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Yamaha 250GETO Service Manual

Summary of 250GETO

  • Page 1

    L250g service manual 6s3-28197-5h-11 6 250g yamaha motor co., ltd. Printed in japan aug. 2005 – 1.4 × 1 ! (e_2) printed on recycled paper 250g, l250g a3cover 06.6.9 19:09 page 1.

  • Page 2

    Notice this manual has been prepared by yamaha primarily for use by yamaha dealers and their trained mechanics when performing maintenance procedures and repairs to yamaha equipment. It has been written to suit the needs of persons who have a basic understanding of the mechanical and electrical conc...

  • Page 3: Specification

    Specification general information periodic check and adjustment fuel system power unit bracket unit electrical system troubleshooting index contents lower unit 9 8 7 6 2 1 gen info spec chk adj fuel powr lowr brkt elec trbl shtg 3 4 5 6s35h11_01 9/2/05 6:41 pm page 1.

  • Page 4

    6s35h11_01 9/2/05 6:41 pm page 2.

  • Page 5: General Information

    6s35h11 1- 9 8 7 6 5 4 3 2 1 general information how to use this manual ............................................................................... 1-1 manual format .......................................................................................... 1-1 symbol ...............................

  • Page 6

    Gen info 1- 6s35h11 general information 1-1 how to use this manual manual format the format of this manual has been designed to make service procedures clear and easy to under- stand. Use the information below as a guide for effective and quality service. 9 parts are shown and detailed in an explode...

  • Page 7

    How to use this manual 6s35h11 9 8 7 6 5 4 3 2 1 1-2 gen info symbol the symbols below indicate the content of a chapter. General information fuel system bracket unit specification power unit electrical system periodic check and adjustment lower unit troubleshooting symbols 1 to 6 indicate specific ...

  • Page 8

    Gen info 1- 6s35h11 general information 1-3 safety while working to prevent an accident or injury and to ensure quality service, follow the safety procedures provided below. Fire prevention gasoline is highly flammable. Keep gasoline and all flammable products away from heat, sparks, and open flames...

  • Page 9

    Safety while working 1-4 6s35h11 9 8 7 6 5 4 3 2 1 6. Keep a supply of clean, lint-free cloths for wiping up spills, etc. Good working practice special service tool use the recommended special service tools to protect parts from damage. Use the right tool in the right manner–do not improvise. Tighte...

  • Page 10

    1-5 gen info 6s35h11 general information identification applicable model this manual covers the following model. Serial number the outboard motor serial number is stamped on a label attached to the port clamp bracket. 1 model name 2 approved model code 3 transom height 4 serial number yamaha motor c...

  • Page 11

    6s35h11 1-6 9 8 7 6 5 4 3 2 1 identification/special service tool special service tool digital tachometer 90890-06760 leakage tester 90890-06840 vacuum/pressure pump gauge set 90890-06756 digital caliper 90890-06704 timing light 90890-03141 compression gauge 90890-03160 flywheel holder 90890-06522 f...

  • Page 12

    Gen info 1- 6s35h11 general information 1-7 support 90890-02394 pressure pin b 90890-02390 b driver rod l3 90890-06652 driver rod ls 90890-06606 gear puller 90890-06540 dial gauge set 90890-01252 cylinder gauge 90890-06759 bearing separator 90890-06534 pinion nut holder 90890-06715 ring nut wrench e...

  • Page 13

    Special service tool 1-8 6s35h11 9 8 7 6 5 4 3 2 1 puller head 90890-06514 stopper guide plate 90890-06501 bearing housing puller claw l 90890-06502 center bolt 90890-06504 stopper guide stand 90890-06538 drive shaft holder 6 90890-06520 bearing depth plate 90890-06603 bearing puller assembly 90890-...

  • Page 14

    6s35h11 1-9 gen info general information magnet base b 90890-06844 bearing outer race puller assembly 90890-06523 outer race puller claw b 90890-06533 slide hammer handle 90890-06531 bearing outer race attachment 90890-06622, 90890-06624, 90890-06626 90890-06628, 90890-06658 ball bearing attachment ...

  • Page 15

    6s35h11 1-10 9 8 7 6 5 4 3 2 1 special service tool magnet base plate 90890-07003 cylinder-end screw wrench 90890-06568 ptt piston vice attachment 90890-06572 ring nut wrench 4 90890-06510 ignition tester 90890-06754 digital circuit tester 90890-03174 backlash indicator 90890-06706 ring nut wrench 9...

  • Page 16

    Test harness (3 pins) 90890-06870 gen info 1-11 6s35h11 general information ptt oil pressure gauge assembly 90890-06580 test harness (2 pins) 90890-06867 tilt rod wrench 90890-06569 test harness (3 pins) 90890-06857 test harness (4 pins) 90890-06871 test harness (6 pins) 90890-06872 6s35h11_01 9/2/0...

  • Page 17

    6s35h11 1-12 9 8 7 6 5 4 3 2 1 special service tool/feature and benefit feature and benefit power unit piston an aluminum piston with heat treatment is used to obtain durability and reliability. Molybdenum coating is given to the skirt of piston to obtain more lubrication and reduce friction. 1st or...

  • Page 18

    Gen info 1-13 6s35h11 general information cylinder sleeve the slit of exhaust port is removed and smoother curved exhaust port is used on, which can pre- vent the piston rings from scuffing with lesser fuel. Exhaust slit sleeve 250a 250g cylinder body the shallow water jacket is designed to increase...

  • Page 19

    6s35h11 1-14 9 8 7 6 5 4 3 2 1 feature and benefit engine mount bolt a fully thread bolt coated with a sealing agent has been used for mounting the engine. This gives a sealing function to the bolt, which will prevent the bolt from sticking by saltwater enter- ing into the bolt hole for crystallizin...

  • Page 20

    Gen info 1-15 6s35h11 general information bracket/upper case ptt unit the components of clamp bracket and ptt unit are the same as 250a. Manual valve 20.6 mpa, 210 kgf/cm , 2 2,988 psi main valve gear pump up relief valve 12.3 mpa, 125 kgf/cm , 1,784 psi 2 down relief valve 5.7 mpa, 58 kgf/cm , 827 ...

  • Page 21

    6s35h11 1-16 9 8 7 6 5 4 3 2 1 feature and benefit lower unit oil passage the oil passages have been added to the drive shaft at pinion end and the lower case between gear housing and shifter room to increase the gear oil fluidity, so that the lubrication ability has increased. 86.5 mm (3.41 in) dri...

  • Page 22

    Gen info 1-17 6s35h11 general information exhaust passage components a hard anodic oxide coating has been given to the exhaust passage's components to obtain corro- sion-resistance. The effected components are as follows, • exhaust pipe 61a-41132-20 • muffler 61a-14711-30 example; muffler m mark m i...

  • Page 23

    6s35h11 1-18 9 8 7 6 5 4 3 2 1 feature and benefit forward gear thrust bearing the forward gear bearing is newly designed to receive the thrust force from propeller at the outer race, which can obtain durability and reliability. Compared with the taper roller bearing, this structure can remove the t...

  • Page 24

    Gen info 1-19 6s35h11 general information fuel system premixing system new auto lube system (auto oil blend system) is used to obtain simple structure. The oil is supplied to the fuel line via the mechanical oil pump, and obtained simple oil hose deliv- ery layout. This can obtain easier servicing. ...

  • Page 25

    6s35h11 1-20 9 8 7 6 5 4 3 2 1 feature and benefit 2) oil indicator control this engine has the oil warning indicators. When the key switch is turned to on, all indicators light for 3 seconds to check the bulbs. The indicators on tachometer show the oil level condition as below. Note: sw-3 is on: en...

  • Page 26

    Gen info 1-21 6s35h11 general information cooling system the cooling water flow diagram is as follows. Cooling water inlet water pump exhaust guide flushing device pilot hole rectifier/regulator propeller boss lower case upper case exhaust outer cover pcv cylinder body thermostat cylinder head sea, ...

  • Page 27

    6s35h11 1-22 9 8 7 6 5 4 3 2 1 feature and benefit electrical system hour meter hour meter has been built in the engine for easier management of service interval. The meter shows the elapsed engine operation hours after the engine was manufactured. Hour is counted by the signal of crank position sen...

  • Page 28

    Gen info 1-23 6s35h11 general information ignition control the micro-computer controls the ignition timing due to the throttle valve angle and engine rpm at every 0.01 seconds. When starting the engine, the ignition timing is fixed to btdc7. If the engine condition is in an emergency, the ignition i...

  • Page 29

    6s35h11 1-24 9 8 7 6 5 4 3 2 1 feature and benefit/propeller selection c c select the propeller which is not exceed 5,500 r/min. Otherwise can not obtain the correct engine performance, it becames could result engine damaged. Regular rotation model counter rotation model propeller selection the perf...

  • Page 30

    Predelivery check to make the delivery process smooth and efficient, the predelivery checks should be completed as explained below. Checking the fuel system 1. Check that the fuel hoses is securely connected and that the fuel tank is filled with fuel. C c for break-in period, use the fuel and oil mi...

  • Page 31

    6s35h11 1-26 9 8 7 6 5 4 3 2 1 predelivery check checking the outboard motor mounting height 1. Check that the anti-cavitation plate is aligned with the bottom of the boat. If the mounting height is too high, cavitation will occur and propulsion will be reduced. Also, the engine speed will increase ...

  • Page 32

    Checking the steering system 1. Check that the steering operates smooth- ly. 2. Check that there is no interference with wires or hoses when the outboard motor is steered. Checking the gear shift and throttle operation 1. Check that the gear shift operates smoothly when the remote control lever is s...

  • Page 33

    6s35h11 1-28 9 8 7 6 5 4 3 2 1 predelivery check break-in during the test run, perform the break-in operation in the following 5 stages. 1. 10 minutes a at the lowest possible speed. A fast idle in neutral is best. 2. 50 minutes b at 1/2 throttle (approxi- mately 3,000 r/min) or less. Vary engine sp...

  • Page 34

    Gen info 1-29 6s35h11 general information after test run 1. Check for water in the gear oil. 2. Check for fuel leakage in the cowling. 3. Flush the cooling water passage with fresh water using the flushing kit 1 and with the engine running at idle. C c be sure to supply sufficient water when flushin...

  • Page 35: Specification

    6s35h11 9 8 7 6 5 4 3 2 1 spec specification general specification .....................................................................................2-1 maintenance specification ............................................................................2-3 power unit...............................

  • Page 36

    Spec 2-1 6s35h11 specification general specification item unit model 250get l250get dimension overall length mm (in) 854 (33.6) overall width mm (in) 562 (22.1) overall height (x) mm (in) 1,785 (70.3) (u) mm (in) 1.912 (75.3) boat transom height (x) mm (in) 635 (25.0) (u) mm (in) 762 (30.0) weight (...

  • Page 37

    Item unit model 250get l250get fuel and oil fuel type regular unleaded gasoline ron (*1) 87 engine oil 2-stroke outboard motor oil engine oil grade nmma-certified tc-w3 engine oil tank capacity oil tank l (us gt, 1.2 (1.27, 1.06) imp gt) remote oil tank l (us gt, 10.5 (11.10, 9.24) imp gt) gear oil ...

  • Page 38

    Spec 2-3 6s35h11 specification maintenance specification power unit item unit model 250get l250get power unit minimum compression kpa 430 pressure (*1) (kgf/cm 2 , psi) (4.3, 61) cylinder head warpage limit mm (in) 0.10 (0.0039) (lines indicate straightedge position) cylinders bore size mm (in) 90.0...

  • Page 39

    6s35h11 2-4 9 8 7 6 5 4 3 2 1 maintenance specification item unit model 250get l250get piston rings top ring dimension b mm (in) 1.970–1.990 (0.0776–0.0783) dimension t mm (in) 2.700–2.900 (0.1063–0.1142) end gap mm (in) 0.30–0.50 (0.0118–0.0197) side clearance mm (in) 0.02–0.06 (0.0008–0.0024) over...

  • Page 40

    Spec 2-5 6s35h11 specification item unit model 250get l250get carburetor id mark 6s300 main jet (m.J.) # 158 [su, pu, pm] 164 [sm, pl] 162 [sl] main nozzle (m.N.) mm (in) 4.5 (0.18) pilot jet (p.J.) # 74 [su], 78 [pu], 80 [sm, sl], 84 [pm, pl] pilot air jet (p.A.J.) # 50 [su, pu] 60 [sm, pm, sl, pl]...

  • Page 41

    6s35h11 2-6 9 8 7 6 5 4 3 2 1 maintenance specification item unit model 250get l250get spark plug gap mm (in) 0.9–1.0 (0.035–0.039) ignition coil resistance primary coil (b/w–b) Ω 0.18–0.24 at 20°c (68°f) secondary coil (b/w–spark plug wire) k Ω 2.72–3.68 at 20°c (68°f) spark plug cap resistance k Ω...

  • Page 42

    Spec 2-7 6s35h11 specification item unit model 250get l250get charge coil output peak voltage (r–br) at cranking (unloaded) v 120 at cranking (loaded) v 150 at 1,500 r/min (loaded) v 170 at 3,500 r/min (loaded) v 170 (b/r–l) at cranking (unloaded) v 120 at cranking (loaded) v 150 at 1,500 r/min (loa...

  • Page 43

    6s35h11 2-8 9 8 7 6 5 4 3 2 1 maintenance specification item unit model 250get l250get ptt system trim sensor trim sensor resistance Ω 9–11 at 20°c (68°f) (p–b) resistance Ω 248–388 at 20°c (68°f) (p–b) fluid type atf dexron 2 motor type 61a02 output kw 0.38 brushes standard length mm (in) 12.0 (0.4...

  • Page 44

    Spec 2-9 6s35h11 specification 420 (16.5) 32 ˚ 281 (11.0) 631 (24.8) x : 1,155(45.5) u : 1,271(50.0) 556 (22.3) 181 (7.1) 74.0 (2.9) 185 (7.3) 70 ˚ 3˚ 12˚ x : 846 (33.3) u : 923 (36.3) u : 89 (3.5) x : 69 (2.7) 79 (3.1) 673 (26.5) x : 52 (2.0) u : 58 (2.3) 441 (17.4) 818 (32.2) x : 1,077 (42.4) u : ...

  • Page 45

    6s35h11 2-10 9 8 7 6 5 4 3 2 1 maintenance specification 79 (3.1) 13 (0.5) 180 (7.1) 163.5 (6.4) 254 (10.0) 55.5 (2.2) 411 (16.2) 163.5 (6.4) 125.4 (4.9) 125.4 (4.9) 101.5 (4.0) 101.5 (4.0) 180 (7.1) 13 (0.5) 50.8 (2.0) 18.5 (0.7) 6s32002m clamp bracket mm (in) 6s35h11_02a 05.9.5 14:15 page 11.

  • Page 46

    Spec 2-11 6s35h11 specification tightening torque specified torque part to be tightened thread size tightening torques n·m kgf·m ft·lb fuel system intake silencer screw — 3 0.3 2.2 throttle sensor screw — 4 0.4 3.0 hour meter cover screw — 3 0.3 2.2 oil pump bolt m6 7 0.7 5.2 power unit power unit b...

  • Page 47

    Part to be tightened thread size tightening torques n·m kgf·m ft·lb lower unit (regular rotation model) check screw — 9 0.9 6.6 drain screw — 9 0.9 6.6 lower case mount bolt m10 47 4.7 34.7 water pump housing bolt m8 18 1.8 13.3 shift rod cover bolt m6 8 0.8 5.9 trim tab bolt m10 42 4.2 31.0 propell...

  • Page 48

    Spec 2-13 6s35h11 specification general torque this chart specifies tightening torques for standard fasteners with a standard iso thread pitch. Tightening torque specification for special components or assemblies are provided in applicable sections of this manu- al. To avoid warpage, tighten multi-f...

  • Page 49

    6s35h11 9 8 7 6 5 4 3 2 1 3 1 periodic check and adjustment maintenance interval chart .......................................................................... 3-1 top cowling .................................................................................................. 3-2 checking the top co...

  • Page 50

    Chk adj 6s35h11 3-1 maintenance interval chart use the following chart as a guideline for general maintenance. Adjust the maintenance intervals according to the operating conditions of the outboard motor. Periodic check and adjustment chk adj initial every refer item actions 10 hours 50 hours 100 ho...

  • Page 51

    Top cowling checking the top cowling 1. Check the fitting by pushing the cowling with both hands. Adjust the fittings if nec- essary. 2. Loosen the bolts 1. 3. Move the hook 2 up or down slightly to adjust its position. Note: 9 to loosen the fitting, move the hook 2 in direction a. 9 to tighten the ...

  • Page 52

    4. Check the spark plug gap a. Adjust if out of specification. 5. Install the spark plug temporary tight, then to the specified torque with a spark plug wrench. Checking the thermostat 1. Remove the thermostat covers 1, gas- kets 2, and thermostats 3. 2. Suspend the thermostats 3 in a con- tainer wi...

  • Page 53

    3. Place a thermometer in the water and slowly heat the water. 4. Check the thermostat valve opening at the specified water temperatures. Replace if out of specification. 5. Install the new gaskets, thermostats and thermostat covers, and then tighten the cover bolts to specified torques. 6s35h11 3-4...

  • Page 54

    Chk adj 3-5 6s35h11 periodic check and adjustment 4. Loosen the throttle lever tightening screw 4 to clockwise on the upper and lower carburetors. Note: the screw 4 is left hand thread. 5. Make sure that the throttle valve is in the fully closed position. 6. Tighten the throttle lever tightening scr...

  • Page 55

    6s35h11 3-6 9 8 7 6 5 4 3 2 1 control system 7. Align the mark 5 on the accelerator cam with the center of the roller 6 on the mid- dle carburetor and tighten the throttle lever tightening screw 1. 8. Install the throttle cable and intake silencer. Note: after synchronizing the carburetor, start the...

  • Page 56

    Chk adj 3-7 6s35h11 periodic check and adjustment 4. If the specified engine idle speed cannot be obtained, adjust the pilot screws. Note: when adjust the pilot screws, adjust it in the all of cylinders. Checking the stopper and throttle link position 1. Measure the length of throttle link rod. 2. M...

  • Page 57

    6s35h11 3-8 9 8 7 6 5 4 3 2 1 control system adjusting the throttle cable note: before adjusting the throttle cable, the throttle stop screw should be properly adjusted. 1. Loosen the locknut 1, remove the clip 2 and then remove the throttle cable joint 3. 2. Set the remote control lever to the full...

  • Page 58

    Checking the gear shift operation 1. Check that the gear shift operates smoothly when shifting it from neutral to forward or reverse. Adjust the shift cable if necessary. 2. Set the gear shift to the neutral position. 3. Loosen the locknut 1, remove the clip 2, and then remove the shift cable joint ...

  • Page 59

    3. Check that the atdc 4° scale a on the flywheel magnet is aligned with the point- er b on the timing plate. 4. If the ignition timing is out of specification. Refer to “adjusting the timing plate” p5-46 in chapter 5. Checking the choke solenoid 1. Check that the choke solenoid face a is between th...

  • Page 60

    Checking the ptt fluid level 1. Fully tilt the outboard motor up, and then support it with the tilt stop lever 1. W after tilting up the outboard motor, be sure to support it with the tilt stop lever. Otherwise, the outboard motor could sud- denly lower if the ptt unit should lose fluid pressure. 2....

  • Page 61

    6s35h11 3-12 9 8 7 6 5 4 3 2 1 bracket/lower unit changing the gear oil 1. Tilt the outboard motor so that the gear oil drain screw at the lowest point possi- ble. 2. Place a drain pan under the drain screw 1, remove the drain screw, then the check screw 2 and let the oil drain com- pletely. 3. Chec...

  • Page 62

    Chk adj 3-13 6s35h11 periodic check and adjustment c c do not oil, grease, or paint the anodes or the trim tab, otherwise they will be ineffec- tive. Note: if it is necessary to disassemble the outboard motor to check an anode, refer to the applic- able disassembly procedure in this manual. 2. Repla...

  • Page 63

    6s35h11 3-14 9 8 7 6 5 4 3 2 1 lower unit/general checking the battery 1. Check the battery electrolyte level. If the level is at or below the minimum level mark a, add distilled water until the level is between the maximum and minimum level marks. 2. Check the specific gravity of the elec- trolyte....

  • Page 64

    Chk adj 3-15 6s35h11 periodic check and adjustment note: apply grease to the grease nipple until it flows from the bushings a. 6s330060 6s330070 6s330080 2. Apply low temperature resistant grease to the area shown. 3. Apply corrosion resistant grease to the area shown. 6s330090 a c 6g430540 6s330100...

  • Page 65: Fuel System

    6s35h11 9 8 7 6 5 4 3 2 1 fuel system hose routing ................................................................................................. 4-1 fuel hose and breather hose .................................................................. 4-1 fuel line .........................................

  • Page 66

    Fuel 4-1 6s35h11 fuel system hose routing fuel hose and breather hose 1 fuel hose (fuel tank-to-fuel filter) 2 fuel hose (fuel filter-to-fuel pumps) 3 fuel hose (fuel pumps-to-carburetors) 4 oil hose (remote oil tank-to-engine oil tank) 5 oil hose (engine oil tank-to-oil injection pump) 6 oil hose (...

  • Page 67

    6s35h11 4-2 9 8 7 6 5 4 3 2 1 hose routing port stb 6s34001b 1 2 3 4 5 6 7 8 1 breather hose (upper-to-lower) 2 breather hose (manifold-to-cylinder body #2) 3 breather hose (manifold-to-cylinder body #4) 4 breather hose (manifold-to-cylinder body #6) 5 breather hose (manifold-to-cylinder body #1) 6 ...

  • Page 68

    Fuel 4-3 6s35h11 fuel system fuel line 6s34020e no. Part name q’ty remarks 1 bolt 2 m6 × 16 mm 2 fuel filter assembly 1 3 lock tie 23 4 fuel hose 1 5 fuel hose 1 6 fuel hose 1 7 oil hose 1 8 fuel hose 1 9 fuel hose 1 10 fuel pump assembly 2 11 gasket 2 12 fuel hose 2 13 fuel hose 2 14 fuel hose 1 15...

  • Page 69

    6s35h11 4-4 9 8 7 6 5 4 3 2 1 6s34020e no. Part name q’ty remarks 18 bolt 4 m6 × 50 mm 19 holder 3 20 hose 1 fuel line 6s35h11_04 9/9/05 1:23 pm page 5.

  • Page 70

    Fuel 4-5 6s35h11 fuel system 6s34040e no. Part name q’ty remarks 1 bolt 1 m6 × 16 mm 2 washer 1 3 holder 1 4 bolt 1 m6 × 14 mm 5 bracket 1 6 fuel filter assembly 1 7 o-ring 1 8 o-ring 1 9 fuel filter element 1 10 spring 1 11 float 1 12 fuel filter cup 1 13 nut 1 14 o-ring 1 not reusable not reusable...

  • Page 71

    6s35h11 4-6 9 8 7 6 5 4 3 2 1 carburetror 3 n·m (0.3 kgf·m, 2.2 ft·lb) 6s34050e no. Part name q’ty remarks 1 screw 12 ø6 × 55 mm 2 intake silencer 1 3 hose 1 4 hose 1 5 gasket 3 6 nut 12 7 upper carburetor assembly 1 8 middle carburetor assembly 1 9 lower carburetor assembly 1 10 link rod 1 11 rod 2...

  • Page 72

    Fuel 4-7 6s35h11 fuel system 6 n·m (0.6 kgf·m, 4.4 ft·lb) 2 n·m (0.2 kgf·m, 1.5 ft·lb) 10 n·m (1.0 kgf·m, 7.4 ft·lb) 4 n·m (0.4 kgf·m, 3.0 ft·lb) 4 n·m (0.4 kgf·m, 3.0 ft·lb) 6s34060e no. Part name q’ty remarks 1 plug 6 2 gasket 6 3 screw 3 4 plate 3 5 pilot screw 6 6 spring 6 7 screw 3 8 gasket 3 9...

  • Page 73

    6s35h11 4-8 9 8 7 6 5 4 3 2 1 6 n·m (0.6 kgf·m, 4.4 ft·lb) 2 n·m (0.2 kgf·m, 1.5 ft·lb) 10 n·m (1.0 kgf·m, 7.4 ft·lb) 4 n·m (0.4 kgf·m, 3.0 ft·lb) 4 n·m (0.4 kgf·m, 3.0 ft·lb) 6s34060e no. Part name q’ty remarks 18 gasket 6 19 main jet 6 20 float chamber 3 21 plug 6 22 gasket 6 23 pilot jet 6 24 scr...

  • Page 74

    Fuel 4-9 6s35h11 fuel system 6 n·m (0.6 kgf·m, 4.4 ft·lb) 2 n·m (0.2 kgf·m, 1.5 ft·lb) 10 n·m (1.0 kgf·m, 7.4 ft·lb) 4 n·m (0.4 kgf·m, 3.0 ft·lb) 4 n·m (0.4 kgf·m, 3.0 ft·lb) 6s34060e no. Part name q’ty remarks 35 screw 2 ø5 × 10 mm 36 throttle sensor 1 37 pin 1 38 joint 1 39 arm 1 6s35h11_04 9/9/05...

  • Page 75

    6s35h11 4-10 9 8 7 6 5 4 3 2 1 carburetor disassembling the carburetor note: 9 before disassembling the carburetors, make sure to note the number of times the pilot screw is turned out from the seated position to its set position. 9 disassembled jets and other components should be sorted out and kep...

  • Page 76

    Fuel 4-11 6s35h11 fuel system 6. Install the pilot screw, and then turn in until it is lightly seated, and then turn out by the specified number of turns. Note: when disassemble the carburetor, be sure to set the pilot screw by the specified times. 7. Install the carburetor assembly. Assembling the ...

  • Page 77

    6s35h11 4-12 9 8 7 6 5 4 3 2 1 carburetor adjusting the throttle sensor 1. Remove the hour meter cover 1 and intake silencer cover. 2. Remove the throttle link rod 2 from the upper carburetor. 3. Check the throttle valve to fully closed position. 4. Connect the test harness to the throttle sensor. 5...

  • Page 78

    Fuel 4-13 6s35h11 fuel system fuel pump 6g44030e no. Part name q’ty remarks 1 base 2 2 gasket 2 3 diaphragm 2 4 body assembly 2 5 nut 8 6 screw 8 ø5 × 28 mm 7 washer 8 8 check valve 8 9 body 2 10 gasket 2 11 diaphragm 2 12 collar 4 13 o-ring 4 14 cover 2 15 plate 2 16 spring 2 17 screw 6 ø5 × 35 mm ...

  • Page 79

    6s35h11 4-14 9 8 7 6 5 4 3 2 1 fuel pump checking the fuel pump 1. Place a drain pan under the fuel hose connections, and then disconnect the fuel hoses from the fuel pumps. 2. Connect the special service tool to the fuel pump inlet. 3. Cover the fuel pump outlet with a finger, and then apply the sp...

  • Page 80

    Fuel 4-15 6s35h11 fuel system note: make sure that the gaskets and diaphragms are kept in place through the assembly process. Assembling the fuel pump note: clean the parts and soak the valves and the diaphragms in gasoline before assembly to obtain prompt operation of the fuel pumps when starting t...

  • Page 81

    6s35h11 4-16 9 8 7 6 5 4 3 2 1 oil injection system 3 n·m (0.3 kgf·m, 2.2 ft·lb) 7 n·m (0.7 kgf·m, 5.2 ft·lb) 6s34110e no. Part name q’ty remarks 1 oil level sensor 1 2 oil filter 1 3 washer 1 4 oil tank 1 5 air vent hose 1 6 emergency switch 1 7 collar 3 8 grommet 3 9 lock tie 6 10 water trap 1 11 ...

  • Page 82

    Fuel 4-17 6s35h11 fuel system 3 n·m (0.3 kgf·m, 2.2 ft·lb) 7 n·m (0.7 kgf·m, 5.2 ft·lb) 6s34110e no. Part name q’ty remarks 18 oil pump link rod 1 19 bolt 2 m6 × 20 mm 20 oil pump 1 21 o-ring 1 22 cover 1 23 screw 4 ø5 × 20 mm not reusable 6s35h11_04 9/9/05 1:23 pm page 18.

  • Page 83

    6s35h11 4-18 9 8 7 6 5 4 3 2 1 oil pump bolt: 7 n·m (0.7 kgf·m, 5.2 ft·lb) assembling the oil tank 1. Install the washer 1, oil filter 2, and oil level sensor 3 into the oil tank 4. Note: 9 align the alignment marks a on the oil filter 2 and oil level sensor 3. 9 align the alignment marks b on the o...

  • Page 84

    Fuel 4-19 6s35h11 fuel system 4. When there are no air bubbles left, tight- en the air bleed screw. 5. Disconnect the oil pump link rod joint 2 from the oil pump lever. 6. Disconnect the oil hose (translucent) and start the engine. 7. Make sure that the engine oil is come out of the outlet of oil pu...

  • Page 85

    10. Connect the oil pump link rod 4 to the oil pump lever. Check the oil pump lever clearance a between the oil pump lever and stopper. 11. If the oil pump lever clearance is out of specification, remove the oil pump link rod and adjust the length until the speci- fied clearance. 6s35h11 4-20 9 8 7 ...

  • Page 86: Power Unit

    Powr 6s35h11 power unit power unit ..................................................................................................... 5-1 checking the compression pressure ....................................................... 5-1 removing the power unit ............................................

  • Page 87

    6s35h11 9 8 7 6 5 4 3 2 1 checking the piston pin ......................................................................... 5-33 checking the connecting rod small end axial play ................................ 5-34 checking the connecting rod big end side clearance ........................... 5-34 ...

  • Page 88

    Powr 5-1 6s35h11 power unit power unit checking the compression pressure 1. Start the engine, warm it up for 5 min- utes, and then turn it off. 2. Remove the lock plate from the engine stop lanyard switch on the remote control box or switch panel. 3. Remove the all spark plug caps and all spark plug...

  • Page 89

    6s35h11 9 8 7 6 5 4 3 2 1 5-2 power unit 25 n·m (2.5 kgf·m, 18.4 ft·lb) 25 n·m (2.5 kgf·m, 18.4 ft·lb) 8 n·m (0.8 kgf·m, 5.9 ft·lb) 6s35010e no. Part name q’ty remarks 1 grommet 3 2 flywheel cover 1 3 dowel 2 4 gasket 1 5 bolt 4 m6 × 20 mm 6 bolt 3 m6 × 16 mm 7 retaining plate 1 8 grommet 1 9 bolt 6...

  • Page 90

    Powr 5-3 6s35h11 power unit 3 n·m (0.3 kgf·m, 2.2 ft·lb) 200 n·m (20 kgf·m, 148 ft·lb) 10 n·m (1.0 kgf·m, 7.4 ft·lb) 6s35020e no. Part name q’ty remarks 1 flywheel magnet 1 2 nut 1 3 washer 1 4 bolt 4 m6 × 35 mm 5 stator assembly 1 6 bolt 2 m6 × 20 mm 7 screw 3 ø5 × 30 mm 8 pulser coil assembly 1 9 ...

  • Page 91

    6s35h11 5-4 9 8 7 6 5 4 3 2 1 power unit 3 n·m (0.3 kgf·m, 2.2 ft·lb) 200 n·m (20 kgf·m, 148 ft·lb) 10 n·m (1.0 kgf·m, 7.4 ft·lb) 6s35020e no. Part name q’ty remarks 18 bolt 1 m6 × 16 mm 19 hour meter 1 20 screw 2 ø5 × 20 mm 21 bolt 4 m6 × 30 mm 22 grommet 4 23 clamp 2 24 collar 4 25 case 1 26 cover...

  • Page 92

    Powr 5-5 6s35h11 power unit 8 n·m (0.8 kgf·m, 5.9 ft·lb) 18 n·m (1.8 kgf·m, 13.3 ft·lb) 3 n·m (0.3 kgf·m, 2.2 ft·lb) 18 n·m (1.8 kgf·m, 13.3 ft·lb) 6s35030e no. Part name q’ty remarks 1 control lever 1 2 bolt 1 m8 × 40 mm 3 wave washer 1 4 collar 1 5 throttle link rod 1 6 lock nut 1 7 joint 1 8 acce...

  • Page 93

    6s35h11 5-6 9 8 7 6 5 4 3 2 1 power unit 8 n·m (0.8 kgf·m, 5.9 ft·lb) 18 n·m (1.8 kgf·m, 13.3 ft·lb) 3 n·m (0.3 kgf·m, 2.2 ft·lb) 18 n·m (1.8 kgf·m, 13.3 ft·lb) 6s35030e no. Part name q’ty remarks 18 lever 1 19 spring 1 20 washer 1 21 bracket 1 22 bolt 2 m6 × 20 mm 23 stay 1 24 cap 1 25 lock nut 1 2...

  • Page 94

    Powr 5-7 6s35h11 power unit 4 n·m (0.4 kgf·m, 3.0 ft·lb) 18 n·m (1.8 kgf·m, 13.3 ft·lb) 18 n·m (1.8 kgf·m, 13.3 ft·lb) 7 n·m (0.7 kgf·m, 5.2 ft·lb) 6s35040e no. Part name q’ty remarks 1 bolt 2 m8 × 45 mm 2 bolt 1 m8 × 35 mm 3 bolt 1 m8 × 16 mm 4 negative battery cable 1 5 nut 1 6 spring washer 1 7 p...

  • Page 95

    6s35h11 5-8 9 8 7 6 5 4 3 2 1 power unit 6s35050e no. Part name q’ty remarks 1 case 1 2 grommet 4 3 bolt 4 m6 × 28 mm 4 collar 4 5 bolt 6 m6 × 20 mm 6 bolt 4 m6 × 14 mm 7 ignition coil 6 8 plug cap 6 9 ground lead 1 10 bolt 2 m6 × 16 mm 11 plate 1 12 wire harness 1 13 holder 1 14 bolt 4 m6 × 24 mm 1...

  • Page 96

    Powr 5-9 6s35h11 power unit 6s35060e no. Part name q’ty remarks 1 ptt relay 1 2 clamp 2 3 bolt 2 m6 × 30 mm 4 wireharness 1 5 ground lead 1 6 starter relay 1 7 holder 1 8 screw 3 ø5 × 12 mm 9 stay 2 10 fuse 2 80a 11 spare fuse 1 80a 12 positive battery lead 1 13 fuse holder 1 14 fuse 1 20a 15 bolt 2...

  • Page 97

    6s35h11 5-10 9 8 7 6 5 4 3 2 1 power unit 6s35060e no. Part name q’ty remarks 18 bolt 6 m6 × 30 mm 19 clamp 1 20 clip 2 21 hose 2 22 grommet 4 23 collar 4 24 case 1 6s35h11_05 9/2/05 10:35 am page 13.

  • Page 98

    Powr 5-11 6s35h11 power unit removing the power unit note: it is recommended to loosen the flywheel magnet nut before removing the power unit to improve working efficiency. 1. Remove the junction box cover, and then disconnect the negative battery cable 1, positive battery cable 2, positive battery ...

  • Page 99

    6s35h11 5-12 9 8 7 6 5 4 3 2 1 power unit 9. Remove the apron r. 10. Remove the power unit by removing the bolts t and y. Removing the flywheel magnet 1. Remove the timing plate 1. Note: make an alignment mark a at the installation point of the timing plate, and then remove the timing plate 1. 2. Lo...

  • Page 100

    Powr 5-13 6s35h11 power unit c c to prevent damage to the engine or tools, screw in the flywheel puller set bolts evenly and completely so that the fly- wheel puller is parallel to the flywheel magnet. Note: apply force to the crankshaft end until the fly- wheel magnet comes off the tapered portion ...

  • Page 101

    6s35h11 5-14 9 8 7 6 5 4 3 2 1 power unit 5. Remove the starter relay 7, the ptt relay assembly 8, and rectifier regulator 9 onto the power unit. 6. Disconnect the ignition coil leads, and then remove the cdi unit 0 and case q. 6s350525 8 7 9 6s350420 q 0 6s35h11_05 9/2/05 10:35 am page 17.

  • Page 102

    Powr 5-15 6s35h11 power unit 12mm (0.47in) 7mm (0.27in) 7mm (0.27in) 7mm (0.27in) 4 n·m (0.4 kgf·m, 3.0 ft·lb) 8 n·m (0.8 kgf·m, 5.9 ft·lb) 3 n·m (0.3 kgf·m, 2.2 ft·lb) 6s35070e no. Part name q’ty remarks 1 intake manifold 1 2 reed valve assembly 6 3 gasket 6 4 reed valve set 6 5 gasket 1 6 bolt 19 ...

  • Page 103

    6s35h11 5-16 9 8 7 6 5 4 3 2 1 intake manifold 12mm (0.47in) 7mm (0.27in) 7mm (0.27in) 7mm (0.27in) 4 n·m (0.4 kgf·m, 3.0 ft·lb) 8 n·m (0.8 kgf·m, 5.9 ft·lb) 3 n·m (0.3 kgf·m, 2.2 ft·lb) 6s35070e no. Part name q’ty remarks 18 bolt 1 m6 × 20 mm 19 bracket 1 20 hose 3 21 hose 1 6s35h11_05 9/2/05 10:35...

  • Page 104

    Powr 5-17 6s35h11 power unit removing the intake manifold 1. Remove the carburetor assemblies and the fuel hoses. 2. Disconnect the hoses 1. Note: mark the hoses connecting position, before disconnect. 3. Remove the intake manifold bolts in the sequence shown. Checking the reed valve 1. Check the re...

  • Page 105

    6s35h11 5-18 9 8 7 6 5 4 3 2 1 intake manifold/exhaust cover 11 n·m (1.1 kgf·m, 8.1 ft·lb) 5 n·m (0.5 kgf·m, 3.7 ft·lb) 10 n·m (1.0 kgf·m, 7.4 ft·lb) 10 n·m (1.0 kgf·m, 7.4 ft·lb) 10 n·m (1.0 kgf·m, 7.4 ft·lb) 6s35080e no. Part name q’ty remarks 1 bolt 4 m6 × 35 mm 2 cover 2 3 thermostat 2 4 gasket ...

  • Page 106

    Powr 5-19 6s35h11 power unit 11 n·m (1.1 kgf·m, 8.1 ft·lb) 5 n·m (0.5 kgf·m, 3.7 ft·lb) 10 n·m (1.0 kgf·m, 7.4 ft·lb) 10 n·m (1.0 kgf·m, 7.4 ft·lb) 10 n·m (1.0 kgf·m, 7.4 ft·lb) 6s35080e no. Part name q’ty remarks 18 lock tie 2 19 hose 1 not reusable 6s35h11_05 9/2/05 10:35 am page 22.

  • Page 107

    6s35h11 5-20 9 8 7 6 5 4 3 2 1 exhaust cover checking the pcv 1. Remove the pressure control valve. 2. Check the pressure control valve for wear or deformation. Replace the control valve if necessary. 3. Check the grommet for deformation. Replace the grommet if necessary. 4. Check the spring for fat...

  • Page 108

    Powr 5-21 6s35h11 power unit 25 n·m (2.5 kgf·m, 18.4 ft·lb) 5 n·m (0.5 kgf·m, 3.7 ft·lb) 11 n·m (1.1 kgf·m, 8.1 ft·lb) 15 n·m (1.5 kgf·m, 11.1 ft·lb) 30 n·m (3.0 kgf·m, 22.1 ft·lb) 6s35090e no. Part name q’ty remarks 1 gasket 2 2 cylinder head 2 3 thermo switch 2 4 gasket 2 5 cylinder head cover 2 6...

  • Page 109

    6s35h11 5-22 9 8 7 6 5 4 3 2 1 cylinder head removing the cylinder head 1. Remove the spark plugs. 2. Remove the cylinder head cover bolts in the sequence shown. 3. Remove the thermoswitch. 4. Remove the cylinder head bolts in the sequence shown. C c do not scratch or damage the mating sur- faces of...

  • Page 110

    Powr 5-23 6s35h11 power unit 12mm (0.47in) 7mm (0.27in) 100 n·m (10 kgf·m, 73.8 ft·lb) 4 n·m (0.4 kgf·m, 3.0 ft·lb) 8 n·m (0.8 kgf·m, 5.9 ft·lb) 20 n·m (2.0 kgf·m, 14.8 ft·lb) 40 n·m (4.0 kgf·m, 29.5 ft·lb) 6s35100e no. Part name q’ty remarks 1 crankcase 1 2 dowel 2 3 bolt 4 m10 × 70 mm 4 bolt 4 m10...

  • Page 111

    6s35h11 5-24 9 8 7 6 5 4 3 2 1 crankcase 12mm (0.47in) 7mm (0.27in) 100 n·m (10 kgf·m, 73.8 ft·lb) 4 n·m (0.4 kgf·m, 3.0 ft·lb) 8 n·m (0.8 kgf·m, 5.9 ft·lb) 20 n·m (2.0 kgf·m, 14.8 ft·lb) 40 n·m (4.0 kgf·m, 29.5 ft·lb) 6s35100e no. Part name q’ty remarks 18 oil seal 1 19 nut 1 20 bolt 3 m6 × 20 mm 2...

  • Page 112

    Powr 5-25 6s35h11 power unit 19 n·m (1.9 kgf·m, 14.0 ft·lb) 36 n·m (3.6 kgf·m, 26.6 ft·lb) * 19 n·m (1.9 kgf·m, 14.0 ft·lb) 36 n·m (3.6 kgf·m, 26.6 ft·lb) 23 n·m (2.3 kgf·m, 17.0 ft·lb) 8 n·m (0.8 kgf·m, 5.9 ft·lb) 6s35110e no. Part name q’ty remarks 1 bolt 12 2 piston and connecting rod assembly 6 ...

  • Page 113

    6s35h11 5-26 9 8 7 6 5 4 3 2 1 crankcase 19 n·m (1.9 kgf·m, 14.0 ft·lb) 36 n·m (3.6 kgf·m, 26.6 ft·lb) * 19 n·m (1.9 kgf·m, 14.0 ft·lb) 36 n·m (3.6 kgf·m, 26.6 ft·lb) 23 n·m (2.3 kgf·m, 17.0 ft·lb) 8 n·m (0.8 kgf·m, 5.9 ft·lb) 6s35110e no. Part name q’ty remarks 18 plug 2 19 gasket 2 20 stopper 2 21...

  • Page 114

    Powr 5-27 6s35h11 power unit 6s35120e no. Part name q’ty remarks 1 connecting rod 6 2 piston (starboard side) 3 3 washer 12 4 needle bearing 6 5 clip 12 6 piston pin 6 7 piston ring set 6 8 piston (port side) 3 not reusable 6s35h11_05 9/2/05 10:35 am page 30

  • Page 115

    6s35h11 5-28 9 8 7 6 5 4 3 2 1 crankcase removing the crankcase 1. Remove the crankshaft balancer nut. C c apply force in the direction arrows shown, to prevent the flywheel holder from slip- ping off easily. 2. Remove the crankshaft balancer c c to prevent damage to the engine or tools, screw in th...

  • Page 116

    Powr 5-29 6s35h11 power unit removing the piston, connecting rod assembly and crankshaft assembly 1. Remove the connecting rod bolts and the connecting rod caps, and then remove the piston with connecting rod. Note: 9 be sure to keep the bearings in the order as they were removed. 9 mark each piston...

  • Page 117

    6s35h11 5-30 9 8 7 6 5 4 3 2 1 crankcase 2. Remove the crankshaft assembly. 3. Remove the roller bearing 1 and main bearing 2. Note: be sure to keep the main bearings 2 in the order as they were removed. Disassembling the piston and con- necting rod assembly 1. Remove the clips 1 with pliers, and th...

  • Page 118

    Powr 5-31 6s35h11 power unit checking the oil pump driven gear and the oil pump drive gear 1. Check the oil pump driven gear and the oil pump drive gear for cracks, damage, or wear. Replace if necessary. Checking the piston diameter 1. Measure the piston outside diameter at the specified measuring p...

  • Page 119

    6s35h11 5-32 9 8 7 6 5 4 3 2 1 crankcase checking the cylinder bore 1. Measure the cylinder bore (d 1 —d 6 ) at measuring points a, b, and c, and in direction d (d 1 , d 3 , d 5 ), which is parallel to the crankshaft, and direction e (d 2 , d 4 , d 6 ), which is at a right angle to the crankshaft. A...

  • Page 120

    Powr 5-33 6s35h11 power unit 2. Level the piston rings 1 in a cylinder with a piston crown. 3. Check the piston ring end gap a at the specified measuring point b. Replace the piston ring set if out of specification. Checking the piston ring side clear- ance 1. Measure the piston ring side clearance....

  • Page 121

    6s35h11 5-34 9 8 7 6 5 4 3 2 1 crankcase checking the connecting rod small end axial play 1. Measure the connecting rod small end axial play. Replace the bearing and con- necting rod if above specification. Note: to measure the axial play, set the dial gauge at the connecting rod small end and paral...

  • Page 122

    Powr 5-35 6s35h11 power unit 2. Measure the crankshaft runout. Replace the crankshaft if above specification. Assembling the crankshaft 1. Install the oil pump drive gear 1. C c do not reuse the oil pump drive gear, always replace it with a new one. Crankshaft runout limit c: 0.02 mm (0.0008 in) c c...

  • Page 123

    6s35h11 5-36 9 8 7 6 5 4 3 2 1 crankcase 2. Install a new o-ring 3 and the stopper ring 4 onto the roller bearing, and then install the roller bearing assembly onto the crankshaft 5. Assembling the oil seal housing 1. Apply grease to the new oil seals and then install them into the oil seal housing....

  • Page 124

    Powr 5-37 6s35h11 power unit 2. Install the 2nd piston ring 7 and top ring 8 onto the piston. C c do not scratch the pistons or break the piston rings. Note: install the piston rings with the recess for the locating pin facing up toward the piston crown. Assembling the power unit 1. Set the cranksha...

  • Page 125

    6s35h11 5-38 9 8 7 6 5 4 3 2 1 crankcase note: 9 fit dowels 1 on the cylinder block into the dowel holes 2 in the main bearings. 9 align the projection 3 and the projection 4 of the roller bearing with the groove in the cylinder block. 9 align the seal ring end gaps a with the cylinder center line. ...

  • Page 126

    Powr 5-39 6s35h11 power unit s60v5690 7. Install the crankcase onto the cylinder block, and then tighten the crankcase bolts to the specified torques in two stages and in the sequence shown. Note: • apply engine oil to the crankcase bolts before installation. • tighten crankcase bolts z—, to the spe...

  • Page 127

    6s35h11 5-40 9 8 7 6 5 4 3 2 1 crankcase 9. Install the crankshaft balancer, and then tighten the crankshaft balancer nut to the specified torque. C c apply force to the direction of the arrows shown, to prevent the flywheel holder from slipping off easily note: apply engine oil to the crankshaft ba...

  • Page 128

    Powr 5-41 6s35h11 power unit 13. Install the thermoswitche u onto the cylinder head i. 14. Install the new gaskets o and the cylin- der head covers p, and then tighten the cylinder head cover bolts a to the speci- fied torques in two stages and in the sequence shown. 6g450780 u i 12. Install the new...

  • Page 129

    6s35h11 5-42 9 8 7 6 5 4 3 2 1 crankcase note: apply loctite 572 to the cylinder head cover bolts before installation. 15. Install the spark plugs temporary tight d, then to the specified torque e with a spark plug wrench. 16. Install the new gasket s and the intake manifold assembly d, and then tig...

  • Page 130

    Powr 5-43 6s35h11 power unit 20. Install the starter relay z, the ptt relay assembly x, and rectifier regulator c onto the power unit. 21. Install the hour meter v onto the power unit. 18. Install the starter motor g, crank position sensor h, pulser coil assembly j and stator coil k onto the power u...

  • Page 131

    6s35h11 5-44 9 8 7 6 5 4 3 2 1 crankcase 3. Install the apron 6. 22. Install the carburetor assemblies b and choke solenoid n onto the power unit. Installing the power unit 1. Clean the power unit matching surface, and install the dowels 1 and a new gas- ket 2. 2. Install the power unit 3, and then ...

  • Page 132

    Powr 5-45 6s35h11 power unit 10. Install the woodruff key and flywheel magnet. 11. Tighten the flywheel magnet nut to the specified torque. C c apply force in the direction of the arrows shown, to prevent the flywheel holder from slipping off easily. Note: apply engine oil to the flywheel magnet nut...

  • Page 133

    6s35h11 5-46 9 8 7 6 5 4 3 2 1 crankcase note: 9 align the marks a on the timing plate o, which you made during disassembly. 9 for adjustment procedures, following “adjusting the timing plate” steps. 16. Install the all removed parts. Adjusting the timing plate note: remove the all spark plugs and l...

  • Page 134

    Powr 5-47 6s35h11 power unit 4. As look at the dial gauge, slightly turn the flywheel counterclockwise to the speci- fied position. 5. Align the timing plate with the flywheel at btdc 19 ° and install the timing plate 2. Note: when finish the adjusting of timing plate, fly- wheel must be turn clockw...

  • Page 135: — Memo —

    — memo — 9 8 7 6 5 4 3 2 1 6s35h11 5-48 6s35h11_061 05.9.5 14:14 page 1.

  • Page 136: Lower Unit

    Lowr 6s35h11 lower unit lower unit (regular rotation model) .............................................................6-1 removing the lower unit ............................................................................6-4 removing the water pump and shift rod ....................................

  • Page 137

    6s35h11 9 8 7 6 5 4 3 2 1 lower unit (counter rotation model) ..........................................................6-30 removing the lower unit ..........................................................................6-33 removing the water pump and shift rod .....................................

  • Page 138

    Lowr 6-1 6s35h11 lower unit 42 n·m (4.2 kgf·m, 31.0 ft·lb) 54 n·m (5.4 kgf·m, 39.8 ft·lb) 47 n·m (4.7 kgf·m, 34.7 ft·lb) 47 n·m (4.7 kgf·m, 34.7 ft·lb) 9 n·m (0.9 kgf·m, 6.6 ft·lb) 9 n·m (0.9 kgf·m, 6.6 ft·lb) 6s36010e no. Part name q’ty remarks 1 lower unit 1 2 plate 1 3 rubber seal 1 4 check screw...

  • Page 139

    6s35h11 6-2 9 8 7 6 5 4 3 2 1 lower unit (regular rotation model) 8 n·m (0.8 kgf·m, 5.9 ft·lb) 18 n·m (1.8 kgf·m, 13.3 ft·lb) 6s36020e no. Part name q’ty remarks 1 shift rod 1 2 oil seal 1 3 cover 1 4 o-ring 1 5 spring 1 6 circlip 1 7 bolt 3 m6 × 20 mm 8 seal 1 9 woodruff key 1 10 bolt 4 m8 × 45 mm ...

  • Page 140

    Lowr 6-3 6s35h11 lower unit 8 n·m (0.8 kgf·m, 5.9 ft·lb) 18 n·m (1.8 kgf·m, 13.3 ft·lb) 6s36020e no. Part name q’ty remarks 18 outer plate cartridge 1 19 gasket 1 20 dowel 2 21 dowel 2 not reusable 6s35h11_061 05.9.5 14:14 page 6.

  • Page 141

    6s35h11 6-4 9 8 7 6 5 4 3 2 1 lower unit (regular rotation model) 3. Mark the trim tab 1 at the area shown, and then remove it. 4. Loosen the bolts 2, and then remove the lower unit from the upper case. Removing the lower unit 1. Drain the gear oil. For draining proce- dures, see chapter 3, “changin...

  • Page 142

    Lowr 6-5 6s35h11 lower unit removing the water pump and shift rod 1. Remove the water pump housing 1 and impeller 2. 2. Remove the woodruff key 3. 3. Remove the outer plate cartridge 4, gasket 5 and dowels 6. 4. Set the gear shift to the neutral position at the lower unit. Make sure that the shift r...

  • Page 143

    6s35h11 6-6 9 8 7 6 5 4 3 2 1 lower unit (regular rotation model)/propeller shaft housing (regular rotation model) propeller shaft housing (regular rotation model) 6 n·m (0.6 kgf·m, 4.4 ft·lb) 30 n·m (3.0 kgf·m, 22.1 ft·lb) 4 n·m (0.4 kgf·m, 3.0 ft·lb) 18 n·m (1.8 kgf·m, 13.3 ft·lb) 6s36030e no. Par...

  • Page 144

    Lowr 6-7 6s35h11 lower unit 6 n·m (0.6 kgf·m, 4.4 ft·lb) 30 n·m (3.0 kgf·m, 22.1 ft·lb) 4 n·m (0.4 kgf·m, 3.0 ft·lb) 18 n·m (1.8 kgf·m, 13.3 ft·lb) 6s36030e no. Part name q’ty remarks 18 oil seal 2 19 ring 1 20 bolt 2 m8 × 20 mm 21 cooling water inlet cover 2 22 nut 1 23 screw 1 24 bolt 2 m8 × 36 mm...

  • Page 145

    6s35h11 6-8 9 8 7 6 5 4 3 2 1 propeller shaft housing (regular rotation model) removing the propeller shaft hous- ing assembly 1. Remove the bolts 1, ring 2 and bolts 3. Note: before removing the propeller shaft from the lower case, remove the shift rod. 2. Remove the propeller shaft housing use the...

  • Page 146

    2. Check the teeth and dogs of the reverse gear. Replace if cracked or worn. 3. Check the bearings. Replace if pitted or if there is rumbling. Checking the propeller shaft 1. Check the propeller shaft. Replace if bent or worn. 2. Measure the propeller shaft runout. 3. Check the dog clutch, shift rod...

  • Page 147

    6s35h11 6-10 9 8 7 6 5 4 3 2 1 propeller shaft housing (regular rotation model) assembling the propeller shaft housing 1. Install the needle bearing into the pro- peller shaft housing to the specified depth. Note: 9 install the needle bearing with the manufac- ture identification mark a facing towar...

  • Page 148

    Lowr 6-11 6s35h11 lower unit 4. Install the reverse gear 7 and original shim(s) 8 into the propeller shaft hous- ing using a press. Note: 9 be sure to select the reverse gear shim(s) if replacing the propeller shaft housing, lower case, or ball bearing. 9 to select the shims, see “shimming (regu- la...

  • Page 149

    6s35h11 6-12 9 8 7 6 5 4 3 2 1 propeller shaft housing/drive shaft and lower case (regular rotation model) drive shaft and lower case (regular rotation model) 142 n·m (14.2 kgf·m, 104.7 ft·lb) 6s36040e 18 n·m (1.8 kgf·m, 13.3 ft·lb) no. Part name q’ty remarks 1 drive shaft 1 2 cover 1 3 oil seal 2 4...

  • Page 150

    Lowr 6-13 6s35h11 lower unit 142 n·m (14.2 kgf·m, 104.7 ft·lb) 6s36040e 18 n·m (1.8 kgf·m, 13.3 ft·lb) no. Part name q’ty remarks 18 needle bearing 2 19 forward gear 1 not reusable 6s35h11_061 05.9.5 14:14 page 16.

  • Page 151

    Removing the drive shaft 1. Loosen the pinion nut. 2. Remove the pinion nut 3, washer 4, pinion 5, drive shaft housing 6, thrust bearing 7, pinion shim(s) 8 from lower case. 3. Pull out the forward gear. 6s35h11 6-14 9 8 7 6 5 4 3 2 1 drive shaft and lower case (regular rotation model) disassembling...

  • Page 152

    2. Remove the needle bearings from the forward gear using a chisel. C c do not reuse the bearing, always replace it with a new one. Disassembling the lower case 1. Remove the needle bearing. Note: since the diameter of the passage in the lower case and the diameter of the special service tool 1 are ...

  • Page 153

    Assembling the forward gear 1. Install new needle bearings into the for- ward gear to the specified depth. Note: be careful not to let the stopper c get out of position when using the driver rod. 2. Install a new inner race into the forward gear using a press. 6s35h11 6-16 9 8 7 6 5 4 3 2 1 drive sh...

  • Page 154

    Lowr 6-17 6s35h11 lower unit assembling the drive shaft housing 1. Install the needle bearing into the drive shaft housing to the specified depth. 2. Apply grease to new oil seals, new o- ring, and then install them into the drive shaft housing to the specified depth. Note: install an oil seal halfw...

  • Page 155

    6s35h11 6-18 9 8 7 6 5 4 3 2 1 drive shaft and lower case (regular rotation model) 4. Install the drive shaft housing 9, and then tighten the drive shaft housing bolt 0. Note: apply loctite 572 to the drive shaft hous- ing bolts before installation. Installing the propeller shaft housing 1. Set the ...

  • Page 156

    Lowr 6-19 6s35h11 lower unit installing the water pump and shift rod 1. Install the shift rod assembly 1 and seal 2. Note: 9 check the gear shift to the neutral position, when installing the shift rod. 9 after assembling the lower unit, check that the shift rod operates smoothly, and check that the ...

  • Page 157

    6s35h11 6-20 9 8 7 6 5 4 3 2 1 drive shaft and lower case (regular rotation model) 5. Install the new o-ring 9 and insert car- tridge 0 into the pump housing q. Note: align the insert cartridge projections a with the holes b in the pump housing. 6. Install the new o-ring w and pump hous- ing assembl...

  • Page 158

    Lowr 6-21 6s35h11 lower unit 2. Set the gear shift to the neutral position at the lower unit. Make sure that the shift rod is in the neutral position using a spe- cial service tool. 3. Install the 2 dowels 1 into the lower unit. 4. Install the lower unit into the upper case, and then tighten the low...

  • Page 159

    6s35h11 6-22 9 8 7 6 5 4 3 2 1 drive shaft and lower case (regular rotation model) 8. Insert a gear oil tube or gear oil pump into the drain hole and slowly fill the gear oil until oil flows out of the check hole and no air bubbles are visible. 9. Install the new gasket, check screw 7 and quickly in...

  • Page 160

    Lowr 6-23 6s35h11 lower unit shimming (regular rotation model) t3 m3 m4 m2 6s36050ea t2 t1 m1 f r p 6s35h11_061 05.9.5 14:14 page 26.

  • Page 161

    6s35h11 6-24 9 8 7 6 5 4 3 2 1 shimming (regular rotation model) shimming note: 9 shimming is not required when assembling the original lower case and inner parts. 9 shimming is required when assembling the original inner parts and a new lower case. 9 shimming is required when replacing the inner pa...

  • Page 162

    Lowr 6-25 6s35h11 lower unit example: if “t3” is 0.70 mm, then the pinion shim is 0.68 mm. If “t3” is 0.74 mm, then the pinion shim is 0.72 mm. Selecting the forward gear shim 1. Turn the thrust bearing 1 2 or 3 times to seat the roller bearing outer race 2, and then measure the bearing height (m1) ...

  • Page 163

    6s35h11 6-26 9 8 7 6 5 4 3 2 1 shimming (regular rotation model) example: if “t1” is 0.45 mm, then the forward gear shim is 0.42 mm. If “t1” is 0.40 mm, then the forward gear shim is 0.38 mm. Selecting the reverse gear shim 1. Measure the bearing 1 height (m2) as shown. Note: 9 select the shim thick...

  • Page 164

    Lowr 6-27 6s35h11 lower unit 2. Calculate the reverse gear shim thick- ness (t2) as shown in the examples below. Note: “r” is the deviation of the lower case dimen- sion from standard, and “a” is the deviation of the propeller shaft housing from standard. The “r” mark a is stamped on the trim tab mo...

  • Page 165

    6s35h11 6-28 9 8 7 6 5 4 3 2 1 shimming (regular rotation model)/backlash (regular rotation model) 5. Set the lower unit upside down. Note: install the dial gauge so that the plunger a contacts the mark b on the backlash indica- tor. 6. Slowly turn the drive shaft clockwise and counterclockwise, and...

  • Page 166

    Lowr 6-29 6s35h11 lower unit 8. Remove the special service tools from the propeller shaft. 9. Apply a load to the reverse gear by installing the propeller 8, the spacer 9 (without the washer 0), then the washer q as shown. Note: while turning the drive shaft clockwise and counterclockwise 5-6 times ...

  • Page 167

    6s35h11 6-30 9 8 7 6 5 4 3 2 1 backlash (regular rotation model)/lower unit (counter rotation model) lower unit (counter rotation model) 42 n·m (4.2 kgf·m, 31.0 ft·lb) 54 n·m (5.4 kgf·m, 39.8 ft·lb) 47 n·m (4.7 kgf·m, 34.7 ft·lb) 47 n·m (4.7 kgf·m, 34.7 ft·lb) 9 n·m (0.9 kgf·m, 6.6 ft·lb) 9 n·m (0.9...

  • Page 168

    Lowr 6-31 6s35h11 lower unit 8 n·m (0.8 kgf·m, 5.9 ft·lb) 18 n·m (1.8 kgf·m, 13.3 ft·lb) 6s36070e no. Part name q’ty remarks 1 shift rod 1 2 oil seal 1 3 cover 1 4 o-ring 1 5 spring 1 6 circlip 1 7 bolt 3 m6 × 20 mm 8 seal 1 9 woodruff key 1 10 bolt 4 m8 × 45 mm 11 cover 1 12 seal 1 13 water pump ho...

  • Page 169

    6s35h11 6-32 9 8 7 6 5 4 3 2 1 lower unit (counter rotation model) 8 n·m (0.8 kgf·m, 5.9 ft·lb) 18 n·m (1.8 kgf·m, 13.3 ft·lb) 6s36070e no. Part name q’ty remarks 18 outer plate cartridge 1 19 gasket 1 20 dowel 2 21 dowel 2 not reusable 6s35h11_061 05.9.5 14:14 page 35.

  • Page 170

    Lowr 6-33 6s35h11 lower unit removing the lower unit 1. Drain the gear oil. For draining proce- dures, see chapter 3, “changing the gear oil.” 2. Set the gear shift to the neutral position, and place a block of wood between the anti-cavitation plate and propeller to keep the propeller from turning, ...

  • Page 171

    6s35h11 6-34 9 8 7 6 5 4 3 2 1 lower unit (counter rotation model) removing the water pump and shift rod 1. Remove the water pump housing 1 and impeller 2. 2. Remove the woodruff key 3. 3. Remove the outer plate cartridge 4, gasket 5 and dowels 6. 4. Set the gear shift to the neutral position at the...

  • Page 172

    Lowr 6-35 6s35h11 lower unit propeller shaft housing (counter rotation model) 108 n·m (10.8 kgf·m, 79.7 ft·lb) 6 n·m (0.6 kgf·m, 4.4 ft·lb) 4 n·m (0.4 kgf·m, 3.0 ft·lb) 30 n·m (3.0 kgf·m, 22.1 ft·lb) 18 n·m (1.8 kgf·m, 13.3 ft·lb) 6s36080e no. Part name q’ty remarks 1 shift rod joint 1 2 ball 2 3 sh...

  • Page 173

    6s35h11 6-36 9 8 7 6 5 4 3 2 1 propeller shaft housing (counter rotation model) 108 n·m (10.8 kgf·m, 79.7 ft·lb) 6 n·m (0.6 kgf·m, 4.4 ft·lb) 4 n·m (0.4 kgf·m, 3.0 ft·lb) 30 n·m (3.0 kgf·m, 22.1 ft·lb) 18 n·m (1.8 kgf·m, 13.3 ft·lb) 6s36080e no. Part name q’ty remarks 18 propeller shaft shim — 19 ne...

  • Page 174

    Lowr 6-37 6s35h11 lower unit removing the propeller shaft hous- ing assembly 1. Remove the bolts 1, ring 2 and bolts 3. Note: before removing the propeller shaft from the lower case, remove the shift rod. 2. Pull out the propeller shaft housing assembly 4. 3. Remove the propeller shaft assembly 1 7 ...

  • Page 175

    6s35h11 6-38 9 8 7 6 5 4 3 2 1 propeller shaft housing (counter rotation model) 4. Remove the bearing outer race 8, taper roller bearing 9, thrust bearing 0, and propeller shaft shim(s) q using a press. C c 9 do not press the propeller shaft threads a directly. 9 do not reuse the taper roller bearin...

  • Page 176

    Lowr 6-39 6s35h11 lower unit checking the propeller shaft 1. Check the each propeller shaft. Replace if bent or worm the spline. 2. Measure the propeller shaft runout. 3. Check the dog clutch, shift rod joint, and slider. Replace if cracked or worn. Assembling the forward gear 1. Install the new nee...

  • Page 177

    6s35h11 6-40 9 8 7 6 5 4 3 2 1 propeller shaft housing (counter rotation model) 2. Install the new bushing 4 into the for- ward gear 5. Assembling the propeller shaft housing 1. Install the needle bearing into the pro- peller shaft housing to the specified depth. Note: 9 install the needle bearing w...

  • Page 178

    Lowr 6-41 6s35h11 lower unit 4. Install the original shim(s) 6 and thrust bearing 7 with the propeller shaft 2 into the propeller shaft housing. Note: 9 be sure to select the propeller shaft shim(s) if replacing the propeller shaft, propeller shaft housing, thrust bearing or taper roller bearing. 9 ...

  • Page 179

    6s35h11 6-42 9 8 7 6 5 4 3 2 1 propeller shaft housing (counter rotation model) 8. Install the original shim(s) t, forward gear y, and dog clutch u using a press. Note: 9 be sure to select the forward gear shim(s) if replacing the propeller shaft housing, taper roller bearing, or lower case. 9 to se...

  • Page 180

    Lowr 6-43 6s35h11 lower unit drive shaft and lower case (counter rotation model) 142 n·m (14.2 kgf·m, 104.7 ft·lb) 6s36090e 18 n·m (1.8 kgf·m, 13.3 ft·lb) no. Part name q’ty remarks 1 drive shaft 1 2 cover 1 3 oil seal 2 4 bolt 4 m8 × 25 mm 5 drive shaft housing 1 6 needle bearing 1 7 o-ring 1 8 pin...

  • Page 181

    6s35h11 6-44 9 8 7 6 5 4 3 2 1 drive shaft and lower case (counter rotation model) 142 n·m (14.2 kgf·m, 104.7 ft·lb) 6s36090e 18 n·m (1.8 kgf·m, 13.3 ft·lb) no. Part name q’ty remarks 18 needle bearing 1 19 reverse gear 1 20 washer 1 21 needle bearing 2 6s35h11_061 05.9.5 14:15 page 47.

  • Page 182

    Lowr 6-45 6s35h11 lower unit disassembling the drive shaft housing 1. Remove the cover, oil seals, and needle bearing. Disassembling the reverse gear 1. Remove the needle bearings from the reverse gear using a chisel. C c do not reuse the bearing, always replace it with a new one. Removing the drive...

  • Page 183

    6s35h11 6-46 9 8 7 6 5 4 3 2 1 drive shaft and lower case (counter rotation model) disassembling the lower case 1. Remove the needle bearing. Note: since the diameter of the passage in the lower case and the diameter of the special service tool 1 are both 40 mm (1.57 in), the special service tool ma...

  • Page 184

    Lowr 6-47 6s35h11 lower unit 3. Install the needle bearing into the lower case. Note: 9 apply gear oil to the needle bearing before installation. 9 the needle bearing contains 24 rollers. Assembling the reverse gear 1. Install new needle bearings into the reverse gear to the specified depth. Note: b...

  • Page 185

    6s35h11 6-48 9 8 7 6 5 4 3 2 1 drive shaft and lower case (counter rotation model) assembling the drive shaft housing 1. Install the needle bearing into the drive shaft housing to the specified depth. 2. Apply grease to new oil seals, new o- ring, and then install them into the drive shaft housing t...

  • Page 186

    Lowr 6-49 6s35h11 lower unit 3. Install the drive shaft 5 into the lower case. Then install the pinion 6, washer 7 and pinion nut 8, and then tighten the nut 8 to the specified torque. Note: install the drive shaft by lifting it up slightly, then aligning it with the pinion and the spline of the dri...

  • Page 187

    6s35h11 6-50 9 8 7 6 5 4 3 2 1 drive shaft and lower case (counter rotation model) 4. Install the propeller shaft housing bolts 4, and then tighten the bolts to the spec- ified torque. 5. Install the ring 5 and bolts 6. Note: apply loctite 271 to the drive shaft hous- ing bolts 4 and loctite 572 to ...

  • Page 188

    Lowr 6-51 6s35h11 lower unit note: 9 when installing the pump housing, apply grease to the inside of the housing, and then turn the drive shaft clockwise while pushing down the pump housing. 9 align the cover projection c with the hole d in the pump housing. Installing the lower unit w when installi...

  • Page 189

    6s35h11 6-52 9 8 7 6 5 4 3 2 1 drive shaft and lower case (counter rotation model) 6. Install the grommet 5. 7. Install the propeller and propeller nut 6, and then temporarily tighten the nut. Place a block of wood between the anti- cavitation plate and propeller to keep the propeller from turning, ...

  • Page 190

    Lowr 6-53 6s35h11 lower unit note: if the grooves in the propeller nut 6 do not align with the cotter pin hole, tighten the nut until they are aligned. 8. Insert a gear oil tube or gear oil pump into the drain hole and slowly fill the gear oil until oil flows out of the check hole and no air bubbles...

  • Page 191

    6s35h11 6-54 9 8 7 6 5 4 3 2 1 drive shaft and lower case (counter rotation model)/shimming (counter rotation model) shimming (counter rotation model) t3 m3 m4 m5 6s36060el t2 t1 m1 t'4 m6-10 m7 f r p 6s35h11_061 05.9.5 14:15 page 57.

  • Page 192

    Lowr 6-55 6s35h11 lower unit shimming note: 9 shimming is not required when assembling the original lower case and inner parts. 9 shimming is required when assembling the original inner parts and a new lower case. 9 shimming is required when replacing the inner part(s). Selecting the pinion shim 1. ...

  • Page 193

    6s35h11 6-56 9 8 7 6 5 4 3 2 1 shimming (counter rotation model) example: if “t3” is 0.70 mm, then the pinion shim is 0.68 mm. If “t3” is 0.74 mm, then the pinion shim is 0.72 mm. Selecting the reverse gear shim 1. Turn the thrust bearing 1 2 or 3 times to seat the bearing retainer 2, and then measu...

  • Page 194

    Lowr 6-57 6s35h11 lower unit example: if “t1” is 0.45 mm, then the reverse gear shim is 0.42 mm. If “t1” is 0.40 mm, then the reverse gear shim is 0.38 mm. 2. Calculate the reverse gear shim thick- ness (t1) as shown in the examples below. Note: “f” is the deviation of the lower case dimen- sion fro...

  • Page 195

    6s35h11 6-58 9 8 7 6 5 4 3 2 1 shimming (counter rotation model) selecting the forward gear shim 1. Turn the taper roller bearing outer race 1 2 or 3 times to seat the rollers, and then measure the bearing height (m5) and (m6) as shown. Note: 9 select the shim thickness (t2) by using the specified m...

  • Page 196

    6-59 6s35h11 lowr lower unit if “m5” is 21.95 mm and “m6” is 16.78 mm and “r” is (– 1) and “a” is (+ 2), then t2 = 6.50 + (– 1)/100 – (+ 2)/100 – 21.95 + 16.78 mm = 6.50 – 0.01 – 0.02 – 21.95 + 16.78 mm = 1.30 mm 3. Select the forward gear shim(s) (t2) as follows. Example: if “t2” is 1.35 mm, then t...

  • Page 197

    6s35h11 6-60 9 8 7 6 5 4 3 2 1 shimming (counter rotation model) 3. Calculate the propeller shaft shim thick- ness (t4) as shown in the examples below. Note: “a” and “b” are the deviations of the propeller shaft housing dimensions from standard. The “a” mark a and “b” mark b are stamped on the prope...

  • Page 198

    Lowr 6-61 6s35h11 lower unit 7. Install the shim(s) 6, thrust bearing 4, propeller shaft 5, taper roller bearing 7 and claw washer 8, and then tighten the ring nut 9 to the specified torque. 8. Measure the propeller shaft axial free play. Reselect the propeller shaft shim(s) (t’4), if out of specifi...

  • Page 199

    6s35h11 6-62 9 8 7 6 5 4 3 2 1 shimming (counter rotation model)/backlash (counter rotation model) 4. Install the backlash indicator onto the drive shaft (22.4 mm [0.88 in] in diame- ter), then the dial gauge onto the lower unit. 5. Set the lower unit upside down. Note: install the dial gauge so tha...

  • Page 200

    Lowr 6-63 6s35h11 lower unit 11. Turn the shift rod to the neutral position d with the shift rod push arm. 12. Turn the drive shaft counterclockwise approximately 30°. 13. Turn the shift rod to the reverse position c with the shift rod push arm. 14. Slowly turn the drive shaft clockwise and counterc...

  • Page 201: — Memo —

    6s35h11 6-64 9 8 7 6 5 4 3 2 1 — memo — 6s35h11_061 05.9.5 14:15 page 67.

  • Page 202: Bracket Unit

    6s35h11 bracket unit bottom cowling ..............................................................................................7-1 upper case, steering arm ..............................................................................7-5 disassembling the upper case .................................

  • Page 203

    6s35h11 9 8 7 6 5 4 3 2 1 tilt cylinder and trim cylinder .....................................................................7-38 disassembling the tilt cylinder and trim cylinder .....................................7-40 checking the tilt cylinder and trim cylinder ..................................

  • Page 204

    Brkt 7-1 6s35h11 bracket unit bottom cowling 5 n·m (0.5 kgf·m, 3.7 ft·lb) 8 n·m (0.8 kgf·m, 5.9 ft·lb) 6s37010e no. Part name q’ty remarks 1 bolt 3 m8 × 45 mm 2 bolt 1 m8 × 45 mm 3 washer 1 4 grommet 8 5 collar 4 6 seal 4 7 ground lead 1 8 hose 1 9 cooling water pilot hole 1 10 grommet 1 11 ptt moto...

  • Page 205

    6s35h11 7-2 9 8 7 6 5 4 3 2 1 bottom cowling 5 n·m (0.5 kgf·m, 3.7 ft·lb) 8 n·m (0.8 kgf·m, 5.9 ft·lb) 6s37010e no. Part name q’ty remarks 18 bottom cowling 1 19 bolt 2 m6 × 30 mm 20 bolt 1 m6 × 12 mm 21 spring 1 22 nut 2 23 stay 1 24 washer 1 25 bushing 2 26 seal 1 27 grease nipple 1 28 bracket 1 2...

  • Page 206

    Brkt 7-3 6s35h11 bracket unit 8 n·m (0.8 kgf·m, 5.9 ft·lb) 8 n·m (0.8 kgf·m, 5.9 ft·lb) 8 n·m (0.8 kgf·m, 5.9 ft·lb) 8 n·m (0.8 kgf·m, 5.9 ft·lb) 8 n·m (0.8 kgf·m, 5.9 ft·lb) 6s37020e no. Part name q’ty remarks 1 clamp 2 2 bolt 1 m6 × 20 mm 3 plate 1 4 bolt 1 m8 × 20 mm 5 holder 1 6 grommet 1 7 bolt...

  • Page 207

    6s35h11 7-4 9 8 7 6 5 4 3 2 1 bottom cowling 8 n·m (0.8 kgf·m, 5.9 ft·lb) 8 n·m (0.8 kgf·m, 5.9 ft·lb) 8 n·m (0.8 kgf·m, 5.9 ft·lb) 8 n·m (0.8 kgf·m, 5.9 ft·lb) 8 n·m (0.8 kgf·m, 5.9 ft·lb) 6s37020e no. Part name q’ty remarks 18 clamp lever 1 19 holder 1 20 spring hook 1 21 hook 1 22 hook 1 23 clamp...

  • Page 208

    Brkt 7-5 6s35h11 bracket unit 72 n·m (7.2 kgf·m, 53.1 ft·lb) 72 n·m (7.2 kgf·m, 53.1 ft·lb) 8 n·m (0.8 kgf·m, 5.9 ft·lb) 6s37030e no. Part name q’ty remarks 1 upper case assembly 1 2 cover 2 3 ground lead 1 4 bolt 1 m6 × 10 mm 5 bolt 1 m6 × 17 mm 6 speed sensor adapter 1 7 dowel 1 8 lock tie 1 9 hos...

  • Page 209

    6s35h11 7-6 9 8 7 6 5 4 3 2 1 upper case, steering arm 18 n·m (1.8 kgf·m, 13.3 ft·lb) å 6s37045e no. Part name q’ty remarks 1 upper case 1 2 dowel 2 3 upper mount 2 4 washer 2 5 rubber washer 2 6 washer 2 7 bolt 2 m14 × 190 mm 8 bracket 1 9 muffler assembly 1 10 rubber seal 1 11 mount housing 2 12 g...

  • Page 210

    Brkt 7-7 6s35h11 bracket unit 18 n·m (1.8 kgf·m, 13.3 ft·lb) å 6s37045e no. Part name q’ty remarks 18 bolt 2 m8 × 30 mm 19 extension 1 u-transom 20 bolt 3 m6 × 35 mm 21 bolt 4 m10 × 45 mm 22 bolt 2 m14 × 205 mm 23 circlip 1 24 bushing 1 25 grommet 1 26 rubber seal 2 not reusable 6s35h11_072 05.9.9 0...

  • Page 211

    6s35h11 7-8 9 8 7 6 5 4 3 2 1 upper case, steering arm 18 n·m (1.8 kgf·m, 13.3 ft·lb) 18 n·m (1.8 kgf·m, 13.3 ft·lb) 18 n·m (1.8 kgf·m, 13.3 ft·lb) s60v7050 no. Part name q’ty remarks 1 muffler 1 2 exhaust manifold 1 3 gasket 1 4 lower exhaust guide 1 5 gasket 1 6 upper exhaust guide 1 7 flushing ho...

  • Page 212

    Brkt 7-9 6s35h11 bracket unit disassembling the upper case 1. Remove the muffler assembly 1 and rubber seal 2 from the upper case 3. å u-transom 2. Remove the muffler 4, cooling water pipe 5, and rubber dampers 6. 3. Remove the exhaust manifold 7. 4. Remove the lower exhaust guide 8 from the upper e...

  • Page 213

    6s35h11 7-10 9 8 7 6 5 4 3 2 1 upper case, steering arm checking the upper case 1. Check the rubber dampers. Replace if deterioration or cracks. 2. Check the cooling water pipe. Replace if deformation or corrosion. 3. Check the exhaust guide, exhaust mani- fold, and muffler. Replace if deformation o...

  • Page 214

    Brkt 7-11 6s35h11 bracket unit 4. Install the rubber damper 9 and clip 0 onto the muffler q. 5. Install the cooling water pipe w onto the muffler q. 6. Install the muffler q onto the exhaust guide assembly e, and then tighten the bolts r to the specified torque. 7. Install the muffler assembly t dur...

  • Page 215

    6s35h11 7-12 9 8 7 6 5 4 3 2 1 upper case, steering arm 10. Install the bracket o, and then tighten the bolts p. Note: first tighten the center located, when tighten the bolts a. 11. Install the lower mounts a and mount housings s. S60v7240 s a s60v7230 u o i p 6s370017 a 6s35h11_072 05.9.9 0:42 pag...

  • Page 216

    Brkt 7-13 6s35h11 bracket unit 6s37040e no. Part name q’ty remarks 1 steering arm 1 2 washer 2 3 bushing 2 4 bracket assembly 1 5 o-ring 1 6 bushing 1 7 steering yoke 1 8 circlip 1 9 damper 1 not reusable 6s35h11_072 05.9.9 0:42 page 14.

  • Page 217

    6s35h11 7-14 9 8 7 6 5 4 3 2 1 upper case, steering arm removing the steering arm 1. Remove the circlip 1. 2. Remove the steering yoke 2 as shown. Note: use a spacer 3 ( a= 30 mm) and gear puller 4 (commercially available). 3. Remove the steering arm from the swivel bracket by pulling the arm off th...

  • Page 218

    Brkt 7-15 6s35h11 bracket unit 4. Install the steering yoke 9 to the steer- ing arm 3 by aligning the center a of the yoke with the center b of the steering arm. Note: hold the steering arm after tilt up the swivel bracket, and then strike the steering yoke until the circlip installing slot visible....

  • Page 219

    6s35h11 7-16 9 8 7 6 5 4 3 2 1 upper case, steering arm/clamp bracket and swivel bracket a 4 n·m (0.4 kgf·m, 3.0 ft·lb) 36 n·m (3.6 kgf·m, 26.6 ft·lb) 4 n·m (0.4 kgf·m, 3.0 ft·lb) 3 n·m (0.3 kgf·m, 2.2 ft·lb) 22 n·m (2.2 kgf·m, 16.2 ft·lb) 6s37050e no. Part name q’ty remarks 1 through tube 1 2 port ...

  • Page 220

    Brkt 7-17 6s35h11 bracket unit a 4 n·m (0.4 kgf·m, 3.0 ft·lb) 36 n·m (3.6 kgf·m, 26.6 ft·lb) 4 n·m (0.4 kgf·m, 3.0 ft·lb) 3 n·m (0.3 kgf·m, 2.2 ft·lb) 22 n·m (2.2 kgf·m, 16.2 ft·lb) 6s37050e no. Part name q’ty remarks 18 pin 1 19 bolt 1 m6 × 10 mm 20 spring 1 21 spring holder 1 22 port tilt stop lev...

  • Page 221

    6s35h11 7-18 9 8 7 6 5 4 3 2 1 clamp bracket and swivel bracket removing the ptt unit 1. Fully tilt the outboard motor up, and then support it with the tilt stop lever 1. W 9 after tilting up the outboard motor, be sure to support it with the tilt stop lever. Otherwise, the outboard motor could sudd...

  • Page 222

    Brkt 7-19 6s35h11 bracket unit installing the clamp bracket 1. Install the tilt stop levers and spring onto the swivel bracket assembly. 2. Install the trim sensor 1 onto the star- board clamp bracket. Note: adjust the trim sensor after installing the ptt unit. 3. Install the friction plate 2 onto t...

  • Page 223

    2. Install the ptt unit mount bolts 2 onto both clamp brackets together with the ptt unit 3, and then tighten them. 3. Install the tilt ram upper end into the swiv- el bracket with the shaft 4 and circlip 5. 4. Tighten the self-locking nut 6 to the specified torque. 5. Install the anode 7. 6. Pass t...

  • Page 224

    Brkt 7-21 6s35h11 bracket unit 2. Loosen the screws 2. 3. Adjust the position of the trim sensor, and then tighten the screws 2 temporary. Note: 9 to decrease the resistance, turn the trim sensor in direction a. 9 to increase the resistance, turn the trim sensor in direction b. 4. Fully tilt the out...

  • Page 225

    6s35h11 7-22 9 8 7 6 5 4 3 2 1 clamp bracket and swivel bracket/ptt unit 2 n·m (0.2 kgf·m, 1.5 ft·lb) 7 n·m (0.7 kgf·m, 5.2 ft·lb) 7 n·m (0.7 kgf·m, 5.2 ft·lb) 7 n·m (0.7 kgf·m, 5.2 ft·lb) 11 n·m (1.1 kgf·m,8.1 ft·lb) 15 n·m (1.5 kgf·m, 11.1 ft·lb) 15 n·m (1.5 kgf·m, 11.1 ft·lb) 6s37060e no. Part na...

  • Page 226

    Brkt 7-23 6s35h11 bracket unit 2 n·m (0.2 kgf·m, 1.5 ft·lb) 7 n·m (0.7 kgf·m, 5.2 ft·lb) 7 n·m (0.7 kgf·m, 5.2 ft·lb) 7 n·m (0.7 kgf·m, 5.2 ft·lb) 11 n·m (1.1 kgf·m,8.1 ft·lb) 15 n·m (1.5 kgf·m, 11.1 ft·lb) 15 n·m (1.5 kgf·m, 11.1 ft·lb) 6s37060e no. Part name q’ty remarks 18 o-ring 1 19 o-ring 1 20...

  • Page 227

    6s35h11 7-24 9 8 7 6 5 4 3 2 1 ptt unit checking the hydraulic pressure 1. Check the hydraulic pressure. Check the internal parts if out of specification. 2. Fully extend the ptt rams. 3. Loosen the pipe joints 1, and then remove the pipe joint a. 4. Install the special service tools. Note: put the ...

  • Page 228

    Brkt 7-25 6s35h11 bracket unit 10. Loosen the pipe joints 3, and then remove the pipe joint b. 11. Install the special service tools as shown. Note: put the ptt unit in the drain pan. 12. Connect the ptt motor leads to the bat- tery terminals to extend the trim rams, and then measure the hydraulic p...

  • Page 229

    6s35h11 7-26 9 8 7 6 5 4 3 2 1 ptt unit 17. Place the ptt unit in an upright position. 18. Remove the reservoir cap 4, and then check the fluid level in the reservoir. W make sure that the trim and tilt rams are fully extended when removing the reser- voir cap, otherwise fluid can spurt out from the...

  • Page 230

    Brkt 7-27 6s35h11 bracket unit 6s37080e no. Part name q’ty remarks 1 frame 1 2 bolt 2 m5 × 100 mm 3 o-ring 1 4 brush holder assembly 1 5 spring 4 6 brush 2 7 screw 5 ø4 × 10 mm 8 stator assembly 1 9 wave washer 3 10 bearing 2 11 armature 1 12 o-ring 1 13 ptt motor base 1 14 oil seal 1 not reusable n...

  • Page 231

    6s35h11 7-28 9 8 7 6 5 4 3 2 1 ptt motor disassembling the ptt motor 1. Remove the ptt motor, o-ring, and joint from the ptt unit. W 9 make sure that the trim and tilt rams are fully extended when removing the ptt motor, otherwise fluid can spurt out from the unit due to internal pressure. 9 do not ...

  • Page 232

    Brkt 7-29 6s35h11 bracket unit checking the ptt motor 1. Check the commutator. Clean with 600– grit sandpaper and compressed air if dirty. 2. Measure the commutator diameter. Replace the armature if below specifica- tion. 3. Measure the commutator undercut b. Replace the armature if below specifica-...

  • Page 233

    6s35h11 7-30 9 8 7 6 5 4 3 2 1 ptt motor 6. Check the base. Replace if cracked or damaged. 7. Check the bearing and oil seal. Replace if damaged or worn. Assembling the ptt motor 1. Install the new oil seal 1 and bearing 2 into the motor base 3 as shown. 2. Install the wave washer and bearing into t...

  • Page 234

    Brkt 7-31 6s35h11 bracket unit 2 n·m (0.2 kgf·m, 1.5 ft·lb) 4 n·m (0.4 kgf·m, 3.0 ft·lb) 6s37070e no. Part name q’ty remarks 1 gear housing 1 1 2 ball 2 3 screw 3 ø4 × 30 mm 4 gear pump filter 1 5 drive gear 1 6 gear housing 2 1 7 bolt 4 m5 × 12 mm 8 pin 2 9 o-ring 2 10 joint 1 11 o-ring 1 12 driven...

  • Page 235

    6s35h11 7-32 9 8 7 6 5 4 3 2 1 gear pump s60v7110 1 2 5 4 3 6 7 9 10 11 12 13 14 6 8 10 11 12 13 14 15 16 17 t r . . 4 n · m (0.4 kgf · m, 3.0 ft · ib) t r . . 4 n · m (0.4 kgf · m, 3.0 ft · ib) no. Part name q’ty remarks 1 trim down plate 1 2 seal 1 3 screw 2 ø5 × 10 mm 4 trim down spring 1 5 main ...

  • Page 236

    Brkt 7-33 6s35h11 bracket unit disassembling the gear pump and main valve 1. Remove the manual valve 1 and gear pump 2. 2. Remove the main valves 3 and valve support 4. 3. Remove the pins 5, and then remove the bolts. Note: use the 4 mm pin punch 6, until remove the gear pump housing 1 7 press the p...

  • Page 237

    6s35h11 7-34 9 8 7 6 5 4 3 2 1 gear pump 3. Remove the springs 6 pins 7,washers 8, valve seats 9, valve seals 0, balls q, relief valve seat w, o-ring e and fil- ter r. Checking the gear pump 1. Check the drive gear 1 and driven gear 2. Replace if damaged, scratched or excessive worn. Checking the ma...

  • Page 238

    Brkt 7-35 6s35h11 bracket unit assembling the relief valve 1. Install the relief valve filter 1 and new o- ring 2 into the ptt body. 2. Assemble the valve seal 3 onto the valve seat 4 first. 3. Install the balls 5, valve seats 4, wash- ers 6, pins 7, springs (long length 8, short length 9), and reli...

  • Page 239

    6s35h11 7-36 9 8 7 6 5 4 3 2 1 gear pump assembling the gear pump 1. Install the drive gear 1 and driven gear 2 and balls 3 into the gear housing 1 4, and then install the gear housing 2 5. 2. Install the bolts 6, and then tighten to temporary. Note: when assembling the gear pump, press the pins 7 f...

  • Page 240

    Brkt 7-37 6s35h11 bracket unit 6. Install the new o-rings r, joint t ,gear pump filter y, and then install the new o- ring u, valve seat i, new o-ring o, ball p, manual valve assembly a and circlip s. Gear pump screw e: 2 n·m (0.2 kgf·m, 1.5 ft·lb) manual valve a: 2 n·m (0.2 kgf·m, 1.5 ft·lb) 6s3703...

  • Page 241

    6s35h11 7-38 9 8 7 6 5 4 3 2 1 gear pump/tilt cylinder and trim cylinder 160 n·m (16.0 kgf·m, 118 ft·lb) 7 n·m (0.7 kgf·m, 5.2 ft·lb) 55 n·m (5.5 kgf·m, 40.6 ft·lb) 90 n·m (9.0 kgf·m, 66.4 ft·lb) 6s37090e no. Part name q’ty remarks 1 circlip 2 2 dust seal 2 3 trim cylinder end screw 2 4 o-ring 2 5 t...

  • Page 242

    Brkt 7-39 6s35h11 bracket unit 160 n·m (16.0 kgf·m, 118 ft·lb) 7 n·m (0.7 kgf·m, 5.2 ft·lb) 55 n·m (5.5 kgf·m, 40.6 ft·lb) 90 n·m (9.0 kgf·m, 66.4 ft·lb) 6s37090e no. Part name q’ty remarks 18 o-ring 1 19 backup ring 1 20 o-ring 1 21 spring 1 22 adapter 1 23 tilt piston 1 24 o-ring 1 25 backup ring ...

  • Page 243

    6s35h11 7-40 9 8 7 6 5 4 3 2 1 tilt cylinder and trim cylinder disassembling the tilt cylinder and trim cylinder 1. Remove the tilt cylinder from ptt unit. 2. Hold the tilt cylinder 1 in a vice using aluminum plates a on both sides. 3. Loosen the tilt cylinder end screw, and then remove the tilt ram...

  • Page 244

    Brkt 7-41 6s35h11 bracket unit 10. Hold the ptt body 6 in a vice using alu- minum plates a on both sides. 11. Loosen the trim cylinder end screws 7, and then remove them. 12. Remove the trim ram assemblies. 13. Drain the ptt fluid. 14. Remove the circlip 8, adapter 9, and spring 0 from the trim pist...

  • Page 245

    6s35h11 7-42 9 8 7 6 5 4 3 2 1 tilt cylinder and trim cylinder checking the valve 1. Check the tilt piston absorber valves 1. Clean if there is dirt or residue. Assembling the tilt ram c c do not use a rag when assembling the ptt unit as dust and particles on the ptt unit components can lead to poor...

  • Page 246

    Brkt 7-43 6s35h11 bracket unit assembling the trim ram 1. Install the new o-ring 1, backup ring 2, spring 3, adapter 4, and circlip 5 to the trim piston 6. 2. Install the new dust seal 7, circlip 8, and new o-ring 9 to the trim cylinder end screw 0. 3. Install the trim cylinder end screw 0 onto the ...

  • Page 247

    6s35h11 7-44 9 8 7 6 5 4 3 2 1 tilt cylinder and trim cylinder 1. Hold the ptt body 1 in a vice using alu- minum plates a on both sides. 2. Fill the trim cylinders with the recom- mended fluid to the correct level b as shown. 3. Install the trim ram assembly into the trim cylinder, and then tighten ...

  • Page 248

    Brkt 7-45 6s35h11 bracket unit 4. Install the new o-ring 2 and ptt motor 3, and then tighten the bolts 4 to the specified torque. Note: align the armature shaft with the recess in the joint. Installing the reservoir 1. Install the new o-ring 1 and reservoir 2, and then tighten the bolts 3 to the spe...

  • Page 249

    6s35h11 7-46 9 8 7 6 5 4 3 2 1 tilt cylinder and trim cylinder 3. Install the tilt piston assembly into the tilt cylinder, and then tighten the tilt cylinder end screw 1 to the specified torque. Note: place the tilt cylinder end screw at the bottom of the tilt ram and install the tilt piston assem- ...

  • Page 250

    Brkt 7-47 6s35h11 bracket unit 8. Check the fluid level when the rams are fully extended. If the fluid level is low, add sufficient fluid, and then repeat step 7. Bleeding the ptt unit (built-in) 1. Fully tilt the outboard motor up and down a few times. Note: connect the ptt motor leads to the batte...

  • Page 251

    6s35h11 7-48 9 8 7 6 5 4 3 2 1 tilt cylinder and trim cylinder/ptt electrical system ptt electrical system checking the fuse 1. Check the fuse (80a) for continuity. Replace if there is no continuity. Checking the ptt relay 1. Remove the ptt relay from junction box. 2. Connect the test harness, and t...

  • Page 252

    Brkt 7-49 6s35h11 bracket unit checking the ptt switch 1. Check the ptt switch for continuity. Replace if out of specification. Checking the trim sensor 1. Measure the trim sensor resistance. Replace if out of specification. Note: turn the lever 1 and measure the resis- tances it gradually changes. ...

  • Page 253: Electrical System

    6s35h11 9 8 7 6 5 4 3 2 1 elec electrical system checking the electrical component .............................................................8-1 measuring the peak voltage ......................................................................8-1 electrical component .................................

  • Page 254

    Elec 8-1 6s35h11 electrical system checking the electrical component measuring the peak voltage to check the electrical components or mea- sure the peak voltage, use the special service tools. A faulty electrical components can be easily checked by measuring the peak volt- age. The specified engine ...

  • Page 255

    6s35h11 8-2 9 8 7 6 5 4 3 2 1 checking the electrical component/electrical component electrical component port view 2 5 1 3 4 6 7 8 9 6 å ∫ ç ∂ © ƒ ´ 6s380010 1 throttle sensor 2 hour meter 3 spark plug 4 spark plug cap 5 ptt switch 6 oil feed pump coupler 7 pulser coil coupler 8 throttle sensor cou...

  • Page 256

    Elec 8-3 6s35h11 electrical system starboard view 7 5 6 3 4 2 1 8 9 0 6s380020 1 spark plug cap 2 spark plug 3 engine temperature sensor 4 crank position sensor 5 pulse coil assembly 6 stator assembly 7 starter motor 8 choke solenoid 9 shift cut switch 0 shift cut switch coupler 6s35h11_08 05.9.23 8...

  • Page 257

    6s35h11 8-4 9 8 7 6 5 4 3 2 1 electrical component junction box 4 1 5 2 3 7 6 å ´ ∫ ç ∂ ∆ ƒ ˆ ˙ © section a section b section c 6s380040 1 rectifier regulator 2 ptt relay 3 fuse holder (80a) 4 starter relay 5 fuse holder (20a) 6 lighting coil coupler 7 crank position sensor coupler å to stator assem...

  • Page 258

    Elec 8-5 6s35h11 electrical system 4 1 5 2 3 7 6 å ´ ∫ ç ∂ ∆ ƒ ˆ ˙ © section a section b section c 6s380040 ˙ do not out the leads from slot of the box. ˆ clamp with battery lead and ptt relay lead. ∆ clamp with ground lead, battery leads, bat- tery cable and ptt relay leads. Section a wiring for re...

  • Page 259

    6s35h11 8-6 9 8 7 6 5 4 3 2 1 electrical component aft view 5 3 1 6 4 2 7 ∂ å ∫ ç ´ ´ 6s380050 top bottom 1 ignition coil #1 2 ignition coil #2 3 ignition coil #3 4 ignition coil #4 5 ignition coil #5 6 ignition coil #6 7 cdi unit å to locate the charge coil coupler. ∫ to locate the coupler to cente...

  • Page 260

    Elec 8-7 6s35h11 electrical system top view 9 8 1 0 q w 1 2 5 6 7 3 2 4 6s380030 1 spark plug 2 thermoswitch 3 ignition coil #1 4 ignition coil #2 5 oil level gauge 6 emergency switch 7 throttle sensor 8 pulser coil assembly 9 stator assembly 0 starter motor q crank position sensor w engine temperat...

  • Page 261

    6s35h11 8-8 9 8 7 6 5 4 3 2 1 electrical component/ignition and ignition control system ignition and ignition control system checking the ignition spark gap 1. Disconnect the spark plug caps from the spark plugs. 2. Connect a spark plug cap to the special service tool. 3. Crank the engine and observ...

  • Page 262

    Elec 8-9 6s35h11 electrical system checking the cdi unit 1. Remove the cdi unit cover. 2. Connect the digital circuit tester with peak voltage adaptor b to the ignition coil lead and the ground. 3. Measure the cdi unit output peak volt- age. If less than specification, measure the charge coil output...

  • Page 263

    6s35h11 8-10 9 8 7 6 5 4 3 2 1 ignition and ignition control system 4. Disconnect the pulser coil coupler. 5. Connect the digital circuit tester to the pulser coil coupler (pulser coil side). 6. Measure the pulser coil resistance. Replace the pulser coil resistance if out of specification. 7. Connec...

  • Page 264

    Elec 8-11 6s35h11 electrical system checking the crank position sensor 1. Remove the junction box cover. 2. Connect the test harness to the crank position sensor. 3. Measure the crank position sensor output peak voltage. Replace the crank position sensor if less than specification. 4. Disconnect the...

  • Page 265

    6s35h11 8-12 9 8 7 6 5 4 3 2 1 ignition and ignition control system checking the crank position sensor air gap 1. Remove the flywheel magnet cover. 2. Measure the crank position sensor air gap a. Adjust if out of specification. 3. Loosen the screws 1 and adjust the crank position sensor air gap. 4. ...

  • Page 266

    Elec 8-13 6s35h11 electrical system checking the charge coil 1. Remove the cdi unit cover. 2. Connect the test harness to the charge coil. 3. Measure the charge coil output peak volt- age. Replace the stator assembly if less than specification. 4. Disconnect the charge coil coupler. 5. Connect the d...

  • Page 267

    6s35h11 8-14 9 8 7 6 5 4 3 2 1 ignition and ignition control system 6. Measure the charge coil resistance. Replace the stator assembly if out of specification. Checking the thermoswitch 1. Place the thermoswitches in a container of water and slowly heat the water. 2. Check the switches for continuit...

  • Page 268

    Elec 8-15 6s35h11 electrical system starting system checking the fuse 1. Check the fuse for continuity. Replace the fuse if there is no continuity. Checking the engine start switch 1. Disconnect the 10-pin main harness cou- pler. 2. Check the engine start switch for conti- nuity at the 10-pin main h...

  • Page 269

    6s35h11 8-16 9 8 7 6 5 4 3 2 1 ignition and ignition control system/starting system checking the starter relay 1. Remove the starter relay 1. 2. Connect the digital circuit tester leads to the starter relay terminals. 3. Connect the positive battery terminal to the brown (br) lead 2. 4. Connect the ...

  • Page 270

    Elec 8-17 6s35h11 electrical system no. Part name q’ty remarks 1 bolt 2 m8 × 25 mm 2 starting motor bracket 1 3 retainer 2 4 starter motor pinion 1 5 front bracket 1 6 washer — 7 armature 1 8 stator 1 9 spring 4 10 brush holder 1 11 washer 1 12 washer 1 13 nut 1 14 washer 2 15 rear bracket 1 16 scre...

  • Page 271

    6s35h11 8-18 9 8 7 6 5 4 3 2 1 starter motor removing the starter motor pinion 1. Slide the pinion stopper 1 down using the box wrench, and then remove the clips 2. 2. Remove the starter motor pinion. Checking the starter motor pinion 1. Check the teeth of the pinion for cracks or wear. Replace the ...

  • Page 272

    Elec 8-19 6s35h11 electrical system 2. Check the brush holder assembly for continuity. Replace the brush holder if out of specifications. Checking the starter motor operation 1. Check the operation of the starter motor after installing it onto the power unit. Checking the choke solenoid 1. Disconnec...

  • Page 273

    6s35h11 8-20 9 8 7 6 5 4 3 2 1 6s35h11 starter motor/charging system checking the rectifier regulator c c if the battery cable are connected in reverse, the rectifier regulator can be damaged. 1. Remove the junction box cover, and then remove the fuse holder from junction box. 2. Connect the digital...

  • Page 274

    Elec 8- 6s35h11 electrical system 8-21 6s35h11 4. Check the rectifier regulator for continu- ity. Replace if out of specification. Note: set the measurement range a, push the “shift” switch to display the mark b, and then checking the rectifier regulator conti- nuity. Rectifier regulator output peak...

  • Page 275

    å: engine oil tank ∫: remote oil tank 6s35h11 9 8 7 6 5 4 3 2 1 6s35h11 8-22 charging system/oil feed control system checking the hour meter 1. Remove the hour meter cover. 2. Disconnect the hour meter coupler. 3. Connect the positive battery lead to the yellow (y) terminal 1. 4. Connect the negativ...

  • Page 276

    Elec 8- 6s35h11 electrical system 8-23 6s35h11 checking the oil pump (remote oil tank) 1. Connect the positive battery lead to the brown (br) lead. 2. Connect the negative battery lead to the blue (l) lead. 3. Listen to the operating sound of the oil pump (remote oil tank). Replace if there is no so...

  • Page 277: Troubleshooting

    6s35h11 9 8 7 6 5 4 3 2 1 trbl shtg trbl shtg troubleshooting troubleshooting the power unit ..................................................................9-1 troubleshooting the power unit using the diagnostic flash indicator.........9-1 troubleshooting the power unit (trouble code not availabl...

  • Page 278

    Trbl shtg 9-1 6s35h11 trbl shtg troubleshooting troubleshooting the power unit troubleshooting the power unit using the diagnostic flash indicator note: 9 when checking the diagnostic cord, to start the engine. 9 the diagnostic signal code is the same among yamaha outboard motors. 9 the diagnosis fl...

  • Page 279

    6s35h11 9-2 9 8 7 6 5 4 3 2 1 troubleshooting the power unit troubleshooting the power unit (trouble code not available) the trouble shooting when a trouble code is not available consists of the following 4 items. Symptom 1: specific trouble conditions symptom 2: trouble conditions of an area or ind...

  • Page 280

    Trbl shtg 9-3 6s35h11 troubleshooting refer symptom 2 cause 1 cause 2 checking step to page deterioration or dirty fuel replace the new fuel. — 3-2 4-14 4-10 symptom 1: engine will not start (engine cranks) — fuel supplied to the carburetor improperly check the fuel line. Fuel not sup- plied — fuel ...

  • Page 281

    6s35h11 9-4 9 8 7 6 5 4 3 2 1 trouble shooting the power unit refer symptom 2 cause 1 cause 2 checking step to page 8-13 8-10 5-3 8-8 pulser coil malfunction measure the pulser coil output peak voltage and resistance. Change the pulser coil and check the ignition spark. Pulser coil out- put peak vol...

  • Page 282

    Trbl shtg 9-5 6s35h11 troubleshooting refer symptom 2 cause 1 cause 2 checking step to page fuel not sup- plied properly carburetor malfunction disassemble and check the carburetor. 4-10 float height improperly spark plug malfunction spark plug sparks improp- erly *1 short, open or loose connection ...

  • Page 283

    6s35h11 9-6 9 8 7 6 5 4 3 2 1 troubleshooting the power unit refer symptom 2 cause 1 cause 2 checking step to page symptom 1: limited engine speed (below 2,000 r/min) clogged cooling water inlet check the cooling water inlet. 3-4 9buzzer comes on 9overheat warn- ing indicator comes on 9cooling water...

  • Page 284

    Trbl shtg 9-7 6s35h11 troubleshooting refer symptom 2 cause 1 cause 2 checking step to page troubleshooting the ptt unit symptom 1: ptt unit does not operate ptt switch malfunction check the ptt switch. 7-49 ptt relay does not operate — short, open, or loose connection of the wiring harness check th...

  • Page 285

    6s35h11 9-8 9 8 7 6 5 4 3 2 1 troubleshooting the power unit refer symptom 2 cause 1 cause 2 checking step to page symptom 1: ptt unit does not hold the outboard motor up manual valve opened check the manual valve. — insufficient ptt fluid add sufficient fluid. 3-11 — manual valve malfunction — ptt ...

  • Page 286

    I-1 6s35h11 index a. Adjusting the throttle cable ...................... 3-8 adjusting the throttle sensor .................. 4-12 adjusting the timing plate ...................... 5-46 adjusting the trim sensor .........................7-20 aft view ....................................................

  • Page 287

    6s35h11 i-2 9 8 7 6 5 4 3 2 1 checking the lower case ................6-16, 6-47 checking the lower unit for air leakage . 3-13 checking the main valve .........................7-34 checking the oil filter ..............................4-18 checking the oil level sensor...................8-22 checki...

  • Page 288

    I-3 6s35h11 index h. Hose routing ............................................ 4-1 how to use this manual ........................... 1-1 i. Identification ............................................. 1-5 ignition and ignition control system ...........8-8 installing the clamp bracket ................

  • Page 289

    6s35h11 i-4 9 8 7 6 5 4 3 2 1 t. Test run .................................................. 1-28 tightening torque .....................................2-11 top cowling .............................................. 3-2 top view .....................................................8-7 troubleshooti...

  • Page 290

    6s35h11 wiring diagram 250g, l250g 1 throttle sensor 2 ptt switch 3 oil level sensor (engine oil tank) 4 emergency switch 5 thermoswitch 6 spark plug 7 ignition coil 8 cdi unit 9 pulser coil 0 charge coil q ignition coil w crank position sensor e engine temperature sensor r fuse (20a) t fuse (80a) y...

  • Page 291

    Notice this manual has been prepared by yamaha primarily for use by yamaha dealers and their trained mechanics when performing maintenance procedures and repairs to yamaha equipment. It has been written to suit the needs of persons who have a basic understanding of the mechanical and electrical conc...

  • Page 292: L250G

    L250g service manual 6s3-28197-5h-11 6 250g yamaha motor co., ltd. Printed in japan aug. 2005 – 1.4 × 1 ! (e_2) printed on recycled paper 250g, l250g a3cover 06.6.9 19:09 page 1.

  • Page 293

    250g, l250g 1 2 3 2 1 2 1 2 2 1 3 1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 1 2 3 1 2 3 1 2 3 1 2 1 2 1 2 20a 4 6 1 3 5 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 3132 33 34 35 36 37 3839 40 41 42 1 2 1 2 2 1 3 1 2 3 4 1 2 3 4 1 2 80a 80a g /l g /r g /w y /w y /w y /r b b...