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Yamaha F90D Service Manual

Other manuals for F90D: Ower's Manual
Manual is about: Outboard Motor F90D

Summary of F90D

  • Page 1

    F90d service manual 6d8-28197-1g-11 lit-18616-02-86 *lit186160286*.

  • Page 2

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

  • Page 3: Contents

    Contents general information 1 gen info specifications 2 spec periodic checks and adjustments 3 chk adj fuel system 4 fuel power unit 5 powr lower unit 6 lowr bracket unit 7 brkt electrical systems 8 elec troubleshooting 9 trbl shtg index – +.

  • Page 4: General Information

    6d81g11 gen info 1 2 3 4 5 6 7 8 9 general information how to use this manual ................................................................................. 1-1 manual format............................................................................................ 1-1 symbols......................

  • Page 5

    Gen info general information 1-1 6d81g11 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 6

    6d81g11 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 7

    Gen info general information 1-3 6d81g11 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 8

    6d81g11 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 9

    Gen info general information 1-5 6d81g11 identification 1 applicable model this manual covers the following model. Serial number the outboard motor serial number is stamped on a label attached to the port clamp bracket. 1 model name 2 approved model code 3 transom height 4 serial number propeller se...

  • Page 10

    6d81g11 1-6 1 2 3 4 5 6 7 8 9 selection when the engine speed is at the full throttle operating range (5,000–6,000 r/min), the ideal propeller for the boat is one that pro- vides maximum performance in relation to boat speed and fuel consumption. Predelivery checks 1 to make the delivery process smo...

  • Page 11

    Gen info general information 1-7 6d81g11 checking the gear oil level 1. Check the gear oil level. Checking the battery 1. Check the capacity, electrolyte level, and specified gravity of the battery. 2. Check that the positive and negative bat- tery leads are securely connected. Checking the outboard...

  • Page 12

    6d81g11 1-8 1 2 3 4 5 6 7 8 9 warning the shift/throttle cable joint must be screwed in a minimum of 8.0 mm (0.31 in) c. Checking the steering system 1. Check the steering friction for proper adjustment. 2. Check that the steering operates smoothly. 3. Check that there is no interference with wires ...

  • Page 13

    Gen info general information 1-9 6d81g11 3. Check that the engine turns off when the engine stop lanyard is pulled from the engine stop lanyard switch. Checking the cooling water pilot hole 1. Check that cooling water is discharged from the cooling water pilot hole. Test run 1. Start the engine, and...

  • Page 14: Specifications

    6d81g11 spec 1 2 3 4 5 6 7 8 9 specifications general specifications................................................................................... 2-1 maintenance specification ............................................................................ 2-3 power unit..............................

  • Page 15

    Spec specifications 2-1 6d81g11 general specifications 2 item unit model f90tr dimension overall length mm (in) 817 (32.2) overall width mm (in) 479 (18.9) overall height (l) mm (in) 1,582 (62.3) (x) mm (in) 1,710 (67.3) boat transom height (l) mm (in) 508 (20.0) (x) mm (in) 635 (25.0) weight (witho...

  • Page 16

    6d81g11 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 mca: marine cranking ampere abyc: american boat and yacht council sae: society of automotive engineers rc: reserve capacity fuel and oil fuel type reg...

  • Page 17

    Spec specifications 2-3 6d81g11 maintenance specification 2 power unit item unit model f90tr power unit minimum compression pressure (*1) kpa (kgf/cm 2 , psi) 860 (8.6, 124.7) oil pressure (*2) kpa (kgf/cm 2 , psi) 510 (5.1, 74.0) at engine idle speed cylinder head warpage limit mm (in) 0.1 (0.0039)...

  • Page 18

    6d81g11 2-4 1 2 3 4 5 6 7 8 9 oil ring dimension b mm (in) 2.38–2.48 (0.0937–0.0976) dimension t (*) mm (in) 2.40 (0.0945) end gap mm (in) 0.20–0.70 (0.0079–0.0276) side clearance mm (in) 0.03–0.15 (0.0012–0.0059) camshafts intake (a) mm (in) 36.48–36.58 (1.4362–1.4402) exhaust (a) mm (in) 36.90–37....

  • Page 19

    Spec specifications 2-5 6d81g11 valve lifters valve lifter outside diameter mm (in) 27.965–27.980 (1.1010–1.1016) valve lifter-to-cylinder head clearance mm (in) 0.020–0.056 (0.0008–0.0022) valve shims valve shim thickness (in 0.025 mm increments) mm (in) 2.0–3.3 (0.08–0.13) connecting rods big end ...

  • Page 20

    6d81g11 2-6 1 2 3 4 5 6 7 8 9 lower unit electrical oil pump discharge at 97–103 °c (207–217 °f) with 10w-30 engine oil l (us gal, imp gal)/min 5.9 (1.559, 1.298) at 1,000 r/min pressure at 97–103 °c (207–217 °f) with 10w-30 engine oil kpa (kgf/cm 2 , psi) 118.0 (1.18, 17.1) at 1,000 r/min relief va...

  • Page 21

    Spec specifications 2-7 6d81g11 ecm output peak voltage (b/r, b/w – ground) at cranking (loaded) v 210 at 1,500 r/min (loaded) v 290 at 3,500 r/min (loaded) v 290 pulser coil output peak voltage (w/r, w/b – b) at cranking (unloaded) v 3.6 at cranking (loaded) v 3.4 at 1,500 r/min (loaded) v 18.2 at ...

  • Page 22

    6d81g11 2-8 1 2 3 4 5 6 7 8 9 charging system fuse a 20 stator coil output peak voltage (w – w) at cranking (unloaded) v 12.4 at 1,500 r/min (unloaded) v 45.3 at 3,500 r/min (unloaded) v 98.3 stator coil resistance (*) (w – w) at 20 °c (68 °f) Ω 0.24–0.36 rectifier regulator output peak voltage (r–g...

  • Page 23

    Spec specifications 2-9 6d81g11 dimensions exterior 527 (20.7) 366 (14.4) 49 (1.9) 27 (1.1) l : 766 (30.2) x: 842 (33.1) 857 (33.7) 666 (26.2) l : 917 (36.1) x: 1,044 (41.1) l : 536 (21.1) x : 663 (26.1) l : 25 (1.0) x : 24 (0.9) 191 (7.5) 171 (6.73) 62 (2.4) 66˚ 574 (22.6) 28 (1.1) 164 (6.5) 651 (2...

  • Page 24

    6d81g11 2-10 1 2 3 4 5 6 7 8 9 clamp bracket 348.5 (13.7) 180 (7.1) 163.5 (6.4) 163.5 (6.4) 180 (7.1) 18.5 (0.7) 254 (10.0) 13 (0.5) 80 (3.1) 50.8 (2.0) 55.5 (2.2) 13 (0.5) 125.4 (4.9) 125.4 (4.9) mm (in) s6d82020 maintenance specification.

  • Page 25

    Spec specifications 2-11 6d81g11 tightening torques 2 specified torques part to be tightened thread size tightening torques n·m kgf·m ft·lb fuel system fuel filter cup — 3 0.3 2.2 fuel pump mounting bolt m6 10 1.0 7.4 fuel pump screw m6 4 0.4 3.0 sensor assembly screw m5 3.7 0.37 2.7 idle speed cont...

  • Page 26

    6d81g11 2-12 1 2 3 4 5 6 7 8 9 cylinder head bolt 1st m8 14 1.4 10.3 2nd 28 2.8 20.7 1st m10 15 1.5 11.1 2nd 30 3.0 22.1 3rd 90° spark plug — 25 2.5 18.4 cylinder block plug m14 23 2.3 17.0 oil filter joint — 49 4.9 36.1 oil filter — 18 1.8 13.3 exhaust cover bolt 1st m6 6 0.6 4.4 2nd 12 1.2 8.9 ano...

  • Page 27

    Spec specifications 2-13 6d81g11 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 28

    6d81g11 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 29

    Chk adj periodic checks and adjustments 3-1 6d81g11 special service tools 3 digital tachometer yu-39951-b battery powered timing light ym-33277-a pressure/vacuum tester yb-35956-a oil filter wrench yu-38411.

  • Page 30

    6d81g11 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 31

    Chk adj periodic checks and adjustments 3-3 6d81g11 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 32

    6d81g11 3-4 1 2 3 4 5 6 7 8 9 power unit 3 checking the engine oil 1. Place the outboard motor in an upright position. 2. Remove the oil dipstick, wipe it clean, and then insert it back into the dipstick hole. 3. Remove the oil dipstick again to check the oil level and to check the oil for dis- colo...

  • Page 33

    Chk adj periodic checks and adjustments 3-5 6d81g11 2. Remove the oil dipstick and oil filler cap 1. 3. Place a drain pan under the drain hole, and then remove the drain bolt 2 and let the oil drain completely. Note: be sure to clean up any oil spills. 4. Install the drain bolt, and then tighten it ...

  • Page 34

    6d81g11 3-6 1 2 3 4 5 6 7 8 9 5. Pour the specified amount of the recom- mended engine oil into the oil filler hole. 6. Install the oil filler cap and oil dipstick, and then start the engine and warm it up for 5 minutes. 7. Turn the engine off, and then check the oil level and correct it if necessar...

  • Page 35

    Chk adj periodic checks and adjustments 3-7 6d81g11 5. Check the spark plug gap a. Adjust if out of specification. 6. Install the spark plugs, tighten them fin- ger tight, then to the specified torque using a spark plug wrench. 7. Install the spark plug wire cover. Checking the thermostat 1. Remove ...

  • Page 36

    6d81g11 3-8 1 2 3 4 5 6 7 8 9 6. Install the thermostat and cover. 7. Connect the cooling water hose, and then install the flywheel magnet cover. Checking the cooling water passage 1. Check the cooling water inlet cover 1 and cooling water inlet for clogs. Clean if necessary. 2. Place the lower unit...

  • Page 37

    Chk adj periodic checks and adjustments 3-9 6d81g11 3. Loosen the locknut 1, remove the clip 2, and then disconnect the throttle cable joint 3. 4. Loosen the locknut 4, and then discon- nect the throttle link rod joint 5 from the ball joint of the throttle body. 5. Check that the stopper 6 on the th...

  • Page 38

    6d81g11 3-10 1 2 3 4 5 6 7 8 9 warning the throttle cable joint must be screwed in a minimum of 8.0 mm (0.31 in) c. 12. Connect the throttle cable joint, install the clip, and then tighten the locknut. 13. Check the throttle cable for smooth oper- ation and, if necessary, repeat steps 2– 12. 14. Ins...

  • Page 39

    Chk adj periodic checks and adjustments 3-11 6d81g11 bracket unit 3 checking the power trim and tilt operation 1. Fully tilt the outboard motor up and down a few times and check the entire trim and tilt range for smooth operation. Check the power trim and tilt fluid level if necessary. Note: be sure...

  • Page 40

    6d81g11 3-12 1 2 3 4 5 6 7 8 9 lower unit 3 checking the gear oil level 1. Fully tilt the outboard motor down. 2. Remove the check screw 1, and then check the gear oil level in the lower case. Note: if the oil is at the correct level, the oil should overflow out of the check hole when the check scre...

  • Page 41

    Chk adj periodic checks and adjustments 3-13 6d81g11 4. Insert a gear oil tube or gear oil pump into the drain hole and slowly fill the gear oil until oil flows out of the check hole and no air bubbles are visible. 5. Install the check screw and quickly install the drain screw, and then tighten them...

  • Page 42

    6d81g11 3-14 1 2 3 4 5 6 7 8 9 general 3 checking the anodes 1. Check the anodes and trim tab for scales, grease, or oil. Clean if necessary. Caution: do not oil, grease, or paint the anodes or the trim tab, otherwise they will be ineffec- tive. Note: if it is necessary to disassemble the outboard m...

  • Page 43

    Chk adj periodic checks and adjustments 3-15 6d81g11 2. Check the specific gravity of the electro- lyte. Fully charge the battery if out of specification. Warning battery electrolyte is dangerous; it con- tains sulfuric acid which is poisonous and highly caustic. Always follow these preventive measu...

  • Page 44

    6d81g11 3-16 1 2 3 4 5 6 7 8 9 note: apply grease to the grease nipple until it flows from the bushings a. 2. Apply low temperature resistant grease to the area shown. 3. Apply corrosion resistant grease to the area shown. S60c3710 a a a a s6d83190 c general.

  • Page 45: Fuel System

    6d81g11 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 46

    Fuel fuel system 4-1 6d81g11 special service tools 4 pressure/vacuum tester yb-35956-a fuel pressure gauge yb-06766 fuel pressure gauge adapter b yb-06942.

  • Page 47

    6d81g11 4-2 1 2 3 4 5 6 7 8 9 hose routing 4 fuel and blowby hoses 1 blowby hose 2 fuel hose (primary pump-to-fuel filter) 3 fuel hose (fuel filter-to-fuel pump) 4 fuel hose (fuel pump-to-strainer) 5 fuel hose (strainer-to-vapor separator) 6 high-pressure fuel hose (vapor separator-to-fuel rail) 7 f...

  • Page 48

    Fuel fuel system 4-3 6d81g11 fuel filter and fuel pump 4 no. Part name q’ty remarks 1 nut 1 2 fuel filter assembly 1 3 o-ring 1 not reusable 4 fuel filter element 1 5 o-ring 1 not reusable 6 float 1 7 cup 1 8 fuel hose 1 9 fuel pump 1 10 bolt 2 m6 × 30 mm 11 fuel hose 1 12 strainer 1 13 bolt 1 m6 × ...

  • Page 49

    6d81g11 4-4 1 2 3 4 5 6 7 8 9 4 no. Part name q’ty remarks 1 screw 3 ø6 × 35 mm 2 cover 1 3 gasket 1 not reusable 4 fuel pump body 2 assembly 1 5 diaphragm 1 6 pin 1 7 spring 1 8 fuel pump body 1 1 9 spring 1 10 plunger 1 11 nut 3 s6d84030 4 7 8 9 10 1 2 3 5 6 t r . . 4 n · m (0.4 kgf · m, 3.0 ft · ...

  • Page 50

    Fuel fuel system 4-5 6d81g11 checking the fuel pump 1. Place a drain pan under the fuel hose connections, and then disconnect the fuel hoses from the fuel pump. 2. Connect the special service tool to the fuel pump inlet. 3. Cover the fuel pump outlet with a finger, and then apply the specified posit...

  • Page 51

    6d81g11 4-6 1 2 3 4 5 6 7 8 9 3. Slowly let up on the plunger and dia- phragm, and then remove them. Checking the diaphragm and valves 1. Check the diaphragm for tears and the valves for cracks. Replace if necessary. Assembling the fuel pump note: clean the parts and soak the valves and the diaphrag...

  • Page 52

    Fuel fuel system 4-7 6d81g11 intake manifold 4 no. Part name q’ty remarks 1 intake silencer 1 2 bolt 2 m6 × 80 mm 3 bushing 4 4 collar 2 5 intake manifold assembly 1 6 bolt 4 m8 × 30 mm 7 collar 5 8 bolt 1 m8 × 100 mm 9 spacer 1 10 bolt 3 m6 × 45 mm 11 collar 3 12 holder 1 13 gasket 1 not reusable 1...

  • Page 53

    6d81g11 4-8 1 2 3 4 5 6 7 8 9 4 no. Part name q’ty remarks 1 intake manifold 1 2 sensor assembly 1 3 screw 4 ø5 × 13 mm 4 o-ring 1 not reusable 5 idle speed control 1 6 o-ring 1 not reusable 7 throttle body assembly 1 8 bolt 3 m6 × 16 mm 9 gasket 1 not reusable 10 throttle position sensor 1 11 screw...

  • Page 54

    Fuel fuel system 4-9 6d81g11 checking the throttle position sensor 1. Check the throttle position sensor output voltage using the yamaha diagnostic system. If the output voltage is out of specification, replace the throttle posi- tion sensor. Installing the throttle position sensor 1. Install the th...

  • Page 55

    6d81g11 4-10 1 2 3 4 5 6 7 8 9 vapor separator 4 no. Part name q’ty remarks 1 vapor separator 1 2 bolt 3 m6 × 30 mm 3 grommet 3 4 collar 3 5 fuel hose 1 6 fuel inlet hose 1 7 hose 1 8 joint 1 9 hose 1 10 hose 1 11 hose 1 12 hose 1 13 clamp 1 14 clamp 1 15 quick connector 1 16 clamp 1 not reusable 17...

  • Page 56

    Fuel fuel system 4-11 6d81g11 4 no. Part name q’ty remarks 1 screw 6 ø5 × 14 mm 2 gasket 1 not reusable 3 float chamber 1 4 damper 1 5 drain screw 1 6 o-ring 1 not reusable 7 joint screw 1 8 o-ring 1 not reusable 9 fuel hose 1 10 fuel cooler 1 11 screw 2 ø6 × 15 mm 12 fuel hose 1 13 hose 1 14 hose 1...

  • Page 57

    6d81g11 4-12 1 2 3 4 5 6 7 8 9 4 no. Part name q’ty remarks 1 cover 1 2 pressure regulator 1 3 bolt 2 m6 × 12 mm 4 o-ring 1 not reusable 5 joint screw 1 6 o-ring 1 not reusable 7 electric fuel pump 1 8 grommet 1 9 collar 1 10 filter 1 11 screw 3 ø4 × 6 mm 12 wiring harness 1 13 float 1 14 needle val...

  • Page 58

    Fuel fuel system 4-13 6d81g11 reducing the fuel pressure 1. Remove the cap 1. 2. Cover the pressure check valve a of the vapor separator with a rag, and then press in the pressure check valve a using a thin screwdriver to release the fuel pressure. Warning always reduce the fuel pressure in the high...

  • Page 59

    6d81g11 4-14 1 2 3 4 5 6 7 8 9 warning • when connecting the fuel pressure gauge, first cover the connection between the gauge and the adapter with a clean, dry rag to prevent fuel from leaking out. • gently screw in the gauge until it is firmly connected. 4. Turn the engine start switch to on, and ...

  • Page 60

    Fuel fuel system 4-15 6d81g11 6. Check that the fuel pressure reduces when vacuum pressure is applied to the pressure regulator. If the fuel pressure does not reduce, replace the pressure regulator. Note: when the vacuum pressure reaches the specified level, the fuel pressure reduces. Draining the f...

  • Page 61

    6d81g11 4-16 1 2 3 4 5 6 7 8 9 note: remove the float pin in the direction of the arrow a shown. 2. Remove the needle valve and other com- ponents. Checking the vapor separator 1. Check the needle valve for bends or wear. Replace if necessary. 2. Check the float for deterioration. Replace if necessa...

  • Page 62

    Fuel fuel system 4-17 6d81g11 3. Check the float height d as shown. Adjust the float height if out of specifica- tion. Note: • the float should be resting on the needle valve, but not compressing it. • take measurements at the position shown, opposite the float pivot. 4. Install the float chamber. A...

  • Page 63

    6d81g11 4-18 1 2 3 4 5 6 7 8 9 canister 4 no. Part name q’ty remarks 1 bolt 1 m6 × 16 mm 2 bracket 1 3 canister 1 4 bolt 2 m6 × 28 mm 5 grommet 2 6 bracket 1 7 collar 2 8 hose 1 9 hose 1 10 hose 1 11 filter 1 12 hose 1 13 clamp 1 14 bolt 1 m6 × 10 mm 15 holder 1 16 bolt 1 m6 × 16 mm 17 bracket 1 s6d...

  • Page 64

    Fuel fuel system 4-19 6d81g11 checking the canister 1. Check the canister for cracks. Replace if necessary. 2. Connect the special service tool to the atmospheric port 1 and cover the other ports, each with a finger. 3. Apply the specified positive pressure and check that there is no air leakage. Re...

  • Page 65: Power Unit

    Powr 6d81g11 power unit special service tools ..................................................................................... 5-1 power unit....................................................................................................... 5-3 checking the compression pressure ...............

  • Page 66

    6d81g11 1 2 3 4 5 6 7 8 9 cylinder block .............................................................................................. 5-39 disassembling the cylinder block ............................................................ 5-40 checking the piston diameter ..................................

  • Page 67

    Powr power unit 5-1 6d81g11 special service tools 5 compression gauge yu-33223 compression gauge extension yb-06563 flywheel magnet holder yb-06139 universal puller yb-06117 crankshaft holder yb-06552 valve spring compressor ym-01253 valve spring compressor attachment yb-06320 valve guide remover/in...

  • Page 68

    6d81g11 5-2 1 2 3 4 5 6 7 8 9 oil filter wrench yu-38411 special service tools.

  • Page 69

    Powr power unit 5-3 6d81g11 power unit 5 checking the compression pressure 1. Start the engine, warm it up for 5 min- utes, and then turn it off. 2. Remove the engine stop lanyard from the engine stop lanyard switch on the remote control box. 3. Remove the spark plug wire cover and all spark plugs, ...

  • Page 70

    6d81g11 5-4 1 2 3 4 5 6 7 8 9 5 no. Part name q’ty remarks 1 damper 1 2 grommet 2 3 grommet 1 4 flywheel magnet cover 1 5 power unit 1 6 oil dipstick 1 7 gasket 1 not reusable 8 dowel 2 9 bolt 5 m6 × 16 mm 10 bolt 6 m10 × 130 mm 11 screw 2 ø6 × 40 mm 12 nut 2 13 apron 1 14 bolt 2 m8 × 35 mm 15 holde...

  • Page 71

    Powr power unit 5-5 6d81g11 5 no. Part name q’ty remarks 1 nut 1 2 washer 1 3 flywheel magnet 1 4 screw 1 ø4 × 10 mm 5 screw 3 ø6 × 30 mm 6 stator coil 1 7 bolt 4 m6 × 30 mm 8 stator assembly 1 9 collar 2 10 bolt 1 m6 × 15 mm 11 woodruff key 1 12 bolt 1 m6 × 15 mm 13 holder 1 14 grommet 1 s6d85020 2...

  • Page 72

    6d81g11 5-6 1 2 3 4 5 6 7 8 9 5 no. Part name q’ty remarks 1 timing belt 1 2 bolt 2 m10 × 35 mm 3 dowel 2 4 driven sprocket 2 5 bolt 2 m6 × 15 mm 6 bracket 1 7 bolt 1 m10 × 45 mm 8 timing belt tensioner 1 9 spring 1 10 plastic tie 1 not reusable 11 hose 1 12 clamp 1 13 nut 1 14 drive sprocket 1 15 p...

  • Page 73

    Powr power unit 5-7 6d81g11 5 no. Part name q’ty remarks 1 screw 5 ø6 × 30 mm 2 cover 1 3 spark plug wire 4 4 holder 2 5 holder 2 6 bolt 1 m6 × 12 mm 7 holder 1 8 clamp 1 9 hose 1 10 plastic tie 1 not reusable 11 ignition coil 2 12 bracket 2 13 bolt 4 m6 × 25 mm 14 holder 2 15 starter motor 1 16 bol...

  • Page 74

    6d81g11 5-8 1 2 3 4 5 6 7 8 9 5 no. Part name q’ty remarks 18 nut 1 19 cap 1 20 positive battery lead 1 21 nut 1 22 negative battery lead 1 23 bolt 1 m6 × 20 mm 24 junction box cover 1 25 bolt 1 m6 × 10 mm 26 cap 1 27 oil pressure switch 1 28 bolt 1 m4 × 8 mm 29 holder 1 30 bolt 1 m6 × 25 mm 31 clam...

  • Page 75

    Powr power unit 5-9 6d81g11 5 no. Part name q’ty remarks 1 oil filler cap 1 2 o-ring 1 3 cylinder head cover 1 4 screw 8 ø4 × 8 mm 5 plate 1 6 grommet 2 7 gasket 1 not reusable 8 bolt 14 m6 × 30 mm 9 camshaft cap 2 10 camshaft cap 8 11 bolt 4 m7 × 48 mm 12 bolt 16 m7 × 37 mm 13 oil seal 2 not reusab...

  • Page 76

    6d81g11 5-10 1 2 3 4 5 6 7 8 9 checking the valve clearance caution: • do not turn the flywheel magnet coun- terclockwise, otherwise the valve sys- tem may be damaged. • do not remove the ignition timing pointer. • do not turn the flywheel magnet or the driven sprockets when the timing belt is not i...

  • Page 77

    Powr power unit 5-11 6d81g11 4. Install the driven sprockets 0, timing belt 9, and spring 8, and then tighten the tensioner bolt. 5. Check the intake valve clearance for cyl- inders #1 and #2, and the exhaust valve clearance for cylinders #1 and #3. Adjust if out of specification. Note: • check the ...

  • Page 78

    6d81g11 5-12 1 2 3 4 5 6 7 8 9 11. Remove the valve shim c from the valve lifter d using a thin screwdriver. 12. Measure the valve shim thickness with a micrometer, and then note the measure- ment. 13. Select the necessary valve shim by cal- culating its thickness with the following formula. Example...

  • Page 79

    Powr power unit 5-13 6d81g11 replacing the timing belt caution: • do not turn the drive sprocket counter- clockwise, otherwise the valve system may be damaged. • do not remove the ignition timing pointer. • do not turn the drive sprocket or the driven sprockets when the timing belt is not installed....

  • Page 80

    6d81g11 5-14 1 2 3 4 5 6 7 8 9 6. Disconnect the cooling water hose 3 and remove the bracket 4. 7. Remove the spring 5 and timing belt tensioner 6, and then remove the timing belt 7 from the driven sprockets, then from the drive sprocket. 8. Check that the hole a on the retaining plate and the proje...

  • Page 81

    Powr power unit 5-15 6d81g11 10. Install a new timing belt 8 onto the drive sprocket with its part number in the upright position, and then install the belt onto the driven sprockets by turning it counterclockwise. Caution: • do not twist, turn inside out, or bend the timing belt beyond the maximum ...

  • Page 82

    6d81g11 5-16 1 2 3 4 5 6 7 8 9 18. Install the stator assembly and woodruff key. 19. Install the flywheel magnet. Caution: apply force in the direction of the arrows shown to prevent the flywheel holder from slipping off easily. Note: apply engine oil to the flywheel magnet nut before installation. ...

  • Page 83

    Powr power unit 5-17 6d81g11 removing the timing belt and sprockets caution: • do not turn the drive sprocket counter- clockwise, otherwise the valve system may be damaged. • do not turn the drive sprocket or the driven sprockets when the timing belt is not installed. Otherwise the piston and valves...

  • Page 84

    6d81g11 5-18 1 2 3 4 5 6 7 8 9 checking the timing belt and sprockets 1. Check the interior and exterior of the tim- ing belt for cracks, damage, or wear. Replace if necessary. 2. Check the drive sprocket and driven sprockets for cracks, damage, or wear. Replace if necessary. Installing the sprocket...

  • Page 85

    Powr power unit 5-19 6d81g11 3. Install the retaining plate 3, woodruff key 4, drive sprocket 5, and nut 6, and then tighten the nut. Note: • apply engine oil to the drive sprocket nut before installation. • tighten the drive sprocket nut finger tight. 4. Check that the hole c on the retaining plate...

  • Page 86

    6d81g11 5-20 1 2 3 4 5 6 7 8 9 throttle link 4 no. Part name q’ty remarks 1 throttle cam 1 2 bolt 1 m6 × 35 mm 3 collar 1 4 wave washer 2 5 washer 2 6 spring 1 7 washer 2 8 throttle lever 1 9 bolt 1 m6 × 25 mm 10 collar 1 11 throttle link rod 1 12 nut 1 13 throttle link rod joint 1 14 bracket 1 15 b...

  • Page 87

    Powr power unit 5-21 6d81g11 ecm 5 no. Part name q’ty remarks 1 wiring harness 1 2 bracket 1 3 bolt 2 m6 × 15 mm 4 bolt 2 m6 × 12 mm 5 bracket 1 6 bracket 1 7 bracket 1 8 bolt 2 m6 × 20 mm 9 collar 4 10 grommet 4 11 bolt 4 m6 × 30 mm 12 ecm 1 13 rectifier regulator 1 14 bolt 2 m6 × 25 mm 15 bolt 2 m...

  • Page 88

    6d81g11 5-22 1 2 3 4 5 6 7 8 9 junction box 5 no. Part name q’ty remarks 1 screw 1 ø6 × 25 mm 2 main and fuel pump relay 1 3 power trim and tilt relay 1 4 washer 2 5 nut 2 6 cap 2 7 bolt 2 m6 × 20 mm 8 ground lead 1 9 fuse 1 30 a 10 fuse 3 20 a 11 cap 1 12 cap 3 13 starter relay 1 14 holder 1 15 scr...

  • Page 89

    Powr power unit 5-23 6d81g11 5 no. Part name q’ty remarks 18 holder 1 19 junction box 1 20 collar 5 21 grommet 5 22 bolt 2 m6 × 10 mm 23 clamp 1 24 grommet 1 s6d85060 1 2 9 13 11 10 12 4 3 7 5 6 14 15 16 18 19 21 20 17 8 4 5 6 22 22 24 23 t r . . 3 n · m (0.3 kgf · m, 2.2 ft · ib) t r . . 4 n · m (0...

  • Page 90

    6d81g11 5-24 1 2 3 4 5 6 7 8 9 cylinder head 5 no. Part name q’ty remarks 1 cylinder head 1 2 exhaust valve 8 3 intake valve 8 4 gasket 1 not reusable 5 collar 2 6 bolt 5 m8 × 55 mm 7 bolt 2 m6 × 25 mm 8 cover 1 9 thermostat 1 10 bolt 10 m10 × 143 mm 11 spark plug 4 12 bolt 2 m8 × 40 mm 13 bolt 2 m6...

  • Page 91

    Powr power unit 5-25 6d81g11 5 no. Part name q’ty remarks 18 valve lifter 16 19 valve cotter 32 20 valve spring retainer 16 21 valve spring 16 22 valve spring seat 16 23 valve seal 16 not reusable 24 valve guide 16 not reusable s6d85080 1 4 7 8 9 5 6 3 13 14 22 20 18 17 19 21 23 24 24 16 15 12 11 10...

  • Page 92

    6d81g11 5-26 1 2 3 4 5 6 7 8 9 removing the cylinder head 1. Remove the cylinder head cover. 2. Remove camshaft caps 1 and 2 in the sequence shown. 3. Remove the camshaft (intake) 3, cam- shaft (exhaust) 4, and oil seals 5. 4. Remove the valve shims 6 from the valve lifters 7. Note: do not mix the v...

  • Page 93

    Powr power unit 5-27 6d81g11 6. Remove the intake and exhaust valves. Note: be sure to keep the valves, springs, and other parts in the order as they were removed. Checking the valve lifters 1. Check the valve lifters for damage, scratches, or wear. Replace if necessary. Checking the valve springs 1...

  • Page 94

    6d81g11 5-28 1 2 3 4 5 6 7 8 9 4. Measure the valve stem runout. Replace if above specification. Checking the valve guides note: before checking the valve guide make sure that the valve stem diameter is within specifi- cation. 1. Measure the valve guide inside diameter a. 2. Calculate the valve stem...

  • Page 95

    Powr power unit 5-29 6d81g11 2. Install the new valve guide 2 by striking the special tool from the camshaft side to the specified position a. Note: • before installing the valve guide, mark its installation position b as shown. • apply engine oil to the surface of the new valve guide. 3. Insert the...

  • Page 96

    6d81g11 5-30 1 2 3 4 5 6 7 8 9 refacing the valve seat 1. Reface the valve seat with the valve seat cutters. 2. Cut the surface of the valve seat with a 45° cutter by turning the cutter clockwise until the valve seat face has become smooth. A slag or rough surface caution: do not over cut the valve ...

  • Page 97

    Powr power unit 5-31 6d81g11 5. Use a 45° cutter to adjust the contact width of the valve seat to specification. B previous contact width c specified contact width 6. If the valve seat contact area is too wide and situated in the center of the valve face, use a 30° cutter to cut the top edge of the ...

  • Page 98

    6d81g11 5-32 1 2 3 4 5 6 7 8 9 2. Measure the camshaft runout. Replace if above specification. 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. Checking the cylinder head 1. Eliminate carbon de...

  • Page 99

    Powr power unit 5-33 6d81g11 installing the valves 1. Install a new valve seal 1 onto the valve guide. 2. Install the valve 2, valve spring seat 3, valve spring 4, and valve spring retainer 5 in the sequence shown, and then attach the special service tools. Note: the valve spring can be installed in...

  • Page 100

    6d81g11 5-34 1 2 3 4 5 6 7 8 9 caution: do not reuse the cylinder head gasket, always replace it with a new one. 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 tighten the m8 bolts to 14 n·m (1.4...

  • Page 101

    Powr power unit 5-35 6d81g11 6. Install the camshaft caps in the proper position as shown and with the stamped numbers facing upside down. 7. Tighten the camshaft cap bolts to the specified torques in two stages and in the sequence shown. Note: apply engine oil to the camshaft caps and camshaft cap ...

  • Page 102

    6d81g11 5-36 1 2 3 4 5 6 7 8 9 exhaust cover 5 no. Part name q’ty remarks 1 gasket 1 not reusable 2 screw 3 ø4 × 13 mm 3 anode 3 4 exhaust cover 1 5 gasket 1 not reusable 6 cooling water temperature sensor 1 7 holder 1 8 bolt 2 m6 × 15 mm 9 holder 1 10 bolt 1 m6 × 10 mm 11 gasket 1 not reusable 12 g...

  • Page 103

    Powr power unit 5-37 6d81g11 5 no. Part name q’ty remarks 18 plug 1 m18 × 17 mm 19 grommet 1 20 anode 1 21 cover 1 22 bolt 1 m8 × 25 mm 23 bolt 18 m6 × 30 mm 24 bolt 1 m6 × 20 mm 25 joint 1 26 oil filter 1 27 gasket 1 not reusable 28 plug 1 m14 × 12 mm 29 plastic tie 1 not reusable 30 hose 1 s6d8509...

  • Page 104

    6d81g11 5-38 1 2 3 4 5 6 7 8 9 removing the exhaust cover 1. Remove the exhaust cover bolts in the sequence shown. 2. Remove the exhaust cover. Checking the pressure control valve 1. Remove the pressure control valve. 2. Check the pressure control valve for wear or damage. Replace if necessary. 3. C...

  • Page 105

    Powr power unit 5-39 6d81g11 cylinder block 5 no. Part name q’ty remarks 1 bolt 4 m6 × 20 mm 2 dowel 10 3 bolt 10 m10 × 135 mm 4 crankcase 1 5 bolt 10 m8 × 55 mm 6 cylinder block 1 7 main bearing 5 8 main bearing 4 9 main bearing 1 10 oil seal 1 not reusable 11 crankshaft 1 12 oil seal 1 not reusabl...

  • Page 106

    6d81g11 5-40 1 2 3 4 5 6 7 8 9 disassembling the cylinder block 1. Place a rag under the oil filter, and then remove the filter using the oil filter wrench. Note: be sure to clean up any oil spills. 2. Remove the crankcase bolts in the sequence shown, and then remove the crankcase. Note: do not remo...

  • Page 107

    Powr power unit 5-41 6d81g11 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 (0.8 ...

  • Page 108

    6d81g11 5-42 1 2 3 4 5 6 7 8 9 checking the piston ring grooves 1. Measure the piston ring grooves. Replace the piston if out of specification. Checking the piston ring side clearance 1. Measure the piston ring side clearance. Replace the piston and piston rings as a set if out of specification. Pis...

  • Page 109

    Powr power unit 5-43 6d81g11 checking the connecting rod big end side clearance 1. Measure the connecting rod big end side clearance a. Replace the connecting rod or crankshaft or both if out of specifi- cation. Checking the crankshaft 1. Measure the crankshaft journal diameter a, crankpin diameter ...

  • Page 110

    6d81g11 5-44 1 2 3 4 5 6 7 8 9 note: install the bearings in their original positions. 3. Put a piece of plastigauge (pg-1) onto the crankpin, parallel to the crankshaft. Note: be sure not to put the plastigauge (pg-1) over the oil hole in the crankpin of the crank- shaft. 4. Install the connecting ...

  • Page 111

    Powr power unit 5-45 6d81g11 6. Remove the connecting rod cap and measure the width of the compressed plastigauge (pg-1) on each crankpin. Replace the connecting rod bearing if out of specification. Selecting the connecting rod bearing note: use a metric gauge in this procedure. 1. When replacing th...

  • Page 112

    6d81g11 5-46 1 2 3 4 5 6 7 8 9 caution: the (*) mark indicates that the colors of the upper and lower bearings are differ- ent. Example: if the “connecting rod big end inside diame- ter a” is 47.050 mm and the “crankpin mark” is 92, then the “calculated value” = 47.050 – 43.992 = 3.058 mm suitable c...

  • Page 113

    Powr power unit 5-47 6d81g11 7. Tighten the crankcase bolts to the speci- fied torques in two stages and in the sequence shown. Note: • do not move the crankshaft until the crank- shaft journal oil clearance measurement has been completed. • tighten the m10 bolts to 19 n·m (1.9 kgf·m, 14.0 ft·lb) fi...

  • Page 114

    6d81g11 5-48 1 2 3 4 5 6 7 8 9 note: cylinder block journal inside diameters (#1– #5) and crankshaft journal diameters (#1–#5) can be determined by the stamped value as described below. Crankshaft journal diameter = 47.900 + (stamped value/1,000) example: #1 = 92 → 47.992 cylinder block journal insi...

  • Page 115

    Powr power unit 5-49 6d81g11 assembling the power unit 1. Install the oil ring 1, second ring 2, and top ring 3 onto the pistons with the “t” marks a on the piston rings facing upward. 2. Offset the piston ring end gaps as shown. Caution: do not scratch the piston or break the pis- ton rings. Note: ...

  • Page 116

    6d81g11 5-50 1 2 3 4 5 6 7 8 9 6. Set the crankshaft 8 and oil seals 9 and 0 into the cylinder block as shown. 7. Install the connecting rod cap 5 to the connecting rod, and then tighten the new connecting rod bolts a to the specified torques in two stages. Caution: do not reuse the connecting rod b...

  • Page 117

    Powr power unit 5-51 6d81g11 11. Tighten the crankcase bolts to the speci- fied torques in two stages and in the sequence shown. Caution: the oil seals must be installed before tightening the crankcase bolts. Note: • tighten the m10 bolts to 19 n·m (1.9 kgf·m, 14.0 ft·lb) first, and then tighten the...

  • Page 118

    6d81g11 5-52 1 2 3 4 5 6 7 8 9 5. Connect the flushing hose, cooling water pilot hose, and canister hose. 6. Connect the fuel hose and shift position switch coupler. 7. Connect the ptt motor leads and ptt switch coupler, and then install the junc- tion box cover. 8. Connect the trim sensor coupler a...

  • Page 119: Lower Unit

    6d81g11 lowr 1 2 3 4 5 6 7 8 9 lower unit special service tools ..................................................................................... 6-1 lower unit ....................................................................................................... 6-4 removing the lower unit ......

  • Page 120

    Lowr lower unit 6-1 6d81g11 special service tools 3 gland nut wrench yb-34447 bearing housing puller yb-06207 universal puller yb-06117 slide hammer yb-06096 bearing puller legs yb-06523 bearing housing needle bearing remover yb-06112, yb-06153 driver handle (large) yb-06071 propeller shaft oil seal...

  • Page 121

    6d81g11 6-2 1 2 3 4 5 6 7 8 9 drive shaft holder yb-06151 drive shaft needle bearing remover and installer yb-06155 drive shaft seal installer yb-06244 forward gear bearing cup installer yb-06276-b forward gear outer race installer yb-06085 shift rod push arm yb-06052 pinion shim selecting tool yb-3...

  • Page 122

    Lowr lower unit 6-3 6d81g11 dial indicator gauge yu-03097 magnetic base stand yu-a8438.

  • Page 123

    6d81g11 6-4 1 2 3 4 5 6 7 8 9 lower unit 6 no. Part name q’ty remarks 1 lower unit 1 2 hose 1 3 check screw 1 4 gasket 2 not reusable 5 dowel 2 6 bolt 4 m10 × 40 mm/l-transom model 7 drain screw 1 8 grommet 1 9 bolt 1 m10 × 45 mm 10 bolt 1 m8 × 60 mm/l-transom model 11 spacer 1 12 propeller 1 13 was...

  • Page 124

    Lowr lower unit 6-5 6d81g11 6 no. Part name q’ty remarks 18 dowel 2 x-transom model 19 extension 1 x-transom model 20 stud bolt 4 m10 × 180 mm/x-transom model 21 washer 4 x-transom model 22 spring washer 4 x-transom model 23 nut 4 x-transom model 24 bolt 1 m8 × 190 mm/x-transom model.

  • Page 125

    6d81g11 6-6 1 2 3 4 5 6 7 8 9 6 no. Part name q’ty remarks 1 bolt 2 m6 × 16 mm 2 o-ring 1 not reusable 3 oil seal 1 not reusable 4 oil seal housing 1 5 o-ring 1 not reusable 6 circlip 1 7 shift rod 1 8 woodruff key 1 9 screw 2 ø4 × 12 mm 10 bolt 2 m8 × 75 mm 11 cover 1 12 bolt 2 m8 × 50 mm 13 seal 1...

  • Page 126

    Lowr lower unit 6-7 6d81g11 6 no. Part name q’ty remarks 18 gasket 1 not reusable 19 outer plate cartridge 1 20 gasket 1 not reusable 21 oil seal housing 1 22 o-ring 1 not reusable 23 gasket 1 not reusable 24 oil seal 2 not reusable.

  • Page 127

    6d81g11 6-8 1 2 3 4 5 6 7 8 9 removing the lower unit 1. Drain the gear oil. 2. Set the gear shift to the neutral position, and place a block of wood between the anti-cavitation plate and propeller to keep the propeller from turning, and then remove the propeller nut and propeller. Warning • do not ...

  • Page 128

    Lowr lower unit 6-9 6d81g11 removing the water pump and shift rod 1. Remove the water pump housing and impeller. 2. Remove the woodruff key. 3. Remove the outer plate cartridge and oil seal housing. 4. Remove the shift rod assembly 1. Note: pull up the shift rod assembly a little a to dis- connect i...

  • Page 129

    6d81g11 6-10 1 2 3 4 5 6 7 8 9 propeller shaft housing 6 no. Part name q’ty remarks 1 slider 1 2 shift plunger 1 3 dog clutch 1 4 spring 1 5 propeller shaft 1 6 shim 1 0.3 mm 7 washer 1 8 reverse gear 1 9 thrust washer 1 10 ball bearing 1 not reusable 11 o-ring 1 not reusable 12 propeller shaft hous...

  • Page 130

    Lowr lower unit 6-11 6d81g11 removing the propeller shaft housing assembly 1. Straighten the claw washer tabs a, and then remove the ring nut and claw washer. 2. Pull out the propeller shaft housing assembly. 3. Remove the propeller shaft assembly. Disassembling the propeller shaft assembly 1. Remov...

  • Page 131

    6d81g11 6-12 1 2 3 4 5 6 7 8 9 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 the reverse gear for crac...

  • Page 132

    Lowr lower unit 6-13 6d81g11 assembling the propeller shaft housing 1. Install the needle bearing into the propel- ler shaft housing to the specified depth. Note: install the needle bearing with the manufac- ture identification mark a facing toward the oil seal (propeller side). 2. Apply grease to t...

  • Page 133

    6d81g11 6-14 1 2 3 4 5 6 7 8 9 bearing outer race attachment 9: yb-06109 propeller shaft housing.

  • Page 134

    Lowr lower unit 6-15 6d81g11 drive shaft and lower case 6 no. Part name q’ty remarks 1 drive shaft 1 2 taper roller bearing 1 not reusable 3 pinion shim — 4 sleeve 1 5 hose 1 6 plastic tie 1 not reusable 7 joint 1 8 nut 1 9 cooling water inlet cover 2 10 screw 1 ø5 × 40 mm 11 seal 1 12 plate 1 13 fo...

  • Page 135

    6d81g11 6-16 1 2 3 4 5 6 7 8 9 6 no. Part name q’ty remarks 18 pinion 1 19 nut 1 20 lower case 1 drive shaft and lower case.

  • Page 136

    Lowr lower unit 6-17 6d81g11 removing the drive shaft 1. Remove the drive shaft assembly and pinion, and then pull out the forward gear. Disassembling the drive shaft 1. Install the pinion nut 1, tighten it finger tight, and then remove the drive shaft bearing 2 using a press. Caution: • do not pres...

  • Page 137

    6d81g11 6-18 1 2 3 4 5 6 7 8 9 note: install the claws as shown. 2. Remove the drive shaft bearing outer race, shim(s), and drive shaft sleeve. Note: install the claws as shown. 3. Remove the needle bearing. Checking the pinion and forward gear 1. Check the teeth of the pinion, and the teeth and dog...

  • Page 138

    Lowr lower unit 6-19 6d81g11 assembling the lower case 1. Install the needle bearing into the lower case to the specified depth. Note: install the needle bearing with the manufac- ture identification mark a facing upward. 2. Install the sleeve, original shim(s), and taper roller bearing outer race. ...

  • Page 139

    6d81g11 6-20 1 2 3 4 5 6 7 8 9 2. Install a new needle bearing into the for- ward gear to the specified depth. Assembling the drive shaft 1. Install a new drive shaft bearing into the drive shaft using a press. Installing the drive shaft 1. Install the forward gear, then the drive shaft assembly, pi...

  • Page 140

    Lowr lower unit 6-21 6d81g11 3. Install the shim 4 and propeller shaft housing assembly 5 into the lower case, and then install the straight key 6, claw washer 7, and ring nut 8. 4. Tighten the ring nut to the specified torque. Note: • to secure the ring nut, bend one tab a of the claw washer into a...

  • Page 141

    6d81g11 6-22 1 2 3 4 5 6 7 8 9 3. Install a new o-ring 5 onto the oil seal housing 6. 4. Install a new gasket 7, the oil seal hous- ing 6, a new gasket 8, the outer plate cartridge 9, and a new gasket 0. 5. Install the woodruff key into the drive shaft. 6. Align the groove on the impeller a with the...

  • Page 142

    Lowr lower unit 6-23 6d81g11 2. Align the alignment mark a on the bush- ing with the alignment mark b on the bracket. 3. Install the dowels 1 into the lower unit. 4. Install the lower unit into the upper case, and then tighten the lower case mounting bolts (nuts) to the specified torque. È x-transom...

  • Page 143

    6d81g11 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 144

    Lowr lower unit 6-25 6d81g11 shimming 6.

  • Page 145

    6d81g11 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 146

    Lowr lower unit 6-27 6d81g11 5. Measure the clearance (m) between the shim selecting tool and the pinion as shown. Note: measure the pinion at three points to find the clearance average. 6. Select the pinion shims (t3). Note: the sum of t3 and m0 should be more than m. Selecting the forward gear shi...

  • Page 147

    6d81g11 6-28 1 2 3 4 5 6 7 8 9 note: tighten the nut four turns after it contacts the spring. 3. Measure the clearance (m) between the gauge pin and the press plate. 4. Select the forward gear shims (t1). Note: the sum of t1 and m should not be more than m0. Backlash 6 measuring the forward gear bac...

  • Page 148

    Lowr lower unit 6-29 6d81g11 4. Install the backlash indicator onto the drive shaft (20 mm [0.79 in] in diameter), then the dial gauge onto the lower unit. Note: install the dial gauge so that the plunger a contacts the mark b on the backlash indica- tor. 5. Slowly turn the drive shaft clockwise and...

  • Page 149: Bracket Unit

    Brkt 6d81g11 bracket unit special service tools ..................................................................................... 7-1 shift rod .......................................................................................................... 7-2 bottom cowling .............................

  • Page 150

    6d81g11 1 2 3 4 5 6 7 8 9 tilt cylinder and trim cylinder ..................................................................... 7-35 disassembling the trim cylinder............................................................... 7-38 disassembling the tilt cylinder ......................................

  • Page 151

    Brkt bracket unit 7-1 6d81g11 special service tools 7 bearing installer yb-41446 bearing cup installer yb-06167 driver handle (large) yb-06071 driver handle (small) yb-06229 roller bearing installer/remover yb-06432 oil seal installer yb-06023 drive shaft needle bearing installer and remover yb-0619...

  • Page 152

    6d81g11 7-2 1 2 3 4 5 6 7 8 9 shift rod 7 no. Part name q’ty remarks 1 bolt 1 2 spring 1 3 ball 1 4 washer 1 5 bushing 2 6 bolt 2 m6 × 25 mm 7 bracket 1 8 shift rod 1 9 screw 2 ø4 × 16 mm 10 plate 1 11 shift position switch 1 12 bolt 2 m6 × 50 mm 13 bushing 1 14 bracket 1 15 cotter pin 1 not reusabl...

  • Page 153

    Brkt bracket unit 7-3 6d81g11 bottom cowling 7 no. Part name q’ty remarks 1 bolt 2 m6 × 16 mm 2 washer 2 3 lever 2 4 washer 2 5 bushing 4 6 bolt 4 m6 × 30 mm 7 base 2 8 lever 2 9 spring 2 10 bolt 2 m6 × 20 mm 11 hook 2 12 cooling water outlet 1 13 canister outlet 1 14 bolt 4 m8 × 35 mm 15 grommet 4 ...

  • Page 154

    6d81g11 7-4 1 2 3 4 5 6 7 8 9 7 no. Part name q’ty remarks 18 bottom cowling 1 19 grommet 4 20 collar 4 21 bolt 1 m6 × 20 mm 22 holder 1 23 bolt 2 m6 × 20 mm 24 bracket 1 25 bolt 3 m6 × 25 mm 26 plate 3 27 power trim and tilt switch 1 28 grommet 1 29 grommet 3 30 bolt 1 m6 × 20 mm 31 plate 1 32 grom...

  • Page 155

    Brkt bracket unit 7-5 6d81g11 7 no. Part name q’ty remarks 35 adapter 1 36 gasket 1 37 joint 1 38 joint 1 39 plastic tie 1 not reusable 40 hose 1 41 bolt 1 m6 × 20 mm 42 bolt 2 m6 × 25 mm 43 retaining plate 1 44 bolt 1 m6 × 20 mm 45 plate 1 46 grommet 1 47 rubber seal 1 48 clamp 1 s6d87020 1 21 22 2...

  • Page 156

    6d81g11 7-6 1 2 3 4 5 6 7 8 9 upper case 7 no. Part name q’ty remarks 1 oil seal 1 not reusable 2 bolt 6 m6 × 45 mm 3 oil pump assembly 1 4 dowel 2 5 o-ring 2 not reusable 6 upper case assembly 1 7 cover 2 8 bolt 4 m10 × 40 mm 9 grommet 1 10 grommet 1 11 nut 2 12 nut 2 13 washer 2 14 washer 2 15 gre...

  • Page 157

    Brkt bracket unit 7-7 6d81g11 7 no. Part name q’ty remarks 1 oil seal 1 not reusable 2 screw 6 ø6 × 10 mm 3 gasket 1 not reusable 4 o-ring 1 not reusable 5 shaft 1 6 o-ring 1 not reusable 7 oil seal 1 not reusable 8 oil seal 2 not reusable 9 o-ring 1 not reusable 10 oil seal housing 1 11 screw 4 ø6 ...

  • Page 158

    6d81g11 7-8 1 2 3 4 5 6 7 8 9 7 no. Part name q’ty remarks 1 bolt 3 m8 × 45 mm 2 upper mount 1 3 plate 1 4 washer 2 5 washer 2 6 bolt 2 m12 × 194 mm 7 bolt 4 m8 × 40 mm 8 muffler assembly 1 9 gasket 1 10 drain bolt 1 m14 × 12 mm 11 damper 1 12 rubber seal 1 13 gasket 1 not reusable 14 gasket 1 not r...

  • Page 159

    Brkt bracket unit 7-9 6d81g11 7 no. Part name q’ty remarks 18 dowel 2 19 upper case 1 20 drive shaft bushing 1 21 circlip 1 22 lower mount 2 23 washer 2 24 washer 2 25 washer 2 26 bolt 2 m12 × 200 mm s6d87050 a a 1 2 6 5 26 25 24 22 23 7 13 12 8 15 17 20 21 19 16 18 18 14 a lt 572 lt 572 lt 572 lt 5...

  • Page 160

    6d81g11 7-10 1 2 3 4 5 6 7 8 9 7 no. Part name q’ty remarks 1 exhaust guide 1 2 gasket 1 not reusable 3 dowel 2 4 gasket 1 not reusable 5 oil strainer 1 6 collar 3 7 bolt 3 m6 × 25 mm 8 bolt 12 m6 × 25 mm 9 oil pan 1 10 gasket 1 not reusable 11 exhaust manifold 1 12 bolt 4 m6 × 70 mm 13 gasket 1 not...

  • Page 161

    Brkt bracket unit 7-11 6d81g11 7 no. Part name q’ty remarks 18 muffler 1 19 bolt 1 m6 × 50 mm 20 grommet 1 21 spacer 1 22 pipe 1 s6d87060 17 19 18 20 21 22 14 15 12 8 3 3 9 7 4 13 10 11 1 2 5 6 16 16 a a lt 572 lt 572 lt 572 lt 572 lt 572 lt 572 lt 572 lt 572 a a t r . . 11 n · m (1.1 kgf · m, 8.1 f...

  • Page 162

    6d81g11 7-12 1 2 3 4 5 6 7 8 9 removing the upper case 1. Place a drain pan under the drain hole, and then remove the drain bolt 1 and let the oil drain completely. 2. Remove the oil pump assembly and mount covers. 3. Disconnect the ground lead and speed- ometer hose. 4. Remove the upper and lower m...

  • Page 163

    Brkt bracket unit 7-13 6d81g11 3. Install new oil seals into the oil seal hous- ing. 4. Install new o-rings and the gasket, and then tighten the screws to the specified torque. Disassembling the upper case 1. Remove the muffler assembly from the upper case. 2. Remove the circlip, then the drive shaf...

  • Page 164

    6d81g11 7-14 1 2 3 4 5 6 7 8 9 checking the oil strainer 1. Check the oil strainer for dirt or residue. Clean if necessary. Assembling the oil pan 1. Install a new gasket onto the exhaust guide 1. 2. Install a new gasket and the oil strainer 2 onto the exhaust guide, and then tighten the bolts to th...

  • Page 165

    Brkt bracket unit 7-15 6d81g11 assembling the upper case 1. Install the drive shaft bushing into the upper case, and then install the circlip. 2. Install the muffler assembly 3 by insert- ing the tip of the water pipe 4 into the joint hole a of the upper case. 3. Install the muffler assembly bolts 5...

  • Page 166

    6d81g11 7-16 1 2 3 4 5 6 7 8 9 note: before tightening the lower mounting nut, be sure to connect the ground lead to the lower mounting bolt. 6. Install the mount covers 8. 7. Install the oil pump assembly 9 and the bolts 0, and then tighten them to the specified torque. Note: when installing the oi...

  • Page 167

    Brkt bracket unit 7-17 6d81g11 steering arm 7 no. Part name q’ty remarks 1 nut 2 2 steering hook 1 3 stud bolt 2 m10 × 40 mm 4 steering arm 1 5 washer 1 6 bushing 1 7 o-ring 2 not reusable 8 bushing 2 9 washer 1 10 steering yoke 1 11 damper 1 12 circlip 1 a a a 11 7 6 5 4 8 12 10 9 7 8 1 2 3 t r . ....

  • Page 168

    6d81g11 7-18 1 2 3 4 5 6 7 8 9 removing the steering arm 1. Remove the circlip 1. 2. Remove the steering yoke 2 by striking it with a plastic hammer. 3. Remove the steering arm from the swivel bracket by pulling the arm off the bracket. Installing the steering arm 1. Install the washer 1, bushing 2,...

  • Page 169

    Brkt bracket unit 7-19 6d81g11 clamp brackets and swivel bracket 7 no. Part name q’ty remarks 1 swivel bracket 1 2 clamp bracket 1 3 clamp bracket 1 4 self-locking nut 1 5 screw 1 ø6 × 12 mm 6 washer 2 7 bushing 2 8 trim sensor cam 1 9 screw 1 ø6 × 25 mm 10 plate 1 11 anode 1 12 bolt 1 m6 × 14 mm 13...

  • Page 170

    6d81g11 7-20 1 2 3 4 5 6 7 8 9 7 no. Part name q’ty remarks 1 swivel bracket 1 2 tilt stop lever 1 3 bushing 4 4 distance collar 2 a: 30.3–30.6 mm (1.19–1.20 in) 5 pin 2 6 hook 1 7 bolt 1 m6 × 10 mm 8 spring 1 9 tilt stop lever 1 10 trim sensor 1 11 screw 2 ø6 × 15 mm 12 bolt 1 m6 × 10 mm 13 clamp 2...

  • Page 171

    Brkt bracket unit 7-21 6d81g11 removing the clamp brackets 1. Remove the power trim and tilt unit. For removal procedure, see “removing the power trim and tilt unit.” 2. Remove the anode 1. 3. Disconnect the ground lead 2. 4. Remove the trim sensor cam screw 3. 5. Loosen the self-locking nut 4 and t...

  • Page 172

    6d81g11 7-22 1 2 3 4 5 6 7 8 9 4. Fully tilt the outboard motor up, and then support it with the tilt stop lever 3. Warning after tilting up the outboard motor, be sure to support it with the tilt stop lever. Otherwise, the outboard motor could sud- denly lower if the power trim and tilt unit should...

  • Page 173

    Brkt bracket unit 7-23 6d81g11 power trim and tilt unit 7 no. Part name q’ty remarks 1 power trim and tilt unit 1 2 circlip 1 3 shaft 1 4 circlip 2 5 shaft 1 6 bushing 2 7 bushing 1 8 ground lead 1 9 bolt 1 m6 × 10 mm 10 bushing 2 11 bushing 2 12 collar 1 13 holder 2 14 bolt 2 m6 × 10 mm s6d87270 2 ...

  • Page 174

    6d81g11 7-24 1 2 3 4 5 6 7 8 9 removing the power trim and tilt unit 1. Fully tilt the outboard motor up, and then support it with the tilt stop lever 1. Warning after tilting up the outboard motor, be sure to support it with the tilt stop lever. Otherwise, the outboard motor could sud- denly lower ...

  • Page 175

    Brkt bracket unit 7-25 6d81g11 power trim and tilt motor 7 no. Part name q’ty remarks 1 power trim and tilt motor 1 2 bolt 4 m6 × 20 mm 3 o-ring 1 not reusable 4 joint 1 5 o-ring 1 not reusable 6 reservoir cap 1 7 screw 3 ø5 × 25 mm 8 stator 1 9 o-ring 1 not reusable 10 armature 1 11 washer 1 12 bus...

  • Page 176

    6d81g11 7-26 1 2 3 4 5 6 7 8 9 7 no. Part name q’ty remarks 18 circuit breaker 1 19 spring 2 20 ptt motor base 1 21 oil seal 1 not reusable 22 plate 1 23 screw 2 ø4 × 10 mm 1 2 3 4 5 6 t r . . 4 n · m (0.4 kgf · m, 3.0 ft · ib) t r . . 7 n · m (0.7 kgf · m, 5.2 ft · ib) a a a a a a 9 10 11 12 8 7 14...

  • Page 177

    Brkt bracket unit 7-27 6d81g11 disassembling the power trim and tilt motor 1. Remove the power trim and tilt motor, o- ring, and joint from the power trim and tilt unit. Caution: • make sure that the tilt ram is fully extended when removing the power trim and tilt motor, otherwise fluid can spurt ou...

  • Page 178

    6d81g11 7-28 1 2 3 4 5 6 7 8 9 3. Measure the commutator undercut a. Replace the armature if below specifica- tion. 4. Check the armature for continuity. Replace if out of specifications. 5. Check the circuit breaker for continuity. Replace if there is no continuity. 6. Measure the brush length. Rep...

  • Page 179

    Brkt bracket unit 7-29 6d81g11 assembling the power trim and tilt motor 1. Install a new oil seal 1 and the bushing 2 into the motor base 3 as shown. 2. Attach the circuit breaker 4 onto the brush 5 together with the brush holder 6 and connect the wire lead 7. 3. Install the springs 8 into the motor...

  • Page 180

    6d81g11 7-30 1 2 3 4 5 6 7 8 9 gear pump 7 no. Part name q’ty remarks 1 gear pump assembly 1 2 spacer 2 3 pin 1 4 lever 1 5 bolt 1 m3 × 16 mm 6 bolt 1 m3 × 35 mm 7 spring 2 8 shuttle piston 1 9 backup ring 1 10 down-relief valve seat 1 11 washer 1 12 spring 1 13 pin 1 14 cap 1 15 bolt 2 m5 × 30 mm 1...

  • Page 181

    Brkt bracket unit 7-31 6d81g11 7 no. Part name q’ty remarks 18 holder 1 19 spring 1 20 washer 1 21 up-relief valve seat 1 22 bolt 2 m5 × 25 mm 23 o-ring 1 not reusable 24 shuttle piston 1 25 bolt 2 m5 × 45 mm 26 bolt 2 m5 × 50 mm 27 filter 1 28 plate 1 29 o-ring 2 not reusable 30 filter 2 31 o-ring ...

  • Page 182

    6d81g11 7-32 1 2 3 4 5 6 7 8 9 7 no. Part name q’ty remarks 1 manual release spring 1 2 ball 2 3 bracket 1 4 bolt 1 m3 × 5 mm 5 bolt 2 m5 × 6 mm 6 washer 2 7 o-ring 2 not reusable 8 adapter 2 9 spring 2 10 ball 2 11 gear 2 12 drive shaft 1 13 pin 2 14 driven shaft 1 15 ball 2 16 pin 2 s6d87550 t r ....

  • Page 183

    Brkt bracket unit 7-33 6d81g11 disassembling the gear pump 1. Remove the manual valve, then the gear pump and filters. 2. Remove the relief valve seat caps, then the up-relief valve seat 1 and down- relief valve seat 2. 3. Remove the lever 3, then the shuttle pistons 4. 4. Remove the gear pump brack...

  • Page 184

    6d81g11 7-34 1 2 3 4 5 6 7 8 9 4. Install the adapters 6 into the gear pump cover. 5. Install the balls 7 into the gear pump cover with the manual release spring 8. 6. Install the gear pump bracket 9 by installing the bolts, then tightening them to the specified torques. 7. Install the shuttle pisto...

  • Page 185

    Brkt bracket unit 7-35 6d81g11 tilt cylinder and trim cylinder 7 no. Part name q’ty remarks 1 power trim and tilt assembly 1 2 dust seal 1 not reusable 3 backup ring 1 4 o-ring 1 not reusable 5 trim cylinder end screw 1 6 o-ring 1 not reusable 7 tilt cylinder end screw assembly 1 8 backup ring 1 9 o...

  • Page 186

    6d81g11 7-36 1 2 3 4 5 6 7 8 9 7 no. Part name q’ty remarks 18 valve 5 19 spring 5 20 washer 1 21 tilt cylinder 1 22 ball 6 23 o-ring 1 not reusable 24 backup ring 1 25 tilt piston 1 26 ball 1 27 ball 2 28 valve 2 29 spring 2 30 pin 2 31 dowel 2 32 washer 1 33 tilt piston assembly 1 34 o-ring 1 not ...

  • Page 187

    Brkt bracket unit 7-37 6d81g11 7 no. Part name q’ty remarks 35 free piston 1 36 circlip 1 37 cylinder base 1 38 spring 2 39 washer 1 40 circlip 1 41 trim cylinder 1 s6d87390 10 11 12 13 14 15 16 7 2 17 34 35 36 37 38 39 40 41 38 1 18 19 20 21 22 33 23 24 26 27 28 29 30 25 32 31 31 3 4 5 6 8 9 t r . ...

  • Page 188

    6d81g11 7-38 1 2 3 4 5 6 7 8 9 disassembling the trim cylinder 1. Hold the power trim and tilt unit 1 in a vise using aluminum plates a on both sides. 2. Loosen the trim cylinder end screw 2, and then remove it. Warning make sure that the ram is fully extended before removing the end screw. 3. Drain...

  • Page 189

    Brkt bracket unit 7-39 6d81g11 4. Remove the bolt 3, then the tilt piston 4. Checking the tilt cylinder and trim cylinder 1. Check the power trim and tilt unit for cracks or corrosion. Replace if neces- sary. 2. Check the inner walls of the trim cylinder and tilt cylinder for scratches. Replace if n...

  • Page 190

    6d81g11 7-40 1 2 3 4 5 6 7 8 9 6. Install the new o-rings 9 and 0, and backup ring a onto the trim piston b. 7. Install the balls c, valves d, and springs e into the trim piston, and then install the washer f and trim piston to the tilt cylin- der g. 8. Install the filter h and washer i to the trim ...

  • Page 191

    Brkt bracket unit 7-41 6d81g11 15. Install the tilt cylinder end screw 8, and then tighten it to the specified torque. Caution: do not damage the check valve b when tightening the end screw. 16. Install the free piston u into the tilt cylin- der g by installing the circlip v. 17. Install the cylinde...

  • Page 192

    6d81g11 7-42 1 2 3 4 5 6 7 8 9 5. Install a new o-ring, the joint, and the power trim and tilt motor 5 by installing the bolts, then tightening them to the specified torque. 6. Add fluid of the recommended type to the first level at the bottom of the trim cylin- der. 7. Install the balls 6 into the ...

  • Page 193

    Brkt bracket unit 7-43 6d81g11 bleeding the power trim and tilt unit 1. Tighten the manual valve 1 by turning it clockwise. 2. Place the power trim and tilt unit in an upright position. 3. Remove the reservoir cap, and then check the fluid level in the reservoir. Note: if the fluid is at the correct...

  • Page 194

    6d81g11 7-44 1 2 3 4 5 6 7 8 9 note: • repeat this procedure so that the ram goes up and down four or five times (be sure to wait a few seconds before switching the leads). • if the ram does not move up and down eas- ily, push and pull on the ram to assist oper- ation. 8. Check the fluid level when ...

  • Page 195

    Brkt bracket unit 7-45 6d81g11 6. Support the outboard motor 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 if the power trim and tilt unit should lose fluid pressure. 7. Re...

  • Page 196

    6d81g11 7-46 1 2 3 4 5 6 7 8 9 3. Connect the light green (lg) lead to the positive battery terminal and the black (b) lead to the negative battery terminal as shown. 4. Check for continuity between terminals 2 and 3. Replace if there is no continu- ity. 5. Connect the digital circuit tester between...

  • Page 197: Electrical Systems

    6d81g11 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 198

    Elec electrical systems – + 8-1 6d81g11 special service tools 8 spark checker ym-34487 digital multimeter yu-34899-a peak volt meter adapter yu-39991 test harness (2 pins) yb-06792 test harness (3 pins) yb-06791 test harness (6 pins) yb-06848 pressure/vacuum tester yb-35956-a.

  • Page 199

    6d81g11 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 200

    Elec electrical systems – + 8-3 6d81g11 electrical components 8 port view 1 idle speed control 2 sensor assembly (intake air temperature and intake air pressure) 3 pulser coil 4 oil pressure switch 5 fuel injector 6 electric fuel pump 7 throttle position sensor s6d88010 1 7 2 6 5 3 4 5.

  • Page 201

    6d81g11 8-4 1 2 3 4 5 6 7 8 9 starboard view 1 ignition coil 2 cooling water temperature sensor 3 starter motor 4 junction box 5 spark plug s6d88020 1 5 2 3 4 electrical components.

  • Page 202

    Elec electrical systems – + 8-5 6d81g11 bow view 1 ecm 2 sensor assembly (intake air temperature and intake air pressure) 3 idle speed control 4 throttle position sensor 5 rectifier regulator 6 power trim and tilt relay 7 starter relay 8 main and fuel pump relay 9 fuse (20a) (ecm, ignition coil, ele...

  • Page 203

    6d81g11 8-6 1 2 3 4 5 6 7 8 9 top view 1 fuel injection 2 shift position switch 3 sensor assembly (intake air temperature and intake air pressure) 4 idle speed control 5 stator coil 6 power trim and tilt switch 7 starter motor s6d88040 1 3 4 2 5 6 7 electrical components.

  • Page 204

    Elec electrical systems – + 8-7 6d81g11 ignition and ignition control system 8 checking the ignition spark 1. Remove the spark plug wire cover. 2. Disconnect the spark plug caps from the spark plugs. 3. Connect a spark plug cap to the special service tool. 4. Crank the engine and observe the spark t...

  • Page 205

    6d81g11 8-8 1 2 3 4 5 6 7 8 9 checking the ecm 1. Disconnect an ignition coil coupler. 2. Connect the test harness (2 pins) to the ignition coil. 3. Measure the ecm output peak voltage. If below specification, measure the pulser coil output peak voltage. Replace the ecm if the output peak voltage of...

  • Page 206

    Elec electrical systems – + 8-9 6d81g11 2. Connect a computer to the outboard motor and use the yamaha diagnostic system to display the intake air tempera- ture. 3. If the ambient temperature and the dis- played intake air temperature differ by more than ± 5 °c (± 9 °f), replace the sensor assembly....

  • Page 207

    6d81g11 8-10 1 2 3 4 5 6 7 8 9 checking the main and fuel pump relay (main control) 1. Remove the main and fuel pump relay 1. 2. Connect the digital circuit tester leads to the relay terminals 2 and 3. 3. Connect the positive battery terminal to the relay terminal 4. 4. Connect the negative battery ...

  • Page 208

    Elec electrical systems – + 8-11 6d81g11 2. Listen for the operating sound of the electric fuel pump 1. Check the fuel sys- tem if there is no sound. Note: after the engine start switch is turned to on, the electric fuel pump will operate for 3 sec- onds. Checking the main and fuel pump relay (fuel ...

  • Page 209

    6d81g11 8-12 1 2 3 4 5 6 7 8 9 s60v8265 br b fuel control system / starting system.

  • Page 210

    Elec electrical systems – + 8-13 6d81g11 starter motor 8 no. Part name q’ty remarks 1 clip 1 2 pinion stopper 1 3 starter motor pinion 1 4 spring 1 5 bolt 2 m6 × 35 mm 6 housing 1 7 bearing 1 8 clutch assembly 1 9 e-clip 1 not reusable 10 washer 1 11 bracket 1 12 pinion shaft 1 13 planetary gear 3 1...

  • Page 211

    6d81g11 8-14 1 2 3 4 5 6 7 8 9 8 no. Part name q’ty remarks 18 brush assembly 1 19 brush spring 4 20 brush holder 1 21 plate 1 22 washer 1 23 bracket 1 24 screw 2 ø4 × 15 mm 25 bolt 2 m6 × 120 mm 26 rubber seal 1 27 shift lever 1 28 spring 1 29 magnet switch assembly 1 30 washer 1 31 nut 1 s63p8050 ...

  • Page 212

    Elec electrical systems – + 8-15 6d81g11 disassembling the starter motor 1. Slide the pinion stopper 1 down as shown, and then remove the clip 2. Note: remove the clip with a thin screwdriver. 2. Remove the bolts, and then disassemble the starter motor. Checking the starter motor pinion 1. Check the...

  • Page 213

    6d81g11 8-16 1 2 3 4 5 6 7 8 9 checking the brushes 1. Measure the brush length. Replace the brush assembly if below specification. 2. Check the brush holder assembly for continuity. Replace if out of specification. Checking the magnet switch 1. Connect the tester leads between the magnet switch ter...

  • Page 214

    Elec electrical systems – + 8-17 6d81g11 3. Measure the stator coil output peak volt- age. Replace the stator coil if below specification. Checking the rectifier regulator 1. Disconnect the stator coil coupler. 2. Connect the test harness (6 pins) between the rectifier regulator and sta- tor coil co...

  • Page 215: Troubleshooting

    6d81g11 trbl shtg 1 2 3 4 5 6 7 8 9 troubleshooting special service tools ..................................................................................... 9-1 yamaha diagnostic system .......................................................................... 9-2 introduction.......................

  • Page 216

    Trbl shtg troubleshooting 9-1 6d81g11 special service tools 9 yamaha diagnostic system 60v-85300-02 yamaha diagnostic system 60v-ws853-02 diagnostic test lead yb-06795 yamaha diagnostic system installation manual.

  • Page 217

    6d81g11 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 218

    Trbl shtg troubleshooting 9-3 6d81g11 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 219

    6d81g11 9-4 1 2 3 4 5 6 7 8 9 connecting the communication cable to the outboard motor bow view s6d89010 3-pin communication coupler yamaha diagnostic system.

  • Page 220

    Trbl shtg troubleshooting 9-5 6d81g11 note: • check that all electrical connections are tight and free from corrosion, and that the battery is fully charged to 12 v. • to diagnose a mechanical malfunction, use the troubleshooting charts pertaining to the trouble located in this chapter. Also, when c...

  • Page 221

    6d81g11 9-6 1 2 3 4 5 6 7 8 9 check the wiring harnesses for continuity. Replace the starter relay. Listen for the operation sound of the starter relay. Check the power unit. Can the oper- ation sound be heard? Yes yes no is there continuity? Replace the fuse. Yes no replace the starter motor. No ch...

  • Page 222

    Trbl shtg troubleshooting 9-7 6d81g11 symptom: engine cranks, but will not start (engine stop lanyard switch is operating nor- mally). • check the ignition system. • check the fuel system. • check the compression pressure of the power unit. Wet spark plugs? Check the condition of the spark plugs. Wa...

  • Page 223

    6d81g11 9-8 1 2 3 4 5 6 7 8 9 does the engine start? Wet spark plugs? Within specification? Within specification? Failure in starting operation failure in starting operation check the fuel system. Check the condition of the spark plugs again. Check the compression pres- sure of the combustion chambe...

  • Page 224

    Trbl shtg troubleshooting 9-9 6d81g11 symptom: engine can be started, but does not remain on. • check the fuel system. • check the ignition system. • check the compression pressure of the power unit. Fuel system is the vent screw open? Water or residue? Kinks or fuel leakage? Check for water or resi...

  • Page 225

    6d81g11 9-10 1 2 3 4 5 6 7 8 9 ignition system compression pressure yes no within specification? No within specification? Yes no check the ignition system using the yamaha diagnostic system. Replace the ignition coil. Check the ignition spark using the spark checker. Replace the spark plug. Check th...

  • Page 226

    Trbl shtg troubleshooting 9-11 6d81g11 symptom: engine does not accelerate when the throttle is opened quickly. The engine turns off when the throttle is opened quickly. Acceleration is tardy and the engine is likely to stop at any moment. • check the engine using the diagnostic flash indicator or t...

  • Page 227

    6d81g11 9-12 1 2 3 4 5 6 7 8 9 lubrication system check the oil pump for debris or oil leaks. Check the engine oil level. Check the oil pressure. Check the oil pressure switch. Clean or replace the defective parts. At specified level? Within specification? Check the oil passage. Yes yes no no yes ye...

  • Page 228

    Trbl shtg troubleshooting 9-13 6d81g11 bracket unit 9 symptom: power trim and tilt unit does not operate. Listen for the operation sound of the power trim and tilt relay. Listen for the operation sound of the power trim and tilt motor. Check that the manual valve is closed. Check the power trim and ...

  • Page 229

    6d81g11 9-14 1 2 3 4 5 6 7 8 9 check the fluid passages for clogs or debris. Clean the passages. Check the internal parts (valves, pistons, gears, etc.). Clean or replace the filters. No yes no yes add fluid to the correct level. At specified level? Yes no disassemble the power trim and tilt unit, a...

  • Page 230

    Trbl shtg troubleshooting 9-15 6d81g11 symptom: power trim and tilt unit does not hold the outboard motor up. Check that the manual valve is closed. Check the power trim and tilt fluid level. Close the valve. Add fluid to the correct level. At specified level? Is it closed? Yes yes no no check the f...

  • Page 231

    6d81g11 9-16 1 2 3 4 5 6 7 8 9 symptom: shift mechanism of the forward gear and reverse gear does not operate properly. Check the operation of the shift rod. Check the condition of the shift rod connection between the lower case and upper case. Replace the shift rod. Check the shift cables and links...

  • Page 232

    Trbl shtg troubleshooting 9-17 6d81g11 electrical systems 9 symptom: battery becomes weaker quickly. • check the charging system. Measure the rectifier regulator output peak voltage. Replace the stator coil. Within specification? Within specification? Replace the rectifier regulator. Yes yes no no m...

  • Page 233

    6d81g11 9-18 1 2 3 4 5 6 7 8 9 self-diagnosis 9 diagnosing the electronic control system 1. Connect the special service tool to the outboard motor as shown. Note: when performing this diagnosis, all of the electrical wires must be properly connected. 2. Start the engine and let it idle. 3. Check the...

  • Page 234

    Trbl shtg troubleshooting 9-19 6d81g11 4. If a flash pattern listed in the diagnostic code chart is displayed, check the mal- functioning part according to the flash pattern. Note: when more than one problem is detected, the light of the special service tool flashes in the pattern of the lowest numb...

  • Page 235

    6d81g11 i-1 1 2 3 4 5 6 7 8 9 index a. Adjusting the float .....................................4-17 adjusting the throttle link and throttle cable .............................................3-8 adjusting the trim sensor ..........................7-21 after test run ..................................

  • Page 236

    Index i-2 6d81g11 checking the piston ring side clearance ...5-42 checking the piston rings..........................5-41 checking the power trim and tilt fluid level.........................................................3-11 checking the power trim and tilt motor .....7-27 checking the power trim...

  • Page 237

    6d81g11 i-3 1 2 3 4 5 6 7 8 9 index i. Identification................................................1-5 ignition and ignition control system.............8-7 installing the clamp brackets.....................7-21 installing the cylinder head .......................5-33 installing the drive shaft ......

  • Page 238

    Index i-4 6d81g11 u. Upper case..................................................7-6 v. Vapor separator ........................................4-10 ventilation ...................................................1-3 y. Yamaha diagnostic system ........................9-2.

  • Page 239

    F90tr sb r lg up free down 2 3 1 4 3 1 2 1 2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 6 7 5 1 2 3 8 4 1 2 3 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18...

  • Page 240

    Wiring diagram f90tr 1 ignition coil 2 spark plug 3 power trim and tilt switch (tiller handle) (optional) 4 power trim and tilt switch (bottom cowling) 5 battery 6 cooling water temperature sensor 7 starter motor 8 fuse (30 a) 9 fuse (20 a) 0 neutral switch (optional) a starter relay b power trim an...

  • Page 241

    Yamaha motor corporation, usa printed in usa jul. 2004 – 0.0 × 1 cr (e).