- DL manuals
- Yamaha
- Outboard Motor
- F100D
- Service Manual
Yamaha F100D Service Manual
Summary of F100D
Page 1
F80b f100d service manual 6d9-28197-3g-11.
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: Contents
Contents general information 1 gen info specifications 2 spec periodic checks and adjustments 3 chk adj fuel system 4 fuel power unit 5 powr lower unit 6 lowr bracket unit 7 brkt electrical systems 8 elec troubleshooting 9 trbl shtg index – +.
Page 5: General Information
6d93g11 gen info 1 2 3 4 5 6 7 8 9 general information how to use this manual ................................................................................. 1-1 manual format............................................................................................ 1-1 symbols......................
Page 6
Gen info general information 1-1 6d93g11 how to use this manual 1 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. 1 parts are shown and detailed in an exploded...
Page 7
6d93g11 1-2 1 2 3 4 5 6 7 8 9 symbols the symbols below are designed to indicate the content of a chapter. General information specifications periodic checks and adjustments fuel system power unit lower unit bracket unit electrical systems troubleshooting gen info spec chk adj fuel powr lowr brkt el...
Page 8
Gen info general information 1-3 6d93g11 safety while working 1 to prevent an accident or injury and to ensure quality service, follow the safety pro- cedures provided below. Fire prevention gasoline is highly flammable. Keep gasoline and all flammable products away from heat, sparks, and open flame...
Page 9
6d93g11 1-4 1 2 3 4 5 6 7 8 9 6. Keep a supply of clean, lint-free cloths for wiping up spills, etc. Good working practices special service tools use the recommended special service tools to protect parts from damage. Use the right tool in the right manner—do not improvise. Tightening torques follow...
Page 10
Gen info general information 1-5 6d93g11 identification 1 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 propeller se...
Page 11
6d93g11 1-6 1 2 3 4 5 6 7 8 9 selection when the engine speed is at the full throttle operating range (5,000–6,000 r/min), the ideal propeller for the boat is one that pro- vides maximum performance in relation to boat speed and fuel consumption. Predelivery checks 1 to make the delivery process smo...
Page 12
Gen info general information 1-7 6d93g11 checking the gear oil level 1. Check the gear oil level. Checking the battery 1. Check the capacity, electrolyte level, and specified gravity of the battery. 2. Check that the positive and negative bat- tery leads are securely connected. Checking the outboard...
Page 13
6d93g11 1-8 1 2 3 4 5 6 7 8 9 warning the shift/throttle cable joint must be screwed in a minimum of 8.0 mm (0.31 in) c. Checking the steering system 1. Check the steering friction for proper adjustment. 2. Check that the steering operates smoothly. 3. Check that there is no interference with wires ...
Page 14
Gen info general information 1-9 6d93g11 3. Check that the engine turns off when the engine stop lanyard is pulled from the engine stop lanyard switch. Checking the cooling water pilot hole 1. Check that cooling water is discharged from the cooling water pilot hole. Test run 1. Start the engine, and...
Page 15: Specifications
6d93g11 spec 1 2 3 4 5 6 7 8 9 specifications general specifications................................................................................... 2-1 maintenance specification ............................................................................ 2-3 power unit..............................
Page 16
Spec specifications 2-1 6d93g11 general specifications 2 item unit model f80bet f100det dimension overall length mm (in) 817 (32.2) overall width mm (in) 479 (18.9) overall height (l) mm (in) 1,582 (62.3) (x) mm (in) 1,710 (67.3) boat transom height (l) mm (in) 508 (20.0) (x) mm (in) 635 (25.0) weig...
Page 17
6d93g11 2-2 1 2 3 4 5 6 7 8 9 (*1) ron: research octane number pon: pump octane number = (ron + motor octane number)/2 (*2) meeting both api and sae requirements (*3) cca: cold cranking ampere en: european norm (european standard) iec: international electrotechnical commission fuel and oil fuel type...
Page 18
Spec specifications 2-3 6d93g11 maintenance specification 2 power unit item unit model f80bet f100det power unit minimum compression pressure (*1) kpa (kgf/cm 2 , psi) 860 (8.6, 124.7) oil pressure (*2) kpa (kgf/cm 2 , psi) 510 (5.1, 74.0) at engine idle speed cylinder head warpage limit mm (in) 0.1...
Page 19
6d93g11 2-4 1 2 3 4 5 6 7 8 9 oil ring dimension b mm (in) 2.38–2.48 (0.0937–0.0976) dimension t (*) mm (in) 2.40 (0.0945) end gap mm (in) 0.20–0.70 (0.0079–0.0276) side clearance mm (in) 0.03–0.15 (0.0012–0.0059) camshafts intake (a) mm (in) 36.48–36.58 (1.4362–1.4402) exhaust (a) mm (in) 36.90–37....
Page 20
Spec specifications 2-5 6d93g11 valve lifters valve lifter outside diameter mm (in) 27.965–27.980 (1.1010–1.1016) valve lifter-to-cylinder head clearance mm (in) 0.020–0.056 (0.0008–0.0022) valve shims valve shim thickness (in 0.025 mm increments) mm (in) 2.0–3.3 (0.08–0.13) connecting rods big end ...
Page 21
6d93g11 2-6 1 2 3 4 5 6 7 8 9 lower unit electrical oil pump discharge at 97–103 °c (207–217 °f) with 10w-30 engine oil l (us gal, imp gal)/min 5.9 (1.559, 1.298) at 1,000 r/min pressure at 97–103 °c (207–217 °f) with 10w-30 engine oil kpa (kgf/cm 2 , psi) 118.0 (1.18, 17.1) at 1,000 r/min relief va...
Page 22
Spec specifications 2-7 6d93g11 ecm output peak voltage (b/r, b/w – ground) at cranking (loaded) v 210 at 1,500 r/min (loaded) v 290 at 3,500 r/min (loaded) v 290 pulser coil output peak voltage (w/r, w/b – b) at cranking (unloaded) v 3.6 at cranking (loaded) v 3.4 at 1,500 r/min (loaded) v 18.2 at ...
Page 23
6d93g11 2-8 1 2 3 4 5 6 7 8 9 charging system fuse a 20 stator coil output peak voltage (w – w) at cranking (unloaded) v 12.4 at 1,500 r/min (unloaded) v 45.3 at 3,500 r/min (unloaded) v 98.3 stator coil resistance (*) (w – w) at 20 °c (68 °f) Ω 0.24–0.36 rectifier regulator output peak voltage (r–g...
Page 24
Spec specifications 2-9 6d93g11 dimensions exterior 527 (20.7) 366 (14.4) 49 (1.9) 27 (1.1) l : 766 (30.2) x: 842 (33.1) 857 (33.7) 666 (26.2) l : 917 (36.1) x: 1,044 (41.1) l : 536 (21.1) x : 663 (26.1) l : 25 (1.0) x : 24 (0.9) 191 (7.5) 171 (6.73) 62 (2.4) 66˚ 574 (22.6) 28 (1.1) 164 (6.5) 651 (2...
Page 25
6d93g11 2-10 1 2 3 4 5 6 7 8 9 clamp bracket 348.5 (13.7) 180 (7.1) 163.5 (6.4) 163.5 (6.4) 180 (7.1) 18.5 (0.7) 254 (10.0) 13 (0.5) 80 (3.1) 50.8 (2.0) 55.5 (2.2) 13 (0.5) 125.4 (4.9) 125.4 (4.9) mm (in) s6d82020 maintenance specification.
Page 26
Spec specifications 2-11 6d93g11 tightening torques 2 specified torques part to be tightened thread size tightening torques n·m kgf·m ft·lb fuel system fuel filter cup — 3 0.3 2.2 fuel pump mounting bolt m6 10 1.0 7.4 fuel pump screw m6 4 0.4 3.0 sensor assembly screw m5 3.7 0.37 2.7 idle speed cont...
Page 27
6d93g11 2-12 1 2 3 4 5 6 7 8 9 cylinder head bolt 1st m8 14 1.4 10.3 2nd 28 2.8 20.7 1st m10 15 1.5 11.1 2nd 30 3.0 22.1 3rd 90° spark plug — 25 2.5 18.4 cylinder block plug m14 23 2.3 17.0 oil filter joint — 49 4.9 36.1 oil filter — 18 1.8 13.3 exhaust cover bolt 1st m6 6 0.6 4.4 2nd 12 1.2 8.9 ano...
Page 28
Spec specifications 2-13 6d93g11 general torques this chart specifies tightening torques for standard fasteners with a standard iso thread pitch. Tightening torque specifications for special components or assemblies are provided in applicable sections of this man- ual. To avoid warpage, tighten mult...
Page 29
6d93g11 chk adj 1 2 3 4 5 6 7 8 9 periodic checks and adjustments special service tools ..................................................................................... 3-1 maintenance interval chart............................................................................ 3-2 top cowling ......
Page 30
Chk adj periodic checks and adjustments 3-1 6d93g11 special service tools 3 digital tachometer 90890-06760 leakage tester 90890-06840 oil filter wrench 64 90890-01426.
Page 31
6d93g11 3-2 1 2 3 4 5 6 7 8 9 maintenance interval chart 3 use the following chart as a guideline for general maintenance. Adjust the maintenance intervals according to the operating conditions of the outboard motor. Note: when operating in salt water, turbid or muddy water, the engine should be flu...
Page 32
Chk adj periodic checks and adjustments 3-3 6d93g11 top cowling 3 checking the top cowling 1. Check the fitting by pushing the cowling with both hands. Adjust if necessary. 2. Loosen the bolts 1. 3. Move the hook 2 up or down slightly to adjust its position. Note: • to loosen the fitting, move the h...
Page 33
6d93g11 3-4 1 2 3 4 5 6 7 8 9 power unit 3 checking the engine oil 1. Place the outboard motor in an upright position. 2. Remove the oil dipstick, wipe it clean, and then insert it back into the dipstick hole. 3. Remove the oil dipstick again to check the oil level and to check the oil for dis- colo...
Page 34
Chk adj periodic checks and adjustments 3-5 6d93g11 2. Remove the oil dipstick and oil filler cap 1. 3. Place a drain pan under the drain hole, and then remove the drain bolt 2 and let the oil drain completely. Note: be sure to clean up any oil spills. 4. Install the drain bolt, and then tighten it ...
Page 35
6d93g11 3-6 1 2 3 4 5 6 7 8 9 5. Pour the specified amount of the recom- mended engine oil into the oil filler hole. 6. Install the oil filler cap and oil dipstick, and then start the engine and warm it up for 5 minutes. 7. Turn the engine off, and then check the oil level and correct it if necessar...
Page 36
Chk adj periodic checks and adjustments 3-7 6d93g11 5. Check the spark plug gap a. Adjust if out of specification. 6. Install the spark plugs, tighten them fin- ger tight, then to the specified torque using a spark plug wrench. 7. Install the spark plug wire cover. Checking the thermostat 1. Remove ...
Page 37
6d93g11 3-8 1 2 3 4 5 6 7 8 9 6. Install the thermostat and cover. 7. Connect the cooling water hose, and then install the flywheel magnet cover. Checking the cooling water passage 1. Check the cooling water inlet cover 1 and cooling water inlet for clogs. Clean if necessary. 2. Place the lower unit...
Page 38
Chk adj periodic checks and adjustments 3-9 6d93g11 3. Loosen the locknut 1, remove the clip 2, and then disconnect the throttle cable joint 3. 4. Loosen the locknut 4, and then discon- nect the throttle link rod joint 5 from the ball joint of the throttle body. 5. Check that the stopper 6 on the th...
Page 39
6d93g11 3-10 1 2 3 4 5 6 7 8 9 warning the throttle cable joint must be screwed in a minimum of 8.0 mm (0.31 in) c. 12. Connect the throttle cable joint, install the clip, and then tighten the locknut. 13. Check the throttle cable for smooth oper- ation and, if necessary, repeat steps 2– 12. 14. Ins...
Page 40
Chk adj periodic checks and adjustments 3-11 6d93g11 bracket unit 3 checking the power trim and tilt operation 1. Fully tilt the outboard motor up and down a few times and check the entire trim and tilt range for smooth operation. Check the power trim and tilt fluid level if necessary. Note: be sure...
Page 41
6d93g11 3-12 1 2 3 4 5 6 7 8 9 lower unit 3 checking the gear oil level 1. Fully tilt the outboard motor down. 2. Remove the check screw 1, and then check the gear oil level in the lower case. Note: if the oil is at the correct level, the oil should overflow out of the check hole when the check scre...
Page 42
Chk adj periodic checks and adjustments 3-13 6d93g11 4. Insert a gear oil tube or gear oil pump into the drain hole and slowly fill the gear oil until oil flows out of the check hole and no air bubbles are visible. 5. Install the check screw and quickly install the drain screw, and then tighten them...
Page 43
6d93g11 3-14 1 2 3 4 5 6 7 8 9 general 3 checking the anodes 1. Check the anodes and trim tab for scales, grease, or oil. Clean if necessary. Caution: 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 m...
Page 44
Chk adj periodic checks and adjustments 3-15 6d93g11 2. Check the specific gravity of the electro- lyte. Fully charge the battery if out of specification. Warning battery electrolyte is dangerous; it con- tains sulfuric acid which is poisonous and highly caustic. Always follow these preventive measu...
Page 45
6d93g11 3-16 1 2 3 4 5 6 7 8 9 note: apply grease to the grease nipple until it flows from the bushings a. 2. Apply low temperature resistant grease to the area shown. 3. Apply corrosion resistant grease to the area shown. S60c3710 a a a a s6d83190 c general.
Page 46: — Memo —
Chk adj periodic checks and adjustments 3-17 6d93g11 — memo —.
Page 47: Fuel System
6d93g11 fuel 1 2 3 4 5 6 7 8 9 fuel system special service tools ..................................................................................... 4-1 hose routing ................................................................................................... 4-2 fuel and blowby hoses..........
Page 48
Fuel fuel system 4-1 6d93g11 special service tools 4 vacuum/pressure pump gauge set 90890-06756 fuel pressure gauge 90890-06786 fuel pressure gauge adapter b 90890-06942.
Page 49
6d93g11 4-2 1 2 3 4 5 6 7 8 9 hose routing 4 fuel and blowby hoses 1 blowby hose 2 fuel hose (primary pump-to-fuel filter) 3 fuel hose (fuel filter-to-fuel pump) 4 fuel hose (fuel pump-to-strainer) 5 fuel hose (strainer-to-vapor separator) 6 high-pressure fuel hose (vapor separator-to-fuel rail) 7 f...
Page 50
Fuel fuel system 4-3 6d93g11 fuel filter and fuel pump 4 no. Part name q’ty remarks 1 nut 1 2 fuel filter assembly 1 3 o-ring 1 not reusable 4 fuel filter element 1 5 o-ring 1 not reusable 6 float 1 7 cup 1 8 fuel hose 1 9 fuel pump 1 10 bolt 2 m6 × 30 mm 11 fuel hose 1 12 strainer 1 13 bolt 1 m6 × ...
Page 51
6d93g11 4-4 1 2 3 4 5 6 7 8 9 4 no. Part name q’ty remarks 1 screw 3 ø6 × 35 mm 2 cover 1 3 gasket 1 not reusable 4 fuel pump body 2 assembly 1 5 diaphragm 1 6 pin 1 7 spring 1 8 fuel pump body 1 1 9 spring 1 10 plunger 1 11 nut 3 s6d84030 4 7 8 9 10 1 2 3 5 6 t r . . 4 n · m (0.4 kgf · m, 3.0 ft · ...
Page 52
Fuel fuel system 4-5 6d93g11 checking the fuel pump 1. Place a drain pan under the fuel hose connections, and then disconnect the fuel hoses from the fuel pump. 2. Connect the special service tool to the fuel pump inlet. 3. Cover the fuel pump outlet with a finger, and then apply the specified posit...
Page 53
6d93g11 4-6 1 2 3 4 5 6 7 8 9 3. Slowly let up on the plunger and dia- phragm, and then remove them. Checking the diaphragm and valves 1. Check the diaphragm for tears and the valves for cracks. Replace if necessary. Assembling the fuel pump note: clean the parts and soak the valves and the diaphrag...
Page 54
Fuel fuel system 4-7 6d93g11 intake manifold 4 no. Part name q’ty remarks 1 intake silencer 1 f80bet 2 bolt 2 m6 × 80 mm 3 bushing 4 4 collar 2 5 intake manifold assembly 1 6 bolt 4 m8 × 30 mm 7 collar 5 8 bolt 1 m8 × 100 mm 9 spacer 1 10 bolt 3 m6 × 45 mm 11 collar 3 12 holder 1 13 gasket 1 not reu...
Page 55
6d93g11 4-8 1 2 3 4 5 6 7 8 9 4 no. Part name q’ty remarks 1 intake manifold 1 2 sensor assembly 1 3 screw 4 ø5 × 13 mm 4 o-ring 1 not reusable 5 idle speed control 1 6 o-ring 1 not reusable 7 throttle body assembly 1 8 bolt 3 m6 × 16 mm 9 gasket 1 not reusable 10 throttle position sensor 1 11 screw...
Page 56
Fuel fuel system 4-9 6d93g11 checking the throttle position sensor 1. Check the throttle position sensor output voltage using the yamaha diagnostic system. If the output voltage is out of specification, replace the throttle posi- tion sensor. Installing the throttle position sensor 1. Install the th...
Page 57
6d93g11 4-10 1 2 3 4 5 6 7 8 9 vapor separator 4 no. Part name q’ty remarks 1 vapor separator 1 2 bolt 3 m6 × 30 mm 3 grommet 3 4 collar 3 5 fuel hose 1 6 fuel inlet hose 1 7 hose 1 8 joint 1 9 hose 1 10 hose 1 11 hose 1 12 hose 1 13 clamp 1 14 clamp 1 15 quick connector 1 16 clamp 1 not reusable 17...
Page 58
Fuel fuel system 4-11 6d93g11 4 no. Part name q’ty remarks 1 screw 6 ø5 × 14 mm 2 gasket 1 not reusable 3 float chamber 1 4 damper 1 5 drain screw 1 6 o-ring 1 not reusable 7 joint screw 1 8 o-ring 1 not reusable 9 fuel hose 1 10 fuel cooler 1 11 screw 2 ø6 × 15 mm 12 fuel hose 1 13 hose 1 14 hose 1...
Page 59
6d93g11 4-12 1 2 3 4 5 6 7 8 9 4 no. Part name q’ty remarks 1 cover 1 2 pressure regulator 1 3 bolt 2 m6 × 12 mm 4 o-ring 1 not reusable 5 joint screw 1 6 o-ring 1 not reusable 7 electric fuel pump 1 8 grommet 1 9 collar 1 10 filter 1 11 screw 3 ø4 × 6 mm 12 wiring harness 1 13 float 1 14 needle val...
Page 60
Fuel fuel system 4-13 6d93g11 reducing the fuel pressure 1. Remove the cap 1. 2. Cover the pressure check valve a of the vapor separator with a rag, and then press in the pressure check valve a using a thin screwdriver to release the fuel pressure. Warning always reduce the fuel pressure in the high...
Page 61
6d93g11 4-14 1 2 3 4 5 6 7 8 9 warning • when connecting the fuel pressure gauge, first cover the connection between the gauge and the adapter with a clean, dry rag to prevent fuel from leaking out. • gently screw in the gauge until it is firmly connected. 4. Turn the engine start switch to on, and ...
Page 62
Fuel fuel system 4-15 6d93g11 4. Disconnect the pressure regulator hose, and then connect the special service tools to the pressure regulator. Warning • when connecting the fuel pressure gauge, first cover the connection between the gauge and the adapter with a clean, dry rag to prevent fuel from le...
Page 63
6d93g11 4-16 1 2 3 4 5 6 7 8 9 warning reduce the fuel pressure before loosen- ing the vapor separator drain screw, or pressurized fuel will spray out and may result in serious injury. Removing the fuel hose clamp 1. Remove the fuel hose clamp by cutting the crimped section of the clamp. Caution: if...
Page 64
Fuel fuel system 4-17 6d93g11 2. Check the float for deterioration. Replace if necessary. 3. Check the filter for dirt or residue. Clean if necessary. Assembling the vapor separator 1. Install the needle valve, float, and float pin, and then check the float for smooth operation. Note: • do not reuse...
Page 65
6d93g11 4-18 1 2 3 4 5 6 7 8 9 note: when adjusting the float height, do not bend the lever e. Float height d: 35.0 ± 1.0 mm (1.38 ± 0.04 in) vapor separator.
Page 66
Fuel fuel system 4-19 6d93g11 canister 4 no. Part name q’ty remarks 1 bolt 1 m6 × 16 mm 2 bracket 1 3 canister 1 4 bolt 2 m6 × 28 mm 5 grommet 2 6 bracket 1 7 collar 2 8 hose 1 9 hose 1 10 hose 1 11 filter 1 12 hose 1 13 clamp 1 14 bolt 1 m6 × 10 mm 15 holder 1 16 bolt 1 m6 × 16 mm 17 bracket 1 s6d8...
Page 67
6d93g11 4-20 1 2 3 4 5 6 7 8 9 checking the canister 1. Check the canister for cracks. Replace if necessary. 2. Connect the special service tool to the atmospheric port 1 and cover the other ports, each with a finger. 3. Apply the specified positive pressure and check that there is no air leakage. R...
Page 68: Power Unit
Powr 6d93g11 power unit special service tools ..................................................................................... 5-1 power unit....................................................................................................... 5-3 checking the compression pressure ...............
Page 69
6d93g11 1 2 3 4 5 6 7 8 9 cylinder block .............................................................................................. 5-40 disassembling the cylinder block ............................................................ 5-41 checking the piston diameter ..................................
Page 70
Powr power unit 5-1 6d93g11 special service tools 5 compression gauge 90890-03160 compression gauge extension m14 90890-06563 flywheel holder 90890-06522 flywheel puller 90890-06521 crankshaft holder 20 90890-06552 valve spring compressor 90890-04019 valve spring compressor attachment 90890-06320 va...
Page 71
6d93g11 5-2 1 2 3 4 5 6 7 8 9 valve seat cutter 90890-06312, 90890-06315, 90890-06324, 90890-06326, 90890-06328, 90890-06555 piston slider 90890-06530 oil filter wrench 64 90890-01426 special service tools.
Page 72
Powr power unit 5-3 6d93g11 power unit 5 checking the compression pressure 1. Start the engine, warm it up for 5 min- utes, and then turn it off. 2. Remove the engine stop lanyard from the engine stop lanyard switch on the remote control box. 3. Remove the spark plug wire cover and all spark plugs, ...
Page 73
6d93g11 5-4 1 2 3 4 5 6 7 8 9 5 no. Part name q’ty remarks 1 damper 1 2 grommet 2 3 grommet 1 4 flywheel magnet cover 1 5 power unit 1 6 oil dipstick 1 7 gasket 1 not reusable 8 dowel 2 9 bolt 5 m6 × 16 mm 10 bolt 6 m10 × 130 mm 11 screw 2 ø6 × 40 mm 12 nut 2 13 apron 1 14 bolt 2 m8 × 35 mm 15 holde...
Page 74
Powr power unit 5-5 6d93g11 5 no. Part name q’ty remarks 1 nut 1 2 washer 1 3 flywheel magnet 1 4 screw 1 ø4 × 10 mm 5 screw 3 ø6 × 30 mm 6 stator coil 1 7 bolt 4 m6 × 30 mm 8 stator assembly 1 9 collar 2 10 bolt 1 m6 × 15 mm 11 woodruff key 1 12 bolt 1 m6 × 15 mm 13 holder 1 14 grommet 1 s6d85020 2...
Page 75
6d93g11 5-6 1 2 3 4 5 6 7 8 9 5 no. Part name q’ty remarks 1 timing belt 1 2 bolt 2 m10 × 35 mm 3 dowel 2 4 driven sprocket 2 5 bolt 2 m6 × 15 mm 6 bracket 1 7 bolt 1 m10 × 45 mm 8 timing belt tensioner 1 9 spring 1 10 plastic tie 1 not reusable 11 hose 1 12 clamp 1 13 nut 1 14 drive sprocket 1 15 p...
Page 76
Powr power unit 5-7 6d93g11 5 no. Part name q’ty remarks 1 screw 5 ø6 × 30 mm 2 cover 1 3 spark plug wire 4 4 holder 2 5 holder 2 6 bolt 1 m6 × 12 mm 7 holder 1 8 clamp 1 9 hose 1 10 plastic tie 1 not reusable 11 ignition coil 2 12 bracket 2 13 bolt 4 m6 × 25 mm 14 holder 2 15 starter motor 1 16 bol...
Page 77
6d93g11 5-8 1 2 3 4 5 6 7 8 9 5 no. Part name q’ty remarks 18 nut 1 19 cap 1 20 positive battery lead 1 21 nut 1 22 negative battery lead 1 23 bolt 1 m6 × 20 mm 24 junction box cover 1 25 bolt 1 m6 × 10 mm 26 cap 1 27 oil pressure switch 1 28 bolt 1 m4 × 8 mm 29 holder 1 30 bolt 1 m6 × 25 mm 31 clam...
Page 78
Powr power unit 5-9 6d93g11 5 no. Part name q’ty remarks 1 oil filler cap 1 2 o-ring 1 3 cylinder head cover 1 4 screw 8 ø4 × 8 mm 5 plate 1 6 grommet 2 7 gasket 1 not reusable 8 bolt 14 m6 × 30 mm 9 camshaft cap 2 10 camshaft cap 8 11 bolt 4 m7 × 48 mm 12 bolt 16 m7 × 37 mm 13 oil seal 2 not reusab...
Page 79
6d93g11 5-10 1 2 3 4 5 6 7 8 9 checking the valve clearance caution: • do not turn the flywheel magnet coun- terclockwise, otherwise the valve sys- tem may be damaged. • do not remove the ignition timing pointer. • do not turn the flywheel magnet or the driven sprockets when the timing belt is not i...
Page 80
Powr power unit 5-11 6d93g11 4. Install the driven sprockets 0, timing belt 9, and spring 8, and then tighten the tensioner bolt. 5. Check the intake valve clearance for cyl- inders #1 and #2, and the exhaust valve clearance for cylinders #1 and #3. Adjust if out of specification. Note: • check the ...
Page 81
6d93g11 5-12 1 2 3 4 5 6 7 8 9 11. Remove the valve shim c from the valve lifter d using a thin screwdriver. 12. Measure the valve shim thickness with a micrometer, and then note the measure- ment. 13. Select the necessary valve shim by cal- culating its thickness with the following formula. Example...
Page 82
Powr power unit 5-13 6d93g11 replacing the timing belt caution: • do not turn the drive sprocket counter- clockwise, otherwise the valve system may be damaged. • do not remove the ignition timing pointer. • do not turn the drive sprocket or the driven sprockets when the timing belt is not installed....
Page 83
6d93g11 5-14 1 2 3 4 5 6 7 8 9 6. Disconnect the cooling water hose 3 and remove the bracket 4. 7. Remove the spring 5 and timing belt tensioner 6, and then remove the timing belt 7 from the driven sprockets, then from the drive sprocket. 8. Check that the hole a on the retaining plate and the proje...
Page 84
Powr power unit 5-15 6d93g11 10. Install a new timing belt 8 onto the drive sprocket with its part number in the upright position, and then install the belt onto the driven sprockets in a counter- clockwise direction. Caution: • do not twist, turn inside out, or bend the timing belt beyond the maxim...
Page 85
6d93g11 5-16 1 2 3 4 5 6 7 8 9 18. Install the stator assembly and woodruff key. 19. Install the flywheel magnet. Caution: apply force in the direction of the arrows shown to prevent the flywheel holder from slipping off easily. Note: apply engine oil to the flywheel magnet nut before installation. ...
Page 86
Powr power unit 5-17 6d93g11 removing the timing belt and sprockets caution: • do not turn the drive sprocket counter- clockwise, otherwise the valve system may be damaged. • do not turn the drive sprocket or the driven sprockets when the timing belt is not installed. Otherwise the piston and valves...
Page 87
6d93g11 5-18 1 2 3 4 5 6 7 8 9 checking the timing belt and sprockets 1. Check the interior and exterior of the tim- ing belt for cracks, damage, or wear. Replace if necessary. 2. Check the drive sprocket and driven sprockets for cracks, damage, or wear. Replace if necessary. Installing the sprocket...
Page 88
Powr power unit 5-19 6d93g11 3. Install the retaining plate 3, woodruff key 4, drive sprocket 5, and nut 6, and then tighten the nut. Note: • apply engine oil to the drive sprocket nut before installation. • tighten the drive sprocket nut finger tight. 4. Check that the hole c on the retaining plate...
Page 89
6d93g11 5-20 1 2 3 4 5 6 7 8 9 throttle link 4 no. Part name q’ty remarks 1 throttle cam 1 2 bolt 1 m6 × 35 mm 3 collar 1 4 wave washer 2 5 washer 2 6 spring 1 7 washer 2 8 throttle lever 1 9 bolt 1 m6 × 25 mm 10 collar 1 11 throttle link rod 1 12 nut 1 13 throttle link rod joint 1 14 bracket 1 15 b...
Page 90
Powr power unit 5-21 6d93g11 ecm 5 no. Part name q’ty remarks 1 wiring harness 1 2 bracket 1 3 bolt 2 m6 × 15 mm 4 bolt 2 m6 × 12 mm 5 bracket 1 6 bracket 1 7 bracket 1 8 bolt 2 m6 × 20 mm 9 collar 4 10 grommet 4 11 bolt 4 m6 × 30 mm 12 ecm 1 13 rectifier regulator 1 14 bolt 2 m6 × 25 mm 15 bolt 2 m...
Page 91
6d93g11 5-22 1 2 3 4 5 6 7 8 9 junction box 5 no. Part name q’ty remarks 1 screw 1 ø6 × 25 mm 2 main and fuel pump relay 1 3 power trim and tilt relay 1 4 washer 2 5 nut 2 6 cap 2 7 bolt 2 m6 × 20 mm 8 ground lead 1 9 fuse 1 30 a 10 fuse 3 20 a 11 cap 1 12 cap 3 13 starter relay 1 14 holder 1 15 scr...
Page 92
Powr power unit 5-23 6d93g11 5 no. Part name q’ty remarks 18 holder 1 19 junction box 1 20 collar 5 21 grommet 5 22 bolt 2 m6 × 10 mm 23 clamp 1 24 grommet 1 s6d95020 1 2 9 13 11 10 12 4 3 7 5 6 14 15 16 18 19 21 20 17 8 4 5 6 22 22 24 23 t r . . 3 n · m (0.3 kgf · m, 2.2 ft · ib) t r . . 4 n · m (0...
Page 93
6d93g11 5-24 1 2 3 4 5 6 7 8 9 cylinder head 5 no. Part name q’ty remarks 1 cylinder head 1 2 exhaust valve 8 3 intake valve 8 4 gasket 1 not reusable 5 collar 2 6 bolt 5 m8 × 55 mm 7 bolt 2 m6 × 25 mm 8 cover 1 9 thermostat 1 10 bolt 10 m10 × 143 mm 11 spark plug 4 12 bolt 2 m8 × 40 mm 13 bolt 2 m6...
Page 94
Powr power unit 5-25 6d93g11 5 no. Part name q’ty remarks 18 valve lifter 16 19 valve cotter 32 20 valve spring retainer 16 21 valve spring 16 22 valve spring seat 16 23 valve seal 16 not reusable 24 valve guide 16 not reusable s6d85080 1 4 7 8 9 5 6 3 13 14 22 20 18 17 19 21 23 24 24 16 15 12 11 10...
Page 95
6d93g11 5-26 1 2 3 4 5 6 7 8 9 removing the cylinder head 1. Remove the cylinder head cover. 2. Remove camshaft caps 1 and 2 in the sequence shown. 3. Remove the camshaft (intake) 3, cam- shaft (exhaust) 4, and oil seals 5. 4. Remove the valve shims 6 from the valve lifters 7. Note: do not mix the v...
Page 96
Powr power unit 5-27 6d93g11 6. Remove the intake and exhaust valves. Note: be sure to keep the valves, springs, and other parts in the order as they were removed. Checking the valve lifters 1. Check the valve lifters for damage, scratches, or wear. Replace if necessary. Checking the valve springs 1...
Page 97
6d93g11 5-28 1 2 3 4 5 6 7 8 9 4. Measure the valve stem runout. Replace if above specification. Checking the valve guides note: before checking the valve guide make sure that the valve stem diameter is within specifi- cation. 1. Measure the valve guide inside diameter a. 2. Calculate the valve stem...
Page 98
Powr power unit 5-29 6d93g11 2. Install the new valve guide 2 by striking the special tool from the camshaft side to the specified position a. Note: • before installing the valve guide, mark its installation position b as shown. • apply engine oil to the surface of the new valve guide. 3. Insert the...
Page 99
6d93g11 5-30 1 2 3 4 5 6 7 8 9 refacing the valve seat 1. Reface the valve seat with the valve seat cutters. 2. Cut the surface of the valve seat with a 45° cutter by turning the cutter clockwise until the valve seat face has become smooth. A slag or rough surface caution: do not over cut the valve ...
Page 100
Powr power unit 5-31 6d93g11 4. Use a 60° cutter to adjust the contact width of the bottom edge of the valve seat. B previous contact width 5. Use a 45° cutter to adjust the contact width of the valve seat to specification. B previous contact width c specified contact width 6. If the valve seat cont...
Page 101
6d93g11 5-32 1 2 3 4 5 6 7 8 9 caution: do not get the lapping compound on the valve stem and valve guide. 10. After every lapping procedure, be sure to clean off any remaining lapping com- pound from the cylinder head and the valve. 11. Check the valve seat contact area of the valve again. Checking...
Page 102
Powr power unit 5-33 6d93g11 2. Check the cylinder head warpage using a straightedge 1 and thickness gauge 2 in the directions shown. Replace if above specification. Installing the valves 1. Install a new valve seal 1 onto the valve guide. 2. Install the valve 2, valve spring seat 3, valve spring 4,...
Page 103
6d93g11 5-34 1 2 3 4 5 6 7 8 9 4. Lightly tap the valve spring retainer with a plastic hammer to set the valve cotters securely. Installing the cylinder head 1. Check that the piston of cylinder #1 is at tdc. 2. Install a new gasket and the cylinder head, and then tighten the bolts to the specified ...
Page 104
Powr power unit 5-35 6d93g11 3. Install the valve shims and valve lifters. Note: • apply engine oil to the valve shims and valve lifters before installation. • install the valve shims and valve lifters in their original positions. 4. Install the camshaft (intake) 1 and cam- shaft (exhaust) 2 with th...
Page 105
6d93g11 5-36 1 2 3 4 5 6 7 8 9 9. Install the sprockets and timing belt. Note: for sprocket and timing belt installation pro- cedures, see “installing the sprockets and timing belt.” t r . . Cylinder head cover bolt: 1st: 8 n·m (0.8 kgf·m, 5.9 ft·lb) 2nd: 8 n·m (0.8 kgf·m, 5.9 ft·lb) s6d85520 s1280b...
Page 106
Powr power unit 5-37 6d93g11 exhaust cover 5 no. Part name q’ty remarks 1 gasket 1 not reusable 2 screw 3 ø4 × 13 mm 3 anode 3 4 exhaust cover 1 5 gasket 1 not reusable 6 cooling water temperature sensor 1 7 holder 1 8 bolt 2 m6 × 15 mm 9 holder 1 10 bolt 1 m6 × 10 mm 11 gasket 1 not reusable 12 gro...
Page 107
6d93g11 5-38 1 2 3 4 5 6 7 8 9 5 no. Part name q’ty remarks 18 plug 1 m18 × 17 mm 19 grommet 1 20 anode 1 21 cover 1 22 bolt 1 m8 × 25 mm 23 bolt 18 m6 × 30 mm 24 bolt 1 m6 × 20 mm 25 joint 1 26 oil filter 1 27 gasket 1 not reusable 28 plug 1 m14 × 12 mm 29 plastic tie 1 not reusable 30 hose 1 s6d85...
Page 108
Powr power unit 5-39 6d93g11 removing the exhaust cover 1. Remove the exhaust cover bolts in the sequence shown. 2. Remove the exhaust cover. Checking the pressure control valve 1. Remove the pressure control valve. 2. Check the pressure control valve for wear or damage. Replace if necessary. 3. Che...
Page 109
6d93g11 5-40 1 2 3 4 5 6 7 8 9 cylinder block 5 no. Part name q’ty remarks 1 bolt 4 m6 × 20 mm 2 dowel 10 3 bolt 10 m10 × 135 mm 4 crankcase 1 5 bolt 10 m8 × 55 mm 6 cylinder block 1 7 main bearing 5 8 main bearing 4 9 main bearing 1 10 oil seal 1 not reusable 11 crankshaft 1 12 oil seal 1 not reusa...
Page 110
Powr power unit 5-41 6d93g11 disassembling the cylinder block 1. Place a rag under the oil filter, and then remove the filter using the oil filter wrench. Note: be sure to clean up any oil spills. 2. Remove the crankcase bolts in the sequence shown, and then remove the crankcase. Note: do not remove...
Page 111
6d93g11 5-42 1 2 3 4 5 6 7 8 9 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 20 mm (0....
Page 112
Powr power unit 5-43 6d93g11 3. Check the piston ring end gap d at the specified measuring point. Replace if out of specification. Checking the piston ring grooves 1. Measure the piston ring grooves. Replace the piston if out of specification. Checking the piston ring side clearance 1. Measure the p...
Page 113
6d93g11 5-44 1 2 3 4 5 6 7 8 9 checking the crankshaft 1. Measure the crankshaft journal diameter a, crankpin diameter b, and crankpin width c. Replace the crankshaft if out of specification. 2. Measure the crankshaft runout. Replace the crankshaft if above specification. Checking the crankpin oil c...
Page 114
Powr power unit 5-45 6d93g11 2. Install the upper bearing into the con- necting rod 1 and the lower bearing into the connecting rod cap 2. Note: install the bearings in their original positions. 3. Put a piece of plastigauge (pg-1) onto the crankpin, parallel to the crankshaft. Note: be sure not to ...
Page 115
6d93g11 5-46 1 2 3 4 5 6 7 8 9 6. Remove the connecting rod cap and measure the width of the compressed plastigauge (pg-1) on each crankpin. Replace the connecting rod bearing if out of specification. Selecting the connecting rod bearing note: use a metric gauge in this procedure. 1. When replacing ...
Page 116
Powr power unit 5-47 6d93g11 5. Select the suitable color b for the con- necting rod bearing from the table below according to the calculated values. Caution: the (*) mark indicates that the colors of the upper and lower bearings are differ- ent. Example: if the “connecting rod big end inside diame-...
Page 117
6d93g11 5-48 1 2 3 4 5 6 7 8 9 5. Install the remaining half of the bearings into the crankcase. 6. Install the crankcase onto the cylinder block and apply engine oil onto the threads of the crankcase bolts. 7. Tighten the crankcase bolts to the speci- fied torques in two stages and in the sequence ...
Page 118
Powr power unit 5-49 6d93g11 2. Check the crankshaft journal mark on the crankshaft 1 and the cylinder block mark on the cylinder block 2. 3. Subtract crankshaft journal diameters #1–#5 from cylinder block journal inside diameters #1–#5. Note: cylinder block journal inside diameters (#1– #5) and cra...
Page 119
6d93g11 5-50 1 2 3 4 5 6 7 8 9 assembling the power unit 1. Install the oil ring 1, second ring 2, and top ring 3 onto the pistons with the “t” marks a on the piston rings facing upward. 2. Offset the piston ring end gaps as shown. Caution: do not scratch the piston or break the pis- ton rings. Note...
Page 120
Powr power unit 5-51 6d93g11 6. Set the crankshaft 8 and oil seals 9 and 0 into the cylinder block as shown. 7. Install the connecting rod cap 5 to the connecting rod, and then tighten the new connecting rod bolts a to the specified torques in two stages. Caution: do not reuse the connecting rod bol...
Page 121
6d93g11 5-52 1 2 3 4 5 6 7 8 9 caution: the oil seals must be installed before tightening the crankcase bolts. Note: • tighten the m10 bolts to 19 n·m (1.9 kgf·m, 14.0 ft·lb) first, and then tighten the m8 bolts to 14 n·m (1.4 kgf·m, 10.3 ft·lb). • make a mark d on the m10 bolts and the crankcase, a...
Page 122
Powr power unit 5-53 6d93g11 6. Connect the fuel hose and shift position switch coupler. 7. Connect the ptt motor leads and ptt switch coupler, and then install the junc- tion box cover. 8. Connect the battery leads. 9. Connect the shift cable and throttle cable, and then adjust their lengths. For a...
Page 123: Lower Unit
6d93g11 lowr 1 2 3 4 5 6 7 8 9 lower unit special service tools ..................................................................................... 6-1 lower unit ....................................................................................................... 6-4 removing the lower unit ......
Page 124
Lowr lower unit 6-1 6d93g11 special service tools 3 ring nut wrench 3 90890-06511 ring nut wrench extension 90890-06513 bearing housing puller claw l 90890-06502 stopper guide plate 90890-06501 center bolt 90890-06504 bearing separator 90890-06534 stopper guide stand 90890-06538 bearing puller assem...
Page 125
6d93g11 6-2 1 2 3 4 5 6 7 8 9 driver rod ss 90890-06604 bearing depth plate 90890-06603 driver rod ls 90890-06606 ball bearing attachment 90890-06655 bearing inner race attachment 90890-06639, 90890-06643, 90890-06661 drive shaft holder 5 90890-06519 pinion nut holder new: 90890-06715 current: 90890...
Page 126
Lowr lower unit 6-3 6d93g11 driver rod ll 90890-06605 shift rod push arm 90890-06052 pinion height gauge 90890-06710 digital caliper 90890-06704 shimming plate 90890-06701 backlash indicator 90890-06706 magnet base plate 90890-07003 dial gauge set 90890-01252 magnetic base b 90890-06844.
Page 127
6d93g11 6-4 1 2 3 4 5 6 7 8 9 lower unit 6 no. Part name q’ty remarks 1 lower unit 1 2 hose 1 3 check screw 1 4 gasket 2 not reusable 5 dowel 2 6 bolt 4 m10 × 40 mm/l-transom model 7 drain screw 1 8 grommet 1 9 bolt 1 m10 × 45 mm 10 bolt 1 m8 × 60 mm/l-transom model 11 spacer 1 12 propeller 1 13 was...
Page 128
Lowr lower unit 6-5 6d93g11 6 no. Part name q’ty remarks 18 dowel 2 x-transom model 19 extension 1 x-transom model 20 stud bolt 4 m10 × 180 mm/x-transom model 21 washer 4 x-transom model 22 spring washer 4 x-transom model 23 nut 4 x-transom model 24 bolt 1 m8 × 190 mm/x-transom model.
Page 129
6d93g11 6-6 1 2 3 4 5 6 7 8 9 6 no. Part name q’ty remarks 1 bolt 2 m6 × 16 mm 2 o-ring 1 not reusable 3 oil seal 1 not reusable 4 oil seal housing 1 5 o-ring 1 not reusable 6 circlip 1 7 shift rod 1 8 woodruff key 1 9 screw 2 ø4 × 12 mm 10 bolt 2 m8 × 75 mm 11 cover 1 12 bolt 2 m8 × 50 mm 13 seal 1...
Page 130
Lowr lower unit 6-7 6d93g11 6 no. Part name q’ty remarks 18 gasket 1 not reusable 19 outer plate cartridge 1 20 gasket 1 not reusable 21 oil seal housing 1 22 o-ring 1 not reusable 23 gasket 1 not reusable 24 oil seal 2 not reusable.
Page 131
6d93g11 6-8 1 2 3 4 5 6 7 8 9 removing the lower unit 1. Drain the gear oil. 2. Set the gear shift to the neutral position, and place a block of wood between the anti-cavitation plate and propeller to keep the propeller from turning, and then remove the propeller nut and propeller. Warning • do not ...
Page 132
Lowr lower unit 6-9 6d93g11 removing the water pump and shift rod 1. Remove the water pump housing and impeller. 2. Remove the woodruff key. 3. Remove the outer plate cartridge and oil seal housing. 4. Remove the shift rod assembly 1. Note: pull up the shift rod assembly a little a to dis- connect i...
Page 133
6d93g11 6-10 1 2 3 4 5 6 7 8 9 propeller shaft housing 6 no. Part name q’ty remarks 1 slider 1 2 shift plunger 1 3 cross pin 1 4 dog clutch 1 5 spring 1 6 propeller shaft 1 7 washer 1 8 reverse gear 1 9 thrust washer 1 10 ball bearing 1 not reusable 11 o-ring 1 not reusable 12 propeller shaft housin...
Page 134
Lowr lower unit 6-11 6d93g11 removing the propeller shaft housing assembly 1. Straighten the claw washer tabs a, and then remove the ring nut and claw washer. 2. Pull out the propeller shaft housing assembly. 3. Remove the propeller shaft assembly. Disassembling the propeller shaft assembly 1. Remov...
Page 135
6d93g11 6-12 1 2 3 4 5 6 7 8 9 caution: do not reuse the bearing, always replace it with a new one. 3. Remove the oil seals and needle bear- ing. Checking the propeller shaft housing 1. Clean the propeller shaft housing using a soft brush and cleaning solvent, and then check it for cracks. Replace i...
Page 136
Lowr lower unit 6-13 6d93g11 assembling the propeller shaft housing 1. Install the needle bearing into the propel- ler shaft housing to the specified depth. Note: • install the needle bearing with the manufac- ture identification mark a facing toward the oil seal (propeller side). • when using the d...
Page 137
6d93g11 6-14 1 2 3 4 5 6 7 8 9 bearing inner race attachment 0: 90890-06661 propeller shaft housing.
Page 138
Lowr lower unit 6-15 6d93g11 drive shaft and lower case 6 no. Part name q’ty remarks 1 drive shaft 1 2 taper roller bearing 1 not reusable 3 pinion shim — 4 sleeve 1 5 hose 1 6 plastic tie 1 not reusable 7 joint 1 8 nut 1 9 cooling water inlet cover 2 10 screw 1 ø5 × 40 mm 11 seal 1 12 plate 1 13 fo...
Page 139
6d93g11 6-16 1 2 3 4 5 6 7 8 9 6 no. Part name q’ty remarks 18 pinion 1 19 nut 1 20 lower case 1 drive shaft and lower case.
Page 140
Lowr lower unit 6-17 6d93g11 removing the drive shaft 1. Remove the drive shaft assembly and pinion, and then pull out the forward gear. Disassembling the drive shaft 1. Install the pinion nut 1, tighten it finger tight, and then remove the drive shaft bearing 2 using a press. Caution: • do not pres...
Page 141
6d93g11 6-18 1 2 3 4 5 6 7 8 9 note: install the claws as shown. 2. Remove the drive shaft bearing outer race, shim(s), and drive shaft sleeve. Note: install the claws as shown. 3. Remove the needle bearing. Checking the pinion and forward gear 1. Check the teeth of the pinion, and the teeth and dog...
Page 142
Lowr lower unit 6-19 6d93g11 assembling the lower case 1. Install the needle bearing into the lower case to the specified depth. Note: • install the needle bearing with the manufac- ture identification mark a facing upward. • when using the driver rod, do not strike the special tool in a manner that...
Page 143
6d93g11 6-20 1 2 3 4 5 6 7 8 9 2. Install a new needle bearing into the for- ward gear to the specified depth. Assembling the drive shaft 1. Install a new drive shaft bearing into the drive shaft using a press. Installing the drive shaft 1. Install the forward gear, then the drive shaft assembly, pi...
Page 144
Lowr lower unit 6-21 6d93g11 3. Install the propeller shaft housing assem- bly 4 into the lower case, and then install the straight key 5, claw washer 6, and ring nut 7. 4. Tighten the ring nut to the specified torque. Note: • to secure the ring nut, bend one tab a of the claw washer into a slot in ...
Page 145
6d93g11 6-22 1 2 3 4 5 6 7 8 9 3. Install a new o-ring 5 onto the oil seal housing 6. 4. Install a new gasket 7, the oil seal hous- ing 6, a new gasket 8, the outer plate cartridge 9, and a new gasket 0. 5. Install the woodruff key into the drive shaft. 6. Align the groove on the impeller a with the...
Page 146
Lowr lower unit 6-23 6d93g11 2. Align the alignment mark a on the bush- ing with the alignment mark b on the bracket. 3. Install the dowels 1 into the lower unit. 4. Install the lower unit into the upper case, and then tighten the lower case mounting bolts (nuts) to the specified torque. È x-transom...
Page 147
6d93g11 6-24 1 2 3 4 5 6 7 8 9 6. Install the propeller and propeller nut, and then tighten the nut finger tight. Place a block of wood between the anti- cavitation plate and propeller to keep the propeller from turning, and then tighten the nut to the specified torque. Warning • do not hold the pro...
Page 148
Lowr lower unit 6-25 6d93g11 shimming 6.
Page 149
6d93g11 6-26 1 2 3 4 5 6 7 8 9 shimming note: • shimming is not required when assembling the original lower case and inner parts. • shimming is required when assembling the original inner parts and a new lower case. • shimming is required when replacing the inner part(s). Selecting the pinion shims ...
Page 150
Lowr lower unit 6-27 6d93g11 4. Calculate the pinion shim thickness (t3) as shown in the examples below. Note: “p” is the deviation of the lower case dimen- sion from standard. The “p” mark a is stamped on the trim tab mounting surface of the lower case in 0.01 mm units. If the “p” mark unreadable, ...
Page 151
6d93g11 6-28 1 2 3 4 5 6 7 8 9 note: “f” is the deviation of the lower case dimen- sion from standard. The “f” mark a is stamped on the trim tab mounting surface of the lower case in 0.01 mm units. If the “f” mark unreadable, assume that “f” is zero and check the backlash when the unit is assembled....
Page 152
Lowr lower unit 6-29 6d93g11 3. Install the special service tool so that it pushes against the propeller shaft. Note: tighten the center bolt while turning the drive shaft until the drive shaft can no longer be turned. 4. Install the backlash indicator onto the drive shaft (20 mm [0.79 in] in diamet...
Page 153: — Memo —
6d93g11 6-30 1 2 3 4 5 6 7 8 9 — memo — backlash.
Page 154: Bracket Unit
Brkt 6d93g11 bracket unit special service tools ..................................................................................... 7-1 shift rod .......................................................................................................... 7-2 bottom cowling .............................
Page 155
6d93g11 1 2 3 4 5 6 7 8 9 tilt cylinder and trim cylinder ..................................................................... 7-35 disassembling the trim cylinder............................................................... 7-38 disassembling the tilt cylinder ......................................
Page 156
Brkt bracket unit 7-1 6d93g11 special service tools 7 bearing outer race attachment 90890-06625, 90890-06628 driver rod ll 90890-06605 driver rod l3 90890-06652 driver rod ls 90890-06606 ball bearing attachment 90890-06638 needle bearing attachment 90890-06612, 90890-06653 cylinder-end screw wrench ...
Page 157
6d93g11 7-2 1 2 3 4 5 6 7 8 9 shift rod 7 no. Part name q’ty remarks 1 bolt 1 2 spring 1 3 ball 1 4 washer 1 5 bushing 2 6 bolt 2 m6 × 25 mm 7 bracket 1 8 shift rod 1 9 screw 2 ø4 × 16 mm 10 plate 1 11 shift position switch 1 12 bolt 2 m6 × 50 mm 13 bushing 1 14 bracket 1 15 cotter pin 1 not reusabl...
Page 158
Brkt bracket unit 7-3 6d93g11 bottom cowling 7 no. Part name q’ty remarks 1 bolt 2 m6 × 16 mm 2 washer 2 3 lever 2 4 washer 2 5 bushing 4 6 bolt 4 m6 × 30 mm 7 base 2 8 lever 2 9 spring 2 10 bolt 2 m6 × 20 mm 11 hook 2 12 cooling water outlet 1 13 canister outlet 1 14 bolt 4 m8 × 35 mm 15 grommet 4 ...
Page 159
6d93g11 7-4 1 2 3 4 5 6 7 8 9 7 no. Part name q’ty remarks 18 bottom cowling 1 19 grommet 4 20 collar 4 21 bolt 1 m6 × 20 mm 22 holder 1 23 bolt 2 m6 × 20 mm 24 bracket 1 25 bolt 3 m6 × 25 mm 26 plate 3 27 power trim and tilt switch 1 28 grommet 1 29 grommet 3 30 bolt 1 m6 × 20 mm 31 plate 1 32 grom...
Page 160
Brkt bracket unit 7-5 6d93g11 7 no. Part name q’ty remarks 35 adapter 1 36 gasket 1 37 joint 1 38 joint 1 39 plastic tie 1 not reusable 40 hose 1 41 bolt 1 m6 × 20 mm 42 bolt 2 m6 × 25 mm 43 retaining plate 1 44 bolt 1 m6 × 20 mm 45 plate 1 46 grommet 1 47 rubber seal 1 48 clamp 1 s6d87020 1 21 22 2...
Page 161
6d93g11 7-6 1 2 3 4 5 6 7 8 9 upper case 7 no. Part name q’ty remarks 1 oil seal 1 not reusable 2 bolt 6 m6 × 45 mm 3 oil pump assembly 1 4 dowel 2 5 o-ring 2 not reusable 6 upper case assembly 1 7 cover 2 8 bolt 4 m10 × 40 mm 9 grommet 1 10 grommet 1 11 nut 2 12 nut 2 13 washer 2 14 washer 2 15 gre...
Page 162
Brkt bracket unit 7-7 6d93g11 7 no. Part name q’ty remarks 1 oil seal 1 not reusable 2 screw 6 ø6 × 10 mm 3 gasket 1 not reusable 4 o-ring 1 not reusable 5 shaft 1 6 o-ring 1 not reusable 7 oil seal 1 not reusable 8 oil seal 2 not reusable 9 o-ring 1 not reusable 10 oil seal housing 1 11 screw 4 ø6 ...
Page 163
6d93g11 7-8 1 2 3 4 5 6 7 8 9 7 no. Part name q’ty remarks 1 bolt 3 m8 × 45 mm 2 upper mount 1 3 plate 1 4 washer 2 5 washer 2 6 bolt 2 m12 × 194 mm 7 bolt 4 m8 × 40 mm 8 muffler assembly 1 9 gasket 1 10 drain bolt 1 m14 × 12 mm 11 damper 1 12 rubber seal 1 13 gasket 1 not reusable 14 gasket 1 not r...
Page 164
Brkt bracket unit 7-9 6d93g11 7 no. Part name q’ty remarks 18 dowel 2 19 upper case 1 20 drive shaft bushing 1 21 circlip 1 22 lower mount 2 23 washer 2 24 washer 2 25 washer 2 26 bolt 2 m12 × 200 mm s6d97020 a a 1 2 6 5 26 25 24 22 23 7 13 12 8 15 17 20 21 19 16 18 18 14 a lt 572 lt 572 lt 572 lt 5...
Page 165
6d93g11 7-10 1 2 3 4 5 6 7 8 9 7 no. Part name q’ty remarks 1 exhaust guide 1 2 gasket 1 not reusable 3 dowel 2 4 gasket 1 not reusable 5 oil strainer 1 6 collar 3 7 bolt 3 m6 × 25 mm 8 bolt 12 m6 × 25 mm 9 oil pan 1 10 gasket 1 not reusable 11 exhaust manifold 1 12 bolt 4 m6 × 70 mm 13 gasket 1 not...
Page 166
Brkt bracket unit 7-11 6d93g11 7 no. Part name q’ty remarks 18 muffler 1 19 bolt 1 m6 × 50 mm 20 grommet 1 21 spacer 1 22 pipe 1 s6d87060 17 19 18 20 21 22 14 15 12 8 3 3 9 7 4 13 10 11 1 2 5 6 16 16 a a lt 572 lt 572 lt 572 lt 572 lt 572 lt 572 lt 572 lt 572 a a t r . . 11 n · m (1.1 kgf · m, 8.1 f...
Page 167
6d93g11 7-12 1 2 3 4 5 6 7 8 9 removing the upper case 1. Place a drain pan under the drain hole, and then remove the drain bolt 1 and let the oil drain completely. 2. Remove the oil pump assembly and mount covers. 3. Disconnect the ground lead and speed- ometer hose. 4. Remove the upper and lower m...
Page 168
Brkt bracket unit 7-13 6d93g11 3. Install new oil seals into the oil seal hous- ing. 4. Install new o-rings and the gasket, and then tighten the screws to the specified torque. Disassembling the upper case 1. Remove the muffler assembly from the upper case. 2. Remove the circlip, then the drive shaf...
Page 169
6d93g11 7-14 1 2 3 4 5 6 7 8 9 checking the oil strainer 1. Check the oil strainer for dirt or residue. Clean if necessary. Assembling the oil pan 1. Install a new gasket onto the exhaust guide 1. 2. Install a new gasket and the oil strainer 2 onto the exhaust guide, and then tighten the bolts to th...
Page 170
Brkt bracket unit 7-15 6d93g11 assembling the upper case 1. Install the drive shaft bushing into the upper case, and then install the circlip. 2. Install the muffler assembly 3 by insert- ing the tip of the water pipe 4 into the joint hole a of the upper case. 3. Install the muffler assembly bolts 5...
Page 171
6d93g11 7-16 1 2 3 4 5 6 7 8 9 7. Install the oil pump assembly 9 and the bolts 0, and then tighten them to the specified torque. Note: when installing the oil pump assembly onto the upper case, pour a small amount of engine oil into the oil inlet or oil outlet of the oil pump assembly. T r . . Uppe...
Page 172
Brkt bracket unit 7-17 6d93g11 steering arm 7 no. Part name q’ty remarks 1 nut 2 2 steering hook 1 3 stud bolt 2 m10 × 40 mm 4 steering arm 1 5 washer 1 6 bushing 1 7 o-ring 2 not reusable 8 bushing 2 9 washer 1 10 steering yoke 1 11 damper 1 12 circlip 1 a a a 11 7 6 5 4 8 12 10 9 7 8 1 2 3 t r . ....
Page 173
6d93g11 7-18 1 2 3 4 5 6 7 8 9 removing the steering arm 1. Remove the circlip 1. 2. Remove the steering yoke 2 by striking it with a plastic hammer. 3. Remove the steering arm from the swivel bracket by pulling the arm off the bracket. Installing the steering arm 1. Install the washer 1, bushing 2,...
Page 174
Brkt bracket unit 7-19 6d93g11 clamp brackets and swivel bracket 7 no. Part name q’ty remarks 1 swivel bracket 1 2 clamp bracket 1 3 clamp bracket 1 4 self-locking nut 1 5 screw 1 ø6 × 12 mm 6 washer 2 7 bushing 2 8 trim sensor cam 1 9 screw 1 ø6 × 25 mm 10 plate 1 11 anode 1 12 bolt 1 m6 × 14 mm 13...
Page 175
6d93g11 7-20 1 2 3 4 5 6 7 8 9 7 no. Part name q’ty remarks 1 swivel bracket 1 2 tilt stop lever 1 3 bushing 4 4 distance collar 2 a: 30.3–30.6 mm (1.19–1.20 in) 5 pin 2 6 hook 1 7 bolt 1 m6 × 10 mm 8 spring 1 9 tilt stop lever 1 10 trim sensor 1 11 screw 2 ø6 × 15 mm 12 bolt 1 m6 × 10 mm 13 clamp 2...
Page 176
Brkt bracket unit 7-21 6d93g11 removing the clamp brackets 1. Remove the power trim and tilt unit. For removal procedure, see “removing the power trim and tilt unit.” 2. Remove the anode 1. 3. Disconnect the ground lead 2. 4. Remove the trim sensor cam screw 3. 5. Loosen the self-locking nut 4 and t...
Page 177
6d93g11 7-22 1 2 3 4 5 6 7 8 9 4. Fully tilt the outboard motor up, and then support it with the tilt stop lever 3. Warning 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 power trim and tilt unit should...
Page 178
Brkt bracket unit 7-23 6d93g11 power trim and tilt unit 7 no. Part name q’ty remarks 1 power trim and tilt unit 1 2 circlip 1 3 shaft 1 4 circlip 2 5 shaft 1 6 bushing 2 7 bushing 1 8 ground lead 1 9 bolt 1 m6 × 10 mm 10 bushing 2 11 bushing 2 12 collar 1 13 holder 2 14 bolt 2 m6 × 10 mm s6d87270 2 ...
Page 179
6d93g11 7-24 1 2 3 4 5 6 7 8 9 removing the power trim and tilt unit 1. Fully tilt the outboard motor up, and then support it with the tilt stop lever 1. Warning after tilting up the outboard motor, be sure to support it with the tilt stop lever. Otherwise, the outboard motor could sud- denly lower ...
Page 180
Brkt bracket unit 7-25 6d93g11 power trim and tilt motor 7 no. Part name q’ty remarks 1 power trim and tilt motor 1 2 bolt 4 m6 × 20 mm 3 o-ring 1 not reusable 4 joint 1 5 o-ring 1 not reusable 6 reservoir cap 1 7 screw 3 ø5 × 25 mm 8 stator 1 9 o-ring 1 not reusable 10 armature 1 11 washer 1 12 bus...
Page 181
6d93g11 7-26 1 2 3 4 5 6 7 8 9 7 no. Part name q’ty remarks 18 circuit breaker 1 19 spring 2 20 ptt motor base 1 21 oil seal 1 not reusable 22 plate 1 23 screw 2 ø4 × 10 mm 1 2 3 4 5 6 t r . . 4 n · m (0.4 kgf · m, 3.0 ft · ib) t r . . 7 n · m (0.7 kgf · m, 5.2 ft · ib) a a a a a a 9 10 11 12 8 7 14...
Page 182
Brkt bracket unit 7-27 6d93g11 disassembling the power trim and tilt motor 1. Remove the power trim and tilt motor, o- ring, and joint from the power trim and tilt unit. Caution: • make sure that the tilt ram is fully extended when removing the power trim and tilt motor, otherwise fluid can spurt ou...
Page 183
6d93g11 7-28 1 2 3 4 5 6 7 8 9 3. Measure the commutator undercut a. Replace the armature if below specifica- tion. 4. Check the armature for continuity. Replace if out of specifications. 5. Check the circuit breaker for continuity. Replace if there is no continuity. 6. Measure the brush length. Rep...
Page 184
Brkt bracket unit 7-29 6d93g11 assembling the power trim and tilt motor 1. Install a new oil seal 1 and the bushing 2 into the motor base 3 as shown. 2. Attach the circuit breaker 4 onto the brush 5 together with the brush holder 6 and connect the wire lead 7. 3. Install the springs 8 into the motor...
Page 185
6d93g11 7-30 1 2 3 4 5 6 7 8 9 gear pump 7 no. Part name q’ty remarks 1 gear pump assembly 1 2 spacer 2 3 pin 1 4 lever 1 5 bolt 1 m3 × 16 mm 6 bolt 1 m3 × 35 mm 7 spring 2 8 shuttle piston 1 9 backup ring 1 10 down-relief valve seat 1 11 washer 1 12 spring 1 13 pin 1 14 cap 1 15 bolt 2 m5 × 30 mm 1...
Page 186
Brkt bracket unit 7-31 6d93g11 7 no. Part name q’ty remarks 18 holder 1 19 spring 1 20 washer 1 21 up-relief valve seat 1 22 bolt 2 m5 × 25 mm 23 o-ring 1 not reusable 24 shuttle piston 1 25 bolt 2 m5 × 45 mm 26 bolt 2 m5 × 50 mm 27 filter 1 28 plate 1 29 o-ring 2 not reusable 30 filter 2 31 o-ring ...
Page 187
6d93g11 7-32 1 2 3 4 5 6 7 8 9 7 no. Part name q’ty remarks 1 manual release spring 1 2 ball 2 3 bracket 1 4 bolt 1 m3 × 5 mm 5 bolt 2 m5 × 6 mm 6 washer 2 7 o-ring 2 not reusable 8 adapter 2 9 spring 2 10 ball 2 11 gear 2 12 drive shaft 1 13 pin 2 14 driven shaft 1 15 ball 2 16 pin 2 s6d87550 t r ....
Page 188
Brkt bracket unit 7-33 6d93g11 disassembling the gear pump 1. Remove the manual valve, then the gear pump and filters. 2. Remove the relief valve seat caps, then the up-relief valve seat 1 and down- relief valve seat 2. 3. Remove the lever 3, then the shuttle pistons 4. 4. Remove the gear pump brack...
Page 189
6d93g11 7-34 1 2 3 4 5 6 7 8 9 4. Install the adapters 6 into the gear pump cover. 5. Install the balls 7 into the gear pump cover with the manual release spring 8. 6. Install the gear pump bracket 9 by installing the bolts, then tightening them to the specified torques. 7. Install the shuttle pisto...
Page 190
Brkt bracket unit 7-35 6d93g11 tilt cylinder and trim cylinder 7 no. Part name q’ty remarks 1 power trim and tilt assembly 1 2 dust seal 1 not reusable 3 backup ring 1 4 o-ring 1 not reusable 5 trim cylinder end screw 1 6 o-ring 1 not reusable 7 tilt cylinder end screw assembly 1 8 backup ring 1 9 o...
Page 191
6d93g11 7-36 1 2 3 4 5 6 7 8 9 7 no. Part name q’ty remarks 18 valve 5 19 spring 5 20 washer 1 21 tilt cylinder 1 22 ball 6 23 o-ring 1 not reusable 24 backup ring 1 25 tilt piston 1 26 ball 1 27 ball 2 28 valve 2 29 spring 2 30 pin 2 31 dowel 2 32 washer 1 33 tilt piston assembly 1 34 o-ring 1 not ...
Page 192
Brkt bracket unit 7-37 6d93g11 7 no. Part name q’ty remarks 35 free piston 1 36 circlip 1 37 cylinder base 1 38 spring 2 39 washer 1 40 circlip 1 41 trim cylinder 1 s6d87390 10 11 12 13 14 15 16 7 2 17 34 35 36 37 38 39 40 41 38 1 18 19 20 21 22 33 23 24 26 27 28 29 30 25 32 31 31 3 4 5 6 8 9 t r . ...
Page 193
6d93g11 7-38 1 2 3 4 5 6 7 8 9 disassembling the trim cylinder 1. Hold the power trim and tilt unit 1 in a vise using aluminum plates a on both sides. 2. Loosen the trim cylinder end screw 2, and then remove it. Warning make sure that the ram is fully extended before removing the end screw. 3. Drain...
Page 194
Brkt bracket unit 7-39 6d93g11 4. Remove the bolt 3, then the tilt piston 4. Checking the tilt cylinder and trim cylinder 1. Check the power trim and tilt unit for cracks or corrosion. Replace if neces- sary. 2. Check the inner walls of the trim cylinder and tilt cylinder for scratches. Replace if n...
Page 195
6d93g11 7-40 1 2 3 4 5 6 7 8 9 6. Install the new o-rings 9 and 0, and backup ring a onto the trim piston b. 7. Install the balls c, valves d, and springs e into the trim piston, and then install the washer f and trim piston to the tilt cylin- der g. 8. Install the filter h and washer i to the trim ...
Page 196
Brkt bracket unit 7-41 6d93g11 15. Install the tilt cylinder end screw 8, and then tighten it to the specified torque. Caution: do not damage the check valve b when tightening the end screw. 16. Install the free piston u into the tilt cylin- der g by installing the circlip v. 17. Install the cylinde...
Page 197
6d93g11 7-42 1 2 3 4 5 6 7 8 9 5. Install a new o-ring, the joint, and the power trim and tilt motor 5 by installing the bolts, then tightening them to the specified torque. 6. Add fluid of the recommended type to the first level at the bottom of the trim cylin- der. 7. Install the balls 6 into the ...
Page 198
Brkt bracket unit 7-43 6d93g11 10. Install the reservoir cap 9. Bleeding the power trim and tilt unit 1. Tighten the manual valve 1 by turning it clockwise. 2. Place the power trim and tilt unit in an upright position. 3. Remove the reservoir cap, and then check the fluid level in the reservoir. Not...
Page 199
6d93g11 7-44 1 2 3 4 5 6 7 8 9 note: • repeat this procedure so that the ram goes up and down four or five times (be sure to wait a few seconds before switching the leads). • if the ram does not move up and down eas- ily, push and pull on the ram to assist oper- ation. 8. Check the fluid level when ...
Page 200
Brkt bracket unit 7-45 6d93g11 2. Fully tilt the outboard motor up, and then release it to let it lower by its own weight four to five times. 3. Tighten the manual valve by turning it clockwise. 4. Let the fluid settle for 5 minutes. 5. Push and hold the power trim and tilt switch in the up position...
Page 201
6d93g11 7-46 1 2 3 4 5 6 7 8 9 2. Connect the digital circuit tester between power trim and tilt relay terminals 2 and 3. 3. Connect the light green (lg) lead to the positive battery terminal and the black (b) lead to the negative battery terminal as shown. 4. Check for continuity between terminals ...
Page 202
Brkt bracket unit 7-47 6d93g11 checking the trim sensor 1. Measure the trim sensor resistance. Replace if out of specification. Note: turn the lever 1 and measure the resistance as it gradually changes. Trim sensor resistance: pink (p) – black (b) 238.8–378.8 Ω at 20 °c (68 °f) a 9–11 Ω at 20 °c (68...
Page 203: Electrical Systems
6d93g11 elec – + 1 2 3 4 5 6 7 8 9 electrical systems special service tools ..................................................................................... 8-1 checking the electrical components............................................................ 8-2 measuring the peak voltage ...........
Page 204
Elec electrical systems – + 8-1 6d93g11 special service tools 8 ignition tester 90890-06756 digital circuit tester 90890-03174 peak voltage adapter b 90890-03172 test harness (2 pins) 90890-06792 test harness (3 pins) 90890-06791 test harness (6 pins) 90890-06848 vacuum/pressure pump gauge set 90890...
Page 205
6d93g11 8-2 1 2 3 4 5 6 7 8 9 checking the electrical components 8 measuring the peak voltage note: before troubleshooting the peak voltage, check that all electrical connections are tight and free from corrosion, and that the battery is fully charged to 12 v. The condition of the ignition system ca...
Page 206
Elec electrical systems – + 8-3 6d93g11 electrical components 8 port view 1 idle speed control 2 sensor assembly (intake air temperature and intake air pressure) 3 pulser coil 4 oil pressure switch 5 fuel injector 6 electric fuel pump 7 throttle position sensor s6d88010 1 7 2 6 5 3 4 5.
Page 207
6d93g11 8-4 1 2 3 4 5 6 7 8 9 starboard view 1 ignition coil 2 cooling water temperature sensor 3 starter motor 4 junction box 5 spark plug s6d88020 1 5 2 3 4 electrical components.
Page 208
Elec electrical systems – + 8-5 6d93g11 bow view 1 ecm 2 sensor assembly (intake air temperature and intake air pressure) 3 idle speed control 4 throttle position sensor 5 rectifier regulator 6 power trim and tilt relay 7 starter relay 8 main and fuel pump relay 9 fuse (20a) (ecm, ignition coil, ele...
Page 209
6d93g11 8-6 1 2 3 4 5 6 7 8 9 top view 1 fuel injection 2 shift position switch 3 sensor assembly (intake air temperature and intake air pressure) 4 idle speed control 5 stator coil 6 power trim and tilt switch 7 starter motor s6d88040 1 3 4 2 5 6 7 electrical components.
Page 210
Elec electrical systems – + 8-7 6d93g11 ignition and ignition control system 8 checking the ignition spark 1. Remove the spark plug wire cover. 2. Disconnect the spark plug caps from the spark plugs. 3. Connect a spark plug cap to the special service tool. 4. Crank the engine and observe the spark t...
Page 211
6d93g11 8-8 1 2 3 4 5 6 7 8 9 checking the ecm 1. Disconnect an ignition coil coupler. 2. Connect the test harness (2 pins) to the ignition coil. 3. Measure the ecm output peak voltage. If below specification, measure the pulser coil output peak voltage. Replace the ecm if the output peak voltage of...
Page 212
Elec electrical systems – + 8-9 6d93g11 2. Connect a computer to the outboard motor and use the yamaha diagnostic system to display the intake air tempera- ture. 3. If the ambient temperature and the dis- played intake air temperature differ by more than ± 5 °c (± 9 °f), replace the sensor assembly....
Page 213
6d93g11 8-10 1 2 3 4 5 6 7 8 9 checking the main and fuel pump relay (main control) 1. Remove the main and fuel pump relay 1. 2. Connect the digital circuit tester leads to the relay terminals 2 and 3. 3. Connect the positive battery terminal to the relay terminal 4. 4. Connect the negative battery ...
Page 214
Elec electrical systems – + 8-11 6d93g11 2. Listen for the operating sound of the electric fuel pump 1. Check the fuel sys- tem if there is no sound. Note: after the engine start switch is turned to on, the electric fuel pump will operate for 3 sec- onds. Checking the main and fuel pump relay (fuel ...
Page 215
6d93g11 8-12 1 2 3 4 5 6 7 8 9 s60v8265 br b fuel control system / starting system.
Page 216
Elec electrical systems – + 8-13 6d93g11 starter motor 8 no. Part name q’ty remarks 1 clip 1 2 pinion stopper 1 3 starter motor pinion 1 4 spring 1 5 bolt 2 m6 × 35 mm 6 housing 1 7 bearing 1 8 clutch assembly 1 9 e-clip 1 not reusable 10 washer 1 11 bracket 1 12 pinion shaft 1 13 planetary gear 3 1...
Page 217
6d93g11 8-14 1 2 3 4 5 6 7 8 9 8 no. Part name q’ty remarks 18 brush assembly 1 19 brush spring 4 20 brush holder 1 21 plate 1 22 washer 1 23 bracket 1 24 screw 2 ø4 × 15 mm 25 bolt 2 m6 × 120 mm 26 rubber seal 1 27 shift lever 1 28 spring 1 29 magnet switch assembly 1 30 washer 1 31 nut 1 s63p8050 ...
Page 218
Elec electrical systems – + 8-15 6d93g11 disassembling the starter motor 1. Slide the pinion stopper 1 down as shown, and then remove the clip 2. Note: remove the clip with a thin screwdriver. 2. Remove the bolts, and then disassemble the starter motor. Checking the starter motor pinion 1. Check the...
Page 219
6d93g11 8-16 1 2 3 4 5 6 7 8 9 checking the brushes 1. Measure the brush length. Replace the brush assembly if below specification. 2. Check the brush holder assembly for continuity. Replace if out of specification. Checking the magnet switch 1. Connect the tester leads between the magnet switch ter...
Page 220
Elec electrical systems – + 8-17 6d93g11 3. Measure the stator coil output peak volt- age. Replace the stator coil if below specification. Checking the rectifier regulator 1. Disconnect the stator coil coupler. 2. Connect the test harness (6 pins) between the rectifier regulator and sta- tor coil co...
Page 221: Troubleshooting
6d93g11 trbl shtg 1 2 3 4 5 6 7 8 9 troubleshooting special service tools ..................................................................................... 9-1 yamaha diagnostic system .......................................................................... 9-2 introduction.......................
Page 222
Trbl shtg troubleshooting 9-1 6d93g11 special service tools 9 yamaha diagnostic system 60v-85300-02 yamaha diagnostic system 60v-ws853-02 diagnostic flash indicator b 90890-06865 yamaha diagnostic system installation manual.
Page 223
6d93g11 9-2 1 2 3 4 5 6 7 8 9 yamaha diagnostic system 9 introduction features the newly developed yamaha diagnostic system provides quicker detection and analysis of engine malfunctions for quicker troubleshooting procedures than traditional methods. By connecting your computer to the ecm (electron...
Page 224
Trbl shtg troubleshooting 9-3 6d93g11 hardware requirements make sure that your computer meets the following requirements before using this software. Computer: ibm-compatible computer operating system: microsoft (windows 95,) windows 98, windows me, windows 2000, or windows xp (english version) cpu:...
Page 225
6d93g11 9-4 1 2 3 4 5 6 7 8 9 connecting the communication cable to the outboard motor bow view s6d89010 3-pin communication coupler yamaha diagnostic system.
Page 226
Trbl shtg troubleshooting 9-5 6d93g11 note: • check that all electrical connections are tight and free from corrosion, and that the battery is fully charged to 12 v. • to diagnose a mechanical malfunction, use the troubleshooting charts pertaining to the trouble located in this chapter. Also, when c...
Page 227
6d93g11 9-6 1 2 3 4 5 6 7 8 9 check the wiring harnesses for continuity. Replace the starter relay. Listen for the operation sound of the starter relay. Check the power unit. Can the operation sound be heard? Yes yes no is there continuity? Replace the fuse. Yes no disassemble and check the starter ...
Page 228
Trbl shtg troubleshooting 9-7 6d93g11 symptom: engine cranks, but will not start (engine stop lanyard switch is operating nor- mally). • check the ignition system. • check the fuel system. • check the compression pressure of the power unit. Check the condition of the spark plugs. Warning • do not to...
Page 229
6d93g11 9-8 1 2 3 4 5 6 7 8 9 does the engine start? Wet spark plugs? Within specification? Within specification? Failure in starting operation failure in starting operation check the fuel system. Check the condition of the spark plugs again. Check the compression pres- sure of the combustion chambe...
Page 230
Trbl shtg troubleshooting 9-9 6d93g11 symptom: engine can be started, but does not remain on. • check the fuel system. • check the ignition system. • check the compression pressure of the power unit. Fuel system is the vent screw open? Water or residue? Kinks or fuel leakage? Check for water or resi...
Page 231
6d93g11 9-10 1 2 3 4 5 6 7 8 9 ignition system compression pressure check the spark plug wire resis- tance and check the spark plug cap for corrosion or rust. (8-7) check the ignition spark using the ignition tester. (8-7) check the ignition coil resis- tance. (8-7) check the pulser coil output peak...
Page 232
Trbl shtg troubleshooting 9-11 6d93g11 symptom: engine does not accelerate when the throttle is opened quickly. The engine turns off when the throttle is opened quickly. Acceleration is tardy and the engine is likely to stop at any moment. • check the engine using the diagnostic flash indicator or t...
Page 233
6d93g11 9-12 1 2 3 4 5 6 7 8 9 lubrication system check the oil pump for debris or oil leaks. Check the engine oil level. Check the oil pressure. (5-3) check the oil pressure switch. (8-9) clean or replace the defective parts. At specified level? Within specification? Check the oil passage. Yes yes ...
Page 234
Trbl shtg troubleshooting 9-13 6d93g11 bracket unit 9 symptom: power trim and tilt unit does not operate. Listen for the operation sound of the power trim and tilt relay. Listen for the operation sound of the power trim and tilt motor. Check that the manual valve is closed. Disassemble and check the...
Page 235
6d93g11 9-14 1 2 3 4 5 6 7 8 9 check the fluid passages for clogs or debris. Clean the passages. Check the internal parts (valves, pistons, gears, etc.). Clean or replace the filters. No yes no yes add fluid to the correct level. At specified level? Yes no disassemble the power trim and tilt unit, a...
Page 236
Trbl shtg troubleshooting 9-15 6d93g11 symptom: power trim and tilt unit does not hold the outboard motor up. Check that the manual valve is closed. Check the power trim and tilt fluid level. Close the valve. Add fluid to the correct level. At specified level? Is it closed? Yes yes no no check the f...
Page 237
6d93g11 9-16 1 2 3 4 5 6 7 8 9 symptom: shift mechanism of the forward gear and reverse gear does not operate properly. Check the operation of the shift rod. Check the shift rod connection between the lower case and upper case and check the shift rod for bends and wear. Replace the shift rod. Check ...
Page 238
Trbl shtg troubleshooting 9-17 6d93g11 electrical systems 9 symptom: battery becomes weaker quickly. • check the charging system. Measure the rectifier regulator output peak voltage. Replace the stator coil. Within specification? Within specification? Replace the rectifier regulator. Yes yes no no m...
Page 239
6d93g11 9-18 1 2 3 4 5 6 7 8 9 self-diagnosis 9 diagnosing the electronic control system 1. Connect the special service tool to the outboard motor as shown. Note: when performing this diagnosis, all of the electrical wires must be properly connected. 2. Start the engine and let it idle. 3. Check the...
Page 240
Trbl shtg troubleshooting 9-19 6d93g11 4. If a flash pattern listed in the diagnostic code chart is displayed, check the mal- functioning part according to the flash pattern. Note: when more than one problem is detected, the light of the special service tool flashes in the pattern of the lowest numb...
Page 241
6d93g11 i-1 1 2 3 4 5 6 7 8 9 index a. Adjusting the float .....................................4-17 adjusting the throttle link and throttle cable .............................................3-8 adjusting the trim sensor ..........................7-21 after test run ..................................
Page 242
Index i-2 6d93g11 checking the piston clearance..................5-42 checking the piston diameter ...................5-41 checking the piston ring grooves..............5-43 checking the piston ring side clearance ...5-43 checking the piston rings..........................5-42 checking the power tri...
Page 243
6d93g11 i-3 1 2 3 4 5 6 7 8 9 index h. Hose routing................................................4-2 how to use this manual...............................1-1 i. Identification................................................1-5 ignition and ignition control system.............8-7 installing the cla...
Page 244
Index i-4 6d93g11 u. Upper case..................................................7-6 v. Vapor separator ........................................4-10 ventilation ...................................................1-3 y. Yamaha diagnostic system ........................9-2.
Page 245: — Memo —
6d93g11 i-5 1 2 3 4 5 6 7 8 9 index — memo —.
Page 246
Wiring diagram f80bet, f100det 1 ignition coil 2 spark plug 3 power trim and tilt switch (tiller handle) (optional) 4 power trim and tilt switch (bottom cowling) 5 battery 6 cooling water temperature sensor 7 starter motor 8 fuse (30 a) 9 fuse (20 a) 0 neutral switch (optional) a starter relay b pow...
Page 248
Yamaha motor co., ltd. Printed in the netherlands nov. 2004 – 1.2 × 1 cr (e).
Page 249
F80bet, f100det 1 2 4 3 sb r lg up free down 2 3 1 4 3 2 1 1 2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 6 7 5 1 2 3 8 4 1 2 3 1 2 3 4 5 6 7 8 9 10 11 12...