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Yamaha F150A Service Manual

Other manuals for F150A: Owner's Manual, Service Manual
Manual is about: Outboard Engine

Summary of F150A

  • Page 1

    F150a fl150a service manual 63p-28197-3f-11 290503.

  • Page 2: Notice

    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 4: Gen

    Gen info 63p3f11 general information how to use this manual ................................................................................. 1-1 manual format............................................................................................ 1-1 symbols........................................

  • Page 5

    63p3f11 1 2 3 4 5 6 7 8 9 predelivery checks ...................................................................................... 1-22 checking the fuel system ........................................................................ 1-22 checking the gear oil level ...................................

  • Page 6: Gen

    Gen info general information 1-1 63p3f11 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: Gen

    63p3f11 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

    Gen info general information 1-3 63p3f11 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

    63p3f11 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

    Gen info general information 1-5 63p3f11 identification 1 applicable models this manual covers the following models. 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 applicable...

  • Page 11: Features and Benefits

    63p3f11 1-6 1 2 3 4 5 6 7 8 9 features and benefits 1 crankshaft and cylinder the center of the crankshaft is offset 10 mm (0.39 in) from the center of the cylinder to make more space to incorporate the throttle body assembly. This design produces good engine balance and allows a compact design. Exh...

  • Page 12: Gen

    Gen info general information 1-7 63p3f11 balancer a two-piece balancer is used in the crankcase to reduce the secondary forces of inertia produced by reciprocating pistons. The balancer shaft 1 is driven by the gear on the crankshaft. The balancer shaft 2 is driven by the gear on the balancer shaft ...

  • Page 13

    63p3f11 1-8 1 2 3 4 5 6 7 8 9 connecting rod a direction mark for installing the connecting rod to the crankshaft in the proper direction is on the connecting rod cap. The direction mark should face the flywheel. The connecting rod and connecting rod cap are manufactured as a single piece. Then, the...

  • Page 14: Gen

    Gen info general information 1-9 63p3f11 intake system multi-point, group fuel injection with four separate throttle valves is adopted for the intake system. Intake air volume is calculated according to engine speed, intake air pressure, and throttle position, and then the fuel injection volume is d...

  • Page 15

    63p3f11 1-10 1 2 3 4 5 6 7 8 9 the shape of the fuel injectors is the same for the f115, f150, f200 and f225. Therefore, each fuel injector is identified by color because the specifications of each fuel injector are different. È model É injector color Ê first three digits Ë orange Ì yellow Í ivory t...

  • Page 16: Gen

    Gen info general information 1-11 63p3f11 64e type power trim and tilt unit the 64e type clamp bracket and power trim and tilt unit used for current v4 and v6 outboard motors have been adopted. This allows easier interchanging of yamaha outboards with the same classification because the mounting dim...

  • Page 17

    63p3f11 1-12 1 2 3 4 5 6 7 8 9 cooling system the cooling water flow diagram is as follows. To cool the propeller damper, the cooling system is designed so that fresh cooling water is taken in from the front of the trim tab and supplied to the exhaust passage of the lower case to cool the exhaust ga...

  • Page 18: Gen

    Gen info general information 1-13 63p3f11 lubrication system the lubrication oil flow diagram is as follows. There is a small hole in the relief valve to allow oil to drain from the oil filter bracket so that it does not remain in the oil filter. This prevents oil from spilling out when replacing th...

  • Page 19

    63p3f11 1-14 1 2 3 4 5 6 7 8 9 a dual oil drain system is adopted. An oil drain bolt is located on the bottom of the oil pan. A long dipstick guide, which reaches the bottom of the oil pan, can also be used to pump out the oil completely with an oil-extracting tool. 1 drain bolt 2 dipstick guide s63...

  • Page 20: Gen

    Gen info general information 1-15 63p3f11 fuel system a fuel pressure regulator is incorporated onto the outlet of the electric fuel pump to obtain a compact design and simple fuel delivery. Fuel discharged from the pressure regulator returns to the vapor separator after being cooled in the fuel coo...

  • Page 21

    63p3f11 1-16 1 2 3 4 5 6 7 8 9 rectifier regulator a water-cooled rectifier regulator is incorporated onto the exhaust outer cover. This allows for a compact engine design and produces a large electric current output for charging the battery under low engine speed. È charging current (a) É engine sp...

  • Page 22: Gen

    Gen info general information 1-17 63p3f11 technical tips 1 electronic control system the electronic control system consists of the sensors and the ecm (electronic control module). Under various conditions, the ecm provides the best suitable engine operation. 1 intake air pressure sensor 2 engine tem...

  • Page 23

    63p3f11 1-18 1 2 3 4 5 6 7 8 9 fail-safe control if the electrical components malfunction, the ecm controls the ignition and fuel injection as shown in the table. During fail-safe control, the engine idle speed increases to 900 r/min except if the neutral switch is off when the outboard motor is sta...

  • Page 24: Gen

    Gen info general information 1-19 63p3f11 warning control this outboard motor is equipped with warning control functions to avoid serious engine damage. The engine speed is limited to approximately 2,000 r/min if the engine overheats, if the oil pressure is low, or if a dual engine system (des) is o...

  • Page 25

    63p3f11 1-20 1 2 3 4 5 6 7 8 9 shift cut control this outboard motor is equipped with a shift cut control system for easier shifting. This device misfires and retards the ignition of some cylinders to fluctuate the engine speed instantly when the engine is running from 400 to 2,000 r/min. This allow...

  • Page 26: Gen

    Gen info general information 1-21 63p3f11 propeller selection 1 the performance of a boat and outboard motor will be critically affected by the size and type of propeller you choose. Propellers greatly affect boat speed, acceleration, engine life, fuel economy, and even boating and steering capabili...

  • Page 27: Predelivery Checks

    63p3f11 1-22 1 2 3 4 5 6 7 8 9 predelivery checks 1 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 are securely connected and that the fuel tank is full with fuel. Caution: this i...

  • Page 28: Gen

    Gen info general information 1-23 63p3f11 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 abnorma...

  • Page 29

    63p3f11 1-24 1 2 3 4 5 6 7 8 9 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 or hoses when the outboard motor is steered. Checking the gear shift and throttle operatio...

  • Page 30: Gen

    Gen info general information 1-25 63p3f11 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 then check that the gear shift operates smoothly. 2. Check the engine idle speed after the engine has been wa...

  • Page 31: Spec

    63p3f11 spec 1 2 3 4 5 6 7 8 9 specifications general specifications................................................................................... 2-1 maintenance specification ............................................................................ 2-3 power unit..............................

  • Page 32: Spec

    Spec specifications 2-1 63p3f11 general specifications 2 item unit model f150aet fl150aet dimension overall length mm (in) 822 (32.4) overall width mm (in) 511 (20.1) overall height (l) mm (in) 1,714 (67.5) (x) mm (in) 1,842 (72.5) boat transom height (l) mm (in) 508 (20.0) (x) mm (in) 635 (25.0) we...

  • Page 33

    63p3f11 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) cca: cold cranking ampere en: european norm (european standard) iec: international electrotechnical commission fuel and oil fuel type regular unleaded gasoline fuel minimum rat...

  • Page 34: Spec

    Spec specifications 2-3 63p3f11 maintenance specification 2 power unit item unit model f150aet fl150aet power unit minimum compression pressure (*1) kpa (kgf/cm 2 , psi) 880 (8.8, 128) lubrication oil pressure (*2) kpa (kgf/cm 2 , psi) 450 (4.5, 65.3) at engine idle speed cylinder head warpage limit...

  • Page 35

    63p3f11 2-4 1 2 3 4 5 6 7 8 9 oil ring dimension b mm (in) 2.40–2.47 (0.0945–0.0972) dimension t mm (in) 2.30–2.70 (0.0906–0.1063) end gap mm (in) 0.15–0.60 (0.0059–0.0236) side clearance mm (in) 0.04–0.13 (0.0016–0.0051) camshafts intake (a) mm (in) 45.300–45.400 (1.7835–1.7874) exhaust (a) mm (in)...

  • Page 36: Spec

    Spec specifications 2-5 63p3f11 valve lifters valve lifter outside diameter mm (in) 32.982–32.997 (1.2985–1.2990) valve lifter-to-cylinder head clearance mm (in) 0.020–0.055 (0.0008–0.0022) valve shims valve shim thickness (in 0.020 mm increments) mm (in) 2.3–2.9 (0.09–0.12) connecting rods big-end ...

  • Page 37

    63p3f11 2-6 1 2 3 4 5 6 7 8 9 lower unit oil pump discharge at 97–103 °c (207–217 °f) with 10w-30 engine oil l (us gal, lmp gal)/min 8.0 (2.113, 1.760) at 700 r/min pressure kpa (kgf/cm 2 , psi) 132.0–162.0 (1.32–1.62, 19.1–23.5) relief valve opening pressure kpa (kgf/cm 2 , psi) 392–490 (3.92–4.90,...

  • Page 38: Spec

    Spec specifications 2-7 63p3f11 electrical item unit model f150aet fl150aet ignition and ignition control system ignition timing (cylinder #1) degree tdc at engine idle speed spark plug gap mm (in) 1.0–1.1 (0.039–0.043) ignition coil resistance primary coil (r – b/w) at 20 °c (68 °f) Ω 1.53–2.07 sec...

  • Page 39

    63p3f11 2-8 1 2 3 4 5 6 7 8 9 starter motor type sliding gear output kw 1.40 cranking time limit second 30 brushes standard length mm (in) 15.5 (0.61) wear limit mm (in) 9.5 (0.37) commutator standard diameter mm (in) 29.0 (1.14) wear limit mm (in) 28.0 (1.10) mica standard undercut mm (in) 0.5–0.8 ...

  • Page 40: Spec

    Spec specifications 2-9 63p3f11 dimensions exterior s63p2010 mm (in) 12˚ 4˚ 256 (10.1) 433 (17.0) 629 (24.8) l: 1,032 (40.7) x: 1,148 (45.2) 164 (6.5) 698 (27.5) 75 (3.0) l: 946 (37.2) x: 1,073 (42.2) l: 516 (20.3) x: 643 (25.3) 210 (8.3) 27(1.1) 45 (1.8) 16 (0.6) 162(6.4) x: 80 (3.1 ) l: 60 (2. 4) ...

  • Page 41

    63p3f11 2-10 1 2 3 4 5 6 7 8 9 clamp bracket s63p2020 mm (in) 82 (3.2) 13 (0.5) 180 (7.1) 163.5 (6.4) 254 (10.0) 55.5 (2.2) 367 (14.4) 163.5 (6.4) 125.4 (4.9) 125.4 (4.9) 180 (7.1) 13 (0.5) 50.8 (2.0) 18.5 (0.7) maintenance specification.

  • Page 42: Spec

    Spec specifications 2-11 63p3f11 tightening torques 2 specified torques part to be tightened thread size tightening torques n·m kgf·m ft·lb fuel system fuel filter holder bolt m6 8 0.8 5.9 fuel filter bracket bolt m6 8 0.8 5.9 fuel pump mounting bolt m6 10 1.0 7.4 fuel pump screw ø6 4 0.4 3.0 fuel c...

  • Page 43

    63p3f11 2-12 1 2 3 4 5 6 7 8 9 exhaust cover bolt 1st m6 6 0.6 4.4 2nd 12 1.2 8.9 thermostat cover bolt 1st m6 6 0.6 4.4 2nd 12 1.2 8.9 exhaust cover plug m14 23 2.3 17.0 m18 55 5.5 40.6 oil filter union bolt — 34 3.4 25.1 balancer bolt 1st m6 7 0.7 5.2 2nd 13 1.3 9.6 1st m8 18 1.8 13.3 2nd 31 3.1 2...

  • Page 44: Spec

    Spec specifications 2-13 63p3f11 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 45: Chk

    63p3f11 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 46: Chk

    Chk adj periodic checks and adjustments 3-1 63p3f11 special service tools 3 oil filter wrench 90890-06830 digital tachometer 90890-06760 timing light 90890-03141 leakage tester 90890-06840

  • Page 47: Maintenance Interval Chart

    63p3f11 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 48: Chk

    Chk adj periodic checks and adjustments 3-3 63p3f11 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 49: Power Unit

    63p3f11 3-4 1 2 3 4 5 6 7 8 9 note: be sure not to spill any fuel when removing the fuel filter cup. Power unit 3 checking the engine oil 1. Place the outboard motor in an upright position. 2. Remove the engine oil dipstick, wipe it clean, and then insert it back into the oil filler hole. 3. Remove ...

  • Page 50: Chk

    Chk adj periodic checks and adjustments 3-5 63p3f11 6. Install the oil filler cap and dipstick, and then start the engine and warm it up for 5 minutes. 7. Turn the engine off, and then check the oil level and correct it if necessary. Changing the engine oil by draining it 1. Start the engine, warm i...

  • Page 51

    63p3f11 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 dipstick, and then start the engine and warm it up for 5 minutes. 7. Turn the engine off, and then check the oil level and correct it if necessary. C...

  • Page 52: Chk

    Chk adj periodic checks and adjustments 3-7 63p3f11 4. Check the spark plug gap a. Adjust if out of specification. 5. Install the spark plugs, tighten them fin- ger tight b, then to the specified torque using a spark plug wrench c. Checking the thermostat 1. Remove the flywheel magnet cover. 2. Remo...

  • Page 53: Control System

    63p3f11 3-8 1 2 3 4 5 6 7 8 9 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 in water, and then start the engine. 3. Check for water flow at the cooling water pilot hole. If there is no water ...

  • Page 54: Chk

    Chk adj periodic checks and adjustments 3-9 63p3f11 4. Turn throttle lever 1 7 and the throttle cam 8 counterclockwise so that they are in the positions shown in the illustration. 5. Check that the throttle valves are fully closed, and then adjust the throttle link rod joint to align its hole with t...

  • Page 55

    63p3f11 3-10 1 2 3 4 5 6 7 8 9 10. Contact the stopper 0 on the throttle lever 2 to the fully closed stopper a on the cylinder block and check that throttle cam roller b is aligned with the align- ment mark c. 11. Adjust the position of the throttle cable joint until its hole is aligned with the set...

  • Page 56: Chk

    Chk adj periodic checks and adjustments 3-11 63p3f11 5. Operate throttle lever 2 to check that the throttle valves fully close and fully open. Note: the throttle valves are fully open when the throttle cam roller 8 is within the range b shown in the illustration. 6. Contact the stopper 4 on the thro...

  • Page 57

    63p3f11 3-12 1 2 3 4 5 6 7 8 9 6. Adjust the position of the shift cable joint until its hole is aligned with the set pin. Caution: the shift cable joint must be screwed in a minimum of 8.0 mm (0.31 in) c. 7. Connect the cable joint, install the clip, and then tighten the locknut. 8. Check the gear ...

  • Page 58: Chk

    Chk adj periodic checks and adjustments 3-13 63p3f11 power trim and tilt unit 3 checking the power trim and tilt operation 1. Fully tilt the outboard motor up and down a few times and check the entire trim and tilt range for smooth operation. Check the power trim and tilt fluid level if necessary. N...

  • Page 59

    63p3f11 3-14 1 2 3 4 5 6 7 8 9 note: if the oil is at the correct level, the oil should overflow out of the check hole when the check screw is removed. 3. If necessary, add sufficient gear oil of the recommended type until it overflows out of the check hole. 4. Install the check screw. Changing the ...

  • Page 60: Chk

    Chk adj periodic checks and adjustments 3-15 63p3f11 checking the lower unit for air leakage 1. Remove the check screw 1, and then install the special service tool. 2. Apply the specified pressure to check that the pressure is maintained in the lower unit for at least 10 seconds. Caution: do not ove...

  • Page 61

    63p3f11 3-16 1 2 3 4 5 6 7 8 9 caution: do not oil, grease, or paint the anodes or the trim tab, otherwise they will be ineffec- tive. 2. Replace the anodes or trim tab if exces- sively eroded. Checking the battery 1. Check the battery electrolyte level. If the level is at or below the minimum level...

  • Page 62: Chk

    Chk adj periodic checks and adjustments 3-17 63p3f11 note: apply grease to the grease nipple until it flows from the bushings a. 2. Apply low temperature resistant grease to the areas shown. 3. Apply corrosion resistant grease to the areas shown. S63p3320 a a s60x3090 a a s60x3100 a a s60x3120 a a s...

  • Page 63: Fuel

    63p3f11 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 64: Fuel

    Fuel fuel system 4-1 63p3f11 special service tools 4 vacuum/pressure pump gauge set 90890-06756 fuel pressure gauge 90890-06786 digital circuit tester 90890-03174 vacuum gauge 90890-03159 digital tachometer 90890-06760 test harness (3 pins) 90890-06793.

  • Page 65: Hose Routing

    63p3f11 4-2 1 2 3 4 5 6 7 8 9 hose routing 4 fuel and blowby hoses 1 blowby hoses 2 fuel hose (fuel tank-to-fuel filter) 3 fuel hoses (fuel filter-to-fuel pumps) 4 fuel hoses (fuel pumps-to-fuel filter) 5 fuel hose (fuel filter-to-vapor separator) 6 high-pressure fuel hose (vapor separator-to-fuel r...

  • Page 66: Fuel

    Fuel fuel system 4-3 63p3f11 fuel filter, fuel pump, and intake silencer 4 no. Part name q’ty remarks 1 intake assembly 1 2 bolt 5 m8 × 40 mm 3 bolt 2 m8 × 20 mm 4 intake silencer 1 5 bolt 2 m6 × 45 mm 6 grommet 4 7 collar 2 8 bolt 6 m6 × 20 mm 9 fuel pump 2 10 bolt 4 m6 × 30 mm 11 fuel filter 1 12 ...

  • Page 67

    63p3f11 4-4 1 2 3 4 5 6 7 8 9 4 no. Part name q’ty remarks 1 throttle lever 1 1 2 throttle cam 1 3 throttle lever 2 1 4 throttle link rod 1 5 bolt 1 m6 × 35 mm 6 bolt 2 m6 × 25 mm 7 collar 3 8 wave washer 3 9 washer 3 10 spring 1 s63p4080 9 1 8 7 6 10 9 2 8 7 5 4 9 3 8 7 6 a a a a a a a a fuel filte...

  • Page 68: Fuel

    Fuel fuel system 4-5 63p3f11 4 no. Part name q’ty remarks 1 bolt 1 m6 × 14 mm 2 bracket 1 3 bolt 1 m6 × 16 mm 4 washer 1 5 holder 1 6 cap 1 7 o-ring 1 not reusable 8 fuel filter element 1 9 float 1 10 spring 1 11 o-ring 1 not reusable 12 cup 1 13 nut 1 s63p4040 7 8 9 10 11 12 13 3 4 5 1 2 6 t r . . ...

  • Page 69

    63p3f11 4-6 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 fuel pump body 2 1 4 fuel pump body 1 1 5 plunger 1 6 spring 1 7 nut 3 8 spring 1 9 pin 1 10 diaphragm 1 11 nut 2 12 spring 2 13 valve 2 14 screw 2 15 gasket 1 not reusable s63p4050 7 8 4 6 5 1 2 15 11 12 3 1...

  • Page 70: Fuel

    Fuel fuel system 4-7 63p3f11 checking the fuel pumps 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 specified pos...

  • Page 71

    63p3f11 4-8 1 2 3 4 5 6 7 8 9 2. Push down on the plunger and the dia- phragm, turn fuel pump body 1 1 approximately 90° to a position where the pin 2 can be removed easily, and then remove the pin. 3. Slowly let up on the plunger and dia- phragm, and then remove them. Checking the diaphragm and val...

  • Page 72: Fuel

    Fuel fuel system 4-9 63p3f11 intake assembly and vapor separator 4 no. Part name q’ty remarks 1 bolt 2 m6 × 25 mm 2 fuel cooler 1 3 vapor separator 1 4 fuel hose 1 5 fuel hose 1 6 hose 1 7 electric fuel pump coupler 1 8 intake assembly 1 9 bolt 3 m6 × 35 mm s63p4010 7 5 6 4 2 1 9 3 t r . . 5 n · m (...

  • Page 73

    63p3f11 4-10 1 2 3 4 5 6 7 8 9 4 no. Part name q’ty remarks 1 o-ring 1 not reusable 2 float chamber 1 3 drain screw 1 4 pressure regulator 1 5 screw 2 m6 × 12 mm 6 o-ring 1 not reusable 7 cover 1 8 screw 7 ø4 × 16 mm 9 electric fuel pump 1 10 filter 1 11 filter holder 1 12 o-ring 1 not reusable 13 c...

  • Page 74: Fuel

    Fuel fuel system 4-11 63p3f11 4 no. Part name q’ty remarks 1 fuel rail 1 2 bolt 2 m8 × 25 mm 3 o-ring 4 not reusable 4 rubber damper 4 not reusable 5 fuel injector 4 6 rubber seal 4 not reusable 7 electric fuel pump lead 1 8 gasket 4 not reusable 9 intake manifold 1 10 screw 2 ø5 × 15 mm 11 intake a...

  • Page 75

    63p3f11 4-12 1 2 3 4 5 6 7 8 9 4 no. Part name q’ty remarks 18 collar 6 19 grommet 3 20 bracket 1 21 screw 4 ø6 × 16 mm 22 screw 2 ø4 × 12 mm 23 throttle position sensor 1 24 o-ring 1 not reusable 25 throttle body #1 1 26 bolt 6 m8 × 70 mm 27 bracket 2 28 screw 4 ø6 × 16 mm 29 throttle joint link ro...

  • Page 76: Fuel

    Fuel fuel system 4-13 63p3f11 measuring the fuel pressure 1. Remove the cap 1. 2. Connect the fuel pressure gauge to the pressure check valve. Warning • when connecting the fuel pressure gauge, first cover the connection between the gauge and the pressure check valve with a clean, dry rag to pre- ve...

  • Page 77

    63p3f11 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 pressure check valve with a clean, dry rag to pre- vent fuel from leaking out. • gently screw in the gauge until it is firmly connected. 4. Start the engine and let ...

  • Page 78: Fuel

    Fuel fuel system 4-15 63p3f11 reducing the fuel pressure 1. Remove the cap 1. 2. Cover the pressure check valve a of the fuel rail with a rag, and then press in the pressure check valve a using a thin screwdriver to release the fuel pressure. Warning always reduce the fuel pressure in the high-press...

  • Page 79

    63p3f11 4-16 1 2 3 4 5 6 7 8 9 synchronizing the throttle valves caution: do not adjust the throttle valve when it is operating properly. Excess adjustment may cause poor engine performance. 1. Remove the caps 1, and then attach the special service tool to the intake manifold as shown. Note: for bes...

  • Page 80: Fuel

    Fuel fuel system 4-17 63p3f11 5. Turn the synchronizing screw 5 so that the vacuum pressure of cylinder #3 or #4 is within 4 kpa (30 mmhg) based on the vacuum pressure of cylinder #1 or #2. Example check results: adjust the difference of the vacuum pressure between cylinders #1 and #4 within 4 kpa (...

  • Page 81

    63p3f11 4-18 1 2 3 4 5 6 7 8 9 note: to measure the output voltage, connect the positive tester probe to the pink wire of the test harness and the negative tester probe to the orange wire of the test harness. 7. Install the intake silencer. 8. Start the engine and measure the throttle position senso...

  • Page 82: Fuel

    Fuel fuel system 4-19 63p3f11 12. Install the throttle joint link rod 3 so the throttle cam roller 4 is aligned with the alignment mark a as shown. Note: make sure that the throttle position sensor output voltage does not change when install- ing the throttle joint link rod. 13. Install the intake s...

  • Page 83: — Memo —

    63p3f11 4-20 1 2 3 4 5 6 7 8 9 — memo — intake assembly and vapor separator.

  • Page 84: Powr

    Powr 63p3f11 power unit special service tools ..................................................................................... 5-1 power unit....................................................................................................... 5-3 checking the compression pressure ...............

  • Page 85

    63p3f11 1 2 3 4 5 6 7 8 9 cylinder block .............................................................................................. 5-38 disassembling the cylinder block ............................................................ 5-41 checking the balancer assembly.................................

  • Page 86: Powr

    Powr power unit 5-1 63p3f11 special service tools 5 compression gauge 90890-03160 compression gauge extension 90890-06563 test harness (3 pins) new: 90890-06869 current: 90890-06769 flywheel holder 90890-06522 oil filter wrench 90890-06830 flywheel puller 90890-06521 valve spring compressor 90890-04...

  • Page 87

    63p3f11 5-2 1 2 3 4 5 6 7 8 9 valve guide reamer 90890-06804 valve seat cutter holder 90890-06316 valve seat cutter 90890-06324, 90890-06325, 90890-06326, 90890-06327 needle bearing attachment 90890-06611, 90890-06654 driver rod l3 90890-06652 piston ring compressor 90890-05158 special service tools.

  • Page 88: Powr

    Powr power unit 5-3 63p3f11 power unit 5 no. Part name q’ty remarks 1 dipstick 1 2 bolt 1 m6 × 20 mm 3 dipstick guide 1 4 o-ring 1 not reusable 5 flywheel magnet cover 1 6 power unit 1 7 spark plug wire cover 1 8 dowel 2 9 gasket 1 not reusable 10 bolt 4 m10 × 35 mm 11 bolt 8 m10 × 140 mm 12 bolt 3 ...

  • Page 89

    63p3f11 5-4 1 2 3 4 5 6 7 8 9 5 no. Part name q’ty remarks 1 nut 1 2 washer 1 3 flywheel magnet 1 4 bolt 4 m6 × 35 mm 5 holder 1 6 bracket 2 7 collar 2 8 holder 1 9 stator coil bracket 1 10 hose 1 11 plastic tie 1 not reusable 12 woodruff key 1 13 stator coil 1 14 screw 4 ø6 × 30 mm power unit.

  • Page 90: Powr

    Powr power unit 5-5 63p3f11 5 no. Part name q’ty remarks 1 starter motor 1 2 bolt 3 m8 × 45 mm 3 terminal 1 4 nut 1 5 cap 1 6 bolt 1 m6 × 10 mm 7 starter motor lead 1 8 ignition coil 2 9 holder 2 10 holder 1 11 bracket 2 12 holder 2 13 bolt 4 m6 × 25 mm 14 oil filter 1 s63p5580 7 6 5 4 3 1 2 8 9 9 1...

  • Page 91

    63p3f11 5-6 1 2 3 4 5 6 7 8 9 5 no. Part name q’ty remarks 1 grommet 1 2 fuse holder 1 3 terminal plate 4 4 terminal 8 5 terminal 8 6 fuse holder 1 7 fuse 2 50 a 8 screw 4 ø5 × 10 mm 9 fuse 2 20 a 10 relay 1 11 fuse 1 30 a 12 screw 6 ø3 × 10 mm 13 screw 3 ø5 × 20 mm s63p5600 3 1 2 4 9 7 9 10 11 1 2 ...

  • Page 92: Powr

    Powr power unit 5-7 63p3f11 5 no. Part name q’ty remarks 1 junction box 1 2 ecm 1 3 bolt 4 m6 × 16 mm 4 wiring harness 1 5 bolt 1 m6 × 20 mm 6 washer 2 7 nut 2 8 cap 2 9 power trim and tilt relay 1 10 bolt 2 m6 × 20 mm 11 starter relay 1 12 holder 1 13 bolt 1 m6 × 10 mm 14 cap 1 15 screw 1 ø6 × 19 m...

  • Page 93

    63p3f11 5-8 1 2 3 4 5 6 7 8 9 5 no. Part name q’ty remarks 18 holder 1 19 bolt 1 m6 × 12 mm 20 intake air temperature sensor 1 21 grommet 1 22 screw 1 ø6 × 19 mm 23 bracket 1 24 screw 1 ø6 × 19 mm 25 holder 1 26 collar 3 27 grommet 3 28 bolt 3 m6 × 35 mm 29 wiring harness 1 s63p5610 29 24 26 27 28 1...

  • Page 94: Powr

    Powr power unit 5-9 63p3f11 5 no. Part name q’ty remarks 1 timing belt 1 2 timing belt tensioner 1 3 bolt 4 m5 × 40 mm 4 drive sprocket 1 5 plate 1 6 woodruff key 1 7 bolt 2 m10 × 35 mm 8 driven sprocket 2 9 oil seal 2 10 dowel 2 11 camshaft 1 12 camshaft 1 13 camshaft cap 2 14 camshaft cap 8 15 bol...

  • Page 95

    63p3f11 5-10 1 2 3 4 5 6 7 8 9 5 no. Part name q’ty remarks 18 screw 8 ø4 × 8 mm 19 plate 1 20 grommet 6 21 cylinder head cover 1 22 bolt 15 m6 × 30 mm 23 holder 2 24 bolt 2 m6 × 10 mm 25 clamp 2 26 hose 1 27 dowel 4 28 dowel 1 power unit.

  • Page 96: Powr

    Powr power unit 5-11 63p3f11 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, and then ins...

  • Page 97

    63p3f11 5-12 1 2 3 4 5 6 7 8 9 checking the oil pressure sensor 1. Connect the test harness (3 pins) to the oil pressure sensor. 2. Start the engine and warm it up for 5 min- utes. 3. Measure the oil pressure sensor input voltage. Check the wiring harness con- nection or replace the ecm if out of sp...

  • Page 98: Powr

    Powr power unit 5-13 63p3f11 5. Check the intake valve clearance for cyl- inders #1 and #2, and exhaust valve clearance for cylinders #1 and #3. Adjust if out of specification. 6. Turn the flywheel magnet 360° clock- wise. 7. Check the intake valve clearance for cyl- inders #3 and #4, and exhaust va...

  • Page 99

    63p3f11 5-14 1 2 3 4 5 6 7 8 9 13. Remove the camshafts. 14. Remove the valve shim 7 from the valve lifter 8 using compressed air. Note: do not mix the valve train parts. Keep them organized in their proper groups. 15. Measure the valve shim thickness using a micrometer, and then note the mea- surem...

  • Page 100: Powr

    Powr power unit 5-15 63p3f11 19. Install the camshaft caps, and then tighten them to the specified torques in two stages and in the sequence shown in the illustration. Note: • install the camshaft caps in the proper posi- tion as shown and with the stamped num- bers facing upside down. • apply engin...

  • Page 101

    63p3f11 5-16 1 2 3 4 5 6 7 8 9 note: do not turn the flywheel magnet counter- clockwise. 24. Check the valve clearances. Adjust if necessary. 25. Install the spark plugs, and then tighten them to the specified torque. 26. Install the cylinder head cover bolts, and then tighten them to the specified ...

  • Page 102: Powr

    Powr power unit 5-17 63p3f11 4. Remove the flywheel magnet. Caution: to prevent damage to the engine or tools, screw in the puller set bolts evenly and completely so that the puller plate is par- allel to the flywheel magnet. Note: apply force to the crankshaft end until the fly- wheel magnet comes ...

  • Page 103

    63p3f11 5-18 1 2 3 4 5 6 7 8 9 9. Install a new timing belt 7 from the drive sprocket side with its part number in the upright position, turn the belt a half turn counterclockwise to align it, and then remove the pin 6. Caution: • do not twist, turn inside out, or bend the timing belt beyond the max...

  • Page 104: Powr

    Powr power unit 5-19 63p3f11 2. Disconnect the battery leads 1. 3. Disconnect the throttle cable 2 and shift cable 3. 4. Remove the junction box cover, and then disconnect the ptt motor leads 4. 5. Disconnect the fuel hose 5. 6. Remove the dipstick guide 6. 7. Disconnect the ptt switch coupler, shif...

  • Page 105

    63p3f11 5-20 1 2 3 4 5 6 7 8 9 caution: to prevent damage to the engine or tools, screw in the puller set bolts evenly and completely so that the puller plate is par- allel to the flywheel magnet. Note: apply force to the crankshaft end until the fly- wheel magnet comes off the tapered portion of th...

  • Page 106: Powr

    Powr power unit 5-21 63p3f11 2. Using a hexagon wrench, turn the timing belt tensioner 1 clockwise to push the timing belt, increase strength gradually, and then insert a ø5.0 mm (0.2 in) pin 2 into the hole e. 3. Remove the timing belt 3 from the driven sprocket side. 4. Remove the timing belt tens...

  • Page 107

    63p3f11 5-22 1 2 3 4 5 6 7 8 9 4. Install the drive sprocket 3 and timing belt tensioner 4, and then tighten the bolts to the specified torques. 5. Check that the “ ” mark c on the plate is aligned with the “i” mark d on the cyl- inder block. Align if necessary. 6. Install the timing belt 5 from the...

  • Page 108: Powr

    Powr power unit 5-23 63p3f11 cylinder head 5 no. Part name q’ty remarks 1 bolt 10 m8 × 55 mm 2 valve shim 16 3 valve lifter 16 4 valve cotter 32 5 valve spring retainer 16 6 valve spring 16 7 valve seal 16 not reusable 8 valve guide 16 not reusable 9 bolt 10 m10 × 120 mm 10 spark plug 4 11 bolt 2 m8...

  • Page 109

    63p3f11 5-24 1 2 3 4 5 6 7 8 9 5 no. Part name q’ty remarks 18 intake valve 8 19 gasket 1 not reusable 20 collar 2 21 anode 1 22 screw 3 ø6 × 16 mm 23 anode 2 cylinder head.

  • Page 110: Powr

    Powr power unit 5-25 63p3f11 5 no. Part name q’ty remarks 1 engine temperature sensor 1 2 washer 1 3 bolt 1 4 plug 1 m14 × 12 mm 5 washer 1 6 engine hanger 1 7 bolt 2 m6 × 20 mm 8 bolt 1 m6 × 16 mm 9 bracket 1 10 o-ring 1 not reusable 11 oil pressure sensor 1 12 o-ring 2 not reusable 13 oil filter b...

  • Page 111

    63p3f11 5-26 1 2 3 4 5 6 7 8 9 5 no. Part name q’ty remarks 18 gasket 1 not reusable 19 thermostat 1 20 cover 1 21 thermoswitch 1 22 holder 1 23 bolt 3 m6 × 30 mm 24 gasket 1 not reusable 25 rectifier regulator 1 26 bolt 6 m6 × 30 mm 27 anode 1 28 grommet 1 29 cover 1 30 bolt 1 m8 × 40 mm 31 bolt 1 ...

  • Page 112: Powr

    Powr power unit 5-27 63p3f11 5 no. Part name q’ty remarks 35 pressure control valve 1 36 spring 1 37 gasket 1 not reusable 38 cover 1 39 bolt 3 m6 × 20 mm 40 washer 1 41 plug 1 m18 × 17 mm 42 holder 1 43 bolt 1 m6 × 12 mm 44 anode 1 45 screw 1 46 anode 7 47 screw 7 ø5 × 27 mm s63p5630 1 2 5 4 6 7 8 ...

  • Page 113

    63p3f11 5-28 1 2 3 4 5 6 7 8 9 removing the cylinder head 1. Remove the camshaft caps in the sequence shown. 2. Remove the camshafts and cylinder head bolts in the sequence shown. Caution: do not scratch or damage the mating sur- faces of the cylinder head and cylinder block. 3. Remove the valve shi...

  • Page 114: Powr

    Powr power unit 5-29 63p3f11 2. Measure the valve spring tilt b. Replace if out of specification. Checking the valves 1. Check the valve face for pitting or wear. Replace if necessary. 2. Measure the valve margin thickness a. Replace if out of specification. 3. Measure the valve stem diameter b. Rep...

  • Page 115

    63p3f11 5-30 1 2 3 4 5 6 7 8 9 2. Calculate the valve stem-to-valve guide clearance as follows. Replace the valve guide if out of specification. Replacing the valve guides 1. Remove the valve guide 1 by striking the special service tool from the combus- tion chamber side. 2. Install a new valve guid...

  • Page 116: Powr

    Powr power unit 5-31 63p3f11 checking the valve seat 1. Eliminate carbon deposits from the valve with a scraper. 2. Apply a thin, even layer of mechanic’s blueing dye (dykem) onto the valve seat. 3. Lap the valve slowly on the valve seat with a valve lapper (commercially avail- able) as shown. 4. Me...

  • Page 117

    63p3f11 5-32 1 2 3 4 5 6 7 8 9 a slag or rough surface caution: do not over cut the valve seat. Be sure to turn the cutter evenly downward at a pres- sure of 40–50 n (4–5 kgf, 8.8–11 lbf) to prevent chatter marks. 3. Use a 30° cutter to adjust the contact width of the top edge of the valve seat. B p...

  • Page 118: Powr

    Powr power unit 5-33 63p3f11 7. If the valve seat contact area is too nar- row and situated near the top edge of the valve face, use a 30° cutter to cut the top edge of the valve seat. If necessary, use a 45° cutter to center the area and set its width. B previous contact width 8. If the valve seat ...

  • Page 119

    63p3f11 5-34 1 2 3 4 5 6 7 8 9 3. Measure the camshaft journal diameter c and cylinder head journal inside diam- eter d. Replace the camshaft and cylin- der head if out of specification. 4. Calculate the camshaft oil clearance e as follows. Replace the camshaft and cylinder head as a set if out of s...

  • Page 120: Powr

    Powr power unit 5-35 63p3f11 2. Install the valve 2, valve spring 3, and valve spring retainer 4 in the sequence shown, and then attach the special ser- vice tool. Note: the valve spring can be installed in any direction. 3. Compress the valve spring, and then install the valve cotter 7 using a thin...

  • Page 121

    63p3f11 5-36 1 2 3 4 5 6 7 8 9 note: • apply engine oil to the cylinder head bolts before installation. • tighten the m10 bolts to the specified torques in two stages first, and then make a mark a on the m10 bolts and the cylinder head, and then tighten the bolts 90° from the mark. • tighten the m8 ...

  • Page 122: Powr

    Powr power unit 5-37 63p3f11 removing the exhaust cover 1. Remove the cover 1 and thermostat 2. 2. Remove the exhaust cover bolts in the sequence shown. Checking the pressure control valve 1. Remove the pressure control valve. 2. Check the pressure control valve 1 for wear or damage. Replace if nece...

  • Page 123: Cylinder Block

    63p3f11 5-38 1 2 3 4 5 6 7 8 9 cylinder block 5 no. Part name q’ty remarks 1 engine hanger 1 2 bolt 3 m6 × 20 mm 3 oil filler cap 1 4 o-ring 1 5 oil filler neck 1 6 gasket 1 not reusable 7 bolt 2 m6 × 45 mm 8 seal 2 not reusable 9 balancer assembly 1 10 bolt 10 m8 × 55 mm 11 bolt 2 m6 × 40 mm 12 o-r...

  • Page 124: Powr

    Powr power unit 5-39 63p3f11 5 no. Part name q’ty remarks 18 oil seal 1 not reusable 19 oil seal 2 not reusable 20 bolt 4 m6 × 40 mm.

  • Page 125

    63p3f11 5-40 1 2 3 4 5 6 7 8 9 5 no. Part name q’ty remarks 1 bolt 10 m10 × 85 mm 2 bolt 10 m8 × 55 mm 3 crankcase 1 4 main bearing cap 1 5 collar 10 6 cylinder block 1 7 oil seal 1 not reusable 8 crankshaft 1 9 main bearing 10 10 oil seal 1 not reusable 11 connecting rod bearing 8 12 piston/connect...

  • Page 126: Powr

    Powr power unit 5-41 63p3f11 disassembling the cylinder block 1. Remove the oil pump. 2. Remove the balancer bolts in the sequence shown. 3. Remove the crankcase bolts in the sequence shown. Note: do not remove the plugs 1 from the crank- case. 4. Remove the connecting rod bolts and the connecting r...

  • Page 127

    63p3f11 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 128: Powr

    Powr power unit 5-43 63p3f11 2. Level the piston ring 1 in the cylinder with a piston crown. 3. Check the piston ring end gap d at the specified measuring point. Replace if out of specification. Checking the piston ring grooves 1. Measure the piston ring grooves. Replace the piston if out of specifi...

  • Page 129

    63p3f11 5-44 1 2 3 4 5 6 7 8 9 checking the crankshaft 1. Check the teeth of the crankshaft gear for cracks or wear. Replace the crank- shaft if necessary. 2. Measure the crankshaft journal diameter a, crankpin diameter b, and crankpin width c. Replace the crankshaft if out of specification. 3. Meas...

  • Page 130: Powr

    Powr power unit 5-45 63p3f11 checking the crankpin oil clearance 1. Clean the bearings and the connecting rod. 2. Install the upper bearing into the con- necting rod 1 and the lower bearing into the connecting rod cap 2. Note: install the connecting rod bearings in their original positions. 3. Put a...

  • Page 131

    63p3f11 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 1. When replacing the connecting rod bear- ing, select the sui...

  • Page 132: Powr

    Powr power unit 5-47 63p3f11 4. Select the suitable color c for the con- necting rod bearing from the table. Note: • example: if the connecting rod big end inside diameter a is “35” and the crankpin mark b is “81,” then select the bearing col- ors in “g.” • if the connecting rod inside diameter can-...

  • Page 133

    63p3f11 5-48 1 2 3 4 5 6 7 8 9 note: do not put the plastigauge (pg-1) over the oil hole in the main journals of the crankshaft. 5. Install the remaining half of the bearings into the main bearing cap and crankcase. Note: install the main bearings in their original posi- tions. 6. Install the main b...

  • Page 134: Powr

    Powr power unit 5-49 63p3f11 3. Select the suitable color c for the main bearing from the table. Note: • example: if the crankshaft journal mark a is “89” and the cylinder block mark b is “28,” then select the bearing colors in “g.” • main bearing #3 is a thrust bearing. Disassembling the oil pump 1...

  • Page 135

    63p3f11 5-50 1 2 3 4 5 6 7 8 9 3. Install a new oil seal into the oil pump housing. 4. Install a new oil seal 6 and the gasket 7, and then tighten the screws 8 to the specified torque. Assembling the pistons and cylinder block 1. Install the oil ring 1, second ring 2, and top ring 3 onto the pistons...

  • Page 136: Powr

    Powr power unit 5-51 63p3f11 3. Install the upper bearing into the con- necting rod 4 and the lower bearing into the connecting rod cap 5. Note: install the connecting rod bearings in their original positions. 4. Install half of the main bearings 6 and the thrust bearing 7 into the cylinder block 8....

  • Page 137

    63p3f11 5-52 1 2 3 4 5 6 7 8 9 note: • main bearing cap bolts 1–6 can be reused three times. • apply engine oil to the main bearing cap bolts before installation. • make a mark b on the main bearing caps and main bearing cap bolts, and then tighten the main bearing cap bolts 90° from the mark. 8. In...

  • Page 138: Powr

    Powr power unit 5-53 63p3f11 10. Install half of the main bearings a into the crankcase. 11. Apply sealant to the mating surface of the crankcase. Note: • install the main bearings in their original positions. • do not get any sealant on the main bear- ings. 12. Install the crankcase onto the cylind...

  • Page 139

    63p3f11 5-54 1 2 3 4 5 6 7 8 9 16. Apply sealant to the mating surface of the balancer assembly. Note: do not get any sealant inside the balancer assembly. 17. Install the balancer assembly onto the crankcase, and then tighten the balancer assembly bolts to the specified torques in two stages and in...

  • Page 140: Powr

    Powr power unit 5-55 63p3f11 20. Before installing the oil filter, be sure to fill it with engine oil through the oil pas- sage j of the oil filter bracket. 21. Install the oil filter, and then tighten it to the specified torque using a 72.5 mm (2.9 in) oil filter wrench. Note: apply a thin coat of ...

  • Page 141

    63p3f11 5-56 1 2 3 4 5 6 7 8 9 4. Connect the ptt switch coupler, shift cut switch coupler, neutral switch coupler, cooling water pilot hose, and flushing hose. 5. Install the dipstick guide 7. 6. Connect the fuel hose 8. 7. Connect the ptt motor leads 9, and then install the junction box cover. 8. ...

  • Page 142: Powr

    Powr power unit 5-57 63p3f11 9. Connect the battery leads b. 10. Install the stator coil assembly. 11. Install the woodruff key. 12. Install the flywheel magnet. Caution: apply force in the direction of the arrows shown to prevent the flywheel holder from slipping off easily. Note: apply engine oil ...

  • Page 143: — Memo —

    63p3f11 5-58 1 2 3 4 5 6 7 8 9 — memo — cylinder block.

  • Page 144: Lowr

    Lowr 63p3f11 lower unit special service tools ..................................................................................... 6-1 lower unit (regular rotation model) ............................................................. 6-4 removing the lower unit .........................................

  • Page 145

    63p3f11 1 2 3 4 5 6 7 8 9 lower unit (counter rotation model) .......................................................... 6-32 removing the lower unit .......................................................................... 6-36 removing the water pump and shift rod....................................

  • Page 146: Lowr

    Lowr lower unit 6-1 63p3f11 special service tools 6 ring nut wrench 4 90890-06512 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 147

    63p3f11 6-2 1 2 3 4 5 6 7 8 9 driver rod ss 90890-06604 bearing depth plate 90890-06603 bearing inner race attachment 90890-06640, 90890-06660 drive shaft holder 6 90890-06520 pinion nut holder new: 90890-06715 current: 90890-06505 bearing outer race puller assembly 90890-06523 ball bearing attachme...

  • Page 148: Lowr

    Lowr lower unit 6-3 63p3f11 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 magnet base b 90890-06844 ring nut wrench 90890-06578 outer race p...

  • Page 149

    63p3f11 6-4 1 2 3 4 5 6 7 8 9 lower unit (regular rotation model) 6 no. Part name q’ty remarks 1 lower unit 1 2 check screw 1 3 gasket 2 not reusable 4 bolt 6 m10 × 45 mm 5 drain screw 1 6 grommet 1 7 bolt 1 m10 × 44 mm 8 bolt 1 m10 × 70 mm / l-transom model 9 spacer 1 10 propeller 1 11 washer 1 12 ...

  • Page 150: Lowr

    Lowr lower unit 6-5 63p3f11 6 no. Part name q’ty remarks 18 extension 1 x-transom model 19 bolt 6 m10 × 45 mm / x-transom model 20 bolt 1 m10 × 200 mm / x-transom model.

  • Page 151

    63p3f11 6-6 1 2 3 4 5 6 7 8 9 6 no. Part name q’ty remarks 1 shift rod 1 2 oil seal 1 not reusable 3 oil seal housing 1 4 o-ring 1 not reusable 5 spring 1 6 circlip 1 7 bolt 3 m6 × 20 mm 8 hose nipple 1 9 o-ring 1 not reusable 10 woodruff key 1 11 bolt 4 m8 × 45 mm 12 cover 1 13 seal 1 14 water pump...

  • Page 152: Lowr

    Lowr lower unit 6-7 63p3f11 6 no. Part name q’ty remarks 18 collar 1 19 spacer 1 20 washer 2 21 wave washer 1 22 impeller 1 23 outer plate cartridge 1 24 gasket 1 not reusable 25 dowel 2 26 dowel 2.

  • Page 153

    63p3f11 6-8 1 2 3 4 5 6 7 8 9 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 154: Lowr

    Lowr lower unit 6-9 63p3f11 checking the water pump and shift rod 1. Check the water pump housing for defor- mation. Replace if necessary. 2. Check the impeller 1 and insert car- tridge 2 for cracks or wear. Replace if necessary. 3. Check the woodruff key 3 and the key- way a in the drive shaft for ...

  • Page 155

    63p3f11 6-10 1 2 3 4 5 6 7 8 9 propeller shaft housing (regular rotation model) 6 no. Part name q’ty remarks 1 shift rod joint 1 2 ball 2 3 shift slider 1 4 ball 2 5 ball 2 6 spring 1 7 dog clutch 1 8 cross pin 1 9 spring 1 10 propeller shaft 1 11 reverse gear shim — 12 washer 1 13 reverse gear 1 14...

  • Page 156: Lowr

    Lowr lower unit 6-11 63p3f11 6 no. Part name q’ty remarks 18 straight key 1 19 needle bearing 1 20 oil seal 2 not reusable 21 claw washer 1 22 ring nut 1 23 cooling water inlet cover 2 24 nut 1 25 screw 1.

  • Page 157

    63p3f11 6-12 1 2 3 4 5 6 7 8 9 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. Disassembling the propeller shaft assembly 1. Remove the spring 1, then the cross pin 2, ...

  • Page 158: Lowr

    Lowr lower unit 6-13 63p3f11 2. Remove the ball bearing. 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 if necessary. 2. Check the teeth and dogs of...

  • Page 159

    63p3f11 6-14 1 2 3 4 5 6 7 8 9 assembling the propeller shaft assembly 1. Install the dog clutch as shown. Note: install the dog clutch 1 with the “f” mark a facing toward the shift slider. Assembling the propeller shaft housing 1. Install the needle bearing into the propel- ler shaft housing to the...

  • Page 160: Lowr

    Lowr lower unit 6-15 63p3f11 3. Install the thrust washer 5 and new ball bearing 6 onto the reverse gear 7 using a press. Note: install the ball bearing with the manufacture identification mark e facing outward (propel- ler side). 4. Install the reverse gear assembly into the propeller shaft housing...

  • Page 161

    63p3f11 6-16 1 2 3 4 5 6 7 8 9 drive shaft and lower case (regular rotation model) 6 no. Part name q’ty remarks 1 drive shaft 1 2 sleeve 1 3 cover 1 4 oil seal 2 not reusable 5 bolt 4 m8 × 25 mm 6 drive shaft housing 1 7 needle bearing 1 8 o-ring 1 not reusable 9 pinion shim — 10 thrust bearing 1 11...

  • Page 162: Lowr

    Lowr lower unit 6-17 63p3f11 removing the drive shaft 1. Remove the drive shaft, drive shaft hous- ing, and pinion, and then pull out the for- ward gear. Disassembling the drive shaft housing 1. Remove the cover, oil seals, and needle bearing. Disassembling the forward gear 1. Remove the taper rolle...

  • Page 163

    63p3f11 6-18 1 2 3 4 5 6 7 8 9 note: install the claws as shown. 2. Remove the needle bearing. Checking the pinion and forward gear 1. Check the teeth of the pinion, and the teeth and dogs of the forward gear for cracks or wear. Replace if necessary. Checking the bearings 1. Check the bearings for p...

  • Page 164: Lowr

    Lowr lower unit 6-19 63p3f11 assembling the lower case 1. Install the original shim(s) and taper roller bearing outer race. Caution: add or remove shim(s), if necessary, if replacing the forward gear or lower case. 2. Install the needle bearing outer case into the lower case. Note: apply gear oil to...

  • Page 165

    63p3f11 6-20 1 2 3 4 5 6 7 8 9 2. Apply grease to a new oil seals, and then install them into the drive shaft housing to the specified depth. Note: install an oil seal halfway into the drive shaft housing, then the other oil seal. Installing the drive shaft 1. Install the forward gear into the lower...

  • Page 166: Lowr

    Lowr lower unit 6-21 63p3f11 installing the propeller shaft housing 1. Install the washer 1 and propeller shaft assembly 2 into the propeller shaft housing assembly 3. 2. Apply grease to a new o-ring, and then install it onto the propeller shaft housing. 3. Install the original shim(s) 4 and propel-...

  • Page 167

    63p3f11 6-22 1 2 3 4 5 6 7 8 9 3. Install the woodruff key into the drive shaft. 4. Align the groove in the impeller 5 with the woodruff key 6, and then install the impeller onto the drive shaft. 5. Install the washers 7, wave washer 8, spacer 9, and collar 0 onto the drive shaft. Note: • the collar...

  • Page 168: Lowr

    Lowr lower unit 6-23 63p3f11 7. Install the new o-ring d and pump hous- ing assembly e into the lower case, tighten the bolts f, and then install the seal g and cover h. Note: • when installing the pump housing, apply grease to the inside of the housing, and then turn the drive shaft clockwise while...

  • Page 169

    63p3f11 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 170: Lowr

    Lowr lower unit 6-25 63p3f11 shimming (regular rotation model) 6 s63p6390 f r p b4 t3 b3 61.0 a3 t1 b1 37.0 16.3 t2 b2 a1 a2.

  • Page 171

    63p3f11 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 172: Lowr

    Lowr lower unit 6-27 63p3f11 5. 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 is unreadabl...

  • Page 173

    63p3f11 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 is unreadable, assume that “f” is zero and check the backlash when the unit is assembl...

  • Page 174: Lowr

    Lowr lower unit 6-29 63p3f11 3. 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. The “r” mark a is stamped on the trim tab mounting surface of the lower case in 0.01 mm units. If the “r” mark is u...

  • Page 175

    63p3f11 6-30 1 2 3 4 5 6 7 8 9 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 that the plunger a contacts the mark b on the backlash indica- tor. 6. ...

  • Page 176: Lowr

    Lowr lower unit 6-31 63p3f11 10. Slowly turn the drive shaft clockwise and counterclockwise and measure the back- lash when the drive shaft stops in each direction. 11. Add or remove shim(s) if out of specifica- tion. M: measurement 12. Remove the special service tools, and then install the water pu...

  • Page 177

    63p3f11 6-32 1 2 3 4 5 6 7 8 9 lower unit (counter rotation model) 6 no. Part name q’ty remarks 1 lower unit 1 2 check screw 1 3 gasket 2 not reusable 4 bolt 6 m10 × 45 mm 5 drain screw 1 6 grommet 1 7 bolt 1 m10 × 44 mm 8 bolt 1 m10 × 70 mm / l-transom model (for europe) 9 spacer 1 10 propeller 1 1...

  • Page 178: Lowr

    Lowr lower unit 6-33 63p3f11 6 no. Part name q’ty remarks 18 extension 1 x-transom model 19 bolt 6 m10 × 45 mm / x-transom model 20 bolt 1 m10 × 200 mm / x-transom model.

  • Page 179

    63p3f11 6-34 1 2 3 4 5 6 7 8 9 6 no. Part name q’ty remarks 1 shift rod 1 2 oil seal 1 not reusable 3 oil seal housing 1 4 o-ring 1 not reusable 5 spring 1 6 circlip 1 7 bolt 3 m6 × 20 mm 8 hose nipple 1 9 o-ring 1 not reusable 10 woodruff key 1 11 bolt 4 m8 × 45 mm 12 cover 1 13 seal 1 14 water pum...

  • Page 180: Lowr

    Lowr lower unit 6-35 63p3f11 6 no. Part name q’ty remarks 18 collar 1 19 spacer 1 20 washer 2 21 wave washer 1 22 impeller 1 23 outer plate cartridge 1 24 gasket 1 not reusable 25 dowel 2 26 dowel 2.

  • Page 181

    63p3f11 6-36 1 2 3 4 5 6 7 8 9 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 182: Lowr

    Lowr lower unit 6-37 63p3f11 checking the water pump and shift rod 1. Check the water pump housing for defor- mation. Replace if necessary. 2. Check the impeller 1 and insert car- tridge 2 for cracks or wear. Replace if necessary. 3. Check the woodruff key 3 and the key- way a in the drive shaft for...

  • Page 183

    63p3f11 6-38 1 2 3 4 5 6 7 8 9 propeller shaft housing (counter rotation model) 6 no. Part name q’ty remarks 1 shift rod joint 1 2 ball 2 3 shift slider 1 4 ball 2 5 ball 2 6 spring 1 7 dog clutch 1 8 cross pin 1 9 spring 1 10 forward gear shim — 11 forward gear 1 12 thrust washer 1 13 taper roller ...

  • Page 184: Lowr

    Lowr lower unit 6-39 63p3f11 6 no. Part name q’ty remarks 18 propeller shaft housing 1 19 straight key 1 20 needle bearing 1 21 oil seal 2 not reusable 22 claw washer 1 23 ring nut 1 24 cooling water inlet cover 2 25 nut 1 26 screw 1.

  • Page 185

    63p3f11 6-40 1 2 3 4 5 6 7 8 9 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. Disassembling the propeller shaft assembly 1. Remove the spring 1, then the cross pin 2, ...

  • Page 186: Lowr

    Lowr lower unit 6-41 63p3f11 disassembling the propeller shaft housing 1. 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 or damage. Replace if necessary. 2. Che...

  • Page 187

    63p3f11 6-42 1 2 3 4 5 6 7 8 9 note: • install the needle bearing with the manufac- ture identification mark a facing toward the oil seal (propeller side). • when using the driver rod, do not strike the special service tool in a manner that will force the stopper c out of place. 2. Apply grease to n...

  • Page 188: Lowr

    Lowr lower unit 6-43 63p3f11 5. Install the thrust washer 0, forward gear a, and dog clutch b using a press. Note: install the dog clutch b with the “f” mark e facing toward the forward gear. 6. Install the spring c, balls, and shift slider d into the propeller shaft, and then install the cross pin ...

  • Page 189

    63p3f11 6-44 1 2 3 4 5 6 7 8 9 drive shaft and lower case (counter rotation model) 6 no. Part name q’ty remarks 1 drive shaft 1 2 sleeve 1 3 cover 1 4 oil seal 2 not reusable 5 bolt 4 m8 × 25 mm 6 drive shaft housing 1 7 needle bearing 1 8 o-ring 1 not reusable 9 pinion shim — 10 thrust bearing 1 11...

  • Page 190: Lowr

    Lowr lower unit 6-45 63p3f11 6 no. Part name q’ty remarks 18 needle bearing 2 not reusable 19 reverse gear 1.

  • Page 191

    63p3f11 6-46 1 2 3 4 5 6 7 8 9 removing the drive shaft 1. Remove the drive shaft assembly and pinion, and then pull out the reverse gear and thrust bearing. Disassembling the drive shaft housing 1. Remove the cover, oil seals, and needle bearing. Disassembling the reverse gear 1. Remove the roller ...

  • Page 192: Lowr

    Lowr lower unit 6-47 63p3f11 2. Remove the needle bearing from the lower case. Checking the pinion and reverse gear 1. Check the teeth of the pinion, and the teeth and dogs of the reverse gear for cracks or wear. Replace if necessary. Checking the bearings 1. Check the bearings for pitting or rum- b...

  • Page 193

    63p3f11 6-48 1 2 3 4 5 6 7 8 9 2. Install the needle bearing outer case into the lower case. Note: apply gear oil to the needle bearing outer case before installation. 3. Install the needle bearing into the needle bearing outer case. Note: apply gear oil or grease to the needle bear- ing before inst...

  • Page 194: Lowr

    Lowr lower unit 6-49 63p3f11 2. Apply grease to new oil seals, and then install them into the drive shaft housing to the specified depth. Note: install an oil seal halfway into the drive shaft housing, then the other oil seal. Installing the drive shaft 1. Install the reverse gear into the lower cas...

  • Page 195

    63p3f11 6-50 1 2 3 4 5 6 7 8 9 caution: add or remove shim(s), if necessary, if replacing the forward gear, taper roller bearing, propeller shaft housing, thrust washer, or lower case. 2. Tighten the ring nut to the specified torque. Note: • to secure the ring nut, bend one tab a of the claw washer ...

  • Page 196: Lowr

    Lowr lower unit 6-51 63p3f11 3. Install the woodruff key into the drive shaft. 4. Align the groove in the impeller 5 with the woodruff key 6, and then install the impeller onto the drive shaft. 5. Install the washers 7, wave washer 8, spacer 9, and collar 0 onto the drive shaft. Note: • the collar a...

  • Page 197

    63p3f11 6-52 1 2 3 4 5 6 7 8 9 installing the lower unit 1. Set the gear shift to the neutral position at the lower unit. 2. Align the center of the set pin a with the mark b on the bottom cowling. 3. Install the two dowels 1 into the lower unit. 4. Install the lower unit into the upper case, and th...

  • Page 198: Lowr

    Lowr lower unit 6-53 63p3f11 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 prope...

  • Page 199

    63p3f11 6-54 1 2 3 4 5 6 7 8 9 shimming (counter rotation model) 6 s63p6740 f r p b4 t3 b3 61.0 a3 t1 b1 36.5 a1 t2 b5 a5 a4 a2 t4 b7 b6 16.7 b2 drive shaft and lower case (counter rotation model) / shimming (counter rotation model).

  • Page 200: Lowr

    Lowr lower unit 6-55 63p3f11 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 1....

  • Page 201

    63p3f11 6-56 1 2 3 4 5 6 7 8 9 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 is unreadable, assume that “p” is zero and check the backlash when the unit is assembl...

  • Page 202: Lowr

    Lowr lower unit 6-57 63p3f11 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 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 is u...

  • Page 203

    63p3f11 6-58 1 2 3 4 5 6 7 8 9 3. Calculate the forward gear shim thick- ness (t2) as shown in the examples below. Note: “r” is the deviation of the lower case dimen- sion from standard. The “r” mark a is stamped on the trim tab mounting surface of the lower case in 0.01 mm units. If the “r” mark is...

  • Page 204: Lowr

    Lowr lower unit 6-59 63p3f11 2. Install the thrust bearing 4 onto the pro- peller shaft 5, and then measure the propeller shaft flange and thrust bearing thickness (m7) as shown. 3. Calculate the propeller shaft shim thick- ness (t4) as shown in the examples below. Note: “a” and “b” are the deviatio...

  • Page 205: Backlash

    63p3f11 6-60 1 2 3 4 5 6 7 8 9 8. Measure the propeller shaft free play. Repeat steps 1–7 if out of specification. Backlash (counter rotation model) 6 measuring the forward and reverse gear backlash 1. Remove the water pump assembly. 2. Set the gear shift to the neutral position at the lower unit. 3...

  • Page 206: Lowr

    Lowr lower unit 6-61 63p3f11 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 measure the back- lash when the drive shaft stops in each direction. 7...

  • Page 207

    63p3f11 6-62 1 2 3 4 5 6 7 8 9 14. Turn the shift rod to the reverse position c with the shift rod push arm. 15. Slowly turn the drive shaft clockwise and counterclockwise and measure the back- lash when the drive shaft stops in each direction. Note: when measuring the reverse gear backlash, turn th...

  • Page 208: Lowr

    Lowr lower unit 6-63 63p3f11 — memo —.

  • Page 209: Brkt

    63p3f11 brkt 1 2 3 4 5 6 7 8 9 bracket unit special service tools ..................................................................................... 7-1 bottom cowling .............................................................................................. 7-2 upper case, steering arm, swiv...

  • Page 210: Brkt

    Brkt bracket unit 7-1 63p3f11 special service tools 7 up relief fitting 90890-06773 down relief fitting 90890-06774 hydraulic pressure gauge 90890-06776 trim and tilt wrench new: 90890-06587 current: 90890-06548.

  • Page 211: Bottom Cowling

    63p3f11 7-2 1 2 3 4 5 6 7 8 9 bottom cowling 7 no. Part name q’ty remarks 1 bracket 1 2 shift cut switch 1 3 bracket 1 4 neutral switch 1 5 screw 2 ø4 × 16 mm 6 plate 1 7 bushing 2 8 grease nipple 1 9 bolt 1 10 bolt 2 m6 × 50 mm 11 screw 2 ø4 × 16 mm 12 plate 1 13 bushing 1 14 washer 1 15 shift leve...

  • Page 212: Brkt

    Brkt bracket unit 7-3 63p3f11 7 no. Part name q’ty remarks 18 spacer 1 19 bushing 1 20 bolt 1 m6 × 35 mm 21 bracket 1 22 ball 1 23 bolt 1 24 grease nipple 1 25 spacer 1 26 circlip 1 27 grommet 1 28 screw 2 ø6 × 20 mm 29 adapter 1 30 hose joint 1 31 flushing hose 1 32 grommet 1 33 trim sensor coupler...

  • Page 213

    63p3f11 7-4 1 2 3 4 5 6 7 8 9 7 no. Part name q’ty remarks 1 bottom cowling 1 2 rubber seal 1 3 grommet 2 4 bolt 4 m8 × 35 mm 5 grommet 4 6 grommet 4 7 collar 4 8 cowling lock lever 2 9 bushing 4 10 plate 2 11 bolt 4 m6 × 30 mm 12 wave washer 2 13 lever 2 14 washer 2 15 bolt 2 m6 × 20 mm 16 stay 2 1...

  • Page 214: Brkt

    Brkt bracket unit 7-5 63p3f11 7 no. Part name q’ty remarks 18 grommet 1 19 holder 1 20 bolt 1 m6 × 20 mm 21 retaining plate 1 22 bolt 2 m6 × 30 mm 23 cable holder 1 24 bolt 2 m6 × 20 mm 25 cable holder 1 26 bolt 1 m6 × 20 mm 27 cable holder 1 28 bolt 1 m6 × 20 mm 29 bracket 2 30 bolt 4 m6 × 20 mm 31...

  • Page 215

    63p3f11 7-6 1 2 3 4 5 6 7 8 9 upper case, steering arm, swivel bracket and clamp brackets 7 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 adapter 1 7 plastic tie 1 not reusable 8 hose 1 9 circlip 1 10 nut 2 11 nut 2 12 washer 4...

  • Page 216: Brkt

    Brkt bracket unit 7-7 63p3f11 7 no. Part name q’ty remarks 18 steering arm 1 19 washer 2 20 washer 2 21 trim stopper 2 22 nut 2 23 bolt 4.

  • Page 217

    63p3f11 7-8 1 2 3 4 5 6 7 8 9 7 no. Part name q’ty remarks 1 upper case 1 2 dowel 2 3 grommet 1 4 damper 1 5 screw 2 ø5 × 15 mm 6 baffle plate 1 7 drive shaft bushing 1 8 circlip 1 9 cap 2 10 bolt 2 m14 × 225 mm 11 washer 2 12 washer 2 13 washer 2 14 lower mount 2 15 washer 2 16 bolt 3 m10 × 45 mm 1...

  • Page 218: Brkt

    Brkt bracket unit 7-9 63p3f11 7 no. Part name q’ty remarks 18 washer 2 19 washer 2 20 upper mount 2 21 washer 2 22 collar 2 23 bolt 2 m8 × 30 mm 24 bolt 4 m10 × 45 mm 25 muffler assembly 1 26 gasket 1 not reusable 27 rubber seal 1 28 washer 1 29 drain bolt 1 m14 × 12 mm 30 bracket 1 s63p7100 lt 572 ...

  • Page 219

    63p3f11 7-10 1 2 3 4 5 6 7 8 9 7 no. Part name q’ty remarks 1 bolt 8 m8 × 35 mm 2 muffler 1 3 dowel 2 4 pipe 1 5 rubber seal 1 6 gasket 2 not reusable 7 plate 1 8 gasket 1 not reusable 9 bolt 4 m8 × 60 mm 10 exhaust manifold 1 11 gasket 1 not reusable 12 bolt 10 m8 × 35 mm 13 oil pan 1 14 dowel 2 15...

  • Page 220: Brkt

    Brkt bracket unit 7-11 63p3f11 7 no. Part name q’ty remarks 18 gasket 1 not reusable 19 gasket 1 not reusable 20 exhaust guide 1 s63p7110 20 19 18 17 16 15 12 14 13 11 10 8 9 6 7 4 5 2 3 lt 572 lt lt 572 lt a a a a t r . . 20 n · m (2.0 kgf · m, 14.8 ft · ib) t r . . 20 n · m (2.0 kgf · m, 14.8 ft ·...

  • Page 221

    63p3f11 7-12 1 2 3 4 5 6 7 8 9 draining the engine oil 1. Place a drain pan under the drain hole, and then remove the drain bolt 1 and let the oil drain completely. 2. Remove the upper and lower mounting nut, and then remove the upper case. 3. Remove the muffler assembly from the upper case. Disasse...

  • Page 222: Brkt

    Brkt bracket unit 7-13 63p3f11 3. Install the oil pan 4, and then tighten the bolts finger tight. 4. Install the exhaust manifold 5 and bolts, and then tighten the bolts finger tight. 5. Tighten the exhaust manifold bolts 6, then the oil pan bolts 7, and then tighten them to the specified torques. 6...

  • Page 223

    63p3f11 7-14 1 2 3 4 5 6 7 8 9 11. Install the upper mounts e and bolts into the upper case. 12. Install the bracket f and bolts, and then tighten the bolts to the specified torque. Removing the steering arm 1. Remove the circlip 1. 2. Remove the steering yoke 2 by striking it with a plastic hammer....

  • Page 224: Brkt

    Brkt bracket unit 7-15 63p3f11 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 steer- ing arm. 5. Install the circlip 0. 6. Inject grease into the grease nipple until grease comes out from both the upper and lower bushings c. Insta...

  • Page 225: Clamp Brackets

    63p3f11 7-16 1 2 3 4 5 6 7 8 9 clamp brackets 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 grease nipple 6 6 ground lead 3 7 washer 1 8 bolt 1 m6 × 11 mm 9 washer 2 10 bushing 6 11 trim sensor 1 12 screw 2 ø6 × 15 mm 13 trim sensor cam 1 ...

  • Page 226: Brkt

    Brkt bracket unit 7-17 63p3f11 7 no. Part name q’ty remarks 18 anode 1 19 through tube 1 20 bolt 1 m8 × 20 mm 21 tilt stop lever 1 22 bush 4 23 collar 1 24 distance collar 2 25 spring pin 2 26 pin 1 27 spring 1 28 spring hook 1 29 bolt 1 m6 × 10 mm 30 tilt stop lever 1.

  • Page 227

    63p3f11 7-18 1 2 3 4 5 6 7 8 9 removing the clamp brackets 1. Remove the power trim and tilt unit. For removal procedures, see “removing the power trim and tilt unit.” 2. Remove the anode. 3. Remove the bolt and grease nipples, and then disconnect the ground leads. 4. Remove the self-locking nut and...

  • Page 228: Brkt

    Brkt bracket unit 7-19 63p3f11 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 229: Power Trim and Tilt Unit

    63p3f11 7-20 1 2 3 4 5 6 7 8 9 power trim and tilt unit 7 no. Part name q’ty remarks 1 power trim and tilt unit 1 2 ptt motor lead 2 3 shaft 1 4 plastic tie 3 not reusable 5 circlip 1 6 bolt 2 m8 × 16 mm 7 washer 2 8 shaft 1 9 bushing 6 10 bolt 1 m6 × 10 mm 11 ground lead 1 s60x7010 1 2 3 4 5 6 6 7 ...

  • Page 230: Brkt

    Brkt bracket unit 7-21 63p3f11 7 no. Part name q’ty remarks 1 power trim and tilt motor 1 2 reservoir 1 3 reservoir cap 1 4 o-ring 1 5 o-ring 1 not reusable 6 bolt 3 m6 × 14 mm 7 bolt 4 m6 × 35 mm 8 o-ring 1 not reusable 9 filter 1 10 joint 1 s60x7180 1 2 3 4 5 6 7 8 9 10 t r . . 5 n · m (0.5 kgf · ...

  • Page 231

    63p3f11 7-22 1 2 3 4 5 6 7 8 9 7 no. Part name q’ty remarks 1 screw 1 ø4 × 15 mm 2 stator 1 3 armature 1 4 o-ring 1 not reusable 5 screw 2 ø4 × 12 mm 6 brush holder 1 7 brush 2 1 8 brush 1 1 9 brush holder 1 10 brush spring 2 11 ptt motor base 1 12 oil seal 1 not reusable 13 bearing 1 not reusable 1...

  • Page 232: Brkt

    Brkt bracket unit 7-23 63p3f11 7 no. Part name q’ty remarks 1 bolt 4 m5 × 16 mm 2 gear pump assembly 1 3 ball 2 4 shuttle piston 2 5 o-ring 2 not reusable 6 main valve 2 7 ball 2 8 bolt 1 9 bolt 2 10 circlip 1 11 manual valve 1 12 o-ring 1 not reusable 13 o-ring 1 not reusable 14 backup ring 1 15 sp...

  • Page 233

    63p3f11 7-24 1 2 3 4 5 6 7 8 9 7 no. Part name q’ty remarks 18 up-relief valve seat 1 19 o-ring 1 not reusable 20 filter 2 21 o-ring 1 not reusable 22 down-relief valve 1 23 valve pin 1 24 o-ring 4 not reusable 25 valve seat 1 26 pin 1 27 ball 1 28 o-ring 1 not reusable s60x7200 1 3 4 5 6 7 8 9 10 1...

  • Page 234: Brkt

    Brkt bracket unit 7-25 63p3f11 7 no. Part name q’ty remarks 1 tilt ram 1 2 trim ram 2 3 cylinder body 1 4 free piston 1 5 backup ring 1 6 o-ring 1 not reusable 7 dust seal 2 not reusable 8 seal 2 not reusable 9 trim cylinder end screw 2 10 o-ring 2 not reusable 11 backup ring 2 12 o-ring 2 not reusa...

  • Page 235

    63p3f11 7-26 1 2 3 4 5 6 7 8 9 7 no. Part name q’ty remarks 18 o-ring 1 not reusable 19 o-ring 1 not reusable 20 washer 1 21 nut 1 22 ball 4 23 valve 4 24 spring 4 s63p7350 1 2 3 4 5 5 6 6 7 7 8 8 9 10 11 11 12 12 13 13 14 15 15 16 16 17 18 18 19 19 20 21 22 23 24 t r . . 78 n · m (7.8 kgf · m, 57.5...

  • Page 236: Brkt

    Brkt bracket unit 7-27 63p3f11 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 237

    63p3f11 7-28 1 2 3 4 5 6 7 8 9 note: hold the power trim and tilt unit with one hand, and pull the upper mount shaft out at a downward angle with the other. 6. Remove the collars. Checking the hydraulic pressure 1. Remove the reservoir cap, and then check the fluid level in the reservoir. Note: if t...

  • Page 238: Brkt

    Brkt bracket unit 7-29 63p3f11 7. Connect the ptt motor leads to the bat- tery terminals to fully retract the trim and tilt rams. 8. Reverse the ptt motor leads between the battery terminals to fully extend the trim and tilt rams, and then measure the hydraulic pressure. 9. Replace the up relief fit...

  • Page 239

    63p3f11 7-30 1 2 3 4 5 6 7 8 9 13. Connect the ptt motor leads to the bat- tery terminals to fully retract the trim and tilt rams, and then measure the hydraulic pressure. If out of specification, overhaul the power trim and tilt unit. 14. Reverse the ptt motor leads between the battery terminals to...

  • Page 240: Brkt

    Brkt bracket unit 7-31 63p3f11 3. Remove the lead holder 1 and rubber spacers 2 from the stator, and then slide them away from the stator. 4. Remove the stator 3. Note: place a clean cloth over the end of the arma- ture shaft, hold it with a pair of pliers, and then carefully slide the stator off of...

  • Page 241

    63p3f11 7-32 1 2 3 4 5 6 7 8 9 2. Check the brush and circuit breaker for continuity. Replace if there is no continu- ity. Caution: do not touch the bimetal b, otherwise the operation of the circuit breaker can be affected. 3. Measure the commutator diameter. Replace if out of specification. 4. Chec...

  • Page 242: Brkt

    Brkt bracket unit 7-33 63p3f11 assembling the power trim and tilt motor 1. Connect the ptt motor leads 1, and then tighten the screws 2. 2. Push the brushes 3 into the brush holder, and then install the armature 4. 3. Install the stator onto the base. Note: place a clean cloth over the end of the ar...

  • Page 243

    63p3f11 7-34 1 2 3 4 5 6 7 8 9 3. Drain the fluid from the reservoir and check it for damage. Replace if neces- sary. 4. Check the reservoir cap and o-ring for damage. Replace if necessary. Disassembling the gear pump housing 1. Remove the gear pump housing. Note: make sure that the o-rings, valve p...

  • Page 244: Brkt

    Brkt bracket unit 7-35 63p3f11 5. Remove the main valves. Warning never look into the pump housing open- ing while removing the main valves because the main valves and power trim and tilt fluid can be forcefully expelled out. Note: to remove the main valves, cover the pump housing with a clean cloth...

  • Page 245

    63p3f11 7-36 1 2 3 4 5 6 7 8 9 2. Install new o-rings 6 onto the main valves 7, and then install the main valves into the gear pump housing. 3. Install the drive gears 8 into the gear pump housing. 4. Install the balls 9, shuttle pistons 0, and balls a into the gear pump cover. Note: apply grease to...

  • Page 246: Brkt

    Brkt bracket unit 7-37 63p3f11 disassembling the tilt cylinder and trim cylinder 1. Loosen the tilt cylinder end screw, and then remove the tilt piston assembly. Caution: make sure that the trim and tilt rams are fully extended before removing the tilt cyl- inder end screw. 2. Drain the fluid. 3. Lo...

  • Page 247

    63p3f11 7-38 1 2 3 4 5 6 7 8 9 checking the tilt cylinder and trim cylinder 1. Disassemble the tilt piston assembly. 2. Check the tilt piston and free piston for scratches. Replace if necessary. 3. Blow the tilt piston absorber valve with compressed air to remove any foreign material. Check the valv...

  • Page 248: Brkt

    Brkt bracket unit 7-39 63p3f11 assembling the tilt piston and trim pistons 1. Install the new dust seal 1 and new o- rings 2 and 3 onto the tilt cylinder end screw. 2. Install the tilt cylinder end screw 4 onto the tilt ram 5. 3. Install new o-rings 6 and 7 onto the tilt piston 8. 4. Install the bal...

  • Page 249

    63p3f11 7-40 1 2 3 4 5 6 7 8 9 assembling the power trim and tilt unit 1. Fill the tilt cylinder with the specified amount of the recommended fluid through the hole a. 2. Push the free piston 1 into the tilt cylin- der until it bottoms out. 3. Fill the trim cylinders with the recom- mended fluid to ...

  • Page 250: Brkt

    Brkt bracket unit 7-41 63p3f11 4. Install the trim piston assemblies into the trim cylinders, and then tighten the trim cylinder end screws to the specified torque. Caution: • make sure that the trim rams are fully extended when installing them. • once installed, never push the trim rams down, other...

  • Page 251

    63p3f11 7-42 1 2 3 4 5 6 7 8 9 10. Install the tilt piston assembly into the tilt cylinder, and then tighten the tilt cylinder end screw to the specified torque. Caution: • make sure that the tilt ram is fully extended when installing it. • once installed, never push the tilt ram down, otherwise flu...

  • Page 252: Brkt

    Brkt bracket unit 7-43 63p3f11 15. Remove the reservoir cap, and then check the fluid level in the reservoir. Note: if the fluid is at the correct level, the fluid should overflow out of the filler hole when the reservoir cap is removed. 16. If necessary, add sufficient fluid of the recommended type...

  • Page 253

    63p3f11 7-44 1 2 3 4 5 6 7 8 9 note: • repeat this procedure so that the rams go up and down four or five times (be sure to wait a few seconds before switching the leads). • if the rams do not move up and down eas- ily, push and pull on the rams to assist operation. 8. Check the fluid level when the...

  • Page 254: Brkt

    Brkt bracket unit 7-45 63p3f11 bleeding the power trim and tilt unit (built-in) 1. Fully turn the manual valve counterclock- wise. 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. Le...

  • Page 255

    63p3f11 7-46 1 2 3 4 5 6 7 8 9 power trim and tilt electrical system 7 1 fuse holder 2 fuse (20 a) 3 fuse (50 a) 4 battery 5 power trim and tilt relay 6 power trim and tilt motor 7 diode 8 trim sensor 9 power trim and tilt switch È to remote control box/switch panel É to trim meter b : black gy : gr...

  • Page 256: Brkt

    Brkt bracket unit 7-47 63p3f11 checking the fuse 1. Check the fuse for continuity. Replace if there is no continuity. Checking the power trim and tilt relay 1. Check the power trim and tilt relay for continuity. Replace if out of specification. Note: be sure to set the measurement range a shown in t...

  • Page 257

    63p3f11 7-48 1 2 3 4 5 6 7 8 9 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. Lead color switch position sky blue (sb) red (r) light green (lg) up free down trim sensor resist...

  • Page 258: Brkt

    Brkt bracket unit 7-49 63p3f11 — memo —.

  • Page 259: Elec

    63p3f11 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 260: Elec

    Elec electrical systems – + 8-1 63p3f11 special service tools 8 ignition tester 90890-06754 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 (3 pins) 90890-06793 test harness (3 pins) 90890-06847 te...

  • Page 261: Checking The Electrical

    63p3f11 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 262: Elec

    Elec electrical systems – + 8-3 63p3f11 electrical components 8 port view 1 ecm 2 starter motor 3 rectifier regulator 4 thermoswitch 5 ignition coil 6 oil pressure sensor 7 junction box 8 fuse holder s63p8010 1 2 3 4 5 6 7 8.

  • Page 263

    63p3f11 8-4 1 2 3 4 5 6 7 8 9 junction box assembly 1 ecm 2 power trim and tilt relay 3 starter relay 4 diode 5 fuse (30 a) 6 main relay 7 fuse (20 a) 8 fuse (50 a) 9 intake air temperature sensor s63p8020 1 9 8 7 6 5 4 3 2 electrical components.

  • Page 264: Elec

    Elec electrical systems – + 8-5 63p3f11 aft view 1 intake air pressure sensor 2 throttle position sensor 3 fuel injector 4 shift cut switch 5 neutral switch 6 ignition coil 7 thermoswitch 8 spark plug s63p8030 7 6 1 2 3 3 4 5 8 a a a-a.

  • Page 265

    63p3f11 8-6 1 2 3 4 5 6 7 8 9 top view 1 fuel injector 2 ignition coil 3 starter motor 4 stator coil 5 engine temperature sensor 6 throttle position sensor 7 idle speed control 8 intake air pressure sensor 9 shift cut switch 0 neutral switch a power trim and tilt switch s63p8040 2 3 4 5 6 7 8 1 9 0 ...

  • Page 266: Elec

    Elec electrical systems – + 8-7 63p3f11 wiring harness connect to: 1 fuse holder 2 fuse holder 3 diagnostic flash indicator 4 starter relay 5 ground 6 power trim and tilt relay 7 ecm 8 intake air temperature sensor 9 personal computer for diagnosis 0 power trim and tilt switch a warning indicator b ...

  • Page 267

    63p3f11 8-8 1 2 3 4 5 6 7 8 9 b : black br : brown g : green gy : gray l : blue lg : light green o : orange p : pink r : red sb : sky blue w : white y : yellow b/o : black/orange b/w : black/white b/y : black/yellow g/b : green/black g/r : green/red g/y : green/yellow l/g : blue/green l/w : blue/whi...

  • Page 268: Elec

    Elec electrical systems – + 8-9 63p3f11 ignition and ignition control system 8 1 spark plug 2 ignition coil 3 thermoswitch 4 oil pressure sensor 5 pulser coil 6 stator coil 7 ecm 8 intake air temperature sensor 9 fuse holder 0 main relay a fuse (20 a) b fuse (50 a) c battery d rectifier regulator e ...

  • Page 269

    63p3f11 8-10 1 2 3 4 5 6 7 8 9 8 b : black g : green o : orange p : pink r : red y : yellow b/o : black/orange b/w : black/white b/y : black/yellow g/b : green/black g/r : green/red g/y : green/yellow l/g : blue/green l/y : blue/yellow p/g : pink/green p/w : pink/white r/y : red/yellow w/b : white/b...

  • Page 270: Elec

    Elec electrical systems – + 8-11 63p3f11 checking the ignition spark gap 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 through the discharge window of the...

  • Page 271

    63p3f11 8-12 1 2 3 4 5 6 7 8 9 checking the ecm 1. Disconnect a 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 272: Elec

    Elec electrical systems – + 8-13 63p3f11 checking the throttle position sensor 1. Remove the flywheel magnet cover. 2. Connect the test harness (3 pins) to the throttle position sensor. 3. Turn the engine start switch to on. 4. Measure the throttle position sensor input voltage. Check the wiring har...

  • Page 273

    63p3f11 8-14 1 2 3 4 5 6 7 8 9 checking the thermoswitch 1. Place the thermoswitches in a container of water and slowly heat the water. 2. Check the switch for continuity at the specified temperatures. Replace if out of specification. A temperature b time c no continuity d continuity checking the sh...

  • Page 274: Elec

    Elec electrical systems – + 8-15 63p3f11 fuel control system 8 1 pulser coil 2 ecm 3 intake air temperature sensor 4 fuse holder 5 main relay 6 fuse (20 a) 7 fuse (50 a) 8 battery 9 engine temperature sensor 0 idle speed control a throttle position sensor b intake air pressure sensor c fuel injector...

  • Page 275

    63p3f11 8-16 1 2 3 4 5 6 7 8 9 8 b : black g : green l : blue o : orange p : pink r : red y : yellow b/y : black/yellow g/b : green/black g/r : green/red g/y : green/yellow p/g : pink/green pu/b : purple/black pu/g : purple/green pu/r : purple/red pu/y : purple/yellow r/y : red/yellow w/b : white/bl...

  • Page 276: Elec

    Elec electrical systems – + 8-17 63p3f11 checking the injectors 1. Measure the resistance of the fuel injec- tors. Replace if out of specification. Note: check the operation of the fuel injectors using the “stationary test” of the yamaha diagnostic system. Checking the main relay 1. Remove the fuse ...

  • Page 277: Starting System

    63p3f11 8-18 1 2 3 4 5 6 7 8 9 starting system 8 1 fuse holder 2 fuse (30 a) 3 fuse (20 a) 4 fuse (50 a) 5 starter relay 6 starter motor 7 battery È to remote control box/switch panel b : black br : brown r : red br/w : brown/white s63p8220 r b br 1 d c b a 0 9 8 7 6 5 4 3 2 e f g 1 3 2 4 h i 17 r 1...

  • Page 278: Elec

    Elec electrical systems – + 8-19 63p3f11 checking the fuses 1. Check the fuses for continuity. Replace if there is no continuity. Checking the starter relay 1. Connect the digital circuit tester leads to the starter relay terminals. 2. Connect the positive battery terminal to the brown (br) lead. 3....

  • Page 279: Starter Motor

    63p3f11 8-20 1 2 3 4 5 6 7 8 9 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 14 outer ge...

  • Page 280: Elec

    Elec electrical systems – + 8-21 63p3f11 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...

  • Page 281

    63p3f11 8-22 1 2 3 4 5 6 7 8 9 removing the starter motor pinion 1. Slide the pinion stopper 1 down as shown, and then remove the clip 2. Note: remove the clip with a thin screwdriver. Checking the starter motor pinion 1. Check the teeth of the pinion for cracks or wear. Replace if necessary. 2. Che...

  • Page 282: Elec

    Elec electrical systems – + 8-23 63p3f11 4. Check the armature for continuity. Replace if out of specifications. Checking the brushes 1. Measure the brush length. Replace the brush assembly if out of specification. 2. Check the brush holder assembly for continuity. Replace if out of specifica- tions...

  • Page 283: Charging System

    63p3f11 8-24 1 2 3 4 5 6 7 8 9 charging system 8 1 stator coil 2 rectifier regulator 3 fuse holder 4 fuse (50 a) 5 accessory battery 6 battery b : black g : green r : red s63p8230 #1/4 #2/3 g g g b r r 1 2 3 4 5 6 7 8 9 0 a b c d e f g h i 3 4 4 r b 19 r 18 r 17 r 16 r b g g r r g 2 1 b b b r b 6 5 ...

  • Page 284: Elec

    Elec electrical systems – + 8-25 63p3f11 checking the stator coil 1. Disconnect the stator coil coupler. 2. Connect the test harness (3 pins) to the stator coil. 3. Measure the stator coil output peak volt- age. Replace the stator coil assembly if below specification. Checking the rectifier regulato...

  • Page 285: Trbl

    63p3f11 trbl shtg 1 2 3 4 5 6 7 8 9 troubleshooting special service tools ..................................................................................... 9-1 yamaha diagnostic system .......................................................................... 9-2 introduction.......................

  • Page 286: Trbl

    Trbl shtg troubleshooting 9-1 63p3f11 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 287: Yamaha Diagnostic System

    63p3f11 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 288: Trbl

    Trbl shtg troubleshooting 9-3 63p3f11 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 289

    63p3f11 9-4 1 2 3 4 5 6 7 8 9 connecting the communication cable to the outboard motor models: f(l)150a bow view s63p9030 3-pin communication coupler yamaha diagnostic system.

  • Page 290: Trbl

    Trbl shtg troubleshooting 9-5 63p3f11 note: • before troubleshooting the outboard motor, check the compression pressure, the mounting and rigging of the outboard motor, and the operation of the engine start switch. Also, make sure that specified fuel has been used and that the battery is fully charg...

  • Page 291

    63p3f11 9-6 1 2 3 4 5 6 7 8 9 yes no check the wiring harness for continuity. Yes repair or replace the wiring har- ness. No disassemble and check the starter motor. Replace the starter relay. Is there continuity? Is there continuity? Power unit.

  • Page 292: Trbl

    Trbl shtg troubleshooting 9-7 63p3f11 ignition system check the condition of the spark plugs. Clean, adjust, or replace the spark plugs. No check the ignition spark using the spark gap tester. Warning • do not touch any of the connections of the spark gap tester leads. • do not let sparks leak out o...

  • Page 293

    63p3f11 9-8 1 2 3 4 5 6 7 8 9 fuel system yes repair or replace the spark plug wires. No good condition? Check the ecm output peak voltage. Check the main relay for conti- nuity. No is there continuity? Yes replace the main relay. Check the electric fuel pump operation. Yes no yes no replace the ele...

  • Page 294: Trbl

    Trbl shtg troubleshooting 9-9 63p3f11 yes no check the starting system or the ignition system. Replace the injectors. Good condition? No yes replace the diaphragm. Check the vapor separator needle valve. No yes replace the needle valve. Check the injector resistance and check the injectors for clogs...

  • Page 295

    63p3f11 9-10 1 2 3 4 5 6 7 8 9 symptom 2: engine speed at wide open throttle is low, engine speed decreases, or engine stalls (poor acceleration or poor deceleration). Yes repair or replace the defective parts. No yes repair or replace the defective part. No check the throttle valves for bends or fo...

  • Page 296: Trbl

    Trbl shtg troubleshooting 9-11 63p3f11 ignition system check the condition of the spark plugs. Clean, adjust, or replace the spark plugs. No check the ignition spark using the spark gap tester. No yes warning • do not touch any of the connections of the spark gap tester leads. • do not let sparks le...

  • Page 297

    63p3f11 9-12 1 2 3 4 5 6 7 8 9 fuel system yes repair or replace the spark plug wires. No good condition? Check the ecm output peak voltage. Check the electric fuel pump operation. Yes no yes no repair or replace the defective parts. Yes no repair or replace the defective parts. Check the fuse holde...

  • Page 298: Trbl

    Trbl shtg troubleshooting 9-13 63p3f11 yes no yes no check the injector resistance and check the injectors for clogs. Replace the pressure regulator. Replace the injectors. Check the starting system or the ignition system. Good condition? Good condition? No yes check the vapor separator nee- dle val...

  • Page 299

    63p3f11 9-14 1 2 3 4 5 6 7 8 9 lubrication system add engine oil to the correct level. No check the oil pump for debris or oil leaks. Yes no check the oil passage. Replace the oil pressure sensor. At specified level? Debris or leaks? Check the engine oil level. Yes check the oil pressure. Within spe...

  • Page 300: Trbl

    Trbl shtg troubleshooting 9-15 63p3f11 symptom 3: engine speed not stable at low speeds. Yes repair or replace the defective part. No check the neutral switch for continuity. Yes repair or replace the defective parts. No check the throttle valve opening of each cylinder. Check the ignition system or...

  • Page 301

    63p3f11 9-16 1 2 3 4 5 6 7 8 9 ignition system check the condition of the spark plugs. Clean, adjust, or replace the spark plugs. No check the ignition spark using the spark gap tester. Yes warning • do not touch any of the connections of the spark gap tester leads. • do not let sparks leak out of t...

  • Page 302: Trbl

    Trbl shtg troubleshooting 9-17 63p3f11 fuel system check the fuel pump dia- phragm. Check the vapor separator nee- dle valve. Yes no replace the diaphragm. Replace the needle valve. Replace the injectors. Check the injector resistance and check the injectors for clogs. Check the ignition system. Goo...

  • Page 303

    63p3f11 9-18 1 2 3 4 5 6 7 8 9 symptom 4: hunting occurs. Symptom 5: engine speed rises even when the throttle position is fixed. Check the throttle valve opening of each cylinder. No synchronize the throttle valves or replace the defective parts. Yes are the throttle valves open excessively? Adjust...

  • Page 304: Trbl

    Trbl shtg troubleshooting 9-19 63p3f11 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. C...

  • Page 305

    63p3f11 9-20 1 2 3 4 5 6 7 8 9 code symptom 1 normal 13 incorrect pulser coil signal 15 incorrect engine temperature sensor signal 18 incorrect throttle position sensor signal 19 incorrect battery voltage 23 incorrect intake air temperature sensor signal 28 incorrect neutral switch signal 29 incorre...

  • Page 306: Numerics

    Index i-1 63p3f11 numerics 64e type power trim and tilt unit................1-11 a. Adjusting the throttle link and throttle cable .............................................3-8 adjusting the throttle link and throttle cable operation (using a thickness gauge) .......3-10 adjusting the throttle po...

  • Page 307

    63p3f11 i-2 1 2 3 4 5 6 7 8 9 index checking the injectors...............................8-17 checking the intake air temperature sensor .....................................................8-13 checking the lower case................. 6-18 , 6-47 checking the lower unit for air leakage .....3-15 ch...

  • Page 308

    Index i-3 63p3f11 e. Ecm ..........................................................1-17 electrical .....................................................2-7 electrical components.................................8-3 electronic control system ..........................1-17 f. Fail-safe control ...........

  • Page 309

    63p3f11 i-4 1 2 3 4 5 6 7 8 9 index removing the steering arm .......................7-14 removing the timing belt and sprockets ...5-20 removing the water pump and shift rod ........................................... 6-8 , 6-36 replacing the oil filter..................................3-5 replacin...

  • Page 310: Wiring Diagram

    Wiring diagram f150aet, fl150aet 1 spark plug 2 ignition coil 3 thermoswitch 4 oil pressure sensor 5 diode 6 starter relay 7 starter motor 8 starting battery 9 accessory battery 0 fuse holder a fuse (30 a) b fuse (20 a) c fuse (50 a) d intake air temperature sensor e power trim and tilt relay f powe...

  • Page 312

    Yamaha motor co., ltd. Printed in the netherlands jul. 2003 – 1.2 × 1 cr (e).

  • Page 313

    15 16 17 18 19 1 2 3 4 7 8 9 10 42 32 22 12 14 35 15 43 44 37 38 39 40 31 33 34 26 27 28 17 18 19 20 29 30 21 23 24 1 2 3 4 8 9 10 5 6 7 11 12 13 14 b/o w/b l/w p/w y p/w p/b r/y g/y b p pu/b pu/y b/y p p/g pu/r l/g b b/w pu/g o l g g/b w/b w/r g/r y/g b/y l/y b w p o g r r r r r r/y r/y r/y r/y y/g...