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Drive shaft holder 4 1: 90890-06518 Pinion nut holder 2: 90890-06505 Socket adapter 2 3: 90890-06507
Bearing separator 1: 90890-06534 2. Remove the needle bearing from the forward gear.
Disassembling the drive shaft
1. Install the pinion nut 1, tighten it finger tight, and then remove the drive shaft bearing 2 using a press.
Check screw Gasket Dowel pin Bolt Drain screw Grommet Bolt Bolt Thrust washer Propeller Washer Washer Cotter pin Propeller nut Trim tab
45 mm 60 mm
Do not press the drive shaft threads a directly. Do not reuse the bearing, always replace it with a new one. Bearing inner race attachment 3: 90890-06639 Do not reuse the bearing, always replace it with a new one. Stopper guide plate 2: 90890-06501 Stopper guide stand 3: 90890-06538 Bearing puller 4: 90890-06535 Bearing puller claw 1 5: 90890-06536
Disassembling the forward gear
1. Remove the taper roller bearing from the forward gear using a press.
The symbols below are designed to indicate the content of a chapter. General information Fuel system Bracket unit
Periodic checks and adjustments Lower unit
Symbols 1 to 6 indicate specific data.
Special tool Specified oil or fluid Specified engine speed Specified tightening torque
5 Specified measurement 6 Specified electrical value (resistance, voltage, electric current)
Symbols 7 to C in an exploded diagram indicate the grade of lubricant and the lubrication point.
A Apply corrosion resistant grease (Yamaha grease D) B Apply low temperature resistant grease (Yamaha grease C) C Apply injector grease
Apply Yamaha 4-stroke motor oil Apply gear oil Apply water resistant grease (Yamaha grease A) Apply molybdenum disulfide grease
Symbols D to H in an exploded diagram indicate the type of sealant or locking agent and the application point.
D Apply Gasket Maker E Apply LOCTITE 271 (red) F Apply LOCTITE 242 (blue)
Unit mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in)
Model F90TR 2.382.48 (0.09370.0976) 2.40 (0.0945) 0.200.70 (0.00790.0276) 0.030.15 (0.00120.0059) 36.4836.58 (1.43621.4402) 36.9037.06 (1.45281.4591) 29.9530.05 (1.17911.1831) 29.9230.08 (1.17801.1842) 24.96024.980 (0.98270.9835) 0.03 (0.0012)
mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in)
0.20 0.03 (0.008 0.001) 0.34 0.03 (0.013 0.001) 29.029.2 (1.141.15) 24.024.2 (0.940.95) 1.992.44 (0.07830.0961) 2.272.72 (0.08940.1071) 1.201.60 (0.04720.0630) 1.201.60 (0.04720.0630) 0.801.20 (0.03150.0472) 1.001.40 (0.03940.0551) 5.9755.990 (0.23520.2358) 5.9605.975 (0.23460.2352) 6.0006.018 (0.23620.2369) 0.0100.043 (0.00040.0017) 0.0250.058 (0.00100.0023) 0.01 (0.0004) 53.20 (2.0945) 2.6 (0.10)
The figure is for reference only.
Specifications Unit mm (in) mm (in) Model F90TR 27.96527.980 (1.10101.1016) 0.0200.056 (0.00080.0022)
Valve lifters Valve lifter outside diameter Valve lifter-to-cylinder head clearance Valve shims Valve shim thickness (in 0.025 mm increments) Connecting rods Big end inside diameter Big end side clearance Crankpin oil clearance Big-end bearing thickness Yellow Green Blue Red Crankshaft Crankshaft journal diameter Crankpin diameter Crankpin width Runout limit Crankcase Crankshaft journal oil clearance Upper crankcase main bearing thickness Green Blue Red Upper crankcase main bearing #3 thickness Green Blue Red Lower crankcase main bearing thickness Yellow Green Blue Red
mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in)
47.02547.045 (1.85141.8522) 0.140.28 (0.00550.0110) 0.0240.044 (0.00090.0017) 1.4991.506 (0.05900.0593) 1.5061.513 (0.05930.0596) 1.5131.520 (0.05960.0598) 1.5201.527 (0.05980.0601) 47.98548.000 (1.88921.8898) 43.98244.000 (1.73161.7323) 21.0021.07 (0.82680.8295) 0.03 (0.0012) 0.0240.044 (0.00090.0017)
mm (in) mm (in) mm (in)
2.9922.999 (0.11780.1181) 2.9993.006 (0.11810.1183) 3.0063.013 (0.11830.1186)
mm (in) mm (in) mm (in) mm (in)
3.0103.017 (0.11850.1188) 3.0173.024 (0.11880.1191) 3.0243.031 (0.11910.1193) 3.0313.038 (0.11930.1196)
Maintenance specification Item Oil pump Discharge at 97103 C (207217 F) with 10W-30 engine oil Pressure at 97103 C (207217 F) with 10W-30 engine oil Relief valve opening pressure Thermostat Opening temperature Fully open temperature Valve open lower limit Unit L (US gal, Imp gal)/min kPa (kgf/cm2, psi) kPa (kgf/cm2, psi) C (F) C (F) mm (in) Model F90TR 5.9 (1.559, 1.298) at 1,000 r/min
118.0 (1.18, 17.1) at 1,000 r/min
441539 (4.415.39, 63.978.2)
5862 (136144) 70 (158) 4.3 (0.17)
Item Gear backlash Pinion-to-forward gear Pinion shims Forward gear shims Unit mm (in) mm mm Model F90TR 0.280.63 (0.01100.0248) 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50
Item Ignition and ignition control system Spark plug gap Ignition coil resistance at 20 C (68 F) Primary coil (R B/W) Secondary coil Spark plug wire resistance #1 #2 #3 #4 Unit Model F90TR
k k k k k
1.532.07 12.49516.905 4.510.7 3.38.0 3.78.9 4.310.2
Specifications Unit Model F90TR
ECM output peak voltage (B/R, B/W Ground) at cranking (loaded) at 1,500 r/min (loaded) at 3,500 r/min (loaded) Pulser coil output peak voltage (W/R, W/B B) at cranking (unloaded) at cranking (loaded) at 1,500 r/min (loaded) at 3,500 r/min (loaded) Pulser coil resistance(*) (W/R, W/B B) Throttle position sensor Output voltage (P B) Cooling water temperature sensor resistance at 0 C (32 F) at 80 C (176 F) Oil pressure switch Operating pressure Fuel control system Fuel injector resistance(*) at 21 C (70 F) Starter motor Type Output Cranking time limit Brushes Standard length Wear limit Commutator Standard diameter Wear limit Mica Standard undercut Wear limit
V V V V
3.6 3.4 18.2 34.3 459561
0.81.2 at engine idle speed
k k kPa (kgf/cm2, psi)
5.216.37 0.2900.354 127.5166.7 (1.281.67, 18.4924.17)
12.0 Sliding gear 1.15.5 (0.61) 9.5 (0.37) 29.0 (1.14) 28.0 (1.10) 0.8 (0.03) 0.2 (0.01)
kW Second mm (in) mm (in) mm (in) mm (in) mm (in) mm (in)
The figures are for reference only.
Maintenance specification Item Charging system Fuse Stator coil output peak voltage (W W) at cranking (unloaded) at 1,500 r/min (unloaded) at 3,500 r/min (unloaded) Stator coil resistance(*) (W W) at 20 C (68 F) Rectifier Regulator output peak voltage (RGround) at 1,500 r/min (unloaded) at 3,500 r/min (unloaded) Power trim and tilt system Trim sensor Setting resistance (P B) Resistance (P B) Fluid type Brushes Standard length Wear limit Commutator Standard diameter Wear limit Mica Standard undercut Wear limit
Model F90TR 20
12.4 45.3 98.3
9378.8 ATF Dexron II 10.0 (0.39) 3.5 (0.14) 22.0 (0.87) 21.0 (0.83) 1.5 (0.06) 1.0 (0.04)
mm (in) mm (in) mm (in) mm (in) mm (in) mm (in)
857 (33.7) 666 (26.2) 366 (14.4) 49 (1.9) 405 (15.9) 27 (1.1) 204 (9.4)
L : 25 (1.0) X: 24 (0.9)
L : 917 (36.1) X: 1,044 (41.1) L : 536 (21.1) 191 (7.5) X: 663 (26.1)
Checking the fuel filter
1. Check the fuel filter element 1 for dirt and residue and check the fuel filter cup 2 for foreign substances and cracks. Clean the cup with straight gasoline and replace the element if necessary.
NOTE: To loosen the fitting, move the hook in direction a. To tighten the fitting, move the hook in direction b. 4. Tighten the bolts. 5. Check the fitting again and, if necessary, repeat steps 24.
Checking the fuel joint and fuel hoses (fuel joint-to-fuel injector)
1. Remove the flywheel magnet cover.
NOTE: Be sure not to spill any fuel when removing the fuel filter cup.
Top cowling / Fuel system / Power unit
Checking the engine oil
1. Place the outboard motor in an upright position. 2. Remove the oil dipstick, wipe it clean, and then insert it back into the dipstick hole. 3. Remove the oil dipstick again to check the oil level and to check the oil for discoloration and its viscosity.
4. Operate the oil changer to extract the oil. NOTE: Be sure to clean up any oil spills. 5. Pour the specified amount of the recommended engine oil into the oil filler hole. Recommended engine oil: 4-stroke motor oil API: SE, SF, SG, SH, or SJ SAE: 10W-30 or 10W-40 Engine oil quantity: Without oil filter replacement: 4.3 L (4.55 US qt, 3.78 Imp qt) 6. Install the oil filler cap and oil dipstick, and then start the engine and warm it up for 5 minutes. 7. Turn the engine off, and then check the oil level and correct it if necessary.
NOTE: Change the oil if it appears milky or dirty. If the engine oil is below the minimum level mark b, add sufficient oil until the level is between a and b.
Changing the engine oil using an oil changer
1. Start the engine, warm it up, and then turn it off. 2. Remove the oil dipstick and oil filler cap 1.
Changing the engine oil by draining it
1. Start the engine, warm it up, and then turn it off.
3. Insert the tube of the oil changer 2 into the dipstick hole 3.
Periodic checks and adjustments 7. Turn the engine off, and then check the oil level and correct it if necessary.
Lubricating the outboard motor
1. Apply water resistant grease to the areas shown.
Battery electrolyte is dangerous; it contains sulfuric acid which is poisonous and highly caustic. Always follow these preventive measures: Avoid bodily contact with electrolyte as it can cause severe burns or permanent eye injury. Wear protective eye gear when handling or working near batteries. Antidote (EXTERNAL): SKIN Wash with water. EYES Flush with water for 15 minutes and get immediate medical attention. Antidote (INTERNAL): Drink large quantities of water or milk followed with milk of magnesia, beaten egg, or vegetable oil. Get immediate medical attention. Batteries generate explosive, hydrogen gas. 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). DO NOT SMOKE when charging or handling batteries. KEEP BATTERIES AND ELECTROLYTE OUT OF REACH OF CHILDREN. NOTE: Batteries vary per manufacturer. The procedures mentioned in this manual may not always apply, therefore, consult the instruction manual of the battery. Disconnect the negative battery lead first, then the positive battery lead. Electrolyte specific gravity: 1.280 at 20 C (68 F)
NOTE: Apply grease to the grease nipple until it flows from the bushings a. 2. Apply low temperature resistant grease to the area shown.
3. Apply corrosion resistant grease to the area shown.
Special service tools...4-1 Hose routing....4-2 Fuel and blowby hoses...4-2 Fuel filter and fuel pump... 4-3 Checking the fuel pump....4-5 Disassembling the fuel pump... 4-5 Checking the diaphragm and valves..4-6 Assembling the fuel pump... 4-6 Intake manifold.... 4-7 Checking the throttle position sensor...4-9 Installing the throttle position sensor..4-9 Checking the idle speed control...4-9 Vapor separator.... 4-10 Reducing the fuel pressure... 4-13 Disconnecting the quick connector... 4-13 Measuring the fuel pressure... 4-13 Checking the pressure regulator... 4-14 Draining the fuel...4-15 Removing the fuel hose clamp...4-15 Installing the fuel hose clamp... 4-15 Disassembling the vapor separator.. 4-15 Checking the vapor separator...4-16 Assembling the vapor separator..4-16 Adjusting the float...4-17 Canister....4-18 Checking the canister... 4-19
Fuel pressure gauge YB-06766
Fuel pressure gauge adapter B YB-06942
Special service tools / Hose routing
Fuel and blowby hoses
Blowby hose Fuel hose (primary pump-to-fuel filter) Fuel hose (fuel filter-to-fuel pump) Fuel hose (fuel pump-to-strainer) Fuel hose (strainer-to-vapor separator) High-pressure fuel hose (vapor separator-to-fuel rail) Fuel hose (pressure regulator-to-fuel cooler) Fuel hose (fuel cooler-to-vapor separator) Canister hose (vapor separator-to-canister) Canister hose (canister-to-idle speed control) Canister hose (canister-to-filter) Canister hose (filter-to-bottom cowling)
Fuel filter and fuel pump
10 N m (1.0 kgf m, 7.4 ft Ib)
3 N m (0.3 kgf m, 2.2 ft Ib)
Part name Nut Fuel filter assembly O-ring Fuel filter element O-ring Float Cup Fuel hose Fuel pump Bolt Fuel hose Strainer Bolt Bracket O-ring
Not reusable Not reusable
4 N m (0.4 kgf m, 3.0 ft Ib)
Part name Screw Cover Gasket Fuel pump body 2 assembly Diaphragm Pin Spring Fuel pump body 1 Spring Plunger Nut
Fuel system 6. Apply the specified positive pressure and check that there is no air leakage. Disassemble the fuel pump if necessary.
Checking the fuel pump
1. Place a drain pan under the fuel hose connections, and then disconnect the fuel hoses from the fuel pump. 2. Connect the special service tool to the fuel pump inlet. 3. Cover the fuel pump outlet with a finger, and then apply the specified positive pressure. Check that there is no air leakage.
NOTE: Assemble the fuel pump valve to the fuel pump body, and moisten the inside of the fuel pump with gasoline to ensure a good seal. Specified pressure: 50 kPa (0.5 kgf/cm2, 7.3 psi)
Pressure/vacuum tester: YB-35956-A Specified pressure: 50 kPa (0.5 kgf/cm2, 7.3 psi) 4. Apply the specified negative pressure and check that there is no air leakage.
Disassembling the fuel pump
1. Disassemble the fuel pump. 2. Push down on the plunger and the diaphragm, turn fuel pump body approximately 90 to a position where the pin 2 can be removed easily, and then remove the pin.
Specified pressure: 30 kPa (0.3 kgf/cm2, 4.4 psi) 5. Connect the special service tool to the fuel pump outlet.
Fuel filter and fuel pump 3. Slowly let up on the plunger and diaphragm, and then remove them.
Checking the diaphragm and valves
1. Check the diaphragm for tears and the valves for cracks. Replace if necessary.
Assembling the fuel pump
NOTE: Clean the parts and soak the valves and the diaphragm in gasoline before assembly to obtain prompt operation of the fuel pump when starting the engine. 1. Align the plunger and diaphragm installation holes a, and then install the plunger into the diaphragm. 2. Push down on the plunger and the diaphragm, and then install the pin 1.
When connecting the fuel pressure gauge, first cover the connection between the gauge and the adapter with a clean, dry rag to prevent fuel from leaking out. Gently screw in the gauge until it is firmly connected. Fuel pressure gauge: YB-06766 Fuel pressure gauge adapter B: YB-06942 Pressure/vacuum tester: YB-35956-A 5. Start the engine and let it idle.
6. Check that the fuel pressure reduces when vacuum pressure is applied to the pressure regulator. If the fuel pressure does not reduce, replace the pressure regulator. NOTE: When the vacuum pressure reaches the specified level, the fuel pressure reduces.
Reduce the fuel pressure before loosening the vapor separator drain screw, or pressurized fuel will spray out and may result in serious injury.
Removing the fuel hose clamp
1. Remove the fuel hose clamp by cutting the crimped section of the clamp.
Draining the fuel
Always reduce the fuel pressure in the high-pressure fuel line before servicing the line or the vapor separator. If the fuel pressure is not released, pressurized fuel may spray out. 3. Place a container under the vapor separator drain hose, and then loosen the drain screw 2. 4. Drain the fuel from the vapor separator drain hose by pressing the pressure check valve using a thin screwdriver.
If the fuel hose clamp is removed without cutting the crimp first, the fuel hose will be damaged.
Installing the fuel hose clamp
1. Crimp the fuel hose clamp properly to securely fasten it.
Do not reuse the fuel hose clamp, always replace it with a new one.
Disassembling the vapor separator
1. Remove the float chamber, float pin, and float.
NOTE: Remove the float pin in the direction of the arrow a shown. 2. Remove the needle valve and other components.
Checking the vapor separator
1. Check the needle valve for bends or wear. Replace if necessary.
NOTE: Do not reuse the float pin, always replace it with a new one. Install the float pin in the direction of the arrow a shown. Install the float pin with its tapered end towards the punch mark b on the vapor separator cover. 2. Check the float height c as shown. Adjust the float height if out of specification.
Do not over cut the valve seat. Be sure to turn the cutter evenly downward at a pressure of 4050 N (45 kgf, 8.811 lbf) to prevent chatter marks. 3. Use a 30 cutter to adjust the contact width of the top edge of the valve seat.
Valve seat contact width a: 1.201.60 mm (0.04720.0630 in)
Refacing the valve seat
1. Reface the valve seat with the valve seat cutters.
b Previous contact width
Neway valve seat kit: YB-91044 2. Cut the surface of the valve seat with a 45 cutter by turning the cutter clockwise until the valve seat face has become smooth.
4. Use a 60 cutter to adjust the contact width of the bottom edge of the valve seat.
Power unit 8. If the valve seat contact area is too narrow and situated near the bottom edge of the valve face, use a 60 cutter to cut the bottom edge of the valve seat. If necessary, use a 45 cutter to center the area and set its width.
5. Use a 45 cutter to adjust the contact width of the valve seat to specification.
b Previous contact width c Specified contact width
6. If the valve seat contact area is too wide and situated in the center of the valve face, use a 30 cutter to cut the top edge of the valve seat, a 60 cutter to cut the bottom edge to center the area and set its width.
9. Apply a thin, even layer of lapping compound onto the valve seat, and then lap the valve using a valve lapper (commercially available).
7. If the valve seat contact area is too narrow and situated near the top edge of the valve face, use a 30 cutter to cut the top edge of the valve seat. If necessary, use a 45 cutter to center the area and set its width.
Do not get the lapping compound on the valve stem and valve guide. 10. After every lapping procedure, be sure to clean off any remaining lapping compound from the cylinder head and the valve. 11. Check the valve seat contact area of the valve again.
Checking the camshafts
1. Measure the cam lobe. Replace if out of specification.
Cam lobe a: Intake: 36.4836.58 mm (1.43621.4402 in) Exhaust: 36.9037.06 mm (1.45281.4591 in) Cam lobe b: Intake: 29.9530.05 mm (1.17911.1831 in) Exhaust: 29.9230.08 mm (1.17801.1842 in) 2. Measure the camshaft runout. Replace if above specification.
NOTE: Apply molybdenum disulfide grease to the cam lobes. Be sure to install the camshaft with the fuel pump drive cam b on the intake side. 5. Check that the camshaft dowel holes c are in the position shown in the illustration. Adjust if necessary.
3. Install the valve shims and valve lifters.
6. Install the camshaft caps in the proper position as shown and with the stamped numbers facing upside down. 7. Tighten the camshaft cap bolts to the specified torques in two stages and in the sequence shown.
NOTE: Apply engine oil to the camshaft caps and camshaft cap bolts before installation. Camshaft cap bolt: 1st: 8 Nm (0.8 kgfm, 5.9 ftlb) 2nd: 17 Nm (1.7 kgfm, 12.5 ftlb)
8. Install the cylinder head cover.
Cylinder head cover bolt: 1st: 8 Nm (0.8 kgfm, 5.9 ftlb) 2nd: 8 Nm (0.8 kgfm, 5.9 ftlb)
9. Install the sprockets and timing belt.
NOTE: For sprocket and timing belt installation procedures, see Installing the sprockets and timing belt.
Cylinder head / Exhaust cover
49 N m (4.9 kgf m, 36.1 ft Ib)
18 N m (1.8 kgf m, 13.3 ft Ib)
23 N m (2.3 kgf m, 17.0 ft Ib)
55 N m (5.5 kgf m, 40.6 ft Ib)
N m (0.6 kgf m, 4.4 ft lb) N m (1.2 kgf m, 8.9 ft lb)
Part name Gasket Screw Anode Exhaust cover Gasket Cooling water temperature sensor Holder Bolt Holder Bolt Gasket Grommet Pressure control valve Spring Cover Bolt Gasket
Part name Plug Grommet Anode Cover Bolt Bolt Bolt Joint Oil filter Gasket Plug Plastic tie Hose
Removing the exhaust cover
1. Remove the exhaust cover bolts in the sequence shown.
Installing the exhaust cover
1. Install a new gasket and the exhaust cover. 2. Install the bolts, and then tighten them to the specified torques in two stages and in the sequence shown.
2. Remove the exhaust cover.
Checking the pressure control valve
1. Remove the pressure control valve. 2. Check the pressure control valve for wear or damage. Replace if necessary. 3. Check the grommet for deformation. Replace if necessary. 4. Check the spring for fatigue or deformation. Replace if necessary.
NOTE: Apply engine oil to the exhaust cover bolts before installation. Exhaust cover bolt: 1st: 6 Nm (0.6 kgfm, 4.4 ftlb) 2nd: 12 Nm (1.2 kgfm, 8.9 ftlb)
Installing the pressure control valve
1. Install a new gasket and the pressure control valve, and then tighten the bolts.
19 N m (1.9 kgf m, 14.0 ft lb) 60
Part name Bolt Dowel Bolt Crankcase Bolt Cylinder block Main bearing Main bearing Main bearing Oil seal Crankshaft Oil seal Connecting rod bearing Piston/connecting rod assembly Bolt Piston ring set Stud bolt
Gland nut wrench YB-34447
Bearing housing needle bearing remover YB-06112, YB-06153
Bearing housing puller YB-06207
Driver handle (large) YB-06071
Universal puller YB-06117
Propeller shaft oil seal installer YB-06269
Slide hammer YB-06096
Drive shaft needle bearing depth stop YB-34473
Bearing puller legs YB-06523
Bearing outer race attachment YB-06109
Drive shaft holder YB-06151
Shift rod push arm YB-06052
Drive shaft needle bearing remover and installer YB-06155
Pinion shim selecting tool YB-34432-9, YB-34432-10A, YB-34432-11A, YB-34432-17
Drive shaft seal installer YB-06244
Forward gear shim selecting tool YB-34446-1, YB-34446-3, YB-34446-5, YB-34446-7
Forward gear bearing cup installer YB-06276-B
Backlash indicator rod YB-06265
Forward gear outer race installer YB-06085
Backlash adjustment plate YB-07003
Dial indicator gauge YU-03097
Magnetic base stand YU-A8438
Special service tools / Lower unit
Part name Lower unit Hose Check screw Gasket Dowel Bolt Drain screw Grommet Bolt Bolt Spacer Propeller Washer Washer Cotter pin Nut Trim tab
Mmm Mmm/L-transom model
Part name Dowel Extension Stud bolt Washer Spring washer Nut Bolt
Remarks X-transom model X-transom model Mmm/X-transom model X-transom model X-transom model X-transom model Mmm/X-transom model
Part name Bolt O-ring Oil seal Oil seal housing O-ring Circlip Shift rod Woodruff key Screw Bolt Cover Bolt Seal Water pump housing Insert cartridge Impeller Dowel
mm Mmm Mmm
Part name Gasket Outer plate cartridge Gasket Oil seal housing O-ring Gasket Oil seal
Not reusable Not reusable Not reusable Not reusable Not reusable
Removing the lower unit
1. Drain the gear oil.
2. Set the gear shift to the neutral position, and place a block of wood between the anti-cavitation plate and propeller to keep the propeller from turning, and then remove the propeller nut and propeller.
5. Loosen the bolts (nuts), and then remove the lower unit from the upper case.
Do not hold the propeller with your hands when loosening or tightening it. Be sure to disconnect the battery leads from the battery and the clip from the engine stop lanyard switch. Put a block of wood between the anticavitation plate and propeller to keep the propeller from turning. 3. Disconnect the speedometer hose 1. 4. Mark the trim tab 2 at the area shown, and then remove it.
Lower unit Propeller shaft oil seal installer 3: YB-06269 Driver handle (large) 4: YB-06071 Depth c: 5.0 0.5 mm (0.20 0.02 in) 3. Install the thrust washer 5 and new ball bearing 6 to the reverse gear 7 using a press.
Assembling the propeller shaft housing
1. Install the needle bearing into the propeller shaft housing to the specified depth.
NOTE: Install the needle bearing with the manufacture identification mark a facing toward the oil seal (propeller side). Driver handle (large) 1: YB-06071 Bearing housing needle bearing remover 2: YB-06153 Depth b: 25.25 0.25 mm (0.99 0.01 in) 2. Apply grease to the new oil seals, and then install them into the propeller shaft housing to the specified depth.
NOTE: Install the ball bearing with the manufacture identification mark d facing outward (propeller side). Drive shaft needle bearing depth stop 8: YB-34473 4. Install the reverse gear assembly into the propeller shaft housing using a press.
NOTE: Install an oil seal halfway into the propeller shaft housing, then the other oil seal.
Bearing outer race attachment 9: YB-06109
Drive shaft and lower case
Part name Drive shaft Taper roller bearing Pinion shim Sleeve Hose Plastic tie Joint Nut Cooling water inlet cover Screw Seal Plate Forward gear shim Taper roller bearing Needle bearing Forward gear assembly Needle bearing
Part name Pinion Nut Lower case
Do not reuse the bearing, always replace it with a new one. Bearing splitter plate 1: (commercially available) 2. Remove the needle bearing from the forward gear.
Drive shaft holder 1: YB-06151
Do not press the drive shaft threads a directly. When removing the drive shaft bearing, do not damage the drive shaft collar 4. Do not reuse the bearing, always replace it with a new one. Bearing splitter plate 3: (commercially available) Do not reuse the bearing, always replace it with a new one.
Disassembling the lower case
1. Remove the taper roller bearing outer race and shim(s).
Drive shaft and lower case NOTE: Install the claws as shown. Slide hammer 1: YB-06096 Bearing puller legs 2: YB-06523 2. Remove the drive shaft bearing outer race, shim(s), and drive shaft sleeve.
Checking the bearings
1. Check the bearings for pitting or rumbling. Replace if necessary.
Checking the drive shaft
1. Check the drive shaft for bends or wear. Replace if necessary. 2. Measure the drive shaft runout.
NOTE: Install the claws as shown.
Runout limit: 0.5 mm (0.020 in)
Checking the lower case
Slide hammer 3: YB-06096 3. Remove the needle bearing. 1. Check the skeg and torpedo for cracks or damage. Replace the lower case if necessary.
Oil pump cover screw: 4 Nm (0.4 kgfm, 3.0 ftlb)
Disassembling the upper case
1. Remove the muffler assembly from the upper case. 2. Remove the circlip, then the drive shaft bushing.
Checking the oil strainer
1. Check the oil strainer for dirt or residue. Clean if necessary.
Assembling the oil pan
1. Install a new gasket onto the exhaust guide 1. 2. Install a new gasket and the oil strainer 2 onto the exhaust guide, and then tighten the bolts to the specified torque.
Oil strainer bolt: 10 Nm (1.0 kgfm, 7.4 ftlb) 3. Install the dowels and oil pan 3 onto the exhaust guide, and then tighten the oil pan bolts 4 finger tight. 4. Install a new gasket and the exhaust manifold 5 onto the oil pan, and then tighten the exhaust manifold bolts 6 to the specified torque. 5. Tighten the oil pan bolts 4 to the specified torque. 6. Tighten the exhaust manifold bolts 6 again to the specified torque.
Oil pan bolt 4: 11 Nm (1.1 kgfm, 8.1 ftlb) Exhaust manifold bolt 6: 11 Nm (1.1 kgfm, 8.1 ftlb) 7. Install new gaskets, the plate 7, and the muffler 8 onto the oil pan. 8. Install the water pipe 9.
Assembling the upper case
1. Install the drive shaft bushing into the upper case, and then install the circlip.
Installing the upper case
1. Install the upper mount 1 and bolts 2 into the upper case. 2. Install the bolts 3, and then tighten them to the specified torque.
Drive shaft needle bearing installer and remover 1: YB-06196 Driver handle (large) 2: YB-06071
2. Install the muffler assembly 3 by inserting the tip of the water pipe 4 into the joint hole a of the upper case. 3. Install the muffler assembly bolts 5, and then tighten them to the specified torque.
Upper mount bolt 3: 28 Nm (2.8 kgfm, 20.7 ftlb)
3. Install the lower mounts 4 onto the upper case.
4. Install the upper and lower mounting bolts into the bracket 5 simultaneously. 5. Install the upper mounting nut 6 and lower mounting nut 7, and then tighten them to the specified torques.
Muffler assembly bolt 5: 20 Nm (2.0 kgfm, 14.8 ftlb)
Upper case NOTE: Before tightening the lower mounting nut, be sure to connect the ground lead to the lower mounting bolt. 6. Install the mount covers 8. 7. Install the oil pump assembly 9 and the bolts 0, and then tighten them to the specified torque.
NOTE: When installing the oil pump assembly onto the upper case, pour a small amount of engine oil into the oil inlet or oil outlet of the oil pump assembly. Upper mounting nut 6: 51 Nm (5.1 kgfm, 37.6 ftlb) Lower mounting nut 7: 51 Nm (5.1 kgfm, 37.6 ftlb) Oil pump bolt 0: 10 Nm (1.0 kgfm, 7.4 ftlb) Grease nipple: 3 Nm (0.3 kgfm, 2.2 ftlb)
90 N m (9.0 kgf m, 66.4 ft Ib)
80 N m (8.0 kgf m, 59.0 ft Ib)
85 N m (8.5 kgf m, 62.7 ft Ib)
Part name Power trim and tilt assembly Dust seal Backup ring O-ring Trim cylinder end screw O-ring Tilt cylinder end screw assembly Backup ring O-ring O-ring Washer Filter O-ring Trim piston Backup ring O-ring Ball
Part name Valve Spring Washer Tilt cylinder Ball O-ring Backup ring Tilt piston Ball Ball Valve Spring Pin Dowel Washer Tilt piston assembly O-ring
Part name Free piston Circlip Cylinder base Spring Washer Circlip Trim cylinder
Disassembling the trim cylinder
1. Hold the power trim and tilt unit 1 in a vise using aluminum plates a on both sides.
NOTE: Place the tilt cylinder in the vise horizontally. 2. Loosen the tilt cylinder end screw 2, and then remove it.
2. Loosen the trim cylinder end screw 2, and then remove it.
Make sure that the ram is fully extended before removing the end screw.
Trim cylinder wrench: YB-06175-2B 3. Drain the power trim and tilt fluid. Do not damage the check valve b when loosening the end screw. Trim cylinder wrench: YB-06175-2B 3. Hold the tilt ram end in a vise using aluminum plates on both sides.
Disassembling the tilt cylinder
1. Hold the tilt cylinder 1 in a vise using aluminum plates a on both sides.
Bracket unit 2. Check the operation of the absorber valve and check for dirt or residue. Clean if necessary.
4. Remove the bolt 3, then the tilt piston 4.
Assembling the tilt cylinder
1. Install a new O-ring, the backup ring, and a new dust seal 1 into the trim cylinder end screw 2. 2. Install the O-ring 3 onto the trim cylinder end screw. 3. Install the tilt ram 4 into the trim cylinder end screw.
Checking the tilt cylinder and trim cylinder
1. Check the power trim and tilt unit for cracks or corrosion. Replace if necessary. 2. Check the inner walls of the trim cylinder and tilt cylinder for scratches. Replace if necessary. 3. Check the outer surface of the tilt piston and free piston for scratches. Replace if necessary. 4. Check the tilt ram for bends or excessive corrosion. Polish with 400- to 600-grit sandpaper if there is light rust or replace if necessary.
4. Install the backup ring 5 and new Orings 6 and 7 into the tilt cylinder end screw 8.
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