deep socket ( : 46 mm, 76 mm deep) is
required for this service.
4
2. Install:
3 • Woodruff key 1
• Pick-up rotor 2
• Drive sprocket 3
• Drive sprocket nut 4
Drive sprocket nut

265 Nm (27.0 m • kgf, 192 ft • lb)
T.
R.
2 Crankshaft holder
YB-06552 / 90890-06552
1
5150
5-12
POWR TIMING BELT E
Å ı
INSTALLING THE DRIVEN SPROCKET 5
Install:
• Driven sprocket bolt
Driven sprocket bolt

60 Nm (6.0 m • kgf, 43 ft • lb)
T.
R.
5160
holder
YB-06139 / 90890-06522

ı For worldwide
INSTALLING THE TIMING BELT 5
CAUTION:
• Never forcefully twist, turn inside out, or
bend the timing belt.
• Do not let oil or grease get onto the tim-
ing belt.
A • A Minimum 25 mm (1.0 in)
5170
Install:
• Timing belt
• Tensioner
Installation steps
(1) Align ø6 hole on the pickup rotor with
the notch in the cylinder block.
(2) Align the marks “ ” on the driven
sprockets with the top edge of the cyl-
inder head.
(3) Install the timing belt onto the driven
sprockets and drive sprocket.
(4) Install the tensioner.
Tensioner bolt
40 Nm (4.0 m • kgf, 29 ft • lb)
T.
R.
(5) Turn the crankshaft clockwise two

times and make sure the drive
sprocket and driven sprockets are cor-
5180 rectly aligned with the marks.
5-13
POWR IGNITION COILS AND STARTER MOTOR E
IGNITION COILS AND STARTER MOTOR 5
REMOVING/INSTALLING THE IGNITION COILS AND STARTER MOTOR 4
25 Nm (2.5 m • kgf, 18 ft • Ib)
10
6 5
Br/W
9
4
8 × 45 mm
8
R
7
1 6 × 30 mm
2
6 × 30 mm
3
1
5190

1 Ignition coil coupler 2
2 Bolt 4
3 Ignition coil 2
4 Spark plug 4
5 Screw 1
6 Relay (magnetic switch) lead 1
7 Nut 1
8 Wire harness lead 2
9 Bolt 3
10 Starter motor 1
procedure.
5-14
POWR ECM AND JUNCTION BOX ASSEMBLY E
ECM AND JUNCTION BOX ASSEMBLY 5
REMOVING/INSTALLING THE CDI UNIT AND JUNCTION BOX ASSEMBLY 4
B 21
19 22
6 × 12 mm 28
15 20
26
B 27 23
14
16
A
25
8
4 24
6 × 16 mm
A
9 5
4
2
6 × 28 mm
3
1
11 7
13
17 6
6 × 28 mm 10
6 × 25 mm
5200 6 × 16 mm 12
18 6 × 16 mm

1 ECM coupler 2
2 Bolt 4
3 ECM 1
4 Collar 8
5 Grommet 1
6 Bolt 2
7 Rectifier/regulator 1
8 Bolt 1
9 Ground lead 2
10 Bolt 1
11 Ground lead 3
5-15
B 21
19 22
6 × 12 mm 28
15 20
26
B 27 23
14
16
A
25
8
4 24
6 × 16 mm
A
9 5
4
2
6 × 28 mm
3
1
11 7
13
17 6
6 × 28 mm 10
6 × 25 mm
5200 6 × 16 mm 12
18 6 × 16 mm

12 Bolt 1
13 Ground lead 2
14 Water temperature sensor 1
coupler
15 Bolt 2
16 Clamp 2
17 Bolt 5
18 Junction box assembly 1
19 Throttle position sensor coupler 1
20 Intake air pressure sensor 1
coupler
5-16
B 21
19 22
6 × 12 mm 28
15 20
26
B 27 23
14
16
A
25
8
4 24
6 × 16 mm
A
9 5
4
2
6 × 28 mm
3
1
11 7
13
17 6
6 × 28 mm 10
6 × 25 mm
5200 6 × 16 mm 12
18 6 × 16 mm

21 Idle speed control valve coupler 1
22 Fuel injectors coupler 4
23 High-pressure fuel pump coupler 1
24 Shift position switch coupler 1
27 Connector 1
28 Oil pressure switch coupler 1
procedure.
5-17
DISASSEMBLING/ASSEMBLING THE JUNCTION BOX ASSEMBLY 4
16
17
3
15
12 2
14
8 13
7
9 5
18 10
11
5210
6 6 × 14 mm

1 Screw 1
2 Main relay coupler 1
3 Main relay 1
4 Bolt 2
5 PTT relay coupler 1
6 PTT relay 1
7 Screw 1
8 Plate 1
9 Screw 1
5-18
16
17
3
15
12 2
14
8 13
7
9 5
18 10
11
5210
6 6 × 14 mm

10 Positive battery lead 1
11 Starter relay coupler 1
12 Starter relay 1
13 Screw 1
14 Diagnostic coupler 1
15 Fuse holder 4
16 Clip 1
17 Wire harness 1
18 Junction box 1
procedure.
5-19
POWR CYLINDER HEAD COVER E
CYLINDER HEAD COVER 5
REMOVING/INSTALLING THE CYLINDER HEAD COVER 4
17 Nm (1.7 m • kgf, 12 ft • Ib)

7 × 48 mm
2 Nm (0.2 m • kgf, 1.4 ft • Ib)
4 × 8 mm
S1280B
LT 5
572
1 6 8
7 M
4
3
1st 8 Nm (0.8 m • kgf, 5.8 ft • Ib)

2 2nd 8 Nm (0.8 m • kgf, 5.8 ft • Ib)
6 × 30 mm 5220

Timing belt and driven sprockets Refer to “TIMING BELT” on page 5-10.
1 Oil filler cap 1
2 Bolt 14
3 Cylinder head cover 1
4 Rubber gasket 1
5 Screw 8
6 Breather cover 1
7 Bolt 2
8 Fuel pump bracket assembly 1
procedure.
5-20
POWR CAMSHAFTS E
CAMSHAFTS 5
REMOVING/INSTALLING THE CAMSHAFTS 4
1st 8 Nm (0.8 m • kgf, 5.8 ft • Ib) 4

2nd 17 Nm (1.7 m • kgf, 12 ft • Ib)
7 × 48 mm
5
E
3
2 3
E 4
Å 0 9 9 0
4 8
7 7
M
4 8 1
E 6 2
E 5 5
1
6 2 6
E
7 × 37 mm 1 4
1st 8 Nm (0.8 m • kgf, 5.8 ft • Ib)
3 3
2nd 17 Nm (1.7 m • kgf, 12 ft • Ib)
4
5230

Cylinder head cover Refer to “CYLINDER HEAD COVER” on
page 5-20.
1 Bolt 16
2 Bolt 4
3 Camshaft cap 2
4 Camshaft cap 8
5 Oil seal 2
6 Camshaft 2
procedure.
5-21
POWR CAMSHAFTS E
CHECKING THE CAMSHAFT 5
1. Measure:
• Camshaft lobe dimensions a and b
Out of specification → Replace the
camshaft.
Camshaft lobe dimension

a IN: 37.22 - 37.38 mm
(1.465 - 1.472 in)
b IN: 29.92 - 30.08 mm
(1.178 - 1.184 in)
a EX: 36.90 - 37.06 mm
(1.453 - 1.459 in)
b EX: 29.92 - 30.08 mm
(1.178 - 1.184 in)
5240
2. Measure:
• Camshaft journal diameter a
• Camshaft cap inside diameter b
a Out of specification → Replace the
camshaft or cylinder head.
Camshaft journal diameter

a: 24.96 - 24.98 mm
b (0.9827 - 0.9835 in)
Camshaft cap inside diameter
b: 25.000 - 25.021 mm
b 5250 (0.984 - 0.985 in)
INSTALLING THE CAMSHAFT 5
Install:
6 1
1 • Camshaft
6 1 • Camshaft cap
7 2
7 2
Installation steps
(1) Before installing the exhaust and
intake camshafts, turn the crankshaft
8 3
until cylinder #1’s piston is at TDC on
8 3 the compression stroke.
(2) Install the camshaft caps in the proper
9 4
position as shown and with the
stamped numbers facing upside down.
9 4
10 5
10 5
5260
5-22
POWR CYLINDER HEAD ASSEMBLY E
CYLINDER HEAD ASSEMBLY 5
REMOVING/INSTALLING THE CYLINDER HEAD ASSEMBLY 4
1st 15 Nm (1.5 m • kgf, 11 ft • Ib)

2nd 30 Nm (3.0 m • kgf, 22 ft • Ib)
3rd 90°
70 Nm (7.0 m • kgf, 51 ft • Ib)*
10 × 145 mm 6 6 × 25 mm
8 × 25 mm
5
7
4
8
3
9 0
E
1
5 6 C
E
9 1 B A
11
13
4 3 B
10
12 2
A D
8 7
LT E
572
1st 14 Nm (1.4 m • kgf, 10 ft • Ib)

6 × 20 mm
2nd 28 Nm (2.8 m • kgf, 20 ft • Ib)
8 × 55 mm 5270

Camshafts Refer to “CAMSHAFTS” on page 5-21.
Intake assembly Refer to “INTAKE ASSEMBLY” on
page 4-3.
1 Bolt (1.5 mm thread pitch) 10
2 Bolt 5
3 Cylinder head assembly 1
5 Dowel pin 2
*: Torque value (for reference only)
5-23
1st 15 Nm (1.5 m • kgf, 11 ft • Ib)

2nd 30 Nm (3.0 m • kgf, 22 ft • Ib)
3rd 90°
70 Nm (7.0 m • kgf, 51 ft • Ib)*
10 × 145 mm 6 6 × 25 mm
8 × 25 mm
5
7
4
8
3
9 0
E
1
5 6 C
E
9 1 B A
11
13
4 3 B
10
12 2
A D
8 7
LT E
572
1st 14 Nm (1.4 m • kgf, 10 ft • Ib)

6 × 20 mm
2nd 28 Nm (2.8 m • kgf, 20 ft • Ib)
8 × 55 mm 5270

6 Bolt 2
7 Thermostat cover 1
8 Thermostat 1
9 Bolt 4
10 Anode cover 2
11 O-ring 2
12 Bolt 2
13 Anode 2
procedure.
5-24
CHECKING THE THERMOSTAT 5
1. Check:
a • Thermostat
Damage/valve does not open →
Replace.
2. Measure:
• Valve operating temperature
• Valve lift a
5280
thermostat.
Water temperature Valve lift
Below
0 mm (0 in)
48 - 52˚C (118 - 126˚F)
Above Min. 4.3 mm
60˚C (140˚F) (0.17 in)
Measuring steps
(1) Suspend the thermostat in a container
filled with water.
(2) Slowly heat the water.
(3) Place a thermometer in the water.
(4) While stirring the water, observe the
thermometer’s indicated temperature.
5-25
POWR VALVES E
VALVES 5
REMOVING/INSTALLING THE VALVES 4
6 7 8
3 4 5 E
1 2
10
7
E
6
E
4
3
2
1 5290

Camshaft and cylinder head Refer to “CAMSHAFTS” on page 5-21
assembly and “CYLINDER HEAD ASSEMBLY” on
page 5-23.
1 Valve pad 16
2 Valve lifter 16
3 Valve cotter 32
4 Spring retainer 16
5 Valve spring 16
5-26
POWR VALVES E
6 7 8
3 4 5 E
1 2
10
7
E
6
E
4
3
2
1 5290

6 Valve stem seal 16
7 Spring seat 16
8 Valve guide 16
9 Intake valve 8
10 Exhaust valve 8
procedure.
5-27
POWR VALVES E
CHECKING THE VALVE 5
a 1. Check:
• Valve
Damage/warpage → Replace.
2. Measure:
• Margin thickness a
Out of specification → Replace.
5300 Margin thickness

IN: 0.8 - 1.2 mm
(0.031 - 0.047 in)
EX: 1.0 - 1.4 mm
(0.039 - 0.055 in)
3. Measure:
• Valve stem diameter a
a Out of specification → Replace.
Valve stem diameter

IN: 5.975 - 5.990 mm
(0.2352 - 0.2358 in)
EX: 5.960 - 5.975 mm
(0.2346 - 0.2352 in)
5310
4. Measure:
• Valve stem runout
Valve stem runout limit

IN and EX
0.01 mm (0.0004 in)
5320 NOTE:
The valve guide, valve seal, and valve
should be replaced as a set.
5-28
POWR VALVES E
CHECKING THE VALVE SPRING 5
1. Measure:
• Free length a
Free length limit

52.25 mm (2.057 in)
5330
2. Measure:
• Valve spring tilt a
Valve spring tilt limit

IN and EX
2.6 mm (0.10 in)
5340
CHECKING THE CYLINDER HEAD 5
Measure:
• Cylinder head warpage
Out of specification → Reface or
replace.
Warpage limit
0.1 mm (0.004 in)
5350
CHECKING THE VALVE GUIDE 5
Measure:
• Valve guide bore a
a
guide.
Valve guide bore

6.000 - 6.018 mm
5360
(0.2362 - 0.2369 in)
Replacement steps
(1) Remove the valve guide with the valve
guide remover/installer.
Valve guide remover

YM-4064-A / 90890-04064
5370
5-29
POWR VALVES E
(2) Install the new valve guide to the spec-

ified position (from the top of the valve
guide bore as shown) a with the valve
guide remover/installer.
Valve guide position

11.5 mm (0.45 in)
(3) After installing the valve guide, bore

5380 the valve guide with the valve guide
reamer.
Valve guide reamer

YM-04066 / 90890-04066
NOTE:
• Heat the cylinder head in an oven to 200˚C
(392˚F) to ease valve guide removal and
installation, and to maintain the correct
5390 interference fit.
• Before installing the valve guide, mark its
installation position b as shown.
CHECKING THE VALVE SEAT 5
1. Measure:
• Valve seat width a
Out of specification → Reface the
valve seat.
a
Valve seat width
Intake
1.2 - 1.6 mm
(0.047 - 0.063 in)
Exhaust
5400 1.2 - 1.6 mm
(0.047 - 0.063 in)
2. Reface:
• Valve seat
CAUTION:
To prevent chatter marks, turn the valve
seat cutter while an even, downward pres-
sure (4 - 5 kg).
5-30
POWR VALVES E
Valve seat cutter set

YM-91043-C / 90890-06803
Valve seat cutter holder
YB-06553 / 90890-06553
Valve seat cutter
(45˚) YB-06555 / 90890-06555
(90˚) YB-06556 / 90890-06556
A B
• Refer to the following chart to deter-
5410
mine the appropriate valve seat cutter.
Valve seat area Valve seat cutter
A 90˚
B 45˚
NOTE:
After refacing the valve seat or replacing
the valve and valve guide, lap the valve seat
and valve face.
INSTALLING THE VALVE 5
1. Install:
• Valve stem seal 1
• Valve 2
• Spring seat 3
• Valve spring 4
• Spring retainer 5
2. Install:
• Valve cotter 6
Valve spring compressor

YM-01253 / 90890-04019
Valve spring compressor adapter
YB-06554 / 90890-06554
NOTE:
Compress the valve spring with the special
tools and install the cotters onto the valve.
5420
5-31
POWR OIL FILTER AND EXHAUST COVER E
OIL FILTER AND EXHAUST COVER 5
REMOVING/INSTALLING THE OIL FILTER AND EXHAUST COVER 4
B C
H
7 8
14 × 12 mm
F
22
23 3 4
D
1
5
2
4 6 E 5
G
24
25
A 9
0
17 19
18
21 17
20 11 6 × 20 mm
10
2
14 7
1 16
13
E 9 8
A
18 Nm (1.8 m • kgf, 13 ft • Ib) 6
6 × 16 mm
1st 6 Nm (0.6 m • kgf, 4.3 ft • Ib)
3 12 8 × 25 mm
2nd 12 Nm (1.2 m • kgf, 8.7 ft • Ib) 15
5430
6 × 30 mm LT
6 × 20 mm
572
572

Camshafts and cylinder head Refer to “CAMSHAFTS” on page 5-21
assembly and “CYLINDER HEAD ASSEMBLY” on
page 5-23.
1 Oil filter 1
2 Oil filter stand 1
3 Bolt 18
4 Exhaust cover 1
6 Bolt 3
7 Pressure control valve (PCV) 1
cover
5-32
B C
H
7 8
14 × 12 mm
F
22
23 3 4
D
1
5
2
4 6 E 5
G
24
25
A 9
0
17 19
18
21 17
20 11 6 × 20 mm
10
2
14 7
1 16
13
E 9 8
A
18 Nm (1.8 m • kgf, 13 ft • Ib) 6
6 × 16 mm
1st 6 Nm (0.6 m • kgf, 4.3 ft • Ib)
3 12 8 × 25 mm
2nd 12 Nm (1.2 m • kgf, 8.7 ft • Ib) 15
5430
6 × 30 mm LT
6 × 20 mm
572
572

8 Spring 1
9 Pressure control valve (PCV) 1 Face the longer side towards the cylinder
block.
10 Grommet 1
12 Bolt 2
13 Anode cover 1
14 O-ring 1
15 Bolt 1
16 Anode 1
5-33
B C
H
7 8
14 × 12 mm
F
22
23 3 4
D
1
5
2
4 6 E 5
G
24
25
A 9
0
17 19
18
21 17
20 11 6 × 20 mm
10
2
14 7
1 16
13
E 9 8
A
18 Nm (1.8 m • kgf, 13 ft • Ib) 6
6 × 16 mm
1st 6 Nm (0.6 m • kgf, 4.3 ft • Ib)
3 12 8 × 25 mm
2nd 12 Nm (1.2 m • kgf, 8.7 ft • Ib) 15
5430
6 × 30 mm LT
6 × 20 mm
572
572

17 Bolt 2
18 Metal clamp 1
19 Engine temperature sensor 1
retainer
20 Engine temperature sensor 1
22 Drain plug 1
23 Washer 1
24 Screw 3
25 Anode 3
procedure.
5-34
INSTALLING THE OIL FILTER 5
Install:
• Oil filter
Oil filter
18 Nm (1.8 m • kgf, 13 ft • lb)
T.
R.
Oil filter wrench
5440
YU-38411 / 90890-01426
Refer to “REPLACING THE ENGINE

OIL/OIL FILTER” on page 3-11.
5-35
CRANKSHAFT AND PISTON/
POWR CONNECTING ROD ASSEMBLY E
CRANKSHAFT AND PISTON/CONNECTING ROD ASSEMBLY 5
REMOVING/INSTALLING THE CRANKSHAFT AND PISTON/CONNECTING ROD

ASSEMBLY 4
8 Nm (0.8 m • kgf, 5.8 ft • Ib)

1st 19 Nm (1.9 m • kgf, 14 ft • Ib)
2nd 60°
50 Nm (5.0 m • kgf, 36 ft • Ib)*
10 × 135 mm GM GM
6 × 25 mm
1
2
3 4
14
6 E
16 E
10
E 12
E 7
11 13
5 11
E 9
11 8
E
1st 14 Nm (1.4 m • kgf, 10 ft • Ib) 11
2nd 28 Nm (2.8 m • kgf, 20 ft • Ib) 15
11 a
8 × 55 mm E
1st 15 Nm (1.5 m • kgf, 11 ft • Ib)

2nd 60°
5450
8 × 38 mm

Oil filter and exhaust cover Refer to “OIL FILTER AND EXHAUST
COVER” on page 5-32.
1 Bolt 4
2 Washer 2
3 Bracket 2
4 Oil pressure switch 1
5 Bolt 10
6 Bolt (1.5 mm thread pitch) 10
7 Crankcase 1
*: Torque value (for reference only)
5-36
8 Nm (0.8 m • kgf, 5.8 ft • Ib)

1st 19 Nm (1.9 m • kgf, 14 ft • Ib)
2nd 60°
50 Nm (5.0 m • kgf, 36 ft • Ib)*
10 × 135 mm GM GM
6 × 25 mm
1
2
3 4
14
6 E
16 E
10
E 12
E 7
11 13
5 11
E 9
11 8
E
1st 14 Nm (1.4 m • kgf, 10 ft • Ib) 11
2nd 28 Nm (2.8 m • kgf, 20 ft • Ib) 15
11 a
8 × 55 mm E
1st 15 Nm (1.5 m • kgf, 11 ft • Ib)

2nd 60°
5450
8 × 38 mm

8 Connecting rod bolt 8 Not reusable
9 Connecting rod cap 4
10 Crankshaft 1
11 Main bearing 5
12 Big end bearing 4
13 Piston/connecting rod assembly 4
14 Oil seal 1
15 Oil seal 1
16 Cylinder block 1
procedure.
5-37
CHECKING THE CYLINDER BLOCK 5
Measure:
• Cylinder bore
D Out of specification → Rebore the cyl-
inder or replace the cylinder block.
D1
D2
Wear
Standard
limit
Cylinder 79.000 - 79.020 mm
—
bore “D” (3.110 - 3.111 in)
20 mm (0.8 in)
70 mm (2.8 in)
D1 and D2 Taper limit 0.08 mm

—
“T” (0.003 in)
120 mm (4.7 in)
Out of 0.05 mm
D3 and D4 —
round limit (0.002 in)
D = Maximum Dia. (D1 - D6)
D5 and D6 T = (maximum D1 or D2) – (minimum D5
or D6)
5460
NOTE:
Measure the cylinder bore in parallel and at
a right angle to the crankshaft. Then, aver-
age the measurements.
CHECKING THE PISTON 5
Measure:
a • Piston diameter
Out of specification → Replace the pis-
ton.
Distance
Piston diameter
a
5470
13 mm 78.928 - 78.949 mm
Standard
(0.51 in) (3.1074 - 3.1082 in)
Oversize piston diameter

Oversize 1: + 0.25 mm (0.001 in)
5-38
CALCULATING THE PISTON-TO-

CYLINDER CLEARANCE 5
Calculate:
• Piston-to-cylinder clearance
ton and piston rings, the cylinder
block or both.
Piston-to-
Cylinder Piston
cylinder = –
bore diameter
clearance
Piston-to-cylinder clearance
0.070 - 0.080 mm
(0.0028 - 0.0031 in)
CHECKING THE PISTON RING 5
1. Measure:
• End gap a
ton rings as a set.
End gap (installed)

Top ring
5480
0.15 - 0.30 mm
(0.006 - 0.012 in)
2nd ring
0.70 - 0.90 mm
(0.028 - 0.035 in)
Oil ring
0.20 - 0.70 mm
(0.008 - 0.028 in)
NOTE:
Push the piston ring into the cylinder with
the piston crown.
5-39
2. Measure:
• Side clearance a
ton and piston rings as a set.
Side clearance
Top ring
0.04 - 0.08 mm
(0.002 - 0.003 in)
5490 2nd ring
0.03 - 0.07 mm
(0.001 - 0.003 in)
Oil ring
0.03 - 0.15 mm
(0.001 - 0.006 in)
CHECKING THE CRANKSHAFT 5
Measure:
• Crankshaft journal diameter
• Crank pin diameter
• Crankshaft runout
crankshaft.
5500 Crankshaft journal diameter limit

47.972 mm (1.8887 in)
Crankshaft runout limit
0.03 mm (0.001 in)
CHECKING THE MAIN-BEARING OIL

CLEARANCE 5
1. Measure:
• Main-bearing oil clearance
upper and lower bearings as a set.
Main-bearing oil clearance

0.024 - 0.044 mm
(0.0009 - 0.0017 in)
NOTE:
Measure the main-bearing oil clearance at
room temperature (20 ˚C (68 ˚F)).
5-40
Measuring steps
3
CAUTION:
Install the bearings in their original posi-
2 tions. Incorrect oil clearance measurements
can lead to engine damage.
1 (1) Clean the bearings, main journals, and

5510
bearing portions of the crankcase and
cylinder block.
(2) Place the cylinder block upside down
on a bench.
(3) Install half of the bearings 1 and the
crankshaft 2 into the cylinder block 3.
(4) Put a piece of Plastigauge on each
main journal in parallel to the crank-
shaft.
NOTE:
5520 Do not put the Plastigauge over the oil
hole in the main journal of the crankshaft.
9 0 (5) Install the other half of the bearings

into the crankcase.
I J (6) Install the crankcase onto the cylinder
block.
(7) Apply engine oil on to the threads and
5 6 F seat of the crankcase bolts.
E (8) Tighten the bolts to the specified
torque in two steps in the order shown
in the illustration.
A 2 B
K 1 L NOTE:
Do not move the crankshaft until the main-
D bearing oil clearance measurement has
3 C
4 been completed.
H G Bolt (M8)
1st: 14 Nm (1.4 m • kgf, 10 ft • lb)
8 7
T.
R.
2nd: 28 Nm (2.8 m • kgf, 20 ft • lb)

5530
Bolt (M10)
1st: 19 Nm (1.9 m • kgf, 14 ft • lb)
2nd: 60˚
50 Nm
(5.0 m • kgf, 36 ft • lb)*
(9) Remove the crankcase.

(10) Measure the width of the compressed
Plastigauge on each main journal.
* Torque valve (for reference only)

5540
5-41
2. Adjust:
• Main-bearing oil clearance
NOTE:
Adjust the main-bearing oil clearance at
room temperature (20˚C (68 ˚F)).
Adjusting steps
CAUTION:
Remove any oil or dust from the cylinder
block and crankcase bearing mounting sur-
faces.
(#1)
NOTE:
(#2)
The cylinder block journal diameters (#1 -
#5) and the crankshaft journal diameters,
(#1 - #5) can be determined by the stamped
(#3) value as described below.
Crankshaft journal diameter = 47.900 +
(stamped value/1000)
(#4) Example: #1 = 92 → 47.992
Cylinder block journal diameter = 54.000 +
(#5)
(stamped value/1000)
Example: #1 = 32 → 54.032
(1) Subtract the crankshaft journal diame-

5550 ters (#1 - #5) from the cylinder block
journal diameters (#1 - #5).
(2) Select the suitable bearing from the
table below according to the calcu-
#1
lated values.
#2
Crankshaft bearing selection table
#3 (20 ˚C (68 ˚F))
Cylinder block
#4 Bearing Bearing
journal diameters –
(cylinder side)/ (crankcase
crankshaft journal
#5 thrust bearing side)
diameters (mm)
5560
6.023 - 6.026 Green Yellow*
6.027 - 6.034 Blue Green*
6.035 - 6.042 Blue Blue
6.043 - 6.049 Red Blue*
6.050 - 6.058 Red Red
5570
5-42
CAUTION:
The (*) mark indicates that the color of the
upper and lower bearings are different.
Install the main-bearings in the middle of
the cylinder block and crankcase journal so
they do not block the oil holes.
NOTE:
Crankshaft bearing #3 is a thrust bearing.
(3) If the difference between the cylinder

block journal diameter and crankshaft
journal diameter is more than the max-
imum value (6.058 mm), replace the
crankshaft, cylinder block, or both.
CHECKING THE CONNECTING ROD

BIG-END OIL CLEARANCE 5
CAUTION:
• Mark the original connecting rod bolts so
they are not confused with the new bolts.
• Do not reuse the original connecting rod
bolts during assembly, only use them
when measuring and adjusting the oil
clearance.
• Before assembly, remove any small metal
particles from the big- end mating surface
and also thoroughly clean it.
1. Measure:
• Big-end oil clearance
upper and lower bearings as a set.
Big-end oil clearance

0.025 - 0.031 mm
(0.0010 - 0.0012 in)
NOTE:
Measure the big-end oil clearance at room
temperature (20 ˚C (68 ˚F)).
5-43
Measuring steps
CAUTION:
Install the bearings in their original posi-
tions. Incorrect oil clearance measurements
can lead to engine damage.
(1) Clean the bearings and bearing por-

5580
tions of the connecting rod.
(2) Install the upper half of the bearing
into the connecting rod and the lower
half into the connecting rod cap.
(3) Put a piece of Plastigauge onto the
crank pin in parallel to the crankshaft.
(4) Assemble the connecting rod onto the
crank pin.
a
NOTE:
• Make sure the projections a and
5590
“YAMAHA” mark on the connecting rod
faces towards the flywheel side.
• Do not move the crankshaft until the big-
end oil clearance measurement has been
completed.
(5) Apply engine oil onto the threads and

seat of the original connecting rod
bolts.
(6) Tighten the original bolts to the speci-
fied torque in two stages.
Bolt
1st: 15 Nm
T.
R.
(1.5 m • kgf, 11 ft • lb)

2nd: 60˚
(7) Remove the connecting rod cap.

(8) Measure the width of the compressed
Plastigauge on each crank pin.
5600
5-44
2. Adjust:
• Big-end oil clearance
NOTE:
Adjust the big-end oil clearance at room
temperature (20 ˚C (68 ˚F)).
Adjusting steps
CAUTION:
Remove any oil or dust from the connect-
ing-rod-bearing mounting surfaces.
(1) Install the connecting rod cap to the

connecting rod.
(2) Tighten the original bolts to the speci-
fied torque in two stages.
Bolt:
1st: 15 Nm (1.5 m • kg, 11 ft • lb)
T.
R.
2nd: 60˚
(3) Measure the connecting rod big end

diameter a.
(4) The crank pin diameters (#1 ~ #4) can
be determined by the stamped value
as described below.
(#1)
NOTE:
Crank pin diameter = 41.900 +
(#2) (stamped value/1,000)
Example: #1 = 92 → 41.992
(#3) (5) Subtract the crank pin diameters (#1 ~

#4) from the connecting rod big end
(#4) diameters (#1 ~ #4).
(6) Select the suitable bearing from the
table below according to the calcu-
lated values.
5-45
Connecting rod bearing selection table

(20 ˚C (68 ˚F))
Connecting rod big
end diameters –
Upper bearing Lower bearing
crank pin diameters
(mm)
3.025 ~ 3.031 Yellow Yellow
3.032 ~ 3.039 Yellow Green*
3.040 ~ 3.046 Green Green
3.047 ~ 3.052 Green Blue*
3.053 ~ 3.058 Blue Blue
3.059 ~ 3.063 Blue Red*
CAUTION:
The (*) mark indicates that the color of the
upper and lower bearings are different.
(7) If the measurement value is more than

the maximum value (3.063 mm),
replace the crankshaft, connecting rod,
or both.
INSTALLING THE PISTON RING 5
45˚ 45˚
#3 #2
UP
CAUTION:
#4 • Do not scratch the piston or break the pis-
ton rings.
#3 #1 #4
• After installing the piston rings, check
#2
#1 that they move smoothly.
5610
Install:
• Oil ring (#3 and #4)
• 2nd ring (#2)
• Top ring (#1)
NOTE:
• Offset the piston-ring end gaps as shown.
• Piston rings should be replaced as a set.
5-46
INSTALLING THE PISTON 5
CAUTION:
Install the piston with the “UP” mark on
the piston crown facing towards the fly-
wheel side.
Install:
5620
• Piston
Piston ring compressor

YU-33294 / 90890-06530
5-47
LOWR E
CHAPTER 6
LOWER UNIT
LOWER UNIT (REGULAR ROTATION MODELS) ......................................... 6-1

REMOVING/INSTALLING THE LOWER UNIT ........................................ 6-1
REMOVING THE PROPELLER ................................................................. 6-3
CHECKING THE PROPELLER................................................................... 6-3
INSTALLING THE PROPELLER................................................................ 6-3
WATER PUMP (REGULAR ROTATION MODELS)........................................ 6-4

REMOVING/INSTALLING THE WATER PUMP....................................... 6-4
CHECKING THE IMPELLER HOUSING ................................................... 6-6
CHECKING THE IMPELLER AND IMPELLER HOUSING CUP................ 6-6
CHECKING THE WOODRUFF KEY .......................................................... 6-6
INSTALLING THE IMPELLER AND IMPELLER HOUSING ..................... 6-6
SHIFT ROD ASSEMBLY (REGULAR ROTATION MODELS) ........................ 6-7

REMOVING/INSTALLING THE SHIFT ROD ASSEMBLY ....................... 6-7
REMOVING THE SHIFT ROD ASSEMBLY .............................................. 6-8
LOWR E
PROPELLER SHAFT HOUSING ASSEMBLY

(REGULAR ROTATION MODELS) ................................................................ 6-9
REMOVING/INSTALLING THE PROPELLER SHAFT HOUSING
ASSEMBLY.............................................................................................. 6-9
1
DISASSEMBLING/ASSEMBLING THE PROPELLER SHAFT
HOUSING .............................................................................................. 6-11
ASSEMBLY............................................................................................ 6-12
REMOVING THE PROPELLER SHAFT HOUSING ASSEMBLY............ 6-13
DISASSEMBLING THE PROPELLER SHAFT HOUSING ...................... 6-13
CHECKING THE REVERSE GEAR.......................................................... 6-14
CHECKING THE BEARING..................................................................... 6-14
CHECKING THE PROPELLER SHAFT HOUSING.................................. 6-14
CHECKING THE DOG CLUTCH ............................................................. 6-15
CHECKING THE PROPELLER SHAFT.................................................... 6-15
2
ASSEMBLING THE PROPELLER SHAFT HOUSING ............................ 6-15
ASSEMBLING THE REVERSE GEAR .................................................... 6-15
INSTALLING THE PROPELLER SHAFT HOUSING ASSEMBLY.......... 6-16
DRIVE SHAFT (REGULAR ROTATION MODELS)....................................... 6-17

3
REMOVING/INSTALLING THE DRIVE SHAFT...................................... 6-17
4
REMOVING THE DRIVE SHAFT ............................................................ 6-19
DISASSEMBLING THE DRIVE SHAFT HOUSING ASSEMBLY ........... 6-19
DISASSEMBLING THE FORWARD GEAR ASSEMBLY ....................... 6-19
CHECKING THE PINION ........................................................................ 6-20
CHECKING THE DRIVE SHAFT.............................................................. 6-20
CHECKING THE DRIVE SHAFT HOUSING ........................................... 6-20
5
CHECKING THE BEARINGS .................................................................. 6-20
ASSEMBLING THE FORWARD GEAR ASSEMBLY ............................. 6-20
ASSEMBLING THE DRIVE SHAFT HOUSING ASSEMBLY ................. 6-21
INSTALLING THE DRIVE SHAFT........................................................... 6-22
6
7
8
9
LOWR E
LOWER CASE ASSEMBLY (REGULAR ROTATION MODELS).................. 6-23

DISASSEMBLING/ASSEMBLING THE LOWER CASE ASSEMBLY .... 6-23
DISASSEMBLING THE LOWER CASE ASSEMBLY ............................. 6-24
CHECKING THE DRIVE SHAFT SLEEVE ............................................... 6-24
CHECKING THE NEEDLE BEARING...................................................... 6-24
ASSEMBLING THE LOWER CASE ASSEMBLY ................................... 6-24
LOWER UNIT (COUNTER ROTATION MODELS)....................................... 6-26

REMOVING/INSTALLING THE LOWER UNIT ...................................... 6-26
REMOVING THE PROPELLER ............................................................... 6-28
CHECKING THE PROPELLER................................................................. 6-28
INSTALLING THE PROPELLER.............................................................. 6-28
WATER PUMP (COUNTER ROTATION MODELS) ..................................... 6-29

REMOVING/INSTALLING THE WATER PUMP..................................... 6-29
CHECKING THE IMPELLER HOUSING ................................................. 6-31
CHECKING THE IMPELLER AND IMPELLER HOUSING CUP.............. 6-31
CHECKING THE WOODRUFF KEY ........................................................ 6-31
INSTALLING THE IMPELLER AND IMPELLER HOUSING ................... 6-31
SHIFT ROD ASSEMBLY (COUNTER ROTATION MODELS)...................... 6-32

REMOVING/INSTALLING THE SHIFT ROD ASSEMBLY ..................... 6-32
REMOVING THE SHIFT ROD ASSEMBLY ............................................ 6-33
LOWR E

(COUNTER ROTATION MODELS).............................................................. 6-34
REMOVING/INSTALLING THE PROPELLER SHAFT HOUSING
ASSEMBLY............................................................................................ 6-34
HOUSING ASSEMBLY.......................................................................... 6-36
DISASSEMBLING/ASSEMBLING THE PROPELLER
SHAFT ASSEMBLY ............................................................................... 6-38
REMOVING THE PROPELLER SHAFT HOUSING ASSEMBLY............ 6-39
REMOVING THE PROPELLER SHAFT ASSEMBLY.............................. 6-39
DISASSEMBLING THE PROPELLER SHAFT HOUSING
ASSEMBLY............................................................................................ 6-40
DISASSEMBLING THE FORWARD GEAR ASSEMBLY ....................... 6-40
CHECKING THE FORWARD GEAR........................................................ 6-41
CHECKING THE BEARING..................................................................... 6-41
CHECKING THE PROPELLER SHAFT HOUSING.................................. 6-41
CHECKING THE DOG CLUTCH ............................................................. 6-41
CHECKING THE PROPELLER SHAFT.................................................... 6-41
ASSEMBLING THE PROPELLER SHAFT HOUSING ASSEMBLY ....... 6-42
INSTALLING THE PROPELLER SHAFT ASSEMBLY ............................ 6-43
INSTALLING THE PROPELLER SHAFT HOUSING ASSEMBLY.......... 6-44
LOWR E
DRIVE SHAFT (COUNTER ROTATION MODELS) ...................................... 6-45

REMOVING/INSTALLING THE DRIVE SHAFT...................................... 6-45
REMOVING THE DRIVE SHAFT ............................................................ 6-47
DISASSEMBLING THE DRIVE SHAFT HOUSING ASSEMBLY ........... 6-47
DISASSEMBLING THE REVERSE GEAR .............................................. 6-47
CHECKING THE PINION ........................................................................ 6-47
CHECKING THE DRIVE SHAFT.............................................................. 6-47
CHECKING THE DRIVE SHAFT HOUSING ........................................... 6-48
CHECKING THE BEARINGS .................................................................. 6-48
ASSEMBLING THE REVERSE GEAR ASSEMBLY................................ 6-48
ASSEMBLING THE DRIVE SHAFT HOUSING ASSEMBLY ................. 6-48
INSTALLING THE DRIVE SHAFT........................................................... 6-49
LOWER CASE ASSEMBLY (COUNTER ROTATION MODELS) ................. 6-50

DISASSEMBLING/ASSEMBLING THE LOWER CASE ASSEMBLY .... 6-50
DISASSEMBLING THE LOWER CASE ASSEMBLY ............................. 6-51
CHECKING THE DRIVE SHAFT SLEEVE ............................................... 6-51
CHECKING THE NEEDLE BEARING...................................................... 6-51
ASSEMBLING THE LOWER CASE ASSEMBLY ................................... 6-52
SHIMMING (REGULAR ROTATION MODELS)

(FOR USA AND CANADA) .......................................................................... 6-53
SELECTING THE PINION SHIMS .......................................................... 6-54
SELECTING THE FORWARD GEAR SHIMS ......................................... 6-56
SELECTING THE REVERSE GEAR SHIMS............................................ 6-58
SHIMMING (REGULAR ROTATION MODELS) (FOR WORLDWIDE) ........ 6-60

SELECTING THE REVERSE GEAR SHIM .............................................. 6-64
LOWR E
BACKLASH (REGULAR ROTATION MODELS) ........................................... 6-66

MEASURING THE FORWARD GEAR BACKLASH ............................... 6-66
MEASURING THE REVERSE GEAR BACKLASH.................................. 6-67
SHIMMING (COUNTER ROTATION MODELS)

(FOR USA AND CANADA) .......................................................................... 6-70
SELECTING THE PROPELLER SHAFT SHIMS...................................... 6-76
SHIMMING (COUNTER ROTATION MODELS) (FOR WORLDWIDE)........ 6-77

SELECTING THE PROPELLER SHAFT SHIMS...................................... 6-83
BACKLASH (COUNTER ROTATION MODELS) .......................................... 6-84

MEASURING THE FORWARD GEAR BACKLASH ............................... 6-84
MEASURING THE REVERSE GEAR BACKLASH.................................. 6-85
LOWR LOWER UNIT (REGULAR ROTATION MODELS) E
LOWER UNIT (REGULAR ROTATION MODELS) 6
REMOVING/INSTALLING THE LOWER UNIT 6
8
43 Nm (4.3 m • kgf, 31 ft • Ib)
9 10 × 45 mm : 12 mm
13
55 Nm (5.5 m • kgf, 40 ft • Ib)
1
2
3
4
5
14
6
A
10
LT
LT
572 11
12 572
37 Nm (3.7 m • kgf, 27 ft • Ib) 37 Nm (3.7 m • kgf, 27 ft • Ib)

6010
10 × 45 mm 10 × 70 mm

1 Speedometer hose 1
2 Cotter pin 1
3 Propeller nut 1
4 Washer 1
5 Washer 1
6 Propeller 1
7 Spacer 1
6-1
8
43 Nm (4.3 m • kgf, 31 ft • Ib)
9 10 × 45 mm : 12 mm
13
55 Nm (5.5 m • kgf, 40 ft • Ib)
1
2
3
4
5
14
6
A
10
LT
LT
572 11
12 572
37 Nm (3.7 m • kgf, 27 ft • Ib) 37 Nm (3.7 m • kgf, 27 ft • Ib)

6010
10 × 45 mm 10 × 70 mm

8 Grommet 1
9 Bolt 1
10 Trim tab 1
11 Bolt 1 (with washer)
13 Dowel pin 2
14 Lower unit 1
procedure.
6-2
REMOVING THE PROPELLER 6
Remove:
• Propeller
WARNING
Do not hold the propeller with your hands
when removing or installing it. Be sure to
remove the battery leads from the batteries
6020
and the engine stop lanyard from the
engine stop lanyard switch. Put a block of
wood between the cavitation plate and pro-
peller to keep the propeller from turning.
CHECKING THE PROPELLER 6
Check:
• Blades
• Splines
Cracks/damage/wear → Replace.
INSTALLING THE PROPELLER 6
Install:
• Propeller
WARNING
6030
NOTE:
If the groove in the propeller nut is not
aligned with the cotter pin hole, tighten the
nut further until they are aligned.
6-3
LOWR WATER PUMP (REGULAR ROTATION MODELS) E
WATER PUMP (REGULAR ROTATION MODELS) 6
REMOVING/INSTALLING THE WATER PUMP 6
18 Nm (1.8 m • kgf, 13 ft • Ib)

8 × 45 mm
1
6
7
LT 2
572
572
4
4
GM 3
5 13
8
9
10 11
A 12
14
15
16
6040

Lower unit Refer to “LOWER UNIT (REGULAR
ROTATION MODELS)” on page 6-1.
1 Bolt 4
2 Impeller housing 1
3 Impeller housing cup 1
4 O-ring 1
5 O-ring 1
6 Grommet 1
7 Spacer 1
8 Collar 1
6-4
18 Nm (1.8 m • kgf, 13 ft • Ib)

8 × 45 mm
1
6
7
LT 2
572
572
4
4
GM 3
5 13
8
9
10 11
A 12
14
15
16
6040

9 Spacer 1
10 Washer 2
11 Wave washer 1
12 Impeller 1
13 Woodruff key 1
14 Impeller plate 1
16 Dowel pin 2
procedure.
6-5
CHECKING THE IMPELLER HOUSING 6
Check:
• Impeller housing
Cracks/damage → Replace.
CHECKING THE IMPELLER AND

IMPELLER HOUSING CUP 6
Check:
• Impeller
• Impeller housing cup
Cracks/damage → Replace any defec-
tive parts.
CHECKING THE WOODRUFF KEY 6
Check:
• Woodruff key
Damage/wear → Replace.
INSTALLING THE IMPELLER AND

IMPELLER HOUSING 6
1. Install:
• Washers 1
• Wave washer 2
• Spacer 3
• Collar 4
6050 NOTE:
• The collar and spacer should fit together
firmly.
• While pulling the drive shaft up, install the
collar with some appropriate tool a that
fits over the drive shaft as shown.
2. Install:
• O-ring 1
• Impeller housing cup 2
• Impeller housing 3
• O-ring 4
NOTE:
• When installing the impeller housing cup,
align its projection with the hole in the
impeller housing.
• When installing the water pump housing,
turn the drive shaft clockwise.
6060
6-6
SHIFT ROD ASSEMBLY
LOWR (REGULAR ROTATION MODELS) E
SHIFT ROD ASSEMBLY (REGULAR ROTATION MODELS) 6
REMOVING/INSTALLING THE SHIFT ROD ASSEMBLY 6
1
4
8 Nm (0.8 m • kgf, 5.8 ft • Ib)
6 × 20 mm
3
5 2
6
8
6070

Impeller plate Refer to “WATER PUMP (REGULAR
2 Shift rod assembly 1
3 Oil seal housing 1
4 Oil seal 1
5 O-ring 1
6 Spring 1
7 Shift rod 1
8 Circlip 1
procedure.
6-7
SHIFT ROD ASSEMBLY
REMOVING THE SHIFT ROD

ASSEMBLY 6
Remove:
• Shift rod assembly
NOTE:
Remove the shift rod assembly when the
shift rod is in the neutral position.
6-8

(REGULAR ROTATION MODELS) 6
REMOVING/INSTALLING THE PROPELLER SHAFT HOUSING ASSEMBLY 6
6080

Gear oil Refer to “CHECKING THE GEAR OIL
LEVEL” on page 3-18.
Shift rod assembly Refer to “SHIFT ROD ASSEMBLY
(REGULAR ROTATION MODELS)” on
page 6-7.
1 Ring nut 1
2 Claw washer 1
3 Propeller shaft housing assembly 1
4 Straight key 1
6-9
6080

5 Reverse gear shim *
6 Propeller shaft assembly 1
7 Washer 2
8 Propeller shaft housing 1
procedure.
*: As required
6-10
DISASSEMBLING/ASSEMBLING THE PROPELLER SHAFT HOUSING 6
6090

1 O-ring 1
2 Reverse gear 1
3 Thrust washer 1
4 Ball bearing 1
5 Oil seal 2
6 Needle bearing 1
procedure.
6-11
DISASSEMBLING/ASSEMBLING THE PROPELLER SHAFT ASSEMBLY 6
8 6 1
7 3 10
4 5 9 2
10
6 1
5
7
2
3
9
8
6100

1 Spring 1
2 Pin 1
3 Dog clutch 1
4 Shift rod joint 1
5 Shift rod joint slider 1
6 Ball 2
7 Ball 2
8 Spring 1
9 Ball 2
10 Propeller shaft 1
procedure.
6-12
REMOVING THE PROPELLER SHAFT

HOUSING ASSEMBLY 6
1. Straighten:
• Claw washer tabs
2. Remove:
• Ring nut
• Claw washer
6110 Ring nut wrench ....................... 1

YB-34447 / 90890-06511
Ring nut wrench extension ..... 2
Å 90890-06513
3. Remove:
• Propeller shaft housing assembly
Propeller shaft housing puller . 1

1 2 YB-06207 / 90890-06502
Universal puller......................... 2
6120
YB-06117
Guide plate................................ 3
90890-06501
ı Center bolt ................................ 4
90890-06504

ı For worldwide
6130
Å DISASSEMBLING THE PROPELLER

SHAFT HOUSING 6
1. Remove:
• Reverse gear
Slide hammer............................ 1
YB-06096
Bearing separator ..................... 2
90890-06534
6140
Guide plate................................ 3
90890-06501
ı Guide plate stand ..................... 4
90890-06538
Bearing puller............................ 5
90890-06535
Small universal claws .............. 6
90890-06536

ı For worldwide
6150
6-13
Å 2. Remove:
• Ball bearing
Slide hammer............................ 1
YB-06096
Guide plate................................ 2
90890-06501
Guide plate stand ..................... 3
90890-06538
6160 Bearing puller............................ 4
90890-06535
ı 90890-06536

ı For worldwide
6170
3. Remove:
• Oil seal
• Needle bearing
Bearing/oil seal attachment .... 1

YB-06196 / 90890-06653
Driver rod .................................. 2
YB-06071 / 90890-06652
6180
CHECKING THE REVERSE GEAR 6
Check:
• Teeth
• Dogs
Wear/damage → Replace the reverse
gear.
CHECKING THE BEARING 6
Check:
• Bearing
Pitting/rumbling → Replace.
CHECKING THE PROPELLER SHAFT

HOUSING 6
Check:
• Propeller shaft housing
6-14
CHECKING THE DOG CLUTCH 6
Check:
• Dog clutch
CHECKING THE PROPELLER SHAFT 6
Check:
• Propeller shaft
Å ASSEMBLING THE PROPELLER

SHAFT HOUSING 6
1. Install:
• Needle bearing
Needle bearing installation

position a
24.75 - 25.25 mm
(0.974 - 0.994 in)
6190

ı YB-06196 / 90890-06653
Driver rod .................................. 2
YB-06071 / 90890-06604
Bearing/oil seal depth plate .... 3
90890-06603

ı For worldwide
6200
2. Install:
• Oil seal
2
Oil seal installation position a
4.75 - 5.25 mm (0.187 - 0.207 in)
a 1
YB-06195
Driver rod .................................. 2
6210 YB-06071
ASSEMBLING THE REVERSE GEAR 6
Install:
• Ball bearing
Bearing/oil seal attachment

YB-06200 / 90890-06661
6220
6-15
INSTALLING THE PROPELLER SHAFT

HOUSING ASSEMBLY 6
Install:
• Claw washer
• Ring nut
Ring nut wrench ....................... 1

6230 YB-34447 / 90890-06511
90890-06513
NOTE:
To secure the ring nut, bend one tab into
the slot in the ring nut and the other tabs
toward the propeller shaft housing assem-
bly.
6-16
LOWR DRIVE SHAFT (REGULAR ROTATION MODELS) E
DRIVE SHAFT (REGULAR ROTATION MODELS) 6
REMOVING/INSTALLING THE DRIVE SHAFT 6
6240

Propeller shaft housing assembly Refer to “PROPELLER SHAFT HOUSING
ASSEMBLY (REGULAR ROTATION
MODELS)” on page 6-9.
1 Nut 1
2 Pinion 1
4 Drive shaft housing assembly 1
5 Pinion shim *
6 Thrust bearing 1
7 Drive shaft 1
*: As required
6-17
6240

8 Forward gear assembly 1
9 O-ring 1
10 Oil seal cover 1
11 Oil seal 2
12 Needle bearing 1
13 Drive shaft housing 1
14 Tapered roller bearing 1 Not reusable
15 Needle bearing 1 Not reusable
16 Forward gear 1
procedure.
6-18
REMOVING THE DRIVE SHAFT 6
Loosen:
• Pinion nut
Drive shaft holder ..................... 1

YB-06151 / 90890-06519
Pinion nut holder ...................... 2
90890-06505
Pinion nut holder attachment . 3
6250 90890-06507
DISASSEMBLING THE DRIVE SHAFT

HOUSING ASSEMBLY 6
Remove:
• Needle bearing

YB-06196 / 90890-06610
Driver rod .................................. 2
YB-06071 / 90890-06652
6260
DISASSEMBLING THE FORWARD

GEAR ASSEMBLY 6
1. Remove:
• Tapered roller bearing
Bearing separator
YB-06219 / 90890-06534
6270
CAUTION:
Do not reuse the bearing, always replace it
with a new one.
2. Remove:
• Needle bearing
Slide hammer............................ 1
YB-06096
Guide plate................................ 2
6280 90890-06501
90890-06538
Bearing puller............................ 4
90890-06535
90890-06536
6-19
CHECKING THE PINION 6
Check:
• Teeth
CHECKING THE DRIVE SHAFT 6
Check:
• Drive shaft
CHECKING THE DRIVE SHAFT

HOUSING 6
Check:
• Drive shaft housing
CHECKING THE BEARINGS 6
Check:
• Bearings
ASSEMBLING THE FORWARD GEAR

ASSEMBLY 6
1. Install:
• Needle bearing

position a
2.5 - 3.5 mm (0.098 - 0.138 in)
6290
YB-06200 / 90890-06612
Driver rod .................................. 2
YB-06071 / 90890-06604
6-20
2. Install:

YB-06200 / 90890-06661
6300
Å ASSEMBLING THE DRIVE SHAFT

HOUSING ASSEMBLY 6
1. Install:
• Needle bearing
Position a
5.75 - 6.25 mm (0.226 - 0.246 in)
6310 Bearing/oil seal attachment .... 1

YB-06196 / 90890-06610
Driver rod .................................. 2
ı YB-06071 / 90890-06604
90890-06603

ı For worldwide
6320
2. Install:
• Oil seal

0.25 - 0.75 mm (0.010 - 0.030 in)

YB-06195 / 90890-06633
Driver rod .................................. 2
6330 YB-06071 / 90890-06652
6-21
INSTALLING THE DRIVE SHAFT 6
Tighten:
• Pinion nut

YB-06151 / 90890-06519
90890-06505
6340 90890-06507
Pinion nut
93 Nm (9.3 m • kgf, 67 ft • lb)
T.
R.
6-22
LOWER CASE ASSEMBLY
LOWER CASE ASSEMBLY (REGULAR ROTATION MODELS) 6
DISASSEMBLING/ASSEMBLING THE LOWER CASE ASSEMBLY 6
6350

Forward gear Refer to “DRIVE SHAFT (REGULAR
1 Drive shaft sleeve 1
2 Needle bearing 1
3 Tapered roller bearing outer race 1
4 Forward gear shim *
5 Water seal 1
6 Plate 1
procedure.
*: As required
6-23
LOWER CASE ASSEMBLY
DISASSEMBLING THE LOWER CASE

ASSEMBLY 6
1. Remove:
• Needle bearing

YB-06194 / 90890-06636
Driver rod .................................. 2
YB-06071 / 90890-06605
6360
2. Remove:
• Tapered roller bearing outer race
Slide hammer............................ 1
YB-06096
Bearing puller............................ 2
90890-06523
Large universal claws............... 3
90890-06532
6370
CHECKING THE DRIVE SHAFT SLEEVE 6
Check:
• Drive shaft sleeve
CHECKING THE NEEDLE BEARING 6
Check:
• Needle bearing
ASSEMBLING THE LOWER CASE

ASSEMBLY 6
1. Install:
• Tapered roller bearing outer race

YB-06199 / 90890-06620
Driver rod .................................. 2
YB-06071 / 90890-06605
6380
6-24
LOWER CASE ASSEMBLY
Å 2. Install:
• Needle bearing

position a
168 ± 0.25 mm (6.61 ± 0.01 in)
position b
184.0 mm (7.24 in)
6390

ı YB-06194 / 90890-06636
Driver rod .................................. 2
YB-06071 / 90890-06602
YB-06213 / 90890-06603
YB-34474

ı For worldwide
6400
6-25
LOWR LOWER UNIT (COUNTER ROTATION MODELS) E
LOWER UNIT (COUNTER ROTATION MODELS) 6
REMOVING/INSTALLING THE LOWER UNIT 6
8 43 Nm (4.3 m • kgf, 31 ft • Ib)

9 10 × 45 mm : 12 mm
55 Nm (5.5 m • kgf, 40 ft • Ib)

1
13
2
M
7
3
4
5
14 6
D
10
12 11
LT LT
572 572
37 Nm (3.7 m • kgf, 27 ft • Ib)

37 Nm (3.7 m • kgf, 27 ft • Ib)
10 × 70 mm
10 × 45 mm 6410

1 Speedometer hose 1
2 Cotter pin 1
3 Propeller nut 1
4 Washer 1
5 Washer 1
6 Propeller 1
7 Spacer 1
6-26
8 43 Nm (4.3 m • kgf, 31 ft • Ib)

9 10 × 45 mm : 12 mm
55 Nm (5.5 m • kgf, 40 ft • Ib)

1
13
2
M
7
3
4
5
14 6
D
10
12 11
LT LT
572 572
37 Nm (3.7 m • kgf, 27 ft • Ib)

37 Nm (3.7 m • kgf, 27 ft • Ib)
10 × 70 mm
10 × 45 mm 6410

8 Grommet 1
9 Bolt 1
10 Trim tab 1
13 Dowel pin 2
14 Lower unit 1
procedure.
6-27
REMOVING THE PROPELLER 6
Remove:
• Propeller
WARNING
6420
CHECKING THE PROPELLER 6
Check:
• Blades
• Splines
Cracks/damage/wear → Replace.
INSTALLING THE PROPELLER 6
Install:
• Propeller
WARNING
6430
NOTE:
If the groove in the propeller nut is not
aligned with the cotter pin hole, tighten the
nut further until they are aligned.
6-28
LOWR WATER PUMP (COUNTER ROTATION MODELS) E
WATER PUMP (COUNTER ROTATION MODELS) 6
REMOVING/INSTALLING THE WATER PUMP 6
18 Nm (1.8 m • kgf, 13 ft • Ib)

8 × 45 mm
1
6
7
LT 2
572
572
4
4
GM 3
5 13
8
9
10 11
A 12
14
15
16
6040

Lower unit Refer to “LOWER UNIT (COUNTER
1 Bolt 4
2 Impeller housing 1
3 Impeller housing cup 1
4 O-ring 1
5 O-ring 1
6 Grommet 1
7 Spacer 1
8 Collar 1
6-29
18 Nm (1.8 m • kgf, 13 ft • Ib)

8 × 45 mm
1
6
7
LT 2
572
572
4
4
GM 3
5 13
8
9
10 11
A 12
14
15
16
6040

9 Spacer 1
10 Washer 2
11 Wave washer 1
12 Impeller 1
13 Woodruff key 1
14 Impeller plate 1
16 Dowel pin 2
procedure.
6-30
CHECKING THE IMPELLER HOUSING 6
Check:
• Impeller housing
CHECKING THE IMPELLER AND

IMPELLER HOUSING CUP 6
Check:
• Impeller
• Impeller housing cup
Cracks/damage → Replace any defec-
tive parts.
CHECKING THE WOODRUFF KEY 6
Check:
• Woodruff key
INSTALLING THE IMPELLER AND

IMPELLER HOUSING 6
1. Install:
• Washers 1
• Wave washer 2
• Spacer 3
• Collar 4
6050 NOTE:
• The collar and spacer should fit together
firmly.
• While pulling the drive shaft up, install the
collar with some appropriate tool a that
fits over the drive shaft as shown.
2. Install:
• O-ring 1
• Impeller housing cup 2
• Impeller housing 3
• O-ring 4
NOTE:
• When installing the impeller housing cup,
align its projection with the hole in the
impeller housing.
• When installing the water pump housing,
turn the drive shaft clockwise.
6060
6-31
SHIFT ROD ASSEMBLY
LOWR (COUNTER ROTATION MODELS) E
SHIFT ROD ASSEMBLY (COUNTER ROTATION MODELS) 6
REMOVING/INSTALLING THE SHIFT ROD ASSEMBLY 6
6450

Impeller plate Refer to “WATER PUMP (COUNTER
2 Shift rod assembly 1
3 Oil seal housing 1
4 Oil seal 1
5 O-ring 1 3.1 × 49.4 mm
6 Spring 1
7 Shift rod 1
8 Circlip 1
procedure.
6-32
SHIFT ROD ASSEMBLY
REMOVING THE SHIFT ROD

ASSEMBLY 6
Remove:
• Shift rod assembly
NOTE:
Remove the shift rod assembly when the
shift rod is in the neutral position.
6-33

(COUNTER ROTATION MODELS) 6
REMOVING/INSTALLING THE PROPELLER SHAFT HOUSING ASSEMBLY 6
6460

Gear oil Refer to “CHANGING AND CHECKING
THE GEAR OIL” on page 3-18.
Shift rod assembly Refer to “SHIFT ROD ASSEMBLY
(COUNTER ROTATION MODELS)” on
page 6-32.
1 Ring nut 1
2 Claw washer 1
3 Propeller shaft housing assembly 1
6-34
6460

4 Straight key 1
5 Thrust washer 1
6 Forward gear shim *
procedure.
*: As required
6-35
DISASSEMBLING/ASSEMBLING THE PROPELLER SHAFT HOUSING ASSEMBLY 6
6470

1 O-ring 1
2 Spring 1
3 Pin 1
4 Dog clutch 1
5 Forward gear assembly 1
6 Propeller shaft assembly 1
7 Thrust bearing 1
8 Propeller shaft shim *
*: As required
6-36
6470

9 Oil seal 2
10 Needle bearing 1
12 Forward gear 1
13 Thrust washer 1
14 Tapered roller bearing outer race 1
15 Tapered roller bearing 1 Not reusable
procedure.
6-37
DISASSEMBLING/ASSEMBLING THE PROPELLER SHAFT ASSEMBLY 6
6480

1 Shift rod joint 1
2 Shift rod joint slider 1
3 Ball 4
4 Spring 1
5 Ball 2
6 Propeller shaft 1
procedure.
6-38

HOUSING ASSEMBLY 6
1. Straighten:
• Claw washer tabs
2. Remove:
• Ring nut
• Claw washer
6110 Ring nut wrench ....................... 1

YB-34447 / 90890-06511
90890-06513
3. Remove:
1
2 • Straight key
• Forward gear shim(s)
Slide hammer attachment....... 1
YB-06335 / 90890-06514
Slide hammer............................ 2
YB-06096 / 90890-06531

ASSEMBLY 6
Remove:
• Propeller shaft assembly
• Forward gear assembly

YB-06207 / 90890-06502
6500
YB-06117
Guide plate................................ 2
90890-06501
Center bolt ................................ 3
90890-06504
6-39
DISASSEMBLING THE PROPELLER

SHAFT HOUSING ASSEMBLY 6
Remove:
• Oil seals
• Needle bearing

YB-06196 / 90890-06653
6510
Driver rod .................................. 2
YB-06071 / 90890-06652
DISASSEMBLING THE FORWARD

GEAR ASSEMBLY 6
Remove:
Bearing separator
YB-06219 / 90890-06534
6540
CAUTION:
Do not reuse the bearing, always replace it
with a new one.
6-40
CHECKING THE FORWARD GEAR 6
Check:
• Teeth
• Dogs
CHECKING THE BEARING 6
Check:
• Bearing
CHECKING THE PROPELLER SHAFT

HOUSING 6
Check:
• Propeller shaft housing
CHECKING THE DOG CLUTCH 6
Check:
• Dog clutch
CHECKING THE PROPELLER SHAFT 6
Check:
• Propeller shaft
6-41
Å ASSEMBLING THE PROPELLER

SHAFT HOUSING ASSEMBLY 6
1. Install:
• Needle bearing

position a
24.75 - 25.25 mm
(0.974 - 0.994 in)
6590

ı YB-06196 / 90890-06610
Driver rod .................................. 2
YB-06071 / 90890-06604
90890-06603

ı For worldwide
6600
Å 2. Install:
• Needle bearing
3. Install:
• Oil seal

4.75 - 5.25 mm (0.187 - 0.207 in)
6590
YB-06195 / 90890-06640
ı Å For USA and Canada

ı For worldwide
6600
6-42

ASSEMBLY 6
Install:
• Forward gear assembly
• Propeller shaft assembly
Ring nut wrench

YB-06578 / 90890-06578
6600
6-43

HOUSING ASSEMBLY 6
Install:
• Forward gear shim(s)
• Straight key
• Claw washer
• Ring nut
6230
Ring nut wrench ....................... 1

YB-34447 / 90890-06511
90890-06513
NOTE:
To secure the ring nut, bend one tab into
the slot in the ring nut and the other tabs
toward the propeller shaft housing assem-
bly.
6-44
LOWR DRIVE SHAFT (COUNTER ROTATION MODELS) E
DRIVE SHAFT (COUNTER ROTATION MODELS) 6
REMOVING/INSTALLING THE DRIVE SHAFT 6
6650

Propeller shaft housing assembly Refer to “PROPELLER SHAFT HOUSING
ASSEMBLY (COUNTER ROTATION
1 Nut 1
2 Pinion 1
4 Drive shaft housing assembly 1
5 Pinion shim *
6 Thrust bearing 1
7 Drive shaft 1
*: As required
6-45
6650

8 Reverse gear assembly 1
9 Thrust bearing 1
10 O-ring 1
11 Oil seal cover 1
12 Oil seal 2
13 Needle bearing 1
14 Drive shaft housing 1
15 Needle bearing 1
16 Reverse gear 1
procedure.
6-46
REMOVING THE DRIVE SHAFT 6
Loosen:
• Pinion nut

YB-06151 / 90890-06519
90890-06505
6250 90890-06507
DISASSEMBLING THE DRIVE SHAFT

HOUSING ASSEMBLY 6
Remove:
• Needle bearing

YB-06196 / 90890-06610
Driver rod .................................. 2
YB-06071 / 90890-06652
6260
DISASSEMBLING THE REVERSE

GEAR 6
Remove:
• Needle bearing
Slide hammer............................ 1
YB-06096
Guide plate................................ 2
90890-06501
6660
90890-06538
Bearing puller............................ 4
90890-06535
90890-06536
CHECKING THE PINION 6
Check:
• Teeth
CHECKING THE DRIVE SHAFT 6
Check:
• Drive shaft
6-47

HOUSING 6
Check:
• Drive shaft housing
CHECKING THE BEARINGS 6
Check:
• Bearings
ASSEMBLING THE REVERSE GEAR

ASSEMBLY 6
Install:
• Needle bearing

position a
6290 2.5 - 3.5 mm (0.098 - 0.138 in)

YB-06200 / 90890-06612
Driver rod .................................. 2
YB-06071 / 90890-06604
Å ASSEMBLING THE DRIVE SHAFT

HOUSING ASSEMBLY 6
1. Install:
• Needle bearing
Position a
5.75 - 6.25 mm (0.226 - 0.246 in)
6310 Bearing/oil seal attachment .... 1

YB-06196 / 90890-06610
Driver rod .................................. 2
ı YB-06071 / 90890-06604
90890-06603

ı For worldwide
6320
6-48
2. Install:
• Oil seal

0.25 - 0.75 mm (0.010 - 0.030 in)

YB-06195
Driver rod .................................. 2
6330 YB-06071
INSTALLING THE DRIVE SHAFT 6
Tighten:
• Pinion nut

YB-06151 / 90890-06519
90890-06505
6340 90890-06507
Pinion nut
93 Nm (9.3 m • kgf, 67 ft • lb)
T.
R.
6-49
LOWER CASE ASSEMBLY
LOWER CASE ASSEMBLY (COUNTER ROTATION MODELS) 6
DISASSEMBLING/ASSEMBLING THE LOWER CASE ASSEMBLY 6
5
4
3
6670 7 Nm (0.7 m • kgf, 5.1 ft • Ib) 5 Nm (0.5 m • kgf, 3.7 ft • Ib)

Reverse gear Refer to “DRIVE SHAFT (COUNTER
1 Drive shaft sleeve 1
2 Needle bearing 1
3 Bearing retainer 1
4 Needle bearing 1
5 Reverse gear shim *
6 Water seal 1
7 Plate 1
procedure.
*: As required
6-50
LOWER CASE ASSEMBLY
DISASSEMBLING THE LOWER CASE

ASSEMBLY 6
1. Remove:
• Needle bearing

YB-06194 / 90890-06636
Driver rod .................................. 2
YB-06071 / 90890-06605
6360
2. Remove:
• Roller bearing
Slide hammer............................ 1
YB-06096
Bearing puller............................ 2
90890-06523
Large universal claws............... 3
90890-06532
6680
3. Remove:
• Needle bearing

YB-06376 / 90890-06607
Driver rod .................................. 2
YB-06071 / 90890-06652
6690

SLEEVE 6
Check:
• Drive shaft sleeve
CHECKING THE NEEDLE BEARING 6
Check:
• Needle bearing
6-51
LOWER CASE ASSEMBLY
ASSEMBLING THE LOWER CASE

ASSEMBLY 6
1. Install:
• Needle bearing

position a
0.75 - 1.25 mm (0.030 - 0.049 in)
6700
YB-06376 / 90890-06607
Driver rod .................................. 2
YB-06071 / 90890-06652
2. Install:
• Bearing retainer

YB-06377 / 90890-06630
Driver rod .................................. 2
YB-06071 / 90890-06605
6710
3. Install:
6720
• Needle bearing

position a
184.0 mm (7.24 in)

YB-06194 / 90890-06636
Driver rod .................................. 2
YB-06071 / 90890-06602
YB-34474 / 90890-06603
6-52
LOWR (FOR USA AND CANADA) E
SHIMMING (REGULAR ROTATION MODELS) (FOR USA AND CANADA) 6
NOTE:
• There is no need to select shims when
reassembling with the original case and
inner parts.
• Shim calculations are required when reas-
sembling with the original inner parts and
a new case (the difference between the
original inner parts and the new case).
• Measurements and adjustments are
required when replacing the inner part(s).
B3
T3
A3 B4
59.0
F
R P
T1 B1 34.0 A2 T2
A1 B2
15.8
6730
6-53
SELECTING THE PINION SHIMS 6
NOTE:
Find the shim thickness (T3) by selecting
shims until the specified value (M0) is
obtained with the special tool.
6740
1. Measure:
M • Specified measurement (M)
Out of specified value (M0) → Adjust.
Specified value (M0) =

1.00 + P/100 mm
Measuring steps
6750 (1) Calculate the specified value (M0).
NOTE:
“P” is the deviation of the lower case
dimension from standard. It is stamped on
the trim tab mounting surface of the lower
case in 0.01-mm units. If the “P” mark is
R-1
missing or unreadable, assume a “P” value

F+5
P+2
of “0”, and check the backlash when the

unit is assembled.
6760
Example:
If “P” is “+5”, then
M0 = 1.00 + (+5)/100 mm
= 1.00 + 0.05 mm
= 1.05 mm
If “P” is “–3”, then
M0 = 1.00 + (–3)/100 mm
= 1.00 – 0.03 mm
= 0.97 mm
6-54
(2) Install the pinion height gauge, drive

shaft, thrust bearing 1, and shim(s) 2.
Pinion height gauge

YB-34432-6, -11
NOTE:
If the original shim(s) is unavailable, start
6770 with a 0.50-mm shim.
(3) Install the pinion and pinion nut.
Pinion nut
93 Nm (9.3 m • kgf, 67 ft • lb)
T.
R.
(4) Measure the specified measurement

M (M).
NOTE:
• Measure the clearance between the pin-
ion height gauge and the lower surface of
the pinion as shown.
• Perform the same measurement at three
points on the pinion.
6750
• Find the average of the measurements (M).
2. Adjust:
• Shim thickness (T3)
Remove or add shim(s).
Available shim thickness

0.10, 0.12, 0.15, 0.18, 0.30, 0.40
and 0.50 mm
NOTE:
(M0) – (M) should be as close to “0” as pos-
sible.
6-55
SELECTING THE FORWARD GEAR

SHIMS 6
NOTE:
6780
1. Measure:
• Specified measurement (M)

1.80 + F/100 mm
Measuring steps
NOTE:
“F” is the deviation of the lower case
case in 0.01-mm units. If the “F” mark is
R-1
missing or unreadable, assume an “F”

F+5
P+2
value of “0”, and check the backlash when

the unit is assembled.
6800
Example:
If “F” is “+5”, then
M0 = 1.80 + (+5)/100 mm
= 1.80 + 0.05 mm
= 1.85 mm
If “F” is “–3”, then
M0 = 1.80 + (–3)/100 mm
= 1.80 – 0.03 mm
= 1.77 mm
6-56
(2) Install the shimming gauge, bearing

1, and shim(s) 2.
Shimming gauge
YB-34446-1, -3, -5, -7
NOTE:
with a 0.50-mm shim.

(M).
6810
2. Adjust:

0.10, 0.12, 0.15, 0.18, 0.30, 0.40
and 0.50 mm
NOTE:
sible.
6-57
SELECTING THE REVERSE GEAR

SHIMS 6
NOTE:
6820
1. Measure:
M Out of specified value (M0) → Adjust.

1.80 – R/100 mm
Measuring steps
NOTE:
“R” is the deviation of the lower case
case in 0.01-mm units. If the “R” mark is
R-1
missing or unreadable, assume an “R”

F+5
P+2

6840
Example:
If “R” is “+5”, then
M0 = 1.80 – (+5)/100 mm
= 1.80 – 0.05 mm
= 1.75 mm
If “R” is “–3”, then
M0 = 1.80 – (–3)/100 mm
= 1.80 + 0.03 mm
= 1.83 mm
6-58
(2) Install the shimming gauge, bearing,

thrust washer, reverse gear, and
shim(s).
M
Shimming gauge
YB-34468-2
NOTE:
6830 • If the original shim(s) is unavailable, start
• Turn the reverse gear assembly a few
times until the gear and bearing are hori-
zontal.

(M).
2. Adjust:

0.10, 0.12, 0.15, 0.18, 0.30, 0.40
and 0.50 mm
NOTE:
sible.
6-59
LOWR (FOR WORLDWIDE) E
SHIMMING (REGULAR ROTATION MODELS) (FOR WORLDWIDE) 6
NOTE:
inner parts.
B3
T3
A3 B4
59.0
F
R P
T1 B1 34.0 A2 T2
A1 B2
15.8
6730
6-60
NOTE:
Select the shim thickness (T3) by using the
specified measurement(s) and the calcula-
tion formula.
Select:
6850 • Shim thickness (T3)
Selecting steps
(1) Measure (M3).
Digital caliper
90890-06704
NOTE:
Install the bearing housing 1, thrust bear-
6860 ing 2, and washer 3.
Pinion nut
93 Nm (9.3 m • kgf, 67 ft • lb)
T.
R.
(3) Install the pinion height gauge.
Pinion height gauge

90890-06702
NOTE:
After the wing nuts contact the fixing plate,
tighten them another 1/4 of a turn.
(4) Measure (M4).
Digital caliper
90890-06704
6870
NOTE:
ion height gauge and the pinion, as
shown.
• Find the average of the measurements
(M4).
6-61
(5) Calculate the pinion shim thickness

(T3).
Pinion shim thickness (T3) =

62.5 + P/100 – M3 – M4
R-1
F+5
P+2
NOTE:
6880 dimension from standard. It is stamped on
unit is assembled.
Example:
If M3 is “46.85 mm”, M4 is “15.12 mm” and
P is “–5”, then
T3 = 62.5 + (–5)/100 – 46.85 – 15.12 mm
= 62.5 – 0.05 – 46.85 – 15.12 mm
= 0.48 mm
(6) Select the pinion shim(s) (T3).

Calculated numeral
at 1/100th place Rounded
numeral
More than or less
0.00 0.02 0.00
0.02 0.05 0.02
0.05 0.08 0.05
0.08 0.10 0.08
0.10, 0.12, 0.15, 0.18, 0.30, 0.40
and 0.50 mm
6-62

SHIMS 6
NOTE:
tion formula.
6890 Select:
Selecting steps
(1) Measure (M1).
Shimming plate ........................ 1

90890-06701
Digital caliper ............................ 2
90890-06704
6900
NOTE:
• Turn the roller bearing outer race two or
three times so the rollers seat. Then, mea-
sure the height of the bearing, as shown.
points on the roller bearing outer race.
(M1).
(2) Calculate the forward gear shim thick-

ness (T1).
Forward gear shim thickness (T1)

(T1) = 24.6 + F/100 – M1
NOTE:
6910 dimension from standard. It is stamped on
6-63
Example:
If M1 is “24.10 mm” and F is “+5”, then
T1 = 24.6 + (+5)/100 – 24.10 mm
= 24.6 + 0.05 – 24.10 mm
= 0.55 mm
(3) Select the forward gear shim(s) (T1).

Calculated numeral
numeral
More than or less
0.00 0.02 0.00
0.02 0.05 0.02
0.05 0.08 0.05
0.08 0.10 0.08
0.10, 0.12, 0.15, 0.18, 0.30, 0.40
and 0.50 mm

SHIM 6
NOTE:
tion formula.
6920
Select:
Selecting steps
(1) Measure (M2).
Shimming plate ........................ 1

90890-06701
Digital caliper ............................ 2
6930 90890-06704
NOTE:
• Measure the height of the gear as shown.
points on the gear.
(M2).
6-64
(2) Calculate the reverse gear shim thick-

ness (T2).
Reverse gear shim thickness

(T2) = M2 – 27.4 – R/100
NOTE:
missing or unreadable, assume a “R” value
unit is assembled.
R-1
F+5
Example:
P+2
If M2 is “27.95 mm”, R is “+2”, then

T2 = 27.95 – 27.4 – (+2)/100 mm
6940 = 27.95 – 27.4 – 0.02 mm
= 0.53 mm
(3) Select the reverse gear shim(s) (T2).

Calculated numeral
numeral
More than or less
0.00 0.02 0.02
0.02 0.05 0.05
0.05 0.08 0.08
0.08 0.10 0.10
0.10, 0.12, 0.15, 0.18, 0.30, 0.40
and 0.50 mm
6-65
LOWR BACKLASH (REGULAR ROTATION MODELS) E
BACKLASH
(REGULAR ROTATION MODELS) 6
NOTE:
• Do not install the water pump compo-
nents when measuring the backlash.
• Measure both the forward and reverse
gear backlashes.
• If both the forward and reverse gear back-
lashes are larger than specification, the
pinion may be too high.
lashes are smaller than specification, the
pinion may be too low.
MEASURING THE FORWARD GEAR

BACKLASH 6
1. Measure:
• Forward gear backlash
Forward gear backlash

0.19 - 0.53 mm (0.007 - 0.021 in)
Measuring steps
(1) Set the shift rod into the neutral posi-
tion.
Shift rod wrench

YB-06052 / 90890-06052
(2) Install the propeller shaft housing

puller so it pushes against the propel-
ler shaft.
6950
YB-06207 / 90890-06502
YB-06117 / 90890-06521
Guide plate................................ 3
90890-06501
Center bolt ................................ 4
90890-06504
Center bolt
6960 10 Nm (1.0 m • kgf, 7.2 ft • lb)
T.
R.
6-66
(3) Install the backlash indicator onto the

drive shaft (on the 22.4 mm (0.88 in)
diameter portion of the drive shaft).
Backlash indicator .................... 5

YB-06265 / 90890-06706
(4) Install the dial gauge onto the lower

unit and have the dial gauge plunger
6970 contact the mark on the backlash indi-
cator.
Magnetic base attaching

plate ........................................... 6
YB-07003 / 90890-07003
Dial gauge set ........................... 7
YU-03097 / 90890-01252
Magnetic base........................... 8
YU-34481 / 90890-06705
(5) Set the lower unit upside down.

(6) Slowly turn the drive shaft clockwise
and counterclockwise. When the drive
shaft stops in each direction, measure
the backlash.
2. Adjust:
• Forward gear shim
Forward gear
Shim thickness
backlash
Less than To be decreased by
0.19 mm (0.007 in) (0.36 – M) × 0.58
More than To be increased by
0.53 mm (0.021 in) (M – 0.36) × 0.58
M: Measurement
MEASURING THE REVERSE GEAR

BACKLASH 6
1. Measure:
• Reverse gear backlash
Reverse gear backlash

0.86 - 1.26 mm (0.034 - 0.050 in)
6-67
Measuring steps
tion.
Shift rod wrench

YB-06052 / 90890-06052
6950
(2) Load the reverse gear by installing the

propeller without the spacer 1 and
then tighten the propeller nut.
Propeller nut
10 Nm (1.0 m • kgf, 7.2 ft • lb)
T.
R.
6980


YB-06265 / 90890-06706

cator.
Magnetic-base plate................. 2
YB-07003 / 90890-07003
Dial gauge set ........................... 3
YU-03097 / 90890-01252
Magnetic base........................... 4
YU-34481 / 90890-06705

the backlash.
6-68
2. Adjust:
• Reverse gear shim
Reverse gear
Shim thickness
backlash
Less than To be increased by
0.86 mm (0.034 in) (1.06 – M) × 0.58
More than To be decreased by
1.26 mm (0.050 in) (M – 1.06) × 0.58
M: Measurement
6-69
SHIMMING (COUNTER ROTATION MODELS) (FOR USA AND CANADA) 6
NOTE:
inner parts.
B3
T3
A3 B4
59.0
F
R P
T1 B1 33.3 A2 T2 T4
A1 B2
15.1
6A10
6-70
NOTE:
shims until the specified measurement (M)
is obtained with the special tool.
6740
1. Measure:
M • Specified measurement (M)

1.00 + P/100 mm
Measuring steps
NOTE:
R-1

F+5
P+2

unit is assembled.
6A20
Example:
If “P” is “+5”, then
M0 = 1.00 + (+5)/100 mm
= 1.00 + 0.05 mm
= 1.05 mm
If “P” is “–3”, then
M0 = 1.00 + (–3)/100 mm
= 1.00 – 0.03 mm
= 0.97 mm
6-71
(2) Install the pinion height gauge, drive

shaft, thrust bearing 1, and shim(s) 2.
Pinion height gauge

YB-34432-6, -11
NOTE:
6770 with a 0.50-mm shim.
Pinion nut
93 Nm (9.3 m • kgf, 67 ft • lb)
T.
R.

M (M).
NOTE:
ion height gauge and the lower surface of
the pinion as shown.
6750
• Find the average of the measurements (M).
2. Adjust:

0.10, 0.12, 0.15, 0.18, 0.30, 0.40
and 0.50 mm
NOTE:
sible.
6-72

SHIMS 6
NOTE:
6780
1. Measure:

25.30 + F/100 mm
Measuring steps
6A30 (1) Calculate the specified value (M0).
NOTE:
R-1

F+5
P+2

6A40
Example:
If “F” is “+5”, then
M0 = 25.30 + (+5)/100 mm
= 25.30 + 0.05 mm
= 25.35 mm
If “F” is “–3”, then
M0 = 25.30 + (–3)/100 mm
= 25.30 – 0.03 mm
= 25.27 mm
6-73
(2) Install the roller bearing 1, thrust

bearing 2, and shim(s) 3.
NOTE:

6A50
(M).
2. Adjust:

0.10, 0.12, 0.15, 0.18, 0.30, 0.40
and 0.50 mm
NOTE:
sible.

SHIMS 6
NOTE:
6820
1. Measure:
M
1.10 – R/100 mm
6A60
6-74
Measuring steps
(1) Calculate the specified value (M0).
NOTE:
R-1
F+5
P+2
6A70
missing or unreadable, assume an “R”
Example:
If “R” is “+5”, then
M0 = 1.10 – (+5)/100 mm
= 1.10 – 0.05 mm
= 1.05 mm
If “R” is “–3”, then
M0 = 1.10 – (–3)/100 mm
= 1.10 + 0.03 mm
= 1.13 mm
(2) Install the shimming gauge, bearing,

thrust washer, forward gear, and
shim(s).
M
Shimming gauge
YB-34468-2
NOTE:
6A60 • If the original shim(s) is unavailable, start
• Turn the forward gear assembly a few
times until the gear and bearing are hori-
zontal.

(M).
6-75
2. Adjust:

0.10, 0.12, 0.15, 0.18, 0.30, 0.40
and 0.50 mm
NOTE:
sible.
SELECTING THE PROPELLER SHAFT

SHIMS 6
NOTE:
6A80 shims until the specified measurement is
1. Install:
• Shim(s) 1
• Thrust bearing 2
• Propeller shaft 3
• Tapered roller bearing 4
6A90
2. Measure:
• Propeller shaft free play
Propeller shaft free play

0.30 ± 0.05 mm
Magnetic base........................... 1
YU-34481 / 90890-06705
6B10
Dial gauge set ........................... 2
YU-03097 / 90890-01252
3. Adjust:

0.10, 0.12, 0.15, 0.18, 0.30, 0.40
and 0.50 mm
6-76
SHIMMING (COUNTER ROTATION MODELS) (FOR WORLDWIDE) 6
NOTE:
inner parts.
B3
T3
A3 B4
59.0
F
R P
T1 B1 33.3 A2 T2 T4
A1 B2
15.1
6A10
6-77
NOTE:
tion formula.
Select:
6850 • Shim thickness (T3)
Selecting steps
(1) Measure (M3).
Digital caliper
90890-06704
NOTE:
Install the bearing housing 1, thrust bear-
6860 ing 2, and washer 3.
Pinion nut
93 Nm (9.3 m • kgf, 67 ft • lb)
T.
R.
(3) Install the pinion height gauge.
Pinion height gauge

90890-06702
NOTE:
After the wing nuts contact the fixing plate,
tighten them another 1/4 of a turn.
(4) Measure (M4).
Digital caliper
90890-06704
6870
NOTE:
ion height gauge and the pinion, as
shown.
(M4).
6-78
(5) Calculate the pinion shim thickness

(T3).
Pinion shim thickness (T3) =

62.5 + P/100 – M3 – M4
R-1
F+5
P+2
NOTE:
6B20 dimension from standard. It is stamped on
unit is assembled.
Example:
If M3 is “46.85 mm”, M4 is “15.12 mm” and
P is “–5”, then
T3 = 62.5 + (–5)/100 – 46.85 – 15.12 mm
= 62.5 – 0.05 – 46.85 – 15.12 mm
= 0.48 mm
(6) Select the pinion shim(s) (T3).

Calculated numeral
numeral
More than or less
0.00 0.02 0.00
0.02 0.05 0.02
0.05 0.08 0.05
0.08 0.10 0.08
0.10, 0.12, 0.15, 0.18, 0.30, 0.40
and 0.50 mm
6-79

SHIMS 6
NOTE:
tion formula.
6890 Select:
Selecting steps
(1) Measure (M1).
Digital caliper
90890-06704
NOTE:
• Measure the combined thickness of the
roller bearing 1 and thrust bearing 2.
• Turn the roller bearing outer race two or
three times so the rollers seat. Then, mea-
sure the height of the bearing, as shown.
points on the roller bearing outer race.
(M1).
6B30
(2) Calculate the reverse gear shim thick-

ness (T1).
Reverse gear shim thickness (T1)

(T1) = 25.3 + F/100 – M1
R-1
F+5
P+2
NOTE:
6-80
Example:
If M1 is “24.80 mm” and F is “+5”, then
T1 = 25.3 + (+5)/100 – 24.80 mm
= 25.3 + 0.05 – 24.80 mm
= 0.55 mm
(3) Select the reverse gear shim(s).

Calculated numeral
numeral
More than or less
0.00 0.02 0.00
0.02 0.05 0.02
0.05 0.08 0.05
0.08 0.10 0.08
0.10, 0.12, 0.15, 0.18, 0.30, 0.40
and 0.50 mm

SHIMS 6
NOTE:
tion formula.
6920 Select:
Selecting steps
(1) Measure (M2).
Shimming plate ........................ 1

90890-06701
Digital caliper ............................ 2
90890-06704
6930
NOTE:
• Measure the height of the gear as shown.
points on the gear.
(M2).
6-81
(2) Calculate the forward gear shim thick-

ness (T2).
Forward gear shim thickness

(T2) = M2 – 28.1 – R/100
R-1
F+5
P+2
NOTE:
missing or unreadable, assume a “R” value
unit is assembled.
Example:
If M2 is “29.10 mm”, R is “+2”, then
T2 = 29.10 – 28.1 – (+2)/100 mm
= 29.10 – 28.1 – 0.02 mm
= 0.98 mm
(3) Select the forward gear shim(s) (T2).

Calculated numeral
numeral
More than or less
0.00 0.02 0.02
0.02 0.05 0.05
0.05 0.08 0.08
0.08 0.10 0.10
0.10, 0.12, 0.15, 0.18, 0.30, 0.40
and 0.50 mm
6-82
SELECTING THE PROPELLER SHAFT

SHIMS 6
NOTE:
shims until the specified measurement is
6A80
1. Install:
• Shim(s) 1
• Thrust bearing 2
• Propeller shaft 3
• Tapered roller bearing 4
6A90
2. Measure:
Propeller shaft free play

0.30 ± 0.05 mm
Magnetic base........................... 1
YU-34481 / 90890-06705
6B10
Dial gauge set ........................... 2
YU-03097 / 90890-01252
3. Adjust:

0.10, 0.12, 0.15, 0.18, 0.30, 0.40
and 0.50 mm
6-83
LOWR BACKLASH (COUNTER ROTATION MODELS) E
BACKLASH
(COUNTER ROTATION MODELS) 6
NOTE:
• Do not install the water pump compo-
nents when measuring the backlash.
• Measure both the forward and reverse
gear backlashes.
lashes are larger than specification, the
pinion may be too high.
lashes are smaller than specification, the
pinion may be too low.
MEASURING THE FORWARD GEAR

BACKLASH 6
1. Measure:
• Forward gear backlash
Forward gear backlash

0.31 - 0.66 mm (0.012 - 0.026 in)
Measuring steps
tion.
Shift rod wrench

YB-06052 / 90890-06052

ler shaft.
6950
YB-06207 / 90890-06502
YB-06117 / 90890-06521
Guide plate................................ 3
90890-06501
Center bolt ................................ 4
90890-06504
Center bolt
6960 10 Nm (1.0 m • kgf, 7.2 ft • lb)
T.
R.
6-84


YB-06265 / 90890-06706

cator.

plate ........................................... 6
YB-07003 / 90890-07003
Dial gauge set ........................... 7
YU-03097 / 90890-01252
Magnetic base........................... 8
YU-34481 / 90890-06705

the backlash.
2. Adjust:
• Forward gear shim
Forward gear
Shim thickness
backlash
Less than To be increased by
0.31 mm (0.012 in) (0.49 – M) × 0.58
More than To be decreased by
0.66 mm (0.026 in) (M – 0.49) × 0.58
M: Measurement
MEASURING THE REVERSE GEAR

BACKLASH 6
1. Measure:
• Reverse gear backlash
Reverse gear backlash

0.86 - 1.21 mm (0.034 - 0.048 in)
6-85
Measuring steps
tion.
Shift rod wrench

YB-06052 / 90890-06052
6950

ler shaft.

YB-06207 / 90890-06502
YB-06117
Guide plate................................ 3
6B60 90890-06501
Center bolt ................................ 4
90890-06504
Center bolt
10 Nm (1.0 m • kgf, 7.2 ft • lb)
T.
R.


YB-06265 / 90890-06706

6B60 contact the mark on the backlash indi-
cator.

plate ........................................... 6
YB-07003 / 90890-07003
Dial gauge set ........................... 7
YU-03097 / 90890-01252
Magnetic base........................... 8
YU-34481 / 90890-06705
6-86
(6) Turn the shift rod into the reverse posi-

tion with the shift rod wrench.
(7) Turn the drive shaft clockwise until the
clutch dog is fully engaged.
6B70
(8) Turn the shift rod into the neutral posi-

(9) Turn the drive shaft counterclockwise
approximately 30˚ more.
6B80
(10) Turn the shift rod into the reverse posi-

the backlash.
NOTE:
When measuring the reverse gear backlash,
6B90
turn the shift rod wrench towards the
reverse position with force.
2. Adjust:
• Reverse gear shim
Reverse gear
Shim thickness
backlash
Less than To be decreased by
0.86 mm (0.034 in) (1.0 – M) × 0.58
More than To be increased by
1.21 mm (0.048 in) (M – 1.0) × 0.58
M: Measurement
6-87
BRKT E
CHAPTER 7
BRACKET UNIT
STEERING HANDLE (OPTION) ...................................................................... 7-1

REMOVING/INSTALLING THE STEERING FRICTION............................ 7-1
REMOVING/INSTALLING THE STEERING HANDLE ............................. 7-2
DISASSEMBLING/ASSEMBLING THE STEERING HANDLE................. 7-4
DISASSEMBLING/ASSEMBLING THE STEERING HANDLE
SUB ASSEMBLY ..................................................................................... 7-7
SHIFT ROD ASSEMBLY ............................................................................... 7-10

REMOVING/INSTALLING THE SHIFT ROD ASSEMBLY ..................... 7-10
BOTTOM COWLING..................................................................................... 7-13

REMOVING/INSTALLING THE BOTTOM COWLING ........................... 7-13
UPPER CASE ASSEMBLY............................................................................ 7-16

REMOVING/INSTALLING THE UPPER CASE ASSEMBLY .................. 7-16
DISASSEMBLING/ASSEMBLING THE OIL PUMP ............................ 7-17-1
DISASSEMBLING THE OIL PUMP ASSEMBLY ................................ 7-17-2
CHECKING THE OIL PUMP ASSEMBLY............................................ 7-17-2
ASSEMBLING THE OIL PUMP ASSEMBLY ...................................... 7-17-2
DISASSEMBLING/ASSEMBLING THE UPPER CASE ASSEMBLY ..... 7-18
OIL PAN......................................................................................................... 7-21

DISASSEMBLING/ASSEMBLING THE OIL PAN .................................. 7-21
CLAMP BRACKETS ...................................................................................... 7-24

REMOVING/INSTALLING THE CLAMP BRACKETS............................. 7-24
STEERING ARM............................................................................................ 7-26

REMOVING/INSTALLING THE STEERING ARM.................................. 7-26
SWIVEL BRACKET ASSEMBLY................................................................... 7-27

DISASSEMBLING/ASSEMBLING THE SWIVEL BRACKET
ASSEMBLY............................................................................................ 7-27
POWER TRIM AND TILT UNIT..................................................................... 7-29

REMOVING/INSTALLING THE POWER TRIM AND TILT UNIT........... 7-29
REMOVING THE POWER TRIM AND TILT UNIT ................................. 7-31
BLEEDING THE POWER TRIM AND TILT UNIT ................................... 7-31
BRKT E
RESERVOIR AND POWER TRIM AND TILT MOTOR ................................. 7-33

REMOVING/INSTALLING THE RESERVOIR AND POWER TRIM
AND TILT MOTOR................................................................................. 7-33
CHECKING THE RESERVOIR................................................................. 7-34
1
CHECKING THE GEAR PUMP HOUSING FILTER ................................ 7-34
INSTALLING THE POWER TRIM AND TILT MOTOR........................... 7-35
FILLING THE RESERVOIR...................................................................... 7-36
BLEEDING THE POWER TRIM AND TILT UNIT ................................... 7-36
MEASURING THE HYDRAULIC PRESSURE ........................................ 7-38
TILT RAM ASSEMBLY AND GEAR PUMP UNIT........................................ 7-41

REMOVING/INSTALLING THE TILT RAM ASSEMBLY AND
GEAR PUMP UNIT ................................................................................ 7-41
REMOVING THE TILT RAM END SCREW ............................................ 7-43
2
REMOVING THE GEAR PUMP UNIT .................................................... 7-43
DISASSEMBLING THE GEAR PUMP UNIT .......................................... 7-43
CHECKING THE TILT RAM .................................................................... 7-44
CHECKING THE GEAR PUMP UNIT...................................................... 7-44
ASSEMBLING THE GEAR PUMP UNIT ................................................ 7-45
INSTALLING THE GEAR PUMP UNIT................................................... 7-46
3
INSTALLING THE TILT RAM ASSEMBLY ............................................ 7-46
TRIM RAM ASSEMBLIES AND FREE PISTON ........................................... 7-48

REMOVING/INSTALLING THE TRIM RAM ASSEMBLIES AND
FREE PISTON ........................................................................................ 7-48
REMOVING THE TRIM RAM END SCREWS ........................................ 7-49
4
REMOVING THE FREE PISTON............................................................. 7-49
CHECKING THE TRIM RAMS ................................................................ 7-50
CHECKING THE FREE PISTON.............................................................. 7-50
CHECKING THE TRIM RAM CYLINDERS ............................................. 7-50
INSTALLING THE FREE PISTON........................................................... 7-50
5
INSTALLING THE TRIM RAMS ............................................................. 7-51
6
7
8
9
BRKT STEERING HANDLE (OPTION) E
STEERING HANDLE (OPTION) 7
REMOVING/INSTALLING THE STEERING FRICTION
7010

1 Bolt 2
2 Nut 2
3 Bolt 2
4 Washer 2
5 Collar 2
6 Nut 2
7 Nut 1
Continued to next page.
7-1
7010

8 Washer 1
9 Steering lock shaft 1
10 Steering lock knob 1
11 Bracket 1
12 Friction piece 2
13 Friction plate 1
procedure.
7-1-1
REMOVING/INSTALLING THE STEERING HANDLE

1 Bolt 2
2 Fitting plate 1
3 Clip 2
4 Throttle cable 1
5 Bolt 1
6 Cable clamp 1
7 Shift cable 1
8 Bolt 1
9 Plate 1
10 Bolt 1
7-2

11 Clamp 1
12 Main switch leads 5
13 Trailer/PTT switch coupler 1
14 Extension, wire harness 1
15 Nut 2
16 Steering handle assembly 1
17 Nut 2
18 Bracket 1
procedure.
7-3
DISASSEMBLING/ASSEMBLING THE STEERING HANDLE
6 × 16 mm
4 Nm (0.4 m • kgf, 2.9 ft • Ib)
8 × 40 mm
18 Nm (1.8 m • kgf, 13 ft • Ib)
5 × 20 mm
6 × 20 mm
6 × 40 mm
6 × 25 mm
5 Nm (0.5 m • kgf, 3.7 ft • Ib)

6 × 16 mm
7030

1 Engine stop lanyard switch leads 2
2 Bolt 1
3 Bolt 1
4 Nut 1
5 Screw 1
6 Cover 1
7 Main switch assembly 1
8 Holder 1
7-4
6 × 16 mm
4 Nm (0.4 m • kgf, 2.9 ft • Ib)
8 × 40 mm
18 Nm (1.8 m • kgf, 13 ft • Ib)
5 × 20 mm
6 × 20 mm
6 × 40 mm
6 × 25 mm
5 Nm (0.5 m • kgf, 3.7 ft • Ib)

6 × 16 mm
7030

9 Screw 1
10 Throttle grip 1
11 Washer 1
12 Spring 1
13 Bushing 1
14 Screw 5
15 Screw 2
16 Cover 1
17 Screw 2
7-5
6 × 16 mm
4 Nm (0.4 m • kgf, 2.9 ft • Ib)
8 × 40 mm
18 Nm (1.8 m • kgf, 13 ft • Ib)
5 × 20 mm
6 × 20 mm
6 × 40 mm
6 × 25 mm
5 Nm (0.5 m • kgf, 3.7 ft • Ib)

6 × 16 mm
7030

18 Power trim and tilt switch 1
19 Nut 1
20 Engine stop lanyard switch 1
21 Screw 2
22 Shift lever cover 1
23 Bolt 1
24 Shift lever 1
25 Bushing 1
26 Steering handle sub assembly 1
procedure.
7-6
DISASSEMBLING/ASSEMBLING THE STEERING HANDLE SUB ASSEMBLY
38 Nm (3.8 m • kgf, 27.5 ft • Ib)
6 × 14 mm
6 × 14 mm
10 × 80 mm
6 × 30 mm
7040

1 Clip 1
2 Cable clamp 1
3 Throttle cable (short) 1
4 Bolt 1
5 Shift cable bracket 1
6 Cotter pin 1
7 Friction adjusting knob 1
8 Bolt 1
9 Bolt 2
10 Throttle shaft 1
11 Friction piece 1
7-7
38 Nm (3.8 m • kgf, 27.5 ft • Ib)
6 × 14 mm
6 × 14 mm
10 × 80 mm
6 × 30 mm
7040

12 Frame 1
13 Clip 1
14 Shift cable (long) 1
15 Throttle arm shaft 1
16 Throttle arm 1
17 Screw 2
18 Spring housing 1
19 Roller 1
20 Actuator 1
21 Spring 1
22 Shift arm 1
7-8
38 Nm (3.8 m • kgf, 27.5 ft • Ib)
6 × 14 mm
6 × 14 mm
10 × 80 mm
6 × 30 mm
7040

23 Bushing 1
24 Nut 1
25 Washer 1
26 Bolt 1
27 Washer 1
28 Wave washer 1
29 Collar 1
30 Bracket 1
31 Washer 1
32 Bushing 2
33 Steering handle 1
procedure.
7-9
BRKT SHIFT ROD ASSEMBLY E
SHIFT ROD ASSEMBLY 7
REMOVING/INSTALLING THE SHIFT ROD ASSEMBLY
12
18 Nm (1.8 m • kgf, 13 ft • Ib)
13
A 14
15
1 4 × 16 mm
16
20
18 21 6
6 × 25 mm
19 2 6 × 40 mm
5
21 3
17 A A
6 × 12 mm
7
A 8
22
11
9
10
23
24 7050

Power unit assembly Refer to “POWER UNIT” on page 5-4.
1 Screw 2
2 Plate 1
3 Shift position switch 1
4 Clip 1
5 Bushing 1
6 Bolt 2
7 Shift bracket 1
7-10
12
18 Nm (1.8 m • kgf, 13 ft • Ib)
13
A 14
15
1 4 × 16 mm
16
20
18 21 6
6 × 25 mm
19 2 6 × 40 mm
5
21 3
17 A A
6 × 12 mm
7
A 8
22
11
9
10
23
24 7050

8 Washer 1
9 Clip 1
10 Bushing 1
11 Shift rod lever 1
12 Bolt 1
13 Spring 1
14 Ball 1
15 Cotter pin 1
16 Washer 1
7-11
12
18 Nm (1.8 m • kgf, 13 ft • Ib)
13
A 14
15
1 4 × 16 mm
16
20
18 21 6
6 × 25 mm
19 2 6 × 40 mm
5
21 3
17 A A
6 × 12 mm
7
A 8
22
11
9
10
23
24 7050

17 Bolt 2
18 Bracket 1
19 Bolt 2
20 Shift rod bracket 1
21 Bushing 2
22 Shift rod 1
23 Grommet 1
24 O-ring 1
procedure.
7-12
BRKT BOTTOM COWLING E
BOTTOM COWLING 7
REMOVING/INSTALLING THE BOTTOM COWLING
5 6 7 6 × 30 mm
8
6 × 12 mm 9
1
4
6 × 16 mm 11
6 × 20 mm
12 2 9
24 10
13
3
14
8 × 35 mm
25 21
23
28
29
22
27
26
19
19
17 18
16
20
6 × 20 mm
7060
15

Power unit Refer to “POWER UNIT” on page 5-4.
1 Bolt 4
2 Bolt 2
3 Spring hook 2
4 Spring 2
5 Bolt 2
6 Washer 2
7 Clamp lever 2
8 Wave washer 2
9 Bushing 4
10 Clamp lever 2
7-13
5 6 7 6 × 30 mm
8
6 × 12 mm 9
1
4
6 × 16 mm 11
6 × 20 mm
12 2 9
24 10
13
3
14
8 × 35 mm
25 21
23
28
29
22
27
26
19
19
17 18
16
20
6 × 20 mm
7060
15

11 Clamp plate 2
12 Bolt 2
13 Bracket 1
14 Trailer switch 1
15 Bolt 1
16 Adaptor 1 For water hose and PTT lead
It differs on specification 17 to 21
17 Gasket 1
18 Hose joint 1
19 Grommet 1
7-14
5 6 7 6 × 30 mm
8
6 × 12 mm 9
1
4
6 × 16 mm 11
6 × 20 mm
12 2 9
24 10
13
3
14
8 × 35 mm
25 21
23
28
29
22
27
26
19
19
17 18
16
20
6 × 20 mm
7060
15

20 Hose 1
21 Bolt 4
22 Bottom cowling 1
23 Grommet 2
24 Water outlet 1
25 Cap 3
26 Collar 4
27 Grommet 4
28 Collar 4
29 Grommet 4
procedure.
7-15
BRKT UPPER CASE ASSEMBLY E
UPPER CASE ASSEMBLY 7
REMOVING/INSTALLING THE UPPER CASE ASSEMBLY
10 Nm (1.0 m • kgf, 7.2 ft • Ib)

3
1
5 4
6 × 45 mm 4 10
5
2
LT
LT
572
53 Nm (5.3 m • kgf, 38 ft • Ib)
11
16
15 LT
LT
572
13
12
8 9
10 × 40 mm
14
73 Nm (7.3 m • kgf, 53 ft • Ib) 6 × 10 mm 7070

Lower unit Refer to “LOWER UNIT (REGULAR
ROTATION MODELS)” on page 6-1 and
“LOWER UNIT (COUNTER ROTATION
Bottom cowling Refer to “BOTTOM COWLING” on
page 7-13.
1 Bolt 6
2 Oil pump assembly 1
3 Seal 1
4 Dowel pin 2
5 O-ring 2
6 Bolt 4
7-16
10 Nm (1.0 m • kgf, 7.2 ft • Ib)

3
1
5 4
6 × 45 mm 4 10
5
2
LT
LT
572
53 Nm (5.3 m • kgf, 38 ft • Ib)
11
16
15 LT
LT
572
13
12
8 9
10 × 40 mm
14
73 Nm (7.3 m • kgf, 53 ft • Ib) 6 × 10 mm 7070

7 Lower mount cover 2
8 Grease nipple 1
9 Bolt 1
10 Damper 2
11 Nut 2
12 Nut 2
13 Washer 2
14 Ground lead 1
15 Washer 2
16 Upper case assembly 1
procedure.
7-17
DISASSEMBLING/ASSEMBLING THE OIL PUMP
1
4 Nm (0.4 m • kg, 2.9 ft • Ib)
2
4
A
3
A
9
8
7
7070

1 Screw 10
3 Shaft 1
4 O-ring 1
5 O-ring 1
6 Housing 1
8 Oil seal 2
9 Oil seal 1
procedure.
7-17-1
DISASSEMBLING THE OIL PUMP

ASSEMBLY
1 1. Remove:
• Cover 1
• Gasket 2
2 • Shaft 3
4
• O-ring 4
3 • O-ring 5
• Housing 6
5 • Gasket 7
CHECKING THE OIL PUMP

ASSEMBLY
1. Check:
• Shaft
Cracks/wear → Replace.
2. Check:
• Oil seals
• O-rings
Tears → Replace.
3. Check:
• Oil passage
Dirt/residue → Clean.
ASSEMBLING THE OIL PUMP

ASSEMBLY
1. Install:
• Oil seal
Bearing installer:
YB-41446
7-17-2
2. Install:
• Oil seal
Bearing cup installer:

YB-06167
3. Install:
• Oil seals
Roller bearing installer/remover:

YB-06432-1A
4. Install:
• Gasket 1
7 • Housing 2
• O-ring 3
• O-ring 4
6 • Shaft 5
4
• Gasket 6
5 A • Cover 7
3 Screw:
4 Nm (0.4 m • kg, 2.9 ft • lb)
T.
R.
NOTE:
1 When installing the oil pump assembly
onto the upper case assembly, pour a small
2 amount of engine oil into the oil inlet or oil
outlet of the oil pump assembly.
7-17-3
DISASSEMBLING/ASSEMBLING THE UPPER CASE ASSEMBLY
8 × 45 mm 1
4
6 × 15 mm
3 12 × 193 mm
LT
572 A
12 2
15
10
20 Nm (2.0 m • kgf, 14 ft • Ib)

16 8 × 40 mm
18 17
19
LT
572
11
14
22
A
13
7
21 5
20 6
8 14 × 235 mm 7080
9

1 Bolt 3
2 Upper mount rubber 1
3 Bolt 2
4 Plate 1
5 Bolt 2
6 Washer 2
7 Rubber 2
8 Lower mount rubber 2
9 Washer 2
7-18
8 × 45 mm 1
4
6 × 15 mm
3 12 × 193 mm
LT
572 A
12 2
15
10
20 Nm (2.0 m • kgf, 14 ft • Ib)

16 8 × 40 mm
18 17
19
LT
572
11
14
22
A
13
7
21 5
20 6
8 14 × 235 mm 7080
9

10 Bolt 4
11 Muffler assembly 1
13 Rubber gasket 1
14 Rubber seal 1
15 Grommet 1
16 Screw 2
17 Baffle plate 1
18 Damper 1
7-19
8 × 45 mm 1
4
6 × 15 mm
3 12 × 193 mm
LT
572 A
12 2
15
10
20 Nm (2.0 m • kgf, 14 ft • Ib)

16 8 × 40 mm
18 17
19
LT
572
11
14
22
A
13
7
21 5
20 6
8 14 × 235 mm 7080
9

19 Grommet 1
20 Circlip 1
21 Drive shaft bushing 1
22 Upper case 1
procedure.
7-20
BRKT OIL PAN E
OIL PAN 7
DISASSEMBLING/ASSEMBLING THE OIL PAN
22
11 Nm (1.1 m • kgf, 8.0 ft • Ib)

6 × 25 mm
21
9
20 10
19
18
LT 4
572 17
LT
572
15 3 1
LT
6 × 30 mm
572 5
16 6 LT
572
2
11 Nm (1.1 m • kgf, 8.0 ft • Ib)
6 × 50 mm
6 × 25 mm 13 14
7
LT 11
572 12
A
6 × 70 mm
11 Nm (1.1 m • kgf, 8.0 ft • Ib) 8 7090

1 Bolt 6
2 Bolt 1
3 Muffler 1
4 Dowel pin 2
5 Spacer 1
6 Grommet 1
7 Water pipe 1
8 Rubber seal 1
7-21
BRKT OIL PAN E
22
11 Nm (1.1 m • kgf, 8.0 ft • Ib)

6 × 25 mm
21
9
20 10
19
18
LT 4
572 17
LT
572
15 3 1
LT
6 × 30 mm
572 5
16 6 LT
572
2
11 Nm (1.1 m • kgf, 8.0 ft • Ib)
6 × 50 mm
6 × 25 mm 13 14
7
LT 11
572 12
A
6 × 70 mm
11 Nm (1.1 m • kgf, 8.0 ft • Ib) 8 7090

9 Exhaust manifold gasket 2 Not reusable
10 Plate 1
11 Exhaust seal 1
12 Bolt 4
13 Exhaust manifold 1
15 Bolt 12
16 Oil pan 1
7-22
BRKT OIL PAN E
22
11 Nm (1.1 m • kgf, 8.0 ft • Ib)

6 × 25 mm
21
9
20 10
19
18
LT 4
572 17
LT
572
15 3 1
LT
6 × 30 mm
572 5
16 6 LT
572
2
11 Nm (1.1 m • kgf, 8.0 ft • Ib)
6 × 50 mm
6 × 25 mm 13 14
7
LT 11
572 12
A
6 × 70 mm
11 Nm (1.1 m • kgf, 8.0 ft • Ib) 8 7090

17 Bolt 3
18 Collar 3
19 Oil strainer 1
20 Rubber gasket 1 Not reusable
22 Exhaust guide 1
procedure.
7-23
BRKT CLAMP BRACKETS E
CLAMP BRACKETS 7
REMOVING/INSTALLING THE CLAMP BRACKETS
7100

Upper case assembly Refer to “UPPER CASE ASSEMBLY” on
page 7-16.
1 Grease nipple 4
2 Ground lead 1
3 Bolt 4
4 Ground lead 1
5 Anode bracket 2
6 Anode 1
7 Trim sensor 1
8 Self-locking nut 1
7-24
BRKT CLAMP BRACKETS E
7100

9 Cam 1
10 Bolt 2
11 Clamp bracket bolt 1
12 Starboard clamp bracket 1
13 Port clamp bracket 1
14 Bushing 2
15 Grease nipple 1
16 Ground lead 1
17 Swivel bracket assembly 1
procedure.
7-25
BRKT STEERING ARM E
STEERING ARM 7
REMOVING/INSTALLING THE STEERING ARM
7110

Upper case assembly Refer to “UPPER CASE ASSEMBLY” on
page 7-16.
1 Circlip 1
2 Steering arm yoke 1
3 Washer 1
4 Washer 1
5 O-ring 1
6 Steering arm 1
7 Washer 1
8 Bushing 2
9 Swivel bracket assembly 1
procedure.
7-26
BRKT SWIVEL BRACKET ASSEMBLY E
SWIVEL BRACKET ASSEMBLY 7
DISASSEMBLING/ASSEMBLING THE SWIVEL BRACKET ASSEMBLY
7120

Steering arm Refer to “STEERING ARM” on page 7-26.
1 Nut 2
2 Trim stopper 2
3 Bolt 1
4 Spring holder 1
5 Spring 1
6 Pin 2
7-27
BRKT SWIVEL BRACKET ASSEMBLY E
7120

7 Starboard tilt stop lever 1
8 Port tilt stop lever 1
9 Bushing 2
10 Bushing 2
11 Tilt stop lever joint assembly 1
procedure.
7-28
BRKT POWER TRIM AND TILT UNIT E
POWER TRIM AND TILT UNIT 7
REMOVING/INSTALLING THE POWER TRIM AND TILT UNIT
7130

Tilt up the outboard
1 Power trim and tilt lead 2
3 Bolt 1
4 Ground lead 1
5 Circlip 1
6 Upper mounting pin 1
7-29
7130

7 Bolt 2
8 Washer 2
9 Lower mounting pin 1
10 Power trim and tilt unit 1
11 Collar 6
procedure.
7-30
REMOVING THE POWER TRIM AND

TILT UNIT
WARNING
After tilting up the outboard, be sure to
support it with the tilt stop levers.
Otherwise, the outboard could suddenly
lower if the power trim and tilt unit should
lose fluid pressure.
NOTE:
Tilt up the outboard and then turn the tilt
stop levers 1 to support it.
Remove:
• Power trim and tilt unit
7140 NOTE:
Slightly lower the tilt ram assembly and
then remove the power trim and tilt unit.
BLEEDING THE POWER TRIM AND

TILT UNIT
NOTE:
Install the power trim and tilt unit onto the
outboard before bleeding.
Bleed:
• Air bubbles
(from the power trim and tilt unit)
Bleeding steps
(1) Connect the battery leads to the bat-
tery.
(2) Loosen the manual valve 1 by turning
it counterclockwise until it stops.
7150
7-31
(3) Tilt up the outboard fully, then release

it, and let it lower by its own weight.
(4) Tighten the manual valve by turning it
clockwise.
(5) Let the power trim and tilt fluid settle
for about 5 minutes.
(6) Push and hold the power trim and tilt
switch in the up position until the out-
board is fully tilted up.
7160
(7) Turn the tilt stop levers to support the
outboard. Then, let the power trim and
tilt fluid settle for about 5 minutes.
(8) Remove the reservoir cap 2 and check
that fluid is up to the brim as shown.
Add fluid if the level is below the brim.
(9) Install the power trim and tilt reservoir
cap.
(10) Repeat the above steps two or three
times until the power trim and tilt fluid
is at the correct level.
7170
7-32
BRKT RESERVOIR AND POWER TRIM AND TILT MOTOR E
RESERVOIR AND POWER TRIM AND TILT MOTOR 7
REMOVING/INSTALLING THE RESERVOIR AND POWER TRIM AND TILT MOTOR
7180

Power trim and tilt unit Refer to “POWER TRIM AND TILT UNIT”
on page 7-29.
1 Reservoir cap 1
2 Bolt 3
3 Reservoir 1
4 Bolt 4
5 Power trim and tilt motor 1
6 O-ring 1
7 Drive pin 1
8 Gear pump housing filter 1
procedure.
7-33
WARNING
• To prevent the hydraulic fluid from spurt-
ing out due to internal pressure, the out-
board should be kept fully tilted up (the
tilt rod at full length).
• After removing the power trim and tilt
motor or reservoir, do not push the tilt
ram down. This may cause hydraulic fluid
to spurt out from the port.
CAUTION:
Do not wipe hydraulic system components
with rags, paper, tissues, or the like, as
fibers from such material will cause mal-
functions if they enter the system.
CHECKING THE RESERVOIR

1. Drain:
• Power trim and tilt fluid
2. Check:
• Reservoir
CHECKING THE GEAR PUMP

HOUSING FILTER
Check:
• Gear pump housing filter
Damage/tears → Replace.
7-34
INSTALLING THE POWER TRIM AND

TILT MOTOR
1. Install:
• Gear pump housing filter 1
• Drive pin 2
2. Fill:
• Gear pump housing
7190 Recommended power trim and

tilt fluid
ATF Dexron II
NOTE:
Add power trim and tilt fluid until it reaches
the top of the gear pump housing.
3. Bleed:
• Air bubbles
NOTE:
• Remove all of the air bubbles with a
syringe or suitable tool as shown.
• Turn the gear pump gears with a screw-
driver and then remove any air between
7200 the gear teeth.
4. Install:
• O-ring 1
• Power trim and tilt motor 2
• Bolt 3
NOTE:
Align the armature shaft with the recess in
the drive pin.
7210
7-35
FILLING THE RESERVOIR
WARNING
To prevent the hydraulic fluid from spurt-
ing out due to internal pressure, the tilt
ram should be kept at full length.
1. Fill:
• Reservoir

tilt fluid
ATF Dexron II
2. Check:
• Power trim and tilt fluid level
Level is low → Add power trim and tilt
fluid to the proper level.
7220
BLEEDING THE POWER TRIM AND

TILT UNIT
NOTE:
This bleeding must be done before install-
ing the power trim and tilt unit onto the out-
board.
1. Bleed:
• Air bubbles
(from the power trim and tilt unit)
Bleeding steps
(1) Set the power trim and tilt unit upright.
(2) Connect the leads of the power trim
and tilt on the battery terminals until
the trim and tilt ram assemblies are
fully compressed.
7230
NOTE:
If the rams will not go down, refer to the fol-
lowing.
A. Connect the leads of the power trim and
tilt on the battery terminals until the trim
and tilt ram assemblies are fully
extended. Then, reverse the leads on the
battery terminals until the trim and tilt
ram assemblies are fully compressed.
7240
7-36
B. If step A was unsuccessful, connect the

leads on the battery terminals and fully
compress the tilt ram assembly by hand.
C. If step B was unsuccessful, loosen the
manual valve, compress the trim and tilt
ram assemblies fully by hand, and then
tighten the manual valve. Then, com-
press and extend the trim and tilt ram
assemblies by connecting the leads on
the battery terminals in the up and down
positions.
D. If step C was unsuccessful, disassemble,
check, and correct any problems with the
power trim and tilt unit.
(3) Connect the leads on the battery termi-

nals in the up position until the trim
and tilt ram assemblies are fully
extended.
7240
(4) Remove the power trim and tilt reser-

voir cap and check that fluid is up to
the brim as shown. Add power trim
and tilt fluid if the level is below the
brim.
(5) Repeat the above steps two or three
times until the fluid is at the correct
level.
7220
2. Check:
• Power trim and tilt unit operation
Unsmooth operation → Bleed the
power trim and tilt unit again.
7-37
MEASURING THE HYDRAULIC

PRESSURE
Check:
• Hydraulic pressure
Out of specification → Repair.
Hydraulic pressure
(with the power trim and tilt ram
assemblies fully extended)
9.8 - 11.8 MPa
(100 - 120 kg/cm2)
assemblies fully compressed)
5.9 - 8.8 MPa (60 - 90 kg/cm2)
NOTE:
Before measuring the hydraulic pressure,
bleed the power trim and tilt unit.
Measuring steps
(1) Fully tilt up the power trim and tilt ram
assemblies.
(2) Remove the circlip 1.
(3) Remove the manual valve 2 and
install the up-relief valve attachment
and hydraulic pressure gauge and
tighten them to the specified torque.
7250
Up-relief valve attachment ...... 3
90890-06773
Hydraulic pressure gauge ........ 4
90890-06776
Hydraulic pressure gauge

9 Nm (0.9 m • kgf, 6.5 ft • lb)
T.
R.
Up-relief valve attachment

4 Nm (0.4 m • kgf, 2.9 ft • lb)
NOTE:
7260
Remove the manual valve and then quickly
attach the special tools before any fluid
comes out.
7-38

nals in the down position until the
power trim and tilt ram assemblies are
fully compressed.
7230

nals in the up position until the power
trim and tilt ram assemblies are fully
extended. Then, measure the hydraulic
pressure.
Hydraulic pressure
assemblies fully extended)
9.8 - 11.8 MPa
7240 (100 - 120 kg/cm2)
(6) After measuring the hydraulic pres-

sure, remove the special tools and
quickly attach the down-relief valve
attachment.
Hydraulic pressure gauge ........ 4

90890-06776
Down-relief valve attachment. 5
90890-06774
7270
Hydraulic pressure gauge

9 Nm (0.9 m • kgf, 6.5 ft • lb)
T.
R.
Down-relief valve attachment

4 Nm (0.4 m • kgf, 2.9 ft • lb)
(7) Remove the reservoir cap and check

that fluid is up to the brim as shown.
Add fluid if the level is below the brim.
(8) Install the reservoir cap.
7220 nals in the down position until the
fully compressed. Then, measure the
hydraulic pressure.
Hydraulic pressure
assemblies fully compressed)
5.9 - 8.8 MPa (60 - 90 kg/cm2)
7-39
(10) After measuring the hydraulic pres-

sure, connect the leads on the battery
terminals in the up position until the
fully extended.
(11) Remove the special tools.
(12) Install the manual valve and circlip.
NOTE:
7280 After measuring the hydraulic pressure,
bleed the power trim and tilt unit.
7240
7-40
BRKT TILT RAM ASSEMBLY AND GEAR PUMP UNIT E
TILT RAM ASSEMBLY AND GEAR PUMP UNIT 7
REMOVING/INSTALLING THE TILT RAM ASSEMBLY AND GEAR PUMP UNIT
7290

Reservoir and power trim and tilt Refer to “RESERVOIR AND POWER TRIM
motor AND TILT MOTOR” on page 7-33.
1 Manual valve 1
2 Tilt ram end screw 1
3 Tilt ram assembly 1
4 O-ring 2
5 Bolt 3
6 Gear pump unit 1
7-41
7290

7 Check valve assembly 1
8 Gear pump 1
9 Shuttle valve 2
10 Check valve 2
11 Up-relief valve assembly 1
12 Down-relief valve assembly 1
procedure.
7-42
REMOVING THE TILT RAM END

SCREW
Loosen:
• Tilt ram end screw
End screw wrench

YB-06548 / 90890-06548
7300
NOTE:
Hold the power trim and tilt unit in a vise
using aluminum plates on both sides.
REMOVING THE GEAR PUMP UNIT

Remove:
• Bolt 1
• Gear pump unit 2
• O-ring 3
7310
• Check valve 4
NOTE:
Place a container under the power trim and
tilt unit.
DISASSEMBLING THE GEAR PUMP

UNIT
1. Remove:
• Bolt 1
• Pump gear 2
• Up-relief valve assembly 3
• Ball (4.76 mm/0.187 in) 4
• Shuttle valve 5
7320
• Ball (3.18 mm/0.125 in) 6
NOTE:
When removing the pump gears, note their
original direction and position for proper
assembly.
7-43
2. Remove:
• Check valves 1 and 2
NOTE:
To remove the check valves, cover the gear
pump housing with a clean cloth and then
blow compressed air through holes a
and b.
7330
CHECKING THE TILT RAM

Check:
• Tilt ram
Excessive scratches → Replace.
Bends/excessive corrosion → Replace.
Rust → Polish.
(with 400 - 600 grit sandpaper)
CHECKING THE GEAR PUMP UNIT

Check:
• Shuttle valves 1
• Check valve assemblies 2
Clogs/damage/wear → Replace.
• Pump gears 3
Damage/wear → Replace the gear
pump unit.
• Down-relief valve assembly 5
Damage/wear → Replace the gear
pump unit.
• Balls 6
7340
7-44
ASSEMBLING THE GEAR PUMP UNIT
CAUTION:
Install all components in their original
direction and position for proper assembly
and operation.
1. Install:
• Balls (3.18 mm/0.125 in) 1
• Shuttle valves 2
NOTE:
Apply grease to the balls to prevent them
from falling out of the gear pump.
7350
2. Install:
• O-ring 1
• Ball (3.18 mm/0.125 in) 2
• Up-relief valve pin 3
• Spring 4
• Up-relief valve 5
7360
3. Install:
• O-rings 1
• Check valves 2
• Balls (4.76 mm/0.187 in) 3
• Pump gears 4
4. Install:
7370 • Gear pump 1
• Bolt 2
• Filter 3
• O-ring 4
• Down-relief valve 5
• Filter 6
NOTE:
Tighten the bolts evenly and make sure the
pump gears turn smoothly.
7380
7-45
INSTALLING THE GEAR PUMP UNIT

1. Install:
• O-rings 1
• Ball 2
• Pin 3
• Check valve 4
• Check valve assembly 5
7390 NOTE:
When installing the check valve assembly,
make sure the pin is on the tilt ram cylinder
side as shown.
2. Install:
7400
• Gear pump unit 1
• Bolt 2
INSTALLING THE TILT RAM

ASSEMBLY
WARNING
To prevent the hydraulic fluid from spurt-
ing out due to internal pressure, the tilt
ram should be kept at full length.
1. Fill:
• Tilt ram cylinder

tilt fluid
ATF Dexron II
NOTE:
7410
7-46
2. Fill:
• Gear pump housing

tilt fluid
ATF Dexron II
NOTE:
7420 Add power trim and tilt fluid through the
hole a until the fluid level is to the top of
the gear pump unit.
3. Install:
• Tilt ram assembly
NOTE:
Place the tilt ram end screw at the bottom
of the tilt ram and install the tilt ram assem-
bly into the tilt ram cylinder.
7430
4. Tighten:
• Tilt ram end screw
End screw wrench

YB-06548 / 90890-06548
Tilt ram end screw

130 Nm (13 m • kgf, 94 ft • lb)
T.
R.
7300
7-47
BRKT TRIM RAM ASSEMBLIES AND FREE PISTON E
TRIM RAM ASSEMBLIES AND FREE PISTON 7
REMOVING/INSTALLING THE TRIM RAM ASSEMBLIES AND FREE PISTON
7440

Tilt ram assembly and gear Refer to “TILT RAM ASSEMBLY AND
pump unit GEAR PUMP UNIT” on page 7-41.
1 Trim ram end screw 2
2 Trim ram 2
3 O-ring 2
4 Seal ring 2
5 Free piston 1
6 O-ring 1
7 Piston ring 1
procedure.
7-48
Å ı REMOVING THE TRIM RAM END

SCREWS
Loosen:
• Trim ram end screw
End screw wrench

YB-06175-1A / 90890-06548
7450
ı For worldwide
NOTE:
REMOVING THE FREE PISTON

1. Drain:
• Power trim and tilt fluid
NOTE:
After removing the trim ram assemblies,
drain the fluid from the power trim and tilt
unit.
2. Install:
• Trim ram assemblies 1
NOTE:
Finger-tighten the trim ram assemblies and
then cover the tilt cylinder openings with a
clean cloth.
3. Remove:
7460 • Free piston 2
WARNING
Never look into the tilt cylinder opening
because the free piston and hydraulic fluid
may be expelled out forcefully.
NOTE:
Remove the free piston by blowing com-
7470 pressed air through the hole a.
7-49
CHECKING THE TRIM RAMS

Check:
• Trim ram
Bends/excessive corrosion → Replace.
Rust → Polish.
(with 400 - 600 grit sandpaper)
CHECKING THE FREE PISTON

Check:
• Free piston
CHECKING THE TRIM RAM

CYLINDERS
Check:
• Trim ram cylinder
Cracks/excessive scratches → Replace
the power trim and tilt unit.
INSTALLING THE FREE PISTON

1. Fill:
• Fluid passages

tilt fluid
ATF Dexron II
Quantity
30 cm3 (1.0 US oz, 1.1 lmp oz)
NOTE:
• Hold the power trim and tilt unit in a vise
• Add power trim and tilt fluid through the
hole a.
7480
7-50
2. Install:
• Piston ring 1
• O-ring 2
• Free piston 3
NOTE:
Push the free piston into the tilt ram cylin-
der until it bottoms out.
7490
INSTALLING THE TRIM RAMS
WARNING
Do not push the trim rams down while
installing them into the trim ram cylinders.
Otherwise, the hydraulic fluid may spurt
out from the unit.
1. Fill:
• Trim ram cylinders

tilt fluid
ATF Dexron II
NOTE:
7500
2. Fill:
• Fluid passages

tilt fluid
ATF Dexron II
NOTE:
7510 Add power trim and tilt fluid through holes
a, b and c until all of the passages are
filled.
7-51
3. Install:
• Trim ram assemblies 1
NOTE:
Place each trim ram end screw at the bot-
tom of each trim ram and install them into
the trim ram cylinders.
7520
Å ı 4. Tighten:
• Trim ram end screw
End screw wrench

YB-06175-1A / 90890-06548
Trim ram end screw

80 Nm (8.0 m • kgf, 58 ft • lb)
T.
R.
7450
ı For worldwide
7-52
– +
ELEC E
CHAPTER 8
ELECTRICAL SYSTEMS
ELECTRICAL COMPONENTS......................................................................... 8-1

(Port view) ................................................................................................ 8-1
(Starboard view) ...................................................................................... 8-2
(Front view) .............................................................................................. 8-3
(Aft view) .................................................................................................. 8-4
(Top view)................................................................................................. 8-5
WIRE HARNESS ............................................................................................. 8-6
ELECTRICAL COMPONENTS ANALYSIS ..................................................... 8-8

DIGITAL CIRCUIT TESTER....................................................................... 8-8
MEASURING THE PEAK VOLTAGE........................................................ 8-8
PEAK VOLTAGE ADAPTOR..................................................................... 8-8
MEASURING A LOW RESISTANCE........................................................ 8-9
IGNITION SYSTEM....................................................................................... 8-10

CHECKING THE FUSES ......................................................................... 8-11
MEASURING THE IGNITION COIL ASSEMBLY................................... 8-11
CHECKING THE IGNITION SPARK GAP ............................................... 8-12
MEASURING THE IGNITION SYSTEM PEAK VOLTAGE .................... 8-13
IGNITION CONTROL SYSTEM .................................................................... 8-15

MEASURING THE PULSER COIL OUTPUT PEAK VOLTAGE.............. 8-16
MEASURING THE ENGINE COOLING WATER TEMPERATURE
SENSOR RESISTANCE ......................................................................... 8-16
CHECKING THE OIL PRESSURE SWITCH CONTINUITY..................... 8-17
MEASURING THE THROTTLE POSITION SENSOR ............................ 8-18
FUEL CONTROL SYSTEM............................................................................ 8-19

MEASURING THE ENGINE COOLING WATER TEMPERATURE
SENSOR RESISTANCE ......................................................................... 8-20
MEASURING THE THROTTLE POSITION SENSOR ............................ 8-20
CHECKING THE FUEL INJECTORS....................................................... 8-21
– +
ELEC E
STARTING SYSTEM..................................................................................... 8-22

CHECKING THE WIRE HARNESS CONTINUITY .................................. 8-23
1
CHECKING THE WIRE CONNECTIONS ................................................ 8-23
CHECKING THE STARTER RELAY ........................................................ 8-23
CHECKING THE SHIFT POSITION SWITCH CONTINUITY .................. 8-24
STARTER MOTOR ........................................................................................ 8-25

DISASSEMBLING/ASSEMBLING THE STARTER MOTOR.................. 8-25
REMOVING THE STARTER MOTOR PINION ....................................... 8-28
CHECKING THE STARTER MOTOR PINION ........................................ 8-28
CHECKING THE ARMATURE ................................................................ 8-28
MEASURING THE BRUSHES ................................................................ 8-29
2
CHECKING THE MAGNETIC SWITCH RELAY...................................... 8-30
CHARGING SYSTEM.................................................................................... 8-31

MEASURING THE LIGHTING COIL OUTPUT PEAK VOLTAGE .......... 8-32
3
MEASURING THE RECTIFIER/REGULATOR OUTPUT
PEAK VOLTAGE .................................................................................... 8-32
POWER TRIM AND TILT SYSTEM .............................................................. 8-33

4
CHECKING THE POWER TRIM AND TILT RELAY................................ 8-34
5
CHECKING THE TRAILER SWITCH CONTINUITY................................ 8-35
MEASURING THE TRIM SENSOR RESISTANCE................................. 8-35
POWER TRIM AND TILT MOTOR................................................................ 8-36

DISASSEMBLING/ASSEMBLING THE POWER TRIM AND
TILT MOTOR.......................................................................................... 8-36
REMOVING THE STATOR ..................................................................... 8-38
REMOVING THE BRUSH ....................................................................... 8-38
CHECKING THE BRUSH ........................................................................ 8-38
CHECKING THE ARMATURE ................................................................ 8-39
6
INSTALLING THE BRUSH ..................................................................... 8-40
INSTALLING THE ARMATURE ............................................................. 8-40
INSTALLING THE STATOR ................................................................... 8-40
7
8
9
– +
ELEC ELECTRICAL COMPONENTS E
ELECTRICAL COMPONENTS 8
(Port view) 8
1 2 3 4
8010
1 Oil pressure switch

2 Throttle position sensor
3 Idle speed control valve
4 Intake air pressure sensor
5 Fuel injector
6 High-pressure fuel pump
8-1
– +
(Starboard view) 8
3 4
2
1
5
8020
1 Ignition coil
2 Engine cooling water temperature sensor
3 Starter motor
4 Relay (magnetic switch)
5 Battery lead terminal
6 Junction box assembly
8-2
– +
(Front view) 8
8
2
4
7
8030
1 Fuse (30A)
2 Main relay
3 ECM
4 Rectifier/regulator
5 Intake air temperature sensor
6 Power trim and tilt relay
7 Starter relay
8 Fuse (20A)
8-3
– +
(Aft view) 8
8040
1 Spark plug
2 Spark plug lead
8-4
– +
(Top view) 8
4
6
5
8
8050
1 Fuel injector
2 Intake air pressure sensor
3 Idle speed control valve
4 Throttle position sensor
5 Trailer switch
7 Starter
8 Lighting coil
8-5
– +
ELEC WIRE HARNESS E
WIRE HARNESS 8
B
6 D
7 8 A
9 F
0 C
1 E G G H H
6 5 4 3 2 1
12 11 10 9 8 7
6 9 3 4 5 8 7 0 A B C D E F G G H H
B B B/W B/R B/Y R B Y Sb Br P/B P/W Sb R R R/Y Y L/W R Sb Br R R R R R R
P P R/Y R/Y B G W P Lg P P/B Lg R/Y B G L/W Lg R/B B R R R R R
W/B
1 B
B
B
B
B
B
B/R
B/W
W/B
B/Y
R/Y
2 W
G
P
G
P/W
P/B
L/W
8060
Connect to: 9 Warning lamp B : Black B/R : Black/red

1 Ground 0 PTT relay Br : Brown B/W : Black/white
2 ECM A Starter relay G : Green B/Y : Black/yellow
3 Ignition coil B Main relay Lg : Light green L/W : Blue/white
4 Ignition coil C Trailer switch P : Pink P/B : Pink/black
5 Engine cooling water D Starter relay R : Red P/W : Pink/white
temperature sensor E Rectifier/regulator Sb : Sky blue R/B : Red/black
6 Trim meter F Starter motor W : White R/Y : Red/yellow
7 Trim sensor G Fuse 20A Y : Yellow W/B : White/black
8 Remote control H Fuse 30A
8-6
– +
ELEC WIRE HARNESS E
4
A
6
3 8 9 9 9
9
5 7
3
1
2 0
4 3 4 5 7 6 8 9 0 A 9 9 9
W/B W/R B B B B/Y R/Y R/Y P/W O B G G/B P/G O R/Y B L Pu/B Pu/Y Pu/G
R/Y R/Y R/Y R/Y B Pu/R L/Y R/Y R/Y R/Y R/Y
B B B B B B P
R/Y R/Y G/Y G/R
3 B
O
O
P/G
P
L
Pu/R
Pu/G
Pu/B
Pu/Y
R/Y
G/R
G/B
2 G/Y
G
B/Y
L/Y
P/W
W/B
W/R
B
B
8070
Connect to: 8 Intake air pressure O : Orange Pu/B : Purple/black

1 Pulser coil sensor P : Pink Pu/G : Purple/green
2 ECM 9 Fuel injectors B/Y : Black/yellow Pu/R : Purple/red
3 Ground lead 0 Shift position switch G/B : Green/black Pu/Y : Purple/yellow
4 Intake air temperature A High-pressure fuel pump G/R : Green/red R/Y : Red/yellow
sensor G/Y : Green/yellow W/B : White/black
5 Oil pressure switch B : Black L/Y : Blue/yellow W/R : White/red
6 Idle speed control valve G : Green P/G : Pink/green
7 Throttle position sensor L : Blue P/W : Pink/white
8-7
– +
ELEC ELECTRICAL COMPONENTS ANALYSIS E
ELECTRICAL COMPONENTS
ANALYSIS 8
DIGITAL CIRCUIT TESTER 8
Digital tester
J-39299 / 90890-06752
NOTE:
8080
“ ” indicates a continuity of electric-
ity which means a closed circuit at the
respective switch position.
MEASURING THE PEAK VOLTAGE 8
NOTE:
• When checking the condition of the igni-
tion system it is useful to know the peak
voltage.
• Cranking speed is dependant on many
factors (e.g., fouled or weak spark plugs, a
weak battery). If one of these is defective,
the peak voltage will be lower than speci-
fication.
• If the peak voltage measurement is not
within specification the engine will not
operate properly.
PEAK VOLTAGE ADAPTOR 8
NOTE:
The peak voltage adaptor should be used
with the digital circuit tester.
Peak voltage adaptor

YU-39991 / 90890-03169
8090
8-8
– +
ELEC ELECTRICAL COMPONENTS ANALYSIS E
NOTE:
• When measuring the peak voltage, set the
selector to the DC voltage mode.
• Make sure the peak voltage adaptor leads
are properly installed in the digital tester.
• Make sure the positive pin (the “+” mark
facing up as shown) on the peak voltage
8100
adaptor is installed into the positive termi-
nal of the digital tester.
• The test harness is needed for the follow-
ing tests.
Measuring steps
(1) Disconnect the coupler connections.
(2) Connect the test harness between the
couplers.
(3) Connect the peak voltage adaptor
probes to the connectors which are
being checked.
(4) Start or crank the engine and observe
the measurement.
8110
MEASURING A LOW RESISTANCE 8
When measuring a resistance of 10 Ω or

less with the digital tester, the correct mea-
surement cannot be obtained because of
the tester’s internal resistance.
To obtain the correct value, subtract the
internal resistance from the displayed mea-
surement.
Correct value
Displayed measurement –
internal resistance
NOTE:
The internal resistance of the digital tester
can be obtained by connecting both of its
probes.
8-9
– +
ELEC IGNITION SYSTEM E
IGNITION SYSTEM 8
0 8
B
R
R B
G
G
9 G
G
R
B
4
B
G
G G R
2 R/Y
4
1 1
R/Y
1 2 B/R
B
W/R W/B
B/R
13 2 R/Y
R/Y
W/B B W/R
14
B/W
B/W
R/Y
R R
B
A W/R W/B
B P O
R/Y R
B P O
6
3
W
B 5
W
B
25 26 27 28 29 30 1 2 3 4 5 6 7 8 9 10 11 12
P :2 B/R : T
31 32 33 34 35 36 13 14 15 16 17 18 19 20 21 22 23 24 W/B : D B/W : Z
W/R : E
30 29 28 27 26 25 12 11 10 9 8 7 6 5 4 3 2 1 O :F
36 35 34 33 32 31 24 23 22 21 20 19 18 17 16 15 14 13
W :P
8120
1 Spark plugs 9 Battery R : Red

2 Ignition coils 0 Fuse (30A) W : White
3 Throttle position sensor A Fuse (20A) B/R : Black/red
(TPS) B Main relay B/W : Black/white
4 Pulser coils R/Y : Red/yellow
5 10P coupler B : Black W/B : White/black
6 ECM G : Green W/R : White/red
7 Lighting coil O : Orange
8 Rectifier/regulator P : Pink
8-10
– +
Refer to “CHECKING THE BATTERY”

on page 3-21.
CHECKING THE FUSES 8
1. Check:
• Fuse holder continuity
No continuity → Check the fuse holder
leads.
2. Check:
• Fuse holder lead continuity
No continuity → Replace the fuse
holder.
Continuity → Check the fuse.
3. Check:
• Fuse continuity
No continuity → Replace.
• Fuse rating
Fuse rating
1: 12 V - 20 A
2: 12 V - 30 A
8180
MEASURING THE IGNITION COIL

ASSEMBLY 8
Measure:
• Ignition coil assembly resistance
Ignition coil assembly resistance

18.97 - 35.23 kΩ
(For cylinder No. 1, 4)
18.55 - 34.45 kΩ
(For cylinder No. 2, 3)
8240
8-11
– +
CHECKING THE IGNITION SPARK GAP 8
WARNING
• Do not touch any of the connections of
the spark gap tester lead wires.
• Do not let sparks leak out of the removed
spark plug cap.
• Keep flammable gas or liquids away,
8130
since this test can produce sparks.
Check:
• Ignition spark gap
Spark is weak → Check the ignition
system.
Checking steps
(1) Remove the spark plugs from the
engine.
(2) Connect a spark plug cap to the spark
gap tester.
(3) Set the spark gap length on the adjust-
ing knob.
Spark gap tester

8160 YM-34487 / 90890-06754
(4) Crank the engine and observe the

spark through the discharge window
of the spark gap tester.
8170
8-12
– +
MEASURING THE IGNITION SYSTEM

PEAK VOLTAGE 8
WARNING
When checking the peak voltage do not
touch any of the connections of the digital
tester lead wires.
NOTE:
• If there is no spark or the spark is weak,
continue with the ignition system test.
• If a good spark is obtained, the problem is
not with the ignition system, but possibly
with the spark plug(s) or another compo-
nent.
1. Measure:
NOTE:
• The peak voltage adaptor should be used
with the digital circuit tester.
• When measuring the peak voltage, set the
B/R
Peak voltage adaptor

YU-39991 / 90890-03169
• ECM unit output peak voltage

B/W
Below specification → Check the wire
harness.
Correct the wire harness → Replace
the ECM unit.
ECM unit output peak voltage

8190 Black/red (B/R) – Ground
Black/white (B/W) – Ground
Unloaded Loaded
r/min
Cranking 1,500 3,500
V 5.0 122 242 245

90890-06792
8-13
– +
2. Measure:
8210
• Pulser coil output peak voltage
Below specification → Replace the
pulser coil.
Pulser coil output peak voltage

White/black (W/B) – Black (B)
White/red (W/R) – Black (B)
W/B B W/R
Unloaded Loaded
r/min
V 3.5 3.0 26 44

90890-06791
8-14
– +
ELEC IGNITION CONTROL SYSTEM E
IGNITION CONTROL SYSTEM 8
R
7
8
8
9
R
9
W/B
4 4
W/R
W/R
B B
W/B
W/B
W/R B W/R
W/R
2
3 5
6
1 B/Y B
B
B P O
B/Y B
P/W
R/Y R O B
P
B
B/Y B
P O
P/W
O :F
25 26 27 28 29 30 1 2 3 4 5 6 7 8 9 10 11 12
P :2
31 32 33 34 35 36 13 14 15 16 17 18 19 20 21 22 23 24
B/Y : Q
P/W : 6
R/Y : O
30 29 28 27 26 25 12 11 10 9 8 7 6 5 4 3 2 1
36 35 34 33 32 31 24 23 22 21 20 19 18 17 16 15 14 13
W/B : D
W/R : E
8250
1 ECM B : Black
2 Engine cooling water temperature sensor O : Orange
3 Oil pressure switch P : Pink
4 Pulser coils R : Red
5 Throttle position sensor (TPS) B/Y : Black/yellow
6 Main relay P/W : Pink/white
7 Battery R/Y : Red/yellow
8 Fuse (30A) W/B : White/black
9 Fuse (20A) W/R : White/red
8-15
– +

on page 3-21.
Refer to “CHECKING THE FUSES” on

page 8-11.
MEASURING THE PULSER COIL

OUTPUT PEAK VOLTAGE 8
Refer to “MEASURING THE IGNITION

SYSTEM PEAK VOLTAGE” on
page 8-13.
MEASURING THE ENGINE COOLING

WATER TEMPERATURE SENSOR
RESISTANCE 8
Measure:
• Engine cooling water temperature
sensor resistance
8260 Engine cooling water
temperature sensor resistance
Black/yellow (B/Y) – Black (B)
5 ˚C (41 ˚F): 4.62 kΩ
20 ˚C (68 ˚F): 2.44 kΩ
100 ˚C (212 ˚F): 0.19 kΩ
Measuring steps
(1) Place the engine cooling water tem-
perature sensor in a container filled
with water.
(2) Place a thermometer in the water.
(3) Slowly heat the water.
(4) Measure the resistance when the spec-
ified temperature is reached.
8-16
– +
CHECKING THE OIL PRESSURE

SWITCH CONTINUITY 8
Measure:
• Oil pressure switch continuity
Mity vac
YB-35956 / 90890-06756
8270
Oil pressure switch continuity
pressure
150 kPa (1.5 kg/cm2, 21.33 psi)
and below
8-17
– +
8280
MEASURING THE THROTTLE
POSITION SENSOR 8
NOTE:
When measuring the output voltage, set the
Measure:
• Throttle position sensor output volt-
age
Out of specification → Adjust the
throttle position sensor.
Refer to “ADJUSTING THE THROTTLE
POSITION SENSOR” on page 3-7.
P B Throttle position sensor output
voltage
0.732 ± 0.014 V
Measuring steps
(1) Connect the test harness (3-pin) as
shown.

90890-06793
(2) Connect the battery leads to a 12-V

battery.
(3) Turn the engine switch to the on posi-
tion.
(4) Measure the throttle position sensor
output voltage.
(5) Start the engine and measure the out-
put voltage again.
NOTE:
Make sure the throttle position sensor out-
put voltage is within specification when the
throttle is fully closed and fully opened.
8-18
– +
ELEC FUEL CONTROL SYSTEM E
FUEL CONTROL SYSTEM 8
2 R/Y
5
R/Y W/B
B B
W/R
B
W/R
B
6 Y
R/Y
W/B W/B
W/R
1
#3 #1
3
B
P
O
Pu/Y R/Y
Pu/R R/Y
R/Y
R/Y
O P B 7
Pu/R
Pu/Y R/Y
B Y
#4 #2
R G
B
Y
O P B
G
R/Y R
R/Y
Pu/G R/Y R/Y R/Y
R/Y R/Y
R/Y M
Pu/B L L
Pu/B
R
Pu/G
4 L G
B Y
Y R R/Y
B B
R/Y G
G/Y R/Y R/Y
B/Y
B B
B/Y B/Y G
B R/Y
B G B
B
B G/B
E B G/Y B
B B G/B G/R G/R 8
C P/G
0 9
O
25 26 27 28 29 30 1 2 3 4 5 6 7 8 9 10 11 12
B/Y : 1 W/B :D Pu/R : L P/G
31 32 33 34 35 36 13 14 15 16 17 18 19 20 21 22 23 24 P :2 W/R :E Pu/B : M B R R
B B
P/G : 3 O :F L :N O
O :4 G :G R/Y : O D B A
30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13
Pu/G : 9 G/B :H B/Y : Q B/Y
+ -
36 35 34 33 32 31 12 11 10 9 8 7 6 5 4 3 2 1
Pu/Y : 0 G/Y :I B/G : Y B

R/Y : B G/R :J B/Y
8290
1 Fuel injectors 0 Fuse (20A) B : Black G/Y : Green/yellow

2 Joint connector A Battery G : Green P/G : Pink/green
3 Throttle position sensor B Engine cooling water L : Blue Pu/B : Purple/black
4 High-pressure fuel pump temperature sensor O : Orange Pu/G : Purple/green
5 Pulser coil C Intake air pressure P : Pink Pu/R : Purple/red
6 10P connector sensor R : Red Pu/Y : Purple/yellow
7 ECM D Intake air temperature Y : Yellow R/Y : Red/yellow
8 Main relay sensor B/Y : Black/yellow W/B : White/black
9 Fuse (30A) E Idle speed control valve G/B : Green/black W/R : White/red
G/R : Green/red
8-19
– +

on page 3-21.

page 8-11.
MEASURING THE ENGINE COOLING

WATER TEMPERATURE SENSOR
RESISTANCE 8
Refer to “MEASURING THE ENGINE

COOLING WATER TEMPERATURE
SENSOR RESISTANCE” on page 8-16.
MEASURING THE THROTTLE

POSITION SENSOR 8
Refer to “MEASURING THE THROT-

TLE POSITION SENSOR” on
page 8-18.
8-20
– +
CHECKING THE FUEL INJECTORS 8
1. Check:
• Fuel injector operating sound
No sound (no fuel is being sprayed) →
Check the high-pressure fuel pump.
1
Checking steps
8320 (2) Fully close the throttle valves.
(3) Attach the screwdriver 1 onto the fuel
injector body and check if all of the fuel
injectors have a solenoid valve operat-
ing sound.
2. Check:
• High-pressure fuel pump operating
sound
Correct → Replace the fuel injector (no
sound).
No sound → Check the main relay.
NOTE:
• The high-pressure fuel pump should
sound when the engine start switch is
turned on.
• Disconnect the Brown (Br) starter relay
1 lead 1 to prevent the engine from start-
ing.
8330
3. Check:
• Main relay continuity
main relay.
R
Engine Lead color
R/Y
R/Y start Red/yellow
switch Red (R)
G
Y (R/Y)
B
8340 OFF
ON
Correct → Replace the high-pressure

fuel pump.
8-21
– +
ELEC STARTING SYSTEM E
STARTING SYSTEM 8
6 M
2
5
Br
R
Br/W
Br
1
Br/W
3 B
Br
Br
B B
8350
1 Fuse (30A) B : Black

2 10P connector Br : Brown
3 Starter relay R : Red
4 Battery Br/W : Brown/white
6 Starter motor
8-22
– +

on page 3-21.

page 8-11.
CHECKING THE WIRE HARNESS

CONTINUITY 8
Check:
• Wire harness continuity
CHECKING THE WIRE CONNECTIONS 8
Check:
• Wire connections
Poor connection → Properly connect.
CHECKING THE STARTER RELAY 8
1 Check:
• Starter relay continuity
+ -
3 Checking steps
(1) Connect the tester and battery between
2 4
the starter relay terminals.
8360
Positive digital tester probe 1 →
Starter relay terminal
Negative digital tester probe 2 →
Starter relay terminal
Positive battery terminal →
Brown lead 3
Negative battery terminal →
Black lead 4
(2) Check that there is continuity between
the starter relay terminals.
8-23
– +
CHECKING THE SHIFT POSITION

SWITCH CONTINUITY 8
a
b Check:
• Continuity
Lead color
Switch
position Blue/Yellow
Black (B)
8370 (L/Y)
Home
a
position
b Depressed
8-24
– +
ELEC STARTER MOTOR E
STARTER MOTOR 8
DISASSEMBLING/ASSEMBLING THE STARTER MOTOR 8
6
19 7
8
9 2
A
18 6 × 52 mm
29
20
A
28 5
12
27
23
4
17
16 26
3
15 25
14
13
24 1
A
10 11
22
4 × 14 mm
6 × 120 mm
21 8380

Starter motor Refer to “IGNITION COILS AND STARTER
MOTOR” on page 5-14.
1 Nut 1
2 Bolt 2
3 Relay (magnetic switch) 1
4 Rubber dust 1
5 Spring 1
6 Starter motor pinion clip 1
7 Starter motor pinion stopper 1
8 Starter motor pinion 1
9 Spring 1
8-25
– +
6
19 7
8
9 2
A
18 6 × 52 mm
29
20
A
28 5
12
27
23
4
17
16 26
3
15 25
14
13
24 1
A
10 11
22
4 × 14 mm
6 × 120 mm
21 8380

10 Bolt 2
11 Screw 2
12 Yoke assembly 1
13 Rear cover 1
14 Thrust washer 1
15 Plate 1
16 Brush holder assembly 1
17 Brush assembly 1
18 Armature 1
19 Center bracket plate 1
8-26
– +
6
19 7
8
9 2
A
18 6 × 52 mm
29
20
A
28 5
12
27
23
4
17
16 26
3
15 25
14
13
24 1
A
10 11
22
4 × 14 mm
6 × 120 mm
21 8380

20 Shift lever 1
21 Outer ring gear 1
22 Planetary gear 3
23 E-ring 1
24 Pinion shaft 1
25 Center bracket 1
26 Thrust washer 1
27 Clutch assembly 1
28 Bearing 1
29 Housing 1
procedure.
8-27
– +
REMOVING THE STARTER MOTOR

1 PINION 8
Remove:
• Clips 1
NOTE:
Slide the pinion gear down as shown and
then remove the clips 1 with a thin screw
8390 driver.
CHECKING THE STARTER MOTOR

PINION 8
1. Check:
• Starter motor pinion teeth
2. Check:
• Starter motor pinion movement
8400
Incorrect → Replace.
NOTE:
Rotate the starter motor pinion counter-
clockwise and make sure it moves
smoothly. Also, rotate the starter motor pin-
ion clockwise and make sure it locks.
8410
CHECKING THE ARMATURE 8
1. Check:
• Commutator
(with 600 grit sandpaper)
8420
2. Measure:
• Commutator diameter
Commutator diameter limit

28.0 mm (1.10 in)
8430
8-28
– +
3. Check:
• Commutator undercut
Dirt/foreign matter → Clean.
(with compressed air)
8440
4. Measure:
• Commutator undercut a
armature.
Commutator undercut limit

0.2 mm (0.01 in)
8450
5. Check:
• Armature continuity
Armature continuity
Commutator
Continuity
segments a
8460
Segment –
No continuity
Armature core b
Segment –
No continuity
Armature shaft c
MEASURING THE BRUSHES 8
1. Measure:
• Brush length
brush assembly.
Brush length limit a

9.5 mm (0.37 in)
8470
8-29
– +
2. Check:
• Brush assembly continuity
2 1 Out of specification → Replace the
brush assembly.
Brush assembly continuity
Brush 1 – Brush 2 No continuity

8480
CHECKING THE MAGNETIC SWITCH

RELAY 8
Check:
• Magnetic switch relay continuity
Checking steps
(1) Remove the terminal 1 from the mag-
netic switch relay.
NOTE:
Remove the terminal to prevent the pinion
gear from turning.
1 (2) Connect the tester leads between the

magnetic switch relay terminals as
shown.
(3) Connect the Brown/white (Br/W) lead
to the positive battery terminal.
8481
(4) Connect the starter motor body to the
negative battery terminal.
CAUTION:
Do not connect the battery for more than
one second. Otherwise, the magnetic
switch relay may be damaged.
(5) Check that there is continuity between

the magnetic switch relay terminals.
(6) Check that there is no continuity after
the Br/W lead is removed.
NOTE:
The starter motor pinion should be pushed
out while the magnetic switch is on.
(7) Install the terminal to the magnetic

switch relay.
8-30
– +
ELEC CHARGING SYSTEM E
CHARGING SYSTEM 8
B G B
G
G G
2 1
G
R R
G
B B
8490
1 Stator coil B : Black

2 Rectifier/regulator G : Green
3 Fuse (30A) R : Red
4 Battery
8-31
– +
ELEC CHARGING SYSTEM E

page 8-11.

on page 3-21.
MEASURING THE LIGHTING COIL

OUTPUT PEAK VOLTAGE 8
Measure:
• Lighting coil output peak voltage
Measure with the rectifier/regulator
output wire (red) disconnected.
B R
lighting coil.
Lighting coil output peak voltage

Green (G) – Green (G)
G
Unloaded Loaded Unloaded
r/min
V 9.3 7.4 37 89

90890-06790
8200
MEASURING THE RECTIFIER/

REGULATOR OUTPUT PEAK
VOLTAGE 8
Measure:
• Rectifier/regulator output peak voltage
rectifier/regulator.
B R
Rectifier/regulator output peak
voltage
Red (R) – Black (B)
G
Unloaded Loaded
r/min
V — 7.5 12.5 13.0

90890-06790
8200
8-32
– +
ELEC POWER TRIM AND TILT SYSTEM E
POWER TRIM AND TILT SYSTEM 8
2
Sb R Lg
Up
Free
Down
Lg
B
Sb Sb Lg Sb
Sb
1 M
Lg
Sb R
Lg
Sb Lg R
3
Lg R
Lg
Sb
6
R Lg Å
B ı R
B
Sb
B
P
R
B P
B
B
P
B
B B
P 4
B
+ - P P
B
8500
1 Power trim and tilt motor B : Black

2 Trailer switch Lg : Light green
3 10P connector P : Pink
4 Trim sensor R : Red
5 Battery Sb : Sky blue
6 Power trim and tilt relay
Å To remote control
ı To trim meter
8-33
– +

on page 3-21.
-
CHECKING THE POWER TRIM AND
TILT RELAY 8
1. Check:
• Power trim and tilt relay continuity
1 Out of specification → Replace.
+ 2 Power trim and tilt relay

continuity
Sb Lg 8510
Sky blue (Sb) – Black (B)
Continuity
Light green (Lg) – Black (B)
- Terminal 1 – Terminal -
Continuity
Terminal 2 – Terminal -
2 1 Terminal 1 – Terminal +
No continuity
Terminal 2 – Terminal +
Sb Lg
+ 2. Check:
• Power trim and tilt relay operation
B 8520
Checking steps
(1) Connect the digital tester between
- power trim and tilt relay terminals 1
and +.
(2) Connect a 12-V battery as shown.
Light green (Lg) lead → Positive terminal
1+ Terminal - → Negative terminal
Lg (3) Check that there is continuity between
the power trim and tilt relay terminals.
8530
(4) Connect the digital tester between
power trim and tilt relay terminals +
- and 2.
(5) Connect a 12-V battery as shown.
Sky blue (Sb) lead → Positive terminal
Terminal - → Negative terminal
+2 (6) Check that there is continuity between
Sb the power trim and tilt relay terminals.
8540
8-34
– +
CHECKING THE TRAILER SWITCH

CONTINUITY 8
Check:
• Trailer switch continuity
Lead color
Switch Light
8550 position Sky blue Red (R) green
(Sb)
(Lg)
Up
Free
Down
MEASURING THE TRIM SENSOR

RESISTANCE 8
Measure:
• Trim sensor resistance
Trim sensor resistance

8560
238.8 - 378.8 Ω at 20 ˚C
(68 ˚F) a
9 - 11 Ω at 20 ˚C (68 ˚F) b
NOTE:
Turn the lever 1 and measure the resis-
tance as it gradually changes.
8-35
– +
ELEC POWER TRIM AND TILT MOTOR E
POWER TRIM AND TILT MOTOR 8
DISASSEMBLING/ASSEMBLING THE POWER TRIM AND TILT MOTOR 8
8570

Power trim and tilt motor Refer to “RESERVOIR AND POWER TRIM
AND TILT MOTOR” on page 7-33.
1 Screw 1
2 Lead holder 1
3 Screw 2
4 Stator 1
5 Armature 1
6 O-ring 1
7 Screw 2
8-36
– +
8570

8 Brush holder 2
9 Brush 2
10 Spring 2
11 Lower cover 1
12 Oil seal 1
13 Bearing 1
procedure.
8-37
– +
REMOVING THE STATOR 8
Remove:
• Stator 1
CAUTION:
• Keep the power trim and tilt motor leads
inside the stator.
• Do not allow grease or oil to contact the
8580
commutator.
NOTE:
• Remove the lead holder 2 and rubber
spacer 3 from the stator and slide them
towards the leads.
• Hold the end of the armature shaft with a
clean cloth and pull off the stator.
REMOVING THE BRUSH 8
1. Remove:
• Sky blue power trim and tilt motor
lead 1
NOTE:
Hold the brush with a screwdriver as
shown. Then, disconnect the sky blue lead.
8590
2. Remove:
• Brush holders 1
• Brushes 2
CAUTION:
Do not touch the bimetal a; touching it
may affect the operation of the breaker.
8600
CHECKING THE BRUSH 8
1. Measure:
• Brush length a
Brush length
4.8 mm (0.19 in)
8610
8-38
– +
2. Check:
• Brush continuity
CAUTION:
Do not touch the bimetal a; touching it
may affect the operation of the breaker.
8620
CHECKING THE ARMATURE 8
1. Measure:
• Commutator diameter a
Commutator diameter limit

21.0 mm (0.83 in)
8630
2. Measure:
• Commutator undercut a
armature.
Commutator undercut limit

0.85 mm (0.03 in)
8640
3. Check:
• Armature continuity
Armature continuity
Commutator segments Continuity

Segment-laminations No continuity
8650
Segment-shaft No continuity
8660
8-39
– +
INSTALLING THE BRUSH 8
Install:
• Brushes 1
• Brush holders 2
• Power trim and tilt motor leads 3
• Screw 4
CAUTION:
8670
Do not touch the bimetal; touching it may
affect the operation of the breaker.
INSTALLING THE ARMATURE 8
Install:
• Armature 1
NOTE:
Push the brushes into the holder and then
install the armature.
8680
INSTALLING THE STATOR 8
Install:
• Stator 1
NOTE:
Place a clean cloth over the end of the
armature shaft and carefully push the arma-
ture into the stator with a pair of pliers as
8690 shown.
8-40
TRBL
ANLS E
CHAPTER 9
TROUBLE ANALYSIS
TROUBLE ANALYSIS ..................................................................................... 9-1

TROUBLE ANALYSIS CHART ................................................................. 9-1 1
SELF-DIAGNOSIS ........................................................................................... 9-5
DIAGNOSIS CODE INDICATION ............................................................. 9-5
DIAGNOSIS THE ELECTRONIC CONTROL SYSTEM ............................ 9-5
TROUBLE SHOOTING FOR ELECTRIC FUEL INJECTION............................ 9-7

2
3
4
5
6
7
8
9
TRBL
ANLS TROUBLE ANALYSIS E
TROUBLE ANALYSIS 9
NOTE:
The following items should be checked before the “TROUBLE ANALYSIS CHART” is con-
sulted.
1. The battery is charged and its specified gravity is within specification.
2. There are no incorrect wiring connections.
3. Wiring connections are properly secured and are not rusty.
4. The engine stop lanyard is installed onto the engine stop lanyard switch.
5. The shift position is in neutral.
6. Fuel is reaching the vapor separator.
7. The rigging and engine setting are correct.
8. The engine is free from any “Hull problem”.
TROUBLE ANALYSIS CHART 9
Trouble mode Check elements

IRREGULAR WARNING INDICATION
TILT MOTOR WILL NOT RUN
POOR BATTERY CHARGING

ENGINE WILL NOT START
ENGINE WILL NOT STOP
LIMITED ENGINE SPEED

POOR ACCELERATION
POOR PERFORMANCE
LOOSE TILT HOLDING

LOW OIL PRESSURE
Reference
Relative part
LOOSE STEERING
HARD STARTING
chapter
ENGINE STALLS
HARD SHIFTING
ROUGH IDLING
OVERHEATING
HIGH IDLING
FUEL SYSTEM
Low-pressure fuel line
• Fuel line 3
• Fuel filter 3
• Fuel pump 4
High-pressure fuel line
• Vapor separator 4
• High-pressure fuel
4
pump
• High-pressure fuel line 3
• Fuel injectors 4
Link adjustment 3
9-1
TRBL



POOR ACCELERATION
POOR PERFORMANCE
LOOSE TILT HOLDING

LOW OIL PRESSURE
Reference
Relative part
LOOSE STEERING
HARD STARTING
chapter
ENGINE STALLS
HARD SHIFTING
ROUGH IDLING
OVERHEATING
HIGH IDLING
POWER UNIT
Compression 3
Cylinder head gaskets 5
Cylinder block 5
Crankcase 5
Piston rings 5
Pistons 5
Bearings 5
Thermostat 5
Water passages 5
Valve(s) and valve
5
seat(s)
Valve clearance
5
adjusting shim(s)
Camshaft(s) 5
Timing belt 5
Oil pump 6
• Engine oil 3
Oil filter 3
Oil pressure switch 8
LOWER UNIT
Neutral position 6
Dog clutch 6
Gears 6
Water inlets 6
Water pump 6
Propeller shaft(s) 6
Shift rod joint/pin 6
Shift cam 6
Shift shaft 6
Lower case 6
9-2
TRBL



POOR ACCELERATION
POOR PERFORMANCE
LOOSE TILT HOLDING

LOW OIL PRESSURE
Reference
Relative part
LOOSE STEERING
HARD STARTING
chapter
ENGINE STALLS
HARD SHIFTING
ROUGH IDLING
OVERHEATING
HIGH IDLING
BRACKET UNIT
Bracket 7
Rubber mount 7
Shift rod 7
Fluid level 3
Relief valve 7
Fluid passages —
Power trim and tilt motor 7
ELECTRICAL
Ignition system
• Pulser coils 8
• ECM 8
• Ignition coils 8
• Spark plugs 3
Ignition/fuel control system
• Engine stop lanyard
—
switch
• Main relay 8
• High-pressure fuel
8
pump resistor
• Intake aie pressure
8
sensor
• Intake air temperature
8
sensor
• Engine cooling water
8
temperature sensor
• Throttle position
8
sensor
• Idle speed control
4
assembly
9-3
TRBL



POOR ACCELERATION
POOR PERFORMANCE
LOOSE TILT HOLDING

LOW OIL PRESSURE
Reference
Relative part
LOOSE STEERING
HARD STARTING
chapter
ENGINE STALLS
HARD SHIFTING
ROUGH IDLING
OVERHEATING
HIGH IDLING
Starting system
• Engine start switch —
• Shift position switch 8
• Starter relay 8
• Starter motor 8
Charging system
• Lighting coil 8
• Rectifier/regulator 8
• Fuses 8
• Battery leads —
• Battery —
Power trim and tilt system
• Trailer switch 8
• Power trim and tilt
8
relay
9-4
TRBL
ANLS SELF-DIAGNOSIS E
SELF-DIAGNOSIS 9
DIAGNOSIS CODE INDICATION 9
1. Normal condition
(no defective part or irregular process-
ing is found)
Single flash is given every 4.95 seconds.
a : Light on, 0.33 second
b : Light off, 4.95 seconds
9010
2. Trouble code indication

Example: The illustration indicates code
number 23.
a : Light on, 0.33 second
b : Light off, 0.33 second
c : Light off, 1.65 seconds
d : Light off, 4.95 seconds
9020
DIAGNOSIS THE ELECTRONIC

CONTROL SYSTEM 9
1. Install:
• Diagnostic indicator
Diagnostic test lead

YB-06795
9030
NOTE:
When performing this diagnosis, all of the
electrical wires must be properly con-
nected.
2. Check:
• Diagnosis code
Code 1 is indicated → Normal.
Code 13 - 29 indicated → Check the
applicable parts.
Code 37 - 59 indicated → Microcom-
puter processing information.
9-5
TRBL
ANLS SELF-DIAGNOSIS E
Checking steps
(1) Remove the diagnosis connector (3-
pins) cap.
(2) Connect the special tools to the out-
board motor as shown.
(3) Start the engine and let it idle.
(4) Check the diagnostic indicator’s flash
pattern to determine if there are any
malfunctions.
NOTE:
When more than one problem is detected,
the diagnostic tester’s light 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.
9040
Diagnosis code chart 8
Code Symptoms
1 Normal
Incorrect pick-up coil input
13
signal
Incorrect engine cooling water
15 temperature sensor input
signal
Incorrect throttle position
18
sensor input signal
Incorrect battery positive
19
voltage
Incorrect intake air temperature
23
sensor input signal
28 Incorrect shift position switch
Incorrect intake air pressure
29 sensor input signal (out of
normal operating range)
Microcomputer processing
37 - 59
information
(37) Intake passage air leakage
Engine stop lanyard switch
(44)
control operating
Ignition timing is being slightly
(49) corrected (when starting a cold
engine)
Memory data over written
(59)
abnormally
9-6
TRBL TROUBLE SHOOTING FOR ELECTRIC FUEL
ANLS INJECTION E
TROUBLE SHOOTING FOR ELECTRIC FUEL INJECTION 9
Items Symptoms
1. Poor starting/ 1. No firing. The starter motor cranks the engine, but no firing is
Engine will generated in the cylinder.
not start 2. The firing is generated in the cylinder, but the engine soon stops.
3. Start-up time is too long. The engine will not start-up easily.
1. Check the high-pressure fuel lines.
1) Check for fuel line

leaks
2) Check the fuel Fuel pressure is 1 Check the 20-A fuse

pressure out of specification
2 Check the main relay
3) Check the operation
of the fuel injector 3 Check the high-pres-
sure fuel pump opera-
tion
4) Check the diagnosis
cord 4 Check the main relay
drive’s ECM output
5 Check the pressure

regulator
2. Check the ignition system.
1) Check the wire harness
2) Check the ignition spark
3) Check the ignition coil
4) Check the ECM output peak

voltage
5) Check the pulser coil output

peak voltage
9-7
ANLS INJECTION E
Items Symptoms
2. Erratic idling 1. The engine speed is not constant when idling.
speed 2. The engine stalls when the throttle lever is pulled back.
3. The engine stalls when the throttle lever is opened or during
outboard operation.

leaks

tion
cord 4 Check the pressure
regulator

voltage

peak voltage
3. Check the ignition timing.

1) Check the diagnosis 1 Check the pulser coil
cords diagnosis cord
2 Check the engine cooling

water temperature sen-
sor diagnosis cord
3 Check the intake air tem-

perature sensor diagno-
sis cord
9-8
ANLS INJECTION E
Items Symptoms
3. Erratic engine 1. The engine is started, but will not run smoothly. The engine speed
speed drops during acceleration.

leaks

tion
cord 4 Check the main relay
drive’s ECM output
5 Check the pressure

regulator

voltage

peak voltage
3. Check the ignition timing.

1) Check the diagnosis 1 Check the pulser coil
cords diagnosis cord
2 Check the engine cooling

water temperature sen-
sor diagnosis cord
3 Check the intake air tem-

perature sensor diagno-
sis cord
9-9
WIRING DIAGRAM F115TR, LF115TR
L Oil pressure switch
Sb P/W
2 Power trim and N M S

1 Engine cooling tilt motor
temperature sensor P/W
B/Y Lg
B/Y B/Y
B B
B/W B/W
R/Y
B/R B/R G Pulser coil 1 R Throttle position
B R/Y
B
H Lighting coil sensor
P B
G
3 Spark plug B Power trim and B
P
#1
B/R
B P
tilt relay G O
B/R G P
Sb
B/R 5 Trim R/Y R/Y R/Y O
#4 R/Y W/B R/Y R/Y R/Y R/YR/Y
R/Y R/Y B/W sensor R
B I Pulser coil 2 S Intake air
W/R
P
B B R/Y pressure sensor
R/Y B P/G
P/B
4 Ignition coil P/W
W/B W/R
G/R R/Y G/Y
G Lg R/Y G/B R/Y G P/G
B/W B
B
#2 B O
W R/Y
B/W
P B
Lg G/B G
B/W R
#3 Sb W/B W/R O
Y Lg Lg
R/Y R/Y Sb B/Y
Br
J ECM G/R G/Y
P B
Lg
W/B
R/Y T Injector #1
R/Y P/G
Å Tiller handle model Sb O W/R
R/Y
B/Y
O B B Sb B O
L/Y
R/Y
Lg W/R W/B G B
B P/W B Pu/R
P/B R G/B
O B/Y
P Pu/R
W G/Y B
B
6 Engine 7 Main switch W P/B P B
B
G/R
stop switch W B R Y Br
P/B P
B
B M Air temperature
UP B
FREE
P
B B Pu/R sensor • •
START G/R B Pu/B S4 I2 S2 S3 I2 S1
B W P/B
B/W P/B Pu/G
L
B/Y
G/W
C Starter relay Pu/Y U Injector #2
B R/Y
G/R G/W P/B P/W
R R/Y W/B
Sb B R R P B
B N ISC R/Y
R/Y
R Lg W B R Y Br G G Y R/Y B
R Y P/W B Pu/B
G/W Br Sb P P Sb B L
W P/B B
Br Br/W B Pu/B
Br B B/Y G
G/R
G/W L/W
Sb B/W
Lg
G G
P Lg Lg W
R B/R
G/R P B
P/B W Br Br
Y O O
W B B
P/B G O/W B V Injector #3
L 8 Starter motor B R/Y
W
N B
Br L R/Y
R/Y
M
Pu/Y
S D Diagnosis Pu/Y
connector K Rectifier/regulator
B N M S
RR R
Br/W B
O Fuel pump
E Main relay W Injector #4
R/Y
B G G
W/B R/B
G R/Y
R Pu/G
B
W/B R/B Pu/G
B
B
R R/Y
R
B B G R/Y
R
Br
Y B
R
P Fuse 1
R 30A
R/B Y R R/Y X Shift position switch
W/B B R/Y G R
9 Battery B R P Fuse 2 L/Y
B
Br
R 30A B
L/Y
Y R B B
B
R/Y Q Fuse 3 L/Y
G R
R R R 20A
R R
R/Y
L/W COLOR CODE
Sb Lg Lg R
Sb
R RR Q Fuse 4 B : Black B/R : :Black/red Pu/B : Purple/black
Lg
Sb
R 20A Br : Brown B/W : Black/white Pu/G : Purple/green
R : Green B/Y : Black/yellow Pu/R : Purple/red
Å Tiller handle model R
G
Sb R L : Blue Br/W : Brown/white Pu/Y : Purple/yellow
0 Power trim and tilt switch A Trailer switch
Lg Lg : Light green G/R : Green/red R/B : Red/black
Sb R Lg Sb R Lg
L/W
UP UP
FREE FREE O : Orange G/W : Green/white R/Y : Red/yellow
DOWN DOWN
Sb Lg Sb Lg P : Pink G/Y : Green/yellow W/B : White/black
Sb R Lg Sb R Lg
Lg Sb R Pu : Purple G/B : Green/black W/R : White/red
Sb
R R : Red L/W : Blue/white
Lg F Diagnosis lamp Sb : Sky blue L/Y : Blue/yellow
Lg R R Sb
connector W : White P/B : Pink/black
Y : Yellow P/G : Pink/green
B/O : Black/orange P/W : Pink/white
YAMAHA MOTOR CORPORATION, USA
Printed in USA
Oct. 2003 – 0.0 × 1 CR
(E)
Four-Stroke
JET DRIVE
Operation and Service Manual
Four-Stroke Jet Drive Operation and Service Manual
©2002 by Yamaha Motor Corporation, U.S.A.
September 2002
All rights reserved. Any reprinting

or unauthorized use
without written permission of
Yamaha Motor Corporation, U.S.A.
is expressly prohibited.
Printed in U.S.A.
Specifications, features and options are subject to
change without notice.
02-467
TABLE OF CONTENTS
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
FEATURES AND ADVANTAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
LOCATION OF MAIN COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
MODEL IDENTIFICATION AND SERIAL NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ENGINE MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
MOUNTING HEIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
TEST RUNNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
TRANSOM ELEVATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
ANTI-CAVITATION PLATES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SHIFTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
REMOTE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SHALLOW WATER OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
INTAKE BLOCKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
MOORING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
THROTTLE USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
TILT AND TRIM USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
MAINTENANCE, LUBRICATION, AND STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
BEARING LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
IMPELLER CLEARANCE SETTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
LINKAGE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SALT WATER OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
SHIFT CAM ASSEMBLY WITH NEUTRAL ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
NEUTRAL ADJUSTMENT OF ALL MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
TRIM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
IDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
PERFORMANCE TIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
OVERHAUL PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
F40MJH & F40EJR (F40) 4-STROKE 3-CYLINDER

PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
ASSEMBLY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
TILLER STEERING SHIFT CABLE PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
TILLER STEERING SHIFT CABLE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
F60 4-STROKE 4-CYLINDER

PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
LIMITED WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
TILLER HANDLE TEMPLATES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

INTRODUCTION
This Four-Stroke Jet Drive Operation and Service Manual is designed to be used in conjunction
with your Yamaha Outboard Motor Owner’s and Service Manuals. It contains operating instructions
as well as service and maintenance information that applies specifically to Yamaha Jet Drives.
Refer to your Outboard Owner’s and Service Manuals regarding general operating and service
information.
The related Outboard Owner’s and Service Manuals refer to horsepower rating for Yamaha’s pro-
peller-driven models. The actual performance output of Yamaha’s Jet Drive models cannot be pos-
itively rated because the output varies with type of hull, load, forward speed, and the angle of
planing achieved. Generally, the industry standard for determining the performance level of a jet-
driven outboard is that its output is approximately 70% of that of a propeller-driven unit with the
same powerhead.
This Operation and Service Manual covers several Yamaha Jet Drive models. Where there are
model-year differences, references are made to applicable models. In addition, references are
made throughout the manual to the model designation (which includes the engine’s prop-shaft mod-
el horsepower) or to the engine’s configuration. The following chart explains the corresponding des-
ignations:
4-Stroke
Engine Horsepower Jet Drive Model
Model Designation Engine Configuration Designation
F40 3-cylinder 30
F60 4-cylinder 40
F90 4-cylinder 65
F115 4-cylinder 80
Read both this manual and your Outboard Motor manual before attempting to put your Yamaha Jet
Drive Outboard Motor into service. You should be familiar with all the control positions, and know
where each control is set during operation.
1
FEATURES AND ADVANTAGES obtain reverse, a gate is swung into position
over the outlet, directing the pressure stream in
Your Yamaha Jet Drive Outboard Motor was the opposite direction, thus creating a reverse
specifically designed to allow boating in loca- thrust to propel the boat backwards.
tions where a propeller-driven craft is unable to Conventional controls are used for throttle,
operate, such as in ankle-deep water, white- shifting, and steering.
water rapids, over sand bars, shoals, etc.
Because there is no propeller housing extend-
ing below the hull, your Yamaha Jet Drive
allows passage over obstructions that would
damage a regular outboard.
Shore landings are made easier because you
don’t have to tilt the motor.
A “fish’s eye view” gives a further comparison
of the difference between a propeller-driven
boat and a jet drive.
LOCATION OF MAIN COMPONENTS
EXHAUST TUBE
GREASE NIPPLE
VENT HOSE
JET DRIVE
JET DRIVE CASING

WATER
INTAKE GRILLE INTAKE ASSEMBLY
MOTOR ADAPTER PLATE CONTROL CABLE

OR ROD
CONTROL CABLE
ANCHOR BRACKET
Your Yamaha Jet Drive’s simple design offers

reliable operation with minimal moving parts.
Water is drawn into the unit through the intake CAM GATE
grille by an impeller, driven directly by the
engine drive shaft. The water is then forced at
high pressure through an outlet nozzle that is REVERSE GATE
directed away from the stern of the boat. This IMPELLER (INTERNAL)
action creates an opposite force, similar to that
of a jet engine, and drives the boat forward.
When the boat reaches planing speed, the jet
drive discharges water freely into the air and
only the intake grille touches the water. To
2
MODEL IDENTIFICATION AND NOTE: Transom height is especially critical for
SERIAL NUMBERS jet-driven outboards, which are usually mount-
ed 6” to 7” higher than propeller-driven out-
OUTBOARD IDENTIFICATION boards; therefore, it is advisable to use a full
See your Yamaha Outboard Motor Owner’s transom with your Jet Drive.
Manual for outboard and motor identification MOTOR SELECTION
number locations.
MOTOR SIZING
JET DRIVE IDENTIFICATION
A boat operating at slow speed requires con-
The Jet Drive Model Letter is stamped on the
siderably more depth than one that is planing
rear, port-side casing. The Jet Drive Serial
on the surface of the water. It is important,
Number is stamped on the starboard side of
therefore, to use sufficient horsepower, and to
the casing.
not overload your boat beyond its ability to
NOTE: The outboard motor and jet-drive unit plane.
model and serial numbers are important when
The accompanying graph is based on experi-
you need to have service performed or place
ence obtained with sled-type boats, using an
an order for parts. For easy reference, please
outboard-style jet. Gross weights shown
record these numbers on the inside front cover
include the motor, hull, fuel, passengers, and
of this manual, and also on the inside front cov-
all gear. For a given horsepower, loading
er of your Yamaha Outboard Motor Owner’s
beyond the listed limits will obviously give
Manual.
reduced performance.
Conversely, slight overpowering, based upon
anticipated load, will result in quicker planing,
reduced throttle settings for a given speed,
and, subsequently, increased efficiency of
operation.
APPLICATION AND SIZING
HULL SELECTION
Best performance is obtained by selecting a
light, shallow-draft hull, with a relatively flat (5°
angle, or less), wide bottom. Vee or Multi-Vee
hulls are not recommended (additional drag
would be placed on the Jet Drive’s water intake NOTE: The performance output levels of jet-
housing) because of their greater tendency to driven outboards do not reflect true perfor-
produce cavitation. Aluminum boats are pre- mance compared to propeller-driven outboards
ferred because of their light weight and dura- of the same powerhead horsepower. The Jet-
bility. These boats typically have optimum hull Driven model is usually figured to have an out-
shapes, too. put level equal to 70% of the propeller-driven
As a rule, the bottom width for your jet drive model. Keep in mind that boat loading, weight,
should be at least 48”, and the centerline and hull configuration can significantly affect
length at least 13’. the performance of your Jet Drive outboard.
3
ENGINE MOUNTING If smooth operation is obtained with the initial
setting, you should raise the motor in 1/4”
MOUNTING HEIGHT steps until cavitation does occur. Then lower
Your Yamaha Jet Drive must be mounted 6” to the motor 1/4”, and mark and lock that location.
7” higher on the transom than propeller-driven This height setting will never need to be
outboards. Therefore, optimum mounting for changed, regardless of the load being carried.
15” shafts is on a 20” transom; and for 20”
shafts, a 25” transom. CAUTION:
The positioning of motor height is important Slight cavitation on sharp turns or in rough
and must be done carefully. One-quarter inch water is acceptable, but excessive cavita-
above the optimum location will allow air to tion is harmful to both motor and pump,
enter the pump and will result in cavitation and and should be avoided.
power loss. Too low a setting will result in The motor tilt pin should be set so the engine
unnecessary drag, water spray, and reduction is in a vertical position when the boat is plan-
in speed. ing. If the boat rides bow-high, or tends to be
The initial height setting is accomplished by stern heavy, tilt the motor down one step. This
placing a yardstick or other straightedge will point the jet stream lower, giving added lift
against the boat bottom (not the keel). The top to the stern.
of the leading edge of the water intake is NOTE: If the tilt angle is changed, then the
adjusted to line up with the top edge of the motor height must be rechecked.
straightedge.
TRANSOM ELEVATORS
In some applications, an elevated transom may
be required for proper motor height. When
using a bolted-on bracket, set the intake height
1/2” below the bottom of the boat in order to
obtain the widest range of adjustability, as
shown.
F40 & F50

MODELS
F80 & F115
MODELS
TEST RUNNING
CAUTION:
When starting your motor for the first time,
make sure water comes out the small hole
at the rear, starboard side of the motor, just
below the powerhead. If no water exits with-
in a short period of time, shut off the motor
and consult your dealer.
1. Glue two pieces of 3/4” exterior plywood
After making the initial motor-height setting, it together, using waterproof glue. Clamp or
is time to test-run the boat. If cavitation occurs nail.
(air enters the pump, which causes loss of
2. Bolt to transom at height shown. Use zinc-
thrust and motor overrevving), then you must
plated hardware, with flat washers on both
lower the engine 1/4” at a time until smooth
sides.
operation is obtained.
4
3. Make two diagonal braces from 1/2” elec-
trical conduit. Flatten each end in a vise,
and drill 1/4” holes in them. Determine the
position and angle of the forward bend.
Attach the braces to the boat in a solid
location, such as to the seats or gunwales.
Avoid attachment to flexible aluminum pan-
els.
ANTI-CAVITATION PLATES
To reduce spray, or to further reduce cavitation
in rough water, a 1/32”-thick metal plate can be
installed to block the entrance of air into the
water in front of the jet pump’s intake scoop.
Installation of this plate will also allow a slight-
ly higher motor-mounting point (which, of
course, will reduce drag).
The position for proper mounting is shown in CAUTION:
the first part of the accompanying illustration.
After one of these procedures is undertak-
An alternate mounting position for the plate en, the motor height and tilt settings should
(with the plate attached to a keel or wedge), for be checked, and reset as necessary, to
use in “white water,” is shown in the second avoid excessive cavitation that could lead
and third parts of the illustration. The third part to impeller damage.
shows the width of the plate, as well as the
width of the drop-bottom wedge that positions NOTE: Either of the above modifications
the intake in more solid water. This installation, should utilize only marine-grade woods; sili-
however, reduces shallow-water capabilities con-base, waterproofing sealing compounds
and should be used only when necessary. (between components and around screws);
and marine-grade paints. Remember, once
you adopt one of these modifications, if
removed or changed, damage may result to
your hull if precautions are not taken to fill
and/or waterproof any holes.
5
OPERATING INSTRUCTIONS Running upstream is easier, as the river speed
is subtracted from the boat’s speed, and the
SHIFTING shore doesn’t go by as fast. You can throttle
WARNING back and maneuver your way through tight
areas with good control. At narrow and poten-
The impeller is always engaged and pro- tially rough or dangerous passages, you
duces a certain amount of thrust while the should stop and study the layout. Look down-
motor is running. “Neutral” is achieved stream so you will recognize it on the return
when the reverse gate is in a middle posi- trip. Once through a bad spot, you may wish to
tion that balances forward and reverse run down and travel back up the same stretch
thrust. Since the Neutral position on the to memorize the course you find to be the best.
shift control may not precisely balance the
thrust, be sure to secure the boat to the If you are not sure of a tight area on a down-
dock or beach the bow of the boat during stream run, it is better to drift through on the
cold starts to avoid the possibility of being oars with the motor tipped up, or work the boat
thrown off balance as the motor starts. through on a rope.
Except for low-speed maneuvering, do not use SHALLOW WATER OPERATION

the reverse gate to slow or stop the boat; this
will cause the motor to kick up and out of the The life of both impeller and water intake hous-
water, similar to hitting a submerged object in a ing can be greatly increased by avoiding the
propeller-driven craft. intake of sand and gravel. Intake suction, act-
ing on the bottom, will cause your jet drive to
REMOTE CONTROL work like a dredge when the intake comes with-
in 2 or 3 inches of the bottom. It is best to shut
When using a remote control with a fast-idle
off the motor and drift up to the shore when
feature, the throttle can be advanced with the
landing, and to shove off with an oar when
transmission in Neutral for cold engine starts.
leaving. You can idle through areas less than 1-
When using this fast-idle starting feature, the
foot deep, but there should be more than 1 foot
shift cam may not immediately engage when
of water under the boat when opening the
the throttle is returned to the Neutral position
throttle for cruising or planing.
due to water pressure action on the reverse
gate. After the motor has warmed up for 30 Once planing, boat speed will prevent sucking
seconds or so, stop the motor, move the throt- in gravel. While great suction exists at the
tle lever through the shifting mode until the cam water intake, your boat passes over the bottom
has engaged, place it in Neutral, and restart so quickly that before rocks, sand, and debris
the motor. Subsequent warm starts in Neutral have time to lift, the boat is past the disturbed
will not require this operation. area.
STEERING While boating in particularly shallow areas,

remember that running on a full plane will make
Experiment with steering your boat in an open the boat ride higher in the water. This can allow
area before attempting downstream river run- you to travel through areas that might be
ning. Remember when running downstream, impossible to traverse at slow speeds. Be sure
your speed relative to the shore is the boat’s you know the type of river bottom before
speed added to the speed of the river. You may attempting this, however, in case the boat hits
find quick response to the helm, but due to its bottom or runs aground. You should attempt
relatively flat-bottomed hull and lack of skeg, planing only in areas where the bottom is sand
your boat will tend to skid in turns. You must or gravel. If you hit bottom where there are
start your turns early and use sufficient power large underwater obstacles or sharp rocks, you
to maintain steering control. may damage the boat and motor.
WARNING If you do run aground, shut the motor off imme-
If you attempt too tight a turn, at too high a diately and drag the boat to deeper water.
speed, your boat could spin out, or even Occasionally, when running aground, a small
roll over. rock may lodge between the impeller and
6
intake housing wall, and the motor will come to MOORING
a stop. Neither starter motor nor starter rope
If you tie your boat up at a sandy beach, where
will be able to turn it over. To remove the jam,
the action of waves causes the boat to rise and
you can remove the six screws holding the
fall, be sure to tip the motor up out of the water.
water intake housing to free the rock or,
Failure to do this will result in the buildup of
remove the motor cover and carefully rotate
sand inside the intake housing, around the
the flywheel counterclockwise.
impeller. It is advisable to tie the boat up and
WARNING shut off the motor any time it is likely to be idled
for a sustained period of time.
Be sure to remove the spark plug wires
before attempting to turn the flywheel.
THROTTLE USE
NOTE: Your jet drive is equipped with a key to
As with any outboard, you will get maximum
protect it in the event of a rock jam. See
economy by not running at full throttle. Running
“IMPELLER CLEARANCE SETTING” in
at one-third to one-half throttle, with the boat at
“MAINTENANCE.”
a steep angle, leaving a large wake, will also
CAUTION: waste fuel.
Do not attempt to use a wrench on the fly- TILT AND TRIM USE
wheel locknut to rotate the flywheel back-
ward because you may loosen the nut. It is important for you to learn how to use the
Proper tightening, while afloat, without the Power Trim and Tilt function properly, on those
proper tools is not possible, and major models equipped with this feature.
damage to your motor could occur. The Power Trim and Tilt function is convenient
NOTE: Gravel passing through the pump will for use while drifting, and when operating at
wear and round off the leading edges of the low throttle in very shallow areas. When under
impeller blades. For maximum performance, power, however, the engine should not be
file these edges occasionally to keep them as trimmed out in an effort to gain speed as is
sharp as when new. See “IMPELLER” in done with conventional propeller-drive motors.
“MAINTENANCE.” When planing, the engine drive shaft should be
either vertical or tucked under, toward the boat
INTAKE BLOCKAGE in order to provide a good scoop angle for the
Occasionally, when either holding or proceed- water intake grille. Tilting the motor outward,
ing slowly upstream in a fast-moving, shallow beyond a vertical position, reduces the scoop
area, you will lose power. This is usually angle and can cause impeller slippage, as well
caused by suction holding flat rocks, lily pads, as cavitation burns on the impeller blades.
paper, or other debris against the intake grille Manual-tilt models should be adjusted with the
and restricting water intake. If you quickly stop tilt pin to provide a vertical engine position
the motor and restart it, this sort of material will while under plane. See “TEST RUNNING.”
fall away and full power will be restored. If,
however, rocks have been jammed between
the grille bars, with the motor off, they must be
removed by prying them out with a suitable
tool.
7
MAINTENANCE, LUBRICATION, See the Assembly Instructions for your model
AND STORAGE later in this manual for more detailed instruc-
tions.
GENERAL
NOTE: Your jet drive is equipped with a shear
Occasionally, check all mounting bolts, intake key to protect it in the event of a rock jam. This
screws, linkage connections, etc., to be sure key can be located by removing the water
they are tight. intake housing and the drive shaft nut. The key
holds the jet drive impeller on the drive shaft.
BEARING LUBRICATION This is similar to that on a propeller drive. After
The need for frequent lubrication of your replacing the key, draw the shaft nut up tight
Yamaha Jet Drive Outboard cannot be (17 ft-lb) to remove any play between the
overemphasized. We recommend lubrication impeller and shaft. Note the position of the
after each day’s use and every 10 hours of impeller shim washers, and replace them in the
operation. Make greasing a regular part of same order as removed.
your cleanup. Use only Yamalube Marine
LINKAGE ADJUSTMENT
Grease, or NLG1 No. 1-rated greases with a
suitable grease gun. Occasionally, check the adjustment of the shift
linkage. In “Forward,” the reverse gate should
The bearing lubrication fitting is located at the
be firmly locked. This will eliminate rattle and
top-left-front of the jet drive casing. It is capped
prevent wave action from accidentally shifting
with a fitting on the end of the excess-grease
the gate into reverse. (See “ADJUSTMENTS”
exit hose. Pump in enough grease to just fill the
for the proper procedures.)
hose. To remove the hose from the fitting,
press the end cap upward and toward the cas- SALT WATER OPERATION
ing; to refit it, press the hose end cap over the
fitting. Both aluminum and stainless steel have been
extensively used in the construction of your jet
Every 30~40 hours, pump in enough extra drive. These and other materials have been
grease to purge any moisture. The texture of either treated or are inherently resistant to cor-
the old grease coming out of the hose will pro- rosion. In addition, the intake grille, special key,
vide you with an indication of conditions inside and exhaust tube are galvanized to further min-
the bearing housing. A gradual increase in imize corrosion. It is still recommended, when
moisture content indicates seal wear. If the not in use, the motor be tipped up so the jet dri-
grease begins to turn a dark, dirty gray, the ve casing is out of the water.
bearing(s) and seals should be inspected
CAUTION:
and replaced as necessary. Some discol-
oration of the grease is normal during the
break-in period on a new set of seals. If your jet drive is used in salt water more
than fresh water, remove all mounting hard-
IMPELLER CLEARANCE SETTING ware, and grease it at least once every six
If the impeller clearance between the impeller months. Failure to do this may result in the
edge and the water intake casing wall exceeds hardware being difficult, if not impossible,
about 1/32” (usually due to wear from opera- to remove at a later date.
tion in water with a sand or gravel bottom), the NOTE: To facilitate removal of an impeller that
clearance can be adjusted. There are shim has frozen to the drive shaft, use a hammer
washers underneath the impeller. Move one or and a block of wood, and tap the impeller
more shims from underneath to on top of the blades in the direction of engine rotation. This
impeller. This locates the impeller further into will release the shear key.
the tapered casing to reduce the clearance. Be
sure to grease the shaft hole in the impeller, ADDED NOTE: A slightly distorted shear key
the key, sleeve, and shaft threads any time it may be reused.
becomes necessary to remove the impeller.
8
STORAGE d. Shift to forward. The roller should be at the
Consult your Outboard Owner’s Manual for end of the slot in the cam so the gate can-
preparing the motor part of your jet drive for not be forcibly rotated toward reverse. Pull
storage. In addition, clean and grease all hard- on the gate by hand to verify this.
ware. Remove and refit the jet drive impeller,
If the forward lock condition is not met,
greasing the bore, key, and plastic sleeve.
readjust the cable positions, giving less
ADJUSTMENTS importance to the roller position in neutral.
SHIFT CAM ASSEMBLY e. If the neutral position is too far out of

WITH NEUTRAL ADJUSTMENT adjustment, the tendency for the gate to
move toward reverse, under water pres-
A shift mechanism has been incorporated that sure, will put tension on the cable while in
includes an adjustable shift cam. When prop- neutral. In some remote control boxes, this
erly adjusted and in the neutral position, the makes it difficult to re-engage the shift
forward thrust of the jet-driven outboard will be mode with the motor running in the high-
negligible. speed idle, cold-starting setting. It is then
NEUTRAL ADJUSTMENT OF ALL MODELS necessary to stop the motor, operate the
shift handle to engage the shifting pin, and
a. Loosen the inner pivot bolt for the shift then restart the motor.
cam.
b. Using a light finger pressure on the gate, CAUTION:
move the gate toward reverse until the cam If not properly adjusted, the reverse gate
roller is nested in the neutral notch of the can be engaged by forward motion of the
cam. Holding the gate in this position, boat. This will cause the engine to kick up
rotate the eccentric until the gate clears the and out of the water, similar to hitting a sub-
underside of the nozzle hood by the width merged object in a propeller-driven craft.
of the clearance gauge. Keep the high lift
side of the eccentric facing in the upper Do not be concerned if, after proper linkage
side of the circle during this adjustment. and cable adjustments, the reverse gate does
Tighten the bolt to lock the hex cam eccen- not fully close when the shifter is operated;
tric in this position. Torque to 8~9 ft-lb. water pressure will close it all the way during
Recheck the setting. normal operation.
CLEARANCE GAUGES-FULL SIZE TRIM

On some applications, your boat may tend to
TRACE AND CUT OUT TO USE TO SET
ECCENTRIC FOR NEUTRAL POSITION. pull to starboard. This condition can easily be
corrected by bending the trailing edge of the
flow-straightening fins located at the top and
bottom of the exhaust tube 1/16” toward the
starboard side of the motor.
c. Adjust the shift cable ends and the cable

anchor bracket on the jet drive so the roller
is in the neutral nest when the shift handle
is in neutral. Tighten both the cable and
nuts.
9
IDLE CAUTION:
In most cases, the stock idle adjustment will Do not trim the engine out beyond horizon-
produce an acceptable neutral. However, since tal, so the jet stream points up into the air
neutral is a balance between forward and or the bow lifts. This will reduce the ram
reverse forces, some slight creeping of the angle on the water intake and will cause
boat may occur at idle. A minor idle-speed severe cavitation burns on the impeller
adjustment should correct this tendency. blades.
PERFORMANCE TIPS Power trim is also useful when running

slowly in shallow water, such as when
Here are some pointers for obtaining maximum backing off the beach. In these conditions,
performance from Jet Drive outboards: the engine can be tilted back 15° to 20°,
reducing the tendency to pick up gravel.
1. Keep the leading edges of the impeller
Keep your eye on the cooling water pilot
sharp. Edges that have been blunted by
hole to make sure the engine is getting
gravel beyond 1/32” tend to break up the
water.
water. This results in slippage and engine
overspeeding. 8. Stainless steel impellers are available.
They can extend life in areas where it is dif-
2. Keep the grille bars parallel to prevent large
ficult to avoid gravel intake.
rocks or other debris from entering the
impeller, causing damage or possibly lodg- If you have trouble locating these impellers
ing in the nozzle. on the market, contact your Yamaha
Outboard Dealer.
3. Select as light a hull as possible for the
intended use. If you experience difficulty removing the
impeller, remember the impeller doesn’t
4. Keep the boat bottom smooth and free of
corrode with the shaft. To prevent this there
dents. This will reduce drag and air entrap-
is a delrin® sleeve separating them. What
ment.
can happen, however, is that the driving
5. The optimum bottom width is 48 to 60 inch- torque causes the flat on the shaft to “cam”
es. Beyond 60”, the boat rides so high that or wedge the key in the impeller.
air is allowed to enter the pump. This is
To relieve this wedging, rotate the impeller
likely in choppy water particularly when
on the shaft until the keyway in the impeller
running with the wind. Less than 48”, on
is perpendicular to the flat on the shaft. This
the other hand, can make it difficult to reach
can be done with a soft hammer on a block
a plane with a heavy load.
of wood, or by using a C-clamp on one
6. A slight vee in the boat bottom gives better blade and bumping that.
steering and helps to keep solid water in
The impeller is now free to pull it. If neces-
the pump. A 3” drop at centerline on a 60”
sary, use two wood levers, about 3/4” x 1-
bottom is enough. Beyond that, shallow
1/2” x 12”, wedged under the blades
draft is sacrificed.
against the housing flanges to assist with
7. The power trim is useful to bring a heavy removing the impeller.
load on plane. Tipping the engine under
points the jet stream down, which helps lift
the stern. After reaching a plane, trim the
engine out until the jet stream is horizontal
(the engine driveshaft is vertical).
10
9. Some larger displacement jet drives can FOR F40 AND F60 MODELS ONLY:
experience a performance problem above
4. Before pressing on the collar, first, install
4500 rpm up to 5500 rpm. On affected
the coated thrust washer with the gray
units, there may be little or no change in
teflon coating facing the bearing. Note the
boat speed, only increased noise. This may
direction of the thrust face, and press the
be impeller cavitation. This can happen if
new bearing onto the shaft, pressing
the impeller liner is pushed too far into the
against the inner race only. Press against
foot.
the thrust ring, locking it in its groove.
Look into the jet from the bottom of the foot.
FOR F90 AND F115 MODELS ONLY:
If the liner is pushed too far in, you’ll notice
a lip that the water is going around. To cor- Using Yamaha special tool #YB-06075,
rect the problem, remove the grates and note the direction of the thrust faces, and
grind down this lip to make a smooth path press the new bearings on the shaft,
for the water. pressing against the inner races only.
Press against the thrust ring, locking it in its
OVERHAUL PROCEDURES groove. (See the illustrations on the next
page.)
NOTE: It is recommended that these proce-
dures be performed by only your authorized 5. To install the seals, install the inner seal
Yamaha Outboard Motor Dealer. retainer ring first. Place a light film of
grease on each surface before pressing in
DISASSEMBLY
the seals. The round spring of each seal
Refer to “ASSEMBLY AND INSTALLATION,” faces outward.
and reverse the procedures outlined there.
BEARING HOUSING
1. Remove the large beveled circlip from the
bearing housing. Gently warm the housing
with a torch until it is just too hot to com-
fortably touch.
CAUTION:
Do not apply too much heat, because the
seals may be damaged. 6. Install the outer seal retaining rings before
2. Holding the drive shaft vertically, bump the pressing in the outer seals; align the
impeller end of the shaft against a wooden notched ends of the retaining ring to strad-
block until the housing slides down off the dle the small vent hole drilled in the ring
bearings. groove.
3. Note the direction of thrust faces of the 7. Grease all seal lips. Fill the cavity around
bearing(s), and press the bearing(s) off the the spring in the seals with grease and
drive shaft. Leave the round thrust ring on install the outer seals.
the shaft, unless it is damaged. Remove 8. Grease the two O-rings and install them in
the seals from the bearing housing and their grooves in the upper seal housing.
upper seal housing. Clean all parts thor- Apply a thin film of grease inside the hous-
oughly and remove all burrs. ing bore to ease entry of the bearing(s) and
NOTE: The inner seals are located on both O-rings.
sides by spiral seal-retaining rings that must be
removed prior to extraction of the inner seals.
11
FOR F40 AND F60 MODELS ONLY: F40 & F60 MODELS
9. Slip the bearing housing over the shaft.

Heat the housing slightly again. It is impor-
tant to slide the housing on squarely,
and to not use a hammer, or in any way
apply impact loads to the balls. If you
use a hand press, press only against the
outer race of the bearing. Only a light
press is needed if everything is lined up
properly.
FOR F90 AND F115 MODELS ONLY:

Slip the bearing housing over the shaft.
Support the bearings and drive shaft, using F90 & F115 MODELS
Yamaha special tool #YB-06205-2. Heat
the the housing slightly again. It is impor-
tant to slide the housing on squarely,
and to not use a hammer, or in any way
apply impact loads to the balls. If you
use a hand press, press only against the
outer race of the bearings. Only a light
press is needed if everything is lined up
properly.
NOTE: When using a special tool #YB-06205-
2, the housing will slide on only part way; there-
fore, remove the tool, slide the seal housing
into place as a spacer, reinstall the tool, and
continue pressing the housing until it fully bot- REASSEMBLY
toms out; remove the seal housing assembly.
To re-assemble your jet drive, follow the
10. FOR F40 AND F60 MODELS ONLY: assembly procedures in “ASSEMBLY AND
Install the spacer washer. INSTALLATION.”
FOR F90 AND F115 MODELS ONLY: LINER REPLACEMENT
Install the backup washer against the upper
bearing, with the dished center section F40/F60
facing upward. 1. Remove the intake assembly from the jet
11. Install the upper seal housing assembly drive casing by removing the six bolts hold-
being careful not to damage the O-rings as ing it in place.
they pass the snap ring groove. Only finger 2. Remove and discard the two bolts holding
pressure should be necessary here. the liner inside the intake assembly.
12. Install the beveled circlip bevel-side 3. Lift out the old liner. If needed, use a ham-
upward. mer and a long drift inserted through the
13. Fit the drive shaft assembly into the jet dri- intake grille to tap on the bottom edge of
ve casing, and fill with grease, using the the old liner to help loosen it.
grease gun supplied with the jet drive. If 4. Insert the new liner, being careful to align
using a hand-lever gun, pump very slowly the holes in the liner with the holes in the
avoiding build up of internal grease pres- intake assembly. Use a soft hammer, if
sure and damaging either the seals or the needed, to tap the liner into place.
housing.
12
5. Install two new 1/4-20 x 5/8" bolts to hold the F90/F115
liner in place. Grease the bolt threads first,
1. Remove the six nuts holding the intake
then tighten the bolts to 11 ft-lb.
assembly to the jet drive casing. Remove the
6. Use a grinder, if needed, to remove any part intake assembly.
of the bolts that protrude inside the liner.
2. The liner is held in place by a 1/8"-thick
Sand or file off any burrs in the liner/bolt
flange. Lift the old liner out of the intake
area.
assembly and install the new one.
CAUTION: 3. Reinstall the intake assembly temporarily
with two nuts, then check clearance between
The impeller can be damaged if the liner is the liner and the impeller. It should be 1/32”.
not smooth inside in the mounting bolt area. If necessary, move shims above or below
7. Reinstall the intake assembly temporarily the impeller as described in the Assembly
with two bolts, then check clearance Instructions on Page 28 (F90) or Page 34
between the liner and the impeller. It (F115) to achieve the proper clearance.
should be 1/32”. If necessary, move shims 8. Remove the six mounting nuts again, grease
above or below the impeller as described in the threads of the studs, then reinstall them.
the Assembly Instructions on Page 16 (F40) Tighten the nuts to 12 ft-lb.
or Page 22 (F60) to achieve the proper
clearance.
8. Remove the six mounting bolts again,
grease the threads, then reinstall them.
Tighten the bolts to 9 ft-lb.
13
F40 PARTS LIST
4-STROKE 3-CYLINDER
14
F40 PARTS LIST
4-STROKE 3-CYLINDER
REF REF
NO DESCRIPTION QTY. NO DESCRIPTION QTY.
1 Shift Rod Guide 1 44 Shaft Only, AJS-43, 14T 24 9/16 LG 1
2 Water Tube Ext. AJ 1 Shaft Assy Complete, AJS-43, 14T 2/1275 Key
3 Bolt Hex Hd M8 1.25 x 30mm 5 44 Shaft Only, AJL-43, 14T 29 9/16 LG 1
4 Adapter Plate AJ 1 Shaft Ass’y Complete, AJL-43, 14T w/1275 Key
5 Dowel Pin 6 x 16mm 2 45 Key, Tee Water Pump 1
6 Washer Spring Lock M10 5 46 Shaft Bearing Thrust Ring 1
7 Bolt Hex Hd M10 1.25 x 35mm 4 47 Collar Backfit 1
8 Washer Spring Lock 5/16 5 48 Thrust Washer 1
9 Dowel Pin 3/16 x 1/2 2 49 Bearing 1
10 Bolt Hex Hd 5/16-18 x 2-1/2 2 50 Truarc 1
11 Bolt Hex Hd 5/16-18 x 2-3/4 2 51 Spacer
Volute with Gate AJ 53 Upper Seal Carrier w/Seals & O-Rings 1
13 Volute with Exhaust Tube AJ 1 54 Spirolox 4
14 Exhaust Tube Ass’y Medium 2 1 55 Seal Inner 2
15 Clip Exhaust Tube 1 1 56 Seal Outer 2
16 Nyloc 10-32 2 57 O-Ring 3/32 x 1-15/16 x 2-1/8 2
17 Washer Fiber 3/8 1 58 Bearing Carrier w/Seals & O-Rings AJ 1
18 Bolt Hex Hd 3/8-16 x 1/2 1 59 O-Ring 1/16 x 5/16 x 7/16 3
19 Ball End 1/4 x 10-32 Cable 1 60 Washer Spring Lock 1/4 4
20 Lube Hose Ass’y 1 61 Bolt Hex Hd 1/4-20 x 3/4 4
21 Zirc Fitting 1/4-28 1 62 Impeller 6-1/8 w/36 Sleeve 1
22 Grease Gun 1 63 Shaft Sleeve Plastic Medium 1
23 Grease 10 oz. Tube 1 64 Impeller Tee Key 1/2 Round 1
24 Reverse Gate, Medium 1 65 Shim Washer Medium 7
25 Nyliner 3/8 1D x 11/16 2 66 Nutkeeper Med/Pkg 2 per bag 1
26 Spring Gate Pivot 3/8 1 67 Shaft Nut 5/8-18 Brass 1
27 Pin Gate Pivot 3/8 Medium 2 Intake Ass’y 6-1/8 w/Grill & liner
28 Shaft Roller 1 68 Liner 6-1/8 w/Hardware 1
29 Nyloc 1/4-28 2 69 Washer Spring Lock 1/4 2
30 Roller Ass’y 1 70 Bolt Hex Hd 1/4-20 x 5/8 2
31 1/4 Washer 1 71 Intake Painted Only 1
32 Shift Cam Medium 1 72 Grill Rod 2
33 Nyloc 1/4-20 1 73 Grill Bar Medium 9
34 Bolt Hex Hd 1/4-20 x 3/4 1 74 Bolt Hex Hd 1/4-20 x 3/4 6
35 Bushing C 1 Bracket Ass’y Morse w/Clamp & Hdwr
36 Washer Cam 1 75 Bracket Cable Support 1
37 Shim-Cam 2 76 Shim Morse 1
38 Cam Eccentric Drilled 1 77 Clamp Chrys 1
39 Bolt Hex Hd 1/4-20 x 1 Patch 1 78 Fil Hd Slotted 10-24 x 5/8 2
40 Bolt Hex Hd 1/4-20 x 3/4 Patch 2 79 1/4 Washer 2
41 Spring Gate Bumper 1 80 Bolt Hex Hd 1/4-20 x 5/8 2
42 Gate Bumper 1 81 Nyloc 10-24 2
43 Fil Hd Slotted 10-32 x 1-1/4 patch 1 82 Cushion-Shift Rod Guide 1
83 Spacer-Water Tube 1
84 Rubber Washer 1
85 Cup 1
Note: Flush Screw & Washer Metric

SIZE TORQUE
17 Washer Fiber M8 1
1/4-20 (M6) 8-9 Ft-lbs. 18 Bolt Hex Hd M8 1.25 x 12 1
5/16-18 (M8) 12 Ft-lbs.

3/8-16 (M10) 22 Ft-lbs.
15
F40 ASSEMBLY INSTRUCTIONS
1. Place the engine on the transom of your 5. The large 3/4” adapter plate is attached to
boat, so it is mounted vertically, in the nor- the exhaust housing to hold the jet drive.
mal fashion. Two 6 x 16mm dowels locate the plate, four
M10 x 35mm bolts with lock washers and
2. Install the jet drive shaft assembly into the one M8 x 30mm bolt with lock washer
spiral pump housing locking it in place with secure it. Grease the threads.
the four 1/4-20 x 3/4” bolts and lock wash-
ers. Use grease on the threads. Tighten to 6. Next, attach the jet-drive unit to the motor.
8 ft-lb. Use two 5/16-18” x 2-1/2” bolts (front), two
5/16-18” x 2-3/4” bolts (rear) from below
3. Insert the clear plastic 1/2” long x 3/8” dia. with lockwashers, one 3/8-16” x 1-1/2” bolt
sleeve in the 3/8” hole in the main housing, and lockwasher, above rear, inside the
just ahead of the cooling water pump. motor mid-section and two 3/16” x 1/2”
dowel pins.
CAUTION:
Grease the bolt threads, drive shaft spline
The 4-stroke jet unit must use a newly (generously), and rubber water tube pilot.
designed water pump housing which is Guide the jet drive unit into place. Tighten
supplied by Yamaha. Failure to use this the five bolts.
housing will result in engine damage.
7. Next, install the impeller. Grease the shaft
Install the water pump assembly using only threads, key and impeller bore. Place the
the 4-stroke water pump housing on top of plastic sleeve inside the impeller, hold the
the stainless steel plate. Use four M8 x key in the nose of the impeller with your
30mm bolts and the special steel washers forefinger and slide onto the driveshaft.
under the bolt heads. Be sure also, to Install the seven shim washers, rubber
install the water pump impeller drive key washer, cup and nut retainer on the shaft,
and dowel pins. Grease the threads. up against the impeller, and bring the nut
Before tightening the bolts, press the 3- up snug by hand. Be careful the retainer
7/8” long x 1/2” dia. plastic shift rod guide does not fall into the thread groove and
into the clear plastic sleeve, through the jam the nut.
stainless steel plate, until it bottoms.
Tighten the bolts. Place the water intake in position and
secure with two bolts. Observe the clear-
4. Remove the plastic water tube guide and ance between the impeller blade edge and
rubber sleeve from the outlet of the cooling the intake liner. Then, remove the intake.
pump. Install the 5/8” dia. x 1/4” long plas-
tic spacer in the outlet, followed by the rub- When, after use in sand and gravel, the
ber sleeve and the brass water tube blade clearance becomes more than about
extension. If there is a burr on the end of 1/32” between the impeller edge and the
the motor cooling tube, file it smooth so the water intake liner, one or more of the stain-
O-ring inside the water tube extension will less steel shim washers can be transferred
slide on. from the bottom stack to the top of the
impeller. This moves the impeller down into
the tapered casing to reduce the clearance.
NOTE: Shims should not be used above
the impeller on new installations, where no
wear has occurred, unless the blade clear-
ance exceeds 1/32”. Insufficient blade
clearance will do more harm than good
from any performance gains it might pro-
vide.
16
When the impeller clearance is satisfactory, 11. Refer to “Engine Mounting” on page 5 to
bump the nut up snug with a wrench. If the finish installation.
ears of the retainer do not line up with the
flats on the nut, spin the nut off, turn the CAUTION:
retainer over and tighten the nut again. In When starting the engine for the first time,
one of these two positions, you will have watch to see that cooling water comes out
alignment and can fold the ears up against of the small hole at the rear side of engine
the nut to retain it. The flat in the retainer is just below the powerhead. This is to check
angled to the ears to allow for this. your assembly of the cooling water pump
8. Place the intake casing in position with the and its connections.
lower end at the rear and tighten the six
1/4-20” x 3/4” hex head bolts. No lock-
washers are used.
9. If your jet drive was ordered for use with a
steering tiller handle, see “Shift Cable
Assembly.”
10. If your motor is equipped for remote con-
trols, proceed as follows:
Attach the shift cable and cable anchor
bracket to the jet drive. With the shift han-
dle and the reverse gate in forward, with
the cam roller at the end of the slot, adjust
the cable end and/or cable anchor position
to this condition. Shift to reverse and back
to forward. The roller should be at the end
of the cam slot so the gate cannot be
forcibly rotated toward reverse. Pull on the
gate by hand to verify this.
If this forward lock condition is not met, re-
adjust the cable positions.
17
F40
SHIFT CABLE ASSEMBLY – TILLER STEERING
REF. DESCRIPTION QTY.

1 Cable 4’ Mor 33C Supreme AJS 1
2 Cable 4-1/2’ Mor 33C Supreme - AJL 1
3 Clamp Chrys 1
4 Shim Morse 1
5 Fil Hd Slotted 10-32 x 1-1/4 2
6 Nyloc 10-32 3
7 Ball End #10 x 10 - 32 Cable 1
8 Screw Hex Hd 10-32 x 3/4 Mod 1
9 Shim Washer Large 1
10 Shim Washer Small 1
18
F40 TILLER STEERING –
SHIFT CABLE ASSEMBLY
1. Remove the plastic covers from the shift 7. Attach the lower end of the cable to the jet
handle and the steering arm. Remove the drive, with the ball rod end threaded on the
shift handle. cable, as far as it will go, and the cable
anchor bracket slid forward and locked.
2. Cut out the template for the shift handle
Twist the cable in the U-clamp, so the cable
and the cable anchor position on the steer-
rests against the motor cowling. Tighten the
ing arm.(See page 40)
clamp screws.
3. Fold the cable anchor pattern along the
8. Place the shift handle in forward, solidly in
dotted lines and place it on the steering
the detent. The reverse gate cam roller
arm with the fork up inside, straddling the
must be at the end of the slot in the cam.
threaded boss. Tape in position.
If these conditions are not met, slide the
4. Place the shift handle pattern over the han- cable anchor bracket on the jet drive and/or
dle boss. Tape in position. Center punch adjust the threaded rod end on the cable.
the three hole locations and drill through
9. Shift to reverse and back to forward. Do not
using a 3/16” drill. The holes in the steering
be concerned if the gate does not reach
arm are long, reaching through the thread-
reverse. There is clearance at this position
ed boss itself.
and water pressure will close the gate.
5. Attach the ball rod end to the shift handle
10. In forward, with the roller at the end of the
and tighten the thin-head hex screw and
cam slot, the gate cannot be forcibly rotat-
lock nut. Remove the flanged plastic bush-
ed toward reverse. Pull on the gate by hand
ing, place the 1/16” thick spacer washer on
to verify this.
the handle and replace the flanged bush-
ing. Place the smaller 1/16” thick spacer 11. Lock the nuts on the cable against the rod
over the square driver and install the han- ends to complete the adjustment and install
dle. the plastic covers.
6. Thread the shift cable all the way into the CAUTION:
shift handle rod end. Attach the cable body
You must return the throttle to idle before
to the steering arm using the shim, U-
shifting.
clamp, two #10-32 x 1-1/4” screws and lock
nuts.
19
F60 PARTS LIST
4-STROKE 4 -CYLINDER
20
F60 PARTS LIST
4-STROKE 4-CYLINDER
REF REF
1 Shift Rod Guide AJ 1 49 Bearing 1
2 Water Tube Ext, AJ 1 50 Truarc 1
3 Bolt Hex Hd M8 1.25 x 30mm 5 51 Spacer 1
4 Adapter Plate AJ 1 52 Truarc 1
5 Dowel Pin 6 x 16 mm 2 53 Upper Sel Carrier w/Seals & O-Rings 1
6 Washer Spring Lock M10 5 54 Spirolox 4
7 Bolt Hex Hd M10 1.25 x 35mm 4 55 Seal Inner 2
8 Washer Spring Lock 5/16 5 56 Seal Outer 2
9 Dowel Pin 3/16 x 1/2 2 57 O-Ring 3/32 x 1-15/16 x 2-1/8 2
10 Bolt Hex Hd 5/16-18 x 2-1/2 2 58 Bearing Carrier w/Seals & O-Rings AJ 1
11 Bolt Hex Hd 5/16-18 x 2-3/4 2 59 O-Ring 1/16 x 5/16 x 7/16 3
12 Bolt Hex Hd 3/8-16 x 1-1/2 1 60 Washer Spring Lock 1/4 4
Volute with Gate AJ 61 Bolt Hex Hd 1/4-20 x 3/4 4
13 Volute w/Exhaust Tube AJ 1 62 Impeller 6-1/8 w/36 Sleeve Full 8.23 1
14 Exhaust Tube Ass’y Medium 2 1 63 Shaft Sleeve Plastic Medium 1
15 Clip Exhaust Tube 1 1 64 Impeller Tee Key 1/2 Round 1
16 Nyloc 10-32 2 65 Shim Washer Medium 7
17 Washer Fiber 3/8 1 66 Nutkeeper Med/Pkg 2 per bag 1
18 Bolt Hex Hd 3/8-16 x 1/2 1 67 Shaft Nut 5/8-18 Brass 1
19 Ball End 1/4 x 10-32 Cable 1 Intake Ass’y 6-1/8 w/Grill & Liner
20 Lube Hose Ass’y 1 68 Liner 6 1/8 w/Hardware 1
21 Zirc Fitting 1/4-28 1 69 Washer Spring Lock 1/4 2
22 Grease Gun 1 70 Bolt Hex Hd 1/4-20 x 5/8 2
23 Grease 10 oz. Tube 1 71 Intake Painted Only 1
24 Reverse Gate, Medium 1 72 Grill Rod 2
25 Nyliner 3/8 1D x 11/16 2 73 Grill Bar Medium 9
26 Spring Gate Pivot 3/8 1 74 Bolt Hex Hd 1/4-20 x 3/4 6
27 Pin Gate Pivot 3/8 Medium 2 Bracket Ass’y Morse w/Clamp & Hardware
28 Shaft Roller 1 75 Bracket Cable Support 1
29 Nyloc 1/4-28 2 76 Shim Morse 1
30 Roller Ass’y 1 77 Clamp Chrys 1
31 1/4 Washer 1 78 FIl Hd Slotted 10-24 x 5/8 2
32 Shift Cam Medium 1 79 1/4 Washer 2
33 Nyloc 1/4-20 1 80 Bolt Hex Hd 1/4-20 x 5/8 2
34 Bolt Hex Hd 1/4-20 x 3/4 1 81 Nyloc 10-24 2
35 Bushing Cam 1 82 Rubber Washer 1
36 Washer Cam 1 83 Cup 1
37 Shim Cam 2
38 Cam Eccentric Drilled 1 NOTE: Flush Screw & Washer
39 Bolt Hex Hd 1/4-20 x 1 Patch 1 (metric on blue volutes.)
40 Bolt Hex Hd 1/4-20 x 3/4 Patch 2
41 Spring Gate Bumper 1 17 Washer Fiber M8 1
42 Gate Bumper 1 18 Bolt Hex Hd M8 1.25 x 12 1
43 Fil Hd Slotted 10-32 x 1-1/4 Patch 1
44 Shaft Only, AJS, 14T 25-1/36 LG 1
Shaft Ass’y Complete, AJS, 14T W/1275 Key
44 Shaft Only, AJL, 14T 30-1/16 LG 1
Shaft Ass’y Complete, AJL, 14T W/1275 Key SIZE TORQUE
44 Shaft Only, AJL, 14T 4-Stroke 1 1/4-20 (M6) 8-9 Ft-lbs.
Shaft Ass’y Complete, AJL, 14T, 4-Stroke
44 Shaft Only, AJL, 16T, 4-Stroke 1 5/16-18 (M8) 12 Ft-lbs.
Shaft Ass’y Complete AJL, 16T, 4-Stroke 3/8-16 (M10) 22 Ft-lbs.
45 Key, Tee Water Pump 1
46 Shaft Bearing Thrust Ring 1
47 Collar Backfit 1
48 Thrust Washer 1
21
F60 ASSEMBLY INSTRUCTIONS
1. Place the engine on the transom of your 7. Next, install the impeller. Grease the shaft
boat, so it is mounted vertically, in the nor- threads, key and impeller bore. Place the
mal fashion. plastic sleeve inside the impeller, hold the
key in the nose of the impeller with your
2. Install the jet drive shaft assembly into the forefinger and slide onto the driveshaft.
spiral pump housing locking it in place with Install the eight shim washers and nut
the four 1/4-20 x 3/4” bolts and lock wash- retainer on the shaft, up against the
ers. Use grease on the threads. impeller, and bring the nut up snug by
hand. Be careful that the retainer does
CAUTION:
not fall into the thread groove and jam
Yamaha has designed a new water pump the nut.
housing that must be used on the 4-stroke
Place the water intake in position and
engine. Failure to use this housing will
secure with two bolts. Observe the clear-
result in engine failure.
ance between the impeller blade edge and
3. Install the water pump assembly using only the intake liner. Then, remove the intake.
the 4-stroke water pump housing on top of
When, after use in sand and gravel, the
the gasket and stainless steel plate. Use
blade clearance becomes more than about
four M8 x 30mm bolts and the special steel
1/32” between the impeller edge and the
washers under the bolt heads. Be sure to
water intake liner, one or more of the stain-
install the water pump impeller drive key
less steel shim washers can be transferred
and dowel pins. Grease the threads.
from the bottom stack to the top of the
4. Install the plastic shift rod guide in the impeller. This moves the impeller down
spline of the shift rod and the brass water into the tapered casing to reduce the clear-
tube extension onto the copper water tube. ance.
If there is a burr on the end of the water
Shims should not be used above the
tube, file it smooth so the O-ring inside the
impeller on new installations, where no
water tube extension will slide on.
wear has occurred, unless the blade clear-
5. The large 3/4” adapter plate is attached to ance exceeds 1/32”. Insufficient blade
the exhaust housing to hold the jet drive. clearance will do more harm than good
Two 6 x 16mm dowels locate the place, from any performance gains it might pro-
four M10 x 35mm bolts with lock washers vide.
and one M8 x 30mm bolt with lock washer
When the impeller clearance is satisfactory,
secure it. Grease the bolt threads.
bump the nut up snug with a wrench. If the
6. Next, attach the jet drive to the motor. Use ears of the retainer do not line up with the
two 5/16-18 x 2-1/2 bolts (front), two 5/16- flats on the nut, spin the nut off, turn the
18 x 2-3/4 bolts (rear) from below with lock- retainer over and tighten the nut again. In
washers, one 3/8-16 x 1-1/2 bolt and one of these two positions you will have
lockwasher, above rear, inside the motor alignment and can fold the ears up against
mid-section, and two 3/16 x 1/2 dowel pins. the nut to retain it. The flat in the retainer is
Grease the bolt threads, driveshaft spline, angled to the ears to allow for this.
and rubber water tube pilot generously. 8. Place the intake casing in position with the
Guide the jet into place. Tighten the five lower end at the rear and tighten the six
bolts. nuts. No lock washers are used. Grease
the threads.
22
9. If your jet drive was ordered for use with a 12. Refer to “Engine Mounting” on page 5 to
steering tiller handle, see “Shift Cable and finish installation.
Handle Assembly Instructions.”
CAUTION:
10. If your motor is equipped for remote con-
trols, proceed as follows: When starting the engine for the first time,
watch to see that cooling water comes out
Attach the shift cable and cable anchor
of the small hole at the rear side of engine
bracket to the jet drive.
just below the powerhead. This is to check
Using a light finger pressure on the gate, your assembly of the cooling water pump
move the gate toward reverse until the cam and its connections.
roller is nested in the neutral notch of the
The cooling system can be flushed by
cam.
removing the slotted screw next to the
Adjust the shift cable end and the cable grease fitting. A hose coupling is available
anchor bracket on the jet drive, such that from a Yamaha Outboard Dealer. Turn on
the roller is in the neutral notch when the the water gently, start the motor, set the idle
shift handle is in neutral. Tighten hardware. and watch for cooling water at the tell tale.
Adjust water pressure if needed. Replace
Shift to forward. The roller must be at
the screw after flushing.
the end of the cam slot so the gate can-
not be forcibly rotated toward reverse.
Pull on the gate by hand to verify this.
If this forward lock condition is not met, re-
adjust the cable positions, giving less
importance to the roller position in neutral.
11. If the neutral position is too far out of
adjustment, the tendency of the gate to
move toward reverse, under water pres-
sure, will put tension on the cable in neu-
tral. In some remote control boxes, this
makes it difficult to re-engage the shift
mode with the motor running in the high
speed idle, cold start setting. It is then nec-
essary to stop the motor, operate the shift
handle to engage the shifting pin and then
restart the motor.
Proper cable adjustment will prevent this
problem but it is most important that the for-
ward locking condition be met if a compro-
mise is to be made.
23
F60 TILLER STEERING – SHIFT CABLE PARTS LIST

1 Cable 4’ Mor 33C Supreme Short 1
1 Cable 5’ Mor 33C Supreme Long 1
2 Hex Nut 10-32 Jam 3
3 Clamp Chrys 1
4 Fil Hd Slotted 10-24 x 5/8 2
5 Nyloc 10-24 2
6 Ball End No. 10 x 10-32 Cable 1
7 Bolt Hex Hd 10-32 x 3/4 1
8 Washer Spring Lock No. 10 1
24
1. Cut out the drilling template on page 41, 5. Place the reverse gate in forward with the
including the large centering hole. Fold the cam roller at the end of the slot in the cam.
template to fit the raised section on the Place the shift handle in forward, solidly in
handle. the detent. Adjust the ball rod end to reach
this position. Install the hex #10-32 x 3/4"
Place the template on the steering handle,
bolt, star lock washer, and nut.
holding it in place with masking tape at
each end. Remove the plastic cover under 6. Shift to reverse and forward. The cam roller
the handle. Center punch the two hole should be at the end of the slot in the cam
locations and drill through using a 3/16" such that the gate cannot be forcibly rotat-
drill. Remove the template. ed toward reverse. Pull on the gate to veri-
fy this. Readjust the rod end position, if
2. Remove the plastic cover from the shift
necessary, to satisfy this condition. Lock
handle. Center punch for a 3/16" hole on
the jam nut and install the plastic covers on
the centerline of the handle and as close to
the handle and tiller arm.
the threaded boss as possible while still
being able to get the #10-32 nut inside, with CAUTION:
the hex flat against the boss. Drill through.
3. Attach the lower end of the cable to the jet
shifting.
drive with the terminal end threaded on the
cable as far as it will go and the cable
bracket slid forward and locked.
4. Attach the upper cable anchor to the han-
dle using the two #10-24 x 5/8" screws and
nylock nuts.
NUT AS CLOSE TO BOSS AS POSSIBLE
25
F90 PARTS LIST
4-STROKE 4-CYLINDER
26
F90 PARTS LIST
4-STROKE 4-CYLINDER
REF REF
1 Pump Adapter, Y 1 42 Bolt Hex Hd 1/4-20 x 1 Patch 1
2 Bolt Hex Hd 5/16-18 x 3-1/2 2 43 Bolt Hex Hd 1/4-20 x 3/4 Patch 2
3 Bolt Hex Hd 5/16-18 x 2-1/2 2 44 Spring Gate Bumper 1
4 Adapter Plate Y 1 45 Gate Bumper 1
5 Shift Guide Y 1 46 Fil Hd Slotted 10-32 x 1-1/4 Patch 1
6 Dowel Pin 6 x 16mm 2 Shaft Ass’y. Complete, Y100-4 18T 5/16
7 Washer Spring Lock M10 8 47 Shaft Only, Y100-4 18T 1
8 Bolt Hex Hd M10-1.25 x 35mm 4 48 Shaft Bearing Thrust Ring 1
9 Washer Spring Lock 5/16 9 49 Bearing 2
10 Bolt Hex Hd M8 - 1.25 x 30mm 1 50 Truarc 1
11 Dowel Pin 3/16 x 1/2 2 51 Backup Washer 1
13 Bolt Hex Hd 3/8-16 x 2-3/4 2 53 Upper Seal Carrier WSeals & O-Rings 1
14 Bolt hex Hd 3/8-16 x 3 1 54 Spirolox 4
15 Bolt Hex Hd 3/8-16 x 1-1/4 1 55 Seal Inner 2
Volute with Gate Y 56 Seal outer 2
16 Volute with Exhaust Tube Y 1 57 O-Ring 3/32 x 2-5/16 x 2-1/2 2
17 Exhaust Tube Ass’y Large 2-1/2 1 58 Bearing Carrier w/Seals & O-Rings 5/16 1
18 Clip Exhaust Tube 1-3/8 1 59 O-Ring 1/16 x 5/16 x 7/16 3
19 Nyloc 10-32 2 60 Bolt Hex Hd 5/16-18 x 1 Patch 4
20 Washer Fiber M8 1 61 Impeller 7-3/8 w/136 Sleeve 1
21 Bolt Hex Hd M8 x 1.25 x 12mm 1 62 Shaft Sleeve Plastic Large 1
22 Ball End 1/4 x 10-32 Cable 1 63 Impeller Tee Key 1/2 round 1
23 Lube Hose Ass’y 1 64 Shim Washer Large 7
24 Zirc Fitting 1/4-28 1 65 Nut Keeper Large/Pkg. 2 per bag 1
25 Grease Gun 1 66 Shaft Nut 3/4-16 Brass 1
26 Grease, 10 oz. Tube No. 630-AA 1 Intake Ass’y Flanged with Grill Liner
27 Reverse Gate Large 1 67 Liner 7-3/8 Flanged 1
28 Nyliner 1/2 ID x 13/16 2 68 Intake Painted Only 1
29 Spring Gate Pivot 1/2 2 69 Grill Rod 2
30 Pin Gate Pivot 1/2 Large 2 70 Grill Bar Large 9
31 Shaft Roller 1 71 Stud-Intake Large 6
32 Nyloc 1/4-28 2 72 Nyloc 5/16-18 6
33 Roller Ass’y 1 Bracket Ass’y Morse w/Clamp & Hdwr
34 1/4 Washer 1 73 Bracket Cable Support 1
35 Shift Cam Large 1 74 Shim Morse 1
36 Nyloc 1/4-20 1 75 Clamp Chrys 1
37 Bolt Hex Hd 1/4-20 x 3/4 1 76 Fil Hd Slotted 10-24 x 5/8 2
38 Bushing Cam 1 77 1/4 Washer 2
39 Washer Cam 1 78 Bolt Hex Hd 1/4-20 x 5/8 2
40 Shim-Cam 2 79 Nyloc 10-24 2
41 Cam Eccentric Drilled 1 80 Rubber Washer 1
81 Cup 1
SIZE TORQUE
1/4-20 (M6) 8-9 Ft-lbs.

5/16-18 (M8) 12 Ft-lbs.
3/8-16 (M10) 22 Ft-lbs.
27
F90 ASSEMBLY INSTRUCTIONS Guide the jet into place. Tighten the five
bolts.
1. Place the engine on the transom of your
boat so it is mounted vertically, in the nor- 6. Next, install the impeller. Grease the shaft
mal fashion. threads, key and impeller bore. Place the
plastic sleeve inside the impeller, hold the
2. Install the jet drive shaft assembly into the key in the nose of the impeller with your
spiral pump housing, locking it in place with forefinger and slide onto the driveshaft.
the four 5/16-18 x 1" bolts with lock wash- Install the eight shim washers and nut
ers (apply grease to the threads). Torque to retainer on the shaft, up against the
12 ft-lb. impeller, and bring the nut up snug by
CAUTION: hand. Be careful that the retainer does
not fall into the thread groove and jam
The 4-stroke jet unit must us a newly the nut.
designed water pump housing which is
supplied by Yamaha. Failure to use this Place the water intake in position and
housing will result in engine failure. secure with two bolts. Observe the clear-
ance between the impeller blade edge and
3. Install the 1-3/8” thick aluminum adapter the intake liner. Then, remove the intake.
and stainless steel plate, with the gaskets Shims should not be used above the
and dowel pins. Install the water pump impeller on new installations, where no
assembly using these special 4-stroke wear has occurred, unless the blade clear-
water pump housing on top of the stain- ance exceeds 1/32”. Insufficient blade
less-steel plate. Use four M8 x 30mm bolts clearance will do more harm than good
(apply grease to the threads) and the spe- from any performance gains it might pro-
cial steel washers under the bolt heads. Be vide.
sure to install the water pump drive key.
When, after use in sand and gravel, the
Before tightening the bolts, press the 3-
blade clearance becomes more than about
7/8” long x 1/2” plastic shift rod guide into
1/32” between the impeller edge and the
the clear plastic sleeve, through the stain-
water intake liner, one or more of the stain-
less-steel plate, until it bottoms. Torque the
less steel shim washers can be transferred
bolts to 12 ft-lb.
from the bottom stack to the top of the
4 The large 3/4” adapter plate is attached to impeller. This moves the impeller down
the exhaust housing to hold the jet drive. A into the tapered casing to reduce the clear-
3/8” x 1-1/2” pin in front of the plate guides ance.
the disconnected shift rod. Two 6 x 16mm
Bump the nut with a wrench. If the ears of
dowels locate the plate, four M10 x 35mm
the retainer do not line up with the flats on
bolts with lockwashers and one M8 x
the nut, spin the nut off, turn the retainer
30mm bolt with lockwasher secure it, 22 ft-
over and tighten the nut again. In one of
lbs. Grease bolt threads and the end of the
these positions, you will have alignment
pin where it slides in the shift rod.
and can fold the ears up against the nut to
5. Next, attach the jet drive to the motor. Two retain it. The flat in the retainer is angled to
3/16” x 1/2” dowel pins center the jet drive the ears to allow for this.
on the adapter plate. Four 3/8-16” bolts
and lock washers from below and one 3/8-
16” x 1-1/4” bolt from above/rear, are used.
Select the lower bolt lengths to suit the dif-
ferent counter bore depths, so all bolts
enter the adapter plate the same depth.
Grease the bolt threads, driveshaft spline,
and rubber water tube pilot generously.
28
7. Place the intake casing in position, with the CAUTION:
lower end at the rear, and tighten the six
nuts. No lockwashers are used. Grease the When starting the engine for the first time,
threads. Tighten to 12 ft-lb. watch to see that cooling water comes out
of the small hole at the rear side of engine
8. Attach the shift cable and cable anchor
just below the powerhead. This is to check
bracket to the jet drive. With the shift han-
your assembly of the cooling water pump
dle and the reverse gate in forward, with
and its connections.
the cam roller at the end of the slot,
adjust the cable end and/or cable anchor The cooling system can be flushed by
position to this condition. Shift to reverse removing the slotted screw next to the
and back to forward. The roller should grease fitting. A hose coupling is available
be at the end of the cam slot so the gate from a Yamaha Outboard Dealer. Turn on
cannot be forcibly rotated toward the water gently, start the motor, set to idle
reverse. Pull on the gate by hand to ver- and watch for cooling water at the tell tale.
ify this. Adjust water pressure, if needed. Replace
If this forward lock condition is not met, the screw after flushing.
readjust the cable positions.
9. Refer to “Engine Mounting” on page 5 to
finish installation.
SETTING ENGINE HEIGHT
29
F90 TILLER STEERING – SHIFT CABLE ASSEMBLY

1 Cable 5’ Mor 33C Supreme 1
2 Hex Nut 10-32 Jam 2
3 Clamp Chrys 1
4 Shim Morse 1
5 Fil Hd Slotted 10-32 x 1-1/4 2
6 Nyloc 10-32 3
7 Ball End #10 x 10 - 32 Cable 1
8 Screw Hex Hd 10-32 x 3/4 Mod 1
9 Shim Washer Large 1
10 Shim Washer Small 1
30
1. Remove the plastic covers from the shift 7. Attach the lower end of the cable to the jet
handle and the steering arm. Remove the drive, with the ball rod end threaded on the
shift handle. cable, as far as it will go, and the cable
anchor bracket slid forward and locked.
2. Cut out the template for the shift handle
Twist the cable in the U-clamp, so the cable
and the cable anchor position on the steer-
rests against the motor cowling. Tighten the
ing arm. (See page 41)
clamp screws.
3. Fold the cable anchor pattern along the
8. Place the shift handle in forward, solidly in
dotted lines and place it on the steering
the detent. The reverse gate cam roller
arm with the fork up inside, straddling the
must be at the end of the slot in the cam.
threaded boss. Tape in position.
If these conditions are not met, slide the
4. Place the shift handle pattern over the han- cable anchor bracket on the jet drive and/or
dle boss. Tape in position. Center punch adjust the threaded rod end on the cable.
the three hole locations and drill through
9. Shift to reverse and back to forward. Do not
using a 3/16” drill. The holes in the steering
be concerned if the gate does not reach
arm are long, reaching through the thread-
reverse. There is clearance at this position
ed boss itself.
and water pressure will close the gate.
5. Attach the ball rod end to the shift handle
10. In forward, with the roller at the end of the
and tighten the thin-head hex screw and
cam slot, the gate cannot be forcibly rotat-
lock nut. Remove the flanged plastic bush-
ed toward reverse. Pull on the gate by hand
ing, place the 1/16” thick spacer washer on
to verify this.
the handle and replace the flanged bush-
ing. Place the smaller 1/16” thick spacer 11. Lock the nuts on the cable against the rod
over the square driver and install the han- ends to complete the adjustment and install
dle. the plastic covers.
6. Thread the shift cable all the way into the CAUTION:
shift handle rod end. Attach the cable body
to the steering arm using the shim, U-
shifting.
clamp, two #10-32 x 1-1/4” screws and lock
nuts.
31
F115 PARTS LIST
4-STROKE 4-CYLINDER
32
F115 PARTS LIST
4-STROKE 4-CYLINDER
REF REF
1 Pump Adapter AA 1 50 Upper Seal Carrier W/Seals & O-Rings 1
2 Bolt Hex Hd 5/16-18 x 2-1/2 4 51 Spirolox RR-150S 4
3 Adapter Plate AA 1 52 Seal Inner 2
4 Shift Rod Guide AA-Rod 1 53 Seal Outer 2
5 Dowel Pin 8 x 12m 2 54 O-Ring 3/32 x 2 5/16 x 2-1/2 2
6 Washer Spring Lock M10 12 55 Bearing Carrier w/Seals & O-Rings 5/16 1
7 Bolt Hex Hd M10-1.25 x 35mm 7 56 O-Ring 1/16 x 5/16 x 7/16 3
8 Dowel Pin 3/16 x 1/2 2 57 Bolt Hex Hd 5/16-18 x 1 Patch 4
9 Bolt Hex Hd 3/8-16 x 2-1/4 2 58 Impeller 7-3/8D w/136 Sleeve V-4 1
10 Bolt Hex Hd 3/8-16 x 2-3/4 1 58 Impeller 4 Blade w/136 Sleeve V-6 1
11 Bolt Hex Hd 3/8-16 x 3 1 58 Impeller 7 3/8 1
12 Bolt Hex Hd 3/8-16 x 1-1/2 1 59 Shaft Sleeve Plastic Large 1
Volute with Gate AA 60 Impeller Tee Key 1/2 Round 1
13 Volute with Exhaust Tube AA 1 61 Shim Washers 7
14 Exhaust Tube Ass’y Large 2-1/2 1 62 Nutkeeper (2 per bag) 1
15 Clip Exhaust Tube 1-3/8 1 63 Shaft Nut 3/4-16 Brass 1
16 Nyloc 10-32 2 Intake Ass’y Flanged w/Grill Bar & Liner
17 Washer fiber M8 1 64 Liner 7-3/8 Flanged 1
18 Bolt Hex Hd M8 1.25 x 12MM 1 65 Intake Painted Only 1
19 Ball End 1/4 x 10-32 Cable 1 66 Grill Rod 2
20 Lube Hose Ass’y 1 67 Grill Bar Large 9
21 Zirc Fitting 1/4-28 1 68 Stud - Intake Large 6
22 Grease Gun 1 69 Nyloc 5/16-18 6
23 Grease 10 oz. Tube 1 Bracket Ass’y Morse w/Clamp & Hdwr
24 Reverse Gate Large 1 70 Bracket Cable Support 1
25 Nyliner 1/2 ID x 13/16 2 71 Shim Morse 1
26 Spring Gate Pivot 1/2 1 72 Clamp Chrys 1
27 Pin Gate Pivot 1/2 Large 2 73 Fil Hd Slotted 10-24 x 5/8 2
28 Shaft Roller 1 74 Washer Spring Lock 5/16 8
29 Nyloc 1/4-28 2 75 Bolt Hex Hd 1/4-20 x 5/8 2
30 Roller Ass’y 1 76 Nyloc 10-24 2
31 1/4 Washer 77 Rubber Washer 1
32 Shift Cam Large 1 78 Cup 1
33 Nyloc 1/4-20 1
34 Bolt Hex Hdl 1/4-20 x 3/4 1
35 Bushing Cam 1
36 Washer Cam 1
37 Shim - Cam 2
38 Cam Eccentric Drilled 1
39 Bolt Hex Hd 1/4-20 x 1 Patch 1
40 Bolt Hex Hd 1/4-20 x 3/4 Patch 2
41 Spring Gate Bump 2
42 Gate Bumper 1
43 FIl Hd Slotted 10-32 x 1-1/4 Patch
Shaft Ass’y Complete
44 Shaft Only, AAX, 20T 35-11/16 LG 1
Shaft Ass’y Complete, AA4,6 20T-5/16
44 Shaft Only, AAX, 20T 35-11/16 LG 1
44 Shaft Ass’y Complete, AAX, 20T-5/16
44 Shaft Only, AA115-4 18T 31 9/16 LG 1
Shaft Ass’y Complete, AA115-4 18T-5/16
45 Shaft Bearing Thrust Ring 1
46 Bearing 2
47 Truarc 1
48 Backup Washer 1
49 Truarc 1
SIZE TORQUE
1/4-20 (M6) 8-9 Ft-lbs.

5/16-18 (M8) 12 Ft-lbs.
3/8-16 (M10) 22 Ft-lbs.
33
F115 ASSEMBLY INSTRUCTIONS Grease the bolt threads, driveshaft spline,
and rubber water tube pilot generously.
1. Place the engine on the transom of your Guide the jet into place. Tighten to 22 ft-lb.
boat, so it is mounted vertically, in the nor-
mal fashion. 6. Next, install the impeller. Grease the shaft
threads, key and impeller bore. Place the
2. Install the jet drive shaft assembly into the plastic sleeve inside the impeller, hold the
spiral pump housing, locking it in place with key in the nose of the impeller with your
the four 5/16-18 x 1” bolts and lock wash- forefinger and slide onto the driveshaft.
ers. Use grease on the threads. Tighten to Install the seven shim washers, rubber
15 ft-lb. washer and cup and nut retainer on the
shaft, up against the impeller, and bring the
CAUTION:
nut up snug by hand. Be careful that the
The F115 4-stroke must use a newly retainer does not fall into the thread
designed water pump housing and car- groove and jam the nut.
tridge for jet application. Failure to use the Place the water intake in position and
new housing and cartridge will result in secure with two bolts. Observe the clear-
engine failure. ance between the impeller blade edge and
the intake liner. Then, remove the intake.
3. Install the water pump assembly on top of NOTE: Shims should not be used above
the 3/4” thick aluminum adapter and stain- the impeller on new installations, where no
less steel plate. Use the specially designed wear has occurred, unless the blade clear-
water pump housing and cartridge. No gas- ance exceeds 1/32”. Insufficient blade
kets are used over or under the aluminum clearance will do more harm than good
adapter. Be sure to install the water from any performance gains it might pro-
pump impeller drive key removed from vide.
the propeller drive. Lock in place using Then, bump the nut up snug with a wrench.
four 5/16-18” x 2-1/2” bolts and lock wash- If the ears of the retainer do not line up with
ers. Grease the threads. Tighten to 10 ft-lb. the flats on the nut, spin the nut off, turn the
4. The large 3/4” adapter place is attached to retainer over and tighten the nut again. In
the exhaust housing to hold the jet drive. A one of these two positions, you will have
1/4” x 2” plastic shift rod guide in front of alignment and can fold the ears up against
the place guides the disconnected shift rod. the nut to retain it. The flat in the retainer is
Two 8 x 12mm dowels locate the plate, angled to the ears to allow for this.
seven M10 x 34mm bolts with lockwashers When, after use in sand and gravel, the
secure it. Grease the bolt threads and the blade clearance becomes more than about
end of the pin where it slides in the shift 1/32” between the impeller edge and the
rod. Tighten to 22 ft-lb. water intake liner, one or more of the stain-
5. Next, attach the jet drive to the motor. Two less steel shim washers can be transferred
3/16” x 1/2” dowel pins center the jet drive from the bottom stack to the top of the
on the adapter plate. Four 3/8-16 bolts from impeller. This moves the impeller down into
below and one 3/8-16” x 1-1/2” bolt from the tapered casing to reduce the clearance.
above rear with lock washers are used. 7. Place the intake casing in position, with the
Select the lower bolt lengths to suit the dif- lower end at the rear, and tighten the six
ferent counter bore depths so all bolts enter nuts. No lockwashers are used. Grease the
the adapter plate the same depth. The threads. Tighten to 12 ft-lb.
upper rear bolt is reached through the trim
tab opening in the motor exhaust housing. 8. Attach the shift cable and cable anchor
bracket to the jet drive.
34
CAUTION:
If your motor is a 115HP 4-Stroke, two 9. With the shift handle and the reverse gate
cables will be attached to the cable anchor in forward, with the cam roller at the end of
bracket and roller cam, to provide neutral the slot, adjust the cable and/or cable
start protection. The outer cable comes anchor position to this condition. Shift to
from the remote control box to operate the reverse and back to forward. The roller
reverse gate. It does not enter the motor should be at the end of the cam slot so
housing. The shorter inner cable enters the the gate cannot be forcibly rotated
motor housing to operate the neutral start toward reverse. Pull on the gate by hand
safety switch and is driven by the move- to verify this.
ment of the reverse gate if tiller handle is If this forward lock condition is not met,
installed. The neutral start switch prevents readjust the cable positions.
starting the motor in forward or reverse and
the remote model neutral switch is removed 9* Shift to neutral and adjust the cable end
(see 9* below). in the motor housing so the neutral start
switch is activated. Check adjustment
If the F115 model you have has the coming from both forward and reverse to
engine’s shift switch and plate removed, compensate free play in cable linkage.
the harness for the switch leading from the (115HP 4-Stroke only.)
ECU must be capped off with part #
68V-82582-10. Failure to install this cap may 10. Refer to “Engine Mounting” on page 5 to
lead to performance problems or hard finish installation.
starting due to the ECU recognizing a code
28 (open switch problem).
SETTING MOTOR HEIGHT
35
CAUTION: When running in a bay, lake or wide river in
windy conditions, (particularly when run-
When starting the engine for the first time, ning with the wind), the jet can suck in air
watch to see that the cooling water comes when crossing the wave crests. This will
out of the small hole at the rear side of the result in overspeeding and cause severe
engine just below the powerhead. This is to strain on the driveshaft when the engine is
check your assembly of the cooling water suddenly brought back to normal speed, as
pump and its connections. the impeller once again grabs solid water.
If your boat is used frequently under these
CAUTION: conditions, the engine height should be set
lower than normal to minimize overspeed-
F115 ing. Running at reduced throttle will help
It is important on high horsepower installa- when winds are strong. You can also exper-
tions to mount the motor at the correct iment with a plate extending from the hull
height and to use the power tilt properly. bottom to the top of the leading edge of the
water intake (See page 6). This tends to
Power tilt is convenient for drifting and reduce air intake as well as to reduce spray.
when operating at low throttle in very shal-
low areas. When under power, however, the
engine should not be tilted out, in an effort
to gain speed, as is done with propellers.
The engine driveshaft should be vertical
when planing or tilted toward the boat in
order to provide a scooping angle on the
water intake grille. Tilting the motor out
beyond a vertical position reduces the
scoop angle and can cause impeller slip-
page and cavitation burns on the impeller
blades.
36
SPECIFICATIONS – FOUR-STROKE JET DRIVE MODELS
ITEM/MODEL UNITS F40MJH F60TJR F90TJR

DIMENSIONS
Boat Transom Height mm (in.) 508 (20) 508 (20) 635 (25.0)
Weight kg (lb.) 92 (203) 115 (254) 177 (391)
PERFORMANCE
Full Throttle rpm 5000 ~ 6000 5000 ~ 6000 5000 ~ 6000
Maximum Output BHP/rpm 40/5500 60/5500 90/5500
Idle speed rpm 750 ~ 850 750 ~ 850 750 ~ 850
ENGINE
Type Four-Stroke Four-Stroke Four-Stroke
Number of Cylinders 3 4 4
Bore and Stroke mm 65 x 75 63 x 75 79.0 x 81.4
in. 2.55 x 2.95 2.48 x 2.95 3.11 x 3.20
Total Piston Displacement cc (cu. in.) 747 (44.8) 935 (57.1) 1,596 (97.39)
Cooling System Water Water Water
Ignition System CDI CDI CDI
Spark Plug NGK DPR6EA-9 DPR6EA-9 LFR5A-11
Spark Plug Gap mm 0.9 0.9 1.1
in. 0.035 0.035 0.043
DRIVE UNIT
Gear Shifting Fwd/Neut/Rev Fwd/Neut/Rev Fwd/Neut/Rev
Gear Ratio 1:1 Direct 1:1 Direct 1:1 Direct
Impeller Clearance mm 0.790 0.790 0.790
(Minimum) in. 0.031 0.031 0.031
LUBRICATION
Bearing Grease Yamalube Yamalube Yamalube
Marine Grease Marine Grease Marine Grease
Interval Every 10 hrs., Every 10 hrs., Every 10 hrs.,

after each use, after each use, after each use,
and prior to and prior to and prior to
storage. storage. storage.
37
SPECIFICATIONS – FOUR-STROKE JET DRIVE MODELS
ITEM/MODEL UNITS F115TJR

DIMENSIONS
Boat Transom Height mm (in.) 635 (25.0)
Weight kg (lb.) 188 (415)
PERFORMANCE
Full Throttle rpm 5000 ~ 6000
Maximum Output BHP/rpm 115/5500
Idle speed rpm 650 ~ 750
ENGINE
Type Four-Stroke
Number of Cylinders 4
Bore and Stroke mm 79.0 x 88.8
in. 3.11 x 3.50
Total Piston Displacement cc (cu. in.) 1,741 (106.2)
Cooling System Water
Ignition System CDI
Spark Plug NGK LFR5A-11
Spark Plug Gap mm 1.1
in. 0.043
DRIVE UNIT
Gear Shifting Fwd/Neut/Rev
Gear Ratio 1:1 Direct
Impeller Clearance mm 0.790
(Minimum) in. 0.031
LUBRICATION
Bearing Grease Yamalube
Marine Grease
Interval Every 10 hrs.,

after each use,
and prior to
storage.
38
YAMAHA MOTOR CORPORATION, U.S.A.
FOUR-STROKE JET DRIVE OUTBOARD MOTOR
THREE YEAR LIMITED WARRANTY
Yamaha Motor Corporation, U.S.A. hereby warrants that new 1. Racing or competition use, modification of original parts,
Yamaha four-stroke Jet Drive outboard motors will be free from abnormal strain.
defects in material and workmanship for the period of time stated 2. Lack of proper maintenance and off-season storage as
herein, subject to certain stated limitations. described in the Owner’s Manual; installation of parts or
accessories that are now equivalent in design and quality gen-
PERIOD OF WARRANTY. Any new Yamaha four-stroke Jet uine Yamaha parts.
Drive outboard motor purchased and registered with Yamaha 3. Operation of the motor at an rpm other than specified; use of
Motor Corporation, U.S.A. for pleasure use in the United States lubricants or oils that are not suitable for outboard motor use.
will be warranted against defects in material or workmanship for 4. Damage as a result of accidents, collisions, contact with for-
a period of three (3) years from the date of purchase, subject to eign materials, or submersion.
exclusions noted herein. Any Yamaha Jet Drive outboard motor 5. Growth of marine organism on motor surfaces.
purchased and utilized for commercial applications will be war- 6. Normal deterioration.
ranted for a period of one (1) year from the date of purchase, sub-
ject to exclusions noted herein. Yamaha peripheral equipment SPECIFIC PARTS EXCLUDED FROM WARRANTY. Parts
included with the motor, such as gauges, fuel tanks, and hoses, replaced due to normal wear or routine maintenance such as oil,
remote control boxes, and wiring external from the motor unit, spark plugs, shear pins, Jet Drive impellers and liners, fuel and oil
will be warranted for one (1) year from the date of purchase of filters, brushes for the starter motor and power tilt motor, water
either pleasure or commercial use. Replacement parts used in pump impellers, and anodes, are not covered by warranty.
warranty repairs will be warranted for the balance of the applica-
ble warranty period. Charges for removal of the motor from a boat and transporting the
motor to and from an authorized Yamaha Outboard Motor Dealer
The second and third year of warranty (if applicable) shall be lim- are excluded from warranty coverage.
ited to covering the cost of parts and labor for major components
only. The major components covered are: Specific parts excluded from warranty are:
Power Unit Section • Jet Drive Impeller
• Power Head • Jet Drive Liner
• Intake Manifold • Bearings which are water-damaged as a result of improper
• Carburetor Assembly and its Related Components maintenance
• Fuel Injection System and its Related Components Specific parts excluded from the second and third year of war-
• Fuel and Oil Pump Assemblies ranty (if applicable) are:
Lower Unit Section Bracket Section • Top and Bottom Cowling
• Exhaust System • Bracket System • Electric Components (other than ignition system)
• Upper Casing • Power Trim and Tilt Assembly • Rubber Components (such as hoses, tubes, rubber seals,
fittings, and clamps)
Also covered during the second year of warranty is:
• Jet Drive Pump Assembly Specific parts excluded from the third year of warranty are:
• Jet Drive Pump Assembly
WARRANTY REGISTRATION. To be eligible for warranty
coverage, the Jet Drive outboard motor must be registered with TRANSFER OF WARRANTY. Transfer of the warranty from
Yamaha Motor Corporation, U.S.A. Warranty registration can be the original purchaser to any subsequent purchaser is possible
accomplished by any authorized Yamaha Outboard Motor Dealer. by having the motor inspected by an authorized Yamaha
Upon receipt of the registration, an Owner’s Warranty Card will Outboard Motor Dealer and requesting the dealer to submit a
be sent by Yamaha to the registered purchaser. change of registration to Yamaha Motor Corporation, U.S.A.
within ten (10) days of the transfer.
OBTAINING REPAIRS UNDER WARRANTY. To receive
repairs under this warranty, a valid Owner’s Warranty Card must YAMAHA MOTOR CORPORATION, U.S.A. MAKES NO
be presented to an authorized Yamaha Outboard Motor Dealer. OTHER WARRANTY OF ANY KIND, EXPRESSED OR
IMPLIED. ALL IMPLIED WARRANTIES OF MER-
During the period of warranty, any authorized Yamaha outboard CHANTABILITY AND FITNESS FOR A PARTICULAR PUR-
dealer will, free of charge, repair or replace, at Yamaha’s option, POSE WHICH EXCEED THE OBLIGATIONS AND TIME
any parts adjudged defective by Yamaha due to faulty workman- LIMITS STATED IN THIS WARRANTY ARE HEREBY DIS-
ship or material from the factory. All replaced parts will become CLAIMED BY YAMAHA MOTOR CORPORATION, U.S.A.
the property of Yamaha Motor Corporation, U.S.A. AND EXCLUDED FROM THIS WARRANTY.
CUSTOMER’S RESPONSIBILITY. Under the terms of this SOME STATES DO NOT ALLOW LIMITATIONS ON HOW
warranty, the customer will be responsible for ensuring that the LONG AN IMPLIED WARRANTY LASTS, SO THE ABOVE
Jet Drive outboard motor is properly operated, maintained, and LIMITATIONS MAY NOT APPLY TO YOU. ALSO EXCLUD-
stored as specified in the applicable Owner’s Manual. ED FROM THIS WARRANTY ARE ANY INCIDENTAL OR
The owner of the Jet Drive outboard motor shall give notice to an CONSEQUENTIAL DAMAGES INCLUDING LOSS OF USE.
authorized Yamaha Outboard Motor Dealer of any and all appar- SOME STATES DO NOT ALLOW THE EXCLUSION OR
ent defects within ten (10) days of discovery and make the motor LIMITATION OF INCIDENTAL OR CONSEQUENTIAL
available at that time for inspection and repairs at the dealer’s DAMAGES, SO THE ABOVE EXCLUSION MAY NOT
place of business. APPLY TO YOU.
GENERAL EXCLUSIONS FROM WARRANTY. This war- THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS,
ranty will not cover the repair of damage if the damage is a result AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH
of abuse or neglect of the product. Examples of abuse and neglect VARY FROM STATE TO STATE.
include, but are not limited to:
Effective Date 06/01 YAMAHA MOTOR CORPORATION, U.S.A.
LIT-18790-4J-02 Post Office Box 6555
06/01 Cypress, California 90630
39
F40 TILLER HANDLE TEMPLATE (See page 20 for instructions)
41
42
LIT-18619-00-02
©2002 Yamaha Motor Corporation, U.S.A. Printed in U.S.A.

Yamaha Outboard F115 Service Repair Manual

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What is the purpose of this manual?

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What are some important safety notices mentioned in the manual?

What are some important safety notices mentioned in the manual?

F115C

HOW TO USE THIS MANUAL

Model name F115AET FL115AET

Indication F115AET FL115AET

HOW TO USE THIS MANUAL

E F Symbol F to H in an exploded diagram

I J Symbols I to N in an exploded diagram

IDENTIFICATION ............................................................................................ 1-1

SPECIAL TOOLS ............................................................................................. 1-5

STARTING SERIAL NUMBERS

SAFETY WHILE WORKING 1

The procedures given in this manual are

OILS, GREASES AND SEALING

Under normal conditions of use, there

GOOD WORKING PRACTICES

DISASSEMBLY AND ASSEMBLY

3. After assembly, check that moving parts

4. Install bearings with the manufacturer’s

Using the correct special tools recom-

A Up-relief valve attachment

REMOVING AND INSTALLING

P Slide hammer attachment

GENERAL SPECIFICATIONS.......................................................................... 2-1

MAINTENANCE SPECIFICATIONS................................................................ 2-3

TIGHTENING TORQUES .............................................................................. 2-13

(lines indicate straightedge

Camshaft journal diameter mm (in) 24.96 - 24.98 (0.9827 - 0.9835)

Valve open lower limit mm (in) 4.3 (0.17)

MAINTENANCE INTERVAL CHART .............................................................. 3-1

TOP COWLING ............................................................................................... 3-2

FUEL SYSTEM ................................................................................................ 3-2

CONTROL SYSTEM........................................................................................ 3-4

COOLING SYSTEM ...................................................................................... 3-11

POWER UNIT ................................................................................................ 3-11

POWER TRIM AND TILT SYSTEM .............................................................. 3-16

GENERAL ...................................................................................................... 3-20

MAINTENANCE INTERVAL CHART 3

Use the following chart as a guide to general maintenance intervals.

CHECKING THE TOP COWLING FIT 3

CHECKING THE FUEL LINE 3

CHECKING THE FUEL FILTER 3

MEASURING THE FUEL PRESSURE

Fuel pressure gauge ................. 1

(2) Turn the main switch to on, and then

CHECKING AND ADJUSTING THE

ADJUSTING THE SHIFT CABLE 3

(6) Install the shift cable joint onto the set

ADJUSTING THE THROTTLE CABLE 3

3160 (6) Install the throttle cable joint onto the

ADJUSTING THE THROTTLE

Throttle position sensor output

3170 Measuring steps

Test harness (3-pin)

General adjusting tool

(3) Tighten the screws.

SYNCHRONIZING THE THROTTLE