F(L)225F

F(L)250D
F(L)300B

SUPPLEMENTARY
SERVICE MANUAL

6CE-28197-3P-1X
 Preface
This supplementary service manual has been prepared to introduce new service and new data
information for F(L)225F, F(L)250D, F(L)300B. For complete information on service procedures, it is
necessary to use this supplementary service manual along with the following manual.

F(L)225F, F(L)250D, F(L)300B SERVICE MANUAL: 6CE-28197-3N-11

Important information
Particularly important information is distinguished in this manual by the following notations:

 The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS
INVOLVED!

A WARNING indicates a hazardous situation which, if not avoided, could result in death or
serious injury.

A NOTICE indicates special precautions that must be taken to avoid damages to the out-
board motor or other property.

TIP:
A TIP provides key information to make procedures easier or clearer.

F(L)225F, F(L)250D, F(L)300B

SUPPLEMENTARY
SERVICE MANUAL
©2011 by Yamaha Motor Co., Ltd.
1st Edition, June 2011
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
 Supplementary contents
GEN
General information INFO 0
Specification SPEC 1
TECH
Technical feature and description FEA 2
RIG
Rigging information GING 3
TRBL
Troubleshooting SHTG 4
Electrical system ELEC 5
Fuel system FUEL 6
Power unit POWR 7
Lower unit LOWR 8
Bracket unit BRKT 9
Maintenance MNT 10
Index

Appendix A
 General information

Safety while working ........................................................1

Rotating part ..................................................................................1
Hot part ..........................................................................................1
Electric shock ................................................................................1
Propeller ........................................................................................1
Handling of gasoline ......................................................................1
Ventilation ......................................................................................1
Self-protection ...............................................................................2
Working with crane ........................................................................2
Handling of gas torch ....................................................................2
Part, lubricant, and sealant ............................................................2
Handling of sealant ........................................................................3
Special service tool .......................................................................3
Tightening torque ..........................................................................3
Non-reusable part ..........................................................................3
Disassembly and assembly ...........................................................3

How to use this manual ........................................................4

Manual format ...............................................................................4
Abbreviation ..................................................................................5

Lubricant, sealant, and thread locking agent .....................6

Symbol ..........................................................................................6

Special service tool ...............................................................7

Specification

Model feature .........................................................................8

Model designation .........................................................................8
Serial number ................................................................................8

Model data .............................................................................9

Dimension and weight ...................................................................9
Performance ..................................................................................9
Power unit ...................................................................................10
Lower unit ....................................................................................11
Bracket unit .................................................................................11
Fuel and oil requirement ..............................................................12
Battery requirement .....................................................................13
PTT fluid requirement ..................................................................13

Electrical system technical data ........................................14

Fuel injection control system .......................................................14
Specified tightening torque ................................................15
Power unit ...................................................................................15
Lower unit (regular rotation model) .............................................15
Lower unit (counter rotation model) .............................................16

General tightening torque ..................................................16

Technical feature and description

Power unit system ..............................................................17

Oil cooler .....................................................................................17

Cooling system ...................................................................18

Cooling diagram ..........................................................................18

Electrical system

Fuel control unit and component ......................................20

Checking the low-pressure fuel pump and
high-pressure fuel pump ..............................................................20

Fuel system

Hose routing ........................................................................22

Cooling water hose ......................................................................22

Power unit

Junction box ........................................................................24

Removing the Rectifier Regulator ...............................................27
Installing the Rectifier Regulator .................................................27

Oil cooler and oil pump assembly .....................................28

Removing the oil filter bracket .....................................................30
Removing the oil cooler ...............................................................30
Installing the oil cooler .................................................................30
Installing the oil filter bracket .......................................................31
Cylinder block sensor and switch .....................................33
Removing the cooling water cover ..............................................36
Removing the thermostat ............................................................36
Checking the cooling water cover anode ....................................36
Installing the thermostat ..............................................................36
Installing the cooling water cover ................................................37

Cylinder block .....................................................................38

Disassembling the cylinder block ................................................40
Assembling the cylinder block .....................................................41

Lower unit

Lower unit
(regular rotation model, X-transom model) ......................45

Lower unit
(regular rotation model, U-transom model) ......................47

Propeller shaft housing (regular rotation model) .............49

Removing the propeller shaft housing assembly .........................51
Installing the propeller shaft housing assembly ...........................52

Lower unit
(counter rotation model, X-transom model) .....................54

Lower unit
(counter rotation model, U-transom model) .....................56

Propeller shaft housing (counter rotation model) ............58

Removing the propeller shaft housing assembly .........................60
Installing the propeller shaft housing assembly ...........................60

Maintenance

Outline ..................................................................................61
Maintenance interval chart 1 .......................................................61
Maintenance interval chart 2 .......................................................63
 General information 0

Safety while working Handling of gasoline

To prevent an accident or injury and to pro- • Gasoline is highly flammable. Keep gaso-
vide quality service, observe the following line and all flammable products away from
heat, sparks, and open flames.
safety procedures.
• Gasoline is poisonous and can cause injury 0
Rotating part or death. Handle gasoline with care. Never
• Hands, feet, hair, jewelry, clothing, personal siphon gasoline by mouth. If you swallow
flotation device straps, and so on, can
become entangled with internal rotating
some gasoline, inhale a lot of gasoline
vapor, or get some gasoline in your eyes, 1
parts of the engine, resulting in serious see your doctor immediately. If gasoline
injury or death. spills on your skin, wash with soap and
• Keep the top cowling installed whenever
possible. Do not remove or install the top
water. If gasoline spills on your clothing,
change your clothes.
2
cowling when the engine is running.
• Only operate the engine with the top cowl-
ing removed according to the specific
instructions in the manual. Keep hands,
3
feet, hair, jewelry, clothing, personal flota-
tion device straps, and so on, away from
any exposed moving parts. 4
Hot part
During and after operation, engine parts are
hot enough to cause burns. Do not touch any Ventilation
5
parts under the top cowling until the engine • Gasoline vapor and exhaust gas are
has cooled. heavier than air and extremely poisonous. If

Electric shock
gasoline vapor or exhaust gas is inhaled in 6
large quantities, it may cause loss of con-
Do not touch any electrical parts while start- sciousness and death within a short time.
ing or operating the engine. Otherwise, shock
or electrocution could result.
• When test running an engine indoors (for
example, in a water tank) make sure to do 7
so where adequate ventilation can be main-
Propeller tained.
Do not hold the propeller with your hands
when loosening or tightening the propeller 8
nut.

9
10

A
1
Self-protection Handling of gas torch
• Protect your eyes by wearing safety • Improper handling of a gas torch may result
glasses or safety goggles during all opera- in burns. For information on the proper han-
tions involving drilling and grinding, or when dling of the gas torch, see the operation
using an air compressor. manual issued by the manufacturer.
• Protect your hands and feet by wearing pro- • When using a gas torch, keep it away from
tective gloves and safety shoes when nec- the gasoline and oil, to prevent a fire.
essary. • Components become hot enough to cause
burns. Do not touch any hot components
directly.

Working with crane

• Outboard motors weighing 18.0 kg (39.7 lb)
and over must be carried by a crane. Part, lubricant, and sealant
• Use the wire ropes of adequate strength, Use only genuine Yamaha parts, lubricants,
and lift up the outboard motor using the and sealants, or those recommended by
three-point suspension. Yamaha, when servicing or repairing the out-
• If the outboard motor does not have three board motor.
or more points to be suspended, support it
using additional ropes, or the like, so that
the outboard motor can be lifted and carried
in a stable manner.

2
Handling of sealant Non-reusable part
• Wear protective gloves to protect your skin, Always use new gaskets, seals, O-rings, cot-
when using the sealants. ter pins, and so on, when installing or assem-
• See the material safety data sheet issued bling parts.
by the manufacturer. Some of the sealants 0
may be harmful to human health.

1
2
Disassembly and assembly
• Use compressed air to remove dust and dirt 3
Special service tool during disassembly.
Use the recommended special service tools • Apply engine oil to the contact surfaces of
to work safely, and to protect parts from dam-
age.
moving parts before assembly.
4
5
6
• Install bearings so that the bearing identifi-
Tightening torque
cation mark is facing in the direction indi- 7
cated in the installation procedure. In
When tightening nuts, bolts, and screws, fol-
addition, make sure to lubricate the bear-
low the tightening instructions provided
throughout the manual. If the tightening order
is not specified, tighten the large sizes first,
ings liberally.
• Apply a thin coat of water resistant grease 8
to the lip and periphery of an oil seal before
and then tighten the small sizes, starting from
installation.
the center and moving outward.
• Check that moving parts operate normally
after assembly.
9
10

A
3
How to use this manual
Manual format
The format of this manual has been designed to make service procedures clear and easy to under-
stand. Use the following information as a guide for effective and quality service.

• Parts are shown and detailed in an exploded diagram and are listed in the component list (see a
in the following figure for an example page).
• The component list consists of part names and quantities, as well as bolt and screw dimensions
(see b in the following figure).
• Symbols are used to indicate important aspects of a procedure, such as the grade of lubricant and
the lubrication points (see c in the following figure).
• Tightening torque specifications are provided in the exploded diagrams (see d in the following fig-
ure), and in the related detailed instructions. Some torque specifications are listed in stages as
torque figures or angles in degrees.
• Separate procedures and illustrations are used to explain the details of removal, checking, and
installation where necessary (see e in the following figure for an example page).

TIP:
For troubleshooting procedures, see “Troubleshooting” in the service manual for the applicable
model.

4
Abbreviation
The following abbreviations are used in this service manual.
Abbreviation Description
API American Petroleum Institute 0
ATF Automatic Transmission Fluid
CCA Cold Cranking Ampere
DOHC
ECM
Double Overhead Camshaft
Electronic Control Module
1
EN European Norm (European standard)
F
IEC
Forward
International Electro-technical Commission
2
ISO International Organization for Standardization
N
OCV
Neutral
Oil Control Valve
3
PORT Port side
PTT
R
Power Trim and Tilt
Reverse
4
RON Research Octane Number
SAE
STBD
Society of Automotive Engineers
Starboard side
5
TCI Transistor-Controlled Ignition
YDIS Yamaha Diagnostic System
6
7
8
9
10

A
5
Lubricant, sealant, and thread locking agent
Symbol
Symbols in an exploded diagram or illustration indicate the grade of lubricant and the lubrication
points.
Symbol Name Application
Yamaha 4-stroke motor oil Lubricant

Gear oil Lubricant

Water resistant grease Lubricant

(Yamaha grease A)

Corrosion resistant grease Lubricant

(Yamaha grease D)

WR-No.2 grease Lubricant

Symbols in an exploded diagram or illustration indicate the type of sealant or thread locking agent
and the application points.
Symbol Name Application
Gasket Maker Sealant

ThreeBond 1280B Sealant

ThreeBond 1303 Thread locking agent

ThreeBond 1322 Thread locking agent

LOCTITE 271 (red) Thread locking agent

LOCTITE 572 (white) Sealant

6
Special service tool
For all markets except U.S.A. and Canada
Special service tools with Yamaha part numbers (90890-*****) are distributed by the Parts Division.

Digital circuit tester Bearing housing puller claw L 0

90890-03174 90890-06502

1
2
Oil filter wrench Stopper guide plate
90890-06830 90890-06501
3
4
Piston ring compressor
90890-05158
Center bolt
90890-06504 5
6

Ring nut wrench extension Slide hammer handle

7
90890-06513 90890-06531

8
9
Ring nut wrench 6 Puller head
90890-06677 90890-06514
10

A
7
 Specification 1

Model feature
Model designation

F 300 B E T X
a b c d e f

F: 4-stroke regular rotation

a Model description
FL: 4-stroke counter rotation
b Model name 300: 225/250/300
c Product generation B: A and later
d E: Electric starter
Functions
e T: PTT
X: UL (25 in)
f Transom height
U: SUL (30 in)

Serial number Approved Starting

The outboard motor serial number is indi- Model name
model code serial No.
cated on a label affixed to the port clamp
F225FET 6CL 1001084–
bracket.
FL225FET 6CM 1000190–
F250DET 6CG 1002208–
FL250DET 6CH 1000678–
F300BET 6CE 1003590–
FL300BET 6CF 1001446–

c a

b d
YAMAHA MOTOR CO., LTD.
MADE IN JAPAN
PAYS D'ORIGINE JAPON

a Model name
b Approved model code
c Transom height
d Serial number

8
Model data
Dimension and weight
Model

Overall length
Item Unit
mm (in)
F225FET FL225FET F250DET
958.0 (37.7)
FL250DET 0
Overall width mm (in) 634.0 (25.0)
Overall height
X mm (in)
2017.0
1890.0 (74.4) 1
U mm (in) — 2017.0 (79.4)
(79.4)
Boat transom height
X mm (in) 643.0 (25.3) 2
770.0
U mm (in) — 770.0 (30.3)
(30.3)
Weight (without propeller)
X kg (lb) 260.0 (573)
3
268.0
U kg (lb) — 268.0 (591)
(591)

Model
4
Item Unit
F300BET FL300BET
Overall length mm (in) 958.0 (37.7)
Overall width
Overall height
mm (in) 634.0 (25.0) 5
X mm (in) 1890.0 (74.4)
U
Boat transom height
mm (in) 2017.0 (79.4)
6
X mm (in) 643.0 (25.3)
U mm (in) 770.0 (30.3)
Weight (without propeller)
X kg (lb) 260.0 (573)
7
U kg (lb) 268.0 (591)

Performance 8
Model
Item Unit
F225FET FL225FET F250DET FL250DET
Maximum output
At 5500 r/min kW (HP) 165.5 (225) 183.8 (250) 9
Full throttle operating range r/min 5000–6000
Maximum fuel consumption
At 5500 r/min
L (US gal,
Imp gal)/hr
76.0 (20.1, 16.7) 84.0 (22.2, 18.5) 10
Engine idle speed r/min 600–700

Model
Item Unit
F300BET FL300BET
Maximum output
At 5500 r/min kW (HP) 220.6 (300)
Full throttle operating range r/min 5000–6000 A
9
 Model
Item Unit
F300BET FL300BET
Maximum fuel consumption
L (US gal,
At 5500 r/min 97.0 (25.6, 21.3)
Imp gal)/hr
Engine idle speed r/min 600–700

Power unit
Model
Item Unit
F225FET FL225FET F250DET FL250DET
Type 4-stroke, DOHC
Cylinder quantity V6
Total displacement cm3 (cu. in) 4169.0 (254.4)
Bore stroke mm (in) 96.0 96.0 (3.78 3.78)
Compression ratio 10.3:1
Control system Digital Electronic Control
Starting system Electric
Fuel system Fuel injection
Ignition control system TCI
Advance type Microcomputer
Maximum generator output V, A 12.0, 70.0
Spark plug LFR6A-11 (NGK)
Firing order 1–2–3–4–5–6 (normal operation)
Cooling system Water
Exhaust system Propeller boss
Lubrication system Wet sump

Model
Item Unit
F300BET FL300BET
Type 4-stroke, DOHC
Cylinder quantity V6
Total displacement cm³ (cu. in) 4169.0 (254.4)
Bore stroke mm (in) 96.0 96.0 (3.78 3.78)
Compression ratio 10.3:1
Control system Digital Electronic Control
Starting system Electric
Fuel system Fuel injection
Ignition control system TCI
Advance type Microcomputer
Maximum generator output V, A 12.0, 70.0
Spark plug LFR6A-11 (NGK)
Firing order 1–2–3–4–5–6 (normal operation)
Cooling system Water
Exhaust system Propeller boss
Lubrication system Wet sump

10
Lower unit
Model
Item Unit
F225FET FL225FET F250DET FL250DET
Gear shift positions
Gear ratio
F-N-R
1.75 (21/12)
0
Reduction gear type Spiral bevel gear
Clutch type Dog clutch
Propeller shaft type
Clock- Counter
Spline
Clock- Counter
1
Propeller direction (rear view)
wise clockwise wise clockwise
Propeller mark T TL T TL

Model
2
Item Unit
F300BET FL300BET
Gear shift positions
Gear ratio
F-N-R
1.75 (21/12) 3
Reduction gear type Spiral bevel gear
Clutch type Dog clutch
Propeller shaft type
Propeller direction (rear view) Clockwise
Spline
Counter clockwise
4
Propeller mark T TL

Bracket unit
Model
5
Item Unit
F225FET FL225FET F250DET FL250DET
Trim angle
At 12º boat transom degree –3 to 16 6
Tilt-up angle degree 67
Steering angle degree 32 + 32
Trim and tilt system PTT
7
Model
Item Unit
F300BET FL300BET
Trim angle
At 12º boat transom degree –3 to 16
8
Tilt-up angle degree 67
Steering angle degree 32 + 32
Trim and tilt system PTT 9
10

A
11
Fuel and oil requirement
Model
Item Unit
F225FET FL225FET F250DET FL250DET
Fuel type Regular unleaded gasoline
Minimum fuel octane number RON 90
4-stroke motor oil with combination of the fol-
Engine oil
lowing SAE and API oil classifications
API SE, SF, SG, SH, SJ, SL
Engine oil grade (*1)
SAE 5W-30, 10W-30, 10W-40
Total engine oil quantity (oil pan L (US qt,
7.1 (7.50, 6.25)
capacity) Imp qt)
Gear oil type Hypoid gear oil
API GL-5
Gear oil grade (*2)
SAE 90, 80W-90
L (US qt,
Gear oil quantity 1.040 (1.10, 0.92)
Imp qt)
(*1) If the recommended engine oil grades are not available, use engine oil with an API classification
of SH, SJ, or SL and an SAE classification of 15W-40, 20W-40, or 20W-50.
(*2) Meeting both API and SAE requirements.
Model
Item Unit
F300BET FL300BET
Fuel type Premium unleaded gasoline
Minimum fuel octane number RON 94
4-stroke motor oil with combination of the fol-
Engine oil
lowing SAE and API oil classifications
API SE, SF, SG, SH, SJ, SL
Engine oil grade (*1)
SAE 5W-30, 10W-30, 10W-40
Total engine oil quantity (oil pan L (US qt,
7.1 (7.50, 6.25)
capacity) Imp qt)
Gear oil type Hypoid gear oil
Gear oil grade (*2) API GL-5
SAE 90, 80W-90
L (US qt,
Gear oil quantity 1.040 (1.10, 0.92)
Imp qt)
(*1) If the recommended engine oil grades are not available, use engine oil with an API classification
of SH, SJ, or SL and an SAE classification of 15W-40, 20W-40, or 20W-50.
(*2) Meeting both API and SAE requirements.

12
Battery requirement
Model
Item Unit
F225FET FL225FET F250DET FL250DET
Minimum cold cranking amps
CCA/EN A 640.0
0
Minimum rated capacity
20HR/IEC Ah 80.0

Model
1
Item Unit
F300BET FL300BET
Minimum cold cranking amps
CCA/EN
Minimum rated capacity
A 640.0 2
20HR/IEC Ah 80.0

PTT fluid requirement 3

Model
Item Unit
F225FET FL225FET F250DET FL250DET
Fluid type ATF DEXRON II 4
Model
Item Unit
F300BET FL300BET
Fluid type ATF DEXRON II 5
6
7
8
9
10

A
13
Electrical system technical data
Fuel injection control system
Model
Item Unit
F225FET FL225FET F250DET FL250DET
Low-pressure fuel pump
Input voltage V 12.0
Resistance (*1)
At 20 °C (68 °F) Ω 0.5–4.0
High-pressure fuel pump
Input voltage V 12.0
Resistance (*1)
At 20 °C (68 °F) Ω 0.3–10.0
(*1) The figures are for reference only.
Model
Item Unit
F300BET FL300BET
Low-pressure fuel pump
Input voltage V 12.0
Resistance (*1)
At 20 °C (68 °F) Ω 0.5–4.0
High-pressure fuel pump
Input voltage V 12.0
Resistance (*1)
At 20 °C (68 °F) Ω 0.3–10.0
(*1) The figures are for reference only.

14
Specified tightening torque
Specified tightening torques are provided for specific nuts, bolts, and screws. When tightening these
fasteners, follow the tightening torque specifications indicated throughout the manual to meet the
design aims of the outboard motor.
0
Power unit
Tightening torques
Part to be tightened
PTT motor lead bolt
Screw size
M6
N·m
4
kgf·m
0.4
ft·lb
3.0
1
Terminal bolt M8 25 2.5 18.4
PTT relay nut — 5 0.5 3.7
Starter motor nut — 9 0.9 6.6 2
1st 6 0.6 4.4
Rectifier Regulator cover bolt M6
2nd 12 1.2 8.9
Oil pump cover screw
Oil cooler bolt
1st
M6
M6
6
4 0.4
0.6
3.0
4.4
3
2nd 12 1.2 8.9
Bracket bolt M6 12 1.2 8.9
Oil filter union bolt
Oil pressure sensor
UNF
—
49
13
4.9
1.3
36.1
9.6
4
Oil filter — 18 1.8 13.3
Thermostat housing bolt M6 12 1.2 8.9
Thermostat cover bolt M6 12 1.2 8.9 5
Knock sensor — 32 3.2 23.6
Knock sensor bracket bolt M6 12 1.2 8.9
Pulley bracket bolt
1st
2nd
M8
14
28
1.4
2.8
10.3
20.7 6
1st 40 4.0 29.5
Connecting rod bolt M9
2nd 90°
1st
2nd
M10
55 5.5
90°
40.6 7
Crankcase bolt
1st 14 1.4 10.3
M8
2nd 28 2.8 20.7

Lower unit (regular rotation model)

8
Tightening torques
Part to be tightened Screw size
Water inlet cover bolt M5
N·m
2
kgf·m
0.2
ft·lb
1.5
9
Drain screw — 9 0.9 6.6
Check screw — 9 0.9 6.6
Trim tab bolt
Propeller nut
M10
—
42
54
4.2
5.4
31.0
39.8
10
Lower case mounting bolt (X-transom model) M10 47 4.7 34.7
Lower case stud bolt (U-transom model) — 23 2.3 17.0
Lower case mounting nut (U-transom model) — 47 4.7 34.7
Lower case mounting bolt (U-transom model) M10 47 4.7 34.7
Water inlet cover screw M5 1 0.1 0.7
Propeller shaft housing ring nut
Cover bolt
—
M8
155
8
15.5
0.8
114.3
5.9
A
15
Lower unit (counter rotation model)
Tightening torques
Part to be tightened Screw size
N·m kgf·m ft·lb
Water inlet cover bolt M5 2 0.2 1.5
Drain screw — 9 0.9 6.6
Check screw — 9 0.9 6.6
Trim tab bolt M10 42 4.2 31.0
Propeller nut — 54 5.4 39.8
Lower case mounting bolt (X-transom model) M10 47 4.7 34.7
Lower case stud bolt (U-transom model) — 23 2.3 17.0
Lower case mounting nut (U-transom model) — 47 4.7 34.7
Lower case mounting bolt (U-transom model) M10 47 4.7 34.7
Water inlet cover screw M5 1 0.1 0.7
Propeller shaft housing ring nut — 155 15.5 114.3
Cover bolt M8 8 0.8 5.9

General tightening torque

This chart indicates the tightening torques for
standard fasteners with a standard ISO
thread pitch.
Width General torque
Screw
across specifications
size (B)
flats (A) N·m kgf·m ft·lb
8 mm M5 5 0.5 3.7
10 mm M6 8 0.8 5.9
12 mm M8 18 1.8 13.3
14 mm M10 36 3.6 26.6
17 mm M12 43 4.3 31.7

16
 Technical feature and description 2

Power unit system

Oil cooler
The large oil cooler, which supersedes previously-used oil filter bracket, has been incorporated onto
the cylinder block to improve the engine cooling performance.
0
2011 model

Oil filter bracket

2
3
4
5
2012 model
6
7
8
9

Cooling water cover 10

A
B

A Engine oil flow

B Cooling water flow
A
17
Cooling system
Cooling diagram
Thermostat Rectifier Regulator

Fuel cooler
C
C

B
A

A
B

Oil cooler

Cooling water cover

Exhaust guide

Upper case

Water pump

Water inlet
D

A B C Indicates a connection between the symbols.

D Cooling water flow

18
 Thermostat (PORT) Thermostat (STBD)
Rectifier Regulator
0
Cylinder block (PORT) Cylinder block (STBD)
1
E
Flushing device Pilot hole 2
Cylinder head (PORT) Cylinder head (STBD)
3
Cooling water
cover

4
Cylinder block
Fuel cooler Oil cooler
(crankcase)
5

Exhaust guide Exhaust guide

6
Oil pan Oil pan 7
Upper case
F 8
Water pump Lower case Trim tab

Water inlet Propeller boss

9

Water 10
D

D Cooling water flow

E When flushing the cooling water passages
F Dynamic water pressure when the boat is cruising
A
19
 Electrical system 5

Fuel control unit and component High-pressure fuel pump input voltage:
Checking the low-pressure fuel Red/Yellow (R/Y)–Black (B)
pump and high-pressure fuel pump 12.0 V (battery voltage)
1. Check the operation of the low-pressure
fuel pump and high-pressure fuel pump 7. Measure the resistance of the fuel pump
using the YDIS “Stationary test” and motors.
check the operating sound.

2. Disconnect the low-pressure fuel pump

coupler a.

3. Turn the engine start switch to ON, and

then measure the input voltage between
the low-pressure fuel pump coupler
terminal and ground.

R/Y b
a

Low-pressure fuel pump a resistance

(reference data):
0.5–4.0 Ω at 20 °C (68 °F)
High-pressure fuel pump b resistance
(reference data):
Digital circuit tester: 90890-03174 0.3–10.0 Ω at 20 °C (68 °F)

Low-pressure fuel pump input voltage: 8. Remove the intake manifold (STBD).
Red/Yellow (R/Y)–Ground
12.0 V (battery voltage) 9. Remove the fuse holder c, and then
disconnect the fuse holder coupler c.
4. Turn the engine start switch to OFF.

5. Disconnect the high-pressure fuel pump c

coupler b.

6. Connect the tester probes to the

terminals of the high-pressure fuel pump
coupler b, and then measure the input
voltage within 5 seconds after turning the c
engine start switch to ON.

B R/Y 10. Disconnect the engine ECM coupler d.

20
 0
d

1
11. Check the wiring harness for continuity.

a c
2
5 1
2 1 12 7
3
d
b
4
2 1

56
5
Wiring harness continuity:
a Terminal 1–c Terminal 7 6
a Terminal 2–d Terminal 56
b Terminal 1–c Terminal 1
b Terminal 2–Ground
7
12. Connect the fuse holder coupler c, and
then install the fuse holder c.

13. Install the intake manifold (STBD). 8

14. Connect the engine ECM coupler d.

15. Connect the low-pressure fuel pump 9

coupler a and high-pressure fuel pump
coupler b.
10

A
21
 Fuel system 6

Hose routing
Cooling water hose

c j h f
g i

a
t
k g
d

b
d
a
a
c b b l

b u

s
m
n
o
p
f
i
fa q r v e

a Cooling water hose (cylinder block to joint) j Cooling water hose (cooling water cover to
b Cooling water hose (joint to fuel cooler) joint)
c Cooling water hose (joint to oil cooler) k Cooling water hose (thermostat cover
d Cooling water hose (fuel cooler to oil [STBD] to joint)
cooler) l Cooling water hose (joint to Rectifier Reg-
e Cooling water hose (oil cooler to joint) ulator)
f Cooling water hose (joint to cylinder block) m Cooling water hose (Rectifier Regulator to
g Cooling water hose (joint to joint) joint)
h Cooling water hose (joint to joint) n Cooling water hose (joint to joint)
i Cooling water hose (cylinder block to cool- o Cooling water hose (joint to cooling water
ing water cover) outlet)

22
 c j h f
g i 0
d

1
e

2
a
t

d
k g 3
b
d 4
a
a
c b b l

d
5
b u

s
6
m

o
n
7
p

i
f
8
fa q r v e

p Cooling water hose (flushing hose adapter a Oil cooler

9
to joint) b Fuel cooler (vapor separator)
q Cooling water hose (joint to joint) c Cooling water cover
r Cooling water hose (joint to cylinder block
[PORT])
d Rectifier Regulator
e Cooling water outlet (on the bottom cowl-
10
s Cooling water hose (joint to cylinder block ing)
[STBD]) f Flushing hose adapter
t Cooling water hose (thermostat cover
[PORT] to cylinder block)
u Cooling water hose (thermostat cover
[STBD] to joint)
v Cooling water hose (joint to cylinder block) A
23
 Power unit 7

Junction box
a 6 N·m (0.6 kgf·m, 4.4 ft·lb)
b 12 N·m (1.2 kgf·m, 8.9 ft·lb) 22
24 21
19
20
15 25
16 18
23
17 28
25

30 27 26
29 9 N·m (0.9 kgf·m, 6.6 ft·lb)
14 7
6

5
38 9 8
11 8
2
1 31 32

33
3 7 37
13
4 10
35 36
10 34
4 2 12 6 25 N·m (2.5 kgf·m, 18.4 ft·lb)
9
5 N·m (0.5 kgf·m, 3.7 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb)
1

No. Part name Q’ty Remarks

1 Cap 2
2 PTT motor lead bolt 2 M6 10 mm
3 PTT relay 1
4 Bolt 2 M6 20 mm
5 Junction box 1
6 Bolt 5 M6 30 mm
7 Grommet 5
8 Collar 5
9 Holder 2
10 Holder 2
11 Holder 1
12 Holder 1
13 Bracket 2
14 Bolt 1 M6 15 mm
15 Bolt 3 M6 35 mm
16 Rectifier Regulator 1
17 Gasket 1 39

24
 a 6 N·m (0.6 kgf·m, 4.4 ft·lb)
b 12 N·m (1.2 kgf·m, 8.9 ft·lb) 22

19 24 21
0
20
15 25
16 18
23
1
17 28
25

30 27 26 2
29 9 N·m (0.9 kgf·m, 6.6 ft·lb)
14 7
6
3
5
38 9 8

1
2
11 8
32
4
31

3
13
33
7 37
5
4 10
35 36
4 2 12
10
9
34
6 25 N·m (2.5 kgf·m, 18.4 ft·lb) 6
5 N·m (0.5 kgf·m, 3.7 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb)
1

No. Part name Q’ty Remarks 7

18 Cover 1
19 Rectifier Regulator cover bolt 6 M6 25 mm
20
21
Hose
Joint
1
1
8
22 Hose 1
23
24
Hose
Hose
1
1 9
25 Joint 2
26 Hose 1
27
28
Hose
Hose
1
1
10
29 Power source lead 1
30 Isolator lead 1
31 Bolt 1 M8 16 mm
32 Terminal 1
33 Terminal bolt 1 M8 20 mm
34 Bolt 2 M6 15 mm
A
25
 a 6 N·m (0.6 kgf·m, 4.4 ft·lb)
b 12 N·m (1.2 kgf·m, 8.9 ft·lb) 22
24 21
19
20
15 25
16 18
23
17 28
25

30 27 26
29 9 N·m (0.9 kgf·m, 6.6 ft·lb)
14 7
6

5
38 9 8
11 8
2
1 31 32

33
3 7 37
13
4 10
35 36
10 34
4 2 12 6 25 N·m (2.5 kgf·m, 18.4 ft·lb)
9
5 N·m (0.5 kgf·m, 3.7 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb)
1

No. Part name Q’ty Remarks

35 Bracket 1
36 Bracket 1
37 Bolt 2 M6 20 mm
38 Starter motor nut 1

26
Removing the Rectifier Regulator
1. Remove the ground lead a.
c
2. Disconnect the cooling water hoses b
and c. 0
c

a
b
1
2
b a
Rectifier Regulator cover bolts c:
3. Remove the Rectifier Regulator a. 1st: 6 N·m (0.6 kgf·m, 4.4 ft·lb) 3
2nd: 12 N·m (1.2 kgf·m, 8.9 ft·lb)

a 2. Install the Rectifier Regulator d.

4
d

5
4. Remove the cover b and gasket c. 6
3. Install the ground lead a.

4. Connect the cooling water hoses b and

7
c.

b
c 8
c

Installing the Rectifier Regulator b a 10

1. Install a new gasket a and the cover b,
and then tighten the Rectifier Regulator
cover bolts c to the specified torques in
2 stages. NOTICE: Do not reuse a gas-
ket, always replace it with a new one.

A
27
Oil cooler and oil pump assembly
49 N·m (4.9 kgf·m, 36.1 ft·lb)
11
17
12 18
18 N·m (1.8 kgf·m, 13.3 ft·lb)
13
15

19
14 19
20
16
20

21
1 10
8
9
24
8 18
2 5
6 27 17
26 23
28
4 28 4 N·m (0.4 kgf·m, 3.0 ft·lb) 24
3
22
24

29
30 25
7 31 a 6 N·m (0.6 kgf·m, 4.4 ft·lb)
12 N·m (1.2 kgf·m, 8.9 ft·lb) b 12 N·m (1.2 kgf·m, 8.9 ft·lb)
13 N·m (1.3 kgf·m, 9.6 ft·lb) 31

No. Part name Q’ty Remarks

1 Oil filter 1
2 Union bolt 1
3 Oil pressure sensor 1
4 O-ring 1 39
5 Gasket 1 39
6 Bracket 1
7 Bracket bolt 5 M6 40 mm
8 Joint 2
9 Hose 1
10 Hose 1
11 Oil filler cap 1
12 O-ring 1 39
13 Oil filler neck 1
14 O-ring 1 39
15 Holder 1
16 Bolt 2 M6 25 mm
17 Gasket 2 39

28
49 N·m (4.9 kgf·m, 36.1 ft·lb)
11
17
12 18
18 N·m (1.8 kgf·m, 13.3 ft·lb)
13
15 0
19
14

16
19
20 1
20

1 10
21 2
8
9

8
24
18
3
2 5
6 27 17 23
28
26
4
4 28 4 N·m (0.4 kgf·m, 3.0 ft·lb) 24
3
22
24
5
29
30 25
7
12 N·m (1.2 kgf·m, 8.9 ft·lb)
31 a 6 N·m (0.6 kgf·m, 4.4 ft·lb)
b 12 N·m (1.2 kgf·m, 8.9 ft·lb) 6
13 N·m (1.3 kgf·m, 9.6 ft·lb) 31

No. Part name Q’ty Remarks 7

18 Bolt 12 M6 40 mm
19 Screw 2 M6 16 mm
20
21
Anode
Cover
2
1
8
22 Oil cooler 1
23
24
Hose
Plastic tie
1
4 9
25 Oil pump assembly 1
26 Relief valve 1
27
28
Oil seal
O-ring
1
2
39
39
10
29 Gasket 1 39
30 Oil seal 1 39
31 Oil seal 2 39

A
29
Removing the oil filter bracket e
1. Remove the oil filter a.
f

c
a
b
a

Oil filter wrench b: 90890-06830

2. Remove the oil pressure sensor c, b

O-ring d, and oil filter union bolt e.
e
3. Remove the oil filter bracket f and d
gasket g.
Installing the oil cooler

Do not reuse a gasket, always replace it

with a new one.
g
e f
1. Install the anodes a.

2. Install a new gasket b, the oil cooler c,

a new gasket d, and the cover e, and
then tighten the oil cooler bolts f to the
d specified torques in 2 stages and in the
c order a, b, and so on.

3. Install the hoses g and h, and then

Removing the oil cooler fasten the hose h using the plastic tie
1. Remove the hoses a and b. i.

2. Remove the cover c, oil cooler d,

gaskets e, and anodes f.

30
 d f

a
0
a
b

g e
1
c 2
f

b
h
i a
3
c c

f k
d e 4
j h
c b
g d 5
Oil filter bracket bolt c:
c 12 N·m (1.2 kgf·m, 8.9 ft·lb)
a
b
2. Install the oil filter union bolt d, and then 6
e tighten it to the specified torque.

f i l
3. Install a new O-ring e and the oil
pressure sensor f, and then tighten the
7
oil pressure sensor to the specified
Oil cooler bolt f:
torque.
1st: 6 N·m (0.6 kgf·m, 4.4 ft·lb)
2nd: 12 N·m (1.2 kgf·m, 8.9 ft·lb) 8
Installing the oil filter bracket d
9
Do not reuse a gasket or O-ring, always
replace it with a new one.

f
e 10
1. Install a new gasket a and the oil filter
bracket b, and then tighten the oil filter
Oil filter union bolt d:
bracket bolts c to the specified torque in
49 N·m (4.9 kgf·m, 36.1 ft·lb)
the order a, b, and so on.
Oil pressure sensor f:
13 N·m (1.3 kgf·m, 9.6 ft·lb)

A
31
4. Add a small amount of engine oil through
the oil passage a of the oil filter bracket.

5. Install the oil filter g, and then tighten it

to the specified torque.

h g

Oil filter wrench h: 90890-06830

Oil filter g: 18 N·m (1.8 kgf·m, 13.3 ft·lb)

32
Cylinder block sensor and switch
34 12 N·m (1.2 kgf·m, 8.9 ft·lb)
12 N·m (1.2 kgf·m, 8.9 ft·lb)
1 1
33
2
3 1
9
34
a 14 N·m (1.4 kgf·m, 10.3 ft·lb)
b 28 N·m (2.8 kgf·m, 20.7 ft·lb)
13
14
0
12
11 9 11
1 12 N·m (1.2 kgf·m, 8.9 ft·lb)
10
7
6
4
5 6
12
13
32 N·m (3.2 kgf·m, 23.6 ft·lb)
24 26 1
22 25
8 29
10 23

14
33 20
21
2
14 27
28
15
17 30
3
14 29
18 28 31
16 27
36 35
4
14 39
32 40
19
35 5
44 42
15

43
41
36
6
44 38 37

No. Part name Q’ty Remarks 7

1 Clamp 4
2 Hose 1
3
4
Hose
Joint
1
1
8
5 Hose 1
6
7
Clamp
Joint
2
1 9
8 Knock sensor bracket bolt 4 M6 25 mm
9 Housing 2
10
11
Gasket
Thermostat
2
2
39
10
12 Gasket 2 39
13 Cover 2
14 Plastic tie 6
15 Holder 2
16 Hose 1
17 Hose 1
A
33
 34 12 N·m (1.2 kgf·m, 8.9 ft·lb)
12 N·m (1.2 kgf·m, 8.9 ft·lb)
1 1
33
2 a 14 N·m (1.4 kgf·m, 10.3 ft·lb)
34 13
3 1 b 28 N·m (2.8 kgf·m, 20.7 ft·lb) 14
9 12
11 9 11
1 12 N·m (1.2 kgf·m, 8.9 ft·lb)
10
7 4 12
6 32 N·m (3.2 kgf·m, 23.6 ft·lb) 26
5 6 13 24
22 25
8 29
10 23
33 20
14 21
14 27
28
15
17 30
14 29
18 28 31
16 27
36 35
14 39
32 40
19
35

44 42
15
36
43
41
44 38 37

No. Part name Q’ty Remarks

18 Joint 1
19 Hose 1
20 Bracket 1
21 Knock sensor 1
22 Pulley bracket bolt 4 M8 30 mm
23 Bracket 1
24 Engine temperature sensor 1
25 Hose 1
26 Holder 1
27 Bolt 2 M6 12 mm
28 Holder 2
29 Thermoswitch 2
30 Bolt 1 M6 16 mm
31 Bracket 1
32 Plastic tie 1
33 Thermostat cover bolt 4 M6 25 mm / Width across flats: 10 mm
34 Thermostat housing bolt 6 M6 25 mm / Width across flats: 8 mm

34
 34 12 N·m (1.2 kgf·m, 8.9 ft·lb)
12 N·m (1.2 kgf·m, 8.9 ft·lb)
1 1
33
2
3 1
9
34
a 14 N·m (1.4 kgf·m, 10.3 ft·lb)
b 28 N·m (2.8 kgf·m, 20.7 ft·lb)
13
14
0
12
11 9 11
1 12 N·m (1.2 kgf·m, 8.9 ft·lb)
10
7
6
4
5 6
12
13
32 N·m (3.2 kgf·m, 23.6 ft·lb)
24 26 1
22 25
8 29
10 23

14
33 20
21
2
14 27
28
15
17 30
3
14 29
18 28 31
16 27
36 35
4
14 39
32 40
19
35 5
44 42
15

43
41
36
6
44 38 37

No. Part name Q’ty Remarks 7

35 Screw 2 M6 16 mm
36 Anode 2
37
38
Gasket
Cooling water cover
1
1
39 8
39 Hose 1
40
41
Bolt
Bolt
8
1
M6
M6
20 mm
12 mm 9
42 Holder 1
43 Hose 1
44 Plastic tie 2
10

A
35
Removing the cooling water cover
d
1. Disconnect the hoses a and b, and
then remove the cooling water cover c. a

b
a e
f
c

Checking the cooling water cover

anode
1. Check the anodes. Replace if eroded.
b
Clean if there is grease, oil, or scales.
NOTICE: Do not apply grease, oil, or
paint to the anodes.

2. Remove the anodes d. Installing the thermostat

Do not reuse a gasket, always replace it

with a new one.
d

1. Install the thermoswitches a.

2. Install new gaskets b and the thermostat

housings c, and then tighten the
thermostat housing bolts d to the
d specified torque.

3. Install new gaskets e to the thermostats

a.
Removing the thermostat
1. Remove the hoses a and thermostat 4. Install the thermostats a, thermostat
covers b, and then remove the thermo- covers f, and hoses g, and then tighten
stats a and gaskets c. the thermostat cover bolts h to the
specified torque.
2. Remove the thermostat housings d and
gaskets e.

3. Remove the thermoswitches f.

36
 c d
a

e b 0
c
d
f

h
a
b
1

g 2
Thermostat housing bolt d:
12 N·m (1.2 kgf·m, 8.9 ft·lb) 3
Thermostat cover bolt h:
12 N·m (1.2 kgf·m, 8.9 ft·lb)

Installing the cooling water cover

3. Tighten the cooling water cover bolts d
in the order a, b, and so on. 4
4. Connect the hoses e and f, and then
Do not reuse a gasket, always replace it
with a new one.
fasten the cooling water hose f using
the plastic tie g.
5
d
1. Install the anodes a. h
e
g 6
d
a
c
7
a
b

f
e 8
f g
a
9
2. Install a new gasket b, the cooling water
cover c, and the cooling water cover
10
bolts d.

A
37
Cylinder block
a 55 N·m (5.5 kgf·m, 40.6 ft·lb)
4 4 b 90°
5 5
1
3 3 24
2
22 25
2

4 5
8
4 5 9

6 11

7 13
9
10
14
16 20 21 12

17 10 23
19
19 26
15
18
16 a 40 N·m (4.0 kgf·m, 29.5 ft·lb) a 14 N·m (1.4 kgf·m, 10.3 ft·lb)
b 90° b 28 N·m (2.8 kgf·m, 20.7 ft·lb)

No. Part name Q’ty Remarks

1 Cylinder block 1
2 Anode 2
3 Screw 2 M5 26 mm
4 Screw 4 M6 25 mm
5 Anode 4
6 Screw 2 M6 45 mm
7 Anode 2
8 Oil seal 1 39
9 Thrust bearing (upper) 2
10 Thrust bearing (lower) 2
11 Crankshaft journal bearing (upper) 4
12 Crankshaft journal bearing (lower) 4
13 O-ring 2 39
14 Piston ring set 6
15 Piston 6
16 Clip 12 39
17 Piston pin 6

38
 a 55 N·m (5.5 kgf·m, 40.6 ft·lb)
4 4 b 90°

1
5 5 0
3 3 24
2
2
22 25 1
4 5

4 5
8 2
9

6 11
3
7 13
9

14
20 21
10
4
16 12

17 10

19
23
5
19 26
15

16 a 40 N·m (4.0 kgf·m, 29.5 ft·lb)

18
a 14 N·m (1.4 kgf·m, 10.3 ft·lb)
6
b 90° b 28 N·m (2.8 kgf·m, 20.7 ft·lb)

No. Part name Q’ty Remarks 7

18 Connecting rod assembly 6
19 Connecting rod bolt 12 39 M9 42 mm
20
21
Crankpin bearing
Collar
12
1 39
8
22 Crankshaft 1
23
24
Crankcase
Crankcase bolt
1
8 M10 105 mm 9
25 Crankcase bolt 8 M10 130 mm
26 Crankcase bolt 16 M8 50 mm

10

A
39
Disassembling the cylinder block
1. Remove the crankcase a and thrust TIP:
bearings b. • To prevent mixing the pistons, connecting
rods, and connecting rod caps, mark each
with an identification number b of the cor-
a
responding cylinder.
• Mark each connecting rod and connecting
rod cap with mark c on the side facing
toward the flywheel magnet end of the
crankshaft.
b • Make sure to keep the parts in the order of
removal.

3. Remove the crankshaft e, crankshaft

journal bearings f, thrust bearings g,
and oil seal h.

2. Remove the connecting rod caps a, and

then remove the crankpin bearings c, h
connecting rods, and piston assemblies f
d. g
g
f f

a
c c

4. Remove the collar i.

c i
j
d l
k d

e
b
l

40
 Bearing splitter plate j:
(commercially available)
a
Gear puller k: (commercially available)
General cylindrical tool l:
d = 19 mm (0.7 in)
0
e = 90 mm (3.5 in)

5. Remove the piston pin clips m and piston

pin n, and then remove the connecting
1
rod f.
2. Assemble the piston b, the connecting
m rod a, the piston pin c, and new piston
pin clips d.
2
n g d d
3
d c c

b 4
f
m

a
5
d
TIP:
• Remove the piston pin from the side
marked with g.
b
6
• Make sure to keep the parts in the order of TIP:
removal. • Face the mark b on the connecting rod a

6. Remove the piston rings.

in the same direction as the mark c on the
piston crown.
7
• Install the piston pin from the side marked
Assembling the cylinder block with c.
Before assembling the cylinder block, check • Do not align the piston pin clip end with the
groove d in the piston pin boss.
8
the crankcase bolts.

Do not reuse a connecting rod bolt, collar,

3. Install the oil rings e, 2nd ring f, and
top ring g.
9
oil seal, or piston pin clip, always replace
it with a new one. 4. Offset the piston ring end gaps. NOTICE:
Be careful not to scratch the pistons
or break the piston rings.
10
1. Install a new collar a by striking it using
a plastic hammer.

A
41
 f
e h

#5 #4
#3 f f
g
#2
#1
45˚ 45˚
#5 #2

k
#1
#4 #3

TIP: TIP:
• Make sure that the “2R” marks h on the Install the crankshaft journal bearings f in
2nd ring f and “1R” marks k on the top the original positions.
ring g are facing up.
• Make sure that the piston rings move 7. Install a new oil seal g onto the
smoothly. crankshaft h, and then install the
crankshaft and thrust bearings i.
5. Install the crankpin bearings e into the
connecting rod a and connecting rod i
cap m.
a
e
m h

TIP:
Install the crankpin bearings in the original TIP:
positions. Install each thrust bearing with its grooves
facing outward.
6. Install the crankshaft journal bearings f.
8. Install the piston j so that the mark n
on the piston crown is facing toward the
flywheel magnet end of the crankshaft.

42
 TIP:
• Make sure that the marks p on the con-
necting rod and connecting rod cap m face
toward the flywheel magnet end of the
crankshaft.
0
• In the second tightening stage for the con-
necting rod bolts l, mark the connecting
j rod bolts and the connecting rod cap with
identification marks r, and then tighten the
1
bolts 90° from the marks on the connecting
k
rod caps.
• Make sure that the crankshaft turns 2
smoothly.

10. Install the crankshaft journal bearings m

in the original positions.
3
n
11. Apply a thin, even layer of sealant onto
Piston ring compressor k: 90890-05158
the mating surface of the crankcase n. 4
9. Install the connecting rod caps m to the
connecting rods, and then tighten new
connecting rod bolts l to the specified
torques in 2 stages.
m 5
r 90˚
p
l
n 6
m m

TIP:
8
Do not apply any sealant to the crankshaft
journal bearings.

Connecting rod bolt l:

9
12. Install the thrust bearings o.
1st: 40 N·m (4.0 kgf·m, 29.5 ft·lb)
2nd: 90°
10

A
43
 s 90˚
o
e f
m n
A B
w x
a rq b
i j
s t
d c
l k
v u
p o
z y

h g
TIP:
• Install each thrust bearing with its grooves C
facing outward. F E r s q D
• Fit the protrusion on each thrust bearing
into the slot in the crankcase. Crankcase bolts q and r a–p (M10):
1st: 55 N·m (5.5 kgf·m, 40.6 ft·lb)
2nd: 90°
13. Install new O-rings p and the crankcase
Crankcase bolt s q–F (M8):
n, and then tighten the crankcase bolts
1st: 14 N·m (1.4 kgf·m, 10.3 ft·lb)
q and r to the specified torques in 2
2nd: 28 N·m (2.8 kgf·m, 20.7 ft·lb)
stages and in the order a, b, and so on.

14. Tighten the crankcase bolts s to the TIP:

specified torques in 2 stages and in the • In the second tightening stage for the M10
order q, r, and so on. bolts q and r, mark the M10 bolts and the
crankcase n with identification marks s,
q n and then tighten the bolts 90° from the
marks on the crankcase.
• Make sure that the crankshaft turns
s smoothly.
r

44
 Lower unit 8

Lower unit (regular rotation model, X-transom model)

12 42 N·m (4.2 kgf·m, 31.0 ft·lb)

11
54 N·m (5.4 kgf·m, 39.8 ft·lb) 0
9 N·m (0.9 kgf·m, 6.6 ft·lb)
15

9
14
16 1
10 13
3
8 9
18
17 2
7 20 19

3
9 N·m (0.9 kgf·m, 6.6 ft·lb) 21
4
6
5 22 23 5
22
4
3
2 1
47 N·m (4.7 kgf·m, 34.7 ft·lb)
6
2 N·m (0.2 kgf·m, 1.5 ft·lb)

No. Part name Q’ty Remarks 7

1 Water inlet cover (PORT) 1
2 Water inlet cover bolt 1 M5 40 mm
3
4
Gasket
Drain screw
2
1
39 8
5 Water inlet cover (STBD) 1
6
7
Self-locking nut
Hose nipple
1
1 9
8 O-ring 1 39
9 Dowel 2
10
11
Check screw
Trim tab bolt
1
1 M10 45 mm
10
12 Grommet 1
13 Lower unit 1
14 Propeller 1
15 Cotter pin 1 39
16 Propeller nut 1
17 Washer 1
A
45
 12 42 N·m (4.2 kgf·m, 31.0 ft·lb)

11
54 N·m (5.4 kgf·m, 39.8 ft·lb)
9 N·m (0.9 kgf·m, 6.6 ft·lb)
15

14
9 16

10 13
3
8 9 17
18
7 20 19

9 N·m (0.9 kgf·m, 6.6 ft·lb) 21

6
5 22 23
22
4
3 47 N·m (4.7 kgf·m, 34.7 ft·lb)
2 1
2 N·m (0.2 kgf·m, 1.5 ft·lb)

No. Part name Q’ty Remarks

18 Spacer 1
19 Damper 1 39
20 Spacer 1
21 Trim tab 1
22 Lower case mounting bolt 7 M10 45 mm
23 Lower case mounting bolt 1 M10 70 mm

46
Lower unit (regular rotation model, U-transom model)
17
42 N·m (4.2 kgf·m, 31.0 ft·lb)
16
23 N·m (2.3 kgf·m, 17.0 ft·lb)
0
54 N·m (5.4 kgf·m, 39.8 ft·lb)
15
14 13
1
21

20
13 13 22 2
19
12 18
13
26 25
24
23
3
11 3
10
9
4
9 N·m (0.9 kgf·m, 6.6 ft·lb) 27

8
7
5
6 29
5 31
28
4 30
9 N·m (0.9 kgf·m, 6.6 ft·lb) 3
1 47 N·m (4.7 kgf·m, 34.7 ft·lb)
6
2 N·m (0.2 kgf·m, 1.5 ft·lb) 2 47 N·m (4.7 kgf·m, 34.7 ft·lb)

No. Part name Q’ty Remarks 7

1 Water inlet cover (PORT) 1
2 Water inlet cover bolt 1 M5 40 mm
3
4
Gasket
Drain screw
2
1
39 8
5 Water inlet cover (STBD) 1
6
7
Self-locking nut
Hose nipple
1
1 9
8 O-ring 1 39
9 Bolt 1 M6 20 mm
10
11
Adapter
Plastic tie
1
1
10
12 Extension 1
13 Dowel 4
14 Rubber seal 1
15 Lower case stud bolt 6
16 Trim tab bolt 1 M10 45 mm
17 Grommet 1
A
47
 17
42 N·m (4.2 kgf·m, 31.0 ft·lb)
23 N·m (2.3 kgf·m, 17.0 ft·lb) 16

54 N·m (5.4 kgf·m, 39.8 ft·lb)

15
14 13

21

20
13 13 22
19
12 18 23
13 24
26 25
11 3
10
9
9 N·m (0.9 kgf·m, 6.6 ft·lb) 27

8
7 6 29 31
5
28
4 30
9 N·m (0.9 kgf·m, 6.6 ft·lb) 3
1 47 N·m (4.7 kgf·m, 34.7 ft·lb)
2 N·m (0.2 kgf·m, 1.5 ft·lb) 2 47 N·m (4.7 kgf·m, 34.7 ft·lb)

No. Part name Q’ty Remarks

18 Check screw 1
19 Lower unit 1
20 Propeller 1
21 Cotter pin 1 39
22 Propeller nut 1
23 Washer 1
24 Spacer 1
25 Damper 1 39
26 Spacer 1
27 Trim tab 1
28 Lower case mounting nut 6
29 Washer 6
30 Lower case mounting bolt 1 M10 170 mm
31 Lower case mounting bolt 1 M10 200 mm

48
Propeller shaft housing (regular rotation model)
7 9 8 10 12 11 13
3
4
14
0
8
1
1 23
2 13
12

11
2
10
9 18
7
8
21
22
3
20 30
8 19
6
5
29 4
17
30
16
15
25
5
28
27
1 N·m (0.1 kgf·m, 0.7 ft·lb) 26

25 155 N·m (15.5 kgf·m, 114.3 ft·lb) 6

24 8 N·m (0.8 kgf·m, 5.9 ft·lb)

No. Part name Q’ty Remarks 7

1 Self-locking nut 1
2 Water inlet cover (STBD) 1
3
4
Water pipe
Rubber seal
1
2
8
5 Water inlet cover screw 1 M5 45 mm
6
7
Water inlet cover (PORT)
Slider
1
1 9
8 Ball 2
9 Shift plunger 1
10
11
Spring
Dog clutch
1
1
10
12 Cross pin 1
13 Propeller shaft 1
14 Reverse gear shim (T2) —
15 Reverse gear 1
16 Thrust washer 1
17 Ball bearing 1 39
A
49
 7 9 8 10 12 11 13
3 14
4

1 23
2 13
12

11
10
9 18
8 22
7 21
20 30
8 19
6
29
5
17
30
16 25
15
28
27
1 N·m (0.1 kgf·m, 0.7 ft·lb) 26

25 155 N·m (15.5 kgf·m, 114.3 ft·lb)

24 8 N·m (0.8 kgf·m, 5.9 ft·lb)

No. Part name Q’ty Remarks

18 O-ring 1 39
19 Washer 1
20 Propeller shaft shim (T4) —
21 Taper roller bearing 1 39
22 Propeller shaft housing 1
23 Rubber seal 1
24 Needle bearing 1 39
25 Oil seal 2 39
26 Key 1
27 Claw washer 1
28 Propeller shaft housing ring nut 1
29 Cover 1
30 Cover bolt 2 M8 25 mm

50
Removing the propeller shaft
housing assembly
1. Remove the water pipe a and rubber
seals b. d
0
e
b
a
1
Ring nut wrench extension d:
90890-06513
Ring nut wrench 6 e: 90890-06677
2
5. Remove the propeller shaft housing ring
nut f and claw washer g. 3
f

2. Remove the cover c. g

4
c
5
6. Remove the propeller shaft housing
assembly.
6
j
3. Straighten the tab a on the claw washer
that is bent outward.
i 7

h
h 8
a

Bearing housing puller claw L h:

9
90890-06502
Stopper guide plate i: 90890-06501
4. Loosen the propeller shaft housing ring
Center bolt j: 90890-06504 10
nut. 7. Remove the O-ring k, propeller shaft
assembly l, and reverse gear shims m.

A
51
 k
l
e
m

d
8. Remove the taper roller bearing b,
propeller shaft shims n, washer o, and
reverse gear assembly c.

3. Install the original reverse gear shims f,

propeller shaft housing assembly e
along with the propeller shaft assembly
g, and key h.

h g

e
f
c
o
n
b

Installing the propeller shaft housing

assembly

Do not reuse a bearing or O-ring, always

replace it with a new one. 4. Install the claw washer i.

1. Install the reverse gear a, the washer b,

the original propeller shaft shims c, and i
a new taper roller bearing a.
b

TIP:
a
b Make sure to fit the protrusion b on the pro-
c peller shaft housing into the slot c in the
a
claw washer i.
2. Install a new O-ring d and the propeller
shaft housing assembly e.
52
5. Install the propeller shaft housing ring nut
n
j, and then tighten it to the specified
torque.
m

0
k
1
l
Cover bolt n:
j 8 N·m (0.8 kgf·m, 5.9 ft·lb) 2
Ring nut wrench extension k: 9. Install the rubber seals o and water pipe
90890-06513 p.
Ring nut wrench 6 l: 90890-06677 3
Propeller shaft housing ring nut j:
o
155 N·m (15.5 kgf·m, 114.3 ft·lb)

6. Turn the propeller shaft 10 turns or more,

p
4
and then tighten the propeller shaft
housing nut j to the specified torque.
Propeller shaft housing ring nut j:
5
155 N·m (15.5 kgf·m, 114.3 ft·lb)

7. Bend one of the 4 tabs on the claw

washer outward, and bend the other 3
6
tabs inward.

7
8
9
8. Install the cover m, and then tighten the
cover bolts n to the specified torque.
10

A
53
Lower unit (counter rotation model, X-transom model)
12 42 N·m (4.2 kgf·m, 31.0 ft·lb)

11
54 N·m (5.4 kgf·m, 39.8 ft·lb)
15
9 N·m (0.9 kgf·m, 6.6 ft·lb)

9 16

10 13
3 14
8 17
9 18
7 20 19

9 N·m (0.9 kgf·m, 6.6 ft·lb) 21

6
5 22 23
22
4
47 N·m (4.7 kgf·m, 34.7 ft·lb)
3
2 1
2 N·m (0.2 kgf·m, 1.5 ft·lb)

No. Part name Q’ty Remarks

1 Water inlet cover (PORT) 1
2 Water inlet cover bolt 1 M5 40 mm
3 Gasket 2 39
4 Drain screw 1
5 Water inlet cover (STBD) 1
6 Self-locking nut 1
7 Hose nipple 1
8 O-ring 1 39
9 Dowel 2
10 Check screw 1
11 Trim tab bolt 1 M10 45 mm
12 Grommet 1
13 Lower unit 1
14 Propeller 1
15 Cotter pin 1 39
16 Propeller nut 1
17 Washer 1

54
 12 42 N·m (4.2 kgf·m, 31.0 ft·lb)

11
54 N·m (5.4 kgf·m, 39.8 ft·lb)
15
0
9 N·m (0.9 kgf·m, 6.6 ft·lb)

9 16 1
10 13
3 14
8 9 18
17 2
7 20 19

3
9 N·m (0.9 kgf·m, 6.6 ft·lb) 21
4
6
5 22 23 5
22
4
3
2 1
47 N·m (4.7 kgf·m, 34.7 ft·lb)
6
2 N·m (0.2 kgf·m, 1.5 ft·lb)

No. Part name Q’ty Remarks 7

18 Spacer 1
19 Damper 1 39
20
21
Spacer
Trim tab
1
1
8
22 Lower case mounting bolt 7 M10 45 mm
23 Lower case mounting bolt 1 M10 70 mm
9
10

A
55
Lower unit (counter rotation model, U-transom model)
17
42 N·m (4.2 kgf·m, 31.0 ft·lb)
23 N·m (2.3 kgf·m, 17.0 ft·lb) 16

54 N·m (5.4 kgf·m, 39.8 ft·lb)

15
14 13

21

13 13 22
19 20
12 18 23
13 24
26 25
11 3
10
9
9 N·m (0.9 kgf·m, 6.6 ft·lb) 27

8
7 6 29 31
5
28
4 30
9 N·m (0.9 kgf·m, 6.6 ft·lb) 3
1 47 N·m (4.7 kgf·m, 34.7 ft·lb)
2 N·m (0.2 kgf·m, 1.5 ft·lb) 2 47 N·m (4.7 kgf·m, 34.7 ft·lb)

No. Part name Q’ty Remarks

1 Water inlet cover (PORT) 1
2 Water inlet cover bolt 1 M5 40 mm
3 Gasket 2 39
4 Drain screw 1
5 Water inlet cover (STBD) 1
6 Self-locking nut 1
7 Hose nipple 1
8 O-ring 1 39
9 Bolt 1 M6 20 mm
10 Adapter 1
11 Plastic tie 1
12 Extension 1
13 Dowel 4
14 Rubber seal 1
15 Lower case stud bolt 6
16 Trim tab bolt 1 M10 45 mm
17 Grommet 1

56
 17
42 N·m (4.2 kgf·m, 31.0 ft·lb)
16
23 N·m (2.3 kgf·m, 17.0 ft·lb)
0
54 N·m (5.4 kgf·m, 39.8 ft·lb)
15
14 13
1
21

13 13 22 2
19 20
12 18
13
26 25
24
23
3
11 3
10
9
4
9 N·m (0.9 kgf·m, 6.6 ft·lb) 27

8
7
5
6 29
5 31
28
4 30
9 N·m (0.9 kgf·m, 6.6 ft·lb) 3
1 47 N·m (4.7 kgf·m, 34.7 ft·lb)
6
2 N·m (0.2 kgf·m, 1.5 ft·lb) 2 47 N·m (4.7 kgf·m, 34.7 ft·lb)

No. Part name Q’ty Remarks 7

18 Check screw 1
19 Lower unit 1
20
21
Propeller
Cotter pin
1
1 39
8
22 Propeller nut 1
23
24
Washer
Spacer
1
1 9
25 Damper 1 39
26 Spacer 1
27
28
Trim tab
Lower case mounting nut
1
6
10
29 Washer 6
30 Lower case mounting bolt 1 M10 170 mm
31 Lower case mounting bolt 1 M10 200 mm

A
57
Propeller shaft housing (counter rotation model)
7 9 8 10 12 11 17 8 N·m (0.8 kgf·m, 5.9 ft·lb)
16
3
4
15
14
8
13
1 12
2

11
10 20
9 18 29
8 19
7

8
6
5 17 28
24

22 27 29
24 26
21 25

1 N·m (0.1 kgf·m, 0.7 ft·lb)

23
155 N·m (15.5 kgf·m, 114.3 ft·lb)

No. Part name Q’ty Remarks

1 Self-locking nut 1
2 Water inlet cover (STBD) 1
3 Water pipe 1
4 Rubber seal 2
5 Water inlet cover screw 1 M5 45 mm
6 Water inlet cover (PORT) 1
7 Slider 1
8 Ball 2
9 Shift plunger 1
10 Spring 1
11 Dog clutch 1
12 Cross pin 1
13 Forward gear shim (T2) —
14 Forward gear 1
15 Thrust washer 1
16 Taper roller bearing 1 39
17 Propeller shaft 1

58
 7 9 8 10 12 11 17 8 N·m (0.8 kgf·m, 5.9 ft·lb)
16
3
4 0
15
14
8
13
1
1 12
2

2
11
10 20
9 18
7
8 19 29
3
8
6
5 17 28
4
24

21
22 24
25
26
27 29
5
1 N·m (0.1 kgf·m, 0.7 ft·lb)
23 6
155 N·m (15.5 kgf·m, 114.3 ft·lb)

No. Part name Q’ty Remarks 7

18 O-ring 1 39
19 Thrust bearing 1
20
21
Propeller shaft shim (T4)
Propeller shaft housing
—
1
8
22 Rubber seal 1
39
23
24
Needle bearing
Oil seal
1
2 39 9
25 Key 1
26 Claw washer 1
27
28
Propeller shaft housing ring nut
Cover
1
1
10
29 Cover bolt 2 M8 25 mm

A
59
Removing the propeller shaft 3. Install the claw washer, ring nut, cover,
housing assembly and water pipe. See steps 4, 5, and 7–9
1. Remove the water pipe, cover, propeller in “Installing the propeller shaft housing
shaft housing ring nut, and claw washer. assembly” (page 52).
See steps 1–5 in “Removing the propel-
ler shaft housing assembly” (page 51).

2. Remove the propeller shaft housing

assembly, key, and forward gear shims.

Slide hammer a: 90890-06531

Puller head b: 90890-06514

Installing the propeller shaft housing

assembly

Do not reuse a bearing or O-ring, always

replace it with a new one.

1. Install a new O-ring a.

2. Install the original forward gear shims b,

propeller shaft housing c, and key d.

c
b

60
 Maintenance 10

Outline
• To obtain long product life, Yamaha strongly recommends that the specified periodic checks and
maintenance be performed according to the maintenance interval charts.
• If replacement parts are necessary, use only genuine Yamaha parts of equivalent design and qual-
ity. Any parts of inferior quality may cause a malfunction, and the resulting loss of control could 0
endanger the operator and passengers. Yamaha genuine parts and accessories are available
from Yamaha dealers.
• The service intervals provided in the maintenance interval charts are based upon “typical” operat-
ing conditions that include speed variations, sufficient time for engine warm up and cool-down,
1
medium to light load, and an average cruising speed in the 3000–4000 r/min range. If your normal
operating conditions are more intensive, more frequent servicing will be required, especially the
engine oil and gear oil changes. Examples of the intensive operation will be: wide-open-throttle,
trolling, or idling operation for extended periods of time, carrying heavy loads, and frequent start-
2
ing and stopping or shifting. In most cases, the frequent maintenance pays off in increased engine
life and greater owner satisfaction.
• The maintenance cycle on these charts is based on usage of 100 hours per year and regular 3
flushing of the cooling water passages. Adjust the maintenance frequency when operating the
engine under adverse conditions, such as extended trolling.
• Disassembly or repairs may be necessary depending on the outcome of maintenance checks.
• Expendable or consumable parts and lubricants will lose their effectiveness over time and through 4
normal usage regardless of the warranty period.
• When operating the outboard motor in salt water, or in muddy, turbid (cloudy), or acidic water, flush
the engine using clean water after each use.
5
Maintenance interval chart 1
The “F” symbol indicates the check-ups which the owners or operators may carry out themselves.
The “U” symbol indicates work to be carried out by a Yamaha dealer. 6
Initial Every
Item Actions 20 hours 100 hours 300 hours 500 hours

Anode(s) (external) Inspection or replacement

(3 months) (1 year)

F/U
(3 years) (5 years)
7
as necessary
Anode (cylinder head Inspection or replacement
exhaust passage)
Anodes (cylinder head,
as necessary
Replacement
U
8
cylinder block, cylinder
block thermostat portion, U
oil cooler cover, exhaust 9
guide)
Battery (electrolyte level, Inspection
F/U F/U
terminal)
Battery (electrolyte level,Fill, charging or replacing
10
U
terminal) as necessary
Cooling water leakage Inspection or replacement
U U
as necessary
Cowling lock lever Inspection F/U
Engine starting condition/ Inspection
F/U F/U
noise
A
61
 Initial Every
Item Actions 20 hours 100 hours 300 hours 500 hours
(3 months) (1 year) (3 years) (5 years)
Engine idle speed/noise Inspection F/U F/U
Engine oil Replacement F/U F/U
Engine oil filter (cartridge) Replacement U
Fuel filter (can be Inspection or replacement
F/U F/U
disassembled) as necessary
Fuel line (High pressure) Inspection or replacement
U U
as necessary
Fuel line (Low pressure) Inspection or replacement
U U
as necessary
Fuel pump Inspection or replacement
U
as necessary
Fuel/engine oil leakage Inspection U U
Gear oil Replacement F/U F/U
Greasing points Greasing F/U F/U
Impeller/water pump Inspection or replacement
U
housing as necessary
Impeller/water pump Replacement
U
housing
OCV (Oil Control Valve) Replacement
U
filter
Power trim and tilt unit Inspection F/U F/U
Propeller/propeller nut/ Inspection or replacement
F/U F/U
cotter pin as necessary
Spark plug(s) Inspection or replacement
F/U
as necessary
Ignition coils/ignition coil Inspection or replacement
U U
leads as necessary
Water from the cooling Inspection
F/U F/U
water pilot hole
Thermostat Inspection or replacement
U
as necessary
Timing belt Inspection or replacement
U
as necessary
Valve clearance Inspection and
U
adjustment
Cooling water inlet Inspection F/U F/U
Main switch/stop switch Inspection or replacement
U U
as necessary
Wire harness Inspection or replacement
connections/wire coupler as necessary U U
connections
Connector connections/ Inspection or replacement
U U
lead connections as necessary
(Yamaha) Meter/gauge Inspection U U

62
Maintenance interval chart 2
Every
Item Actions
1000 hours
Exhaust guide/exhaust
manifold
Inspection or replacement
as necessary
U
0
Timing belt Replacement U

1
2
3
4
5
6
7
8
9
10

A
63
 — MEMO —

64
Jun. 2011 – ** × 1 ABE
(E)