Yamaha 225G, 250B, L250B Service Manual (En)

225G, 250B,
L250B
SERVICE
MANUAL
65L-28197-Z8-11
E
PREFACE
This manual has been prepared by the Yamaha Motor Company, Ltd. 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 concepts and procedures inherent in the
work, for without such knowledge attempted repairs or service to the equipment could render
it unsafe or unfit for use.
Because the Yamaha Motor Company, Ltd. has a policy of continuously improving its prod-
ucts, models may differ in detail from the descriptions and illustrations given in this publica-
tion. Use only the latest edition of this manual. Authorized Yamaha dealers are notified
periodically of modifications and significant changes in specifications and procedures, and
these are incorporated in successive editions of this manual.
225G, 250B, L250B

SERVICE MANUAL
1998 Yamaha Motor Co., Ltd.
1st Edition, November 1998
All rights reserved.
No part of this publication may be
reproduced or transmitted in any form or by
any means including photocopying and
recording without the written permission of
the copyright holder.
Such written permission must also be
obtained before any part of this publication
is stored in a retrieval system of any nature.
E
HOW TO USE THIS MANUAL

MANUAL FORMAT
All of the procedures in this manual are organized in a sequential, step-by-step format. The
information has been compiled to provide the mechanic with an easy to read, handy refer-
ence that contains comprehensive explanations of all disassembly, repair, assembly, and
inspection operations.
For instance, the condition of a faulty component will precede an arrow symbol and the
course of action required will follow the symbol.
• Bearings
Pitting/scratches → Replace.
To assist you in finding your way through this manual, the section title and major heading is
given at the top of every page.
MODEL INDICATION
Multiple models are mentioned in this manual and their model indications are noted as fol-
lows.
Model name 200HETO 225FETO L225FETO 225GETO 250BETO L250BETO
USA and
V200TR S225TR L225TR V225TR S250TR L250TR
Canada name
Indication 200HETO 225FETO L225FETO 225GETO 250BETO L250BETO
ILLUSTRATIONS
The illustrations within this service manual represent all of the designated models.
CROSS REFERENCES
The cross references have been kept to a minimum. Cross references will direct you to the
appropriate section or chapter.
E
IMPORTANT INFORMATION
In this Service Manual particularly important information is distinguished in the following
ways.
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS
INVOLVED!
WARNING
Failure to follow WARNING instructions could result in severe injury or death to the machine
operator, a bystander, or a person inspecting or repairing the outboard motor.
CAUTION:
A CAUTION indicates special precautions that must be taken to avoid damage to the out-
board motor.
NOTE:
A NOTE provides key information to make procedures easier or clearer.
E
HOW TO USE THIS MANUAL

1 The main points regarding removing/installing and disassembling/assembling procedures
are shown in the exploded views.
2 The numbers in the exploded views indicate the required sequence of the procedure and
should be observed accordingly.
3 Symbols are used in the exploded views to indicate important aspects of the procedure.
A list of meanings for these symbols is provided on the following page.
4 It is important to refer to the job instruction charts at the same time as the exploded views.
These charts list the sequence that the procedures should be carried out in, as well as pro-
viding explanations on part names, quantities, dimensions and important points relating
to each relevant task.
Example:
O-ring size 39.5 × 2.5 mm: inside diameter (D) × ring diameter (d)
5 In addition to tightening torques, the dimensions of the bolts and screws are also men-
tioned.
Example:
Bolt and screw size 10 × 25 mm : bolt and screw diameter (D) × length (L)
D
6 In addition to the exploded views and job instruction charts, this manual provides individ-
ual illustrations when further explanations are required to explain the relevant procedure.
E
1 2 SYMBOLS
Symbols 1 to 9 are designed as thumb-
GEN tabs to indicate the content of a chapter.
INFO SPEC
1 General information
3 4 2 Specifications
3 Periodic inspections and adjustments
INSP FUEL 4 Fuel system
ADJ 5
6
Power unit
Lower unit
5 6 7 Bracket unit
8 Electrical systems
9 Trouble analysis
POWR LOWR
7 8
– +
BRKT ELEC
9 0
Symbols 0 to E indicate specific data.
0 Special tool
TRBL A Specified liquid
ANLS B Specified engine speed
C Specified torque
A B D Specified measurement
E Specified electrical value
[Resistance (Ω), Voltage (V), Electric current
(A)]
C D
T.
R.
E F Symbol F to H in an exploded diagram

indicate the grade of lubricant and the loca-
tion of the lubrication point.
E
F Apply Yamaha 2-stroke outboard motor oil
G H (TC-W3)
G Apply water resistant grease
A M (Yamaha grease A, Yamaha marine grease)
H Apply molybdenum disulfide oil
I J Symbols I to N in an exploded diagram

indicate the grade of the sealing or locking
GM 4 agent and the location of the application
point.
K L I Apply Gasket Maker

J Apply Yamabond #4
LT LT
(Yamaha bond number 4)
K Apply LOCTITE No. 271 (Red LOCTITE)
271 242
L Apply LOCTITE No. 242 (Blue LOCTITE)
M N M Apply LOCTITE No. 572
N Apply silicon sealant
LT SS
LT
572
E
CONTENTS
GENERAL INFORMATION GEN
INFO
1
SPECIFICATIONS
SPEC 2
PERIODIC INSPECTIONS AND
ADJUSTMENTS INSP
ADJ
3
FUEL SYSTEM
FUEL 4
POWER UNIT
POWR 5
LOWER UNIT
LOWR 6
BRACKET UNIT
BRKT 7
– +
ELECTRICAL SYSTEMS
ELEC 8
TROUBLE ANALYSIS TRBL
ANLS
9
GEN
INFO E
CHAPTER 1
GENERAL INFORMATION
IDENTIFICATION............................................................................................. 1-1
SERIAL NUMBER ..................................................................................... 1-1
STARTING SERIAL NUMBERS ............................................................... 1-1
1
SAFETY WHILE WORKING ............................................................................ 1-2
FIRE PREVENTION ................................................................................... 1-2
VENTILATION........................................................................................... 1-2
SELF-PROTECTION.................................................................................. 1-2
OILS, GREASES AND SEALING FLUIDS................................................ 1-2
2
GOOD WORKING PRACTICES ................................................................ 1-3
DISASSEMBLY AND ASSEMBLY ........................................................... 1-4
SPECIAL TOOLS ............................................................................................. 1-5

MEASURING ............................................................................................ 1-5
REMOVING AND INSTALLING ............................................................... 1-7
3
4
5
6
7
8
9
GEN
INFO IDENTIFICATION E
IDENTIFICATION 1
SERIAL NUMBER
The outboard motor’s serial number is
stamped on a label which is attached to the
port clamp bracket.
NOTE:
As an antitheft measure, a special label on
S65L1010 which the outboard motor’s serial number
is stamped is bonded to the port clamp
bracket. The label is specially treated so
that peeling it off causes cracks across the
serial number.
1 Model name
2 Approval model code
3 Transom height
4 Serial number
1020
STARTING SERIAL NUMBERS

The starting serial number blocks are as fol-
lows:
Model name Approval Starting
World- model serial
USA Canada code number
wide
200HETO V200TR — 66X L: 000589 ~
X: 102470 ~
225FETO S225TR S225TR 62J
U: 200423 ~
X: 100950 ~
L225FETO L225TR — 62K
U: 200132 ~
225GETO V225TR — 66K L: 300483 ~
X: 102033 ~
250BETO S250TR S250TR 61A
U: 200711 ~
X: 101047 ~
L250BETO L250TR — 61B
U: 200263 ~
1-1
GEN
INFO SAFETY WHILE WORKING E
SAFETY WHILE WORKING 1

The procedures given in this manual are
those recommended by Yamaha to be fol-
lowed by Yamaha dealers and their
mechanics.
FIRE PREVENTION
Gasoline (petrol) is highly flammable.
Petroleum vapor is explosive if ignited.
Do not smoke while handling gasoline and
keep it away from heat, sparks and open
flames.
1030
VENTILATION
Petroleum vapor is heavier than air and is
deadly if inhaled in large quantities. Engine
exhaust gases are harmful to breathe.
When test-running an engine indoors,
maintain good ventilation.
1040
SELF-PROTECTION
Protect your eyes with suitable safety
glasses or safety goggles, when grinding or
when doing any operation which may
cause particles to fly off. Protect hands and
feet by wearing safety gloves or protective
shoes if appropriate to the work you are
doing.
1050
OILS, GREASES AND SEALING

FLUIDS
Use only genuine Yamaha oils, greases and
sealing fluids or those recommended by
Yamaha.
1060
1-2
GEN
Under normal conditions of use, there

should be no hazards from the use of the
lubricants mentioned in this manual, but
safety is all-important, and by adopting
good safety practices, any risk is minimized.
A summary of the most important precau-
tions is as follows:
1. While working, maintain good stan-
dards of personal and industrial
hygiene.
2. Clothing which has become contami-
nated with lubricants should be
changed as soon as practicable, and
laundered before further use.
3. Avoid skin contact with lubricants; do
not, for example, place a soiled wiping-
rag in your pocket.
4. Hands and any other part of the body
which have been in contact with lubri-
cants or lubricant-contaminated cloth-
ing, should be thoroughly washed with
hot water and soap as soon as practica-
ble.
5. To protect the skin, the application of a
suitable barrier cream to the hands
before working, is recommended.
6. A supply of clean lint-free cloths should
be available for wiping purposes.
GOOD WORKING PRACTICES

1. The right tools
Use the recommended special tools to
protect parts from damage. Use the
right tool in the right manner – do not
improvise.
2. Tightening torque
Follow the tightening torque instruc-
1070 tions. When tightening bolts, nuts and
screws, tighten the large sizes first, and
tighten inner-positioned fixings before
outer-positioned ones.
1-3
GEN
3. Non-reusable items
Always use new gaskets, packings, O-
rings, split-pins, circlips, etc., on reas-
sembly.
1080
DISASSEMBLY AND ASSEMBLY

1. Clean parts with compressed air when
disassembling.
2. Oil the contact surfaces of moving parts
before assembly.
1090
3. After assembly, check that moving parts

operate normally.
1100
4. Install bearings with the manufacturer’s

markings on the side exposed to view,
and liberally oil the bearings.
5. When installing oil seals, apply a light
coating of water-resistant grease to the
outside diameter.
1-4
GEN
INFO SPECIAL TOOLS E
SPECIAL TOOLS 1
Using the correct special tools recom-
mended by Yamaha, will aid the work and
enable accurate assembly and tune-up.
Improvising and using improper tools can
damage the equipment.
NOTE:
• For U.S.A. and Canada, use part numbers
that start with “J-”, “YB-”, “YM-”, “YU-”
or “YW-”.
1 • For others countries, use part numbers
a b that start with “90890-”.
MEASURING
1 Tachometer
P/N. YU-08036-A ............................ a
90890-06760 ........................... b
2 3
2 Pressure tester
P/N. YB-35956
90890-06762
3 Mity vac
P/N. YB-35956
90890-06756
4 4 Pinion height gauge
a b
P/N. YB-06441 ................................ a
90890-06702 ........................... b
5 Dial gauge set
P/N. YU-03097
90890-01252
6 Magnetic base
5 6 P/N. YU-34481
90890-06705
7 Digital caliper
P/N. 90890-06704
8 Backlash indicator
P/N. YB-06265
7 8 90890-06706
9 Magnetic base attaching plate
P/N. YB-07003
90890-07003
0 Fuel pressure gauge
P/N. YB-06766
9 0 90890-06766
1-5
GEN
A Hydraulic pressure gauge

A B P/N. 90890-06776
B Up-relief valve attachment
P/N. 90890-06773
Down-relief valve attachment
P/N. 90890-06774
C Digital tester
C P/N. J-39299
90890-06752
D Peak voltage adapter
P/N. YU-39991 ................................ a
90890-03169 ........................... b
E Spark gap tester
D P/N. YM-34487 ............................... a
a b 90890-06754 ........................... b
F Diagnostic indicator
P/N. YB-06765
90890-06765
G Shimming gauge
P/N. YB-06439, YB-06440
H Shimming plate
E
a b P/N. 90890-06701
I Shift rod wrench
P/N. YB-06052
90890-06052
J Test harness
P/N. YB-06443, YB-06767,
YB-06768, YB-06769,
YB-06770, YB-38831,
YB-38832
F G
90890-06757, 90890-06767,
90890-06768, 90890-06769,
90890-06770, 90890-06771,
90890-06772
H I
1-6
GEN
REMOVING AND INSTALLING

1 1 Flywheel magnet assembly holder
a b
P/N. YB-06139 ................................ a
90890-06522 ........................... b
2 Universal puller
P/N. YB-06117 ................................ a
2 90890-06521 ........................... b
a b 3 Bearing/oil seal attachment
P/N. YB-06196 ................................ a
90890-06610 ........................... b
4 Driver rod
P/N. YB-06071
90890-06604, 90890-06605,
3 90890-06606, 90890-06652
a b 5 Bearing/oil seal attachment
P/N. YB-06432
6 Bearing/oil seal attachment
P/N. YB-06194, YB-06246,
YB-06276-B, YB-06337,
4 5
YB-06430
90890-06622, 90890-06656,
90890-06657, 90890-06658
7 Piston ring compressor
P/N. YU-33294 ................................ a
6
90890-06530 ........................... b
8 Bearing separator
P/N. YB-06219 ................................ a
90890-06534 ........................... b
9 Guide plate stand
P/N. 90890-06538
0 Guide plate
P/N. 90890-06501
7
a b
8
a b
9 0
1-7
GEN
A Bearing puller
A B P/N. 90890-06535
B Bearing/oil seal attachment
P/N. 90890-06659, 90890-06661,
90890-06662
C Ring nut wrench
C D P/N. 90890-06510
D Ring nut wrench
P/N. YB-06048
E Propeller shaft housing puller
P/N. YB-06207 ................................ a
E 90890-06502 ........................... b
a b
F Center bolt
P/N. 90890-06504
G Slide hammer
P/N. YB-06096
90890-06531
H Small universal claws
F G
P/N. 90890-06536
I Bearing/oil seal depth plate
P/N. YB-06213, YB-06433 .............. a
90890-06603 ........................... b
J Drive shaft holder
H P/N. YB-06201
90890-06520
K Pinion nut holder
P/N. 90890-06505
L Pinion nut holder attachment
I P/N. 90890-06507
a b
M Bearing/oil seal attachment
P/N. 90890-06636, 90890-06653,
90890-06654, 90890-06655
N Bearing puller
P/N. YB-06029
J K 90890-06523
O Large universal claws
P/N. 90890-06532
L M
N O
1-8
GEN
P Slide hammer attachment

P Q P/N. YB-06335
90890-06514
Q Puller bolt
P/N. YB-41707
R Bearing/oil seal attachment
R S P/N. YB-06437
S Bearing/oil seal attachment
P/N. YB-06435
T Bearing/oil seal attachment
P/N. YB-06434
T U U End screw wrench
P/N. YB-06175-2B, YB-06548
90890-06541, 90890-06544,
90890-06548
1-9
SPEC E
CHAPTER 2
SPECIFICATIONS
GENERAL SPECIFICATIONS .......................................................................... 2-1
MAINTENANCE SPECIFICATIONS................................................................ 2-3

1
POWER UNIT............................................................................................ 2-3
LOWER UNIT............................................................................................ 2-5
ELECTRICAL ............................................................................................. 2-5
DIMENSIONS ........................................................................................... 2-9
TIGHTENING TORQUES .............................................................................. 2-11

2
SPECIFIED TORQUES ............................................................................ 2-11
GENERAL TORQUES ............................................................................. 2-13
3
4
5
6
7
8
9
SPEC GENERAL SPECIFICATIONS E
GENERAL SPECIFICATIONS 2
Model
Worldwide 200HETO 225FETO L225FETO 225GETO 250BETO L250BETO
Item Unit
USA V200TR S225TR L225TR V225TR S250TR L250TR
Canada — S225TR — — S250TR —
DIMENSION
Overall length mm (in) 864 (34.0) 854 (33.6) 864 (34.0) 854 (33.6)
Overall width mm (in) 562 (22.1)
Overall height
(L) mm (in) 1,685 (66.3) — 1,685 (66.3) —
(X) mm (in) — 1,785 (70.3) — 1,785 (70.3)
(U) mm (in) — 1,912 (75.3) — 1,912 (75.3)
Boat transom height
(L) mm (in) 508 (20.0) — 508 (20.0) —
(X) mm (in) — 635 (25.0) — 635 (25.0)
(U) mm (in) — 762 (30.0) — 762 (30.0)
WEIGHT
(with stainless steel
propeller)
(L) kg (lb) 235.5 (519) — — 235.5 (519) — —
(X) kg (lb) — 237 (523) 239 (538) — 237 (523) 239 (538)
(U) kg (lb) — 242 (534) 244 (539) — 242 (534) 244 (539)
PERFORMANCE
Maximum output kW (hp) @ 147.1 (200) 165.5 (225) 183.9 (250)
5,000 r/min
Full throttle operating r/min 4,500 - 5,500
range
Maximum fuel L (US gal, 100 (26.4, 94 (24.8, 20.7) 107 (28.3, 23.5)
consumption lmp gal)/hr 22.0)
@ 5,500 r/min
POWER UNIT
Type 2 stroke - V
Number of cylinders 6
Displacement cm3(cu. in) 3,130 (191.0)
Bore × stroke mm (in) 90.0 × 82.0 (3.54 × 3.23)
Compression ratio Cylinders Cylinders #1 - #4: 6.0 Cylinders #1 - #4: 5.9
#1 - #4: 5.4 Cylinders #5 - #6: 5.8 Cylinders #5 - #6: 5.7
Cylinders
#5 - #6: 5.2
Fuel system Electronic fuel injection
Fuel injection system Sequential injection
Intake system Reed valve
Induction system Loop charge
Starting system Electric
Ignition control Microcomputer (CDI)
system
Alternator output 12 - 35A
Spark plugs (NGK) BR8HS-10 BR9HS-10
2-1
Model
Item Unit
Cooling system Water
Exhaust system Through prop boss
Lubrication system Oil injection
FUEL AND OIL
Fuel type Unleaded regular gasoline
Fuel rating *PON 86
RON 91
Engine oil type 2-stroke outboard engine oil

Engine oil grade TC-W3
Engine oil capacity
(engine oil tank) L (US qt, 1.2 (1.27, 1.06)
lmp qt)
(sub-oil tank) L (US qt, 10.5 (11.1, 9.2)
lmp qt)
Gear oil type Hypoid gear oil SAE 90
Gear oil total quantity cm3 (US 1,150 (38.9, 40.5) 1,000 1,150 (38.9, 40.5) 1,000
oz, lmp oz) (33.8, 35.2) (33.8, 35.2)
BRACKET
Trim angle Degree –4 - 16 –3 - 16 –4 - 16 –3 - 16
(at 12˚ boat transom)
Tilt-up angle Degree 70
Steering angle Degree 35 + 35
DRIVE UNIT
Gear shift positions F-N-R
Gear ratio 1.81 (29/16)
Reduction gear type Spiral bevel gear
Clutch type Dog clutch
Propeller shaft type Spline
Propeller direction Clockwise Counter- Clockwise Counter-
(rear view) clockwise clockwise
Propeller mark M T/M TL/ML M T/M TL/ML

ELECTRICAL
Battery capacity Ah (kC) 100 (360)
Minimum cold A 512
cranking performance
* PON: Pump Octane Number

RON: Research Octane Number
2-2
MAINTENANCE SPECIFICATIONS 2
POWER UNIT
Model
Item Unit
CYLINDER HEADS
Warpage limit mm (in) 0.1 (0.004)
(lines indicate
straightedge position)
CYLINDERS
Bore size mm (in) 90.00 - 90.02 (3.543 - 3.544)
Wear limit mm (in) 90.1 (3.55)
Taper limit mm (in) 0.08 (0.003)
Out-of-round limit mm (in) 0.05 (0.002)
PISTONS
Piston diameter mm (in) 89.840 - 89.860 (3.5370 - 3.5378)
(D)
Measuring point (H) mm (in) 10 (0.4)
Piston-to-cylinder mm (in) 0.155 - 0.161 (0.0061 - 0.0063)
clearance
<Limit> mm (in) 0.201 (0.0079)
Oversize piston diameter
1st mm (in) 90.15 (3.549)
2nd mm (in) 90.40 (3.559)
PISTON RINGS
Type Keystone
(B) mm (in) 2.0 (0.079)
(T) mm (in) 2.8 (0.110)
End gap (installed) mm (in) 0.30 - 0.40 (0.012 - 0.016)
<Limit> mm (in) 0.60 (0.024)
Side clearance mm (in) 0.02 - 0.06 (0.001 - 0.002)
CRANKSHAFT
Runout limit mm (in) 0.05 (0.002)
2-3
Model
Item Unit
CONNECTING RODS
Small-end axial mm (in) 2.0 (0.08)
play limit (F)
Big-end side mm (in) 0.12 - 0.26 (0.005 - 0.010)
clearance (E)
OIL INJECTION PUMP
ID mark 65L00
Oil discharge cm3 (US oz, 39.6 ± 7.8
(for 3 minutes) Imp oz) @ (1.339 ± 0.264, 1.397 ± 0.275)
1,500 r/min
Bleeding Screw type
REED VALVES
Reed valve stopper mm (in) 9.0 ± 0.3 7.9 ± 0.3 9.0 ± 0.3 (0.35 ± 0.01)
height a (0.35 ± (0.31 ± 0.01)
0.01)
Warpage limit b mm (in) 0.2 (0.008)

THERMOSTATS
Opening temperature ˚C (˚F) 48 - 52 (118 - 126)
Full-open temperature ˚C (˚F) 60 (140)
Valve open lower limit mm (in) 3 (0.12)

ENGINE SPEED
Idling speed r/min 730 ± 30
2-4
SPEC MAINTENANCE SPECIFICATIONS E
LOWER UNIT
Model
Item Unit
GEAR BACKLASH
Pinion - forward gear mm (in) 0.19 - 0.40 0.32 - 0.52 0.19 - 0.40 0.32 - 0.52
(0.007 - 0.016) (0.013 - (0.007 - 0.016) (0.013 -
0.020) 0.020)
Pinion - reverse gear mm (in) 0.64 - 0.93 (0.025 - 0.037)
Pinion shims mm 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50
Forward gear shims mm 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50
Reverse gear shims mm 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50
ELECTRICAL
Model
Item Unit
IGNITION SYSTEM
Ignition timing Degree ATDC 10 ATDC 8 - BTDC 17.8 ATDC 10 ATDC 8 - BTDC 17.8
- BTDC 20 - BTDC 18
CDI unit (B/O, B/Y, B/L,
B/Br, B/G, B/W – B)
Output peak voltage lower
limit
@ cranking 1 V 80
@ cranking 2 V 100
@ 1,500 r/min V 150
@ 3,500 r/min V 130
Charge coil (R – Br, B/R – L)
limit
@ cranking 1 V 85
@ cranking 2 V 110
@ 1,500 r/min V 150
@ 3,500 r/min V 150
Pulser coil (W/R, W/Y, W/G,
W/B, W/L, W/Br – B)
limit
@ cranking 1 V 3.0
@ cranking 2 V 3.0
@ 1,500 r/min V 16
@ 3,500 r/min V 30
* Cranking 1: Open circuit voltage.
Cranking 2: Loaded circuit voltage.
2-5
Model
Item Unit
IGNITION CONTROL SYSTEM
Crank position sensor
(G/W – G/L)
Crank-position-sensor-to- mm (in) 0.5 - 1.5 (0.02 - 0.06)
flywheel gap
limit
@ cranking 1 V 6.0
@ cranking 2 V 0.5
@ 1,500 r/min V 3.0
@ 3,500 r/min V 4.0
Engine cooling water
temperature sensor
Resistance (B/Y – B/Y)
@ 5˚C (41˚F) kΩ 128
@ 20˚C (68˚F) kΩ 54 - 69
@ 100˚C (212˚F) kΩ 3.02 - 3.48
Throttle position sensor
Input voltage (O – R) V 4.75 - 5.25
Output voltage (P – O) V 0.48 - 0.52
Thermo switch (P – B)
OFF → ON ˚C (˚F) 84 - 90 (183 - 194)
ON → OFF ˚C (˚F) 60 - 74 (140 - 165)
FUEL CONTROL SYSTEM
Oxygen density sensor
Heater resistance (W – W) Ω 100
Output voltage (Gy – B) V 0.0 - 1.0
Atmospheric pressure sensor
Output voltage V 3.2 - 4.6
(at 101.32 kPa) (P – B)
Intake air temperature sensor
Output voltage V 3.4 - 5.3
(at 20 ˚C (68 ˚F)) (B/Y – B/Y)
High-pressure fuel pump Ω 0.53 - 0.57
resistor resistance
STARTING SYSTEM
Fuse 1 V-A 14-80
Fuse 2 V-A 12-30
2-6
Model
Item Unit
STARTER MOTOR
Type Bendix
Output kW 1.1
Rating Second 30
Brushes
Standard length mm (in) 16.0 (0.63)
Commutator
Standard diameter mm (in) 33.0 (1.30)
Mica
Standard undercut mm (in) 0.8 (0.03)
CHARGING SYSTEM
Rectifier/regulator (R – B)
limit
@ cranking 1 V —
@ cranking 2 V —
@ 1,500 r/min V 12
@ 3,500 r/min V 12
Lighting coil (G – G)
limit
@ cranking 1 V —
@ cranking 2 V —
@ 1,500 r/min V 14
@ 3,500 r/min V 14
OIL FEED PUMP CONTROL
SYSTEM
Oil level sensor
(engine oil tank)
Float position a mm (in) 2.5 - 5.5 (0.10 - 0.22)
“OFF”
Float position b mm (in) 32.5 - 35.5 (1.28 - 1.40)
“ON”
Float position c mm (in) 76 - 79 (2.99 - 3.11)
“ON”
Oil level gauge
(sub-oil tank)
Float position d “ON” mm (in) 150 - 153 (5.91 - 6.02)
2-7
Model
Item Unit
POWER TRIM AND TILT
SYSTEM
Trim sensor
Resistance (P – B) Ω 582 - 494 - 742 582 - 494 - 742
873 873
Resistance (O – B) Ω 800 - 1,200
POWER TRIM AND TILT
MOTOR
Fluid type ATF Dexron II
Brushes
Standard length mm (in) 9.8 12.0 (0.47) 9.8 12.0 (0.47)
(0.39) (0.39)
Wear limit mm (in) 4.8 4.0 (0.16) 4.8 4.0 (0.16)
(0.19) (0.19)
Commutator
Standard diameter mm (in) 22.0 25.0 (0.98) 22.0 25.0 (0.98)
(0.87) (0.87)
Wear limit mm (in) 21.0 24.0 (0.94) 21.0 24.0 (0.94)
(0.83) (0.83)
Mica
Standard undercut mm (in) 1.35 — 1.35 —
(0.05) (0.05)
Wear limit mm (in) 0.85 — 0.85 —
(0.03) (0.03)
2-8
DIMENSIONS
Symbol Models
Unit
L1 mm (in) 591 (23.3) 566 (22.3) 591(23.3) 566 (22.3)
L2 mm (in) 179 (7.0) 181 (7.1) 179 (7.0) 181 (7.1)
L4 mm (in) 685 (27.0) 673 (26.5) 685 (27.0) 673 (26.5)
L5 (L) mm (in) 61 (2.4) — 61 (2.4) —
(X) mm (in) — 69 (2.7) — 69 (2.7)
(U) mm (in) — 89 (3.5) — 89 (3.5)
L6 (L) mm (in) 1,045 (41.2) — 1,045 (41.2) —
(X) mm (in) — 1,155 (45.5) — 1,155 (45.5)
(U) mm (in) — 1,271 (50.0) — 1,271 (50.0)
L7 mm (in) 624 (24.6) 631 (24.8) 624 (24.6) 631 (24.8)
H1 (L) mm (in) 950 (37.4) — 950 (37.4) —
(X) mm (in) — 1,077 (42.4) — 1,077 (42.4)
(U) mm (in) — 1,203 (47.4) — 1,203 (47.4)
H2 mm (in) 735 (28.9) 710 (28.0) 735 (28.9) 710 (28.0)
H3 mm (in) 216 (8.5)
H4 (L) mm (in) 515 (20.3) — 515 (20.3) —
(X) mm (in) — 642 (25.3) — 642 (25.3)
(U) mm (in) — 768 (30.2) — 768 (30.2)
H6 (L) mm (in) 768 (30.2) — 768 (30.2) —
(X) mm (in) — 846 (33.3) — 846 (33.3)
(U) mm (in) — 923 (36.3) — 923 (36.3)
H7 mm (in) 268 (10.6) 242 (9.5) 268 (10.6) 242 (9.5)
H9 mm (in) 923 (36.3) 818 (32.2) 923 (36.3) 818 (32.2)
W1 mm (in) 281 (11.1)
W5 mm (in) 419 (16.5) 420 (16.5) 419 (16.5) 420 (16.5)
2-9
Symbol Models
Unit
B1 mm (in) 125.4 (4.9)
B2 mm (in) 254 (10.0)
B3 mm (in) 163.5 (6.4)
B4 mm (in) 50.8 (2.0)
B5 mm (in) 180 (7.1)
B6 mm (in) 367 (14.4) 411 (16.2) 367 (14.4) 411 (16.2)
B9 mm (in) 18.5 (0.7)
C3 mm (in) 82 (3.2) 79 (3.1) 82 (3.2) 79 (3.1)
D1 mm (in) 13 (0.5)
D2 mm (in) 55.5 (2.2)
2-10
TIGHTENING TORQUES 2
SPECIFIED TORQUES
Tightening torques
Part to be tightened Thread size
Nm m • kgf ft • lb
POWER UNIT
Intake silencer M6 3 0.3 2.2
Fuel injection unit M6 10 1.0 7.2
Fuel filter nut holder M6 8 0.8 5.8
Oil pump M6 7 0.7 5.1
Emergency switch — 4 0.4 2.9
Flywheel magnet assembly M20 190 19 137
Negative battery lead M8 18 1.8 13
Junction box cover M5 3 0.3 2.2
Power unit mount M8 21 2.1 15
Starter motor lead M6 9 0.9 6.5
Atmospheric pressure sensor M6 3 0.3 2.2
Intake air temperature sensor M12 8 0.8 5.8
Shift cutoff switch M4 3 0.3 2.2
Starter motor M8 30 3.0 22
Oxygen density sensor cover M6 9 0.9 6.5
Oxygen density sensor bracket M6 14 1.4 10
Oxygen density sensor M18 49 4.9 35
Knocking sensor — 28 2.8 20
Engine cooling water temperature sensor — 15 1.5 11
Reed valve assembly M6 10 1.0 7.2
Reed valve M5 3 0.3 2.2
Reed valve stopper M3 1 0.1 0.7
1st 4 0.4 2.9
Pressure control valve cover M6
2nd 8 0.8 5.8
Spark plug M14 25 2.5 18
1st 4 0.4 2.9
Cylinder head cover M6
2nd 8 0.8 5.8
1st 15 1.5 11
Cylinder head M8
2nd 28 2.8 20
1st 4 0.4 2.9
Exhaust cover M6
2nd 8 0.8 5.8
Torsional damper M32 100 10 72
1st 4 0.4 2.9
M6
2nd 8 0.8 5.8
Crankcase
1st 20 2.0 14
M10
2nd 40 4.0 29
1st 28 2.8 20
2nd 45 4.5 33
Connecting rod 3rd M8 0 0 0
4th 28 2.8 20
5th 45 4.5 33
2-11
Tightening torques
LOWER UNIT
Propeller M18 55 5.5 40
Trim tab M10 43 4.3 31
Lower unit M10 48 4.8 35
Propeller shaft housing assembly M8 24 2.4 17
Grease nipple — 6 0.6 4.3
Ring nut (counter rotation models) — 110 11 80
Pinion nut M22 145 14.5 105
Gear oil drain screw — 7 0.7 5.1
Gear oil level check screw — 7 0.7 5.1
BRACKET UNIT (EXCEPT FOR 200H, 225G/V200, V225)
Flushing hose M5 5 0.5 3.6
Upper mount M12 73 7.3 53
Lower mount M14 73 7.3 53
Exhaust manifold assembly M8 21 2.1 15
Extension muffler M6 8 0.8 5.8
Muffler M8 21 2.1 15
Exhaust manifold M8 21 2.1 15
Lower exhaust manifold guide M8 21 2.1 15
Clamp bracket M22 15 1.5 11
Trim stopper — 37 3.7 27
BRACKET UNIT (FOR 200H, 225G/V200, V225)
Flushing hose M5 5 0.5 3.6
Upper mount M12 53 5.3 38
Lower mount M14 73 7.3 53
Exhaust manifold assembly M8 21 2.1 15
Muffler M8 18 1.8 13
Exhaust manifold M8 18 1.8 13
Lower exhaust manifold guide M8 18 1.8 13
Clamp bracket M22 15 1.5 11
Trim sensor stopper M6 2 0.2 1.4
Trim stopper — 37 3.7 27
POWER TRIM AND TILT UNIT (EXCEPT FOR 200H, 225G/V200, V225)
Power trim and tilt reservoir cap — 8 0.8 5.8
Power trim and tilt reservoir M6 8 0.8 5.8
Power trim and tilt motor M6 8 0.8 5.8
Gear pump M4 4 0.4 2.9
Tilt ram end screw — 90 9.0 65
Trim ram end screw — 160 16 116
Manual valve seat — 2 0.2 1.4
2-12
SPEC TIGHTENING TORQUES E
Tightening torques
POWER TRIM AND TILT UNIT (FOR 200H, 225G/V200, V225)
Power trim and tilt reservoir cap — 8 0.8 5.8
Power trim and tilt reservoir 1/4” 5 0.5 3.6
Power trim and tilt motor 1/4” 5 0.5 3.6
Manual valve — 4 0.4 2.9
Tilt ram end screw — 130 13 94
Gear pump unit 5/16” 9 0.9 6.5
Gear pump — 6 0.6 4.3
Trim ram end screw — 80 8.0 52
General torque
GENERAL TORQUES
specifications This chart specifies tightening torques for
Nut (A) Bolt (B)
standard fasteners with a standard ISO
Nm m•kgf ft•lb
thread pitch. Tightening torque specifica-
8 mm M5 5 0.5 3.6 tions for special components or assemblies
10 mm M6 8 0.8 5.8 are provided in applicable sections of this
12 mm M8 18 1.8 13 manual. To avoid warpage, tighten multi-
14 mm M10 36 3.6 25 fastener assemblies in a crisscross fashion
17 mm M12 43 4.3 31 and progressive stages until the specified
tightening torque is reached. Unless other-
wise specified, tightening torque specifica-
tions require clean, dry threads.
Components should be at room tempera-
ture.
2140
2-13
INSP
E
ADJ
CHAPTER 3
PERIODIC INSPECTIONS AND ADJUSTMENTS
MAINTENANCE INTERVAL CHART .............................................................. 3-1
TOP COWLING................................................................................................ 3-2

1
INSPECTING THE LOCK RELEASE ......................................................... 3-2
INSPECTING THE TOP COWLING FIT .................................................... 3-2
FUEL SYSTEM ................................................................................................ 3-3

INSPECTING THE FUEL LINE.................................................................. 3-3
INSPECTING THE FUEL FILTER .............................................................. 3-4
2
MEASURING THE FUEL PRESSURE
(HIGH-PRESSURE FUEL LINE) ............................................................... 3-4
CONTROL SYSTEM........................................................................................ 3-5

SYNCHRONIZING THE THROTTLE VALVES.......................................... 3-5
3
ADJUSTING THE ENGINE IDLING SPEED ............................................. 3-6
4
ADJUSTING THE THROTTLE POSITION SENSOR................................ 3-7
ADJUSTING THE REMOTE CONTROL SHIFT CABLE ........................... 3-8
ADJUSTING THE REMOTE CONTROL THROTTLE CABLE................... 3-9
COOLING SYSTEM....................................................................................... 3-10

INSPECTING THE COOLING WATER DISCHARGE ............................. 3-10
OIL INJECTION SYSTEM ............................................................................. 3-10

SYNCHRONIZING THE OIL PUMP........................................................ 3-10
AIR BLEEDING THE OIL INJECTION SYSTEM..................................... 3-11
5
MEASURING THE OIL PUMP DISCHARGE .......................................... 3-12
POWER TRIM AND TILT SYSTEM............................................................... 3-14

INSPECTING THE POWER TRIM AND TILT FLUID LEVEL .................. 3-14 6
LOWER UNIT ................................................................................................ 3-15
INSPECTING THE GEAR OIL LEVEL ..................................................... 3-15
CHANGING AND INSPECTING THE GEAR OIL ................................... 3-15
INSPECTING THE LOWER UNIT (FOR AIR LEAKS)............................. 3-16 7
GENERAL ...................................................................................................... 3-17
8
INSPECTING THE ANODES .................................................................. 3-17
INSPECTING THE BATTERY ................................................................. 3-17
INSPECTING THE SPARK PLUGS......................................................... 3-18
LUBRICATION POINTS.......................................................................... 3-19
9
INSP
ADJ MAINTENANCE INTERVAL CHART E
MAINTENANCE INTERVAL CHART 3

Use the following chart as a guide to general maintenance intervals.
Dependant on operating conditions, adjust the maintenance intervals accordingly.
Initial Every
Refer
Item Remarks 10 hours 50 hours 100 hours 200 hours to page
(Break-in) (3 months) (6 months) (1 year)
TOP COWLING
Top cowling fit Inspect 3-2
FUEL SYSTEM
Fuel line Inspect 3-3
Fuel filter Clean/inspect 3-4
POWER UNIT
Water leakage Inspect —
Motor exterior Inspect —
Exhaust leakage Inspect —
Cooling water passage Clean/flush —
CONTROL SYSTEM
Engine idling speed Inspect/adjust 3-6
Throttle position Inspect/adjust 3-7
sensor
Remote control shift Inspect/adjust 3-8
cable
Remote control Inspect/adjust 3-9
throttle cable
OIL INJECTION SYSTEM
Oil tank water drain Clean —
Oil pump lever Inspect/adjust 3-10
POWER TRIM AND TILT UNIT
Power trim and tilt fluid Inspect 3-14
LOWER UNIT
Gear oil Change 3-15
Lower unit leakage Inspect 3-16
Propeller Inspect 6-3, 6-26
GENERAL
Anodes Inspect/replace 3-17
Battery Inspect/charge (every month) 3-17
Spark plugs Clean/adjust/replace 3-18
Wiring and connectors Adjust/reconnect —
Bolts and nuts Tighten —
Lubrication points Grease 3-19
3-1
INSP
ADJ TOP COWLING E
TOP COWLING 3
INSPECTING THE LOCK RELEASE 3
1. Inspect:
• Lock release
Dull release → Adjust the top release
wire.
3001
2. Adjust:
• Release wire length
Adjustment steps
(1) Push each locking plate down until it
locks.
(2) Loosen the locknuts 1.
(3) Turn the adjusting nuts 2 until the
3002
ends of both wires 3 touch the locking
plates 4.
(4) Secure the locknuts 1.
3003
INSPECTING THE TOP COWLING FIT 3

1. Inspect:
• Top cowling fitting
Loose/unlatched → Adjust the top
cowling hook.
3010
3-2
INSP
ADJ TOP COWLING/FUEL SYSTEM E
2. Adjust:
• Top cowling hook position
Adjustment steps
(1) Loosen the bolts 1 approximately 1/4
of a turn.
(2) Move the top cowling hook either up
or down slightly.
3020
(3) Secure the bolts.
(4) Check the top cowling fitting and
repeat the adjustment if necessary.
NOTE:
• Moving the latch towards the seal will
loosen the top cowling.
• Moving the latch away from the seal will
tighten the top cowling.
FUEL SYSTEM 3
INSPECTING THE FUEL LINE 3
1. Inspect:
• High-pressure fuel line
Cracks/damage/leaks → Replace.
Refer to “HIGH-PRESSURE FUEL
LINE” on page 4-1.
3025
3-3
INSP
ADJ FUEL SYSTEM E
2. Inspect:
• Plastic locking tie
Loosen → Retighten or replace.
3. Inspect:
• Low-pressure fuel line
Refer to “LOW-PRESSURE FUEL
LINE” on page 4-21.
3030
INSPECTING THE FUEL FILTER 3

Inspect:
• Fuel filter element
• Fuel filter cup
Clogs/cracks/leaks → Replace.
Foreign matter → Clean.
Refer to “FUEL FILTER” on page 4-23.
3040
MEASURING THE FUEL PRESSURE

(HIGH-PRESSURE FUEL LINE) 3
Measure:
1 • Fuel pressure (high-pressure fuel line)
Out of specification → Inspect the
high-pressure fuel line.
Fuel pressure
(high-pressure fuel line)
250 kPa (2.5 kg/cm2, 35.6 psi)
Measuring steps
(1) Install the fuel pressure gauge onto the
pressure check valve.
Fuel pressure gauge ................. 1

YB-06766 / 90890-06766
(2) Start the engine, run it at idle speed for

3050 1 minute, and then measure the fuel
pressure.
3-4
INSP
ADJ CONTROL SYSTEM E
CONTROL SYSTEM 3
SYNCHRONIZING THE THROTTLE
VALVES 3
1. Inspect:
• Throttle valve synchronization
Uneven opening → Adjust.
Inspecting steps
(1) Remove the intake silencer 1.
(2) Disconnect the throttle lever rod 2.
(3) Turn the throttle stop screw 3 until it
does not touch the stopper.
NOTE:
Record the number of turns so the throttle
stop screw can be properly reset when the
synchronizing has been achieved.
3060 (4) Verify that all the throttle valves are

fully closed when the throttle link rod
4 is connected.
2. Adjust:
• Throttle valve opening
Adjustment steps
(1) Turn the screws 1 clockwise for all of
the cylinders except #4.
(2) Fully close throttle valve #1 2.
(3) Turn screw #1 counterclockwise.
(4) Close the valves and turn the screws
for cylinders #2, #3, #5, and #6 coun-
terclockwise.
(5) Turn in the throttle stop screw 3 the
proper amount of turns.
NOTE:
Cylinder #4’s screw does not need to be
adjusted.
3070
3-5
INSP
ADJUSTING THE ENGINE IDLING

SPEED 3
1. Measure:
• Engine idling speed
Out of specification → Adjust.
Engine idling speed

730 ± 30 r/min
Measuring steps
(1) Start the engine and allow it to warm
up for a few minutes.
(2) Install the tachometer onto the spark
plug lead of cylinder #1.
Tachometer
YU-08036-A / 90890-06760
3082
2. Adjust:
• Engine idling speed
Adjustment steps
(1) Loosen the pickup adjustment screw 1.
(2) Align the center of the throttle control
lever cam roller 2 with the mark a.
3080
(3) Turn the throttle stop screw 3 in direc-

tion b or c until the specified engine
idling speed is obtained.
Engine idling speed
Direction b
increases.
Engine idling speed
Direction c
decreases.
3090
3-6
INSP
(4) Tighten the pickup adjustment screw

1 while pressing down on the throttle
1 control lever cam roller 2.
NOTE:
Turn the pickup adjustment screw 1 coun-
terclockwise to tighten it.
2
3081
ADJUSTING THE THROTTLE

POSITION SENSOR 3
1. Measure:
• Throttle position sensor output volt-
age
(with the throttle valves fully closed)
Throttle position sensor output

voltage (pink (P) – orange (O))
0.50 ± 0.02 V
NOTE:
• Be sure to adjust the throttle valve’s open-
ing before measuring the throttle position
sensor output voltage.
• When measuring the throttle position sen-
sor output voltage, set the digital tester to
3101
the manual range.
3102
Measuring steps
(1) Disconnect the throttle link rod 1 at
the #1 throttle valve.
(2) Connect the test harness (3-pin) as
shown.
Test harness (3-pin)

YB-06443 / 90890-06757
(3) Connect the digital tester probes to the

test harness (3-pin) as shown.
(4) Turn the engine start switch on.
(5) Measure the output voltage (with the
throttle valves fully closed).
3-7
INSP
2. Adjust:
• Throttle position sensor
3100 Adjustment steps

(1) Loosen the screws 2.
(2) Adjust the position of the throttle posi-
tion sensor until the specified output
voltage is obtained.

voltage (pink (P) – orange (O))
0.50 ± 0.02 V
(3) Tighten the screws.

(4) Connect the throttle link rod.
ADJUSTING THE REMOTE CONTROL

SHIFT CABLE 3
1. Inspect:
• Shift operation
Incorrect → Adjust.
2. Adjust:
• Remote control shift cable length
Adjustment steps
(1) Disconnect the shift cable joint 1.
(2) Set the remote control lever to the
neutral position.
(3) Align the center of the set pin a with
the mark b on the bottom cowling.
(4) Adjust the position of the shift cable
joint until its hole aligns with the set
pin c.
(5) Install the clip 2 and tighten the lock-
nut 3.
3120
CAUTION:
The remote control cable joint must be
screwed in more than 8 mm (0.31 in).
3110
3-8
INSP
ADJUSTING THE REMOTE CONTROL

THROTTLE CABLE 3
NOTE:
Before adjusting the remote control throttle
cable, be sure to adjust the throttle valves’
opening and engine idling speed.
1. Inspect:
• Throttle operation
NOTE:
Make sure the throttle valves are fully
closed when the remote control lever is
fully closed position.
2. Adjust:
3130
• Remote control throttle cable length
Adjustment steps
(1) Disconnect the throttle cable joint 1.
(2) Set the remote control lever to the
fully closed position.
(3) Align the center of the throttle control
lever cam roller 2 with the mark a.
(4) Adjust the position of the throttle cable
joint until its hole aligns with the set
pin on the throttle control lever 3.
(5) Install the clip 4 and tighten the lock-
nut 5.
CAUTION:
The remote control cable joint must be
screwed in more than 8 mm (0.31 in).
3-9
INSP
ADJ COOLING SYSTEM/OIL INJECTION SYSTEM E
COOLING SYSTEM 3
INSPECTING THE COOLING WATER
DISCHARGE 3
Inspect:
• Cooling water discharge
No discharge → Clean and inspect the
cooling water passage.
3140
Inspecting steps
(1) Place the lower unit in water.
(2) Start the engine.
(3) Check that water flows from the cool-
ing water outlet.
OIL INJECTION SYSTEM 3

SYNCHRONIZING THE OIL PUMP 3
1. Inspect:
• Oil pump lever position
NOTE:
Make sure the oil pump lever 1 touches the
3160 stopper a (fully closed position) when the
throttle valves are closed.
2. Adjust:
• Oil pump lever position
Adjustment steps
(1) Disconnect the oil pump link rod joint
2.
(2) Fully close the throttle valves.
3150 (3) Turn the oil pump lever 1 so it con-
tacts the stopper a (fully closed posi-
tion).
(4) Adjust the position of the oil pump link
rod joint until its hole aligns with the
set pin on the oil pump lever 1.
(5) Tighten the locknut 3.
(6) Install the washer and clip.
CAUTION:
After adjustment, make sure the oil pump
lever operates properly.
3-10
INSP
ADJ OIL INJECTION SYSTEM E
AIR BLEEDING THE OIL INJECTION

SYSTEM 3
Bleed:
• Air bubbles
(from the oil injection system)
Bleeding steps
(1) Fill the fuel tank with the fuel/oil mix-
ture (50:1).
Recommended fuel
Fuel type
Unleaded regular gasoline
Fuel rating
PON: 86
RON: 91
Recommended engine oil
Engine oil type
2-stroke outboard engine oil
Engine oil grade
TC-W3
CAUTION:
Only use the fuel/oil mixture (50:1) or
engine malfunctions or seizure may result.

from the oil pump lever.
(4) Turn the oil pump lever 1 and keep it in

the fully-opened position until the fuel/
oil mixture flows out of the oil pump
feed hoses.
3180
3-11
INSP
MEASURING THE OIL PUMP

DISCHARGE 3
Measure:
• Oil pump discharge
Out of specification → Check all of the
oil pump components and replace any
defective parts.
Engine oil discharge (3 minutes)

39.6 ± 7.8 cm3
(1.339 ± 0.264 US oz,
1.397 ± 0.275 Imp oz)
NOTE:
When measuring the oil pump discharge,
observe the following.
• The engine oil temperature should be 10 -
30 ˚C (50 - 86 ˚F).
• Before measuring the oil pump discharge,
completely bleed any air from the oil
injection system and make sure that no air
bubbles are present in the engine oil
which is flowing out of the oil feed hose.
• When using the graduated cylinder, make
sure no engine oil clings to its walls; oth-
erwise, the measurement will be incor-
rect.
• Use only the specified engine oil of the
3190 proper viscosity. If the viscosity is too
high or too low, the discharge measure-
ment will be incorrect.
• Calculate the rate of discharge per minute.
The longer the measurement time, the
higher the accuracy of the measurement.
3-12
INSP
Measuring steps
(1) Fill the fuel tank with the fuel/oil mix-
ture (50:1) and fill the oil tank with
engine oil.
Recommended fuel
Fuel type
Unleaded regular gasoline
Fuel rating
PON: 86
RON: 91
Recommended engine oil
Engine oil type
2-stroke outboard engine oil
Engine oil grade
TC-W3
CAUTION:
Only use the fuel/oil mixture (50:1) or
engine malfunctions or seizure may result.

from the oil pump lever.
(3) Move the oil pump lever 1 to the fully-
opened position.
(4) Remove the oil inlet hose 2 from the
vapor separator.
(5) Install the oil inlet hose onto the grad-
uated cylinder.
3180 NOTE:
The measuring range on the graduated cyl-
inder should be divided into 0.1-cc incre-
ments.

(7) Set the engine idling speed at
1,500 r/min.
Refer to “ADJUSTING THE ENGINE
IDLING SPEED” on page 3-6.
(8) Measure the engine oil discharge for 3
minutes.
3185
3-13
INSP
ADJ POWER TRIM AND TILT SYSTEM E
POWER TRIM AND TILT SYSTEM3

INSPECTING THE POWER TRIM AND
TILT FLUID LEVEL 3
Inspect:
• Power trim and tilt fluid level
Level is low → Add power trim and tilt
fluid to the proper level.
Recommended power trim and

tilt fluid
Å ı ATF Dexron II
WARNING
When removing the power trim and tilt res-
ervoir cap, the power trim and tilt fluid may
spurt out due to internal pressure. There-
fore, fully tilt up the outboard (the tilt ram
3195 assembly fully extended) and then slowly
remove the power trim and tilt reservoir
cap.
Inspecting steps
(1) Tilt the outboard all the way up and
lock it with the tilt stop levers 1.
WARNING
3200 After tilting up the outboard, be sure to
support it with the tilt stop levers.
Å Otherwise, the outboard could suddenly
lower if the power trim and tilt unit should
lose fluid pressure.
(2) Remove the reservoir cap 2 and

inspect the fluid level.
NOTE:
The fluid level should be directly below the
3210
check hole as shown.
ı
(3) Add power trim and tilt fluid if needed,
and then install the reservoir cap.
Reservoir cap
8 Nm (0.8 m • kgf, 5.8 ft • lb)
T.
R.
Å 200H, 225G/V200, V225

ı 225F, L225F, 250B, L250B/S225, L225, S250,
L250
3205
3-14
INSP
ADJ LOWER UNIT E
LOWER UNIT 3
INSPECTING THE GEAR OIL LEVEL 3
Inspect:
• Gear oil level
Level is low → Add gear oil to the
proper level.
CHANGING AND INSPECTING THE

GEAR OIL 3
1. Inspect:
• Gear oil
Milky oil → Replace the oil seal.
Slag oil → Check the gears, bearings,
and clutch dog.
Inspecting steps
(1) Tilt up the outboard slightly.
(2) Place a container under the gear oil
drain screw 1.
(3) Remove the gear oil drain screw and
gear oil level check screw 2.
2. Fill:
• Gear oil
(with the specified amount of the rec-
ommend gear oil)
Recommended gear oil

GEAR CASE LUBE (USA) or
Hypoid gear oil, SAE 90
Total amount
Regular rotation models
1,150 cm3
(38.9 US oz, 40.5 Imp oz)
Counter rotation models
3220 1,000 cm3
(33.8 US oz, 35.2 Imp oz)
3-15
INSP
ADJ LOWER UNIT E
Filling steps
(1) Place the outboard in an upright posi-
tion.
(2) Insert the gear oil tube into the drain
hole and slowly fill the gear oil until oil
flows out of the check hole and no air
bubbles are visible.
(3) Install the gear oil level check screw
and then quickly install the gear oil
3230
drain screw.
Gear oil level check screw

7 Nm (0.7 m • kgf, 5.1 ft • lb)
T.
R.
Gear oil drain screw
7 Nm (0.7 m • kgf, 5.1 ft • lb)
INSPECTING THE LOWER UNIT

(FOR AIR LEAKS) 3
Inspect:
• Lower unit holding pressure
Pressure drops → Inspect the seals
and components.
Lower unit holding pressure

100 kPa (1.0 kg/cm2, 14.2 psi)
Inspecting steps
CAUTION:
Do not overpressurize the lower unit.
Excessive pressure may damage the oil
seals.
(1) Remove the gear oil level check screw.

3240
(2) Install the pressure tester into the
check hole.
Pressure tester
YB-35956 / 90890-06762
(3) Apply the specified pressure.
NOTE:
The lower unit should hold the specified
pressure for 10 seconds.
3-16
INSP
ADJ GENERAL E
GENERAL 3
INSPECTING THE ANODES 3
Inspect:
• Anodes 1
• Trim tab 2
Scales → Clean.
Grease/oil → Clean.
Excessive wear → Replace.
CAUTION:
Do not oil, grease or paint the anode, or it
will not operate properly.
INSPECTING THE BATTERY 3
WARNING
3250 Battery electrolytic fluid is dangerous; it
contains sulfuric acid and therefore is poi-
sonous and highly caustic.
Always follow these preventive measures:
• Avoid bodily contact with electrolytic
fluid as it can cause severe burns or per-
manent eye injury.
• Wear protective eye gear when handling
or working near batteries.
Antidote (EXTERNAL):
• SKIN - Flush with water.
• EYES - Flush with water for 15 minutes
and get immediate medical attention.
Antidote (INTERNAL):
• Drink large quantities of water or milk fol-
lowed by milk of magnesia, beaten egg,
or vegetable oil. Get immediate medical
attention.
Batteries also generate explosive hydrogen
gas; therefore, you should always follow
these preventive measures:
• Charge batteries in a well-ventilated area.
• Keep batteries away from fire, sparks, or
open flames (e.g., welding equipment,
lighted cigarettes, etc.).
• DO NOT SMOKE when charging or han-
dling batteries.
KEEP BATTERIES AND ELECTROLYTIC
FLUID OUT OF REACH OF CHILDREN.
3-17
INSP
ADJ GENERAL E
NOTE:
• Batteries vary among manufacturers.
Therefore, the following procedures may
not always apply. Consult your battery
manufacturer’s instructions.
• First, disconnect the negative lead, then
the positive lead.
Inspect:
• Electrolyte level
Below the minimum level mark →
Add distilled water to the proper level.
• Electrolyte specific gravity
Less than specification → Recharge
the battery.
Electrolyte specific gravity

1.280 at 20˚C (68˚F)
INSPECTING THE SPARK PLUGS 3

1. Inspect:
• Electrodes 1
Cracks/excessive wear → Replace.
• Insulator color 2
Distinctly different color →
Check the engine condition.
3260 Color guide

Medium to light tan color
Normal
Whitish color
• Lean fuel mixture
• Plugged jet(-s)
• Air leak
• Wrong setting
Blackish color
• Rich mixture
• Excessive oil usage
• Defective ignition system
• Defective spark plug
2. Clean:
• Spark plug
(with a spark plug cleaner or wire
brush.)
3-18
INSP
ADJ GENERAL E
3. Measure:
• Spark plug gap a
Out of specification → Regap.
Spark plug gap

0.9 - 1.0 mm (0.035 - 0.039 in)
3270
4. Tighten:
• Spark plug
Spark plug
25 Nm (2.5 m • kgf, 18 ft • lb)
T.
R.
NOTE:
• Before installing the spark plug, clean the
3280 gasket surface and spark plug surface.
Also, it is suggested to apply a thin film of
anti-seize compound to the spark plug
threads to prevent thread seizure.
• If a torque wrench is not available, a good
estimate of the correct tightening torque
is to finger tighten a the spark plug and
then tighten it another 1/4 to 1/2 of a
turn b.
LUBRICATION POINTS 3
Apply:
• Water resistant grease
3290
3300
3-19
INSP
ADJ GENERAL E
3310
3320
3330
3340
3350
3-20
FUEL E
CHAPTER 4
FUEL SYSTEM
HIGH-PRESSURE FUEL LINE ......................................................................... 4-1

REMOVING/INSTALLING THE HIGH-PRESSURE FUEL LINE ............... 4-1
REDUCING THE FUEL PRESSURE
(HIGH-PRESSURE FUEL LINE) ............................................................... 4-3
INSPECTING THE PRESSURE REGULATOR.......................................... 4-4
FUEL INJECTORS ........................................................................................... 4-5

REMOVING/INSTALLING THE FUEL INJECTORS ................................. 4-5
DISASSEMBLING/ASSEMBLING THE FUEL INJECTORS .................... 4-6
INSPECTING THE FILTERS...................................................................... 4-7
FUEL HOSES................................................................................................... 4-8

REMOVING/INSTALLING THE FUEL HOSES......................................... 4-8
REMOVING THE HOSE CLAMPS............................................................ 4-9
INSTALLING THE HOSE CLAMPS .......................................................... 4-9
VAPOR SEPARATOR.................................................................................... 4-10

REMOVING/INSTALLING THE VAPOR SEPARATOR .......................... 4-10
REMOVING/INSTALLING THE PRESSURE REGULATOR ................... 4-11
DISASSEMBLING/ASSEMBLING THE VAPOR SEPARATOR ............. 4-13
REMOVING THE HIGH-PRESSURE FUEL PUMP FILTER .................... 4-14
INSTALLING THE HIGH-PRESSURE FUEL PUMP FILTER .................. 4-14
HIGH-PRESSURE FUEL PUMP .................................................................... 4-15

DISASSEMBLING/ASSEMBLING THE HIGH-PRESSURE
FUEL PUMP ........................................................................................... 4-15
THROTTLE CONTROL LEVER CAM ............................................................ 4-18

REMOVING/INSTALLING THE THROTTLE CONTROL
LEVER CAM ........................................................................................... 4-18
THROTTLE POSITION SENSOR .................................................................. 4-19

REMOVING/INSTALLING THE THROTTLE POSITION SENSOR ........ 4-19
INSTALLING THE THROTTLE POSITION SENSOR ............................. 4-20
LOW-PRESSURE FUEL LINE........................................................................ 4-21

REMOVING/INSTALLING THE LOW-PRESSURE FUEL LINE.............. 4-21
DISASSEMBLING/ASSEMBLING THE LOW-PRESSURE FUEL LINE . 4-22
FUEL E
FUEL FILTER ................................................................................................. 4-23

DISASSEMBLING/ASSEMBLING THE FUEL FILTER........................... 4-23
FUEL PUMP................................................................................................... 4-24

DISASSEMBLING/ASSEMBLING THE FUEL PUMP ............................ 4-24
INSPECTING THE CHECK VALVE ......................................................... 4-26
INSPECTING THE FUEL PUMPS........................................................... 4-26 1
OIL INJECTION SYSTEM ............................................................................. 4-28
REMOVING/INSTALLING THE OIL INJECTION SYSTEM ................... 4-28
DISASSEMBLING/ASSEMBLING THE OIL INJECTION SYSTEM....... 4-30
OIL TANK ...................................................................................................... 4-31

2
DISASSEMBLING/ASSEMBLING THE OIL TANK................................ 4-31
3
4
5
6
7
8
9
FUEL HIGH-PRESSURE FUEL LINE E
HIGH-PRESSURE FUEL LINE 4

REMOVING/INSTALLING THE HIGH-PRESSURE FUEL LINE
4010
Order Job/Part Q’ty Remarks

1 Screw 6
2 Intake silencer 1
3 Suction hose 1 (intake silencer-to-throttle body)
4 Oil tank air vent hose 1 (intake silencer-to-oil tank)
5 Throttle link rod 1
6 Oil pump link rod 1
7 Throttle position sensor coupler 1
8 Fuel injector coupler 1
9 High-pressure fuel pump 1
resistor coupler
Continued on next page.
4-1
4010

10 Main relay connector 1
11 Plastic locking tie 2 Not reusable
12 Fuel inlet hose 1 (fuel pump-to-vapor separator)
13 Oil inlet hose 1 (oil pump-to-vapor separator)
14 Nut 2
15 Bolt 12 (with washer)
16 Gasket 1 Not reusable
17 Fuel injection unit 1
For installation, reverse the removal
procedure.
4-2
REDUCING THE FUEL PRESSURE

(HIGH-PRESSURE FUEL LINE)
WARNING
Always reduce the fuel pressure in the
high-pressure fuel line before servicing the
line or the vapor separator. If the fuel pres-
sure is not released, pressurized fuel may
spray out.
1. Reduce:
• Fuel pressure (high-pressure fuel line)
2 Reducing steps
pressure check valve.

YB-06766 / 90890-06766
1 (2) Place the drain hose into a container.
(3) Open the valve 2 and release the
pressure.
2. Drain:
• Fuel
3
WARNING
Reduce the fuel pressure before removing
4060
the vapor separator drain screw, or pres-
surized fuel will spray out and may result in
serious injury.
NOTE:
Remove the drain screw 3 and drain the
vapor separator of any fuel.
4-3
INSPECTING THE PRESSURE

REGULATOR
Inspect:
• Pressure regulator
Faulty → Replace the pressure regula-
tor.
Inspecting steps
pressure check valve and then install
the Mity vac onto the pressure regula-
tor vacuum hose.

YB-06766 / 90890-06766
Mity vac ..................................... 2
YB-35956 / 90890-06756

4015
(3) Apply vacuum pressure with the Mity
vac.
Vacuum pressure
Approx.
25 kPa (0.25 kg/cm2, 3.56 psi)
(4) Inspect the fuel pressure.
NOTE:
Make sure the fuel pressure in the high-
pressure fuel line lowers conversely in rela-
tion to the amount of pressure that is
applied to the pressure regulator.
4-4
FUEL FUEL INJECTORS E
FUEL INJECTORS 4
REMOVING/INSTALLING THE FUEL INJECTORS
4020

Intake silencer Refer to “HIGH-PRESSURE FUEL LINE”
on page 4-1.
Before performing the following
procedure, reduce the fuel pressure
(high-pressure fuel line).
2 Bolt 4
3 Washer 4
4 Fuel rail 1
5 Dowel pin 2
7 Fuel injector 6
procedure.
4-5
4
DISASSEMBLING/ASSEMBLING THE FUEL INJECTORS
4030

1 Rubber seal 1
2 Rubber damper 1
3 O-ring 1
4 Filter 1
For assembly, reverse the disassembly
procedure.
4-6
INSPECTING THE FILTERS

Check:
• Filter
Damage/tears → Replace.
Contaminants → Clean.
4040
4-7
FUEL FUEL HOSES E
FUEL HOSES 4
REMOVING/INSTALLING THE FUEL HOSES
1
3
4
1
1
2
4050

Intake silencer Refer to “HIGH-PRESSURE FUEL LINE”
on page 4-1.
Before performing the following
procedure, reduce the fuel pressure
(high-pressure fuel line).
1 Hose clamp 4 Not reusable
2 Fuel hose 1 (fuel pump-to-fuel rail)
3 Fuel hose 1 (fuel rail-to-pressure check valve)
4 Fuel rail 1
procedure.
4-8
FUEL FUEL HOSES E
REMOVING THE HOSE CLAMPS

Remove:
• Hose clamp
NOTE:
Remove the hose clamp by cutting its joint.
4070 CAUTION:
The fuel hose will be damaged if a hose
clamp is removed without cutting the joint.
INSTALLING THE HOSE CLAMPS

Install:
• Hose clamp
WARNING
Do not reuse hose clamps, only use new
ones.
4080
NOTE:
Properly crimp the hose clamp so it is
securely fastened.
4-9
FUEL VAPOR SEPARATOR E
VAPOR SEPARATOR 4
REMOVING/INSTALLING THE VAPOR SEPARATOR
7
8
9
4 × 14 mm
3
5
6
3 4
2
6 × 30 mm
4090

Fuel hoses Refer to “FUEL HOSES” on page 4-8.
connector
2 Bolt 3
3 Large washer 6
4 Small washer 3
5 Collar 3
6 Grommet 3
7 Screw 1
8 Fuel outlet joint holder 1
9 Vapor separator 1
procedure.
4-10
4
REMOVING/INSTALLING THE PRESSURE REGULATOR
3 4 × 14 mm
1
2
6 × 14 mm
4
5 3
10 6 3
7
8
3 11
10
8 7
9 6
4100

1 Screw 1
2 Pressure check valve holder 1
3 Hose 3 (vapor separator and pressure regulator-
to-throttle body)
4 Screw 2
5 Pressure regulator 1
6 O-ring 1
4-11
3 4 × 14 mm
1
2
6 × 14 mm
4
5 3
10 6 3
7
8
3 11
10
8 7
9 6
4100

7 Filter 1
8 Fuel return joint 1
9 O-ring 1
10 O-ring 1
11 Cap 1
procedure.
4-12
4
DISASSEMBLING/ASSEMBLING THE VAPOR SEPARATOR
4 × 14 mm
9
3 3
7
5
2
1
4110

1 Drain screw 1
2 O-ring 1 4.8 × 1.9 mm
3 Screw 9
4 O-ring 1
5 Float chamber 1
6 High-pressure fuel pump filter 1
7 Rubber damper holder 1
8 Rubber damper 1
9 Vapor separator body 1
procedure.
4-13
REMOVING THE HIGH-PRESSURE

FUEL PUMP FILTER
Remove:
• High-pressure fuel pump filter
NOTE:
To remove the high-pressure fuel pump fil-
ter, turn it clockwise.
4120
INSTALLING THE HIGH-PRESSURE

FUEL PUMP FILTER
Install:
• Rubber damper 1
• Rubber damper holder 2
• High-pressure fuel pump filter 3
NOTE:
4130 • Make sure the rubber damper is correctly
installed in its holder.
• Firmly push the high-pressure fuel pump
filter into the bottom of the high-pressure
fuel pump and then turn the filter counter-
clockwise until it clicks.
4140
4-14
FUEL HIGH-PRESSURE FUEL PUMP E
HIGH-PRESSURE FUEL PUMP 4

DISASSEMBLING/ASSEMBLING THE HIGH-PRESSURE FUEL PUMP
4150

1 Positive high-pressure fuel pump 1 (red lead)
terminal cap
2 Negative high-pressure fuel 1 (blue lead)
pump terminal cap
3 Nut 1 (M4) a = 7 mm
4 Spring washer 1
5 Nut 1 (M5) b = 8 mm
6 Spring washer 1
7 Positive high-pressure fuel pump 1
terminal
4-15
4150

8 Negative high-pressure fuel 1
pump terminal
9 O-ring 2 4.5 × 1.5 mm
10 Washer 2 (white)
11 Collar 1
12 O-ring 1 45.7 × 3.5 mm
13 High-pressure fuel pump guide 1
plate
15 Insulator 2
4-16
4150

16 O-ring 2 8 × 1.3 mm
17 Screw 1
18 Float pin 1
19 Float 1
20 Clip 1
21 Needle valve 1
procedure.
4-17
FUEL THROTTLE CONTROL LEVER CAM E
THROTTLE CONTROL LEVER CAM 4

REMOVING/INSTALLING THE THROTTLE CONTROL LEVER CAM
4170

1 Throttle link 1
3 Wave washer 1
4 Collar 1
5 Throttle control lever cam 1
procedure.
4-18
FUEL THROTTLE POSITION SENSOR E
THROTTLE POSITION SENSOR 4

REMOVING/INSTALLING THE THROTTLE POSITION SENSOR
4180

1 Screw 2
2 Throttle position sensor 1
3 Screw 3
4 Washer 3
5 Throttle position sensor bracket 1
6 Collar 3
7 Grommet 3
8 Spacer 1
9 Spring 1
procedure.
4-19
FUEL THROTTLE POSITION SENSOR E
INSTALLING THE THROTTLE

POSITION SENSOR
NOTE:
During installation, make sure the throttle
position sensor is properly adjusted.
Install:
• Throttle position sensor
Refer to “ADJUSTING THE THROTTLE
POSITION SENSOR” on page 3-7.
4-20
FUEL LOW-PRESSURE FUEL LINE E
LOW-PRESSURE FUEL LINE 4

REMOVING/INSTALLING THE LOW-PRESSURE FUEL LINE
4190

1 Bolt 2
2 Bracket 1
3 Bolt 1
4 Holder 1
9 Low-pressure fuel line 1
procedure.
4-21
FUEL LOW-PRESSURE FUEL LINE E
4
DISASSEMBLING/ASSEMBLING THE LOW-PRESSURE FUEL LINE
4200

2 Fuel hose 1 (hose joint-to-fuel filter)
3 Fuel filter 1
4 Fuel hose 1 (check valve-to-fuel filter)
5 Check valve 1
6 Fuel hose assembly 1 (check valve-to-fuel pump)
7 Fuel pump 3
8 Fuel hose assembly 1 (fuel pump-to-vapor separator)
procedure.
4-22
FUEL FUEL FILTER E
FUEL FILTER 4
DISASSEMBLING/ASSEMBLING THE FUEL FILTER
4210

1 Bolt 1
2 Fuel filter nut holder 1
3 Fuel filter nut 1
4 Fuel filter cup 1
5 O-ring 1
6 Fuel filter element 1
7 Spring 1
8 O-ring 1
9 Bolt 1
10 Fuel filter bracket 1
11 Fuel filter cap 1
procedure.
4-23
FUEL FUEL PUMP E
FUEL PUMP 4
DISASSEMBLING/ASSEMBLING THE FUEL PUMP
4220

1 Screw 3
2 Diaphragm body 1
3 Diaphragm 1
5 Fuel pump base 1
7 Diaphragm 1
4-24
FUEL FUEL PUMP E
4220

8 Spring seat 1
9 Spring 1
10 Screw 4
11 Fuel pump valve 4
12 Nut 4
13 Fuel pump body 1
procedure.
4-25
FUEL FUEL PUMP E
INSPECTING THE CHECK VALVE

Inspect:
• Check valve operation
Damage/reverse air flow → Replace.
Inspecting steps
NOTE:
Do not overpressurize the check valve.
Excessive pressure may cause air to leak
out.
(1) Install the Mity vac onto the check

valve as shown.
Mity vac
YB-35956 / 90890-06756
(2) Apply the specified pressure with the

4230 Mity vac.
Check valve pressure

80 kPa (0.8 kg/cm2, 11.4 psi)
NOTE:
Make sure no air comes out of the opposite
side of the check valve.
INSPECTING THE FUEL PUMPS

1. Inspect:
• Diaphragm
• Fuel pump valves
Damage → Replace.
2. Inspect:
• Fuel pump
Reverse air flow → Replace.
4-26
FUEL FUEL PUMP E
Inspecting steps
NOTE:
Do not overpressurize the fuel pump.
Excessive pressure may cause air to leak
out.
(1) Install the Mity vac onto the fuel pump

as shown.
Mity vac
YB-35956 / 90890-06756
(2) Apply the specified pressure with the

Mity vac.
Fuel pump pressure a

50 kPa (0.5 kg/cm2, 7.1 psi)
Fuel pump negative
pressure b
4240 30 kPa (0.3 kg/cm2, 4.3 psi)
NOTE:
• Make sure no air comes out of the oppo-
site side of the fuel pump.
• To eliminate any gaps between the fuel
pump valves and the fuel pump body, and
to ensure a better seal, make sure the
inside of the fuel pump is wet (i.e., with
gas).
4-27
FUEL OIL INJECTION SYSTEM E
OIL INJECTION SYSTEM 4

REMOVING/INSTALLING THE OIL INJECTION SYSTEM
4250

1 Bolt 2
2 Bracket 1
3 Bolt 1
4 Holder 1
5 Oil level sensor coupler 1
6 Emergency switch connector 2
7 Clip 1
8 Washer 1
9 Oil pump link rod 1
4-28
4250

11 Oil hose 1 (oil hose assembly joint-to-vapor
separator)
12 Bolt 2
13 O-ring 1
14 Oil tank air vent hose 1 (intake silencer-to-oil tank)
16 Oil hose 1 (sub oil tank-to-oil tank)
17 Bolt 3
18 Oil tank assembly 1
19 Collar 3
20 Grommet 3
procedure.
4-29
4
DISASSEMBLING/ASSEMBLING THE OIL INJECTION SYSTEM
4260

1 Oil tank air vent hose 1 (oil tank-to-intake silencer)
3 Oil hose 1 (oil tank-to-oil pump)
4 Oil tank assembly 1
5 Metal clamp 12
6 Oil hose assembly 1 (oil pump-to-vapor separator)
7 Oil hose 6 (oil pump-to-oil hose assembly)
8 Oil pump 1
procedure.
4-30
FUEL OIL TANK E
OIL TANK 4
DISASSEMBLING/ASSEMBLING THE OIL TANK
4270

1 Oil level sensor 1
2 Oil strainer 1
3 Washer 1
4 Oil tank 1
5 Emergency switch cap 1
6 Emergency switch 1
procedure.
4-31
POWR E
CHAPTER 5
POWER UNIT
FLYWHEEL MAGNET ASSEMBLY ................................................................ 5-1

REMOVING/INSTALLING THE FLYWHEEL MAGNET ASSEMBLY ...... 5-1
REMOVING THE FLYWHEEL MAGNET ASSEMBLY ............................. 5-2
INSTALLING THE FLYWHEEL MAGNET ASSEMBLY ........................... 5-3
POWER UNIT .................................................................................................. 5-4

DISCONNECTING/CONNECTING THE LEADS ...................................... 5-4
DISCONNECTING/CONNECTING THE HOSES...................................... 5-6
REMOVING/INSTALLING THE POWER UNIT ........................................ 5-7
STATOR ASSEMBLY...................................................................................... 5-9

REMOVING/INSTALLING THE STATOR ASSEMBLY............................ 5-9
CDI UNIT ....................................................................................................... 5-11

REMOVING/INSTALLING THE CDI UNIT ASSEMBLY......................... 5-11
REMOVING/INSTALLING THE CDI UNIT ............................................. 5-13
HIGH-PRESSURE FUEL PUMP RESISTOR.................................................. 5-14

REMOVING/INSTALLING THE HIGH-PRESSURE FUEL
PUMP RESISTOR .................................................................................. 5-14
JUNCTION BOX ASSEMBLY....................................................................... 5-16

REMOVING/INSTALLING THE JUNCTION BOX ASSEMBLY............. 5-16
DISASSEMBLING/ASSEMBLING THE JUNCTION BOX ASSEMBLY 5-19
WIRE HARNESSES ....................................................................................... 5-22

REMOVING/INSTALLING THE MAIN WIRE HARNESS ....................... 5-22
REMOVING/INSTALLING THE SUB WIRE HARNESS ......................... 5-23
SHIFT CUTOFF SWITCH............................................................................... 5-24

REMOVING/INSTALLING THE SHIFT CUTOFF SWITCH..................... 5-24
STARTER MOTOR ........................................................................................ 5-25

REMOVING/INSTALLING THE STARTER MOTOR .............................. 5-25
OXYGEN DENSITY SENSOR....................................................................... 5-26

REMOVING/INSTALLING THE OXYGEN DENSITY SENSOR ............. 5-26
INSPECTING THE OXYGEN DENSITY SENSOR.................................. 5-27
SENSORS...................................................................................................... 5-28
REMOVING/INSTALLING THE SENSOR .............................................. 5-28
POWR E
REED VALVES .............................................................................................. 5-29

REMOVING/INSTALLING THE REED VALVES..................................... 5-29
INSPECTING THE REED VALVE ASSEMBLY ....................................... 5-31
EXTERNAL FITTINGS................................................................................... 5-32

REMOVING/INSTALLING THE EXTERNAL FITTINGS ......................... 5-32
PRESSURE CONTROL VALVE AND THERMOSTAT.................................. 5-34

1
REMOVING/INSTALLING THE PRESSURE CONTROL VALVE AND
THERMOSTAT....................................................................................... 5-34
INSPECTING THE PRESSURE CONTROL VALVE................................ 5-36
INSPECTING THE THERMOSTATS ...................................................... 5-36 2
CYLINDER HEADS ........................................................................................ 5-37
3
REMOVING/INSTALLING THE CYLINDER HEADS .............................. 5-37
INSPECTING THE CYLINDER HEADS................................................... 5-39
CRANKCASE ................................................................................................. 5-40

REMOVING/INSTALLING THE CRANKCASE ....................................... 5-40
REMOVING THE TORSIONAL DAMPER .............................................. 5-43
INSTALLING THE CRANKCASE............................................................ 5-43
INSTALLING THE TORSIONAL DAMPER............................................. 5-43
CYLINDER BODY ASSEMBLY ..................................................................... 5-44

4
DISASSEMBLING/ASSEMBLING THE CYLINDER BODY
5
ASSEMBLY ............................................................................................ 5-44
DISASSEMBLING/ASSEMBLING THE PISTON AND
CONNECTING ROD ASSEMBLIES....................................................... 5-45
DISASSEMBLING/ASSEMBLING THE CRANKSHAFT ASSEMBLY ... 5-46
REMOVING THE BEARING AND OIL PUMP DRIVE GEAR.................. 5-47
INSPECTING THE CYLINDER BODY..................................................... 5-47
INSPECTING THE PISTONS .................................................................. 5-48
CALCULATING THE PISTON-TO-CYLINDER CLEARANCE ................. 5-49
INSPECTING THE PISTON PINS AND SMALL-END BEARINGS ........ 5-49
INSPECTING THE PISTON RINGS ........................................................ 5-50
INSPECTING THE OIL PUMP DRIVEN GEAR ....................................... 5-51
6
INSPECTING THE LABYRINTH RINGS ................................................. 5-51
INSPECTING THE CRANKSHAFT ......................................................... 5-51
INSTALLING THE OIL PUMP DRIVE GEAR .......................................... 5-52
INSTALLING THE BEARING.................................................................. 5-53
INSTALLING THE PISTON RINGS AND PISTON................................. 5-53
INSTALLING THE CRANKSHAFT ASSEMBLY..................................... 5-54
7
INSTALLING THE PISTON AND CONNECTING ROD
ASSEMBLIES......................................................................................... 5-54
8
9
POWR FLYWHEEL MAGNET ASSEMBLY E
FLYWHEEL MAGNET ASSEMBLY 5

REMOVING/INSTALLING THE FLYWHEEL MAGNET ASSEMBLY 5
5010

1 Flywheel magnet assembly cover 1
2 Flywheel magnet assembly nut 1
3 Washer 1
4 Flywheel magnet assembly 1
5 Woodruff key 1
procedure.
5-1
Å REMOVING THE FLYWHEEL

MAGNET ASSEMBLY 5
Remove:
• Flywheel magnet assembly
Removing steps
(1) Remove the flywheel magnet assem-
bly nut.
5020
Flywheel magnet assembly
holder
ı YB-06139 / 90890-06522
Å For USA and Canada

ı Except for USA and Canada
NOTE:
The major load should be applied in the
direction of the arrows. If the load is not
applied as shown, the flywheel magnet
5030
assembly holder may easily slip off of the
flywheel magnet assembly.
Å ı
(2) Remove the flywheel magnet assem-
bly.
Universal puller
YB-06117 / 90890-06521

5040
NOTE:
• The major load should be applied in the
direction of the arrows.
• Apply the load until the flywheel magnet
assembly comes off the tapered portion of
the crankshaft.
CAUTION:
5050
To prevent damage to the engine or tools,
screw in the universal puller set-bolts
evenly and completely so that the puller
plate is parallel to the flywheel magnet
assembly.
5-2
Å INSTALLING THE FLYWHEEL

MAGNET ASSEMBLY 5
Install:
• Flywheel magnet assembly nut

holder
YB-06139 / 90890-06522
5060
ı
NOTE:
The major load should be applied in the
direction of the arrows. If the load is not
applied as shown, the flywheel magnet
assembly holder may easily slip off of the
flywheel magnet assembly.
5070
Flywheel magnet assembly nut
190 Nm (19 m • kgf, 137 ft • lb)
T.
R.
5-3
POWR POWER UNIT E
POWER UNIT 5
DISCONNECTING/CONNECTING THE LEADS 5
5080

Battery leads (from the battery)
Remote control shift and throttle
rods and cables
1 Bolt 1
2 Negative battery lead 1
3 Fuse cover 1
4 Screw 2
5 Junction box cover 1
5-4
POWR POWER UNIT E
5
5
5080

6 Positive battery lead 2
7 Power trim and tilt lead 1 (sky blue)
8 Power trim and tilt lead 1 (light green)
9 Power trim and tilt lead 2 (black)
10 Shift cutoff switch coupler 1
11 Trim sensor connector 1
procedure.
5-5
POWR POWER UNIT E
5
DISCONNECTING/CONNECTING THE HOSES 5
5090

1 Pilot water hose 1
3 Fuel hose 1 (fuel joint-to-fuel filter)
4 Oil hose 1 (sub oil tank-to-oil tank)
5 Trailer switch coupler 1
6 Bolt 1
7 Ground lead 1
procedure.
5-6
POWR POWER UNIT E
5
REMOVING/INSTALLING THE POWER UNIT 5
5100

1 Clip 1
2 Bushing 1
3 Shift rod lever 1
4 Bolt 2
5 Forward apron 1
6 Bolt 4
5-7
POWR POWER UNIT E
5
5
5100

7 Rear apron 1
8 Bolt 6
9 Bolt 8
10 Power unit 1
12 Dowel pin 2
procedure.
5-8
POWR STATOR ASSEMBLY E
STATOR ASSEMBLY 5
REMOVING/INSTALLING THE STATOR ASSEMBLY 5
5110

Flywheel magnet assembly Refer to “FLYWHEEL MAGNET
ASSEMBLY” on page 5-1.
1 Screw 4
2 CDI unit cover 1
3 Lighting coil coupler 1
4 Charge coil coupler 1
5 Bolt 1
6 Ground lead 1
7 Pulser coil coupler 1
5-9
POWR STATOR ASSEMBLY E
5
5
5110

8 Bolt 4
9 Stator assembly holder 1
10 Stator assembly 1
11 Screw 3
12 Pulser coil assembly 1
13 Crank position sensor coupler 1
14 Screw 2
15 Crank position sensor 1
procedure.
5-10
POWR CDI UNIT E
CDI UNIT 5
REMOVING/INSTALLING THE CDI UNIT ASSEMBLY 5
5120

CDI unit cover Refer to “STATOR ASSEMBLY” on
page 5-9.
1 Bolt 2
2 Ground lead 2
3 Bolt 2
4 CDI unit coupler holder 1
5 CDI unit coupler guide 1
6 CDI unit coupler 2
7 Oxygen density sensor coupler 1 (black coupler)
8 Bolt 1
5-11
POWR CDI UNIT E
5
5
5120

9 Ground lead 1
resistor coupler
12 Bolt 1
13 Ground lead 1
14 Spark plug cap 6
15 Bolt 4
16 CDI unit assembly 1
procedure.
5-12
POWR CDI UNIT E
5
REMOVING/INSTALLING THE CDI UNIT 5
5130

1 Ignition coil connector 6
2 Bolt 6
3 Ignition coil 6
4 Ground lead 6
5 Bolt 4
6 Ground lead 3
7 Bolt 4
8 CDI unit 1
9 Collar 4
10 Grommet 4
11 CDI unit case 1
procedure.
5-13
POWR HIGH-PRESSURE FUEL PUMP RESISTOR E
HIGH-PRESSURE FUEL PUMP RESISTOR 5

REMOVING/INSTALLING THE HIGH-PRESSURE FUEL PUMP RESISTOR 5
4160

resistor coupler
resistor assembly
4 Collar 3
5 Screw 2 (with washer)
5-14
POWR HIGH-PRESSURE FUEL PUMP RESISTOR E
5
5
4160

resistor cover
7 Screw 2 (with washer)
8 High-pressure fuel pump resistor 1
9 Grommet 3
resistor mounting base
procedure.
5-15
POWR JUNCTION BOX ASSEMBLY E
JUNCTION BOX ASSEMBLY 5

REMOVING/INSTALLING THE JUNCTION BOX ASSEMBLY 5
5140

1 Fuse cover 1
2 Junction box cover 1
3 Nut 1
4 Starter motor lead 1
5 Intake air temperature sensor 1
coupler
6 Atmospheric pressure sensor 1
coupler
7 Clip 1
8 Cooling water hose 1 (exhaust outer cover-to-rectifier/
regulator)
5-16
5
5
5150

9 Positive battery lead 2
10 Power trim and tilt lead 1 (sky blue)
11 Power trim and tilt lead 1 (green)
12 Power trim and tilt lead 2 (black)
13 Main relay coupler 1
14 Power trim and tilt relay coupler 1
15 Oxygen density sensor coupler 1 (blue coupler)
16 Fuse connector (30A) 1
5-17
5
5
5150

17 Starter relay connector 1
18 Thermo switch connector 1 (except for 200H, 225G/V200, V225)
19 Main relay connector 3
20 Bolt 2
21 Ground lead 4
22 Ground lead plate 1
23 Bolt 5
24 Junction box assembly 1
procedure.
5-18
5
DISASSEMBLING/ASSEMBLING THE JUNCTION BOX ASSEMBLY 5

1 Fuse holder 1
2 Fuse coupler 3
3 Fuse (80A) 2
4 Bolt 2
5 Power trim and tilt relay 1
6 Screw 1
7 Main relay 1
8 Screw 1
5-19
5
5

9 Starter relay holder 1
10 Starter relay 1
11 Screw 2
12 Atmospheric pressure sensor 1
13 Nut 1
14 Intake air temperature sensor 1
15 Bolt 2
16 Rectifier/regulator 1
5-20
5
5

17 Bolt 4
18 Clip 2
19 Cooling water hose 1 (to exhaust outer cover)
20 Cooling water hose 1 (to pilot water outlet)
21 Collar 5
22 Grommet 5
23 Junction box 1
procedure.
5-21
POWR WIRE HARNESSES E
WIRE HARNESSES 5
REMOVING/INSTALLING THE MAIN WIRE HARNESS 5
6 × 14 mm
2
1
3
4
PON ML K JI
X W V U T S RQ
b a ` ] \ [ ZY
5170

Trim sensor connector Refer to “POWER UNIT” on page 5-4.
Trailer switch coupler Refer to “POWER UNIT” on page 5-4.
CDI unit coupler Refer to “CDI UNIT” on page 5-11.
Junction box assembly Refer to “JUNCTION BOX ASSEMBLY”
on page 5-16.
1 Bolt 1
2 Ground lead 1
3 Emergency switch connector 2
4 Oil level sensor coupler 1
procedure.
5-22
POWR WIRE HARNESSES E
5
REMOVING/INSTALLING THE SUB WIRE HARNESS 5
5180

Crank position sensor coupler Refer to “STATOR ASSEMBLY” on
page 5-9.
Pulser coil coupler Refer to “STATOR ASSEMBLY” on
page 5-9.
CDI unit coupler Refer to “CDI UNIT” on page 5-11.
1 Bolt 1
2 Ground lead 1
3 Thermo switch connector 4
4 Throttle position sensor coupler 1
5 Engine cooling water 1
temperature sensor coupler
6 Knocking sensor connector 1
procedure.
5-23
POWR SHIFT CUTOFF SWITCH E
SHIFT CUTOFF SWITCH 5

REMOVING/INSTALLING THE SHIFT CUTOFF SWITCH 5
5185

1 Bolts 2 (with washers)
2 Shift cutoff switch assembly 1
3 Bolt 1
4 Shift rod lever bracket 1
5 Bushing 2
6 Spring 1
7 Collar 1
8 Shift cutoff switch bracket 1
9 Screws 2
10 Shift cutoff switch 1
procedure.
5-24
POWR STARTER MOTOR E
STARTER MOTOR 5
REMOVING/INSTALLING THE STARTER MOTOR 5
30 Nm (3.0 m • kgf, 22 ft • Ib)

8 × 45 mm
1
5190

Negative battery lead Refer to “POWER UNIT” on page 5-4.
Starter motor lead Refer to “JUNCTION BOX ASSEMBLY”
on page 5-16.
1 Bolt 1
2 Bolt 1
3 Bolt 1
4 Starter motor 1
procedure.
5-25
POWR OXYGEN DENSITY SENSOR E
OXYGEN DENSITY SENSOR 5

REMOVING/INSTALLING THE OXYGEN DENSITY SENSOR 5
5200

1 Plastic locking tie 1
2 Rubber cap 1
4 Oxygen density sensor cover 1
6 Oxygen density sensor assembly 1
8 Oxygen density sensor bracket 1
9 Oxygen density sensor 1
10 Oxygen density sensor joint 1
procedure.
5-26
POWR OXYGEN DENSITY SENSOR E
INSPECTING THE OXYGEN DENSITY

SENSOR 5
Inspect:
• Oxygen density sensor
Any silicon solvent → Clean.
WARNING
Do not let any silicon anticorrosion solvent
5205
touch the oxygen density sensor or its
accuracy will be affected.
Refer to “INSPECTING THE OXYGEN

DENSITY SENSOR” on page 8-23.
5-27
POWR SENSORS E
SENSORS 5
REMOVING/INSTALLING THE SENSOR 5
5206

1 Bolt 2
2 Retainer 2
3 Thermo switch 2
4 Knocking sensor 1
5 Engine cooling water 1
temperature sensor
procedure.
5-28
POWR REED VALVES E
REED VALVES 5
REMOVING/INSTALLING THE REED VALVES 5
5210

Fuel injection unit Refer to “HIGH-PRESSURE FUEL LINE”
on page 4-1.
1 Recirculation hose 12
4 Intake manifold 1
5 Screw 12
7 Reed valve assembly 6
5-29
POWR REED VALVES E
5
5
5210

8 Screw 10
9 Reed valve stopper 4
10 Metal reed 4
11 Reed valve seat 1
procedure.
5-30
POWR REED VALVES E
INSPECTING THE REED VALVE

ASSEMBLY 5
1. Inspect:
• Reed valve
Cracks/damage → Replace.
2. Measure:
• Warpage limit a
Out of specification → Replace.
Warpage limit
0.2 mm (0.008 in)
5220
3. Measure:
• Reed valve stopper height a
Reed valve stopper height

200H, 225G, 250B, L250B/
V200, V225, S250, L250:
9.0 ± 0.35 mm (0.35 ± 0.01 in)
225F, L225F/S225, L225:
5230 7.9 ± 0.35 mm (0.31 ± 0.01 in)
5-31
POWR EXTERNAL FITTINGS E
EXTERNAL FITTINGS 5
REMOVING/INSTALLING THE EXTERNAL FITTINGS 5
10
6 × 25 mm
9 9
7 6
5
6 × 30 mm
2 3
4
5240

Fuel injection unit Refer to “HIGH-PRESSURE FUEL LINE”
on page 4-1.
Low-pressure fuel line Refer to “LOW-PRESSURE FUEL LINE”
on page 4-21.
Oil injection system Refer to “OIL INJECTION SYSTEM” on
page 4-28.
Junction box Refer to “JUNCTION BOX ASSEMBLY”
on page 5-16.
Starter motor Refer to “STARTER MOTOR” on
page 5-25.
1 Bolt 1
2 Washer 1
5-32
POWR EXTERNAL FITTINGS E
5
5
10
6 × 25 mm
9 9
7 6
5
6 × 30 mm
2 3
4
5240

3 Wave washer 1
4 Throttle control lever assembly 1
5 Collar 1
6 Bolt 1
7 Clamp bracket 1
8 Clamp 2
procedure.
5-33
POWR PRESSURE CONTROL VALVE AND THERMOSTAT E
PRESSURE CONTROL VALVE AND THERMOSTAT 5

REMOVING/INSTALLING THE PRESSURE CONTROL VALVE AND THERMOSTAT5
5245

1 Bolt 4
2 Damper bracket 2
3 Bolt 4
4 Clamp 1
5 Anode cover 4
6 Grommet 4
7 Anode 4
9 Cooling water hose 1
10 Bolt 2
5-34
5
5
5245

11 Pressure control valve cover 1
13 Spring 1
14 Pressure control valve 1
15 Pressure control valve seat 1
16 Bolt 4
17 Thermostat cover 2
19 Thermostat 2
procedure.
5-35
INSPECTING THE PRESSURE

CONTROL VALVE 5
Inspect:
• Pressure control valve seat 1
• Pressure control valve 2
• Pressure control valve cover 3
Cracks/damage → Replace any defec-
tive parts.
5310
• Spring 4
Damage/wear → Replace.
INSPECTING THE THERMOSTATS 5

1. Inspect:
• Thermostat
Damage/valve does not open →
Replace.
2. Measure:
• Thermostat opening temperature
• Valve lift a
5260
Water temperature Valve lift

Below 48 - 52 ˚C 0 mm
(118 - 126 ˚F) (0 in)
Above 60 ˚C Min. 3 mm
(140 ˚F) (0.12 in)
Measuring steps
(1) Suspend the thermostat in a container
filled with water.
(2) Place a thermometer in the water.
(3) Slowly heat the water.
(4) While stirring the water, check that the
thermostat opens at the specified tem-
perature.
5-36
POWR CYLINDER HEADS E
CYLINDER HEADS 5
REMOVING/INSTALLING THE CYLINDER HEADS 5
5250

Ground lead Refer to “CDI UNIT” on page 5-11.
Spark plug cap Refer to “CDI UNIT” on page 5-11.
CDI unit assembly Refer to “CDI UNIT” on page 5-11.
Cooling water hose Refer to “JUNCTION BOX ASSEMBLY”
on page 5-16.
1 Spark plug 6
2 Bolt 3
3 Bolt 37
4 Bolt 12
5 Cylinder head cover 2
5-37
5
5
5250

7 Cylinder head 2
9 Bolt 25
10 Clamp 1
11 Exhaust cover 1
13 Bolt 7
14 Clamp 2
15 Cylinder cover 1
procedure.
5-38
INSPECTING THE CYLINDER HEADS 5

1. Inspect:
• Combustion chamber
Carbon deposits → Clean.
• Water jacket
Mineral deposits/rust→ Clean.
CAUTION:
5265
Do not scratch the contacting surfaces of
the cylinder head and cylinder head cover.
2. Measure:
• Cylinder head warpage
(with a straightedge and thickness
gauge)
Out of specification → Resurface or
replace.
Warpage limit
5270 0.1 mm (0.004 in)
Resurfacing steps
(1) Place a 400 - 600 grit wet sandpaper on
the surface plate.
(2) Resurface the cylinder head by moving
it in a figure-eight motion along the
sandpaper.
NOTE:
Rotate the cylinder head several times to
5280
ensure an even surface.
5290
5-39
POWR CRANKCASE E
CRANKCASE 5
REMOVING/INSTALLING THE CRANKCASE 5
5320

Flywheel magnet assembly Refer to “FLYWHEEL MAGNET
ASSEMBLY” on page 5-1.
Power unit Refer to “POWER UNIT” on page 5-4.
Pulser coil assembly Refer to “STATOR ASSEMBLY” on
page 5-9.
Intake manifold Refer to “REED VALVES” on page 5-29.
External fittings Refer to “EXTERNAL FITTINGS” on
page 5-32.
1 Damper nut 1
2 Torsional damper 1
5-40
POWR CRANKCASE E
5
5
5320

3 Bolt 4
4 Oil seal housing 1
5 O-ring 1
6 Circlip 1
7 Oil seal 1
8 Bolt 14
9 Bolt 4
5-41
POWR CRANKCASE E
5
5
5320

10 Bolt 4
11 Collar 1
12 O-ring 1
13 Washer 1
14 Oil pump driven gear 1
15 Crankcase 1
16 Dowel pin 2
procedure.
5-42
POWR CRANKCASE E
REMOVING THE TORSIONAL

DAMPER 5
1. Remove:
• Damper nut

holder
YB-06139 / 90890-06522
5330
Å 2. Remove:
• Torsional damper
Universal puller
YU-06117 / 90890-06521

5335
INSTALLING THE CRANKCASE 5

5340
Apply:
• Gasket Maker
(onto the crankcase mating surfaces)
NOTE:
• Clean the mating surfaces of the crank-
case and cylinder body before applying
Gasket Maker.
• Do not allow any sealant to overflow from
the mating surfaces.
5350
INSTALLING THE TORSIONAL

DAMPER 5
Install:
• Damper nut

holder
YB-06139 / 90890-06522
5355
5-43
POWR CYLINDER BODY ASSEMBLY E
CYLINDER BODY ASSEMBLY 5

DISASSEMBLING/ASSEMBLING THE CYLINDER BODY ASSEMBLY 5
5360

Cylinder heads Refer to “CYLINDER HEADS” on
page 5-37.
Crankcase Refer to “CRANKCASE” on page 5-40.
1 Connecting rod bolt 12
2 Connecting rod cap 6
3 Big-end bearing 6
4 Piston/connecting rod assembly 6
5 Crankshaft assembly 1
procedure.
5-44
5
DISASSEMBLING/ASSEMBLING THE PISTON AND CONNECTING ROD
ASSEMBLIES 5
5370

1 Piston pin clip 12 Not reusable
2 Piston pin 6
3 Piston 6
4 Washer 12
5 Small-end bearing 6
6 Piston ring 12
7 Connecting rod 6
procedure.
5-45
5
DISASSEMBLING/ASSEMBLING THE CRANKSHAFT ASSEMBLY 5
5600

1 Needle bearing 1
2 O-ring 1
3 Oil seal 1
4 Clip 2
5 Main journal bearing 2
6 Labyrinth ring 9
7 Ball bearing 1
8 Circlip 1
9 Ball bearing 1
10 Oil pump drive gear 1
11 Crankshaft 1
procedure.
5-46
REMOVING THE BEARING AND OIL

PUMP DRIVE GEAR 5
Remove:
• Bearing
• Oil pump drive gear
Bearing separator ..................... 1

YB-06219 / 90890-06534
Guide plate stand ..................... 2
90890-06538
Guide plate................................ 3
90890-06501
Bearing puller............................ 4
90890-06535
5610
INSPECTING THE CYLINDER BODY 5

1. Inspect:
• Cylinder sleeves
Cracks/score marks → Replace.
• Cylinder body water jacket
Mineral deposits/rust → Clean.
CAUTION:
the crankcase and cylinder head.
2. Inspect:
• Exhaust passages
Carbon deposits → Clean.
CAUTION:
the cylinder and exhaust inner cover.
5-47
3. Measure:
• Cylinder bore diameter “D”
(with a cylinder bore gauge)
NOTE:
Measure the cylinder bore diameter at three
positions for both D1 and D2. Then, average
5410 the measurements.
Wear
Standard
limit
Cylinder
90.00 - 90.02 mm 90.1 mm
bore diame-
(3.543 - 3.544 in) (3.55 in)
ter “D”
0.08 mm
Taper limit T —
(0.003 in)
5420
Out of round 0.05 mm
—
limit R (0.002 in)
T = (maximum D1 or D2) – (minimum D5
or D6)
R = Maximum (D1 – D2) or (D3 – D4) or
(D5 – D6)
A: 10 mm (0.4 in) below the top of the cylinder

B: 5 mm (0.2 in) above the exhaust port
C: 5 mm (0.2 in) below the scavenging port
5430
INSPECTING THE PISTONS 5

Measure:
• Piston diameter
(with a micrometer)
Measuring
Piston diameter
point “H”
5440
10 mm 89.840 - 89.860 mm
Standard
(0.4 in) (3.5370 - 3.5378 in)
5-48
Oversize piston diameter

1st oversize*
90.15 mm (3.549 in)
2nd oversize
90.40 mm (3.559 in)
*: Except for USA
NOTE:
When measuring the piston diameter, posi-
tion the micrometer in relation to the piston
pin hole as shown.
CALCULATING THE PISTON-TO-

CYLINDER CLEARANCE 5
Calculate:
• Piston-to-cylinder clearance a
Out of specification → Replace the pis-
ton and piston rings, the cylinder or
both.
5450 Piston-to- Cylinder

Piston
cylinder = bore –
diameter
clearance diameter
Piston-to-cylinder clearance
0.155 - 0.161 mm
(0.0061 - 0.0063 in)
INSPECTING THE PISTON PINS AND

SMALL-END BEARINGS 5
1. Inspect:
• Piston pin
• Small-end bearing
Heat discoloration → Replace.
Damage/scratches → Replace.
5-49
2. Measure:
• Piston pin diameter
(with a micrometer)
Piston pin diameter

25.995 - 26.000 mm
(1.0234 - 1.0236 in)
5460
3. Measure:
• Piston pin boss diameter
(with a micrometer)
Piston pin boss diameter

26.004 - 26.015 mm
(1.0238 - 1.0242 in)
5470
INSPECTING THE PISTON RINGS 5

NOTE:
• Before inspecting the piston rings, be sure
to inspect the cylinder body.
• Piston rings should always be replaced as
a set (per piston).
1. Measure:
• Piston ring end gap a
(with a thickness gauge)
Piston ring end gap

0.30 - 0.40 mm
(0.012 - 0.016 in)
Piston ring end gap limit
5480 0.60 mm (0.024 in)
Measuring point “H”
5 mm (0.2 in)
NOTE:
Push the piston ring into the cylinder with
the piston crown.
5490
5-50
2. Measure:
• Piston ring side clearance b
(with a thickness gauge)
Out of specification → Replace the pis-
ton and piston rings as a set.
Piston ring side clearance

0.02 - 0.06 mm
(0.001 - 0.002 in)
5500
NOTE:
When measuring the piston ring side clear-
ance, the outside of the piston ring should
be flush with the piston wall.
INSPECTING THE OIL PUMP DRIVEN

GEAR 5
Inspect:
• Oil pump driven gear
Cracks/pitting/wear → Replace.
5510
INSPECTING THE LABYRINTH RINGS5

1. Inspect:
• Labyrinth ring 1
Cracks/damage/wear → Replace.
2. Measure:
• Labyrinth ring wear a or b + c
5620 Labyrinth ring wear limit

0.10 mm (0.004 in)
INSPECTING THE CRANKSHAFT 5

1. Measure:
• Crankshaft runout
(with V-blocks and a dial gauge)
Runout limit
5630 0.05 mm (0.002 in)
5-51
2. Measure:
• Small-end axial play
Out of specification → Replace the
connecting rod.
Small-end axial play limit

2.0 mm (0.08 in)
5640
3. Measure:
• Big-end side clearance
connecting rod.
Big-end side clearance

0.12 - 0.26 mm (0.005 - 0.010 in)
5650
4. Inspect:
• Crankshaft bearing
Pitting/rumbling → Replace.
5. Inspect:
Cracks/pitting/wear → Replace.
INSTALLING THE OIL PUMP DRIVE

GEAR 5
Install:

YB-06219 / 90890-06534
Bearing/oil seal attachment .... 2
90890-06661
5660
90890-06622
5-52
INSTALLING THE BEARING 5

Install:
• Bearing

YB-06219 / 90890-06534
90890-06662
90890-06622
5670
INSTALLING THE PISTON RINGS AND

PISTON 5
1. Install:
• 2nd piston ring
• Top piston ring
CAUTION:
• Align each piston ring end gap with its
5520
respective locating pin.
• After installing the piston rings, check
that they move smoothly.
2. Install:
• Small-end bearing 1
• Washers 2
• Piston 3
• Piston pin 4
• Piston pin clips 5
CAUTION:
5530
The washers must be installed with their
convex sides facing towards the piston.
NOTE:
The embossed YAMAHA mark a on the
connecting rod must face the same direc-
tion as the “UP” mark on the piston.
5-53
INSTALLING THE CRANKSHAFT

ASSEMBLY 5
Install:
• Cylinder body
• Crankshaft assembly
NOTE:
• Align the crankshaft labyrinth ring end
5570 gaps with their respective locating pins.
• Install the bearing locating pins into the
cylinder body.
5575
INSTALLING THE PISTON AND

CONNECTING ROD ASSEMBLIES 5
Install:
• Piston and connecting rod assembly
Piston ring compressor

YU-33294 / 90890-06530
5580
NOTE:
• Before installing the piston and connect-
5590 ing rod assemblies, lubricate the cylinder
walls with 2-stroke outboard engine oil.
• Reinstall the piston and connecting rod
assemblies in their original cylinders.
• Install the piston and connecting rod
assemblies with the “S” mark in the star-
board side cylinders, and those with the
“P” mark in the port side cylinders.
• The “UP” mark on the piston crown must
face towards the flywheel.
5-54
LOWR E
CHAPTER 6
LOWER UNIT
LOWER UNIT (REG LAR ROTATION MODELS) ........................................... 6-1

REMOVING/INSTALLING THE LOWER UNIT ........................................ 6-1
REMOVING THE PROPELLER ................................................................. 6-3
INSPECTING THE PROPELLER ............................................................... 6-3
1
INSTALLING THE PROPELLER................................................................ 6-3
WATER PUMP (REGULAR ROTATION MODELS)........................................ 6-4

REMOVING/INSTALLING THE WATER PUMP....................................... 6-4
INSPECTING THE IMPELLER HOUSING ................................................ 6-6
2
INSPECTING THE IMPELLER AND IMPELLER HOUSING CUP ............ 6-6
INSPECTING THE WOODRUFF KEY....................................................... 6-6
INSTALLING THE IMPELLER AND IMPELLER HOUSING ..................... 6-6
SHIFT ROD ASSEMBLY (REGULAR ROTATION MODELS)......................... 6-7

REMOVING/INSTALLING THE SHIFT ROD ASSEMBLY ....................... 6-7
3
REMOVING THE SHIFT ROD ASSEMBLY .............................................. 6-8
PROPELLER SHAFT HOUSING ASSEMBLY

(REGULAR ROTATION MODELS) ................................................................ 6-9
REMOVING/INSTALLING THE PROPELLER SHAFT
4
HOUSING ASSEMBLY............................................................................ 6-9
5
DISASSEMBLING/ASSEMBLING THE PROPELLER
SHAFT HOUSING.................................................................................. 6-10
DISASSEMBLING/ASSEMBLING THE PROPELLER
SHAFT ASSEMBLY ............................................................................... 6-11
REMOVING THE PROPELLER SHAFT HOUSING ASSEMBLY............ 6-13
DISASSEMBLING THE PROPELLER SHAFT HOUSING ...................... 6-13
6
INSPECTING THE REVERSE GEAR....................................................... 6-14
INSPECTING THE BEARING.................................................................. 6-14
INSPECTING THE PROPELLER SHAFT HOUSING .............................. 6-14
INSPECTING THE DOG CLUTCH .......................................................... 6-15
INSPECTING THE PROPELLER SHAFT................................................. 6-15
ASSEMBLING THE PROPELLER SHAFT HOUSING ............................ 6-15
DRIVE SHAFT (REGULAR ROTATION MODELS)....................................... 6-16

REMOVING/INSTALLING THE DRIVE SHAFT...................................... 6-16
REMOVING THE DRIVE SHAFT ............................................................ 6-18
7
DISASSEMBLING THE DRIVE SHAFT HOUSING ASSEMBLY ........... 6-18
DISASSEMBLING THE FORWARD GEAR ASSEMBLY ....................... 6-18
INSPECTING THE PINION ..................................................................... 6-19
INSPECTING THE DRIVE SHAFT .......................................................... 6-19
INSPECTING THE DRIVE SHAFT HOUSING ........................................ 6-19
INSPECTING THE BEARINGS ............................................................... 6-19
8
ASSEMBLING THE FORWARD GEAR ASSEMBLY ............................. 6-19
9
ASSEMBLING THE DRIVE SHAFT HOUSING ASSEMBLY ................. 6-20
INSTALLING THE DRIVE SHAFT........................................................... 6-20
LOWR E
LOWER CASE ASSEMBLY (REGULAR ROTATION MODELS) .................. 6-21

DISASSEMBLING/ASSEMBLING THE LOWER CASE ASSEMBLY .... 6-21
DISASSEMBLING THE LOWER CASE ASSEMBLY ............................. 6-22
INSPECTING THE NEEDLE BEARING................................................... 6-22
ASSEMBLING THE LOWER CASE ASSEMBLY ................................... 6-22
LOWER UNIT (COUNTER ROTATION MODELS) ....................................... 6-24

REMOVING/INSTALLING THE LOWER UNIT ...................................... 6-24
REMOVING THE PROPELLER ............................................................... 6-26
INSPECTING THE PROPELLER ............................................................. 6-26
INSTALLING THE PROPELLER.............................................................. 6-26
WATER PUMP (COUNTER ROTATION MODELS) ..................................... 6-27

REMOVING/INSTALLING THE WATER PUMP..................................... 6-27
INSPECTING THE IMPELLER HOUSING .............................................. 6-29
INSPECTING THE IMPELLER AND IMPELLER HOUSING CUP .......... 6-29
INSPECTING THE WOODRUFF KEY..................................................... 6-29
INSTALLING THE IMPELLER AND IMPELLER HOUSING ................... 6-29
SHIFT ROD ASSEMBLY (COUNTER ROTATION MODELS) ...................... 6-30

REMOVING/INSTALLING THE SHIFT ROD ASSEMBLY ..................... 6-30
REMOVING THE SHIFT ROD ASSEMBLY ............................................ 6-31

(COUNTER ROTATION MODELS) .............................................................. 6-32
REMOVING/INSTALLING THE PROPELLER SHAFT
HOUSING ASSEMBLY.......................................................................... 6-32
DISASSEMBLING/ASSEMBLING THE PROPELLER SHAFT
HOUSING ASSEMBLY.......................................................................... 6-33
DISASSEMBLING/ASSEMBLING THE FRONT PROPELLER
SHAFT ASSEMBLY ............................................................................... 6-35
REMOVING THE PROPELLER SHAFT HOUSING ASSEMBLY............ 6-37
REMOVING THE REAR PROPELLER SHAFT ........................................ 6-37
DISASSEMBLING THE PROPELLER SHAFT HOUSING ASSEMBLY . 6-38
DISASSEMBLING THE FORWARD GEAR ............................................ 6-38
INSPECTING THE FORWARD GEAR .................................................... 6-39
INSPECTING THE BEARING.................................................................. 6-39
INSPECTING THE PROPELLER SHAFT HOUSING .............................. 6-39
INSPECTING THE DOG CLUTCH .......................................................... 6-39
INSPECTING THE PROPELLER SHAFTS .............................................. 6-39
ASSEMBLING THE FORWARD GEAR .................................................. 6-39
ASSEMBLING THE PROPELLER SHAFT HOUSING ASSEMBLY ....... 6-40
INSTALLING THE REAR PROPELLER SHAFT ...................................... 6-41
LOWR E
DRIVE SHAFT (COUNTER ROTATION MODELS) ...................................... 6-42

REMOVING/INSTALLING THE DRIVE SHAFT...................................... 6-42
REMOVING THE DRIVE SHAFT ............................................................ 6-44
DISASSEMBLING THE DRIVE SHAFT HOUSING ASSEMBLY ........... 6-44
DISASSEMBLING THE REVERSE GEAR .............................................. 6-44
INSPECTING THE PINION ..................................................................... 6-45
INSPECTING THE DRIVE SHAFT .......................................................... 6-45
INSPECTING THE DRIVE SHAFT HOUSING ........................................ 6-45
INSPECTING THE BEARINGS ............................................................... 6-45
ASSEMBLING THE REVERSE GEAR .................................................... 6-45
ASSEMBLING THE DRIVE SHAFT HOUSING ASSEMBLY ................. 6-46
INSTALLING THE DRIVE SHAFT........................................................... 6-46
LOWER CASE ASSEMBLY (COUNTER ROTATION MODELS).................. 6-47

DISASSEMBLING/ASSEMBLING THE LOWER CASE ASSEMBLY .... 6-47
DISASSEMBLING THE LOWER CASE ASSEMBLY ............................. 6-48
INSPECTING THE NEEDLE BEARINGS ................................................ 6-48
ASSEMBLING THE LOWER CASE ASSEMBLY ................................... 6-49
SHIMMING (REGULAR ROTATION MODELS)........................................... 6-50

SELECTING THE PINION SHIMS .......................................................... 6-51
SELECTING THE FORWARD GEAR SHIMS ......................................... 6-53
SELECTING THE REVERSE GEAR SHIMS............................................ 6-55
SELECTING THE REVERSE GEAR SHIM .............................................. 6-60
BACKLASH (REGULAR ROTATION MODELS)........................................... 6-62

MEASURING THE FORWARD GEAR BACKLASH ............................... 6-62
MEASURING THE REVERSE GEAR BACKLASH.................................. 6-64
SHIMMING (COUNTER ROTATION MODELS)........................................... 6-66

SELECTING THE PROPELLER SHAFT SHIMS...................................... 6-72
SELECTING THE PROPELLER SHAFT SHIMS...................................... 6-78
BACKLASH (COUNTER ROTATION MODELS)........................................... 6-79

MEASURING THE FORWARD GEAR BACKLASH ............................... 6-79
MEASURING THE REVERSE GEAR BACKLASH.................................. 6-80
LOWR LOWER UNIT (REGULAR ROTATION MODELS) E
LOWER UNIT (REG LAR ROTATION MODELS) 6

REMOVING/INSTALLING THE LOWER UNIT
6010

1 Cotter pin 1
2 Propeller nut 1
3 Washer 1
4 Washer 1
5 Propeller 1
6 Spacer 1
7 Cap 1
6-1
6010

8 Bolt 1
9 Trim tab 1
12 Lower unit 1
13 Dowel pin 2
14 Rubber seal 1
15 Plate 1
procedure.
6-2
REMOVING THE PROPELLER

Remove:
• Propeller
WARNING
Do not hold the propeller with your hands
when removing or installing it. Be sure to
remove the battery leads from the batteries
6016
and the lanyard engine stop switch. Put a
block of wood between the cavitation plate
and propeller to keep the propeller from
turning.
INSPECTING THE PROPELLER

Inspect:
• Blades
• Splines
INSTALLING THE PROPELLER

Install:
• Propeller
WARNING
6017
turning.
NOTE:
If the groove in the propeller nut is not
aligned with the cotter pin hole, tighten the
nut further until they are aligned.
6-3
LOWR WATER PUMP (REGULAR ROTATION MODELS) E
WATER PUMP (REGULAR ROTATION MODELS) 6

REMOVING/INSTALLING THE WATER PUMP
6020

Lower unit Refer to “LOWER UNIT (REGULAR
ROTATION MODELS)” on page 6-1.
1 Bolt 4
2 Plate washer 4
3 Impeller housing 1
4 Impeller housing cup 1
5 Grommet 1
6 Spacer 1
7 Collar 1
6-4
6020

8 Spacer 1
9 Washer 2
10 Wave washer 1
11 Impeller 1
12 Woodruff key 1
13 Impeller plate 1
15 Dowel pin 2
procedure.
6-5
INSPECTING THE IMPELLER

HOUSING
Inspect:
• Impeller housing
INSPECTING THE IMPELLER AND

IMPELLER HOUSING CUP
Inspect:
• Impeller
• Impeller housing cup
tive parts.
INSPECTING THE WOODRUFF KEY

Inspect:
• Woodruff key
INSTALLING THE IMPELLER AND

IMPELLER HOUSING
1. Install:
• Washers 1
• Wave washer 2
• Spacer 3
• Collar 4
6025 NOTE:
• The collar and spacer should fit together
firmly.
• Install the collar with some appropriate
tool a that fits over the drive shaft as
shown.
2. Install:
• O-ring 1
• Impeller housing cup 2
• Impeller housing 3
• O-ring 4
NOTE:
• When installing the impeller housing cup,
align its projection with the hole in the
impeller housing.
• When installing the water pump housing,
turn the drive shaft clockwise.
6030
6-6
SHIFT ROD ASSEMBLY
LOWR (REGULAR ROTATION MODELS) E
SHIFT ROD ASSEMBLY (REGULAR ROTATION MODELS) 6

REMOVING/INSTALLING THE SHIFT ROD ASSEMBLY
6035

Impeller plate Refer to “WATER PUMP (REGULAR
2 Shift rod assembly 1
3 Shift rod 1
4 Spring 1
6 Oil seal 1
procedure.
6-7
SHIFT ROD ASSEMBLY
REMOVING THE SHIFT ROD

ASSEMBLY
Remove:
• Shift rod assembly
NOTE:
Remove the shift rod assembly when the
shift rod is in the neutral position.
6-8

(REGULAR ROTATION MODELS) 6
REMOVING/INSTALLING THE PROPELLER SHAFT HOUSING ASSEMBLY
6040

Gear oil Refer to “CHANGING AND INSPECTING
THE GEAR OIL” on page 3-15.
Shift rod assembly Refer to “SHIFT ROD ASSEMBLY
(REGULAR ROTATION MODELS)” on
page 6-7.
1 Bolt 2
2 Ring 1
3 Bolt 2
4 Propeller shaft housing assembly 1
5 Propeller shaft assembly 1
6 Washer 1
procedure.
6-9
6
DISASSEMBLING/ASSEMBLING THE PROPELLER SHAFT HOUSING
6045

1 O-ring 1
2 O-ring 1
3 Reverse gear 1
4 Reverse gear shim *
5 Ball bearing 1
6 Oil seal 2
7 Needle bearing 1
8 Grease nipple 1
9 Propeller shaft housing 1
procedure.
*: As required
6-10
6
DISASSEMBLING/ASSEMBLING THE PROPELLER SHAFT ASSEMBLY
6100

1 Spring 1
2 Pin 1
3 Dog clutch 1
4 Shift rod joint 1
5 Shift rod joint slider 1
6 Ball 2
7 Spring nut 1
6-11
6100

8 Shift plunger 2
9 Spring 1
10 Washer 1
11 Spring nut 1
12 Pin 1
13 Propeller shaft 1
procedure.
6-12
Å REMOVING THE PROPELLER SHAFT

HOUSING ASSEMBLY
Remove:
• Propeller shaft housing assembly
Propeller shaft housing puller . 1

1 2 YB-06207 / 90890-06502
Universal puller......................... 2
YB-06117
6054
Guide plate................................ 3
90890-06501
ı Center bolt ................................ 4
90890-06504

6055
Å DISASSEMBLING THE PROPELLER

SHAFT HOUSING
1. Remove:
• Reverse gear
Slide hammer............................ 1
YB-06096
90890-06534
6060
Guide plate................................ 3
90890-06501
ı Guide plate stand ..................... 4
90890-06538
Bearing puller............................ 5
90890-06535
Small universal claws .............. 6
90890-06536

6065
6-13
Å 2. Remove:
• Ball bearing
Slide hammer............................ 1
YB-06096
Guide plate................................ 2
90890-06501
90890-06538
6070 Bearing puller............................ 4
90890-06535
ı 90890-06536

6075
3. Remove:
• Oil seal
• Needle bearing

YB-06196 / 90890-06653
Driver rod .................................. 2
YB-06071 / 90890-06652
6080
INSPECTING THE REVERSE GEAR

Inspect:
• Teeth
• Dogs
Wear/damage → Replace the reverse
gear.
INSPECTING THE BEARING

Inspect:
• Bearing
INSPECTING THE PROPELLER SHAFT

HOUSING
Inspect:
• Propeller shaft housing
6-14
INSPECTING THE DOG CLUTCH

Inspect:
• Dog clutch

Inspect:
• Propeller shaft
Å ASSEMBLING THE PROPELLER

SHAFT HOUSING
1. Install:
• Needle bearing
Needle bearing installation

position a
25.05 - 25.55 mm
(0.986 - 1.006 in)
6085

ı YB-06196 / 90890-06653
Driver rod .................................. 2
YB-06071 / 90890-06604
Bearing/oil seal depth plate .... 3
90890-06603

6086
2. Install:
• Oil seal
Oil seal installation position a

4.75 - 5.25 mm (0.187 - 0.207 in)
6090
3. Install:
• Ball bearing
Bearing attachment.................. 1
YB-06430 / 90890-06656
Driver rod .................................. 2
YB-06071 / 90890-06606
6091
6-15
LOWR DRIVE SHAFT (REGULAR ROTATION MODELS) E
DRIVE SHAFT (REGULAR ROTATION MODELS) 6

REMOVING/INSTALLING THE DRIVE SHAFT
6105

Propeller shaft housing assembly Refer to “PROPELLER SHAFT HOUSING
ASSEMBLY (REGULAR ROTATION
MODELS)” on page 6-9.
1 Nut 1
2 Pinion 1
4 Drive shaft housing assembly 1
5 Pinion shim *
6 Thrust bearing 1
7 Drive shaft 1
*: As required
6-16
6105

8 Forward gear assembly 1
9 O-ring 1
10 Oil seal cover 1
11 Oil seal 2
12 Needle bearing 1
13 Drive shaft housing 1
14 Tapered roller bearing 1 Not reusable
15 Bushing 1
16 Forward gear 1
procedure.
6-17
REMOVING THE DRIVE SHAFT

Loosen:
• Pinion nut
Drive shaft holder ..................... 1

YB-06201 / 90890-06520
Pinion nut holder ...................... 2
90890-06505
Pinion nut holder attachment . 3
6110 90890-06507
DISASSEMBLING THE DRIVE SHAFT

HOUSING ASSEMBLY
Remove:
• Needle bearing

YB-06196 / 90890-06610
Driver rod .................................. 2
YB-06071 / 90890-06652
6120
Å ı DISASSEMBLING THE FORWARD

GEAR ASSEMBLY
1. Remove:
• Tapered roller bearing
Bearing separator
YB-06219 / 90890-06534
6140
CAUTION:
Do not reuse the bearing, always replace it
with a new one.
2. Remove:
• Bushing

YB-06437
Driver rod .................................. 2
YB-06071
6145
6-18
INSPECTING THE PINION

Inspect:
• Teeth
INSPECTING THE DRIVE SHAFT

Inspect:
• Drive shaft

HOUSING
Inspect:
• Drive shaft housing
INSPECTING THE BEARINGS

Inspect:
• Bearings
ASSEMBLING THE FORWARD GEAR

ASSEMBLY
1. Install:
• Bushing
Bushing installation position a

2.3 - 2.7 mm (0.09 - 0.10 in)

YB-06437
Driver rod .................................. 2
6150
YB-06071
Å ı 2. Install:

YB-06276-B / 90890-06659
Driver rod .................................. 2
YB-06071

6155 ı Except for USA and Canada
6-19
Å ASSEMBLING THE DRIVE SHAFT

HOUSING ASSEMBLY
1. Install:
• Needle bearing

position a
4.25 - 4.75 mm (0.167 - 0.187 in)
6125
YB-06196 / 90890-06610
ı Driver rod .................................. 2
YB-06071 / 90890-06604
90890-06603

6126
2. Install:
• Oil seals

0.25 - 0.75 mm (0.010 - 0.030 in)
6130
INSTALLING THE DRIVE SHAFT

Tighten:
• Pinion nut
Pinion nut
145 Nm (14.5 m • kgf, 105 ft • lb)
T.
R.
NOTE:
Tighten the pinion nut with the same tools
that were used for removal.
6-20
LOWER CASE ASSEMBLY
LOWER CASE ASSEMBLY (REGULAR ROTATION MODELS) 6

DISASSEMBLING/ASSEMBLING THE LOWER CASE ASSEMBLY
6160

Forward gear Refer to “DRIVE SHAFT (REGULAR
1 Needle bearing outer case 1
2 Needle bearing 24
3 Tapered roller bearing outer race 1
4 Forward gear shim *
procedure.
*: As required
6-21
LOWER CASE ASSEMBLY
DISASSEMBLING THE LOWER CASE

ASSEMBLY
1. Remove:
• Needle bearing outer case

YB-06432 / 90890-06655
Driver rod .................................. 2
YB-06071 / 90890-06605
6313
Å 2. Remove:
• Tapered roller bearing outer race
Slide hammer............................ 1
YB-06096
Bearing puller............................ 2
90890-06523
Large universal claws............... 3
90890-06532
6170
ı
6171
INSPECTING THE NEEDLE BEARING

Inspect:
• Needle bearing
ASSEMBLING THE LOWER CASE

ASSEMBLY
1. Install:
• Tapered roller bearing outer race

YB-06432 / 90890-06658
Driver rod .................................. 2
YB-06071 / 90890-06605
6175
6-22
LOWER CASE ASSEMBLY
Å 2. Install:

YB-06432 / 90890-06655
Bearing puller............................ 2
YB-06029 / 90890-06523
plate ........................................... 3
6180 YB-06213

ı
6181
6-23
LOWR LOWER UNIT (COUNTER ROTATION MODELS) E
LOWER UNIT (COUNTER ROTATION MODELS) 6

REMOVING/INSTALLING THE LOWER UNIT
6011

1 Cotter pin 1
2 Propeller nut 1
3 Washer 1
4 Washer 1
5 Propeller 1
6 Spacer 1
7 Cap 1
6-24
6011

8 Bolt 1
9 Trim tab 1
12 Lower unit 1
13 Dowel pin 2
14 Rubber seal 1
15 Plate 1
procedure.
6-25
REMOVING THE PROPELLER

Remove:
• Propeller
WARNING
6018
turning.

Inspect:
• Blades
• Splines
INSTALLING THE PROPELLER

Install:
• Propeller
WARNING
6019
turning.
NOTE:
If the groove in the propeller nut is not
aligned with the cotter pin hole, tighten the
nut further until they are aligned.
6-26
LOWR WATER PUMP (COUNTER ROTATION MODELS) E
WATER PUMP (COUNTER ROTATION MODELS) 6

REMOVING/INSTALLING THE WATER PUMP
6020

Lower unit Refer to “LOWER UNIT (COUNTER
1 Bolt 4
2 Plate washer 4
3 Impeller housing 1
4 Impeller housing cup 1
5 Grommet 1
6 Spacer 1
7 Collar 1
6-27
6020

8 Spacer 1
9 Washer 2
10 Wave washer 1
11 Impeller 1
12 Woodruff key 1
13 Impeller plate 1
15 Dowel pin 2
procedure.
6-28
INSPECTING THE IMPELLER

HOUSING
Inspect:
• Impeller housing
INSPECTING THE IMPELLER AND

IMPELLER HOUSING CUP
Inspect:
• Impeller
• Impeller housing cup
tive parts.
INSPECTING THE WOODRUFF KEY

Inspect:
• Woodruff key
INSTALLING THE IMPELLER AND

IMPELLER HOUSING
1. Install:
• Washers 1
• Wave washer 2
• Spacer 3
• Collar 4
6025 NOTE:
• The collar and spacer should fit together
firmly.
• Install the collar with some appropriate
tool a that fits over the drive shaft as
shown.
2. Install:
• O-ring 1
• Impeller housing cup 2
• Impeller housing 3
• O-ring 4
NOTE:
• When installing the impeller housing cup,
align its projection with the hole in the
impeller housing.
• When installing the water pump housing,
turn the drive shaft clockwise.
6030
6-29
SHIFT ROD ASSEMBLY
LOWR (COUNTER ROTATION MODELS) E
SHIFT ROD ASSEMBLY (COUNTER ROTATION MODELS) 6

REMOVING/INSTALLING THE SHIFT ROD ASSEMBLY
6195

Impeller plate Refer to “WATER PUMP (COUNTER
2 Shift rod assembly 1
3 Shift rod 1
4 Spring 1
6 Oil seal 1
procedure.
6-30
SHIFT ROD ASSEMBLY
REMOVING THE SHIFT ROD

ASSEMBLY
Remove:
• Shift rod assembly
NOTE:
Remove the shift rod assembly when the
shift rod is in the neutral position.
6-31

(COUNTER ROTATION MODELS) 6
REMOVING/INSTALLING THE PROPELLER SHAFT HOUSING ASSEMBLY
6200

Gear oil Refer to “CHANGING AND INSPECTING
THE GEAR OIL” on page 3-15.
Shift rod assembly Refer to “SHIFT ROD ASSEMBLY
(COUNTER ROTATION MODELS)” on
page 6-30.
1 Bolt 2
2 Ring 1
3 Bolt 2
4 Propeller shaft housing assembly 1
5 Front propeller shaft assembly 1
6 Thrust washer 1
procedure.
6-32
6
DISASSEMBLING/ASSEMBLING THE PROPELLER SHAFT HOUSING ASSEMBLY
6205

1 O-ring 1
2 O-ring 1
3 Forward gear 1
4 Forward gear shim *
5 Ring nut 1
6 Claw washer 1
7 Tapered roller bearing outer race 1
8 Tapered roller bearing 1
9 Rear propeller shaft 1
10 Thrust bearing 1
*: As required
6-33
6205

11 Propeller shaft shim *
12 Bushing 1
13 Needle bearing 1
14 Needle bearing 1
15 Oil seal 2
16 Needle bearing 1
17 Grease nipple 1
18 Propeller shaft housing 1
procedure.
*: As required
6-34
6
DISASSEMBLING/ASSEMBLING THE FRONT PROPELLER SHAFT ASSEMBLY
6235

1 Spring 1
2 Pin 1
3 Dog clutch 1
4 Shift rod joint 1
5 Shift rod joint slider 1
6 Ball 2
7 Spring nut 1
6-35
6235

8 Shift plunger 2
9 Spring 1
10 Washer 1
11 Spring nut 1
12 Pin 1
13 Front propeller shaft 1
procedure.
6-36
REMOVING THE PROPELLER SHAFT

HOUSING ASSEMBLY
Remove:
• Propeller shaft housing assembly
Slide hammer attachment....... 1
YB-06335 / 90890-06514
Slide hammer............................ 2
YB-06096 / 90890-06531
6215
Å REMOVING THE REAR PROPELLER

SHAFT
1. Remove:
• Forward gear

YB-06219 / 90890-06534
Slide hammer............................ 2
YB-06096
6216
Guide plate................................ 3
90890-06501
ı Guide plate stand ..................... 4
90890-06538
Center bolt ................................ 5
90890-06504

6217
2. Remove:
• Ring nut
• Claw washer
Ring nut wrench

YB-06048 / 90890-06510
3. Remove:
6218
• Rear propeller shaft

YB-06207 / 90890-06502
Universal puller
YB-06117
Guide plate................................ 2
90890-06501
Center bolt ................................ 3
90890-06504
6220
6-37
Å DISASSEMBLING THE PROPELLER

SHAFT HOUSING ASSEMBLY
1. Remove:
• Needle bearing
Slide hammer............................ 1
YB-06096
Guide plate................................ 2
90890-06501
6221
90890-06538
ı Bearing puller............................ 4
90890-06535
90890-06536

6222
2. Remove:
• Oil seal
• Needle bearing

YB-06196 / 90890-06610
Driver rod .................................. 2
YB-06071 / 90890-06652
6223
Å DISASSEMBLING THE FORWARD

GEAR
Remove:
• Bushing
• Needle bearing
Slide hammer............................ 1
YB-06096
6224
Guide plate................................ 2
90890-06501
ı 90890-06538
Bearing puller............................ 4
90890-06535
90890-06536

6225
6-38
INSPECTING THE FORWARD GEAR

Inspect:
• Teeth
• Dogs
INSPECTING THE BEARING

Inspect:
• Bearing

HOUSING
Inspect:
• Propeller shaft housing
INSPECTING THE DOG CLUTCH

Inspect:
• Dog clutch

SHAFTS
Inspect:
• Propeller shafts
Å ASSEMBLING THE FORWARD GEAR

Install:
• Needle bearing
• Bushing

position a
11.8 - 12.2 mm (0.46 - 0.48 in)
6231
YB-06337 / 90890-06610
ı Driver rod .................................. 2
YB-06071 / 90890-06604
YB-06433 / 90890-06603

6232
6-39
Å ASSEMBLING THE PROPELLER

SHAFT HOUSING ASSEMBLY
1. Install:
• Needle bearing

position a
44.75 - 45.25 mm
(1.762 - 1.781 in)
6233

ı YB-06337 / 90890-06610
Driver rod .................................. 2
YB-06071 / 90890-06604
90890-06603

6234
Å 2. Install:
• Needle bearing

position a
25.05 - 25.55 mm
(0.986 - 1.006 in)

6236 YB-06196 / 90890-06610
Driver rod .................................. 2
ı YB-06071 / 90890-06604
90890-06603

6237
3. Install:
• Oil seal

4.75 - 5.25 mm (0.187 - 0.207 in)
6238
6-40
INSTALLING THE REAR PROPELLER

SHAFT
1. Install:
• Rear propeller shaft

YB-06430 / 90890-06656
6241
Driver rod .................................. 2
YB-06071 / 90890-06606
2. Install:
• Claw washer
• Ring nut
Ring nut wrench

YB-06048 / 90890-06510
Ring nut
6242 110 Nm (11 m • kgf, 80 ft • lb)
T.
R.
3. Install:
• Forward gear
6239
6-41
LOWR DRIVE SHAFT (COUNTER ROTATION MODELS) E
DRIVE SHAFT (COUNTER ROTATION MODELS) 6

REMOVING/INSTALLING THE DRIVE SHAFT
6240

Propeller shaft housing assembly Refer to “PROPELLER SHAFT HOUSING
ASSEMBLY (COUNTER ROTATION
MODELS)” on page 6-32.
1 Nut 1
2 Pinion 1
4 Drive shaft housing assembly 1
5 Pinion shim *
6 Thrust bearing 1
7 Drive shaft 1
*: As required
6-42
6240

8 Reverse gear assembly 1
9 Thrust bearing 1
10 O-ring 1
11 Oil seal cover 1
12 Oil seal 2
13 Needle bearing 1
14 Drive shaft housing 1
15 Needle bearing 2
16 Reverse gear 1
procedure.
6-43
REMOVING THE DRIVE SHAFT

Loosen:
• Pinion nut
Drive shaft holder ..................... 1

YB-06201 / 90890-06520
Pinion nut holder ...................... 2
90890-06505
Pinion nut holder attachment . 3
6110 90890-06507
DISASSEMBLING THE DRIVE SHAFT

HOUSING ASSEMBLY
Remove:
• Needle bearing

YB-06196 / 90890-06610
Driver rod .................................. 2
YB-06071 / 90890-06652
6120
Å DISASSEMBLING THE REVERSE

GEAR
1. Remove:
• Needle bearings
Slide hammer............................ 1
YB-06096
Guide plate................................ 2
90890-06501
6243
90890-06538
ı Bearing puller............................ 4
90890-06535
90890-06536

6225
6-44
INSPECTING THE PINION

Inspect:
• Teeth

Inspect:
• Drive shaft

HOUSING
Inspect:
• Drive shaft housing
INSPECTING THE BEARINGS

Inspect:
• Bearings
Å ASSEMBLING THE REVERSE GEAR

Install:
• Needle bearings

position a
20.7 - 21.2 mm (0.82 - 0.83 in)
position b
6246 4.3 - 4.7 mm (0.17 - 0.18 in)
ı Bearing/oil seal attachment .... 1

YB-06435 / 90890-06653
Driver rod .................................. 2
YB-06071 / 90890-06604
90890-06603

6247
6-45
Å ASSEMBLING THE DRIVE SHAFT

HOUSING ASSEMBLY
1. Install:
• Needle bearing

position a
4.25 - 4.75 mm (0.167 - 0.187 in)
6125
YB-06196 / 90890-06610
ı Driver rod .................................. 2
YB-06071 / 90890-06604
90890-06603

6126
2. Install:
• Oil seals

0.25 - 0.75 mm (0.010 - 0.030 in)
6130
INSTALLING THE DRIVE SHAFT

Tighten:
• Pinion nut
Pinion nut
145 Nm (14.5 m • kgf, 105 ft • lb)
T.
R.
NOTE:
Tighten the pinion nut with the same tools
that were used for removal.
6-46
LOWER CASE ASSEMBLY
LOWER CASE ASSEMBLY (COUNTER ROTATION MODELS) 6

DISASSEMBLING/ASSEMBLING THE LOWER CASE ASSEMBLY
6290

Reverse gear Refer to “DRIVE SHAFT (COUNTER
1 Needle bearing 24
2 Needle bearing outer case 1
3 Bearing retainer 1
4 Reverse gear shim *
5 Needle bearing 1
procedure.
*: As required
6-47
LOWER CASE ASSEMBLY
DISASSEMBLING THE LOWER CASE

ASSEMBLY
1. Remove:

YB-06194 / 90890-06636
Driver rod .................................. 2
YB-06071 / 90890-06605
6313
Å 2. Remove:
• Bearing retainer
YB-06117 / 90890-06521
Puller bolt .................................. 2
YB-41707
Bearing puller............................ 3
90890-06523
6411
ı
6412
3. Remove:
• Needle bearing

YB-06434 / 90890-06654
Driver rod .................................. 2
YB-06071 / 90890-06652
6413
INSPECTING THE NEEDLE BEARINGS

Inspect:
• Needle bearings
6-48
LOWR LOWER UNIT (DUAL PROPELLER MODELS) E
ASSEMBLING THE LOWER CASE

ASSEMBLY
1. Install:
• Needle bearing

YB-06434 / 90890-06654
Driver rod .................................. 2
YB-06071 / 90890-06652
6416
2. Install:
• Bearing retainer

YB-06430 / 90890-06657
Driver rod .................................. 2
YB-06071 / 90890-06605
6417
Å 3. Install:

YB-06246 / 90890-06636
Bearing puller............................ 2
YB-06029 / 90890-06523
plate ........................................... 3
6180 YB-06213

ı
6181
6-49
LOWR SHIMMING (REGULAR ROTATION MODELS) E
SHIMMING (REGULAR ROTATION MODELS) 6

NOTE:
• There is no need to select shims when
reassembling with the original case and
inner parts.
• Shim calculations are required when reas-
sembling with the original inner parts and
a new case (the difference between the
original inner parts and the new case).
• Measurements and adjustments are
required when replacing the inner part(s).
B4
T3
A3 B3
65.0
A B
F R
P
B5
T1 T2 B2
B1 39.4 41.0
A1 A2
6495
6-50
SHIMMING (REGULAR ROTATION MODELS)
LOWR (FOR USA AND CANADA) E
SELECTING THE PINION SHIMS

NOTE:
Find the shim thickness (T3) by selecting
shims until the specified value (M0) is
obtained with the special tool.
6505
1. Measure:
• Specified measurement (M)
Out of specified value (M0) → Adjust.
Specified value (M0) =

1.00 + P/100 mm
Measuring steps
6520 (1) Calculate the specified value (M0).
NOTE:
• “P” is the deviation of the lower case
dimension from standard. It is stamped
on the trim tab mounting surface of the
lower case in 0.01-mm units. If the “P”
mark is missing or unreadable, assume a
“P” value of “0”, and check the backlash
when the unit is assembled.
• If the “P” mark is negative (–), then sub-
6510
tract the “P” value from the measure-
ment.
Example:
If “P” is “+5”, then
M0 = 1.00 + (+5)/100 mm
= 1.00 + 0.05 mm
= 1.05 mm
If “P” is “–3”, then
M0 = 1.00 + (–3)/100 mm
= 1.00 – 0.03 mm
= 0.97 mm
6-51
(2) Install the pinion height gauge, drive

shaft, thrust bearing 1, and shim(s) 2.
Pinion height gauge

YB-06441
NOTE:
If the original shim(s) is unavailable, start
6515 with a 0.50-mm shim.
(3) Install the pinion and pinion nut.
Pinion nut
145 Nm (14.5 m • kgf, 105 ft • lb)
T.
R.
(4) Measure the specified measurement

(M).
NOTE:
• Measure the clearance between the pin-
ion height gauge and the lower surface of
the pinion as shown.
• Perform the same measurement at three
points on the pinion.
• Find the average of the measurements (M).
2. Adjust:
• Shim thickness (T3)
Remove or add shim(s).
Available shim thickness

0.10, 0.12, 0.15, 0.18, 0.30, 0.40
and 0.50 mm
NOTE:
(M0) – (M) should be as close to “0” as pos-
sible.
6-52
SELECTING THE FORWARD GEAR

SHIMS
NOTE:
6525
1. Measure:

0.60 – F/100 mm
Measuring steps
NOTE:
• “F” is the deviation of the lower case
lower case in 0.01-mm units. If the “F”
mark is missing or unreadable, assume an
“F” value of “0”, and check the backlash
• If the “F” mark is negative (–), then sub-
6530
tract the “F” value from the measure-
ment.
Example:
If “F” is “+5”, then
M0 = 0.60 – (+5)/100 mm
= 0.60 – 0.05 mm
= 0.55 mm
If “F” is “–3”, then
M0 = 0.60 – (–3)/100 mm
= 0.60 + 0.03 mm
= 0.63 mm
6-53
(2) Install the shimming gauge, bearing ,

and shim(s) 1.
Shimming gauge
YB-06439
NOTE:

(M).
2. Adjust:

0.10, 0.12, 0.15, 0.18, 0.30, 0.40
and 0.50 mm
NOTE:
sible.
6-54
SELECTING THE REVERSE GEAR

SHIMS
NOTE:
6545
1. Measure:

0.50 – R/100 mm
Measuring steps
NOTE:
• “R” is the deviation of the lower case
lower case in 0.01-mm units. If the “R”
“R” value of “0”, and check the backlash
• If the “R” mark is negative (–), then add
6550
the “R” value to the measurement.
Example:
If “R” is “+5”, then
M0 = 0.50 – (+5)/100 mm
= 0.50 – 0.05 mm
= 0.45 mm
If “R” is “–3”, then
M0 = 0.50 – (–3)/100 mm
= 0.50 + 0.03 mm
= 0.53 mm
6-55
(2) Install the shimming gauge, bearing,

and shim(s) 1.
Shimming gauge
YB-06439
NOTE:

(M).
2. Adjust:

0.10, 0.12, 0.15, 0.18, 0.30, 0.40
and 0.50 mm
NOTE:
sible.
6-56
LOWR (EXCEPT FOR USA AND CANADA) E

NOTE:
Select the shim thickness (T3) by using the
specified measurement(s) and the calcula-
tion formula.
Select:
6505 • Shim thickness (T3)
Selecting steps
(1) Measure (M3).
Digital caliper
90890-06704
NOTE:
Install the bearing housing 1, thrust bear-
6580 ing 2, and washer 3.
Pinion nut
145 Nm (14.5 m • kgf, 105 ft • lb)
T.
R.
(3) Install the pinion height gauge.
Pinion height gauge

90890-06702
NOTE:
After the wing nuts contact the fixing plate,
tighten them another 1/4 of a turn.
(4) Measure (M4).
Digital caliper
90890-06704
6585
NOTE:
ion height gauge and the pinion, as
shown.
• Find the average of the measurements
(M4).
6-57
(5) Calculate the pinion shim thickness

(T3).
Pinion shim thickness (T3) =

82.0 + P/100 – M3 – M4
NOTE:
6590 dimension from standard. It is stamped
• If the “P” mark is negative (–), then add
the “P” value to the measurement.
Example:
If M3 is “50.75 mm”, M4 is “30.52 mm” and
P is “-5”, then
T3 = 82.0 + (–5)/100 – 50.75 – 30.52 mm
= 82.0 – 0.05 – 50.75 – 30.52 mm
= 0.68 mm
(6) Select the pinion shim(s) (T3).

Calculated numeral
at 1/100th place Rounded
numeral
More than or less
0.00 0.02 0.00
0.02 0.05 0.02
0.05 0.08 0.05
0.08 0.10 0.08
0.10, 0.12, 0.15, 0.18, 0.30, 0.40
and 0.50 mm
6-58

SHIMS
NOTE:
tion formula.
6525 Select:
Selecting steps
(1) Measure (M1).
Shimming plate ........................ 1

90890-06701
Digital caliper ............................ 2
90890-06704
6600
NOTE:
• Turn the roller bearing outer race two or
three times so the rollers seat. Then, mea-
sure the height of the bearing, as shown.
points on the roller bearing outer race.
(M1).
(2) Calculate the forward gear shim thick-

ness (T1).
Forward gear shim thickness

(T1) = 29.5 + F/100 – M1
NOTE:
ment.
6-59
Example:
If M1 is “29.10 mm” and F is “+5”, then
T1 = 29.5 + (+5)/100 – 29.10 mm
= 29.5 + 0.05 – 29.10 mm
= 0.45 mm
(3) Select the forward gear shim(s) (T1).

Calculated numeral
numeral
More than or less
0.00 0.02 0.00
0.02 0.05 0.02
0.05 0.08 0.05
0.08 0.10 0.08
0.10, 0.12, 0.15, 0.18, 0.30, 0.40
and 0.50 mm

SHIM
NOTE:
tion formula.
6545 Select:
Selecting steps
(1) Measure (M5).
Shimming plate ........................ 1

90890-06701
Digital caliper ............................ 2
90890-06704
6620
NOTE:
(M5).
6-60
(2) Calculate the reverse gear shim thick-

ness (T2).
Reverse gear shim thickness

(T2) = 21.0 + R/100 – A/100 – M5
NOTE:
lower case in 0.01-mm units.
• If the “R” or “A” mark is missing or
unreadable, assume a “R” and “A” value
of “0”, and check the backlash when the
unit is assembled.
• If the “R” or “A” mark is negative (–), then
subtract the “R” and “A” value from the
measurement.
6625
Example:
If M5 is “19.92 mm”, R is “+3” and A is “–5”,
then
T2 = 21.0 + (+3)/100 – (–5)/100 – 19.92 mm
= 21.0 + 0.03 + 0.05 – 19.92 mm
= 1.16 mm
A–3 B
6644
(3) Select the reverse gear shim(s) (T2).

Calculated numeral
numeral
More than or less
0.00 0.02 0.02
0.02 0.05 0.05
0.05 0.08 0.08
0.08 0.10 0.10
0.10, 0.12, 0.15, 0.18, 0.30, 0.40
and 0.50 mm
6-61
LOWR BACKLASH (REGULAR ROTATION MODELS) E
BACKLASH
(REGULAR ROTATION MODELS) 6
NOTE:
• Do not install the water pump compo-
nents when measuring the backlash.
• Measure both the forward and reverse
gear backlashes.
• If both the forward and reverse gear back-
lashes are larger than specification, the
pinion may be too high.
lashes are smaller than specification, the
pinion may be too low.
MEASURING THE FORWARD GEAR

BACKLASH
1. Measure:
• Forward gear backlash
Forward gear backlash

0.19 - 0.40 mm (0.007 - 0.016 in)
Measuring steps
(1) Set the shift rod into the neutral posi-
tion.
Shift rod wrench

YB-06052 / 90890-06052
(2) Install the propeller shaft housing

puller so it pushes against the propel-
ler shaft.
6645
YB-06207 / 90890-06502
YB-06117
Guide plate................................ 3
90890-06501
Center bolt ................................ 4
90890-06504
Center bolt
6650 10 Nm (1.0 m • kgf, 7.2 ft • lb)
T.
R.
6-62
(3) Install the backlash indicator onto the

drive shaft (on the 22.4 mm (0.88 in)
diameter portion of the drive shaft).
Backlash indicator .................... 5

YB-06265 / 90890-06706
(4) Install the dial gauge onto the lower

unit and have the dial gauge plunger
6655 contact the mark on the backlash indi-
cator.
Magnetic-base plate................. 6
YB-07003 / 90890-07003
Dial gauge set ........................... 7
YU-03097 / 90890-01252
Magnetic base........................... 8
YU-34481 / 90890-06705
(5) Set the lower unit upside down.

(6) Slowly turn the drive shaft clockwise
and counterclockwise. When the drive
shaft stops in each direction, measure
the backlash.
2. Adjust:
• Forward gear shim
Forward gear
Shim thickness
backlash
Less than To be decreased by
0.19 mm (0.007 in) (0.30 – M) × 0.78
More than To be increased by
0.40 mm (0.016 in) (M – 0.30) × 0.78
M: Measurement
6-63
MEASURING THE REVERSE GEAR

BACKLASH
1. Measure:
• Reverse gear backlash
Reverse gear backlash

0.64 - 0.93 mm (0.025 - 0.037 in)
Measuring steps
tion.
Shift rod wrench

YB-06052 / 90890-06052
6645
(2) Load the reverse gear by installing the

counter rotation propeller without the
spacer 1 and then tighten the propel-
ler nut.
Propeller nut
10 Nm (1.0 m • kgf, 7.2 ft • lb)
T.
R.
6665


YB-06265 / 90890-06706

cator.
YB-07003 / 90890-07003
Dial gauge set ........................... 3
YU-03097 / 90890-01252
Magnetic base........................... 4
YU-34481 / 90890-06705
6-64

the backlash.
2. Adjust:
• Reverse gear shim
Reverse gear
Shim thickness
backlash
Less than To be increased by
0.64 mm (0.025 in) (0.79 – M) × 0.78
More than To be decreased by
0.93 mm (0.037 in) (M – 0.79) × 0.78
M: Measurement
6-65
LOWR SHIMMING (COUNTER ROTATION MODELS) E
SHIMMING (COUNTER ROTATION MODELS) 6

NOTE:
• There is no need to select shims when
reassembling with the original case and
inner parts.
• Shim calculations are required when reas-
sembling with the original inner parts and
a new case (the difference between the
original inner parts and the new case).
• Measurements and adjustments are
required when replacing the inner part(s).
B4
T3
A3 B3
65.0
A B
B8
B5
F R
P
A5
T1 T2 A4
B1 38.4 50.5 A2
A1
T4
B7
B6
6500
6-66
SHIMMING (COUNTER ROTATION MODELS)

NOTE:
shims until the specified measurement (M)
is obtained with the special tool.
6505
1. Measure:

1.00 + P/100 mm
Measuring steps
NOTE:
• If the “P” mark is negative (–), then sub-
6510
tract the “P” value from the measure-
ment.
Example:
If “P” is “+5”, then
M0 = 1.00 + (+5)/100 mm
= 1.00 + 0.05 mm
= 1.05 mm
If “P” is “–3”, then
M0 = 1.00 + (–3)/100 mm
= 1.00 – 0.03 mm
= 0.97 mm
6-67
(2) Install the pinion height gauge, drive

shaft, thrust bearing 1, and shim(s) 2.
Pinion height gauge

YB-06441
NOTE:
Pinion nut
145 Nm (14.5 m • kgf, 105 ft • lb)
T.
R.

(M).
NOTE:
ion height gauge and the lower surface of
the pinion as shown.
• Find the average of the measurements (M).
2. Adjust:

0.10, 0.12, 0.15, 0.18, 0.30, 0.40
and 0.50 mm
NOTE:
sible.
6-68

SHIMS
NOTE:
6525
1. Measure:

30.60 + F/100 mm
Measuring steps
NOTE:
6530
ment.
Example:
If “F” is “+5”, then
M0 = 30.60 + (+5)/100 mm
= 30.60 + 0.05 mm
= 30.65 mm
If “F” is “–3”, then
M0 = 30.60 + (–3)/100 mm
= 30.60 – 0.03 mm
= 30.57 mm
6-69
(2) Install the bearing retainer 1, thrust

bearing 2, and shim(s) 3.
NOTE:
with a 0.50-mm shim.

6540
(M).
2. Adjust:

0.10, 0.12, 0.15, 0.18, 0.30, 0.40
and 0.50 mm
NOTE:
sible.

SHIMS
NOTE:
6685
1. Measure:

0.60 – R/100 mm
6690
6-70
Measuring steps
(1) Calculate the specified value (M0).
NOTE:
lower case in 0.01-mm units. If the “R”
6550
“R” value of “0”, and check the backlash
• If the “R” mark is negative (–), then add
the “R” value to the measurement.
Example:
If “R” is “+5”, then
M0 = 0.60 – (+5)/100 mm
= 0.60 – 0.05 mm
= 0.55 mm
If “R” is “–3”, then
M0 = 0.60 – (–3)/100 mm
= 0.60 + 0.03 mm
= 0.63 mm
(2) Install the shimming gauge, bearing,

and shim(s) 1.
Shimming gauge
YB-06440
NOTE:

(M).
6-71
2. Adjust:

0.10, 0.12, 0.15, 0.18, 0.30, 0.40
and 0.50 mm
NOTE:
sible.
SELECTING THE PROPELLER SHAFT

SHIMS
NOTE:
6695 shims until the specified measurement is
1. Install:
• Shim(s) 1
• Thrust bearing 2
• Rear propeller shaft 3
• Tapered roller bearing 4
• Claw washer 5
• Ring nut 6
6696
2. Measure:
• Propeller shaft free play
Propeller shaft free play

0.30 ± 0.05 mm (0.012 ± 0.002 in)
Magnetic base........................... 1
YU-34481
6570
Dial gauge set ........................... 2
YU-03097
3. Adjust:

0.10, 0.12, 0.15, 0.18, 0.30, 0.40
and 0.50 mm
6-72

NOTE:
tion formula.
Select:
6505 • Shim thickness (T3)
Selecting steps
(1) Measure (M3).
Digital caliper
90890-06704
NOTE:
Install the bearing housing 1, thrust bear-
6580 ing 2, and washer 3.
Pinion nut
145 Nm (14.5 m • kgf, 105 ft • lb)
T.
R.
(3) Install the pinion height gauge.
Pinion height gauge

90890-06702
NOTE:
After the wing nuts contact the fixing plate,
tighten them another 1/4 of a turn.
(4) Measure (M4).
Digital caliper
90890-06704
6585
NOTE:
ion height gauge and the pinion, as
shown.
(M4).
6-73
(5) Calculate the pinion shim thickness

(T3).
Pinion shim thickness (T3) =

82.0 + P/100 – M3 – M4
NOTE:
• If the “P” mark is negative (–), then add
the “P” value to the measurement.
Example:
If M3 is “50.75 mm”, M4 is “30.52 mm” and
P is “–5”, then
T3 = 82.0 + (–5)/100 – 50.75 – 30.52 mm
= 82.0 – 0.05 – 50.75 – 30.52 mm
= 0.68 mm
(6) Select the pinion shim(s) (T3).

Calculated numeral
numeral
More than or less
0.00 0.02 0.00
0.02 0.05 0.02
0.05 0.08 0.05
0.08 0.10 0.08
0.10, 0.12, 0.15, 0.18, 0.30, 0.40
and 0.50 mm
6-74

SHIMS
NOTE:
tion formula.
6680 Select:
Selecting steps
(1) Measure (M1).
Digital caliper
90890-06704
NOTE:
• Measure the combined thickness of the
bearing retainer 1 and thrust bearing 2.
(M1).
6605
(2) Calculate the reverse gear shim thick-

ness (T1).
Reverse gear shim thickness

(T1) = 30.6 + F/100 – M1
NOTE:
ment.
6610
6-75
Example:
If M1 is “29.90 mm” and F is “+5”, then
T1 = 30.6 + (+5)/100 – 29.90 mm
= 30.6 + 0.05 – 29.90 mm
= 0.75 mm
(3) Select the reverse gear shim(s).

Calculated numeral
numeral
More than or less
0.00 0.02 0.00
0.02 0.05 0.02
0.05 0.08 0.05
0.08 0.10 0.08
0.10, 0.12, 0.15, 0.18, 0.30, 0.40
and 0.50 mm

SHIMS
NOTE:
tion formula.
6685 Select:
Selecting steps
(1) Measure (M5) and (M6).
Shimming plate ........................ 1

90890-06701
Digital caliper ............................ 2
90890-06704
6700
NOTE:
(M5) and (M6).
6705
6-76
(2) Calculate the forward gear shim thick-

ness (T2).
Forward gear shim thickness

(T2) = 6.50 + R/100 – A/100 – M5
+ M6
NOTE:
6625 • “R” is the deviation of the lower case
lower case in 0.01-mm units.
• If the “R” or “A” mark is missing or
unreadable, assume a “R” and “A” value
of “0”, and check the backlash when the
unit is assembled.
• If the “R” or “A” mark is negative (–), then
A–3 B
subtract the “R” and “A” value from the
6644
measurement.
Example:
If M5 is “19.90 mm”, M6 is “14.80 mm”, R
is“+7” and A is “–5”, then
T2 = 6.50 + (+7)/100 – (–5)/100 – 19.90 + 14.80 mm
= 6.50 + 0.07 + 0.05 – 19.90 + 14.80 mm
= 1.52 mm
(3) Select the forward gear shim(s) (T2).

Calculated numeral
numeral
More than or less
0.00 0.02 0.02
0.02 0.05 0.05
0.05 0.08 0.08
0.08 0.10 0.10
0.10, 0.12, 0.15, 0.18, 0.30, 0.40
and 0.50 mm
6-77
SELECTING THE PROPELLER SHAFT

SHIMS
NOTE:
shims until the specified measurement is
6695
1. Install:
• Shim(s) 1
• Thrust bearing 2
• Rear propeller shaft 3
• Tapered roller bearing 4
• Claw washer 5
• Ring nut 6
6696
2. Measure:
Propeller shaft free play

0.30 ± 0.05 mm (0.012 ± 0.002 in)
Magnetic base........................... 1
90890-06705
6570
Dial gauge set ........................... 2
90890-01252
3. Adjust:

0.10, 0.12, 0.15, 0.18, 0.30, 0.40
and 0.50 mm
6-78
LOWR BACKLASH (COUNTER ROTATION MODELS) E
BACKLASH
(COUNTER ROTATION MODELS)6
NOTE:
• Do not install the water pump compo-
nents when measuring the backlash.
• Measure both the forward and reverse
gear backlashes.
lashes are larger than specification, the
pinion may be too high.
lashes are smaller than specification, the
pinion may be too low.
MEASURING THE FORWARD GEAR

BACKLASH
1. Measure:
• Forward gear backlash
Forward gear backlash

0.32 - 0.52 mm (0.013 - 0.020 in)
Measuring steps
tion.
Shift rod wrench

YB-06052 / 90890-06052
(2) Install the propeller shaft housing

puller so it pushes against the propel-
ler shaft.
6645
YB-06207 / 90890-06502
YB-06117
Guide plate................................ 3
90890-06501
Center bolt ................................ 4
90890-06504
Center bolt
6650 10 Nm (1.0 m • kgf, 7.2 ft • lb)
T.
R.
6-79


YB-06265 / 90890-06706

cator.
YB-07003 / 90890-07003
Dial gauge set ........................... 7
YU-03097 / 90890-01252
Magnetic base........................... 8
YU-34481 / 90890-06705

the backlash.
2. Adjust:
• Forward gear shim
Forward
Shim thickness
gear backlash
Less than To be increased by
0.32 mm (0.013 in) (0.42 – M) × 0.78
More than To be decreased by
0.52 mm (0.020 in) (M – 0.42) × 0.78
M: Measurement
MEASURING THE REVERSE GEAR

BACKLASH
1. Measure:
• Reverse gear backlash
Reverse gear backlash

0.64 - 0.93 mm (0.025 - 0.037 in)
6-80
Measuring steps
tion.
Shift rod wrench

YB-06052 / 90890-06052
6645


YB-06265 / 90890-06706

cator.
YB-07003 / 90890-07003
Dial gauge set ........................... 3
YU-03097 / 90890-01252
Magnetic base........................... 4
YU-34481 / 90890-06705
(5) Turn the shift rod into the reverse posi-

tion with the shift rod wrench.
(6) Turn the drive shaft clockwise until the
clutch dog is fully engaged.
6715
(7) Turn the shift rod into the neutral posi-

(8) Turn the drive shaft counterclockwise
approximately 30˚ more.
6720
6-81
(9) Turn the shift rod into the reverse posi-

the backlash.
NOTE:
When measuring the reverse gear backlash,
6725
turn the shift rod wrench towards the
reverse position with force.
2. Adjust:
• Reverse gear shim
Reverse gear
Shim thickness
backlash
Less than To be decreased by
0.64 mm (0.025 in) (0.79 – M) × 0.78
More than To be increased by
0.93 mm (0.037 in) (M – 0.79) × 0.78
M: Measurement
6-82
BRKT E
CHAPTER 7
BRACKET UNIT
BOTTOM COWLING ....................................................................................... 7-1

REMOVING/INSTALLING THE BOTTOM COWLING ............................. 7-1
DISASSEMBLING/ASSEMBLING THE BOTTOM COWLING ................ 7-3
1
SHIFT ROD ASSEMBLY ................................................................................. 7-6
DISASSEMBLING/ASSEMBLING THE SHIFT ROD ASSEMBLY ........... 7-6
UPPER CASE ASSEMBLY.............................................................................. 7-8

REMOVING/INSTALLING THE UPPER CASE ASSEMBLY
2
(200H, 225G/V200, V225) ........................................................................ 7-8
(225F, L225F, 250B, L250B/S225, L225, S250, L250)............................. 7-9
DISASSEMBLING/ASSEMBLING THE UPPER CASE ASSEMBLY ..... 7-11 3
EXHAUST MANIFOLD ASSEMBLY............................................................. 7-14
4
DISASSEMBLING/ASSEMBLING THE EXHAUST MANIFOLD
ASSEMBLY (200H, 225G/V200, V225) ................................................. 7-14
DISASSEMBLING/ASSEMBLING THE EXHAUST MANIFOLD
ASSEMBLY (225F, L225F, 250B, L250B/S225, L225, S250, L250) ...... 7-16
STEERING ARM............................................................................................ 7-18

REMOVING/INSTALLING THE STEERING ARM .................................. 7-18
POWER TRIM AND TILT UNIT..................................................................... 7-19

REMOVING/INSTALLING THE POWER TRIM AND TILT UNIT
5
(200H, 225G/V200, V225) ...................................................................... 7-19
(225F, L225F, 250B, L250B/S225, L225, S250, L250)........................... 7-20
REMOVING THE POWER TRIM AND TILT UNIT
(200H, 225G/V200, V225) ...................................................................... 7-22
BLEEDING THE POWER TRIM AND TILT UNIT ................................... 7-22
6
CLAMP BRACKETS....................................................................................... 7-24
REMOVING/INSTALLING THE CLAMP BRACKETS
(200H, 225G/V200, V225) ...................................................................... 7-24
7
(225F, L225F, 250B, L250B/S225, L225, S250, L250)........................... 7-26
8
9
BRKT E
SWIVEL BRACKET ASSEMBLY ................................................................... 7-28

DISASSEMBLING/ASSEMBLING THE SWIVEL BRACKET
ASSEMBLY (200H, 225G/V200, V225) ................................................. 7-28
DISASSEMBLING/ASSEMBLING THE SWIVEL BRACKET
ASSEMBLY (225F, L225F, 250B, L250B/S225, L225, S250, L250) ...... 7-30
RESERVOIR AND POWER TRIM AND TILT MOTOR

(200H, 225G/V200, V225)............................................................................ 7-32
REMOVING/INSTALLING THE RESERVOIR AND
POWER TRIM AND TILT MOTOR......................................................... 7-32
INSPECTING THE RESERVOIR.............................................................. 7-33
INSPECTING THE GEAR PUMP HOUSING FILTER ............................. 7-33
INSTALLING THE POWER TRIM AND TILT MOTOR ........................... 7-34
FILLING THE RESERVOIR...................................................................... 7-35
MEASURING THE HYDRAULIC PRESSURE ........................................ 7-37
TILT RAM ASSEMBLY AND GEAR PUMP UNIT

(200H, 225G/V200, V225)............................................................................ 7-40
REMOVING/INSTALLING THE TILT RAM ASSEMBLY AND
GEAR PUMP UNIT ................................................................................ 7-40
REMOVING THE TILT RAM END SCREW ............................................ 7-42
REMOVING THE GEAR PUMP UNIT .................................................... 7-42
DISASSEMBLING THE GEAR PUMP UNIT .......................................... 7-42
INSPECTING THE TILT RAM ................................................................. 7-43
INSPECTING THE GEAR PUMP UNIT .................................................. 7-43
ASSEMBLING THE GEAR PUMP UNIT ................................................ 7-44
INSTALLING THE GEAR PUMP UNIT................................................... 7-45
INSTALLING THE TILT RAM ASSEMBLY ............................................ 7-45
TRIM RAM ASSEMBLIES AND FREE PISTON

(200H, 225G/V200, V225)............................................................................ 7-47
REMOVING/INSTALLING THE TRIM RAM ASSEMBLIES AND
FREE PISTON......................................................................................... 7-47
REMOVING THE TRIM RAM END SCREWS ........................................ 7-48
REMOVING THE FREE PISTON............................................................. 7-48
INSPECTING THE TRIM RAMS ............................................................. 7-49
INSPECTING THE FREE PISTON........................................................... 7-49
INSPECTING THE TRIM RAM CYLINDERS .......................................... 7-49
INSTALLING THE FREE PISTON........................................................... 7-49
INSTALLING THE TRIM RAMS ............................................................. 7-50
BRKT E
TILT CYLINDER, RESERVOIR AND POWER TRIM AND TILT MOTOR

(225F, L225F, 250B, L250B/S225, L225, S250, L250)................................. 7-52
REMOVING/INSTALLING THE TILT CYLINDER, RESERVOIR AND
POWER TRIM AND TILT MOTOR......................................................... 7-52
INSPECTING THE RESERVOIR.............................................................. 7-54
INSPECTING THE GEAR PUMP HOUSING FILTER ............................. 7-54
FILLING THE RESERVOIR...................................................................... 7-55
TILT RAM ASSEMBLY AND TRIM RAM ASSEMBLIES

(225F, L225F, 250B, L250B/S225, L225, S250, L250)................................. 7-57
REMOVING/INSTALLING THE TILT RAM ASSEMBLY AND
TRIM RAM ASSEMBLIES ..................................................................... 7-57
REMOVING THE TILT RAM END SCREW AND TRIM RAM
END SCREW .......................................................................................... 7-59
INSPECTING THE TILT RAM ................................................................. 7-59
INSPECTING THE FREE PISTON........................................................... 7-59
INSPECTING THE TILT RAM CYLINDER .............................................. 7-59
INSPECTING THE TRIM RAMS ............................................................. 7-60
INSPECTING THE TRIM RAM CYLINDERS .......................................... 7-60
INSTALLING TILT RAM END SCREW AND TRIM RAM
END SCREW .......................................................................................... 7-60
RELIEF VALVE (225F, L225F, 250B, L250B/S225, L225, S250, L250)........ 7-61
REMOVING/INSTALLING THE RELIEF VALVE..................................... 7-61
MAIN VALVE AND VALVE RETAINER

(225F, L225F, 250B, L250B/S225, L225, S250, L250)................................. 7-63
REMOVING/INSTALLING THE MAIN VALVE AND
VALVE RETAINER ................................................................................. 7-63
MANUAL VALVE
(225F, L225F, 250B, L250B/S225, L225, S250, L250)................................. 7-65
REMOVING/INSTALLING THE MANUAL VALVE ................................ 7-65
BRKT BOTTOM COWLING E
BOTTOM COWLING 7
REMOVING/INSTALLING THE BOTTOM COWLING
7010

1 Bolt 1
2 Holder 1
3 Bolt 1
4 Holder 1
5 Bolt 2
6 Bracket 1
7 Battery lead 2
8 Hose guide 1
9 Power trim and tilt lead 1
7-1
7010

10 Trim sensor lead 1
11 Grommet 1
12 Bolt 4
13 Ground lead 1
14 Speedometer hose 1
15 Grommet 1
16 Screw 1
17 Flushing hose 1 Salt water models
18 Bottom cowling 1
procedure.
7-2
7
DISASSEMBLING/ASSEMBLING THE BOTTOM COWLING
7030

1 Rubber seal 1
2 Collar 4
3 Grommet 4
4 Bolt 6
5 Rear lock 2
6 Front lock 1
7 Pilot water outlet 1
8 Emergency cable 1 (short)
9 Emergency cable 1 (long)
10 Bolt 1
7-3
7030

11 Cable holder 1
12 Release cable 1
13 Bolt 1
14 Actuating lever 1
15 Return spring 1
16 Release lever 1
17 Wave washer 1
18 Grommet 2
19 Bolt 1
20 Cable holder 1
7-4
7030

21 Wire harness clamp 1
22 Rubber cap 4
23 Cable guide 1
24 Bolt 1
25 Cable holder 1
26 Ground lead 1
27 Bolt 2
28 Trailer switch holder 1
29 Trailer switch 1
30 Bottom cowling 1
procedure.
7-5
BRKT SHIFT ROD ASSEMBLY E
SHIFT ROD ASSEMBLY 7

DISASSEMBLING/ASSEMBLING THE SHIFT ROD ASSEMBLY
7040

1 Bolt 2
2 Spring plate 1
3 Shift rod 1
4 Bolt 1
5 Nut 2
6 Plate 1
7 Pin 1
7-6
BRKT SHIFT ROD ASSEMBLY E
7040

8 Washer 1
9 Shift rod bracket 1
10 Collar 2
11 Grommet 1
12 Grease nipple 1
13 Clip 1
14 Shift rod lever 1
procedure.
7-7
BRKT UPPER CASE ASSEMBLY E
UPPER CASE ASSEMBLY 7

REMOVING/INSTALLING THE UPPER CASE ASSEMBLY (200H, 225G/V200, V225)
7050

Bottom cowling Refer to “BOTTOM COWLING” on
page 7-1.
1 Bolt 1
2 Ground lead 1 (upper case-to-swivel bracket)
3 Bolt 2
4 Lower mount cover 2
5 Cap nut 2
6 Self-locking nut 2
7 Upper case assembly 1
8 Rubber seal 1
procedure.
7-8
7
(225F, L225F, 250B, L250B/S225, L225, S250, L250)
7045

Bottom cowling Refer to “BOTTOM COWLING” on
page 7-1.
1 Bolt 1
2 Ground lead 1 (upper case-to-swivel bracket)
3 Bolt 1
4 Speedometer hose unit 1
7-9
7045

5 Dowel pin 1
7 Speedometer hose 1
8 Lower mount cover 2
9 Cap nut 2
11 Upper case assembly 1
procedure.
7-10
7
DISASSEMBLING/ASSEMBLING THE UPPER CASE ASSEMBLY
7060

1 Bolt 3
2 Upper mount bracket 1
3 Upper mount 2
4 Bolt 2
5 Bolt 4
6 Lower mount bracket 2
7 Lower mount 2
8 Ground lead 1
7-11
7060

9 Bolt 2
10 Bolt 2
11 Bolt 1
12 Muffler assembly 1
13 Rubber seal 1
14 Bolt 2 U transom models
15 Muffler 1 U transom models
16 Rubber seal 1 U transom models
7-12
7060

17 Rubber seal 1 U transom models
18 Upper case 1
19 Dowel pin 2
20 Circlip 1 U transom models
21 Bushing 1 U transom models
procedure.
7-13
BRKT EXHAUST MANIFOLD ASSEMBLY E
EXHAUST MANIFOLD ASSEMBLY 7

DISASSEMBLING/ASSEMBLING THE EXHAUST MANIFOLD ASSEMBLY
(200H, 225G/V200, V225)
7070

1 Bolt 5
2 Muffler 1
4 Water tube 1
5 Water seal 1
6 Bolt 4
7-14
7070

7 Exhaust manifold 1
9 Bolt 4
10 Lower exhaust manifold guide 1
12 Upper exhaust manifold guide 1
procedure.
7-15
7
DISASSEMBLING/ASSEMBLING THE EXHAUST MANIFOLD ASSEMBLY
(225F, L225F, 250B, L250B/S225, L225, S250, L250)
7065

1 Bolt 6
2 Muffler 1
3 Water tube 1
4 Water seal 1
5 Bolt 4
6 Exhaust manifold 1
7-16
7065

8 Bolt 4
9 Lower exhaust manifold guide 1
11 Upper exhaust manifold guide 1
12 Plastic locking tie 1 Not reusable Salt water models
13 Flushing hose 1 Salt water models
procedure.
7-17
BRKT STEERING ARM E
STEERING ARM 7
REMOVING/INSTALLING THE STEERING ARM
7090

Upper case assembly Refer to “UPPER CASE ASSEMBLY” on
page 7-8.
1 Circlip 1
2 Steering arm yoke 1
3 Washer 1
4 Washer 1
5 O-ring 1
6 Steering arm 1
7 Washer 1
8 Bushing 2
procedure.
7-18
BRKT POWER TRIM AND TILT UNIT E
POWER TRIM AND TILT UNIT 7

(200H, 225G/V200, V225)
7110

Tilt up the outboard
3 Ground lead 1
4 Circlip 3
5 Upper mounting pin 1
6 Lower mounting pin 1
7 Power trim and tilt unit 1
8 Collar 6
procedure.
7-19
7
(225F, L225F, 250B, L250B/S225, L225, S250, L250)
7095

page 7-8.
3 Bolt 4
4 Ground lead 1
5 Anode bracket 2
7-20
7095

6 Anode 1
7 Bolt 8
8 Circlip 1
9 Upper mounting pin 1
10 Power trim and tilt unit 1
11 Collar 2
12 Collar 2
procedure.
7-21
REMOVING THE POWER TRIM AND

TILT UNIT (200H, 225G/V200, V225)
WARNING
After tilting up the outboard, be sure to
support it with the tilt stop levers.
Otherwise, the outboard could suddenly
lower if the power trim and tilt unit should
lose fluid pressure.
NOTE:
Tilt up the outboard and then turn the tilt
stop levers 1 to support it.
Remove:
• Power trim and tilt unit
7120 NOTE:
Slightly lower the tilt ram assembly and
then remove the power trim and tilt unit.
Å BLEEDING THE POWER TRIM AND

TILT UNIT
NOTE:
Install the power trim and tilt unit onto the
outboard before bleeding.
Bleed:
7130 • Air bubbles
(from the power trim and tilt unit)
ı
Bleeding steps
(1) Connect the battery leads to the bat-
tery.
(2) Loosen the manual valve 1 by turning
it counterclockwise until it stops.
Å 200H, 225G/V200, V225
ı 225F, L225F, 250B, L250B/S225, L225, S250,
L250
7125
7-22
(3) Tilt up the outboard fully, then release

it, and let it lower by its own weight.
(4) Tighten the manual valve by turning it
clockwise.
(5) Let the power trim and tilt fluid settle
for about 5 minutes.
(6) Push and hold the trailer switch in the
up position until the outboard is fully
tilted up.
7140
(7) Turn the tilt stop levers to support the
outboard. Then, let the power trim and
Å tilt fluid settle for about 5 minutes.
(8) Remove the reservoir cap 2 and check
that fluid is up to the brim as shown.
Add fluid if the level is below the brim.
(9) Install the power trim and tilt reservoir
cap.
(10) Repeat the above steps two or three
times until the power trim and tilt fluid
is at the correct level.
7142
Å 200H, 225G/V200, V225
ı 225F, L225F, 250B, L250B/S225, L225, S250,
ı L250
7141
7-23
BRKT CLAMP BRACKETS E
CLAMP BRACKETS 7
REMOVING/INSTALLING THE CLAMP BRACKETS (200H, 225G/V200, V225)
7080

page 7-8.
Power trim and tilt unit Refer to “POWER TRIM AND TILT UNIT”
on page 7-19.
1 Rubber cap 3
2 Grease nipple 3
3 Ground lead 1
4 Bolt 4
5 Ground lead 1
6 Anode bracket 2
7 Anode 1
7-24
7080

8 Screw 2
9 Trim sensor 1
11 Bolt 2
12 Clamp bracket bolt 1
13 Washer 2
14 Starboard clamp bracket 1
15 Port clamp bracket 1
16 Bushing 2
17 Swivel bracket assembly 1
procedure.
7-25
7
(225F, L225F, 250B, L250B/S225, L225, S250, L250)
7075

on page 7-19.
1 Rubber cap 3
2 Grease nipple 3
3 Ground lead 1
4 Screw 1
6 Clamp bracket bolt 1
7 Washer 2
7-26
7075

8 Starboard clamp bracket 1
9 Port clamp bracket 1
10 Bushing 2
11 Screw 2
12 Trim sensor 1
13 Screw 4
14 Slide plate 2
15 Swivel bracket assembly 1
procedure.
7-27
BRKT SWIVEL BRACKET ASSEMBLY E
SWIVEL BRACKET ASSEMBLY 7

DISASSEMBLING/ASSEMBLING THE SWIVEL BRACKET ASSEMBLY
(200H, 225G/V200, V225)
7100

Steering arm Refer to “STEERING ARM” on page 7-18.
1 Nut 2
2 Trim stopper 2
3 Bolt 1
4 Spring holder 1
5 Spring 1
6 Pin 2
7-28
7100

7 Starboard tilt stop lever 1
8 Port tilt stop lever 1
9 Bushing 2
10 Bushing 2
11 Tilt stop lever joint assembly 1
12 Swivel bracket 1
procedure.
7-29
7
DISASSEMBLING/ASSEMBLING THE SWIVEL BRACKET ASSEMBLY
(225F, L225F, 250B, L250B/S225, L225, S250, L250)
7096

Clamp brackets Refer to “CLAMP BRACKETS” on
page 7-24.
1 Nut 2
2 Trim stopper 2
3 Bolt 1
4 Spring holder 1
5 Spring 1
6 Pin 2
7-30
7096

7 Starboard tilt stop lever 1
8 Port tilt stop lever 1
9 Bushing 2
10 Bushing 2
11 Tilt stop lever joint assembly 1
12 Swivel bracket 1
procedure.
7-31
BRKT (200H, 225G/V200, V225) E

(200H, 225G/V200, V225) 7
REMOVING/INSTALLING THE RESERVOIR AND POWER TRIM AND TILT MOTOR
7160

on page 7-19.
1 Reservoir cap 1
2 Bolt 3
3 Reservoir 1
4 Bolt 4
5 Power trim and tilt motor 1
6 O-ring 1
7 Drive pin 1
8 Gear pump housing filter 1
procedure.
7-32
BRKT (200H, 225G/V200, V225) E
WARNING
• To prevent the hydraulic fluid from spurt-
ing out due to internal pressure, the out-
board should be kept fully tilted up (the
tilt rod at full length).
• After removing the power trim and tilt
motor or reservoir, do not push the tilt
ram down. This may cause hydraulic fluid
to spurt out from the port.
CAUTION:
Do not wipe hydraulic system components
with rags, paper, tissues, or the like, as
fibers from such material will cause mal-
functions if they enter the system.
INSPECTING THE RESERVOIR

1. Drain:
• Power trim and tilt fluid
2. Inspect:
• Reservoir
INSPECTING THE GEAR PUMP

HOUSING FILTER
Inspect:
• Gear pump housing filter
7-33
BRKT (200H, 225G/V200, V225) E
INSTALLING THE POWER TRIM AND

TILT MOTOR
1. Install:
• Gear pump housing filter 1
• Drive pin 2
2. Fill:
• Gear pump housing
7170 Recommended power trim and

tilt fluid
ATF Dexron II
NOTE:
Add power trim and tilt fluid until it reaches
the top of the gear pump housing.
3. Bleed:
• Air bubbles
NOTE:
• Remove all of the air bubbles with a
syringe or suitable tool as shown.
• Turn the gear pump gears with a screw-
driver and then remove any air between
7180 the gear teeth.
4. Install:
• O-ring 1
• Power trim and tilt motor 2
• Bolt 3
NOTE:
Align the armature shaft with the recess in
the drive pin.
7190
7-34
BRKT (200H, 225G/V200, V225) E
FILLING THE RESERVOIR
WARNING
To prevent the hydraulic fluid from spurt-
ing out due to internal pressure, the tilt
ram should be kept at full length.
1. Fill:
• Reservoir

tilt fluid
ATF Dexron II
2. Inspect:
7200
BLEEDING THE POWER TRIM AND

TILT UNIT
NOTE:
This bleeding must be done before install-
ing the power trim and tilt unit onto the out-
board.
1. Bleed:
• Air bubbles
Bleeding steps
(1) Set the power trim and tilt unit upright.
(2) Connect the leads of the power trim
and tilt on the battery terminals until
the trim and tilt ram assemblies are
fully compressed.
7210
NOTE:
If the rams will not go down, refer to the fol-
lowing.
A. Connect the leads of the power trim and
tilt on the battery terminals until the trim
and tilt ram assemblies are fully
extended. Then, reverse the leads on the
battery terminals until the trim and tilt
ram assemblies are fully compressed.
7220
7-35
BRKT (200H, 225G/V200, V225) E
B. If step A was unsuccessful, connect the

leads on the battery terminals and fully
compress the tilt ram assembly by hand.
C. If step B was unsuccessful, loosen the
manual valve, compress the trim and tilt
ram assemblies fully by hand, and then
tighten the manual valve. Then, com-
press and extend the trim and tilt ram
assemblies by connecting the leads on
the battery terminals in the up and down
positions.
D. If step C was unsuccessful, disassemble,
check, and correct any problems with the
power trim and tilt unit.
(3) Connect the leads on the battery termi-

nals in the up position until the trim
extended.
7220
(4) Remove the power trim and tilt reser-

voir cap and inspect that fluid is up to
the brim as shown. Add power trim
and tilt fluid if the level is below the
brim.
times until the fluid is at the correct
level.
7230
2. Inspect:
• Power trim and tilt unit operation
Unsmooth operation → Bleed the
power trim and tilt unit again.
7-36
BRKT (200H, 225G/V200, V225) E
MEASURING THE HYDRAULIC

PRESSURE
Inspect:
• Hydraulic pressure
Out of specification → Repair.
Hydraulic pressure
(with the power trim and tilt ram
assemblies fully extended)
9.8 - 11.8 MPa
(100 - 120 kg/cm2)
assemblies fully compressed)
5.9 - 8.8 MPa (60 - 90 kg/cm2)
NOTE:
Before measuring the hydraulic pressure,
bleed the power trim and tilt unit.
Measuring steps
(1) Fully tilt up the power trim and tilt ram
assemblies.
(2) Remove the circlip 1.
(3) Remove the manual valve 2 and
install the up-relief valve attachment
and hydraulic pressure gauge and
tighten them to the specified torque.
7240
Up-relief valve attachment ...... 3
90890-06773
Hydraulic pressure gauge ........ 4
90890-06776
Hydraulic pressure gauge

9 Nm (0.9 m • kgf, 6.5 ft • lb)
T.
R.
Up-relief valve attachment

4 Nm (0.4 m • kgf, 2.9 ft • lb)
NOTE:
7250
Remove the manual valve and then quickly
attach the special tools before any fluid
comes out.
7-37
BRKT (200H, 225G/V200, V225) E

nals in the down position until the
power trim and tilt ram assemblies are
fully compressed.
7210

nals in the up position until the power
trim and tilt ram assemblies are fully
extended. Then, measure the hydraulic
pressure.
Hydraulic pressure
assemblies fully extended)
9.8 - 11.8 MPa
7220 (100 - 120 kg/cm2)
(6) After measuring the hydraulic pres-

sure, remove the special tools and
quickly attach the down-relief valve
attachment.
Hydraulic pressure gauge ........ 4

90890-06776
Down-relief valve attachment. 5
90890-06774
7260
Hydraulic pressure gauge

9 Nm (0.9 m • kgf, 6.5 ft • lb)
T.
R.
Down-relief valve attachment

4 Nm (0.4 m • kgf, 2.9 ft • lb)
(7) Remove the reservoir cap and check

that fluid is up to the brim as shown.
Add fluid if the level is below the brim.
(8) Install the reservoir cap.
7270 nals in the down position until the
fully compressed. Then, measure the
hydraulic pressure.
Hydraulic pressure
assemblies fully compressed)
5.9 - 8.8 MPa (60 - 90 kg/cm2)
7-38
BRKT (200H, 225G/V200, V225) E
(10) After measuring the hydraulic pres-

sure, connect the leads on the battery
terminals in the up position until the
fully extended.
(11) Remove the special tools.
(12) Install the manual valve and circlip.
NOTE:
7280 After measuring the hydraulic pressure,
bleed the power trim and tilt unit.
7220
7-39
BRKT (200H, 225G/V200, V225) E
TILT RAM ASSEMBLY AND GEAR PUMP UNIT (200H, 225G/V200, V225)7
REMOVING/INSTALLING THE TILT RAM ASSEMBLY AND GEAR PUMP UNIT
7290

Reservoir and power trim and tilt Refer to “RESERVOIR AND POWER TRIM
motor AND TILT MOTOR (200H, 225G/V200,
V225)” on page 7-32.
1 Manual valve 1
2 Tilt ram end screw 1
3 Tilt ram assembly 1
4 O-ring 2
5 Bolt 3
6 Gear pump unit 1
7-40
BRKT (200H, 225G/V200, V225) E
7290

7 Check valve assembly 1
8 Gear pump 1
9 Shuttle valve 2
10 Check valve 2
11 Up-relief valve assembly 1
12 Down-relief valve assembly 1
procedure.
7-41
BRKT (200H, 225G/V200, V225) E
REMOVING THE TILT RAM END

SCREW
Loosen:
• Tilt ram end screw
End screw wrench

YB-06548 / 90890-06548
7300
NOTE:
Hold the power trim and tilt unit in a vise
using aluminum plates on both sides.
REMOVING THE GEAR PUMP UNIT

Remove:
• Bolt 1
• Gear pump unit 2
• O-ring 3
7310
• Check valve 4
NOTE:
Place a container under the power trim and
tilt unit.
DISASSEMBLING THE GEAR PUMP

UNIT
1. Remove:
• Bolt 1
• Pump gear 2
• Up-relief valve assembly 3
• Ball (4.76 mm/0.187 in) 4
• Shuttle valve 5
7320
• Ball (3.18 mm/0.125 in) 6
NOTE:
When removing the pump gears, note their
original direction and position for proper
assembly.
7-42
BRKT (200H, 225G/V200, V225) E
2. Remove:
• Check valves 1 and 2
NOTE:
To remove the check valves, cover the gear
pump housing with a clean cloth and then
blow compressed air through holes a
and b.
7330
INSPECTING THE TILT RAM

Inspect:
• Tilt ram
Excessive scratches → Replace.
Bends/excessive corrosion → Replace.
Rust → Polish.
(with 400 - 600 grit sandpaper)
INSPECTING THE GEAR PUMP UNIT

Inspect:
• Shuttle valves 1
• Check valve assemblies 2
Clogs/damage/wear → Replace.
• Pump gears 3
Damage/wear → Replace the gear
pump unit.
• Down-relief valve assembly 5
Damage/wear → Replace the gear
pump unit.
• Balls 6
7335
7-43
BRKT (200H, 225G/V200, V225) E
ASSEMBLING THE GEAR PUMP UNIT
CAUTION:
Install all components in their original
direction and position for proper assembly
and operation.
1. Install:
• Balls (3.18 mm/0.125 in) 1
• Shuttle valves 2
NOTE:
Apply grease to the balls to prevent them
from falling out of the gear pump.
7340
2. Install:
• O-ring 1
• Ball (3.18 mm/0.125 in) 2
• Up-relief valve pin 3
• Spring 4
• Up-relief valve 5
7350
3. Install:
• O-rings 1
• Check valves 2
• Balls (4.76 mm/0.187 in) 3
• Pump gears 4
4. Install:
7360 • Gear pump 1
• Bolt 2
• Filter 3
• O-ring 4
• Down-relief valve 5
• Filter 6
NOTE:
Tighten the bolts evenly and make sure the
pump gears turn smoothly.
7370
7-44
BRKT (200H, 225G/V200, V225) E
INSTALLING THE GEAR PUMP UNIT

1. Install:
• O-rings 1
• Ball 2
• Pin 3
• Check valve 4
• Check valve assembly 5
7380 NOTE:
When installing the check valve assembly,
make sure the pin is on the tilt ram cylinder
side as shown.
2. Install:
7390
• Gear pump unit 1
• Bolt 2
INSTALLING THE TILT RAM

ASSEMBLY
WARNING
1. Fill:
• Tilt ram cylinder

tilt fluid
ATF Dexron II
NOTE:
7400
7-45
BRKT (200H, 225G/V200, V225) E
2. Fill:
• Gear pump housing

tilt fluid
ATF Dexron II
NOTE:
7410 Add power trim and tilt fluid through the
hole a until the fluid level is to the top of
the gear pump unit.
3. Install:
• Tilt ram assembly
NOTE:
Place the tilt ram end screw at the bottom
of the tilt ram and install the tilt ram assem-
bly into the tilt ram cylinder.
7420
4. Tighten:
End screw wrench

YB-06548 / 90890-06548
Tilt ram end screw

130 Nm (13 m • kgf, 94 ft • lb)
T.
R.
7430
7-46
BRKT (200H, 225G/V200, V225) E
TRIM RAM ASSEMBLIES AND FREE PISTON (200H, 225G/V200, V225) 7

REMOVING/INSTALLING THE TRIM RAM ASSEMBLIES AND FREE PISTON
7440

Tilt ram assembly and gear Refer to “TILT RAM ASSEMBLY AND
pump unit GEAR PUMP UNIT (200H, 225G/V200,
V225)” on page 7-40.
1 Trim ram end screw 2
2 Trim ram 2
3 O-ring 2
4 Seal ring 2
5 Free piston 1
6 O-ring 1
7 Piston ring 1
procedure.
7-47
BRKT (200H, 225G/V200, V225) E
Å ı REMOVING THE TRIM RAM END

SCREWS
Loosen:
• Trim ram end screw
End screw wrench

YB-06175-1A / 90890-06548
7450
NOTE:
REMOVING THE FREE PISTON

1. Drain:
NOTE:
After removing the trim ram assemblies,
drain the fluid from the power trim and tilt
unit.
2. Install:
• Trim ram assemblies 1
NOTE:
Finger-tighten the trim ram assemblies and
then cover the tilt cylinder openings with a
clean cloth.
3. Remove:
7460 • Free piston 2
WARNING
Never look into the tilt cylinder opening
because the free piston and hydraulic fluid
may be expelled out forcefully.
NOTE:
Remove the free piston by blowing com-
7470 pressed air through the hole a.
7-48
BRKT (200H, 225G/V200, V225) E
INSPECTING THE TRIM RAMS

Inspect:
• Trim ram
Rust → Polish.
INSPECTING THE FREE PISTON

Inspect:
• Free piston
INSPECTING THE TRIM RAM

CYLINDERS
Inspect:
• Trim ram cylinder
Cracks/excessive scratches →
Replace the power trim and tilt unit.
INSTALLING THE FREE PISTON

1. Fill:
• Fluid passages

tilt fluid
ATF Dexron II
Quantity
30 cm3 (1.0 US oz, 1.1 lmp oz)
NOTE:
• Hold the power trim and tilt unit in a vise
• Add power trim and tilt fluid through the
hole a.
7480
7-49
BRKT (200H, 225G/V200, V225) E
2. Install:
• Piston ring 1
• O-ring 2
• Free piston 3
NOTE:
Push the free piston into the tilt ram cylin-
der until it bottoms out.
7490
INSTALLING THE TRIM RAMS
WARNING
Do not push the trim rams down while
installing them into the trim ram cylinders.
Otherwise, the hydraulic fluid may spurt
out from the unit.
1. Fill:
• Trim ram cylinders

tilt fluid
ATF Dexron II
NOTE:
7500
2. Fill:
• Fluid passages

tilt fluid
ATF Dexron II
NOTE:
7510 Add power trim and tilt fluid through holes
a, b and c until all of the passages are
filled.
7-50
BRKT (200H, 225G/V200, V225) E
3. Install:
• Trim ram assemblies 1
NOTE:
Place each trim ram end screw at the bot-
tom of each trim ram and install them into
the trim ram cylinders.
7520
Å ı 4. Tighten:
End screw wrench

YB-06175-1A / 90890-06548
Trim ram end screw

80 Nm (8.0 m • kgf, 58 ft • lb)
T.
R.
7530
7-51
BRKT (225F, L225F, 250B, L250B/S225, L225, S250, L250) E

(225F, L225F, 250B, L250B/S225, L225, S250, L250) 7
REMOVING/INSTALLING THE TILT CYLINDER, RESERVOIR AND POWER TRIM
AND TILT MOTOR
7600

on page 7-19.
1 Reservoir cap 1
2 Bolt 3
3 Reservoir 1
4 O-ring 1 70.5 × 66.5 mm
5 Bolt 3
6 Power trim and tilt motor 1
7 O-ring 1 70.5 × 66.5 mm
8 Gear pump housing filter 1
7-52
7600

9 Drive pin 1
10 Screw 3
11 Gear pump 1
12 O-ring 3 8.5 × 5.5 mm
13 Delivery pipe 2
14 Circlip 1
15 Mounting pin 1
16 Tilt cylinder unit 1
17 Bushing 2
procedure.
7-53
WARNING
• To prevent the hydraulic fluid from spurt-
ing out due to internal pressure, the out-
board should be kept fully tilted up (the
tilt rod at full length).
• After removing the power trim and tilt
motor or reservoir, do not push the tilt
ram down. This may cause hydraulic fluid
to spurt out from the port.
CAUTION:
Do not wipe hydraulic system components
with rags, paper, tissues, or the like, as
fibers from such material will cause mal-
functions if they enter the system.
INSPECTING THE RESERVOIR

1. Drain:
2. Inspect:
• Reservoir
INSPECTING THE GEAR PUMP

HOUSING FILTER
Inspect:
• Gear pump housing filter
7-54
FILLING THE RESERVOIR
WARNING
1. Fill:
• Reservoir

tilt fluid
ATF Dexron II
2. Inspect:
7610
BLEEDING THE POWER TRIM AND

TILT UNIT
NOTE:
This bleeding must be done before install-
ing the power trim and tilt unit onto the out-
board.
1. Bleed:
• Air bubbles
Bleeding steps
(1) Set the power trim and tilt unit upright.
(2) Connect the leads of the power trim
and tilt on the battery terminals until
the trim and tilt ram assemblies are
fully compressed.
7620
NOTE:
If the rams will not go down, refer to the fol-
lowing.
A. Connect the leads of the power trim and
tilt on the battery terminals until the trim
extended. Then, reverse the leads on the
battery terminals until the trim and tilt
ram assemblies are fully compressed.
7630
7-55
B. If step A was unsuccessful, connect the

leads on the battery terminals and fully
compress the tilt ram assembly by hand.
C. If step B was unsuccessful, loosen the
manual valve, compress the trim and tilt
ram assemblies fully by hand, and then
tighten the manual valve. Then, com-
press and extend the trim and tilt ram
assemblies by connecting the leads on
the battery terminals in the up and down
positions.
D. If step C was unsuccessful, disassemble,
check, and correct any problems with the
power trim and tilt unit.

nals in the up position until the trim
extended.
7630
(4) Remove the power trim and tilt reser-

voir cap and inspect that fluid is up to
the brim as shown. Add power trim
and tilt fluid if the level is below the
brim.
times until the fluid is at the correct
level.
7610
2. Inspect:
• Power trim and tilt unit operation
Unsmooth operation → Bleed the
power trim and tilt unit again.
7-56

(225F, L225F, 250B, L250B/S225, L225, S250, L250) 7
REMOVING/INSTALLING THE TILT RAM ASSEMBLY AND TRIM RAM
ASSEMBLIES
7640

on page 7-19.
1 Tilt ram assembly 1
2 O-ring 1 45.7 × 38.7 mm
3 Seal ring 1
4 Free piston 1
5 O-ring 1 45.7 × 38.7 mm
6 Tilt cylinder 1
7 Trim ram end screw 2
8 O-ring 2 45.7 × 38.7 mm
7-57
7640

9 Circlip 2
10 Dust seal 2
11 Trim ram 2
12 O-ring 2 45.7 × 38.7 mm
13 Seal ring 2
14 Circlip 2
15 Damper 2
16 Spring 2
procedure.
7-58
REMOVING THE TILT RAM END

SCREW AND TRIM RAM END SCREW
Loosen:
End screw wrench

YB-06175-2B / 90890-06544
7650
End screw wrench

YB-06175-1A / 90890-06541
NOTE:

Inspect:
• Tilt ram
Rust → Polish.
INSPECTING THE FREE PISTON

Inspect:
• Free piston

CYLINDER
Inspect:
• Tilt ram cylinder
Replace.
7-59
INSPECTING THE TRIM RAMS

Inspect:
• Trim ram
Rust → Polish.
INSPECTING THE TRIM RAM

CYLINDERS
Inspect:
• Trim ram cylinder
Replace the power trim and tilt unit.
INSTALLING TILT RAM END SCREW

AND TRIM RAM END SCREW
Tighten:
End screw wrench

YB-06175-1A / 90890-06541
7650 Trim ram end screw

160 Nm (16 m • kgf, 116 ft • lb)
T.
R.
End screw wrench

YB-06175-2B / 90890-06544
Tilt ram end screw

90 Nm (9.0 m • kgf, 65 ft • lb)
T.
R.
NOTE:
7-60
RELIEF VALVE (225F, L225F, 250B, L250B/
BRKT S225, L225, S250, L250) E
RELIEF VALVE (225F, L225F, 250B, L250B/S225, L225, S250, L250) 7

REMOVING/INSTALLING THE RELIEF VALVE
7660

Reservoir Refer to “TILT CYLINDER, RESERVOIR
AND POWER TRIM AND TILT MOTOR
(225F, L225F, 250B, L250B/S225, L225,
S250, L250)” on page 7-52.
1 Screw 2
2 Trim down spring 1
3 Valve seal 1
4 Trim down plate 1
5 Trim down seat 1
6 Screw 2
7 Relief valve 1
8 Valve support pin 2
7-61
RELIEF VALVE (225F, L225F, 250B, L250B/
BRKT S225, L225, S250, L250) E
7660

9 Down relief spring 1 8.8 × 14.5 mm
10 Up relief spring 1 8.8 × 15.8 mm
11 Washer 2
12 Valve seat 2
13 Valve seal 2
14 Check ball 2 3.2 mm
15 Relief valve 1
16 O-ring 1 12.5 × 9.5 mm
17 Filter 1
procedure.
7-62
MAIN VALVE AND VALVE RETAINER (225F,
BRKT L225F, 250B, L250B/S225, L225, S250, L250) E
MAIN VALVE AND VALVE RETAINER

(225F, L225F, 250B, L250B/S225, L225, S250, L250) 7
REMOVING/INSTALLING THE MAIN VALVE AND VALVE RETAINER
7670

on page 7-19.
1 Main valve 2
2 O-ring 2 14.5 × 11.5 mm
3 O-ring 2 17.1 × 12.3 mm
4 Shuttle piston 1
5 O-ring 1 12.6 × 8.8 mm
6 Circlip 1
7-63
MAIN VALVE AND VALVE RETAINER (225F,
BRKT L225F, 250B, L250B/S225, L225, S250, L250) E
7670

7 Valve retainer 1
8 O-ring 1 9.6 × 5.8 mm
9 O-ring 1 10.6 × 6.8 mm
10 Valve seal 1
11 Spring 1 6.2 × 27 mm
12 Spring seat 1
13 Valve seal 1
procedure.
7-64
MANUAL VALVE (225F, L225F, 250B, L250B/
BRKT S225, L225, S250, L250) E
MANUAL VALVE (225F, L225F, 250B, L250B/S225, L225, S250, L250) 7

REMOVING/INSTALLING THE MANUAL VALVE
7680

on page 7-19.
1 Circlip 1
2 Manual valve 1
3 O-ring 1 22.6 × 17.8 mm
4 Circlip 1
5 Actuator pin 1
6 Spring 1 8.8 × 13 mm
7 Check ball 1 4.0 mm
8 Valve seat 1
9 O-ring 1 8.5 × 5.5 mm
procedure.
7-65
– +
ELEC E
CHAPTER 8
ELECTRICAL SYSTEMS
ELECTRICAL COMPONENTS ......................................................................... 8-1

(Port view) ................................................................................................ 8-1
(Starboard view) ...................................................................................... 8-2
(Junction box assembly)......................................................................... 8-3
1
(Aft view) .................................................................................................. 8-4
2
(Top view)................................................................................................. 8-5
WIRE HARNESS.............................................................................................. 8-6
ELECTRICAL COMPONENTS ANALYSIS.................................................... 8-10

DIGITAL CIRCUIT TESTER..................................................................... 8-10
MEASURING THE PEAK VOLTAGE ...................................................... 8-10
PEAK VOLTAGE ADAPTOR................................................................... 8-10
MEASURING A LOW RESISTANCE...................................................... 8-11
3
4
IGNITION SYSTEM....................................................................................... 8-12
INSPECTING THE IGNITION SPARK GAP............................................ 8-13
MEASURING THE IGNITION SYSTEM PEAK VOLTAGE .................... 8-14
INSPECTING THE SPARK PLUG CAPS ................................................ 8-16
IGNITION CONTROL SYSTEM .................................................................... 8-17

MEASURING THE PULSER COIL OUTPUT PEAK VOLTAGE.............. 8-18
MEASURING THE CRANK POSITION SENSOR OUTPUT PEAK
VOLTAGE............................................................................................... 8-18
MEASURING THE ENGINE COOLING WATER TEMPERATURE
5
SENSOR RESISTANCE ......................................................................... 8-18
INSPECTING THE THERMO SWITCH CONTINUITY............................ 8-19
INSPECTING THE SHIFT CUTOFF SWITCH ......................................... 8-20
INSPECTING THE KNOCKING SENSOR .............................................. 8-20
INSPECTING THE OIL LEVEL SENSOR CONTINUITY......................... 8-20
MEASURING THE THROTTLE POSITION SENSOR OUTPUT
6
VOLTAGE............................................................................................... 8-21
7
8
9
– +
ELEC E
FUEL CONTROL SYSTEM ............................................................................ 8-22

MEASURING THE PULSER COIL OUTPUT PEAK VOLTAGE.............. 8-23
MEASURING THE CRANK POSITION SENSOR OUTPUT PEAK
VOLTAGE............................................................................................... 8-23
INSPECTING THE OXYGEN DENSITY SENSOR.................................. 8-23
MEASURING THE ENGINE COOLING WATER TEMPERATURE
SENSOR RESISTANCE ......................................................................... 8-25
INSPECTING THE ATMOSPHERIC PRESSURE SENSOR.................... 8-25
INSPECTING THE INTAKE AIR TEMPERATURE SENSOR .................. 8-25
MEASURING THE THROTTLE POSITION SENSOR OUTPUT
VOLTAGE............................................................................................... 8-26
MEASURING THE HIGH-PRESSURE FUEL PUMP RESISTOR
RESISTANCE ......................................................................................... 8-26
INSPECTING THE KNOCKING SENSOR .............................................. 8-26
INSPECTING THE FUEL INJECTORS.................................................... 8-27
STARTING SYSTEM..................................................................................... 8-28

INSPECTING THE FUSES ...................................................................... 8-29
INSPECTING THE WIRE HARNESS CONTINUITY............................... 8-29
INSPECTING THE WIRE CONNECTIONS ............................................. 8-30
INSPECTING THE STARTER RELAY..................................................... 8-30
STARTER MOTOR ........................................................................................ 8-31

DISASSEMBLING/ASSEMBLING THE STARTER MOTOR.................. 8-31
REMOVING THE STARTER MOTOR PINION ....................................... 8-34
INSPECTING THE STARTER MOTOR PINION ..................................... 8-34
INSPECTING THE ARMATURE ............................................................. 8-34
MEASURING THE BRUSHES ................................................................ 8-35
CHARGING SYSTEM.................................................................................... 8-37

MEASURING THE RECTIFIER/REGULATOR OUTPUT PEAK
VOLTAGE............................................................................................... 8-38
MEASURING THE LIGHTING COIL OUTPUT PEAK VOLTAGE .......... 8-38
OIL FEED PUMP CONTROL SYSTEM ......................................................... 8-40

INSPECTING THE OIL LEVEL SENSOR/SWITCH CONTINUITY.......... 8-41
INSPECTING THE EMERGENCY SWITCH............................................ 8-42
INSPECTING THE OIL PUMP (SUB-OIL TANK) ................................... 8-42
– +
ELEC E
POWER TRIM AND TILT SYSTEM............................................................... 8-43

INSPECTING THE POWER TRIM AND TILT RELAY............................. 8-44
INSPECTING THE TRAILER SWITCH CONTINUITY ............................ 8-45
MEASURING THE TRIM SENSOR RESISTANCE................................. 8-45
INSPECTING THE THERMO SWITCH CONTINUITY
(EXCEPT FOR 200H, 225G/V200, V225) ............................................... 8-45
POWER TRIM AND TILT MOTOR (200H, 225G/V200, V225) .................... 8-46
DISASSEMBLING/ASSEMBLING THE POWER TRIM AND
TILT MOTOR.......................................................................................... 8-46
REMOVING THE STATOR ..................................................................... 8-48
REMOVING THE BRUSH ....................................................................... 8-48
INSPECTING THE BRUSH ..................................................................... 8-48
INSTALLING THE BRUSH ..................................................................... 8-50
INSTALLING THE ARMATURE ............................................................. 8-50
INSTALLING THE STATOR ................................................................... 8-50
POWER TRIM AND TILT MOTOR

(225F, L225F, 250B, L250B/S225, L225, S250, L250)................................. 8-51
DISASSEMBLING/ASSEMBLING THE POWER TRIM AND
TILT MOTOR.......................................................................................... 8-51
INSPECTING THE BRUSH ..................................................................... 8-53
– +
ELEC ELECTRICAL COMPONENTS E
ELECTRICAL COMPONENTS 8
(Port view) 8
8010
1 Fuel injector 7 Throttle position sensor coupler (3P)

2 Throttle position sensor 8 Pulser coil coupler (6P)
3 High-pressure fuel pump resistor couplers 9 Oil level sensor coupler (6P)
(2P) 0 Emergency switch connectors
4 High-pressure fuel pump connectors A High-pressure fuel pump
5 Fuel injector coupler (6P)
6 Oil level sensor
8-1
– +
(Starboard view) 8
8020
1 Engine cooling water temperature sensor

coupler (2P)
2 Crank position sensor coupler (2P)
3 Oxygen density sensor
4 Starter motor
5 Atmospheric pressure sensor
6 Intake air temperature sensor
7 Junction box assembly
8 Shift cutoff switch coupler (2P)
8-2
– +
(Junction box assembly) 8
8030
1 Lighting coil coupler (3P) Å Complete assembly

2 Fuse (80A) ı Sub-assembly
3 Power trim and tilt relay Ç To power trim and tilt motor
4 Main relay Î To wire harness
5 Oxygen density sensor coupler (2P) ‰ To battery
6 Atmospheric pressure sensor Ï To starter motor
7 Fuse (30A) Ì To fuel injector unit
8 Intake air temperature sensor Ó To CDI unit
9 Starter relay È To lighting coil
0 Rectifier/regulator Ô To oxygen density sensor
8-3
– +
(Aft view) 8
8040
1 Ignition coils 7 Knocking sensor

2 Ignition coil connectors 8 Knocking sensor connector
3 Thermo switch connectors 9 Wire harness
4 Charge coil coupler (4P) 0 CDI unit couplers (24P, 18P)
5 Oxygen density sensor coupler (2P) A Sub-wire harness
6 CDI unit
8-4
– +
(Top view) 8
8050
1 Battery leads 9 Knocking sensor

2 Remote control wire harness 0 CDI unit
3 Remote control coupler (10P) A Oil level sensor
4 Crank position sensor B Emergency switch
5 Oxygen density sensor C Trailer switch
6 Engine cooling water temperature sensor D High-pressure fuel pump
7 Thermo switches E High-pressure fuel pump resistor
8 Spark plugs
8-5
– +
ELEC WIRE HARNESS E
WIRE HARNESS 8
1 6
0
2 7
3
4 8
PON ML K JI 5 8 93
X W V U T S RQ
b a ` ] \ [ ZY
A
3
C
B D
E
G
F
1 2 3 4 8 5 6 8 7 0 9 3 3
L
Y/R L/G L/R L/W B/R Gy P L/Y O B Br B/Y W Gy R L/Y Y Lg B R Br B B
L B L/W L/R B L/G G Gy G/R L/R L/R P Y/R B/Y Y L R/Y R/Y R B B Sb B Br B B
R
L
Y
Br
W
G
P
A
Sb
Lg
R
B
Gy C
B/R
Y/R
G/R D
B Lg Sb Y
Lg R
B/Y
Sb
B/Y E B/R
L
Y B
B B
G P
O
F
8060
Connect to: B : Black W : White R/Y : Red/yellow

1 Emergency switch Br : Brown Y : Yellow Y/R : Yellow/red
2 Oil level sensor G : Green B/R : Black/red
3 Ground Gy : Gray B/Y : Black/yellow
4 CDI unit L : Blue G/R : Green/red
5 Shift cutoff switch Lg : Light green L/G : Blue/green
6 Fuse (80A) O : Orange L/R : Blue/red
7 Power trim and tilt relay P : Pink L/W : Blue/white
8 Main relay R : Red L/Y : Blue/yellow
9 Starter relay Sb : Sky blue P/B : Pink/black
8-6
– +
ELEC WIRE HARNESS E
1 6
0
2 7
3
4 8
PON ML K JI 5 8 93
X W V U T S RQ
b a ` ] \ [ ZY
A
3
C
B D
E
G
F
1 2 3 4 8 5 6 8 7 0 9 3 3
L
Y/R L/G L/R L/W B/R Gy P L/Y O B Br B/Y W Gy R L/Y Y Lg B R Br B B
L B L/W L/R B L/G G Gy G/R L/R L/R P Y/R B/Y Y L R/Y R/Y R B B Sb B Br B B
R
L
Y
Br
W
G
P
A
Sb
Lg
R
B
Gy C
B/R
Y/R
G/R D
B Lg Sb Y
Lg R
B/Y
Sb
B/Y E B/R
L
Y B
B B
G P
O
F
8060
0 Oxygen density sensor B : Black Sb : Sky blue L/Y : Blue/yellow

A Remote control Br : Brown W : White R/Y : Red/yellow
B Oil level switch (sub-oil tank) G : Green Y : Yellow Y/R : Yellow/red
C Trim sensor Gy : Gray B/R : Black/red
D Oil level meter L : Blue B/Y : Black/yellow
E Intake air temperature sensor Lg : Light green G/R : Green/red
F Atmospheric pressure sensor O : Orange L/G : Blue/green
G Trailer switch P : Pink L/R : Blue/red
R : Red L/W : Blue/white
8-7
– +
ELEC WIRE HARNESS E
8070
Connect to: B : Black W/G : White/green

1 Thermo switches G : Green W/L : White/blue
2 Ground lead O : Orange W/R : White/red
3 Pulser coil P : Pink W/Y : White/yellow
4 Throttle position sensor B/Y : Black/yellow Y/W : Yellow/white
5 CDI unit G/L : Green/blue
6 Knocking sensor G/W : Green/white
7 Crank position sensor W/B : White/black
8 Engine cooling water temperature sensor W/Br : White/brown
8-8
– +
ELEC WIRE HARNESS E
8080
Connect to: Br : Brown

1 Fuel injectors L : Blue
2 Main relay Pu/B : Purple/black
3 High-pressure fuel pump resistor Pu/G : Purple/green
4 CDI unit Pu/L : Purple/blue
5 High-pressure fuel pump Pu/R : Purple/red
Pu/W : Purple/white
Pu/Y : Purple/yellow
8-9
– +
ELEC ELECTRICAL COMPONENTS ANALYSIS E
ELECTRICAL COMPONENTS
ANALYSIS 8
DIGITAL CIRCUIT TESTER 8
Digital tester
J-39299 / 90890-06752
NOTE:
8090
“ ” indicates a continuity of electric-
ity which means a closed circuit at the
respective switch position.
MEASURING THE PEAK VOLTAGE 8

NOTE:
• When checking the condition of the igni-
tion system it is useful to know the peak
voltage.
• Cranking speed is dependant on many
factors (e.g., fouled or weak spark plugs, a
weak battery). If one of these is defective,
the peak voltage will be lower than speci-
fication.
• If the peak voltage measurement is not
within specification the engine will not
operate properly.
PEAK VOLTAGE ADAPTOR 8

NOTE:
The peak voltage adaptor should be used
with the digital circuit tester.
Peak voltage adaptor

YU-39991 / 90890-03169
8100
8-10
– +
ELEC ELECTRICAL COMPONENTS ANALYSIS E
NOTE:
• When measuring the peak voltage, set the
selector to the DC voltage mode.
• Make sure the peak voltage adaptor leads
are properly installed in the digital tester.
• Make sure the positive pin (the “+” mark
facing up as shown) on the peak voltage
8120
adaptor is installed into the positive termi-
nal of the digital tester.
• The test harness is needed for the follow-
ing tests.
Measuring steps
(1) Disconnect the coupler connections.
(2) Connect the test harness between the
couplers.
(3) Connect the peak voltage adaptor
probes to the connectors which are
being checked.
(4) Start or crank the engine and observe
the measurement.
8140
MEASURING A LOW RESISTANCE 8

When measuring a resistance of 10 Ω or
less with the digital tester, the correct mea-
surement cannot be obtained because of
the tester’s internal resistance.
To obtain the correct value, subtract the
internal resistance from the displayed mea-
surement.
Correct value
Displayed measurement –
internal resistance
NOTE:
The internal resistance of the digital tester
can be obtained by connecting both of its
probes.
8-11
– +
ELEC IGNITION SYSTEM E
IGNITION SYSTEM 8
8190
1 Charge coil B : Black B/L : Black/blue W/B : White/black

2 Pulser coil Br : Brown B/O : Black/orange W/Br : White/brown
3 CDI unit L : Blue B/R : Black/red W/G : White/green
4 Ignition coils R : Red B/W : Black/white W/L : White/blue
W : White B/Y : Black/yellow W/R : White/red
B/Br : Black/brown G/L : Green/blue W/Y : White/yellow
B/G : Black/green G/W : Green/white
8-12
– +
INSPECTING THE IGNITION SPARK

GAP 8
WARNING
• Do not touch any of the connections of
the spark gap tester lead wires.
• Do not let sparks leak out of the removed
spark plug cap.
8200
• Keep flammable gas or liquids away,
since this test can produce sparks.
Inspect:
• Ignition spark gap
Above specification → Replace the
spark plug.
Below specification → Inspect the CDI
unit output.
8210
Ignition spark gap
9 mm (0.4 in)
Inspecting steps
(1) Remove the spark plugs from the
engine.
(2) Connect a spark plug cap to the spark
gap tester.
(3) Set the spark gap length on the adjust-
ing knob.
8220
Spark gap tester
YM-34487 / 90890-06754
(4) Crank the engine and observe the

spark through the discharge window
of the spark gap tester.
8230
8240
8-13
– +
MEASURING THE IGNITION SYSTEM

PEAK VOLTAGE 8
WARNING
When checking the peak voltage do not
touch any of the connections of the digital
tester lead wires.
NOTE:
• If there is no spark or the spark is weak,
continue with the ignition system test.
• If a good spark is obtained, the problem is
not with the ignition system, but possibly
with the spark plug(s) or another compo-
nent.
1. Measure:
• CDI unit output peak voltage
ignition coil.
Below specification → Measure the
charge coil output peak voltage.
CDI unit output peak voltage

Black/white (B/W) – Black (B)
Black/green (B/G) – Black (B)
Black/brown (B/Br) – Black (B)
8250
Black/orange (B/O) – Black (B)
Black/yellow (B/Y) – Black (B)
Black/blue (B/L) – Black (B)
Circuit Loaded
r/min
Cranking 1,500 3,500
V 80 100 150 130
8-14
– +
2. Measure:
• Charge coil output peak voltage
Above specification → Measure the
pulser coil output peak voltage.
Below specification → Replace the
charge coil.
Charge coil output peak voltage

Red (R) – Brown (Br)
Black/red (B/R) – Blue (L)
Circuit Loaded
r/min
V 85 110 150 150

YB-38831 / 90890-06771
8260
3. Measure:
• Pulser coil output peak voltage
CDI unit.
pulser coil.
Pulser coil output peak voltage

White/red (W/R) – Black (B)
White/black (W/B) – Black (B)
White/yellow (W/Y) – Black (B)
White/green (W/G) – Black (B)
White/blue (W/L) – Black (B)
White/brown (W/Br) – Black (B)
Circuit Loaded
r/min
V 3.0 3.0 16 30

8270 YB-38832 / 90890-06772
8-15
– +
INSPECTING THE SPARK PLUG

CAPS 8
1. Inspect:
• Spark plug cap
Loose connection → Tighten.
Replacement steps
8280
(1) To remove the spark plug cap turn it
counterclockwise.
(2) To install the spark plug cap turn it
clockwise until it is tight.
2. Measure:
• Spark plug cap resistance
Spark plug cap resistance

4.0 - 6.0 kΩ
8290
8-16
– +
ELEC IGNITION CONTROL SYSTEM E
IGNITION CONTROL SYSTEM 8
8300
1 Pulser coil B : Black L/W : Blue/white

2 Crank position sensor G : Green L/Y : Blue/yellow
3 Engine cooling water temperature sensor O : Orange R/B : Red/black
4 Thermo switches P : Pink W/B : White/black
5 Knocking sensor R : Red W/Br : White/brown
6 Throttle position sensor B/Y : Black/yellow W/G : White/green
7 Oil level sensor G/L : Green/blue W/L : White/blue
8 CDI unit G/W : Green/white W/R : White/red
9 Shift cutoff switch L/G : Blue/green W/Y : White/yellow
L/R : Blue/red Y/R : Yellow/red
8-17
– +
MEASURING THE PULSER COIL

OUTPUT PEAK VOLTAGE 8
Refer to “MEASURING THE IGNITION
SYSTEM PEAK VOLTAGE” on
page 8-14.
MEASURING THE CRANK POSITION

SENSOR OUTPUT PEAK VOLTAGE 8
Measure:
• Crank position sensor output peak
voltage
Below specification → Replace.
Crank position sensor output

peak voltage
Green/white (G/W) –
Green/blue (G/L)
Circuit Loaded
r/min
V 6.0 0.5 3.0 4.0

YB-06767 / 90890-06767
8310
MEASURING THE ENGINE COOLING

WATER TEMPERATURE SENSOR
RESISTANCE 8
Measure:
• Engine cooling water temperature
sensor resistance
Engine cooling water

temperature sensor resistance
Black/yellow (B/Y) –
Black/yellow (B/Y)
5 ˚C (41 ˚F): 128 kΩ
20 ˚C (68 ˚F): 54 - 69 kΩ
100 ˚C (212 ˚F): 3.02 - 3.48 kΩ
8-18
– +
Measuring steps
(1) Place the engine cooling water tem-
perature sensor in a container filled
with water.
(4) Measure the resistance when the spec-
ified temperature is reached.
8320
INSPECTING THE THERMO SWITCH

CONTINUITY 8
Inspect:
• Thermo switch continuity
Thermo switch continuity

temperature
8330
Pink (P) – Black (B)
a 84 - 90 ˚C (183 - 194 ˚F)
b 60 - 74 ˚C (140 - 165 ˚F)
1 No continuity Å Temperature
2 Continuity ı Time
Measuring steps
(1) Place the thermo switch in a container
filled with water.
8340
(4) Measure the continuity when the spec-
ified temperature is reached.
8-19
– +
INSPECTING THE SHIFT CUTOFF

SWITCH 8
1. Inspect:
• Shift cutoff switch continuity
Lead color
Switch
position Blue/yellow (L/Y) –
8341 Black (B)
Home a No continuity
On b Continuity
2. Inspect:
• Shift cutoff switch
Does not return to the home position
→ Replace.
INSPECTING THE KNOCKING

SENSOR 8
Inspect:
• Knocking sensor output pulse
No pulse output → Replace.
Inspecting steps
(1) Set the digital tester to the AC voltage
8342 mode.
(2) Connect the tester leads to the knock-
ing sensor leads and the sensor body.
(3) Lightly tap the sensor and check that
several millivolts are generated.
INSPECTING THE OIL LEVEL SENSOR

CONTINUITY 8
Refer to “INSPECTING THE OIL LEVEL
SENSOR/SWITCH CONTINUITY” on
page 8-41.
8-20
– +
8360
MEASURING THE THROTTLE
POSITION SENSOR OUTPUT
VOLTAGE 8
Measure:
• Throttle position sensor output volt-
age
Out of specification → Check the CDI
unit.

voltage
Orange (O) – Pink (P)
0.48 - 5.25 V
Measuring steps
shown.

YB-06443 / 90890-06757
(2) Connect the battery leads to a 12-V

battery.
(3) Turn the engine switch to the on posi-
tion.
(4) Measure the throttle position sensor
output voltage.
NOTE:
Make sure the throttle position sensor out-
put voltage is within specification when the
throttle is fully closed and fully opened.
8-21
– +
ELEC FUEL CONTROL SYSTEM E
FUEL CONTROL SYSTEM 8
8390
1 Pulser coil 9 Main relay L : Blue Pu/G : Purple/green

2 Crank position sensor 0 High-pressure fuel O : Orange Pu/L : Purple/blue
3 Oxygen density sensor pump resistor G : Green Pu/R : Purple/red
4 Engine cooling water A High-pressure fuel P : Pink Pu/W : Purple/white
temperature sensor pump R : Red Pu/Y : Purple/yellow
5 Atmospheric pressure B Knocking sensor Y : Yellow R/Y : Red/yellow
sensor C Fuel injectors B/Y : Black/yellow W/B : White/black
6 Intake air temperature B/W : Black/white W/Br : White/brown
sensor B : Black G/L : Green/blue W/G : White/green
7 Throttle position sensor Br : Brown G/W : Green/white W/L : White/blue
8 CDI unit Gy : Gray L/Y : Blue/yellow W/R : White/red
Pu/B : Purple/black W/Y : White/yellow
8-22
– +
MEASURING THE PULSER COIL

Refer to “MEASURING THE IGNITION
SYSTEM PEAK VOLTAGE” on
page 8-14.
MEASURING THE CRANK POSITION

SENSOR OUTPUT PEAK VOLTAGE 8
Refer to “MEASURING THE CRANK
POSITION SENSOR OUTPUT PEAK
VOLTAGE” on page 8-18.
8400 INSPECTING THE OXYGEN DENSITY

SENSOR 8
1. Measure:
• Oxygen density sensor heater resis-
tance
Oxygen density sensor heater

resistance
White (W) – White (W)
100 Ω
2. Measure:
• Oxygen density sensor output voltage
Oxygen density sensor output

voltage
Gray (Gy) – Black (B)
0.0 - 1.0 V
8-23
– +
Measuring steps
WARNING
To prevent an explosion when performing
this procedure, keep all flammable prod-
ucts (e.g., gasoline) away from the testing
area and make sure there is proper ventila-
tion.
(1) Remove the oxygen density sensor.

Refer to “OXYGEN DENSITY SEN-
SOR” on page 5-26.
(2) Remove any oil from the oxygen den-
sity sensor with acetone or a similar
solvent and allow the sensor to thor-
oughly dry.
(3) Heat the front end of the oxygen den-
sity sensor 1 with a gas torch 2 (in
the center of its blue flame a) for 10 -
15 seconds. Then, remove the oxygen
density sensor from the flame and
check the voltage change and time.
1 b
CAUTION:
a • Do not heat the oxygen density sensor
above 800 ˚C (1,472 ˚F) or continuously for
more than 1 minute at a time or the sen-
sor will be damaged.
• Do not use a burner with an oxygen tank.
1 The sensor may be damaged by a flame
of high temperature.
a Inner cone
b Outer cone
NOTE:
If the instantaneous change in the output
voltage is 0.6 V or greater the oxygen den-
2
sity sensor is OK.
8405
Gy B
8-24
– +
MEASURING THE ENGINE COOLING

WATER TEMPERATURE SENSOR
RESISTANCE 8
Refer to “MEASURING THE ENGINE
COOLING WATER TEMPERATURE
SENSOR RESISTANCE” on page 8-18.
8410
INSPECTING THE ATMOSPHERIC
PRESSURE SENSOR 8
Measure:
• Atmospheric pressure sensor output
voltage
Atmospheric pressure sensor

output voltage
3.2 - 4.6 V
Measuring steps
(1) Connect the test harness between the
atmospheric pressure sensor and the
wire harness as shown.

YB-06769 / 90890-06769
(2) Turn the engine start switch to the on

position.
(3) Measure the atmospheric pressure
INSPECTING THE INTAKE AIR

TEMPERATURE SENSOR 8
Measure:
• Intake air temperature sensor output
voltage
Intake air temperature sensor

output voltage
Black/yellow (B/Y) –
Black/yellow (B/Y)
3.4 - 5.3 V at 20˚C (68˚F)
8-25
– +
Measuring steps
shown.

YB-06768 / 90890-06768
(2) Turn the engine start switch to the on

position.
(3) Measure the intake air temperature
8440
MEASURING THE THROTTLE

POSITION SENSOR OUTPUT
VOLTAGE 8
Refer to “MEASURING THE THROT-
TLE POSITION SENSOR OUTPUT
VOLTAGE” on page 8-21.
MEASURING THE HIGH-PRESSURE

FUEL PUMP RESISTOR RESISTANCE8
Inspect:
• High-pressure fuel pump resistor
resistance
High-pressure fuel pump resistor

8470 resistance
Brown (Br) – Blue (L)
0.53 - 0.57 Ω
INSPECTING THE KNOCKING

SENSOR 8
Refer to “INSPECTING THE KNOCK-
ING SENSOR” on page 8-20.
8-26
– +
INSPECTING THE FUEL INJECTORS 8

1. Inspect:
• Fuel injector operating sound
No sound (no fuel is being sprayed) →
Inspect the high-pressure fuel pump.
Inspecting steps
(1) Remove the intake silencer 1.
(3) Fully close the throttle valves.
(4) Attach the screwdriver 2 onto the fuel
injector body and check if all of the fuel
injectors have a solenoid valve operat-
ing sound.
8490
2. Inspect:
• High-pressure fuel pump operating
sound
Correct → Replace the fuel injector (no
sound).
No sound → Inspect the main relay.
NOTE:
8480 • The high-pressure fuel pump should
sound when the engine start switch is
turned on.
• Disconnect the Brown (Br) starter relay
lead 1 to prevent the engine from start-
ing.
3. Inspect:
• Main relay continuity
Correct → Replace the high-pressure
fuel pump.
8460 main relay.
Engine Lead color

start Red/yellow
switch Red (R)
(R/Y)
OFF
ON
8-27
– +
ELEC STARTING SYSTEM E
STARTING SYSTEM 8
8500
1 Battery B : Black
2 Fuse (80A) Br : Brown
3 Fuse (30A) R : Red
4 10P connector R/W : Red/white
5 Starter relay
6 Starter motor
8-28
– +

Refer to “INSPECTING THE BAT-
TERY” on page 3-17.
INSPECTING THE FUSES 8

1. Inspect:
• Fuse holder continuity
No continuity → Check the fuse holder
leads.
2. Inspect:
• Fuse holder lead continuity
No continuity → Replace the fuse
holder.
Continuity → Inspect the fuse.
3. Inspect:
• Fuse continuity
No continuity → Replace.
• Fuse rating
Fuse rating
1: 12 V - 80 A
2: 12 V - 30 A
8510
INSPECTING THE WIRE HARNESS

CONTINUITY 8
Inspect:
• Wire harness continuity
8-29
– +
INSPECTING THE WIRE

CONNECTIONS 8
Inspect:
• Wire connections
Poor connection → Properly connect.
INSPECTING THE STARTER RELAY 8

Inspect:
• Starter relay continuity
Inspecting steps
(1) Connect the tester and battery
between the starter relay terminals.
8520
Positive digital tester probe 1 →
Starter relay terminal
Negative digital tester probe 2 →
Starter relay terminal
Positive battery terminal →
Brown lead 3
Negative battery terminal →
Black lead 4
(2) Inspect that there is continuity
between the starter relay terminals.
8-30
– +
ELEC STARTER MOTOR E
STARTER MOTOR 8
DISASSEMBLING/ASSEMBLING THE STARTER MOTOR 8
8530

Starter motor Refer to “STARTER MOTOR” on
page 5-25.
1 Bolt 2
2 Starter motor bracket 1
3 Clip 2
4 Starter motor pinion stopper 1
5 Spring 1
6 Starter motor pinion 1
8-31
– +
8
8
8530

7 Bolt 2
8 Upper cover 1
9 Washer 3
10 Lower bracket 1
11 Stator 1
12 Armature 1
13 Washer 2
14 Nut 1
8-32
– +
8
8
8530

15 O-ring 1
16 Screw 2
17 Brush assembly 1
18 Spring 3
19 Brush holder 1
20 Bolt 1
21 Clamp 1
procedure.
8-33
– +
REMOVING THE STARTER MOTOR

PINION 8
Remove:
• Clips 1
NOTE:
Slide the pinion stopper 1 down as shown
and then remove the clips 2.
8540
INSPECTING THE STARTER MOTOR

PINION 8
1. Inspect:
• Starter motor pinion teeth
2. Inspect:
• Starter motor pinion movement
Incorrect → Replace.
8550
NOTE:
Rotate the starter motor pinion clockwise
and make sure it moves smoothly. Also,
rotate the starter motor pinion counter-
clockwise and make sure it locks.
INSPECTING THE ARMATURE 8

1. Inspect:
• Commutator
(with 600 grit sandpaper)
8560
2. Measure:
• Commutator diameter
Commutator diameter limit

31.0 mm (1.22 in)
8570
8-34
– +
3. Inspect:
• Commutator undercut
Dirt/foreign matter → Clean.
(with compressed air)
8580
4. Measure:
• Commutator undercut a
armature.
Commutator undercut limit

0.2 mm (0.01 in)
8590
5. Inspect:
• Armature continuity
Armature continuity
Commutator
Continuity
segments a
8600
Segment –
No continuity
Armature core b
Segment –
No continuity
Armature shaft c
MEASURING THE BRUSHES 8

1. Measure:
• Brush length a
brush assembly.
Brush length limit

12.0 mm (0.47 in)
8610
8-35
– +
2. Inspect:
• Brush assembly continuity
brush assembly.
Brush assembly continuity
Brush 1 – Brush 2 Continuity

8620
Brush 1 – Brush 3
Brush 2 – Brush 3
No continuity
Brush (1, 2, 3) –
Brush assembly holder 4
8-36
– +
ELEC CHARGING SYSTEM E
CHARGING SYSTEM 8
8630
1 Lighting coil B : Black

2 Rectifier/regulator G : Green
3 Fuses (80A) R : Red
4 Battery R/W : Red/white
8-37
– +
MEASURING THE RECTIFIER/

REGULATOR OUTPUT PEAK
VOLTAGE 8
Measure:
• Rectifier/regulator output peak voltage
Below specification → Check the light-
ing coil.
8640 Rectifier/regulator output peak
voltage
Red (R) – Black (B)
8650
Circuit Loaded
r/min
V — — 12 12

YB-06770 / 90890-06770
NOTE:
Before measuring the rectifier/regulator
output peak voltage, disconnect the lighting
coil coupler 1 and remove the fuses 2.
8660
MEASURING THE LIGHTING COIL

Measure:
• Lighting coil output peak voltage
rectifier/regulator.
lighting coil.
8670
Lighting coil output peak voltage

Green (G) – Green (G)
Circuit Loaded
r/min
V — — 14 14

YB-06770 / 90890-06770
8-38
– +

Refer to “INSPECTING THE FUSES”
on page 8-29.

8-39
– +
ELEC OIL FEED PUMP CONTROL SYSTEM E
OIL FEED PUMP CONTROL SYSTEM 8
8680
1 Fuse (80A) B : Black L/W : Blue/white

2 Fuse (30A) Br : Brown R/W : Red/white
3 10P connector L : Blue Y/R : Yellow/red
4 Oil level sensor R : Red
5 Emergency switch Y : Yellow
6 CDI unit B/R : Black/red
7 4P coupler G/R : Green/red
8 Oil level switch (sub-oil tank) L/G : Blue/green
9 Oil pump (sub-oil tank) L/R : Blue/red
8-40
– +

on page 8-29.
INSPECTING THE OIL LEVEL

SENSOR/SWITCH CONTINUITY 8
Inspect:
• Oil level sensor/switch continuity
Lead color
Float Blue/ Blue/ Blue/
position Black white green red
(B)
(L/W) (L/G) (L/R)
Å ON
Å OFF
ı ON
ı OFF
Ç ON
Ç OFF
Float distance
8690
a: 2.5 - 5.5 mm (0.10 - 0.22 in)
b: 32.5 - 35.5 mm (1.28 - 1.40 in)
c: 76 - 79 mm (2.99 - 3.11 in)
d: 150 - 153 mm (5.91 - 6.02 in)
8700
8-41
– +
INSPECTING THE EMERGENCY

SWITCH 8
1. Inspect:
• Emergency switch continuity
Switch Lead color

position Blue (L) – Black (B)
8710
Home a No continuity
On b Continuity
2. Inspect:
• Emergency switch
Does not automatically return to the
home position → Replace.
INSPECTING THE OIL PUMP

(SUB-OIL TANK) 8
Inspect:
• Oil pump (sub-oil tank)
Incorrect operation → Replace.
NOTE:
Connect the oil pump leads to a 12-V bat-
8720 tery and make sure the oil pump operates
properly.
Blue (L) lead → Positive battery terminal

Brown (Br) lead →
Negative battery terminal
8-42
– +
ELEC POWER TRIM AND TILT SYSTEM E
POWER TRIM AND TILT SYSTEM 8
8730
1 Battery 9 Thermo switch B : Black

2 Fuse (80A) (except for 200H, 225G/V200, Gy : Gray
3 Fuse (30A) V225) Lg : Light green
4 Trailer switch 0 Trim sensor O : Orange
5 10P connector P : Pink
6 Power trim and tilt relay Å To remote control R : Red
7 Terminal ı To trim meter Sb : Sky blue
(for 200H, 225G/V200, V225) R/W : Red/white
8 Power trim and tilt motor P/B : Pink/black
8-43
– +

on page 8-29.

INSPECTING THE POWER TRIM AND

TILT RELAY 8
1. Inspect:
• Power trim and tilt relay continuity
Power trim and tilt relay

continuity
8740
Sky blue (Sb) – Black (B)
Continuity
Light green (Lg) – Black (B)
Terminal 1 – Terminal -
Continuity
Terminal 2 – Terminal -
Terminal 1 – Terminal +
No continuity
Terminal 2 – Terminal +
2. Inspect:
• Power trim and tilt relay operation
8750
Inspecting steps
(1) Connect the digital tester between
power trim and tilt relay terminals 1
and +.
(2) Connect a 12-V battery as shown.
Light green (Lg) lead → Positive terminal
Black (B) lead → Negative terminal
(3) Check that there is continuity between
the power trim and tilt relay terminals.
8760
(4) Connect the digital tester between
power trim and tilt relay terminals +
and 2.
(5) Connect a 12-V battery as shown.
Sky blue (Sb) lead → Positive terminal
Black (B) lead → Negative terminal
(6) Check that there is continuity between
the power trim and tilt relay terminals.
8770
8-44
– +
INSPECTING THE TRAILER SWITCH

CONTINUITY 8
Inspect:
• Trailer switch continuity
Lead color
Switch Light
8780 position Sky blue Red (R) green
(Sb)
(Lg)
Up
Free
Down
MEASURING THE TRIM SENSOR

RESISTANCE 8
Measure:
• Trim sensor resistance
Trim sensor resistance

8790
225F, L225F, 250B, L250B/
S225, L225, S250, L250:
494 - 742 Ω at 20 ˚C (68 ˚F)
200H, 225G/V200, V225:
582 - 873 Ω at 20 ˚C (68 ˚F)
Orange (O) – Black (B)
800 - 1,200 Ω at 20 ˚C (68 ˚F)
NOTE:
Turn the lever 1 and measure the resis-
tance as it gradually changes.
INSPECTING THE THERMO SWITCH

CONTINUITY (EXCEPT FOR 200H,
225G/V200, V225) 8
Refer to “INSPECTING THE THERMO
SWITCH CONTINUITY” on page 8-19.
8-45
– +
ELEC (200H, 225G/V200, V225) E
POWER TRIM AND TILT MOTOR (200H, 225G/V200, V225) 8

DISASSEMBLING/ASSEMBLING THE POWER TRIM AND TILT MOTOR 8
8860

Power trim and tilt motor Refer to “RESERVOIR AND POWER TRIM
AND TILT MOTOR (200H, 225G/V200,
V225)” on page 7-32.
1 Screw 1
2 Lead holder 1
3 Screw 2
4 Stator 1
5 Armature 1
6 O-ring 1
7 Screw 2
8-46
– +
ELEC (200H, 225G/V200, V225) E
8
8
8860

8 Brush holder 2
9 Brush 2
10 Spring 2
11 Lower cover 1
12 Oil seal 1
13 Bearing 1
procedure.
8-47
– +
ELEC (200H, 225G/V200, V225) E
REMOVING THE STATOR 8

Remove:
• Stator 1
CAUTION:
• Keep the power trim and tilt motor leads
inside the stator.
• Do not allow grease or oil to contact the
8870
commutator.
NOTE:
• Remove the lead holder 2 and rubber
spacer 3 from the stator and slide them
towards the leads.
• Hold the end of the armature shaft with a
clean cloth and pull off the stator.
REMOVING THE BRUSH 8

1. Remove:
• Sky blue power trim and tilt motor
lead 1
NOTE:
Hold the brush with a screwdriver as
shown. Then, disconnect the sky blue lead.
8880
2. Remove:
• Brush holders 1
• Brushes 2
CAUTION:
Do not touch the bimetal a; touching it
may affect the operation of the breaker.
8890
INSPECTING THE BRUSH 8

1. Measure:
• Brush length a
Brush length
4.8 mm (0.19 in)
8810
8-48
– +
ELEC (200H, 225G/V200, V225) E
2. Inspect:
• Brush continuity
CAUTION:
Do not touch the bimetal a; touching it
may affect the operation of the breaker.
8900

1. Measure:
• Commutator diameter a

21.0 mm (0.83 in)
8820
2. Measure:
• Commutator undercut a
armature.
Commutator undercut limit

0.85 mm (0.03 in)
8830
3. Inspect:
Armature continuity
Commutator segments Continuity

Segment-laminations No continuity
8840
Segment-shaft No continuity
8850
8-49
– +
ELEC (200H, 225G/V200, V225) E
INSTALLING THE BRUSH 8

Install:
• Brushes 1
• Brush holders 2
• Power trim and tilt motor leads 3
• Screw 4
CAUTION:
8910
Do not touch the bimetal; touching it may
affect the operation of the breaker.
INSTALLING THE ARMATURE 8

Install:
• Armature 1
NOTE:
Push the brushes into the holder and then
install the armature.
8920
INSTALLING THE STATOR 8

Install:
• Stator 1
NOTE:
Place a clean cloth over the end of the
armature shaft and carefully push the arma-
ture into the stator with a pair of pliers as
8930 shown.
8-50
– +
ELEC (225F, L225F, 250B, L250B/S225, L225, S250, L250) E

(225F, L225F, 250B, L250B/S225, L225, S250, L250) 8
DISASSEMBLING/ASSEMBLING THE POWER TRIM AND TILT MOTOR 8
8800

Power trim and tilt motor Refer to “TILT CYLINDER, RESERVOIR
AND POWER TRIM AND TILT MOTOR
(225F, L225F, 250B, L250B/S225, L225,
S250, L250)” on page 7-52.
1 Screw 2
2 Lead holder 1
3 Bolt 2
4 Lower cover 1
5 Oil seal 1
6 Bearing 1
8-51
– +
8
8
8800

7 Stator 1
8 O-ring 2 75.2 × 72.0 mm
9 Armature 1
10 Wave washer 1
11 Bearing 1
12 Brush 4
13 Spring 4
14 Brush holder 1
15 Upper cover 1
procedure.
8-52
– +
INSPECTING THE BRUSH 8

1. Measure:
• Brush length a
Brush length
4.0 mm (0.16 in)
8810

1. Measure:
• Commutator diameter a

24.0 mm (0.95 in)
8820
2. Inspect:
Armature continuity
Commutator segments Continuity

Segment-laminations No continuity
8840
Segment-shaft No continuity
8850
8-53
TRBL
ANLS E
CHAPTER 9
TROUBLE ANALYSIS
TROUBLE ANALYSIS ..................................................................................... 9-1

TROUBLE ANALYSIS CHART ................................................................. 9-1 1
SELF-DIAGNOSIS ........................................................................................... 9-4
DIAGNOSIS CODE INDICATION ............................................................. 9-4
DIAGNOSIS THE ELECTRONIC CONTROL SYSTEM ............................ 9-4
TROUBLE SHOOTING FOR ELECTRIC FUEL INJECTION............................ 9-6

2
3
4
5
6
7
8
9
TRBL
ANLS TROUBLE ANALYSIS E
TROUBLE ANALYSIS 9
NOTE:
The following items should be checked before the “TROUBLE ANALYSIS CHART” is con-
sulted.
1. The battery is charged and its specified gravity is within specification.
2. There are no incorrect wiring connections.
3. Wiring connections are properly secured and are not rusty.
4. The lanyard is installed onto the engine stop switch.
5. The shift position is in neutral.
6. Fuel is reaching the carburetor/vapor separator.
7. The rigging and engine setting are correct.
8. The engine is free from any “Hull problem”.
TROUBLE ANALYSIS CHART 9

Trouble mode Check elements
IRREGULAR WARNING INDICATION
TILT MOTOR WILL NOT RUN
POOR BATTERY CHARGING

ENGINE WILL NOT START
ENGINE WILL NOT STOP
LIMITED ENGINE SPEED

POOR ACCELERATION
POOR PERFORMANCE
LOOSE TILT HOLDING
Reference
Relative part
LOOSE STEERING
HARD STARTING
chapter
ENGINE STALLS
HARD SHIFTING
ROUGH IDLING
OVERHEATING
HIGH IDLING
FUEL SYSTEM
Low-pressure fuel line
• Fuel line 3
• Fuel filter 3
• Fuel pump 4
High-pressure fuel line
• Vapor separator 4
• High-pressure fuel
4
pump
• High-pressure fuel line 3
• Fuel injectors 4
Link adjustment 3
POWER UNIT
Compression 3
Reed valves 5
Cylinder head gaskets 5
Seal 5
Cylinder block 5
Crankcase 5
9-1
TRBL



POOR ACCELERATION
POOR PERFORMANCE
LOOSE TILT HOLDING

Reference
Relative part
LOOSE STEERING
HARD STARTING
chapter
ENGINE STALLS
HARD SHIFTING
ROUGH IDLING
OVERHEATING
HIGH IDLING
Piston rings 5
Pistons 5
Bearings 5
Thermostat 5
Water passages 5
LOWER UNIT
Neutral position 6
Dog clutch 6
Gears 6
Water inlets 6
Water pump 6
Propeller shaft(s) 6
Shift rod joint/pin 6
Shift cam 6
Shift shaft 6
Lower case 6
BRACKET UNIT
Bracket 7
Rubber mount 7
Shift rod 7
POWER TRIM AND TILT UNIT
Fluid level 3
Relief valve 7
Fluid passages —
Power trim and tilt motor 7
ELECTRICAL
Ignition system
• Charge coil 8
• Pulser coils 8
• CDI unit 8
• Ignition coils 8
• Spark plugs 3
Ignition/fuel control system
• Lanyard switch —
9-2
TRBL



POOR ACCELERATION
POOR PERFORMANCE
LOOSE TILT HOLDING

Reference
Relative part
LOOSE STEERING
HARD STARTING
chapter
ENGINE STALLS
HARD SHIFTING
ROUGH IDLING
OVERHEATING
HIGH IDLING
• Main relay 8
• High-pressure fuel
8
pump resistor
• Crank position sensor 8
• Atmospheric pressure
8
sensor
• Intake air temperature
8
sensor
• Oxygen density sensor 8
• Engine cooling water
8
temperature sensor
• Throttle position sensor 8
• Thermo switch 8
• Shift cutoff switch 8
• Knocking sensor 8
Starting system
• Engine start switch —
• Neutral switch 8
• Starter relay 8
• Starter motor 8
Charging system
• Lighting coil 8
• Rectifier/regulator 8
• Fuses 8
• Battery leads —
• Battery —
Oil feed pump control system
• Oil level sensor
8
(engine oil tank)
• Oil level switch
8
(sub-oil tank)
Power trim and tilt system
• Trailer switch 8
• Power trim and tilt relay 8
• Trim sensor 8
9-3
TRBL
ANLS SELF-DIAGNOSIS E
SELF-DIAGNOSIS 9
DIAGNOSIS CODE INDICATION 9
1. Normal condition
(no defective part or irregular process-
ing is found)
2. Single flash is given every 5 seconds.
a : Light on, 0.3 second
b : Light off, 5 seconds
9010
3. Trouble code indication

Example: The illustration indicates code
number 23.
a : Light on, 0.3 second
b : Light off, 0.3 second
c : Light off, 1.7 seconds
d : Light off, 5 seconds
9020
DIAGNOSIS THE ELECTRONIC

CONTROL SYSTEM 9
1. Install:
• Diagnostic indicator
Diagnostic indicator
YB-06765 / 90890-06765
9030
NOTE:
When performing this diagnosis, all of the
electrical wires must be properly con-
nected.
2. Inspect:
• Diagnosis code
Code 1 is indicated → Normal.
Code 13 - 31 indicated → Check the
applicable parts.
Code 32 - 44 indicated → Replace the
CDI unit.
9-4
TRBL
ANLS SELF-DIAGNOSIS E
Inspecting steps
(1) Start the engine and let it idle.
(2) Check the diagnostic indicator’s flash
pattern to determine if there are any
malfunctions.
NOTE:
When more than one problem is detected,
the diagnostic tester’s light flashes in the
pattern of the lowest numbered problem.
After that problem is corrected, the light
flashes in the pattern of the next lowest
numbered problem. This continues until all
of the problems are detected and corrected.
Diagnosis code chart 8

Code Symptoms
9040 13 Incorrect pulser coil input signal
14 No crank position sensor input signal
Incorrect engine cooling water tem-
15
perature sensor input signal
Incorrect knocking sensor input sig-
17
nal
Incorrect throttle position sensor
18
input signal
Incorrect atmospheric pressure sen-
22 sor input signal (out of normal oper-
ating range)
Incorrect intake air temperature sen-
23
sor input signal
31 No tachometer pulse being output
32 ~ Microcomputer processing informa-
44 tion
Shift cutoff control (during ignition
(32)
cutoff operation)
Ignition timing is being slightly cor-
(33)
rected (when starting a cold engine)
Fuel injection period is being slightly
(35)
corrected (when knocking control)
Ignition timing is being slightly cor-
(36)
rected (when knocking control)
Overrevolution control (during igni-
(41)
tion cutoff operation)
(42) Overheat control/oil empty control
(43) Buzzer sounding
(44) Engine stop switch control operating
9-5
TRBL TROUBLE SHOOTING FOR ELECTRIC FUEL
ANLS INJECTION E
TROUBLE SHOOTING FOR ELECTRIC FUEL INJECTION 9

Items Symptoms
1. Poor starting/ 1. No firing. The starter motor cranks the engine, but no firing is
Engine will generated in the cylinder.
not start 2. The firing is generated in the cylinder, but the engine soon stops.
3. Start-up time is too long. The engine will not start-up easily.
1. Inspect the high-pressure fuel lines.
1) Inspect for fuel

line leaks
2) Inspect the fuel Fuel pressure is 1 Inspect the 30-A fuse

pressure out of specification
2 Inspect the high-pres-
sure fuel pump opera-
3) Inspect the
tion
operation of the
fuel injector 3 Inspect the main relay
4) Inspect the 4 Inspect the main relay

diagnosis cord drive’s ECU output
5 Inspect the pressure

regulator
2. Inspect the ignition system.
1) Inspect the wire harness
2) Inspect the ignition spark
3) Inspect the ignition coil
4) Inspect the CDI unit output

peak voltage
5) Inspect the charge coil output

peak voltage
6) Inspect the pulser coil output

peak voltage
9-6
ANLS INJECTION E
Items Symptoms
2. Erratic idling 1. The engine speed is not constant when idling.
speed 2. The engine stalls when the throttle lever is pulled back.
3. The engine stalls when the throttle lever is opened or during
outboard operation.
1) Inspect for fuel

line leaks

3) Inspect the
tion
operation of the


5) Inspect the oxygen regulator
density sensor

peak voltage

peak voltage

peak voltage
3. Inspect the ignition timing.

1) Inspect the diagnosis 1 Inspect the pulser coil
cords diagnosis cord
2 Inspect the crank position

sensor diagnosis cord
3 Inspect the engine cool-

ing water temperature
9-7
ANLS INJECTION E
Items Symptoms
3. Erratic 1. The engine is started, but will not run smoothly. The engine speed
engine speed drops during acceleration.
1) Inspect for fuel

line leaks

3) Inspect the
tion
operation of the


5) Inspect the oxygen regulator
density sensor

peak voltage

peak voltage

peak voltage
3. Inspect the ignition timing.

1) Inspect the diagnosis 1 Inspect the pulser coil
cords diagnosis cord
2 Inspect the crank position

3 Inspect the engine cool-

ing water temperature
9-8
200HETO, 225FETO, L225FETO, 225GETO, 250BETO, L250BETO/
WIRING DIAGRAM
COLOR CODE
B : Black B/L : Black/blue Pu/L : Purple/blue
V200TR, S225TR, L225TR, V225TR, S250TR, L250TR Br : Brown B/O : Black/orange Pu/R : Purple/red
G : Green B/R : Black/red Pu/W: Purple/white
Gy : Gray B/W : Black/white Pu/Y : Purple/yellow
L : Blue B/Y : Black/yellow R/W : Red/white
Lg : Light green G/L : Green/blue R/Y : Red/yellow
O : Orange G/R : Green/red W/B : White/black
P : Pink G/W : Green/white W/Br : White/brown
R : Red L/G : Blue/green W/G : White/green
Sb : Sky blue L/R : Blue/red W/L : White/blue
G Oxygen density W : White L/W : Blue/white W/R : White/red
1 Fuel injectors 2 Throttle position
B/W Gy B sensor Y : Yellow L/Y : Blue/yellow W/Y : White/yellow
P R
P
#2 #1
sensor B B/Br : Black/brown Pu/B : Purple/black Y/R : Yellow/red
Gy
Pu/R R B/G : Black/green Pu/G : Purple/green Y/W : Yellow/white
R/Y w
P w
O
Pu/Y Pu/B Pu/R Pu/B Pu/Y B R W M Thermo switch
O B O
Pu/B R/Y Pu/R K Terminal (except for
Pu/B
Pu/Y
(for 200H, 225G/ L Power trim 200H, 225G/
R/Y
V200, V225) and tilt motor V200, V225)
N
W/Y W/B W/R W/B W/Y
#4 #3 Pu/W Pu/L Pu/G Pu/L Pu/W C Pulser coil B R
Sb Sb M
W/R
E Lighting
Pu/Y G S
R/Y W/B coil Lg
B
W/Y
W/G B
G B
W/L
R/Y G B
W/Br
Pu/G Pu/G W/Br W/L W/G W/L W/Br G Sb Lg
B
R/Y R/Y Br R/Y
R B/R
B/R G G G B
Pu/L R
#6 #5 B/R F Crank position
Br B Lg N Fuse(80A) N Fuse(80A)
Pu/L sensor
L B
R/Y
L R/Y L Br L D Charge coil
B Lg
P G/L G/W J Sb
R/Y B
Pu/W Pu/W
Power trim Sb Lg
P P P P R R
R/Y R/Y and tilt relay
R/W
B B B B R
R/W
R/W R
= = R/W
3 High-pressure Thermo B Ignition coil B Ignition coil Thermo R
switch R
fuel pump switch B/W B/W B/O B/W G/L G/W
resistor
L Br R
Br 2 1 O Fuse(30A)
H Rectifier/ B R
A B/G B/Y A R R
R
Spark Spark regulator
B Ignition coil 9 CDI unit B Ignition coil
Br plug plug
R/Y B/W B/W
R R
I Engine Q Battery lead
4
B 3 cooling water terminal
B/L B
L
A A temperature B/Y B/Y
B B
L Spark Spark sensor
R
plug B Ignition coil B Ignition coil plug

W/Br W/G W/B Br L/R Y L R/Y R B
B/W B/Br B/W
W/L W/Y W/R B/Y W Gy Br Br R Battery
N Br B
L Sb Br B N
R
M
R
6
G/L L/R
5 B/Y Lg R Br M R Battery
S
A A P Starter relay
L/Y S
4 High-pressure Spark Spark R/Y

B Y/R
plug
R/Y S Starter motor
fuel pump plug R/Y
R/Y R/Y
P R
B G/W O L/G B/R O B R R
Y/W B/Y G L/W Gy Gy P B G/R R/Y
B
B Y Y B
G
Y/W T Main relay
B
Y
B
R/Y
B B
5 Trailer Lg Sb Lg R/Y
R
switch
B L/Y B
Sb R
Sb
U Shift cutoff switch L
R
Lg 7 Knocking sensor L/W L/R P O B/Y G/R B/R Y R/Y G L/Y G R Y
Lg Lg Sb R Sb Br B
L/G L/R B B/Y Gy Y/R L Br W P L/Y Lg Sb R/Y Lg R Br Y P
R R Sb
G G B Sb
L/G L/W Y/R L/W L/G Lg
P W
Y/R G
L/W W
L/G Sb R
Lg
L/R B B B Å To remote
L/R L Y Y Y Y
B B/R
control
Y/R
B L/R B Y Oil pump
LB Lg
6 Oil level B/Y L (sub-oil tank)
B B/R L B Br
sensor L
O
G/R Y/R Y B/R Y B
Br Br
Gy Gy N
Br B Br
B O B Y B L L M
Y Y/R
L L S @
O
B B P B
B
P B/R
8 Emergency switch B
W Intake air X Trim sensor P Gy B/R G/R L B/R L B/R L
Z Oil level switch
VAtmospheric temperature
ı To trim Ç To oil level (sub-oil tank)
pressure sensor sensor
meter meter
YAMAHA MOTOR CO., LTD.
Printed in USA
Nov. 1998 – ?.? × 1 CR
(200HETO, 225FETO, L225FETO, 225GETO, 250BETO, L250BETO)
Printed on recycled paper

Yamaha 225G, 250B, L250B Service Manual (En)

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Yamaha 225G, 250B, L250B Service Manual (En)

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225G, 250B,

225G, 250B, L250B

HOW TO USE THIS MANUAL

Model name 200HETO 225FETO L225FETO 225GETO 250BETO L250BETO

Indication 200HETO 225FETO L225FETO 225GETO 250BETO L250BETO

HOW TO USE THIS MANUAL

E F Symbol F to H in an exploded diagram

I J Symbols I to N in an exploded diagram

K L I Apply Gasket Maker

SPECIAL TOOLS ............................................................................................. 1-5

STARTING SERIAL NUMBERS

SAFETY WHILE WORKING 1

OILS, GREASES AND SEALING

Under normal conditions of use, there

GOOD WORKING PRACTICES

DISASSEMBLY AND ASSEMBLY

3. After assembly, check that moving parts

4. Install bearings with the manufacturer’s

A Hydraulic pressure gauge

REMOVING AND INSTALLING

P Slide hammer attachment

GENERAL SPECIFICATIONS .......................................................................... 2-1

MAINTENANCE SPECIFICATIONS................................................................ 2-3

TIGHTENING TORQUES .............................................................................. 2-11

Engine oil type 2-stroke outboard engine oil

Propeller mark M T/M TL/ML M T/M TL/ML

* PON: Pump Octane Number

Warpage limit b mm (in) 0.2 (0.008)

Valve open lower limit mm (in) 3 (0.12)

MAINTENANCE INTERVAL CHART .............................................................. 3-1

TOP COWLING................................................................................................ 3-2

FUEL SYSTEM ................................................................................................ 3-3

CONTROL SYSTEM........................................................................................ 3-5

COOLING SYSTEM....................................................................................... 3-10

OIL INJECTION SYSTEM ............................................................................. 3-10

POWER TRIM AND TILT SYSTEM............................................................... 3-14

MAINTENANCE INTERVAL CHART 3

INSPECTING THE TOP COWLING FIT 3

INSPECTING THE FUEL FILTER 3

MEASURING THE FUEL PRESSURE

Fuel pressure gauge ................. 1

(2) Start the engine, run it at idle speed for

3060 (4) Verify that all the throttle valves are

ADJUSTING THE ENGINE IDLING

Engine idling speed

(3) Turn the throttle stop screw 3 in direc-

(4) Tighten the pickup adjustment screw

ADJUSTING THE THROTTLE

Throttle position sensor output

Test harness (3-pin)

(3) Connect the digital tester probes to the

3100 Adjustment steps

Throttle position sensor output

(3) Tighten the screws.

ADJUSTING THE REMOTE CONTROL

ADJUSTING THE REMOTE CONTROL

OIL INJECTION SYSTEM 3

AIR BLEEDING THE OIL INJECTION

(2) Disconnect the oil pump link rod joint