PREFACE CONTENTS

This manual covers the construction, function and

serving procedures for the Honda BF135A•BF150A
outboard motors.
SPECIFICATIONS 1
All information contained in this manual is based on the
SERVICE INFORMATION 2
latest product information available at the time of
printing. We reserve the right to make changes at anytime
without notice.
MAINTENANCE 3
No part of this publication may be reproduced, stored in
ENGINE COVER/COVER LOCK 4
a retrieval system, or transmitted, in any form, by any
means, electronic, mechanical, photocopying, recording,
or otherwise, without prior written permission of the
PROGRAMMED-FUEL INJECTION 5
publisher. This includes text, figures, and tables.
ALTERNATOR 6
As you read this manual, you will find information that is
preceded by a NOTICE symbol. The purpose of this
message is to help prevent damage to the outboard
ENGINE REMOVAL/INSTALLATION 7
motor, other property, or the environment.

SAFETY MESSAGES
THERMOSTAT/RELIEF VALVE/FLUSH VALVE 8
Your safety, and the safety of others, are very important.
CRANKSHAFT PULLEY/CAM CHAIN 9
To help you make informed decisions, we have provided
safety messages and other safety information throughout
this manual. Of course, it is not practical or possible to
CYLINDER HEAD/VALVES 10
warn you about all the hazards associated with servicing
these outboard motors. You must use your own good
OIL PUMP/FLYWHEEL 11
judgment.

You will find important safety information in a variety of

CRANKCASE/BALANCER 12
forms, including: CYLINDER BLOCK/CRANKSHAFT/PISTONS 13
• Safety Labels –– on the engine cover.
PROPELLER/GEAR CASE/EXTENSION CASE/
• Safety messages –– Preceded by a safety alert symbol
OIL CASE 14
and one of three signal words, DANGER, WARNING, MOUNTING CASE/STERN BRACKET/SWIVEL
or CAUTION. CASE/POWER TRIM/TILT ASSEMBLY 15
These signal words mean: STEERING ROD/REMOTE CONTROL BOX 16
DANGER CABLES/SHIFT LINK BRACKET/SHIFT ARM/
You WILL be KILLED or
SERIOUSLY HURT if you don't NEUTRAL SWITCH 17
follow instructions.

WARNING
ELECTRICAL EQUIPMENT 18
You CAN be KILLED or
SERIOUSLY HURT if you don't
follow instructions.
OPERATION 19
CAUTION You CAN be HURT if you don't
SYSTEM DIAGRAM/WIRING DIAGRAM 20
follow instructions.
21
• Instructions –– how to service this outboard motor
correctly and safely. 21
Honda Motor Co., Ltd.
Service Publications Office

Date of lssue: November, 2003

© Honda Motor Co., Ltd.
INDEX
1. SPECIFICATIONS ........................................................ 1-1 3. MAINTENANCE ............................................................ 3-1
1. SPECIFICATIONS .................................................. 1-1 1. MAINTENANCE SCHEDULE ................................ 3-1
2. DIMENSIONAL DRAWINGS.................................. 1-4 2. ENGINE OIL............................................................ 3-2
3. OIL FILTER .............................................................. 3-3
2. SERVICE INFORMATION ............................................ 2-1 4. GEAR CASE OIL .................................................... 3-4
1. THE IMPORTANCE OF PROPER SERVICING ...... 2-1 5. SPARK PLUGS ...................................................... 3-6
2. IMPORTANT SAFETY PRECAUTIONS ................ 2-1 6. VALVE CLEARANCE .............................................. 3-9
3. SERVICE RULES .................................................... 2-2 7. FUEL STRAINER (LOW PRESSURE SIDE) ........ 3-15
4. SYMBOLS USED IN THIS MANUAL .................... 2-2 8. FUEL STRAINER (HIGH PRESSURE SIDE) ........ 3-18
5. SERIAL NUMBER LOCATIONS ............................ 2-2 9. WATER SEPARATOR with WATER LEVEL
6. MAINTENANCE STANDARDS .............................. 2-3 SENSOR .............................................................. 3-19
7. TORQUE VALUES .................................................. 2-7 10. IDLING .................................................................. 3-22
8. SPECIAL TOOLS .................................................. 2-10 11. SHIFT CONTROL CABLE .................................... 3-24
9. TROUBLESHOOTING .......................................... 2-14 12. THROTTLE CONTROL CABLE/
a. ENGINE····························································· 2-14 THROTTLE LINK .................................................. 3-26
HARD STARTING ············································· 2-14 13. REMOTE CONTROL LEVER FRICTION .............. 3-28
CYLINDER COMPRESSION TEST··················· 2-15 14. ALTERNATOR BELT ............................................ 3-28
ENGINE DOES NOT RUN SMOOTHLY ·········· 2-16
b. IGNITION (POWER) SYSTEM ························· 2-20 4. ENGINE COVER/COVER LOCK .................................. 4-1
ENGINE DOES NOT START ···························· 2-20 1. ENGINE COVER .................................................... 4-2
FUSE LOAD CHART········································· 2-21 2. FRONT SEPARATE COVER.................................... 4-7
FUSE BOX CONNECTION TABLE··················· 2-22 3. L./R. ENGINE UNDER COVERS ............................ 4-9
c. STARTER SYSTEM ·········································· 2-23 4. UNDER COVER FRONT BRACKET/
ENGINE DOES NOT START ·····························2-23 L./R. SIDE COVER BRACKETS ............................ 4-20
d. IGNITION SYSTEM ·········································· 2-25
ENGINE IS HARD TO START ·························· 2-25 5. PROGRAMMED-FUEL INJECTION ............................ 5-1
e. FUEL SYSTEM ················································· 2-28 1. SERVICE PRECAUTIONS ...................................... 5-2
ENGINE IS HARD TO START ·························· 2-28 2. CIRCUIT DIAGRAM................................................ 5-3
f. CHARGING SYSTEM ······································· 2-30 3. VACUUM CONNECTIONS .................................... 5-5
BATTERY UNDER CHARGED ·························· 2-30 4. PARTS LOCATION/
ACG INDICATOR LINE INSPECTION ·············· 2-31 ECM TERMINAL LAYOUT .................................... 5-6
g. ALERT SYSTEM ··············································· 2-32 5. TROUBLESHOOTING .......................................... 5-11
OIL ALERT SYSTEM ········································ 2-32 6. TROUBLESHOOTING WITH
OVERHEAT ALERT SYSTEM ··························· 2-32 HDS TESTER ........................................................ 5-13
ALTERNATOR WARNING SYSTEM················ 2-32 a. TROUBLESHOOTING GUIDE BY DTC············ 5-15
FULL WATER (IN WATER SEPARATOR) b. TROUBLESHOOTING ······································ 5-18
WARNING SYSTEM········································· 2-32 MIL DOES NOT COME ON······························ 5-18
MIL WARNING SYSTEM ································· 2-32 MIL COMES ON BUT DTC CODE DOES NOT
WARNING SYSTEM········································· 2-32 APPEAR ···························································· 5-21
WARNING BUZZER SOUNDS ALERT SYSTEM INITIAL OPERATION IS
CONTINUOUSLY·············································· 2-33 FAULTY ····························································· 5-23
OIL PRESSURE INSPECTION·························· 2-35 NEUTRAL SWITCH MALFUNCTION ·············· 5-26
INTERMITTENT PROLONGED SOUND OF TACHOMETER MALFUNCTION ······················ 5-27
WARNING BUZZER KEEPS SOUNDING········ 2-37 ECM TROUBLESHOOTING ····························· 5-28
INTERMITTENT SHORT SOUND OF MAP SENSOR TROUBLESHOOTING ············· 5-28
WARNING BUZZER KEEPS SOUNDING········ 2-38 CKP SENSOR TROUBLESHOOTING ·············· 5-30
h. SHIFT MECHANISM ········································ 2-39 ECT SENSOR 1 TROUBLESHOOTING ··········· 5-33
i. POWER TRIM/TILT ASSEMBLY ······················ 2-40 TP SENSOR TROUBLESHOOTING················· 5-34
POWER TRIM/TILT ASSEMBLY DOES CMP SENSOR TROUBLESHOOTING ············· 5-36
NOT MOVE ························································2-40 IAT SENSOR TROUBLESHOOTING················ 5-38
POWER TRIM/TILT ASSEMBLY DOES BARO SENSOR TROUBLESHOOTING ··········· 5-39
NOT HOLD························································ 2-41 IAC VALVE TROUBLESHOOTING ··················· 5-41
POWER TRIM/TILT MOTOR DOES VTEC SOLENOID VALVE
NOT MOVE······················································· 2-42 TROUBLESHOOTING ······································ 5-42
POWER TRIM/TILT ASSEMBLY QUICK KNOCK SENSOR TROUBLESHOOTING ········ 5-43
REFERENCE CHART········································· 2-43 A/F SENSOR HEATER TROUBLE-
CHECK POINT ·················································· 2-44 SHOOTING ······················································· 5-44
10. CABLE/HARNESS ROUTING .............................. 2-45 A/F SENSOR TROUBLESHOOTING················ 5-49
11. TUBE ROUTING .................................................. 2-66 ECT SENSOR 2 TROUBLESHOOTING ··········· 5-51
12. LUBRICATION ...................................................... 2-77 ECT SENSOR 3 TROUBLESHOOTING ··········· 5-52
 EOP SWITCH (HIGH PRESSURE SIDE) 12. SILENCER CASE/THROTTLE BODY/
TROUBLESHOOTING ······································ 5-54 INTAKE MANIFOLD .......................................... 5-128
ECT SENSOR 4 TROUBLESHOOTING ··········· 5-55 13. FUEL INJECTOR/PRESSURE REGULATOR...... 5-136
7. TROUBLESHOOTING WITHOUT 14. FUEL PUMP (LOW PRESSURE SIDE) .............. 5-142
HDS TESTER ........................................................5-57 15. FUEL STRAINER (LOW PRESSURE SIDE)/
a. TROUBLESHOOTING GUIDE·························· 5-59 WATER SEPARATOR.......................................... 5-144
b. TROUBLESHOOTING ······································ 5-61 16. EOP (ENGINE OIL PRESSURE) SWITCH (HIGH
MIL DOES NOT COME ON······························ 5-61 PRESSURE SIDE) .............................................. 5-146
MIL ON BUT MIL DOES NOT BLINK WITH 17. EOP (ENGINE OIL PRESSURE) SWITCH (LOW
SCS CIRCUIT SHORTED·································· 5-64 PRESSURE SIDE) .............................................. 5-146
ALERT SYSTEM INITIAL OPERATION IS 18. ECT (ENGINE COOLANT TEMPERATURE)
FAULTY ····························································· 5-66 SENSOR 1 .......................................................... 5-147
NEUTRAL SWITCH MALFUNCTION ·············· 5-70 19. ECT (ENGINE COOLANT TEMPERATURE)
TACHOMETER MALFUNCTION ······················ 5-70 SENSOR 2, 3, 4 .................................................. 5-148
MAP SENSOR TROUBLESHOOTING ············· 5-71 20. BARO (BAROMETRIC PRESSURE)
CKP SENSOR TROUBLESHOOTING ·············· 5-72 SENSOR ..............................................................5-149
ECT SENSOR 1 TROUBLESHOOTING ··········· 5-74 21. KNOCK SENSOR................................................ 5-149
TP SENSOR TROUBLESHOOTING················· 5-75 22. CMP (CAMSHAFT POSITION) SENSOR .......... 5-149
CMP SENSOR TROUBLESHOOTING ············· 5-77 23. CKP (CRANKSHAFT POSITION) SENSOR ...... 5-150
IAT SENSOR TROUBLESHOOTING················ 5-78 24. VTEC SOLENOID VALVE.................................... 5-150
BARO SENSOR TROUBLESHOOTING ··········· 5-80 25. VAPOR CHAMBER/CHECK VALVE .................... 5-151
IAC VALVE TROUBLESHOOTING ··················· 5-81 26. EXHAUST MANIFOLD ...................................... 5-152
VTEC SOLENOID VALVE TROUBLE-
SHOOTING ······················································· 5-82 6. ALTERNATOR .............................................................. 6-1
KNOCK SENSOR TROUBLESHOOTING ········ 5-83 1. SILENCER DUCT .................................................... 6-2
ECT SENSOR 2 TROUBLESHOOTING ··········· 5-84 2. ALTERNATOR ........................................................ 6-5
ECT SENSOR 3 TROUBLESHOOTING ··········· 5-86
EOP SWITCH (HIGH PRESSURE SIDE) 7. ENGINE REMOVAL/INSTALLATION .......................... 7-1
TROUBLESHOOTING ······································ 5-87 1. REMOVAL .............................................................. 7-2
ECT SENSOR 4 TROUBLESHOOTING ··········· 5-89 2. INSTALLATION ...................................................... 7-6
A/F SENSOR HEATER TROUBLE-
SHOOTING ······················································· 5-90 8. THERMOSTAT/RELIEF VALVE/FLUSH VALVE.......... 8-1
A/F SENSOR TROUBLESHOOTING················ 5-92 1. THERMOSTAT ........................................................ 8-2
8. IDLE CONTROL SYSTEM .................................... 5-93 2. WATER RELIEF TUBE/RELIEF VALVE .................. 8-5
TROUBLESHOOTING ······································ 5-93 3. FLUSH VALVE ...................................................... 8-10
IDLE ADJUSTING SCREW
ADJUSTMENT ················································· 5-94 9. CRANKSHAFT PULLEY/CAM CHAIN ........................ 9-1
THROTTLE BODY INSPECTION/ 1. DISASSEMBLY ...................................................... 9-2
CLEANING ························································ 5-95 2. ASSEMBLY ............................................................ 9-9
IAC VALVE REPLACEMENT····························· 5-95
9. FUEL SUPPLY SYSTEM ...................................... 5-96 10. CYLINDER HEAD/VALVES........................................ 10-1
TROUBLESHOOTING ······································ 5-96 1. CYLINDER HEAD COVER REMOVAL.................. 10-2
PGM-FI MAIN RELAY HARNESS 2. CYLINDER HEAD COVER DISASSEMBLY.......... 10-4
INSPECTION····················································· 5-97 3. CAMSHAFT/ROCKER ARM DISASSEMBLY ...... 10-5
INJECTOR HARNESS INSPECTION ············· 5-100 4. CAMSHAFT/ROCKER ARM INSPECTION ........ 10-13
HOW TO RELIEVE FUEL PRESSURE············ 5-102 5. CYLINDER HEAD ASSEMBLY REMOVAL ........ 10-19
FUEL PRESSURE MEASUREMENT·············· 5-102 6. CYLINDER HEAD ASSEMBLY
FUEL LINE INSPECTION································ 5-104 DISASSEMBLY .................................................. 10-20
FUEL INJECTOR INSPECTION······················ 5-105 7. CYLINDER HEAD ASSEMBLY INSPECTION .... 10-23
PRESSURE REGULATOR INSPECTION········ 5-106 8. VALVE GUIDE REPLACEMENT ........................ 10-26
FUEL PUMP (HIGH PRESSURE SIDE) 9. VALVE SEAT RECONDITIONING ...................... 10-28
INSPECTION··················································· 5-107 10. CYLINDER HEAD ASSEMBLY ASSEMBLY ...... 10-30
10. IAB (INTAKE AIR BYPASS) CONTROL 11. CYLINDER HEAD ASSEMBLY
SYSTEM ............................................................ 5-109 INSTALLATION .................................................. 10-32
IAB CONTROL VALVE INSPECTION ············· 5-109 12. CAMSHAFT/ROCKER ARM ASSEMBLY .......... 10-34
SHUTTER VALVE DIAPHRAGM 13. CYLINDER HEAD COVER ASSEMBLY.............. 10-38
INSPECTION··················································· 5-110 14. CYLINDER HEAD COVER INSTALLATION ...... 10-40
11. VAPOR SEPARATOR/FUEL PUMP (HIGH
PRESSURE SIDE ) .............................................. 5-111
11. OIL PUMP/FLYWHEEL .............................................. 11-1 16. STEERING ROD/REMOTE CONTROL BOX ............ 16-1
1. EOP SWITCH/OIL FILTER FLANGE .................... 11-2 1. STEERING ROD.................................................... 16-1
2. OIL PUMP ............................................................ 11-6 2. REMOTE CONTROL BOX (OPTIONAL
3. FLYWHEEL.......................................................... 11-12 PART) .................................................................... 16-2
3. CONTROL PANEL (OPTIONAL PART) ................ 16-7
12. CRANKCASE/BALANCER ........................................ 12-1 4. INSPECTION ........................................................ 16-9
1. CRANKCASE/BALANCER CASE ASSEMBLY
REMOVAL ............................................................ 12-2 17. CABLES/SHIFT LINK BRACKET/SHIFT ARM/
2. BALANCER CASE ASSEMBLY NEUTRAL SWITCH .................................................... 17-1
DISASSEMBLY .................................................... 12-5 1. REMOTE CONTROL CABLE/GROMMET ............ 17-2
3. INSPECTION ........................................................ 12-6 2. SHIFT LINK BRACKET/NEUTRAL
4. BALANCER CASE ASSEMBLY ASSEMBLY ...... 12-7 SWITCH .............................................................. 17-11
5. CRANKCASE/BALANCER CASE ASSEMBLY 3. SEAL HOLDER.................................................... 17-20
INSTALLATION .................................................... 12-8
18. ELECTRICAL EQUIPMENT ........................................ 18-1
13. CYLINDER BLOCK/CRANKSHAFT/PISTONS .......... 13-1 1. STARTER MOTOR................................................ 18-1
1. DISASSEMBLY .................................................... 13-2 2. STARTER CABLE................................................ 18-15
2. INSPECTION ........................................................ 13-8 3. ECM/PGM-FI MAIN RELAY/FUSE BOX ............ 18-19
3. BEARING SELECTION ...................................... 13-15 4. POWER TILT RELAY/CONNECTOR
4. ASSEMBLY ........................................................ 13-19 BRACKET A ........................................................ 18-27

14. PROPELLER/GEAR CASE/EXTENSION CASE/ 19. OPERATION .............................................................. 19-1

OIL CASE.................................................................... 14-1 1. DOHC (SWING ARM TYPE) + VTEC .................. 19-1
1. PROPELLER .......................................................... 14-2 2. CHAIN DRIVE CAM DRIVE SYSTEM .................. 19-2
2. GEAR CASE ASSEMBLY [*1].............................. 14-3 3. INDEPENDENT CYLINDER HEAD/CYLINDER
3. WATER PUMP/SHIFT ROD [*1] .......................... 14-7 BLOCK COOLING SYSTEM................................ 19-3
4. PROPELLER SHAFT HOLDER 4. AIR/FUEL RATIO O2 FEEDBACK CONTROL
ASSEMBLY [*1] ................................................ 14-17 BY A/F SENSOR .................................................. 19-4
5. PROPELLER SHAFT/PROPELLER
SHAFT HOLDER [*1] ........................................ 14-18 20. WIRING DIAGRAM/SYSTEM DIAGRAM ................ 20-1
6. VERTICAL SHAFT/BEVEL GEAR [*1]................ 14-27
7. SHIM SELECTION [*1] ...................................... 14-35
8. SHIM POSITION [*1] ........................................ 14-40
9. BACKLASH ADJUSTMENT [*1] ...................... 14-41
10. GEAR CASE ASSEMBLY [*2]............................ 14-42
11. WATER PUMP/SHIFT ROD [*2] ........................ 14-46
12. PROPELLER SHAFT HOLDER
ASSEMBLY [*2] ................................................ 14-56
13. PROPELLER SHAFT/PROPELLER
SHAFT HOLDER [*2] ........................................ 14-57
14. VERTICAL SHAFT/BEVEL GEAR [*2]................ 14-68
15. SHIM SELECTION [*2] ...................................... 14-77
16. SHIM POSITION [*2] ........................................ 14-84
17. BACKLASH ADJUSTMENT [*2] ...................... 14-85
18. ANODE METAL/WATER SCREEN .................... 14-88
19. EXTENSION CASE/LOWER RUBBER
MOUNT .............................................................. 14-89
20. OIL CASE ............................................................ 14-94

15. MOUNTING CASE/STERN BRACKET/SWIVEL

CASE/POWER TRIM/TILT ASSEMBLY .................... 15-1
1. MOUNTING CASE .............................................. 15-2
2. STERN BRACKET/SWIVEL CASE
REMOVAL/INSTALLATION ................................15-10
3. STERN BRACKET/SWIVEL CASE/
POWER TRIM/TILT ASSEMBLY ........................ 15-14
4. POWER TRIM/TILT ASSEMBLY ........................ 15-36
5. AIR BLEEDING .................................................. 15-48
6. BLOW PRESSURE INSPECTION ...................... 15-50
7. POWER TILT MOTOR ASSEMBLY.................... 15-53
Abbreviations
ACG Alternator
A/F Air Fuel Ratio
API American Petroleum Institute
Approx. Approximately
Assy. Assembly
ATDC After Top Dead Center
ATF Automatic Transmission Fluid
ATT Attachment
BAT Battery
BDC Bottom Dead Center
BTDC Before Top Dead Center
BARO Barometric Pressure
CKP Crankshaft Position
Comp. Complete
CMP Camshaft Position
CYL Cylinder
DLC Data Link Connector
ECT Engine Coolant Temperature
ECM Engine Control Module
EOP Engine Oil Pressure
EX Exhaust
F Front or Forward
GND Ground
IAB Intake Air Bypass
IAC Idle Air Control
IAT Intake Air Temperature
I.D. Inside Diameter
IG or IGN Ignition
IN Intake
INJ Injection
L. Left
MAP Manifold Absolute Pressure
MIL Malfunction Indicator Lamp
O.D. Outside Diameter
OP Optional Part
PGM-FI Programmed-Fuel Injection
P/N Part Number
Qty Quantity
R. Right
SAE Society of Automotive Engineers
SCS Service Check Signal
STD Standard
SW Switch
TDC Top Dead Center
TP Throttle Position

Bl Black G Green Br Brown Lg Light green

Y Yellow R Red O Orange P Pink
Bu Blue W White Lb Light blue Gr Gray
1.SPECIFICATIONS
1. SPECIFICATIONS 2. DIMENSIONAL DRAWINGS

1. SPECIFICATIONS
• DIMENSIONS AND WEIGHTS

Model BF135A
Description code BARJ BASJ BARJ BASJ
Types LC LD LCD XC XD XCC XCD
Overall length 845 mm (33.3 in)
Overall width 580 mm (22.8 in)
Overall height 1,665 mm (65.6 in) 1,790 mm (70.5 in)
Dry weight (*1) 220 kg (485 lbs) 223 kg (492 lbs) 226 kg (498 lbs)
Operating weight (including oil) 228 kg (503 lbs) 231 kg (509 lbs) 234 kg (516 lbs)

*1: With propeller mounted.

Model BF150A
Description code BANJ BAPJ BANJ BAPJ
Types LC LD LCD XC XD XCC XCD
Overall length 845 mm (33.3 in)
Overall width 580 mm (22.8 in)
Overall height 1,665 mm (65.6 in) 1,790 mm (70.5 in)
Dry weight (*1) 220 kg (485 lbs) 223 kg (492 lbs) 226 kg (498 lbs)
Operating weight (including oil) 228 kg (503 lbs) 231 kg (509 lbs) 234 kg (516 lbs)

*1: With propeller mounted.

• FRAME

Model BF135A•BF150A
Types LC LD LCD XC XD XCC XCD
Transom height (*1) 508 mm (20.0 in) 635 mm (25.0 in)
Tilting angle 72°
Tilting stage Stageless
Swivel angle 30° right and left
Trim angle – 4° to 16°

*2: Transom angle is at 12°.

1-1
• TYPES OF Honda BF135A•BF150A OUTBOARD MOTORS
It may be necessary to refer to this chart for reference purposes when reading this manual.

Model BF135A•BF150A
Types LC LD LCD XC XD XCC XCD
Shaft length type L L L XL XL XL XL
Remote control (○) (○) (○) (○) (○) (○) (○)
Control panel (○) (○) (○) (○) (○) (○) (○)
Counter rotation ○ ○ ○

Power trim/tilt ○ ○ ○ ○ ○ ○ ○

L: Long shaft XL: Extra-long shaft (○): Optional part

1-2
• ENGINE
Model BF135A BF150A
Description code BEARJ BEANJ
Type 4-stroke, D.O.H.C., 4-cylinder 4-stroke, D.O.H.C., VTEC, 4-cylinder
Displacement 2,354 cm3 (143.6 cu-in)
Bore x stroke 87 x 99 mm (3.4 x 3.9 in)
Rated power (Full throttle range) 100.7 kW (135 HP) 111.9 kW (150 HP)
at 5,000 – 6,000 min–1 (rpm) at 5,000 – 6,000 min–1 (rpm)
Maximum torque 196 N.m (20.0 kgf.m, 145 lbf.ft) 202 N.m (20.6 kgf.m, 149 lbf.ft)
Compression ratio 9.6 : 1
Fuel consumption ratio 350 g/kW.h (257 g/HP.h, 0.575 lb/HP.h) 320 g/kW.h (235 g/HP.h, 0.526 lb/HP.h)
Cooling system Forced water circulation by impeller pump with thermostat
Ignition system Full transistorized, battery ignition
Ignition timing 0˚ ± 2˚ at 750 min–1 (rpm) B.T.D.C.
Spark plug IZFR6K11 (NGK), SKJ20DR-M11 (DENSO)
Fuel supply system Programmed fuel injection
Fuel injection system Electronic control
Fuel injection nozzle Multi-hole type
Fuel pipe Rubber tubes
Lubrication system Pressure lubrication by trochoid pump
Lubrication capacity 7.35r (7.8 US qt, 6.5 lmp qt)
[with oil filter replacement: 6.7r (7.1 US qt, 5.9 lmp qt)]
[without oil filter replacement: 6.5r (6.9 US qt, 5.7 lmp qt)]
Starting system Electric starter
Stopping system Primary circuit ground
Fuel used Unleaded gasoline with a pump octane number 86 or higher
Fuel pump Electric and mechanical plunger type
Exhaust system Underwater type
Recommended oil SAE 10W-30

• LOWER UNIT
Clutch Dog clutch (Forward – Neutral – Reverse)
Gear ratio 0.467 (14/30)
Reduction Spiral bevel
Gear case oil capacity 0.98r (1.04 US qt, 0.86 lmp qt)
Propeller rotating direction Clockwise (viewed from rear): LC, LD, XC and XD types
Counterclockwise (viewed from rear): LDC, XCC and XCD types
Propeller driving system Spline

1-3
1-4
1,665 mm (65.6 in) 382 mm
[ ]: Extra-long shaft type

[1,790 mm (70.5 in)] (15.0 in)

30°
2. DIMENSIONAL DRAWINGS

845 mm (33.3 in)

12°
508 mm (20.0 in)
[635 mm (25.0 in)]
(22.8 in)
580 mm
 ANSI INV. S 16/32 x 15T x 30 x 1.5 mm

M18 x 1.5

ø4
• PROPELLER SHAFT

7 mm
(0.3 in)
(ø0.2)

(1.12 in)
28.5 mm
-0.04
ø16.9 +0.03
(ø0.67 +0.001
-0.002 )

0
ø24.9 -0.1
0

57.5 ± 0.5 mm
(ø0.98 -0.003 )

(2.26 ± 0.02 in)

151 mm (5.9 in)

(2.22 in)
56.5 mm
-0.041
ø30 -0.020
(ø1.2 -0.0008
-0.0016 )

1-5
2. SERVICE INFORMATION
1. THE IMPORTANCE OF PROPER SERVICING 7. TORQUE VALUES
2. IMPORTANT SAFETY PRECAUTIONS 8. SPECIAL TOOLS
3. SERVICE RULES 9. TROUBLESHOOTING
4. SYMBOLS USED IN THIS MANUAL 10. CABLE/HARNESS ROUTING
5. SERIAL NUMBER LOCATIONS 11. TUBE ROUTING
6. MAINTENANCE STANDARDS 12. LUBRICATION

1. THE IMPORTANCE OF PROPER SERVICING

Proper servicing is essential to the safety of the operator and
the reliability of the outboard motor. Any error or oversight WARNING
made by the technician while servicing can easily result in Improper servicing can cause an unsafe condition
faulty operation, damage to the outboard motor or injury to the that can lead to serious injury or death.
operator.
Follow the procedures and precautions in this
shop manual carefully.

Some of the most important precautions are given below.

However, we cannot warn you of every conceivable hazard that
WARNING
can arise in performing maintenance or repairs. Only you can Failure to properly follow maintenance
decide whether or not you should perform a given task. instructions and precautions can cause you to be
seriously hurt or killed.

Follow the procedures and precautions in this

shop manual carefully.
2. IMPORTANT SAFETY PRECAUTIONS
Make sure you have a clear understanding of all basic shop safety practices and that you are wearing appropriate
clothing and using safety equipment. When performing any service task, be especially careful of the following:
• Read all of the instructions before you begin, and make sure you have the tools, the replacement or repair parts, and
the skills required to perform the tasks safely and completely.
• Protect your eyes by using proper safety glasses, goggles, or face shields any time you hammer, drill, grind, or work
around pressurized air or liquids, and springs or other stored-energy components. If there is any doubt, put on eye
protection.
• Use other protective wear when necessary, for example, gloves or safety shoes. Handling hot or sharp parts can cause
severe burns or cuts. Before you grab something that looks like it can hurt you, stop and put on gloves.
• Protect yourself and others whenever you have engine-powered equipment up in the air.
Any time you lift an outboard motor with a hoist, make sure that the hoist hook is securely attached to the outboard
motor.

Make sure the engine is off before you begin any servicing procedures, unless the instruction tells you to do otherwise.
This will help eliminate several potential hazards:
• Carbon monoxide poisoning from engine exhaust. Be sure there is adequate ventilation whenever you run the engine.
• Burns from hot parts. Let the engine and exhaust system cool before working in those areas.
• Injury from moving parts. If the instruction tells you to run the engine, be sure your hands, fingers, and clothing are
out of the way.

Gasoline vapors and hydrogen gasses from batteries are explosive. To reduce the possibility of a fire or explosion, be
careful when working around gasoline or batteries.
• Use only a nonflammable solvent, not gasoline, to clean parts.
• Never drain or store gasoline in an open container.
• Keep all cigarettes, sparks, and flames away from the battery and all fuel-related parts.

2-1
3. SERVICE RULES
1. Use genuine Honda or Honda-recommended parts and lubricants or their equivalents. Parts that do not meet Honda's
design specifications may damage the unit.
2. Use the special tools designed for the product.
3. Install new gaskets, O-rings, etc. when reassembling.
4. When torquing bolts or nuts, begin with larger-diameter or inner bolts first and tighten to the specified torque
diagonally, unless a particular sequence is specified.
5. Clean parts in cleaning solvent upon disassembly. Lubricate any sliding surfaces before reassembly.
6. After reassembly, check all parts for proper installation and operation.
7. Many screws used in this machine are self-tapping. Be aware that cross-threading or overtightening these screws will
strip the threads and ruin the hole.
8. Use only metric tools when servicing this unit. Metric bolts, nuts and screws are not interchangeable with non-metric
fasteners. The use of incorrect tools and fasteners will damage the unit.

4. SYMBOLS USED IN THIS MANUAL

As you read this manual, you may find the following symbols with the instructions.

A special tool is required to perform the procedure.

Apply grease.

(Molybdenum : Use molybdenum oil solution (mixture of the engine oil and molybdenum grease with the ratio 1 : 1).
disulfide oil)

Apply oil.

○ x ○ (○) Indicates the diameter, length, and quantity of metric flange bolts used.

P. 1-1 Indicates the reference page.

5. SERIAL NUMBER LOCATIONS

The engine serial number is stamped on the right side of the cylinder block and the product identification number is
located on the right side of the stern bracket. Always specify these numbers when inquiring about the engine or when
ordering parts in order to obtain the correct parts for the outboard motor being serviced.

ENGINE SERIAL NUMBER PRODUCT IDENTIFICATION NUMBER

2-2
6. MAINTENANCE STANDARDS
• ENGINE Unit: mm (in)

Parts Item Standard Service limit

Engine Idle speed (in neutral) 750 ± 50 min (rpm)
–1
–
Trolling speed 650 ± 50 min–1 (rpm) –
Cylinder compression 1,532 – 1,728 930
[kPa (kgf/cm2, psi) at 200 min–1 (rpm)] (15.6 – 17.6, 222 – 250) (9.5, 135)
Compression gap between cylinders
– 200 (2.0, 28)
[kPa (kgf/cm2, psi)]
Spark plugs Gap 1.0 – 1.1 (0.039 – 0.043) 1.3 (0.051)
Valves Valve clearance IN 0.21 – 0.25 (0.008 – 0.010) –
EX 0.28 – 0.32 (0.011 – 0.013) –
Overall length IN 108.7 – 109.5 (4.28 – 4.31) –
EX 108.3 – 109.1 (4.26 – 4.30) –
Valve O.D. IN 34.85 – 35.15 (1.372 – 1.384) –
EX 29.85 – 30.15 (1.175 – 1.187) –
Stem O.D. IN 5.475 – 5.485 (0.2156 – 0.2159) 5.445 (0.2144)
EX 5.450 – 5.460 (0.2146 – 0.2150) 5.420 (0.2134)
Stem-to-guide clearance IN 0.030 – 0.055 (0.0012 – 0.0022) 0.08 (0.003)
EX 0.055 – 0.080 (0.0022 – 0.0031) 0.11 (0.004)
Valve seats Seat width IN/EX 1.25 – 1.55 (0.049 – 0.061) 2.0 (0.08)
Seat installation height IN/EX 44.0 – 44.6 (1.73 – 1.76) –
Valve guides Guide I.D. IN/EX 5.51 – 5.53 (0.217 – 0.218) 5.55 (0.219)
Guide extrusion amount IN 15.2 – 16.2 (0.60 – 0.64) –
EX 15.5 – 16.5 (0.61 – 0.65) –
Valve springs Free length IN 49.64 (1.954) –
EX 49.64 (1.954) –
Rocker arms Rocker arm I.D. IN 17.019 – 17.035 (0.6700 – 0.6707) –
EX 17.012 – 17.039 (0.6698 – 0.6708) –
Rocker arm shaft O.D. IN/EX 16.983 – 16.994 (0.6686 – 0.6690) –
Rocker arm-to-rocker arm IN 0.025 – 0.052 (0.0010 – 0.0020) 0.08 (0.003)
shaft clearance EX 0.018 – 0.056 (0.0007 – 0.0022) 0.08 (0.003)
Pistons Skirt O.D. A 86.98 – 86.99 (3.4244 – 3.4248) 86.93 (3.4224)
B 86.97 – 86.98 (3.4240 – 3.4244) 86.92 (3.4220)
Piston-to-cylinder clearance 0.02 – 0.04 (0.001 – 0.002) 0.05 (0.002)
Piston pin bore I.D. 21.960 – 21.963 (0.8646 – 0.8647) –

2-3
 Unit: mm (in)

Parts Item Standard Service limit

Pistons Ring groove width Top 1.23 – 1.24 (0.0484 – 0.0488) 1.25 (0.0492)
Second 1.24 – 1.25 (0.0488 – 0.0492) 1.25 (0.0492)
Oil 2.005 – 2.025 (0.0789 – 0.0797) 2.05 (0.081)
Piston pins Pin O.D. 21.961 – 21.965 (0.8646 – 0.8648) 21.953 (0.8643)
Pin-to-pin bore clearance –0.005 – +0.002 (–0.0002 – +0.0001) 0.005 (0.0002)
Piston rings Ring side clearance Top 0.045 – 0.070 (0.0018 – 0.0028) 0.13 (0.005)
Second 0.040 – 0.065 (0.0016 – 0.0026) 0.13 (0.005)
Ring end gap Top 0.20 – 0.35 (0.008 – 0.014) 0.6 (0.02)
Second 0.50 – 0.65 (0.020 – 0.026) 0.75 (0.030)
Oil 0.20 – 0.70 (0.008 – 0.028) 0.8 (0.031)
Ring thickness Top 1.170 – 1.185 (0.0461 – 0.0467) –
Second 1.175 – 1.190 (0.0463 – 0.0469) –
Cylinder head Warpage – 0.05 (0.002) Min.
Camshaft journal I.D. 29.000 – 29.024 (1.1417 – 1.1427) –
Head height 103.95 – 104.05 (4.093 – 4.096) –
Cylinder block Cylinder sleeve I.D. A or I 87.01 – 87.02 (3.4256 – 3.4260) 87.07 (3.4279)
B or II 87.00 – 87.01 (3.4252 – 3.4256) 87.07 (3.4279)
Gap between upper and lower points –
– 0.05 (0.002)
of sleeve I.D.
Warpage 0.07 (0.003) Max. 0.10 (0.004)
Connecting Small end I.D. 23.969 – 23.982 (0.9437 – 0.9442) –
rods Small end-to-piston pin clearance 0.005 – 0.015 (0.0002 – 0.0006) 0.02 (0.001)
Big end axial clearance 0.15 – 0.35 (0.006 – 0.014) 0.4 (0.02)
Connecting rod bearing oil clearance 0.032 – 0.066 (0.0013 – 0.0026) 0.077 (0.0030)
Crankshaft Journal O.D. Main No. 1, 2, 4, 5 54.984 – 54.992 (2.1647 – 2.1650) –
No. 3 54.976 – 55.000 (2.1644 – 2.1654) –
Pin 47.976 – 48.000 (1.8888 – 1.8898) –
Journal cylindricity 0.005 (0.0002) Max. 0.010 (0.0004)
Journal roundness 0.005 (0.0002) Max. 0.010 (0.0004)
Crankshaft runout 0.03 (0.001) Max. 0.04 (0.002)
Crankshaft axial clearance 0.10 – 0.35 (0.004 – 0.014) 0.45 (0.018)
Main bearing oil clearance No. 1, 2, 4, 5 0.017 – 0.041 (0.0007 – 0.0016) 0.05 (0.002)
No. 3 0.025 – 0.049 (0.0010 – 0.0019) 0.055 (0.0022)
Thrust metal side clearance 0.10 – 0.35 (0.004 – 0.014) 0.45 (0.018)

2-4
 Unit: mm (in)

Parts Item Standard Service limit

Camshaft Camshaft axial clearance 0.05 – 0.20 (0.002 – 0.008) 0.4 (0.02)
Camshaft runout 0.03 (0.001) Max. 0.4 (0.02)
Journal O.D. No. 1 28.955 – 28.970 (1.1400 – 1.1405) –
No. 2 – No. 5 28.925 – 28.940 (1.1388 – 1.1394) –
Cam height IN:PRI/SEC 32.626 – 32.931 (1.2845 – 1.2965) –
IN:MID 35.369 – 35.654 (1.3925 – 1.4037) –
EX 33.927 – 34.212 (1.3357 – 1.3469) –
Camshaft oil clearance No. 1 0.030 – 0.069 (0.0012 – 0.0027) 0.15 (0.006)
No. 2 – No. 5 0.060 – 0.099 (0.0024 – 0.0039) 0.15 (0.006)
Oil pump Body I.D. 84.000 – 84.030 (3.3071 – 3.3083) –
Inner rotor-to-outer rotor clearance 0.04 – 0.16 (0.002 – 0.006) 0.20 (0.008)
Outer rotor-to-oil pump body clearance 0.02 – 0.07 (0.001 – 0.003) 0.12 (0.005)
Outer rotor height 9.480 – 9.500 (0.3732 – 0.3740) –
Pump body depth 9.520 – 9.550 (0.3748 – 0.3760) –
Outer rotor-to-oil body side clearance 0.14 – 0.19 (0.006 – 0.007) 0.20 (0.008)
Vapor separator Float height 28.5 – 33.5 (1.12 – 1.32) –
Fuel pump Discharge volume 45 mR (1.5 Us oz, 1.6 Imp oz)
–
[with pump operated for 2 sec. at 12V] or more
Fuel line Fuel pressure [kPa (kgf/cm2, psi)] 270 – 320 (2.8 – 3.3, 40 – 47) –
Alternator Brush length 10.5 (0.41) 8.4 (0.33)
Brush spring pressure 3.2 N (0.33 kgf, 0.73 lbf) –
Rotor coil resistance 2.9 Ω –
Slip ring O.D. 14.4 (0.57) 14.0 (0.55)
Belt tension Used 392 – 490 N
–
Measured at the center of belt belt (40 – 50 kgf, 88 – 100 lbf)
between the pulleys with belt New 490 – 588 N
tension gauge. –
belt (50 – 60 kgf, 110 – 132 lbf)
Belt deflection Used 10.6 – 11.1
–
Measured with 98 N (10 kgf, 22 lbf) belt (0.42 – 0.44)
of force applied to the center of belt New 10.1 – 10.6
between the pulleys) –
belt (0.40 – 0.42)
Starter motor Brush length 12.3 (0.48) 7.0
Insulator length (Mica depth) 0.4 – 0.5 (0.016 – 0.020) 0.2 (0.008)
Commutator O.D. 29.4 (1.16) 28.8 (1.13)
Commutator runout – 0.1 (0.004)
PRI: Primary, MID: Mid, SEC: Secondary

2-5
• FRAME Unit: mm (in)

Parts Item Standard Service limit

Propeller Shaft O.D. At forward bevel gear
24.987 – 25.000 (0.9837 – 0.9843) 24.966 (0.9829)
shaft (LC, LD, XC and XD types)
At reverse bevel gear
24.987 – 25.000 (0.9837 – 0.9843) 24.966 (0.9829)
(LCD, XCC and XCD types)
At needle bearing 30.007 – 30.020 (1.1814 – 1.1819) 29.990 (1.1807)
Vertical
Shaft O.D. (at needle bearing) 28.556 – 28.575 (1.1242 – 1.1250) 28.545 (1.1238)
shaft

2-6
7. TORQUE VALUES
Thread dia. (mm) Torque value
Item
and pitch (length) N.m kgf.m lbf.ft
• ENGINE
Lower block bolt (*1) M11 x 1.5 29 3.0 22
M8 x 1.25 26 2.7 20
Crankcase bolt M6 x 1.0 12 1.2 9
Oil case bolt M10 x 1.25 34 3.5 25
Lower block orifice M10 x 1.0 10 1.0 7
Oil jet bolt M8 x 0.75 (Special bolt) 16 1.6 12
No.1 camshaft holder 10 mm sealing bolt M10 x 1.0 (Special bolt) 20 2.0 14
Cylinder head bolt (*2) M11 x 1.5 39 4.0 29
Cylinder head cover nut M6 x 1.0 12 1.2 9
Spark plug M14 x 1.25 18 1.8 13
Connecting rod bolt (*3) M8 x 0.75 (Special bolt) 20 2.0 14
Crankshaft pulley bolt M16 x 1.5 245 25.0 181
Balancer chain guide bolt M6 x 1.0 12 1.2 9
Balancer driven sprocket bolt M10 x 1.25 44 4.5 33
Balancer case assembly bolt (8 x 50 mm/8 x 75 mm) M8 x 1.25 22 2.2 16
(8 x 55 mm) M8 x 1.25 27 2.8 20
(10 x 105 mm) M10 x 1.25 44 4.5 33
Balancer holder bolt M6 x 1.0 12 1.2 9
M8 x 1.25 27 2.8 20
Chain case special bolt M6 x 1.0 (Special bolt) 12 1.2 9
Chain case bolt M6 x 1.0 12 1.2 9
M6 x 1.0 (SH bolt) 12 1.2 9
Chain case cover bolt M6 x 1.0 12 1.2 9
Cam chain tensioner bolt M6 x 1.0 12 1.2 9
Cam chain guide bolt M6 x 1.0 12 1.2 9
Cam chain guide B bolt M8 x 1.25 22 2.2 16
Cam chain tensioner arm bolt M8 x 1.25 (Special bolt) 22 2.2 16
Exhaust camshaft sprocket bolt M10 x 1.25 72 7.3 53
VTC flange bolt M12 x 1.25 (Special bolt) 113 11.5 83
Camshaft holder bolt M8 x 1.25 22 2.2 16
M6 x 1.0 12 1.2 9
Camshaft collar bolt M14 x 1.0 (Special bolt) 39 4.0 29
CMP pulse plate bolt M14 x 1.0 (Special bolt) 39 4.0 29
Valve adjusting lock nut (IN side) M7 x 0.75 20 2.0 14
Valve adjusting lock nut (EX side) M7 x 0.75 14 1.4 10
Oil filter M20 x 1.5 12 1.2 9
Oil drain plug bolt M12 x 1.5 23 2.3 17
Throttle body bolt M8 x 1.25 22 2.2 16
IAC valve bolt M8 x 1.25 22 2.2 16
Injector base bolt, nut M8 x 1.25 24 2.4 17
Fuel pipe bolt M8 x 1.25 22 2.2 16
Pressure regulator nut M18 x 1.0 27 2.8 20
IAB control valve bolt M5 x 0.8 5.4 0.55 4.0

*1: Tighten the lower block bolts to 29 N.m (3.0 kgf.m, 22 lbf.ft) first, then tighten them to additional 56° (Angle method).
*2: Tighten the new cylinder head bolts to 39 N.m (4.0 kgf.m, 29 lbf.ft) (Snag torque), then tighten them to additional 278°.
(Tighten to 90° at first, then to 90°, and to 98° in this order) (Angle method).
At assembly, tighten the lower block bolts to 39 N.m (4.0 kgf.m, 29 lbf.ft) (Snag torque), then tighten them to
additional 180°. (Tighten to 90° at first, then to 90° in this order) (Angle method).
*3: Tighten the connecting rod bolts to 20 N.m (2.0 kgf.m, 14 lbf.ft) (Snag torque), then tighten them to additional 90°
(Angle method).
• SH bolt: Small head bolt.

2-7
 Thread dia. (mm) Torque value
Item
and pitch (length) N.m kgf.m lbf.ft
• ENGINE
Mounting case bolt M12 x 1.25 64 6.5 47
M10 x 1.25 44 4.5 33
M8 x 1.25 26 2.7 20
Mounting case nut M10 x 1.25 44 4.5 33
Plug hole coil bolt M6 x 1.0 12 1.2 9
Flywheel boss bolt M8 x 1.25 32 3.3 24
Flywheel bolt M12 x 1.0 118 12.0 87
Alternator bolt M10 x 1.25 44 4.5 33
nut M8 x 1.25 26 2.7 20
Alternator pulley lock nut M14 x 1.5 110 11.2 81
Starter motor bolt M10 x 1.25 44 4.5 33
Starter motor front bracket screw M5 screw 2.5 0.25 1.8
Starter motor bolt screw M5 5 0.5 3.6
Starter solenoid switch screw M6 screw 6 0.6 4.3
EOP switch (Low pressure side) PT 1／8 8 0.8 5.8
EOP switch (High pressure side) M10 x 1.25 22 2.2 16
ECT sensor M10 x 1.25 12 1.2 9
A/F sensor M18 x 1.5 42 4.3 31
Knock sensor M12 x 1.25 31 3.2 23
MAP sensor bolt M5 x 0.8 3.4 0.35 2.5
ECM bolt M6 x 1.0 5 0.5 3.6
Intake manifold bolt, nut M8 x 1.25 26 2.7 20
Exhaust manifold bolt M10 x 1.25 39 4.0 29
Exhaust guide bolt M8 x 1.25 26 2.7 20
Water separator body screw M5 screw 3.4 0.35 2.5
Fuel strainer body screw M5 screw 3.4 0.35 2.5
Fuel pump (low pressure side) bolt M6 x 1.0 12 1.2 9
Vapor separator assembly bolt M8 x 1.25 26 2.7 20
Vapor separator stay bolt M8 x 1.25 26 2.7 20
Service check bolt M6 x 1.0 12 1.2 9
Vapor separator cover screw M5 screw 3.4 0.35 2.5
Water jacket cover screw M5 screw 3.4 0.35 2.5
Strainer cover screw M5 screw 3.4 0.35 2.5
Pump cover screw M5 screw 3.4 0.35 2.5
Pump harness assembly screw M4 screw 2.1 0.21 1.5
Float pin screw 2.1 0.21 1.5
Fuel pump case bolt M6 x 1.0 12 1.2 9
Plate stay A bolt M6 x 1.0 12 1.2 9
• GEAR CASE
Propeller shaft holder bolt M10 x 1.25 34 3.5 25
18 mm castle nut (*1) M18 x 1.5 1 0.1 0.7
Gear case bolt M10 x 1.25 34 3.5 25
Oil level bolt M8 x 1.25 3.4 0.35 2.5
Oil drain bolt M8 x 1.25 3.4 0.35 2.5
Water screen screw M5 x 0.8 1 0.1 0.7
Sensor nipple M8 x 1.0 3 0.3 2.2
Bearing holder (LCD, XCC and XCD types only) M100 x 2.0 191 19.5 141
Impeller housing bolt M8 x 1.25 19.7 2.0 14
64 mm lock nut M64 x 1.5 123 12.5 90
Pinion gear nut M18 x 1.0 142 14.5 105
• EXTENSION CASE/MOUNTING CASE
Extension case bolt M10 x 1.25 39 4.0 29
Lower rubber mounting bolt M12 x 1.25 83 8.5 61
Upper rubber mounting bolt M12 x 1.25 83 8.5 61

*1: If the split pin cannot be set by tightening the 18 mm castle nuts to 1 N.m (0.1 kgf.m, 0.7 lbf.ft), tighten the 18 mm
castle nut until the split pin can be set. Note that the maximum torque of the 18 mm castle nut is 44 N.m (4.5 kgf.m,
33 lbf.ft).

2-8
 Thread dia. (mm) Torque value
Item
and pitch (length) N.m kgf.m lbf.ft
• STERN BRACKET
7/8-14 UNF self-locking nut 7/8-14 UNF 34 3.5 25
25 x 2.0 mm self-locking nut M25 x 2.0 34 3.5 25
10 mm self-locking nut M10 x 1.25 34 3.5 25
• POWER TRIM/TILT ASSEMBLY
Cylinder cap comp. 162 16.5 119
Rod guide comp. 78 8.0 58
Manual valve M14 x 1.5 3.5 0.35 2.5
Socket bolt A/B 8.5 0.85 6.1
Power tilt motor assembly bolt 1/4-20 UNF 5 0.5 3.6
Power tilt motor assembly code holder screw M4 screw 1.4 0.14 1.0
Oil tank bolt 5 0.5 3.6
Oil tank cap 2.5 0.25 1.8
• FRAME/ELECTRICAL
Grease fitting M6 x 1.0 3 0.3 2.2
Neutral switch nut M20 x 1.0 2.5 0.25 1.8
Starter motor B terminal washer-nut M8 x 1.25 11 1.1 8
Alternator B terminal washer-nut M6 x 1.0 8 0.8 5.8
Alternator fuse box B terminal washer-nut M6 x 1.0 8 0.8 5.8
Alternator fuse box bolt M6 x 1.0 5 0.5 3.6
Fuse box bracket bolt M6 x 1.0 5 0.5 3.6
PGM-FI main relay bolt M6 x 1.0 5 0.5 3.6
ECM bracket bolt M6 x 1.0 5 0.5 3.6
L./R. engine under cover screw M6 screw 4.5 0.45 3.3
Starter motor bolt M10 x 1.25 44 4.5 33

• Use the standard torque values for the bolts, nuts and screws that are not listed in this table.

STANDARD TORQUE VALUES

Thread dia. (mm) Torque value

Item
and pitch (length) N.m kgf.m lbf.ft
Screw 5 mm 4.2 0.42 3.0
6 mm 9 0.9 6.5
Bolt and nut 5 mm 5.2 0.52 3.8
6 mm 10 1.0 7
8 mm 21.5 2.15 16
10 mm 34 3.5 25
12 mm 54 5.5 40
Flange bolt and nut 6 mm (SH bolt) 9 0.9 6.5
6 mm (CT bolt) 12 1.2 9
6 mm 12 1.2 9
8 mm 26 2.7 20
10 mm 39 4.0 29

• CT bolt: Self-tapping bolt

• SH bolt: Small head bolt

2-9
8. SPECIAL TOOLS
• Special tools applicable to the parts except gear case

Tool name Tool number Application

1 Ring gear holder 070PB-ZY60100 Flywheel boss, flywheel removal/installation
2 SCS service check connector 070PZ-ZY30100 ECU troubleshooting, idling adjustment
3 Test harness 070PZ-ZY60100 ECU troubleshooting
4 Float level gauge 07401-0010000 Vapor separator float level inspection
5 Oil pressure gauge attachment 07406-0030000 Oil pressure test
6 Fuel pressure gauge set 07406-0040003 Fuel pressure inspection
7 Oil pressure gauge set 07506-3000001 Oil pressure test
8 Valve guide driver, 5.5 mm 07742-0010100 Valve guide removal/installation
9 Pin driver, 6.0 mm 07744-0010500 Balancer shaft hold
10 Attachment, 32 x 35 mm 07746-0010100 22 x 35 x 7 mm water seal installation,
Lower mount center hosing removal
11 Attachment, 37 x 40 mm 07746-0010200 Alternator front bearing installation
12 Attachment, 52 x 55 mm 07746-0010400 Alternator rear bearing, Chain case oil seal
installation
13 Attachment, 24 x 26 mm 07746-0010700 Alternator front bearing removal,
14 x 26 x 8 mm water seal installation
14 Driver, 22 mm I.D. 07746-0020100 Alternator rear bearing installation
15 Attachment, 15 mm I.D. 07746-0020200 Alternator rear bearing installation
16 Driver, 40 mm I.D. 07746-0030100 Lower mount center housing installation
17 Pilot, 12 mm 07746-0040100 14 x 26 x 8 mm water seal installation
18 Pilot, 15 mm 07746-0040300 Alternator front bearing removal/installation
19 Pilot, 20 mm 07746-0040500 Mounting case needle bearing installation
20 Pilot, 30 mm 07746-0040700 Lower mount center housing removal
21 Pilot, 22 mm 07746-0041000 22 x 35 x 7 mm water seal installation
22 Driver 07749-0010000 Driver for 10 through 13, 17 through 21,
33 through 35 and 48
23 Valve spring compressor 07757-0010000 Valve keeper removal/installation
24 Valve spring compressor attachment 07757-PJ10100
25 Valve seat cutter, 45° 35 mm 07780-0010400 Valve seat reconditioning (IN)
26 Valve seat cutter, 45° 33 mm 07780-0010800 Valve seat reconditioning (EX)
27 Valve seat cutter, 32° 38.5 mm 07780-0012400 Valve seat reconditioning (IN)
28 Valve seat cutter, 32° 33 mm 07780-0012900 Valve seat reconditioning (EX)
29 Valve seat cutter, 60° 30 mm 07780-0014000 Valve seat reconditioning (EX)
30 Valve seat cutter, 60° 37.5 mm 07780-0014100 Valve seat reconditioning (IN)
31 Cutter holder, 5.5 mm 07781-0010101 Valve seat reconditioning (IN/EX)
32 Sensor socket wrench, 22 x 150L 07906-PD10000 A/F sensor removal/installation
33 Attachment, 28 x 30 mm 07946-1870100 Mounting case needle bearing installation
34 Oil seal driver attachment, 72 mm 07947-6340201 Oil pump body oil seal installation
35 Oil seal driver 07947-SB00100 Oil pump cover oil seal installation
36 Oil filter wrench 07HAA-PJ70101 Oil filter removal/installation
37 Valve guide reamer, 5.525 mm 07HAH-PJ70100 Valve guide reaming
38 Socket wrench, 19 mm 07JAA-001020A Crankshaft pulley bolt removal/installation
39 Handle 07JAB-001020B
40 Pulley holder attachment, HEX 50 mm 07JAB-0010400
41 Belt tension gauge 07JGG-0010101 Alternator belt tension inspection
42 Air supply 07LAJ-PR30102 VTEC system, VTEC valve inspection
43 Stem seal driver 07PAD-0010000 Valve stem seal A/B installation

2-10
 Tool name Tool number Application
44 Pin wrench, 6 mm 07SPA-ZW10100 Piston rod comp. removal/installation
45 Pin wrench, 4 mm 07SPA-ZW10200 Rod guide comp. removal/installation
46 Oil pressure gauge joint A 07SPJ-ZW10100 Power trim/tilt assembly blow pressure
inspection
47 Oil pressure gauge joint B 07SPJ-ZW10200
48 Oil seal driver attachment, 96 07ZAD-PNA0100 Crankshaft oil seal installation
49 VTEC air adapter 07ZAJ-PNA0101 VTEC system, VTEC valve inspection
50 VTEC air stopper 07ZAJ-PNA0200
51 Air joint adapter 07ZAJ-PNA0300
1 4 7
3
2 6
5

10 – 13
8 14 15 16
9

17 – 21 23
22 24
25, 26 27, 28 29, 30

35
36
31 33 34
32
37

38 40 41
39
42

46 47
43 48
44 45

51
49 50

2-11
• Special tools applicable to all types of gear case

Tool name Tool number Application

1 Outer driver attachment, 30 x 37 070PD-ZY60200 30 x 37 x 26 mm needle bearing installation
2 Gauge adapter, 110 mm 070PJ-ZY30100 Vertical shaft pinion gear shim adjustment
3 Attachment, 32 x 35 mm 07746-0010100 23 x 36 x 6 mm water seal installation
4 Attachment, 62 x 68 mm 07746-0010500 30 x 37 x 26 mm needle bearing installation
5 Pilot, 35 mm 07746-0040800 Needle bearing (outer race) removal
6 Driver 07749-0010000 Driver for 3 and 12
7 Lock nut wrench, 30/64 mm 07916-MB00002 Vertical shaft lock nut removal/installation
8 Remover weight 07741-0010201 30 x 37 x 26 mm needle bearing removal
9 Remover handle 07936-3710100
10 Bearing remover, 30 mm 07936-8890300
11 Oil seal driver 07947-SB00100 30 x 45 x 7 mm water seal installation
12 Oil seal driver attachment, 21 mm 07947-ZV00100 12 x 21 x 6 mm oil seal installation
13 Oil seal driver attachment, 27.5 x 44 mm 07948-9540000 Needle bearing installation
14 Driver handle, 15 x 280 mm 07949-3710001 Needle bearing (outer race) removal
15 Driver shaft, B 07964-MB00200 30 x 62 x 40 mm taper roller bearing
installation
16 Attachment, 78 x 90 mm 07GAD-SD40101 Needle bearing installation
17 Vertical shaft holder 07SPB-ZW10200 Vertical shaft pinion gear nut removal/
installation
18 Puller jaws 07SPC-ZW0010Z Forward bevel gear backlash inspection
19 Puller bolt 07SPC-ZW0011Z
20 Backlash indicator tool 07SPJ-ZW0030Z
21 Backlash indicator attachment 07SPK-ZW10100
22 Shaft installer, 15 x 370 mm 07VMF-KZ30200 Needle bearing installation
23 Bearing driver attachment, 37 mm 07ZMD-MBW0200 Needle bearing (outer race) removal

• Special tools applicable to LC, LD, XC and XD types of gear case

Tool name Tool number Application

24 Driver handle, 480 mm 070GD-0010100 50 x 90 x 28 mm taper bearing (outer
race) installation
25 Taper bearing installer attachment 070PF-ZY60100
26 Remover weight 07741-0010201 50 x 90 x 28 mm taper bearing (outer
race) removal
27 Remover handle 07936-3710100
28 Bearing race puller 070PC-ZY3A100
29 Attachment, 62 x 68 mm 07746-0010500 Reverse bevel gear installation
30 Pilot, 35 mm 07746-0040800 Reverse bevel gear removal/installation
31 Attachment, 27.2 07747-0010300 Reverse bevel gear removal
32 Driver 07749-0010000 Driver for 29, 30, 31 and 33
33 Oil seal driver, 52 x 55 mm 07NAD-P200100 50 x 90 x 28 mm taper bearing (inner race)
or installation
07NAD-P20A100

• Special tools applicable to LCD, XCC and XCD types of gear case

Tool name Tool number Application

34 Remover weight 07741-0010201 Reverse bevel gear, 50 x 90 x 28 mm
radial ball bearing removal [Puller jaws of
35 Remover handle 07936-3710100 the bearing race puller (07LPC-ZV30100)
36 Bearing race puller 070PC-ZY3A100 are removed and replaced with the puller
37 Puller jaws, 25 mm 07WPC-ZW50100 jaws of part number 07WPC-ZW50100.]
38 Taper bearing driver attachment 070PD-ZY60100 50 x 90 x 28 mm taper bearing (outer race)
removal
39 Attachment, 62 x 68 mm 07746-0010500 50 x 90 x 28 mm taper bearing (inner race/
outer race) installation

2-12
• Special tools applicable to LCD, XCC and XCD types of gear case

Tool name Tool number Application

40 Pilot, 35 mm 07746-0040800 Forward bevel gear removal
41 Attachment, 27.2 07747-0010300 Forward bevel gear removal
42 Driver 07749-0010000 Driver for 38, 39, 40 and 41
43 Oil seal driver, 65 mm 07JAD-PL90100 50 x 90 x 20 mm radial ball bearing
or installation
07JAD-PL9A100
44 Backlash indicator tool 07SPJ-ZW0030Z Reverse bevel gear backlash inspection
45 Backlash indicator attachment 07SPK-ZW10100
46 Pin spanner wrench, 110 mm 07WAA-S1G0100 Bearing holder assembly removal/installation

1 2 3 6, 32, 42 7
4, 29, 39 5, 30, 40

10 11 12 13
8, 26, 34 9, 27, 35

16 17 18
14, 24 15

19

21, 45 23 25
20, 44 22 28, 36

43
31, 41 33 37 38 46

2-13
 BF135A•BF150A

9. TROUBLESHOOTING
a. ENGINE
• HARD STARTING
• Use a known-good battery for troubleshooting.
Turn the ignition switch ON. Check whether Does not come ON. Perform ignition (power) system trouble-
the MIL comes ON for 2 seconds. shooting (P. 2-20).

Comes ON.

Check whether the warning buzzer sounds Does not sound.

twice.

Sounds. Perform warning system troubleshooting if the

warning buzzer sounds twice but keeps
sounding (intermittent sound).

Check whether the starter motor turns. Does not turn. Perform starting system troubleshooting (P. 2-
23).
Turns.

Check the fuel level in the fuel tank. No fuel or low level. Add fuel and restart the engine.

Fuel level OK.

Perform the following checks.
• Check for collapsed or pinched fuel line.
• Check whether the air vent knob of the tank
Remove the vapor separator drain screw Fuel flow restricted. is closed.
and check whether the fuel flows out freely. • Check the primer bulb for air leakage.
• Squeeze the primer bulb and check whether
the fuel reaches the vapor separator.
Fuel flows freely. If there is no problem, perform fuel supply sys-
tem troubleshooting (P. 5-96).
• When gasoline overflow from the vapor sep-
arator is detected, check the vapor separa-
tor (P. 5-111 thru. 120).

Remove the spark plugs and check for wet Abnormal. Perform fuel supply system troubleshooting
fouled electrodes. (P. 5-96).

Normal.

Dry the spark plug electrodes and check

whether the engine starts.

Does not start.

Perform the following checks and adjust-

Check whether the cylinder compression is Low compression. ments.
normal (P. 2-15). • Check valve clearance(P. 3-9)
• Check valve timing (P. 9-12)
Compression OK. • Check for loose cylinder head
• Check for damaged cylinder head gasket,
valves and valve seats.
Perform ignition system troubleshooting (P. • Check for worn pistons, piston rings and
2-25). cylinders.

2-14
BF135A•BF150A

• CYLINDER COMPRESSION TEST

THROTTLE ARM
1) Move the remote control lever to the “N” (Neutral) position.
2) Remove the clip of the emergency stop switch.
3) Remove the engine cover and disconnect the fuel injector
connectors of each cylinder.
4) Disconnect the ignition coil connector of each cylinder and
remove the spark plugs.

THROTTLE CONTROL CABLE

5) Disconnect the throttle control cable from the throttle arm.

THROTTLE ARM
6) Install a compression gauge in the No. 1 plug hole.
7) Set the throttle in the full throttle position by pulling the throt-
tle arm against the full throttle stopper with hand as shown.
8) Set the ignition switch in the “START” position and turn the
starter motor. Measure the cylinder compression.
9) Check the compression on all cylinders.

Cylinder 1,352 - 1,728 kPa (15.6 - 17.6 kgf/cm2,

compression 222 - 250 psi) at 200 min-1 (rpm)

COMPRESSION GAUGE
(Commercially available)

2-15
 BF135A•BF150A

• ENGINE DOES NOT RUN SMOOTHLY

• Perform “g. ALERT SYSTEM” (P. 2-32) troubleshooting when the warning buzzer sounds.
Perform the following troubleshooting when the warning buzzer does not sound but the engine does not run smoothly.

Engine starts, but stalls Faulty spark plug. Replace or clean (P. 3-8).
soon. Idle speed is not
stable or stalls.
Secondary air being sucked. • Retighten the IAC valve. Replace
• Loosely tightened IAC valve, dam- the gasket if damaged (P. 5-95).
aged gasket • Retighten the throttle body.
• Loosely tightened throttle body, Replace the seal ring if damaged
damaged seal ring (P. 5-131).
• Loosely tightened intake manifold, • Retighten the intake manifold (P.
damaged seal ring 5-132).
• Damaged fuel injector seal ring • Replace the fuel injector O-ring if
• Loosely tightened injector base, damaged (P. 5-136).
damaged gasket • Retighten the injector base.
Replace the gasket if damaged
(P. 5-139).

Low pressure fuel system faulty. Perform fuel supply system trouble-
shooting (P. 5-96).

High pressure fuel system faulty. Perform fuel supply system trouble-
shooting (P. 5-96).

Idle control system faulty. Perform idle control system trouble-

shooting (P. 5-93).

2-16
BF135A•BF150A

Engine speed does not Throttle link and/or cable misadjust- Adjust the throttle link and/or cable
increase. ed. (P. 3-26).

Propeller mismatched. Replace with the correct propeller.

High pressure fuel strainer clogged. Replace the (high pressure) fuel
strainer (P. 3-18).

Low pressure fuel strainer clogged. Replace the (low pressure) fuel
strainer (P. 3-15).

Low pressure fuel system faulty. Perform fuel supply system trouble-
shooting (P. 5-96).

High pressure fuel system faulty. Perform fuel supply system trouble-
shooting (P. 5-96).

Valve clearance misadjusted. Adjust the valve clearance (P. 3-9).

Variable intake system faulty. Perform variable intake system

troubleshooting (P. 5-109).

Neutral switch faulty (BF150A only). Replace the neutral switch (P. 17-
11)

Low-octane gasoline used. Use the recommended gasoline.

VTEC system faulty (BF150A only). Perform VTEC system trouble-

shooting (P. 5-42 or 5-82).

2-17
 BF135A•BF150A

Engine starts, but stalls Throttle link and/or cable misadjust- Adjust the throttle link and/or cable
soon. Idle speed is not ed. (P. 3-26).
stable or stalls.

Throttle shaft not move smoothly. Check the throttle body and clean if
necessary (P. 5-95).

Idle control system faulty. Perform idle control system trouble-

shooting (P. 5-93).

Secondary air being sucked. • Retighten the IAC valve. Replace

• Loosely tightened IAC valve, dam- the gasket if damaged (P. 5-95).
aged gasket • Retighten the throttle body.
• Loosely tightened throttle body, Replace the seal ring if damaged
damaged seal ring (P. 5-132).
• Loosely tightened intake manifold, • Retighten the intake manifold (P.
damaged seal ring 5-133).
• Damaged fuel injector seal ring • Replace the fuel injector O-ring if
• Loosely tightened injector base, damaged (P. 5-136).
damaged gasket • Retighten the injector base.
Replace the gasket if damaged
(P. 5-139).

2-18
BF135A•BF150A

Engine sometimes mis- Water in the fuel. • Check for water in the low pres-
fires or stalls. sure fuel strainer. Replace if nec-
essary (P. 3-15).
• Check for water in the water sep-
arator and drain if necessary (P.
3-19).
• Check for water in the fuel tank
and drain if necessary.

High pressure fuel strainer clogged. Replace the (high pressure) fuel
strainer (P. 3-18).

Low pressure fuel strainer clogged. Replace the (low pressure) fuel
strainer (P. 3-15).

Fuel tube faulty. • Check for pinched or collapsed

tube line and correct if necessary.
• Check the air vent knob of the
tank. Open the air vent knob if it is
closed.
• Check the primer bulb for air leak-
age. Replace if necessary.

High pressure fuel system faulty. Perform fuel supply system trouble-
shooting (P. 5-96).

Excessive engine speed Propeller mismatched. Replace with the correct propeller.

Propeller faulty. Replace the propeller.

Outboard installation setting incor- Adjust the installation setting.

rect (e.g. transom height, tilt angle,
etc.)

2-19
 BF135A•BF150A

b. IGNITION (POWER) SYSTEM

• ENGINE DOES NOT START

Turn the ignition switch ON. Check Does not

whether the warning buzzer sounds sound.
twice.

Check for blown No. 3 (10A), No. 7 NO Replace the blown fuse(s).
(30A) and the No. 4 (15A) fuses. Remove the cause of the
Are the fuses normal? blown fuse(s) before replace-
ment (see FUSE LOAD
YES CHART on P. 2-20).
Sounds.
Check the PGM-FI main relay. NO Replace the PGM-FI main
Is the main relay normal? relay.

YES

Check the ignition switch. NO Replace the ignition switch.

Is the ignition switch normal?

YES

Check the power line of the main NO Replace or repair the main
wire harness. wire harness.
Is the main wire harness normal?

YES

Perform MIL troubleshooting of “MIL

DOES NOT COME ON” (P. 5-18 or
5-61).

Check the No. 5 (10A) fuse. NO Replace the No. 5 (10A) fuse.
Is the fuse normal? Remove the cause of the blown fuse
before replacement (see FUSE LOAD
YES CHART on P. 2-20).

Turn the ignition switch ON and check Does not come ON. Open in the wire harness between the
whether the alternator indicator light indicator light and No. 5 (10A) fuse.
comes ON (with the engine stopped). • Replace or repair the wire harness.
• Replace the indicator light.
Comes ON.

Perform the following checks and

repair if necessary.
• Open in the wire between the MIL
and ECM.
• Blown MIL.
If there is no problem, replace the
ECM with a new one and recheck.

2-20
BF135A•BF150A

• FUSE LOAD CHART

W/Bl To ALTERNATOR (DETECTION

TERMINAL)

POWER TILT
SWITCH Lg To POWER TRIM/TILT RELAY
Lb To POWER TRIM/TILT RELAY

POWER TRIM/
TILT SWITCH

Bl/R To ECM
No. 3 (10A)
FUSE
W/Bl Bl/Y Bl/Y To BUZZER
Bl/Y To INDICATOR LIGHT
Bl/Y To TACHOMETER
IGNITION
Bl/Y To TRIM METER
SWITCH
Bl/W

Bl/Y To VOLTMETER (OPTION)

BATTERY Bl/Y To HOUR METER (OPTION)
Bl/Y
No. 1 (30A) A/F RELAY
FUSE
W/G W To A/F SENSOR
G/O To ECM (LAF)

PGM-FI MAIN RELAY

No. 7 (30A) No. 4 (15A)
FUSE FUSE
W/Y W/Bl Y/Bl Y/Bl To ECM (LGP1, LGP2)

MAIN Y/Bl To INJECTOR

Y/Bl To CKP SENSOR

No. 2 (10A) Y/Bl To CMP SENSOR

No. 6 (15A)
FUSE
FUSE
W/Y W/G Y/G To IGNITION COIL
No. 5 (10A)
FUSE
START W/R Y/R Y/R To ALTERNATOR (IG TERMINAL)
FUEL
Y/R To INDICATOR LIGHT (ACG, MIL)
Y/R To IAB CONTROL VALVE
Y/R To DATA LINK CONNECTOR

Lg/R To ECM (FLR1, FLR2)

Bu/R To FUEL PUMP

W To STARTER MAGNETIC
SWITCH

Bl/Bu Bl

ALTERNATOR NEUTRAL SWITCH

(90A) FUSE
W To ALTERNATOR (OUTPUT
TERMINAL)

2-21
 BF135A•BF150A

• FUSE BOX CONNECTION TABLE

Fuse No. Fuse capacity Connect to

1 30A A/F sensor heater
2 10A High pressure side fuel pump
3 10A Power trim/tilt relay, Alternator (detection terminal), Ignition switch, PGM-FI main relay,
Warning buzzer, Indicator light (oil, overheat), Meters
4 15A ECM, Fuel injector, CMP sensor, CKP sensor
5 10A Alternator (IG terminal), A/F relay, Indicator light (MIL, ACG), IAB control valve,
data link connector
6 15A Ignition coil
7 30A PGM-FI main relay

FUSE BOX

ALTERNATOR (90A) FUSE

2-22
BF135A•BF150A

c. STARTING SYSTEM
• ENGINE DOES NOT START
• Before starting troubleshooting, check each wire for connection and correct as necessary.

Check whether the remote control Not in “N” (Neutral) Move the remote control lever in the
lever is in the “N” (Neutral) position. position. “N” (Neutral) position.

In “N” (Neutral) position.

Check whether the engine turns with Does not

the ignition switch in the “START” posi- turn.
tion.
• Check the overrunning
clutch and replace as nec-
Check by sound whether the starter YES essary.
motor is turning. • Check the starter motor
Is the starter motor turning? magnetic clutch and replace
as necessary.
NO • Check the planetary gear
and replace as necessary.

Check the No. 3 (10A) fuse and the NO Replace the blown fuse(s).
No. 7 (30A) fuse. Remove the cause of the
Are the fuses normal? blown fuse(s) before replace-
ment (see FUSE LOAD
Engine turns. CHART on P. 2-20).
YES

Check the battery for charging level. NO Perform charging system

Is the battery fully charged? troubleshooting (P. 2-29).

YES

Check the battery terminals for con- NO Remove corrosion from the
nection and corrosion. terminals and connect the ter-
Are the battery terminals in good minals securely.
condition

YES

Check the neutral switch (P. 17-13). NO Replace the neutral switch.
Is the switch in good condition?

YES

Check the PGM-FI main relay (P. 18- NO Replace the PGM-FI main
24). Is the PGM-FI main relay in relay.
good condition?

YES

To P. 2-24 (A). To P. 2-24 (B).

2-23
 BF135A•BF150A

From P. 2-23 (A) From P. 2-23 (B)

Check the ignition switch (P. 16-9). NO Replace the ignition switch.
Is the ignition switch in good condi-
tion?

YES

Replace the starter motor with a new NO Repair or replace the wire har-
one and recheck. ness.
Does the starter motor turn?

YES

Replace the starter motor.

Check the engine speed. YES Perform ignition system trouble-

Is it normal? shooting (P. 2-25).

NO

Check the battery for charging level. NO Charge the battery.

Is the battery fully charged?

YES

Check the battery terminals for con- NO Remove corrosion from the terminals
nection and corrosion. and connect the terminals securely.
Are the battery terminals in good con-
dition?

YES

Replace the starter motor with a new NO Check inside the engine and repair the
one and recheck. faulty parts.
Does the starter motor turn?

YES

Replace the starter motor.

2-24
BF135A•BF150A

d. IGNITION SYSTEM
• ENGINE IS HARD TO START
* Before troubleshooting, turn the ignition switch ON and check whether the MIL comes ON for 2 seconds and the warn-
ing buzzer sounds twice intermittently.
If the MIL does not come ON or the warning buzzer does not sound, perform power system troubleshooting (P. 2-20).

Check the No. 6 (15A) fuse. NO • Check for short in the wire harness of the
Is the fuse normal? No. 6 (10A) fuse load line. Replace or repair
the wire harness as necessary.
YES • Replace the No. 6 (15A) fuse.

Check whether the emergency stop switch NO Set the clip securely.
clip is disconnected.
Is the clip set securely?

YES

Measure the spark plug gap. NO Replace the spark plugs.

Standard plug gap: 1.0 – 1.1 mm
Service limit: 1.3 mm
Is the spark plug gap within the service
limit?

YES

Clean the spark plugs and install them. YES Wet fouled spark plugs.
Start the engine according to the starting
procedure.
Does the engine start?

NO

Install the new spark plugs and restart. YES Replace the spark plugs.
Does the engine start?

NO

Check the emergency stop switch. NO Replace the emergency stop switch.
Is the emergency stop switch normal?

YES

Check for short in the black/red wire of the YES Replace or repair the wire harness.
emergency stop switch.
Is there continuity between the harness
side black/red terminal and the black ter-
minal?

NO

To P. 2-26

2-25
 BF135A•BF150A

From P. 2-25

Check the CKP sensor connector. No Connect the CKP sensor connector properly
Is the connector connected securely? and recheck.

Yes

Check for open circuit in the ignition coil’s No Replace or repair the wire harness. (Open cir-
power line. cuit in the wire between the No. 6 (15A) fuse
and the ignition coil.)
1 Disconnect the 3P connectors from
each of the ignition coils.
2 Turn the ignition switch ON. Measure
the voltage between the No. 3
(Yellow/Green) terminal of each har-
ness side 3P connector and the engine
ground.

Ignition coil
harness side
3P connector
Viewing from
terminal side

Is there the battery voltage?

Yes

Check for open circuit in the ignition coil’s No • Replace or repair the wire harness. (Open
ground line. circuit in the wire harness between the igni-
1 Turn the ignition switch OFF. tion coil and the engine ground.)
2 Check for continuity between the No. 2 • Check the engine ground and repair as nec-
(Black/White) terminal of the respective essary.
harness side 3P connectors and the
engine ground.

Ignition coil
harness side
3P connector
Viewing from
terminal side

Is there continuity?

Yes

To P. 2-27

2-26
BF135A•BF150A

From P. 2-26

Check for short circuit in the ignition coil’s Yes Replace or repair the wire harness (Short cir-
signal line. cuit in the wire harness between the ignition
1 Turn the ignition switch OFF. Check for coil and the ECM).
continuity between the No. 1 (Blue,
Blue/Black, White/Green, Blue/Red) ter-
minal of the respective harness side 3P
connectors and the engine ground.

No. 1 ignition coil: Blue

No. 2 ignition coil: Blue/Black
No. 3 ignition coil: White/Green
No. 4 ignition coil: Blue/Red

Ignition coil
harness side
3P connector
Viewing from
terminal side

Is there continuity?

No

Replace the ignition coil and recheck. Yes Replace the ignition coil.
Does the engine start?

No

Substitute a known-good ECM and

recheck.

2-27
 BF135A•BF150A

e. FUEL SYSTEM
• ENGINE IS HARD TO START
• When the gasoline is flowing out of the vapor separator, check the vapor separator (P. 5-112 thru. 5-120).

Turn the ignition switch ON and check NO

the fuel pump operation.
Is there the operation sound for 2 sec-
onds after the ignition switch is ON?

Check the No. 2 (10A) fuse. NO • Check for short in the wire
Is the fuse normal? harness between the No. 2
(10A) fuse and the fuel
pump. Replace or repair the
YES wire harness as necessary.
• Replace the No. 2 (10A)
Yes fuse.

Check the PGM-FI main relay. NO Replace the PGM-FI main

Is the PGM-FI main relay normal? relay.

YES

Check for open circuit in the fuel NO Replace or repair the wire har-
pump ground line. ness (Open circuit in the
1 Turn the ignition switch OFF and ground line).
disconnect the fuel pump 2P con-
nector.
2 Check for continuity between the
No. 2 (Black/White) terminal of the
harness side 2P connector and
the engine ground.

Fuel pump
harness side
2P connector
Viewing from
terminal side

Is there continuity?

YES

To P. 2-29 (A) To P. 2-29 (B)

2-28
BF135A•BF150A

From P. 2-28 (A) From P. 2-28 (B)

Check for open circuit in the fuel NO Replace or repair the wire har-
pump power line. ness (Open circuit in the fuel
1 Disconnect the main relay 2P pump power line).
connector.
2 Check for continuity between the
No. 1 (Blue/Red) terminal of the
harness side main relay 2P con-
nector and the No. 1 (Blue/Red)
terminal of the fuel pump 2P con-
nector.
PGM-FI main
Fuel pump relay harness
harness side side 2P
2P connector connector

Viewing from
terminal side
Is there continuity?

YES

Check the (high pressure) fuel pump NO Replace the (high pressure)
(P. 5-107). fuel pump.
Is the fuel pump normal?

YES

Substitute a known-good ECM and

recheck.

Check the low pressure fuel system (P. NO Repair the faulty part.
5-96).
Is the low pressure fuel system nor-
mal?

YES

Check the high pressure fuel system NO Repair the faulty part.
(P. 5-96).
Is the high pressure fuel system nor-
mal?

YES

Perform idle control system trouble-

shooting. If it is normal, Substitute a
known-good ECM and recheck

2-29
 BF135A•BF150A

f. CHARGING SYSTEM
• BATTERY UNDER CHARGED
Is the alternator belt tension correct NO Adjust the alternator belt tension (P. 3-29).
(Inspection: P. 3-29)?

YES

Start the engine and let it idle to warm up. YES Replace the battery.
Measure the voltage between the battery
terminals when the engine speed is 3,000
min-1 (rpm).
Is the voltage between the terminals 13.5V
or above?

NO

Check for open circuit in the IG line. NO Replace or repair the wire harness (Open in
1 Turn the ignition switch OFF and discon- the wire between the alternator and No. 5
nect the alternator 4P connector. fuse).
2 Measure the voltage between the No. 2
(Yellow/Red) terminal of the alternator 4P
connector and the engine ground.

Alternator
harness side 4P
connector

Viewing from terminal side

Is there the battery voltage with the ignition

switch ON?

Yes

Check for open circuit in the BAT line. NO Replace or repair the wire harness (Open in
1 Turn the ignition switch OFF and discon- the wire between the alternator and the igni-
nect the alternator 4P connector. tion switch).
2 Measure the voltage between the No. 1
(White/Black) terminal of the alternator
4P connector and the engine ground.

Alternator
harness side 4P
connector

Viewing from terminal side

Is there the battery voltage with the ignition
switch ON?

Yes

Disassemble and service the alternator (P.

6-9).

2-30
BF135A•BF150A

• ALTERNATOR INDICATOR LINE INSPECTION

Turn the ignition switch ON. YES Start the engine. Yes End of inspection (Good)
Does the alternator indicator Does the alternator indicator
lightcome ON? light go OFF?

NO No

Check for short circuit in the L YES Replace or repair the wire har-
line. ness (Short in the wire
1 Stop the engine and discon- between the ECM and the
nect the alternator 4P con- alternator).
nector.
Does the alternator indicator
light come ON with the ignition
switch ON?

NO

Disassemble and service the

alternator.

Check the No. 5 (15A) fuse. NO • Check for short circuit in the
Is the fuse normal? wire harness of the No. 5
(10A) fuse load line. Replace
YES or repair the main harness if
necessary.
• Replace the No. 5 (15A)
fuse.

Check for open circuit in the L NO Check for open circuit in the NO Replace or repair the wire har-
line. wire harness (White/Blue) ness (Open in the wire
1 Stop the engine and discon- between the ECM and the between the ECM and alter-
nect the alternator 4P con- alternator. nator).
nector. Is the wire harness normal?
2 Connect the No. 4 (White/
Blue) terminal of the alterna- YES
tor 4P connector to the body
to short using a jumper wire. Check the alternator indicator • Check the alternator indica-
NO
light. tor light bulb. Replace the
Alternator Is the alternator indicator light bulb as necessary.
harness side 4P normal? • If the bulb is normal, replace
connector the alternator indicator light.
Viewing from YES
terminal side

Substitute a known-good ECM

and recheck.
Does the alternator indicator
light come ON with the ignition
switch ON?

YES

Disassemble and service the

alternator (P. 6-9).

2-31
 BF135A•BF150A

g. ALERT SYSTEM
• OIL ALERT SYSTEM
When the oil pressure switch (low pressure side) detects low oil pressure, the ECM receives the signal from the oil pres-
sure switch and decreases the engine speed gradually to 1,800 min-1 (rpm). The warning buzzer sounds and the oil indi-
cator light goes OFF this time. When the problem is removed, the engine speed increases gradually and the engine is
restored to the normal running.
• OVERHEAT ALERT SYSTEM
When the ECM detects overheat by receiving the signal from the thermo sensor, it decreases the engine speed gradu-
ally to 1,800 min-1 (rpm). The warning buzzer sounds and the overheat indicator light comes ON. When the problem is
not removed within 20 seconds, the ECM decreases the engine speed further until it stops. When the problem is removed
during this control, the ECM increases the engine speed gradually until the engine is restored to the normal running.
• ALTERNATOR WARNING SYSTEM
The IC regulator is equipped in the alternator to detect the disconnected sensor terminal, disconnected output terminal,
overcharge and undercharge when generation stops. When a problem is detected, the IC regulator turns the alternator
indicator lightON and the ECM sounds the warning buzzer (intermittent prolonged sound) by receiving the signal from
the IC regulator.
• FULL WATER (IN WATER SEPARATOR) WARNING SYSTEM
When the water level in the water separator is above the specified level, the water level sensor detects the condition and
transmits the signal to the ECM to sound the warning buzzer.
• MIL WARNING SYSTEM
The MIL indicator light comes ON and the buzzer sounds (intermittent prolonged sound) when the ECM detects a prob-
lem by its diagnostic function.
• WARNING SYSTEM
Condition Indicator light Warning indicator light Warning buzzer
Oil indicator Overheat ACG MIL
light (Green) indicator indicator (Red)
light (Red) light (Red)
Ignition switch ON (Initial check) ON for 2 sec. ON for 2 sec. ON ON for 2 sec. Sounds twice
2 sec. after turning ignition switch ON OFF OFF ON OFF Stop
Normal operation ON OFF OFF OFF Stop
Engine oil pressure dropped OFF OFF OFF OFF Continuous sound
Overheat ON ON OFF OFF Continuous sound
MIL faulty ON*1 OFF*2 OFF ON Intermittent
prolonged sound
Alternator faulty ON OFF ON OFF Intermittent
prolonged sound
Water separator full ON OFF OFF OFF Intermittent short
sound

When two or more problems occur simultaneously, warning for each problem is indicated simultaneously.
When a problem occurred simultaneously with the malfunction of the MIL:
*1: The oil indicator light blinks when a problem with the high pressure oil pressure switch is detected.
*2: The overheat indicator light blinks when a problem with the overheat sensor is detected.
The warning buzzer of the prolonged sound takes precedence over the short sound.
Example: When the problems with the alternator and full water separator are detected simultaneously, the warning
buzzer is the intermittent prolonged sound.
Example: When the overheat and a problem with the alternator are detected simultaneously, the warning buzzer is the
continuous sound.

2-32
BF135A•BF150A

• WARNING BUZZER SOUNDS CONTINUOUSLY

Check the indicator light. YES

Is the overheat indicator light
ON?

NO (OFF) To P. 2-36

Is the oil indicator light OFF? NO Check the oil indicator light. NO Replace the oil indicator light.
(ON) Is the oil indicator light normal?

YES

Check the warning buzzer. NO Replace the buzzer.

YES (OFF) Is the warning buzzer normal?

YES

Check for short in the buzzer YES Replace or repair the wire har-
line. ness (Short in wire harness
1 Turn the ignition switch OFF between the buzzer and ECM).
and disconnect the remote
control cable 14P connec-
tor.
2 Check for continuity bet-
ween the No. 7 (Yellow/
Green) terminal and the
engine ground

Remote control cable

14P connector
Viewing from terminal
side
Is there continuity?

NO

Substitute a known-good ECM

and recheck.

Stop the engine and check the No Add the oil to the correct level.
oil level.
Is the oil level correct?

Yes

To P. 2-34

2-33
 BF135A•BF150A

From P. 2-33

Start the engine. YES Snap the engine (4,000 min-1 YES Normal (End of inspection)
Is the oil indicator light ON with /rpm or above under no load)
the engine idling? and check the oil indicator and
warning buzzer.
Do the oil indicator light come
ON and the buzzer stop sound-
ing?

NO NO

Disconnect the high pressure YES Replace the oil pressure

side oil pressure switch 2P con- switch.
nector.
Do the oil indicator light come
ON and the buzzer stop sound-
ing?

NO

Check for short in the high pres- YES Replace or repair the wire har-
sure side oil pressure switch ness (Short in the wire har-
line. ness between the high pres-
1 Turn the ignition switch OFF. sure side oil pressure switch
2 Check for continuity between and ECM).
the No. 1 (Green/Red) termi-
nal of the harness side oil
pressure switch 2P connec-
tor and the engine ground.
Oil pressure
switch 2P
connector
Viewing from
terminal side

Is there continuity?

NO

Substitute a known-good ECM

and recheck.

Disconnect the low pressure NO Check for short in the low pres- NO Replace or repair the wire har-
side oil pressure switch wire. sure side oil pressure switch ness (Short in the wire har-
Do the oil indicator light come line. ness between the low pres-
ON and the warning buzzer 1 Turn the ignition switch OFF. sure side oil pressure switch
stop sounding? 2 Check for continuity between and ECM).
the oil pressure switch ter-
minal and the engine ground.
Is there continuity?
YES
YES

Substitute a known-good ECM

and recheck.
To P. 2-35

2-34
BF135A•BF150A

From P. 2-34

Check the oil pressure. No Perform the following checks

Is the oil pressure within the and repair or replace as nec-
specification? essary.
• Clogged oil strainer
• Clogged oil filter
Yes • Faulty oil pump
• Clogged oil passage

Replace the oil pressure switch Yes Oil pressure switch is faulty.
and start the engine.
Do the oil indictor light come ON
and the buzzer stop sounding?

No

Substitute a known-good ECM

and recheck.

• OIL PRESSURE INSPECTION

OIL PRESSURE
1) Remove the switch cover. Remove the 4 mm screw and the GAUGE SET
oil pressure switch wire. 07506-3000001
2) Remove the oil pressure switch.
3) Install the oil pressure gauge attachment as shown.
TORQUE: 8 N • m (0.8 kgf • m, 5.8 lbf • ft)

4) Install the oil pressure gauge set.

5) Start the engine and measure the oil pressure.
Oil pressure 0.147 MPa (1.5 kgf/cm2, 21.3 psi)
at 2,050 min-1 (rpm)

6) Clean the threads of the switch and apply the liquid gasket OIL PRES-
(Three Bond 1215 or equivalent) to the indicated area. SURE GAUGE
ATTACHMENT
Install the oil pressure switch to the specified torque. 07406-0030000
TORQUE: 8.3 N • m (0.85 kgf • m, 6.1 lbf • ft)

LIQUID
GASKET
APPLICATION
AREA

2-35
 BF135A•BF150A

From P. 2-33

Stop the engine and check the YES Clean the water screen.
water screen.
Is the water screen clogged?

NO

Start the engine and check the NO • Check the water pump and
water check port with the engine replace if necessary.
idling. • Check the water tube for
Does the cooling water flow blockage and deformation.
through the water check port Replace if necessary.
continuously?

YES

Put the outboard motor into gear YES The system is restored to nor-
and let the engine idle for a few mal operation.
minutes to cool it down.
Do the overheat indicator light
go OFF and the warning buzzer
stop sounding?

NO

Check the thermostat. NO Replace the thermostat.

Is the thermostat normal?

YES

Perform ECT sensor 2, 3, and 4

troubleshooting (P. 5-51, 52, and
55 or 5-84. 86, and 89).

2-36
BF135A•BF150A

• INTERMITTENT PROLONGED SOUND OF WARNING BUZZER KEEPS SOUNDING

Is the MIL ON? YES Perform MIL troubleshooting (P.
5-18 or 5-61).
NO

Is the alternator indicator light NO Check for open in the indicator NO Replace or repair the wire har-
ON? light power line. ness (Open in the wire har-
1 Turn the ignition switch OFF ness between the indicator
Yes and disconnect the indicator light and No. 5 (10A) fuse).
light 3P connector.
2 Turn the ignition switch ON.
Measure the voltage bet-
ween the No. 3 (Yellow/Black)
terminal of the harness side
3P connector and the engine
ground.
Harness side
connector
Viewing from
terminal side

Is there the battery voltage?

Yes

• Check for blown bulb. Replace

if necessary.
• If the bulb is not blown out,
replace the indicator light.

Is the alternator belt tension No Adjust the alternator belt ten-

correct? sion.

YES

Is the alternator fuse (90A) nor- NO Replace the fuse.

mal?

YES

Check the alternator 4P con- NO Replace the fuse.

nector for connection.
Is the alternator 4P connector
connected properly?

YES

Measure the voltage between NO Check the load. If there is no

the measurement battery ter- problem, replace the battery.
minals.
Is the voltage 13.5V or above?

YES

Perform alternator trouble-

shooting (P. 2-31).

2-37
 BF135A•BF150A

• INTERMITTENT SHORT SOUND OF WARNING BUZZER KEEPS SOUNDING

Stop the engine. Check the water separa- YES Drain the water from the water separator
tor and the low pressure fuel strainer. and/or the low pressure fuel strainer (P. 3-15).
Is the water accumulated in the water sep-
arator and/or low pressure fuel strainer?

NO

Disconnect the water level sensor 2P con- YES Replace the water level sensor in the water
nector. separator.
Does the buzzer stop sounding with the
ignition switch turned ON?

NO

Check for short in the water level sensor YES Replace or repair the wire harness (Short in
line. the wire between the water level sensor and
1 Turn the ignition switch OFF. ECM).
2 Check for continuity between the No. 2
(Green/Red) terminal of the water level
switch harness side 2P connector and
the engine ground.

Water level switch

harness side
2P connector
Viewing from
terminal side

Is there continuity?

NO

Substitute a known-good ECM and

recheck.

2-38
BF135A•BF150A

h. SHIFT MECHANISM

Shift lever does not move. Shift cable corroded or stuck with Replace: P. 15-3
salt.

Shift cable misadjusted. Adjust: P. 3-25

Shift arm damaged. Replace: P. 17-11

Shift detent arm damaged. Replace: P. 17-12

Shift rod and shift rod A bent or Replace: P. 14-4, 9, 43, and 48
twisted.

Shift shaft A and/or B bent. Replace: P. 15-3

In gear case assembly: Replace: P. 14-18 and 57

• Clutch shifter damaged
• Shift slider damaged

2-39
 BF135A•BF150A

i. POWER TRIM/TILT ASSEMBLY

• POWER TRIM/TILT ASSEMBLY DOES NOT MOVE

Check the motor sound. Does not sound Perform troubleshooting of “POWER
TRIM/TILT MOTOR DOES NOT TURN” (P. 2-
42).
Sounds

Check the manual valve for looseness. Loose Tighten the manual valve securely.

Tight

Check for oil leakage from power trim/tilt Leaking Replace the O-ring and oil seal at the leaking
assembly. point.

OK

Check the oil level with the piston rods fully Low level Add the oil to the specified level (P. 15-47).
extended (P. 15-47).

OK

Check for air in the system. Air in the system Bleed air from the system (P. 15-48).

No air

Power trim/tilt assembly faulty.

Repair the faulty part(s) by referring to
POWER TRIM/TILT ASSEMBLY QUICK
REFERENCE CHART (P. 2-43).

2-40
BF135A•BF150A

• POWER TRIM/TILT ASSEMBLY DOES NOT HOLD

Check the manual valve for tightness. Loose Tighten the manual valve securely.

Tight

Check for oil leakage from the power Leaking Replace the O-ring and oil seal of the leaking
trim/tilt assembly. point.

Not leaking

Check for oil leakage from the cylinder sur- Leaking Replace the power trim/tilt assembly.
face.

Not leaking

Check the hydraulic pressure (P. 15-50). Abnormal Replace the motor assembly or gear pump
assembly.
Normal

Check the oil level (P. 15-47). Low level Add the oil to the specified level (P. 15-47).

Normal

Check for air in the system. Air in the system Bleed air from the system (P. 15-48).

No air in the system

Replace the power trim/tilt assembly.

2-41
 BF135A•BF150A

• POWER TRIM/TILT MOTOR DOES NOT TURN

Connect the 12V battery directly to the

motor terminals and check whether
the motor turns.

Does not turn.

Turns
Check for open circuit in the motor Open Replace the front bracket.
wire. circuit

No open circuit

Check the motor for overheating. Overheats Cool down the motor.

Does not overheat

Check the breaker inside the motor. Abnormal Replace the breaker.

Normal

Check for oil inside the motor. Oil Replace the motor assem-
bly.
No oil

Disassemble the motor and replace

the faulty parts.

Check the power trim/tilt relay (P. 18- Abnormal Replace the power trim/tilt relay.
29).

Normal

Check the power trim/tilt switch (P. 16- Abnormal Replace the power trim/tilt switch.
10).

Normal

Replace or repair the wire harness.

2-42
 BF135A•BF150A

• POWER TRIM/TILT ASSEMBLY QUICK REFERENCE CHART

Symptom Pressure check
Does Does Lower chamber Upper chamber
not not tilt Does not hold hydraulic pres- hydraulic pres- Check point Check/repair method
tilt up down sure lower than sure lower than
spec. or pres- spec. or pres-
(See page 2-44)
Lowers Extends sure drops. sure drops.
— — Motor assembly Check the motor assembly.
Manual valve Check that the manual valve is installed
securely. Replace if it is damaged.
Check the O-ring surface for damage
and replace if necessary.
If there is no damage, clean the O-ring
and install on the manual valve properly.
— — Backup ring Check the backup ring for damage and
O-ring replace if necessary.
(Piston rod B) Check the O-ring surface for damage
and replace if necessary.
If the backup ring and O-ring are nor-
mal, clean and install on the piston rod
B properly.
Backup ring Check the backup ring for damage and
O-ring replace if necessary.
(Free piston) Check the O-ring surface for damage
and replace if necessary.
If the backup ring and O-ring are nor-
mal, clean and install on the free piston
properly.
— — — Check valve Check the ball seat and the neighboring
(Free piston) area for damage and replace the free
piston as an assembly if necessary. (Do
not disassemble the free piston.)
— — — O-ring Check the O-ring surface for damage
(Piston rod comp.) and replace if necessary.
— — — Shock relief valve Check the ball seat and the neighboring
(Piston rod comp.) area for damage and replace the piston
rod comp. as an assembly if necessary.
(Do not disassemble the piston rod
comp.)
— — — Dust seal, O-ring Check the dust seal and O-ring for dam-
(Cylinder cap) age and foreign material (oil leakage).
Replace if necessary.
— — — — Oil (ATF) Check the oil level and add the oil if
necessary.
— — Pump assembly If the pump turns idle or excessively
heavy, replace the pump assembly. (Do
not disassemble the pump assembly.)
Up relief valve The valves are built in the pump assem-
— — — — Down relief valve bly. Replace the pump assembly if nec-
essary. (Do not disassemble the pump
— — Lower chamber assembly.)
check valve
— — Lower chamber
spool valve
Upper chamber
check valve
— — Upper chamber
spool valve

2-43
BF135A•BF150A

• CHECK POINTS
LOWER CHAMBER SPOOL VALVE
PUMP
UP RELIEF VALVE

UPPER CHAMBER
SPOOL VALVE

DOWN RELIEF
VALVE

UPPER CHAMBER
CHECK VALVE

LOWER CHAMBER
MANUAL VALVE CHECK VALVE

DUST SEAL/O-RING PISTON ROD ASSEMBLY

MOTOR
OIL (ATF)

SHOCK
RELIEF VALVE
PUMP ASSEMBLY

O-RING/
O-RING BACKUP RING
FREE PISTON

O-RING/
BACKUP RING CHECK VALVE O-RING/
BACKUP
RING

2-44
10. CABLE/HARNESS ROUTING
After securing the cables and harnesses with the harness band
clips, cut the end of the harness band clips so that the projected
length is 5 – 10 mm (0.2 – 0.4 in) as shown.
[1]
HARNESS
5 – 10 mm BAND CLIP
(0.2 – 0.4 in)

[3] [6] ALTERNATOR FUSE

VTEC SOLENOID VALVE CABLE (WHITE CABLE)
1P CONNECTOR [BF150A only] Connect the cable to the
alternator B terminal as shown.
[4] A/F (AIR FUEL RATIO)
[2] HARNESS BAND CLIP SENSOR 4P CONNECTOR
60°
[1] WATER RELIEF TUBE A [5] ALTERNATOR
4P CONNECTOR
[16]
A/F (AIR FUEL RATIO) SENSOR

[15]
VTEC SOLENOID
VALVE [BF150A only]
[7]
[14] HARNESS BAND CLIP
WATER TUBE CLAMP Clamp the alternator
Set the water relief fuse cable and the
tube A in the clamp main wire harness.
of the larger diameter
side and the main
wire harness in the
clamp of the smaller
diameter side. [8]
ECT (ENGINE
COOLANT
[13] TEMPERATURE)
ECT (ENGINE SENSOR 1
COOLANT 2P CONNECTOR
TEMPERATURE)
SENSOR 3
2P CONNECTOR [9] EOP (ENGINE OIL
PRESSURE)
SWITCH (HIGH
[12] PRESSURE SIDE)
ECT (ENGINE 2P CONNECTOR
COOLANT
TEMPERATURE)
SENSOR 3 [10]
EOP (ENGINE OIL
PRESSURE) SWITCH
[11] COVER LOCK (LOW PRESSURE
CABLE B SIDE)

2-45
[1] HARNESS BAND CLIP
Clamp the main wire harness and
the ECT sensor 3 wire as shown.

[1]-1 ECT (ENGINE COOLANT

TEMPERATURE) SENSOR 3
WIRE

[2] [3]
[1]-2 ECT (ENGINE ECT (ENGINE
ENGINE SIDE COOLANT COOLANT
TEMPERATURE) TEMPERATURE)
SENSOR 4 SENSOR 4
2P CONNECTOR [4]
A/F (AIR FUEL RATIO)
[1]-3 MAIN WIRE HARNESS SENSOR 4P CONNECTOR

[18] [5]
HARNESS BAND VTEC SOLENOID
CLIP VALVE
1P CONNECTOR
[17] [BF150A only]
A/F (AIR FUEL
RATIO) SENSOR [6]
ALTERNATOR
4P CONNECTOR
[16]
WATER TUBE
CLAMP [7]
ALTERNATOR
FUSE CABLE
[15] MAIN WIRE (WHITE CABLE)
HARNESS
[8]
[14] ECT (ENGINE
ECT (ENGINE COOLANT
COOLANT TEMPERATURE)
TEMPERATURE) SENSOR 1
SENSOR 3 2P CONNECTOR
2P CONNECTOR

[9]
[13] EOP (ENGINE OIL
ECT (ENGINE COOLANT [11] VTEC SOLENOID PRESSURE)
[10] SWITCH (HIGH
TEMPERATURE) SENSOR 3 VALVE EOP (ENGINE OIL PRESSURE SIDE)
[BF150A only] PRESSURE) 2P CONNECTOR
[12] HARNESS BAND CLIP SWITCH
(LOW PRESSURE
Clamp the main wire harness and SIDE)
the ECT sensor 3 wire as shown.

[12]-1ECT (ENGINE COOLANT

TEMPERATURE) 3 WIRE

[12]-2
ENGINE SIDE

[12]-3 MAIN WIRE HARNESS

2-46
 [3] HARNESS BAND CLIP
Clamp the VTEC solenoid valve wire [BF150A
only] and the A/F sensor wire as shown.

[3]-1
A/F (AIR FUEL
RATIO) SENSOR
4P CONNECTOR
[3]-2
INSIDE

[3]-3 VTEC SOLENOID VALVE

WIRE [BF150A only]
[5]
ECT (ENGINE
COOLANT
[2] A/F (AIR FUEL RATIO) [4] TEMPERATURE
SENSOR 4P CONNECTOR MAIN WIRE SENSOR 4
HARNESS 2P CONNECTOR

[1]
HARNESS BAND
CLIP

[6]
ECT (ENGINE
[8] VTEC SOLENOID VALVE [7] COOLANT
[BF150A only] VTEC SOLENOID VALVE TEMPERATURE)
1P CONNECTOR SENSOR 4
[BF150A only]

2-47
 [2] ALTERNATOR FUSE
[1] CABLE (WHITE CABLE)
ALTERNATOR
4P CONNECTOR
[3]
MAIN WIRE
HARNESS

[4]
ECT (ENGINE
COOLANT
TEMPERATURE)
SENSOR 1

[5]
ECT (ENGINE
COOLANT
TEMPERATURE)
SENSOR 1
2P CONNECTOR

[6]
EOP (ENGINE OIL
[8] HARNESS BAND CLIP PRESSURE) SWITCH
(HIGH PRESSURE
Clamp the alternator SIDE) 2P CONNECTOR
fuse cable and the
main wire harness as [7]
shown. EOP (ENGINE OIL
PRESSURE) SWITCH
(LOW PRESSURE SIDE)

[10] CKP (CRANKSHAFT

POSITION) SENSOR

[9]
CKP (CRANKSHAFT
POSITION) SENSOR
3P CONNECTOR

[11]
HARNESS BAND
CLIP

2-48
 [5] ALTERNATOR FUSE BOX B TERMINAL
Install the alternator fuse box B terminal
at 30° from the horizontal line as shown.

[5]-1 ALTERNATOR FUSE

BOX B TERMINAL

[3] ALTERNATOR
[2] FUSE BOX FUSE BOX (90A)

30°
[1] HARNESS BAND CLIP [4] WIRE HARNESS
Clamp the alternator CLIP
fuse cable and the
main wire harness.
[6] STARTER CABLE
[26]
ALTERNATOR
FUSE CABLE [7] MAIN WIRE
(WHITE CABLE) HARNESS

[25] [8]
ENGINE SPEED OFFSET HARNESS
CHECK CONNECTOR BAND
[BLUE CONNECTOR]
(2P CONNECTOR) [9]
HARNESS BAND
[24]PGM-FI MAIN RELAY CLIPS
4P CONNECTOR
[10]
A/F (AIR FUEL
[23]
RATIO) RELAY
DLC (DATA LINK
CONNECTOR) [RED [11]
CONNECTOR] ECM CONNECTOR C
(4P CONNECTOR) (6P CONNECTOR)
[22] [12]
PGM-FI MAIN RELAY STARTER CABLE
2P CONNECTOR 1P CONNECTOR
(WHITE CABLE)
[21]
PGM-FI MAIN RELAY [13]
6P CONNECTOR A/F (AIR FUEL
RATIO) RELAY
[20] 4P CONNECTOR
POWER TILT SWITCH
3P CONNECTOR [14]
[15] HARNESS ECM CONNECTOR A
[4] WIRE HARNESS
CLIP (26P CONNECTOR)
CLIP
[18]
[19] STARTER CABLE [16] ECM CONNECTOR B
POWER TILT SWITCH 3P CONNECTOR (34P CONNECTOR)
WIRE
[17] [15] HARNESS CLIP
ECM (ENGINE CONTROL
MODULE)

2-49
 [1] HARNESS BAND CLIP [2] ALTERNATOR FUSE BOX (90A)

[16]
PGM-FI MAIN RELAY

[3]
[15] STARTER CABLE
ALTERNATOR FUSE
CABLE (WHITE CABLE)

[14]
STARTER CABLE [4]
3P CONNECTOR MAIN WIRE
HARNESS

[13]
PGM-FI MAIN RELAY
CONNECTOR WIRE [5]
ALTERNATOR
FUSE CABLE
[12] HARNESS BAND
CLIPS

[11]
PGM-FI MAIN RELAY [1]
CONNECTOR HARNESS BAND
CLIP

[10] POWER TILT

SWITCH WIRE

[6] ELECTRIC PART CASE

[9] WIRE HARNESS CLIP
[8] Set the alternator fuse cable and the
Clamp the alternator fuse POSITIVE (+) starter cable in the cable holder of the
cable, PGM-FI main relay STARTER electric part case as shown.
wire and the power tilt switch CABLE
wire at the grommet.
[6]-1 [6]-2
[5] ALTERNATOR ELECTRIC PART STARTER
FUSE CABLE CASE CABLE

[7] HARNESS BAND CLIP

Clamp the alternator fuse
cable and the PGM-FI main
relay connector wire as
shown.
[6]-4
CABLE [6]-3
HOLDER ALTERNATOR FUSE
CABLE

2-50
 [2]
[1] POWER TILT SWITCH HARNESS BAND
3P CONNECTOR CLIPS

[4] STARTER CABLE

[10] PGM-FI MAIN RELAY [3]

CONNECTOR HARNESS BAND
CLIP

[9]
POWER TILT [4] STARTER CABLE
SWITCH WIRE

[5] HARNESS CLIP

[8] WIRE HARNESS CLIP
Clamp the alternator fuse
cable, PGM-FI main relay
wire and the power tilt switch [6] STARTER CABLE
[7]
wire at the grommet. 3P CONNECTOR
ALTERNATOR
FUSE CABLE

[7]
ALTERNATOR FUSE CABLE
[7]
[11] ALTERNATOR FUSE CABLE
8 mm WASHER-NUT (2)

[12]
8 mm WASHER

[13]
POSITIVE (+)
STARTER CABLE 90°

[14]
STARTER MOTOR B
TERMINAL

[15] [13]
Connect the alternator fuse POSITIVE (+)
cable terminal and the positive STARTER
(+) starter cable terminal so that CABLE
they are at right angle to the
vertical center line as shown.

2-51
[1] [4] CLIP A
[2] [3] HARNESS BAND CLIP
POWER TILT STARTER Clamp the alternator
SWITCH Clamp the starter fuse cable.
CABLE cable.
3P CONNECTOR

[5]
ALTERNATOR
[10] FUSE CABLE
POWER TILT
SWITCH

[9]
POSITIVE (+) STARTER [6] CABLE BRACKET A
CABLE [2]
STARTER Clamp the alternator fuse cable
CABLE and the starter cable as shown.
[5] ALTERNATOR FUSE CABLE [6]-1
ALTERNATOR
[7] NEGATIVE (–) STARTER CABLE FUSE CABLE
[8] WIRE HARNESS CLIP Connect the negative (–) starter
Clamp the alternator fuse cable by pushing the starter [6]-2
cable and the starter cable cable negative (–) terminal ENGINE
and check that the cables against the projection on the SIDE
do not interfere with the crankcase.
[7]-2
shift arm.
PROJECTION
[7]-1
STARTER
CABLE
NEGATIVE (-)
TERMINAL [6]-3 STARTER CABLE

2-52
<REMOTE CONTROL CABLE GROMMET viewed from outer side of the outboard motor>

[1] [2]
REMOTE CONTROL CABLE REMOTE CONTROL CABLE
(Shift side) (Throttle side)

[3]
[8] REMOTE CONTROL
INDICATOR LIGHT CABLE
WIRE
[4]
SPEED SENSOR
TUBE A

[5] BATTERY ISOLATOR

(Optional part)
[7] STARTER CABLE
[6] FUEL TUBE A

[9]
FRONT BRACKET [10] WHIT TAPE

[11] STARTER CABLE

[12]
REMOTE CONTROL Install aligning the end of
CABLE GROMMET the white tape on the
starter cable with the end
of the under cover front
bracket.

[9] FRONT BRACKET

WHITE TAPE
[12] REMOTE CONTROL
CABLE GROMMET

[13] TIE WIRES

[3] Install the remote control cable and
REMOTE CONTROL the indicator light wire with the tie
CABLE wire on the respective cables set
against the remote control cable
grommet.

[8]
INDICATOR LIGHT
WIRE

2-53
 [7] [8] TP (THROTTLE
POWER TILT RELAY POSITION)
[4] 3P CONNECTOR SENSOR
REMOTE CONTROL CABLE 3P CONNECTOR
14P CONNECTOR
[3] HARNESS [9] TP (THROTTLE
[5] MAIN WIRE BAND CLIP [3] POSITION)
[3] HARNESS BAND HARNESS SENSOR
CLIP HARNESS
BAND
CLIP [10]
[2] REMOTE CONTROL [6] WATER LEVEL
CABLE (Throttle side) SPEED SENSOR
SENSOR 2P CONNECTOR
TUBE A
[1]
REMOTE CONTROL
CABLE (Shift side)

[11]
COVER
LOCK
CABLE A

[12] TRIM ANGLE

SENSOR
3P CONNECTOR
[21]
STARTER [13] POWER TILT MOTOR
CABLE 2P CONNECTOR

[1] [2]
[20] CABLE BRACKET A REMOTE REMOTE CONTROL
INSTALLATION: P. 2-52 CONTROL CABLE (Throttle side)
CABLE (Shift
[19] side) [6]
ALTERNATOR FUSE SPEED SENSOR
CABLE [18] TUBE A
INDICATOR LIGHT
6P CONNECTOR [15]
FUEL TUBE A [14] REMOTE CONTROL
CABLE
[17] INDICATOR LIGHT
WIRE [16] STARTER
CABLES

2-54
[1] FRAME GROUND TERMINALS
• Connect the black, blue, green/red
and the green/white wires to the
upper frame ground terminal, and the
green, blue, black/white and the
green/black wires to the lower frame
ground terminal.
• Install by pushing the frame ground
terminals against the corresponding
projections on the crankcase. [2]
POWER TILT RELAY
GROUND TERMINAL
[1]-1 PROJECTION [1]-2
Install by pushing the ground
FRAME
terminal against the projection on
GROUND
the crankcase.
TERMINAL
[6] COVER LOCK
CABLE A
[1]-1
PROJECTION [2]-1
GROUND [5]
TERMINAL POWER TILT RELAY
3P CONNECTOR
[2]-2 PROJECTION
[1]-2 FRAME GROUND
TERMINAL [7] TRIM ANGLE
[4] NEUTRAL SWITCH
SENSOR 3P
2P CONNECTOR
[3] CONNECTOR
HARNESS
BAND CLIP

[8]
POWER TILT
MOTOR
2P
CONNECTOR
[3]
HARNESS
BAND CLIP

[18]
CLIP A

[17]
STARTER
CABLE [9] TRIM ANGLE
SENSOR WIRE

[10] POWER TILT

MOTOR WIRE

[15]
[16] CABLE BRACKET A [11] WIRE BAND
NEUTRAL
INSTALLATION: P. 2-52 SWITCH [13]
[12] UNDERCASE
POWER TILT RELAY
GROMMET C
[3] 1P CONNECTOR
[14] ALTERNATOR
FUSE CABLE HARNESS
BAND CLIP [14] ALTERNATOR
FUSE CABLE

2-55
 [2] TP (THROTTLE
[1] TP (THROTTLE POSITION) [3]
POSITION) SENSOR HARNESS BAND [4] POWER TILT RELAY
SENSOR CLIP 3P CONNECTOR
3P CONNECTOR

[5] [6] HARNESS CLIP

WATER LEVEL Clamp the main wire
[19] MAIN WIRE SENSOR harness and the
HARNESS 3P CONNECTOR water level sensor
wire at its taped part.

[3] HARNESS
BAND CLIP

[18] HARNESS CLIP

[7]
WIRE HARNESS CLIP
[17] CLIP A
Clamp the power tilt
relay 3P connector,
2P connector and
[16] NEUTRAL the 1P connector
SWITCH wires.
2P CONNECTOR
[8]
TRIM ANGLE SENSOR
[15] ALTERNATOR 2P CONNECTOR
FUSE CABLE
[9]
WATER LEVEL SENSOR
[14] POWER TILT WIRE
MOTOR WIRE
[12] TRIM ANGLE [10] POWER TILT MOTOR
SENSOR WIRE 2P CONNECTOR

[11] SPEED SENSOR TUBE A

[13] UNDERCASE GROMMET C
• Clamp the power tilt motor wire, trim angle
sensor wire and the speed sensor tube A.
• Install the undercase grommet C aligning the
taped ends of the power tilt motor wire and [13]-1 [13]-2
the trim angle sensor wire with the end of the FRONT Wires and
undercase grommet C LOCK tube are not
• Check that the wires and tube are not interfering
interfering with the front lock of the under with the front
cover front bracket. lock.
[13]-7
UNDERCASE
GROMMET C

[13]-6
SPEED SENSOR [13]-3 TAPE
TUBE A
[13]-4
[13]-5 TRIM ANGLE POWER TILT
SENSOR WIRE MOTOR WIRE

2-56
[1] POWER TILT RELAY GROUND TERMINAL
Install pushing the ground [4] WIRE HARNESS CLIP
terminal against the projection [3] Clamp the power tilt relay 3P
[2]
on the crankcase. POWER TILT connector, 2P connector and
HARNESS BAND
RELAY the 1P connector wires as
CLIP
shown.

[1]-1
GROUND
TERMINAL

[1]-2 PROJECTION
[2]
HARNESS BAND
CLIP
[10] MAIN WIRE
HARNESS

[2]
HARNESS BAND
CLIP

[5]
[9] NEUTRAL POWER TILT
SWITCH MOTOR
2P CONNECTOR 2P CONNECTOR

[8] CLIP A [6] POWER TILT RELAY

[7] 1P CONNECTOR
[2] HARNESS ALTERNATOR FUSE
BAND CLIP CABLE
[2]
HARNESS BAND
CLIP
[17]
IAT (INTAKE AIR
TEMPERATURE)
SENSOR [10] MAIN WIRE
HARNESS

[16] IAT (INTAKE AIR

TEMPERATURE) [11]
SENSOR IAC (IDLE AIR
2P CONNECTOR CONTROL) VALVE
2P CONNECTOR
[15]
MAP (MANIFOLD
ABSOLUTE [12]
PRESSURE) IAC (IDLE AIR
SENSOR CONTROL)
3P CONNECTOR VALVE

[2]
HARNESS BAND
CLIP

[13] HARNESS CLIP

[14] MAP (MANIFOLD
ABSOLUTE PRESSURE) Clamp the MAP sensor
SENSOR wire in the recess of the
intake manifold.

2-57
[3] HARNESS BAND CLIP [6] WIRE BAND
Clamp the main wire harness, BARO Clamp the main wire harness, BARO
sensor wire and the IAB control valve wire sensor wire and the IAB control valve
as shown. wire as shown.
[3]-2 [6]-2
MAIN WIRE [6]-1 ENGINE MAIN WIRE
[3]-1 SIDE
ENGINE HARNESS HARNESS
SIDE

[5]
BARO
[3]-4 [3]-3
(BAROMETRIC [6]-4 [6]-3
BARO IAB (IDLE AIR
PRESSURE) BARO (BAROMETRIC IAB (IDLE AIR
(BAROMETRIC BYPASS)
SENSOR 3P PRESSURE) SENSOR BYPASS)
PRESSURE) CONTROL
CONNECTOR WIRE CONTROL
SENSOR WIRE VALVE WIRE
VALVE WIRE
[4] [7] ECT (ENGINE [8]
BARO (BAROMETRIC COOLANT ECT (ENGINE
[2] PRESSURE) SENSOR TEMPERATURE) COOLANT
MAIN WIRE SENSOR 2 TEMPERATURE)
HARNESS 2P CONNECTOR SENSOR 2

[9]
MAIN WIRE
HARNESS

[10]
[1] HARNESS
HARNESS BAND CLIP
BAND
CLIPS

[11]
No.1 FUEL
INJECTOR
2P CONNECTOR

[10]
HARNESS BAND
CLIP [12] WIRE HARNESS CLIP
[13]
Clamp the main wire harness and the
IAB (IDLE AIR
overheat sensor 1 wire.
BYPASS)
CONTROL [12]-2
VALVE WIRE [12]-1 MAIN WIRE HARNESS
ENGINE
SIDE

[12]-1 OVERHEAT SENSOR 1

WIRE

2-58
 [2] HARNESS BAND CLIP
Clamp the main wire harness, joint
connector 1 wire and the joint connector 2
wire as shown.

[2]-2 ENGINE SIDE

[2]-1 [2]-3
JOINT JOINT
CONNECTOR 2 CONNECTOR 1
WIRE WIRE

[2]-4 [3]
MAIN WIRE PRESSURE
HARNESS REGULATOR
[1] RETURN HOSE [1]
MAIN WIRE HARNESS MAIN WIRE
HARNESS

[9]
JOINT CONNECTOR 1 WIRE
[5] HOSE CLIP [4]
[8] JOINT CONNECTOR 2 WIRE Clamp the main wire harness TUBE CLAMP D10.7
[6] and the pressure regulator Check that the
[7] JOINT CONNECTOR ASSEMBLY IAB (IDLE AIR return hose. main wire harness
BYPASS) does not interfere
[5]-1 ENGINE [5]-2
[7]-2 ENGINE SIDE CONTROL VALVE with the tube
SIDE MAIN WIRE
[7]-1 2P CONNECTOR clamp D10.7.
JOINT HARNESS
CONNECTOR 1

[5]-3 PRESSURE REGULATOR

[7]-3 JOINT CONNECTOR 2 RETURN HOSE

2-59
 [1] HARNESS BAND CLIP [2] MAIN WIRE
HARNESS

[3]
No.1 IGNITION COIL

[4] ECT (ENGINE

COOLANT
[17] TEMPERATURE
No.1 FUEL INJECTOR SENSOR 3
2P CONNECTOR 2P CONNECTOR

[5]
[2] No.1 IGNITION COIL
MAIN WIRE 3P CONNECTOR
HARNESS
[6]
No.2 IGNITION COIL

[7]
[16] No.2 IGNITION COIL
No.2 FUEL INJECTOR 3P CONNECTOR
2P CONNECTOR
[8]
[15] No.3 IGNITION COIL
No.3 FUEL INJECTOR
2P CONNECTOR [9]
No.3 IGNITION COIL
3P CONNECTOR

[10]
No.4 IGNITION COIL
[14] COVER LOCK
CABLE A
[11]
No.4 IGNITION COIL
[13] COVER LOCK 3P CONNECTOR
CABLE B
[12] CMP SENSOR
3P CONNECTOR [1] HARNESS BAND
CLIP
[10]
No.4 IGNITION COIL
[18]
CMP (CAMSHAFT
POSITION)
SENSOR
[11] No.4 IGNITION COIL
3P CONNECTOR

[1] HARNESS
[19]
BAND CLIP
CMP (CAMSHAFT
POSITION)
SENSOR
3P CONNECTOR

2-60
[2] HOSE CLAMP
• Set the fuel hose (high pressure side) in the clamp of the larger
diameter side and the main wire harness in the smaller diameter
side.
• Clamp the fuel hose (high pressure side) at the left-hand side to
the marked point.
[2]-4
[2]-1 ENGINE HOSE CLAMP
SIDE [2]-2 MAIN WIRE
HARNESS

[2]-3 FUEL HOSE (HIGH

[2]-3 FUEL HOSE (HIGH [2]-5
PRESSURE SIDE)
PRESSURE SIDE) MARKING
[6]
[3] [4] No.2 FUEL INJECTOR
KNOCK SENSOR [5] 2P CONNECTOR
MAIN WIRE KNOCK
HARNESS 1P CONNECTOR
[1] SENSOR
HARNESS
BAND CLIP [7]
No.3 FUEL INJECTOR
2P CONNECTOR

[13]
CABLE
CLIP

[12]
FUEL PUMP
2P CONNECTOR [10] [8]
COVER LOCK COVER LOCK
[9] CABLE B
[11] FUEL HOSE (HIGH CABLE A
No.4 FUEL INJECTOR
PRESSURE SIDE) 2P CONNECTOR

2-61
 [5] HARNESS BAND CLIP
Clamp the main wire
harness and the knock
sensor wire.

[5]-1 KNOCK SENSOR

WIRE
[3] HARNESS CLIP
Clamp the main wire harness
and the water level sensor [5]-2 MAIN WIRE
wire at the taped part. HARNESS

[2] WATER LEVEL

SENSOR WIRE [6]
[4] MAIN WIRE [7]
KNOCK SENSOR
HARNESS KNOCK SENSOR
1P CONNECTOR
[1]
WATER LEVEL
SENSOR
2P CONNECTOR

[8]
COVER LOCK
CABLE A

[9]
CABLE CLIP

[10] SPIRAL TUBE

[13]
UNDERCASE Wind the spiral tube around the
GROMMET C power tilt motor wire, trim angle
sensor wire and the speed sensor
INSTALLATION: P. 2-56 tube A.

[12] 14 mm CLIPS
INSTALLATION: P. 2-63 [11] WIRE HARNESS CLIP
Clamp the power tilt motor wire, trim angle
sensor wire and the speed sensor tube A.
Avoid clamping on the spiral tube.

2-62
[1] 14 mm CLIPS
• Clamp the power tilt motor wire, trim [1]-1 SPEED SENSOR [1]-3
angle sensor wire and the speed sensor [1]-1 SPEED SENSOR TUBE A POWER
tube A. TUBE A TILT
• Install the 14 mm clip aligning the tape
[1]-4 PROJECTIONS MOTOR
end of the power tilt motor wire with the
WIRE
14 mm clip end.
• Tighten the two 5 x 10 mm rivet screws [1]-7
while pushing the respective 14 mm clips SPIRAL
against the corresponding projection of TUBE
the mounting case.
[1]-3 [1]-5 TAPE
[1]-2 TRIM ANGLE POWER
SENSOR WIRE TILT [1]-2 [1]-6
MOTOR TRIM ANGLE [1]-5 14 mm CLIP (2)
WIRE SENSOR WIRE TAPE

[2] GROUND CABLE

[10] SPIRAL TUBE

Set the spiral tube
on the power tilt
motor wire, trim
angle sensor wire
and the speed
sensor wire as
shown.

[9] TRIM ANGLE SENSOR

[8] TRIM ANGLE

SENSOR WIRE [3] POWER TILT
MOTOR WIRE

[7] WIRE HARNESS CLIP

Clamp the power tilt motor wire,
trim angle sensor wire and the
speed sensor tube A. Avoid
clamping on the spiral tube. [4] CORRUGATED TUBE
[6]
SPEED Wind the corrugated tube
SENSOR around the power tilt motor
TUBE B wire. Be sure that the tube is
[5] MOTOR CORD BUSHING set upright.
Pass the power tilt motor wire, [4]-4 CORRUGATED TUBE
trim angle sensor wire and the [5]-1 TRIM ANGLE
speed sensor tube B through the SENSOR WIRE
motor cord bushing. Align the
tape end of the power tilt motor
wire with the end of the motor [5]-2 SPEED SENSOR
cord bushing. TUBE A

[5]-3 POWER TILT

MOTOR WIRE

[4]-2 POWER TILT

[5]-4 TAPE MOTOR WIRE

2-63
• Side-mount remote control

[1] [2] [3] [4]

EMERGENCY IGNITION WARNING SOLENOID
STOP SWITCH SWITCH BUZZER SWITCH

[6] [7] POWER TRIM/TILT

INDICATOR SWITCH
LIGHT

[8]
POWER TRIM/TILT
SWITCH WIRE

[5] REMOTE CONTROL CABLE B

[4]
SOLENOID
SWITCH

[2]
IGNITION
SWITCH

[1]
EMERGENCY
STOP SWITCH

[5] REMOTE CONTROL [3]

*1: WARNING
CABLE B
*2: BUZZER

[5] [8]
[7]
REMOTE POWER
POWER
CONTROL TRIM/TILT
TRIM/TILT
CABLE B SWITCH
SWITCH
WIRE

*1: Power trim/tilt switch wire routing when the remote

[1] View from ignition switch side:
control lever is installed as shown in the drawing A.
[2] DRAWING A [3] DRAWING B
*2: Power trim/tilt switch wire routing when the remote
control lever is installed as shown in the drawing B.

[5] REMOTE
CONTROL
LEVER

[4] IGNITION
SWITCH

2-64
• Control panel

[3]
INDICATOR LIGHT
[OIL PRESSURE LIGHT/
OVERHEAT LIGHT]

[4] WARNING BUZZER

[2]
IGNITION SWITCH

[5]
WIRE HARNESS BAND

[1]
EMERGENCY STOP
SWITCH

[6]
SWITCH PANEL HARNESS
CONNECTION: P. 16-8

2-65
11. TUBE ROUTING
[1] WATER RELIEF TUBE A
• Install at approximately
right angles to the
horizontal line.
• After installation, check
the tube for twist, bend,
etc. [1]-2 [2]
WATER 7 x 120 mm TUBE
RELIEF
[1]-1 Approx. 90° TUBE A
[3]
TUBE CLAMP D10.5

[13] 7 x 90 mm TUBE

[12] WATER TUBE CLAMP

INSTALLATION: P. 2-45

[11] FUEL TUBE JOINT

[10] 7 x 75 mm TUBE

[8] TUBE CLAMP D25.0

Install at 8 mm (0.3 in)
from the tube end.

[9] 4-WAY JOINT

[8] TUBE CLAMP D25.0

Install at 8 mm (0.3 in)
from the tube end.

[7] WATER TUBE CLAMP B

[6] WATER RELIEF TUBE B

• Install at 33° from the horizontal line.
• After installation, check the tube for
twist, bend, etc.
[4]
WATER
TUBE E

[3] TUBE CLAMP D10.5

[6]-1
Approx.
33° [6]-2
WATER [5] TUBE CLAMP D25.0
RELIEF
TUBE B

2-66
 [2] TUBE CLAMP D25.0
Install the tube clamp with the lugs facing in the direction
shown.

[2]-1
WATER
RELIEF
TUBE A

[2]-2 <Cylinder head cover viewed from the front>

[1]
WATER RELIEF
TUBE A

[6]
TUBE CLAMP D10.5

[8]
7 x 90 mm TUBE

[6]
TUBE CLAMP D10.5

[7]
FUEL TUBE JOINT

[6] TUBE CLAMP D10.5

[4] 7 x 120 mm TUBE
[5] 7 x 75 mm TUBE [3] TUBE CLAMP D10.5
Install with the lugs
facing down.
[3] TUBE CLAMP D10.5
Install with the lugs facing
down.

2-67
 [2] TUBE CLAMP D10.5
[1] TUBE CLAMPS D10.5

[3]
7 x 160 mm TUBE

[2] TUBE CLAMP D10.5

[4]
WATER RELIEF
TUBE C

[6] 7 x 40 mm TUBE
[1] TUBE CLAMPS D10.5

[5] T-JOINT
[2]
TUBE CLAMP D10.5

[7]
7 x 200 mm TUBE

[8]
12 mm TUBE CLIP B1
[9] 8 x 300 mm TUBE
[2] TUBE CLAMP D10.5

[8]
12 mm TUBE
CLIP B1

[2] TUBE CLAMP D10.5

[9] 8 x 300 mm TUBE

[7] 7 x 200 mm TUBE

2-68
 [1] 4 x 7 x 160 mm VINYL TUBE

[2]
FUEL TUBE A

[3]
SPEED SENSOR
TUBE A

[4]
UNDERCASE
GROMMET C

[3] SPEED SENSOR

TUBE A

[2] FUEL TUBE A

[5]
4 x 7 x 160 mm VINYL
TUBE
Insert into the hole in the
under cover front bracket
securely.

[6] RECESS

[8] 3.5 x 430 mm FUEL TUBE

[7] HOLE Set in the recess in the
under cover front bracket.

2-69
 [1] WATER SEPARATOR
with WATER LEVEL [2] TUBE CLIP B12
SENSOR

[3]
FUEL TUBE C

[2]
TUBE CLIP B12

[6]
FUEL TUBE HOLDER

[5] 14 mm FUEL TUBE [4] FUEL TUBE A

CLIP

[6] [5]
FUEL TUBE HOLDER [4] FUEL TUBE A 14 mm FUEL TUBE
CLIP

2-70
[1] PRESSURE REGULATOR
CONTROL TUBE
Connect the pressure regulator
control tube aligning the marked part
on the tube with the end of the 3.5 [5] FUEL TUBE CLAMP
mm tube clamp. Set the breather tube in the clamp of
[1]-1 [1]-2 the larger diameter side and the
PRESSURE REGULATOR 3.5 mm pressure regulator control tube in the
CONTROL TUBE TUBE smaller diameter side.
CLIP [2]
BREATHER
TUBE [6] TUBE CLAMP D25.0
INSTALLATION: P. 2-67
[3]
[4]
3.5 mm TUBE
18.5 mm [7] WATER RELIEF
CLIPS
CLAMP TUBE A
[1]-3 MARKING
INSTALLATION:
P. 2-66

[4]
18.5 mm
CLAMP
[8]
AIR VENT
TUBE D

[20]
DIAPHRAGM
TUBE
[9] TUBE CLAMP
[19] IAB CONTROL VALVE D10.7
TUBE
[11] INSTALLATION:
CHECK P. 2-59
[18] AIR VENT TUBE A VALVE
[15] [10]
[17] HOSE CLAMP AIR VENT [12]
[14] PRESSURE
TUBE B AIR VENT
Set the air vent tube B in the T-JOINT REGULATOR
TUBE C
clamp of the larger diameter RETURN HOSE
side and the pressure regulator
return hose in the smaller [13] HOSE CLAMP
diameter side. [16] PIPE CLAMP Set the air vent tube A in the
Set the air vent tube A in the clamp of the larger diameter
clamp of the larger diameter side and the pressure
side and the air vent tube D in regulator return hose in the
the smaller diameter side. smaller diameter side.

2-71
 [3]
WATER RELIEF TUBE A
INSTALLATION: P. 2-66 [4] 14 mm FUEL TUBE CLIP
[2] Install aligning the end of the 14 mm fuel
TUBE CLAMP tube clip with the end of the white mark
[1] BREATHER TUBE
D17.0 on the air vent tube.
[4]-1
AIR VENT
TUBE A

[4]-2
WHITE MARK

[4]-3
14 mm
FUEL TUBE
CLIP

[5] AIR VENT TUBE A

[6] 14 mm FUEL TUBE CLIP

[7] FUEL TUBE B

[8] 14 mm FUEL TUBE CLIP

• Clamp the fuel tube B.
• Check the fuel tube B protection tube
for protrusion from the end of the 14
mm fuel tube clip. The protection tube
should protrude 2 mm (0.1 in) max.
from the clip.

[8]-1
FUEL TUBE B

[6]-1
[7] FUEL TUBE B
2 mm (0.1 in)
MAX.
[13] FUEL TUBE JOINT [9]
14.5 mm [8]-3
[9]
TUBE 14 mm
[12] 14.5 mm TUBE
CLIP B1 FUEL TUBE
FUEL TUBE D CLIP B1
CLIP
[10] FUEL PUMP
[11] 14 mm FUEL TUBE CLIP
Clamp the fuel tube B.

2-72
[2] HOSE CLAMP [3] [5] SENSOR HOSE CLIP
Set the fuel tube E in FUEL HOSE
the clamp of the larger (HIGH [4] Clamp the fuel hose [6]
diameter side and the PRESSURE TUBE (high pressure side) AIR VENT
7 x 400 mm tube in the SIDE) CLIP and the fuel tube B. TUBE A
smaller diameter side. B12
[7]
14 mm FUEL TUBE
[1] CLIP
TUBE
CLIP [8]
14 mm FUEL TUBE
CLIP
INSTALLATION:
P. 2-72

[9]
FUEL TUBE B

[10]
14.5 mm TUBE
CLIP B1

[11] FUEL PUMP

[10]
14.5 mm TUBE
CLIP B1
[19]
7 x 400 mm
TUBE [12]
14 mm FUEL TUBE
[13] CLIP
[4] TUBE CLIP
B12 FUEL TUBE D Clamp the fuel
[9] tube B.
FUEL TUBE B
[18] FUEL TUBE E [4] TUBE CLIP B12
[16] [4]
AIR VENT TUBE CLIP
[17] TUBE A B12
[1] [14] FUEL TUBE JOINT
WATER TUBE F
TUBE CLIP
[15] SENSOR HOSE CLIP
• Clamp the fuel tube B and fuel [15]-1 [15]-2
tube E. FUEL TUBE B SENSOR HOSE
• Install the sensor hose clip CLIP
aligning with the end of the
protection tube on the fuel tube E.

[15]-4 PROTECTION
TUBE [15]-3
FUEL TUBE E

2-73
 [4] HOSE CLAMP
Set the air vent tube B in the
clamp of the larger diameter
side and the pressure regulator
return hose in the smaller [5] [6] TUBE CLIP
diameter side. AIR VENT
[3] VAPOR Clamp the air vent tube
TUBE B
CHAMBER E and the fuel hose
(high pressure side) as
[2] shown.
PRESSURE REGULATOR
RETURN HOSE [7]
FUEL HOSE (HIGH
PRESSURE SIDE)
[1] HOSE CLAMP
INSTALLATION:
P. 2-61

[13]
7 x 400 mm TUBE

[11]
TUBE CLAMP
D10.7
[10]
AIR VENT TUBE E
[12] TUBE CLIP [8] TUBE CLAMP D32.5
Install with the lugs facing down.
[12]-1 [9] OIL TUBE
7 x 400 mm • Install the oil tube aligning the
TUBE [12]-2 TUBE CLIP
projection on the oil tube
installation part with the [9]-1
projection of the oil tube. PROJECTION
• Install the tube clamp D32.5
with the lugs in the position
shown.
[9]-4 TUBE CLAMP D32.5

[9]-1
PROJECTION
[12]-3 LUGS [9]-3 OIL TUBE

[9]-2 LUGS

2-74
 [3]
WATER SEPARATOR
with WATER LEVEL
SENSOR
[1]
4 x 7 x 160 mm
VINYL TUBE [5]
FUEL STRAINER [7]
INSTALLATION: MAIN WIRE
P. 2-69 HARNESS
[6] [8] HOSE CLAMP
[4]
TUBE CLIP
[2] FUEL TUBE C INSTALLATION: P. 2-61
B12
SPEED SENSOR
TUBE A

[9]
FUEL HOSE
(HIGH
PRESSURE
SIDE)

[10]
FUEL TUBE E

[11]
WATER TUBE F

[12]
3.5 x 430 mm FUEL TUBE
[18] INSTALLATION: P. 2-69
UNDERCASE
[13] WATER CHECK
GROMMET C
GROMMET
INSTALLATION:
P. 2-56
[16] [14] 7 x 400 mm TUBE
[15] 14 mm CLIP FUEL TUBE A
INSTALLATION:
P. 2-63 [15] 14 mm CLIP
INSTALLATION: P. 2-63
[17] 14 mm FUEL
TUBE CLIP

2-75
 [3] SPEED SENSOR TUBE PLATE
Install the speed sensor tube plate [3]-1
so that the distance between the SPEED SENSOR
end of the plate and the end of the TUBE B
speed sensor tube B is 15 – 20 mm
(0.6 – 0.8 in). [3]-1
[2] SPEED
SPEED SENSOR SENSOR
TUBE PLATE 15 – 20 mm TUBE
(0.6 – 0.8 in) PLATE
[1]
SPEED SENSOR
TUBE B

[4]
TUBE CLIP B8

[10]
SPEED SENSOR
TUBE A
[6]
WIRE
BAND

[9] JOINT A
[5] SPEED SENSOR
TUBE C

[7] MOTOR CORD BUSHING

INSTALLATION: P. 2-63
[8] SPEED SENSOR TUBE B
• Pass the trim angle sensor wire, [8]-5 [8]-7
[8]-3
power tilt motor wire and the speed [8]-1 [8]-2 SPEED WIRE [8]-8
TRIM
sensor tube B through the hole in the MOTOR UP SENSOR BANDS SPEED
ANGLE
motor cord bushing as shown. CORD TUBE B SENSOR
SENSOR
• Install the speed sensor tube B so that BUSHING TUBE A
WIRE
the distance between the end of the
motor cord bushing and the end of
the speed sensor tube B is 10 – 15 mm
(0.4 – 0.6 in).
[8]-6 REAR
[8]-9
[8]-1 JOINT A
[8]-5 SPEED MOTOR 10 – 15 mm
[8]-4
SENSOR CORD (0.4 – 0.6 in)
POWER TILT
TUBE B MOTOR WIRE BUSHING

2-76
12. LUBRICATION
Apply oil or marine grease to the following parts. [2]

[1]
(Marine grease)

② ①
①

④
②
⑤

⑥
① THROTTLE PLATE
① DETENT ARM ROLLER ② THROTTLE ARM
② NEUTRAL SWITCH ③ THROTTLE ARM LINK PIN
[6] ④ SHIFT SLIDE PIVOT/SHIFT PIVOT PLATE
⑤ LINK PIN
⑥ SHIFT LINK PIN
②
[3]

②
①

① COVER LOCK CABLE B CABLE

END
② R. SIDE LOCK

① SHIFT ROD A
[5] ② VERTICAL SHAFT

[4]

MOUNTING PLATE
PROPELLER SHAFT

2-77
 [2]

[1]

② [3]

(Marine grease)

②
THROTTLE BODY
①

① COVER LOCK CABLE A/B

CABLE END
② L. SIDE LOCK ③

① FRONT ROCK CABLE

② FRONT ROCK
③ COVER OPEN SHAFT

[5]

② [4]

① ② ①

① TILTING SHAFT ① DETENT SPRING ROLLER

② TILTING SHAFT (THREADS) ② TILTING BRACKET CAM

2-78
 [1]

COVER LOCK BOLTS

[4] [5]
①

[3]

② ②

① UPPER CYLINDER BUSHING/

TILT STOPPER BEARING PIN
② SLIDING SURFACE OF THRUST
RECEIVER
SWIVEL CASE

[2]

LOWER CYLINDER BUSHINGS/

COLLAR/WAVE WASHERS

2-79
3. MAINTENANCE
1. MAINTENANCE SCHEDULE 9. WATER SEPARATOR with WATER
2. ENGINE OIL LEVEL SENSOR
3. OIL FILTER 10. IDLING
4. GEAR CASE OIL 11. SHIFT CONTROL CABLE
5. SPARK PLUGS 12. THROTTLE CONTROL CABLE/
6. VALVE CLEARANCE THROTTLE LINK
7. FUEL STRAINER (LOW PRESSURE 13. REMOTE CONTROL LEVER FRICTION
SIDE) 14. ALTERNATOR BELT
8. FUEL STRAINER (HIGH PRESSURE
SIDE)

1. MAINTENANCE SCHEDULE
REGULAR SERVICE PERIOD (1) First Every Every Every
Refer
Item Perform at every indicated month or Each After month 6 month year 2 year
to
operating hour interval, whichever use use or or or or
page
comes first. 20 Hrs. 100 Hrs. 200 Hrs. 400 Hrs.
Engine oil Check level ○
3-2
Change ○ ○
Gear case oil Change ○ ○ 3-4
Engine oil filter Replace ○ 3-3
Alternator belt Check-adjust ○ 3-28
Throttle linkage Check-adjust ○ ○ 3-26
Idling speed Check-adjust ○ ○ 3-22
Valve clearance Check-adjust ○ 3-9
Spark plug Check ○ ○
3-8
Clean ○ ○
Replace ○ 3-7
Propeller and
Check ○ 14-2
cotter pin
Anode metal Check ○ 14-88
Lubrication Grease ○ (2) ○ (2) 2-77
Water separator Check ○ 3-19
Fuel strainer Check ○
3-15
Replace ○
Fuel strainer
Replace ○ 3-18
(High pressure type)
Thermostat Check ○ 8-3
Fuel line Check ○
5-104
Replace Every 2year (Replace if necessary)
Battery and cable
Check level-tightness ○ –
connection
Bolt and nuts Check-tightness ○ ○ –
Crankcase breather
Check ○ –
tube
Cooling water
Clean ○ (3) –
passages
(1) For professional commercial use, log hours of operation to determine proper maintenance intervals.
(2) Lubricate more frequently when used in salt water.
(3) When operating in salt water, turbid or muddy water, the engine should be flushed with clean water after each use.

3-1
2. ENGINE OIL [1] DIPSTICK

Oil Level Inspection:

[2]
Check the engine oil level with the engine stopped and the UPPER
LIMIT
outboard motor in the vertical position.

1) Remove the engine cover.

2) Remove the dipstick and wipe it clean. [3]

LOWER
3) Insert the dipstick all the way in the oil level pipe, then pull LIMIT
it out and read the oil level.

4) If the oil level is low, remove the oil filler cap and add the
recommended oil to reach the upper limit mark on the
dipstick.

5) Reinstall the oil filler cap and dipstick.

Oil Change:

Drain the used oil while the engine is warm. Warm oil drains
quickly and completely.
[1]
1) Remove the oil filler cap and the drain plug cover. OIL FILLER
CAP
2) Attach the drain plug cover to the oil drain guide of the oil
case.

3) Place a suitable oil container next to the outboard motor,

and remove the oil drain plug bolt.

Please dispose of used motor oil in a manner that is

compatible with the environment. We suggest you take
used oil in a sealed container to your local recycling canter
or service station for reclamation. Do not throw it in the
trash, pour it on the ground, or down a drain.

CAUTION [1]
Used engine oil contains substances that have been DRAIN
PLUG
identified as carcinogenic.
COVER
If repeatedly left in contact with the skin for prolonged
periods, it may cause skin cancer.
[1] 12 mm [2] OIL DRAIN
Wash your hands thoroughly with soap and water as DRAIN PLUG PLUG BOLT
soon as possible after contact with used engine oil. WASHER

4) Replace the 12 mm drain plug washer with a new one, and

reinstall the oil drain plug bolt. Tighten the oil drain plug
[3]
bolt to the specified torque.
DRAIN
PLUG
TORQUE: 23 N.m (2.3 kgf.m, 17 lbf.ft) GUIDE

5) Reinstall the drain plug cover.

3-2
6) Refill with the recommended engine oil to the upper limit
mark on the dipstick.
[1] SAE Viscosity Grades
Without oil filter replacement:
Engine oil 6.5R (6.9 US qt, 5.7 Imp qt)
capacity With oil filter replacement:
6.7R (7.1 US qt, 5.9 Imp qt)

Recommended SAE 10W-30

engine oil API Service classification SG/SH/SJ
[2] AMBIENT TEMPERATURE
NOTICE
Using nondetergent oil can shorten the engine’s service life
and using 2-stroke oil can damage the engine.

7) Install the engine cover (P. 4-2). [1] OIL FILTER

3. OIL FILTER
Replacement:
1) Drain the engine oil, then reinstall the oil drain plug bolt
and drain plug cover, as described in the oil change [2]
procedure. OIL FILTER
WRENCH
2) Place a shop towel under the oil filter to absorb any spilled 07HAA-PJ70101
oil, then remove the oil filter with an special tool.
TOOL:
Oil filter wrench 07HAA-PJ70101
3) Drain the used oil filter into a suitable container for oil
disposal (P. 3-2).
4) Clean the filter mounting base, and coat the seal of the new
oil filter with clean engine oil.
• Use only a genuine Honda oil filter or a filter of equivalent
quality specified for you model. Using the wrong Honda
filter, or a not-Honda filter which is not of equivalent
quality, may cause engine damage.
5) Screw on the new oil filter by hand, until the seal contacts [1] RUBBER SEAL
the filter mounting base, then use an special tool to tighten
the filter an additional 7/8 turn.

TOOL:
Oil filter wrench 07HAA-PJ70101
TORQUE: 12 N.m (1.2 kgf.m, 9 lbf.ft)
6) Refill the engine with the specified amount of the
recommended oil, as described in the oil change
procedure.
Reinstall the oil filter cap and dipstick.
7) Start the engine, and check the leaks.
8) Stop the engine, and check the oil level as described on
page 3-2. If necessary, add oil to the upper limit mark on the
dipstick.
9) Reinstall the engine cover.

3-3
4. GEAR CASE OIL
Inspection:

1) Place the outboard motor on a level surface and position it

vertically.

2) Remove the oil level bolt and check whether the gear case
oil flows out of the gear case. If it flows out, be sure to catch
the oil in a suitable container.
Replace the O-ring on assembly.

3) If the oil does not flow out, add oil.

4) Coat a new O-ring with clean engine oil and install the O- [1]
ring on the oil level bolt. 5.5 x 1.5 mm
Set the oil level bolt on the gear case and tighten the bolt O-RING
to the specified torque. [2] OIL LEVEL BOLT
TORQUE: 3.4 N.m (0.35 kgf.m, 2.5 lbf.ft)

Addition of gear oil:

[1] OIL LEVEL BOLT
1) Remove the oil drain bolt, and install the commercially
available gear oil pump in the oil drain bolt hole.
Replace the O-ring on assembly.

2) Remove the oil level bolt, and add the gear oil until it flows
out of the oil level bolt hole.
Replace the O-ring on assembly.

Gear oil capacity 0.98R (1.04 US qt, 0.86 Imp qt)

Recommended MARINE SAE 90 Hypoid gear oil API

gear oil Service classification (GL-4)
[2] OIL DRAIN
BOLT
3) Check for the metal particles on the magnet end of the oil
drain bolt.
[3] MAGNET
4) If there are metal particles on the magnet end of the oil [2]
drain bolt, disassemble the gear case assembly and check OIL DRAIN
(See section 14). BOLT

5) After adding the gear oil, apply clean engine oil to the new
O-rings and install them on the oil drain bolt and the oil
level bolt.
Set the oil drain bolt and the oil level bolt on the gear case,
and tighten the bolts to the specified torque. [4]
GEAR OIL PUMP
TORQUE: 3.4 N.m (0.35 kgf.m, 2.5 lbf.ft) (Commercially
available)

3-4
Replacement:
[1] OIL LEVEL BOLT
1) Place the outboard motor on a level surface and tilt up the
outboard motor.

2) Remove the oil level bolt and the oil drain bolt, and drain
the old oil.
Replace the O-rings on assembly.
If there is water in the oil, the water will flow out first when
the oil drain bolt is removed, or the oil will be a milky color.
If water in the gear oil is detected, check the gaskets and
water seals for damage, and check the torque on the gear
case bolts.

3) Check for the metal particles on the magnet end of the oil
drain bolt (P. 3-4).
[2] OIL DRAIN
4) If there are metal particles on the magnet end of the oil BOLT
drain bolt, disassemble the gear case assembly and check
(See section 14).

5) Install a commercially available gear oil pump in the oil

drain bolt hole, and add gear oil until it flows out of the oil
level bolt hole.

Gear oil capacity 0.98R (1.04 US qt, 0.86 Imp qt)

[1]
Recommended MARINE SAE 90 Hypoid gear oil API 5.5 x 1.5 mm
gear oil Service classification (GL-4) O-RING

6) After adding the gear oil, apply clean engine oil to the new
O-rings and install them on the oil drain bolt and the oil
level bolt. [2]
Set the oil drain bolt and the oil level bolt on the gear case, OIL DRAIN BOLT
and tighten the bolts to the specified torque.

TORQUE: 3.4 N.m (0.35 kgf.m, 2.5 lbf.ft)

[1]
GEAR OIL PUMP
(Commercially
available)

3-5
5. SPARK PLUGS [1]
SCREWDRIVER
Removal:

1) Remove the engine cover (P. 4-2).

[2] SLOT
2) Set a screwdriver in the slot in the two mud guard clips at
the top of the under cover grommet, and raise the mud
guard clips.

Remove the two mud guard clips. [4]

[3]
MUD GUARD MUD GUARD
3) Detach the upper part of the under cover grommet. CLIP CLIP (2)

[5]
UNDER COVER
GROMMET

4) Remove the two 6 x 25 mm socket bolts and remove the

PHC cover.

[1]
PHC COVER

[2] 6 x 25 mm SOCKET
BOLT (2)

3-6
5) Remove the 6 x 25 mm socket bolts and remove each
ignition coil from the corresponding spark plug. [1]
No.1 IGNITION
Pull out each ignition coil halfway. COIL

6) Disconnect the ignition coil 3P connector from each

ignition coil.
[2]
No.2 IGNITION
Remove each ignition coils.
COIL
NOTICE
• Do not pull out the ignition coils excessively.
[3]
• Do not drop the ignition coils and do not strike on the No.3 IGNITION
COIL
ignition coils, either, during removal/installation of the
coils.
[4]
• Do not reuse the ignition coils when they are dropped.
No.4 IGNITION
COIL
7) Clean any dirt from around the spark plug bases.

[5] IGNITION COIL

[6]
6 x 25 mm
SOCKET
BOLT (2)

[7] IGNITION COIL

3P CONNECTOR

8) Remove the spark plugs using a spark plug wrench.

[1] SPARK PLUG

WRENCH

3-7
Inspection/Cleaning:
1) Visually inspect the spark plugs. Discard the plugs if the [1]
insulators are cracked or chipped. SEALING
1.0 – 1.1 mm WASHER
2) Remove carbon or other deposits with a plug cleaner. (0.039 – 0.043 in)
NOTICE
Do not spray the cleaner more than 20 seconds.
3) Measure the plug gap with a wire-type feeler gauge.
[3] Damaged
If the measurement is out of the specification, replace the
washer
spark plug.

1.0 – 1.1 mm (0.039 – 0.043 in)

Spark plug gap
Service limit: 1.3 mm (0.051 in)
[2] Cracked
insulation
Recommended IZFR6K11 (NGK)
spark plug SKJ20DR-M11 (DENSO)
[4] [5]
4) Replace the spark plugs with the new ones if the center Worn or Center
electrode is rounded as shown. deformed electrode
electrodes
NOTICE
• These outboard motors are equipped with the iridium
spark plugs. Do not adjust the spark plug gap.
• After cleaning the spark plugs with a plug cleaner,
remove the sand thoroughly from the spark plugs.
• Never clean the spark plugs with a stiff wire brush. It can
damage the fine-grain film of the iridium chips of the
iridium spark plug.
5) Make sure each sealing washer is in good condition.
With each spark plug sealing washer attached, thread the
spark plugs in by hand to seat the sealing washers and
prevent crossthreading.
Then tighten with a plug wrench (an additional 1/2 turn if a
new plug) to compress the sealing washer. If you are [2]
reusing a plug, tighten 1/8 – 1/4 turn after the plug seats. MUD GUARD
[1] CLIPS
TORQUE: 18 N.m (1.8 kgf.m, 13 lbf.ft) Lip on reverse
side of grommet.
NOTICE
A loose spark plugs can become very hot and can damage
the engine. Overtightening the spark plugs can damage the
threads in the engine.
6) Install the ignition coils and tighten each with the 6 x 25
mm socket bolt securely (P. 3-7).
7) Connect the ignition coil 3P connector to each ignition coil
and install the PHC cover (P. 3-6 and 7).
8) Push in the two mud guard clips at the top of the under
cover grommet securely until they click.
9) Check that the lip at the reverse side of the under cover
grommet is engaged with the L./R. engine under covers
securely.
• Check that the under cover grommet adheres to the
engine under covers securely.
• If the projections on the reverse side of the under cover [3] Projections on
grommet are out of position, set them on the under cover [4] UNDER COVER reverse side of
grommet properly. GROMMET grommet.

10) Install the engine cover (P. 4-2).

3-8
6. VALVE CLEARANCE
[1]
Inspection/Adjustment: UNDER COVER
GROMMET
• Valve clearance inspection and adjustment must be
performed with the engine cold.

1) Remove the engine cover (P. 4-2).

2) Move the remote control lever to the “N” (Neutral)

position.

3) Set a screwdriver in the slot in the six mud guard clips, and
raise the mud guard clips (P. 3-6).
Remove the six mud guard clips.

4) Remove the under cover grommet.

5) Remove the PHC cover (P. 3-6).

Remove the four ignition coils and the four spark plugs (P.
3-7).
Remove the L./R. engine under covers (P. 4-9).

[2] MUD GUARD

CLIP (6)

6) Remove the two 6 x 22 mm flange bolts and remove the R.

side cover bracket from the engine assembly. [1] R. SIDE COVER
BRACKET

6 x 22 (2)

7) Disconnect the breather tube and main wire harness from

the cylinder head cover. [1]
Hold the main wire harness at the exhaust manifold side. CYLINDER
HEAD
COVER

[3]
[2] MAIN
BREATHER WIRE
TUBE HARNESS

3-9
8) Clamp the fuel tube B and D with the commercially
[1] TUBE CLIP [2] FUEL TUBE B
available tube clips as shown, and disconnect the fuel tube
(Commercially
B and D from the fuel pump (low pressure side). available)

WARNING
Gasoline is highly flammable and explosive.

You can be burned or seriously injured when handling

fuel.

• Keep heat, sparks and flame away.

• Handle fuel only outdoors.
• Wipe up spills immediately.

• Before disconnecting the fuel tubes, be sure to clamp the

fuel tubes with a tube clips to prevent the gasoline from
leaking. [4] FUEL TUBE D [3] FUEL PUMP

9) Disconnect the oil tube from the mounting case.

[1] OIL TUBE

[2] MOUNTING
CASE

10) Move the water relief tube A from your side of the
projection on the cylinder head cover to the other side. [1] WATER RELIEF
TUBE A [2]
PROJECTION

[3]
CYLINDER HEAD
COVER

3-10
11) Remove the six 6 mm hex. cap nuts and the six head cover washers, and remove the cylinder head cover.

[1] CYLINDER HEAD

COVER

[2]
HEAD COVER
WASHER (6)

[3]
6 mm HEX.
CAP NUT (6)

12) Release the pressure regulator control tube from the two 3.5 mm tube clips of the silencer duct assembly.
Remove the harness band clip, that clamps the main wire harness, from the silencer duct assembly.

13) Remove the breather tube from the 18.5 mm clamp and the guide of the silencer duct assembly.

[1]
SILENCER DUCT [2] 18.5 mm CLAMP
ASSEMBLY

[3] BREATHER
TUBE

[4]
[8] GUIDE PRESSURE
REGULATOR
CONTROL TUBE

[7]
MAIN WIRE [5] 3.5 mm TUBE CLIP
HARNESS

[5] 3.5 mm TUBE CLIP [6] HARNESS BAND CLIP

3-11
14) Remove the four 6 x 25 mm flange bolts and the four 6 mm
washers, and remove the silencer duct assembly. [2]
SILENCER DUCT
[1] ASSEMBLY
6 x 25 (4)
6 mm
WASHER (4)

15) Attach the wrench to the 16 x 49 mm washer bolt on the

crankshaft pulley as shown. [1] [2] 16 x 49 mm
Turn the crankshaft pulley clockwise. WRENCH WASHER BOLT

16) Align the cutout in the crankshaft pulley with the “ ” mark
on the chain case.

• Do not turn the crankshaft pulley counterclockwise.

[3]
[3] CRANKSHAFT
CRANKSHAFT PULLEY
PULLEY

[4]
CUTOUT

[5] CHAIN
CASE [6]
“ ” MARK

3-12
17) Holding the cutout in the crankshaft pulley aligned with the
“ ” mark on the chain case, check that the “ ” mark on [1] [3]
[2] “ ” MARKS
the intake camshaft sprocket is in alignment with the EXHAUST INTAKE
“ ” mark on the exhaust camshaft sprocket. (The No.1 CAMSHAFT CAMSHAFT
piston is at the top dead center of its compression stroke SPROCKET SPROCKET
this time.)

• Perform this check on each cylinder with its piston at the

top dead center of its compression stroke (i.e. both the
intake and exhaust rocker arms are not lifted).

18) With the engine in the position described in step 17, check
the intake and exhaust valve clearances on the No.1
cylinder by inserting a feeler gauge between the
intake/exhaust side rocker arm valve adjusting screw and
the valve stem end.

0.21 – 0.25 mm
IN
(0.008 – 0.010 in)
Valve clearance
0.28 – 0.32 mm
EX
(0.011 – 0.013 in)

[1] [2] VALVE

[6] [5]
VALVE ADJUSTING ADJUSTING
INTAKE EXHAUST
LOCK NUT SCREW
SIDE SIDE

No.1 No.1

No.2 No.2

No.3 No.3

No.4 No.4

[3] FEELER GAUGE

19) If adjustment is necessary, loosen the valve adjusting lock

nut while holding the valve adjusting screw with a
screwdriver.

20) Insert a feeler gauge between the intake/exhaust side

rocker arm valve adjusting screw and the valve stem end.

21) Adjust the intake and exhaust valve clearances by turning

the valve adjusting screw.

22) After adjustment, secure the valve adjusting screw and

loosely tighten the lock nut.

23) Recheck the valve clearances again. Tighten the valve

adjusting lock nut to the specified torque.

TORQUE: [3] FEELER GAUGE [4] SCREWDRIVER

Intake side: 20 N.m (2.0 kgf.m, 14 lbf.ft)
Exhaust side: 14 N.m (1.4 kgf.m, 10 lbf.ft)

3-13
24) After adjusting the intake and exhaust valve clearances of
[1] No.3 PISTON AT TOP DEAD CENTER OF
the No.1 cylinder, turn the crankshaft pulley clockwise by
COMPRESSION STROKE:
increments of 180° and bring the piston of each cylinder at
the top dead center of its compression stroke.
Repeat the procedure from step 18 through step 23.

[5] [4]
INTAKE EXHAUST
SIDE SIDE

No.1 No.1

No.2 No.2

[2] No.4 PISTON AT TOP DEAD CENTER OF

COMPRESSION STROKE:

No.3 No.3

No.4
No.4

[3] No.2 PISTON AT TOP DEAD CENTER OF

COMPRESSION STROKE:

3-14
25) After adjusting the valve clearances on each cylinder, install
[1]
the silencer duct assembly on the silencer case.
SILENCER 6 x 25 (4)
DUCT
26) Set the four 6 x 25 mm flange bolts and the four 6 mm ASSEMBLY
washers, then tighten the four 6 x 25 mm flange bolts
securely.

[2]
6 mm
WASHER
(4)

27) Set the breather tube in the guide of the silencer duct
assembly and secure the tube with the 18.5 mm clamp. [1] SILENCER DUCT [2]
ASSEMBLY 18.5 mm
28) Secure the pressure regulator control tube with the two 3.5 CLAMP
mm tube clips of the silencer duct assembly.

Connect the pressure regulator control tube aligning the

marked part on the tube with the end of the 3.5 mm tube
clip (P. 2-70).

29) Set the main wire harness’ harness band clip on the
silencer duct assembly.
[6]
30) Install the cylinder head cover (P. 10-40). GUIDE

[3] PRESSURE
[5] [4] REGULATOR
3.5 mm TUBE HARNESS CONTROL
CLIP (2) BAND CLIP TUBE

7. FUEL STRAINER (LOW PRESSURE [1]

FUEL STRAINER
SIDE) (LOW PRESSURE
SIDE)
Inspection:

1) Remove the engine cover (P. 4-2).

2) Visually check the fuel strainer cup (low pressure side) for
water or foreign material in the cup. Check the fuel strainer
for contamination.

3) If there is water or foreign material in the fuel strainer cup,

or if the fuel strainer is contaminated, disassemble the
strainer and clean it (P. 3-16).

3-15
Removal:
[1] FUEL TUBE E

WARNING
Gasoline is highly flammable and explosive.

You can be burned or seriously injured when handling fuel.

[2]
• Keep heat, sparks and flame away. TUBE CLIPS
• Handle fuel only outdoors. (Commercially
• Wipe up spills immediately. available)

1) Clamp the fuel tube C and E securely with the two [3] FUEL TUBE C
commercially available tube clips.

2) Remove the strainer suspension from the fuel strainer stay. [1] FUEL STRAINER
STAY
3) Disconnect the fuel tube C and E from the fuel strainer (low
pressure side).
Remove the strainer suspension from the fuel strainer cup.

• Before disconnecting the fuel tubes, be sure to clamp the

fuel tubes with a tube clips to prevent the gasoline from
leaking.

[2] STRAINER
SUSPENSION

Disassembly/Cleaning:

1) Remove the three 5 x 12 mm screws from the fuel strainer

body, then remove the plate and the fuel strainer cup. [1]
PLATE
2) Clean the water or sediment in the cup, and if necessary, [2] 5 x 12 mm
replace the strainer. SCREW (3)

3) Replace the O-ring with a new one on assembly.

Assembly:
[3]
1) Install a new fuel strainer on the fuel strainer body. [6] FUEL
O-RING STRAINER
CUP
2) Set a new O-ring on the fuel strainer cup.
Install the fuel strainer cup and the plate on the fuel strainer
body.

3) Tighten the three 5 x 12 mm screws to the specified torque.

[4]
TORQUE: 3.4 N.m (0.35 kgf.m, 2.5 lbf.ft) FUEL
[5]
FUEL STRAINER
STRAINER BODY

3-16
4) Install the strainer suspension on the fuel strainer cup so
that its projections are at the fuel strainer body side. [1] FUEL STRAINER BODY

5) Install the fuel strainer (low pressure side) on the fuel

[2] PROJECTIONS
strainer stay securely.

[3] FUEL STRAINER

STAY

[4] STRAINER
SUSPENSION

6) Check that the center of the 5 x 12 mm screw at the fuel

tube C installation part is in line with the center of the [1] FUEL [2] “ ” MARK
strainer suspension as shown. STRAINER
STAY
7) Connect the fuel tube C to the “ ” mark side of the fuel [3]
FUEL TUBE E
strainer. Connect the fuel tube E to the “ ” mark side of
the fuel strainer.

• After connecting the tubes, check for gasoline leakage.

8) Install the engine cover (P. 4-2).

[5] “ ” MARK [4]

FUEL TUBE C

[7]
STRAINER
[6] 5 x 12 mm SCREW SUSPENSION

[8] Screw center must be in line

with the suspension center.

3-17
8. FUEL STRAINER (HIGH PRESSURE
SIDE)
• Disconnect the battery cable from the battery negative (-)
terminal before relieving the fuel pressure.
• Replace the sealing washers when the service check bolt is
loosened or removed.
• Catch the draining gasoline from the filter to avoid
contaminating the engine parts with the gasoline.

WARNING
Gasoline is highly flammable and explosive.

You can be burned or seriously injured when handling fuel.

• Keep heat, sparks and flame away.

• Handle fuel only outdoors.
• Wipe up spills immediately.

Replace the fuel filter (high pressure side) at the replacement

interval shown or in the following case.
• Regular replacement period of every 2 years or 400 operating
hours
• When the fuel pressure does mot reach 270 – 320 kPa (2.8 –
3.3 kgf/cm2, 40 – 47 psi) with the pressure regulator control
tube connected, be sure that the fuel pump unit (P. 5-107) and
the pressure regulator (P. 5-106) are normal, and replace the
fuel filter (high pressure side).
Replacement:
1) Remove the engine cover (P. 4-2). [1]
Remove the L./R. engine under covers (P. 4-9). STRAINER

2) Relieve the fuel pressure following the instruction of “How

to relieve fuel pressure” (P. 5-102).
3) Remove the three screw-washers from the strainer cover
while wrapping the strainer cover with a cloth or shop
towel.
Replace the O-ring on assembly.
4) Remove the strainer. Replace the fuel strainer if it is
contaminated or damaged.
Assembly:
1) Apply the engine oil to a new O-ring and install it on the [8]
strainer cover. 5 mm [2] SPRING
2) Install the spring, strainer and washer in the case, then SCREW-
install the strainer cover. WASHER
(3) [3]
3) Tighten the three screw-washers to the specified torque.
WASHER
TORQUE: 3.4 N.m (0.35 kgf.m, 2.5 lbf.ft)
4) After tightening the screw-washers, check for gasoline
leakage. [4] O-RING
5) Set a new sealing washer on the service check bolt, and
tighten the service check bolt to the specified torque.
[5] STRAINER
TORQUE: 12 N.m (1.2 kgf.m, 9 lbf.ft) [7] SERVICE COVER
6) Install the L./R. engine under covers (P. 4-14). CHECK [6] SEALING
Install the engine cover (P. 4-2). BOLT WASHER

3-18
9. WATER SEPARATOR with WATER [1]
LEVEL SENSOR WATER SEPARATOR

WARNING
Gasoline is highly flammable and explosive.

You can be burned or seriously injured when handling fuel.

• Keep heat, sparks and flame away.

• Handle fuel only outdoors.
• Wipe up spills immediately.

Inspection:
[1] CONNECTOR [2] HARNESS
1) Remove the engine cover (P. 4-2). BRACKET A CLIP
2) Check the water separator for water accumulation or
sediment. If water or sediment is found, or the water filled
alert buzzer is sound, remove the water separator as
follows.

Removal/Cleaning: [3]
WATER LEVEL
• Turn the ignition switch to the OFF position, disconnect the SENSOR
battery negative (-) cable, then positive (+) cable. 2P
CONNECTOR
1) Open the harness clip. Remove the water level sensor 2P
connector from the connector bracket A.
Disconnect the water level sensor 2P connector.
[2] FUEL TUBE C
2) Clamp the fuel tube A and C with the commercially [1]
available tube clips securely. FUEL TUBE A

[3]
TUBE CLIPS
(Commercially
available)
[4] WATER SEPARATOR

3) Remove the strainer suspension from the fuel strainer stay.

[1]
FUEL STRAINER STAY
4) Disconnect the fuel tube A and C from the water separator
with water level sensor.

• Before disconnecting the fuel tubes, be sure to clamp the

fuel tubes with a tube clips to prevent the gasoline from
leaking.

Remove the strainer suspension from the water separator

cup.
[2] STRAINER
SUSPENSION

3-19
Disassembly:

1) Remove the three 5 x 12 mm screws from the water [1]

separator body, then remove the plate and the water 5 x 12 mm
separator cup. SCREW (3)

2) Clean the water separator cup. Replace the fuel strainer

with a new one if it is contaminated. [2]
Replace the O-ring with a new one on assembly. PLATE

[3]
WATER
SEPARATOR
CUP

[4]
O-RING

[5]
WATER
SEPARATOR
BODY

Water level sensor float check:

1) Check the float in the water separator cup for smooth

operation.

2) If it does not operate smoothly, replace the water separator

cup.

Water level sensor continuity check:

1) With the water separator cup removed, hold the cup

upright (i.e. as if it is mounted) and check for continuity
between the 2P connecter terminals. There must be no
continuity between the terminals.

2) With the water separator cup removed, hold the cup upside
down and check for continuity between the 2P connector
terminals. There must be continuity between the terminals.
[1] FLOAT
3) If there is any abnormality during the check, replace the
water separator cup.

Assembly:

1) Set a new O-ring on the water separator cup. Install the

water separator cup and the plate on the water separator
body.

2) Tighten the three 5 x 12 mm screws to the specified torque. [2] NORMAL [3] UPSIDE DOWN
(AS INSTALLED) (INVERTED CUP)
TORQUE: 3.4 N.m (0.35 kgf.m, 2.5 lbf.ft)

3-20
3) Install the strainer suspension on the water separator cup
so that its projections are at the water separator body side. [1] WATER SEPARATOR
BODY
4) Install the water separator with water level sensor on the
[2]
fuel strainer stay securely.
PROJECTIONS

[3]
[4] FUEL STRAINER STRAINER
STAY SUSPENSION

5) Check that the center of the 5 x 12 mm screw at the fuel

tube A installation part is in line with the center of the [2] FUEL TUBE C
strainer suspension as shown. [1]
“ ” MARK
[3]
6) Connect the fuel tube A to the “ ” mark side of the water
FUEL STRAINER
separator with water level sensor. Connect the fuel tube C STAY
to the “ ” mark side of the water separator with water
level sensor.

• After connecting the tubes, check for gasoline leakage.

[5]
“ ” MARK [4] FUEL TUBE A

[6] 5 x 12 mm SCREW

[7]
STRAINER
SUSPENSION

[8] Center of screw must be in

line with suspension center.

3-21
7) Connect the water level sensor 2P connector and install the
[1]
2P connector on the connector bracket A. CONNECTOR
Route the water level sensor wire through the harness clip. BRACKET A [2] TAPED PART
Clamp at the taped part of the water level sensor wire and
close the harness clip.

8) Install the engine cover (P. 4-2).

[3] HARNESS
CLIP

[4] WATER LEVEL SENSOR

2P CONNECTOR

10. IDLING [1]

ELECTRIC
Inspection: PART COVER

Check the following before starting the idling inspection.

– Spark plug gap (These models are equipped with the iridium
spark plugs. If the spark plug gap is out of the specification,
replace the spark plug with a new one.) (P. 3-8).

– MIL must be OFF.

1) Place the outboard motor vertically (with the engine level

to the ground), and set the remote control lever in the “N”
(Neutral) position.

2) Remove the propeller. Set the outboard motor gear case in

a test tank filled with water.
Remove the engine cover (P. 4-2).

3) Remove the electric part cover.

[1] ENGINE SPEED CHECK
CONNECTOR [Blue 2P connector]
4) Install the commercially available digital tachometer
(KOWA: KEK-8-MT600) or the HDS (Honda Diagnostic
System).

How to connect the digital tachometer (KOWA: KEK-8-

MT600):
1) Disconnect the engine speed check connector (Blue
connector: 2P connector).

2) Connect the 2P connector of the cable that is included in

the digital tachometer kit (KOWA: KEK-8-MT600) to the
engine side 2P connector.
[2]
CABLE included in
digital tachometer
kit.

3-22
 3) Connect the pin jack, that is the opposite side from the
cable 2P connector, to the digital tachometer. [1]
PIN JACK

[2] DIGITAL TACHOMETER

(KOWA: KEK-8-MT600)

How to connect the HDS (Honda Diagnostic System):

1) Disconnect the data link connectors (Red connector: 4P [1] DATA LINK CONNECTORS (DLC)
connector). [RED: 4P CONNECTOR]

2) Connect the 4P connector that goes to the HDS to the

engine side 4P connector.

[2]
HDS 4P CONNECTOR

5) Start the engine and let it warm up sufficiently. Run the

engine under no load until the engine speed stabilizes, and
check the idling speed.
[1]
HDS (Honda
Specified idle speed
750 ± 50 min–1 (rpm) Diagnostic
(At neutral) System)

• If the idle speed is out of the specification, adjust the idle

(P. 5-94).

• When the idle speed is outside the specification or when

a problem symptom shown on the Idle Control System
Troubleshooting Guide (P. 5-93) appears, perform the
adjustment.

6) Install the engine cover (P. 4-2).

3-23
11. SHIFT CONTROL CABLE [1] FLAT PART OF [2] NEUTRAL SWITCH
DETENT ARM END
Inspection:

1) Remove the engine cover (P. 4-2).

Remove the front separate cover (P. 4-7).

2) Move the remote control lever to the “N” (Neutral)

position.

Check that the detent arm roller sets in the groove in the
shift arm as shown.

Check that the center of the neutral switch end aligns with
the center of the flat part of the detent arm.
[3] Align.
3) If the center of the neutral switch end does not align with
the center of the flat part of the detent arm, check the
detent arm for deformation and damage.

Replace the detent arm with a new one if necessary (P. 17-
13).

If the detent arm roller is not in the groove in the shift arm,
adjust (P. 3-25).
[5]
SHIFT
ARM
GROOVE

[4] DETENT ARM

ROLLER

[4] DETENT ARM

ROLLER

[5]
SHIFT ARM [1] FLAT PART OF
GROOVE DETENT ARM

[3]
Align.

[2] NEUTRAL
SWITCH END

[4] DETENT ARM

ROLLER

3-24
Adjustment:
[1] SHIFT PIVOT [2] LOCK NUT
1) Move the remote control lever to the “N” (Neutral)
position.

2) Loosen the shift pivot lock nut of the remote control cable
(shift side) and detach the shift pivot from the shift link pin.

3) Check that the detent arm roller sets in the groove in the
shift arm.

4) Turn the shift pivot right or left so that the shift pivot sets
on the shift link pin smoothly.

5) Set the shift pivot on the shift link pin. Move the remote [4] SHIFT LINK
PIN [3] SHIFT ARM
control lever back and forth several times to check that the
detent arm roller is in the groove in the shift arm securely.
[1] SHIFT PIVOT
Check that the center of the neutral switch end aligns with
the center of the flat part of the detent arm.

Tighten the lock nut securely. [2] LOCK NUT

If the detent arm roller is not in the groove in the shift arm,
readjust.

6) After adjustment, install the front separate cover (P. 4-7).

[5] [6] FLAT PART OF
Install the engine cover (P. 4-2). GROOVE IN DETENT ARM
SHIFT ARM

[7] Align.

[8] NEUTRAL
SWITCH END

[9]
DETENT ARM
ROLLER

3-25
12. THROTTLE CONTROL CABLE/ [4] “N” (NEUTRAL)
THROTTLE LINK [3] “F” (FORWARD)

Inspection: [2]
REMOTE
CONTROL
1) Remove the engine cover (P. 4-2). LEVER
Remove the front separate cover (P. 4-7).

2) Move the remote control lever to the “F” (Forward) full [1]
open position. FULL
OPEN
NOTICE POSITION
• If it is hard to move the remote control lever to the “F”
(Forward) position with the engine stopped, move the
lever while turning the propeller or propeller shaft.
[1] THROTTLE ARM [2] SHIFT LINK
• Do not move the remote control lever with force, or BRACKET
damage to the gearshift system can result.

3) With the remote control lever in the “F” (Forward) full open
position, check that the throttle arm is in contact with the
full open stopper of the shift link bracket.

[3]
FULL OPEN
STOPPER

4) With the throttle arm in the position described in step 3,

check for clearance between the throttle cam of the throttle [1] THROTTLE [2]
body and the full open side stopper. It must be 1 mm (0.04 CAM STOPPER
in) or below. (FULL
OPEN
SIDE)

[3] 1 mm (0.04 in) OR BELOW

5) Move the remote control lever to the “N” (Neutral) position

and check that the throttle cam of the throttle body is in the
full close position.
[3]
Check the clearance between the throttle cam and the full STOPPER
close side stopper. It must be 1 mm (0.04 in) or below. (FULL
CLOSE
6) If either of the above step 3, 4 or 5 is not satisfied, adjust as SIDE)
follows (P. 3-27).
[1]
If step 3 is not satisfied: Go to <Throttle arm not in full open
THROTTLE
position>. CAM

If step 4 or 5 is not satisfied: Go to <Throttle cam not in full [2] 1 mm (0.04 in) OR BELOW
open position>.

3-26
Adjustment:
[1] LINK PIN [2]
THROTTLE
<Throttle arm not in full open position>
ARM
1) Loosen the shift pivot lock nut of the remote control cable
(throttle side), and remove the shift pivot from the throttle
arm link pin.

[4]
SHIFT
2) Screw in the shift pivot a little until the throttle arm contacts PIVOT
the full open stopper, and temporarily install the shift pivot [3] LOCK NUT
on the throttle arm.

3) Move the remote control lever to the “F” (Forward) full

open position (P. 3-26).

4) Check that step 3, 4 and 5 under the section of Inspection [1] SHIFT PIVOT
are satisfied (P. 3-26).
If not, perform the adjustment procedure from step 1.
If the throttle arm is in contact with the full open side
stopper but the step 4 or 5 is not satisfied, go to <Throttle
cam not in full open position>.

5) Move the remote control lever to the “N” (Neutral) and

tighten the shift pivot lock nut securely.

<Throttle cam not in full open position>

• Perform this adjustment with the remote control cable
(throttle side) installed on the throttle arm.
[3]
• Be sure that the throttle arm is in contact with the full open
THROTTLE
side stopper. [2] LOCK NUT ROD

1) Remove the throttle rod linkage pivot from the throttle

plate and loosen the linkage pivot lock nut. [1]
LINKAGE
2) With the throttle arm in contact with the full open side PIVOT
stopper, turn the throttle rod linkage pivot right or left to
adjust the clearance between the throttle cam and the full
open side stopper. It must be 1 mm (0.04 in) or below.

3) Temporarily install the linkage pivot on the throttle plate.

4) Check that step 3, 4 and 5 under the section of Inspection

are satisfied (P. 3-26).

If step 3 is not satisfied, readjust following the procedure of

<Throttle arm not in full open position>.

If the throttle cam is in contact with the full open side [4] THROTTLE PLATE
stopper but the step 5 is not satisfied, go to <Throttle cam
not in full open position>.

5) Tighten the linkage pivot lock nut securely.

3-27
Check item:
[1] 5 x 16 mm
<Side-mount remote control type only> HEX. BOLT
1) Remove the remote control box cover B and C (P. 16-2).

2) Move the remote control lever to the full open position and
be sure that the link joint arm is in contact with the 5 x 16
mm hex. bolt.
If not in contact, tighten the 5 x 16 mm hex. bolt unit it
contacts the link joint arm.

3) Install the remote control box cover B and C (P. 16-2).

[2] LINK JOINT ARM

13. REMOTE CONTROL LEVER

FRICTION
Inspection/Adjustment:

1) Check the remote control lever for smooth operation.

If the lever movement is too light or too heavy, adjust the
friction.

2) Adjust by turning the friction adjusting bolt right or left.

[1] FRICTION ADJUSTING BOLT

14. ALTERNATOR BELT

Inspection:

1) Remove the engine cover (P. 4-2).

Remove the silencer duct assembly (P. 3-11 and 12).

2) Check the alternator belt for wear and damage.

Replace the alternator belt if necessary (P. 3-29).

3) Check the alternator belt and the related parts for stain with
oil, etc. If stained, clean the stained parts and replace the
alternator belt.

4) Check the belt tension and belt deflection (P. 3-29).

[1] ALTERNATOR
BELT

3-28
a. Best tension check using belt tension gauge:

1) Set the special tool at the center between the alternator belt
pulleys, and measure the belt tension.

TOOL:
[1]
Belt tension gauge 07JGG-0010101
BELT TENSION
GAUGE
329 – 490 N 07JGG-0010101
Used belt
(40 – 50 kgf, 88 – 110 lbf)
Belt tension
490 – 588 N
New belt
(50 – 60 kgf, 110 – 132 lbf)

2) If the belt tension is out of the specification, adjust the belt

tension.
[1] BELT
b. Belt deflection inspection DEFLECTION

1) Measure the belt deflection by pushing the alternator belt

at the center between the pulleys with 98 N (10 kgf, 22 lbf)
of force.

10.6 – 11.1 mm
Used belt [2] When pushed with
(0.42 – 0.44 in)
Belt deflection 98 N (10 kgf, 22 lbf)
10.1 – 10.6 mm of force.
New belt
(0.40 – 0.42 in)

2) If the belt deflection is out of the specification, adjust the

belt tension.

Belt Tension Adjustment: 10 x 80 [1]

8 mm FLANGE
NUT
1) If the belt tension or belt deflection is out of the
specification, loosen the 10 x 80 mm flange bolt and the 8
mm flange nut, and adjust the belt tension or deflection by
turning the special adjusting bolt right or left.

2) After adjustment, tighten the 8 mm flange nut and the 10 x

80 mm flange bolt in this order to the specified torque.
[2]
TORQUE: SPECIAL
8 mm flange nut: 26 N.m (2.7 kgf.m, 20 lbf.ft) [3] ALTERNATOR ADJUSTING
BELT BOLT
10 x 80 mm flange bolt: 44 N.m (4.5 kgf.m, 33 lbf.ft)

3) After tightening the bolt and nut to the specified torque,

check the alternator belt tension and deflection again. [1] 8 mm FLANGE
10 x 80
If the measurement is still out of the specification, repeat NUT
the step 1 and 2.

Replacement:

1) Loosen the 10 x 80 mm flange bolt and the 8 mm flange

nut.
2) Loosen the special adjusting bolt and move the alternator
assembly fully to the engine side. [2]
SPECIAL
ADJUSTING
[3] ALTERNATOR ASSEMBLY BOLT

3-29
3) Remove the alternator belt by removing it from the [1]
alternator pulley first, then from the crankshaft pulley. ALTERNATOR
BELT
• Do not contaminate the alternator belt with oil or grease.

• Do not bend the alternator belt. Store the belt by hanging

it on the wall.

Installation:

1) Install a new alternator belt on the crankshaft pulley first,

then install the other end of the belt on the alternator
pulley.

NOTICE
Do not turn the crankshaft pulley counterclockwise.

[2] CRANKSHAFT
PULLEY

[3] ALTERNATOR
PULLEY

2) Tighten the special adjusting bolt.

Tighten the 8 mm flange nut and the 10 x 80 mm flange bolt
in this order to the specified torque.
[1]
TORQUE: 10 x 80 8 mm FLANGE
8 mm flange nut: 26 N.m (2.7 kgf.m, 20 lbf.ft) NUT
10 x 80 mm flange bolt: 44 N.m (4.5 kgf.m, 33 lbf.ft)

3) After tightening the nut and bolt to the specified torque,

check the belt tension and deflection (P. 3-29).

4) Install the silencer duct assembly (P. 3-11 and 12).

Install the engine cover (P. 4-2).

[2] SPECIAL
[3] ALTERNATOR ADJUSTING
ASSEMBLY BOLT

3-30
 4. ENGINE COVER/COVER LOCK
1. ENGINE COVER 4. UNDER COVER FRONT BRACKET/
2. FRONT SEPARATE COVER L./R. SIDE COVER BRACKETS
3. L./R. ENGINE UNDER COVERS

4.5 N.m (0.45 kgf.m,

3.3 lbf.ft)

4.5 N.m (0.45 kgf.m,

3.3 lbf.ft)

4-1
1. ENGINE COVER
a. REMOVAL/INSTALLATION

Remove the engine cover by pulling the cover lock lever toward you.

b. DISASSEMBLY/ASSEMBLY

[1] ENGINE COVER

[2] ENGINE COVER SEAL

ASSEMBLY:
Install the engine cover seal in
the direction shown.

[2]-1 [2]-2
INSIDE OUTSIDE

[3]
COVER LOCK
LEVER

c. HOOK BRACKET ASSEMBLY REMOVAL

[1] [2]
6 x 20 mm SOCKET HOOK BRACKET
1) Remove the 6 x 20 mm socket bolt and the 6 x 16 mm BOLT
socket bolt, then remove the hook bracket assembly (Front ASSEMBLY
(2) [Rear L./R. sides only]
side hook bracket only). (1) [Front side only]

Remove the two 6 x 20 mm socket bolts and remove the

hook bracket assembly (Rear L./R. side hook brackets only).

2) Remove the three 6.5 x 10 x 11.5 mm distance collars from

the engine cover (Front side hook bracket only).

Remove the four 6.5 x 10 x 11.5 mm distance collars from

the engine cover (Rear L./R. side hook brackets only).

[3]
[4] 6.5 x 10 x 11.5 mm
6 x 16 mm DISTANCE COLLAR
SOCKET BOLT (4) [Rear L./R. sides only]
[Front side only] (3) [Front side only]

4-2
d. HOOK BRACKET DISASSEMBLY/ASSEMBLY
[4]
FRONT SIDE: COVER LOCK
BOLT

[5] HOOK DAMPER

[3]
6.5 x 10 x 11.5 mm
[2] DISTANCE COLLAR (3) [6] 12 mm WASHER
6 x 20 mm SOCKET
BOLT

[7] LOCK ADJUSTING

SPRING

[8] HOOK BRACKET

[1]
6 x 16 mm SOCKET
BOLT [9] 6 mm WASHER

[10] 6 mm HEX. NUT

L./R. SIDES:

[3] COVER LOCK BOLT

[4] HOOK DAMPER

[2]
6.5 x 10 x 11.5 mm [5] 12 mm WASHER
DISTANCE COLLAR (3)

[6]
LOCK ADJUSTING
SPRING

[7] HOOK BRACKET

[1]
6 x 20 mm SOCKET
BOLT (2)
[8] 6 mm WASHER

[9] 6 mm HEX. NUT

4-3
e. HOOK BRACKET ASSEMBLY
[1]
1) Apply grease to the cover lock bolt installation part of the COVER LOCK
hook bracket. BOLT

2) Install the lock adjusting spring, 12 mm washer and the

hook damper on the hook bracket. [2]
HOOK
3) Apply grease to the flanged part of the cover lock bolt. DAMPER
Apply grease to the straight part under the flange of the
cover lock bolt, too. Install the cover lock bolt on the hook
bracket.
[3]
4) Position the 6 mm washer and 6 mm hex. nut on the cover LOCK
lock bolt and tighten the 6 mm hex. nut securely. [7] ADJUSTING
12 mm SPRING
WASHER

[4]
6 mm
WASHER

[6]
HOOK [5]
BRACKET 6 mm HEX.
NUT

f. HOOK BRACKET ASSEMBLY INSTALLATION

[2]
[1] HOOK BRACKET
1) Install the four 6.5 x 10 x 11.5 mm distance collars on the 6 x 20 mm SOCKET BOLT
engine cover (Rear L./R. side hook brackets only). ASSEMBLY
(2) [Rear L./R. sides only]
(1) [Front side only]
Install the three 6.5 x 10 x 11.5 mm distance collars on the
engine cover (Front side hook bracket only).

2) Position the hook bracket assembly on the engine cover

and secure it with the two 6 x 20 mm socket bolts (Rear
L./R. side hook brackets only).

Position the hook bracket assembly on the engine cover

and secure it with the 6 x 20 mm socket bolt and the 6 x 16
mm socket bolt (Front side hook bracket only).

[3]
6.5 x 10 x 11.5 mm
[4] DISTANCE COLLAR
6 x 16 mm SOCKET (4) [Rear L./R. sides only]
BOLT (3) [Front side only]
[Front side only]

4-4
g. ADJUSTMENT

• HOOK BRACKET

1) Install the engine cover on the outboard motor and lock it

securely.

2) Measure the clearance between the engine cover and the

L./R. engine under covers.

• Measure the clearance at the three points, i.e. at the front

and at the rear right and left sides.

3) Check that the measurement is within 17.5 – 18.5 mm (0.69

– 0.73 in) at each point.

4) If the measurement is out of the specification, adjust the

clearance.

17.5 – 18.5 mm
(0.69 – 0.73 in)

5) To adjust, remove the engine cover and set a wrench or

equivalent tool in the cutout in the tapered part of the cover [1]
lock bolt. Loosen the 6 mm hex. nut of the hook bracket Set a wrench or
equivalent tool at
assembly.
tapered part.
6) After assembly, loosely tighten the 6 mm hex. nut.

7) Install the engine cover on the outboard motor and lock it

securely. Measure the clearance between the engine cover
and the L./R. engine under covers again.

If the clearance is out of the specification, repeat step 5.

If the clearance is within the specification, remove the

engine cover and tighten the 6 mm hex. nut securely.

8) Install the engine cover (P. 4-2).

[2] 6 mm HEX. NUT

4-5
h. ENGINE COVER DISASSEMBLY

Remove the hook bracket assembly (P. 4-2).

[1]
ENGINE COVER
AIR GUIDE
[2]
4 x 10 mm SELF-
TAPPING SCREW (8)

[3] ENGINE COVER

i. ENGINE COVER ASSEMBLY

1) Clean the engine cover and engine cover air guide mating
surfaces. [1]
Apply the sealant.
2) Apply the sealant (Shin-Etsu Chemical KE45 or equivalent) (Shin-Etsu Chemical
to the indicated position of the engine cover air guide. KE45 or equivalent)

3) Tighten the engine cover air guide with the eight 4 x 10 mm

self-tapping screws securely.

4) Install the hook bracket assembly (P. 4-4).

4-6
2. FRONT SEPARATE COVER
a. REMOVAL
1) Remove the engine cover (P. 4-2).
2) Loosen the undercase grommet band and remove it from the remote control cable grommet.
3) Remove the 6 x 17 mm special bolt and the three 6 x 25 mm screws, then detach the front separate cover.
4) Remove the front separate cover.

[2]
UNDERCASE
GROMMET BAND

[3]
6 x 17 mm SPECIAL
BOLT

[1]
FRONT SEPARATE
COVER

[4]
6 x 25 mm SCREW (3)

b. INSTALLATION [1] <Rear side>

[2]
1) Install the front separate cover by aligning the recess at the RECESS
rear of the front separate cover (i.e. R. engine under cover
side) with the projection of the R. engine under cover.
[5]
2) Install by aligning the projection at the front (i.e. under PROJECTION
cover front bracket side) of the front separate cover with
the recess of the under cover front bracket.
[4] [3]
R. ENGINE FRONT
UNDER SEPARATE
COVER COVER
[7]
[6] <Front side> [2] RECESS UNDER COVER
[5] FRONT BRACKET
PROJECTION

[3]
FRONT SEPARATE
COVER

4-7
3) Loosely tighten the three 6 x 25 mm screws and one 6 x 17
mm special bolt. [2]
[1] 6 x 17 mm SPECIAL
• Check that the special bolt is not on the case but it is BOLT
6 x 25 mm
tightened properly. SCREW (3)

4) Tighten the 6 x 25 mm screws and the 6 x 17 mm special

bolt securely in the numbered sequence shown in two or
three steps.

5) Install the undercase grommet band on the remote control

cable grommet and fasten the band securely. ① ②

Install the engine cover (P. 4-2).

[3] UNDERCASE
GROMMET BAND

4-8
3. L./R. ENGINE UNDER COVERS
a. REMOVAL

Remove the following parts.

– Engine cover (P. 4-2)
– Front separate cover (P. 4-7)
– Electric part cover (P. 3-22)
[1]
1) Remove the flush plug cap from the R. engine under cover. FLUSH PLUG
CAP

2) Open the wire harness clip. Remove the power tilt switch
[1]
3P connector from the connector bracket B. CONNECTOR
BRACKET B
3) Disconnect the power tilt switch 3P connector.

[3]
WIRE HARNESS [2] POWER TILT SWITCH
CLIP 3P CONNECTOR

4) Set a screwdriver in the slot in each mud guard clip as

shown and raise the mud guard clips. [1]
SCREWDRIVER
Remove the six mud guard clips.

5) Remove the under cover grommet. [2]

SLOT

[3]
MUD GUARD
CLIP

[4]
MUD GUARD
CLIP (6)

[5]
UNDER COVER
GROMMET

4-9
6) Loosen the two 5 x 10 mm rivet screws and remove the two
14 mm clips. [1] 14 mm CLIP (2)

[2]
5 x 10 mm RIVET
SCREW (2)

7) Remove the three 6 x 25 mm screws and the eleven 6 x 17 mm special bolts from the L./R. engine under covers.

[1] [2]
L. ENGINE UNDER COVER R. ENGINE UNDER COVER

[4] 6 x 25 mm SCREWS [3] 6 x 17 mm SPECIAL

BOLT (11)

8) Detach the L. engine under cover from the projection of the

L. side cover bracket. [1] L. ENGINE UNDER [2] PROJECTION
COVER

[3]
L. SIDE COVER
BRACKET

4-10
9) Open the L. engine under cover and disconnect the 7 x 400
mm tube from the water check grommet. [2]
7 x 400 mm
TUBE

[1]
WATER
CHECK
GROMMET

10) Detach the R. engine under cover from the projection of the
[1] PROJECTION [2]
R. side cover bracket.
R. ENGINE UNDER
COVER

[3] R. SIDE
COVER
BRACKET
11) Remove the L./R. engine under covers.

[2]
R. ENGINE UNDER
COVER

[1] L. ENGINE UNDER

COVER

4-11
b. R. ENGINE UNDER COVER DISASSEMBLY

[1] 16 mm HEX. NUT

[6]
POWER TILT
SWITCH STAY

[5]
POWER TILT
SWITCH STAY
GROMMET
[2] WATER JOINT
CAP

[3] R. ENGINE UNDER

COVER

[4] POWER TILT SWITCH

c. INSPECTION
[1] UP (Up)
• POWER TILT SWITCH

Check for continuity between the terminals with the switch in

each position.

Lb W/Bl Lg
UP (Up)
DN (Down)
[2] DN (Down)
: Continuity

4-12
d. COMPONENTS DRAWING

[1] [3] 14 mm CLIP (2)

6 x 25 mm SCREWS [2] [5]
L. ENGINE
4.5 N.m (0.45 kgf.m, UNDER [4] POWER TILT SWITCH
3.3 lbf.ft) 7 x 400 mm TUBE 3P CONNECTOR
COVER

[6]
FLUSH PLUG CAP

[7] 6 x 17 mm SPECIAL
BOLT (11)

[13]
WATER CHECK
GROMMET

[10] 5 x 10 mm RIVET
SCREW (2)

[8] DRAIN PLUG

[11] UNDER COVER [9] COVER
GROMMET R. ENGINE UNDER
[12] MUD GUARD COVER
CLIP (6)

4-13
e. R. ENGINE UNDER COVER ASSEMBLY
1) Position the water joint cap on the R. engine under cover and tighten the 16 mm hex. nut securely. Note the
installation direction of the water joint cap.
2) Position the power tilt switch on the power tilt switch grommet with the “UP” mark on the power tilt switch facing
up.
3) Install the power tilt switch on the R. engine under cover and install the power tilt switch stay as shown.
Secure the power tilt switch stay with the locking lugs of the power tilt switch.

[1] 16 mm HEX. NUT

[7] POWER TILT

SWITCH STAY

[6] POWER TILT [2]

SWITCH STAY WATER JOINT
GROMMET CAP

[4] [3]
LOCKING R. ENGINE UNDER
[5] POWER TILT
LUGS COVER
SWITCH

f. INSTALLATION
[1]
7 x 400 mm
1) If the water check grommet is not mounted on the L. engine
TUBE
under cover, install it from the outside of the L. engine
under cover.

2) Connect the 7 x 400 mm tube to the water check grommet.

[2]
WATER
CHECK
GROMMET

3) Install the L. engine under cover aligning the bottom edge

of the L. engine under cover with the extension case as
shown.

[1]
L. ENGINE
UNDER
COVER

[2] Align.

[3] EXTENSION
CASE

4-14
4) Install the L. engine under cover aligning the hole in the L.
engine under cover with the projection on the L. side cover [1] L. ENGINE UNDER [2] PROJECTION
COVER
bracket.

[4]
HOLE

[3]
L. SIDE COVER
BRACKET

5) Check that the cover lock cable A is set on the L. engine

under cover as shown. [1]
L. SIDE COVER
BRACKET

[4]
COVER LOCK
CABLE A

[2]
L. ENGINE
UNDER
COVER

[3] Cross section

viewed from
A-A side.
A
A

[2] L. ENGINE UNDER

COVER

6) Hold the power tilt switch wire above the R. engine under
cover.

7) Install the R. engine under cover aligning the bottom of the

R. engine under cover with the extension case as shown.

Note that the 8 x 300 mm tube with the flush plug cap is [1] R. ENGINE
outside the R. engine under cover this time. UNDER
COVER

[2] Align.

[3]
EXTENSION CASE

4-15
8) Align the projections at the front side (i.e. swivel case side)
of the L. engine under cover with the recess in the R. engine [1] RECESS
under cover as shown.
[2]
R. ENGINE
UNDER
[4] COVER
PROJECTIONS

[3]
L. ENGINE UNDER
COVER

9) With the R. engine under cover held in alignment with the

L. engine under cover described in step 7, install the R. [1] PROJECTION [2] R. ENGINE UNDER
COVER
engine under cover by aligning the hole in the R. engine
under cover with the projection on the R. side cover
bracket.

[3]
HOLE

[4] R. SIDE
COVER
BRACKET

10) Check that the cover lock cable B sets underside the R.
engine under cover as shown.
[1]
Cross-section [2]
viewed from A-A R. ENGINE UNDER
side. COVER

[3] COVER LOCK A

CABLE B
[3]
COVER LOCK
CABLE B

[2]
R. ENGINE UNDER
COVER

4-16
11) Install the L./R. engine under covers aligning the projection
on the rear (i.e. cylinder head cover side) of the L. engine [1] L. ENGINE UNDER
under cover with the recess in the R. engine under cover. COVER

Install the L./R. engine under covers, too, aligning the

projections at the upper part of the L. engine under cover [2] PROJECTION
with the recess at the upper part of the R. engine under
cover.
[3]
• Check that each alignment performed in step 4 through RECESS
step 11 is not out of alignment.

[4] R. ENGINE UNDER

COVER

12) Loosely tighten the three 6 x 25 mm screws and the eleven [1] [2] [4]
6 x 17 mm special bolts on the L./R. engine under covers. L. ENGINE PROJECTIONS R. ENGINE UNDER
UNDER COVER
• Check that the special bolts are not on the case but they COVER
are tightened properly.

13) Tighten the three 6 x 25 mm screws to the specified torque

and the eleven 6 x 17 mm special bolts to the standard
torque in the numbered sequence and in two or three steps
securely.

TORQUE:
[3]
6 x 25 mm screws: 4.5 N.m (0.45 kgf.m, 3.3 lbf.ft)
RECESS
STANDARD TORQUE:
6 x 17 mm special bolts: 4.2 N.m (0.42 kgf.m, 3.0 lbf.ft)

• Check that each alignment performed in step 4 through

step 11 is not out of alignment.

[1] [2]
L. ENGINE UNDER COVER R. ENGINE UNDER COVER

⑫ ⑪
⑥
①

⑬ ⑦
②
⑭
④ ⑨

③ ⑤ ⑩ ⑧

[3] 6 x 25 mm SCREWS
[4] 6 x 17 mm SPECIAL
BOLT (11)

4-17
14) Check that the end of each 14 mm clip aligns with the end
of the taped part of the power tilt motor wire as shown. [2] 5 x 10 mm [3]
RIVET POWER TILT
SCREW (2) MOTOR WIRE
15) Tighten the two 5 x 10 mm rivet screws securely while
pushing the end of the two 14 mm clips against the
corresponding projection on the L. engine under cover. [1] [4]
PROJECTIONS SPIRAL
Take care not to let the alignment points described in the TUBE
previous step come out of alignment.
[5] TAPING

[6] 14 mm
CLIP (2)
[5] TAPING

[7] 14 mm
CLIPS

[2]
5 x 10 mm RIVET
SCREW (2)

16) Insert the under cover grommet into the idle exhaust port
as shown. [1] [2]
IDLE EXHAUST PORT UNDER COVER
17) Insert the four projections on the under cover grommet into GROMMET
the holes in the engine under covers.

18) Aligning the holes in the under cover grommet with the
holes in the engine under cover, set the six mud guard clips
in the respective holes.

• Do not push in the head of the mud guard clips.

[6] HOLE (4)

[3]
CLIP
[5] PROJECTION (4) HEAD

[4] MUD GUARD

CLIP (6)

4-18
19) Push in the head of the mud guard clips in the numbered
sequence securely. [1] LIP on the reverse side
of the grommet.
20) Check that the lip on the reverse side of the under cover
grommet is set on the engine under cover.
⑤ ⑥
• Check that the under cover grommet adheres to the
engine under cover securely.

① ②

③ ④

21) Connect the power tilt switch 3P connector.

[2] ALTERNATOR FUSE [3] CONNECTOR
CABLE BRACKET B
22) Install the power tilt switch 3P connector on the connector
bracket B. [1]
PGM-FI
Clamp the alternator fuse cable, PGM-FI main relay wire MAIN RELAY
WIRE
and the power tilt switch wire with the wire harness clip.

[6]
WIRE [4]
HARNESS [5] POWER TILT
CLIP POWER TILT SWITCH
SWITCH WIRE 3P CONNECTOR

23) Tighten the flush plug cap on the R. engine under cover.

24) Install the following parts.

– Electric part cover (P. 3-22)
– Front separate cover (P. 4-7)
– Engine cover (P. 4-2)

[1]
FLUSH PLUG
CAP

4-19
4. UNDER COVER FRONT BRACKET/ [1]
4 x 7 x 160 mm
[2] COVER LOCK
CABLE A
L./R. SIDE COVER BRACKETS VINYL TUBE
[3]
LOCK
Remove the following pars.
NUT
– Engine cover (P. 4-2)
– Front separate cover (P. 4-7)
– L./R. engine under cover (P. 4-9)
– Remote control cable/grommet (P. 17-2)

a. UNDER COVER FRONT BRACKET

[6]
REMOVAL: FRONT
LOCK
1) Remove the 4 x 7 x 160 mm vinyl tube and the 3.5 x 430
mm fuel tube from the under cover front bracket.
[5] UNDER COVER [4] 3.5 x 430 mm
FRONT BRACKET FUEL TUBE
2) Loosen the cover lock cable A lock nut and remove the
cover lock cable A from the front lock.
3) Remove the trim angle sensor 3P connector and the power
[1] POWER TILT MOTOR [2] TRIM ANGLE
tilt motor 2P connector from the connector bracket A. SENSOR
2P CONNECTOR
3P CONNECTOR
Disconnect the trim angle sensor 3P connector and the
power tilt motor 2P connector.

[3]
CONNECTOR
BRACKET A

4) Remove the undercase grommet C outside from the under

cover front bracket. [1] WIRES
[2] TUBE
Pull out the tube and wires through the hole in the under
cover front bracket.

[5]
HOLE [3]
UNDER
COVER
[4] FRONT
UNDERCASE BRACKET
GROMMET C

4-20
5) Remove the two 8 x 30 mm hex. bolts and the two 8 mm
washers, then remove the under cover front bracket.
[1]
UNDER COVER
FRONT BRACKET

[2] 8 mm WASHER (2)

[3] 8 x 30 mm
HEX. BOLT (2)

DISASSEMBLY:
1) Remove the 6 mm E-ring and the 8 mm washer from the lock front shaft.
2) Remove the lock front shaft from the under cover front bracket.
Remove the cover lock lever, two cover lock bushing As, 10 mm washer and the two 10 mm wave washers.
Check the cover lock bushing A for scores, scratches and other damage. Replace the cover lock bushing A with a new
one if necessary.

[8]
LOCK FRONT [1]
SHAFT UNDER COVER
FRONT BRACKET

[7]
COVER LOCK
BUSHING A (2)

[2]
[6] 8 mm WASHER
10 mm WASHER

[5]
10 mm WAVE
WASHER (2)

[4] COVER LOCK LEVER [3] 6 mm E-RING

4-21
3) Remove the 6 mm E-ring from the cover open shaft.
[1] [2]
Remove the cover lock bushing B in a manner of bringing COVER OPEN UNDER
SHAFT COVER
it to the lock lever return spring side.
FRONT
BRACKET
With the return spring compressed with the bushing B,
hold the cover open shaft at a slightly inclined angle.

Remove the cover open shaft with care not to let its head [4]
contact the under cover front bracket. COVER LOCK
BUSHING B [3] HEAD

4) Remove the cover lock bushing B, 8 mm washer, and the

lock lever return spring from the cover open shaft. [4]
COVER LOCK [5] 6 mm E-RING
Check the cover lock bushing B for scores, scratches and BUSHING B
other damage. Replace the cover lock bushing B with a new
one if necessary.

[7]
LOCK
LEVER
RETURN
SPRING

[6] 8 mm WASHER

[1] COVER OPEN SHAFT

5) Remove the 6 mm E-ring, 8 mm washer and the cover lock

bushing A from the front lock.
[1] FRONT LOCK
Check the cover lock bushing A for scores, scratches and
other damage. Replace the cover lock bushing A with a new
one if necessary. [2] 6 mm E-RING

[3]
6) Lower the front lock and detach the hook of the cover lock 8 mm WASHER
hook spring from the hole in the under cover front bracket.
[4]
Remove the cover lock bushing from the under cover front COVER LOCK
bracket and hold it at the front lock side. BUSHING A

7) Set the front lock in the position shown.

With the front lock set at a slightly inclined angle in the [7]
position shown, remove the front lock from the under cover BRACKET
front bracket. CAP

Remove the cover lock bushing and the cover lock hook
spring from the front lock.

8) Remove the bracket cap. [6]

COVER LOCK [5]
BUSHING COVER LOCK
HOOK SPRING

[1] FRONT
LOCK

4-22
COMPONENTS DRAWING:

[3]
6 mm E-RING (3)

[2] [4] 8 mm WASHER (3)

UNDER COVER
[1]
FRONT BRACKET
LOCK FRONT SHAFT

[5]
COVER LOCK
BUSHING A (3)

[15] COVER LOCK

BUSHING B

[14] LOCK LEVER

RETURN SPRING

[13]
COVER OPEN
SHAFT

[12]
10 mm
WASHER

[11]
10 mm WAVE
WASHER (2) [6]
[9] BRACKET
COVER LOCK CAP
HOOK SPRING
[10]
COVER LOCK
LEVER
[8] COVER LOCK
BUSHING

[7] FRONT LOCK

4-23
b. L. SIDE COVER BRACKET
[1]
REMOVAL: COVER LOCK
CABLE A
1) Loosen the lock nuts on the cover lock cable A and B, and [3]
COVER LOCK
disconnect the cover lock cable A and B from the side lock.
[2] LOCK NUT CABLE B

[4] SIDE LOCK

[2] LOCK NUT

2) Remove the two 8 x 55 mm flange bolts and remove the

L. side cover bracket.

[1]
L. SIDE COVER
BRACKET

8 x 55 (2)

4-24
DISASSEMBLY:
[2] 6 mm E-RING
1) Remove the 6 mm E-ring and the 8 mm washer from the
side lock.
[1]
8 mm WASHER [3]
2) Lower the side lock and detach the hook of the cover lock
COVER LOCK
hook spring from the hole in the L. side cover bracket. BUSHING A (2)

Remove the side lock from the L. side cover bracket.

Remove the cover lock hook spring from the side lock.

3) Remove the two cover lock bushing As from the L. side

cover bracket.

Check the two cover lock bushing As for wear and damage
that are mounted on the side lock installation parts on the
L. side cover bracket.

Check the cover lock bushing A for scores, scratches and

other damage. Replace the cover lock bushing A with a new
one if necessary.
[5] COVER LOCK
HOOK SPRING

[6]
L. SIDE COVER [4]
BRACKET SIDE LOCK

COMPONENTS DRAWING:

[2] 6 mm E-RING
[1] 8 mm WASHER [3]
COVER LOCK
CABLE B

[4]
L. SIDE COVER
BRACKET

[5]
COVER LOCK
BUSHING A (2)

[6]
COVER
LOCK HOOK
SPRING

[8]
[9] CABLE CLIP COVER LOCK
CABLE A 8 x 55 (2) [7] SIDE LOCK

4-25
c. R. SIDE COVER BRACKET

REMOVAL:

1) Loosen the lock nut on the cover lock cable B, and [1] LOCK NUT
disconnect the cover lock cable B from the side lock.

[2] SIDE LOCK

[3] COVER LOCK

CABLE B

2) Remove the two 6 x 22 mm flange bolts and remove the R.

side cover bracket.

6 x 22 (2)

[1] R. SIDE COVER

BRACKET

4-26
DISASSEMBLY:
[2]
6 mm E-RING [3] COVER LOCK
1) Remove the 6 mm E-ring and the 8 mm washer from the BUSHING A (2)
side lock.

2) Lower the side lock and detach the hook of the cover lock
hook spring from the hole in the R. side cover bracket.
[1]
Remove the side lock from the R. side cover bracket. 8 mm WASHER

Remove the cover lock hook spring from the side lock.

3) Remove the two cover lock bushing As from the R. side

cover bracket.

Check the cover lock bushing A for scores, scratches and [4]
COVER LOCK
other damage. Replace the cover lock bushing A with a new
HOOK SPRING
one if necessary.

[5]
R. SIDE COVER
BRACKET

COMPONENTS DRAWING:
[1] 6 mm E-RING [2] 8 mm WASHER

[3] COVER LOCK

BUSHING A (2)

[4] R. SIDE COVER

BRACKET

6 x 22 (2)

[5] COVER LOCK

HOOK SPRING

[7]
COVER LOCK
CABLE B [6] SIDE LOCK

4-27
d. R. SIDE COVER BRACKET/L. SIDE COVER
[2] 6 mm E-RING [3] COVER LOCK
BRACKET/UNDER COVER FRONT BRACKET
BUSHING A (2)
ASSEMBLY
[1]
8 mm WASHER
R. SIDE COVER BRACKET:

1) Apply marine grease to the outer surface of the cover lock

bushing As, and install them on the R. side cover bracket.
[7] (MARINE
2) Apply marine grease to the side lock shaft. GREASE)

3) Install the cover lock hook spring on the side lock aligning [5]
the hook of the spring with the hole in the side lock. HOLE
[4]
Install the cover lock hook spring on the R. side cover COVER LOCK
bracket aligning another hook of the spring with the hole in HOOK SPRING
the R. side cover bracket.

4) Install the 8 mm washer and the 6 mm E-ring on the side

lock.
[7] (MARINE
GREASE)

[5]
[6] R. SIDE COVER HOLE
BRACKET

L. SIDE COVER BRACKET:

[2] 6 mm E-RING
[1] 8 mm
1) Apply marine grease to the cover lock bushing As and WASHER
install them on the L. side cover bracket. [3]
COVER LOCK
2) Apply marine grease to the side lock shaft. BUSHING A (2)

[4]
3) Install the cover lock hook spring on the side lock aligning [7] (MARINE HOLE
the hook of the spring with the hole in the side lock. GREASE) [5]
COVER
Install the cover lock hook spring on the L. side cover LOCK
HOOK
bracket aligning another hook of the spring with the hole in
SPRING
the L. side cover bracket.

4) Install the 8 mm washer and the 6 mm E-ring on the side

lock.
[4]
HOLE

[7] (MARINE
GREASE)

[8] L. SIDE COVER

BRACKET
[6] SIDE LOCK

4-28
UNDER COVER FRONT BRACKET: [3]
[2] 6 mm E-RING
8 mm WASHER
1) Install the bracket cap.
[1] COVER LOCK
2) Apply marine grease to the front lock shaft and the outer BUSHING A
surface of the cover lock bushing. [4]
(MARINE
GREASE)
3) Apply marine grease to the outer surface of the cover lock
hook spring. Install the cover lock hook spring aligning its
hook with the hole in the front lock. [9]
BRACKET CAP
4) Set the front lock in the position shown. Install the front
lock on the under cover front bracket at an inclined angle. [7]
HOLE
5) Install the cover lock hook spring on the under cover front
bracket aligning its hook with the hole in the under cover [8] COVER LOCK
front bracket. BUSHING [5]
COVER
6) Apply marine grease to the outer surface of a cover lock LOCK
HOOK
bushing A and install it on the under cover front bracket.
SPRING
7) Install the 8 mm washer and the 6 mm E-ring on the front [6]
lock. FRONT
LOCK
[7] HOLE
[4] (MARINE
GREASE)
[6] FRONT LOCK

[10] UNDER COVER

FRONT BRACKET

[6]
FRONT
LOCK

8) Apply marine grease to the outer surface of the cover open

[1]
shaft, lock lever return spring, 8 mm washer and the cover
UNDER
lock bushing B. Install the lock lever return spring, 8 mm COVER [2] (MARINE
washer, and the cover lock bushing B on the cover open FRONT GREASE)
shaft. BRACKET

Hold the lock lever return spring compressed with the

cover lock bushing B.
[6]
COVER
9) Install the cover open shaft at an inclined angle in the under OPEN
cover front bracket. SHAFT

10) Install the cover lock bushing B in the under cover front [3]
[5] COVER LOCK
bracket. LOCK
BUSHING B
LEVER
RETURN
11) Install the 6 mm E-ring on the cover open shaft.
SPRING
[4]
[2] (MARINE GREASE) 8 mm WASHER

4-29
12) Apply marine grease to the outer surface of the 10 mm washer, two 10 mm wave washers and the cover lock bushing
A and to the inner wall of the lock front shaft hole in the under cover front bracket.

13) Install the two cover lock bushing As, 10 mm washer and the two 10 mm wave washers on the cover lock lever as
shown. Install the cover lock lever on the under cover front bracket.

14) Install the lock front shaft.

Install the 8 mm washer and the 6 mm E-ring on the lock front shaft.

[1]
LOCK FRONT [2]
SHAFT UNDER COVER
FRONT BRACKET

[5] (MARINE GREASE)

[9] COVER LOCK

BUSHING A (2) [3] 8 mm WASHER

[8] 10 mm WASHER

[7] 10 mm WAVE
WASHER (2)
[5] (MARINE
[6] COVER LOCK LEVER GREASE) [4] 6 mm E-RING

e. R. SIDE COVER BRACKET/L. SIDE COVER

[1]
BRACKET/UNDER COVER FRONT BRACKET R. SIDE COVER
INSTALLATION BRACKET

1) Install the R. side cover bracket with the two 6 x 22 mm

flange bolts.

6 x 22 (2)

2) Install the L. side cover bracket with the two 6 x 55 mm

flange bolts. [1] L. SIDE COVER
BRACKET

8 x 55 (2)

4-30
3) Install the under cover front bracket securely with the two
8 x 30 mm hex. bolts and the two 8 mm washers.

[1]
UNDER COVER
FRONT BRACKET

[2]
8 mm WASHER (2)
[3]
8 x 30 mm
HEX. BOLT (2)

4) Pass the tube and the wires through the hole in the under
cover front bracket. [1] [2] WIRES
[3] TUBE
UNDER
COVER
FRONT
BRACKET

[5]
UNDERCASE
GROMMET C [4] HOLE

5) Connect the trim angle sensor 3P connector and the power

tilt motor 2P connector. Install the power tilt motor 2P [1]
TRIM ANGLE SENSOR
connector on the lower side of the connector bracket A and
3P CONNECTOR
the trim angle sensor 3P connector on the upper side of the
connector bracket A.
[2]
POWER TILT
MOTOR
2P CONNECTOR

[3]
CONNECTOR
BRACKET A

4-31
6) Check that the taped ends of the power tilt motor wire and
trim angle sensor wire are in alignment with the end of the [2]
undercase grommet C. Install the undercase grommet C on Wires and tube must not
[1] interfere with the lock lever.
the under cover front bracket so they engage securely in
the groove of the undercase grommet C. FRONT
LOCK
Move the front lock with a hand and check that the wires
and tube do not interfere with the front lock.

[3] TAPED PART

[7]
UNDERCASE
GROMMET C

[6] [4]
SPEED POWER
SENSOR TILT
TUBE A [5] TRIM ANGLE MOTOR
SENSOR WIRE WIRE

7) Adjust the length between the end of the cable outer and
the end of the nut of the cover lock cable A (longer one) so 20 mm (0.8 in)
that it is 20 mm (0.8 in) as shown.

8) Holding the nut in the position described in step 7, position [1]

the inner cable end of the cover lock cable A on the front UNDER COVER
lock and position the cable A nut on the under cover front FRONT
bracket. BRACKET SIDE
Tighten the washer side lock nut securely.

• Check that the nut set in step 7 is not out of the position.
If it is, repeat the procedure from step 7. [2]
4 x 7 x 160 mm
[3] COVER LOCK
VINYL TUBE
9) Position the 4 x 7 x 160 mm vinyl tube and the 3.5 x 430 mm CABLE A
fuel tube on the under cover front bracket.
[4]
LOCK
NUT

[5]
3.5 x 430 mm
FUEL TUBE

[6] FRONT LOCK

4-32
10) Adjust the length between the other end of the cable outer
and the end of the nut of the cover lock cable A so that it is
13 mm (0.5 in) as shown.

11) Holding the nut in the position described in step 10,

position the inner cable end of the cover lock cable A on the 13 mm (0.5 in)
side lock and position the cable A nut on the L. side cover
bracket.
Tighten the washer side lock nut securely. [2]
[1]
COVER LOCK L. SIDE COVER
• Check that the nut set in step 10 is not out of the position. BRACKET SIDE
CABLE A
If it is, repeat the procedure from step 10.
[4]
[3] LOCK
12) Check for clearance between the end of the long hole in the STOPPER [5]
NUT
side lock and the inner cable end as shown. There must be Contact.
no clearance.

If there is clearance, repeat the procedure from step 7.

Check that the side lock is in contact with the stopper of the
L. side cover bracket.

[7] No clearance.

[6] SIDE LOCK

13) Adjust the length between the end of the cable outer and
13 mm (0.5 in)
the end of the nut of the cover lock cable B (shorter one) so [1]
that it is 13 mm (0.5 in) as shown. L. SIDE
COVER
14) Holding the nut in the position described in step 13, BRACKET
position the inner cable end of the cover lock cable B on the SIDE
side lock and position the cable B nut on the L. side cover
bracket.
[2] COVER LOCK
Tighten the washer side lock nut securely. CABLE B

• Check that the nut set in step 13 is not out of the position. [3] SIDE LOCK [4] STOPPER
If it is, repeat the procedure from step 13.

15) Check for clearance between the end of the long hole in the
side lock and the inner cable end as shown. There must be [5]
no clearance. Contact.

If there is clearance, repeat the procedure from step 7. [6]

LOCK
Check that the side lock is in contact with the stopper of the NUT
L. side cover bracket.
[7] No clearance.

[2] COVER
LOCK
CABLE B

4-33
16) Adjust the length between the other end of the cable outer
and the end of the nut of the cover lock cable B so that it is
13 mm (0.5 in) as shown.

17) Holding the nut in the position described in step 16, 13 mm

position the inner cable end of the cover lock cable B on the (0.5 in) [2]
side lock and position the cable B nut on the R. side cover R. SIDE
bracket. COVER
BRACKET
Tighten the washer side lock nut securely. SIDE
[1]
COVER LOCK [3] Contact.
• Check that the nut set in step 16 is not out of the position. CABLE B [4]
STOPPER
If it is, repeat the procedure from step 16.

18) Check for clearance between the end of the long hole in the
side lock and the inner cable end as shown. There must be
no clearance.

If there is clearance, repeat the procedure from step 7.

Check that the side lock is in contact with the stopper of the
[5] No clearance.
R. side cover bracket.

[7] LOCK NUT [6] SIDE LOCK

19) After installing the cover lock cable A and B, operate the
[1] View of each bracket from the top:
cover lock lever and check the front lock and the L./R. side
locks for smooth operation.
[2] FRONT LOCK [3]
20) Pull up the cover lock lever (i.e. release the cover lock). or SIDE LOCK COVER LOCK
Look down the cover lock bolt hole of each of the under BOLT HOLE
cover front bracket and the L./R. side cover brackets and (The front lock
and side lock
check that the front lock and the side lock do not appear.
must not appear
when viewing the
21) If the front lock or side lock appears when looking down the cover lock bolt
cover lock bolt hole, perform the following check. hole from the top
with the lever
<When L. side bracket side appears> pulled up.)
Loosen the lock nut at the cover lock cable A of the L. side
bracket, and adjust by turning the adjusting nut right or left.
[4] L. SIDE COVER BRACKET SIDE:
<When R. side bracket side appears> [6] LOCK NUT
Loosen the lock nut at the cover lock cable B of the R. side [5] COVER LOCK
bracket, and adjust by turning the adjusting nut right or left. CABLE A

22) Install the following parts.

– Remote control cable/grommet (P. 17-5)
– L./R. engine under cover (P. 4-14)
– Front separate cover (P. 4-7)
– Engine cover (P. 4-2)

[7] ADJUSTING NUT

4-34
5. PROGRAMMED FUEL INJECTION BF135A•BF150A

1. SERVICE PRECAUTIONS 15. FUEL STRAINER (LOW PRESSURE SIDE)/

2. CIRCUIT DIAGRAM WATER SEPARATOR
3. VACUUM CONNECTIONS 16. EOP (ENGINE OIL PRESSURE) SWITCH
(HIGH PRESSURE SIDE)
4. PARTS LOCATION/ECM TERMINAL LAYOUT
17. EOP (ENGINE OIL PRESSURE) SWITCH
5. TROUBLESHOOTING
(LOW PRESSURE SIDE)
6. TROUBLESHOOTING WITH HDS TESTER
18. ECT (ENGINE COOLANT TEMPERATURE)
7. TROUBLESHOOTING WITHOUT HDS SENSOR 1
TESTER
19. ECT (ENGINE COOLANT TEMPERATURE)
8. IDLE CONTROL SYSTEM SENSOR 2, 3, 4
9. FUEL SUPPLY SYSTEM 20. BARO (BAROMETRIC PRESSURE)
10. IAB (INTAKE AIR BYPASS) CONTROL SENSOR
SYSTEM 21. KNOCK SENSOR
11. VAPOR SEPARATOR/FUEL PUMP 22. CMP (CAMSHAFT POSITION) SENSOR
(HIGH PRESSURE SIDE)
23. CKP (CRANKSHAFT POSITION) SENSOR
12. SILENCER CASE/THROTTLE BODY/
24. VTEC SOLENOID VALVE (BF150A Only)
INTAKE MANIFOLD
25. VAPOR CHAMBER/CHECK VALVE
13. FUEL INJECTOR/PRESSURE REGULATOR
26. EXHAUST MANIFOLD
14. FUEL PUMP (LOW PRESSURE SIDE)
SYSTEM DIAGRAM ...........................End of book

5-1
BF135A•BF150A

1. SERVICE PRECAUTIONS • Apply the recommended engine oil to the O-rings before
installation. Avoid using the vegetable oil and the alco-
• PGM-FI (PROGRAMMED FUEL INJECTION) holic grease.
TROUBLESHOOTING
• First, check the MIL of the indicator.
• Be sure to turn the ignition switch OFF before discon- O-RING
necting and connecting the ECM connector.
• After inspection and repair, clear the DTC (P. 5-14) or
reset the ECM memory (P. 5-57).

INJECTOR

• CHECK AFTER OPERATION

• Check the parts for secure installation and the bolts,
screws and other fasteners for secure tightening.
• Connect the battery cable to the battery negative (–) ter-
PGM-FI MIL minal.

• FUEL LINE SERVICE

• FUEL LEAK CHECK
• Do not smoke while working on the fuel system. Keep
• Turn the ignition switch ON (but do not turn the starter)
open flame or sparks away from the work area.
after connecting the fuel lines. The fuel pump unit (high
• Disconnect the battery cable from the battery negative pressure side) should operate for approximately 2 sec-
(–) terminal. onds and the fuel pressure in the high pressure side fuel
• Before removing and installing the fuel line, relieve the line should rise. Repeat this operation 2 or 3 times and
fuel pressure by loosening the service check bolt of the check for fuel leakage.
high pressure side fuel strainer, as described in “How to
relieve fuel pressure” (P. 5-102).
• WHEN THE BOAT IS EQUIPPED WITH RADIO
EQUIPMENT
SHOP TOWEL
• The ECM and its wires are designed to be unaffected by
radio waves. However, the ECM can malfunction when it
senses an extremely powerful electric wave. Note the fol-
lowing to avoid malfunction of the ECM.
• Install the antenna and the body of the radio equipment
at least 50 cm (20.0 in) away from the ECM, remote con-
trol cable A and the remote control box.
• Antenna wire must not be too long. Do not route the
antenna wire along the remote control cable A and other
cables/wires.
• Do not mount the radio equipment of large output power
on the boat. (The maximum output power of the radio
SERVICE CHECK BOLT equipment should be 10W when mounted on a boat.)
12 N • m (1.2 kgf • m, 9 lbf • ft) • Install the D-GPS antenna and the body unit at least 3 m
(10 ft) away from the engine.
• Replace the sealing washers during reassembly. • Connect the D-GPS antenna ground wire to ground.
• Replace the O-rings when the fuel line is removed/
installed or replaced.

5-2
 BF135A•BF150A

2. CIRCUIT DIAGRAM

To STARTER MOTOR

BATTERY ECT (ENGINE COOLANT TEMPERATURE) SENSOR 3

IGNITION SWITCH ECT (ENGINE COOLANT TEMPERATURE) SENSOR 2
PGM-FI MAIN RELAY IAT (INTAKE AIR TEMPERATURE) SENSOR
INJECTOR ECT (ENGINE COOLANT TEMPERATURE) SENSOR 1
IGNITION COIL TP (THROTTLE POSITION) SENSOR
VTEC SOLENOID VALVE BARO (BAROMETRIC PRESSURE) SENSOR
IAC (IDLE AIR CONTROL) VALVE MAP (MANIFOLD ABSOLUTE PRESSURE) SENSOR
KNOCK SENSOR CKP (CRANKSHAFT POSITION) SENSOR
EOP (ENGINE OIL PRESSURE) SWITCH CMP (CAMSHAFT POSITION) SENSOR
(HIGH PRESSURE SIDE) FUEL PUMP (HIGH PRESSURE SIDE)
ECT (ENGINE COOLANT TEMPERATURE) SENSOR 4

5-3
BF135A•BF150A

A/F (AIR FUEL RATIO) SENSOR TACHOMETER PULSE CHECK CONNECTOR

A/F (AIR FUEL RATIO) SENSOR RELAY TACHOMETER (OPTION)
IAB (INTAKE AIR BYPASS) CONTROL VALVE DATA LINK CONNECTOR
FUEL GAUGE EMERGENCY STOP SWITCH
BUZZER TRIM METER (OPTION)
MIL TRIM ANGLE SENSOR
ACG INDICATOR LIGHT EOP (ENGINE OIL PRESSURE) SWITCH
IC REGULATOR (ALTERNATOR) (LOW PRESSURE SIDE)
INDICATOR LIGHT WATER LEVEL SWITCH
OVERHEAT INDICATOR LIGHT NEUTRAL SWITCH
OIL INDICATOR LIGHT

5-4
 BF135A•BF150A

3. VACUUM CONNECTIONS

To MOUNT
CASE

A
A

VAPOR SEPARATOR IAB (INTAKE AIR BYPASS) CONTROL SOLENOID

FUEL PUMP VALVE
HIGH PRESSURE SIDE FUEL FILTER DIAPHRAGM
VAPOR FILTER INJECTOR
SILENCER CASE WATER SEPARATOR
TP (THROTTLE POSITION) SENSOR FUEL STRAINER
MAP (MANIFOLD ABSOLUTE PRESSURE) BREATHER CHAMBER
SENSOR FUEL PUMP (LOW PRESSURE SIDE)
IAC (IDLE AIR CONTROL) VALVE PRESSURE REGULATOR
VACUUM TANK

5-5
BF135A•BF150A

4. PARTS LOCATION/ECM TERMINAL LAYOUT

IAT (INTAKE AIR TEMPERATURE) SENSOR KNOCK SENSOR

BARO (BAROMETRIC PRESSURE) SENSOR FUEL PUMP (HIGH PRESSURE SIDE)
ECT (ENGINE COOLANT TEMPERATURE) SENSOR 2 WATER LEVEL SENSOR
INJECTOR TP (THROTTLE POSITION) SENSOR
IAB (INTAKE AIR BYPASS) CONTROL SOLENOID MAP (MANIFOLD ABSOLUTE PRESSURE) SENSOR
VALVE IAC (IDLE AIR CONTROL) VALVE

5-6
 BF135A•BF150A

A/F (AIR FUEL RATIO) SENSOR PGM-FI MAIN RELAY

VTEC SOLENOID VALVE EOP (ENGINE OIL PRESSURE) SWITCH
ECT (ENGINE COOLANT TEMPERATURE) SENSOR 4 (HIGH PRESSURE SIDE)
CKP (CRANKSHAFT POSITION) SENSOR EOP (ENGINE OIL PRESSURE) SWITCH
ECT (ENGINE COOLANT TEMPERATURE) SENSOR 1 (LOW PRESSURE SIDE)
ECM (ENGINE CONTROL MODULE) CMP (CAMSHAFT POSITION) SENSOR
A/F (AIR FUEL RATIO) SENSOR RELAY ECT (ENGINE COOLANT TEMPERATURE) SENSOR 3

5-7
BF135A•BF150A

• ECM TERMINAL LAYOUT

ECM CONNECTOR A

HARNESS SIDE CONNECTOR

VIEWED FROM THE TERMINAL SIDE

Terminal Wire Terminal

Name Content/Signal
No. color mark
1 G/W LG2 Logic ground 2 (Common with B17)
2 G/R SG2 Sensor ground 2
3 Not used
4 W/Bl AFV1 A/F sensor (V) Power source for the A/F sensor
5 W/Bu PA BARO sensor At ignition switch ON: Approx. 3V
6 R/G TOH3 ECT sensor 4 Detects cylinder block temperature.
7 Not used
8 Not used
9 Not used
10 Not used
11 Br/W VCC2 Sensor power 2 At ignition switch ON: Approx. 5V
12 Lg/Bl VCC3 Sensor power 3 At ignition switch ON: Approx. 5V
13 Lg/R FLR2 Fuel pump relay 2
14 Bl/Y AFC1 A/F sensor (C)
15 R/Bu KS Knock sensor
16 R TOH2 ECT sensor 3 Detects exhaust port temperature.
17 Y/R OPSH EOP switch (High pressure side) At switch ON: Approx. 0V
At switch OFF: Battery voltage
18 Not used
19 Br EFD Fuel filter water level switch At switch ON (High water level): Approx. 0V
At switch OFF: Battery voltage
20 G/Y VTS VTEC solenoid valve Power to drive solenoid valve:
High engine rpm (4,300 min-1/rpm or above): ON
21 G FUP Fuel gauge Power to drive fuel gauge
22 Not used
23 Not used
24 Bl/R EMS2 Emergency stop switch 2 At switch ON: Approx. 0V
At switch OFF: Battery voltage
25 G/O LAFR A/F sensor heater relay Power to drive A/F sensor heater relay
26 Bl SVS IAB solenoid valve Power to drive IAB solenoid valve
High engine rpm (4,300 min-1/rpm or above): ON

5-8
 BF135A•BF150A

ECM CONNECTOR B

HARNESS SIDE CONNECTOR

VIEWED FROM THE TERMINAL SIDE

Terminal Wire Terminal

Name Content/Signal
No. color mark
1 Not used
2 G TDC CMP sensor CMP sensor signal
3 Bu CRK CKP sensor CKP sensor signal
4 Br/Y VCC1 Sensor power 1 Power for sensor (5V)
5 W/R PB MAP sensor Detects vacuum at the intake manifold.
6 G/R SG1 Sensor ground 1
7 R/Bl THL TP sensor Detects throttle position.
8 R/W TE ECT sensor 1 Detects cylinder block engine temperature.
9 Not used
10 Lg/R FLR1 Fuel pump relay 1 Power to drive fuel pump relay
11 R/Y TA IAT sensor Detects intake air temperature.
12 R/Bl TOH1 ECT sensor 2 Detects cylinder head temperature.
13 R/Bu NTSW Neutral switch At switch ON (Neutral): Approx. 0V
At switch OFF: Battery voltage
14 P OPSL EOP switch (Low pressure side) At switch ON: Approx. 0V
At switch OFF: Battery voltage
15 Bu K-LINE Communication signal At ignition switch ON: Approx. 12V
16 Lg/W SCS Service check signal
17 G/Bl LG1 Logic ground 1
18 Y/G BUZZ Buzzer Power to sound buzzer
19 W/Bu ACGL Alternator indicator light Inputs alternator indicator light ON signal.
20 Bl/R EMS1 Emergency stop switch 1 At switch ON: Approx. 0V
At switch OFF: Battery voltage
21 Br INJ1 No. 1 injector Power to drive No. 1 injector
22 Bu IGN1 No. 1 ignition coil Outputs No. 1 ignition signal.
23 R INJ2 No. 2 injector Power to drive No. 2 injector
24 Bu/Bl IGN2 No. 2 ignition coil Outputs No. 2 ignition signal.
25 R/Bu WARNL MIL Power to turn MIL ON
26 G/W EACVP IAC valve (+) Power to drive IAC valve (+)
27 Bu INJ3 No. 3 injector Power to drive No. 3 injector
28 W/G IGN3 No. 3 ignition coil Outputs No. 3 ignition signal
29 Y INJ4 No. 4 injector Power to drive No. 4 injector
30 Bu/R IGN4 No. 4 ignition signal Outputs No. 4 ignition signal
31 R OHL Overheat indicator light Overheat indicator light ON line
32 Y OPL Oil pressure light Oil indicator light ON line
33 Gr TACHO Tachometer pulse Drives tachometer.
34 Bl EACVM IAC valve (–) Power to drive IAC valve (–)

5-9
BF135A•BF150A

ECM CONNECTOR C

HARNESS SIDE CONNECTOR

VIEWED FROM THE TERMINAL SIDE

Terminal Wire Terminal

Name Content/Signal
No. color mark
1 Y/Bl IGP1 ECM main power 1 (Common with C5) At ignition switch ON: Battery voltage
2 G PG1 Power ground 1 (Common with C6)
3 Bl/W AFHT A/F sensor heater
4 W AFHT+ A/F sensor heater (+)
5 Y/Bl IGP2 ECM main power 2 (Common with C1) At ignition switch ON: Battery voltage
6 G/R PG2 Power ground 2 (Common with C2)

5-10
 BF135A•BF150A

5. TROUBLESHOOTING 3. Perform the troubleshooting by referring to the “Trou-

bleshooting Guide by DTC” (P. 5-15) or “Troubleshoot-
The ECM (Engine Control Module) has the self-diagnosis ing Guide by No. of Blinks” (P. 5-59).
function which memorizes the failure code and turns the Check each connector and wire harness for secure
MIL (Malfunction Indicator Light) ON when it detects an connection and damage before troubleshooting.
abnormality with the input/output system. Repair the connector and wire harness if necessary.

• If the MIL does not come ON but the engine failure

4. After troubleshooting, perform repairs as needed and
(abnormality other than monitoring ECM) occurred,
perform the necessary work (P. 5-14 or 5-58).
detect the probable problem part by referring to the
Quick Reference Chart of Troubleshooting by System on
page 5-12, and troubleshoot accordingly.

• HOW TO CARRY OUT TROUBLESHOOTING

When the MIL comes ON or blinks or any abnormality
occurs during running, identify the problem detected by
ECM according to the following procedure, and trou-
bleshoot accordingly.

To troubleshoot, connect the tester probe to a commer-

cially available digital circuit tester. Note that the tester
probe must agree with the connector terminal of the digi-
tal circuit tester not to apply excessive force to the con-
nector terminal.

1. Turn the ignition switch ON and check that the MIL

comes ON.

PGM-FI MIL

2. When the MIL is ON or blinking, check the DTC

(Diagnostic Trouble Code) using the HDS tester (P. 5-
13).
Or, use the short connector to blink the MIL and trou-
bleshoot the problem indicated by the number of blinks
of the MIL (P. 5-57).

5-11
BF135A•BF150A

• QUICK REFERENCE CHART OF TROUBLESHOOTING BY SYSTEM

When the MIL does not come ON but the engine becomes faulty, refer to the following troubleshooting chart and check
the parts in the numbered order shown on the chart.

Idle Control System

Check point Idle

IAC Neutral Vacuum
adjusting
screw valve switch pipe

Symptom Ref. page 5-94 5-95 17-13 5-5

Engine does not start 2 1
Engine starts but stalls soon 1 2 3
Engine speed is higher than the specified idle speed 3 2 1
after warm up.
Engine speed is higher than the specified trolling speed 3 4 1 2
after warm up.
Engine speed is lower than the specified idle speed 2 1 3
after warm up.
Engine speed is lower than the specified trolling speed 2 1 3
after warm up.
Engine speed is not stable during idling and trolling. 2 1 4 3

Low Pressure Fuel Supply System

Check point Low Low Low
Water Vapor
pressure pressure pressure
fuel line separator fuel strainer fuel pump separator

Symptom Ref. page 5-104 3-19 3-15 5-142 5-111

Engine does not start 3 1 2 4
Engine starts but stalls soon 3 1 2 4
Engine speed is not stable during idling and trolling, 1 2
or engine stalls.
Engine sometimes misfires or stalls soon 3 1 2 4
Engine stalls soon at hot restart of the engine. 1

High Pressure Fuel Supply System

Check point High High High
Fuel Pressure
pressure pressure pressure
fuel line fuel pump fuel strainer injector regulator

Symptom Ref. page 5-104 5-107 3-18 5-105 5-106

Engine does not start 1 2 3
Engine starts but stalls soon 1 2 3
Engine speed is not stable during idling and trolling, 1 2 3
or engine stalls.
Engine speed does not rise 1 3 3 3 2
Engine sometimes misfires or stalls soon 1 3 2 3

5-12
 BF135A•BF150A

6. TROUBLESHOOTING WITH HDS • WHEN USING HDS POCKET TESTER DURING

CRUISING
TESTER 1. Remove the engine cover and the electric part cover
• DTC (DIAGNOSTIC TROUBLE CODE) CHECK (Section 4).
1. Remove the engine cover and the electric part cover 2. Remove the cap from the under cover front bracket.
(Section 4). Route the extension wire in the HDS pocket tester kit
through the front cover bracket.
• Set the grommet on the under cover front bracket
2. Disconnect the 4P (Red) connector and connect the
securely.
HDS pocket tester to the data link connector (DLC).
4P CONNECTOR
(RED) UNDER COVER
FRONT BRACKET

CAP

3. Disconnect the red 4P connector from the DLC (Data

TESTER WIRE DATA LINK Link Connector) and secure the DLC wire as sown.
CONNECTOR (DLC) • Route the extension wire of the tester in the position
shown so that it does not interfere with the parts.
4. Connect the extension wire to the DLC.

CLAMP DLC

HDS POCKET
TESTER

3. Turn the ignition switch ON and check the DTC shown

on the HDS pocket tester.
EXTENSION WIRE
Refer to the HDS pocket tester's operation manual for OF TESTER
how to use the HDS pocket tester.

5-13
BF135A•BF150A

5. Secure the extension wire as shown with the band. • TO CLEAR DTC
EXTENSION WIRE 1. Remove the engine cover and the electric part cover.
OF TESTER

2. Connect the HDS pocket tester to the data link con-

nector (DLC).

3. Turn the ignition switch ON.

4. Clear the DTC using the HDS pocket tester.

Refer to the HDS pocket tester's operation manual for
how to use the HDS pocket tester.
• When abnormality remains in the system, the DTC
cannot be cleared as the ECM continues self-diag-
nosis.

WIRE BAND
• FINAL PROCEDURE
6. Connect the extension wire to the HDS pocket tester. (AFTER TROUBLESHOOTING)
7. Install the electric part cover and the engine cover in 1. Clear the DTC.
the reverse order of removal.
2. Disconnect the HDS pocket tester wire from the data
link connector.

3. Install the cap on the under cover front bracket.

4. Install the electric part cover and the engine cover.

5-14
 BF135A•BF150A

a. TROUBLESHOOTING GUIDE BY DTC

DTC PGM-FI MIL Detected unit Probable problem part Ref. page
– MIL does not ECM • Open circuit in MIL wire 5-18
or come ON/blinks • Blown MIL bulb
0-2, • Open circuit in ECM ground wire or
0-5, poor grounding
0-8 • Faulty ECM
– MIL stays ON ECM • Open circuit in ECM power supply line 5-21
or • Short circuit in data link connector wire
0-2, • Short circuit in MIL wire
0-5, • Short circuit in sensor power supply line
0-8 • Faulty ECM
3-1 MIL stays ON MAP sensor (Voltage too low) • Short circuit in MAP sensor wire 5-28
• Faulty MAP sensor
• Faulty ECM
3-2 MIL stays ON MAP sensor (Voltage too high) • Open circuit in MAP sensor wire 5-29
• Faulty MAP sensor
• Faulty ECM
4-1 MIL stays ON CKP sensor (No pulse) • Open/short circuit in CKP sensor wire 5-30
• CKP sensor
• Faulty ECM
4-2 MIL stays ON CKP sensor (Abnormal pulse) • Faulty CKP sensor 5-32
• Faulty ECM

6-1 MIL stays ON ECT sensor 1 (Voltage too low) • Short circuit in ECT sensor 1 5-33
• Faulty ECT sensor 1
• Faulty ECM
6-2 MIL stays ON ECT sensor 1 (Voltage too high) • Open circuit in ECT sensor 1 wire 5-33
• Faulty ECT sensor 1
• Faulty ECM
7-1 MIL stays ON TP sensor (Voltage too low) • Open/short circuit in TP sensor wire 5-34
• Faulty TP sensor
• Faulty ECM
7-2 MIL stays ON TP sensor (Voltage too high) • Open circuit in TP sensor wire 5-35
• Faulty TP sensor
• Faulty ECM
8-1 MIL stays ON CMP sensor (No pulse) • Open/short circuit in CMP sensor 5-36
• Faulty DC1 sensor
• Faulty ECM
8-2 MIL stays ON CMP sensor (Abnormal pulse) • Open/short circuit in CMP sensor 5-37
• Faulty CMP sensor
• Faulty ECM

–: DTC does not appear.

5-15
BF135A•BF150A

DTC PGM-FI MIL Detected unit Probable problem part Ref. page
10-1 MIL comes ON IAT sensor (Voltage too low) • Short circuit in IAT sensor wire 5-38
• Faulty IAT sensor
• Faulty ECM
10-2 MIL comes ON IAT sensor (Voltage too high) • Open circuit in IAT sensor wire 5-38
• Faulty IAT sensor
• Faulty ECM
13-1 MIL comes ON BARO sensor (Voltage too low) • Short circuit in BARO sensor wire 5-39
• Faulty BARO sensor
• Faulty ECM
13-2 MIL comes ON BARO sensor (Voltage too high) • Open circuit in BARO sensor wire 5-40
• Faulty BARO sensor
• Faulty ECM
14-1 MIL comes ON IAC valve (Abnormal current flow) • Open/short circuit in IAC valve wire 5-41
• Faulty IAC valve
• Faulty ECM
21-1 MIL comes ON VTEC solenoid valve • Open/short circuit in VTEC solenoid valve 5-42
(Abnormal output)(BF150A only) • Faulty VTEC solenoid valve
• Faulty ECM
23-1 MIL comes ON Knock sensor (Abnormal detection) • Open/short circuit in knock sensor wire 5-43
• Faulty knock sensor
• Faulty ECM
41-3 MIL comes ON A/F sensor heater • Open/short circuit in A/F sensor heater wire 5-44
(Abnormal current flow) • Faulty A/F sensor heater
• Faulty ECM
41-4 MIL comes ON A/F sensor heater • Open/short circuit in A/F sensor heater wire 5-46
(Abnormal current flow) • Faulty A/F sensor heater
• Faulty ECM
48-5 MIL comes ON A/F sensor heater • Open circuit in A/F sensor heater wire 5-49
(Abnormal current flow) • Faulty A/F sensor
• Faulty ECM
48-6 MIL comes ON A/F sensor heater • Short circuit in A/F sensor wire C line 5-50
(Abnormal current flow) • Faulty A/F sensor
• Faulty ECM
48-7 MIL comes ON A/F sensor heater • Short circuit in A/F sensor wire V line 5-50
(Abnormal current flow) • Faulty A/F sensor
• Faulty ECM

5-16
 BF135A•BF150A

DTC PGM-FI MIL Detected unit Probable problem part Ref. page
140-1 MIL comes ON ECT sensor 2 (Voltage too low) • Short circuit in ECT sensor 2 wire 5-51
• Faulty ECT sensor 2
• Faulty ECM
140-2 MIL comes ON ECT sensor 2 (Voltage too high) • Open circuit in ECT sensor 2 wire 5-51
• Faulty ECT sensor 2
• Faulty ECM
141-1 MIL comes ON ECT sensor 3 (Voltage too low) • Short circuit in ECT sensor 3 wire 5-52
• Faulty ECT sensor 3
• Faulty ECM
141-2 MIL comes ON ECT sensor 3 (Voltage too high) • Open circuit in ECT sensor 3 wire 5-53
• Faulty ECT sensor 3
• Faulty ECM
142-1 MIL comes ON EOP switch • Open/short circuit in EOP switch wire 5-54
(Abnormal signal) • Faulty ECM

143-1 MIL comes ON ECT sensor 4 (Voltage too low) • Short circuit in ECT sensor 4 wire 5-55
• Faulty ECT sensor 3
• Faulty ECM
143-2 MIL comes ON ECT sensor 4 (Voltage too high) • Open circuit in ECT sensor 4 wire 5-56
• Faulty ECT sensor 4
• Faulty ECM

When multiple DTC’s main codes are indicated:

DTC
main PGM-FI MIL Detected unit Probable problem part Ref. page
codes
7, 13 MIL comes ON • Open circuit in VCC line
(power source for sensor)

6,7 MIL comes ON • Open circuit in SG (sensor ground) line

10,13
48,140
141,143

5-17
BF135A•BF150A

b. TROUBLESHOOTING 2. Main power line check

-1. Disconnect the remote control harness 14P connector.
• MIL Does Not Come ON -2. Measure the voltage between the No. 3 (White/Black)
terminal of the main harness side 14P connector and
1. Fuse check the engine ground.
-1. Turn the ignition switch ON and check that the warning • Note that voltage is constantly applied to the
buzzer sounds twice. White/Black terminal. Take care not to short-circuit
the terminal.
Does the buzzer sound twice?
YES – Perform “6. Alternator indicator light check”
NO – Go to the step 2. MAIN HARNESS SIDE
BLACK/WHITE
14P CONNECTOR
-2. Check the No. 4 (15A) fuse.

Is the fuse normal?

YES – Go to the step 3.
NO – Repair open in the wire between the No. 4
fuse and the ECM, and between the No. 4 VIEWED FROM THE
fuse and the injector. After repair, replace the TERMINAL SIDE
No. 4 fuse.
Is there the battery voltage?
-3. Check the No. 7 (30A) fuse.
YES – Go to the step 3.
NO – Repair open in the main harness.
Is the fuse normal?
YES – Go to the step 4. -3. Turn the ignition switch ON. Check for continuity
NO – Repair short in the wire between the PGM-FI between the No. 1 (White/Black) terminal and the No.
main relay and the fuse box, and between the 2 (Black/Yellow) terminal of the remote control box har-
PGM-FI main relay and the starter magnetic ness side 14P connector.
switch. After repair, replace the No. 7 fuse.

-4. Check the No. 3 (30A) fuse.

REMOTE CONTROL
HARNESS SIDE 14P
Is the fuse normal? CONNECTOR
YES – Perform “2. Main power line check”.
NO – Repair short in the wire between the fuse box BLACK/YELLOW
and the ignition switch, between the fuse box WHITE/BLACK
and the alternator, and between the fuse box
and the power trim/tilt switch or power tilt
switch. After repair, replace the No. 3 fuse.

VIEWED FROM THE

TERMINAL SIDE

Is there the continuity?

YES – Perform “3. IGP power line check”.
NO – Go to the step 4.

-4. Check the ignition switch (P. 16-9).

Is the ignition switch normal?

YES – Repair open in the remote control box har-
ness.
NO – The ignition switch is faulty.

5-18
 BF135A•BF150A

3. IGP power line check 4. ECM power line check

-1. Turn the ignition switch OFF. Disconnect the PGM-FI -1. Turn the ignition switch OFF and disconnect the fuse
main relay 6P connector. box 3P connector.
-2. Turn the ignition switch ON. Measure the voltage -2. Turn the ignition switch ON. Measure the voltage
between the No. 2 (Black/Yellow) terminal of the PGM- between the No. 3 (Yellow/Black) terminal of the fuse
FI main relay harness side 6P connector and the box side 3P connector and the engine ground.
engine ground.

PGM-FI MAIN RELAY HARNESS FUSE BOX SIDE 3P CONNECTOR

SIDE 6P CONNECTOR
BLACK/YELLOW YELLOW/BLACK

VIEWED FROM THE

TERMINAL SIDE
VIEWED FROM THE
TERMINAL SIDE Is there the battery voltage?
YES – Go to the step 3.
Is there the battery voltage? NO – The PGM-FI main relay is faulty, or the fuse
YES – Go to the step 3. box is faulty.
NO – Repair open in the main harness.
-3. Turn the ignition switch OFF and disconnect the ECM
-3. Turn the ignition switch OFF. Check for continuity connector C.
between the No. 6 (Black) terminal of the PGM-FI main -4. Check for the continuity between the No. 2 (Yellow/
relay 6P connector and the engine ground. Black) terminal of the fuse box harness side 3P con-
nector and the respective terminals of the No. 1
PGM-FI MAIN RELAY HARNESS (Yellow/Black) and No. 5 (Yellow/Black) terminals of
SIDE 6P CONNECTOR the ECM connector C.

ECM CONNECTOR C
BLACK
IGP2 FUSE BOX HARNESS
(YELLOW/BLACK) SIDE 3P CONNECTOR

VIEWED FROM THE

TERMINAL SIDE YELLOW/BLACK
IGP1
(YELLOW/BLACK)
Is there the continuity?
VIEWED FROM THE
YES – Perform “4. ECM power line check”. TERMINAL SIDE
NO – Repair open in the main harness (Black).

Is there the continuity?

YES – Perform “5. MIL power line check”.
NO – Repair open in the wire of the main harness.

5-19
BF135A•BF150A

5. MIL power line check 6. Alternator indicator light check

-1. Turn the ignition switch OFF and disconnect the fuse -1. Turn the ignition switch ON and check the alternator
box 3P connector. indicator light.
-2. Turn the ignition switch ON. Measure the voltage
between the No. 2 (Yellow/Red) terminal of the fuse Does the alternator indicator light come ON?
box side 3P connector and the engine ground YES – Perform “8. Function test”.
NO – Replace the MIL.

FUSE BOX SIDE 3P CONNECTOR

7. MIL line check
-1. Turn the ignition switch OFF and disconnect the ECM
YELLOW/RED connector B.
-2. Disconnect the MIL 6P connector.
-3. Check for continuity between the No. 25 (Red/Blue)
terminal of the ECM harness side connector B and the
No. 4 (Red/Blue) terminal of the MIL harness side 6P
VIEWED FROM THE
connector.
TERMINAL SIDE
MIL HARNESS SIDE ECM CONNECTOR B
Is there the battery voltage? 6P CONNECTOR
YES – Go to the step 3.
NO – The PGM-FI main relay is faulty. WARNL
(RED/BLUE)
-3. Turn the ignition switch OFF and connect the fuse box
3P connector.
-4. Disconnect the MIL 6P connector.
-5. Turn the ignition switch ON. Measure the voltage
between the No. 6 (Yellow/Black) terminal of the MIL
VIEWED FROM THE
6P harness side connector and the engine ground. TERMINAL SIDE

Is there the continuity?

MIL HARNESS SIDE YES – Go to the step 4.
6P CONNECTOR NO – Repair open in the main harness.

-4. Check for continuity between the No. 4 (Yellow/ Black)

YELLOW/BLACK terminal and the No. 6 (Red/Blue) terminal of the MIL
6P connector.

MIL 6P CONNECTOR
VIEWED FROM THE
TERMINAL SIDE

YELLOW/BLACK RED/BLUE
Is there the battery voltage?
YES – Perform “6. Alternator indicator light check”.
NO – Repair open in the main wire harness.
VIEWED FROM THE
TERMINAL SIDE

Is there the continuity?

YES – Substitute a known-good ECM and recheck.
NO – MIL is faulty or open circuit in the MIL harness
wire.

5-20
 BF135A•BF150A

8. Function test • MIL Comes ON but DTC Code

-1. Turn the ignition switch OFF and connect the HDS
pocket tester.
Does Not Appear
-2. Turn the ignition switch ON and perform the function 1. ECM power line check
test. (See the HDS pocket tester's operation manual for -1. Turn the ignition switch OFF and disconnect the ECM
the test procedure.) connector C.
-2. Turn the ignition switch ON. Measure the voltage
Does the MIL blink? between the respective terminals of the No. 2
YES – Substitute a known-good ECM and recheck. (Yellow/Black) and No. 6 (Yellow/Black) terminals of the
NO – Check the MIL. ECM connector C and the engine ground.
If the MIL is normal, repair the main wire har-
ness (open in the Red/Blue wire between the ECM CONNECTOR C
MIL and ECM).
IGP2
(YELLOW/BLACK)
IGP1
(YELLOW/BLACK)

VIEWED FROM THE

TERMINAL SIDE

Is there the battery voltage?

YES – Perform “2. Data link connector check”.
NO – Repair open in the main harness.

2. Data link connector check

-1. Turn the ignition switch OFF and disconnect the HDS
pocket tester.
-2. Turn the ignition switch ON. Measure the voltage
between the No. 4 (Yellow/Red) terminal of the data
link connector and the engine ground.

DATA LINK CONNECTOR

YELLOW/RED

VIEWED FROM THE

TERMINAL SIDE

Is there the battery voltage?

YES – Go to the step 3.
NO – Repair open in the main harness.

5-21
BF135A•BF150A

-3. Turn the ignition switch OFF and disconnect the ECM Is there the continuity?
connector B. YES – Perform “3. DTC recheck”.
-4. Check for the continuity between the No. 3 (Light NO – Repair open in the main harness.
green/White) terminal of the data link connector and
the engine ground. 3. DTC recheck
-1. Turn the ignition switch OFF and connect the HDS
DATA LINK CONNECTOR pocket tester.
-2. Turn the ignition switch ON and check the DTC with
the HDS pocket tester.
LIGHT GREEN/WHITE
Is the main code 0 (either of 0-2, 0-5 or 0-8)?
YES – Substitute a known-good ECM and recheck.
NO – Troubleshoot the problem of the DTC.
VIEWED FROM THE
TERMINAL SIDE

Is there the continuity?

YES – Repair short in the main harness.
NO – Go to the step 5.

-5. Check for the continuity between the No. 3 (Light

green/White) terminal of the data link connector and
the No. 16 (Light green/White) terminal of the ECM
harness side connector B.

ECM CONNECTOR B
DATA LINK
CONNECTOR

SCS
(LIGHT GREEN/
VIEWED FROM THE
WHITE)
TERMINAL SIDE

Is there the continuity?

YES – Go to the step 6.
NO – Repair open in the main harness.

-6. Check for the continuity between the service check

connector No. 1 (Black) terminal and the engine
ground.
DATA LINK
CONNECTOR

GND
(BLACK)

VIEWED FROM THE

TERMINAL SIDE

5-22
 BF135A•BF150A

• Alert System Initial Operation Is 2. Buzzer line check

-1. Turn the ignition switch OFF and disconnect the
Faulty Yellow/Green terminal from the buzzer.
1. Function test -2. Connect the Yellow/Green terminal of the buzzer to the
-1. Turn the ignition switch OFF and connect the HDS Black terminal with a jumper wire to short.
pocket tester. -3. Turn the ignition switch ON and check that the buzzer
-2. Turn the ignition switch ON and test the buzzer using sounds.
the HDS pocket tester.
Does the buzzer sound?
Does the buzzer sound? YES – Repair open in the wire harness (wire
YES – Go to the step 3. between the buzzer and ECM).
NO – Perform “2. Buzzer line check”. NO – Go to the step 4.

-3. Test the MIL using the HDS pocket tester. -4. Perform the unit check of the buzzer.

Does the MIL blink? Is the buzzer normal?

YES – Go to the step 4. YES – Go to the step 5.
NO – Perform “3. MIL line check”. NO – The buzzer is faulty.

-4. Test the overheat indicator light using the HDS pocket -5. Perform the unit check of the ignition switch (P. 16-9).
tester.
Is the ignition switch normal?
Does the overheat indicator light blink? YES – Go to the step 6.
YES – Go to the step 5. NO – The ignition switch is faulty.
NO – Perform “4. Overheat indicator line check”.
-6. Disconnect the remote control box harness side 14P
-5. Test the oil pressure indicator light using the HDS connector.
pocket tester. -7. Turn the ignition switch ON. Check for the continuity
between the No. 1 (White/Black) and the No. 2
Does the oil pressure indicator light blink? (Black/Yellow) terminals of the remote control box har-
ness side 14P connector.
YES – End of the test
NO – Perform “5. Oil pressure indicator line check”.

REMOTE CONTROL BOX

HARNESS SIDE 14P
CONNECTOR

BLACK/YELLOW
WHITE/BLACK

VIEWED FROM THE

TERMINAL SIDE

Is there continuity?
YES – Repair open in the main harness.
NO – Repair open in the remote control box har-
ness.

5-23
BF135A•BF150A

3. MIL line check -5. Check for continuity between the No. 4 (Yellow/ Black)
-1. Turn the ignition switch OFF and disconnect the MIL terminal and the No. 6 (Red/Blue) terminal of the MIL
6P connector. 6P connector.
-2. Turn the ignition switch ON. Measure the voltage
between the No. 2 (Yellow/Red) terminal of the MIL 6P MIL 6P CONNECTOR
main harness side connector and the engine ground.

MIL HARNESS SIDE 6P

YELLOW/BLACK RED/BLUE
CONNECTOR

YELLOW/RED
VIEWED FROM THE
TERMINAL SIDE

Is there the continuity?

VIEWED FROM THE YES – Substitute a known-good ECM and recheck.
TERMINAL SIDE
NO – The MIL is faulty or repair open in the MIL har-
Is there the battery voltage? ness.
YES – Go to the step 3.
NO – Repair open in the main wire harness.

-3. Turn the ignition switch OFF and disconnect the ECM
connector B.
-4. Check for the continuity between the No. 25 (Red/Blue)
terminal of the ECM harness side connector B and the
No. 4 (Red/Blue) terminal of the MIL main harness side
6P connector.

MIL HARNESS SIDE ECM CONNECTOR B

6P CONNECTOR

WHITE/BLACK

VIEWED FROM THE

TERMINAL SIDE
Is there the continuity?
YES – Go to the step 5.
NO – Repair open in the main harness.

5-24
 BF135A•BF150A

4. Overheat indicator line check -3. Turn the ignition switch OFF and connect the indicator
-1. Turn the ignition switch OFF. Disconnect the Red ter- light Yellow terminal.
minal of the indicator light and connect the Black ter- -4. Disconnect the remote control harness 14P connector.
minal to short. -5. Check for the continuity between the No. 6 (Yellow) and
-2. Turn the ignition switch ON and check the overheat the No. 2 (Black/Yellow) terminals of the remote control
indicator light. harness side 14P connector.

Does the overheat indicator light come ON?

YES – Repair open in the wire harness (between the REMOTE CONTROL
ECM and the indicator light). HARNESS SIDE 14P
NO – Go to the step 3. CONNECTOR
BLACK/YELLOW
-3. Turn the ignition switch OFF and connect the indicator
light Red terminal.
-4. Disconnect the remote control harness 14P connector. YELLOW
-5. Check for the continuity between the No. 7 (Red) ter-
minal and the No. 2 (Black/Yellow) terminal of the
remote control harness side 14P connector.
VIEWED FROM THE
TERMINAL SIDE
REMOTE CONTROL Is there the continuity?
HARNESS SIDE 14P YES – Repair open in the main harness.
CONNECTOR
NO – The indicator light is faulty or repair open in
BLACK/YELLOW the remote control harness wire.

RED

VIEWED FROM THE

TERMINAL SIDE
Is there the continuity?
YES – Repair open in the wire of the main harness.
NO – The indicator light is faulty or repair open in
the remote control harness.

5. Oil pressure indicator line check

-1. Turn the ignition switch OFF. Disconnect the Yellow ter-
minal of the indicator light and connect the Black ter-
minal to short.
-2. Turn the ignition switch ON and check the oil pressure
indicator light.

Does the oil pressure indicator light come ON?

YES – Go to the step 3.
NO – Repair open in the wire harness (between the
ECM and the indicator light).

5-25
BF135A•BF150A

• Neutral Switch Malfunction -4. Disconnect the ECM connector B.

-5. Check for the continuity between the No. 13
• Before following test, perform the neutral position check. (Black/Blue) terminal of the ECM harness side con-
Engine speed does not increase in gears (BF150A only). nector B and the No. 1 (Black/Blue) terminal of the
neutral switch harness side 2P connector.
1. Switch condition check with the HDS pocket tester
-1. Turn the ignition switch OFF and connect the HDS ECM CONNECTOR B
pocket tester. NEUTRAL SWITCH
-2. Turn the ignition switch ON and check the neutral HARNESS SIDE 2P
switch condition using the HDS pocket tester. CONNECTOR

Does the switch position agree with the indication of

the tester?
YES – Substitute a known-good ECM and recheck.
NO – Perform “2. Neutral switch line check”. NTSW
(BLACK/BLUE)
2. Neutral switch line check VIEWED FROM THE
TERMINAL SIDE
-1. Turn the neutral switch OFF and disconnect the neutral
switch 2P connector.
-2. Check for the continuity between the No. 1 (Black/Blue) Is there the continuity?
terminal of the neutral switch harness side 2P connec- YES – Perform “3. Neutral switch check”.
tor and the engine ground. NO – Repair open in the main harness.

3. Neutral switch check

NEUTRAL SWITCH HARNESS -1. Turn the ignition switch OFF and disconnect the neu-
SIDE 2P CONNECTOR tral switch 2P connector.
-2. Check for the continuity between the No. 1 (Black) ter-
BLACK/BLUE minal and the No. 2 (Black/Blue) terminal of the neutral
switch side 2P connector.

NEUTRAL SWITCH SIDE 2P

CONNECTOR
VIEWED FROM THE
TERMINAL SIDE

Is there the continuity?

YES – Repair short in the wire of the main harness.
NO – Go to the step 3.
VIEWED FROM THE
-3. Check for the continuity between the No. 2 (Black) ter- TERMINAL SIDE
minal of the neutral switch harness side 2P connector
and the engine ground. Is there the continuity with the gear in Neutral and
no continuity with the gear in other than Neutral?
YES – Substitute a known-good ECM and recheck.
NEUTRAL SWITCH HARNESS
NO – The neutral switch is faulty.
SIDE 2P CONNECTOR

BLACK

VIEWED FROM THE

TERMINAL SIDE

Is there the continuity?

YES – Go to the step 4.
NO – Repair open in the main wire harness.

5-26
 BF135A•BF150A

• Tachometer Malfunction -4. Check for the continuity between the No. 12 (Gray) ter-
minal of the main harness side 14P connector and the
1. Engine speed check using the HDS pocket tester. No. 33 (Gray) terminal of the ECM harness side con-
-1. Turn the ignition switch OFF and connect the HDS nector B.
pocket tester.
-2. Start the engine and check the engine speed with the MAIN HARNESS SIDE ECM CONNECTOR B
HDS pocket tester. 14P CONNECTOR

Do the tachometer and tester readings agree?

YES – Normal (Temporary problem has been
removed.)
NO – Perform “2. Tachometer power line check”.

*Tolerance of genuine Honda tachometer: TACHO

At 2,000 rpm:±160 rpm (GRAY) VIEWED FROM THE
At 4,000 rpm:+200 rpm TERMINAL SIDE
–150 rpm
At 6,000 rpm:+200 rpm
–150 rpm Is there the continuity?
YES – Check for open in the remote control harness
and meter harness wires. If the harnesses are
2. Tachometer power line check
normal, substitute a known-good ECM and
-1. Turn the ignition switch OFF and disconnect the recheck.
Yellow/Black and the Black terminals of the tachome- NO – Repair open in the wire of the main harness.
ter.
-2. Turn the ignition switch ON and measure the voltage
between the meter harness side Yellow/Black and the
Black terminals.

Is there the battery voltage?

YES – Perform “3. Tachometer pulse line check”.
NO – Repair open in the wire of the meter harness.

3. Tachometer pulse line check

-1. Turn the ignition switch OFF and disconnect the ECM
connector B.
-2. Disconnect the remote control harness 14P connector.
-3. Check for the continuity between the No. 12 (Gray) ter-
minal of the main harness side 14P connector and the
engine ground.

MAIN HARNESS SIDE

14P CONNECTOR

GRAY

VIEWED FROM THE

TERMINAL SIDE

Is there the continuity?

YES – Repair short in the main harness.
NO – Go to the step 4.

5-27
BF135A•BF150A

• ECM Troubleshooting • MAP Sensor Troubleshooting

DTC 0-2, 0-5, 0-8: Inside of ECM is faulty DTC 3-1: MAP sensor voltage is low
1. Symptom reproduction test 1. Symptom reproduction test
-1. Connect the HDS pocket tester. -1. Connect the HDS pocket tester and clear the DTC
-2. Turn the ignition switch ON and wait for 1 second or once. If the DTC can not be cleared, go on the trou-
more. bleshooting.
-3. Clear the DTC once. -2. Turn the ignition switch ON.
-4. Start the engine and check the DTC again. -3. Check the MAP sensor voltage using the HDS pocket
tester.
Does the DTC 0-2, 0-5, and/or 0-8 appear?
YES – Substitute a known-good ECM and recheck. Is the measured voltage 0.22 to 3.15V?
NO – Temporary failure inside ECM (Disappeared) YES – Temporary failure (Disappeared)
NO – Perform “2. MAP sensor signal line short-cir-
cuit test”.

2. MAP sensor signal line short-circuit test

-1. Turn the ignition switch OFF and disconnect the MAP
sensor 3P connector.
-2. Disconnect the ECM connector A.
-3. Check for the continuity between the No. 2 (White/Red)
terminal of the MAP sensor harness side 3P connec-
tor and the body ground.

MAP SENSOR HARNESS

SIDE 3P CONNECTOR

PB (WHITE/RED)

VIEWED FROM THE

TERMINAL SIDE

Is there the continuity?

YES – Repair short in the wire between the MAP
sensor and ECM.
NO – Perform “3. MAP sensor check”.

3. MAP sensor check

-1. Connect the ECM connector A and the MAP sensor
3P connector.
-2. Turn the ignition switch ON and read the MAP sensor
voltage using the HDS pocket tester.

Is the voltage 2.76 – 2.96V?

YES – Substitute a known-good ECM and recheck.
NO – Replace the MAP sensor.

5-28
 BF135A•BF150A

DTC 3-2: MAP sensor voltage is high Is there the continuity?

1. Symptom reproduction test YES – Perform “4. MAP sensor ground line open cir-
-1. Connect the HDS pocket tester and clear the DTC cuit check”.
once. If the DTC can not be cleared, go on the trou- NO – Repair open in the wire between the MAP
bleshooting. sensor and the ECM.
-2. Turn the ignition switch ON.
-3. Check PB voltage using the HDS pocket tester. 4. MAP sensor ground line open circuit check
-1. Check for the continuity between the No. 1
Is the measured voltage 0.22 – 3.15V? (Green/Red) terminal of the MAP sensor harness side
YES – Temporary failure (Disappeared) 3P connector and the body ground.
NO – Perform “2. MAP sensor power line check”.
MAP SENSOR HARNESS
2. MAP sensor power line check SIDE 3P CONNECTOR
-1. Turn the ignition switch OFF and disconnect the MAP
sensor 3P connector.
SG1
-2. Turn the ignition switch ON. (GREEN/RED)
-3. Measure the voltage between the No. 3 (Brown/Yellow)
terminal and the No. 1 (Green/Red) terminal of the
MAP sensor harness side 3P connector.

VIEWED FROM THE

MAP SENSOR HARNESS
TERMINAL SIDE
SIDE 3P CONNECTOR

SG1 VCC1 Is there the continuity?

(GREEN/RED) (BROWN/YELLOW) YES – Perform “5. MAP sensor signal line open cir-
cuit check”.
NO – Repair open in the wire between the MAP
sensor and the ECM.
VIEWED FROM THE
TERMINAL SIDE
5. MAP sensor signal line open circuit check
Is the measured voltage 4.75 – 5.25V? -1. Connect the ECM connector A.
YES – Perform “5. MAP sensor signal line open cir- -2. Turn the ignition switch ON.
cuit check”. -3. Measure the voltage between the No. 2 (White/Red)
NO – Perform “3. MAP sensor power line open cir- terminal and the No. 1 (Green/Red) terminal of the
cuit check”. MAP sensor harness side 3P connector.

3. MAP sensor power line open circuit check MAP SENSOR HARNESS
SIDE 3P CONNECTOR
-1. Turn the ignition switch OFF and disconnect the ECM
connector B.
-2. Check for the continuity between the No. 3 SG1 PB
(Brown/Yellow) terminal of the MAP sensor harness (GREEN/RED) (WHITE/RED)
side 3P connector and the No. 4 (Brown/Yellow) termi-
nal of the ECM harness side connector B.

VIEWED FROM THE

ECM CONNECTOR B TERMINAL SIDE
MAP SENSOR
HARNESS SIDE
3P CONNECTOR
Is the measured voltage 4.75 – 5.25V?
YES – Perform “7. MAP sensor check”.
NO – Perform “6. MAP sensor signal line open cir-
cuit check”.

VIEWED FROM THE VCC1

TERMINAL SIDE (BROWN/YELLOW)

5-29
BF135A•BF150A

6. MAP sensor signal line open circuit check • CKP Sensor Troubleshooting
-1. Turn the ignition switch OFF and disconnect the ECM
connector B. DTC 4-1: No CKP pulse
-2. Check for the continuity between the No. 2 (White/Red) 1. Symptom reproduction test
terminal of the MAP sensor harness side 3P connec- -1. Connect the HDS pocket tester and clear the DTC
tor and the No. 5 (White/Red) terminal of the ECM con- once. If the DTC can not be cleared, go on the trou-
nector B. bleshooting.
-2. Start the engine and let it run at idling under no load.
ECM CONNECTOR B -3. Check the DTC using the HDS pocket tester.
MAP SENSOR
HARNESS SIDE
Does the DTC 4-1 appear?
3P CONNECTOR
YES – Perform “2. CKP sensor power line check”.
NO – Temporary failure (Disappeared)

2. CKP sensor power line check

-1. Turn the ignition switch OFF and disconnect the CKP
PB sensor 3P connector.
(WHITE/RED)
-2. Turn the ignition switch ON. Measure the voltage
VIEWED FROM THE between the No. 1 (Yellow/Black) terminal and the No.
TERMINAL SIDE
2 (Green/Red) terminal of the CKP sensor harness
side connector.
Is there the continuity?
YES – Perform “7. MAP sensor check”. CKP SENSOR HARNESS
NO – Repair open in the wire between the MAP SIDE 3P CONNECTOR
sensor and ECM. IGP LG1
(YELLOW/BLACK) (GREEN/RED)
7. MAP sensor check
-1. Connect the ECM connector B and the MAP sensor
3P connector.
-2. Turn the ignition switch ON and read the PB voltage
VIEWED FROM THE
using the HDS pocket tester. TERMINAL SIDE

Is the voltage 2.76 – 2.96V?

YES – Substitute a known-good ECM and recheck. Is there the battery voltage?
NO – Replace the MAP sensor. YES – Perform “4. CKP sensor signal line open cir-
cuit check”.
NO – Perform “3. CKP sensor power line open cir-
cuit check”.

5-30
 BF135A•BF150A

3. CKP sensor power line open circuit check 5. CKP sensor signal line short circuit check
-1. Turn the ignition switch ON and measure the voltage -1. Turn the ignition switch OFF. Check for continuity
between the No. 1 (Yellow/Black) terminal of the CKP between the No. 3 (Blue) terminal of the CKP sensor
sensor harness side 3P connector and the engine harness side 3P connector and the engine ground.
ground.
CKP SENSOR HARNESS
CKP SENSOR HARNESS SIDE 3P CONNECTOR
SIDE 3P CONNECTOR
IGP CRK (Bu)
(YELLOW/BLACK)

VIEWED FROM THE VIEWED FROM THE

TERMINAL SIDE TERMINAL SIDE

Is there the battery voltage? Is there the continuity?

YES – Repair open in the CKP sensor ground line. YES – Perform “6. CKP sensor ground line short cir-
NO – Repair open in the wire between the No. 4 cuit check”.
fuse and the CKP sensor. NO – Repair open in the wire between the CKP
sensor and the ECM.
4. CKP sensor signal line open circuit check
-1. Turn the ignition switch ON and measure the voltage 6. CKP sensor ground line open circuit check
between the No. 3 (Blue) terminal of the CKP sensor -1. Turn the ignition switch OFF. Check for continuity
harness side 3P connector and the engine ground. between the No. 2 (Green/Black) terminal of the CKP
sensor harness side 3P connector and the engine
CKP SENSOR HARNESS ground.
SIDE 3P CONNECTOR
CKP SENSOR HARNESS
SIDE 3P CONNECTOR
CRK (BLUE)

LG1 (GREEN/BLACK)

VIEWED FROM THE

TERMINAL SIDE
VIEWED FROM THE
TERMINAL SIDE
Is the measured voltage 4.75 – 5.25V?
YES – Perform “5. CKP sensor signal line short cir-
cuit check”. Is there the continuity?
NO – Repair open in the wire between the CKP YES – Perform “7. CKP sensor check”.
sensor and the ECM. NO – Repair open in the wire between the CKP
sensor and the ECM.

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BF135A•BF150A

7. CKP sensor check DTC 4-2: CKP pulse is abnormal

-1. Connect the HDS pocket tester and clear the DTC 1. Symptom reproduction test
once. -1. Connect the HDS pocket tester and clear the DTC
-2. Start the engine and let it run at idling under no load. once. If the DTC can not be cleared, go on the trou-
Check the DTC with the HDS pocket tester. bleshooting.
-2. Start the engine and let it run at idling under no load.
Does the DTC 4-1 appear? -3. Check the DTC with the HDS pocket tester.
YES – Replace the CKP sensor and recheck. If the
DTC 4-1 appears again, substitute a known- Does the DTC 4-2 appear?
good ECM and recheck. YES – Check the crank pulse plate for deformation
NO – End of the check and damage. Replace the crank pulse plate
with a new one if it is deformed or damaged,
and check again. If abnormal, replace the
CKP sensor and check. If the DTC 4-2 still
appears, replace the ECM.
NO – Temporary failure (Disappeared)

5-32
 BF135A•BF150A

• ECT Sensor 1 Troubleshooting DTC 6-2: ECT sensor 1 voltage is high

DTC 6-1: ECT sensor 1 voltage is low 1. Symptom reproduction test
-1. Connect the HDS pocket tester and clear the DTC
1. Symptom reproduction test
once. If the DTC can not be cleared, go on the trou-
-1. Connect the HDS pocket tester and clear the DTC bleshooting.
once. If the DTC can not be cleared, go on the trou- -2. Turn the ignition switch ON.
bleshooting. -3. Measure the ECT sensor 1 voltage using the HDS
-2. Turn the ignition switch ON. pocket tester.
-3. Check the ECT sensor 1 voltage using the HDS pock-
et tester. Is the measurement 0.23 – 3.15V?
YES – Temporary failure (Disappeared)
Is the measurement 0.23 – 3.15V? NO – Go to the step 2.
YES – Temporary failure (Disappeared)
NO – Perform “2. ECT sensor 1 line short circuit
check”. 2. ECT sensor 1 line check
-1. Turn the ignition switch OFF and disconnect the ECT
sensor 1 connector.
2. ECT sensor 1 line short circuit check
-2. Turn the ignition switch ON. Measure the voltage
-1. Turn the ignition switch OFF and disconnect the ECM between the No. 2 (Red/White) and the No. 1
connector B. (Green/Red) terminals of the ECT sensor 1 harness
-2. Check for the continuity between the No. 2 (Red/White) side 2P connector.
terminal of the ECT sensor 1 harness side 2P con-
nector and the body ground. ECT SENSOR 1 HARNESS
SIDE 2P CONNECTOR
ECT SENSOR 1 HARNESS SG2
SIDE 2P CONNECTOR (GREEN/RED) TE (RED/WHITE)

TE (RED/WHITE)

VIEWED FROM THE

TERMINAL SIDE

VIEWED FROM THE

TERMINAL SIDE
Is the measurement 4.30 – 5.25V?
YES – Perform “4. ECT sensor 1 check”.
NO – Perform “3. ECT sensor 1 signal line open cir-
cuit check”.
Is there the continuity?
YES – Repair short in the wire between the ECM
and the ECT sensor 1. 3. ECT sensor 1 line open circuit check
NO – Perform “3. ECT sensor 1 check”. -1. Turn the ignition switch ON. Measure the voltage
between the No. 2 (Red/White) terminal of the ECT
3. ECT sensor 1 check sensor 1 harness side 2P connector and the engine
-1. Turn the ignition switch OFF and connect the HDS ground.
pocket tester.
ECT SENSOR 1 HARNESS
-2. Turn the ignition switch ON. Check the engine coolant
SIDE 2P CONNECTOR
temperature with the HDS pocket tester.

Is the engine coolant temperature normal? TE (RED/WHIT)

YES – Substitute a known–good ECM and recheck.
NO – Replace the ECT sensor 1 and recheck.

VIEWED FROM THE

TERMINAL SIDE

5-33
BF135A•BF150A

Is the measurement 4.30 – 5.25V? • TP Sensor Troubleshooting

YES – Repair open in the sensor ground line.
NO – Repair open in the wire between the ECM DTC 7-1: TP sensor voltage is low
and the ECT sensor 1. 1. Symptom reproduction test
-1. Connect the HDS pocket tester and clear the DTC
4. ECT sensor 1 check once. If the DTC can not be cleared, go on the trou-
-1. Turn the ignition switch OFF and connect the HDS bleshooting.
pocket tester. -2. Turn the ignition switch ON.
-2. Turn the ignition switch ON and check the engine -3. Measure the TP sensor voltage using the HDS pocket
coolant temperature with the HDS pocket tester. tester.

Is the engine coolant temperature normal? Is the measurement 0.08 – 4.92V?

YES – Substitute a known-good ECM and recheck. YES – Temporary failure (Disappeared)
NO – Replace the ECT sensor 1 and recheck. NO – Perform “2. TP sensor signal line short circuit
check”.

2. TP sensor signal line short circuit check

-1. Turn the ignition switch OFF and disconnect the TP
sensor connector.
-2. Disconnect the ECM connector B.
-3. Check for continuity between the No. 2 (Red/Black) ter-
minal of the TP sensor harness side 3P connector and
the engine ground.

TP SENSOR HARNESS
SIDE 3P CONNECTOR

THL (RED/BLACK)

VIEWED FROM THE

TERMINAL SIDE

Is there the continuity?

YES – Repair short in the wire between the TP sen-
sor and the ECM.
NO – Perform “3. TP sensor check”.

3. TP sensor check
-1. Connect the ECM connector B and the TP sensor 3P
connector.
-2. Turn the ignition switch ON and measure the TP sen-
sor voltage using the HDS pocket tester.

Is the measurement voltage 4.49 – 4.85V at full

open throttle and 0.44 – 0.56V at full close throttle?
YES – Substitute a known-good ECM and recheck.
NO – Replace the TP sensor.

5-34
 BF135A•BF150A

DTC 7-2: TP sensor voltage is high 3. TP sensor power line open circuit check
1. Symptom reproduction test -1. Turn the ignition switch ON. Measure the voltage
-1. Connect the HDS pocket tester and clear the DTC between the No. 3 (Brown/White) terminal of the TP
once. If the DTC can not be cleared, go on the trou- sensor harness side 3P connector and the engine
bleshooting. ground.
-2. Turn the ignition switch ON.
-3. Measure the TP sensor voltage with the HDS pocket TP SENSOR HARNESS
SIDE 3P CONNECTOR
tester.

Is the measurement 0.08 – 4.92V? VCC2

YES – Temporary failure (Disappeared) (BROWN/WHITE)
NO – Perform “2. TP sensor power line check”.

2. TP sensor power line check

-1. Turn the ignition switch OFF and disconnect the TP
VIEWED FROM THE
sensor 3P connector. TERMINAL SIDE
-2. Turn the ignition switch ON. Measure the voltage
between the No. 3 (Brown/White) and the No. 1
(Green/Red) terminals of the TP sensor harness side Is the measurement 4.75 – 5.25V?
3P connector. YES – Repair open in the wire between the TP sen-
sor and the engine ground.
TP SENSOR HARNESS
NO – Repair open in the wire between the TP sen-
SIDE 3P CONNECTOR sor and the ECM.

4. TP sensor signal line open circuit check

SG2 VCC2
(GREEN/RED) (BROWN/WHITE) -1. Turn the ignition switch ON. Measure the voltage
between the No. 2 (Red/Black) terminal of the TP sen-
sor harness side 3P connector and the engine ground.
VIEWED FROM THE
TERMINAL SIDE TP SENSOR HARNESS
SIDE 3P CONNECTOR

Is the measurement 4.75 – 5.25V?

YES – Perform “4. TP sensor signal line open circuit TH (RED/BLACK)
check”.
NO – Perform “3. TP sensor power line open circuit
check”.
VIEWED FROM THE
TERMINAL SIDE

Is the measurement 4.75 – 5.25V?

YES – Perform “5. TP sensor check”.
NO – Repair open in the TP sensor and the ECM.

5-35
BF135A•BF150A

5. TP sensor check • CMP Sensor Troubleshooting

-1. Turn the ignition switch OFF and connect the TP sen-
sor 3P connector. DTC 8-1: No CMP sensor pulse
-2. Measure the TP sensor voltage using the HDS pocket 1. Symptom reproduction test
tester. -1. Connect the HDS pocket tester and clear the DTC
once. If the DTC can not be cleared, go on the trou-
Is the measurement voltage 4.49 – 4.85V at full bleshooting.
open throttle and 0.44 – 0.56V at full close throttle? -2. Start the engine and let it run at idling under no load.
YES – Substitute a known-good ECM and recheck. -3. Check the DTC using the HDS pocket tester.
NO – Replace the TP sensor.
Does the DTC 8-1 appear?
YES – Check the pulse plate. If it is normal, perform
“2. CMP sensor power line check”. If it is
abnormal, replace the pulse plate and
recheck.
NO – Temporary failure (Disappeared)

2. CMP sensor power line check

-1. Turn the ignition switch OFF and disconnect the CMP
sensor 3P connector.
-2. Turn the ignition switch ON. Measure the voltage
between the No. 1 (Yellow/Black) terminal and the No.
2 (Green/Red) terminal of the CMP sensor harness
side 3P connector.

CMP SENSOR HARNESS

SIDE 3P CONNECTOR

IGP
(YELLOW/BLACK)
LG1 (GREEN/RED)

VIEWED FROM THE

TERMINAL SIDE

Is there the battery voltage?

YES – Perform “4. CMP sensor signal line open cir-
cuit check”.
NO – Perform “3. CMP sensor power line open cir-
cuit check”.

5-36
 BF135A•BF150A

3. CMP sensor power line open circuit check DTC 8-2: CMP sensor pulse is abnormal
-1. Turn the ignition switch ON. Measure the voltage 1. Symptom reproduction test
between the No. 1 (Yellow/Black) terminal of the CMP -1. Connect the HDS pocket tester and clear the DTC
sensor harness side 3P connector and the engine once. If the DTC can not be cleared, go on the trou-
ground. bleshooting.
CMP SENSOR HARNESS -2. Start the engine and let it run at idling under no load.
SIDE 3P CONNECTOR -3. Check the DTC using the HDS pocket tester.
IGP
(YELLOW/BLACK) Does the DTC 8-2 appear?
YES – Replace the CMP sensor and recheck. If the
DTC 8-2 appears again, substitute a known-
good ECM and recheck.
NO – Temporary failure (Disappeared)
VIEWED FROM THE
TERMINAL SIDE

Is there the battery voltage?

YES – Repair open in the CMP sensor ground line.
NO – Repair open in the wire between the No. 4
fuse and the CMP sensor.

4. CMP sensor signal line open circuit check

-1. Turn the ignition switch ON. Measure the voltage
between the No. 3 (Green) terminal of the CMP sensor
harness side 3P connector and the engine ground.

CMP SENSOR HARNESS

SIDE 3P CONNECTOR

TDC (GREEN)

VIEWED FROM THE

TERMINAL SIDE

Is the measurement voltage 4.75 – 5.25V?

YES – Perform “5. CMP sensor check”.
NO – Repair open in the wire between the CMP
sensor and the ECM.

5. CMP sensor check

-1. Connect the HDS pocket tester and clear the DTC
once.
-2. Start the engine and let it run at idling under no load.
Check the DTC using the HDS pocket tester.

Does the DTC 8-1 appear?

YES – Replace the CMP sensor and recheck. If the
DTC 8-1 appears again, substitute a known-
good ECM and recheck.
NO – End of the check

5-37
BF135A•BF150A

• IAT Sensor Troubleshooting DTC 10-2: IAT sensor voltage is high

DTC 10-1: IAT sensor voltage is low 1. Symptom reproduction test
-1. Connect the HDS pocket tester and clear the DTC
1. Symptom reproduction test
once. If the DTC can not be cleared, go on the trou-
-1. Connect the HDS pocket tester and clear the DTC bleshooting.
once. If the DTC can not be cleared, go on the trou- -2. Turn the ignition switch ON.
bleshooting. -3. Measure the IAT sensor (TA) voltage using the HDS
-2. Turn the ignition switch ON. pocket tester.
-3. Measure the IAT sensor (TA) voltage using the HDS
pocket tester. Is the measured voltage 0.08 – 4.92V?
YES – Temporary failure (Disappeared)
Is the measurement voltage 0.08 – 4.92V? NO – Perform “2. IAT sensor signal line open circuit
YES – Temporary failure (Disappeared) check”.
NO – Perform “2. IAT sensor line short circuit
check”. 2. IAT sensor signal line open circuit check
-1. Turn the ignition switch OFF and disconnect the IAT
2. IAT sensor line short circuit check
sensor 2P connector.
-1. Turn the ignition switch OFF and disconnect the ECM -2. Turn the ignition switch ON. Measure the voltage
connector B. between the No. 2 (Red/Yellow) terminal of the IAT
-2. Check for the continuity between the No. 2 sensor harness side 2P connector and the engine
(Red/Yellow) terminal of the IAT sensor harness side ground.
2P connector and the body ground.
IAT SENSOR HARNESS
SIDE 2P CONNECTOR
IAT SENSOR HARNESS
SIDE 2P CONNECTOR TA (RED/YELLOW)

TA (RED/YELLOW)

VIEWED FROM THE

TERMINAL SIDE
VIEWED FROM THE
TERMINAL SIDE
Is the measured voltage 4.75 – 5.25V?
YES – Perform “3. IAT sensor ground line open cir-
Is there the continuity? cuit check”.
YES – Repair short in the wire between the ECM NO – Repair open in the wire between the IAT sen-
and the IAT sensor. sor and the ECM.
NO – Perform “3. IAT sensor check”.
3. IAT sensor ground line open circuit check
3. IAT sensor check
-1. Turn the ignition switch OFF.
-1. Turn the ignition switch OFF and connect the HDS -2. Check for the continuity between the No. 1
pocket tester. (Green/Red) terminal of the IAT sensor harness side
-2. Turn the ignition switch ON and check the intake air 2P connector and the body ground.
temperature using the HDS pocket tester.
IAT SENSOR HARNESS
Does the measurement correspond to the ambient SIDE 2P CONNECTOR
temperature?
YES – Substitute a known-good ECM and recheck.
NO – Replace the IAT sensor with a new one and SG2 (GREEN/RED)
recheck.

VIEWED FROM THE

TERMINAL SIDE

5-38
 BF135A•BF150A

Is there the continuity? • BARO Sensor Troubleshooting

YES – Perform “4. IAT sensor check”.
NO – Repair open in the wire between the IAT sen- DTC 13-1: BARO sensor voltage is low
sor and the engine ground. 1. Symptom reproduction test
-1. Connect the HDS pocket tester and clear the DTC
4. IAT sensor check once. If the DTC can not be cleared, go on the trou-
-1. Turn the ignition switch OFF and connect the HDS bleshooting.
pocket tester. -2. Turn the ignition switch ON.
-2. Turn the ignition switch ON and check the intake air -3. Measure the BARO sensor (PA) voltage using the
temperature using the HDS pocket tester. HDS pocket tester.

Does the measurement correspond to the ambient Is the measurement voltage 1.58 – 4.49V?
temperature? YES – Temporary failure (Disappeared)
YES – Substitute a known–good ECM and recheck. NO – Perform “2. BARO sensor signal line short cir-
NO – Substitute a known–good IAT sensor and cuit check”.
recheck.
2. BARO sensor signal line short circuit check
-1. Turn the ignition switch OFF and disconnect the ECM
connector B.
-2. Check for the continuity between the No. 2
(White/Blue) terminal of the BARO sensor harness
side 3P connector and the body ground.

BARO SENSOR HARNESS

SIDE 3P CONNECTOR

PA (WHITE/BLUE)

VIEWED FROM THE

TERMINAL SIDE

Is there the continuity?

YES – Repair short in the wire between the ECM
and the BARO sensor.
NO – Perform “3. BARO sensor check”.

3. BARO sensor check

-1. Turn the ignition switch OFF and connect the BARO
sensor connector and the ECM connector B.
-2. Turn the ignition switch ON. Measure the BARO sen-
sor voltage using the HDS pocket tester.

Is the measurement voltage 2.76 – 2.96V?

YES – Substitute a known-good ECM and recheck.
NO – Replace the BARO sensor and recheck.

5-39
BF135A•BF150A

DTC 13-2: BARO sensor voltage is high Is the measured voltage 4.75 – 5.25V?
1. Symptom reproduction test YES – Repair open in the wire between the BARO
-1. Connect the HDS pocket tester and clear the DTC sensor and the engine ground.
once. If the DTC can not be cleared, go on the trou- NO – Repair open in the wire between the BARO
bleshooting. sensor and the ECM.
-2. Turn the ignition switch ON.
-3. Measure the BARO sensor (PA) voltage using the 4. BARO sensor signal line open circuit check
HDS pocket tester. -1. Turn the ignition switch ON. Measure the voltage
between the No. 2 (White/Blue) terminal of the BARO
Is the measurement voltage 1.58 – 4.49V? sensor harness side 3P connector and the engine
YES – Temporary failure (Disappeared) ground.
NO – Perform “2. BARO sensor power line check”.
BARO SENSOR HARNESS
2. BARO sensor power line check SIDE 3P CONNECTOR
-1. Turn the ignition switch OFF and disconnect the BARO
sensor 3P connector. PA (WHITE/BLUE)
-2. Turn the ignition switch ON. Measure the voltage
between the No. 3 (Brown/White) and the No. 1
(Green/Red) terminals of the BARO sensor harness
side 3P connector.
VIEWED FROM THE
BARO SENSOR HARNESS TERMINAL SIDE
SIDE 3P CONNECTOR

SG2 VCC2 Is the measured voltage 4.75 – 5.25V?

(GREEN/RED) (BROWN/WHITE)
YES – Perform “5. BARO sensor check”.
NO – Repair open in the wire between the BARO
sensor and the ECM.
VIEWED FROM THE 5. BARO sensor check
TERMINAL SIDE
-1. Turn the ignition switch OFF and connect the BARO
sensor connector.
Is the measurement voltage 4.75 – 5.25V? -2. Turn the ignition switch ON and measure the BARO
YES – Perform “4. BARO sensor signal line open cir- sensor voltage using the HDS pocket tester.
cuit check”.
NO – Perform “3. BARO sensor power line open cir- Is the measured voltage 2.76 – 2.96V?
cuit check”. YES – Substitute a known-good ECM and recheck.
NO – Replace the BARO sensor and recheck.
3. BARO sensor power line open circuit check
-1. Turn the ignition switch ON. Measure the voltage
between the No. 3 (Brown/White) terminal of the
BARO sensor harness side 3P connector and the
engine ground.
BARO SENSOR HARNESS
SIDE 3P CONNECTOR

VCC2 (BROWN/WHITE)

VIEWED FROM THE

TERMINAL SIDE

5-40
 BF135A•BF150A

• IAC Valve Troubleshooting -2. Check for the continuity between the IAC valve No. 2
terminal and the body ground.
DTC 14-1: IAC valve current is abnormal
IAC VALVE SIDE 2P
1. Symptom reproduction test CONNECTOR
-1. Connect the HDS pocket tester and clear the DTC
once. If the DTC can not be cleared, go on the trou-
bleshooting.
-2. Start the engine and let it run at idling under no load.
-3. Measure the engine speed using the HDS pocket
tester.

Is the engine speed 650 min-1 (rpm) or above? VIEWED FROM THE
YES – Temporary failure (Disappeared) TERMINAL SIDE
NO – Perform “2. IAC valve open circuit check”.
Is there the continuity?
2. IAC valve open circuit check YES – Replace the IAC valve.
-1. Turn the ignition switch OFF and disconnect the IAC NO – Perform “4. IAC valve line open circuit check”.
valve 2P connector.
-2. Measure the resistance between the No. 1 and No. 2 4. IAC valve line open circuit check
terminals of the IAC valve.
-1. Connect the IAC valve 2P connector.
-2. Disconnect the ECM connector B.
IAC VALVE SIDE 2P
CONNECTOR -3. Measure the resistance between the No. 26
(Green/White) and the No. 34 (Black) terminals of the
ECM connector B.

ECM CONNECTOR B

VIEWED FROM THE EACVM EACVP

TERMINAL SIDE (BLACK) (GREEN/WHITE)

Is the measured resistance 8 – 12 ?

YES – Perform “3. IAC valve short circuit check”.
NO – Replace the IAC valve.
VIEWED FROM THE
3. IAC valve short circuit check TERMINAL SIDE
-1. Check for the continuity between the IAC valve No. 1
terminal and the body ground.
Is the measured resistance 10 – 13 ?
IAC VALVE SIDE 2P YES – Perform “5. IAC valve line short circuit check”.
CONNECTOR NO – Repair open in the wire between the ECM
and the IAC valve.

VIEWED FROM THE

TERMINAL SIDE

Is there the continuity?

YES – Replace the IAC valve.
NO – Go to the step 2.

5-41
BF135A•BF150A

5. IAC valve line short circuit check • VTEC Solenoid Valve Troubleshooting
-1. Check for the continuity between the No. 26
(Green/White) terminal of the ECM connector B and DTC 21-1: VTEC solenoid valve output is abnormal
the engine ground, and between the No. 34 (Black) ter- 1. Symptom reproduction test
minal of the ECM connector B and the engine ground. -1. Connect the HDS pocket tester and clear the DTC
once. If the DTC can not be cleared, go on the trou-
ECM CONNECTOR B bleshooting.
-2. Start the engine and warm it up for 5 minutes by run-
EACVP
EACVM ning the engine at 3,000 min-1 (rpm) under no load.
(GREEN/WHITE)
(BLACK) -3. Disconnect the neutral switch 2P connector.
-4. Increase the engine speed gradually and run the
engine at 4,500 min-1 (rpm) for a few seconds.
-5. Check the DTC again using the HDS pocket tester.

Does the DTC 21-1 appear?

YES – Perform “2. Spool solenoid valve check”.
VIEWED FROM THE
TERMINAL SIDE
NO – Temporary failure (Disappeared)
Is there the continuity? 2. Spool solenoid valve check
YES – Repair short in the wire between the ECM
and the IAC valve. -1. Turn the ignition switch OFF and disconnect the spool
NO – Substitute a known-good ECM and recheck. solenoid valve connector.
-2. Measure the resistance between the spool solenoid
valve side 1P connector (Green/White) terminal and
the body ground.

SOLENOID VALVE SIDE

1P CONNECTOR

VIEWED FROM THE

TERMINAL SIDE

Is the measured resistance 12 – 18 ?

YES – Perform “3. VTEC signal line short circuit
check”.
NO – Replace the spool solenoid valve.

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 BF135A•BF150A

3. VTEC signal line short circuit check • Knock Sensor Troubleshooting

-1. Disconnect the ECM connector A.
-2. Check for the continuity between the No. 20 DTC 23-1: Knock sensor detects failure
(Green/Yellow) terminal of the ECM connector A and 1. Symptom reproduction test
the body ground. -1. Connect the HDS pocket tester and clear the DTC
once. If the DTC can not be cleared, go on the trou-
ECM CONNECTOR A bleshooting.
VTS (GREEN/YELLOW)
-2. Start the engine and warm it up for 5 minutes or more
by running the engine at 5,000 min-1 (rpm) or more
under no load.
-3. Check the DTC again with the HDS pocket tester.

Does the DTC 23-1 appear?

YES – Perform “2. Knock sensor signal line open cir-
cuit check”.
NO – Temporary failure (Disappeared)
VIEWED FROM THE
TERMINAL SIDE 2. Knock sensor signal line open circuit check
Is there the continuity? -1. Turn the ignition switch OFF. Disconnect the knock
YES – Repair short in the wire between the ECM sensor connector and the ECM connector A.
and the spool solenoid valve. -2. Check for the continuity between the (Red/Blue) termi-
NO – Perform “4. VTEC signal line open circuit nal of the knock sensor harness side connector and
check”. the No. 15 (Red/Blue) terminal of the ECM connector
A.
4. VTEC signal line open circuit check
-1. Check for the continuity between the spool solenoid
KNOCK SENSOR
valve harness side connector terminal and the No. 20
ECM CONNECTOR A HARNESS SIDE 1P
(Green/Yellow) terminal of the ECM connector A. CONNECTOR

SPOOL SOLENOID
VALVE HARNESS
SIDE CONNECTOR KS
(RED/BLUE)
ECM CONNECTOR A

VTS (GREEN/YELLOW) VIEWED FROM THE

TERMINAL SIDE

Is there the continuity?

VIEWED FROM THE YES – Perform “3. Knock sensor signal line short cir-
TERMINAL SIDE cuit check”.
NO – Repair open in the wire between the knock
sensor and the ECM.
Is there the continuity?
YES – Substitute a known-good ECM and recheck.
NO – Repair open in the wire between the ECM
and the spool solenoid valve.

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3. Knock sensor signal line short circuit test • A/F Heater Troubleshooting
-1. Check for the continuity between the No. 15 (Red/Blue)
terminal of the ECM connector A and the body ground. DTC 41-3: A/F heater is abnormal
1. Symptom reproduction test
-1. Connect the HDS pocket tester and clear the DTC
ECM CONNECTOR A once. If the DTC can not be cleared, go on the trou-
bleshooting.
KS (RED/BLUE) -2. Start the engine and warm it up 5 minutes or more by
running the engine at 3,000 min-1 (rpm) under no load.
-3. Check the DTC again using the HDS pocket tester.

Does the DTC 41-3 appear?

YES – Perform “2. A/F heater relay check”.
VIEWED FROM THE NO – Temporary failure (Disappeared)
TERMINAL SIDE
2. A/F heater relay check
Is there the continuity?
YES – Repair short in the wire between the ECM -1. Turn the ignition switch OFF and disconnect the A/F
and the spool solenoid valve. sensor 4P connector.
NO – Substitute a known-good ECM and recheck. -2. Turn the ignition switch ON. Measure the voltage
between the No. 3 (White) terminal of the A/F sensor
harness side 4P connector and the engine ground.

A/F SENSOR HARNESS

SIDE 4P CONNECTOR

AFHT+ (WHITE)

VIEWED FROM THE TERMINAL SIDE

Is there the battery voltage?
YES – Perform “3. A/F sensor heater check”.
NO – Go to the step 3.

-3. Turn the ignition switch OFF and disconnect the A/F
heater relay 4P connector.
-4. Measure the voltage between the No. 1 (White/ Green)
terminal of the A/F heater relay harness side 4P con-
nector and the engine ground.
• Note that the battery voltage is constantly applied to
the White/Green terminal. Take care not to short-cir-
cuit the terminal.

A/F HEATER RELAY HARNESS

SIDE 4P CONNECTOR

+B (WHITE/GREEN)

VIEWED FROM THE

TERMINAL SIDE

5-44
 BF135A•BF150A

Is there the battery voltage? -9. Check for the continuity between the No. 3 (White) ter-
YES – Go to the step 5. minal of the A/F heater relay harness side 4P connec-
NO – Blown No. 1 fuse, or repair open in the wire tor and the No. 3 (White) terminal of the A/F sensor
between the A/F heater relay and the No. 1 harness side 4P connector.
fuse.

A/F SENSOR HARNESS A/F HEATER RELAY

-5. Turn the ignition switch ON. Measure the voltage HARNESS SIDE
between the No. 3 (White) terminal of the A/F heater SIDE 4P CONNECTOR
4P CONNECTOR
relay harness side 4P connector and the engine
ground.

A/F HEATER RELAY HARNESS AFHT+ (WHITE) AFHT+ (WHITE)

SIDE 4P CONNECTOR

VIEWED FROM THE

TERMINAL SIDE
AFHT+ (WHITE)

Is there the continuity?

YES – Perform “3. A/F sensor heater check”.
VIEWED FROM THE NO – Repair open in the wire between the A/F
TERMINAL SIDE heater relay and the A/F sensor.

3. A/F sensor heater check

Is there the battery voltage? -1. Turn the ignition switch OFF and disconnect the A/F
YES – Go to the step 6. sensor 4P connector.
NO – Repair open in the wire between the A/F -2. Measure the resistance between the No. 3 (Black) and
heater relay and the No. 5 fuse. the No. 4 (Black) terminals of the A/F sensor side 4P
connector.
-6. Check the A/F heater relay (P. 18-20).

Is the A/F heater relay normal? A/F SENSOR SIDE 4P

CONNECTOR
YES – Go to the step 7.
NO – Replace the A/F heater relay.

-7. Turn the ignition switch OFF and disconnect the ECM AFHT (BLACK) AFHT+ (BLACK)
connector A.
-8. Check for the continuity between the No. 4 (Green/
Orange) terminal of the A/F heater relay harness side VIEWED FROM THE
4P connector and the No. 25 (Green/Orange) terminal TERMINAL SIDE
of the ECM connector A.

A/F HEATER RELAY ECM CONNECTOR A

HARNESS SIDE
Is the resistance 2 – 3 (at room temperature)?
4P CONNECTOR
YES – Perform “4. Heater line short circuit check”.
NO – Replace the A/F sensor.

AFHT-
(GREEN/ORANGE)
VIEWED FROM THE
TERMINAL SIDE

Is there the continuity?

YES – Go to the step 9.
NO – Repair open in the wire between the A/F
heater relay and the ECM.

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BF135A•BF150A

4. Heater line short circuit check DTC 41-4: A/F sensor heater is abnormal
-1. Turn the ignition switch OFF and disconnect the ECM 1. Symptom reproduction test
connector C. -1. Connect the HDS pocket tester and clear the DTC
-2. Check for the continuity between the No. 3 once. If the DTC can not be cleared, go on the trou-
(Black/White) terminal of the ECM connector C and bleshooting.
the engine ground, and between the No. 4 (White) ter- -2. Start the engine and warm it up for 5 minutes or more
minal of the ECM connector C and the engine ground. by running the engine at 3,000 min-1 (rpm) under no
load.
ECM CONNECTOR C -3. Check the DTC again using the HDS pocket tester.

AFHT AFHT+ (WHITE) Does the DTC 41-4 appear?

(BLACK/WHITE) YES – Perform “2. A/F heater relay check”.
NO – Temporary failure (Disappeared)

2. A/F heater relay check

VIEWED FROM THE -1. Turn the ignition switch OFF and disconnect the A/F
TERMINAL SIDE sensor 4P connector.
-2. Turn the ignition switch ON. Measure the voltage
Is there the continuity? between the No. 3 (White) terminal of the A/F sensor
YES – Repair short in the wire between the A/F sen- harness side 4P connector and the engine ground.
sor and the ECM.
NO – Perform “5. Heater line open circuit check”. A/F SENSOR HARNESS
SIDE 4P CONNECTOR
5. Heater line open circuit check
-1. Turn the ignition switch OFF and connect the A/F sen-
AFHT+
sor 4P connector.
(WHITE)
-2. Measure the resistance between the No. 3
(Black/White) and the No. 4 (White) terminals of the
ECM connector C.
VIEWED FROM THE
TERMINAL SIDE
ECM CONNECTOR C

Is there the battery voltage?

AFHT+ (WHITE)
YES – Perform “3. A/F heater harness check”.
AFHT NO – Go to the step 3.
(BLACK/WHITE)
-3. Turn the ignition switch OFF and disconnect the A/F
VIEWED FROM THE heater relay 4P connector.
TERMINAL SIDE -4. Measure the voltage between the No. 1 (White/ Green)
terminal of the A/F heater relay harness side 4P con-
Is the resistance 2 – 3 (at room temperature)? nector and the engine ground.
YES – Replace the A/F sensor and recheck. If it is • Note that the battery voltage is constantly applied
still abnormal, substitute a known-good ECM to the White/Green terminal. Take care not to
and recheck. short-circuit the terminal.
NO – Repair open in the wire between the A/F sen-
A/F HEATER RELAY HARNESS
sor and the ECM. SIDE 4P CONNECTOR

+B (WHITE/GREEN)

VIEWED FROM THE

TERMINAL SIDE

5-46
 BF135A•BF150A

Is there the battery voltage? -9. Check for the continuity between the No. 3 (White) ter-
YES – Go to the step 5. minal of the A/F heater relay harness side 4P connec-
NO – Blown No. 1 fuse, or repair open in the wire tor and the No. 3 (White) terminal of the A/F sensor
between the A/F heater relay and the No. 1 harness side 4P connector.
fuse.
A/F SENSOR A/F HEATER RELAY
-5. Turn the ignition switch ON. Measure the voltage HARNESS SIDE HARNESS SIDE
between the No. 3 (White) terminal of the A/F heater 4P CONNECTOR 4P CONNECTOR
relay harness side 4P connector and the engine
ground.

A/F HEATER RELAY HARNESS AFHT+ AFHT+

SIDE 4P CONNECTOR (WHITE) (WHITE)
VIEWED FROM THE
AFHT+ (WHITE) TERMINAL SIDE

Is there the continuity?

YES – Perform “3. A/F heater check”.
VIEWED FROM THE NO – Repair open in the wire between the A/F
TERMINAL SIDE heater relay and the A/F sensor.

3. A/F heater check

Is there the battery voltage? -1. Turn the ignition switch OFF and disconnect the A/F
YES – Go to the step 6. sensor 4P connector.
NO – Repair open in the wire between the A/F -2. Measure the resistance between the No. 3 (Black) and
heater relay and the No. 5 fuse. the No. 4 (Black) terminals of the A/F sensor side 4P
connector.
-6. Check the A/F heater relay (single unit check) (P. 18-
24).
A/F SENSOR SIDE
4P CONNECTOR
Is the A/F heater relay normal?
YES – Go to the step 7.
NO – Replace the A/F heater relay.
AFHT (BLACK) AFHT+ (BLACK)
-7. Turn the ignition switch OFF and disconnect the ECM
connector A.
-8. Check for continuity between the No. 4 (Green/ VIEWED FROM THE
Orange) terminal of the A/F heater relay harness side TERMINAL SIDE
4P connector and the No. 25 (Green/Orange) terminal
of the ECM connector A.
Is the measured resistance 2 – 3 (at room tem-
A/F HEATER RELAY perature)?
HARNESS SIDE ECM CONNECTOR A
YES – Perform “4. Heater line short circuit check”.
4P CONNECTOR
NO – Replace the A/F sensor.

AFHT-
(GREEN/ORANGE)
VIEWED FROM THE
TERMINAL SIDE

Is there the continuity?

YES – Go to the step 9.
NO – Repair open in the wire between the A/F
heater relay and the ECM.

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BF135A•BF150A

4. Heater line short circuit check -3. Check for the continuity between the No. 3 (Black/
-1. Turn the ignition switch OFF and disconnect the ECM White) terminal of the ECM connector C and the
connector C. respective terminals of the No. 1 (White/Black) and the
-2. Check for the continuity between the No. 3 No. 2 (Black/Yellow) terminals of the A/F sensor har-
(Black/White) terminal of the ECM connector C and ness side 4P connector.
the engine ground, and between the No. 4 (White) ter-
minal of the ECM connector C and the engine ground. A/F SENSOR
HARNESS SIDE
ECM CONNECTOR C
4P CONNECTOR
ECM CONNECTOR C AFV1
AFHT+ (WHITE/
AFHT (WHITE) BLACK)
AFC1
(BLACK/WHITE) (BLACK/ AFHT
YELLOW) (BLACK/ WHITE)
VIEWED FROM THE
TERMINAL SIDE
VIEWED FROM THE
TERMINAL SIDE Is there the continuity?
Is there the continuity? YES – Repair short in the wire between the A/F sen-
sor and the ECM.
YES – Repair short in the wire between the A/F sen- NO – Go to the step 4.
sor and the ECM.
NO – Perform “5. Heater line open circuit check”. -4. Check for continuity between the No. 4 (White) termi-
nal of the ECM connector C and the respective termi-
5. Heater line open circuit check nals of the No. 1 (White/Black) and the No. 2
-1. Turn the ignition switch OFF and connect the A/F sen- (Black/Yellow) terminals of the A/F sensor harness
sor 4P connector. side 4P connector.
-2. Measure the resistance between the No. 3 (Black/
White) terminal and the No. 4 (White) terminal of the
ECM connector C. A/F SENSOR
ECM CONNECTOR C HARNESS SIDE
AFHT+ 4P CONNECTOR
ECM CONNECTOR C (WHITE)
AFC1
AFV1 (BLACK/
(WHITE/ YELLOW)
BLACK)
AFHT+ (WHITE)
AFHT
(BLACK/WHITE) VIEWED FROM THE
TERMINAL SIDE
VIEWED FROM THE
TERMINAL SIDE
Is there the continuity?
YES – Repair short in the wire between the A/F sen-
Is the resistance 2 – 3 (at room temperature)? sor and the ECM.
YES – Perform “6. Sensor line short circuit check”. NO – Replace the A/F sensor and recheck. If it is
NO – Repair open in the wire between the A/F sen- still abnormal, substitute a known-good ECM
sor and the ECM. and recheck.

6. Sensor line short circuit check

-1. Disconnect the ECM connector B.
-2. Disconnect the A/F sensor 4P connector.

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 BF135A•BF150A

• A/F Sensor Troubleshooting -3. Check for the continuity between the No. 2
(Black/Yellow) terminal of the A/F sensor harness side
DTC 48-5: A/F sensor current is abnormal 4P connector and the No. 14 (Black/Yellow) terminal of
1. Symptom reproduction test the ECM connector A.
-1. Connect the HDS pocket tester and clear the DTC
ECM CONNECTOR A A/F SENSOR
once. If the DTC can not be cleared, go on the trou- HARNESS SIDE
bleshooting. 4P CONNECTOR
-2. Start the engine and warm it up for 5 minutes or more
by running the engine at 3,000 min-1 (rpm) under no AFC1
load. (BLACK/
-3. Check the DTC again using the HDS pocket tester. YELLOW)

Does the DTC 48-5 appear?

YES – Perform “2. A/F sensor line open circuit VIEWED FROM THE
check”. TERMINAL SIDE
NO – Temporary failure (Disappears)

2. A/F sensor line open circuit check Is there the continuity?

-1. Turn the ignition switch OFF. Disconnect the A/F sen- YES – Replace the A/F sensor and recheck. If there
sor connector and the ECM connector A. is abnormality, substitute a known-good ECM
-2. Check for the continuity between the No. 1 and recheck.
(White/Black) terminal of the A/F sensor harness side NO – Repair open in the wire between the A/F sen-
4P connector and the No. 4 (White/Black) terminal of sor and the ECM.
the ECM connector A.

ECM CONNECTOR A A/F SENSOR

HARNESS SIDE
4P CONNECTOR

AFV1
(WHITE/BLACK)
VIEWED FROM THE
TERMINAL SIDE

Is there the continuity?

YES – Go to the step 3.
NO – Repair open in the wire between the A/F sen-
sor and the ECM.

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BF135A•BF150A

DTC 48-6: A/F sensor V current is abnormal DTC 48-7: A/F sensor C current is abnormal
1. Symptom reproduction test 1. Symptom reproduction test
-1. Connect the HDS pocket tester and clear the DTC -1. Connect the HDS pocket tester and clear the DTC
once. If the DTC can not be cleared, go on the trou- once. If the DTC can not be cleared, go on the trou-
bleshooting. bleshooting.
-2. Start the engine and warm it up 5 minutes or more by -2. Start the engine and warm it up for 5 minutes or more
running the engine at 3,000 min-1 (rpm) under no load. by running the engine at 3,000 min-1 (rpm) under no
-3. Check the DTC again using the HDS pocket tester. load.
-3. Check the DTC again using the HDS pocket tester.
Does the DTC 48-6 appear?
YES – Perform “2. A/F sensor line short circuit Does the DTC 48-7 appear?
check”. YES – Perform “2. A/F sensor line short circuit
NO – Temporary failure (Disappeared) check”.
NO – Temporary failure (Disappeared)
2. A/F sensor line (V line) short circuit check
-1. Turn the ignition switch OFF. Disconnect the A/F sen- 2. A/F sensor line (C line) short circuit check
sor connector and the ECM connector A. -1. Turn the ignition switch OFF. Disconnect the A/F sen-
-2. Check for the continuity between the No. 1 sor connector and the ECM connector A.
(White/Black) terminal of the A/F sensor harness side -2. Check for the continuity between the No. 2
4P connector and the engine ground. (Black/Yellow) terminal of the A/F sensor harness
side 4P connector and the engine ground.
A/F SENSOR HARNESS A/F SENSOR HARNESS SIDE
SIDE 4P CONNECTOR 4P CONNECTOR

AFV1 AFC1
(WHITE/BLACK) (BLACK/YELLOW)

VIEWED FROM THE

VIEWED FROM THE TERMINAL SIDE
TERMINAL SIDE
Is there the continuity?
YES – Repair short in the wire between the A/F sen- Is there the continuity?
sor and the ECM.
YES – Repair short in the wire between the A/F sen-
NO – Replace the A/F sensor and recheck. If there
sor and the ECM.
is any abnormality, substitute a known-good
NO – Replace the A/F sensor and recheck. If it is
ECM and recheck.
abnormal, substitute a known-good ECM and
recheck.

5-50
 BF135A•BF150A

• ECT Sensor 2 Troubleshooting DTC 140-2: ECT sensor 2 voltage is high

DTC 140-1: ECT sensor 2 voltage is low 1. Symptom reproduction test
-1. Connect the HDS pocket tester and clear the DTC
1. Symptom reproduction test
once. If the DTC can not be cleared, go on the trou-
-1. Connect the HDS pocket tester and clear the DTC bleshooting.
once. If the DTC can not be cleared, go on the trou- -2. Turn the ignition switch ON.
bleshooting. -3. Measure the ECT sensor 2 voltage using the HDS
-2. Turn the ignition switch ON. pocket tester.
-3. Measure the ECT sensor 2 voltage using the HDS
pocket tester. Is the measured voltage 0.08 – 4.99V?
YES – Temporary failure (Disappeared)
Is the measured voltage 0.08 – 4.99V? NO – Perform “2. ECT sensor 2 signal line open cir-
YES – Temporary failure (Disappeared) cuit check”.
NO – Perform “2. ECT sensor 2 signal line short cir-
cuit check”. 2. ECT sensor 2 signal line open circuit check
-1. Turn the ignition switch OFF and disconnect the 2P
2. ECT sensor 2 signal line short circuit check
connector from the ECT sensor 2.
-1. Turn the ignition switch OFF. Disconnect the ECT sen- -2. Turn the ignition switch ON.
sor 2 connector and the ECM connector B. -3. Measure the voltage between the No. 2 (Red/Black)
-2. Check for the continuity between the No. 2 (Red/Black) terminal of the ECT sensor 2 harness side 2P con-
terminal of the ECT sensor 2 harness side 2P con- nector and the engine ground.
nector and the body ground.
ECT SENSOR 2 HARNESS SIDE
ECT SENSOR 2 HARNESS SIDE 2P CONNECTOR
2P CONNECTOR
TOH1 (RED/BLACK)
TOH1 (RED/BLACK)

VIEWED FROM THE

TERMINAL SIDE
VIEWED FROM THE
TERMINAL SIDE
Is the measured voltage 4.75 – 5.25V?
Is there the continuity? YES – Perform “3. ECT sensor 2 ground line open
YES – Repair short in the wire between the ECT circuit check”.
sensor 2 and the ECM. NO – Repair open in the wire between the ECT
NO – Perform “3. ECT sensor 2 check”. sensor 2 and the ECM.

3. ECT sensor 2 check

-1. Turn the ignition switch OFF and connect the ECT sen-
sor 2 2P connector.
-2. Turn the ignition switch ON and measure the ECT sen-
sor 2 temperature using the HDS pocket tester.

Does the measurement correspond to the engine

coolant temperature?
YES – Substitute a known-good ECM and recheck.
NO – Replace the ECT sensor 2.

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BF135A•BF150A

3. ECT sensor 2 ground line open circuit check • ECT Sensor 3 Troubleshooting
-1. Connect the ECM connector B.
-2. Check for the continuity between the No. 1 (Green/ DTC 141-1: ECT sensor 3 voltage is low
Red) terminal of the ECT sensor 2 harness side 2P 1. Symptom reproduction test
connector and the body ground. -1. Connect the HDS pocket tester and clear the DTC
once. If the DTC can not be cleared, go on the trou-
ECT SENSOR 2 HARNESS SIDE bleshooting.
2P CONNECTOR -2. Turn the ignition switch ON.
-3. Measure the ECT sensor 3 voltage using the HDS
SG2 pocket tester.
(GREEN/RED)
Is the measured voltage 0.08 – 4.99V?
YES – Temporary failure (Disappeared)
NO – Perform “2. ECT sensor 3 signal line short cir-
VIEWED FROM THE cuit check”.
TERMINAL SIDE
2. ECT sensor 3 signal line short circuit check
Is there the continuity? -1. Turn the ignition switch OFF. Disconnect the ECT sen-
YES – Perform “4. ECT sensor 2 check”. sor 3 connector and the ECM connector B.
NO – Repair open in the wire between the ECT -2. Check for the continuity between the No. 2 terminal
sensor 2 and the engine ground. (Red) of the ECT sensor 3 harness side 2P connector
and the body ground.
4. ECT sensor 2 check
ECT SENSOR 3 HARNESS SIDE
-1. Turn the ignition switch OFF and connect all the con- 2P CONNECTOR
nectors.
-2. Turn the ignition switch ON. Measure the ECT sensor TOH2 (RED)
2 temperature using the HDS pocket tester.

Does the measurement correspond to the engine

coolant temperature?
YES – Substitute a known-good ECM and recheck. VIEWED FROM THE
NO – Replace the ECT sensor 2. TERMINAL SIDE

Is there the continuity?

YES – Repair short in the wire between the ECT
sensor 3 and the ECM.
NO – Perform “3. ECT sensor 3 check”.

3. ECT sensor 3 check

-1. Turn the ignition switch OFF and connect the ECT sen-
sor 3 2P connector.
-2. Turn the ignition switch ON and measure the ECT sen-
sor 3 temperature using the HDS pocket tester.

Does the measurement agree with the engine

coolant temperature?
YES – Substitute a known-good ECM and recheck.
NO – Replace the ECT sensor 3.

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 BF135A•BF150A

DTC 141-2: ECT sensor 3 voltage is high 3. ECT sensor 3 ground line open circuit check
1. Symptom reproduction test -1. Connect the ECM connector B.
-1. Connect the HDS pocket tester and clear the DTC -2. Check for continuity between the No. 1 (Green/Red)
once. If the DTC can not be cleared, go on the trou- terminal of the ECT sensor 3 harness side 2P con-
bleshooting. nector and the body ground.
-2. Turn the ignition switch ON.
-3. Measure the ECT sensor 3 voltage using the HDS ECT SENSOR 3 HARNESS SIDE
pocket tester. 2P CONNECTOR
SG2
Is the measured voltage 0.08 – 4.99V? (GREEN/RED)
YES – Temporary failure (Disappeared)
NO – Perform “2. ECT sensor 3 signal line open cir-
cuit check”.

2. ECT sensor 3 signal line open circuit check VIEWED FROM THE
-1. Turn the ignition switch OFF and disconnect the 2P TERMINAL SIDE
connector from the ECT sensor 3.
-2. Turn the ignition switch ON. Is there the continuity?
-3. Measure the voltage between the No. 2 (Red) terminal YES – Perform “4. ECT sensor 3 check”.
of the ECT sensor 3 harness side 2P connector and NO – Repair open in the wire between the ECT
the engine ground. sensor 3 and the engine ground.
ECT SENSOR 3 HARNESS SIDE 4. ECT sensor 3 check
2P CONNECTOR
-1. Turn the ignition switch OFF and connect all the con-
TOH2 (RED) nectors.
-2. Turn the ignition switch ON and measure the ECT sen-
sor 3 temperature using the HDS pocket tester.

Does the measurement agree with the engine

coolant temperature?
VIEWED FROM THE YES – When the DTC appears again, substitute a
TERMINAL SIDE known-good ECM and recheck.
NO – Replace the ECT sensor 3.
Is the measured voltage 4.75 – 5.25V?
YES – Perform “3. ECT sensor 3 ground line open
circuit check”.
NO – Repair open in the wire between the ECT
sensor 3 and the ECM.

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BF135A•BF150A

• EOP switch (High pressure side) 3. EOP switch signal line short circuit check
-1. Turn the ignition switch OFF. Disconnect the EOP
Troubleshooting switch 2P connector and the ECM connector A.
DTC 142-1: EOP switch signal is abnormal -2. Check for the continuity between the No. 1
1. Symptom reproduction test (Yellow/Red) terminal of the EOP switch harness side
2P connector and the body ground.
-1. Connect the HDS pocket tester and clear the DTC
once. If the DTC can not be cleared, go on the trou-
EOP SWITCH
bleshooting.
HARNESS SIDE 2P CONNECTOR
-2. Turn the ignition switch ON.
-3. Check the EOP switch signal using the HDS pocket
tester.
OPSH
(YELLOW/RED)
Is there the OFF signal?
YES – Temporary failure (Disappeared)
NO – Perform “2. EOP switch signal line open circuit
check”.
VIEWED FROM THE
2. EOP switch signal line open circuit check TERMINAL SIDE
-1. Turn the ignition switch OFF and disconnect the EOP
switch 2P connector. Is there the continuity?
-2. Turn the ignition switch ON. Measure the voltage YES – Repair short in the wire between the EOP
between the No. 1 (Yellow/Red) terminal of the EOP switch and the ECM.
switch harness side 2P connector and the body NO – Perform “4. EOP switch ground line open cir-
ground. cuit check”.

EOP SWITCH 4. EOP switch ground line open circuit check

HARNESS SIDE 2P CONNECTOR -1. Check for the continuity between the No. 2
OPSH (Green/Red) terminal of the EOP switch harness side
(YELLOW/RED) 2P connector and the body ground.

EOP SWITCH
HARNESS SIDE 2P CONNECTOR

VIEWED FROM THE

TERMINAL SIDE SG2
(GREEN/RED)

Is there the battery voltage?

YES – Perform “3. EOP switch signal line short circuit
check”. VIEWED FROM THE
TERMINAL SIDE
NO – Repair open in the wire between the EOP
switch and the ECM.
Is there the continuity?
YES – Perform “5. EOP switch check”.
NO – Repair open in the wire between the EOP
switch and the ECM.

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 BF135A•BF150A

5. EOP switch check • ECT Sensor 4 Troubleshooting

-1. Turn the ignition switch OFF and connect all the con-
nectors. DTC 143-1: ECT sensor 4 voltage is low
-2. Turn the ignition switch ON and check the EOP switch 1. Symptom reproduction test
using the HDS pocket tester. -1. Connect the HDS pocket tester and clear the DTC
once. If the DTC can not be cleared, go on the trou-
Does the tester shows the switch OFF? bleshooting.
YES – If the DTC appears again, substitute a known- -2. Turn the ignition switch ON.
good ECM and recheck. -3. Measure the ECT sensor 4 voltage using the HDS
NO – Replace the EOP switch. pocket tester.

Is the measured voltage 0.08 – 4.99V?

YES – Temporary failure (Disappeared)
NO – Perform “2. ECT sensor 4 signal line short cir-
cuit check”.

2. ECT sensor 4 signal line short circuit check

-1. Turn the ignition switch OFF. Disconnect the ECT sen-
sor 4 connector and the ECM connector B.
-2. Check for the continuity between the No. 2
(Red/Green) terminal of the ECT sensor 4 harness
side connector and the body ground.
ECT SENSOR 4 HARNESS
SIDE 2P CONNECTOR

TOH3
(RED/GREEN)

VIEWED FROM THE

TERMINAL SIDE

Is there the continuity?

YES – Repair short in the wire between the ECT
sensor 4 and the ECM.
NO – Perform “3. ECT sensor 4 check”.

3. ECT sensor 4 check

-1. Turn the ignition switch OFF and connect the ECT sen-
sor 4 2P connector.
-2. Turn the ignition switch ON. Measure the ECT sensor
4 temperature using the HDS pocket tester.

Does the measurement correspond to the engine

coolant temperature?
YES – If the DTC appears again, substitute a known-
good ECM and recheck.
NO – Replace the ECT sensor 4.

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BF135A•BF150A

DTC 143-2: ECT sensor 4 voltage is high 3. ECT sensor 4 ground line open circuit check
1. Symptom reproduction test -1. Connect the ECM connector B.
-1. Connect the HDS pocket tester and clear the DTC -2. Check for the continuity between the No. 1
once. If the DTC can not be cleared, go on the trou- (Green/Red) terminal of the ECT sensor 4 harness
bleshooting. side 2P connector and the body ground.
-2. Turn the ignition switch ON.
-3. Measure the ECT sensor 4 voltage using the HDS
ECT SENSOR 4 HARNESS SIDE
pocket tester. 2P CONNECTOR

Is the measured voltage 0.08 – 4.99V? SG2

YES – Temporary failure (Disappeared) (GREEN/RED)
NO – Perform “2. ECT sensor 4 signal line open cir-
cuit check”.

2. ECT sensor 4 signal line open circuit check VIEWED FROM THE
-1. Turn the ignition switch OFF and disconnect the 2P TERMINAL SIDE
connector from the ECT sensor 4.
-2. Turn the ignition switch ON. Is there the continuity?
-3. Measure the voltage between the No. 2 (Red/Green) YES – Perform “4. ECT sensor 4 check”.
terminal of the ECT sensor 4 harness side 2P con- NO – Repair open in the wire between the ECT
nector and the engine ground. sensor 4 and the engine ground.

ECT SENSOR 4 HARNESS 4. ECT sensor 4 check

SIDE 2P CONNECTOR -1. Turn the ignition switch OFF and connect all the con-
nectors.
TOH3 -2. Turn the ignition switch ON and measure the ECT sen-
(RED/GREEN) sor 4 temperature using the HDS pocket tester.

Does the measurement correspond to the engine

coolant temperature?
VIEWED FROM THE YES – When the DTC appears again, substitute a
TERMINAL SIDE known-good ECM and recheck.
NO – Replace the ECT sensor 4.
Is the measured voltage 4.75 – 5.25V?
YES – Perform “3. ECT sensor 4 ground line open
circuit check”.
NO – Repair open in the wire between the ECT
sensor 4 and the ECM.

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 BF135A•BF150A

7. TROUBLESHOOTING WITHOUT • ECM Reset Procedure

HDS TESTER 1. Turn the ignition switch OFF.

• Check of Number of Blinks of MIL 2. Short-circuit the 4P (Red) data link connector located
1. Remove the engine cover and the electric part cover inside the electric part cover using the special tool
(Section 4). (SCS short connector).
2. Disconnect the red 4P connector and connect (short-
circuit) the SCS short connector to the DLC (Data Link 3. Turn the ignition switch ON.
Connector).
4P CONNECTOR 4. Turn the emergency stop switch ON (push) and OFF
(RED) (release). Repeat this procedure five times. (Repeat
turning the switch ON for 0.5 sec. or more and turning
it OFF for 0.1 sec. or more.)

5. Check that the buzzer sounds twice.

• The MIL should stay ON.

6. Turn the ignition switch OFF. (ECM reset procedure

completes.)
• Perform the step 4 through the step 6 within 20 sec-
onds.
0.5 sec. or more
ON
SCS SHORT CONNECTOR DLC (DATA LINK (Push)
070PZ-ZY30100 CONNECTOR)
OFF
0.1 sec. or more
(Release)
3. Check the number of blinks of the MIL.
Count the number of blinks when the MIL starts blink- Within 20 sec. ON
ing. The diagnostic trouble code (DTC) is indicated BUZZER
repeatedly. The number of long blinks equals the first OFF
digit and the number of short blinks equals the sec- IGNITION IGNITION
SWITCH ON SWITCH OFF
ond digit of the DTC.
When multiple problems occur simultaneously, the
MIL repeatedly indicates them by blinking separate
codes, one after another.
Separate problems:

See DTC 1.

See DTC 3.

See DTC 14.

Multiple problems:

See DTC 1
and 3.
See DTC 3
and 4.
See DTC 1
and 14

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BF135A•BF150A

• Final Procedure (After Troubleshooting) • Connecting Test Harness

1. Disconnect the SCS short connector from the data link Use the test harness (special tool) and a commercially
connector. available digital circuit tester for troubleshooting.
• Note that the MIL stays ON while the SCS short con- Disconnect the test harness sensor connector if the
nector is connected to the data link connector. instruction tells to do so for troubleshooting.

2. Be sure to reset the ECM after troubleshooting.

The MIL can come ON or blink when the ECM detect-
ed poor or loose contact of a connector. If it is hard to TEST HARNESS
ECM 070PZ-ZY60100 TEST HARNESS SEN-
identify the problem part by following the troubleshoot- SOR CONNECTOR
ing flow chart, check the three connectors of the ECM
and the connector of the probable faulty part, and
clean or repair the connector(s) if necessary.

If the problem cannot be identified by the above pro-

cedure, check by following the troubleshooting for the
fuel supply system (P. 5-96).

C CONNECTOR A CONNECTOR
CONNECTOR A
CONNECTOR C
(6P) (26P)
B CONNECTOR
CONNECTOR B
DIGITAL CIRCUIT (34P)
TESTER
(Commercially available)

5-58
 BF135A•BF150A

a. TROUBLESHOOTING GUIDE
MIL
Detected unit Probable problem part Ref. page
No. of blinks MIL

MIL does OFF ECM • Open circuit in MIL wire 5-61

not come • Blown MIL bulb
• Open circuit or poor grounding of ECM
ON
ground wire
• Faulty ECM
Stays ON ON ECM • Open circuit in ECM power supply line 5-64
• Short circuit in data link connector wire
• Short circuit in MIL wire
• Short circuit in sensor power supply line
• Faulty ECM
3 ON MAP (Sensor voltage) • Open or short circuit in MAP sensor line 5-71
• Faulty MAP sensor
• Faulty ECM

4 ON CKP sensor (Pulse) • Open or short circuit in CKP sensor wire 5-72
• Faulty CKP sensor
• Faulty ECM

6 ON ECT sensor 1 (Sensor voltage) • Open or short circuit in ECT sensor 1 wire 5-74
• Faulty ECT sensor 1
• Faulty ECM

7 ON TP sensor (Sensor voltage) • Open or short circuit in TP sensor wire 5-75

• Faulty TP sensor
• Faulty ECM

8 ON CMP sensor (Pulse) • Open or short circuit in CMP sensor 5-77

• Faulty CMP sensor
• Faulty ECM

10 ON IAT sensor (Sensor voltage) • Open or short circuit in IAT sensor wire 5-78
• Faulty IAT sensor
• Faulty ECM

13 ON BARO sensor (Sensor voltage) • Short circuit in BARO sensor 5-80

• Faulty BARO sensor
• Faulty ECM

14 ON IAC valve (Input/output current) • Open or short circuit in IAC valve wire 5-81
• Faulty IAC valve
• Faulty ECM

21 ON VTEC solenoid • Open circuit or short circuit in VTEC solenoid wire 5-82
(Output current) • Faulty VTEC solenoid
(BF150A only) • Faulty ECM

23 ON Knock sensor (Sensor voltage) • Open circuit or short circuit in knock 5-83
sensor wire
• Faulty knock sensor
• Faulty ECM

5-59
BF135A•BF150A

MIL
Detected unit Probable problem part Ref. page
No. of blinks MIL
24 ON ECT sensor 2 (Low voltage) • Open or short circuit in the ECT sensor 2 wire 5-84
• Faulty ECT sensor 2
• Faulty ECM

25 ON ECT sensor 3 (Low voltage) • Open or short circuit in the ECT sensor 3 wire 5-86
• Faulty ECT sensor 3
• Faulty ECM

26 ON EOP switch (Current) • Open or short circuit in the EOP switch wire 5-87
• Faulty ECM

27 ON ECT sensor 4 • Open or short circuit in the ECT sensor 4 wire 5-89
(Sensor voltage) • Faulty ECT sensor 4
• Faulty ECM

41 ON A/F sensor heater (Current) • Open or short circuit in the A/F sensor 5-90
heater wire
• Faulty A/F sensor heater
• Faulty ECM
48 ON A/F sensor (Current) • Open or short circuit in the A/F sensor wire 5-92
• Faulty A/F sensor
• Faulty ECM

When multiple DTC’s main codes appear:

MIL
Detected unit Probable problem part Ref. page
No. of blinks MIL
7, 13 ON ECM (Sensor voltage) • Open circuit in the VCC (sensor power --
supply) line

6, 7 ON ECM (Sensor voltage) • Open circuit in the SG (sensor ground) line --

10, 13
24, 25
27, 48

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 BF135A•BF150A

b. TROUBLESHOOTING 2. Main power supply line check

-1. Disconnect the remote control harness 14P connector.
• MIL Does Not Come On -2. Measure the voltage between the No. 3 (White/ Black)
terminal of the main harness side 14P connector and
1. Fuse check the engine ground.
-1. Turn the ignition switch ON and check that the warning • Note that the battery voltage is constantly applied to
buzzer sounds twice. the White/Black terminal. Take care not to short-cir-
cuit the terminal.
Does the buzzer sound twice?
YES – Perform "6. Alternator indictor light check".
NO – Go to the step 2. MAIN HARNESS SIDE
14P CONNECTOR
WHITE/BLACK
-2. Check the No. 4 (15A) fuse.

Is the fuse normal?

YES – Go to the step 3.
NO – Repair short in the wire between the No. 4
fuse and the ECM, and between the No. 4
fuse and the injector. After repair, replace the VIEWED FROM THE TERMINAL SIDE
No. 4 fuse. Is there the battery voltage?
YES – Go to the step 3.
-3. Check the No. 7 (30A) fuse.
NO – Repair open in the main harness wire.
Is the fuse normal? -3. Turn the ignition switch ON. Check for the continuity
YES – Go to the step 4. between the No. 1 (White/Black) and the No. 2
NO – Repair short in the wire between the PGM-FI (Black/Yellow) terminals of the remote control box har-
main relay and fuse box, and between the ness side 14P connector.
PGM-FI main relay and starter magnetic
switch. After repair, replace the No. 7 fuse.
REMOTE CONTROL
HARNESS SIDE 14P
-4. Check the No. 3 (10A) fuse. CONNECTOR

Is the fuse normal?

YES – Perform "2. Main power supply line check". BLACK/YELLOW
NO – Repair short in the wire between the fuse box WHITE/BLACK
and ignition switch, between the fuse box and
alternator, between the fuse box and power
trim/tilt switch or the power tilt switch. After
repair, replace the No. 3 fuse.
VIEWED FROM THE TERMINAL SIDE

Is there the continuity?

YES – Perform "3. IGP power supply line check".
NO – Go to the step 4.

-4. Check the ignition switch (P. 16-9).

Is the ignition switch normal?

YES – Repair open in the remote control box har-
ness.
NO – The ignition switch is faulty.

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BF135A•BF150A

3. IGP power supply line check 4. ECM power supply line check
-1. Turn the ignition switch OFF and disconnect the PGM- -1. Turn the ignition switch OFF and disconnect the fuse
FI main relay 6P connector. box 3P connector.
-2. Turn the ignition switch ON. Measure the voltage -2. Turn the ignition switch ON. Measure the voltage
between the No. 2 (Black/Yellow) terminal of the PGM- between the No. 3 (Yellow/Black) terminal of the fuse
FI main relay harness side 6P connector and the box side 3P connector and the engine ground.
engine ground.
FUSE BOX SIDE 3P
CONNECTOR
PGM-FI MAIN RELAY
HARNESS SIDE 6P BLACK/YELLOW YELLOW/BLACK
CONNECTOR

VIEWED FROM THE TERMINAL SIDE

VIEWED FROM THE TERMINAL SIDE

Is there the battery voltage?
Is there the battery voltage? YES – Go to the step 3.
YES – Go to the step 3. NO – PGM-FI main relay is faulty, or fuse box is
NO – Repair open in the main harness wire. faulty.

-3. Turn the ignition switch OFF. Check for the continuity -3. Turn the ignition switch OFF and disconnect the ECM
between the No. 6 (Black) terminal of the PGM-FI main connector C.
relay 6P connector and the engine ground. -4. Check for the continuity between the No.2
(Yellow/Black) terminal of the fuse box harness side 3P
connector and the respective terminals of the No. 1
PGM-FI MAIN RELAY (Yellow/Black) and the No. 5 (Yellow/Black) terminals of
HARNESS SIDE 6P the ECM connector C.
CONNECTOR
BLACK ECM CONNECTOR C FUSE BOX HARNESS
SIDE 3P CONNECTOR

VIEWED FROM THE TERMINAL SIDE

Is there the continuity?
YES – Perform “4. ECM power supply line check”. YELLOW/BLACK
NO – Repair open in the main harness (Black) wire.
VIEWED FROM THE TERMINAL SIDE

Is there the continuity?

YES – Perform “5. MIL power supply line check”.
NO – Repair open in the main harness wire.

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 BF135A•BF150A

5. MIL power supply line check 6. Alternator indicator light check

-1. Turn the ignition switch OFF and disconnect the fuse -1. Turn the ignition switch ON and check the alternator
box 3P connector. indicator light.
-2. Turn the ignition switch ON. Measure the voltage
between the No. 2 (Yellow/Red) terminal of the fuse Does the alternator indicator light come ON?
box side 3P connector and the engine ground. YES – Perform “7. MIL ON line check”.
NO – Replace the MIL.
FUSE BOX SIDE 3P
CONNECTOR
7. MIL ON line check
YELLOW/RED -1. Turn the ignition switch OFF and connect the test har-
ness.
-2. Connect the test harness B-25 terminal to the engine
ground to short-circuit. Turn the ignition switch ON and
VIEWED FROM THE TERMINAL SIDE check the MIL.

Is there the battery voltage?

YES – Go to the step 3. B-25
NO – PGM-FI main relay is faulty.

-3. Turn the ignition switch OFF and connect the fuse box
3P connector.
-4. Disconnect the MIL 6P connector. Does the MIL come ON?
-5. Turn the ignition switch ON. Measure the voltage
between the No. 6 (Yellow/Red) terminal of the MIL YES – Substitute a known-good ECM and recheck.
harness side 6P connector and the engine ground. NO – Repair open in the main harness wire
between the MIL and the ECM.
MIL HARNESS SIDE
6P CONNECTOR
YELLOW/RED

VIEWED FROM THE TERMINAL SIDE

Is there the battery voltage?

YES – Perform “6. Alternator indicator light check”.
NO – Repair open in the main wire harness.

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BF135A•BF150A

• MIL ON but MIL Does Not Blink -6. Connect the SCS short connector to the data link con-
nector to short-circuit.
With SCS Circuit Shorted -7. Measure the voltage between the test harness B-16
1. Engine start check terminal (+) and A-1 (–) terminal, and between the B-
16 terminal (+) and B-17 terminal (–).
-1. Disconnect the SCS short connector and start the
engine. B-16
A-1
Does the engine start?
YES – Perform “2. Data link connector line check”.
NO – Perform “3. Sensor check”.
B-17
2. Data link connector line check
-1. Turn the ignition switch OFF and connect the test har-
ness (P. 5-58). Is the measured voltage 4.30 – 5.25V?
-2. Disconnect the test harness sensor connector. YES – Go to the step 8.
-3. Turn the ignition switch ON. Measure the voltage NO – Go to the step 10.
between the test harness B-16 terminal (+) and A-1
terminal (–), and between the B-16 terminal (+) and B- -8. Disconnect the SCS short connector.
17 terminal (–). -9. Turn the ignition switch OFF. Check for the continuity
between the data link connector No. 1 (Black) terminal
A-1 B-16 and the engine ground.
DATA LINK CONNECTOR

B-17

Is the measured voltage 4.30 – 5.25V?

YES – Go to the step 4.
NO – Substitute a known-good ECM and recheck. VIEWED FROM THE TERMINAL SIDE

-4. Turn the ignition switch OFF and connect the test har-
ness. Is there the continuity?
-5. Turn the ignition switch ON. Measure the voltage YES – Repair open in the main harness between the
between the test harness B-16 terminal (+) and A-1 data link connector and the ECM.
terminal (–), and between the B-16 terminal (+) and B- NO – Repair open in the main harness between the
17 terminal (–). data link connector and the engine ground.
B-16
A-1 -10. Disconnect the SCS short connector from the data link
connector.
-11. Turn the ignition switch OFF and disconnect the ECM
connector A.
B-17 -12. Turn the ignition switch ON and check that the MIL
comes ON.

Does the MIL come ON?

Is the measured voltage 4.30 – 5.25V? YES – Repair short in the main harness (Red/Blue)
YES – Repair open in the wire harness between the between the MIL and the ECM.
ECM and the data link connector. NO – Substitute a known-good ECM and recheck.
NO – Go to the step 6.

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 BF135A•BF150A

3. Sensor check -9. With the ECU connector A disconnected, check for the
-1. Turn the ignition switch ON. continuity between the test harness A-12 terminal and
-2. Disconnect the MAP sensor 3P connector and check the engine ground.
the MIL.
A-12
Does the MIL go OFF?
YES – Replace the MAP sensor.
NO – Go to the step 3.

-3. Connect the MAP sensor 3P connector.

-4. Disconnect the TP sensor 3P connector and check the
MIL.
Is there the continuity?
Does the MIL go OFF? YES – Repair open in the wire between the ECM
and the BARO sensor.
YES – Replace the TP sensor.
NO – Perform “4. ECM main power supply line
NO – Go to the step 5.
check”.
-5. Connect the TP sensor 3P connector.
-6. Disconnect the BARO sensor 3P connector and check 4. ECM main power supply line check
the MIL. -1. Connect the ECM connector A.
-2. Check for the continuity between the test harness C-1
Does the MIL go OFF? terminal and the respective terminals of A-1 and B-17
YES – Replace the BARO sensor. terminals.
NO – Go to the step 7. Measure the voltage between the test harness C-5 ter-
minal and the respective terminals of A-1 and B-17 ter-
-7. Turn the ignition switch OFF and connect the test har- minals.
ness.
-8. Check for the continuity between the test harness B-4 A-1
terminal and the engine ground with the ECM connec-
C-1
tor A disconnected.

C-5
B-4
B-17

Is there the continuity?

YES – Substitute a known-good ECM and recheck.
Is there the continuity? NO – Check the PGM-FI main relay harness (P. 5-
YES – Repair open in the main harness between the 97).
ECM and the MAP sensor.
NO – Go to the step 9.

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BF135A•BF150A

• Alert System Initial Operation Is Faulty -3. Turn the ignition switch OFF and disconnect the
Yellow/Green terminal from the buzzer.
1. Wire harness short-circuit check -4. Connect the Yellow/Green terminal of the buzzer to the
-1. Turn the ignition switch OFF and connect the test har- Black terminal with a jumper wire to short-circuit.
ness. -5. Turn the ignition switch ON and check whether the
-2. Disconnect the ECM connector A, B and C from the buzzer sounds.
ECM.
-3. Turn the ignition switch ON and check whether the Does the buzzer sound?
buzzer sounds. YES – Repair open in the wire between the buzzer
and the ECM.
Does the buzzer sound? NO – Go to the step 6.
YES – Repair short in the wire between the buzzer
and the ECM. -6. Check the buzzer (single unit check).
NO – Go to the step 4.
Is the buzzer normal?
-4. Check the oil pressure indicator light. YES – Go to the step 7.
NO – The buzzer is faulty.
Does the oil pressure indicator light come ON?
YES – Go to the step 5. -7. Check the ignition switch (single unit check) (P. 16-9).
NO – Repair short in the wire between the oil pres-
sure indicator light and the ECM. Is the ignition switch normal?
YES – Go to the step 8.
-5. Check the overheat indicator light. NO – The ignition switch is faulty.

Does the overheat indicator light come ON? -8. Disconnect the remote control box harness side 14P
YES – Repair short in the wire between the overheat connector.
indicator light and the ECM. -9. Turn the ignition switch ON. Check for the continuity
NO – Go to the step 6. between the No. 1 (White/Black) and the No. 2
(Black/Yellow) terminals of the remote control box har-
-6. Check the MIL. ness side 14P connector.

Does the MIL come ON? REMOTE CONTROL

HARNESS SIDE 14P
YES – Repair short in the wire between the MIL and CONNECTOR
the ECM.
NO – Perform "2. Buzzer line check".
BLACK/YELLOW
2. Buzzer line check WHITE/BLACK
-1. Connect the test harness B-18 terminal to the engine
ground to short-circuit.
-2. Turn the ignition switch ON and check that the buzzer
sounds.
VIEWED FROM THE TERMINAL SIDE
Is there the continuity?
YES – Repair open in the main harness.
NO – Repair open in the remote control box har-
ness.
B-18

Does the buzzer sound?

YES – Perform “3. Overheat indicator line check”.
NO – Go to the step 3.

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 BF135A•BF150A

3. Overheat indicator line check 4. Oil pressure indicator line check

-1. Connect the test harness B-31 terminal to the engine -1. Connect the test harness B-32 terminal to the engine
ground to short-circuit. ground to short-circuit.
-2. Turn the ignition switch ON and check that the over- -2. Turn the ignition switch ON and check the oil pressure
heat indicator light comes ON. indicator light.

B-31 B-32

Does the overheat indicator light come ON? Does the oil pressure indicator light come ON?
YES – Perform "4. Oil pressure indicator line check". YES – Go to the step 3.
NO – Go to the step 3. NO – Perform "5. MIL line check".

-3. Turn the ignition switch OFF. Disconnect the indicator -3. Turn the ignition switch OFF. Disconnect the indicator
light Red terminal and connect it to the Black terminal light Yellow terminal and connect it to the Black termi-
with a jumper wire to short-circuit. nal with a jumper wire to short-circuit.
-4. Turn the ignition switch ON and check the overheat -4. Turn the ignition switch ON and check the oil pressure
indicator light. indicator light.

Does the overheat indicator light come ON? Does the oil pressure indicator light come ON?
YES – Repair open in the wire between the ECM YES – Go to the step 5.
and the indicator light. NO – Repair open in the wire between the ECM
NO – Go to the step 5. and the indicator light.

-5. Turn the ignition switch OFF and connect the indicator -5. Turn the ignition switch OFF and connect the indicator
light Red terminal. light Yellow terminal.
-6. Disconnect the remote control harness 14P connector. -6. Disconnect the remote control harness 14P connector.
-7. Check for the continuity between the No. 7 (Red) and -7. Check for the continuity between the No. 6 (Yellow) and
the No. 2 (Black/Yellow) terminals of the remote control the No. 2 (Black/Yellow) terminals of the remote control
harness side 14P connector. harness side 14P connector.

REMOTE CONTROL
HARNESS SIDE 14P BLACK/YELLOW
REMOTE CONTROL BLACK/YELLOW CONNECTOR
HARNESS SIDE 14P
CONNECTOR
YELLOW
RED

VIEWED FROM THE TERMINAL SIDE

VIEWED FROM THE TERMINAL SIDE
Is there the continuity?
YES – Repair open in the main harness.
Is there the continuity? NO – The indicator light is faulty, or repair open in
YES – Repair open in the main harness. the remote control harness.
NO – The indicator light is faulty, or repair open in
the remote control harness.

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BF135A•BF150A

5. MIL line check 6. Alternator indicator line check

-1. Disconnect the ECM connector B and connect the test -1. Turn the ignition switch OFF and disconnect the alter-
harness B-25 terminal to the engine ground to short- nator 4P connector.
circuit. -2. Check for the continuity between the test harness B-19
-2. Turn the ignition switch ON and check the MIL. terminal and the engine ground.

B-25
B-19

Does the MIL come ON? Is there the continuity?

YES – Go to the step 3. YES – Repair short in the wire between the ECM
NO – Perform “6. Alternator indicator line check”. and the alternator.
NO – Go to the step 3.
-3. Turn the ignition switch ON and measure the voltage
between the test harness B-25 terminal and the -3. Check for the continuity between the No. 1
engine ground. (White/Blue) terminal of the alternator harness side 4P
connector and the test harness B-19 terminal.

ALTERNATOR HARNESS
SIDE 4P CONNECTOR

B-25 ACG
(WHITE/BLUE)

B-19
B-19
Is there the battery voltage?
YES – Repair open in the main harness between the VIEWED FROM THE
ECM and the MIL. TERMINAL SIDE
NO – Go to the step 4.

-4. Turn the ignition switch OFF and disconnect the MIL Is there the continuity?
6P connector. YES – Substitute a known-good ECM and recheck.
-5. Turn the ignition switch ON. Measure the No. 2 NO – Repair open in the wire between the ECM
(Yellow/Red) terminal of the MIL 6P main harness side and the alternator.
connector and the engine ground.
7. Water level sensor line check
MIL HARNESS SIDE YELLOW/RED -1. Disconnect the water separator water level sensor 4P
6P CONNECTOR connector.
-2. Check for the continuity between the test harness A-19
terminal and the engine ground.

VIEWED FROM THE TERMINAL SIDE

A-19
Is there the battery voltage?
YES – Check the MIL. If it is normal, replace the MIL
harness.
NO – Perform the troubleshooting of “MIL does not Is there the continuity?
come ON” (P. 5-61). YES – Repair short in the main harness between the
water level sensor and the ECM.
NO – Go to the step 3.

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 BF135A•BF150A

-3. Check for the continuity between the No. 1 (Brown) ter- 9. EOP switch (high pressure side) line check
minal of the water separator water level sensor har- -1. Disconnect the high pressure side EOP switch 2P con-
ness side connector and the test harness A-19 termi- nector.
nal. -2. Check for the continuity between the test harness A-17
terminal and the engine ground.
WATER LEVEL SEN-
SOR HARNESS SIDE
2P CONNECTOR

A-17

VIEWED FROM THE TERMINAL SIDE

Is there the continuity?

Is there the continuity? YES – Repair short in the main harness between the
YES – Perform "8. EOP switch (low pressure side) high pressure side EOP switch and the ECM.
line check". NO – Go to the step 3.
NO – Repair open in the main harness between the
water level sensor and the ECM. -3. Check for the continuity between the test harness A-17
terminal and the No. 1 (Yellow/Red) terminal of the
8. EOP switch (low pressure side) line check EOP switch harness side 2P connector.
-1. Disconnect the low pressure side EOP switch wire.
-2. Check for the continuity between the test harness B-14
terminal and the engine ground.
EOP SWITCH
(HIGH PRESSURE SIDE)
HARNESS SIDE
B-14 2P CONNECTOR
OPSH
(YELLOW/RED)

A-17
VIEWED FROM THE
Is there the continuity?
TERMINAL SIDE
YES – Repair short in the main harness between the
low pressure side EOP switch and the ECM.
NO – Go to the step 3. Is there the continuity?
YES – Connect each connector and recheck. If
-3. Check for the continuity between the test harness B-14 there is any abnormality, substitute a known-
terminal and the EOP switch harness side (Pink) ter- good ECM and recheck.
minal. NO – Repair open in the main harness between the
EOP SWITCH HARNESS
high pressure side EOP switch and the ECM.
SIDE TERMINAL

B-14
PINK

Is there the continuity?

YES – Perform “9. EOP switch (high pressure side)
line check”.
NO – Repair open in the main harness between the
low pressure side EOP switch and the ECM.

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BF135A•BF150A

• Neutral Switch Malfunction • Tachometer Malfunction

Engine speed does not increase in gear (BF150A only) Tachometer does not function so that it corre-
Perform neutral switch inspection (P. 17-13) and neutral sponds to the engine speed.
position adjustment (P. 3-25) before troubleshooting. 1. Tachometer power supply check
-1. Turn the ignition switch OFF and disconnect the
1. Neutral switch line check tachometer’s connecting terminal.
-1. Start the engine and warm it up with the gear in neu- -2. Turn the ignition switch ON and measure the voltage
tral. between the harness side Black/Yellow terminal and
-2. Disconnect the neutral switch 3P connector. Raise the the Black terminal.
engine speed slowly and check that the engine speed
changes when it reaches approx. 4,500 rpm. Is there the battery voltage?
YES – Perform “2. Tachometer pulse line check”.
Does the engine speed change (Does VTEC func- NO – Repair open in the meter harness.
tion)?
YES – Replace the neutral switch. 2. Tachometer pulse line check
NO – Go to the step 3. -1. Turn the ignition switch OFF and connect the test har-
ness.
-3. Stop the engine and connect the test harness. Disconnect the ECM connector A, B and C.
Disconnect the ECM connector A, B and C. -2. Check for the continuity between the test harness B-33
-4. With the neutral switch 2P connector disconnected, terminal and the engine ground.
check for the continuity between the test harness B-13
terminal and the engine ground.

B-13
B-33

Is there the continuity?

Is there the continuity? YES – Repair short in the main harness between the
YES – Repair short in the main harness between the tachometer and the ECM.
ECM and the neutral switch. NO – Go to the step 3.
NO – Substitute a known-good ECM and recheck.
-3. Check for the continuity between the test harness B-33
terminal and the meter harness Gray terminal.

METER HARNESS
TERMINAL

B-33 GRAY

Is there the continuity?

YES – Substitute a known-good ECM and recheck.
NO – Repair open in the main harness between the
tachometer and the ECM.

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 BF135A•BF150A

• MAP Sensor Troubleshooting 3. MAP sensor signal line open circuit check
-1. Connect the ECM connector A.
MIL blinks 3 times. -2. Turn the ignition switch ON.
1. Symptom reproduction test -3. Measure the voltage between the No. 2 (White/Red)
-1. Reset the ECM. terminal of the MAP sensor harness side 3P connec-
-2. Turn the ignition switch OFF and connect the test har- tor and the engine ground.
ness. Hold the sensor connector connected.
-3. Turn the ignition switch ON. MAP SENSOR HARNESS
-4. Measure the voltage between the test harness B-5 ter- SIDE 3P CONNECTOR
minal (+) and the B-6 terminal (–).

PB (WHITE/RED)
B-5 B-6

VIEWED FROM THE TERMINAL SIDE

Is the measurement 4.75 – 5.25V?

Is the measured voltage 0.22 – 3.15V? YES – Perform "4. MAP sensor signal line short cir-
YES – Temporary failure (Disappeared) cuit check".
NO – Perform "2. MAP sensor signal line short cir- NO – Repair open in the wire between the ECM
cuit check". and the MAP sensor.

2. MAP sensor signal line short circuit check 4. MAP sensor signal line short circuit check
-1. Turn the ignition switch OFF and disconnect the MAP -1. Check for the continuity between the No. 2 (White/
sensor 3P connector. Red) terminal of the MAP sensor harness side 3P con-
-2. Turn the ignition switch ON. Measure the voltage nector and the body ground.
between the No. 3 (Brown/Yellow) terminal of the MAP
sensor harness side 3P connector and the engine MAP SENSOR HARNESS
ground. SIDE 3P CONNECTOR
MAP SENSOR HARNESS
SIDE 3P CONNECTOR
VCC1
(BROWN/YELLOW) PB (WHITE/RED)

VIEWED FROM THE TERMINAL SIDE

VIEWED FROM THE TERMINAL SIDE Is there the continuity?

YES – Repair short in the wire between the MAP
sensor and the ECM.
Is the measured voltage 4.75 – 5.25V? NO – Perform “5. MAP sensor ground line open cir-
YES – Perform "3. MAP sensor signal line open cir- cuit check”.
cuit check".
NO – Repair open in the wire between the ECM
and the MAP sensor.

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BF135A•BF150A

5. MAP sensor ground line open circuit check • CKP Sensor Troubleshooting
-1. Check for the continuity between the No. 1 (Green/
Red) terminal of the MAP sensor harness side 3P con- MIL blinks 4 times.
nector and the body ground. 1. Symptom reproduction test
-1. Reset the ECM.
MAP SENSOR HARNESS -2. Start the engine and let it run at idling under no load.
SIDE 3P CONNECTOR
-3. Check the MIL.

SG1 (GREEN/RED) Does the MIL come ON?

YES – Perform "2. CKP sensor power supply line
open circuit check".
NO – Temporary failure (Disappeared)

2. CKP sensor power supply line open circuit check

VIEWED FROM THE TERMINAL SIDE
-1. Turn the ignition switch OFF and disconnect the CKP
Is there the continuity? sensor 3P connector.
YES – Perform “6. MAP sensor check”. -2. Turn the ignition switch ON and measure the voltage
NO – Repair open in the wire between the MAP between the No. 1 (Yellow/Black) terminal of the CKP
sensor and the ECM. sensor harness side 3P connector and the engine
ground.
6. MAP sensor check
-1. Connect the MAP sensor 3P connector. CKP SENSOR HARNESS
-2. Turn the ignition switch ON. Measure the voltage SIDE 3P CONNECTOR
between the test harness B-5 terminal (+) and the B-6
terminal (–). IGP
(YELLOW/BLACK)

B-5 B-6

VIEWED FROM THE TERMINAL SIDE

Is there the battery voltage?
YES – Perform "3. CKP sensor signal line open cir-
cuit check".
Is the measurement 2.76 – 2.96V? NO – Repair open in the wire between the ECM
YES – Substitute a known-good ECM and recheck. and CKP sensor.
NO – Replace the MAP sensor.
3. CKP sensor signal line open circuit check
-1. Turn the ignition switch ON. Measure the voltage
between the No. 3 (Blue) terminal of the CKP sensor
harness side 3P connector and the engine ground.

CKP SENSOR HARNESS

SIDE 3P CONNECTOR

CRK (BLUE)

VIEWED FROM THE TERMINAL SIDE

5-72
 BF135A•BF150A

Is the measured voltage 4.75 – 5.25V? 6. CKP sensor check

YES – Perform "4. CKP sensor signal line short cir- -1. Reset the ECM.
cuit check". -2. Start the engine and let it run at idling under no load.
NO – Repair open in the wire between the CKP Check the MIL.
sensor and the ECM.
Does the MIL come ON?
4. CKP sensor signal line short circuit check YES – Replace the CKP sensor and recheck. If the
-1. Turn the ignition switch OFF. Check for the continuity MIL comes ON again, substitute a known-
between the No. 3 (Blue) terminal of the CKP sensor good ECM and recheck.
harness side 3P connector and the engine ground. NO – End of the check.

CKP SENSOR HARNESS

SIDE 3P CONNECTOR

CRK (BLUE)

VIEWED FROM THE TERMINAL SIDE

Is there the continuity?
YES – Perform "5. CKP sensor ground line open cir-
cuit check".
NO – Repair open in the wire between the CKP
sensor and the ECM.

5. CKP sensor ground line open circuit check

-1. Check for the continuity between the No. 2 (Green/
Black) terminal of the CKP sensor harness side 3P
connector and the engine ground.

CKP SENSOR HARNESS

SIDE 3P CONNECTOR

LG1
(GREEN/BLACK)

VIEWED FROM THE TERMINAL SIDE

Is there the continuity?

YES – Perform "6. CKP sensor check".
NO – Repair open in the wire between the CKP
sensor and the ECM.

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BF135A•BF150A

• ECT Sensor 1 Troubleshooting 3. ECT sensor 1 line short circuit check

-1. Turn the ignition switch OFF and disconnect the ECM
MIL comes ON 6 times. connector B.
1. Symptom reproduction test -2. Check for the continuity between the No. 2 (Red/White)
-1. Reset the ECM. terminal of the ECT sensor 1 harness side 2P con-
-2. Turn the ignition switch OFF and connect the test har- nector and the body ground.
ness.
• Hold the sensor connector connected.
ECT SENSOR 1 HARNESS SIDE
-3. Turn the ignition switch ON. 2P CONNECTOR
-4. Measure the voltage between the test harness B-8 ter-
minal (+) and the A-2 terminal (–). TE (RED/WHITE)

A-2 B-8

VIEWED FROM THE TERMINAL SIDE

Is there the continuity?

Is the measured voltage 0.22 – 3.15V? YES – Repair short in the wire between the ECM
YES – Temporary failure (Disappeared) and the ECT sensor 1.
NO – Perform "2. ECT sensor 1 signal line open cir- NO – Perform "4. ECT sensor 1 ground line short
cuit check". circuit check".

2. ECT sensor 1 signal line open circuit check 4. ECT sensor 1 ground line short circuit check
-1. Turn the ignition switch ON. Measure the voltage -1. Turn the ignition switch OFF. Check for the continuity
between the No. 2 (Red/White) terminal of the ECT between the No. 1 (Green/Red) terminal of the ECT
sensor 1 harness side 2P connector and the engine sensor 1 harness side 2P connector and the engine
ground. ground.

ECT SENSOR 1 HARNESS SIDE

ECT SENSOR 1 HARNESS SIDE 2P CONNECTOR
2P CONNECTOR

SG2 (GREEN/RED)
TE (RED/WHITE)

VIEWED FROM THE TERMINAL SIDE

VIEWED FROM THE TERMINAL SIDE

Is there the continuity?

YES – Perform the 5. ECT sensor 1 check.
Is the measured voltage 4.30 – 5.25V? NO – Repair open in the wire between the ECM
YES – Perform "3. ECT sensor 1 line short circuit and the ECT sensor.
check".
NO – Repair open in the wire between the ECM
and ECT sensor 1.

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 BF135A•BF150A

5. ECT sensor 1 check • TP Sensor Troubleshooting

-1. Turn the ignition switch OFF and disconnect the 2P
connector of the ECT sensor 1. MIL blinks 7 times.
-2. Measure the resistance between the No. 1 and the No. 1. Symptom reproduction test
2 terminals of the ECT sensor 1 side 2P connector. -1. Reset the ECM.
-2. Turn the ignition switch OFF and connect the test har-
ECT SENSOR 1 SIDE ness.
2P CONNECTOR Hold the sensor connector connected.
-3. Turn the ignition switch ON.
-4. Measure the voltage between the B-7 terminal (+) and
the A-2 terminal (–) of the test harness.

VIEWED FROM THE TERMINAL SIDE A-2 B-7

Is the measured voltage 0.08 – 4.92V?

RESISTANCE

YES – Temporary failure (Disappeared)

NO – Perform "2.TP sensor power supply line open
circuit check".

2. TP sensor power supply line open circuit check

-1. Turn the ignition switch ON. Measure the voltage
between the No. 3 (Brown/White) terminal of the TP
sensor harness side 3P connector and the engine
ENGINE COOLANT TEMPERATURE ground.
Is there the resistance corresponding to the engine
coolant temperature? TP SENSOR HARNESS SIDE
YES – Substitute a known-good ECM and recheck. 3P CONNECTOR
NO – Replace the ECT sensor 1.
VCC2
(BROWN/WHITE)

VIEWED FROM THE TERMINAL SIDE

Is the measured voltage 4.75 – 5.25V?

YES – Perform "3. TP sensor signal line open circuit
check".
NO – Repair open in the wire between the TP sen-
sor and the ECM.

5-75
BF135A•BF150A

3. TP sensor signal line open circuit check 5. TP sensor ground line open circuit check
-1. Turn the ignition switch OFF and disconnect the TP -1. Turn the ignition switch OFF and disconnect the TP
sensor connector. sensor 3P connector.
-2. Measure the voltage between the No. 2 (Red/Black) -2. Check for the continuity between the No. 1 (Green/
terminal of the TP sensor harness side 3P connector Red) terminal of the TP sensor harness side 3P con-
and the engine ground. nector and the engine ground.

TP SENSOR HARNESS SIDE TP SENSOR HARNESS SIDE

3P CONNECTOR 3P CONNECTOR

SG2 (GREEN/RED)
THL (RED/BLACK)

VIEWED FROM THE TERMINAL SIDE

VIEWED FROM THE TERMINAL SIDE

Is the measured voltage 4.75 – 5.25V? Is there the continuity?

YES – Perform "4. TP sensor signal line short circuit YES – Perform "6. TP sensor check".
check". NO – Repair open in the wire between the TP sen-
NO – Repair open in the wire between the TP sen- sor and the engine ground.
sor and the ECM.
6. TP sensor check
4. TP sensor signal line short circuit check -1. Turn the ignition switch OFF and connect the TP sen-
-1. Turn the ignition switch OFF and disconnect the TP sor 3P connector.
sensor connector. -2. Measure the voltage between the B-7 terminal and the
-2. Check for the continuity between the No. 2 (Red/ A-2 terminal of the test harness.
Black) terminal of the TP sensor harness side 3P con-
nector and the engine ground.

A-2 B-7
TP SENSOR HARNESS SIDE
3P CONNECTOR

THL (RED/BLACK)
Is the voltage 4.49 – 4.85V when the throttle is fully
open and 0.44 – 0.56V when the throttle is fully
closed?
VIEWED FROM THE TERMINAL SIDE YES – Substitute a known-good ECM and recheck.
NO – Replace the TP sensor.
Is there the continuity?
YES – Repair short in the wire between the TP sen-
sor and the ECM.
NO – Perform "5.TP sensor ground line open circuit
check".

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 BF135A•BF150A

• CMP Sensor Troubleshooting Is the voltage 4.75 – 5.25V?

YES – Perform "4. CMP sensor signal line short cir-
MIL blinks 8 times. cuit check".
1. Symptom reproduction test NO – Repair open in the wire between the CMP
-1. Reset the ECM. sensor and the ECM.
-2. Start the engine and let it run at idling under no load.
-3. Check the MIL. 4. CMP sensor signal line short circuit check
-1. Turn the ignition switch OFF and disconnect the CMP
Does the MIL come ON? sensor 3P connector.
YES – Check the pulse plate. If it is normal, perform -2. Check for the continuity between the No. 3 (Green) ter-
"2. CMP sensor power supply line open circuit minal of the CMP sensor harness side 3P connector
check". If it is abnormal, replace the pulse and the engine ground.
plate and recheck.
NO – Temporary failure (Disappeared) CMP SENSOR HARNESS SIDE
3P CONNECTOR
2. CMP sensor power supply line open circuit check
-1. Turn the ignition switch ON. Measure the voltage TDC (GREEN)
between the No. 1 (Yellow/Black) terminal of the CMP
sensor harness side 3P connector and the engine
ground.

CMP SENSOR HARNESS SIDE VIEWED FROM THE TERMINAL SIDE

3P CONNECTOR
IGP
(YELLOW/BLACK) Is there the continuity?
YES – Repair short in the wire between the CMP
sensor and the ECM.
NO – Perform "5. CMP sensor ground line open cir-
cuit check".
VIEWED FROM THE TERMINAL SIDE
5. CMP sensor ground line open circuit check
-1. Turn the ignition switch OFF and disconnect the CMP
Is there the battery voltage? sensor 3P connector.
YES – Perform "3. CMP sensor signal line open cir- -2. Check for the continuity between the No. 2 (Green/
cuit check". Black) terminal of the CMP sensor harness side 3P
NO – Repair open in the wire between the No. 4 connector and the engine ground.
fuse and the CMP sensor.

3. CMP sensor signal line open circuit check CMP SENSOR HARNESS SIDE
-1. Turn the ignition switch ON. Measure the voltage 3P CONNECTOR
between the No. 3 (Green) terminal of the CMP sensor
harness side 3P connector and the engine ground.
LG1
(GREEN/BLACK)
CMP SENSOR HARNESS SIDE
3P CONNECTOR

TDC (GREEN) VIEWED FROM THE TERMINAL SIDE

Is there the continuity?

YES – Perform “6. CMP sensor check”.
VIEWED FROM THE TERMINAL SIDE NO – Repair open in the wire between the CMP
sensor and the engine ground.

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BF135A•BF150A

6. CMP sensor check • IAT Sensor Troubleshooting

-1. Reset the ECM.
-2. Start the engine and let it run at idling under no load. MIL blinks 10 times.
Check the MIL. 1. Symptom reproduction check
-1. Reset the ECM.
Does the MIL come ON? -2. Turn the ignition switch OFF and connect the test har-
YES – Replace the CMP sensor and recheck. If the ness.
MIL comes ON again, substitute a known- • Hold the sensor connector connected.
good ECM and recheck. -3. Turn the ignition switch ON.
NO – End of the check -4. Measure the voltage between the B-11 terminal (+)
and the A-2 terminal (-) of the test harness.

A-2 B-11

Is the voltage 0.08 – 4.92V?

YES – Temporary failure (Disappeared)
NO – Perform "2. IAT sensor signal line open circuit
check".

2. IAT sensor signal line open circuit check

-1. Turn the ignition switch OFF and disconnect the IAT
sensor 2P connector.
-2. Turn the ignition switch ON. Measure the voltage
between the No. 2 (Red/Yellow) terminal of the IAT
sensor harness side 2P connector and the engine
ground.

IAT SENSOR HARNESS SIDE

2P CONNECTOR

TA (RED/YELLOW)

VIEWED FROM THE TERMINAL SIDE

Is the voltage 4.75 – 5.25V?

YES – Perform “3. IAT sensor signal line short circuit
check”.
NO – Repair open in the wire between the IAT sen-
sor and the ECM.

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 BF135A•BF150A

3. IAT sensor signal line short circuit check 5. IAT sensor check
-1. Turn the ignition switch OFF and disconnect the ECM -1. Turn the ignition switch OFF and disconnect the IAT
connector B. sensor 2P connector.
-2. Check for the continuity between the No. 2 (Red/ -2. Measure the resistance between the No. 1 and the No.
Yellow) terminal of the IAT sensor harness side 2P 2 terminals of the IAT sensor side 2P connector.
connector and the body ground.

IAT SENSOR HARNESS SIDE IAT SENSOR SIDE

2P CONNECTOR 2P CONNECTOR
TA (RED/YELLOW)

VIEWED FROM THE TERMINAL SIDE

VIEWED FROM THE TERMINAL SIDE

Is there the continuity?

YES – Repair short in the wire between the IAT sen-
sor and the ECM.
NO – Perform "4. IAT sensor ground line short cir-
RESISTANCE
cuit check".

4. IAT sensor ground line short circuit check

-1. Turn the ignition switch OFF.
-2. Check for the continuity between the No. 1 (Green/
Red) terminal of the IAT sensor harness side 2P con-
nector and the body ground.

IAT SENSOR HARNESS SIDE INTAKE AIR TEMPERATURE

2P CONNECTOR
Is there the resistance corresponding to the ambient
SG2 (GREEN/RED) temperature?
YES – Substitute a known-good ECM and recheck.
NO – Replace the IAT sensor and recheck.

VIEWED FROM THE TERMINAL SIDE

Is there the continuity?

YES – Perform "5. IAT sensor check".
NO – Repair open in the wire between the IAT sen-
sor and the engine ground.

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BF135A•BF150A

• BARO Sensor Troubleshooting 3. BARO sensor signal line open circuit check
-1. Turn the ignition switch ON. Measure the voltage
MIL blinks 13 times. between the No. 2 (White/Blue) terminal of the BARO
1. Symptom reproduction test sensor harness side 3P connector and the body
-1. Reset the ECM. ground.
-2. Turn the ignition switch OFF and connect the test har-
ness.
• Hold the sensor connector connected. BARO SENSOR HARNESS SIDE
-3. Turn the ignition switch ON. 3P CONNECTOR
-4. Measure the voltage between the A-5 terminal (+) and
the A-2 terminal (–) of the test harness. PA (WHITE/BLUE)

A-5
A-2 VIEWED FROM THE TERMINAL SIDE

Is the voltage 4.75 – 5.25V?

Is there 1.58 – 4.49V? YES – Perform “4. BARO sensor signal line short cir-
YES – Temporary failure (Disappeared) cuit check”.
NO – Perform "2. BARO sensor power supply line NO – Repair open in the wire between the BARO
open circuit check". sensor and the ECM.

2. BARO sensor power supply line open circuit check 4. BARO sensor signal line short circuit check
-1. Turn the ignition switch OFF and disconnect the BARO -1. Turn the ignition switch OFF and disconnect the ECM
sensor 3P connector. connector B.
-2. Turn the ignition switch ON. Measure the voltage -2. Check for the continuity between the No. 2
between the No. 3 (Brown/White) terminal of the (White/Blue) terminal of the BARO sensor harness
BARO sensor harness side 3P connector and the side 3P connector and the body ground.
body ground.
BARO SENSOR HARNESS SIDE
3P CONNECTOR
BARO SENSOR HARNESS SIDE
3P CONNECTOR

VCC2 PA (WHITE/BLUE)
(BROWN/WHITE)

VIEWED FROM THE TERMINAL SIDE

VIEWED FROM THE TERMINAL SIDE

Is there the continuity?
YES – Repair short in the wire between the ECM
Is the voltage 4.75 – 5.25V? and the BARO sensor.
YES – Perform "3. BARO sensor signal line open cir- NO – Perform "5. BARO sensor ground line open
cuit check". circuit check".
NO – Repair open in the wire between the BARO
sensor and the ECM.

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 BF135A•BF150A

5. BARO sensor ground line open circuit check • IAC Valve Troubleshooting
-1. Turn the ignition switch ON. Measure the voltage
between the No. 1 (Green/Red) terminal of the BARO MIL blinks 14 times
sensor harness side 3P connector and the engine 1. Symptom reproduction test
ground. -1. Reset the ECM.
-2. Turn the ignition switch OFF and connect the test har-
BARO SENSOR HARNESS SIDE ness.
3P CONNECTOR • Hold the sensor connector connected.
SG2 -3. Start the engine. Check the engine speed during
(GREEN/RED) idling.

Is the engine speed 650 rpm or above?

YES – Temporary failure (Disappeared)
NO – Perform "2. IAC valve open circuit check".

VIEWED FROM THE TERMINAL SIDE 2. IAC valve open circuit check
-1. Turn the ignition switch OFF and disconnect the IAC
Is there the continuity? valve 2P connector.
YES – Perform "6. BARO sensor check". -2. Measure the resistance between the IAC valve No. 1
NO – Repair open in the wire between the BARO and the No. 2 terminals.
sensor and the engine ground.
IAC VALVE SIDE
2P CONNECTOR
6. BARO sensor check
-1. Turn the ignition switch ON.
-2. Measure the voltage between the A-5 terminal (+) and
the A-2 terminal (–) of the test harness.

VIEWED FROM THE TERMINAL SIDE

A-5
A-2
Is the resistance 8 – 12 ?
YES – Perform "3. IAC valve short circuit check".
NO – Replace the IAC valve.
Is the measurement 2.76 – 2.96V?
YES – Substitute a known-good ECM and recheck. 3. IAC valve short circuit check
NO – Replace the BARO sensor and recheck. -1. Check for the continuity between the IAC valve No. 1
terminal and the body ground.

IAC VALVE SIDE

2P CONNECTOR

VIEWED FROM THE TERMINAL SIDE

Is there the continuity?

YES – Replace the IAC valve.
NO – Go to the step 2.

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BF135A•BF150A

-2. Check for the continuity between the IAC valve No. 2 • VTEC Solenoid Valve Troubleshooting
terminal and the body ground.
MIL blinks 21 times
IAC VALVE SIDE 1. Spool solenoid valve check
2P CONNECTOR
-1. Turn the ignition switch OFF and disconnect the spool
solenoid valve connector.
-2. Measure the resistance between the spool solenoid
valve side 1P connector terminal (Green/White) and
the body ground.

VIEWED FROM THE TERMINAL SIDE SPOOL SOLENOID VALVE

SIDE 1P CONNECTOR

Is there the continuity?

YES – Replace the IAC valve.
NO – Perform "4. IAC valve line open circuit check".

4. IAC valve line open circuit check VIEWED FROM THE TERMINAL SIDE
-1. Connect the IAC valve 2P connector.
-2. Disconnect the ECM connector B.
-3. Measure the resistance between the test harness B-26 Is the measured resistance 12 – 18 ?
terminal and the B-34 terminal. YES – Perform "2. VTEC signal line short circuit
check".
NO – Replace the spool solenoid valve.

2. VTEC signal line short circuit check

B-26 B-34 -1. Turn the ignition switch OFF and connect the test har-
ness.
Hold the ECM connector A disconnected.
-2. Check for the continuity between the test harness A-20
Is the resistance 10 – 13 ? terminal and the engine ground.
YES – Perform "5. IAC valve line short circuit check".
NO – Check for open in the wire between the ECM
and the IAC valve.

5. IAC valve line short circuit check A-20

-1. Check for the continuity between the test harness B-26
terminal and the engine ground, and between the B-34
terminal and the engine ground.

Is there the continuity?

YES – Repair short in the wire between the ECM
and the spool solenoid valve.
NO – Perform “3. VTEC signal line open circuit
B-26 B-34 check”.

Is there the continuity?

YES – Repair short in the wire between the ECM
and the IAC valve.
NO – Substitute a known-good ECM and recheck.

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 BF135A•BF150A

3. VTEC signal line open circuit check • KNOCK Sensor Troubleshooting

-1. Check for the continuity between the spool solenoid
valve harness side connector terminal and A-20 termi- MIL blinks 23 times
nal of the test harness. 1. Symptom reproduction test
-1. Reset the ECM.
SPOOL SOLENOID VALVE -2. Turn the ignition switch OFF and connect the test har-
SIDE CONNECTOR ness.
• Hold the sensor connector connected.
-3. Start the engine and let it warm up by running the
A-20
engine at 5,000 min-1 (rpm) or more for 5 minutes or
more under no load.
-4. Check the MIL.

Is there the continuity? Does the MIL come ON?

YES – Perform "4. Symptom reproduction test". YES – Perform "2. Knock sensor signal line open cir-
NO – Repair open in the wire between the ECM cuit check".
and the spool solenoid valve. NO – Temporary failure (Disappeared)

4. Symptom reproduction test 2. Knock sensor signal line open circuit check
-1. Disconnect the test harness and connect each con- -1. Turn the ignition switch OFF and disconnect the knock
nector securely. sensor 1P connector.
-2. Reset the ECM. -2. Check for the continuity between the knock sensor har-
-3. Start the engine and let it warm up by running the ness side connector (Red/Blue) terminal and the test
engine at 3,000 min-1 (rpm) for 5 minutes under no harness A-15 terminal.
load.
-4. Disconnect the neutral switch 2P connector.
-5. Increase the engine speed gradually until it reaches
4,500 min-1 (rpm), and run the engine for a few sec-
onds.
-6. If there is any abnormality, substitute a known-good A-15
ECM and recheck.

Is there the continuity?

YES – Perform "3. Knock sensor signal line short cir-
cuit check".
NO – Repair open in the wire between knock sen-
sor and the ECM.

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BF135A•BF150A

3. Knock sensor signal line short circuit check • ECT Sensor 2 Troubleshooting
-1. Check for the continuity between the test harness A-15
terminal and the engine ground. MIL blinks 24 times
1. Symptom reproduction test
-1. Reset the ECM.
-2. Turn the ignition switch OFF and connect the test har-
ness.
• Hold the sensor connector connected.
-3. Turn the ignition switch ON.
A-15 -4. Measure the voltage between the test harness B-12
terminal (+) and the A-2 terminal (–).

A-2 B-12
Is there the continuity?
YES – Repair short in the wire between the ECM
and the spool solenoid valve.
NO – Substitute a known-good ECM and recheck.

Is the voltage 0.08 – 4.99V?

YES – Temporary failure (Disappeared)
NO – Perform "2. ECT sensor 2 signal line open cir-
cuit check".

2. ECT sensor 2 signal line open circuit check

-1. Turn the ignition switch OFF. Disconnect the 2P con-
nector from the ECT sensor 2.
-2. Turn the ignition switch ON.
-3. Measure the voltage between the No. 2 (Red/Black)
terminal of the ECT sensor 2 harness side 2P con-
nector and the engine ground.
ECT SENSOR 2 HARNESS SIDE
2P CONNECTOR

TOH1 (RED/BLACK)

VIEWED FROM THE TERMINAL SIDE

Is the voltage 4.75 – 5.25V?

YES – Perform "3. ECT sensor 2 ground line short
circuit check".
NO – Repair open in the wire between the ECT
sensor 2 and the ECM.

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3. ECT sensor 2 ground line short circuit check 5. ECT sensor 2 check
-1. Turn the ignition switch OFF. Disconnect the ECT sen- -1. Turn the ignition switch OFF and disconnect the 2P
sor 2 connector and the ECM connector B. connector of the ECT sensor 2 .
-2. Check for the continuity between the No. 2 (Red/ -2. Measure the resistance between the No. 1 and the No.
Black) terminal of the ECT sensor 2 harness side 2P 2 terminals of the ECT sensor 2 side 2P connector.
connector and the body ground.
ECT SENSOR 2 SIDE
2P CONNECTOR
ECT SENSOR 2 HARNESS SIDE
2P CONNECTOR

TOH1 (RED/BLACK)

VIEWED FROM THE TERMINAL SIDE

VIEWED FROM THE TERMINAL SIDE

Is there the continuity?

YES – Repair short in the wire between the ECT
sensor 2 and the engine ground.

RESISTANCE
NO – Perform “4. ECT sensor 2 ground line open
circuit check”.

4. ECT sensor 2 ground line open circuit check

-1. Reset the ECM connector B.
-2. Check for the continuity between the No. 1 (Green/
Red) terminal of the ECT sensor 2 harness side 2P
connector and the body ground.
ENGINE COOLANT TEMPERATURE
ECT SENSOR 2 HARNESS SIDE
2P CONNECTOR Is there the resistance corresponding to the engine
coolant temperature?
SG2 (GREEN/RED) YES – Substitute a known-good ECM and recheck.
NO – Replace the ECT sensor 2.

VIEWED FROM THE TERMINAL SIDE

Is there the continuity?

YES – Perform "5. ECT sensor 2 check".
NO – Repair open in the wire between the ECT
sensor 2 and the engine ground.

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• ECT Sensor 3 Troubleshooting 3. ECT sensor 3 signal line short circuit check
-1. Turn the ignition switch OFF. Disconnect the ECT sen-
MIL blinks 25 times sor 3 connector and the ECM connector B.
1. Symptom reproduction test -2. Check for the continuity between the No. 2 (Red) ter-
-1. Reset the ECM. minal of the ECT sensor 3 harness side 2P connector
-2. Turn the ignition switch OFF and connect the test har- and the body ground.
ness.
• Hold the sensor connector connected. ECT SENSOR 3 HARNESS SIDE
2P CONNECTOR
-3. Turn the ignition switch ON.
-4. Measure the voltage between the test harness A-16 TOH2 (RED)
terminal (+) and the A-2 terminal (–).

A-2

VIEWED FROM THE TERMINAL SIDE

A-16
Is there the continuity?
YES – Repair short in the wire between the ECT
Is the voltage 0.08 – 4.99V? sensor 3 and the engine ground.
NO – Perform "4. ECT sensor 3 ground line open
YES – Temporary failure (Disappeared) circuit check".
NO – Perform "2. ECT sensor 3 signal line open cir-
cuit check".
4. ECT sensor 3 ground line open circuit check
2. ECT sensor 3 signal line open circuit check -1. Connect the ECM connector B.
-2. Check for the continuity between the No. 1 (Green/
-1. Turn the ignition switch OFF. Disconnect the 2P con- Red) terminal of the ECT sensor 3 harness side 2P
nector from the ECT sensor 3. connector and the body ground.
-2. Turn the ignition switch ON.
-3. Measure the voltage between the No. 2 (Red) terminal
of the ECT sensor 3 harness side 2P connector and ECT SENSOR 3 HARNESS SIDE
the engine ground. 2P CONNECTOR

ECT SENSOR 3 HARNESS SIDE

SG2 (GREEN/RED)
2P CONNECTOR

TOH2 (RED)
VIEWED FROM THE TERMINAL SIDE

VIEWED FROM THE TERMINAL SIDE Is there the continuity?

YES – Perform "5. ECT sensor 3 check".
NO – Repair open in the wire between the ECT
Is the voltage 4.75 – 5.25V? sensor 3 and the engine ground.
YES – Perform "3. ECT sensor 3 signal line short cir-
cuit check".
NO – Repair open in the wire between the ECT
sensor 3 and the ECM.

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5. ECT sensor 3 check • EOP switch (High Pressure Side)

-1. Turn the ignition switch OFF and disconnect the ECT
sensor 3 2P connector.
Troubleshooting
-2. Measure the resistance between the No.1 and No.2 MIL blinks 26 times
terminals of the ECT sensor 3 side 2P connector. 1. Symptom reproduction test
-1. Reset the ECM.
ECT SENSOR 3 SIDE -2. Turn the ignition switch OFF and connect the test har-
2P CONNECTOR ness.
• Hold the sensor connector connected.
-3. Turn the ignition switch ON.
-4. Measure the voltage between the test harness A-17
terminal (+) and A-2 terminal (–).

VIEWED FROM THE TERMINAL SIDE A-2

A-17
RESISTANCE

Is the voltage 0V (OFF signal)?

YES – Temporary failure (Disappeared)
NO – Perform "2. EOP switch signal line open cir-
cuit check".

2. EOP switch signal line open circuit check

-1. Turn the ignition switch OFF and disconnect the EOP
ENGINE COOLANT TEMPERATURE switch 2P connector.
-2. Turn the ignition switch ON. Measure the voltage
between the No.1 (Yellow/Red) terminal of the EOP
Is there the resistance corresponding to the engine
switch harness side 2P connector and the body
coolant temperature? ground.
YES – Substitute a known-good ECM and recheck.
NO – Replace the ECT sensor 3. EOP SWITCH HARNESS SIDE 2P
CONNECTOR

OPSH (YELLOW/RED)

VIEWED FROM THE TERMINAL SIDE

Is there the battery voltage?

YES – Perform “3. EOP switch signal line short circuit
check”.
NO – Repair open in the wire between the EOP
switch and the ECM.

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3. EOP switch signal line short circuit check 5. EOP switch check
-1. Turn the ignition switch OFF. Disconnect the EOP -1. Turn the ignition switch OFF and connect each con-
switch 2P connector and the ECM connector A. nector.
-2. Check for the continuity between the No.1 (Yellow/ -2. Turn the ignition switch ON and measure the voltage
Red) terminal of the EOP switch harness side 2P con- between the test harness A-17 terminal (+) and the A-
nector and the body ground. 2 terminal.

A-2
EOP SWITCH HARNESS SIDE 2P
CONNECTOR

OPSHH A-17
(YELLOW/RED)

Is the voltage 0V (switch OFF)?

VIEWED FROM THE TERMINAL SIDE YES – Substitute a known-good ECM and recheck.
NO – Replace the EOP switch (high pressure side).
Is there the continuity?
YES – Repair short in the wire between the EOP
switch and the ECM.
NO – Perform “4. EOP switch ground line open cir-
cuit check”.

4. EOP switch ground line open circuit check

-1. Check for the continuity between the No.2 (Green/
Red) terminal of the EOP switch harness side 2P con-
nector and the body ground.

EOP SWITCH HARNESS SIDE 2P

CONNECTOR

SG2 (GREEN/RED)

VIEWED FROM THE TERMINAL SIDE

Is there the continuity?

YES – Perform "5. EOP switch check".
NO – Repair open in the wire between the EOP
switch and the ECM.

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• ECT Sensor 4 Troubleshooting 3. ECT sensor 4 signal line short circuit check
-1. Turn the ignition switch OFF. Disconnect the ECT sen-
MIL blinks 27 times sor 4 connector and the ECM connector B.
1. Symptom reproduction test -2. Check for the continuity between the No.2 (Red/
-1. Reset the ECM. Green) terminal of the ECT sensor 4 harness side 2P
-2. Turn the ignition switch OFF and connect the test har- connector and the body ground.
ness.
• Hold the sensor connector connected.
ECT SENSOR 4 HARNESS SIDE
-3. Turn the ignition switch ON. 2P CONNECTOR
-4. Measure the voltage between the test harness A-6 ter-
minal (+) and the A-2 terminal (–).
TOH3 (RED/GREEN)

A-2 A-6

VIEWED FROM THE TERMINAL SIDE

Is there the continuity?

Is the voltage 0.08 – 4.99V? YES – Repair short in the wire between the ECT
sensor 4 and the engine ground.
YES – Temporary failure (Disappeared) NO – Perform “4. ECT sensor 4 ground line open
NO – Perform "2. ECT sensor 4 signal line open cir- circuit check”.
cuit check".
4. ECT sensor 4 ground line open circuit check
2. ECT sensor 4 signal line open circuit check
-1. Connect the ECM connector B.
-1. Turn the ignition switch OFF and disconnect the 2P -2. Check for the continuity between the No.1 (Green/
connector from the ECT sensor 4. Red) terminal of the ECT sensor 4 harness side 2P
-2. Turn the ignition switch ON. connector and the body ground.
-3. Measure the voltage between the No.2 (Red/Green)
terminal of the ECT sensor 4 harness side 2P con-
nector and the engine ground. ECT SENSOR 4 HARNESS SIDE
2P CONNECTOR
ECT SENSOR 4 HARNESS
SIDE 2P CONNECTOR SG2 (GREEN/RED)

TOH3 (RED/GREEN)

VIEWED FROM THE TERMINAL SIDE

VIEWED FROM THE TERMINAL SIDE

Is there the continuity?
YES – Perform "5. ECT sensor 4 check".
Is the voltage 4.75 – 5.25V? NO – Repair open in the wire between the ECT
sensor 4 and the engine ground.
YES – Perform "3. ECT sensor 4 signal line short cir-
cuit check".
NO – Repair open in the wire between the ECT
sensor 4 and the ECM.

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5. ECT sensor 4 check • A/F Sensor Heater Troubleshooting

-1. Turn the ignition switch OFF and disconnect the ECT
sensor 4 2P connector. MIL blinks 41 times
-2. Measure the voltage between the No.1 and No.2 ter- 1. Symptom reproduction test
minals of the ECT sensor 4 side 2P connector. -1. Reset the ECM.
-2. Start the engine and run it at 3,000 rpm for 5 minutes
or more to warm up.
ECT SENSOR 4 SIDE -3. Check the MIL.
2P CONNECTOR
Does the MIL come ON?
YES – Perform "2. A/F relay check".
NO – Temporary failure (Disappeared)

2. A/F relay check

VIEWED FROM THE TERMINAL SIDE -1. Turn the ignition switch OFF and connect the test har-
ness.
Hold the sensor connector connected.
-2. Disconnect the A/F sensor 4P connector.
-3. Turn the ignition switch ON. Measure the voltage
between the test harness C-4 terminal and the engine
RESISTANCE

ground.

C-4

ENGINE COOLANT TEMPERATURE

Is there the battery voltage?
Is there the resistance corresponding to the engine YES – Perform "4. A/F heater check".
coolant temperature? NO – Check the A/F relay and replace if necessary.
YES – Substitute a known-good ECM and recheck. If it is normal, go to the step 4.
NO – Replace the ECT sensor 4.
-4. Turn the ignition switch OFF and disconnect the A/F
relay 4P connector.
-5. Measure the voltage between the No.1 (White/ Green)
terminal of the A/F relay harness side 4P connector
and the engine ground.
• Note that the battery voltage is constantly applied to
the White/Green terminal. Take care not to short-cir-
cuit the terminal.

A/F RELAY HARNESS SIDE

4P CONNECTOR

+B
(WHITE/GREEN)

VIEWED FROM THE TERMINAL SIDE

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 BF135A•BF150A

Is there the battery voltage? 4. A/F heater check

YES – Go to the step 6. -1. Turn the ignition witch OFF and disconnect the A/F
NO – Blown No.1 (30A) fuse, or repair open in the sensor 4P connector.
wire between the A/F relay and the No.1 -2. Measure the resistance between the No.3 (Black) and
(10A) fuse. No.4 (Black) terminals of the A/F sensor’s sensor side
4P connector.
-6. Turn the ignition switch ON. Measure the voltage
between the No.2 (Yellow/Red) terminal of the A/F A/F SENSOR SIDE
relay harness side 4P connector and the engine 4P CONNECTOR
ground.

A/F RELAY HARNESS SIDE AFHT (BLACK) AFHT+ (BLACK)

4P CONNECTOR
IGP
(YELLOW/RED)
VIEWED FROM THE TERMINAL SIDE

Is the resistance 2 – 3 ?
YES – Perform “5. Heater line short circuit check”.
NO – Replace the A/F sensor.
VIEWED FROM THE TERMINAL SIDE
5. Heater line short circuit check
Is there the battery voltage?
-1. Turn the ignition switch OFF and disconnect the ECM
YES – Perform "3. A/F relay drive line check". connector C.
NO – Blown No.5 (10A) fuse, or repair open in the -2. Check for the continuity between the test harness C-3
wire between the A/F relay and the No.5 fuse. terminal and the engine ground, and between the C-4
terminal and the engine ground.
3. A/F relay drive line check
-1. Turn the ignition switch OFF and connect the A/F relay C-3
connector.
-2. Disconnect the ECM connector A. C-4
-3. Turn the ignition switch ON and measure the voltage
between the test harness A-25 and the engine ground.

Is there the continuity?

A-25
YES – Repair short in the wire between the A/F sen-
sor and the ECM.
NO – Perform “6. Heater line open circuit check”.

Is there the battery voltage?

YES – Substitute a known-good ECM and recheck.
NO – Repair open in the A/F relay and the ECM.

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6. Heater line open circuit check • A/F Sensor Troubleshooting

-1. Connect the No.3 (Black/White) and the No.4 (White)
terminals of the A/F sensor harness side 4P connector MIL blinks 48 times
respectively to the engine ground with the jumper 1. Symptom reproduction test
wires. -1. Reset the ECM.
-2. Check for the continuity between the test harness C-3 -2. Start the engine and let it warm up by running the
terminal and the engine ground, and between the C-4 engine at 3,000 rpm for 5 minutes or more under no
terminal and the engine ground. load. Run the engine at idling for an additional one
minute under no load.
C-3 -3. Check the MIL.

C-4 Does the MIL come ON?

YES – Perform "2. A/F sensor line open circuit
check".
NO – Temporary failure (Disappeared)

2. A/F sensor line open circuit check

Is there the continuity? -1. Turn the ignition switch OFF. Disconnect the A/F sen-
YES – Perform "7. Sensor line short circuit check". sor connector and the ECM connector A.
NO – Repair open in the wire between the A/F sen- -2. Connect the No.1 (White/Black) terminal of the A/F
sor and the ECM. sensor harness side 4P connector to the engine
ground to short using a jumper wire.
-3. Check for the continuity between the test harness A-4
7. Sensor line short circuit check
terminal and the engine ground.
-1. Disconnect the ECM connector B.
-2. Disconnect the A/F sensor 4P connector. A-4
-3. Check for the continuity between the test harness C-3
terminal and the respective terminals of A-4 and A-14
terminals, and between the C-4 terminal and the
respective terminals of A-4 and A-14 terminals.

A-4

C-3
Is there the continuity?
C-4 YES – Go to the step 4.
NO – Repair open in the wire between the A/F sen-
A-14 sor and the ECM.

-4. Connect the No.2 (Black/Yellow) terminal of the A/F

Is there the continuity? sensor harness side 4P connector to the engine
YES – Repair short in the wire between the A/F sen- ground to short using a jumper wire.
sor and the ECM. -5. Check for continuity between the test harness A-14 ter-
NO – Replace the A/F sensor and recheck. If it is minal and the engine ground.
still abnormal, substitute a known-good ECM
and recheck.

A-14

Is there the continuity?

YES – Perform "3. A/F sensor line short circuit
check".
NO – Repair open in the wire between the A/F sen-
sor and the ECM.

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 BF135A•BF150A

3. A/F sensor line short circuit check

-1. Turn the ignition switch OFF. Disconnect the A/F sen-
8. IDLE CONTROL SYSTEM
sor connector and the ECM connector A. • Troubleshooting
-2. Check for the continuity between the test harness A-4
terminal and the engine ground. When the MIL does not come ON but an engine failure of
either of the following symptoms occurs at the engine start
A-4 or during idling, inspect the system(s) and part(s) in the
numbered sequence.

• Hard to start
1. Vacuum line
2. IAC valve (P. 5-95)

Is there the continuity? • Engine starts but stalls soon.

YES – Repair short in the wire between the A/F sen- 1. Idle adjusting screw (P. 5-94)
sor and the ECM.
NO – Go to the step 3. 2. IAC valve (P. 5-95)
3. Vacuum line
-3. Check for the continuity between the test harness A-14
terminal and the engine ground.
• Engine speed is higher than the specified
idle speed after warming up.
1. Vacuum line
A-14 2. IAC valve (P. 5-95)
3. Idle adjusting screw (P. 5-94)

• Engine speed is higher than the specified

trolling speed after warming up.
Is there the continuity?
YES – Repair short in the wire between the A/F sen- 1. Neutral switch (P. 17-13)
sor and the ECM. 2. Vacuum line
NO – Replace the A/F sensor and recheck. If there 3. Idle adjusting screw (P. 5-94)
is any abnormality, substitute a known-good
ECM and recheck. 4. IAC valve (P. 5-95)

• Engine speed is lower than the specified

idling or trolling speed after warming up.
1. IAC valve (P. 5-95)
2. Idle adjusting screw (P. 5-94)
3. Vacuum line

• Engine speed is not stable during idling and

trolling.
1. IAC valve (P. 5-95)
2. Idle adjusting screw (P. 5-94)
3. Vacuum line
4. Neutral switch (P. 17-13)

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BF135A•BF150A

• Idle Adjusting Screw Adjustment 6) Adjust the idle speed by turning the adjusting screw.
• If adjustment cannot be made, check each vacuum
Check the following before adjustment.
tube for disconnection and collapse, then check and
• Idle speed inspection (P. 3-22) clean the throttle body (P. 5-95).
• Spark plug (P. 3-6)
• MIL is OFF. (If it is ON, troubleshoot according to the
ADJUSTING SCREW
chart on P. 5-15 or 5-59.)

1) Remove the propeller. Set the outboard motor in a test

tank filled with water.
• Fill the tank with water above the gear case.
2) Connect the HDS tester (P. 5-13).
• If you do not have the HDS tester, connect a digital
tachometer (P. 3-22).

3) Set the SCS mode using the HDS tester.

• If you do not have the HDS tester, disconnect the red
4P connector and connect (short-circuit) the SCS
short connector to the DLC . (P. 5-57). 7) After adjustment, connect the IAC valve 2P connector
and clear the DTC (P. 5-14) or reset the ECM (P. 5-57).
4) Start the engine and let it warm up with the gear in
neutral. 8) Run the engine at idling for 5 minutes or more, then
check the idle speed again.
5) Disconnect the IAC valve 2P connector and check the
idle speed. Specified idle speed 750 ± 50 min-1 (rpm)

Specified idle speed 575 ± 30 min-1 (rpm)

9) If the idle speed is out of the specification, repeat the
procedure from step 5) through step 8). If the idle
2P CONNECTOR speed is still out of the specification, replace the IAC
valve. If the specified idle speed cannot be obtained
yet, replace the ECM with a new one and recheck.

10) After adjustment, apply the paint (Nippon Paint

Unipack #200 or equivalent) to the head of the adjust-
ing screw.
ADJUSTING SCREW

IAC VALVE

Apply paint here.

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 BF135A•BF150A

• Throttle Body Inspection/Cleaning 7) After cleaning, install the throttle rod and the silencer
chamber (P. 5-135).
1) Remove the engine cover.
2) Remove the intake air silencer (P. 5-128).
8) After assembly, check the idle speed and adjust if nec-
3) Turn the throttle cam and check the throttle valve for essary (P. 5-94).
smooth movement and the throttle valve shaft for play.
4) Check that there is no gap between the throttle shaft
stopper and the throttle stop screw.
• The throttle stop screw cannot be adjusted. If it is • IAC Valve Replacement
faulty, replace the throttle body. 1) Remove the engine cover.
THROTTLE STOP SCREW
2) Turn the ignition switch OFF and disconnect the IAC
valve 2P connector.

3) Remove
IAC VALVE the two 8 x 45 mm flange bolts and remove
the IAC valve and IAC valve gasket.

2P CONNECTOR

THROTTLE BODY

5) Check the throttle valve and bore for contamination.

Clean if necessary.

NOTICE IAC VALVE GASKET

• Do not spray the carburetor cleaner directly to the
throttle body.
• Use the genuine Honda carburetor cleaner.
• Do not wipe the throttle valve where is coated with 3) Apply the engine oil to the new IAC valve gasket and
the molybdenum (i.e. both ends of the throttle valve). install it.

6) Wipe the inner wall of the throttle bore and both ends 4) Install the IAC valve and tighten the 8 x 45 mm flange
of the throttle valve with a shop towel or equivalent bolts securely.
material sprayed with the carburetor cleaner.
5) Connect the IAC valve 2P connector securely.

Clean. 6) Start the engine and let it warm up. Running the
engine at idling, check the IAC valve for proper opera-
tion (idle speed inspection; see P. 3-22).

Coated with molybdenum

5-95
BF135A•BF150A

9. FUEL SUPPLY SYSTEM High pressure fuel supply system

• Troubleshooting • Hard to start

When the MIL does not come ON but an engine failure of 1. Fuel line (high pressure side) (P. 5-104)
either of the following symptoms occurs at the engine start 2. Fuel pump (high pressure side) (P. 5-107)
or during idling, inspect the system(s) and part(s) in the
3. Fuel injector (P. 5-105)
numbered sequence.

Low pressure fuel supply system • Engine starts but stalls soon.
1. Fuel line (high pressure side) (P. 5-104)
• Hard to start 2. Fuel injector (P. 5-105)
1. Water separator (P. 3-19) 3. Pressure regulator (P. 5-106)
2. Fuel strainer (low pressure side) (P. 3-15)
3. Fuel line (low pressure side) (P. 5-104) • Engine speed is not stable during idling and
trolling, or engine stalls.
4. Vapor separator (P. 5-111 thru. 5-127)
1. Fuel line (high pressure side) (P. 5-104)
2. Fuel injector (P. 5-105)
• Engine starts but stalls soon.
3. Pressure regulator (P. 5-106)
1. Water separator (P. 3-19)
2. Fuel strainer (low pressure side) (P. 3-15)
• Engine speed does not increase
3. Fuel line (low pressure side) (P. 5-104)
1. Fuel line (high pressure side) (P. 5-104)
4. Vapor separator (P. 5-111 thru. 5-127)
2. Pressure regulator (P. 5-106)
3. Fuel pump (high pressure side) (P. 5-107)
• Engine speed is not stable during idling and
trolling, or engine stalls. 4. Fuel strainer (high pressure side) (P. 3-18)
1. Water separator (P. 3-19) 5. Fuel injector (P. 5-105)
2. Fuel strainer (low pressure side) (P. 3-15)
• Engine sometimes misfires or tends to stall.
• Engine sometimes misfires or tends to stall. 1. Water separator (P. 3-19)
1. Water separator (P. 3-19) 2. Fuel injector (P. 5-105)
2. Fuel strainer (low pressure side) (P. 3-15) 3. Fuel pump (high pressure side) (P. 5-107)
3. Fuel line (low pressure side) (P. 5-104) 4. Pressure regulator (P. 5-106)
4. Fuel pump (low pressure side) (P. 5-142)

• Engine tends to stall at hot restart of the

engine.
1. Vapor separator (P. 5-111 thru. 5-127)

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 BF135A•BF150A

• PGM-FI Main Relay Harness Inspection 5. Turn the ignition switch ON. Measure the voltage
between the No.2 (Black/Yellow) terminal of the PGM-
Check with test harness: FI main relay harness side 6P connector and the
1. Turn the ignition switch OFF and disconnect each con- engine ground.
nector from the PGM-FI main relay.
PGM-FI MAN RELAY HARNESS
SIDE 6P CONNECTOR
2. Connect the test harness.
BLACK/YELLOW
• Disconnect the connector A, B and C from the ECM.

3. Check for the continuity between the No.6 (Black) ter-

minal of the harness side 6P connector and the engine
ground. VIEWED FROM THE TERMINAL SIDE

Is there the battery voltage?

HARNESS SIDE 6P YES – Go to the step 6.
CONNECTOR
NO – Blown No.3 (10A) fuse, or faulty ignition
switch, or open in the wire between the PGM-
BLACK FI main relay and the ignition switch.

6. Measure the voltage between the No.2 (White/Yellow)

terminal of the harness side 2P connector and the
VIEWED FROM THE TERMINAL SIDE engine ground.

Is there the continuity? PGM-FI MAIN RELAY HARNESS

SIDE 2P CONNECTOR
YES – Repair short in the wire between the PGM-FI
main relay and the engine ground.
NO – Go to the step 4. WHITE/YELLOW

4. Measure the voltage between the No.3 (White/Yellow)

terminal of the fuse box side 4P connector and the
engine ground. VIEWED FROM THE TERMINAL SIDE

FUSE BOX SIDE

Is there the battery voltage?
4P CONNECTOR YES – Go to the step 7.
NO – Blown No.3 (10A) fuse, or faulty ignition
switch, or open in the wire between the PGM-
WHITE/YELLOW FI main relay and the ignition switch.

7. Check for the continuity between the No.4 (White/

Black) terminal of the fuse box side 4P connector and
the respective terminals of the C-1 and C-5 terminals
VIEWED FROM THE TERMINAL SIDE of the test harness.
Is there the battery voltage? FUSE BOX SIDE 4P
YES – Go to the step 5. CONNECTOR
C-1
NO – Blown No.7 (30A) fuse, or open in the wire
between the fuse box and the PGM-FI main
relay.

WHITE/BLACK C-5

VIEWED FROM THE TERMINAL SIDE

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BF135A•BF150A

Is there the continuity? Check without test harness:

YES – Go to the step 8. 1. Turn the ignition switch OFF and disconnect each con-
NO – Blown No.4 (15A) fuse, or open in the wire nector from the PGM-FI main relay.
between the PGM-FI main relay and the No.4
(15A) fuse, or open in the wire between the 2. Disconnect the ECM connectors A, B, and C.
No.4 (15A) fuse and the ECM. 3. Check for the continuity between the No.6 (Black) ter-
minal of the harness side 6P connector and the engine
8. Check for the continuity between the NO.3 (Light ground.
green/Red) terminal of the fuse box side 6P connector PGM-FI MAIN RELAY HARNESS
and the respective terminals of the test harness A-13 SIDE 6P CONNECTOR
and B-10 terminals.

BLACK
FUSE BOX SIDE
6P CONNECTOR
A-13
LIGHT GREEN/ VIEWED FROM THE TERMINAL SIDE
RED
B-10 Is there the continuity?
YES – Repair short in the wire between the PGM-FI
main relay and the engine ground.
NO – Go to the step 4.
VIEWED FROM THE
TERMINAL SIDE
4. Measure the voltage between the No.3 (White/Yellow)
terminal of the fuse box side 4P connector and the
Is there the continuity? engine ground.
YES – Go to the step 9.
NO – Repair open in the wire between the PGM-FI FUSE BOX SIDE
main relay and the ECM. 4P CONNECTOR

9. Turn the ignition switch ON. Measure the voltage

between the test harness C-1 terminal (+) and the C- WHITE/YELLOW
2/C-6 terminals (–), and between the C-5 terminal (+)
and the C-2/C-6 (–) terminals.
VIEWED FROM THE TERMINAL SIDE

Is there the battery voltage?

C-2 YES – Go to the step 5.
C-2
NO – Blown No.7 (30A) fuse, or open in the wire
C-1
between the fuse box and the PGM-FI main
C-6 relay.
C-6 C-5

5. Turn the ignition switch ON. Measure the voltage

between the No.2 (Black/Yellow) terminal of the har-
ness side 6P connector and the engine ground.
Is there the battery voltage?
HARNESS SIDE
YES – End of the check (Good) 6P CONNECTOR
NO – Replace the PGM-FI main relay.
BLACK/YELLOW

VIEWED FROM THE TERMINAL SIDE

5-98
 BF135A•BF150A

Is there the battery voltage? 8. Check for the continuity between the terminals of the
YES – Go to the step 6. fuse box harness side 6P connector and ECM con-
NO – Blown No.3 (10A) fuse, or faulty ignition nectors A and B:
switch, or open in the wire between the PGM- Fuse Box
FI main relay and the ignition switch. 6P connector ECM connector A
No.3 (Light green/Red) No.13 (Light green/Red)
6. Measure the voltage between the No.2 (White/Yellow) Fuse Box
terminal of the harness side 2P connector and the 6P connector ECM connector B
engine ground.
No.3 (Light green/Red) No.10 (Light green/Red)
HARNESS SIDE FUSE BOX ECM CONNECTOR A
2P CONNECTOR HARNESS SIDE FLR2
6P CONNECTOR (LIGHT GREEN/RED)
WHITE/YELLOW

LIGHT GREEN/
RED
VIEWED FROM THE TERMINAL SIDE

Is there the battery voltage?

YES – Go to the step 7.
NO – Blown No.3 (10A) fuse, or faulty ignition
FLR1
switch, or open in the wire between the PGM-
(LIGHT GREEN/RED)
FI main relay and the ignition switch.
ECM CONNECTOR B
7. Check for the continuity between the fuse box side 4P VIEWED FROM THE TERMINAL SIDE
connector and ECM connector terminals:
Fuse Box Is there the continuity?
4P connector ECM connector C YES – Go to the step 9.
NO – Repair open in the wire between the PGM-FI
No.4 (White/ Black) No.1 (Yellow/Black) main relay and the ECM.
No.4 (White/ Black) No.5 (Yellow/Black)
9. Turn the ignition switch ON. Measure the voltage
ECM CONNECTOR C between the terminals of the ECM connector C:
FUSE BOX SIDE 4P
CONNECTOR IGP2 No.1 (Yellow/Black) ( ) No. 2 (Green) ( )
(YELLOW/BLACK)
No.1 (Yellow/Black) ( ) No. 6 (Green/red) ( )
No.5 (Yellow/Black) ( ) No. 2 (Green) ( )
No.5 (Yellow/Black) ( ) No. 6 (Green/Red) ( )
WHITE/BLACK IGP2
(YELLOW/BLACK) ECM CONNECTOR A
VIEWED FROM THE TERMINAL SIDE

Is there the continuity?

YES – Go to the step 8.
NO – Blown No.4 (15A) fuse, or open in the wire
between the PGM-FI main relay and the No.4 VIEWED FROM THE TERMINAL SIDE
(15A) fuse, or open in the wire between the
No.4 (15A) fuse and the ECM. Is there the battery voltage?
YES – End of the check (Good)
NO – Replace the PGM-FI main relay.

5-99
BF135A•BF150A

• Injector Harness Inspection Is there the continuity?

YES – Repair open in the wire between the ECM
Check with test harness: and the injector
1. Turn the ignition switch OFF and disconnect each 2P NO – Go to the step 5.
connector from the respective injectors.
5. Connect each injector 2P connector.
2. Connect the test harness.
• Disconnect the connector A, B, and C from the ECM. 6. Turn the ignition switch ON. Check for the voltage
between the test harness and engine ground:
3. Check for the continuity between the test harness and B-21 terminal and the engine ground
each injector harness side 2P connector: B-23 terminal and the engine ground
B-27 terminal and the engine ground
B-21 No.2 (Brown) of the No.1 injector
B-29 terminal and the engine ground
B-23 No.2 (Red) of the No.2 injector
B-27 No.2 (Blue) of the No.3 injector
B-29 No.2 (Yellow) of the No.4 injector

B-21 B-29
B-23 B-27

B-21 B-29
B-23 B-27

Is there the battery voltage?

BROWN RED BLUE YELLOW
YES – End of the check (Good)
No. 1 No. 2 No. 3 No. 4 NO – Check the injector (P. 5-105). If it is normal,
repair open in the wire between the No.4
INJECTOR HARNESS
SIDE 2P CONNECTORS
(15A) fuse and the injector.

VIEWED FROM THE TERMINAL SIDE

Is there the continuity?

YES – Go to the step 4.
NO – Repair open in the wire between the injector
and ECM.

4. Check for the continuity between the test harness and

engine ground:
B-21 terminal and the engine ground,
B-23 terminal and the engine ground
B-27 terminal and the engine ground
B-29 terminal and the engine ground.

B-21 B-29
B-23 B-27

5-100
 BF135A•BF150A

Check without test harness: Is there the continuity?

1. Turn the ignition switch OFF and disconnect the 2P YES – Repair open in the wire between the ECM
connector from the respective injectors. and the injector.
NO – Go to the step 5.

2. Disconnect the ECM connector B and C.

5. Connect the injector 2P connector.

3. Check for the continuity between the ECM connector B

6. Turn the ignition switch ON. Measure the voltage
and each injector harness side 2P connector:
between the No.1 (Yellow/Black) terminal of each
ECM connector B Injector injector harness side terminal and the engine ground.
No.21 (Brown) No.2 (Brown) of the No.1 injector
No.23 (Red) No.2 (Red) of the No.2 injector INJECTOR HARNESS
No.27 (Blue) No.2 (Blue) of the No.3 injector SIDE 2P CONNECTOR
No.29 (Yellow) No.2 (Yellow) of the No.4 injector
YELLOW/BLACK
ECM CONNECTOR B

VIEWED FROM THE TERMINAL SIDE

BROWN RED BLUE YELLOW Is there the battery voltage?

No. 1 No. 2 No. 3 No. 4 YES – End of the check (Good)
INJECTOR HARNESS NO – Check the injector (P. 5-105). If it is normal,
SIDE 2P CONNECTORS repair open in the wire between the No.4
(15A) fuse and the injector.
VIEWED FROM THE TERMINAL SIDE

Is there the continuity?

YES – Go to the step 4.
NO – Repair open in the wire between the injector
and the ECM.

4. Check for the continuity between the injector harness

side 2P connector terminal and engine ground:
No.2 (Brown) of No.1 injector and engine ground.
No.2 (Red) of No.2 injector and engine ground.
No.2 (Blue) of the No.3 injector and engine ground.
No.2 (Yellow) of the No.4 injector and engine ground

INJECTOR HARNESS
SIDE 2P CONNECTORS

No. 1 No. 2 No. 3 No. 4

BROWN BLUE YELLOW

RED

VIEWED FROM THE TERMINAL SIDE

5-101
BF135A•BF150A

• How To Relive Fuel Pressure SHOP

TOWEL

Gasoline is highly flammable and explosive.

You can be burned or seriously injured when handling fuel.
• Keep heat, sparks, and flame away.
• Handle fuel only outdoors.
• Wipe up spills immediately.

• Disconnect the battery cable from the battery negative (-) ter- SERVICE
minal before relieving the fuel pressure. CHECK BOLT
• Replace the sealing washer when the service check bolt is
loosened or removed.
SERVICE
CHECK BOLT
1) Remove the engine cover (P. 4-2).
2) Set an offset wrench on the 6 mm service check bolt of the
vapor separator. Place a shop towel or equivalent material
over the service check bolt.
3) Loosen the service check bolt approximately one turn slow-
ly to relieve the fuel pressure.

4) After relieving the fuel pressure, remove the service check

bolt and replace the 6 mm sealing washer with a new one.
5) Tighten the service check bolt to the specified torque.
TORQUE: 12 N • m (1.2 kgf • m, 9 lbf • ft)
SEALING WASHER
Do not reuse.

• Fuel Pressure Measurement

1) Relieve the fuel pressure according to “How to relive fuel
pressure” explained above.

2) Remove the service check bolt and set the special tool (fuel
pressure gauge set) in the threaded bolt hole.

FUEL PRESSURE GAUGE SET

07406-0040002

5-102
 BF135A•BF150A

3) Disconnect the pressure regulator control tube from the PRESSURE REGULATOR
pressure regulator, and clamp the vacuum tube. CONTROL TUBE
TUBE CLAMP
(Commercially available)
4) Remove the propeller. Set the outboard motor gear case in
a test tank filled with water. Start the engine and measure
the fuel pressure at idling.

Standard fuel pressure 270 – 320 kPa

(At idle speed of (2.8 – 3.3 kgf/cm2,
650 ± 50 min-1 /rpm) 39.8 – 46.9 psi)

5) When the fuel pressure is outside the specified standard

pressure, check the following.
When fuel pressure is higher than standard pres-
sure:
• Check the pressure regulator return hose for kinking, col- PRESSURE REGULATOR
lapse or restrictions.
• Check the pressure regulator for proper operation
SERVICE CHECK BOLT
(Inspection: P. 5-106).
12 N·m (1.2 kgf·m,
When the fuel pressure is lower than the standard 9 lbf·ft)
pressure:
• Check the pressure regulator for proper operation
(Inspection: P. 5-106).
• Check the high pressure side fuel strainer for clogging
(Replacement: P.3-18).
• Check the high pressure side fuel pump for proper oper-
ation (Inspection: P. 5-107).

6) After check, replace the sealing washer with a new one and
tighten the service check bolt to the specified torque.
TORQUE: 12 N • m (1.2 kgf • m, 9 lbf • ft) SEALING WASHER
Do not reuse.

7) Connect the vacuum tube to the pressure regulator.

5-103
BF135A•BF150A

• Fuel Line Inspection

Gasoline is highly flammable and explosive.

You can be burned or seriously injured when handling fuel.
• Keep heat, sparks, and flame away.
• Handle fuel only outdoors.
• Wipe up spills immediately.

1) Check the fuel pipe, fuel hose, pressure regulator return

hose and the fuel tube for damage, gasoline leakage, rust
and other abnormalities.
Check that the hoses and tubes are not interfering with the
neighboring pars.
2) Replace the hose or tube if there is damage, gasoline leak-
age, rust, etc.
Note the following on replacement.
• Relieve the fuel pressure according to "How to relive fuel
pressure" (P. 5-102), then replace the fuel pipe, hoses and
tube.
• Replace the O-rings with the new ones. Apply the engine
oil to the O-rings before installation.

FUEL TUBES

PRESSURE REGULATOR
RETURN HOSE

FUEL PIPE

FUEL HOSE
(HIGH PRESSURE SIDE)

FUEL TUBES
FUEL TUBES

5-104
 BF135A•BF150A

• Fuel Injector Inspection

When the engine is hard to start:

1) Disconnect the fuel injector connector and measure the
resistance between the terminals.

2) If the fuel injector is normal, check the following

• No.7 (10A) fuse
• No.4 (15A) fuse
• Open or short circuit in the injector harness (between
ECM, injectors and No.4 fuse) (P. 5-100).

When the engine starts:

1) Start the engine and warm it up.

2) With the engine running at idling, disconnect the fuel injec-

tor connector of each cylinder and check the idle speed
change and idling stability.
• The fuel injector is normal when the idling condition
changes.
• If the idling condition does not change when the fuel injec-
tor connector is disconnected, replace the fuel injector of
the cylinder and recheck the idling condition.

3) With the engine running at idling, check for the operation

sound of the fuel injectors using a sound scope (or with a
screwdriver or equivalent if a sound scope is not available).
• If there is no operation sound, replace the fuel injector
with a new one and recheck.

4) If no abnormality is detected, replace the ECM.

5-105
BF135A•BF150A

• Pressure Regulator Inspection

Gasoline is highly flammable and explosive.

You can be burned or seriously injured when handling fuel.
• Keep heat, sparks, and flame away.
• Handle fuel only outdoors.
• Wipe up spills immediately.

• If the fuel pressure is lower than the specified standard pres-

sure, check the high pressure side fuel pump (P. 5-107), then
check the pressure regulator.

1) Check that the pressure regulator control tube is not bent,

disconnected and damaged.

FUEL PRESSURE GAUGE

2) Remove the service check bolt. Set the special tool (fuel SET 07406-0040002
pressure gauge set) in the threaded bolt hole.

3) Remove the propeller. Set the gear case in a test tank filled PRESSURE REGULATOR
with water and start the engine. CONTROL TUBE
TUBE CLAMP
(Commercially available)
4) With the engine idling, disconnect the pressure regulator
control tube from the pressure regulator and clamp it.

5) Check the fuel pressure. It should be higher than the pres-

sure measured with the vacuum tube connected.

Standard fuel pressure 270 – 320 kPa

(At idle speed of (2.8 – 3.3 kgf/cm2,
650 ± 50 min-1 /rpm) 40 – 47 psi)

6) When the fuel pressure does not rise, connect the vacuum
tube to the pressure regulator. Pinch the pressure regula-
PRESSURE REGULATOR
tor return hose that goes from the pressure regulator to the
vapor separator a couple of times lightly, and measure the
fuel pressure again.
PRESSURE REGULATOR
SHOP RETURN HOSE
NOTICE TOWEL
Protect the pressure regulator return hose by winding a
shop towel or equivalent material around the hose, and
lightly pinch the hose with the pliers.

7) If the measurement is outside the specified standard pres-

sure, replace the pressure regulator (P. 5-136).

PLIERS

5-106
 BF135A•BF150A

• Fuel Pump (High pressure side) Inspection FUEL PUMP 2P

CONNECTOR

Gasoline is highly flammable and explosive.

You can be burned or seriously injured when handling fuel.
• Keep heat, sparks, and flame away.
• Handle fuel only outdoors.
• Wipe up spills immediately.

• Turn the ignition switch OFF before disconnecting and con-

necting the connectors.
• Use a known-good battery. CONNECTOR BRACKET

1) Remove the engine cover (P. 4-2).

2) Turn the ignition switch ON. Check that the fuel pump oper- BLACK
ation sound can be heard for approximately 2 seconds. ENGINE
Is there the fuel pump operation sound? GROUND
YES – Check the gasoline discharge volume.
NO – Go to the step 3.

3) Remove the high pressure side fuel pump 2P connector

from the connector bracket, and disconnect the connector.

4) Measure the voltage between the Black terminal of the har-

ness side connector and the body ground.
Is there the continuity?
YES – Check the gasoline discharge volume. FUEL PUMP HARNESS
NO – Go to the step 5. SIDE 2P CONNECTOR

5) Attach the positive (+) tester lead to the Blue/Yellow (+) ter-
minal and the negative (–) tester lead to the Black (–) ter-
minal of the harness side connector. Turn the ignition
switch ON and be sure that there is battery voltage for
BLUE/
approximately 2 seconds. YELLOW (+) BLACK (–)
Is there the battery voltage?
YES – Check the gasoline discharge volume (P. 5-108).
NO – Check the PGM-FI main relay harness (P. 5-97).

FUEL PUMP HARNESS

SIDE 2P CONNECTOR

5-107
BF135A•BF150A

• Discharge Volume Check

PRESSURE REGULATOR

Gasoline is highly flammable and explosive.

You can be burned or seriously injured when handling fuel.
• Keep heat, sparks, and flame away.
• Handle fuel only outdoors.
• Wipe up spills immediately.

• Use a known-good battery for discharge volume check.

1) Turn the ignition switch OFF.

2) Disconnect the pressure regulator return hose from the PRESSURE REGULATOR
pressure regulator, and connect a hose that is equivalent to RETURN HOSE
the pressure regulator return hose to the pressure regula-
tor.
PRESSURE REGULATOR
3) Turn the ignition switch ON. Operate the fuel pump for
approximately 2 seconds and measure the gasoline dis-
charge volume.
Standard discharge volume 45 cc (4.75 cu in)
or more

4) If gasoline is not discharged or the discharge volume is too

small, check the following and replace the fuel pump (P. 5-
121).
• Clogged high pressure side fuel filter
• Clogged high pressure side fuel hose/pipe
• Faulty pressure regulator

5) If the high pressure side fuel pump is normal, connect the FUEL PUMP 2P CONNECTOR
2P connector. Set the connector on the connector bracket.

CONNECTOR BRACKET

5-108
 BF135A•BF150A

10. IAB (Intale Air Bypass) 3. IAB control valve check

-1. Connect the vacuum tubes.
CONTROL SYSTEM -2. Disconnect the IAB control valve 2P connector while
running the engine at idling.
• IAB Control Valve Inspection -3. Check the vacuum tube located above the IAB control
valve for vacuum.
1. Vacuum line check
-1. Check the vacuum tubes between the shutter valve Is there the vacuum?
diaphragm and IAB control valve, and between the YES – Perform "4. Ground line short circuit check".
solenoid valve and intake manifold. NO – Replace the IAB control valve.
SHUTTER VALVE DIAPHRAGM
4. Ground line short circuit check
-1. Turn the ignition switch OFF. Disconnect the ECM con-
nector A and the IAB control valve 2P connector.
-2. Check for the continuity between the No.2 (Black) ter-
minal of the IAB control valve harness side 2P con-
nector and the engine ground.

IAB CONTROL VALVE HARNESS

SIDE 2P CONNECTOR

BLACK

INTAKE MANIFOLD VACUUM TUBE

Are the tubes disconnected, torn or clogged? VIEWED FROM THE TERMINAL SIDE
YES – Replace the vacuum tubes.
NO – Perform "2. Operation check at idling".
Is there the continuity?
2. Operation check at idling YES – Repair short in the wire between the ECM
and the IAB control valve.
-1. Start the engine and let it warm up. Run the engine at NO – Substitute a known-good ECM and recheck.
idling.
-2. Disconnect the vacuum tube from the shutter valve 5. Operation check at engine stop and at high engine
diaphragm, and check the vacuum.
speed
Is there the vacuum? -1. Start the engine and run it at idling. Stop the engine
and check the shutter valve diaphragm side vacuum
YES – Perform “5. Operation check at engine stop
tube for the vacuum.
and at high engine speed”.
NO – Go to the step 3.
Is the vacuum removed?
-3. Disconnect the vacuum tube underside the IAB control YES – Perform shutter valve diaphragm check (P. 5-
valve, and check the vacuum. 110).
NO – Perform "6. Signal line open circuit check".
Is there the vacuum?
YES – Perform "3. IAB control valve check".
NO - • Faulty vacuum chamber
• Faulty check valve

5-109
BF135A•BF150A

6. Signal line open circuit check • Shutter Valve Diaphragm Inspection

-1. Turn the ignition switch OFF and disconnect the IAB
control valve 2P connector.
-2. Turn the ignition switch ON. Measure the voltage NOTICE
between the No.1 (Yellow/Black) terminal of the IAB • Do not try to adjust the full close stop screw.
control valve harness side 2P connector and the • Note that the shutter valve diaphragm must not be dis-
engine ground.
assembled. If replacement is necessary, replace as an
assembly of the intake manifold assembly.
IAB CONTROL VALVE HARNESS
SIDE 2P CONNECTOR
1) Check the following.
• Check the shutter valve shaft for play and the stuck
YELLOW/BLACK shaft.
• Check the shutter valve for smooth movement from
the full open to the full close positions.
• Check there is no clearance between the full close
VIEWED FROM THE TERMINAL SIDE screw and the full close stopper when the shutter
valve is in the full close position.
• Move the shutter valve to the full open position and
Is there the battery voltage? check that the shutter valve contacts the full open
YES – Perform "7. IAB control valve check”. stopper.
NO – Repair open in the wire between the ECM
and the IAB control valve
SHUTTER VALVE DIAPHRAGM
7. IAB control valve check
-1. Turn the ignition switch OFF. Disconnect the IAB con-
trol valve 2P connector.
-2. Measure the resistance between the IAB control valve
side 2P connector terminals.

Is the resistance 37 – 44 ?
YES – Substitute a known-good ECM and recheck.
NO – Replace the IAB control valve.

FULL OPEN STOPPER STOP SCREW

2) If there is any abnormality, clean the shutter valve

diaphragm with a contact cleaner and recheck.
If it is still abnormal, replace the intake manifold
assembly.

5-110
 BF135A•BF150A

11. VAPOR SEPARATOR/FUEL PUMP

(HIGH PRESSURE SIDE)
a. REMOVAL

Gasoline is highly flammable and explosive.

You can be burned or seriously injured when handling fuel.
• Keep heat, sparks, and flame away.
• Handle fuel only outdoors.
• Wipe up spills immediately. [2] HARNESS [3] FUEL PUMP 2P
BAND CLIP CONNECTOR
• Relieve the fuel pressure before removing the vapor separa-
[1] CLAMPS
tor.
• Disconnect the battery cable from the battery negative (–)
terminal before relieving the fuel pressure.
• Replace the sealing washer with a new one whenever the
service check bolt was loosened or removed.
[4]
CONNECTOR
1) Remove the engine cover and the L. engine under cover. BRACKET
[6]
FUEL TUBE
2) Relieve the fuel pressure (P. 5-102).
[5] COVER LOCK CABLE

3) Remove the high pressure side fuel pump 2P connector

from the connector bracket and disconnect the connector. [1] JOINT PIPE

4) Remove the harness band clip from the connector bracket.

5) Unclamp the cover lock cable and the fuel tube.

6) Remove the 6 x 25 mm flange bolt and disconnect the high [3]

pressure side fuel hose. Remove the joint pipe and the O- FUEL HOSE
ring. (HIGH [2]
PRESSURE SIDE) O-RING (2)
• Replace the O-ring with a new one. Do not reuse.
6 x 25
7) Disconnect the air vent tube and the pressure regulator
return hose from the vapor separator.
[1] [2] AIR VENT
PRESSURE TUBE
REGULATOR
RETURN
HOSE

[3]
VAPOR
SEPARATOR

5-111
 BF135A•BF150A

8) Disconnect the fuel tube B from the low pressure side fuel
pump.

[1] FUEL TUBE B

9) Disconnect the water tube from the crankcase.

[1] WATER TUBE

10) Remove the two 8 x 35 mm flange bolts, two 8 mm wash-

ers, and one 8 x 30 mm flange bolt. Remove the vapor sep-
arator assembly.

[1]
VAPOR SEPARATOR
ASSEMBLY

[2]
8 mm WASHER (2)

8 x 35 (2)

8 x 30

5-112
 BF135A•BF150A

b. DISASSEMBLY
1) Disconnect the 4.5 x 55 mm fuel tube.
2) Remove the 8 x 35 mm flange bolt and the 8 mm washer.
Remove the vapor separator stay.
3) Remove the collar and the vapor separator grommet.

[1] COLLAR

[7]
VAPOR SEPARATOR [2]
STAY 8 mm WASHER

[6]
8 x 35
3.5 x 420 mm
DRAIN TUBE
[3]
[5] [4] VAPOR SEPARATOR
TUBE CLIP B8 (2) 4.5 x 55 mm GROMMET
FUEL TUBE

4) Remove the 6 x 25 mm flange bolt and remove the high

pressure side fuel hose.
5) Remove the collar and the O-rings.
Replace the O-rings on assembly.
6) Remove the three 5 mm screws and remove the strainer
cover, O-ring, fuel strainer and the spring.
[3]
[1] FUEL HOSE FUEL STRAINER
(HIGH PRESSURE (HIGH PRESSURE SIDE)
SIDE )
6 x 25
[2]
STRAINER COVER

[9]
COLLAR

[5]
O-RING (2)
Do not reuse.

[8] 5 mm SCREW (3)

[7] SERVICE CHECK [5] [4] FILTER SPRING

BOLT O-RING
[6]
Do not reuse.
SEALING WASHER
Do not reuse.

5-113
 BF135A•BF150A

7) Remove the four 5 mm screw-washers. Remove the con-

nector bracket and pump cover.
8) Remove the O-ring from the pump cover and discard it.
Replace the O-ring with a new one on assembly.

9) Remove the pump holder.

10) Remove the 4 mm screw and 4 mm washer, then remove

the pump harness assembly.

[2]
4 mm SCREW [3]
4 mm WASHER
[4]
[1] PUMP HARNESS
5 mm SCREW- ASSEMBLY
WASHER (4)

[8]
PUMP COVER

[5]
[7] CONNECTOR
PUMP HOLDER [6] BRACKET
O-RING
Do not reuse.

5-114
 BF135A•BF150A

11) Remove the O-ring and the seal ring.

[1] [2] INSULATOR
Replace the O-ring with a new one on assembly. [3] PLATE
O-RING
Do not reuse.
12) Remove the plate and the insulator.

13) Remove the high pressure side fuel pump, pump holder and
the O-ring.
Replace the O-ring with a new one on assembly. [6]
SEAL RING

[5]
FUEL PUMP
(HIGH PRESSURE
SIDE)
[4]
PUMP HOLDER

[1]
O-RING
Do not reuse.

14) Remove the four 6 x 25 mm flange bolts. Remove the fuel

pump case and the two O-rings. [1]
O-RING
Replace the O-rings with the new ones on assembly.
Do not reuse.

[2] FUEL PUMP CASE

6 x 25 (4)

5-115
 BF135A•BF150A

15) Remove the eight 5 mm screw-washers and the eight 6 mm

washers. Remove the water jacket cover and the cover gas-
ket.
Replace the cover gasket with a new one on assembly.
[1]
COVER GASKET
Do not reuse.

[2]
5 mm COLLAR (8)
[3]
5 mm WASHER (8)

[9]
TUBE CLIP
[8]
7 x 400 mm
WATER TUBE
[7]
7.3 x 350 mm
WATER TUBE
[4]
5 mm SCREW-
[6] [5] WASHER (8)
TUBE CLIP B12 WATER JACKET COVER

16) Remove the six 5 mm screw-washers. Remove the vapor

[1]
separator cover and the cover gasket. 5 mm SCREW-
Replace the cover gasket with a new one on assembly. WASHER (6)

17) Remove the two screws. Then, remove the float, float pin
[2]
and the float valve. VAPOR
SEPARATOR
COVER
18) Remove the two 6 x 16 mm flange bolts and remove the
vapor separator stay.
[3]
COVER GASKET
6 x 16 (2) Do not reuse.
[4]
FLOAT VALVE

[10] [5]
COLLAR (2) FLOAT PIN

[9]
VAPOR SEPARATOR [6]
GROMMET (2) SCREW (2)

[8]
VAPOR SEPARATOR
STAY

[7]
VAPOR SEPARATOR
CHAMBER

5-116
 BF135A•BF150A

c. INSPECTION
FLOAT HEIGHT
• Check the float height by installing the float properly.

1) Place the vapor separator cover as shown. Measure the

distance between the float and vapor separator cover (i.e.
float height).
• Set the special tool at right angles to the float chamber
mating surface and measure at the highest position of
the float.
Float height 31 ± 2.5 mm (1.22 ± 0.10 in) [1]
FLOAT LEVEL GAUGE
2) If the float height is out of the specification, check the float 07401-0010000
valve and valve seat for wear and damage.

3) If the float valve and valve seat are normal, adjust the float
height by gently bending the brass float tab taking care not
to damage the float.

• FLOAT
[2]
Check the float for damage and deformation, and check for the FLOAT TAB
gasoline in the float. Check the float for smooth movement.

• FLOAT VALVE/VALVE SEAT

Check the float valve head and the float valve seat for scores, [1] VALVE SEAT
scratches, wear and damage.

[2] [3]
Good Replace.

[4] FLOAT VALVE

5-117
 BF135A•BF150A

d. ASSEMBLY
• Vapor Separator Chamber

[2]
5 mm SCREW-WASHER (6)
3.4 N • m (0.35 kgf • m, 2.5 lbf • ft)

[3]
[1]
VAPOR SEPARATOR
COVER GASKET
COVER
Do not reuse.

6 x 16 (2)
12 N • m (1.2 kgf • m, 9 lbf • ft)

COLLAR (2) [4]

FLOAT VALVE

[5]
FLOAT PIN

[6]
SCREW (2)
2.1 N • m (0.21 kgf • m, 1.5 lbf • ft)

[7]
COVER GASKET
[18]
VAPOR SEPARATOR Do not reuse.
GROMMET (2)
[17] [8]
VAPOR SEPARATOR 5 mm COLLAR (8)
STAY [9]
[16] 5 mm
VAPOR SEPARATOR WASHER (8)
CHAMBER

[15] TUBE CLIP

[14]
7 x 400 mm
WATER TUBE

[13]
7.3 x 350 mm
WATER TUBE
[10]
[12] 5 mm SCREW-
TUBE CLIP B12 WASHER (8)
[11] 3.4 N • m (0.35 kgf • m,
WATER JACKET COVER 2.5 lbf • ft)

5-118
 BF135A•BF150A

1) Install the float valve and float pin to the float. [1] SCREW (2) [2]
FLOAT PIN
2) Set the float assembly on the vapor separator cover and
tighten the two screws to the specified torque. [3]
FLOAT
TORQUE: 2.1 N • m (0.21 kgf • m, 1.5 lbf • ft)
[4]
FLOAT VALVE

[5]
VAPOR
SEPARATOR
COVER

3) Install the vapor separator grommets on the vapor separator

[1]
stay. 6 x 16 (2)
COLLAR (2)
[2]
VAPOR SEPARATOR
4) Install the vapor separator stay on the vapor separator GROMMET (2)
chamber and tighten the two 6 x 16 mm flange bolts to the
specified torque.
TORQUE: 12 N • m (1.2 kgf • m, 9 lbf • ft)

5) Install the collars on the vapor separator grommet.

[3]
VAPOR SEPARATOR
STAY

6) Apply a thin coat of the engine oil to the new cover gasket [1]
and install the gasket in the groove in the vapor separator 5 mm SCREW-
chamber securely. WASHER (6)
[2]
VAPOR
7) Install the vapor separator cover and tighten the 5 mm SEPARATOR
screw-washers to the specified torque. COVER
TORQUE: 3.4 N • m (0.35 kgf • m, 2.5 lbf • ft)

[3]
COVER GASKET
Do not reuse.

[4]
VAPOR
SEPARATOR
CHAMBER

5-119
 BF135A•BF150A

8) Apply a thin coat of the engine oil to a new cover gasket and [1]
install it on the water jacket cover. COVER GASKET
Do not reuse.
[2]
9) Set the eight collars on the water jacket cover and install the WATER JACKET
water jacket cover on the vapor separator chamber. COVER

[3]
10) Set the eight 5 mm washers and the eight 5 mm screw- 5 mm
washers, then tighten the screws to the specified torque. COLLAR (8)
TORQUE: 3.4 N • m (0.35 kgf • m, 2.5 lbf • ft)

11) Connect the 7 x 400 mm water tube to the upper tube joint
of the water jacket cover, and secure the connection of the
tube with the tube clip.

12) Connect the 7.3 x 350 mm water tube to the lower tube joint
of the water jacket cover, and secure the connection of the [6]
tube with the tube clip B12. TUBE CLIP

[7] [5]
[9] TUBE CLIP 5 mm
7.3 x 350 mm B12 WASHER (8)
WATER TUBE
[8] [4]
7 x 400 mm 5 mm SCREW-
WATER TUBE WASHER (8)

5-120
 BF135A•BF150A

• Fuel Pump (High Pressure Side)

[7]
4 mm SCREW [8]
[2] 4 mm WASHER
5 mm SCREW-WASHER (4) [9]
3.4 N·m (0.35 kgf·m, 2.4 lbf·ft) PUMP HARNESS
[1] ASSEMBLY
FUEL HOSE [3]
(HIGH PRESSURE FUEL STRAINER [10]
SIDE) (HIGH PRESSURE SIDE) CONNECTOR
[6] BRACKET
PUMP COVER
6 x 25
[5]
FILTER SPRING

[4]
STRAINER
COVER
[17] [11]
O-RING (2) O-RING
Do not reuse. Do not reuse.

[12] TERMINAL HOLDER

[25]
COLLAR [11]
O-RING [13] PLATE
Do not reuse.
[30]
[14] INSULATOR
5 mm SCREW (3) [29] SEAL RING
3.4 N·m (0.35 kgf·m,
2.4 lbf·ft) [28] [15] FUEL PUMP
SEALING WASHER (HIGH PRESSURE SIDE)
[27] Do not reuse. [16] PUMP HOLDER
SERVICE CHECK BOLT
[11]
12 N·m (1.2 kgf·m, O-RING
9 lbf·ft)
Do not reuse.
[25]
[24] VAPOR SEPARATOR COLLAR
STAY
[26]
[23] VAPOR
DRAIN SCREW SEPARATOR
GROMMET

[11]
O-RING
Do not reuse.

[17]
O-RING (2)
[22] Do not reuse.
3.5 x 420 mm [20]
DRAIN TUBE 4.5 x 55 mm
FUEL TUBE 8 x 25
[21]
TUBE CLIP B8 (2) 24 N·m (2.4 kgf·m,
17 lbf·ft)
6 x 25 (4)
12 N·m (1.2 kgf·m, [18] 8 mm WASHER
9 lbf·ft)
[19] FUEL PUMP CASE

5-121
 BF135A•BF150A

1) Apply a thin coat of the engine oil to the new O-rings and set
them on the vapor separator chamber. [1]
O-RING (2)
Do not reuse.
2) Install the pump case with care not to allow the O-rings to
come out of position.

3) Tighten the 6 x 25 mm flange bolts.

TORQUE: 12 N • m (1.2 kgf • m, 9 lbf • ft)

[2]
FUEL PUMP CASE
6 x 25 (4)

4) Apply a thin coat of the engine oil to the new O-ring and set [1]
it on the pump holder. PUMP HOLDER

5) Install the pump holder on the pump case. Be sure to install

it in the direction shown.

6) Install the high pressure side fuel pump on the pump case. [1]
• Install by aligning the projection on the pump with the HIGH PRESSURE
hole in the pump holder. SIDE FUEL PUMP

[2]
PUMP HOLDER

5-122
 BF135A•BF150A

7) Install the pump harness assembly on the pump cover, and [1] 4 mm SCREW
secure the pump harness assembly with the 4 mm screw. [2] 4 mm WASHER

TORQUE: 2.1 N • m (0.21 kgf • m, 1.5 lbf • ft)

[4]
PUMP HARNESS [3]
ASSEMBLY PUMP COVER

8) Set the terminal holder on the pump cover and route each
wire as shown. [1] TERMINAL HOLDER

• Align the bosses on the terminal holder with the holes in

the pump cover.

9) Set the terminals in the positions shown.

[2] TERMINALS

[4] [3]
BLUE/ BLACK
YELLOW WIRE
WIRE

10) Apply a thin coat of engine oil to the new O-ring and install [1]
them on the oil case. BLACK WIRE
TERMINAL
[5]
11) Set the seal ring at the discharge port of the pump.
O-RINGS
Do not reuse.
12) Apply a thin coat of the engine oil to the new O-ring and set
it at the discharge port of the pump. [2]
BLUE/
YELLOW
13) Connect the pump harness assembly terminals to the pump WIRE
terminals as shown. TERMINAL
• Connect the Blue/Yellow wire terminal to the positive (+) [3]
terminal of the pump and the Black wire terminal to the [4] POSITIVE (+)
negative (–) terminal of the pump. SEAL RING TERMINAL

5-123
 BF135A•BF150A

14) Tighten the four 5 mm screw-washers securely.

[1] 5 mm SCREW-WASHER (4)
• Install the connector bracket in the position shown and
3.4 N·m (0.35 kgf·m, 2.4 lbf·ft) [2]
secure with the two 5 mm screw-washers. CONNECTOR
TORQUE: 3.4 N • m (0.35 kgf • m, 2.4 lbf • ft) BRACKET

[3]
PUMP COVER

15) Apply the engine to the new O-ring and install it on the
[3] FUEL STRAINER SET
strainer cover.
[2]
SEAL
16) Install the spring and the fuel strainer, and install the strainer [1]
cover. STRAINER
COVER
• Install the fuel strainer in the direction shown.

17) Tighten the 5 mm washer screws securely.

[4] FILTER
TORQUE: 3.4 N • m (0.35 kgf • m, 2.4 lbf • ft) SPRING

[5] O-RING
Do not reuse.

[6] 5 mm SCREW (3)

18) Apply the engine oil to the new O-rings and install them on 6 x 25 [1] FUEL HOSE
the collar. (HIGH PRESSURE
SIDE)
19) Install the collar on the strainer cover. [2] O-RING (2)
Do not reuse.

20) Set the fuel hose and secure it by tightening the 6 x 25 mm [5]
flange bolt. COLLAR

[4]
21) Using a new sealing washer, tighten the service check bolt SERVICE
to the specified torque. CHECK BOLT
TORQUE: 12 N • m (1.2 kgf • m, 9 lbf • ft)

[3] SEALING WASHER

Do not reuse.

5-124
 BF135A•BF150A

e. INSTALLATION [1] [3]

VAPOR VAPOR
1) Install the vapor separator grommet and the collar on the SEPARATOR SEPARATOR
[2]
fuel pump case. STAY COLLAR GROMMET
2) Loosely tighten the vapor separator stay with the 8 mm
washer and the 8 x 35 mm flange bolt.
Tighten the 8 x 35 mm flange bolt, after installing the
vapor separator assembly on the engine.
3) Connect the 4.5 x 55 mm fuel tube and secure it with the
tube clip B8.
8 x 35
4) Connect the 3.5 x 420 mm drain tube to the vapor separator
stay.

[5]
5) Set the vapor separator assembly on the engine, and loose- 4.5 x 55 mm
ly tighten it with the two 8 mm washers, two 8 x 35 mm FUEL TUBE
[7]
flange bolts and the one 8 x 30 mm flange bolt. 3.5 x 420 mm [4]
Align the projection of the vapor separator stay with the DRAIN TUBE [6] 8 mm
TUBE CLIP B8 (2) WASHER
hole in the engine.

6) Tighten the three 8 x 35 mm flange bolts and one 8 x 30

mm flange bolt to the specified torque.
TORQUE: 26 N • m (2.7 kgf • m, 20 lbf • ft)
[8]
VAPOR SEPARATOR
ASSEMBLY

[11] HOLE [1]

VAPOR
SEPARATOR
STAY

8 x 30
8 x 35 (2)
8 x 35 (2)

[9] 8 mm WASHER (2)

[10] PROJECTION

5-125
 BF135A•BF150A

7) Connect the 7.3 x 350 mm water tube to the cylinder block [1] TUBE CLIP
and secure it with the tube clip.

[2] 7.3 x 350 mm WATER TUBE

8) Connect the fuel tube B to the vapor separator and secure it

[1] TUBE CLIP B12
with the tube clip B12.

[2] FUEL TUBE B

9) Connect the pressure regulator return hose to the vapor [1] [2]
separator, and secure it with the tube clamp D10.5. PRESSURE AIR VENT
REGULATOR TUBE
RETURN [3]
10) Connect the air vent tube to the vapor separator. HOSE VAPOR
SEPARATOR

[4]
TUBE
CLAMP
D10.5

11) Apply the engine oil to the new O-ring and install it on the [1]
joint pipe. JOINT PIPE

12) Set the joint pipe in the fuel tube and install the fuel hose.

13) Tighten the 6 x 25 mm flange bolt to the specified torque.

[3]
FUEL HOSE [2]
(HIGH PRES- O-RING (2)
SURE SIDE 6 x 25 Do not reuse.

5-126
 BF135A•BF150A

14) Connect the fuel pump 2P connector and set the connector [1]
on the connector bracket. [3]
HARNESS FUEL PUMP 2P
BAND CLIP CONNECTOR
15) Install the harness band clip on the connector bracket in the [2]
CLAMPS
position shown in the drawing.

16) Secure the cover lock cable and the fuel hose with the
clamps.

[4]
[6] CONNECTOR
FUEL TUBE BRACKET
[5] COVER LOCK CABLE

17) After assembly, check each fuel tube and clamp and check [1] [2]
that they are not interfering with the neighboring parts. PRESSURE REGULA- FUEL HOSE
TOR RETURN HOSE (HIGH PRESSURE
SIDE)
18) Turn the ignition switch ON. Check that the fuel pump turns
for 2 seconds and that there is no fuel/water leakage.

[4]
FUEL TUBE B
[3] WATER TUBE

5-127
 BF135A•BF150A

12. SILENCER CASE/THROTTLE [1] HARNESS

BAND CLIP
BODY/INTAKE MANIFOLD
a. SILENCER CASE REMOVAL
1) Remove the engine cover.

2) Disconnect the IAT sensor 2P connector and remove the

harness band clip from the silencer case.
[3] IAT SENSOR 2P [2] AIR FLOW
3) Loosen the air flow tube clamp. CONNECTOR TUBE CLAMP

4) Disconnect the crankcase breather tube from the silencer [1] SILENCER
case. CASE

6 x 25 (3)
5) Remove the three 6 x 25 mm flange bolts and the three 6
mm washers. Remove the silencer case.

[2] 6 mm WASHER (3)

• SILENCER CASE DISASSEMBLY/ASSEMBLY

[1] SENSOR GROMMET [2] SILENCER CASE [3]
SILENCER DUCT
ASSEMBLY:
GROMMET
Install in the direction
shown.

[4]
COLLAR (3)

[5]
[10] GROMMET (3)
IAT SENSOR
[6] AIR FLOW
TUBE SPRING
[9] AIR FLOW TUBE
ASSEMBLY:
Install the air flow tube deep on [7] AIR FLOW
the silencer duct until it contacts TUBE CLAMP
the projection on the silencer duct.

[8] VINYL TUBE

[9]-1 PROJECTION

5-128
 BF135A•BF150A

b. THROTTLE BODY/INTAKE MANIFOLD [1]

MAP SENSOR 3P
REMOVAL CONNECTOR

1) Remove the silencer case (P. 5-128).

2) Disconnect the MAP sensor 3P connector and remove the

harness band clip.

[2]
HARNESS
BAND CLIP

3) Remove the water level sensor connector from the the har- [1]
ness clip bracket E. TP SENSOR 3P
CONNECTOR
[2]
4) Disconnect the TP sensor 3P connector and remove the WATER LEVEL
SENSOR
harness band clip from the harness clip bracket E. CONNECTOR

[4]
HARNESS
BAND CLIP [3] HARNESS CLIP BRACKET E

5) Remove the throttle rod. [1]

• Do not loosen the pivot lock nut. THROTTLE
ROD

6) Remove one 8 x 60 mm flange bolt and remove the throttle

body.

7) Remove the throttle body gasket.

• Replace the throttle body gasket with a new one.
• The intake manifold assembly can be removed by skip-
ping the steps 6 and 7 (i.e. with the throttle body mount- [2]
ed). THROTTLE BODY

8) Disconnect the IAB control valve 2P connector.

[1]
IAB CONTROL
VALVE 2P
CONNECTOR

5-129
 BF135A•BF150A

9) Disconnect the pressure regulator vacuum tube from the [1]

intake manifold joint. PRESSURE
REGULATOR
VACUUM
TUBE

[2]
INTAKE MANIFOLD
JOINT

10) Remove the two 8 x 55 mm flange bolts and remove the L. [1]
side cover bracket. L. SIDE COVER BRACKET
• The L. side cover bracket can be removed without dis-
connecting the cover lock cable.

8 x 55 (2)

11) Remove the five 8 x 35 mm flange bolts, two 8 mm washers

and the two 8 mm flange nuts. Remove the intake manifold
assembly.

[1] 8 mm WASHER

8 x 35 (5)

[3]
INTAKE MANIFOLD
ASSEMBLY
[2]
8 mm FLANGE
NUT (2)

5-130
 BF135A•BF150A

c. INTAKE MANIFOLD DISASSEMBLY/ASSEMBLY

[2] SOLENOID VALVE TUBE
ASSEMBLY:
Connect the solenoid valve tube to the top of the
intake air cut-off solenoid valve, and the
diaphragm tube to the lower joint of the intake air
[1] cut-off solenoid valve.
INTAKE MANIFOLD GASKET (4) [2]-1
DIAPHRAGM
ASSEMBLY: TUBE
• Do not reuse.
• Install by aligning the projection
on the gasket with the groove in [2]-2
the intake manifold. SOLENOID
[1]-1 [2]-3 UP VALVE TUBE
PROJECTION
8 x 60 (4) [3]
22 N·m (2.2 kgf·m, [1]-2 DIAPHRAGM TUBE
16 lbf·ft) GROOVE
[4]
INTAKE AIR CUT-OFF
SOLENOID VALVE

[12]
COLLAR (2)
5 x 12
[11]
GROMMET (2)

[10]
THROTTLE BODY

[9]
THROTTLE BODY GASKET [5]
Do not reuse. SHUTTER VALVE DIAPHRAGM
INSPECTION: P. 5-110
Do not disassemble the
[8] shutter valve diaphragm.
IAC VALVE GASKET Replace as an assembly
Do not reuse. of the intake manifold
assembly.

[6]
[7] IAC VALVE INTAKE MANIFOLD
ASSEMBLY
8 x 45 (2)
22 N·m (2.2 kgf·m, 16 lbf·ft)

5-131
 BF135A•BF150A

d. THROTTLE BODY DISASSEMBLY/REASSEMBLY

[1] MAP SENSOR

ASSEMBLY:
Apply the engine oil to the new
O-ring and install it on the MAP [2]
sensor. Install aligning the 5 x 18 mm SCREW
cutout in the set plate with the
lib of the sensor as shown.
[1]-1
MAP [3]
SENSOR SET PLATE

[1]-2
SET
PLATE

[5] O-RING
Do not reuse.

[4]
[6] IDLE ADJUSTING SCREW HARNESS CLIP BRACKET E
ADJUSTMENT: P. 5-93 ASSEMBLY:
Install the bracket aligning
the cutout in the bracket
with the stopper pin.
[5] O-RING
[4]-1
Do not reuse. HARNESS CLIP
BRACKET E

[4]-2 STOPPER PIN

e. INTAKE MANIFOLD INSTALLATION [2] INTAKE MANIFOLD GASKET [3]

AIR VENT TUBE
[1]
PROJECTION
1) Install the new intake manifold gasket on the intake manifold
assembly.
• Install aligning the projection on the gasket with the [6]
GROOVE
groove in the intake manifold.

2) Install the intake manifold assembly on the engine.

• Take care not to pinch the pressure regulator return hose [5] [4]
and the air vent tube at the top of the intake manifold. TOP OF INTAKE PRESSURE REGULATOR
MANIFOLD RETURN HOSE

5-132
 BF135A•BF150A

3) Set the five 8 x 35 mm flange bolts, two 8 mm washers and [1] 8 mm FLANGE NUT (2)
the two 8 mm flange nuts.

4) Tighten the 8 x 35 mm flange bolts and the 8 mm flange

nuts in the numbered sequence in two or three steps to the
specified torque.
TORQUE: 26 N • m (2.7 kgf • m, 20 lbf • ft)

[2] 8 x 35 (2)
and 8 mm WASHER (2) 8 x 35 (3)

5) Install the new throttle body gasket on the intake manifold. [1] THROTTLE BODY GASKET
8 x 60 (4)

6) Install the throttle body and tighten the 8 x 60 mm flange

bolts in the numbered sequence in two or three steps
securely.
TORQUE: 22 N • m (2.2 kgf • m, 16 lbf • ft)

[2] THROTTLE BODY

7) Install the throttle rod. Note the throttle rod installation direc- [1] THROTTLE ROD
tion. Don't loosen the lock nut of the throttle rod

8) Connect the IAB control valve 2P connector. [1]

IAB CONTROL VALVE
2P CONNECTOR

5-133
 BF135A•BF150A

9) Connect the vacuum tube to the pressure regulator. [1]

PRESSURE
REGULATOR
VACUUM
TUBE

[2]
INTAKE MANIFOLD
JOINT

10) Install the L. side cover bracket assembly and tighten the [1]
two 8 x 55 mm flange bolts securely. L. SIDE COVER BRACKET

8 x 55 (2)

11) Connect the MAP sensor 3P connector and set the harness [1]
band clip in the hole in the sensor set plate. MAP SENSOR 3P
CONNECTOR

[2]
HARNESS
BAND CLIP

12) Connect the TP sensor 3P connector and set the harness [1]
band clip in the hole in the harness clip bracket E. TP SENSOR 3P
CONNECTOR
[2]
13) Install the water level sensor connector on the harness clip WATER LEVEL
bracket E. SENSOR
CONNECTOR

[4]
HARNESS
[3]
BAND CLIP
HARNESS CLIP BRACKET E

5-134
 BF135A•BF150A

f. SILENCER CASE INSTALLATION [2] CRANKCASE BREATHER TUBE

[1] SILENCER CASE

1) Install the silencer case and tighten the three 6 x 25 mm
flange bolts and the three 6 mm washers.
6 x 25 (3)
• Check that the wire harnesses are not pinched.
• Set the main harness in the groove in the left lower sec-
tion of the silencer case.

2) Tighten the three 6 x 25 mm flange bolts securely.

3) Connect the crankcase breather tube. [3] 6 mm WASHER (3)

[5] WIRE HARNESS

[4] SILENCER CASE

4) Fasten the air flow tube clamp securely.

[1] HARNESS
BAND CLIP
5) Connect the IAT sensor 2P connector and secure the har-
ness band clip in the hole in the silencer case.

[3] IAT SENSOR 2P [2] AIR FLOW

CONNECTOR TUBE CLAMP

5-135
 BF135A•BF150A

13. FUEL INJECTOR/PRESSURE

REGULATOR
a. FUEL LINE ASSEMBLY REMOVAL

Gasoline is highly flammable and explosive.

You can be burned or seriously injured when handling fuel.

• Keep heat, sparks, and flame away.

• Handle fuel only outdoors.
• Wipe up spills immediately.

[1]
• Relieve the fuel pressure before removing the fuel injectors. L. SIDE COVER BRACKET
• Disconnect the battery cable from the battery negative (–)
terminal before relieving the fuel pressure.
• Replace the sealing washer with a new one when the ser-
vice check bolt had been loosened or removed.

1) Remove the engine cover and the L. engine under cover.

2) Relieve the fuel pressure according to “HOW TO RELIEVE

8 x 55 (2)
FUEL PRESSURE” (P. 5-102).

3) Remove the two 8 x 55 mm flange bolts and move the L.

side cover bracket out of position. [1] HOSE CLIP
4) Remove the three main harness clips from the respective
clip brackets.

5) Disconnect the connector from each injector.

6) Remove the hose clip. Clamp the pressure regulator return

hose and the main wire harness.

[2]
CLIP

[5]
CLIP BRACKET
[4] [3]
INJECTOR 2P MAIN WIRE
CONNECTOR HARNESS

5-136
 BF135A•BF150A

7) Disconnect the pressure regulator control tube and the pres- [1] [2] PRESSURE REGULATOR
sure regulator return hose from the pressure regulator. TUBE CLAMP CONTROL TUBE
D10.7
[3]
8) Remove the pressure regulator. Remove the joint pipe and PRESSURE
the O-rings. REGULATOR
• Replace the O-rings on assembly.
[6]
PRESSURE
REGULATOR
RETURN
[4] O-RING (2)
HOSE
[5] JOINT PIPE Do not reuse.

9) Remove the 6 x 25 mm flange bolt and remove the fuel

hose (high pressure side). [1]
JOINT PIPE

10) Remove the joint pipe and the O-rings.

• Replace the O-rings on assembly.

[3] [2] O-RING (2)

FUEL HOSE Do not reuse.
(HIGH PRESSURE
SIDE) 6 x 25

11) Release the fuel tube (2 places) and the air vent tube (2 [1] AIR VENT TUBE
places) from the 14 mm fuel tube clips.
[2]
12) Remove the two 6 mm flange nuts and remove the fuel line FUEL LINE
assembly. ASSEMBLY

[5] FUEL TUBE

[4]
14 mm FUEL
TUBE CLIP

[3] 8 mm FLANGE NUT (2)

5-137
 BF135A•BF150A

b. FUEL TUBE ASSEMBLY DISASSEMBLY/ASSEMBLY

• Replace the O-rings with the new ones and apply the engine oil to the new O-rings before installation.

[1]
[2]
7.85 x 3.53 mm O-RING (4) 6 x 10 (4)
INJECTOR CLIP (4)
Do not reuse.

[3]
[7] 14 mm FUEL
INJECTOR (4) TUBE CLIP (4)

[4]
[6] CLIP BRACKET (4)
7.47 x 3.6 mm O-RING (4)
Do not reuse.

6 x 14 (4)

[5]
FUEL TUBE

• INJECTOR INSTALLATION [1]

• Apply the engine oil to the new O-rings and install them on INJECTOR
the respective injectors.
[2]
• Install the injectors aligning the projection with the groove in PROJECTION
the fuel line.

[3]
INJECTOR
CLIP (4)

5-138
 BF135A•BF150A

c. INJECTOR BASE REMOVAL/INSTALLATION

1) Remove the fuel injectors (P. 5-136).

2) Remove the silencer case (P. 5-128) and remove the intake manifold (P. 5-129).

3) Remove the five 8 x 25 mm flange bolts and the two 8 mm flange nuts, then remove the injector base and the injector
base gasket.

4) Install the removed parts in the reverse order of removal.

• Replace the injector base gasket on assembly.
• Tighten the 8 x 25 mm flange bolts and the 8 mm flange nuts to the specified torque in the numbered sequence in
a criss-cross pattern in two or three steps.
TORQUE: 24 N • m (2.4 kgf • m, 18 lbf • ft)

[1] INJECTOR BASE GASKET

Do not reuse.

[2]
INJECTOR BASE

[3]
8 mm FLANGE NUT (2)
24 N·m (2.4 kgf·m, 18 lbf·ft)

8 x 25 (5)
24 N·m (2.4 kgf·m, 18 lbf·ft)

5-139
 BF135A•BF150A

d. FUEL TUBE ASSEMBLY INSTALLATION [1]

AIR VENT TUBE
1) Apply the engine oil to the O-rings on the injectors. Install
the fuel line assembly and tighten the 8 mm flange nuts
[2]
securely.
STUD BOLT (2)
• Replace the O-rings on assembly. 22 N·m (2.2 kgf·m,
16 lbf·ft)
2) Set the air vent tube (2 places) and the fuel tube (2 places)
on the 14 mm fuel tube clip.

[6] FUEL TUBE

[5] FUEL LINE
ASSEMBLY
[4] 14 mm FUEL
TUBE CLIP
[3]
8 mm FLANGE NUT (2)

3) Apply the engine oil to the O-rings and install them on the [1]
joint pipe. [2] PRESSURE REGULATOR
PRESSURE
CONTROL TUBE
REGULATOR
RETURN HOSE
4) Install the joint pipe on the fuel line. [3]
PRESSURE
REGULATOR
5) Install the pressure regulator and tighten the joint nut to the
specified torque.
• Install the pressure regulator in the direction shown.
TORQUE: 27 N • m (2.8 kgf • m, 20 lbf • ft) [6]
TUBE
CLAMP
6) Connect the pressure regulator return hose and secure it D10.7 [4] O-RING (2)
with the tube clamp D10.7. [5] Do not reuse.
JOINT PIPE
[3]
7) Connect the pressure regulator control tube. PRESSURE
REGULATOR

10

5-140
 BF135A•BF150A

8) Apply the engine oil to the O-rings and install them on the
joint pipe. [1] COLLAR

9) Install the joint pipe on the fuel line.

10) Connect the fuel hose (high pressure side) and tighten the 6
x 25 mm flange bolt securely.

[3] [2] O-RING (2)

FUEL HOSE Do not reuse.
(HIGH PRESSURE
SIDE) 6 x 25

11) Connect the 2P connector to each injector. [1]

HOSE CLIP
12) Set the three clips of the main harness on the clip brackets.

13) Clamp the pressure regulator return hose and the main wire
harness with the hose clip.

[2]
CLIP

[5]
CLIP BRACKET
[4] [3]
INJECTOR 2P MAIN WIRE
CONNECTOR HARNESS

5-141
 BF135A•BF150A

14. FUEL PUMP (LOW PRESSURE SIDE) [1]

L. SIDE COVER
BRACKET

Gasoline is highly flammable and explosive.

You can be burned or seriously injured when handling fuel.

• Keep heat, sparks, and flame away.

• Handle fuel only outdoors.
• Wipe up spills immediately.

8 x 55 (2)

a. REMOVAL
[1] [2] FUEL TUBE B
1) Remove the engine cover and the L. engine under cover . TUBE CLAMP
(Commercially [3]
available) FUEL
2) Remove the two 8 x 55 mm flange bolts and move the L. PUMP
side cover bracket a side.

3) Clamp the fuel tubes with a commercially available tube

clamps, then disconnect the fuel tubes from the fuel pump.

[4]
FUEL TUBE D

4) Remove the two 6 x 27 mm flange bolts and remove the fuel

[1]
pump. FUEL PUMP

5) Remove the O-rings from the fuel pump.

• Replace the O-rings with the new ones on assembly. 6 x 27 (2)

[2] O-RING (2)

Do not reuse.

b. INSPECTION
[1] PLUNGER
Push the plunger to check for smooth operation.
Replace the plunger if it is faulty.

5-142
 BF135A•BF150A

c. INSTALLATION

[3]
FUEL TUBE B

[2]
TUBE CLIP B11 (2)

[1]
SENSOR HOSE CLIP

[4] 33.2 x 2.4 mm O-RING

Do not reuse.

[9] FUEL TUBE E

6 x 27 (2)
[8] TUBE JOINT 12 N·m (1.2 kgf·m, 9 lbf·ft)
[5] FUEL PUMP
[7] TUBE CLIP B12 (2)
[6] FUEL TUBE D

1) Apply the engine oil to the new O-ring and install it on the
fuel pump. [1]
" " MARK 6 x 27 (2)

2) Install the fuel pump with the " " mark facing up and tighten
the two 6 x 27 mm flange bolts to the specified torque.
TORQUE: 12 N • m (1.2 kgf • m, 9 lbf • ft)

[2]
FUEL PUMP

3) Connect the fuel tube B and D and secure them respectively

with the tube clip B1s. [1]
FUEL TUBE B

4) Install the L. side cover bracket and tighten the 8 x 55 mm [2]

flange bolt securely. TUBE CLIP
B1 (2)

5) After assembly, start the engine and check for the gasoline
leakage from the low pressure side fuel pump.

[3]
FUEL TUBE D

5-143
 BF135A•BF150A

15. FUEL STRAINER (LOW PRESSURE SIDE)/WATER SEPARATOR

Gasoline is highly flammable and explosive.

You can be burned or seriously injured when handling fuel.

• Keep heat, sparks, and flame away.

• Handle fuel only outdoors.
• Wipe up spills immediately.

a. REMOVAL/INSTALLATION
1) Remove the engine cover and the L. engine under cover .
2) Pinch the fuel tube A with the commercially available tube clip and disconnect the fuel tube A from the water separator.
3) Remove the water level sensor 2P connector from the connector bracket and disconnect the connector.
4) Pinch the fuel tube E with the commercially available tube clip and disconnect the fuel tube E from the fuel strainer (low
pressure side).
5) Disconnect the fuel tube C from the water separator and fuel strainer.
6) Remove the fuel strainer and water separator.
7) Remove the 6 x 14 mm flange bolts and fuel strainer stay.
• Installation is the reverse order of removal. [4]
[3] TUBE CLIP [5]
[2] FUEL STRAINER STAY FUEL STRAINER B12 (4) FUEL TUBE E
(LOW PRESSURE SIDE)
[1] CONNECTOR BRACKET
6 X 14 (2)

[6]
FUEL TUBE C

[11]
2P CONNECTOR

[10] HARNESS CLIP

[9] STRAINER SUSPENSION (2)
INSTALLATION:
Align the screw of the tube joint side
with the center of the strainer sus-
pension as shown.
[9]-1
STRAINER
SUSPENSION
[7]
FUEL TUBE A

[9]-2 [8]
SCREW WATER SEPARATOR

5-144
 BF135A•BF150A

b. DISASSEMBLY/REASSEMBLY
• WATER SEPARATOR

[2]
[1] WATER SEPARATOR BODY
WATER SEPARATOR CUP/
WATER LEVEL SWITCH
INSPECTION: P. 3-20

[6]
SET PLATE
[3]
BAFFLE PLATE

[4]
O-RING

[5]
5 x 12 mm
SCREW (3)

• FUEL STRAINER (LOW PRESSURE SIDE)

[2]
FUEL STRAINER BODY
[1]
FUEL STRAINER
(LOW PRESSURE SIDE)

[6]
SET PLATE

[3]
O-RING

[5] [4]
5 x 12 mm STRAINER CUP
SCREW (3)

5-145
 BF135A•BF150A

16. EOP (ENGINE OIL PRESSURE)

SWITCH (HIGH PRESSURE SIDE)
a. INSPECTION
1) Disconnect the high pressure side EOP switch 2P connec-
tor.

2) Check for the continuity between the switch side 2P connec-

tor terminals. [1]
EOP SWITCH 2P
• The high pressure side EOP switch is normal if there is CONNECTOR
continuity.
• Replace the high pressure side EOP switch if there is no
continuity. [1]
13 x 1.5 mm
O-RING
b. REPLACEMENT Do not reuse.
1) Disconnect the high pressure side EOP switch 2P connec-
tor.

2) Remove the EOP switch and the O-ring.

• Replace the O-ring on assembly.

3) Apply the engine oil to the new O-ring and install it on the [3] [2]
switch. EOP SWITCH EOP SWITCH 2P
CONNECTOR

4) Tighten the EOP switch to the specified torque.

TORQUE: 22 N • m (2.2 kgf • m, 16 lbf • ft)

5) After installation, connect the switch connector.

17. EOP (ENGINE OIL PRESSURE)

SWITCH (LOW PRESSURE SIDE)
a. INSPECTION
1) Disconnect the low pressure side EOP switch terminal.

2) Check for the continuity between the switch terminal and the
engine ground.
• The low pressure side EOP switch is normal if there is
continuity.
• Replace the low pressure side EOP switch if there is no
continuity.
[1]
EOP SWITCH

5-146
 BF135A•BF150A

b. REPLACEMENT
1) Disconnect the low pressure side EOP switch terminal.

2) Remove the EOP switch.

3) Clean the EOP switch installation section in the crankcase.

4) Apply the liquid gasket (ThreeBond® #1215 or equivalent) to

the indicated area of the threads of the new EOP switch. [1] EOP SWITCH

5) Install and tighten the EOP switch to the specified torque.

TORQUE: 8 N • m (0.8 kgf • m, 6 lbf • ft)

NOTICE
• Be sure to use the torque wrench to tighten the EOP
switch.
• Do not exceed the specified torque when tightening the
EOP switch. Overtightening will damage the cylinder [1]
block. LIQUID GASKET
6) Connect the EOP switch terminal. APPLICATION AREA

18. ECT (ENGINE COOLANT [1] [2]

13 x 1.5 mm O-RING ECT SENSOR 1
TEMPERATURE) SENSOR 1 Do not reuse.
CONNECTOR

a. REPLACEMENT
1) Disconnect the 2P connector of ECT sensor 1.

2) Remove the ECT sensor 1 and the O-ring.

• Replace the O-ring on assembly.

3) Apply the engine oil to the new O-ring and install it on the
ECT sensor 1.

[3]
4) Tighten the ECT sensor 1 to the specified torque. ECT SENSOR 1
TORQUE: 12 N • m (1.2 kgf • m, 9 lbf • ft)

5) Connect the ECT sensor 1 connector.

5-147
 BF135A•BF150A

19. ECT (ENGINE COOLANT [1] [2] O-RING

ECT SENSOR 2
TEMPERATURE) SENSOR 2, 3, 4 2P CONNECTOR
Do not reuse.

a. REPLACEMENT

1) Disconnect the ECT sensor 2P connector.

2) Remove the ECT sensor and the O-ring.

• Replace the O-ring with a new one on assembly.

3) Apply the engine oil to the new O-ring and install it on the
ECT sensor.

[3] ECT SENSOR 2

4) Tighten the overheat sensor to the specified torque.
TORQUE: 12 N • m (1.2 kgf • m, 9 lbf • ft)
[4]
5) After installation, connect the ECT sensor 2P connector. ECT SENSOR 3
2P CONNECTOR OF

[2] O-RING
Do not reuse. [5] ECT SENSOR 3

[2] O-RING
Do not reuse.

[7] ECT
SENSOR 4 [6] ECT SENSOR 4
2P CONNECTOR

5-148
 BF135A•BF150A

20. BARO (BAROMETRIC PRESSURE) [1]

5 x 18 mm
[2]
BARO SENSOR
SENSOR WASHER BOLT 3P CONNECTOR

a. REPLACEMENT
1) Disconnect the BARO sensor 3P connector.

[3]
2) Remove the 5 x 18 mm washer bolt and remove the BARO BARO
sensor. SENSOR

3) Install the BARO sensor and tighten the 5 x 18 mm washer

bolt securely.

4) After installation, connect the BARO sensor 3P connector.

21. KNOCK SENSOR [1]

KNOCK SENSOR
a. REPLACEMENT
1) Disconnect the knock sensor 1P connector.

2) Remove the knock sensor.

3) Tighten the knock sensor to the specified torque.

TORQUE: 31 N • m (3.1 kgf • m, 22 lbf • ft)

[2]
4) After installation, connect the knock sensor 1P connector. KNOCK SENSOR
1P CONNECTOR

22. CMP (CAMSHAFT POSITION) [1] 15.2 x 1.9 mm O-RING

SENSOR Do not reuse.

a. REPLACEMENT
1) Remove the R./L. side covers.
2) Disconnect the CMP sensor 3P connector.
3) Remove the 6 x 16 mm flange bolt and remove the CMP
sensor and the O-ring.
• Replace the O-ring on assembly.

4) Apply the engine oil to the new O-ring and install it on the
CMP sensor.
5) Tighten the 6 x 16 mm flange bolt. [2]
CMP SENSOR
6) After installation, connect the CMP sensor 3P connector. [3]
CMP SENSOR
7) Install the removed parts in the reverse order of removal. 3P CONNECTOR 6 x 16

5-149
 BF135A•BF150A

23. CKP (CRANKSHAFT POSITION) [1] O-RING

SENSOR Do not reuse.

a. REPLACEMENT
1) Remove the silencer case (P. 5-128).

2) Disconnect the CKP sensor 3P connector.

3) Remove the 6 x 16 mm flange bolt, and remove the CKP

sensor and the O-ring. [2] CKP SENSOR

• Replace the O-ring on assembly.

[3] 6 x 16
4) Apply the engine oil to the new O-ring and install it on the CKP SENSOR 3P
CKP sensor. CONNECTOR

5) Tighten the 6 x 16 mm flange bolt securely.

6) After installing the CKP sensor, connect the CKP sensor 3P

connector.

7) Install the removed parts in the reverse order of removal.

24. VTEC SOLENOID VALVE (BF150A Only) [1] [2]

VTEC SOLENOID VALVE HARNESS
a. REPLACEMENT 1P CONNECTOR BAND CLIP
BRACKET C
1) Disconnect the VTEC solenoid valve 1P connector and dis-
connect the connector from the harness band clip bracket C.

2) Remove the three 6 x 55 mm flange bolts. Remove the

VTEC solenoid valve assembly, gasket and the filter.
[3] FILTER
• Replace the gasket and filter as an assembly of the
VTEC solenoid valve assembly. Do not reuse.

[5] GASKET
3) Install the new gasket and filter on the VTEC solenoid valve.
Do not reuse.

4) Install the VTEC solenoid valve assembly and tighten the 6 x

55 mm flange bolts securely.

5) Connect the VTEC solenoid valve 3P connector and set it

on the harness band clip bracket C.

[4]
VTEC SOLENOID
VALVE ASSEMBLY
6 x 16

5-150
 BF135A•BF150A

25. VAPOR CHAMBER/CHECK VALVE

a. DISASSEMBLY/ASSEMBLY

1) Remove the intake manifold (P. 5-129). [4] CHECK VALVE

ASSEMBLY:
Install with the " " mark
toward the vacuum tube C side.
[1] [3]
CRANKCASE VACUUM TUBE D [4]-1
BREATHER TUBE VACUUM
[2] TUBE C
T-JOINT SIDE

[5]
VACUUM TUBE C

[6]
AIR VENT TUBE B

[13] [7]
PRESSURE AIR VENT TUBE A
REGULATOR
CONTROL
TUBE

[8]
PRESSURE REGULATOR
RETURN HOSE

[9]
SUSPENSION
[12]
VAPOR CHAMBER

[10]
AIR VENT TUBE E

[11]
TUBE CLIP

5-151
 BF135A•BF150A

26. EXHAUST MANIFOLD

[1] WATER RELIEF TUBE A
a. REMOVAL [2]
7 x 120 mm
TUBE
1) Remove the engine cover and the L./R. engine under covers
(P. 4-2 and 4-9).
[3]
7 x 90 mm
2) Disconnect the following water hoses. TUBE
• Water relief tube A/B
• 7 x 90 mm tube
[4]
• 7 x 75 mm tube 7 x 75 mm
• 7 x 120 mm tube TUBE
• Water tube E

[5]
WATER
TUBE E

[6] WATER RELIEF TUBE B

3) BF135A: Disconnect the A/F sensor connector and remove [1]

the connector from the harness band clip bracket. 6 x 14 (3)
CONNECTOR
BF150A: Disconnect the A/F sensor and VTEC solenoid BRACKET
valve connectors, and remove the connectors from the har-
ness band clip bracket.

4) Remove the harness band clip from the connector bracket.

5) Remove the three 6 x 14 mm flange bolts and remove the

connector bracket.

[2]
A/F SENSOR
CONNECTOR

[3]
VTEC SOLENOID VALVE
CONNECTOR (BF150A only)

5-152
 BF135A•BF150A

6) Disconnect the ECT sensor 3 connector.

[1]
ECT SENSOR 3
CONNECTOR

7) Remove the 6 x 55 mm flange bolts and remove the valve

assembly (BF135A) or the VTEC solenoid valve assembly
(BF150A).

[1]
VTEC SOLENOID VALVE
ASSEMBLY (BF150A)
or
VALVE ASSEMBLY (BF135A) 6 x 55 (3)

8) Remove the 6 x 22 mm flange bolts and remove the R. side

cover bracket. [1] R. SIDE COVER BRACKET

6 x 22 (3)

5-153
 BF135A•BF150A

9) Remove the two 10 x 75 mm flange bolts and the three 10 x

45 mm flange bolts. Remove the exhaust manifold and the [1] GASKET
exhaust manifold gasket. Do not reuse.
• Replace the gasket on assembly.
10 x 45 (3)
10) Remove the O-ring from the exhaust manifold.
• Replace the O-ring on assembly.

[4] EXHAUST MANIFOLD

ASSEMBLY
10 x 75 (3)
[3] 79.9 x 3.1 mm [2] 76.4 x 3.1 mm
O-RING O-RING
Do not reuse. Do not reuse.

b. DISASSEMBLY/ASSEMBLY
[2] 6 x 14
[1] EXHAUST MANIFOLD
EXHAUST MANIFOLD COVER (2) 6 x 22 (4) [3]
COVER GASKET (2) WATER
Do not reuse. TUBE
CLAMP
BRACKET

[9] 6 x 18 mm SCREW (2)

[8] ANODE METAL (2)
Replace with new one
if excessively deterio-
rated.
[7] EXHAUST
[6] A/F SENSOR MANIFOLD
DISASSEMBLY/ASSEMBLY:
Remove/install the A/F sensor
using the special tool.
TORQUE:
3.4 N·m (0.35 kgf·m, 2.4 lbf·ft) [4] O-RING
Do not reuse.
[5]-1
SENSOR SOCKET WRENCH,
22 x 150 mm
07906-PD10000

[5] ECT SENSOR 3

12 N·m (1.2 kgf·m, 9 lbf·ft)

5-154
 BF135A•BF150A

c. INSTALLATION
6 x 14 (3)
[1]
CONNECTOR
BRACKET

6 x 55 (3)

[2]
VTEC SOLENOID
VALVE ASSEMBLY

10 x 45 (3)

10 x 75 (2)
[6] GASKET
Do not reuse.
[5]
EXHAUST MANIFOLD
ASSEMBLY [4] 79.9 x 3.1 mm [3] 76.4 x 3.1 mm
O-RING O-RING
Do not reuse. Do not reuse.

[1]
1) Apply the engine oil to the O-rings and install them on the EXHAUST MANIFOLD
exhaust manifold assembly. ASSEMBLY

2) Set the exhaust manifold assembly on the exhaust manifold

guide.

3) Set the new gasket. Align the holes located at the lower left
side, and loosely tighten the 10 x 75 mm flange bolt as
shown.

4) Align the bolt holes by turning the gasket in the direction

[2] GASKET
shown with the arrow. Take care not to damage the gasket.
10 x 75

5-155
 BF135A•BF150A

5) Tighten the two 10 x 75 mm flange bolts and the three 10 x

45 mm flange bolts to the specified torque in the numbered
sequence in two or three steps.

10 x 45 (3)
TORQUE: 39 N • m (4.0 kgf • m, 29 lbf • ft)

10 x 75 (2)

6) Install the R. side cover bracket and tighten the 6 x 22 mm [1] R. SIDE COVER BRACKET
flange bolts securely.

6 x 22 (2)

7) Connect the 2P connector to the ECT sensor 3.

[1]
[2] ECT SENSOR 3
2P CONNECTOR

5-156
 BF135A•BF150A

8) Install the VTEC spool valve assembly (BF150A) or valve

assembly (BF135A) and tighten the 6 x 55 mm flange bolts
securely. [1] FILTER

• Do not allow the gasket and filter to come out of position.

[2] GASKET

[1]
VTEC SPOOL VALVE
ASSEMBLY (BF150A) or
VALVE ASSEMBLY
(BF135A) 6 x 55 (3)

9) Install the harness band clip bracket C and tighten the three [1]
6 x 14 mm flange bolts securely. 6 x 14 (3)
HARNESS BAND
CLIP BRACKET C

10) BF135A: Connect the A/F sensor connector and set the
connector on the harness band clip bracket C.
BF150A: Connect the A/F sensor and the VTEC solenoid
valve connectors and set the connectors on the harness
band clip bracket C.

11) Set the harness band clip on the harness band clip bracket
C.

[2]
A/F SENSOR
CONNECTOR

[3]
VTEC SOLENOID VALVE
CONNECTOR (BF150A only)

5-157
 BF135A•BF150A

12) Connect the following water hoses. [1]

• Water relief tube A/B WATER RELIEF TUBE A
• 7 x 90 mm tube [2]
• 7 x 75 mm tube 7 x 120 mm
TUBE
• 7 x 120 mm tube
• Water tube E [3]
7 x 90 mm
TUBE

[4]
7 x 75 mm
TUBE

[5]
WATER
TUBE E

[6] WATER RELIEF TUBE B

5-158
6. ALTERNATOR
1. SILENCER DUCT 2. ALTERNATOR

110 N.m (11.2 kgf.m, 81 lbf.ft)

26 N.m (2.7 kgf.m,

20 lbf.ft)

44 N.m (4.5 kgf.m,

33 lbf.ft)

8 N.m (0.8 kgf.m,

5.8 lbf.ft)

6-1
1. SILENCER DUCT
[2] SILENCER DUCT
[3]
a. REMOVAL ASSEMBLY
18.5 mm CLAMP

1) Remove the engine cover (P. 4-2). [4]

[1]
PRESSURE
BREATHER
REGULATOR
Release the pressure regulator control tube from the two TUBE
CONTROL
3.5 mm tube clips of the silencer duct assembly. TUBE

Remove the harness band clip, that secures the main wire
harness, from the silencer duct assembly.

2) Release the breather tube from the 18.5 mm clamp and the
guide of the silencer duct assembly.

[8]
GUIDE

[5] MAIN WIRE

[7] 3.5 mm TUBE HARNESS
CLIP (2)
[6] HARNESS
BAND CLIP

3) Remove the four 6 x 25 mm flange bolts and the four 6 mm

[1]
washers, then remove the silencer duct assembly. 6 mm [2] SILENCER DUCT
WASHER 6 x 25 (4) ASSEMBLY
(4)

6-2
b. DISASSEMBLY

Remove the eight 5 x 12 mm self-tapping screws and remove the silencer duct A.

c. COMPONENTS DRAWING

[2] 18.5 mm CLAMP

[1]
5 x 12 mm SELF-TAPPING
SCREW (8)

[3] SILENCER DUCT A

6 x 25 (4) [4] SILENCER DUCT B

[11]
6 mm WASHER (4)

[5]
DUCT GROMMET (4)

[6]
[10] DUCT COLLAR (4)
3.5 mm TUBE
CLIP (2)

[9]
BREATHER TUBE

[8]
PRESSURE REGULATOR [7] HARNESS
CONTROL TUBE BAND CLIP

d. ASSEMBLY

Install the silencer duct A on the silencer duct B and tighten the eight 5 x 12 mm self-tapping screws securely.

6-3
e. INSTALLATION
[1] [2]
1) Install the silencer duct assembly on the silencer case. 6 mm 6 x 25 (4) SILENCER DUCT
WASHER (4) ASSEMBLY
2) Set the four 6 mm washers and the four 6 x 25 mm flange
bolts, then tighten the four 6 x 25 mm flange bolts securely.

3) Set the breather tube in the 18.5 mm clamp and the guide
of the silencer duct assembly.
[2] SILENCER [3]
DUCT 18.5 mm CLAMP
4) Secure the pressure regulator control tube with the two 3.5 ASSEMBLY
mm tube clips of the silencer duct assembly. [4]
[1] PRESSURE
Connect the pressure regulator control tube aligning the BREATHER REGULATOR
marked part on the tube with the end of the 3.5 mm tube TUBE CONTROL
clip (P. 2-71). TUBE

5) Install the main wire harness’ harness band clip on the

silencer duct assembly.

6) Install the engine cover (P. 4-2).

[8]
GUIDE

[5] MAIN WIRE

[7] HARNESS
3.5 mm TUBE
CLIP (2)
[6] HARNESS
BAND CLIP

6-4
2. ALTERNATOR
a. ALTERNATOR ASSEMBLY INSPECTION
(With the alternator assembly mounted on the
outboard motor)
NOTICE
Do not disconnect the battery terminals while the alternator is
running.

• Alternator assembly inspection must be made with the

assembly mounted on the outboard motor.

• Replace the IC regulator when the battery voltage exceeds 16V.

• Before disconnecting the alternator fuse cable, be sure to

disconnect the battery negative (-) terminal.

Check the following before starting the alternator assembly

inspection.
[1]
– Battery condition and cable connection ALTERNATOR
INDICATOR
LIGHT
– Alternator belt for looseness, cut and/or fraying (P. 3-28)

– Alternator 4P connector and alternator fuse cable for

connection

– Blown 90A fuse and 10A fuse

– Open or short circuit in each harness and cable [1] ALTERNATOR 4P CONNECTOR

1) Turn the ignition switch to the “ON” position and check that
the alternator indictor light comes ON.

2) If the alternator indicator light does not come ON,

disconnect the alternator 4P connector and short-circuit the
white/blue terminal of the harness side connector to the
ground.

3) If the indicator light still does not come ON, check the
following.
[2] ALTERNATOR
– Indicator light (P. 16-9)

– Main wire harness for open circuit [1] ALTERNATOR

4P CONNECTOR
4) Start the engine and check that the alternator indicator light [2]
(White/
goes OFF.
Blue)
– The alternator is normal when the light goes OFF.

– If the indicator light is still ON, check each part of the

alternator (P. 6-14) and repeat the above steps 2 and 3.
[3] Harness side connector
• When the alert system functions while the alternator is in viewed from front side
operation, the warning buzzer sounds intermittently.

6-5
b. REMOVAL [1] ALTERNATOR
4P CONNECTOR
Remove the following pars.
– Engine cover (P. 4-2)
– Silencer duct (P. 6-2)

1) Disconnect the battery negative (-) cable from the battery

negative terminal.

Disconnect the alternator 4P connector.

Disconnect the alternator fuse cable from the alternator

assembly.

[3] [2]
ALTERNATOR B TERMINAL ALTERNATOR
WASHER-NUT FUSE CABLE

2) Loosen the 10 x 80 mm flange bolt and the 8 mm flange

nut. [1] 8 mm
FLANGE
NUT
3) Loosen the special adjusting bolt and move the alternator 10 x 80
assembly to the engine side as full as it goes.

[3] [2] SPECIAL

ALTERNATOR ADJUSTING
ASSEMBLY BOLT

4) Detach the alternator belt from the alternator pulley first,

then from the crankshaft pulley. [1] ALTERNATOR
BELT
Remove the alternator belt.
[2] CRANKSHAFT
• Do not contaminate the alternator belt with oil and grease PULLEY
after removal.

• Do not bend the alternator belt. Store the belt by hanging

it on the wall.

[3] ALTERNATOR
PULLEY

6-6
5) Remove the 10 x 80 mm flange bolt. Pull the alternator assembly toward you.

Remove the 8 mm flange nut and remove the alternator assembly from the tensioner bolt.

[2]
[1] ALTERNATOR ASSEMBLY 8 mm FLANGE
10 x 80
NUT

[3] TENSIONER BOLT

c. ALTERNATOR BRACKET DISASSEMBLY

1) Remove the four 8 x 28 mm flange bolts and remove the alternator bracket.
2) Remove the special adjusting bolt and remove the tensioner bolt.
3) Remove the 6 x 16 mm flange bolt and remove the alternator stay.
4) Remove the two 8 x 20 mm flange bolts and remove the engine hanger B.

8 x 20 (2)

[1] ENGINE HANGER B

[2] ALTERNATOR
BRACKET

[3] ALTERNATOR
STAY

6 x 16

8 x 28 (4) [4]
SPECIAL ADJUSTING
[5] TENSIONER BOLT BOLT

6-7
d. ALTERNATOR ASSEMBLY/ALTERNATOR BRACKET COMPONENTS DRAWING

[4]
ALTERNATOR
[5]
BELT
10 x 80 8 mm FLANGE NUT
[1] 26 N.m (2.7 kgf.m,
CRANKSHAFT 44 N.m (4.5 kgf.m,
33 lbf.ft) 20 lbf.ft)
PULLEY

[3] ALTERNATOR
ASSEMBLY

8 x 20 (2)

[2]
ALTERNATOR
4P CONNECTOR

[6]
[12] ALTERNATOR FUSE CABLE
ENGINE HANGER B
[7]
ALTERNATOR B TERMINAL
WASHER-NUT
[11] 8 N.m (0.8 kgf.m, 5.8 lbf.ft)
ALTERNATOR
BRACKET

8 x 28 (4) 6 x 16
[10] TENSIONER
BOLT
[8]
SPECIAL ADJUSTING
[9] ALTERNATOR BOLT
STAY

6-8
e. ALTERNATOR ASSEMBLY DISASSEMBLY
[2] [3]
22 mm OFFSET PULLEY
1) Loosen the pulley lock nut using a 22 mm offset wrench
WRENCH LOCK
and a 10 mm offset wrench. NUT

2) Remove the pulley lock nut and the alternator pulley.

[1]
10 mm OFFSET
WRENCH

[3]
PULLEY LOCK
NUT

[4]
ALTERNATOR
PULLEY

3) Remove the 6 mm hex. nut from the insulator bushing and

remove the insulator bushing. [1] REAR END COVER
BOLT (3)
4) Remove the three rear end cover bolts and the rear end
cover.
[2]
REAR END
COVER

[3]
INSULATOR
BUSHING

[4]
6 mm HEX.
NUT

6-9
5) Remove the two 4 x 6 mm screws from the brush holder
assembly and remove the brush holder assembly. [1]
BRUSH HOLDER
Remove the brush holder insulator from the brush holder INSULATOR
assembly.

[2]
4 x 6 mm
SCREW (2)

[3]
BRUSH
HOLDER
ASSEMBLY

6) Remove the two 4 x 25 mm screw-washers and the 4 x 6

[2]
mm screw from the IC regulator, then remove the IC [3] 4 x 6 mm SCREW
4 x 25 mm SCREW-
regulator. WASHER (4)

[1]
IC REGULATOR

6-10
7) Remove the four 4 x 6 mm screws from the rectifier
assembly.
[1] WIRE (Straighten.)
8) Straighten the four wires as shown and remove the rectifier
assembly.

NOTICE
Replace the stator with a new one if a wire broke near the
small hole in the rectifier assembly.

[2]
4 x 6 mm
SCREW (4)

[3]
RECTIFIER
ASSEMBLY

9) Remove the two 5 mm hex. nuts and the two rear housing
bolts. [1] [2]
5 mm HEX. REAR HOUSING
Remove the rear housing.
NUT (2) BOLT (2)
10) Remove the wave washer.

[3]
REAR
[4] HOUSING
WAVE
WASHER

6-11
11) Remove the rotor from the stator (drive end housing).

Remove the bearing cover from the rotor shaft. [1]

BEARING
COVER

[2]
STATOR
[DRIVE END
HOUSING]

[3] ROTOR

12) Check the rear bearing for abnormal sound and play before
removal. Replace the rear bearing with a new one if there
is abnormal sound or play.

13) Using a commercially available bearing puller as shown, [1]

remove the rear bearing and washer. BEARING
Replace the rear bearing with new one on assembly. PULLER
(Commercially
NOTICE available)
Install a commercially available bearing puller with care not
to damage the rotor fins.
[2] REAR
BEARING

[3]
WASHER

[2] REAR BEARING

6-12
14) Remove the four screws and the retainer plate.

Remove the two stud bolts from the stator [drive end [2] SCREW (4)
housing].
[1]
RETAINER
PLATE

[4]
STATOR
[DRIVE END
HOUSING]

[3]
STUD
BOLT (2)

15) Check the front bearing for abnormal sound or play before
removal.
Replace the front bearing if necessary.
[1]
16) Holding the stator [drive end housing] by attaching the DRIVER
07749-0010000
wood blocks to both sides of the stator [drive end housing]
as shown, remove the front bearing from the stator using
the special tools.

Replace the front bearing with a new one on assembly.

[2] FRONT
BEARING
TOOLS:
Driver 07749-0010000
Attachment, 24 x 26 mm 07746-0010700
Pilot, 15 mm 07746-0040300

[4] ATTACHMENT, [3]

24 x 26 mm PILOT, 15 mm
07746-0010700 07746-0040300

6-13
f. INSPECTION (Unit inspection)

• BRUSH HOLDER ASSEMBLY

Measure the brush length.

If the measurement is less than the service limit, replace the
brush holder assembly.

STANDARD SERVICE LIMIT

10.5 mm (0.41 in) 8.4 mm (0.33 in)

• RECTIFIER ASSEMBLY
• Inspect the rectifier assembly by removing it from the [1] E (GROUND)
outboard motor. P'1 B
Check for continuity between the B terminal and the respective
P terminals (P1, P2, P3 and P4), and between the E terminal and P4
the respective P terminals (P1, P2, P3 and P4).
Note to check for continuity in two directions by reversing the P1
polarities.

There should be continuity only in one direction.

Replace the rectifier assembly as necessary.
P2
P3
[2] Circuit diagram:
B P'1

P1
P2
P3
P4

[1]
E (GROUND)

• ROTOR

1) Check to be sure that there is continuity between the slip [2] ROTOR SHAFT
[1] SLIP
rings.
RINGS
2) Check to see that there is no continuity between a slip ring
and the rotor, and between a slip ring and the rotor shaft.

3) Measure the slip ring O.D.

STANDARD SERVICE LIMIT

14.4 mm (0.57 in) 14.0 mm (0.55 in)
[3]
4) If the measurement is less than the service limit, replace ROTOR
the rotor.

6-14
• STATOR [DRIVE END HOUSING]

Inspect the stator by removing it from the outboard motor. [1] WIRES
[1] WIRES
1) Check to see that there is continuity between the wires.

2) Check to see that there is no continuity between each wire

and the stator core.

[2] STATOR CORE

6-15
g. COMPONENTS DRAWING
[2]
[1] 6 mm HEX. NUT INSULATOR
BUSHING

[3]
4 x 25 mm SCREW-
WASHER (2) [4]
4 x 6 mm
SCREW (7)

[5] BRUSH HOLDER

[23] INSULATOR
RECTIFIER
ASSEMBLY
[6] REAR END
COVER BOLT (3)

[7]
[25] BRUSH REAR END
HOLDER COVER
[24] IC REGULATOR ASSEMBLY
[22] ROTOR

[21] REAR BEARING

[8] REAR HOUSING
[19] WAVE
WASHER

[9]
[20] WASHER REAR
HOUSING
[17] [18] BEARING BOLT (2)
PULLEY LOCK NUT COVER
110 N.m (11.2 kgf.m,
81 lbf.ft)

[10] 5 mm HEX. NUT

[11]
FRONT BEARING
[16]
ALTERNATOR
PULLEY

[15] STATOR
[DRIVE END [12] SCREW (4)
HOUSING] [14] STUD
BOLT (2) [13] RETAINER PLATE

6-16
h. ALTERNATOR ASSEMBLY ASSEMBLY

1) Tighten the two stud bolts on the stator.

2) Apply grease to the outer surface of a new front bearing. [1]

DRIVER
07749-0010000
Drive the front bearing into the stator using the special
tools as shown.

TOOLS:
Driver 07749-0010000
Attachment, 37 x 40 mm 07746-0010200
Pilot, 15 mm 07746-0040300

[3] ATTACHMENT,
37 x 40 mm [2]
07746-0010200 PILOT, 15 mm
07746-0040300

3) Install the retainer plate with the projections toward the

front bearing and tighten it with the four screws. [2] SCREW (4)
[1]
RETAINER
PLATE

[3]
[5] STATOR
PROJECTIONS [DRIVE END
HOUSING]

[4] STUD
BOLTS (2)

6-17
4) Position a washer on the rotor shaft.
[1]
Apply grease to the inner wall of the new rear bearing and REAR
install it on the rotor shaft. BEARING

[2]
[3] WASHER
ROTOR
SHAFT

5) Attach the special tool to the front bearing side of the rotor
shaft, and position the rotor on the hydraulic press. [1]
FRONT
BEARING
TOOL: SIDE
Attachment, 52 x 55 mm 07746-0010400

[3] ATTACHMENT, [2]

52 x 55 mm ROTOR
07746-0010400 SHAFT

6) Attach the special tool to the rear bearing side and install
the rear bearing on the rotor using the hydraulic press.
[1]
TOOLS: DRIVER,
Attachment, 52 x 55 mm 07746-0010400 22 mm I.D.
Driver, 22 mm I.D. 07746-0020100 07746-0020100
Attachment,15 mm I.D. 07746-0020200

[2]
ATTACHMENT,
15 mm I.D.
07746-0020200

[3]
REAR BEARING

6-18
7) Check the rotor slip rings for contamination with grease.
[1]
If it is contaminated with grease, wipe it off thoroughly with BEARING
a clean cloth. COVER

Install the rotor on the stator [drive end housing].

[2]
Install a bearing cover on the rotor shaft. SLIP RINGS

[3]
STATOR
[DRIVE END
HOUSING]

[4]
ROTOR

8) Apply grease to the surface of the rear bearing and install

the wave washer. [2]
[1] HOLES REAR HOUSING
(Four places) BOLT (2)
9) Pass the wire through the respective four holes in the rear
housing.

Install the rear housing on the stator [drive end housing] [3]
5 mm HEX.
and tighten the two 5 mm hex. nuts and the rear housing
NUT (2)
bolts securely.

• Install the rear housing aligning the outer side of the

wave washer with the outer side of the bearing.
[4]
REAR
HOUSING
[6]
WAVE
WASHER [5]
WIRES

6-19
10) Pass the four wires through the four holes at the projection
on the reverse side of the rectifier assembly.
[1]
11) Bend each wire to the rectifier assembly side. WIRE (Bend along
the hole.)
Bend each wire along the respective screw holes.

12) Tighten the four 4 x 6 mm screws securely.

NOTICE
Replace the stator with a new one if a wire broke near the
hole in the rectifier assembly.
[2]
4 x 6 mm
SCREW (4)

[3]
RECTIFIER
ASSEMBLY

13) Assemble the brush holder insulator with the brush holder
assembly. [1]
BRUSH HOLDER
14) Position the brush holder assembly on the IC regulator and INSULATOR
loosely tighten the 4 x 6 mm screw.

• Loosely tighten the 4 x 6 mm screw so that the brush

holder does not move.
[2]
4 x 6 mm SCREW
(Loosely tighten so
the brush holder
does not move.)

[3]
BRUSH HOLDER
ASSEMBLY

[4]
IC REGULATOR

6-20
15) Tighten the two 4 x 25 mm screw-washers and the two 4 x
6 mm screws securely while pushing the brush of the IC [1] 4 x 6 mm SCREW (2) [2]
regulator/brush holder assembly, assembled in step 14, 4 x 25 mm SCREW-
WASHER (2)
lightly against the rotor shaft slip rings.

Tighten the 4 x 6 mm screw securely that has been [3]

tightened loosely in step 14. IC REGULATOR/BRUSH
HOLDER ASSEMBLY
NOTICE
Take care not to damage the rotor shaft slip rings with the
brush during installation.

[4]
SLIP
RINGS

16) Install the rear end cover and tighten the three rear end
cover bolts securely. [1] REAR END
COVER
17) Install the insulator bushing and tighten the 6 mm hex. nut BOLT (3)
securely.

[2] REAR END

COVER

[3]
INSULATOR
BUSHING

[4]
6 mm HEX. NUT

6-21
18) Position the alternator pulley on the rotor shaft and tighten
the pulley lock nut.
[1] [2]
19) Tighten the pulley lock nut to the specified torque using a ALTERNATOR PULLEY LOCK
PULLEY NUT
10 mm offset wrench and a torque wrench.

TORQUE: 110 N.m (11.2 kgf.m, 81 lbf.ft)

[5]
TORQUE
WRENCH [3] PULLEY LOCK
NUT

i. ALTERNATOR BRACKET ASSEMBLY [4]

10 mm
1) Tighten the alternator bracket with the four 8 x 28 mm OFFSET
flange bolts securely. WRENCH
2) Tighten the 6 x 16 mm flange bolt securely while pushing
the alternator stay against the projection on the alternator
bracket.
3) Position the special adjusting bolt on the tensioner bolt.
4) Install the engine hanger B with the two 8 x 20 mm flange
bolts.

8 x 20 (2)

[1]
ENGINE
HANGER B [2]
ALTERNATOR
BRACKET

[3]
PROJECTION [4]
ALTERNATOR
STAY

6 x 16

8 x 28 (4)
[5]
[6] TENSIONER BOLT SPECIAL ADJUSTING
BOLT

6-22
j. INSTALLATION
1) Position the alternator assembly over the tensioner bolt and loosely tighten the 8 mm flange nut.
2) Position the alternator assembly between the projections of the alternator bracket and loosely tighten the 10 x 80 mm
flange bolt.
[1] ALTERNATOR [2]
10 x 80
ASSEMBLY 8 mm FLANGE
NUT

[4]
Between the
projections

[3] TENSIONER BOLT

3) Install the alternator belt on the crankshaft pulley first, then

on the alternator pulley. [1] ALTERNATOR
BELT
NOTICE
Do nut turn the crankshaft pulley counterclockwise.

[2] CRANKSHAFT
PULLEY

[3] ALTERNATOR
PULLEY

6-23
4) Tighten the special adjusting bolt.
[1] 8 mm FLANGE
Inspect and adjust the alternator belt (P. 3-29). 10 x 80 NUT

5) After adjustment, tighten the 8 mm flange nut and 10 x 80

mm flange bolt in this order to the specified torque.

TORQUE:
8 mm flange nut: 26 N.m (2.7 kgf.m, 20 lbf.ft)
10 x 80 mm flange bolt: 44 N.m (4.5 kgf.m, 33lbf.ft)

6) After tightening the nut and the bolt to the specified torque,
check the alternator belt tension and deflection (P. 3-29).

[2] SPECIAL
[3] ADJUSTING
ALTERNATOR ASSEMBLY BOLT

7) Connect the alternator 4P connector to the alternator

assembly. [1] ALTERNATOR 4P CONNECTOR

8) Connect the alternator fuse cable to the alternator

assembly and loosely tighten the alternator B terminal
washer-nut.

9) Tighten the alternator B terminal washer-nut to the

specified torque so that the alternator fuse cable is
connected at 60˚ from the horizontal line as shown.

TORQUE: 8 N.m (0.8 kgf.m, 5.8 lbf.ft)

10) Install the following parts.

– Silencer duct (P. 6-4)
– Engine cover (P. 4-2)

[2] [3] ALTERNATOR

ALTERNATOR FUSE CABLE
B TERMINAL
WASHER-NUT
[2]
ALTERNATOR B TERMINAL
WASHER-NUT

60°

[3] ALTERNATOR
FUSE CABLE

6-24
7. ENGINE REMOVAL/INSTALLATION
1. REMOVAL 2. INSTALLATION

44 N.m (4.5 kgf.m, 26 N.m (2.7 kgf.m,

44 N.m (4.5 kgf.m, 33 lbf.ft) 20 lbf.ft)
33 lbf.ft)
64 N.m (6.5 kgf.m,
47 lbf.ft)

26 N.m (2.7 kgf.m,

20 lbf.ft)

64 N.m (6.5 kgf.m,

64 N.m (6.5 kgf.m,
47 lbf.ft)
47 lbf.ft)

44 N.m (4.5 kgf.m,

33 lbf.ft)

44 N.m (4.5 kgf.m, 26 N.m (2.7 kgf.m,

33 lbf.ft) 20 lbf.ft)

7-1
1. REMOVAL
Remove the following pars. [1]
– Engine cover (P. 4-2). ENGINE HANGER (3)
– L./R. engine under covers (P. 4-9).
– Under cover front bracket/L./R. side cover brackets (P. 4-20).
– Vapor separator (P. 5-111).
– Gear case assembly (P. 14-3 and 42).
1) Hook the hoist hooks on the three engine hangers and
secure the engine not to fall down.
Remove the following parts.
– Extension case/lower rubber mount (P. 14-89).
– Oil case (P. 14-94).
2) Be sure that the engine is held vertically and remove the
following parts.
– Starter motor (P. 18-1).
– Starter cable (P. 18-15).
– Shift link bracket/neutral switch (P. 17-11).

3) Remove the two 6 x 20 mm flange bolts and remove the

6 x 20
seal holder assembly from the engine assembly. [1]
SEAL HOLDER
ASSEBLY

4) Disconnect the air vent tube A and the oil tube from the
mounting case. [1] [2]
AIR VENT TUBE A OIL TUBE

7-2
5) Remove the four 8 x 30 mm flange bolts that secure the
exhaust guide from the underside of the mounting case.

6) Disconnect the water relief tube C from the relief valve

cover (P. 8-6).

[1]
EXHAUST
GUIDE

8 x 30 (4)

7) Remove the two 10 mm cap nuts and the 10 x 70 mm flange

bolt from the engine assembly. [1] 10 x 70
10 mm CAP NUTS

8) Remove the two 8 x 55 mm flange bolts and the 12 x 83

12 x 83 8 x 55
mm flange bolt.

7-3
9) Remove the following bolts and washers from the underside of the mounting case.
• 8 x 100 mm flange bolt (1)
• 10 x 80 mm flange bolt (1)
• 10 x 110 mm flange bolts (2)
• 12 x 70 mm hex. bolt (1)
• 12 x 130 mm hex. bolts (2)
• 12 mm washers (3)

10) Lift up the engine assembly slowly and remove it from the mounting case.

NOTICE
• Be sure that the hoist hooks are set on the three engine
hangers securely.
• Lift up the engine assembly while holding the engine
vertically.

11) Remove the two dowel pins, mounting case gasket, exhaust guide gasket and the oil pump rubber.

[1]
ENGINE ASSEMBLY

[9]
MOUNTING
CASE GASKET
[2]
10 x 16 mm
DOWEL PIN

[8]
OIL PUMP RUBBER
[3]
EXHAUST GUIDE
[7] GASKET
14 x 20 mm
DOWEL PIN

[4]
12 mm WASHER (3)

[6]
12 x 70 mm
HEX. BOLT

10 x 80 [5]
12 x 130 mm
HEX. BOLT (2)
10 x 110 (2) 8 x 100

7-4
COMPONENTS DRAWING 8 x 55 (2)
[2]
[1] ENGINE ASSEMBLY 26 N.m (2.7 kgf.m,
10 mm CAP NUT (2) 20 lbf.ft)
10 x 70 44 N.m (4.5 kgf.m, 33 lbf.ft)
44 N.m (4.5 kgf.m, 33 lbf.ft) 12 x 83
64 N.m (6.5 kgf.m,
47 lbf.ft)

[11]
OIL PUMP RUBBER
[3]
10 x 16 mm
DOWEL PIN

[10]
14 x 20 mm
DOWEL PIN
[4]
EXHAUST
GUIDE GASKET
[9]
MOUNTING CASE
GASKET
[5]
MOUNTING CASE

8 x 30 (4)
26 N.m (2.7 kgf.m, 20 lbf.ft)

[8] [6]
12 x 70 mm HEX. BOLT 12 mm WASHER (3)
64 N.m (6.5 kgf.m, 47 lbf.ft)
[7]
12 x 130 mm HEX. BOLT (2)
64 N.m (6.5 kgf.m, 47 lbf.ft)
10 x 80
44 N.m (4.5 kgf.m, 33 lbf.ft)

10 x 110 (2)
8 x 100
44 N.m (4.5 kgf.m, 33 lbf.ft)
26 N.m (2.7 kgf.m, 20 lbf.ft)

7-5
2. INSTALLATION [1]
SHIFT SHAFT B
1) Align the punch mark on the shift shaft A with the punch
mark on the shift shaft B before installing the engine
assembly.
[2] ALIGNMENT
NOTICE MARKS
• Be sure to align the punch marks securely before
[3]
installing the engine assembly. Install the engine
SHIFT
assembly with care not to let the punch marks come out SHAFT A
of alignment.
• Note that the proper shifting cannot be made unless the
punch marks are in proper alignment.

2) Disconnect the water relief tube B and the 7 x 40 mm tube

from the exhaust guide (P. 8-5, 6). [1]
EXHAUST GUIDE
3) Remove the exhaust guide from the exhaust manifold of
the engine assembly.

4) Apply grease to the exhaust manifold of the engine

assembly and to the sealing surface of the exhaust guide.

5) Install the exhaust guide gasket and the exhaust guide on

the mounting case, and loosely tightem the four 8 x 30 mm
flange bolts.

8 x 30 (4)

[2]
EXHAUST GUIDE
GASKET

6) Install the 10 x 16 mm dowel pin, 14 x 20 mm dowel pin,

mounting case gasket and the oil pump rubber on the [2]
[1] 10 x 55 STUD BOLTS
mounting case. SHIFT SHAFT B

7) Lower the engine assembly slowly while aligning the two

10 x 55 mm stud bolts and the shift shaft B with the
respective installation holes in the engine assembly.

NOTICE
• Take care not to ruin the stepped part of the shift shaft B
and the threaded part of the 10 x 55 mm stud bolts.
• Do not allow the alignment marks on the shift shaft A and
B come out of alignment. If they came out of alignment,
perform the Shift Shaft A/B Alignment procedure
explained for engine installation (P. 17-22).
• Lower the engine assembly slowly while holding the
engine vertically.

7-6
8) Lower the engine assembly slowly onto the mounting case
while aliging the exhaust manifold of the engine assembly [1]
with the exhaust guide. EXHAUST
MANIFOLD
9) Connect the water relief tube B and the 7 x 40 mm tube,
disconnected in step 2, to the exhaut guide (P. 8-7, 9).

NOTICE
Lower the engine assembly onto the mounting case slowly
while holding the engine vertically.

[2]
EXAUST GUIDE

10) Tighten the four 8 x 30 mm flange bolts in the numbered

sequence in two or three steps from the underside of the
mounting case. Tighten to the specified torque.

TORQUE: 26 N.m (2.7 kgf.m, 20 lbf.ft)

②
④

③
①

11) Loosely tighten each bolt and washer at the designated

places from the underside of the mounting case. Then,
tighten them to the specified torque in the numbered
sequence in two or three steps.

TORQUE:
12 x 70 mm hex. bolt,
12 x 130 mm hex. bolt: 64 N.m (6.5 kgf.m, 47 lbf.ft)
②
10 x 80 mm flange bolt,
①
10 x 110 mm flange bolt: 44 N.m (4.5 kgf.m, 33 lbf.ft) ⑦
8 x 100 mm flange bolt: 26 N.m (2.7 kgf.m, 20 lbf.ft) ④
⑤
Tightening
Part name Q' ty ⑥
point
①, ② 12 x 130 mm hex. bolt, 12 mm washer 2
③
③ 12 x 70 mm hex. bolt, 12 mm washer 1
④, ⑤ 10 x 110 mm flange bolt 2
⑥ 10 x 80 mm flange bolt 1
⑦ 8 x 100 mm flange bolt 1

7-7
12) Loosely tighten the bolts and nuts at the designated places
from the top of the engine assembly. Tighten the bolts and 12 x 83 8 x 55
nuts to the specified torque in the numbered sequence in
two or three steps.

TORQUE:
12 x 83 mm flange bolt: 64 N.m (6.5 kgf.m, 47 lbf.ft)
10 x 70 mm flange bolt: 44 N.m (4.5 kgf.m, 33 lbf.ft)
8 x 55 mm flange bolt: 26 N.m (2.7 kgf.m, 20 lbf.ft) ①
10 mm cap nut: 44 N.m (4.5 kgf.m, 33 lbf.ft)
⑥ ⑤
13) Connect the water relief tube C to the relief valve cover (P.
8-7).

[1]
10 mm CAP NUTS 10 x 70

④ ②
③

14) Connect the air vent tube A and the oil tube to the
[1] [2]
mounting case. AIR VENT TUBE A OIL TUBE

15) Tape around the stepped part of the shift shaft B to protect
it.
16) Install the seal holder assembly on the engine assembly
and tighten the two 6 x 20 mm flange bolts (P. 17-23).
Set the starter cable and the alternator fuse cable in the
6 x 20 (2) [1] SEAL HOLDER
cable bracket A (P. 17-23).
17) Install the following parts. ASSEMBLY
– Shift link bracket/neutral switch (P. 17-17) [2]
– Starter cable (P. 18-17) TAPE
– Starter motor (P. 18-14)
– Oil case (P. 14-95)
– Extension case/lower rubber mount (P. 14-91)
– Gear case assembly (P. 14-5 and 44)
– Vapor separator (P. 5-125)
– Under cover front bracket/L./R. side cover brackets (P. 4-
30) [3]
– L./R. engine under covers (P. 4-14) SHIFT
– Engine cover (P. 4-2) SHAFT B

7-8
8. THERMOSTAT/RELIEF VALVE/
FLUSH VALVE

1. THERMOSTAT 3. FLUSH VALVE

2. WATER RELIEF TUBE/RELIEF VALVE

12 N.m (1.2 kgf.m, 9 lbf.ft)

12 N.m (1.2 kgf.m, 9 lbf.ft)

8-1
1. THERMOSTAT
a. DISASSEMBLY
1) Remove the engine cover (P. 4-2).
2) Disconnect the water relief tube A from the thermostat cover.
Do not reuse the thermostat cover O-ring. Replace it with a new one on reassembly.
3) Remove the thermostat.
4) Disconnect the 2P connectors from the ECT sensor 2 and 4, and remove the ECT sensor 2 and 4.
Do not reuse the 9.5 x 1.9 mm O-rings. Replace them with the new ones on reassembly.
5) Release the breather tube from the 18.5 mm clamp of the harness clip bracket B.
6) Remove the two 6 x 14 mm flange bolts from the harness clip bracket B. With the harness clip bracket B raised a little,
remove the harness band clip and the wire harness clip from the harness clip bracket B.

6 x 22 (3) [3]
[1] WATER RELIEF
THERMOSTAT COVER TUBE A
[2]
TUBE CLAMP D25.0
[14]
THERMOSTAT
COVER O-RING
[4]
HARNESS CLIP
[13] BRACKET B
THERMOSTAT
(60˚C: For cylinder block)

6 x 14 (2)
[12]
ECT SENSOR 4

[11]
9.5 x 1.9 mm
O-RING (2)

[10]
THERMOSTAT
(50˚C: For cylinder head)

[5]
[9] 18.5 mm CLAMP
ECT SENSOR 2

[8]
[6]
BREATHER TUBE [7] HARNESS BAND CLIP
WIRE HARNESS CLIP

8-2
b. INSPECTION [1]
• THERMOSTAT THERMOMETER
1) Immerse the thermostat in water.
2) Heat the water and observe the operation of the thermostat
as the water temperature increases.
3) Measure the water temperature when the thermostat starts
[2]
to open. THERMOSTAT
• Don't let the thermometer or the thermostat touch the
container; this may cause a false reading.

Thermostat for cylinder head:

Start opening 48 – 52˚C (118 – 126˚F)
Fully open 60˚C (140 ˚F)

Thermostat for cylinder block:

Start opening 58 – 62˚C (136 – 144˚F)
Fully open 70˚C (158˚F)

4) Measure the lift height when the thermostat is fully open.

Thermostat for cylinder head:

Lift height More than 3.0 mm (0.12 in)

Thermostat for cylinder block:

Lift height More than 3.0 mm (0.12 in)

c. THERMOSTAT IDENTIFICATION [1] <Thermostat for cylinder head> [2]

GROOVES
NOTICE (2 places)
There are two types of thermostat; one for the cylinder head
and the other for the cylinder block. Do not confuse them on
assembly.

Thermostat for cylinder head:

The thermostat for the cylinder head can be identified with the
purple paint (or two grooves) on the thermostat.

[3]
PURPLE PAINT

Thermostat for cylinder block: [1] <Thermostat for cylinder block>

The thermostat for the cylinder block can be identified with no
paint (or three grooves) on the thermostat.
[2] GROOVES
(3 places)

8-3
d. ASSEMBLY
1) Check the thermostats for the identification mark and install each of them in the proper position (P. 8-3).
Install the thermostat for the cylinder head in the ECT sensor 2 installation hole side, and install the thermostat for
the cylinder block in the ECTsensor 4 installation hole side.
2) Install a new thermostat cover O-ring on the thermostat cover, and tighten the thermostat cover with the three 6 x 22
mm flange bolts securely.
3) Set the tube clamp D25.0 on the water relief tube A, and insert the water relief tube A into the thermostat cover
securely.
4) Position the tube clamp D25.0 so that its lugs are toward the direction shown.
5) Install a new 9.5 x 1.9 mm O-ring on the ECT sensor 2 and 4 respectively. Apply a liquid sealant (ThreeBond® #1201
or #1215 or equivalent) to the threads and seat of each sensor.
6) Install the ECT sensor 2 and 4, and tighten them to the specified torque.

TORQUE: 12 N.m (1.2 kgf.m, 9 lbf.ft)

7) Set the 18.5 mm clamp, harness band clip and the wire harness clip on the harness clip bracket B, and tighten the
two 6 x 14 mm flange bolts.
8) Install the engine cover (P. 4-2).

[1] 6 x 22 (3) [3]

THERMOSTAT COVER WATER RELIEF TUBE A
[2]
TUBE CLAMP D25.0
[14]
THERMOSTAT
COVER O-RING
Do not reuse. [4]
HARNESS CLIP
[13] BRACKET B
THERMOSTAT
(60˚C: For cylinder block)

[12]
ECT SENSOR 4
6 x 14 (2)
12 N.m (1.2 kgf.m, 9 lbf.ft)

[11]
9.5 x 1.9 mm
O-RING (2)
Do not reuse.

[10]
THERMOSTAT
(50˚C: For cylinder head)

[5]
[9] 18.5 mm CLAMP
ECT SENSOR 2
12 N.m (1.2 kgf.m, 9 lbf.ft)
[6]
[8] [7] HARNESS BAND CLIP
BREATHER TUBE WIRE HARNESS CLIP

8-4
2. WATER RELIEF TUBE/RELIEF VALVE
Remove the following parts.
– Engine cover (P. 4-2)
– L./R. engine under covers (P. 4-9)

a. REMOVAL OF WATER RELIEF TUBE ASSEMBLY

1) Disconnect the water relief tube A from the thermostat cover.
Remove the water tube clamp from the water relief tube A and the main wire harness.
2) Disconnect the 7 x 90 mm tube, 7 x 120 mm tube and the water tube E from the engine side.
Disconnect the water relief tube B from the water tube clamp B.
3) Disconnect the water relief tube B from the exhaust guide.

b. DISASSEMBLY OF WATER RELIEF TUBE ASSEMBLY

1) Disconnect the water relief tube A and B from the 4-way joint.
2) Disconnect the 7 x 90 mm tube and the 7 x 120 mm tube from the fuel tube joint.
3) Disconnect the fuel tube joint from the 7 x 75 mm tube.
4) Disconnect the 7 x 75 mm tube and the water tube E from the 4-way joint.
[1]
TUBE CLAMP D25.0 (4) [2]
[14] TUBE CLAMP D10.5 (8) [3]
WATER RELIEF THERMOSTAT
TUBE A COVER

[13]
WATER TUBE CLAMP

[12]
7 x 90 mm TUBE

[11]
FUEL TUBE JOINT

[10]
7 x 75 mm TUBE

[8]
[9] 7 x 120 mm
4-WAY JOINT TUBE

[7]
WATER TUBE E

[6]
WATER RELIEF TUBE B
[4]
EXHAUST GUIDE
[5]
WATER TUBE CLAMP B

8-5
c. WATER RELIEF TUBE C/RELIEF VALVE DISASSEMBLY
1) Disconnect the 7 x 160 mm tube, 7 x 40 mm tube and the water relief tube C from the engine side.
2) Disconnect each tube from the T-joint.
3) Remove the two 6 x 22 mm flange bolts and remove the relief valve cover and the relief valve.
Do not reuse the relief valve cover O-ring. Replace it with a new one on assembly.

[1]
TUBE CLAMP D10.5 (6)

[8] 6 x 22 (2)
7 x 160 mm TUBE

[2]
WATER RELIEF TUBE C

[7]
RELIEF VALVE COVER

[6]
T-JOINT

[5]
7 x 40 mm TUBE

[4]
RELIEF VALVE
COVER O-RING [3]
RELIEF VALVE

d. INSPECTION [1]
• RELIEF VALVE RELIEF VALVE [2]
1) Check the rubber part of the relief valve for deterioration RELIEF VALVE
and cracks. Replace the relief valve with a new one if SPRING
necessary.

2) Check the operation of the relief valve spring and replace

the relief valve with a new one if necessary.

[3]
RUBBER PART

8-6
e. WATER RELIEF TUBE C/RELIEF VALVE
[1] RELIEF VALVE COVER SIDE
ASSEMBLY
NOTICE
[2]
Check the tubes for deterioration and cracks before assembly. RELIEF VALVE
Replace if necessary.

1) Install the relief valve on the mount case noting the

installation direction as shown.
2) Set a new relief valve cover O-ring on the relief valve cover,
and install the relief valve cover with the two 6 x 22 mm
flange bolts. [3]
3) Connect the 7 x 160 mm tube, 7 x 40 mm tube and the MOUNTING CASE SIDE
water relief tube C to the T-joint, and clamp each tube with
the tube clamp D10.5.
4) Set the tube clamp D10.5 on the side of each tube where is
opposite to the other end connected to the T-joint, and
connect each tube to the engine side.
Clamp each tube with the tube clamp D10.5.

[1]
TUBE CLAMP D10.5 (6)

[8] 6 x 22 (2)
7 x 160 mm TUBE
[2]
WATER RELIEF
TUBE C

[7]
RELIEF VALVE COVER

[6]
T-JOINT

[5]
7 x 40 mm TUBE

[4]
RELIEF VALVE
COVER O-RING [3]
RELIEF VALVE

8-7
f. ASSEMBLY OF WATER RELIEF TUBE ASSEMBLY [1]
WATER RELIEF
NOTICE TUBE A SIDE
Check the tubes for deterioration and cracks before assembly.
Replace if necessary.

1) Note the connection position of each tube to the 4-way joint

as shown.
[2]
4-WAY JOINT
2) Connect the water relief tube B to the 4-way joint so that its
installation angle is approximately 33˚ as shown.

[3]
WATER RELIEF
TUBE B SIDE
[4]
4-WAY JOINT

[5]
APPROX. 33˚
[6]
WATER RELIEF
TUBE B

3) Connect the water relief tube A to the 4-way joint so that its
[1]
installation angle is approximately 90˚ as shown. 4-WAY JOINT

[3]
APPROX. 90˚ [2]
WATER RELIEF
TUBE A

4) Set the tube clamp D25.0s on the water relief tube A and B. [2]
[1] TUBE CLAMP
D25.0 (2) WATER RELIEF
5) Set the tube clamp D25.0s in the position 8 mm from the TUBE A
end of each tube as shown. 8 mm
(0.3 in)

[3]
4-WAY JOINT

8 mm
(0.3 in) [4]
WATER RELIEF
TUBE B

8-8
6) Connect the 7 x 75 mm tube and the water tube E to the 4-way joint.
7) Connect the 7 x 75 mm tube to the fuel tube joint.
8) Connect the 7 x 90 mm tube and the 7 x 120 mm tube to the fuel tube joint.
9) Connect the 7 x 120 mm tube with the lugs of the tube clamp D10.5s toward down.

g. INSTALLATION OF WATER RELIEF TUBE ASSEMBLY

1) Connect the water relief tube B to the exhaust guide.
Clamp the water relief tube B with the water tube clamp B.
2) Connect the water relief tube A to the thermostat cover and set the tube clamp D25.0 with its lugs toward the direction
shown (i.e. toward the intake manifold side).
Clamp the water relief tube A and the main wire harness with the water tube clamp.
3) Connect the 7 x 90 mm tube and the water tube E to the engine side.
4) Connect the 7 x 120 mm tube to the engine side and set the tube clamp D10.5s with the lugs toward down.
5) Install the following parts.
– L./R. engine under covers (P. 4-14)
– Engine cover (P. 4-2)

NOTICE
Start the engine after connecting the tubes. Check that the
water does not leak from each joint.
[1] [2]
TUBE CLAMP D25.0 (4) TUBE CLAMP D10.5 (8) [3]
THERMOSTAT
COVER
[14]
WATER RELIEF
TUBE A

[13]
WATER TUBE CLAMP

[12]
7 x 90 mm TUBE

[11]
FUEL TUBE JOINT

[10]
7 x 75 mm TUBE
[8]
7 x 120 mm
[9] TUBE
4-WAY JOINT

[7]
WATER TUBE E

[6]
WATER RELIEF TUBE B [4]
EXHAUST GUIDE
[5]
WATER TUBE CLAMP B

8-9
3. FLUSH VALVE
a. DISASSEMBLY
Remove the following parts.
– Engine cover (P. 4-2)
– L./R. engine under cover (P. 4-9)
1) Disconnect the 7 x 200 mm tube from the mount case.

2) Disconnect the 8 x 300 mm tube from the flush valve cover.

Remove the water seal, water hose joint A and the flush plug cap from the 8 x 300 mm tube.

3) Remove the 6 x 16 mm flange bolt, then remove the flush valve cover, flush valve and the flush valve spring.
Do not reuse the 16 mm O-ring on the flush valve cover. Replace with a new one on assembly.

[1]
TUBE CLAMP D10.5 (2) [2] [3]
7 x 200 mm TUBE MOUNT CASE

[4]
FLUSH VALVE
SPRING

[5]
[12] FLUSH VALVE
8 x 300 mm TUBE

[6]
16 mm O-RING

[7]
FLUSH VALVE
COVER

6 x 16
[11]
FLUSH PLUG CAP [10] [9]
WATER HOSE WATER SEAL [8]
JOINT A 13 mm TUBE CLIP B1 (2)

8-10
b. INSPECTION
• FLUSH VALVE
Check the flush valve gasket for deterioration and cracks, and
replace the flush valve if necessary.

[1]
FLUSH VALVE
GASKET

c. ASSEMBLY [2]
FLUSH VALVE COVER SIDE
NOTICE
Check each tube for deterioration and cracks before assembly.
Replace the tubes if necessary.
1) Install a new 16 mm O-ring on the flush valve cover.
2) Install the flush valve spring and the flush valve on the flush valve cover. Note the installation direction of the flush
valve.
3) Tighten the flush valve cover with the 6 x 16 mm flange bolt securely.
4) Install the tube clip B12.5s, flush plug cap, water hose joint A and the water seal on the 8 x 300 mm tube. Connect
the 8 x 300 mm tube to the flush valve cover and clamp the tube with the tube clip B12.5s.
5) Connect the 7 x 200 mm tube to the mount case.
6) Install the following parts.
– L./R. engine under covers (P. 4-14)
– Engine cover (P. 4-2)
[3]
[2] MOUNT CASE
[1] 7 x 200 mm TUBE
TUBE CLAMP D10.5 (2)

[4]
FLUSH VALVE
SPRING

[5]
FLUSH VALVE

[12]
8 x 300 mm TUBE [6]
16 mm O-RING

[7]
FLUSH VALVE
COVER

6 x 16
[11] [10] [9] [8]
FLUSH PLUG CAP WATER HOSE WATER SEAL 13 mm TUBE CLIP B1 (2)
JOINT A

8-11
9. CRANKSHAFT PULLEY/CAM CHAIN
1. DISASSEMBLY 2. ASSEMBLY

245 N.m (25.0 kgf.m, 181 lbf.ft)

12 N.m (1.2 kgf.m, 9 lbf.ft)

12 N.m (1.2 kgf.m, 9 lbf.ft)

12 N.m (1.2 kgf.m, 9 lbf.ft)

12 N.m (1.2 kgf.m, 9 lbf.ft)

12 N.m (1.2 kgf.m, 9 lbf.ft) 12 N.m (1.2 kgf.m, 9 lbf.ft)

22 N.m (2.2 kgf.m, 16 lbf.ft)

22 N.m (2.2 kgf.m, 16 lbf.ft)

12 N.m (1.2 kgf.m, 9 lbf.ft)

9-1
1. DISASSEMBLY [1]
6 x 14 (3)
HARNESS CLIP
Remove the following parts. BRACKET C
– Engine cover (P. 4-2)
– L./R. engine under cover (P. 4-9)
– Silencer duct (P. 6-2)
– Alternator belt (P. 3-29)
– Thermostat (P. 8-2)
– Cylinder head cover (P. 10-2)

Put the No.1 piston at the top dead center of its compression [2]
stroke before disassembly (P. 3-12 and 13). HARNESS
BAND CLIP
1) Detach the A/F sensor 4P connector and the VTEC solenoid (3)
valve 1P connector [BF150A only] from the harness clip
bracket C. Disconnect the connectors.

2) Remove the three harness band clips from the harness clip
bracket C.

3) Remove the three 6 x 14 mm flange bolts from the harness

clip bracket C and remove the harness clip bracket C.

[3] VTEC SOLENOID

[4]
VALVE
A/F SENSOR
1P CONNECTOR
4P CONNECTOR
[BF150A only]

4) Remove the two 8 x 20 mm flange bolts from the engine

hanger B and remove the engine hanger B. [1]
ENGINE HANGER B 8 x 20 (2)

5) Remove the main wire harness from the recesses of the

chain case.

[2] MAIN WIRE

HARNESS

[3]
RECESSES OF
CHAIN CASE

9-2
6) Disconnect the CKP sensor 3P connector from the CKP
sensor. [1] CKP SENSOR
3P CONNECTOR

[2] CKP SENSOR

7) Loosen the 16 x 49 mm bolt-washer using the special tools

as shown.
[1] [2] HANDLE
TOOLS: PULLEY HOLDER 07JAB-001020B
Handle 07JAB-001020B ATTACHMENT,
Pulley holder attachment, HEX 50 mm 07JAB-0010400 HEX 50 mm
Socket wrench, 19 mm 07JAA-001020A 07JAB-0010400

[3]
SOCKET WRENCH,
19 mm
07JAA-001020A

8) Remove the 16 x 49 mm bolt-washer and remove the

crankshaft pulley and the 4.5 x 21 mm key. [1]
16 x 49 mm [2]
BOLT-WASHER CRANKSHAFT
PULLEY

[3]
4.5 x 21 mm
KEY

9-3
9) Remove all bolts securing the chain case.
[1] 10 x 43 (3)
• 10 x 43 mm flange bolts (3)
6 x 37 (SH BOLT)
• 6 x 38 mm (SH) flange bolt (1)
• 6 x 28 mm flange bolts (10) 6 x 28 (10)
• 6 x 31 mm special bolts (2)
• 6 x 25 mm flange bolts (3)

10) Remove the chain case gasket and the chain case O-ring
from the chain case.
Replace the chain case gasket and the chain case O-ring [2]
with new ones on assembly. 6 x 31 mm
SPECIAL
BOLT (2)
[4] CHAIN CASE [5] CHAIN CASE
GASKET O-RING

[3]
CHAIN CASE

6 x 25 (3)

11) Pushing the cam chain tensioner arm toward the cam chain
[1] CAM CHAIN
tensioner, align the hole in the lock with the hole in the cam TENSIONER ARM
chain and insert the pin of 1.5 mm in O.D. into the hole.

NOTICE [2] Push.

Do not remove the pin of 1.5 mm in O.D. from the cam
chain tensioner before installing the cam chain tensioner.

[3] CAM CHAIN

TENSIONER

[4]
O.D. 1.5 mm PIN

[5]
Align hole in lock
with hole in cam
chain.

9-4
12) Remove the two 6 x 30 mm flange bolts and remove the
cam chain tensioner while pushing the cam chain tensioner 6 x 30 (2)
arm toward the cam chain (direction of arrow).

[1] CAM CHAIN

TENSIONER

[2]
CAM CHAIN
TENSIONER ARM

13) Remove the tensioner pivot bolt and the cam chain
tensioner arm. [1] [2] CAM CHAIN
TENSIONER GUIDE
14) Remove the three 6 x 20 mm flange bolts and remove the PIVOT BOLT
cam chain guide.
6 x 20 (3)

[3] CAM CHAIN

TENSIONER ARM

15) Remove the two 8 x 110 mm flange bolts and remove the
cam chain guide B.

8 x 110 (2)

[1] CAM CHAIN

GUIDE B

9-5
16) Remove the crank pulser plate from the crankshaft. [2]
[1] CRANKSHAFT
CRANK PULSER
PLATE

17) Remove the cam chain.

NOTICE
Keep the cam chin away from any magnetic parts and
devices after removal. [1]
CAM CHAIN

9-6
CHAIN CASE DISASSEMBLY:

1) Check the 43 x 58 x 7 mm oil seal for cut and other damage and replace if necessary.

Remove the 43 x 58 x 7 mm oil seal using a commercially available oil seal remover.

Replace the 43 x 58 x 7 mm oil seal with a new one on assembly.

2) Remove the CKP sensor and the chain case cover from the chain case.

Replace the CKP sensor at the 15 x 1.9 mm O-ring with a new one on assembly.

6 x 14 (3)

[2]
CHAIN CASE COVER

[1] CHAIN CASE

[3]
43 x 58 x 7 mm
OIL SEAL

[5] CKP SENSOR

6 x 16
[4] 15 x 1.9 mm O-RING

9-7
COMPONENTS DRAWING: [2] 16 x 49 mm BOLT-WASHER
245 N.m (25.0 kgf.m, 181 lbf.ft)

[3] CRANKSHAFT PULLEY

[1] 6 x 38 (SH BOLT)
12 N.m (1.2 kgf.m, 9 lbf.ft)

10 x 43 (3) 6 x 28 (10)
12 N.m (1.2 kgf.m, 9 lbf.ft)

[4]
6 x 31 mm SPECIAL BOLT (2)
[20]
CKP SENSOR 12 N.m (1.2 kgf.m, 9 lbf.ft)

6 x 14 (3)
12 N.m (1.2 kgf.m, 9 lbf.ft)
[5]
43 x 58 x 7 mm OIL SEAL
[19]
CHAIN CASE COVER

[6] CHAIN CASE

6 x 30 (2)
12 N.m (1.2 kgf.m, 9 lbf.ft)
[7] 15 x 1.9 mm O-RING
6 x 16
[18] CAM CHAIN TENSIONER
6 x 20 (3)
[17] 12 N.m (1.2 kgf.m, 9 lbf.ft)
TENSIONER PIVOT BOLT
22 N.m (2.2 kgf.m, 16 lbf.ft)

[16] CAM CHAIN

[8]
TENSIONER ARM
CAM CHAIN GUIDE

[15] CAM CHAIN

[9]
CRANK PULSER
PLATE
8 x 110 (2)
22 N.m (2.2 kgf.m, 16 lbf.ft)

[14]
CAM CHAIN GUIDE B
6 x 25 (3)
12 N.m (1.2 kgf.m, 9 lbf.ft)
[13]
CHAIN CASE GASKET [12]
CHAIN CASE [11]
O-RING 4.5 x 21 mm KEY [10] CRANKSHAFT

9-8
2. ASSEMBLY [1] <Oil seal installation direction>

CHAIN CASE ASSEMBLY:

1) Apply soapy water to the outer surface of a new 43 x 58 x [2] (Apply grease
7 mm oil seal. to the lip.)

Using the special tools, drive in the 43 x 58 x 7 mm oil seal

until it seats on the chain case as shown.

After installation, apply grease to the oil seal lip.

TOOLS:
Driver 07749-0010000 [3] OIL SEAL
Attachment, 52 x 55 mm 07746-0010400

[4]
DRIVER
07749-0010000

[5]
ATTACHMENT,
52 x 55 mm
07746-0010400

[3] OIL SEAL

2) Remove the old liquid gasket, oil and contamination from

the chain case cover and the chain case mating surfaces.

3) Apply a bead [ø2.0 – 3.0 mm (ø0.08 – 0.12 in)] of the liquid

gasket (ThreeBond® #1280B or equivalent) to the indicated
area of the chain case cover.

NOTICE
Assemble the chain case cover within 5 minutes after
application of the liquid gasket. If it has been left for 5
minutes or longer, remove the old liquid gasket and apply
the liquid gasket again before assembly.

[1] Apply a bead of liquid

gasket as shown.

9-9
4) Install the chain case by tightening the three 6 x 14 mm flange bolts to the specified torque.

TORQUE: 12 N.m (1.2 kgf.m, 9 lbf.ft)

5) Position a new 15 x 1.9 mm O-ring on the CKP sensor and apply engine oil to the O-ring.

Install the CKP sensor by tightening the 6 x 16 mm flange bolt securely.

6 x 14 (3)
12 N.m (1.2 kgf.m, 9 lbf.ft)

[2]
CHAIN CASE COVER

[1] CHAIN CASE

[3] (Apply grease
to the lip.)

[4]
43 x 58 x 7 mm
OIL SEAL

6 x 16

[6] CKP SENSOR

[5] 15 x 1.9 mm O-RING

9-10
CAM CHAIN/CRANKSHAFT PULLEY ASSEMBLY:
[1] CRANKSHAFT
SPROCKET [2] “ ” MARKS
NOTICE
Keep the cam chain away from any magnetic parts and
devices.

1) Align the “ ” mark on the crankshaft sprocket with the “ ”

mark on the cylinder block.

[3] CYLINDER BLOCK

2) Install the cam chain guide and tighten the three 6 x 20 mm

flange bolts to the specified torque.

TORQUE: 12 N.m (1.2 kgf.m, 9 lbf.ft)

[1] [2]
TENSIONER CAM CHAIN
3) Install the cam chain tensioner arm and tighten the PIVOT BOLT GUIDE
tensioner pivot bolt to the specified torque.

TORQUE: 22 N.m (2.2 kgf.m, 16 lbf.ft)

6 x 20 (3)

[3] CAM CHAIN

TENSIONER ARM

9-11
4) Install the cam chain aligning the color plate (one) with the
“ ” mark (or punch mark) on the crankshaft sprocket as [1] CAM CHAIN
shown.

[2] “ ” MARK [3] COLLAR PLATE

(or punch mark) (1 place)

5) Holding the hexagonal part of both the intake and exhaust

[1] <INTAKE SIDE> [2] <EXHAUST SIDE>
camshafts with the wrench or equivalent tool as shown,
align the “ ” mark on the exhaust camshaft sprocket with
[3] HEXAGONAL PART
the “ ” mark on the intake camshaft sprocket. (The No.1
piston is at the top dead center of its compression stroke.)

6) Check that the punch mark on the intake camshaft sprocket

and the punch mark on the exhaust camshaft sprocket are
in the position shown.

7) Holding the No.1 cylinder at the top dead center of its

compression stroke and the punch marks in alignment as
described in step 5, align each punch mark on the intake
and exhaust camshaft sprockets with the mid point of the
corresponding color plates (2 places) of the cam chain, and
install the cam chain. [4] PUNCH MARKS

NOTICE
• Turn the intake camshaft and the exhaust camshaft while
holding the hexagonal part of the intake and exhaust
camshafts with the wrench or equivalent tool and thereby
aligning the alignment marks on both the intake and
exhaust camshaft sprockets.

• Install the cam chain aligning the mid point of the two
color plates with the punch mark on the intake/exhaust
camshaft sprockets. [5] [7] INTAKE
EXHAUST [6] “ ” MARKS
CAMSHAFT
• Check that the color plate (one) of the crankshaft sprocket CAMSHAFT SPROCKET
is not out of alignment. SPROCKET
[8] COLOR PLATES (2 places)
• After installing the cam chain, check that the crankshaft
sprocket and the camshaft sprocket are in alignment with
the No.1 piston at the top dead center of its compression
stroke.

[9]
CAM CHAIN [4] PUNCH MARKS

9-12
8) Pushing the cam chain tensioner arm toward the cam
chain, install the cam chain tensioner by aligning the 6 x 30 (2) [1] 1.5 mm PIN
cutouts of the cam chain tensioner with the recess in the
cam chain tensioner arm. Tighten the two 6 x 30 mm flange
bolts to the specified torque.

TORQUE: 12 N.m (1.2 kgf.m, 9 lbf.ft)

Remove the 1.5 mm pin. [2]

CAM CHAIN
TENSIONER

[3]
CAM CHAIN
TENSIONER
ARM

[4]
RECESS
[5]
CUTOUTS

9) Wipe up oil, etc. from the crankshaft outer surface with a

clean shop towel.

[1] [2]
Install the crankshaft pulser plate on the crankshaft with the
“OUT-SIDE” MARK CRANK PULSER
“OUT-SIDE” mark facing out. PLATE

[3] CRANKSHAFT
(Wipe up oil, etc. from crankshaft
surface with a clean shop towel.)

9-13
10) Install the cam chain guide B and tighten the two 8 x 110
mm flange bolts to the specified torque.

TORQUE: 22 N.m (2.2 kgf.m, 16 lbf.ft)

8 x 110 (2)

[1] CAM CHAIN

GUIDE B

11) Install the new chain case gasket on the chain case.
[1] CHAIN CASE
GASKET

[2] CHAIN CASE

9-14
12) Install the new chain case O-ring on the chain case.
[1]
CHAIN CASE
O-RING

[2] CHAIN CASE

13) Remove the old liquid gasket, oil and the contamination
from the cylinder block/cylinder head and chain case [1]
mating surfaces. Apply bar [2.5 mm
(0.10 in) thick] of the
liquid gasket here
14) Apply a bead [ø2.0 – 3.0 mm (ø0.08 – 0.12 in)] of the liquid
again; i.e. to the bead
gasket (ThreeBond® #1280B or equivalent) to the indicated of the liquid gasket
areas of the chain case. applied before.

Apply bead [2.5 mm (0.10 in) thick] of the liquid gasket

again to the part “A” shown in the drawing; i.e. apply to the
bead of the liquid gasket applied before.

NOTICE [2] PART “A”

Assemble the chain case within 5 minutes after applying
the liquid gasket. If it has been left for 5 minutes or longer,
remove the old liquid gasket and apply the liquid gasket
again before assembly.

[2] PART “A”

[3]
Apply a bead of
liquid gasket.

[3]
Apply a bead of
liquid gasket

9-15
15) Install the chain case on the cylinder block aligning the end
of the chain case at the crankcase side. [1]
10 x 43 (3)
6 x 38 6 x 28 (10)
(SH BOLT)
16) Loosely tighten the two 6 x 31 mm special bolts in the
positions shown. [2]
6 x 31 mm
17) Loosely tighten all the chain case bolts but the two 6 x 31 SPECIAL BOLTS
mm special bolts, and tighten them to the specified torque
in two or three steps in a criss-cross pattern. (Tighten the
three 10 x 43 mm flange bolts to the standard torque.)

TORQUE:
6 x 38 mm (SH) flange bolt (1)/
6 x 28 mm flange bolts (10)/
6 x 31 mm special bolts (2)/
6 x 25 mm flange bolts (3): 12 N.m (1.2 kgf.m, 9 lbf.ft)

STANDARD TORQUE:
10 x 43 mm flange bolts (3): 39 N.m (40 kgf.m, 29 lbf.ft)

NOTICE
• Do not touch the surfaces coated with the liquid gasket. [3] CHAIN CASE
• Take care not to slide the chain case during installation as
it makes the thickness of the liquid gasket uneven.

• Take care not to let the chain case gasket and O-ring come
out of position.

6 x 25 (3)

[3] CHAIN CASE

[4] CYLINDER BLOCK

[5] CRANKCASE

9-16
18) Wipe up oil thoroughly from the threaded part of the
crankshaft where the 16 x 49 mm bolt-washer is tightened, : [1] Wipe up contamination.
and from the crankshaft pulley and the 16 x 49 mm bolt- : [2] Apply engine oil.
: [3] Degrease with degreasing cleaning agent.
washer with a clean shop towel.

19) Wipe up oil from the boss on the side of the crankshaft [4] 16 x 49 mm
pulley with a clean shop towel sprayed with the degreasing BOLT-WASHER
cleaning agent.

20) Apply the engine oil to the threads and the seating surface
of the 16 x 49 mm bolt-washer.

[5]
CRANKSHAFT
PULLEY

[6] CRANKSHAFT

21) Position the 4.5 x 21 mm key and the crankshaft pulley on

[1] [2]
the crankshaft, then loosely tighten the 16 x 49 mm bolt-
16 x 49 mm CRANKSHAFT
washer. BOLT-WASHER PULLEY

[3]
4.5 x 21 mm
KEY

9-17
22) Tighten the 16 x 49 mm bolt-washer to the specified torque
using the special tools as shown.
[1] HANDLE
TOOLS: 07JAB-001020B
Handle 07JAB-001020B
Pulley holder attachment, HEX 50 mm 07JAB-0010400
Socket wrench, 19 mm 07JAA-001020A

TORQUE: 245 N.m (25.0 kgf.m, 181 lbf.ft)

[2] SOCKET WRENCH,

19 mm
[3] PULLEY HOLDER
07JAA-001020A
ATTACHMENT,
HEX 50 mm
07JAB-0010400

23) Connect the CKP sensor 3P connector to the CKP sensor.

[1]
CKP SENSOR
3P CONNECTOR

[2] CKP SENSOR

9-18
24) Position the main wire harness in the recesses of the chain
case. [1] ENGINE HANGER B 8 x 20 (2)

25) Tighten the engine hanger B with the two 8 x 20 mm flange

bolts.
[2]
MAIN WIRE
HARNESS

[3]
RECESSES OF
CHAIN CASE

26) Position the three harness band clips on the harness clip
[1]
bracket C. 6 x 14 (3)
HARNESS CLIP
Tighten the harness clip bracket C with the three 6 x 14 mm BRACKET C
flange bolts securely.

27) Connect the A/F sensor 4P connector and the VTEC

solenoid valve 1P connector [BF150A only], and install
them on the harness clip bracket C.

28) Install the following parts.

– Cylinder head cover (P. 10-40)
– Thermostat (P. 8-4) [2]
– Alternator belt (P. 3-30) HARNESS
– Silencer duct (P. 6-4) BAND CLIP
(3)
– L./R. engine under cover (P. 4-14)
– Engine cover (P. 4-2)

[3] VTEC SOLENOID

[4]
VALVE
A/F SENSOR
1P CONNECTOR
4P CONNECTOR
[BF150A only]

9-19
10. CYLINDER HEAD/VALVE
1. CYLINDER HEAD COVER REMOVAL 8. VALVE GUIDE REPLACEMENT
2. CYLINDER HEAD COVER 9. VALVE SEAT RECONDITIONING
DISASSEMBLY 10. CLYLINDER HEAD ASSEMBLY
3. CAMSHAFT/ROCKER ARM ASSEMBLY
DISASSEMBLY 11. CYLINDER HEAD ASSEMBLY
4. CAMSHAFT/ROCKER ARM INSTALLATION
INSPECTION 12. CAMSHAFT/ROCKER ARM
5. CYLINDER HEAD ASSEMBLY ASSEMBLY
REMOVAL 13. CYLINDER HEAD COVER ASSEMBLY
6. CYLINDER HEAD ASSEMBLY 14. CYLINDER HEAD COVER
DISASSEMBLY INSTALLATION
7. CYLINDER HEAD ASSEMBLY
INSPECTION

12 N.m (1.2 kgf.m, 9 lbf.ft)

[1]
Used bolt:
39 N.m (4.0 kgf.m, 29 lbf.ft) + 90˚ + 90˚
New bolt:
39 N.m (4.0 kgf.m, 29 lbf.ft) + 90˚ + 90˚ + 98˚

113 N.m (11.5 kgf.m, 83 lbf.ft)

72 N.m (7.3 kgf.m, 53 lbf.ft)

22 N.m (2.2 kgf.m, 16 lbf.ft)

12 N.m (1.2 kgf.m, 9 lbf.ft)

22 N.m (2.2 kgf.m, 16 lbf.ft)

39 N.m {4.0 kgf.m,
29 lbf.ft)
22 N.m (2.2 kgf.m, 16 lbf.ft)

12 N.m (1.2 kgf.m, 9 lbf.ft)

10-1
1. CYLINDER HEAD COVER REMOVAL
Remove the following parts.
– Engine cover (P. 4-2)
– L./R. engine under covers (P. 4-9)
– Ignition coil/spark plug (P. 3-6)
1) Disconnect the breather tube and the main wire harness
from the cylinder head cover.

[1] [2]
BREATHER MAIN WIRE
TUBE HARNESS

2) Remove the two 6 x 22 mm flange bolts, then remove the

R. side cover bracket assembly from the engine assembly. [1]
R. SIDE COVER
BRACKET ASSEMBLY

6 x 22 (2)

3) Disconnect the fuel tube B and the fuel tube D from the fuel
[1] TUBE CLIPS [2]
pump (low pressure side). (Commercially FUEL
available) TUBE B
NOTICE
Before disconnecting the fuel tube B and the fuel tube D,
clamp the fuel tubes with the tube clips to prevent gasoline
leakage.

[3] FUEL PUMP

[4] (Low pressure
FUEL TUBE D side)

10-2
4) Disconnect the oil tube from the mounting case.
[1]
OIL TUBE

[2]
MOUNTING CASE

5) Move the water relief tube A from your side of the [1]
projection on the cylinder head cover to the other side. WATER RELIEF
TUBE A

[2]
PROJECTION

[3]
CYLINDER
HEAD
COVER

6) Remove the six 6 mm hex. cap nuts and the six head cover
[1]
washers, then remove the cylinder head cover. CYLINDER HEAD
COVER

[2]
HEAD COVER
WASHER (6)
[3]
6 mm HEX. CAP
NUT

10-3
2. CYLINDER HEAD COVER DISASSEMBLY

[1]
HEAD COVER GASKET
INSPECTION:
Check for damage and
deterioration. Replace if
necessary.

[2]
CYLINDER HEAD COVER

[3]
HEAD COVER WASHER (6)
[4]
6 mm HEX. CAP NUT (6)
12 N.m (1.2 kgf.m, 9 lbf.ft)

[5]
PHC COVER

[11]
SPARK PLUG TUBE SEAL (4)
INSPECTION:
Check the seal lip for a
break or other damage.
Replace if necessary.
[9]
TUBE CLIP [7]
D32.5 6 x 25 mm SOCKET
[10] BOLT (4)
OIL TUBE [8] [6]
IGNITION COIL (4) 6 x 25 mm SOCKET
BOLT (2)

10-4
3. CAMSHAFT/ROCKER ARM
DISASSEMBLY
Remove the following parts.
– Engine cover (P. 4-2)
– L./R. engine under covers (P. 4-9)
– Ignition coil/spark plug (P. 3-6)
– Cylinder head cover (P. 10- 2)
1) Move the remote control lever to the “N” (Neutral)
position.
2) Turn the crankshaft pulley clockwise until it sets the No.1
piston at the top dead center of its compression stroke (P. [1]
3-12). CLIP
Remove the following parts. BRACKET F
– Crankshaft pulley/cam chain (P. 9-2) [2] [3]
3) Disconnect the CMP sensor 3P connector. Remove the HARNESS CMP SENSOR 3P
harness band clip from the clip bracket F. BAND CLIP CONNECTOR

4) Remove the 6 x 16 mm flange bolts from the No.5 rocker

shaft holder, then remove the CMP sensor and the CMP
hole plug.

5) Remove the 15.2 x 1.9 mm O-rings from the CMP sensor

and the CMP hole plug.
Replace the O-rings with the new ones on assembly.

[1]
CMP HOLE PLUG [2]
6 x 16 (2) CMP SENSOR

6) Secure the hex. part of the intake camshaft with a wrench

[1]
or equivalent tool. INTAKE CAMSHAFT

10-5
7) Using a hex. wrench, loosen the 14 mm sealing bolt that
[1]
tightens the camshaft collar.
CAMSHAFT COLLAR

[2]
14 mm SEALING BOLT

8) Remove the VTC flange bolt from the intake camshaft [2]
sprocket. Remove the intake camshaft sprocket from the INTAKE CAMSHAFT
intake camshaft. SPROCKET
[1] [3]
VTC FLANGE INTAKE
BOLT CAMSHAFT

9) Secure the hex. part of the exhaust camshaft with a wrench

[1]
or equivalent tool. EXHAUST CAMSHAFT

10-6
10) Using a hex. wrench, loosen the 14 mm sealing bolt that
[1]
tightens the CMP pulse plate.
CMP PULSE PLATE

[2]
14 mm SEALING BOLT

11) Remove the 10 x 32 mm flange bolt from the exhaust

[2]
camshaft sprocket, then remove the exhaust camshaft 10 x 32 EXHAUST
sprocket from the exhaust camshaft. CAMSHAFT
[1] SPROCKET
EXHAUST
CAMSHAFT

12) Loosen the rocker arm’s lock nut, then loosen the valve [2]
adjusting screw fully. VALVE ADJUSTING
SCREW
[1]
VALVE ADJUSTING
LOCK NUT

10-7
13) Loosen the camshaft holder bolts in the numbered
sequence in two or three steps.

5 4

7 6

e w

t r

a p

d s
1
u y

o i
14) Remove the following bolts.
• Head cover bolts (6)
• 8 x 110 mm flange bolts (2)
9 8
• 8 x 90 mm flange bolts (12)
• 6 x 32 mm flange bolt (1) q 0
• 6 x 20 mm flange bolts (2)
3 2
15) Remove the cam chain guide B, camshaft holder and the
intake and exhaust camshafts.
Remove the 10 dowel pins.

[1]
INTAKE CAMSHAFT

[2] [3]
EXHAUST CAMSHAFT CAM CHAIN
GUIDE B

8 x 110 (2)

[4]
HEAD CAVER
BOLT (6)

8 x 90 (12)

6 x 20 (2)

6 x 32
[6] [5]
10 x 16 mm CAMSHAFT
DOWEL PIN (10) HOLDER (4)

10-8
16) Remove the 14 mm sealing bolts from the intake/exhaust [1] EXHAUST
camshafts, then remove the camshaft collar and the CMP CAMSHAFT
pulse plate.
[2]
CMP
PULSE
PLATE

[3] CAMSHAFT
COLLAR
[5] [4]
INTAKE 14 mm SEALING
CAMSHAFT BOLT (2)

17) Insert the bolts into the rocker shaft holders and remove
the rocker arm assembly from the cylinder head assembly. [1]
ROCKER ARM
ASSEMBLY

[3]
10 x 16 mm
DOWEL PIN (10) [2]
BOLT (4)

10-9
COMPONENTS DRAWING
[3]
[1] VTC FLANGE BOLT
10 x 16 mm 113 N.m (11.5 kgf.m, 83 lbf.ft)
DOWEL PIN (10)
[4] INTAKE CAMSHAFT
[2] SPROCKET
ROCKER ARM
ASSEMBLY 10 x 32
72 N.m (7.3 kgf.m,
53 lbf.ft)

[5]
EXHAUST
CAMSHAFT
SPROCKET

[6]
EXHAUST
CAMSHAFT

[7]
INTAKE
CAMSHAFT

[8]
[22] 15.2 x 1.9 mm O-RING (2) CMP PULSE PLATE

[21] CMP HOLE PLUG [9]

14 mm SEALING BOLT (2)
6 x 16 (2) 39 N.m (4.0 kgf.m,
29 lbf.ft)
[10]
6 x 14 CAMSHAFT COLLAR
6 x 20 (2)
12 N.m (1.2 kgf.m, 9 lbf.ft)
[20]
No.1 CAMSHAFT [11] CLIP BRACKET F
HOLDER
[12] CMP SENSOR
8 x110 (2)
[19] 22 N.m (2.2 kgf.m,
No.2 CAMSHAFT 16 lbf.ft)
HOLDER

[18] 8 x 90 (12)
No.3 CAMSHAFT 22 N.m (2.2 kgf.m,
HOLDER 16 lbf.ft)
[14]
[17] CAM CHAIN
No.4 CAMSHAFT GUIDE B
HOLDER 6 x 32
12 N.m (1.2 kgf.m,
[16] 9 lbf.ft)
10 x 16 mm
DOWEL PIN (10) [15] [13]
No.5 CAMSHAFT HEAD COVER
HOLDER BOLT (6)
22 N.m (2.2 kgf.m,
16 lbf.ft)

10-10
DISASSEMBLY OF ROCKER ARM ASSEMBLY
BF150A:
NOTICE
• Note the location of each part before disassembly. Do not
confuse the parts and install them in their original positions.
• Check the camshaft contact surface of each rocker arm for
wear or damage.
• Insert the bolts in the rocker shaft holders before removing or
installing the rocker arm assembly from/on the cylinder head.

Apply molybdenum disulfide oil to the outer surface of the intake/exhaust rocker shafts on assembly.

[2] [3]
INTAKE ROCKER EXHAUST [1] MOLYBDENUM
[1] MOLYBDENUM ARM ASSEMBLY ROCKER ARM
DISULFIDE OIL DISULFIDE OIL

[4]
No.1 ROCKER SHAFT HOLDER

[5]
No.2 ROCKER SHAFT HOLDER

[6]
No.3 ROCKER SHAFT HOLDER

[7]
No.4 ROCKER SHAFT HOLDER

[11] [8]
INTAKE ROCKER EXHAUST ROCKER
SHAFT SHAFT
[10]
RUBBER BAND [9]
No.5 ROCKER SHAFT HOLDER

10-11
BF135A:
NOTICE
• Note the location of each part before disassembly. Do not
confuse the parts and install them in their original positions.
• Check the camshaft contact surface of each rocker arm for
wear or damage.
• Insert the bolts in the rocker shaft holders before removing or
installing the rocker arm assembly from/on the cylinder head.

Apply molybdenum disulfide oil to the outer surface of the intake/exhaust rocker shafts on assembly.

[2] [3]
INTAKE ROCKER EXHAUST [1] MOLYBDENUM
[1] MOLYBDENUM ARM ASSEMBLY ROCKER ARM DISULFIDE OIL
DISULFIDE OIL

[4]
No.1 ROCKER SHAFT HOLDER

[5]
No.2 ROCKER SHAFT HOLDER

[6]
No.3 ROCKER SHAFT HOLDER

[7]
No.4 ROCKER SHAFT HOLDER

[11] [8]
INTAKE ROCKER EXHAUST ROCKER
SHAFT SHAFT
[10]
RUBBER BAND [9]
No.5 ROCKER SHAFT HOLDER

10-12
4. CAMSHAFT/ROCKER ARM [1] INTAKE CAMSHAFT:
<BF150A> <BF135A>
INSPECTION [2] PRI [3] MID [4] SEC [4] SEC [2] PRI
• CAM HEIGHT
Clean the camshaft and check the cam surface for wear and
damage.

STANDARD SERVICE LIMIT

[5] CAM CHAIN [5] CAM CHAIN
32.626 – 32.931 mm
IN: PRI/SEC
(1.2845 – 1.2965 in) [6] EXHAUST CAMSHAFT:
35.369 – 35.654 mm
IN: MID
(1.3925 – 1.4037 in)
33.927 – 34.212 mm
EX
(1.3357 – 1.3469 in)
PRI: Primary MID: Mid SEC: Secondary
[5] CAM CHAIN

• CAMSHAFT JOURNAL O.D.

Clean the camshaft and check the journals for wear and
damage.

STANDARD SERVICE LIMIT

28.955 – 28.970 mm
No.1
(1.1400 – 1.1405 in)
28.925 – 28.940 mm
No.2 – No.5
(1.1388 – 1.1394 in)

• CAMSHAFT JOURNAL I.D.

STANDARD SERVICE LIMIT

29.000 – 29.024 mm
No.1 – No.5
(1.1417 – 1.1427 in)

10-13
• CAMSHAFT OIL CLEARANCE
1) Clean the camshaft and check the journals for wear and
damage.
[1]
2) Clean the rocker shaft holder bearings and the camshaft PLASTIGAUGE
holder bearings. Install the rocker shaft holders and the
camshaft on the cylinder head assembly.

3) Set a plastigauge on each journal as shown.

NOTICE
• Set a plastigauge in the axial direction on each journal.
• Do not turn the camshaft during the check.

4) Install the camshaft holder on the rocker shaft holder and

tighten the bolts to the specified torque (P. 10-35).

TORQUE:
Head cover bolt,
8 x 90 mm flange bolt,
8 x 110 mm flange bolt: 22 N.m (2.2 kgf.m, 16 lbf.ft)
6 x 20 mm flange bolt,
6 x 32 mm flange bolt: 12 N.m (1.2 kgf.m, 9 lbf.ft)

5) Remove the camshaft holder. Measure the width of the

pressed part of the plastigauge using a scale printed on the
bag of the plastigauge.

NOTICE
Measure the widest width on the plastigauge.

STANDARD SERVICE LIMIT [1]

SCALE
0.030 – 0.069 mm 0.15 mm
No.1
(0.0012 – 0.0027 in) (0.006 in)
0.060 – 0.099 mm 0.15 mm
No.2 – No.5
(0.0024 – 0.0039 in) (0.006 in)

6) If the measurement exceeds the service limit, replace the

camshaft holder, rocker shaft holder and the cylinder head
as a set. Recheck the camshaft oil clearance.
If the measurement still exceeds the service limit, replace
the camshaft.

[2]
PLASTIGAUGE

10-14
• CAMSHAFT AXIAL CLEARANCE
1) Install the rocker shaft holder, camshaft and the camshaft
holder, and tighten the bolts to the specified torque (P. 10-
35).
2) Put the camshaft at the top dead center of the compression
stroke of the No.1 piston (with the dowel pin at your side).
Install the dial indicator.
3) Check the camshaft axial play by pushing and pulling the
camshaft of the opposite side from the indicator.

STANDARD SERVICE LIMIT

0.05 – 0.20 mm 0.4 mm
(0.002 – 0.008 in) (0.02 in)

4) If the measurement exceeds the service limit, replace the

camshaft holder, rocker shaft holder and the cylinder head
[1]
as a set, and recheck. Dowel pin is at your side.
If the measurement still exceeds the service limit, replace
the camshaft.

• CAMSHAFT RUNOUT
1) Place the V blocks or equivalent under the journal at both
ends of the camshaft

2) Install the dial indicator and measure the camshaft runout

by turning the camshaft.

STANDARD SERVICE LIMIT

0.03 mm (0.001 in) Max. 0.4 mm (0.02 in)

3) Replace the camshaft if the measurement exceeds the

service limit.

• ROCKER SHAFT O.D.

STANDARD SERVICE LIMIT
16.983 – 16.994 mm
IN/EX
(0.6686 – 0.6690 in)

NOTICE
Measure the rocker shaft O.D. at the sliding part of the rocker
arm.

10-15
• ROCKER ARM I.D.

STANDARD SERVICE LIMIT

17.019 – 17.035 mm
IN
(0.6700 – 0.6707 in)
17.012 – 17.039 mm
EX
(0.6698 – 0.6708 in)

• ROCKER ARM-TO-ROCKER SHAFT CLEARANCE

STANDARD SERVICE LIMIT

0.025 – 0.052 mm 0.08 mm
IN
(0.0010 – 0.0020 in) (0.003 in)
0.018 – 0.056 mm 0.08 mm
EX
(0.0007 – 0.0022 in) (0.003 in)

If the measurement exceeds the service limit, replace the

rocker arm as an assembly and recheck.
If the measurement still exceeds the service limit, replace the
rocker shaft.
[1] MID ROCKER ARM
• VTEC ROCKER ARM ASEMBLY INSPECTION
(BF150A only)
Check of stuck rocker arm assembly at high lift side:
1) Remove the cylinder head cover (P. 10-2).
2) Put the No.1 piston at the top dead center of the
compression stroke (P. 3-12).
3) Move the secondary rocker arm of the No.1 cylinder up and
down with a finger. Check that the secondary rocker arm
moves independent from the mid rocker arm.

NOTICE
• If it does not, remove and disassemble the rocker arm
assembly to check (P. 10-18).
• If the rocker arm assembly is not normal, replace the [2]
rocker arm as an assembly. SECONDARY
ROCKER ARM
4) Repeat the step 2 and 3 on each cylinder to put the piston
of each cylinder at the top dead center of its compression
stroke. Check the secondary rocker arm.
5) Install the cylinder head cover (P. 10-40).

Check of stuck rocker arm assembly at low lift side:

NOTICE
• Before performing inspection with the special tool(s), check
that the secondary rocker arm moves independently. (See
Check of stuck rocker arm assembly at high lift side.)
• Check with the special tool(s) can be made on the following
conditions.
– At cylinder head disassembly
– Engine power drops significantly at high rpm but the cause
of the problem cannot be identified by following the
troubleshooting chart.

1) Start the engine and let it warm up for five minutes.

2) Remove the cylinder head cover (P. 10-2).
3) Check the valve clearance (P. 3-9).

10-16
NOTICE
• Check that the following conditions are met before using the
air supply (special tool). The following conditions are
essential for use of the air supply, as the specified air [1]
pressure of 290 kPa (3.0 kgf/cm2, 43 psi) must be maintained AIR SUPPLY
at the gauge of the tool. Stop using the other air tools unless 07LAJ-PR30102
the specified air pressure is maintained.
– Check whether the air compressor tank is under the
specified air pressure and the tank gauge shows the value
of the set pressure. [2]
– Connect the air supply to the air intake port located close to AIR JOINT ADAPTER
the compressor. 07ZAJ-PNA0300
– Check as quickly as possible (within 6 seconds), or the air
pressure drops possibly marking it hard to switch the valve
timing to the high lift side.
• Check on each cylinder with the piston at the top dead center
of its compression stroke.
• Oil can spurt out when the air pressure is applied. Adjust the
air pressure with the regulator valve (special tool) and
increase the air pressure gradually.

4) Remove the 10 mm sealing bolt from the No.1 camshaft

holder and install the air stopper (special tool).
5) Remove the two mounting bolts of the No.2 and No.3
camshaft holders (intake side), and install the special tool
as shown.

TOOLS:
Air supply 07LAJ-PR30102
VTEC air adapter 07ZAJ-PNA0101
VTEC air stopper 07ZAJ-PNA0200
Air joint adapter 07ZAJ-PNA0300
[3]
NOTICE 10 mmSEALING
BOLT
Install the VTEC air adapter (special tool) and tighten it by
hand. [5]
VTEC AIR ADAPTR [4]
6) Apply the specified air pressure and check that the valve 07ZAJ-PNA0101 VTEC AIR STOPPER
timing switched to the high lift side.
07ZAJ-PNA0200
Air pressure: 290 kPa (3.0 kgf/cm2, 43 psi)

7) Check that the three intake rocker arms are interconnected

by applying the specified amount of air pressure. Move the [2] MID ROCKER ARM
secondary rocker arm up and down with a finger and check
[1]
that both the mid rocker arm and the primary rocker arm PRIMARY
move up and down, too. ROCKER
8) If there is abnormality in the rocker arm movement, replace ARM
the intake rocker arm as an assembly.
9) Remove the VTEC air adapter (special tool) and tighten the
camshaft holder mounting bolts to the specified torque.

TORQUE: 22 N.m (2.2 kgf.m, 16 lbf.ft)

10) Remove the air stopper (special tool) from the No.1
camshaft holder, and tighten the 10 mm sealing bolt to the
specified torque.
[3]
TORQUE: 20 N.m (2.0 kgf.m, 14 lbf.ft) SECONDARY
ROCKER ARM
11) Install the cylinder head cover (P. 10-40).
12) Check that the MIL does not come ON.

10-17
• VTEC ROCKER ARM/ROCKER ARM INSPECTION BF150A:
1) Disassemble the rocker arm assembly. Check that the [1]
rocker arm pistons move smoothly. ROCKER ARM
PISTONS
NOTICE
• Remove the pistons from the primary rocker arm by
applying low air pressure to the rocker arm. Take care not
to apply excessive air pressure as the pistons can jump
out of the rocker arm.
• After removing the rocker arm assembly, tie the assembly
with a rubber band or equivalent to prevent each
component of the assembly from missing. Note to
remove the rubber band after installation.

2) If the pistons do not move smoothly, replace the rocker arm

as an assembly. BF135A:
[1]
3) Apply the engine oil to the rocker arm pistons on assembly. ROCKER ARM
PISTONS

10-18
5. CYLINDER HEAD ASSEMBLY
REMOVAL
NOTICE ② ①
• Removal of the cylinder head assembly must be made when
the engine is cold (38˚C or below).
• Take care not to damage (scores or scratches) the gasket
mating surfaces with the cylinder head and the cylinder
block. ⑥ ⑤
• Do not bend the cylinder head gaskets as they are the metal
gaskets.
• Keep the cam chain away from the magnetic parts.

Remove the following pars. ⑩ ⑨

– Engine cover (P. 4-2)
– L./R. engine under covers (P. 4-9)
– Ignition coil/spark plug (P. 3-6)
– L./R. side cover brackets (P. 4-24)
– Cylinder head cover (P. 10-2) ⑦ ⑧
1) Move the remote control lever to the “N” (Neutral)
position.
2) Turn the crankshaft pulley clockwise until it puts the No.1
piston at the top dead center of its compression stroke (P.
3-12). ③ ④
Remove the following pars.
– Crankshaft pulley/cam chain (P. 9-2)
– Camshaft/rocker arm (P. 10-5)
– Throttle body/intake manifold (P. 5-129)
– Fuel line assembly (P. 5-136)
– Injector base (P. 5-139)
– Exhaust manifold (P. 5-152) [1]
3) Loosen the 11 x 155 mm bolt washers in the numbered CYLINDER HEAD
sequence shown in two or three steps. GASKET
4) Remove the ten 11 x 155 mm bolt washers from the
cylinder head assembly.

5) Remove the cylinder head assembly. Remove the cylinder

head gasket and the two dowel pins.
Replace the cylinder head gasket with a new one on
assembly.

[2]
14 x 20 mm
DOWEL PIN (2)
[3]
CYLINDER HEAD
ASSEMBLY

10-19
6. CYLINDER HEAD ASSEMBLY [1] PLASTIC HAMMER

DISASSEMBLY [2]
SOCKET
NOTICE
Mark each removed parts and store them securely classifying
them into the groups of the intake side and the exhaust side of
each cylinder. Install each part in the original position on
assembly.

1) Use the socket that matches the diameter of the valve

spring retainer. Attach the socket to the retainer and lightly
tap on the socket to separate the valve keepers from the
retainer.

NOTICE
• Tap at right angles with each valve stem head. Take care
not to bend the valves. [1] [2]
VALVE SPRING VALVE SPRING
• Support the cylinder head with a suitable material to
COMPRESSOR COMPRESSOR
prevent damage to the valve. ATTACHMENT 07757-0010000
07757-PJ10100
2) Change the attachment of the special tool as shown.

TOOLS:
Valve spring compressor 07757-0010000
Valve spring compressor attachment 07757-PJ10100
[3]
ADAPTER

3) Compress the valve springs using the special tools as

shown.
[1]
TOOLS:
VALVE SPRING
Valve spring compressor 07757-0010000 COMPRESSOR
Valve spring compressor attachment 07757-PJ10100 ATTACHMENT,
07757-PJ10100
NOTICE
• Take care not to let the special tools contact the cylinder
head.
• Do not compress the valve springs more than necessary
as it causes weak valve spring.

[2]
VALVE SPRING
COMPRESSOR
07757-0010000

10-20
4) Remove the valve keeper from the groove in the valve
stem. [1]
5) Remove the remaining valve keepers. VALVE KEEPER (2)

6) Remove the valve spring retainer, valve spring, valve, valve

spring seat and the valve stem seal.
Check the valve for chipping and excessive carbon
deposits. Clean the valve if necessary.
Replace the valve stem seal on assembly. [1]
VALVE SPRING
RETAINER

[2]
VALVE SPRING

[3]
VALVE STEM SEAL

[4]
VALVE SPRING
SEAT

[5]
VALVE

10-21
COMPONENTS DRAWING

[1]
14 x 20 mm
DOWEL PIN (2)
[2]
CYLINDER HEAD
GASKET

[3]
VTC HOLE PLUG

[19] 6 x 20 [4]
VTC FILTER CYLINDER HEAD

[18] [5]
VTC STRAINER EXHAUST VALVE GUIDE (8)
[6]
VALVE STEM SEAL B (8)
[7]
EXHAUST VALVE
6 x 20 (2) SPRING (8)

[17]
INTAKE VALVE (8)

[16]
EXHAUST VALVE (8)

[8]
LOST MOTION (8)
[15] INTAKE VALVE GUIDE (8)

[14] VALVE SPRING SEAT (16)

[13] VALVE STEM SEAL A (8) [9]

11 x 155 mm BOLT-WASHER (10)
[12] INTAKE VALVE Used bolt:
SPRING (8) [10] 39 N.m (4.0 kgf.m, 29 lbf.ft) + 90˚ + 90˚
VALVE New bolt:
[11] VALVE SPRING KEEPER (32) 39 N.m (4.0 kgf.m, 29 lbf.ft) + 90˚ + 90˚ + 98˚
RETAINER (16)

10-22
7. CYLINDER HEAD ASSEMBLY
INSPECTION
• VALVE SPRING FREE LENGTH
Measure the free length of the valve springs.

STANDARD SERVICE LIMIT

49.64 mm
IN/EX
(1.954 in)

• VALVE FACE/VALVE STEM O.D.

<Valve face>
Inspect each valve face for pitting or wear irregularities. Inspect
each valve face for even seat. Replace the valve if necessary.
<Valve stem>
1) Check each valve for bend, seizure or damage.
2) Insert each valve into the corresponding valve guide to
check the operation.
3) Measure the valve stem O.D. at the sliding surface of the
valve guide.

STANDARD SERVICE LIMIT [1]

5.475 – 5.485 mm 5.445 mm VALVE FACE
IN
(0.2156 – 0.2159 in) (0.2144 in)
5.450 – 5.460 mm 5.420 mm
EX
(0.2146 – 0.2150 in) (0.2134 in)

• VALVE LENGTH/VALVE O.D.

[1]
OVERALL LENGTH
STANDARD SERVICE LIMIT
108.7 – 109.5 mm
IN
OVERALL (4.28 – 4.31 in) [2]
LENGTH 108.3 – 109.1 mm VALVE
EX O.D.
(4.26 – 4.30 in)
34.85 – 35.15 mm
IN
VALVE (1.372 – 1.384 in)
O.D. 29.85 – 30.15 mm
EX
(1.175 – 1.187 in)

• VALVE GUIDE I.D.

Using the valve guide reamer, 5.525 mm (special tool), ream
the valve guides to remove any carbon deposits before [1]
measuring. Measure and record each valve guide I.D. VALVE GUIDE
REAMER, 5.525 mm
NOTICE 07HAH-PJ70100
Turn the valve guide reamer, 5.525 mm (special tool) clockwise
and never turn it counterclockwise. Continue to turn the
reamer as you lift it from the valve guide.

STANDARD SERVICE LIMIT

5.51 – 5.53 mm 5.55 mm
IN/EX
(0.217 – 0.218 in) (0.219 in)

10-23
• VALVE STEM-TO-VALVE GUIDE CLEARANCE

STANDARD SERVICE LIMIT

0.030 – 0.055 mm 0.08 mm
IN
(0.0012 – 0.0022 in) (0.003 in)
0.055 – 0.080 mm 0.11 mm
EX
(0.0022 – 0.0031 in) (0.004 in)

If the stem-to-guide clearance exceeds the service limit,

replace the valve and the valve guide as a set (P. 10-26).

NOTICE
Recondition the valve seat whenever replacing the valve guide
(P. 10-28).

• VALVE SEAT WIDTH

STANDARD SERVICE LIMIT

1.25 – 1.55 mm 2.0 mm
IN/EX
(0.049 – 0.061 in) (0.08 in)

If the valve seat width is under the standard, or over the service
limit, or if the valve seat is too high/low, recondition the valve [1] VALVE SEAT
seat (P. 10-28). TOO LOW

[2]
SEAT
[3] VALVE SEAT WIDTH
TOO HIGH

• VALVE INTALLATION HEIGHT

[1]
STANDARD SERVICE LIMIT INTALLATION HEIGHT
44.0 – 44.6 mm
IN/EX
(1.73 – 1.76 in)

10-24
• CYLINDER HEAD WARPAGE [1]
1) Remove the carbon deposits from the combustion MEASUREMENT POINT
chamber. Clean off any gasket material from the cylinder
head surface.

2) Check the spark plug holes and valve areas for cracks.

3) Check the cylinder head for warpage using a straight edge

and a feeler gauge.

SERVICE LIMIT 0.05 mm (0.002 in) Min.

NOTICE [2]
Take care not to damage (scores, scratches, etc.) the STRAIGHT EDGE
cylinder head at the mating surface with the gasket.

4) If the measurement exceeds the service limit, recondition.

NOTICE
Reconditioning must be made within the standard value of
the cylinder head height.

[3]
FEELER GAUGE

• CYLINDER HEAD HEIGHT

STANDARD SERVICE LIMIT

103.95 – 104.05 mm
(4.093 – 4.096 in)
[1]
Cylinder head reconditioning procedure: CYLINDER
Apply Prussian Blue compound to the level block to identify the HEAD HEIGHT
warpage, and using a fine oil stone, grind the cylinder head in
the figure of “8” with the warped part being the center of the
ground part. Or use the lapping machine to recondition the
cylinder head.

• 11 x 155 mm BOLT-WASHER (CYLINDER HEAD

BOLT) O.D.
1) Measure the bolt O.D. at two points as shown. 50 mm (2.0 in)

SERVICE LIMIT 10.6 mm (0.42 in)

45 mm
2) If the measurement is below the service limit, replace the
(1.8 in)
bolt.

10-25
8. VALVE GUIDE REPLACEMENT
1) Chill the replacement valve guides in the freezer section of [1]
a refrigerator for about an hour. VALVE GUIDE
DRIVER, 5.5 mm
2) Drive the valve guide out of the combustion chamber side 07742-0010100
using a special tools.

TOOL:
Valve guide driver, 5.5 mm 07742-0010100

CAUTION
When driving the valve guides out, be careful not to
damage head.

3) Remove the new valve guides from the refrigerator one at

a time as needed. [1]
VALVE GUIDE
4) Install the new valve guides from the valve spring side of
the cylinder head. Drive each valve guide as shown.
[2] PROJECTION
15.2 – 16.2 mm HEIGHT
IN
Valve guide (0.60 – 0.64 in)
projection height 15.5 – 16.5 mm
EX
(0.61 – 0.65 in)

5) After installation, inspect the valve guide for damage.

Replace any damaged valve guide.

• VALVE GUIDE REAMING

For best results, be sure the cylinder head is at room
temperature before reaming valve guides. [1]
VALVE GUIDE
1) Coat the reamer and valve guide with cutting oil. REAMER, 5.525 mm
07HAH-PJ70100
2) Rotate the reamer clockwise through the valve guide for
the full length of the reamer.

3) Continue to rotate the reamer clockwise while removing it

from the valve guide.

TOOL:
Valve guide reamer, 5.525 mm 07HAH-PJ70100

10-26
4) Thoroughly clean the cylinder head to remove any cutting
residue.

5) Check the valve guide bore; it should be straight, round and

centered in the valve guide, insert the valve and check
operation. If the valve does not operate smoothly, the guide
may have been bent during installation. Replace the valve
guide if it is bent or damaged.

6) Check the Valve Stem-to-Valve Guide Clearance (P. 10-24).

10-27
9. VALVE SEAT RECONDITIONING
1) Thoroughly clean the combustion chambers and valve
seats to remove carbon deposits. Apply a light coat of
Prussian Blue compound or erasable felt-tipped marker ink
to the valve faces.

2) Insert the valves, and then lift them and snap them closed
[1]
against their seats several times. Be sure the valve does not VALVE FACE
rotate on the seat. The transfered marking compound will
show any area of the seat that is not concentric.

3) Using a 45˚ cutter, remove enough material to produce a

smooth and concentric seat. Follow the Valve Seat Cutter
Manufacturer's Instructions. [1] VALVE SEAT CUTER

Turn the cutter clockwise, never counterclockwise. 45˚

Continue to turn the cutter as you lift it from the valve seat. [2]
IN, 35 mm: 07780-0010400
TOOLS: EX, 33 mm: 07780-0010800 60˚
Cutter holder, 5.5 mm 07781-0010101 [3]
Valve seat cutter, 45˚ 35 mm 07780-0010400 IN, 37.5 mm: 07780-0014100
Valve seat cutter, 45˚ 33 mm 07780-0010800 EX, 30 mm: 07780-0014000
Valve seat cutter, 32˚ 38.5 mm 07780-0012400
Valve seat cutter, 32˚ 33 mm 07780-0012900 32˚
[4]
Valve seat cutter, 60˚ 30 mm 07780-0014000 IN, 38.5 mm: 07780-0012400
Valve seat cutter, 60˚ 37.5 mm 07780-0014100 EX, 33 mm: 07780-0012900

[5]
CUTTER HOLDER,
5.5 mm
07781-0010101

4) Use the 30˚ – 32˚ and 60˚ cutters to narrow and adjust the
[2] OLD SEAT
valve seat so that it contacts the middle of the valve face. WIDTH
The 30˚ – 32˚ cutter removes material from the top edge. [1]
The 60˚ cutter removes material from the bottom edge. Be CONTACT
sure that the width of the finished valve seat is within TOO HIGH
specification. 30˚ – 32˚

[2] OLD SEAT

WIDTH
[3]
CONTACT
TOO LOW
60˚

10-28
• VALVE SEAT WIDTH

STANDARD SERVICE LIMIT

1.25 – 1.55 mm 2.0 mm
IN/EX
(0.049 – 0.061 in) (0.08 in)

5) Make a light pass with the 45˚ cutter to remove any possible
burrs at the edges of the seat. 1.25 – 1.55 mm
(0.049 – 0.061 in)
6) After resurfacing the seats, inspect for even valve seating.
Apply Prussian Blue compound or erasable felt-tipped
marker ink to the valve faces. Insert the valves, and then lift
them and snap them closed against their seats several
times. Be sure the valve does not rotate on teh seat. The
seating surface, as shown by the transferred marking
compound, should have good contact all the way around.

7) Lap the valves into their seats, using a hand valve lapper
and lapping compound (commercially available). [1]
VALVE LAPPER
NOTICE (Commercially
available)
To avoid severe engine damage, be sure to remove all
lapping compound from the cylinder head before
assembly.

8) Check valve clearance after assembly.

10-29
10. CYLINDER HEAD ASSEMBLY
ASSEMBLY [1]
VALVE SPRING
1) Apply molybdenum disulfide oil to the valve stem sliding SEAT
surface and insert the valve into the valve guide.
Check that the valve moves up and down smoothly.
[2]
NOTICE MOLYBDENUM
Do not confuse the intake valve and the exhaust valve on DISULFIDE OIL
assembly.

2) Install the valve spring seat.

[3]
VALVE

3) Apply engine oil to the inner wall of a new valve stem seal.
Set the valve stem seal in the special tool, and push it [1] SPRING (WHITE) [2] SPRING (BLACK)
straight into the valve guide by hand.

TOOL:
Stem seal driver 07PAD-0010000

NOTICE
Note that the valve stem seal A (intake side) has the white [4] VALVE STEM [3] VALVE STEM
spring and the valve stem seal B (exhaust side) has the SEAL A SEAL B
black spring. Do not confuse them on assembly. (INTAKE SIDE) (EXHAUST SIDE)
[5]
VALVE STEM
SEAL

[6]
STEM SEAL
DRIVER
07PAD-0010000

10-30
4) Install the valve spring and the valve spring retainer.
[1]
NOTICE VALVE SPRING
Do not confuse the intake valve spring and the exhaust
valve spring.
<Identification> [2]
The intake side can be identified with the pink paint on the VALVE SPRING
spring. The exhaust side can be identified with the gray RETAINER
paint.
<Installation direction>
Install the intake and the exhaust valve springs with the
paint mark side toward the valve spring retainer.

[1] LOCATION OF VALVE [2]

SPRING PAINT: PAINT

[1]
VALVE SPRING COMPRESSOR
ATTACHMENT
07757-PJ10100

5) Using the same special tool as that used during

disassembly, compress the valve springs and set the valve
keepers in the groove in the respective valve stems
securely.

TOOLS: [3]
Valve spring compressor 07757-0010000 VALVE
Valve spring compressor attachment 07757-PJ10100 KEEPER (2)
[2]
NOTICE VALVE SPRING
• Take care not to let the special tools contact the cylinder COMPRESSOR
head. 07757-0010000
• Do not compress the valve springs more than necessary
as it causes weak valve spring.
• The valve keepers can be installed in the groove in the
valve stem by applying a small mount of grease to the
valve keepers and adhering them to the groove in the
valve stem.

6) Tap on the valve stem head lightly with a plastic hammer [1]
two or three times and set the valve stem and keepers in PLASTIC
the proper position securely. HAMMER

NOTICE
• Tap at right angles with each valve stem head. Take care
not to bend the valve.
• Support the cylinder head with a suitable material to
prevent damage to the valve.

10-31
11. CYLINDER HEAD ASSEMBLY [1]
PROJECTION [2]
INSTALLATION CYLINDER
HEAD
NOTICE GASKET
• Do not let any foreign material enter the gap between the
gasket, cylinder head and the cylinder block.
• Take care not to damage (scores, scratches, etc.) the cylinder
head and the cylinder block at the mating surface with the
gasket.
• Do not bend the cylinder head gaskets as they are the metal
gaskets.
• Keep the cam chain away from the magnetic parts.

1) Clean the cylinder head and cylinder block mounting

surfaces.
2) Install the two dowel pins on the cylinder block. [3] 14 x 20 mm
Install a new cylinder head gasket on the cylinder block by DOWEL PIN (2)
setting the projection of the cylinder head gasket in the
position shown.

3) Align the “ ” mark on the crankshaft sprocket with the [1] CRANKSHAFT
“ ” mark on the cylinder block. SPROCKET

[2] “ ” MARKS

4) Align the dowel pins on the cylinder block with the dowel
[1]
pin installation positions of the cylinder head assembly as CYLINDER HEAD
shown, and install the cylinder head assembly on the ASSEMBLY
cylinder block.

10-32
5) Apply engine oil to the threads and the washer seat of the
ten 11 x 155 mm bolt-washers, and loosely tighten them on
the cylinder head assembly.
[1]
11 x 155 mm
BOLT-WASHER (10)

6) Tighten the 11 x 155 mm bolt-washers to the specified

torque in the numbered sequence in two or three steps.
After tightening to the specified torque, tighten each bolt in
the numbered sequence twice in increments of 90˚.
When a bolt is replaced with a new one, tighten ⑨ ⑩
additionally to 98˚.

TORQUE:
Used bolt: 39 N.m (4.0 kgf.m, 29 lbf.ft) + 90˚ + 90˚
New bolt: 39 N.m (4.0 kgf.m, 29 lbf.ft) + 90˚ + 90˚ + 98˚ ⑤ ⑥

7) Install the following parts.

– Exhaust manifold (P. 5-155)
– Injector base (P. 5-139)
– Fuel line assembly (P. 5-140) ① ②
– Throttle body/intake manifold (P. 5-132)
– Camshaft/rocker arm (P. 10-34)
– Crankshaft pulley/cam chain (P. 9-11)
– Cylinder head cover (P. 10-40)
– L./R. side cover brackets (P. 4-30)
④ ③
– Ignition coil/spark plug (P. 3-8)
– L./R. engine under covers (P. 4-14)
– Engine cover (P. 4-2)

⑧ ⑦

10-33
12. CAMSHAFT/ROCKER ARM [1]
Apply a bead
ASSEMBLY of the liquid
gasket.
1) Degrease the cylinder head mating surface of the No.5
rocker shaft holder with the degreasing cleaning agent.
2) Apply a bead [ø2.0 – 3.0 mm (ø0.08 – 0.12 in)] of the liquid
gasket (ThreeBond® #1280B or equivalent) to the indicated
area of the No.5 rocker shaft holder.

NOTICE
• Assemble the No.5 rocker shaft holder within 5 minutes
after application of the liquid gasket. If it has been left for
5 minutes or longer, remove the old liquid gasket and
apply the liquid gasket again.
• Do not pour the engine oil in the oil tank at least 30
minutes after assembly. [1]
ROCKER ARM
ASSEMBLY
3) Set the ten dowel pins on the cylinder head assembly.

4) Insert the bolts into each of the rocker shaft holders and
install the rocker arm assembly on the cylinder head
assembly.

[3]
10 x 16 mm
DOWEL PIN (10) [2]
BOLT (4)

5) Apply engine oil to the threads and seat of the 14 mm [2] EXHAUST
sealing bolts. CAMSHAFT
Install the camshaft collar on the intake camshaft and the [1]
CMP pulse plate on the exhaust camshaft, then tighten the CAMSHAFT [3]
COLLAR CMP PULSE
14 mm sealing bolts to the specified torque.
PLATE
TORQUE: 39 N.m (4.0 kgf.m, 29 lbf.ft)

NOTICE
• Tighten the bolt while holding the hex. part of the
camshaft with a wrench or equivalent tool.
[5] [4]
• Do not damage (scores, scratches, etc.) the cams and INTAKE 14 mm SEALING
journals of the camshaft journal. CAMSHAFT BOLT (2)

10-34
6) Apply molybdenum disulfide oil to the journals and cam surfaces of the camshafts.

7) Install the intake/exhaust camshafts, ten dowel pins, camshaft holders and the cam chain guide B.

NOTICE
Install the camshafts with the No.1 piston at the top dead
center of the compression stroke (i.e. dowel pin at your
side).
8) Apply engine oil to the threads and seat of each bolt and loosely tighten to the designated position respectively.

[1]
INTAKE CAMSHAFT
[2]
EXHAUST CAMSHAFT [3]
CAM CHAIN GUIDE B

8 x 110 (2)

[4]
HEAD COVER
BOLT (6)

8 x 90 (12)

6 x 20 (2)

[6]
10 x 16 mm 6 x 32
[7] DOWEL PIN (10) [5]
MOLYBDENUM CAMSHAFT
DISULFIDE OIL HOLDER

9) Tighten each bolt to the specified torque in the numbered

sequence in two or three steps.
o u i p
TORQUE:
Head cover bolt,
8 x 90 mm flange bolt,
8 x 110 mm flange bolt: 22 N.m (2.2 kgf.m, 16 lbf.ft) q 9 0 w
6 x 20 mm flange bolt, a
6 x 32 mm flange bolt: 12 N.m (1.2 kgf.m, 9 lbf.ft)
3 1 2 4

7 5 6 8

t e r y
d s

10-35
10) Secure the hex. part of the exhaust camshaft with a wrench
[1]
or equivalent tool.
EXHAUST CAMSHAFT

11) Install the exhaust camshaft sprocket on the exhaust [1]

camshaft by aligning the concave in the exhaust camshaft EXHAUST CAMSHAFT [2]
sprocket with the dowel pin on the exhaust camshaft. SPROCKET CONCAVE
Tighten the 10 x 32 mm flange bolt on the exhaust camshaft
to the specified torque. [3]
EXHAUST
CAMSHAFT
TORQUE: 72 N.m (7.3 kgf.m, 53 lbf.ft)

[4]
DOWEL PIN

12) Secure the hex. part of the intake camshaft with a wrench
[1]
or equivalent tool.
INTAKE CAMSHAFT

10-36
13) Install the intake camshaft sprocket on the intake camshaft [1]
by aligning the concave in the intake camshaft sprocket [2]
INTAKE CAMSHAFT
with the dowel pin on the intake camshaft. CONCAVE [3]
SPROCKET INTAKE
Tighten the VTEC flange bolt on the intake camshaft to the CAMSHAFT
specified torque.

TORQUE: 113 N.m (11.5 kgf.m, 83 lbf.ft)

[4] DOWEL PIN

14) Apply engine oil to the outer surface of the new 15.2 x 1.9
mm O-rings, and install the O-rings on the CMP sensor and
CMP hole plug.

15) Install the CMP sensor (exhaust side) and the CMP hole
plug (intake side) in the CMP sensor holes in the No.5
rocker shaft holder. Tighten the CMP sensor and CMP hole
plug with the 6 x 16 mm flange bolts respectively.

[1]
CMP HOLE PLUG [2]
6 x 16 (2) CMP SENSOR

16) Connect the CMP sensor 3P connector and set the harness
band clip on the clip bracket F.

17) Install the crankshaft pulley/cam chain (P. 9-11) and adjust
the valve clearance (P. 3-9).

18) Install the following parts.

– Cylinder head cover (P. 10-40)
– Ignition coil/spark plug (P. 3-8)
– L./R. engine under covers (P. 4-14)
– Engine cover (P. 4-2)

[1]
CLIP
BRACKET F
[2] [3]
HARNESS BAND CMP SENSOR 3P
CLIP CONNECTOR

10-37
13. CYLINDER HEAD COVER [1] <Spark plug tube seal
installation direction>
ASSEMBLY
1) Install the spark plug tube seals on the cylinder head cover
noting the installation direction of the seal.

[2]
SPARK PLUG TUBE
SEAL (4) [3]
CYLINDER HEAD
COVER

2) Clean the groove of the cylinder head cover and clean the
head cover gasket. [1]
HEAD COVER
3) Install the head cover gasket on the cylinder head cover. GASKET

[2]
CYLINDER HEAD
COVER

10-38
4) Connect the oil tube to the cylinder head cover by aligning
the projection on the oil tube with the projection on the
cylinder head cover.
Check that the oil tube is inserted in the cylinder head cover [1]
CYLINDER HEAD
securely.
COVER
5) Set the tube clip D32.5 with the lugs in the position shown.

[2]
PROJECTIONS

[3]
TUBE CLIP
D32.5

[4]
[5] OIL TUBE
LUGS

10-39
14. CYLINDER HEAD COVER
INSTALLATION
1) Thoroughly clean the cylinder head/cylinder head cover
mating surfaces using a degreasing cleaning agent.
2) Apply a bead [ø2.0 – 3.0 mm (ø0.08 – 0.12 in)] of the liquid [1]
gasket (ThreeBond® #1280B or equivalent) to the cylinder Apply a bead
head/chain case mating surfaces and to the No.5 rocker of liquid
shaft holder as shown. gasket.

NOTICE
• Assemble the cylinder head cover within 5 minutes after
application of the liquid gasket. If it has been left for 5
minutes or longer, remove the old liquid gasket and apply
the liquid gasket again.
• Do not pour the engine oil in the oil tank at least 30
minutes after assembly.

3) Apply soapy water to the spark plug tube seal lip of the
[1]
cylinder head cover. Apply soapy water
to the lip.
4) Install the cylinder head cover on the cylinder head by
aligning the spark plug tube with the spark plug tube seal.
[2]
NOTICE SPARK PLUG
• Check the spark plug tube seals for breakage and fatigue TUBE SEAL (4)
when installing the cylinder head cover.
• After installation, check that the spark plug tube seals are
not turned up but they are set properly.
• Wipe up the oozing soapy water.

5) After installation, swing the cylinder head cover lightly to

make the head cover gasket fit on the cylinder head cover.

6) Install the six head cover washers and loosely tighten the
six 6 mm hex. cap nuts.

[3]
SPARK PLUG
TUBE (4)
[4]
CYLINDER HEAD COVER
[5]
HEAD COVER WASHER (6)
[6]
6 mm HEX. CAP
NUT (6)

10-40
7) Tighten the 6 mm hex. cap nuts to the specified torque in
the numbered sequence in two or three steps.

TORQUE: 12 N.m (1.2 kgf.m, 9 lbf.ft)

③ ④

① ②

⑤ ⑥

8) Move the water relief tube A from the other side of the [1]
projection on the cylinder head cover to your side. WATER RELIEF
TUBE A
[2]
PROJECTION

[3]
CYLINDER HEAD COVER

9) Connect the fuel tube B and D to the fuel pump (low [1] TUBE CLIPS [2]
pressure side). (Commercially FUEL
available) TUBE B

[3]
FUEL PUMP
[4] (Low pressure
FUEL TUBE D side)

10-41
10) Connect the oil tube to the mounting case.
After connection, check that the oil tube is inserted in the [1]
mounting case securely. OIL TUBE

[2]
MOUNTING CASE

11) Install the R. side cover bracket assembly on the engine [1]
assembly and tighten the two 6 x 22 mm flange bolts. R. SIDE COVER
BRACKET ASSEMBLY

6 x 22 (2)

12) Connect the breather tube and the main wire harness to the
cylinder head cover. [1]
PROJECTION
NOTICE
Route the main wire harness so it sets on the projections on
the cylinder head cover securely.

13) Install the following parts.

– Ignition coil/spark plug (P. 3-8)
– L./R. engine under covers (P. 4-14) [2]
– Engine cover (P. 4-2) MAIN WIRE
HARNESS

[3] [2]
BREATHER MAIN WIRE
TUBE HARNESS

10-42
11. OIL PUMP/FLYWHEEL
1. EOP SWITCH/OIL FILTER 2. OIL PUMP
FLANGE 3. FLYWHEEL

12 N.m (1.2 kgf.m, 9 lbf.ft)

8 N.m (0.8 kgf.m, 5.8 lbf.ft)

12 N.m (1.2 kgf.m, 9 lbf.ft)

22 N.m (2.2 kgf.m, 16 lbf.ft)

118 N.m (12.0 kgf.m, 87 lbf.ft)

39 N.m (4.0 kgf.m,

29 lbf.ft)

32 N.m (3.3 kgf.m, 24 lbf.ft)

11-1
1. EOP SWITCH/OIL FILTER FLANGE
a. DISASSEMBLY
Remove the following parts.
– Engine cover (P. 4-2)
– L./R. engine under covers (P. 4-9)
1) Drain the engine oil (P. 3-2) and remove the oil filter using
the special tool as shown.

TOOL:
Oil filter wrench 07HAA-PJ70101

2) Remove the EOP switch (low pressure side).

3) Disconnect the water tube E and 7 x 160 mm tube from the
oil filter flange. [1]
OIL FILTER
4) Remove the oil filter flange.
WRENCH
5) Disconnect the ECT sensor 2P connector and the EOP 07HAA-PJ70101
switch (high pressure side) 2P connector.
Remove the ECT sensor and the EOP switch (high pressure
side).

[3]
ECT SENSOR
[2] [4]
9.5 x 1.9 mm O-RING 12 N.m (1.2 kgf.m, 9 lbf.ft) TUBE CLAMP D10.5 (2)
[1]
13 x 1.5 mm O-RING Do not reuse.
[5]
Do not reuse. EOP SWITCH
(LOW PRESSURE SIDE)
8 N.m (0.8 kgf.m, 5.8 lbf.ft)

6 x 25 (4)

[6]
OIL FILTER
12 N.m (1.2 kgf.m,
9 lbf.ft)

[7]
OIL FILTER FLANGE
[11]
EOP SWITCH
(HIGH PRESSURE SIDE)
6 x 20
22 N.m (2.2 kgf.m, [10]
16 lbf.ft) WATER TUBE E [8]
INSPECTION: [9] 7 x 160 mm TUBE
Check the tube for 22.5 x 24 mm INSPECTION:
deterioration. Replace O-RING (2) Check the tube for deterioration.
the tube if necessary.
Do not reuse. Replace the tube if necessary.

11-2
b. INSPECTION
Check for continuity between the terminal and body.
If there is no continuity, replace the EOP switch

c. ASSEMBLY
1) Apply engine oil to a new 13 x 1.5 mm O-ring and install it
on the ECT sensor.

2) Tighten the ECT sensor to the specified torque and connect

the ECT sensor 2P connector.
[1] [2]
9.5 x 1.9 mm O-RING ECT SENSOR
TORQUE: 12 N.m (1.2 kgf.m, 9 lbf.ft)

3) Apply engine oil to the 9.5 x 1.9 mm O-ring and install it on

the EOP switch (high pressure side).

4) Tighten the EOP switch (high pressure side) to the specified

torque and connect the EOP switch (high pressure side) 2P
connector.

TORQUE: 22 N.m (2.2 kgf.m, 16 lbf.ft)

[4] [3]
13 x 1.5 mm O-RING EOP SWITCH
(High pressure side)

11-3
5) Apply engine oil to a new 22.5 x 24 mm O-ring and install it on the oil filter flange.

6) Install the oil filter flange and tighten the 6 x 20 mm flange bolt and the four 6 x 25 mm flange bolts securely.

7) Connect the water tube E and the 7 x 160 mm tube to the oil filter flange, and clamp the tube with the tube clamp
D10.5 securely.

[1]
WATER TUBE E
[2]
TUBE CLAMP D10.5 (2)

6 x 25 (4)

[3]
OIL FILTER FLANGE

6 x 20

[5] [4]
22.5 x 24 mm O-RING (2) 7 x 160 mm TUBE

8) Apply engine oil to the O-ring that is set in the new oil filter.

[1]
O-RING

9) Clean the oil filter mounting part of the engine side oil filter
flange and apply engine oil to the stud.
Tighten the oil filter by hand.

[1]
OIL FILTER

11-4
10) Then, tighten it to the specified torque using the same
special tool as that used during disassembly.

TOOL:
Oil filter wrench 07HAA-PJ70101

TORQUE: 12 N.m (1.2 kgf.m, 9 lbf.ft)

[1]
OIL FILTER
WRENCH
07HAA-PJ70101

11) Before installing the EOP switch (low pressure side), clean
the switch and apply the liquid gasket (ThreeBond® #1215
or equivalent) to the area shown.

NOTICE
Take care not to put the liquid gasket on the switch end and
the oil passage.
[1]
APPLICATION
AREA

12) Tighten the EOP switch (low pressure side) to the specified
torque using the torque wrench.
[1]
TORQUE: 8 N.m (0.8 kgf.m, 5.8 lbf.ft) EOP SWITCH
TERMINAL
NOTICE
Use the torque wrench to tighten the EOP switch (low
pressure side). Do not overtighten the EOP switch as it can
damage the oil filter flange.

13) Connect the EOP switch terminal to the EOP switch (low
pressure side).

14) Add the specified amount of the engine oil (P. 3-2).
After adding the oil, check each joint for oil leakage.

15) Install the following parts.

– L./R. engine under covers (P. 4-14)
– Engine cover (P. 4-2)

[2]
EOP SWITCH
(LOW PRESSURE SIDE)

11-5
2. OIL PUMP
a. REMOVAL
1) Remove the engine from the outboard motor (P. 7-2).

2) Remove the five 8 x 32 mm flange bolts. Remove the oil pump body assembly, oil pump body gasket, 14 x 20 mm
dowel pin and the 10 x 16 mm dowel pin.
Replace the oil pump body gasket with a new one on assembly.

[2]
14 x 20 mm
DOWEL PIN
[1]
OIL PUMP BODY
ASSEMBLY

[3]
10 x 16 mm
DOWEL PIN

[4]
OIL PUMP BODY
GASKET

8 x 32 (5)

11-6
b. DISASSEMBLY
[2]
6 x 16 mm FLAT
[1] SCREW (9)
31 x 46 x 7 mm OIL SEAL
INSPECTION:
• Check the oil seal lip for
breakage or other damage.
Replace if necessary.
• Do not reuse. Replace on
assembly.

[3]
OIL PUMP COVER

[11]
INNER ROTOR
[4]
5 x 8 mm DOWEL PIN (2)

[10]
OUTER ROTOR

[5]
OIL PUMP BODY

[6]
RELIEF VALVE

[7]
18 mm SEALING BOLT
39 N.m (4.0 kgf.m, 29 lbf.ft)

[9]
46 x 60 x 9 mm OIL SEAL
INSPECTION: [8]
• Check the oil seal lip for RELIEF VALVE
breakage or other damage. SPRING
Replace if necessary.
• Do not reuse. Replace on
assembly.

11-7
c. INSPECTION
• OIL PUMP BODY I.D.

STANDARD SERVICE LIMIT

84.000 – 84.030 mm
(3.3071 – 3.3083 in)

• OIL PUMP BODY DEPTH

STANDARD SERVICE LIMIT

9.520 – 9.550 mm
(0.3748 – 0.3760 in)

• OUTER ROTOR HEIGHT

STANDARD SERVICE LIMIT

9.480 – 9.500 mm
(0.3732 – 0.3740 in)

11-8
• INNER ROTOR-TO-OUTER ROTOR CLEARANCE

STANDARD SERVICE LIMIT

0.04 – 0.16 mm 0.20 mm
(0.002 – 0.006 in) (0.008 in)

• OUTER ROTOR-TO-PUMP BODY CLEARANCE

STANDARD SERVICE LIMIT

0.02 – 0.07 mm 0.12 mm
(0.001 – 0.003 in) (0.005 in)

• OUTER ROTOR-TO-OIL PUMP BODY SIDE

CLEARANCE

STANDARD SERVICE LIMIT

0.14 – 0.19 mm 0.20 mm
(0.006 – 0.007 in) (0.008 in)

11-9
d. ASSEMBLY [1]
1) Apply thread locking agent to the threads of the 18 mm OIL PUMP BODY
sealing bolt.

2) Check the relief valve surface for scores, scratches and

other damage. Apply engine oil to the relief valve and the
relief valve spring.

3) Install the relief valve and the relief valve spring in the oil
pump body, and tighten the 18 mm sealing bolt to the
specified torque.

TORQUE: 39 N.m (4.0 kgf.m, 29 lbf.ft)

[4] [3]
RELIEF RELIEF VALVE
VALVE [2]
SPRING 18 mm SEALING
BOLT

4) Clean the inner rotor and the outer rotor thoroughly. Apply
engine oil to the inner and outer rotors and install them on [2]
the oil pump body. INNER ROTOR
Note to install the rotors in the same direction as the
direction of the rotors noted on disassembly.
[3]
[1] OUTER ROTOR
OIL PUMP
BODY

5) Install the two dowel pins and the oil pump cover on the oil
pump body and tighten the nine 6 x 16 mm flat screws. [2] 6 x 16 mm FLAT
[1] SCREW (9)
Check that the rotors move smoothly. OIL PUMP
COVER

[4] [3]
5 x 8 mm OIL PUMP
DOWEL PIN (2) BODY

11-10
6) Apply soapy water to the outer surface of each new oil seal.
7) Using the special tools, drive the 46 x 60 x 9 mm oil seal into the oil pump body and the 31 x 46 x 7 mm oil seal into
the oil pump cover so they set in the respective position of the dimensions shown.
– Install the 46 x 60 x 9 mm oil seal so that the distance from the oil pump body end to the oil seal surface is 27.4 –
28.0 mm (1.08 – 1.10 in) (dimension A).
– Install the 31 x 46 x 7 mm oil seal so that the distance from the oil pump body end to the oil seal surface is 63.9 –
64.5 mm (2.52 – 2.54 in) (dimension B) with the oil pump cover installed with the flat screws.

TOOLS:
Driver 07749-0010000
Oil seal driver attachment, 72 mm 07947-6340201
Oil seal driver 07947-SB00100

8) After installing the oil seals, apply grease to each oil seal lip.

[1] 46 x 60 x 9 mm [2] <Oil seal installation [5] 31 x 46 x 7 mm [2] <Oil seal installation
OIL SEAL direction> OIL SEAL direction>

[3] (Apply grease [3] (Apply grease

to the lip.) to the lip.)

[4] [4]
DRIVER DRIVER
07749-0010000 07749-0010000
[7]
[9]
[8] OIL SEAL DRIVER
OIL SEAL DRIVER [6]
OIL PUMP BODY 07947-SB00100
ATTACHMENT, 72 mm OIL PUMP COVER
07947-6340201
[10] DIMENSION B

[11] DIMENSION A

e. INSTALLATION [1] [2]

1) Install the 14 x 20 mm dowel pin, 10 x 16 mm dowel pin, OIL PUMP 14 x 20 mm
and the new oil pump body gasket on the engine side. BODY DOWEL PIN
Install the oil pump body and tighten the five 8 x 32 mm ASSEMBLY
flange bolts.

2) Install the engine on the outboard motor (P. 7-6).

[3]
10 x 16 mm
DOWEL PIN

[4]
OIL PUMP
8 x 32 (5) BODY GASKET

11-11
3. FLYWHEEL
a. REMOVAL
1) Remove the engine from the outboard motor (P. 7-2).

2) Remove the oil pump body assembly (P. 11-6).

3) Set the special tool on the starter motor mounting part and
temporarily tighten the special tool using the 10 mm bolts,
10 mm washers and the 10 mm nuts.
[1]
10 mm BOLT (2)
NOTICE
• Do not damage the mating surface of the oil pump body
gasket on the cylinder block.
[2]
• Check that the special tool is set on the ring gear securely.
[3] RING GEAR HOLDER
10 mm NUT (2) 070PB-ZY60100
TOOL:
Ring gear holder 070PB-ZY60100

4) Remove the eight 8 mm special bolts and the flywheel

boss.

[1]
FLYWHEEL BOSS

[2]
8 mm SPECIAL
BOLT (8)

5) Remove the eight 12 mm bolts and the flywheel.

6) Remove the special tool.

[1]
12 mm BOLT (8)

[2]
FLYWHEEL

11-12
b. COMPONENTS DRAWING

[4]
14 x 20 mm
DOWEL PIN
[3]
FLYWHEEL

[2]
12 mm BOLT (8)
118 N.m (12.0 kgf.m, 87 lbf.ft)

[1]
FLYWHEEL BOSS

[5]
10 x 16 mm DOWEL PIN

[8]
8 mm SPECIAL BOLT (8)
32 N.m (3.3 kgf.m, 24 lbf.ft)

8 x 32 (5) [6]
OIL PUMP BODY
GASKET

[7]
OIL PUMP BODY ASSEMBLY

11-13
c. INSPECTION [1]
Check the ring gear for wear and damage. If it is worn or FLYWHEEL
damaged, check the starter motor pinion gear.

[2]
RING GEAR

d. INSTALLATION
1) Clean the crankshaft and flywheel mating surfaces
thoroughly with the degreasing cleaning agent.

2) Apply engine oil to the threads and seating surface of the ① ⑦

12 mm bolts.
⑤ ④
3) Install the flywheel on the crankshaft and loosely tighten
the eight 12 mm bolts. Install the special tool, that had been
used for removal, on the starter motor mounting part (P. 11-
12).
⑥
③
4) Tighten the 12 mm bolts to the specified torque in the
numbered sequence in two or three steps.
⑧ ②
TORQUE: 118 N.m (12.0 kgf.m, 87 lbf.ft)

5) Clean the flywheel and flywheel boss mating surfaces

thoroughly with the degreasing cleaning agent.
6) Apply engine oil to the threads and seating surface of the 8 ①
mm special bolts.
7) Install the flywheel boss on the flywheel and loosely ⑤ ⑦
tighten the eight 8 mm special bolts.
8) Tighten the 8 mm special bolts to the specified torque in the
numbered sequence in two to three steps.

TORQUE: 32 N.m (3.3 kgf.m, 24 lbf.ft) ③ ④

NOTICE
Be sure to clean the mating surfaces of the crankshaft,
flywheel and the flywheel boss thoroughly with the
degreasing cleaning agent. ⑧ ⑥

9) Remove the special tool. ②

10) Install the oil pump body assembly (P. 11-11).
11) Install the engine on the outboard motor (P. 7-6).

11-14
12. CRANKCASE/BALANCER
1. CRANKCASE/BALANCER CASE 4. BALANCER CASE ASSEMBLY
ASSEMBLY REMOVAL ASSEMBLY
2. BALANCER CASE ASSEMBLY 5. CRANKCASE/BALANCER CASE
DISASSEMBLY ASSEMBLY INSTALLATION
3. INSPECTION

12 N.m (1.2 kgf.m, 9 lbf.ft)

44 N.m (4.5 kgf.m, 33 lbf.ft)

22 N.m (2.2 kgf.m, 16 lbf.ft)

22 N.m (2.2 kgf.m, 16 lbf.ft)

44 N.m (4.5 kgf.m, 33 lbf.ft)

12 N.m (1.2 kgf.m, 9 lbf.ft)

12-1
1. CRANKCASE/BALANCER CASE 6 x 25 (15)

ASSEMBLY REMOVAL
Remove the following parts.
– Engine cover (P. 4-2)
– L./R. engine under covers (P. 4-9)
– Silencer case (P. 5-128)
– Throttle body/intake manifold (P. 5-129)
– Silencer duct (P. 6-2)
– Electric parts/main harness (P. 18-1, 15, 19 and 27)
1) Move the remote control lever to the “N” (Neutral)
position.
2) Turn the crankshaft pulley clockwise until it sets the No.1
piston at the top dead center of its compression stroke (P.
3-12).
Remove the following parts.
– Crankshaft pulley/cam chain (P. 9-2)
3) Remove the engine from the outboard motor (P. 7-2).
4) Remove the fifteen 6 x 25 mm flange bolts from the
crankcase.

5) Insert the screwdriver into the recesses of the crankcase

and raise the crankcase little by little.

NOTICE
Take care not to damage the crankcase and lower block
mating surfaces.

[1] [1]
RECESS RECESS

6) Remove the crankcase and the two dowel pins from the
[1]
lower block.
CRANKCASE

[2]
13 x 20 mm
DOWEL PIN (2)

12-2
7) Remove the two chain guide bolts and remove the balancer
chain guide.
Remove the three 6 x 14 mm flange bolts and remove the 6 x 14 (3)
balancer chain tensioner.

8) Hold the rear balancer shaft by inserting the special tool [1]
into the maintenance hole in the front balancer. BALANCER CHAIN
Remove the 10 x 30 mm bolt-washer and remove the TENSIONER
crankshaft sprocket, driven sprocket and the balancer
chain. [2]
[3]
CHAIN GUIDE
BALANCER
TOOL: BOLT (2)
CHAIN GUIDE
Pin driver, 6.0 mm 07744-0010500

NOTICE
Check that the special tool is inserted in the balancer case
[1]
assembly securely. DRIVEN SPROCKET

[2]
MAINTENANCE HOLE
[1] [2]
PIN DRIVER, 6.0 mm 10 x 30 mm
07744-0010500 BOLT-WASHER

[3] [3]
REAR BALANCER SHAFT CRANKSHAFT
[4] SPROCKET
BALANCER CHAIN
9) Remove the special tool from the balancer case assenbly.

10) Remove the two 10 x 105 mm flange bolts, 8 x 75 mm

10 x 105 (2)
flange bolt and the 8 x 50 mm flange bolt. Remove the 8 x 50
balancer case assembly and the two dowel pins.

8 x 75

[2]
18 x 13 mm
[1] DOWEL PIN
BALANCER CASE
ASSEMBLY
[3]
12 x 16 mm
DOWEL PIN

12-3
COMPONENTS DRAWING

6 x 25 (15)
12 N.m (1.2 kgf.m, 9 lbf.ft)
6 x 14

[2]
CABLE
[1] BRACKET B
CRANKCASE

[16]
26 x 2.7 mm O-RING
Do not reuse.

[15]
OIL CAP
10 x 105 (2)
44 N.m (4.5 kgf.m,
8 x 20 (2) 33 lbf.ft)

[14] 8 x 50
ENGINE HANGER 22 N.m (2.2 kgf.m,
16 lbf.ft)

8 x 75
22 N.m (2.2 kgf.m, 16 lbf.ft) [3]
BALANCER CASE
[13] ASSEMBLY
BALANCER CHAIN TENSIONER

6 x 14 (3)
[12] [4]
DRIVEN SPROCKET 13 x 20 mm
DOWEL PIN (2)
[11] [10]
BALANCER CHAIN 12 x 16 mm
DOWEL PIN

[5]
18 x 13 mm
DOWEL PIN
[9]
10 x 30 mm BOLT-WASHER
44 N.m (4.5 kgf.m, 33 lbf.ft)

[6]
BALANCER CHAIN GUIDE

[8]
CRANKSHAFT [7]
SPROCKET CHAIN GUIDE BOLT (2)
12 N.m (1.2 kgf.m, 9 lbf.ft)

12-4
2. BALANCER CASE ASSEMBLY DISASSEMBLY
6 x 32 (3) 8 x 55 (3)
12 N.m (1.2 kgf.m, 27 N.m (2.8 kgf.m, 20 lbf.ft)
9 lbf.ft)

6 x 25 (2)
12 N.m (1.2 kgf.m, [1]
9 lbf.ft) REAR BALANCER
HOLDER

[7]
REAR BALANCER
SHAFT
[2]
BALANCER SHAFT
BEARING (4)
INSPECTION:
Check the bearings for damage
and replace if necessary.
After replacing the bearing,
check the oil clearance (P. 12-6).
[6]
8 x 10 mm
DOWEL PIN (2)

[3]
12 x 16 mm
DOWEL PIN (2)
[5]
FRONT BALANCER
SHAFT

[4]
FRONT BALANCER
HOLDER

12-5
3. INSPECTION
• BALANCER SHAFT JOURNAL O.D.
Measure the O.D. of the balancer shaft No.1 journal.

STANDARD SERVICE LIMIT

19.938 – 19.950 mm 19.92 mm
Front
(0.7850 – 0.7854 in) (0.784 in)
23.938 – 23.950 mm 23.92 mm
Rear
(0.9424 – 0.9429 in) (0.942 in)

If the measurement exceeds the service limit, replace the

balancer shaft.

• BALANCER SHAFT AXIAL FREE PLAY

1) Assemble the balancer case assembly (P. 12-7).
2) Measure the balancer shaft axial play with the dial indicator
by moving the balancer shaft back and force.

STANDARD SERVICE LIMIT

0.060 – 0.140 mm 0.15 mm
(0.0024 – 0.0055 in) (0.006 in)

3) If the measurement exceeds the service limit, replace the

balancer case assembly.

• BALANCER SHAFT OIL CLEARANCE

1) Clean the balancer shaft No.2 journal and the balancer
holder bearing. Check the journal and the bearing for
damage and wear. [1]
2) Assemble the balancer case assembly (P. 12-7). PLASTIGAUGE
3) Remove the rear balancer holder. Set a plastigauge on the
balancer shaft No.2 journal as shown.

NOTICE
• Set the plastigauge in the axial direction on the balancer
shaft No.2 journal.
• Do not turn the balancer shaft while checking oil
clearance.

4) Reinstall the rear balancer holder and tighten the bolts to

the specified torque (P. 12-7).

5) Remove the rear balancer holder. Measure the width of the

pressed part of the plastigauge using the scale printed on
[1]
the bag of the plastigauge. PLASTIGAUGE
NOTICE
Measure the widest width on the plastigauge.

STANDARD SERVICE LIMIT

0.060 – 0.120 mm 0.15 mm
(0.0024 – 0.0047 in) (0.006 in)

6) If the measurement exceeds the service limit, replace the

balancer shaft bearing and recheck the oil clearance. [2]
If the measurement still exceeds the service limit, replace SCALE
the balancer shaft.

12-6
4. BALANCER CASE ASSEMBLY [1]
BALANCER SHAFT
[2]
PROJECTION
ASSEMBLY BEARING

1) Install the four balancer shaft bearings on the front/rear

balancer holders by aligning the projection on each
balancer shaft bearing with the concave at the
corresponding bearing installation part of the front/rear [3]
CONCAVE
balancer shaft.

2) Apply molybdenum disulfide oil to each journal of the [2]

balancer shaft. REAR BALANCER
[1] SHAFT
3) Install the front and rear balancer shafts on the front FRONT [3]
balancer holder while aligning the alignment marks on BALANCER MOLYBDENUM
each of the front and rear balancer shaft gears as shown. SHAFT DISULFIDE OIL

[4] ALIGNMENT
MARKS
[5] FRONT BALANCER
HOLDER

4) Apply engine oil to the threads and seat of the 8 x 55 mm [1] 6 x 32 (3) 8 x 55 (3)
flange bolts. REAR
BALANCER
5) Install the four dowel pins and the rear balancer holder on HOLDER
the front balancer holder. Tighten the bolts to the specified
torque. 6 x 25 (2)

TORQUE:
8 x 55 mm flange bolt: 27 N.m (2.8 kgf.m, 20 lbf.ft) [2]
6 x 32 mm flange bolt, [3] 12 x 16 mm
6 x 25 mm flange bolt: 12 N.m (1.2 kgf.m, 9 lbf.ft) 8 x 10 mm DOWEL PIN
DOWEL PIN (2)
(2)

12-7
5. CRANKCASE/BALANCER CASE 10 x 105 (2)
8 x 50
ASSEMBLY INSTALLATION 8 x 75
1) Apply engine oil to the threads and seat of each bolt. [1]
BALANCER CASE
2) Install the balancer case assembly and the two dowel pins ASSEMBLY
on the lower block and tighten the bolts to the specified
torque.

TORQUE:
10 x 105 mm flange bolt: 44 N.m (4.5 kgf.m, 33 lbf.ft)
8 x 75 mm flange bolt,
[2]
8 x 50 mm flange bolt: 22 N.m (2.2 kgf.m, 16 lbf.ft) 18 x 13 mm
DOWEL PIN

[3]
12 x 16 mm
DOWEL PIN

3) Install the crankshaft sprocket on the crankshaft aligning

[1] [2]
the projection on the crankshaft sprocket with the concave
CRANKSHAFT CRANKSHAFT
in the crankshaft.
SPROCKET
After installation, check that the “ ” mark on the
crankshaft sprocket aligns with the “ ” mark on the
cylinder block.

NOTICE
The No.1 piston is at the top dead center of its compression
stroke when the “ ” mark on the crankshaft sprocket
aligns with the “ ” mark on the cylinder block.

[4]
PROJECTION
[3] CONCAVE

[5]
“ ” MARK

12-8
4) Align the alignment mark on the front balancer holder with [1] [2] [3]
the projection on the rear balancer shaft. REAR BALANCER PROJECTION ALIGNMENT
SHAFT MARK

5) Hold the rear balancer shaft by inserting the special tool [2] MAINTENANCE
into the maintenance hole in the front balancer. HOLE
[1]
TOOL: PIN DRIVER, 6.0 mm
Pin driver, 6.0 mm 07744-0010500 07744-0010500

NOTICE
Check that the special tool is inserted in the balancer case
assembly securely.

[3]
REAR BALANCER SHAFT

6) Install the balancer chain on the crankshaft sprocket while [1] [2]
aligning the “ ” mark on the crankshaft sprocket with the CRANKSHAFT BALANCER
color plate (1 place) of the balancer chain. SPROCKET CHAIN

[4]
[3] “ ” MARK
COLOR PLATE (1 place)

7) Install the driven sprocket on the balancer chain while [1]

aligning the alignment mark on the driven sprocket with COLOR PLATE
the color plates (2 places) of the balancer chain. (2 places)

[4]
ALIGNMENT
MARK

[3] [2]
BALANCER DRIVEN
CHAIN SPROCKET

12-9
8) Install the driven sprocket together with the balancer chain
[2] CONCAVE [3] PROJECTION
on the rear balancer shaft by aligning the concave in the
driven sprocket with the projection on the rear balancer
shaft.
[1]
10 x 30 mm
TORQUE: 44 N.m (4.5 kgf.m, 33 lbf.ft) BOLT-WASHER

After installation, remove the special tool from the balancer

case assembly.

[4]
[5] DRIVEN REAR BALANCER
SPROCKET SHAFT

9) Install the balancer chain guide on the lower block and

tighten the two chain guide bolts to the specified torque.

TORQUE: 12 N.m (1.2 kgf.m, 9 lbf.ft)

[1]
CHAIN GUIDE
BOLT (2)

[2]
BALANCER CHAIN
GUIDE

10) Pushing the balancer chain tensioner against the balancer

chain, install the balancer chain tensioner on the balancer [1] BALANCER CHAIN
holder. Tighten the three 6 x 14 mm flange bolts. TENSIONER

6 x 14 (3)

12-10
After replacing the balancer chain tensioner with new one:
11) Install the set clip, that came together with the new [1]
balancer chain tensioner, on the balancer chain tensioner. BALANCER CHAIN
TENSIONER

[2]
SET CLIP

12) Install the balancer chain tensioner assembled in step 10 on

the rear balancer holder and tighten the three 6 x 14 mm [1]
flange bolts. BALANCER CHAIN
TENSIONER
After installation, remove the set clip from the balancer
chain tensioner.

6 x 14 (3)

13) Install the crankshaft pulley/cam chain (P. 9-11).

NOTICE
• Do not apply the liquid gasket to the chain case and
crankcase mating surfaces.
• Do not tighten the three bolts of the chain case/crankcase
mating side and do not install the crankshaft pulley.
[1]
14) Clean the crankcase and lower block mating surfaces Apply a bead of
thoroughly with the degreasing cleaning agent. liquid gasket.
15) Apply a bead [ø2.0 – 3.0 mm (ø0.08 – 0.12 in)] of the liquid
gasket (ThreeBond® #1280B or equivalent) to the indicated
area of the crankcase.

NOTICE
• Assemble the crankcase within 5 minutes after applying
the liquid gasket. If it has been left for 5 minutes or longer,
remove the old liquid gasket and apply the liquid gasket
again.
• Do not pour the engine oil in the oil tank at least 30
minutes after assembly.

12-11
16) Apply engine oil to the threads and seat of the 6 x 25 mm
flange bolts 6 x 25 (18)

17) Install the two dowel pins and crankcase on the lower block
and loosely tighten the 6 x 25 mm flange bolts.

[1]
CRANKCASE

[2] 13 x 20 mm
DOWEL PIN (2)

18) Tighten the 6 x 25 mm flange bolts to the specified torque

in the numbered sequence in two to three steps.
⑫ ⑬ ⑭
TORQUE: 12 N.m (1.2 kgf.m, 9 lbf.ft)

19) Install the engine on the outboard motor (P. 7-6).

20) Install the following parts. ⑧ ⑨

– Crankshaft pulley (P. 9-17)
– Electric parts/main wire harness (P. 18-14, 17, 19 and 27)
– Silencer duct (P. 6-4) ④
⑤
– Throttle body/intake manifold (P. 5-132)
– Silencer case (P. 5-135)
– L./R. engine under covers (P. 4-14) ①
– Engine cover (P. 4-2) ②

③
⑥

⑩
⑪

⑱ ⑰

⑯ ⑮

12-12
13. CYLINDER BLOCK/CRANKSHAFT/
PISTON

1. DISASSEMBLY 3. BEARING SELECTION

2. INSPECTION 4. ASSEMBLY

26 N.m (2.7 kgf.m,

20 lbf.ft)

20 N.m (2.0 kgf.m,

14 lbf.ft) + 90˚

29 N.m (3.0 kgf.m, 26 N.m (2.7 kgf.m,

22 lbf.ft) + 56˚ 20 lbf.ft)

13-1
1. DISASSEMBLY
a. LOWER BLOCK/CRANKSHAFT/CYLINDER ② ①
BLOCK
Remove the following parts.
– Engine cover (P. 4-2) ⑥ ⑤
– L./R. engine under covers (P. 4-9)
– Cylinder head assembly (P. 10-19) ⑩ ⑨
– Engine assembly (P. 7-2)
– Oil pump (P. 11-6) ⑭ ⑬
– Flywheel (P. 11-12)
– Crankcase/balancer case assembly (P. 12-2)
⑪ ⑫
1) Loosen the bolts in the numbered sequence in two or three
steps. ⑦ ⑧
2) Remove the four 8 x 50 mm flange bolts and ten 8 x 35 mm ③ ④
flange bolts from the lower block.

3) Loosen the ten 11 x 95 mm washer bolts in the numbered

sequence in two or three steps.
② ①
4) Remove the ten 11 x 95 mm washer bolts from the lower
block.

⑥ ⑤

⑩ ⑨

⑦ ⑧

③ ④

5) Insert the screwdriver into the recesses of the lower block

and raise the lower block little by little.

[1] [1]
RECESS RECESS

13-2
6) Remove the lower block, 80 x 98 x 10 mm oil seal and the [1] [2] 80 x 98 x 10 mm
eleven dowel pins from the cylinder block. LOWER BLOCK OIL SEAL
Replace the oil seal on assembly.

[4]
13 x 14 mm
DOWEL PIN (10)

[3]
18 x 22 mm
DOWEL PIN

7) Check the lower main bearings for damage (scores,

[1]
scratches, etc.) and replace if necessary.
LOWER BLOCK
8) Remove the five lower main bearings from the lower block. ORIFICE
NOTICE
Store the removed lower main bearings separately for each
journal.

9) Remove the lower block orifice from the lower block and
check the lower block orifice for blockage.
If it is clogged, clean it with a cleaning solvent and remove
[2]
the blockage by blowing the oil passage with the
LOWER BLOCK
compressed air.
If the blockage cannot be removed by blowing with the
compressed air, replace the lower block orifice with a new
one. [3]
LOWER MAIN
NOTICE BEARING (5)
Remove the blockage with care not to damage the oil
passage of the lower block orifice.

10) Check that the piston is at the bottom dead center of its [1] [2]
stroke. If not, move the piston to the bottom dead center by CONNECTING CONNECTING
ROD CAP ROD BOLT (2)
turning the crankshaft.
[3]
11) Remove the connecting rod bolts, then remove the CONNECTING
[4]
connecting rod cap, connecting rod bearing and the two ROD BEARING
10 x 12 mm
dowel pins. DOWEL PIN (2)
NOTICE
Store the removed connecting rod cap, connecting rod
bearing and the dowel pins classifying them into each
cylinder.

13-3
12) Remove the crankshaft from the cylinder block with care
[1]
not to damage (scores, scratches, etc.) the journals. CRANKSHAFT
Remove the two thrust washers.

13) Before removing the upper main bearings, check each [2]
UPPER MAIN
bearing for damage (scores, scratches, etc.) and replace if
BEARING (5)
necessary.

14) Remove the five upper main bearings from the cylinder
block. [3]
THRUTST
WASHER (2)
NOTICE
Store the upper main bearings separately for each journal.

15) Remove the oil jet orifice and the 6.5 x 1.5 mm O-ring from
the cylinder block, and check the oil jet orifice for blockage.
If it is clogged, clean it with a cleaning solvent and remove
the blockage by blowing the oil passage with the
compressed air.
If the blockage cannot be removed by blowing with the
compressed air, replace the oil jet orifice with a new one.

NOTICE
Remove the blockage with care not to damage the oil
passage of the oil jet orifice.

[4] 6.5 x 1.5 mm O-RING

[5]
OIL JET ORIFICE

16) Remove the oil jet bolt from the No.1/No.2 cylinder of the
cylinder block and remove the oil jet body. [1]
OIL JET BOLT

[2]
OIL JET
BODY

17) Remove the piston assembly from the cylinder by pushing [2]
the piston assembly with the handle of a hammer as CYLINDER BLOCK
shown. [1]
PISTON ASSEMBLY
NOTICE
• Before removing the piston assembly, remove the carbon
deposits from the cylinder with care not to damage
(scores, scratches, etc.) the piston.
• Do not damage the cylinder with the connecting rod.
• Store the removed piston assembly components
separately for each cylinder.

13-4
b. PISTON ASSEMBLY [1] [2]
1) Remove the connecting rod bearing and the piston ring CONNECTING PISTON RING
from the piston assembly. ROD BEARING

NOTICE
• Do not apply excessive force to the piston ring as it can
break the piston ring. Handle the piston ring with care.
• Store the removed connecting rod bearing and the piston
ring separately for each piston. [3]
PISTON RING
PLIERS
(Commercially
available)

2) Apply oil to the piston pin clip. Align the piston pin clip end [1]
gap with the cutout in the piston pin hole. PISTON PIN
CLIP
NOTICE
Do not damage the piston pin clip installation groove.

[2]
CUTOUT

3) Remove the piston pin clips from the cut out at both sides
[1]
of the piston.
PISTON PIN
CLIP
NOTICE
Remove the piston pin clips with care not to let them jump
out of position.

4) Warm up the piston assembly to approximately 70˚C

(158˚F) and remove the piston pin.

CAUTION
Take care not to get your hand, etc. burned during
disassembly.

13-5
c. COMPONENTS DRAWING

8 x 50 (4)
26 N.m (2.7 kgf.m, 20 lbf.ft) 8 x 35 (10)
26 N.m (2.7 kgf.m, 20 lbf.ft)

[2]
LOWER MAIN BEARING (5)
[1]
11 x 95 mm BOLT-WASHER (10)
29 N.m (3.0 kgf.m, 22 lbf.ft) + 56˚ [3]
CRANKSHAFT
[4]
[18] 80 x 98 x 10 mm
LOWER BLOCK OIL SEAL
ORIFICE
10 N.m (1.0 kgf.m,
7 lbf.ft)
[5]
[17] UPPER MAIN
LOWER BLOCK BEARING (5)

[6]
THRUST WASHER (2)
[16]
18 x 22 mm
DOWEL PIN [7]
OIL JET BOLT (2)
16 N.m (1.6 kgf.m, 12 lbf.ft)
[8]
[15] 8 x 10 mm
8 mm BOLT-WASHER (2)
BOLT CAP

[9]
OIL JET BODY (2)
8 x 20 (2)
[14]
13 x 14 mm
DOWEL PIN (10) [12] [11] [10]
OIL JET ORIFICE 6.5 x 1.5 mm CYLINDER BLOCK
[13] O-RING
ENGINE HANGER

13-6
 [1]
TOP RING

[2]
[14] PISTON RING
SECOND RING
[3]
PISTON PIN
[13] CLIP (2)
SIDE RAIL (2)

[4]
PISTON
[12]
OIL RING

[11]
SPACER

[5]
CONNECTING ROD

[10]
PISTON PIN

[6]
10 x 12 mm
DOWEL PIN (2)

[9]
CONNECTING ROD
BEARING (2)

[7]
CONNECTING
ROD CAP

[8]
CONNECTING ROD BOLT (2)
20 N.m (2.0 kgf.m, 14 lbf.ft) + 90˚

13-7
2. INSPECTION
[1]
• PISTON SKIRT O.D. O.D.
1) Check the piston outer surface for damage (scores,
scratches, etc.). Check the piston for warpage and cracks. 11 mm
(0.4 in)
2) Measure and record the piston O.D. at a point 11 mm from
the bottom, and 90˚ to the piston pin bore.

STANDARD SERVICE LIMIT

86.98 – 86.99 mm 86.93 mm
A
(3.4244 – 3.4248 in) (3.4224 in)
86.97 – 86.98 mm 86.92 mm
B
(3.4240 – 3.4244 in) (3.4220 in)

90˚

• CYLNDER SLEEVE I.D.

1) Check the inner wall of the cylinder for damage (scores, [1]
TOP
scratches, etc.).

2) Measure and record the cylinder I.D. at three levels in both

X and Y axis. Take the maximum reading to determine the
cylinder I.D.

STANDARD SERVICE LIMIT

87.01 – 87.02 mm 87.07 mm [2]
A or l
(3.4256 – 3.4260 in) (3.4279 in) MIDDLE [3]
87.00 – 87.01 mm 87.07 mm BOTTOM
B or ll
(3.4252 – 3.4256 in) (3.4279 in) [5] [4]
NO.1 CYLINDER NO.4 CYLINDER
• PISTON-TO-CYLINDER CLEARANCE
[1]
TOP
STANDARD SERVICE LIMIT X
0.02 – 0.04 mm 0.05 mm
(0.001 – 0.002 in) (0.002 in) Y

• CYLINDER SLEEVE I.D. GAP BETWEEN TOP AND

BOTTOM
Determine the gap of the cylinder sleeve I.D. between the top
and the bottom measurements. [2]
MIDDLE [3]
SERVICE LIMIT 0.05 mm (0.002 in) BOTTOM

13-8
• PISTON RING THICKNESS
1) Check the piston ring for damage (scores, scratches, etc.).
2) Measure the piston ring thickness.

STANDARD SERVICE LIMIT

1.170 – 1.185 mm
TOP
(0.0461 – 0.0467 in)
1.175 – 1.190 mm
SECOND
(0.0463 – 0.0469 in)

The oil rings are the combination rings. Replace the top
ring, second ring and the oil rings as a set when either top
or second ring needs replacement.

• PISTON RING GROOVE WIDTH

1) Check the piston ring grooves for uneven wear, damage
and clogged oil hole.
2) Measure the piston ring groove width. [1]
TOP
STANDARD SERVICE LIMIT
1.23 – 1.24 mm 1.25 mm
TOP [2]
(0.0484 – 0.0488 in) (0.0492 in)
SECOND
1.24 – 1.25 mm 1.25 mm
SECOND
(0.0488 – 0.0492 in) (0.0492 in)
2.005 – 2.025 mm 2.05 mm [3]
OIL OIL
(0.0789 – 0.0797 in) (0.081 in)

• PISTON RING SIDE CLEARANCE

Set the piston ring on the piston properly so it is almost flush
with the piston outer surface. Measure the piston ring side
clearance.

STANDARD SERVICE LIMIT

0.045 – 0.070 mm 0.13 mm
TOP
(0.0018 – 0.0028 in) (0.005 in)
0.040 – 0.065 mm 0.13 mm
SECOND
(0.0016 – 0.0026 in) (0.005 in)

The oil rings are the combination rings. Replace the top ring,
second ring and the oil rings as a set when either top or second
ring needs replacement.

• PISTON RING END GAP

Use the piston to push the piston ring into the cylinder and
position it horizontally at 15 to 20 mm from the bottom of the
cylinder.

STANDARD SERVICE LIMIT

[1]
0.20 – 0.35 mm 0.6 mm PISTON RING
TOP
(0.008 – 0.014 in) (0.02 in)
0.50 – 0.65 mm 0.75 mm
SECOND
(0.020 – 0.026 in) (0.030 in)
0.20 – 0.70 mm 0.8 mm
OIL
(0.008 – 0.028 in) (0.031 in)
[2] 15 – 20 mm
If the end gap is larger than the service limit, install a new END GAP (0.6 – 0.8 in)
piston ring and recheck. Check the cylinder sleeve I.D. (P. 13-8).

13-9
• PISTON PIN BORE I.D.

STANDARD SERVICE LIMIT

21.960 – 21.963 mm
(0.8646 – 0.8647 in)

• PISTON PIN O.D.

STANDARD SERVICE LIMIT

21.961 – 21.965 mm 21.953 mm
(0.8646 – 0.8648 in) (0.8643 in)

• PISTON PIN-TO-PIN BORE CLEARANCE

1) Set the cylinder gauge at the piston pin O.D. and zero the
cylinder gauge.

2) Insert the cylinder gauge in the piston pin bore and

measure the piston pin-to-pin bore clearance.

STANDARD SERVICE LIMIT

–0.005 – +0.002 mm 0.005 mm
(–0.0002 – +0.0001 in) (0.0002 in)

• CONNECTING ROD SMALL END I.D.

STANDARD SERVICE LIMIT

23.969 – 23.982 mm
(0.9437 – 0.9442 in)

• CONNECTING ROD SMALL END-TO-PISTON PIN

CLEARANCE
STANDARD SERVICE LIMIT
0.005 – 0.015 mm 0.02 mm
(0.0002 – 0.0006 in) (0.001 in)

13-10
• CONNECTING ROD BIG END AXIAL CLEARANCE

STANDARD SERVICE LIMIT

0.15 – 0.35 mm 0.4 mm
(0.006 – 0.014 in) (0.02 in)

• CRANKSHAFT MAIN JOURNAL O.D. [1] [2]

NO.2 MAIN NO.4 MAIN
STANDARD SERVICE LIMIT JOURNAL JOURNAL
54.984 – 54.992 mm
No.1, 2, 4, 5,
(2.1647 – 2.1650 in)
54.976 – 55.000 mm
No.3
(2.1644 – 2.1654 in)

[5] [4] [3]

NO.1 MAIN NO.3 MAIN NO.5 MAIN
JOURNAL JOURNAL JOURNAL

• CRANK PIN JOURNAL O.D.

[1]
STANDARD SERVICE LIMIT CRANK PINS
47.976 – 48.000 mm
(1.8888 – 1.8898 in)

• CRANKSHAFT JOURNAL (MAIN, PIN)

ROUNDNESS
Measure the crankshaft main journal O.D. and the crank pin
O.D. in the A and B directions. Calculate the gap between the
measurements to determine the roundness.
[1] [2]
STANDARD SERVICE LIMIT ROUNDNESS (Measure at ROUNDNESS: B
the center of the journal.)
0.005 mm (0.0002 in) Max. 0.010 mm (0.0004 in)
A
• CRANKSHAFT JOURNAL (MAIN, PIN)
[3]
CILINDRICITY CYLINDRICITY:
Measure the crankshaft main journal O.D. and the crank pin
O.D. at the points A and B. Calculate the gap between the A B
measurements to determine the cylindricity.
[4]
STANDARD SERVICE LIMIT CYLINDRICITY (Measure at
0.005 mm (0.0002 in) Max. 0.010 mm (0.0004 in) both ends of the journal.)

13-11
• CRANKSHAFT AXIAL CLEARANCE
Install the dial indicator as shown. Measure the crankshaft axial
play by moving the crankshaft back and forth with a
screwdriver.

STANDARD SERVICE LIMIT

0.10 – 0.35 mm 0.45 mm
(0.004 – 0.014 in) (0.018 in)

If the measurement exceeds the service limit, check the thrust

washer and the cylinder block thrust surface. Replace the
thrust washer and recheck.
If the measurement still exceeds the service limit, replace the
crankshaft.

• THRUST METAL SIDE CLEARANCE

Measure the clearance between the No.4 main journal thrust
washer and the crankshaft.

STANDARD SERVICE LIMIT

0.10 – 0.35 mm 0.45 mm
(0.004 – 0.014 in) (0.018 in)

If the measurement exceeds the service limit, check the thrust

washer and the cylinder block thrust surface. Replace the
thrust washer and recheck.
If the measurement still exceeds the service limit, replace the
crankshaft.

• CRANKSHAFT RUNOUT [2]

1) Install the No.1 and No.5 upper main bearings on the [1] NO.5 UPPER
cylinder block. CRANKSHAFT MAIN BEARING

2) Install the crankshaft on the cylinder block.

3) Set the dial indicator on the crankshaft. Measure the

crankshaft runout by turning the crankshaft.

STANDARD SERVICE LIMIT

[3]
0.03 mm (0.001 in) Max. 0.04 mm (0.002 in) CYLINDER
BLOCK
4) If the measurement exceeds the service limit, replace the
crankshaft.

[4]
NO.1 UPPER MAIN
BEARING

13-12
• CYLINDER HEAD SURFACE WARPAGE
1) Take care not to damage (score, scratches, etc.) the mating
surface with the gasket.

2) Measure the surface warpage using a straight edge and a

feeler gauge as shown.

STANDARD SERVICE LIMIT

0.07 mm (0.003 in) Max. 0.10 mm (0.004 in)

• CONNECTING ROD BEARING OIL CLEARANCE

1) Clean the crank pin and the connecting rod bearing. Check
the crank pin and the bearing for damage and wear.
2) Install the crankshaft on the cylinder block. Install the
connecting rod cap on the connecting rod and tighten the
connecting rod bolts to the specified torque (P. 13-22).
3) Remove the connecting rod cap. Set a plastigauge on the
crank pin. [1]
PLASTIGAUGE
NOTICE
• Set the plastigauge in the axial direction.
• Tighten the connecting rod bolts with care not to turn the
crankshaft and connecting rod.

4) Reinstall the connecting rod cap and tighten the connecting

rod bolts to the specified torque (P. 13-22).

5) Remove the connecting rod cap. Measure the pressured

width of the plastigauge using the scale printed on the bag
of the plastigauge.
[1] PLASTIGAUGE
NOTICE
Measure the widest width on the plastigauge.

STANDARD SERVICE LIMIT

0.032 – 0.066 mm 0.077 mm
(0.0013 – 0.0026 in) (0.0030 in)

6) If the measurement exceeds the service limit, check the

connecting rod big end I.D. and the crank pin O.D. If they
are OK, replace with the undersize bearing by referring to
the connecting rod bearing selection table (P. 13-16), and [2] SCALE
measure the oil clearance again.

13-13
• CRANKSHAFT MAIN BEARING OIL CLEARANCE [1]
1) Clean the crankshaft main journals and the main bearings. PLASTIGAUGE
Check the journals and the bearings for damage and wear.
2) Install the upper main bearings and the crankshaft on the
cylinder block. Install the lower main bearings and the
lower block and tighten the bolts to the specified torque (P.
13-24).
3) Remove the lower block and the lower main bearings. Set
the plastigauge on each main journal of the crankshaft as
shown.

NOTICE
• Set the plastgauges in the axial direction.
• Do not turn the crankshaft during this check.

4) Reinstall the lower main bearings and the lower block.

Tighten the bolts to the specified torque (P. 13-24). [1] PLASTIGAUGE

5) Remove the lower block and the lower main bearings.

Measure the pressured width of the plastigauge using the
scale printed on the bag of the plastigauge.

NOTICE
Measure the widest width on the plastigauge. [2]
SCALE
STANDARD SERVICE LIMIT
0.017 – 0.041 mm 0.05 mm
No.1, 2, 4, 5
(0.0007 – 0.0016 in) (0.002 in)
0.025 – 0.049 mm 0.055 mm
No.3
(0.0010 – 0.0019 in) (0.0022 in)

6) If the measurement exceeds the service limit, check the

lower block and the cylinder block main bearing I.D. and
the crankshaft main journal O.D. If they are OK, replace
with the undersize bearing by referring to the connecting
rod bearing selection table (P. 13-18), and measure the oil
clearance again.

• CONNECTING ROD BOLT

35 mm (1.4 in)
1) Measure the O.D. of each connecting rod bolt at two points
as shown, and calculate the gap between the
measurements.

STANDARD 0 – 0.1 mm (0 – 0.004 in) 20 mm (0.8 in)

2) If the gap exceeds the standard value, replace the

connecting rod bolt.

NOTICE
Measure the O.D. on each of the connecting rod bolt.

13-14
3. BEARING SELECTION
a. CONNECTING ROD BEARING
NOTICE
• When replacing the connecting rod bearing, check the crank
pin code letter and the connecting rod code number, and
select the correct bearing by referring to the bearing selection
table.
• If the code letters and/or numbers are not clear, clean the
areas with a cleaning solvent and check again. Do not scrub
with a stiff brush or driver to clean.

1) Check the connecting rod code numbers and record them.

NOTICE
The connecting rod code numbers are for the No.1 and the
subsequent number journals when viewed from the
crankshaft pulley side.

Connecting rod big end I.D.: 51 mm (2.0 in)

[1]
Code No. Tolerance
CONNECTING ROD
1 or l ±0.000 – +0.006 mm (±0.0000 – +0.0002 in) CODE NUMBER
2 or ll +0.006 – +0.012 mm (+0.0002 – +0.0005 in)
3 or lll +0.012 – +0.018 mm (+0.0005 – +0.0007 in)
4 or llll +0.018 – +0.024 mm (+0.0007 – +0.0009 in)

2) Check the crank pin code letters and record them.

[1] CRANK PIN
NOTICE CODE LETTER
The crank pin code letters are for the No.1 and the
subsequent number journals when viewed from the right
side of the position shown or from the crankshaft pulley
side.

3) Select the correct bearing by referring to the crank pin code

letter and the connecting rod code number.

[2] [3] [4] [5]

No.1 No.2 No.3 No.4
[1] CRANK PIN
CODE LETTER

[5] [2]
No.4 No.1

13-15
Connecting rod bearing selection table:
Connecting rod code number
Crank pin
code letter 1 or l 2 or ll 3 or lll 4 or llll
Bearing identification color
Pink/
A Red Pink Yellow
Yellow
Yellow/
B Pink Yellow Green
Green
Green/
C Yellow Green Brown
Brown
Brown/
D Green Brown Black
Black

Selection table:
Connecting rod bearing center thickness: 1.5 mm (0.06 in)
Mark I.D. color Tolerance
G Red –0.008 – –0.005 mm (–0.0003 – –0.0002 in)
F Pink –0.005 – –0.002 mm (–0.0002 – –0.0001 in)
E Yellow –0.002 – +0.001 mm (–0.0001 – +0.00004 in)
D Green +0.001 – +0.004 mm (+0.00004 – +0.0002 in)
C Brown +0.004 – +0.007 mm (+0.0002 – +0.0003 in)
B Black +0.007 – +0.010 mm (+0.0003 – +0.0004 in)
A Blue +0.010 – +0.013 mm (+0.0004 – +0.0005 in)

The connecting rod bearings are available in blue, black,

brown, green, yellow, pink and red of the size identification
color in this order in increments of 0.003 mm (0.0001 in).

4) Note that the oil clearance is set taking the enlarged

amount of the housing caused by crash into consideration.
The bearings are selected so that the oil clearance is 0.032
– 0.066 mm (0.0013 – 0.0026 in).

5) Check the oil clearance after installing the selected bearing

(P. 13-13).

6) Align the projection on the bearing with the cutout in the [1] [2]
connecting rod or cap, and install with care not to damage PROJECTION IDENTIFICATION
the sliding surface. COLOR
NOTICE
• Do not determine the bearing simply by referring to the
selection table, but check the oil clearance.
• If the selection table shows two identification colors, use
a pair of the bearing of each color for the upper and lower
bearings.

13-16
b. CRANKSHAFT MAIN BEARING
NOTICE
• When replacing the main bearing, check the crankshaft main
journal code number and the cylinder block I.D. code letter or
number, and select the correct bearing by referring to the
bearing selection table.
• If the code letter and/or number is not clear, clean the area
with a cleaning solvent and check again. Do not scrub with a
stiff wire brush or driver to clean.

1) Check the cylinder block I.D. code letters or numbers and

record them.

NOTICE
The cylinder block I.D. code letters or numbers are for the
No.1 and the subsequent number journals when viewed
from the left side. [1]
CYLINDER BLOCK I.D.
Cylinder block I.D.: 59 mm (2.3 in) CODE LETTER OR
NUMBER
Code No. Tolerance
1 or A or l ±0.000 – +0.006 mm (±0.0000 – +0.0002 in)
2 or B or ll +0.006 – +0.012 mm (+0.0002 – +0.0005 in) [2] [3]
3 or C or lll +0.012 – +0.018 mm (+0.0005 – +0.0007 in) NO.1 MAIN NO.5 MAIN
JOURNAL JOURNAL
4 or D or llll +0.018 – +0.024 mm (+0.0007 – +0.0009 in)

2) Check the crankshaft main journal code numbers and

record them. [1] CRANKSHAFT
MAIN JOURNAL
NOTICE CODE NUMBER
The crankshaft main journal code numbers are for the No.1
and the subsequent number journals when viewed from
the right side of the position shown or from the crankshaft
pulley side.

3) Select the correct bearing by referring to the cylinder block

I.D. code letter or number and the crankshaft main journal
code number.

[2] [3] [4] [5] [6]

No.1 No.2 No.3 No.4 No.5
[1] CRANKSHAFT
MAIN JOURNAL
CODE NUMBER

[6] [2]
No.5 No.1

13-17
Crankshaft main bearing selection table:

Crankshaft Cylinder block I.D. code letter or number

main journal 1 or A or l 2 or B or ll 3 or C or lll 4 or D or llll
code number Bearing identification color
Pink/
1 Pink Yellow Green
Yellow
Pink/ Green/
2 Yellow Green
Yellow Brown
Green/
3 Yellow Green Brown
Brown
Green/
4 Green Brown Black
Brown
Green/ Black/
5 Brown Black
Brown Blue
Black/
6 Brown Black Blue
Blue

Selection table:
Main bearing center thickness: 2.0 mm (0.08 in)
Mark I.D. color Tolerance
F Pink –0.006 – –0.003 mm (–0.0002 – –0.0001 in)
E Yellow –0.003 – ±0.000 mm (–0.0001 – ±0.0000 in)
D Green ±0.000 – +0.003 mm (±0.0000 – +0.0001 in)
C Brown +0.003 – +0.006 mm (+0.0001 – +0.0002 in)
B Black +0.006 – +0.009 mm (+0.0002 – +0.0004 in)
A Blue +0.009 – +0.012 mm (+0.0004 – +0.0005 in)

The main bearings are available in blue, black, brown, green,

yellow and pink of the size identification color in this order in
increments of 0.003 mm (0.0001 in).

4) Note that the oil clearance is set taking the enlarged

amount of the housing caused by crash into consideration.
The bearings are selected so that the oil clearance for the
No.1, 2, 4 and 5 journals is in the range of 0.017 – 0.041 mm
(0.0007 – 0.0016 in), and the oil clearance for the No.3
journal is in the range of 0.025 – 0.049 mm (0.0010 – 0.0019 [1]
PROJECTION [2]
in). IDENTIFICATION
COLOR
5) Check the oil clearance after installing the selected bearing
(P. 13-14).

6) Align the projection of the bearing with the cutout in the

cylinder block or lower block, and install with care not to
damage the sliding surface.

NOTICE
• Do not determine the bearing simply by referring to the
selection table, but check the oil clearance.
• If the selection table shows two identification colors, use
a pair of the bearing of each color for the upper and lower
bearings.

13-18
4. ASSEMBLY
a. PISTON ASSEMBLY
1) Install the piston pin clip only on one side of the piston.

NOTICE
Take care not to let the piston pin clip jump out of position.

[1]
PISTON PIN
CLIP

2) Warm up the piston to approximately 70˚C (158˚F).

CAUTION
Take care not to get your hand, etc. burned during
assembly.

3) Apply molybdenum disulfide oil to the outer surface of the

piston pin, inner wall of the piston pin hole in the piston
and to the inner wall of the connecting rod small end. [1]
Install the connecting rod on the piston and install the “ ” MARK
piston pin.

NOTICE
[2]
Install the piston pin so that the “ ” mark on the piston MODEL MARK
head points to the model mark on the connecting rod.

4) Install the piston pin clip on the opposite side from where
the piston pin clip was installed in step 3.

NOTICE [3] [4]

MOLYBDENUM PISTON PIN
Take care not to let the piston pin clip jump out of position. DISULFIDE OIL [5]
PISTON PIN
5) Install the connecting rod bearing on the connecting rod by CLIP
aligning the projection on the bearing with the concave in
the connecting rod.
[6]
CONNECTING
ROD BEARING

[8]
PISTON [7]
CONNECTING
ROD

13-19
6) Install the piston rings in the ring grooves in the piston with [1]
the marker marks on the top ring and the second ring TOP RING
facing up.
[2]
Install the side rail (top side) by aligning the lug of the side SECOND RING
rail (top side) with the positioning groove in the ring
groove. [3]
SIDE RAIL
NOTICE (TOP SIDE)
• Clean the ring grooves thoroughly before installing the [4]
piston rings. OIL RINGS
• Install the piston rings with care not to break the piston
rings. Take care not to score or scratch the piston.
• Do not confuse the top ring and the second ring. The top [5]
ring is glossy while the second ring can be identified with [6] SIDE RAIL
SPACER (SKIRT SIDE)
the dark color.
• To install the oil rings, install the spacer first, then install [8]
[7]
the side rails. GROOVE LUG
• Be sure that the lug of the side rail (top side) sets in the
positioning groove securely.

[1] DIMENSIONS OF PISTON RING:

[2] TOP RING

B A: 3.1 mm
B: 1.2 mm
SECOND RING [9] [3]
A: 3.4 mm PISTON SIDE RAIL
A B: 1.2 mm (TOP SIDE)

7) After installing the piston rings, check for smooth

movement of each ring. [Except side rail (top side)] [1] TOP RING

8) Stagger the piston ring end gaps as shown. [2] SECOND RING

NOTICE [3] SIDE RAIL

Do not align with the piston pin and avoid the direction that (TOP SIDE)
makes a right angle with the piston pin.
[4] SPACER
[5] SIDE RAIL
(SKIRT SIDE)
[7] APPROX. 10˚
[6] [8] [9]
SIDE RAIL APPROX. 15˚ SPACER RING
END GAP END GAP
(TOP SIDE) [8] APPROX. 15˚
[FIXED
POSITION] [10] SIDE RAIL
END GAP
[11] (SKIRT SIDE)
APPROX.120˚
[11]
APPROX. 120˚
[12]
PISTON
PIN

[14] [13] SECOND RING

TOP RING END GAP END GAP

13-20
b. LOWER BLOCK/CRANKSHAFT/CYLINDER
BLOCK
1) Apply molybdenum disulfide oil to the piston skirt and the
inner wall of the cylinder sleeve.
[1]
2) Using the handle of a hammer, drive the piston slowly into [2] MOLYBDENUM
“ ” MARK
the cylinder block with the “ ” mark on the piston toward DISULFIDE OIL
the cam chain side.

[3]
PISTON RING
COMPRESSOR
(Commercially
available)
[2]
MOLYBDENUM
DISULFIDE OIL

3) Apply engine oil to the threads and seat of the oil jet bolts.

4) Install the oil jet body on each of the No.1 and No.2 cylinder
and tighten the oil jet bolts to the specified torque. [1]
OIL JET BOLT
TORQUE: 16 N.m (1.6 kgf.m, 12 lbf.ft)
[2]
OIL JET
BODY

5) Apply engine oil to the new 6.5 x 1.5 mm O-ring and install
it on the oil jet orifice.
Install the oil jet orifice on the cylinder block. [1]
CYLINDER
BLOCK

[2]
6.5 x 1.5 mm
O-RING

[3]
OIL JET ORIFICE

13-21
6) Install the upper main bearings on the cylinder block [1] PROJECTION [2]
aligning the projection on the upper main bearing with the UPPER MAIN
concave in the cylinder block. BEARING

7) Apply molybdenum disulfide oil to the crankshaft main

journal, crank pin and the thrust washer mating surfaces.

8) Put the No.2 and No.3 pistons at the bottom dead center of
their stroke. Install the crankshaft on the cylinder block
while aligning it with the No.2 and No.3 connecting rods.
[3]
NOTICE CONCAVE
Install the crankshaft with care not to damage the journals.

[4]
MOLYBDENUM
DISULFIDE OIL

[5]
CRANKSHAFT

[7]
CYLINDER [6]
BLOCK UPPER MAIN
BEARING (5)

9) Install the connecting rod bearing on the connecting rod

[1] [2]
cap aligning the projection on the connecting rod bearing
CONNECTING ROD 10 x 12 mm
with the concave in the connecting rod cap. BEARING DOWEL PIN (2)

10) Install the two dowel pins on the connecting rod cap.

[3]
CONNECTING
ROD CAP

13-22
11) Apply engine oil to the threads and seat of the connecting
rod bolts. [1]
Install the connecting rod cap assembly on the connecting CONNECTING ROD
rod and tighten the two connecting rod bolts to the CAP ASSEMBLY [2]
specified torque. CONNECTING
After tightening to the specified torque, tighten the bolts to ROD BOLT (2)
an additional 90˚.

TORQUE: 20 N.m (2.0 kgf.m) + 90˚

NOTICE
• Install the connecting rod cap assembly aligning the code
number with the number on the counter part.
• Check that the piston is at the bottom dead center of its
stroke before tightening the bolts. It not, turn the
crankshaft to bring the piston at the bottom dead center. [3]
CODE
NUMBER

12) Apply engine oil to the thrust washers and install them on
[1]
the cylinder block No.4 journal.
THRUST WASHER (2)
NOTICE
Install the thrust washers with the grooved side toward the
crankshaft.

[2]
GROOVES

13) Install the lower main bearings on the cylinder block

aligning the projection on the lower main bearing with the
concave in the lower block.
[1]
14) Apply engine oil to the threads of the lower block orifice. LOWER BLOCK
Tighten the lower block orifice on the lower block to the ORIFICE
specified torque.

TORQUE: 10 N.m (1.0 kgf.m, 7 lbf.ft)

[2] LOWER
BLOCK

[3]
LOWER MAIN
BEARING (5)

13-23
15) Clean the cylinder block and lower block mating surfaces
thoroughly with the degreasing cleaning agent. [1]
Apply a bead of
16) Apply a bead [ø2.0 – 3.0 mm (ø0.08 – 0.12 in.)] of the liquid liquid gasket.
gasket (ThreeBond® #1280B or equivalent) to the indicated
area of the cylinder block.

NOTICE
• Assemble the lower block within 5 minutes after applying
the liquid gasket. If it has been left for 5 minutes or longer,
remove the old liquid gasket and apply the liquid gasket
again.
• Do not pour the engine oil in the oil tank at least 30
minutes after assembly.

17) Install the eleven dowel pins and the lower block on the
cylinder block. [1]
LOWER BLOCK

[2]
13 x 14 mm
DOWEL PIN (10)

[3]
18 x 22 mm
DOWEL PIN

13-24
18) Apply engine oil to the threads and the seating face of the
washer of the 11 x 95 mm bolt-washers.

19) Loosely tighten the ten 11 x 95 mm bolt-washers on the

lower block, then tighten the bolt-washers in the numbered
sequence in two or three steps to the specified torque.
After tightening to the specified torque, tighten the bolt- ⑨ ⑩
washers to an additional 56˚ in the numbered order.

TORQUE: 29 N.m (3.0 kgf.m, 22 lbf.ft) + 56˚

⑤ ⑥

① ②

④ ③

⑧ ⑦

20) Apply engine oil to the threads and seating face of both the
8 x 50 mm flange bolts and the 8 x 35 mm flange bolts.

21) Loosely tighten the four 8 x 50 mm flange bolts and ten 8 x

35 mm flange bolts on the lower block. Tighten them to the
specified torque in the numbered sequence in two or three
steps.
⑬ ⑭
TORQUE: 26 N.m (2.7 kgf.m, 20 lbf.ft)

⑨ ⑩

⑤ ⑥

① ②

④ ③

⑧ ⑦

⑫ ⑪

13-25
22) Apply soapy water to the outer surface of the new 80 x 98
x 10 mm oil seal. Apply engine oil to the oil seal lip.

23) Using the special tools as shown, install the 80 x 98 x 10 [2]

mm oil seal on the crankshaft. OIL SEAL DRIVER
Drive in the oil seal so its upper side is 0.2 – 1.2 mm (0.01 – ATTACHMENT,96
[1] 07ZAD-PNA0100
0.05 in) deep from the surface.
DRIVER
07749-0010000
TOOLS:
Driver 07749-0010000
Oil seal driver attachment, 96 07ZAD-PNA0100

NOTICE
Drive in the oil seal with the part number on the oil seal
toward out.

24) Install the following pars. [3]

– Crankcase/balancer case assembly (P. 12-8) OIL SEAL INSTALLATION DEPTH:
– Flywheel (P. 11-14) [4] CRANKSHAFT
– Oil pump (P. 11-11) 0.2 – 1.2 mm
– Engine assembly (P. 7-6) (0.01 – 0.05 in)
– Cylinder head assembly (P. 10-32)
– L./R. engine under covers (P. 4-14)
– Engine cover (P. 4-2)

[5]
80 x 98 x 10 mm
OIL SEAL

13-26
14. PROPELLER/GEAR CASE/EXTENSION
CASE/OIL CASE

1. PROPELLER 12. PROPELLER SHAFT HOLDER

2. GEAR CASE ASSEMBLY [*1] ASSEMBLY [*2]
3. WATER PUMP/SHIFT ROD [*1] 13. PROPELLER SHAFT/PROPELLER
4. PROPELLER SHAFT HOLDER SHAFT HOLDER [*2]
ASSEMBLY [*1] 14. VERTICAL SHAFT/BEVEL GEAR [*2]
5. PROPELLER SHAFT/PROPELLER 15. SHIM SELECTION [*2]
SHAFT HOLDER [*1] 16. SHIM POSITION [*2]
6. VERTICAL SHAFT/BEVEL GEAR [*1] 17. BACKLASH ADJUSTMENT [*2]
7. SHIM SELECTION [*1] 18. ANODE METAL/WATER SCREEN
8. SHIM POSITION [*1] 19. EXTENSION CASE/LOWER RUBBER
9. BACKLASH ADJUSTMENT [*1] MOUNT
10. GEAR CASE ASSEMBLY [*2] 20. OIL CASE
11. WATER PUMP/SHIFT ROD [*2]
[*1]: LC, XC, LD and XD types [*2]: XCC, LCD and XCD types

83 N.m
(8.5 kgf.m,
61 lbf.ft)

34 N.m (3.5 kgf.m, 25 lbf.ft)

[1]
1 N.m (0.1 kgf.m, 0.7 lbf.ft)
Max. torque:
39 N.m (4.0 kgf.m, 29 lbf.ft) 44 N.m (4.5 kgf.m, 33 lbf.ft)

34 N.m (3.5 kgf.m, 25 lbf.ft)

34 N.m (3.5 kgf.m, 25 lbf.ft)

14-1
1. PROPELLER
a. REMOVAL/INSTALLATION

[1]
18 mm CASTLE NUT
INSTALLATION:
TORQUE:
1 N.m (0.1 kgf.m, 0.7 lbf.ft)
If the split pin cannot be set by tightening to
the specified torque, tighten the castle nut
additionally until the split pin can be set.
MAX. TORQUE:
44 N.m (4.5 kgf.m, 33 lbf.ft)

[2]
3-BLADE PROPELLER

[5]
PROPELLER THRUST WASHER
INSTALLATION:
Install the propeller thrust washer as
shown. [4]
PROPELLER WASHER [3]
3 mm SPLIT PIN
[5]-1 [5]-2
GEAR CASE INSTALLATION:
PROPELLER
SIDE • Replace with a new one on
SIDE
assembly.
• Be sure to use the genuine
part (stainless steel) and
bend the pin ends as shown
to stake the nut.

[3]-1
3 mm SPLIT PIN

14-2
2. GEAR CASE ASSEMBLY [*1] [1]
SPEED SENSOR
TUBE B
a. REMOVAL
1) Place the remote control lever in the “N” (Neutral) position.

2) Tilt up the outboard motor to the uppermost position.

3) Disconnect the speed sensor tube B and the speed sensor

tube C.

[2]
SPEED SENSOR
TUBE C

4) Remove the 10 x 32 mm hex. bolt and the 10 mm washer.

Remove the trim tab from the gear case assembly.

[1]
TRIM TAB

[3] [2]
10 mm WASHER 10 x 32 mm
HEX. BOLT

5) Remove the seven 10 x 40 mm hex. bolts and the seven 10

[1]
mm washers, then remove the gear case assembly from 6 x 10 mm
the outboard motor. DOWEL PIN (2)
Remove the two dowel pins.

6) After removing the gear case assembly, lower the outboard [2]
motor to the lowermost position. 10 mm
WASHER (7)

[4]
GEAR CASE
ASSEMBLY

[3]
10 x 40 mm
HEX. BOLT (7)

14-3
7) Remove the shift rod A from the shift shaft A.

[2]
SHIFT
ROD A
[1]
SHIFT
SHAFT A

b. COMPONENTS DRAWING

[1]
SHIFT ROD A

[9]
VERTICAL SHAFT

[8]
6 x 10 mm
DOWEL PIN (2) [2]
10 mm WASHER (7)

[7]
GEAR CASE
ASSEMBLY [3]
10 x 40 mm HEX. BOLT (7)
34 N.m (3.5 kgf.m, 25 lbf.ft)

[4]
TRIM TAB

[6] [5]
10 mm WASHER 10 x 32 mm HEX. BOLT

14-4
c. INSTALLATION [1]
1) Place the remote control lever in the “N” (Neutral) position. CUTOUT

2) Check that the shift rod of the gear case is in the “N”
(Neutral) position.

To check: [3]
Check whether the cutout of the shift rod spline faces in the SHIFT ROD
direction shown. [It indicates that the shift rod is in the “N” [2] CRUISING
(Neutral) position.] DIRECTION

3) If the cutout of the spline is not in the direction shown,

protect the spline with a shop towel or equivalent material [2]
and turn the shift rod right and left with a wrench until the SHIFT ROD
cutout faces toward the specified direction. [1]
SHOP TOWEL

4) Tilt up the outboard motor to the uppermost position.

5) Apply grease to the spline of the shift rod A.
6) Install the shift rod A by aligning the projection of the shift
shaft A with the cutout in the spline of the shift rod A. Check
that the cutout in the spline of the shift rod A is toward the
cruising direction.

[3]
[1] CUTOUT
SHIFT SHAFT A
[2]
PROJECTION [4] CRUISING
DIRECTION

[4]
CRUISING DIRECTION

[5]
SHIFT ROD A

14-5
7) Apply grease to the vertical shaft spline and the shift rod
spline. [2]
Apply grease to the water tube insertion part and to the [1] VERTICAL
inner wall of the water tube seal ring of the impeller WATER TUBE SHAFT
housing. [3]
Apply grease to the inner wall of the vertical shaft bushing WATER TUBE
[XC and XD types only] (P. 14-90). SEAL RING

8) Install the two dowel pins. Aligning the water tube with the
water tube seal ring of the impeller housing, install the
vertical shaft and the crankshaft. Install the shift rod and [4]
shift rod A, too, by aligning the splines. 6 x 10 mm
DOWEL PIN (2)
9) Install the gear case assembly on the outboard motor. [7]
Loosely tighten the seven 10 mm washers and the seven 10 10 mm
x 40 mm hex. bolts. WASHER (7)

[6]
10 x 40 mm
HEX. BOLT (7) [5]
GEAR CASE
ASSEMBLY

10) Connect the speed sensor tube B and the speed sensor [1] SPEED SENSOR
tube C. TUBE B

11) Lower the outboard motor to the lowermost position and

tighten the seven 10 x 40 mm hex. bolts to the specified
torque.

TORQUE: 34 N.m (3.5 kgf.m, 25 lbf.ft)

[2]
SPEED SENSOR
TUBE C

12) Position the trim tab on the gear case assembly.

[1] TRIM TAB
[2] “ ” MARKS
13) Install the trim tab on the gear case assembly aligning the
“ ” mark on the trim tab with the “ ” mark on the gear
case. Tighten the 10 mm washer and the 10 x 32 mm hex.
bolt.
[3]
14) After installing the gear case assembly, adjust the shift
10 x 32 mm
control cable (P. 3-25). HEX. BOLT

[4]
10 mm WASHER

14-6
3. WATER PUMP/SHIFT ROD [*1] [1] [2]
WATER TUBE 8 x 40 mm
SEAL RING
a. DISASSEMBLY HEX. BOLT (4)
Remove the following parts. [8] [3]
– Propeller (P. 14-2) IMPELLER 8 mm
– Gear case assembly (P. 14-3) HOUSING WASHER (4)
1) Remove the speed sensor tube C. [7]
VERTICAL
2) Remove the water tube seal ring from the impeller housing. SHAFT

3) Remove the four 8 x 40 mm hex. bolts and the four 8 mm

washers from the impeller housing. Remove the impeller
housing. [4]
Remove the four distance collars from the impeller DISTANCE
housing. COLLAR (4)

4) Remove the woodruff key from the vertical shaft.

[5]
WOODRUFF
KEY
[6]
SPEED SENSOR
TUBE C

5) Remove the impeller cover, impeller gasket, two dowel

pins, gear case grommet and the rubber setting plate. [1]
IMPELLER COVER
NOTICE
[2]
Replace the impeller gasket with a new one on assembly. GEAR CASE
[5] GROMMET
IMPELLER
GASKET

[3]
RUBBER SETTING
[4] PLATE
6 x 10 mm
DOWEL PIN (2)

14-7
6) Check the pump impeller for cracks, wear or damage from
overheating, and replace if necessary.

7) Remove the pump impeller, pump liner and the water

pump O-ring from the impeller housing.
Replace the O-ring with a new one on assembly.
[1]
IMPELLER [2]
HOUSING PUMP LINER

[3]
[4] PUMP IMPELLER
WATER PUMP
O-RING

8) Remove the two 6 x 20 mm flange bolts and remove the [1]

water seal housing. WATER SEAL
HOUSING 6 x 20 (2)
9) Remove the 58.5 x 3.5 mm O-ring from the water seal
housing.
Replace the O-ring with a new one on assembly.
[2]
58.5 x 3.5 mm
O-RING

10) Before removing the 23 x 36 x 6 mm water seal, check the

water seal lip for cut. Replace if necessary. [1]
WATER SEAL
HOUSING
11) Remove the two 23 x 36 x 6 mm water seals from the water
seal housing using a commercially available oil seal
remover.
Replace the water seals with the new ones on assembly. [2]
23 x 36 x 6 mm
WATER SEALS

14-8
12) Remove the 6 x 12 mm hex. bolt and the pivot washer. [1]
Remove the shift rod holder and the shift rod assembly. SHIFT ROD
HOLDER
[2]
SHIFT ROD
ASSEMBLY
[3]
6 x 12 mm
HEX. BOLT

[4]
PIVOT
WASHER

13) Remove the shift rod spring, 12 mm washer and the 10 mm

E-ring from the shift rod. [2]
SHIFT ROD SPRING
[1] [3]
10 mm 12 mm
E-RING WASHER

[4]
SHIFT ROD

14) Check the 12 x 21 x 6 mm water seal lip for cut and replace [1]
if necessary. 12 x 21 x 6 mm
WATER SEALS
15) Remove the two 12 x 21 x 6 mm water seals from the shift
rod holder using a commercially available oil seal remover.
[2]
16) Remove the 55.6 x 3.5 mm O-ring from the shift rod holder. SHIFT ROD HOLDER

NOTICE
• Replace the 12 x 21 x 6 mm water seals with the new ones [3]
on assembly. 55.6 x 3.5 mm
• Replace the 55.6 x 3.5 mm O-ring with a new one on O-RING
assembly.

14-9
b. COMPONENTS DRAWING
[3]
[2] 8 x 40 mm HEX. BOLT (4)
WATER TUBE SEAL RING
19.7 N.m (2.0 kgf.m, 14 lbf.ft)

[4]
[1] 8 mm
IMPELLER HOUSING WASHER (4)

[5]
DISTANCE
COLLAR (4)
6 x 20 (2)
[6]
WATER PUMP
O-RING
[16]
WATER SEAL
HOUSING
[7]
PUMP LINER

[15]
58.5 x 3.5 mm
O-RING [8]
PUMP IMPELLER

[14]
23 x 36 x 6 mm [9]
WATER SEAL (2) WOODRUFF KEY

[10]
IMPELLER COVER

[11]
IMPELLER GASKET

[12]
VERTICAL SHAFT

[13]
6 x 10 mm
DOWEL PIN (2)

14-10
 [1]
12 x 21 x 6 mm
WATER SEAL (2)
[2]
SHIFT ROD
HOLDER

[15]
55.6 x 3.5 mm
O-RING

[14]
SHIFT ROD SPRING

[13]
12 mm WASHER

[12]
10 mm E-RING

[3]
[11]
[10] GEAR CASE
SHIFT ROD
TUBE JOINT GROMMET

[9]
SPEED SENSOR
TUBE C

[8]
SENSOR NIPPLE

[7]
[4]
6 x 12 mm
RUBBER SETTING
HEX. BOLT
PLATE

[6]
[5]
PIVOT WASHER
WIRE BAND (2)
Do not reuse.

14-11
c. ASSEMBLY
1) Apply soapy water to the circumference of the 12 x 21 x 6 [1] <Water seal installation
mm water seals. direction>

2) Drive the 12 x 21 x 6 mm water seals one by one in the shift

rod holder using the special tools. Note the installation
direction of the water seals.
Be sure to apply grease to the water seal mating surfaces [2]
before installation. 12 x 21 x 6 mm
WATER SEALS
TOOLS: [3]
(Apply grease to the
Driver 07749-0010000
water seal mating
Oil seal driver attachment, 21 mm 07947-ZV00100 surfaces and the lips.)

3) After installing the water seals, apply grease to the water

seal lips.
[4]
DRIVER
07749-0010000

[5]
OIL SEAL DRIVER
[6] ATTACHMENT,
SHIFT ROD 21 mm
HOLDER 07947-ZV00100

4) Position the 10 mm E-ring, 12 mm washer and the shift rod

spring on the shift rod. [2]
SHIFT ROD SPRING
[1] [3]
10 mm 12 mm
E-RING WASHER

[4]
SHIFT ROD

14-12
5) Install the shift rod by aligning the shift cam of the shift rod
[1] CUTOUT [2] No mark in the shift
with the groove in the shift slider so that the cutout of the rod end.
shift rod spline faces in the cruising direction.

NOTICE
• Check that there is no marking in the shift rod end.
• If the shift cam is in alignment with the groove in the shift
slider but the cutout of the spline is not in the cruising [4]
direction, see the step 3 on page 14-5 and adjust CRUISING
accordingly. DIRECTION
[3]
SHIFT ROD
[1] [4]
<LC, XC, LD and XD types> <XCC, LCD and XCD types>
[2] [5]
[3] NO MARK [3] MARK [3]
SHIFT ROD SHIFT ROD SHIFT ROD

[5]
SHIFT CAM

[6]
GROOVE IN SHIFT
SLIDER

6) Apply grease to the circumference of the new 55.6 x 3.5

mm O-ring and install it on the shift rod holder. [2] SHIFT ROD
HOLDER

[1]
55.6 x 3.5 mm
O-RING

7) Install the shift rod holder aligning the projection with the [1] [2] PROJECTION
concave in the gear case and tighten with the pivot washer SHIFT ROD
and the 6 x 12 mm hex. bolt. [3] 6 x 12 mm
HOLDER HEX. BOLT
After installation, check that the cutout of the shift rod
spline faces in the cruising direction. [4] PIVOT
WASHER
[5]
CONCAVE

14-13
8) Apply soapy water to the circumference of the 23 x 36 x 6
[1] 23 x 36 x 6 mm [2] <Water seal installation
mm water seals.
WATER SEALS direction>
9) Drive the 23 x 36 x 6 mm water seals one by one in the
water seal housing using the special tools. Note the
installation direction of the water seals.
Be sure to apply grease to the water seal mating surfaces
before installation.
[3]
TOOLS: (Apply grease to the
Driver 07749-0010000 water seal mating
Attachment, 32 x 35 mm 07746-0010100 surfaces and the lips.)
[4]
DRIVER
10) After installing the water seals, apply grease to the water 07749-0010000
seal lips.

[5]
ATTACHMENT,
32 x 35 mm
[6] 07746-0010100
WATER SEAL
HOUSING

11) Apply grease to the circumference of the new 58.5 x 3.5

mm O-ring and position it on the water seal housing. 6 x 20
[1]
WATER SEAL
12) Install the water seal housing so that the concave faces in HOUSING
the cruising direction, and tighten it with the two 6 x 20 mm
flange bolts.

[4]
VERTICAL
SHAFT

[2]
CONCAVE

[3]
58.5 x 3.5 mm
O-RING

14-14
13) Apply grease to the inner wall of the water pump liner. [2] WOODRUFF KEY
Install the pump impeller in the water pump liner with the [1] INSTALLATION GROOVE
woodruff key installation groove facing up and the pump (Apply grease [3] [2] WOODRUFF KEY
impeller fins in the direction shown. to the inside.) PUMP INSTALLATION
Be sure to align the hole in the pump liner with the hole in IMPELLER GROOVE
the pump impeller.

[4]
WATER PUMP LINER

14) Install the water pump liner in the impeller housing by [2]
aligning the two projections on the pump liner with the two [1] [3] CONCAVES
PROJECTIONS
grooves inside the impeller housing. “A” POINT
Be sure that the part “A” of the water pump liner is in
alignment with the part “B” of the impeller housing, too.

15) Apply grease to the circumference of the new water pump

O-ring and install it on the impeller housing.

[6] [5] [4]

WATER PUMP IMPELLER “B” POINT
LINER HOUSING

16) Install the rubber setting plate, gear case grommet, two
dowel pins, new impeller gasket and the impeller cover. [2]
IMPELLER
[1] COVER
IMPELLER [3]
GASKET GEAR CASE
GROMMET

[5]
6 x 10 mm
DOWEL PIN (2)

[4]
RUBBER SETTING
PLATE

14-15
17) Install the woodruff key in the groove in the vertical shaft.
Align the groove in the pump impeller with the woodruff
key and install the impeller housing by turning it clockwise.
[2]
NOTICE WOODRUFF KEY
• Turn the impeller housing clockwise when it is turned
with the pump impeller mounted. [1]
• After installing the impeller housing, check that the VERTICAL
impeller cover and the impeller gasket are set in the SHAFT
proper position.

[3]
GROOVE IN
[4] PUMP IMPELLER
[5] IMPELLER
GROOVE HOUSING

18) Install the four distance collars on the impeller housing,

and tighten the four 8 mm washers and the four 8 x 40 mm
hex. bolts to the specified torque.

TORQUE: 19.7 N.m (2.0 kgf.m, 14 lbf.ft) [2] WATER TUBE

[1] SEAL RING
19) Apply grease to the inner wall of the water tube seal ring. SPEED SENSOR
TUBE C [3]
Install the water tube seal ring aligning the projection with 8 x 40 mm
the hole in the housing. HEX. BOLT (4)

20) Install the speed sensor tube C. [4]

8 mm WASHER (4)
21) Install the following parts. [5]
– Gear case assembly (P. 14-5) DISTANCE
– Propeller (14-2) COLLAR (4)

[6]
IMPELLER
HOUSING

14-16
4. PROPELLER SHAFT HOLDER
ASSEMBLY [*1]
[2] PROPELLER SHAFT
a. REMOVAL/INSTALLATION HOLDER ASSEMBLY
Remove the following parts.
– Propeller (P. 14-2)
– Gear case assembly (P. 14-3)
– Water pump/shift rod (P. 14-7) [1]
1) Remove the two 10 mm washers and the two 10 x 40 mm RECESS
flange bolts.
2) Insert a screwdriver or equivalent tool into the recess in the
propeller shaft holder and remove the propeller shaft
holder assembly from the gear case.

Installation is the reverse order of removal.

[2]
PROPELLER SHAFT
HOLDER ASSEMBLY

[3]
10 mm WASHER (2)

[1]
GEAR CASE ASSEMBLY

10 x 40 (2)
34 N.m (3.5 kgf.m, 25 lbf.ft)

14-17
5. PROPELLER SHAFT/PROPELLER [1] [2]
8 x 47 mm CLUTCH
SHAFT HOLDER [*1] SHIFTER PIN SHIFTER

a. DISASSEMBLY
Remove the following parts.
– Propeller (P. 14-2)
– Gear case assembly (P. 14-3)
– Water pump/shift rod (P. 14-7)
– Propeller shaft holder assembly (P. 14-17)
1) Remove the cross pin ring and the 8 x 47 mm shifter pin,
then remove the clutch shifter.

[3]
CROSS PIN
RING

2) Remove the shift slider assembly and the two #7 steel balls
from the propeller shaft. Take care not to lose the steel [2]
balls. SHIFT SLIDER
ASSEMBLY

[1]
PROPELLER
SHAFT

[3]
#7 STEEL
BALL (2)

3) Remove the 14 mm circlip from the shift slider assembly.

[1]
SHIFT SLIDER
ASSEMBLY

[2]
14 mm CIRCLIP

14-18
4) Remove the 3 x 12.8 mm roller from the shift slider
assembly using a commercially available pin driver. [1]
3 x 12.8 mm
ROLLER

[2]
SHIFT SLIDER
ASSEMBLY

5) Remove the shift plate from the shift slider, then remove
the two shift springs and the two #9 steel balls. [2]
#9 STEEL BALLS
NOTICE
[1]
Take care not to let the shift springs and the #9 steel balls SHIFT SLIDER
pop out of the shift slider during removal of the shift plate.

[3]
SHIFT PLATE
[4]
SHIFT SPRINGS

6) Remove the reverse bevel gear/bearing assembly and the

propeller shaft from the propeller shaft holder using the
hydraulic press as shown. [2]
[1] PROPELLER
PROPELLER SHAFT
SHAFT HOLDER

[3]
HYDRAULIC
PRESS TABLE

[4]
REVERSE BEVEL
GEAR/BEARING
ASSEMBLY

14-19
7) Before removing the bearing, check the bearing for
abnormal sound and play. Replace if necessary.

8) Install a commercially available universal bearing puller [1]

[2]
between the reverse bevel gear and the bearing. DRIVER
ATTACHMENT, 27.2
07749-0010000
07747-0010300
9) Remove the bearing from the reverse bevel gear using the
special tools as shown. [5]
UNIVERSAL
Replace the bearing with a new one on assembly.
BEARING PULLER
(Commercially
TOOLS: available)
Driver 07749-0010000
Attachment, 27.2 07747-0010300
Pilot, 35 mm 07746-0040800

[3]
50 x 90 x 20 mm
RADIAL BALL
[4] BEARING
PILOT, 35 mm
07746-0040800

10) Check the thrust bearing for abnormal sound and play.
[2] 105 x 3.1 mm
Replace if necessary. [1] O-RING
PROPELLER
11) Remove the thrust bearing, thrust bearing washer and the SHAFT HOLDER
105 x 3.1 mm O-ring from the propeller shaft holder.
Replace the O-ring with a new one on assembly.

[3]
THRUST
BEARING
[4]
THRUST BEARING
WASHER

12) Before removing the 30 x 45 x 7 mm water seals, check the

water seal lips for cut and other damage. Replace the water [1]
seals if necessary. 30 x 45 x 7 mm
WATER SEALS
13) Remove the two 30 x 45 x 7 mm water seals from the
propeller shaft holder using a commercially available oil
seal remover.
Replace the water seals with the new ones on assembly.

[2]
PROPELLER
SHAFT HOLDER

14-20
14) Check the needle bearing for abnormal sound and play
before removal. Replace the needle bearing if necessary.
[1]
15) Remove the needle bearing from the propeller shaft holder REMOVER WEIGHT
[2]
using the special tools as shown. 07741-0010201
REMOVER HANDLE
Replace the needle bearing with a new one on assembly. 07936-3710100

TOOLS:
Remover weight 07741-0010201
Remover handle 07936-3710100
Bearing remover, 30 mm 07936-8890300

[4]
PROPELLER [3]
SHAFT HOLDER BEARING REMOVER,
30 mm
07936-8890300

b. INSPECTION
• CLUTCH SHIFTER [1] CLUTCH PARTS
Check the clutch part of the forward and reverse sides for wear
and damage.

• PROPELLER SHAFT O.D.

[1]
STANDARD SERVICE LIMIT
AT FORWARD
At forward 24.987 – 25.000 mm 24.966 mm BEVEL GEAR
bevel gear (0.9837 – 0.9843 in) (0.9829 in)
At needle 30.007 – 30.020 mm 29.990 mm
bearing (1.1814 – 1.1819 in) (1.1807 in)

[2]
AT NEEDLE
BEARING

14-21
c. COMPONENTS DRAWING
[7]
[6]
14 mm CIRCLIP
[3] 3 x 12.8 mm
CROSS PIN RING ROLLER [9]
[2] SHIFT SPRING (2)
[4]
8 x 47 mm SHIFT
SHIFTER PIN SLIDER

[10]
[1] SHIFT PLATE
CLUTCH SHIFTER
[8]
#9 STEEL BALLS

[5]
#7 STEEL
BALL (2)

[19]
PROPELLER SHAFT [11]
REVERSE
BEVEL GEAR

[12]
50 x 90 x 20 mm
RADIAL BALL
BEARING

[13]
THRUST
BEARING

[14]
THRUST BEARING
WASHER
[15]
105 x 3.1 mm
O-RING
[16]
[17] PROPELLER
30 x 37 x 26 mm SHAFT HOLDER
NEEDLE BEARING
[18]
30 x 45 x 7 mm
WATER SEAL (2)

14-22
d. ASSEMBLY
1) Apply gear oil to the circumference of the new needle
bearing. [1]
[2]
ATTACHMENT,
OUTER DRIVER
2) Install the needle bearing on the propeller shaft holder 62 x 68 mm
ATTACHMENT,
using the special tools and the hydraulic press. 07746-0010500
30 x 37
070PD-ZY60200
TOOLS:
Attachment, 62 x 68 mm 07746-0010500
Outer driver attachment, 30 x 37 070PD-ZY60200

NOTICE
Install the needle bearing with the stamped side toward the
special tools.

[3]
[4] 30 x 37 x 26 mm
PROPELLER NEEDLE BEARING
SHAFT HOLDER

3) Apply soapy water to the circumference of the new 30 x 45

x 7 mm water seals. [1] 30 x 45 x 7 mm [2] <Water seal installation
WATER SEALS direction>
4) Drive the 30 x 45 x 7 mm water seals one by one into the
propeller shaft holder using the special tool. Note the
installation direction of the water seals.
Apply grease to the water seal mating surfaces before
installation.

TOOL: [4]
[3]
Oil seal driver 07947-SB00100 OIL SEAL DRIVER
(Apply grease to the
07947-SB00100
water seal mating
5) After installation of the water seals, apply grease to the surfaces and the lips.)
water seal lips.

[5]
PROPELLER
SHAFT HOLDER

14-23
6) Apply gear oil to the circumference of the new bearing.

7) Install the bearing on the revere bevel gear using the

[1] [2]
special tools and the hydraulic press.
DRIVER ATTACHMENT,
07749-0010000 62 x 68 mm
TOOLS: 07746-0010500
Driver 07749-0010000
Attachment, 62 x 68 mm 07746-0010500
Pilot, 35 mm 07746-0040800 [5]
REVERSE BEVEL [3]
NOTICE GEAR PILOT, 35 mm
07746-0040800
Install the bearing holding the inner part of the bearing.
[4]
50 x 90 x 20 mm
RADIAL BALL
BEARING

8) Apply gear oil to the circumference of the thrust bearing.

9) Soak the propeller shaft holder in the container filled with [2]
[1] PROPELLER
oil with the reverse bevel gear/bearing assembly THERMOMETER SHAFT
installation side toward down. HOLDER
10) Heat the oil to 80 – 90˚C (176 – 194˚F).
11) Check that there is no groove at the spline of the propeller
installation side of the propeller shaft.

[1] [4]
<LC, XC, LD and XD types> <XCC, LCD and XCD types>
[2] No groove [5] Groove

[3]
Heat the oil to 80 – 90˚C
(176 – 194˚F).
[3] [3]
PROPELLER SHAFT PROPELLER SHAFT [4]
REVERSE BEVEL
GEAR/BEARING
12) After the entire of the propeller shaft holder becomes hot, ASSEMBLY
remove the holder from the container, and install the thrust [5]
bearing washer, thrust bearing, propeller shaft and the PROPELLER
reverse bevel gear/bearing assembly in this order quickly SHAFT
on the propeller shaft holder.
Note to install the thrust bearing water with the chamfered
side toward the holder. [8]
THRUST
NOTICE BEARING [6]
THRUST
• Do not heat the oil above 90˚C (194˚F). BEARING
• The entire holder becomes hot. Be sure to wear the WASHER
gloves during the operation.

13) Apply grease to the circumference of the new 105 x 3.1 mm

O-ring and install it on the propeller shaft holder.
[7]
NOTICE CHAMFER
[2]
Wait until the propeller shaft holder cools down before PROPELLER
installing the O-ring. SHAFT HOLDER

14-24
14) Install the shift spring, two #9 steel balls, shift spring and [2]
the shift plate in this order in the shift slider. 3 x 12.8 mm [3]
ROLLER SHIFT SPRINGS
15) Install the 3 x 12.8 mm roller while aligning the hole in the
shift slider with the hole in the shift plate, then install the 14 [1]
mm circlip. SHIFT SLIDER
[4]
SHIFT PLATE

[5]
[6] #9 STEEL BALLS
14 mm CIRCLIP

16) Set the #7 steel balls in the steel ball installation holes in
[2]
the shift slider assembly, then push the shift slider
SHIFT SLIDER
assembly slowly into the propeller shaft. [1] ASSEMBLY
PROPELLER
NOTICE SHAFT
Push the shift slider assembly into the propeller shaft with
care not to allow the #7 steel balls to pop out.

[3]
#7 STEEL BALL (2)

17) With the “F” mark on the clutch shifter toward the forward [2]
[1]
bevel gear (i.e. toward front), assemble the clutch shifter “F” MARK REVERSE BEVEL
with the propeller shaft while aligning the 8 x 47 mm shifter GEAR SIDE
pin installation hole with the long hole in the propeller
shaft.

[3]
FORWARD BEVEL
[4]
GEAR SIDE
SHIFTER PIN
INSTALLATION HOLE
[5]
LONG HOLE IN
PROPELLER SHAFT

[7]
CLUTCH SHIFTER
[6]
PROPELLER SHAFT

14-25
18) Install the 8 x 47 mm shifter pin while aligning the hole in
[2]
the clutch shifter with the hole in the shift slider. 8 x 47 mm
SHIFTER PIN
[1]
HOLE IN SHIFT
SLIDER [3]
SHIFT SLIDER

[5] [4]
HOLE IN CLUTCH CLUTCH SHIFTER
SHIFTER

19) Install the cross pin ring on the clutch shifter.

NOTICE [2]
CROSS PIN RING
Check that the coils of the cross pin ring do not overlap
each other. [1]
CLUTCH SHIFTER

20) Check that the #7 steel balls are set in the groove in the
propeller shaft securely as shown. [1] [3]
CLUTCH SHIFTER PROPELLER
Check procedure: [2] SHAFT
• Be sure that the clutch shifter is not at the reverse bevel GROOVE
gear installation side.
If it is at the reverse bevel gear installation side, pull up
the shift slider assembly slowly.
• Be sure that the #7 steel balls cannot be checked through
the gap between the propeller shaft and shift slider.
If the steel balls can be checked, push in the shift slider
assembly slowly again.

21) Install the following parts. [4]

SHIFT SLIDER
– Propeller shaft holder assembly (P. 14-17) [5]
– Water pump/shift rod (P. 14-12) #7 STEEL BALL (2)
– Gear case assembly (P. 14-5)
– Propeller (P. 14-2)

14-26
6. VERTICAL SHAFT/BEVEL GEAR [*1] [1]
VERTICAL SHAFT
a. DISASSEMBLY
Remove the following parts.
– Propeller (P. 14-2)
– Gear case assembly (P. 14-3)
– Water pump/shift rod (P. 14-7)
– Propeller shaft holder assembly (P. 14-17)
1) Attach the special tool to the end (crankshaft installation
side) of the vertical shaft. [2]
VERTICAL SHAFT [3]
HOLDER PINION GEAR
TOOL:
07SPB-ZW10200 NUT
Vertical shaft holder 07SPB-ZW10200

2) Place a shop towel or equivalent material as shown to

protect the gear case.

3) Holding the special tool, remove the pinion gear nut and
the pinion gear.

[5]
[4]
GEAR CASE
SHOP TOWEL

4) Remove the 64 mm lock nut using the special tool as

shown.
[1]
TOOL: LOCK NUT WRENCH,
Lock nut wrench, 30/64 mm 07916-MB00002 30/64 mm
07916-MB00002
5) Remove the vertical shaft assembly.

NOTICE
Take care not to drop the needle bearing (roller) when
removing the vertical shaft assembly.

6) Check the needle bearing for abnormal sound and play. If [1] FORWARD
there is abnormal sound and play, replace the roller and the BEVEL
outer race as a set. GEAR/TAPER
BEARING
7) Remove the needle bearing (roller). ASSEMBLY

8) Check the taper bearing (inner race) of the forward bevel

gear/taper bearing assembly for noise, play and other
abnormality. Replace together with the outer race as a set [2]
if necessary. NEEDLE
BEARING
9) Remove the forward bevel gear/taper bearing assembly. (ROLLER)

14-27
10) Check the taper bearing (outer race) for damage before
removing it. Replace together with the inner race as a set if [3]
FORWARD
necessary. [1] [2]
BEVEL
REMOVER BEARING RACE
GEAR SHIM
11) Remove the taper bearing (outer race) using the special WEIGHT PULLER
tools as shown. 07741-0010201 070PC-ZY3A100

TOOLS:
Remover weight 07741-0010201
Remover handle 07936-3710100
Bearing race puller 070PC-ZY3A100

12) Remove the forward bevel gear shim from the gear case.
Replace the forward bevel gear shim with a new one on
assembly.
[5] [4]
REMOVER HANDLE 50 x 90 x 28 mm
07936-3710100 TAPER BEARING
(OUTER RACE)

13) Remove the oil slinger from the vertical shaft by expanding
the cut in the oil slinger with a screwdriver.

[1]
OIL SLINGER

[2]
VERTICAL SHAFT

14) Check the taper roller bearing for noise, play and other
abnormality before removing it. Replace the inner race and
the outer race as a set if necessary. [2]
VERTICAL SHAFT
15) Set a commercially available universal bearing puller on
the taper roller bearing (inner race), and install the vertical
shaft on the hydraulic press with the crankshaft installation [1]
side toward up. 30 x 62 x 40 mm [3]
TAPER ROLLER UNIVERSAL
16) Remove the taper roller bearing from the vertical shaft BEARING BEARING PULLER
using the hydraulic press. (Commercially
available)
17) Remove the pinion gear shim from the vertical shaft.
Replace the pinion gear shim with a new one on assembly.

14-28
18) Check the needle bearing (outer race) in the gear case for
damage before removing it. Replace the needle bearing
(outer race) if necessary.

19) Attach the special tools to the needle bearing (outer race) [1]
and place a shop towel or equivalent material under the DRIVER HANDLE,
needle bearing (outer race) as shown. 15 x 280 mm
07949-3710001 [2]
TOOLS: BEARING DRIVER
Driver handle, 15 x 280 mm 07949-3710001 ATTACHMENT,
Bearing driver attachment, 37 mm 07ZMD-MBW0200 37 mm
Pilot, 35 mm 07746-0040800 07ZMD-MBW0200

20) Remove the needle bearing (outer race) from the gear case
using the special tools.

NOTICE [6]
• Remove the needle bearing (outer race) with care not to NEEDLE BEARING
(OUTER RACE)
damage the gear case.
• Replace the needle bearing (outer race) and the roller as
a set on assembly.

[3]
[5] GEAR CASE
PILOT, 35 mm [4]
07746-0040800 SHOP TOWEL

b. INSPECTION
• VERTICAL SHAFT O.D.
STANDARD SERVICE LIMIT
At needle 28.556 – 28.575 mm 28.545 mm
bearing (1.1242 – 1.1250 in) (1.1238 in)

[1]
AT NEEDLE
BEARING

14-29
c. COMPONENTS DRAWING

[1] [2]
VERTICAL SHAFT 64 mm LOCK NUT
123 N.m (12.5 kgf.m, 90 lbf.ft)

[3]
30 x 62 x 40 mm
TAPER ROLLER
BEARING
(INNER RACE)
[4]
30 x 62 x 40 mm
TAPER ROLLER
BEARING
(OUTER RACE)
[3]
30 x 62 x 40 mm
TAPER ROLLER
[16] BEARING
OIL SLINGER (INNER RACE)

[5]
PINION GEAR
SHIM

[15] *1 [6]
GEAR CASE FORWARD BEVEL
GEAR

[7]
50 x 90 x 28 mm
TAPER BEARING
(INNER RACE)
[8]
NEEDLE BEARING
(OUTER RACE)

[9]
NEEDLE BEARING
(ROLLER)
[12]
50 x 90 x 28 mm
TAPER BEARING [10]
[13] (OUTER RACE) PINION GEAR
FORWARD BEVEL
GEAR SHIM
[11]
[14] PINION GEAR NUT
*1: Replace the inner race and the outer race as a set
after removing the taper bearing (inner race) from 142 N.m (14.5 kgf.m, 105 lbf.ft)
the forward bevel gear.

14-30
d. ASSEMBLY
NOTICE [1] [2]
Measure the bearing height from the end of the taper bearing DRIVER OIL SEAL DRIVER,
outer race to the end of the inner race and record the 07749-0010000 52 x 55 mm
07NAD-P200100 or
measurement before installing the 50 x 90 x 28 mm taper
07NAD-P20A100
bearing on the forward bevel gear (P. 14-39).
[3]
[5] FORWARD
1) Apply gear oil to the inner wall and the roller of the new
50 x 90 x 28 mm BEVEL GEAR
taper bearing (inner race). TAPER BEARING
2) Position a wood block or equivalent material underside the (INNER RACE)
forward bevel gear.
3) Install the taper bearing on the forward bevel gear using
the special tools and the hydraulic press.

TOOLS:
Driver 07749-0010000 [4]
Oil seal driver, 52 x 55 mm 07NAD-P200100 WOOD BLOCK
or 07NAD-P20A100

4) Install the new forward bevel gear shim in the gear case.
[2]
FORWARD
5) Apply gear oil to the circumference of the taper bearing [1] BEVEL GEAR
(outer race). DRIVER HANDLE, SHIM
480 mm
6) Install the taper bearing (outer race) in the gear case using 070GD-0010100
the special tools as shown.

TOOLS:
Driver handle, 480 mm 070GD-0010100
Taper vearing installer attachment 070PF-ZY60100

NOTICE
Install the taper bearing (outer race) with the larger
diameter side toward the forward bevel gear. [3]
[4] 50 x 90 x 28 mm
TAPER BEARING TAPER BEARING
7) Install the forward bevel gear/taper bearing assembly in the INSTALLER ATTACHMENT (OUTER RACE)
gear case. 070PF-ZY60100

8) Install the pinion gear on the vertical shaft and loosely

[2]
tighten the pinion gear nut by hand.
VERTICALL
SHAFT
9) Apply gear oil to the inner wall of the inner race, roller and [1]
the circumference of the outer race of the taper roller DRIVER SHAFT, B
bearings. Assemble the inner races and outer race. 07964-MB00200

10) Install the pinion gear shim, taper roller bearing and the
special tool on the vertical shaft.
[3]
TOOL: 30 x 62 x 40 mm
TAPER ROLLER
Driver shaft, B 07964-MB00200
BEARING

14-31
11) Position the vertical shaft on the hydraulic press with the
pinion gear side facing up.
[2]
12) Install the taper roller bearing on the vertical shaft using the PINION GEAR
hydraulic press. NUT
[1]
VERTICAL [3]
NOTICE PINION
SHAFT
• Check that the ends of the special tool are set on the taper GEAR
roller bearing inner race and on the hydraulic press table
securely. [4]
• Do not ruin the threads at the end of the vertical shaft [8] PINION GEAR
(pinion gear nut installation part). 30 x 62 x 40 mm SHIM
TAPER ROLLER
BEARING
13) Remove the pinion gear nut and the pinion gear from the
vertical shaft.

[5]
Set securely.
[7]
DRIVER SHAFT, B
07964-MB00200

[6] HYDRAULIC
PRESS TABLE

14) Install the oil slinger on the vertical shaft aligning the
[2] PROJECTION
projection on the inside of the oil slinger with the concave [1]
of the pinion gear installation side of the vertical shaft. VERTICAL
SHAFT

[3]
CONCAVE
[4]
OIL SLINGER

15) Attach the special tool to the new needle bearing as shown.
Install the needle bearing with the stamped side of the [2]
needle bearing (outer race) toward the special tool. NEEDLE
[1] BEARING
TOOL: OIL SEAL DRIVER
Oil seal driver attachment, 27.5 x 44 mm 07948-9540000 ATTACHMENT,
27.5 x 44 mm
07948-9540000

14-32
16) Install the needle bearing in the gear case using the special
tools.

TOOLS: [1]
Shaft installer, 15 x 370 mm 07VMF-KZ30200 SHAFT INSTALLER,
15 x 370 mm [2]
Attachment, 78 x 90 mm 07GAD-SD40101
07VMF-KZ30200 ATTACHMENT,
Oil seal driver attachment, 27.5 x 44 mm 07948-9540000 78 x 90 mm
07GAD-SD40101
17) After installation, check that the bottom surface of the
needle bearing is flush with the bottom of the gear case.
Apply grease to the needle bearing roller.

[6]
NEEDLE
BEARING

[5]
(Apply grease
to the roller.)

[4] [3]
OIL SEAL DRIVER GEAR CASE
ATTACHMENT,
27.5 x 44 mm
07948-9540000

18) Install the vertical shaft assembly taking care not to bring
the needle bearing roller out of position.
[1]
19) Apply the thread locking agent to the threads and seat of LOCK NUT WRENCH,
the 64 mm lock nut, and tighten the lock nut using the 30/64 mm
special tool. 07916-MB00002

TOOL:
Lock nut wrench, 30/64 mm 07916-MB00002

TORQUE: 123 N.m (12.5 kgf.m, 90 lbf.ft)

14-33
20) Wipe the tapered part of the vertical shaft and pinion gear
[1]
with a shop towel and a degreasing cleaning solvent. VERTICAL SHAFT
21) Attach the special tool to the end (crankshaft installation
side) of the vertical shaft as shown.

TOOL:
Vertical shaft holder 07SPB-ZW10200

22) Place a shop towel in the gear case as shown to protect the
[2]
gear case.
VERTICAL SHAFT [3]
HOLDER PINION GEAR
23) Apply gear oil to the threads and seat of the pinion gear 07SPB-ZW10200 NUT
nut.

24) Install the pinion gear on the vertical shaft. Holding the
special tool in the position, tighten the pinion gear nut to
the specified torque.

TORQUE: 142 N.m (14.5 kgf.m, 105 lbf.ft)

NOTICE
Check that the forward bevel gear/taper bearing assembly
is set properly.

25) Install the following parts.

[5] [4]
– Propeller shaft holder assembly (P. 14-17) GEAR CASE SHOP TOWEL
– Water pump/shift rod (P. 14-12)
– Gear case assembly (P. 14-5)
– Propeller (P. 14-2)

14-34
7. SHIM SELECTION [*1] [1]
PINION GEAR
NUT [2]
NOTICE VERTICAL
Adjust the shim thickness after replacing the gear case, vertical SHAFT
shaft, bearing, taper bearing and the taper roller bearing.

a. PINION GEAR SHIM

Remove the taper roller bearing if it is mounted on the vertical
shaft (P. 14-28).
1) Wipe the tapered part of the vertical shaft and pinion gear [4]
with a shop towel and a degreasing cleaning solvent. PINION GEAR
[3]
2) Install the pinion gear on the vertical shaft and tighten the TAPERED PARTS
pinion gear nut to the specified torque.

TORQUE: 142 N.m (14.5 kgf.m, 105 lbf.ft)

[2]
NOTICE TAPER ROLLER
[1] BEARING SIDE
• Do not install the vertical shaft in the gear case. GAUGE ADAPTER,
• We recommend that you attach the special tool (vertical 110 mm
shaft holder) at the end of the vertical shaft to facilitate 070PJ-ZY30100
tightening of the pinion gear nut to the specified torque
(P. 14-34).

3) Do not confuse the pinion gear side and the taper roller
bearing side of the special tool.
[3]
Do not score and scratch the opposite side (measurement
PINION GEAR
side) from the side where the tool number is stamped. SIDE
TOOL:
Gauge adapter, 110 mm 070PJ-ZY30100
[1] [2] [3] MEASUREMENT
4) Holding the special tool with the side of the stamped tool Tool must not PINION SURFACES
number facing the opposite side from the pinion gear, be get on the nut. GEAR
sure that the tool of the pinion gear nut side is not set on
the nut.
Tighten the bolts by hand while pushing both tools toward
the pinion gear side.

NOTICE [6]
BOLT (2)
• Do not tighten the bolts with a tool.
[4]
• There must be no wobbling in the special tool. It must [5] TOOL NO.
securely set on the pinion gear. PINION GEAR STAMPED
NUT SURFACE

5) Set both tools on both sides of the flange of the vertical [1]
shaft with the side of the special tool stamped with the tool MEASUREMENT
number and the tapered part facing the opposite side from SURFACE
the pinion gear as shown. Tighten the bolts by hand.

NOTICE [2]
• Do not tighten the bolts with a tool. TOOL NO.
• There must be no wobbling in the special tool. It must STAMPED
securely set on the pinion gear. SURFACE
[3]
TAPERED
SURFACE
[4] BOLTS

14-35
6) Hold the vertical shaft upright (with the pinion gear toward
up) and secure the vertical shaft. [1]
DEPTH GAUGE
7) Set the commercially available depth gauge at the gauge (Commercially
adapter of the pinion gear side as shown. Measure the available)
vertical shaft length (distance D) and record it.
[2]
PINION GEAR

[3]
GAUGE ADAPTER,
110 mm
070PJ-ZY30100

8) Assemble the outer race and the inner race of the 30 x 62 x

[1] OUTER RACE
40 mm taper roller bearing, and turn the outer race two or
three turns.

9) Measure the bearing height from the outer race end to the [2]
inner race end as shown, and record the measurement. INNER RACE

10) Measure the height of the taper roller bearing outer race
[1] OUTER RACE
and record it.

14-36
11) Calculate the gap (distance E) between the outer race and
inner race using the measurements obtained in step 9 and
10 and the following formula.

Formula:
Bearing height – Outer race height = Gap (distance E)

Example:
When, bearing height from the outer race end to the inner
race end is 34.9 mm (1.37 in),
And, outer race height is 29.7 mm (1.17 in):

34.9 – 29.7 = 5.2

Therefore, the gap (distance E) is 5.2 mm (0.20 in).

12) Determine the calculation value using the vertical shaft

length (distance D) obtained in step 7 and the gap (distance
E) obtained in step 11 and the following formula.

Formula:
Vertical shaft length (distance D) + Gap (distance E) – 147.2
= Calculation value

Example:
When, vertical shaft length (distance D) is 141.8 mm (5.58
in),
And, gap (distance E) is 5.2 mm (0.20 in):

141.8 + 5.2 – 147.2= –0.20

Therefore, the calculation value is –0.20 mm (–0.008 in). [1]

GEAR CASE
13) Cross reference the calculation value and the engagement
mark located on the trim tab installation part of the gear
case, and select the shim of the appropriate thickness from
the shim selection table accordingly.

• Shim type table

[1] Shim type [2] Thickness
[3] Pinion gear shim A 0.10 mm (0.004 in) [2]
[4] Pinion gear shim B 0.15 mm (0.006 in) ENGAGEMENT
MARK
[5] Pinion gear shim C 0.30 mm (0.012 in)
[6] Pinion gear shim D 0.50 mm (0.020 in)

14-37
• Pinion gear shim selection table [3] Unit: mm (in)
[2] Calculation value
+0.41 (+0.0161) +0.35 (+0.014) +0.30 (+0.0118) +0.25 (+0.010) +0.20 (+0.008) +0.15 (+0.006) +0.10 (+0.004)
– – – – – – –
+0.35 (+0.014) +0.30 (+0.0118) +0.25 (+0.010) +0.20 (+0.008) +0.15 (+0.006) +0.10 (+0.004) +0.05 (+0.002)
F 0.30 (0.0118) 0.35 (0.014) 0.40 (0.0157) 0.45 (0.018) 0.50 (0.020) 0.55 (0.022) 0.60 (0.024)
[1] Engagement
mark on the

E 0.25 (0.010) 0.30 (0.0118) 0.35 (0.014) 0.40 (0.0157) 0.45 (0.018) 0.50 (0.020) 0.55 (0.022)
gear case

D 0.20 (0.008) 0.25 (0.010) 0.30 (0.0118) 0.35 (0.014) 0.40 (0.0157) 0.45 (0.018) 0.50 (0.020)
C 0.15 (0.006) 0.20 (0.008) 0.25 (0.010) 0.30 (0.0118) 0.35 (0.014) 0.40 (0.0157) 0.45 (0.018)
B 0.10 (0.004) 0.15 (0.006) 0.20 (0.008) 0.25 (0.010) 0.30 (0.0118) 0.35 (0.014) 0.40 (0.0157)
A 0.10 (0.004) 0.15 (0.006) 0.20 (0.008) 0.25 (0.010) 0.30 (0.0118) 0.35 (0.014)

[3] Unit: mm (in)

[2] Calculation value
+0.05 (+0.002) ±0 (±0.000) –0.05 (–0.002) –0.10 (–0.004) –0.15 (–0.006) –0.20 (–0.008) –0.25 (–0.010)
– – – – – – –
±0 (±0.000) –0.05 (–0.002) –0.10 (–0.004) –0.15 (–0.006) –0.20 (–0.008) –0.25 (–0.010) –0.31 (–0.0122)
F 0.65 (0.026) 0.70 (0.028) 0.75 (0.030) 0.80 (0.031) 0.85 (0.033) 0.90 (0.035) 0.95 (0.037)
[1] Engagement
mark on the

E 0.60 (0.024) 0.65 (0.026) 0.70 (0.028) 0.75 (0.030) 0.80 (0.031) 0.85 (0.033) 0.90 (0.035)
gear case

D 0.55 (0.022) 0.60 (0.024) 0.65 (0.026) 0.70 (0.028) 0.75 (0.030) 0.80 (0.031) 0.85 (0.033)
C 0.50 (0.020) 0.55 (0.022) 0.60 (0.024) 0.65 (0.026) 0.70 (0.028) 0.75 (0.030) 0.80 (0.031)
B 0.45 (0.018) 0.50 (0.020) 0.55 (0.022) 0.60 (0.024) 0.65 (0.026) 0.70 (0.028) 0.75 (0.030)
A 0.40 (0.0157) 0.45 (0.018) 0.50 (0.020) 0.55 (0.022) 0.60 (0.024) 0.65 (0.026) 0.70 (0.028)

• How to read shim selection table

When the engagement mark on the gear case is E and the calculation value is –0.20 mm (–0.008 in) or more, the shim
thickness is 0.80 mm (0.031 in).
When the calculation value is less than –0.20 mm (–0.008 in), the shim thickness is 0.85 mm (0.033 in). (See Shim
selection table above.)
[3] Unit: mm (in)
[2] Calculation value
+0.05 (+0.002) ±0 (±0.000) –0.05 (–0.002) –0.10 (–0.004) –0.15 (–0.006) –0.20 (–0.008) –0.25 (–0.010)
– – – – – – –
±0 (±0.000) –0.05 (–0.002) –0.10 (–0.004) –0.15 (–0.006) –0.20 (–0.008) –0.25 (–0.010) –0.31 (–0.0122)
F 0.65 (0.026) 0.70 (0.028) 0.75 (0.030) 0.80 (0.031) 0.85 (0.033) 0.90 (0.035) 0.95 (0.037)
[1] Engagement
mark on the

E 0.60 (0.024) 0.65 (0.026) 0.70 (0.028) 0.75 (0.030) 0.80 (0.031) 0.85 (0.033) 0.90 (0.035)
gear case

D 0.55 (0.022) 0.60 (0.024) 0.65 (0.026) 0.70 (0.028) 0.75 (0.030) 0.80 (0.031) 0.85 (0.033)
C 0.50 (0.020) 0.55 (0.022) 0.60 (0.024) 0.65 (0.026) 0.70 (0.028) 0.75 (0.030) 0.80 (0.031)
B 0.45 (0.018) 0.50 (0.020) 0.55 (0.022) 0.60 (0.024) 0.65 (0.026) 0.70 (0.028) 0.75 (0.030)
A 0.40 (0.0157) 0.45 (0.018) 0.50 (0.020) 0.55 (0.022) 0.60 (0.024) 0.65 (0.026) 0.70 (0.028)

• Shim combination
To obtain 0.75 mm (0.030 in) of shim thickness, combine three gear shim As and one gear shim B and one gear shim C,
or combine one gear shim A, one gear shim B and one gear shim D by referring to the shim type table.

14-38
b. FORWARD BEVEL GEAR SHIM
1) Assemble the outer race and the inner race of the new 50 x [1]
90 x 28 mm taper bearing, and turn the outer race two or OUTER RACE
three turns.
[2]
2) Measure the bearing height (distance F) from the outer race INNER RACE
end to the inner race end as shown, and record the
measurement.

3) Determine the calculation value using the bearing height

(distance F) and the following formula.

Formula:
Bearing height (distance F) – 28 = Calculation value

Example:
When bearing height (distance F) is 28.05 mm (1.104 in):

28.05 – 28 = 0.05

Therefore, the calculation value is 0.05 mm (0.002 in).

4) Cross reference the calculation value and the engagement [1]

mark located on the trim tab installation part of the gear GEAR CASE
case, and select the shim of the appropriate thickness from
the shim selection table accordingly.

• Shim type table

[1] Shim type [2] Thickness
[3] Forward bevel gear shim A 0.10 mm (0.004 in)
[4] Forward bevel gear shim B 0.15 mm (0.006 in)
[5] Forward bevel gear shim C 0.30 mm (0.012 in) [2]
[6] Forward bevel gear shim D 0.50 mm (0.020 in) EMGAGEMENT
MARK
• Pinion gear shim selection table [3] Unit: mm (in)
[2] Calculation value
+0.10 (+0.004) +0.05 (+0.002)
– –
+0.05 (+0.002) ±0 (±0.000)
1 0.40 (0.016) 0.45 (0.018)
[1] Engagement
mark on the

2 0.35 (0.014) 0.40 (0.016)

gear case

3 0.30 (0.012) 0.35 (0.014)

4 0.25 (0.010) 0.30 (0.012)
5 0.20 (0.008) 0.25 (0.010)
6 0.15 (0.006) 0.20 (0.008)

Refer to page 14-38 for the information on how to read the

shim selection table and shim combination.

14-39
8. SHIM POSITION [*1]

[1]
30 x 62 x 40 mm
TAPER ROLLER
BEARING
(INNER RACE)

[11]
30 x 62 x 40 mm
TAPER ROLLER
BEARING
(OUTER RACE)

[10]
PINION GEAR SHIM
SELECTION: P. 14-35
[9]
VERTICAL SHAFT

[8]
PINION GEAR
[7]
PINION GEAR NUT
142 N.m (14.5 kgf.m, 105 lbf.ft)
[2]
50 x 90 x 28 mm
TAPER BEARING
(INNER RACE)

[3]
FORWARD BEVEL
GEAR SHIM
SELECTION: P. 14-39
ADJUSTMENT: P. 14-41
[6] [5]
REVERSE BEVEL FORWARD BEVEL [4]
GEAR GEAR 50 x 90 x 28 mm
TAPER BEARING
(OUTER RACE)

14-40
9. BACKLASH ADJUSTMENT [*1]
a. FORWARD BEVEL GEAR BACKLASH [1]
Backlash adjustment must be made after adjustment of each PULLER BOLT
gear shim (P. 14-35). 07SPC-ZW0011Z
Install the parts except the water pump in the gear case (P. 14-
12, 17 and 31).
1) Hold the propeller shaft securely with the special tool as
shown, and tighten the puller bolt to the specified torque.

TOOLS: [2]
Puller jaws 07SPC-ZW0010Z PULLER JAWS
Puller bolt 07SPC-ZW0011Z 07SPC-ZW0010Z

TORQUE: 5 N.m (0.5 kgf.m, 3.6 lbf.ft)

Turn the vertical shaft five to ten turns clockwise to fit the
bevel gear bearing. [1]
BACKLASH [2]
INDICATOR BACKLASH
2) Attach the special tool to the vertical shaft as shown, and INDICATOR TOOL
ATTACHMENT
adjust the dial indicator so its needle is at the line “2” of the 07SPK-ZW10100 07SPJ-ZW0030Z
special tool (backlash indicator tool).

TOOLS: 90˚ 90˚

Backlash indicator tool 07SPJ-ZW0030Z
Backlash indicator attachment 07SPK-ZW10100
90˚ 90˚
3) Turn the vertical shaft lightly right and left and record the
dial indicator reading.
Measure the backlash at the four points (by turning the
vertical shaft 90˚) in the same manner.

NOTICE
Do not turn the propeller shaft when turning the vertical
shaft.

4) Obtain the forward bevel gear backlash using the dial

indicator runout and the following formula. [3]
[4]
VERTICAL DIAL INDICATOR
Formula: SHAFT Adjust the dial indicator needle at
Dial indicator runout ÷ 0.86 = Backlash line “2” of the backlash indicator
tool.
Example:
When dial indicator runout is 0.195 mm (0.0077 in):
0.195 ÷ 0.86 = 0.23
Therefore, the backlash is 0.23 mm (0.009 in).

0.10 – 0.30 mm
Standard value
(0.004 – 0.012 in)

5) If the backlash is too large, increase the forward bevel gear

shim thickness and recheck the backlash.
If the backlash it too small, reduce the forward bevel gear
shim thickness and recheck the backlash.

NOTICE
Use the special tool when 50 x 90 x 28 mm taper bearing
outer race is removed to adjust the backlash again (P. 14-
28).

14-41
10. GEAR CASE ASSEMBLY [*2] [1]
SPEED SENSOR
TUBE B
a. REMOVAL
1) Place the remote control lever in the “N” (Neutral) position.

2) Tilt up the outboard motor to the uppermost position.

3) Disconnect the speed sensor tube B and the speed sensor

tube C.

[2]
SPEED SENSOR
TUBE C

4) Remove the 10 x 32 mm hex. bolt and the 10 mm washer.

Remove the gear case cover from the gear case assembly.

[1]
GEAR CASE
COVER

[3] [2]
10 mm WASHER 10 x 32 mm
HEX. BOLT

5) Remove the seven 10 x 40 mm hex. bolts and the seven 10

[1]
mm washers, then remove the gear case assembly from 6 x 10 mm
the outboard motor. DOWEL PIN (2)

6) After removing the gear case assembly, lower the outboard

motor to the lowermost position. [2]
10 mm
WASHER (7)

[4]
GEAR CASE
ASSEMBLY

[3]
10 x 40 mm
HEX. BOLT (7)

14-42
7) Remove the shift rod A from the shift shaft A.

[2]
SHIFT
ROD A
[1]
SHIFT
SHAFT A

b. COMPONENTS DRAWING

[1]
SHIFT ROD A

[9]
VERTICAL SHAFT

[8]
6 x 10 mm [2]
DOWEL PIN (2) 10 mm WASHER (7)

[7] [3]
GEAR CASE 10 x 40 mm HEX. BOLT (7)
ASSEMBLY
34 N.m (3.5 kgf.m, 25 lbf.ft)

[4]
GEAR CASE COVER

[6] [5]
10 mm WASHER 10 x 32 mm HEX. BOLT

14-43
c. INSTALLATION [1]
1) Place the remote control lever in the “N” (Neutral) position. CUTOUT

2) Check that the shift rod of the gear case is in the “N”
(Neutral) position.

To check:
[3]
Check whether the cutout of the shift rod spline faces in the SHIFT ROD
direction shown. [It indicates that the shift rod is in the “N” [2] CRUISING
(Neutral) position.] DIRECTION

3) If the cutout of the spline is not in the direction shown,

protect the spline with a shop towel or equivalent material [2]
and turn the shift rod right and left with a wrench until the SHIFT ROD
cutout faces toward the specified direction. [1]
SHOP TOWEL

4) Tilt up the outboard motor to the uppermost position.

5) Apply grease to the spline of the shift rod A.
6) Install the shift rod A by aligning the projection of the shift
shaft A with the cutout in the spline of the shift rod A. Check
that the cutout in the spline of the shift rod A is toward the
cruising direction.

[3]
CUTOUT
[1]
SHIFT SHAFT A
[2]
PROJECTION [4] CRUISING
DIRECTION

[4]
CRUISING
DIRECTION

[5]
SHIFT ROD A

14-44
7) Apply grease to the vertical shaft spline and the shift rod
[2]
spline.
[1] VERTICAL
Apply grease to the water tube insertion part and to the SHAFT
inner wall of the water tube seal ring of the impeller WATER TUBE
housing. [3]
Apply grease to the inner wall of the vertical shaft bushing WATER TUBE
[XCC and XCD types only] (P. 14-90). SEAL RING

8) Install the two dowel pins. Aligning the water tube with the
water tube seal ring of the impeller housing, install the
vertical shaft and the crankshaft. Install the shift rod and [4]
shift rod A, too, by aligning the splines. 6 x 10 mm
DOWEL PIN (2)
9) Install the gear case assembly on the outboard motor. [7]
Loosely tighten the seven 10 mm washers and the seven 10 10 mm
x 40 mm hex. bolts. WASHER (7)

[6]
10 x 40 mm
HEX. BOLT (7) [5]
GEAR CASE
ASSEMBLY

10) Connect the speed sensor tube B and the speed sensor
[1] SPEED SENSOR
tube C. TUBE B

11) Lower the outboard motor to the lowermost position and

tighten the seven 10 x 40 mm hex. bolts to the specified
torque.

TORQUE: 34 N.m (3.5 kgf.m, 25 lbf.ft)

[2]
SPEED SENSOR
TUBE C

12) Position the gear case cover on the gear case assembly.
[1] GEAR CASE COVER
[2] “ ” MARKS
13) Install the gear case cover aligning the “ ” mark on the
gear case cover with the “ ” mark on the gear case.
Tighten the 10 mm washer and the 10 x 32 mm hex. bolt.

14) After installing the gear case assembly, adjust the shift
[3]
control cable (P. 3-25). 10 x 32 mm
HEX. BOLT

[4]
10 mm WASHER

14-45
11. WATER PUMP/SHIFT ROD [*2] [1]
[2]
WATER TUBE
SEAL RING 8 x 40 mm
a. DISASSEMBLY HEX. BOLT (4)
Remove the following parts. [8] [3]
– Propeller (P. 14-2) IMPELLER 8 mm
– Gear case assembly (P. 14-42) HOUSING WASHER (4)
1) Remove the speed sensor tube C. [7]
VERTICAL
2) Remove the water tube seal ring from the impeller housing. SHAFT

3) Remove the four 8 x 40 mm hex. bolts and the four 8 mm

washers from the impeller housing. Remove the impeller
housing. [4]
Remove the four distance collars from the impeller DISTANCE
housing. COLLAR (4)

4) Remove the woodruff key from the vertical shaft.

[5] WOODRUFF
KEY
[6]
SPEED SENSOR
TUBE C

5) Remove the impeller cover, impeller gasket, two dowel

pins, gear case grommet and the rubber setting plate. [1]
IMPELLER COVER
NOTICE [2]
Replace the impeller gasket with a new one on assembly. GEAR CASE
[5] GROMMET
IMPELLER
GASKET

[3] RUBBER SETTING

[4] PLATE
6 x 10 mm
DOWEL PIN (2)

14-46
6) Check the pump impeller for cracks, wear or damage from
overheating, and replace if necessary.

7) Remove the pump impeller, pump liner and the water

pump O-ring from the impeller housing.
Replace the O-ring with a new one on assembly.
[1]
IMPELLER [2]
HOUSING PUMP LINER

[3]
[4] PUMP IMPELLER
WATER PUMP
O-RING

8) Remove the two 6 x 20 mm flange bolts and remove the [1]

water seal housing. WATER SEAL
HOUSING 6 x 20 (2)
9) Remove the 58.5 x 3.5 mm O-ring from the water seal
housing.
Replace the O-ring with a new one on assembly.
[2]
58.5 x 3.5 mm
O-RING

10) Before removing the 23 x 36 x 6 mm water seal, check the

water seal lip for cut. Replace if necessary, [1] WATER SEAL
HOUSING
11) Remove the two 23 x 36 x 6 mm water seals from the water
seal housing using a commercially available oil seal
remover.
Replace the water seals with the new ones on assembly. [2]
23 x 36 x 6 mm
WATER SEAL

14-47
12) Remove the 6 x 12 mm hex. bolt and the pivot washer. [1]
Remove the shift rod holder and the shift rod assembly. SHIFT ROD
HOLDER
[2]
SHIFT ROD
ASSEMBLY
[3]
6 x 12 mm
HEX. BOLT

[4]
PIVOT
WASHER

13) Remove the shift rod spring, 12 mm washer and the 10 mm

E-ring from the shift rod. [2]
SHIFT ROD SPRING
[1] [3]
10 mm 12 mm
E-RING WASHER

[4]
SHIFT ROD

14) Check the 12 x 21 x 6 mm water seal lip for cut and replace
if necessary. [1] 12 x 21 x 6 mm
WATER SEAL
15) Remove the two 12 x 21 x 6 mm water seals from the shift
rod holder using a commercially available oil seal remover. [2]
SHIFT ROD
16) Remove the 55.6 x 3.5 mm O-ring from the shift rod holder. HOLDER

NOTICE
• Replace the 12 x 21 x 6 mm water seals with the new ones [3]
on assembly. 55.6 x 3.5 mm
• Replace the 55.6 x 3.5 mm O-ring with a new one on O-RING
assembly.

14-48
b. COMPONENTS DRAWING
[2] [3]
WATER TUBE 8 x 40 mm HEX. BOLT (4)
SEAL RING 19.7 N.m (2.0 kgf.m, 14 lbf.ft)

[4]
[1] 8 mm
IMPELLER HOUSING WASHER (4)

[5]
DISTANCE
COLLAR (4)
6 x 20 (2) [6]
WATER PUMP
O-RING
[16]
WATER SEAL
HOUSING
[7]
PUMP LINER

[15]
58.5 x 3.5 mm
O-RING [8]
PUMP IMPELLER

[14]
23 x 36 x 6 mm [9]
WATER SEAL (2) WOODRUFF KEY

[10]
IMPELLER COVER

[11]
IMPELLER GASKET

[12]
VERTICAL SHAFT

[13]
6 x 10 mm
DOWEL PIN (2)

14-49
 [1]
12 x 21 x 6 mm
WATER SEAL (2)
[2]
SHIFT ROD
HOLDER

[15]
55.6 x 3.5 mm O-RING

[14]
SHIFT ROD SPRING

[13]
12 mm WASHER

[12]
10 mm E-RING

[11] [3]
[10] GEAR CASE
SHIFT ROD
TUBE JOINT GROMMET

[9]
SPEED SENSOR
TUBE C

[8]
SENSOR NIPPLE

[7]
[4]
6 x 12 mm
RUBBER SETTING
HEX. BOLT
PLATE

[6]
[5]
PIVOT WASHER
WIRE BAND (2)
Do not reuse.

14-50
c. ASSEMBLY
1) Apply soapy water to the circumference of the 12 x 21 x 6 [1] <Water seal
mm water seals. installation direction>

2) Drive the 12 x 21 x 6 mm water seals one by one in the shift

rod holder using the special tools. Note the installation
direction of the water seals.
Be sure to apply grease to the water seal mating surfaces [2]
before installation. 12 x 21 x 6 mm
WATER SEALS
TOOLS: [3]
(Apply grease to
Driver 07749-0010000
the seal mating
Oil seal driver attachment, 21 mm 07947-ZV00100 surfaces and lips.)

3) After installing the water seals, apply grease to the water

seal lips.
[4]
DRIVER
07749-0010000

[5]
OIL SEAL DRIVER
[6] ATTACHMENT,
SHIFT ROD 21 mm
HOLDER 07947-ZV00100

4) Position the 10 mm E-ring, 12 mm washer and the shift rod

spring on the shift rod. [2]
SHIFT ROD SPRING
[1] [3]
10 mm 12 mm
E-RING WASHER

[4]
SHIFT ROD

14-51
5) Install the shift rod by aligning the shift cam of the shift rod [2] Mark in the shift
with the groove in the shift slider so that the cutout of the [1] CUTOUT
rod end.
shift rod spline faces in the cruising direction.

NOTICE
• Check for marking in the end of the shift rod.
• If the shift cam is in alignment with the groove in the shift
slider but the cutout of the spline is not in the cruising [4]
direction, see the step 3 on page 14-44 and adjust CRUISING
accordingly. DIRECTION [3]
SHIFT ROD
[1] [4]
<LC, XC, LD and XD types> <XCC, LCD and XCD types>
[2] NO MARK [5] MARK [3]
[3] [3]
SHIFT ROD SHIFT ROD
SHIFT ROD
[5]
CAM

[6]
GROOVE IN SHIFT SLIDER

6) Apply grease to the circumference of the new 55.6 x 3.5

mm O-ring and install it on the shift rod holder. [2] SHIFT ROD
HOLDR

[1]
55.6 x 3.5 mm
O-RING

7) Install the shift rod holder aligning the projection with the [2] PROJECTION
[1]
concave in the gear case and tighten it with the pivot SHIFT ROD
washer and the 6 x 12 mm hex. bolt. [3] 6 x 12 mm
HOLDER HEX. BOLT
After installation, check that the cutout of the shift rod
spline faces in the cruising direction. [4] PIVOT
WASHER
[5]
CONCAVE

14-52
8) Apply soapy water to the circumference of the 23 x 36 x 6
[1] 23 x 36 x 6 mm [2] <Water seal installation
mm water seals. WATER SEALS direction>
9) Drive the 23 x 36 x 6 mm water seals one by one in the
water seal housing using the special tools. Note the
installation direction of the water seals.
Be sure to apply grease to the water seal mating surfaces
before installation.
[3]
TOOLS: (Apply grease to
Driver 07749-0010000 the seal mating
Attachment, 32 x 35 mm 07746-0010100 [4] surfaces and lips.)
DRIVER
07749-0010000
10) After installing the water seals, apply grease to the water
seal lips.

[5]
ATTACHMENT,
32 x 35 mm
[6] 07746-0010100
WATER SEAL
HOUSING

11) Apply grease to the circumference of the new 58.5 x 3.5

mm O-ring and position it on the water seal housing. 6 x 20
[1]
WATER SEAL
12) Install the water seal housing so that the concave faces in HOUSING
the cruising direction, and tighten it with the two 6 x 20 mm
flange bolts.

[4]
VERTICAL
SHAFT

[2]
CONCAVE

[3]
58.5 x 3.5 mm
O-RING

14-53
13) Apply grease to the inner wall of the water pump liner. [2] WOODRUFF KEY
Install the pump impeller in the water pump liner with the [1] INSTALLATION GROOVE
woodruff key installation groove facing up and the pump (Apply grease [3] [2] WOODRUFF KEY
impeller fins in the direction shown. to the inside.) PUMP INSTALLATION
Be sure to align the hole in the pump liner with the hole in IMPELLER GROOVE
the pump impeller.

[4]
WATER PUMP LINER

14) Install the water pump liner in the impeller housing by [2]
aligning the two projections on the pump liner with the two [3] CONCAVES
[1] PROJECTIONS
grooves inside the impeller housing. “A” POINT

15) Be sure that the part “A” of the water pump liner is in
alignment with the part “B” of the impeller housing, too.

[6] [5] [4]

WATER PUMP IMPELLER “B” POINT
LINER HOUSING

16) Install the rubber setting plate, gear case grommet, two
dowel pins, new impeller gasket and the impeller cover.
[2]
[1] IMPELLER COVER
IMPELLER
GASKET [3]
GEAR CASE
GROMMET
[5]
6 x 10 mm
DOWEL PIN (2)

[4]
RUBBER SETTING
PLATE

14-54
17) Install the woodruff key in the groove in the vertical shaft.
Align the groove in the pump impeller with the woodruff
key and install the impeller housing by turning it clockwise.
[2]
NOTICE WOODRUFF KEY
• Turn the impeller housing clockwise when it is turned
with the pump impeller mounted.
• After installing the impeller housing, check that the [1]
impeller gasket is set in the proper position. VERTICAL SHAFT

[3]
GROOVE IN PUMP
[4] IMPELLER
[5] IMPELLER
GROOVE HOUSING

18) Improve the four distance collars on the impeller housing,

and tighten the four 8 mm washers and the four 8 x 40 mm
hex. bolts to the specified torque.
[2]
TORQUE: 19.7 N.m (2.0 kgf.m, 14 lbf.ft) [1] WATER TUBE
SPEED SENSOR SEAL RING
19) Apply grease to the inner wall of the water tube seal ring. TUBE C ASSEMBLY
(5 x 270 mm TUBE) [3]
Install the water tube seal ring aligning the projection with 8 x 40 mm
the hole in the housing. HEX. BOLT (4)

20) Install the speed sensor tube C assembly (5 x 270 mm [4]

tube). 8 mm WASHER (4)
[5]
21) Install the following parts. DISTANCE
– Gear case assembly (P. 14-44) COLLAR (4)
– Propeller (P. 14-2)

[6]
IMPELLER HOUSING

14-55
12. PROPELLER SHAFT HOLDER
ASSEMBLY [*2] [2] PROPELLER
SHAFT HOLDER
a. REMOVAL/INSTALLATION ASSEMBLY
Remove the following parts.
– Propeller (P. 14-2)
– Gear case assembly (P. 14-42)
– Water pump/shift rod (P. 14-46)
1) Remove the two 10 mm washers and the two 10 x 40 mm [1]
flange bolts. RECESSE
2) Insert a screwdriver or equivalent tool into the recess in the
propeller shaft holder and remove the propeller shaft
holder assembly from the gear case.

Installation is the reverse order of removal.

[2]
PROPELLER
SHAFT HOLDER
ASSEMBLY

[3]
10 mm WASHER (2)

[1]
GEAR CASE ASSEMBLY

10 x 40 (2)
34 N.m (3.5 kgf.m, 25 lbf.ft)

14-56
13. PROPELLER SHAFT/PROPELLER [1]
[2]
8 x 47 mm
SHAFT HOLDER [*2] SHIFTER PIN CLUTCH SHIFTER

a. DISASSEMBLY
Remove the following parts.
– Propeller (P. 14-2)
– Gear case assembly (P. 14-42)
– Water pump/shift rod (P. 14-46)
– Propeller shaft holder assembly (P. 14-56)
1) Remove the cross pin ring and the 8 x 47 mm shifter pin,
then remove the clutch shifter.

[3]
CROSS PIN
RING

2) Remove the shift slider assembly and the two #7 steel balls
from the propeller shaft. Take care not to lose the steel [2]
balls. SHIFT SLIDER
ASSEMBLY

[1]
PROPELLER
SHAFT

[3]
#7 STEEL BALL (2)

3) Remove the 14 mm circlip from the shift slider assembly.

[1]
SHIFT SLIDER
ASSEMBY

[2]
14 mm CIRCLIP

14-57
4) Remove the 3 x 12.8 mm roller from the shift slider
assembly using a commercially available pin driver.
[1]
3 x 12.8 mm ROLLER

[2]
SHIFT SLIDER
ASSEMBLY

5) Remove the shift plate from the shift slider, then remove
the two shift springs and the two #9 steel balls.

NOTICE [2]
Take care not to let the shift springs and the #9 steel balls #9 STEEL BALLS
pop out of the shift slider during removal of the shift plate.
[1]
SHIFT SLIDER

[3]
SHIFT PLATE
[4]
SHIFT SPRINGS

6) Prepare the fixing tool of the dimensions shown.

60 mm
(2.4 in) ø10 (0.4 in)
300 mm
(11.8 in)
ø35 (1.4 in)

30 mm ø10
(1.2 in) (0.4 in)
69.5 mm
(2.74 in)
69.5 mm
(2.74 in)

14-58
7) Position the propeller shaft holder assembly on the fixing
tool and secure the holder assembly with the bolt.
[1]
8) Hold the fixing tool with a vise. PIN SPANNER
WRENCH, 110 mm
9) Loosen the bearing holder using the special tool as shown. 07WAA-S1G0100

TOOL:
Pin spanner wrench, 110 mm 07WAA-S1G0100

10) Remove the bearing holder assembly from the propeller

shaft holder.

NOTICE
Avoid holding the propeller shaft holder directly in a vise.
Use the fixing tool to hold it in a vise.

[2]
PROPELLER
[3] SHAFT HOLDER
FIXING TOOL ASSEMBLY

11) Before removing the taper bearing (inner race), check the
inner race for abnormal sound and play. If there is any
abnormal sound or play in the inner race, replace the inner
race and the outer race as a set. [1]
DRIVER
12) Attach a commercially available universal bearing puller 07749-0010000
between the bearing holder and the forward bevel gear.

13) Remove the forward bevel gear from the taper bearing [2]
(inner race) using the special tools and the hydraulic press. [7] ATTACHMENT,
50 x 90 x 28 mm 27.2
TOOLS: TAPER BEARING 07747-0010300
Driver 07749-0010000 (INNER RACE)
Attachment, 27.2 07747-0010300 [3]
[6] UNIVERSAL
Pilot, 35 mm 07746-0040800
BEARING BEARING PULLER
HOLDER (Commercially
available)

[5] [4]
FORWARD BEVEL PILOT, 35 mm
GEAR 07746-0040800

14-59
14) Before removing the taper bearing (outer race), check the
outer race for damage. Replace the inner race and the outer
race as a set if necessary. [1] [2]
TAPER BEARING DRIVER
15) Remove the taper bearing (outer race) from the bearing DRIVER 07749-0010000
holder using the special tools and the hydraulic press. ATTACHMENT
070PD-ZY60100
TOOLS:
Driver 07749-0010000
Taper vearing driver attachment 070PD-ZY60100
[3]
16) Remove the shim from the bearing holder. BEARING
Replace the shim with a new one on assembly. HOLDER

17) Remove the thrust bearing washer and the propeller shaft
from the propeller shaft holder. [1]
PROPELLER
SHAFT HOLDER

[2]
THRUST BEARING
WASHER

[3]
PROPELLER SHAFT

18) Check the thrust bearing for abnormal sound and play. [2]
Replace if necessary. THRUST BEARING
[1] WASHER
19) Remove the thrust bearing, thrust bearing washer, shim PROPELLER
and the 105 x 3.1 mm O-ring from the propeller shaft SHAFT HOLDER
holder.

NOTICE [3] THRUST

• Replace the shim with a new one on assembly. BEARING
• Replace the 105 x 3.1 mm O-ring with a new one on [4]
assembly. THRUST SHIM
[5]
105 x 3.1 mm O-RING

20) Before removing the 30 x 45 x 7 mm water seals, check the

water seal lips for cut and replace if necessary. [1]
30 x 45 x 7 mm
WATER SEALS
21) Remove the two 30 x 45 x 7 mm water seals from the
propeller shaft holder using a commercially available oil
seal remover.
Replace the water seals with the new ones on assembly.

[2]
PROPELLER
SHAFT HOLDER

14-60
22) Check the needle bearing for abnormal sound and play
before removal. Replace the needle bearing if necessary.
[1]
23) Remove the needle bearing from the propeller shaft using REMOVER WEIGHT [2]
the special tools as shown. 07741-0010201 REMOVER HANDLE
Replace the needle bearing with a new one on assembly. 07936-3710100

TOOLS:
Remover weight 07741-0010201
Remover handle 07936-3710100
Bearing remover, 30 mm 07936-8890300

[4]
PROPELLER [3]
SHAFT HOLDER BEARING REMOVER,
30 mm
07936-8890300

b. INSPECTION
• CLUTCH SHIFTER [1] CLUTCH PARTS
Check the clutch part of the forward and reverse sides for wear
and damage

• PROPELLER SHAFT O.D.

[1]
STANDARD SERVICE LIMIT
AT REVERSE
At reverse 24.987 – 25.000 mm 24.966 mm BEVEL GEAR
bevel gear (0.9837 – 0.9843 in) (0.9829 in)
At needle 30.007 – 30.020 mm 29.990 mm
bearing (1.1814 – 1.1819 in) (1.1807 in)

[2] AT NEEDLE
BEARING

14-61
c. COMPONENTS DRAWING
[8]
[7]
14 mm CIRCLIP
[4] CROSS 3 x 12.8 mm
PIN RING ROLLER [10]
[3] [5] SHIFT SPRING (2)
8 x 47 mm SHIFT
SHIFTER PIN SLIDER
[2]
[1] CLUTCH [11]
FORWARD SHIFTER SHIFT PLATE
BEVEL GEAR
[9]
#9 STEEL BALLS

[6] [12]
#7 STEEL BALL (2) FORWARD BEVEL
GEAR SHIM

[13]
THRUST BEARING
WASHER

[24]
PROPELLER SHAFT

[23] [14]
50 x 90 x 28 mm BEARING HOLDER
TAPER BEARING
191 N.m (19.5 kgf.m,
(INNER RACE)
[15] 141 lbf.ft)
50 x 90 x 28 mm
TAPER BEARING
(OUTER RACE)

[16] THRUST
BEARING
[17]
THRUST BEARING
WASHER
[18]
THRUST SHIM
[19]
105 x 3.1 mm O-RING
[20]
PROPELLER SHAFT HOLDER
[21]
[22] 30 x 37 x 26 mm
30 x 45 x 7 mm NEEDLE BEARING
WATER SEAL (2)

14-62
d. ASSEMBLY
1) Apply gear oil to the circumference of the new needle
bearing.
[1]
ATTACHMENT, [2]
2) Install the needle bearing on the propeller shaft holder 62 x 68 mm OUTER DRIVER
using the special tools and the hydraulic press. 07746-0010500 ATTACHMENT,
30 x 37
TOOLS: 070PD-ZY60200
Attachment, 62 x 68 mm 07746-0010500
Outer driver attachment, 30 x 37 070PD-ZY60200

NOTICE
Install the needle bearing with the stamped side toward the
special tools.

[3]
[4] 30 x 37 x 26 mm
PROPELLER NEEDLE
SHAFT HOLDER BEARING

3) Apply soapy water to the circumference of the new 30 x 45

x 7 mm water seals. [1] 30 x 45 x 7 mm [2] <Water seal installation
WATER SEALS direction>
4) Drive the 30 x 45 x 7 mm water seals one by one into the
propeller shaft holder using the special tool. Note the
installation direction of the water seals.
Apply grease to the water seal mating surfaces before
installation.

TOOL: [4] [3]

Oil seal driver 07947-SB00100 OIL SEAL DRIVER (Apply grease to
07947-SB00100 the seal mating
5) After installation of the water seals, apply grease to the surfaces and lips.)
water seal lips.

[5]
PROPELLER
SHAFT HOLDER

14-63
6) Apply gear oil to the circumference of the new 105 x 3.1
mm O-ring and install it on the propeller shaft holder.

7) Install the new thrust shim on the propeller shaft holder. [2]
THRUST
[1] BEARING
8) Install the thrust bearing washer with the chamfered side CHAMFER
toward the thrust shim. [3]
[6]
THRUST BEARING
THRUST SHIM
9) Apply gear oil to the circumference of the thrust bearing WASHER
and install it on the thrust bearing washer.
[5]
105 x 3.1 mm
10) Check that there is the groove at the spline of the propeller O-RING [4] PROPELLER
installation side of the propeller shaft. SHAFT HOLDER

[1] [4]
<LC, XC, LD and XD types> <XCC, LCD and XCD types>
[2] THRUST BEARING
[2] No groove [5] Groove WASHER
[1]
PROPELLER
SHAFT HOLDER

[3] [3]
PROPELLER SHAFT PROPELLER SHAFT

[3]
11) Install the propeller shaft and the thrust bearing washer on
CHAMFER
the propeller shaft holder.
[4]
Install the thrust bearing washer with the chamfered side PROPELLER SHAFT
toward the flange of the propeller shaft.

12) Install the new shim on the bearing holder.

[1]
13) Apply gear oil to the circumference of the taper bearing FORWARD BEVEL
(outer race) and install it on the bearing holder. GEAR SHIM

NOTICE [3]
BEARING [2]
Install the taper bearing (outer race) with the smaller
HOLDER 50 x 90 x 28 mm
diameter side toward the shim. TAPER BEARING
(OUTER RACE)

14) Install the taper bearing (outer race) on the bearing holder
using the special tools and the hydraulic press as shown.
[1] [2]
TOOLS: DRIVER TAPER BEARING
Driver 07749-0010000 07749-0010000 INSTALLER
Taper bearing inataller attachment 070PF-ZY60100 [4] ATTACHMENT
50 x 90 x 28 mm 070PF-ZY60100
TAPER BEARING
(OUTER RACE) [3]
BEARING
HOLDER

14-64
15) Place the wood block under the forward bevel geaar.

16) Place the bearing holder assembly on the forward bevel

gear. [2]
[1] ATTACHMENT,
DRIVER 62 x 68 mm
17) Apply gear oil to the inner wall of the taper bearing inner
07749-0010000 07746-0010500
race and position it in the forward bevel gear.

18) Install the taper bearing inner race on the forward bevel
gear using the special tools and hydraulic press.

TOOLS: [6]
Driver 07749-0010000 50 x 90 x 28 mm
Attachment, 62 x 68 mm 07746-0010500 TAPER BEARING
(INNER RACE)
NOTICE
Install by applying gear oil between the inner and outer
races of the taper bearing.

[5]
BEARING [4]
HOLDER FORWARD [3]
ASSEMBLY BEVEL GEAR WOOD BLOCK

19) Apply gear oil to the threads and seat of the bearing holder
assembly.
[2]
20) Position the bearing holder assembly on the propeller PIN SPANNER
shaft. [1]
BEARING WRENCH, 110 mm
Loosely tighten the bearing holder assembly by hands 07WAA-S1G0100
HOLDER
against the propeller shaft holder. ASSEMBLY

21) Attach the fixing tool, that had been used during propeller
shaft/propeller shaft holder removal, on the propeller shaft
holder assembly and secure with the bolt.

22) Tighten the bearing holder to the specified torque using the
special tool as shown.

TOOL:
Pin spanner wrench, 110 mm 07WAA-S1G0100

TORQUE: 191 N.m (19.5 kgf.m, 141 lbf.ft)

NOTICE
Avoid holding the propeller shaft holder directly in a vise.
Use the fixing tool to hold it in a vise.
[3]
PROPELLER SHAFT
HOLDER ASSEMBLY
[4]
FIXING TOOL

14-65
23) Install the shift spring, two #9 steel balls, shift spring and [2]
the shift plate in this order in the shift slider. 3 x 12.8 mm [3]
ROLLER SHIFT SPRINGS
24) Install the 3 x 12.8 mm roller aligning the hole in the shift [1]
slider with the hole in the shift plate, then install the 14 mm SHIFT
circlip. SLIDER

[4]
SHIFT PLATE

[5]
[6] #9 STEEL BALLS
14 mm CIRCLIP

25) Set the #7 steel balls in the steel ball installation holes in
[2] SHIFT SLIDER
the shift slider assembly, and push the shift slider assembly
ASSEMBLY
slowly into the propeller shaft. [1]
PROPELLER
NOTICE SHAFT
Push the shift slider assembly into the propeller shaft with
care not to allow the #7 steel balls to pop out.

[3]
#7 STEEL BALL (2)

26) With the “F” mark on the clutch shifter toward the reverse
bevel gear (i.e. toward front), assemble the clutch shifter [1] “F” MARK [2] FORWARD BEVEL
with the propeller shaft while aligning the 8 x 47 mm shifter GEAR SIDE
pin installation hole with the long hole in the propeller
shaft.

[3]
REVERSE BEVEL
GEAR SIDE [4] SHIFTER PIN
INSTALLATION HOLE
[5]
LONG HOLE IN
PROPELLER SHAFT

[7]
CLUTCH SHIFTER
[6]
PROPELLER SHAFT

14-66
27) Install the 8 x 47 mm shifter pin while aligning the hole in
[2]
the clutch shifter with the hole in the shift slider.
8 x 47 mm
SHIFTER PIN
[1]
HOLE IN SHIFT
SLIDER [3]
SHIFT SLIDER

[5] [4]
HOLE IN CLUTCH CLUTCH SHIFTER
SHIFTER

28) Install the cross pin ring on the clutch shifter.

NOTICE [2]
CROSS PIN RING
Check that the coils of the cross pin ring do not overlap
each other. [1]
CLUTCH SHIFTER

29) Check that the #7 steel balls are set in the groove in the
propeller shaft securely as shown. [1] [3]
CLUTCH SHIFTER PROPELLER
Check procedure: SHAFT
[2]
• Be sure that the clutch shifter is not at the forward bevel GROOVE
gear installation side.
If it is at the forward bevel gear installation side, pull up
the shift slider assembly slowly.
• Be sure that the #7 steel balls cannot be checked through
the gap between the propeller shaft and shift slider.
If the steel balls can be checked, push in the shift slider
assembly slowly again.
[4]
30) Install the following parts.
SHIFT SLIDER
– Propeller shaft holder assembly (P. 14-56) [5]
– Water pump/shift rod (P. 14-51) #7 STEEL BALL (2)
– Gear case assembly (P. 14-44)
– Propeller (P. 14-2)

14-67
14. VERTICAL SHAFT/BEVEL [1]
GEAR [*2] VERTICAL SHAFT

a. DISASSEMBLY
Remove the following pars.
– Propeller (P. 14-2)
– Gear case assembly (P. 14-42)
– Water pump/shift rod (P. 14-46)
– Propeller shaft holder assembly (P. 14-56)
1) Attach the special tool to the end (crankshaft installation
side) of the vertical shaft.

TOOL:
Vertical shaft holder 07SPB-ZW10200 [2]
VERTICAL SHAFT
2) Place a shop towel or equivalent material as shown to HOLDER
protect the gear case. 07SPB-ZW10200 [3]
PINION GEAR
3) Holding the special tool, remove the pinion gear nut and NUT
the pinion gear.

[5] [4]
GEAR CASE SHOP TOWEL

4) Remove the 64 mm lock nut using the special tool as

shown.

TOOL: [1]
Lock nut wrench, 30/64 mm 07916-MB00002 LOCK NUT WRENCH,
30/64 mm
07916-MB00002
5) Remove the vertical shaft assembly.

NOTICE
Take care not to drop the needle bearing (roller) when
removing the vertical shaft assembly.

14-68
6) Check the needle bearing for abnormal sound and play.
Replace the roller and the outer race as a set if necessary.

7) Remove the needle bearing (roller).

[1]
NEEDLED BEARING
(ROLLER)

8) Replace the puller jaws of the special tool as shown.

TOOLS:
Bearing race puller 070PC-ZY3A100 [1]
PULLER JAWS, 25 mm
Puller jaws, 25 mm 07WPC-ZW50100
07WPC-ZW50100
(Replacement tool)

[2]
BEARING RACE
PULLER
070PC-ZY3A100
[3]
Removed tool

9) Remove the reverse bevel gear using the special tools with
the new puller jaws replaced in step 8 as shown.
[1] [2] [3]
REMOVER BEARING RACE REVERSE
TOOLS:
WEIGHT PULLER BEVEL GEAR
Remover weight 07741-0010201
Remover handle 07936-3710100 07741-0010201 070PC-ZY3A100
Bearing race puller 070PC-ZY3A100
Puller jaws, 25 mm 07WPC-ZW50100

[5] [4]
REMOVER HANDLE PULLER JAWS, 25 mm
07936-3710100 07WPC-ZW50100

14-69
10) Check the bearing for abnormal noise and play before
removal. Replace if necessary. [3]
[1] [2] 50 x 90 x 20 mm
11) Remove the 50 x 90 x 20 mm radial ball bearing using the REMOVER BEARING RACE RADIAL BALL
special tools as shown. WEIGHT PULLER BEARING
07741-0010201 070PC-ZY3A100
TOOLS:
Remover weight 07741-0010201
Remover handle 07936-3710100
Bearing race puller 070PC-ZY3A100
Puller jaws, 25 mm 07WPC-ZW50100

12) Remove the reverse bevel gear shim from the gear case.

NOTICE [4]
[6] [5]
• Replace the 50 x 90 x 20 mm radial ball bearing with a REVERSE
REMOVER PULLER JAWS,
new one on assembly. BEVEL
HANDLE 25 mm
• Replace the reverse bevel gear shim on assembly. GEAR SHIM
07936-3710100 07WPC-ZW50100

13) Remove the oil slinger from the vertical shaft expanding
the cut in the oil slinger using a screwdriver.

[1]
OIL SLINGER

[2]
VERTICAL SHAFT

14) Check the taper roller bearing for noise, play and other
abnormality before removing it. Replace the inner race and [2]
the outer race as a set if necessary. VERTICAL
SHAFT
15) Position a commercially available universal bearing puller
on the taper roller bearing (inner race), and position the
vertical shaft on the hydraulic press with the crankshaft [1]
installation side toward up. 30 x 62 x 40 mm [3]
TAPER ROLLER UNIVERSAL
16) Remove the taper roller bearing from the vertical shaft BEARING BEARING PULLER
using the hydraulic press. (Commercially
available)
17) Remove the shim from the vertical shaft.
Replace the shim with a new one on assembly.

14-70
18) Check the needle bearing (outer race) for damage before
removal. Replace if necessary.

19) Position the special tools on the needle bearing (outer race)
and the shop towel under the needle bearing (outer race) as [1]
shown. DRIVER HANDLE,
15 x 280 mm
TOOLS: 07949-3710001 [2]
Driver handle, 15 x 280 mm 07949-3710001 BEARING DRIVER
Bearing driver attachment, 37 mm 07ZMD-MBW0200 ATTACHMENT,
37 mm
Pilot, 35 mm 07746-0040800
07ZMD-MBW0200
20) Remove the needle bearing (outer race) from the gear case
using the special tools.

NOTICE
• Remove the needle bearing (outer race) with care not to [6]
damage the gear case. NEEDLE BEARING
• Replace the needle bearing (outer race) and the roller as (OUTER RACE)
a set on assembly.

[3]
[5] GEAR CASE
PILOT, 35 mm [4]
07746-0040800 SHOP TOWEL

b. INSPECTION
• VERTICAL SHAFT O.D.
STANDARD SERVICE LIMIT
At needle 28.556 – 28.575 mm 28.545 mm
bearing (1.1242 – 1.1250 in) (1.1238 in)

[1]
AT NEEDLE
BEARING

14-71
c. COMPONENTS DRAWING

[1] [2]
VERTICAL SHAFT 64 mm LOCK NUT
123 N.m (12.5 kgf.m, 90 lbf.ft)

[3]
30 x 62 x 40 mm
TAPER ROLLER
BEARING
(INNER RACE)

[4]
30 x 62 x 40 mm
TAPER ROLLER
BEARING
(OUTER RACE)

[3]
30 x 62 x 40 mm
TAPER ROLLER
[14] BEARING
OIL SLINGER (INNER RACE)

[5]
PINION GEAR SHIM

[6]
REVERSE BEVEL
GEAR
[13]
GEAR CASE

[7]
NEEDLE BEARING
(OUTER RACE)

[8]
NEEDLE BEARING
(ROLLER)

[9]
PINION GEAR
[11]
50 x 90 x 20 mm
RADIAL BALL
[12] BEARING
REVERSE BEVEL
GEAR SHIM [10]
PINION GEAR NUT
142 N.m (14.5 kgf.m, 105 lbf.ft)

14-72
d. ASSEMBLY
1) Apply gear oil to the circumference of the new bearing.
[1]
2) Place a wood block under the reverse bevel gear. OIL SEAL DRIVER,
65 mm [2]
07JAD-PL90100 or 50 x 90 x 20 mm
3) Install the bearing on the reverse bevel gear using the 07JAD-PL9A100 RADIAL BALL
special tool and the hydraulic press. BEARING
[4]
TOOL: REVERSE BEVEL
Oil seal driver, 65 mm 07JAD-PL90100 GEAR
or 07JAD-PL9A100

[3]
WOOD BLOCK

4) Soak the gear case in the container filled with oil with the
[1] [2]
bearing installation side toward down.
THEMOMETER GEAR CASE
5) Heat the oil to 80 – 90˚C (176 – 194˚F).

6) After the entire of the bearing installation side of the gear

case becomes hot, remove the gear case from the
container and install the bevel gear shim and the reverse
bevel gear/bearing assembly on the gear case quickly.

NOTICE
• Do not heat the oil above 90˚C (194˚F).
• The entire gear case becomes hot. Be sure to wear the
gloves during the operation.
• Do not apply the force of 8,829 N (900 kgf, 1984 lbf) or
above during installation.
[3]
Heat the oil to 80 – 90˚C [5]
(176 – 194˚F). REVERSE BEVEL
[4] GEAR/BEARING
REVERSE BEVEL ASSEMBLY
GEAR SHIM

[6]
GEAR CASE

14-73
7) Position the pinion gear on the vertical shaft and loosely
tighten the pinion gear nut by hand.

8) Apply gear oil to the inner wall of the inner race, roller and [2]
the circumference of the outer race of the taper roller VERTICAL
bearings. Assemble the inner race and the outer race. SHAFT

9) Position the shim, taper roller bearing and the special tool [1]
on the vertical shaft. DRIVER SHAFT, B
07964-MB00200
TOOL:
Driver shaft, B 07964-MB00200

[3]
30 x 62 x 40 mm
TAPER ROLLER
BEARING

10) Position the vertical shaft on the hydraulic press with the
pinion gear toward up as shown.
[2]
11) Install the taper roller bearing on the vertical shaft using the PINION GEAR
hydraulic press. NUT
[1] [3]
NOTICE VERTICAL PINION
• Check that the ends of the special tool are set on the taper SHAFT GEAR
roller bearing inner race and the hydraulic press table
securely. [4]
• Do not ruin the threads at the end of the vertical shaft [8] PINION GEAR
(pinion gear nut installation part). 30 x 62 x 40 mm SHIM
TAPER ROLLER
BEARING
12) Remove the pinion gear nut and the pinion gear from the
vertical shaft.

[5]
Set securely.
[7]
DRIVER SHAFT, B
07964-MB00200

[6] HYDRAULIC
PRESS TABLE

14-74
13) Install the oil slinger on the vertical shaft aligning the
[2] PROJECTION
projection on the inside of the oil slinger with the recess of
[1]
the pinion gear installation side of the vertical shaft.
VERTICAL SHAFT

[3]
CONCAVE
[4]
OIL SLINGER

14) Attach the special tool to the new needle bearing as shown.
Install the needle bearing with the stamped side of the [2]
needle bearing (outer race) toward the special tool. NEEDLE
[1] BEARING
TOOL: OIL SEAL DRIVER
Oil seal driver attachment, 27.5 x 44 mm 07948-9540000 ATTACHMENT,
27.5 x 44 mm
07948-9540000

15) Install the needle bearing in the gear case using the special
tools.
[1] [2]
TOOLS: SHAFT INSTALLER, ATTACHMENT,
Shaft installer, 15 x 370 mm 07VMF-KZ30200 15 x 370 mm 78 x 90 mm
Attachment, 78 x 90 mm 07GAD-SD40101 07VMF-KZ30200 07GAD-SD40101
Oil seal driver attachment, 27.5 x 44 mm 07948-9540000

16) After installation, check that the bottom surface of the

needle bearing is flush with the bottom of the gear case.
Apply grease to the needle bearing roller.

[6]
(Apply grease
to the roller.)

[5]
NEEDLE
BEARING

[4]
OIL SEAL DRIVER
ATTACHMENT,
27.5 x 44 mm
07948-9540000 [3]
GEAR CASE

14-75
17) Install the vertical shaft assembly with care not to let the
needle bearing roller come out of position.
[1]
18) Apply gear oil to the threads and seat of the 64 mm lock LOCK NUT WRENCH,
nut, and tighten the lock nut using the special tool. 30/64 mm
07916-MB00002
TOOL:
Lock nut wrench, 30/64 mm 07916-MB00002

TORQUE: 123 N.m (12.5 kgf.m, 90 lbf.ft)

19) Wipe the tapered part of the vertical shaft and pinion gear [1]
with a shop towel and a degreasing cleaning solvent. VERTICAL SHAFT

20) Attach the special tool to the end (crankshaft installation

side) of the vertical shaft as shown.

TOOL:
Vertical shaft holder 07SPB-ZW10200

21) Place a shop towel in the gear case as shown to protect the [2]
gear case. VERTICAL SHAFT
HOLDER [3]
22) Apply gear oil to the threads and seat of the pinion gear 07SPB-ZW10200 PINION GEAR
nut. NUT

23) Tighten the pinion gear nut to the specified torque while
installing the pinion gear on the vertical shaft and holding
the special tool in position.

TORQUE: 142 N.m (14.5 kgf.m, 105 lbf.ft)

NOTICE
Check that the forward bevel gear/taper bearing assembly
is set properly.

24) Install the following parts. [5]

– Propeller shaft holder assembly (P. 14-56) GEAR CASE [4]
SHOP TOWEL
– Water pump/shift rod (P. 14-51)
– Gear case assembly (P. 14-44)
– Propeller (P. 14-2)

14-76
15. SHIM SELECTION [*2] [1]
PINION GEAR NUT
NOTICE [2]
Adjust the shim thickness after replacing the gear case, vertical VERTICAL
shaft, bearing, taper bearing and the taper roller bearing. SHAFT

a. PINION GEAR SHIM

Remove the 30 x 62 x 40 mm taper roller bearing if it is
mounted on the vertical shaft (P. 14-70).
1) Wipe the tapered part of the vertical shaft and the pinion [4]
PINION GEAR
gear with a shop towel and a degreasing cleaning solvent. [3]
2) Install the pinion gear on the vertical shaft and tighten the TAPERED PARTS
pinion gear nut to the specified torque.

TORQUE: 142 N.m (14.5 kgf.m, 105 lbf.ft)

[2]
NOTICE TAPER ROLLER
[1] BEARING SIDE
• Do not install the vertical shaft in the gear case. GAUGE ADAPTER,
• We recommend that you attach the special tool (vertical 110 mm
shaft holder) at the end of the vertical shaft to facilitate 070PJ-ZY30100
tightening of the pinion gear nut to the specified torque
(P. 14-76).

3) Do not confuse the pinion gear side and the taper roller
bearing side of the special tool.
[3]
Do not score and scratch the opposite side (measurement
PINION GEAR
side) from the side where the tool number is stamped. SIDE

TOOL:
Gauge adapter, 110 mm 070PJ-ZY30100
[1] [2] [3] MEASUREMENT
4) Holding the special tool with the side of the stamped tool Tool must not PINION SURFACES
number facing the opposite side from the pinion gear, be get on the nut. GEAR
sure that the tool of the pinion gear nut side is not set on
the nut.
Tighten the bolts by hand while pushing both tools toward
the pinion gear side.

NOTICE [6]
BOLT (2)
• Do not tighten the bolts with a tool. [4]
• There must be no wobbling in the special tool. It must [5] TOOL NO.
securely set on the pinion gear. PINION GEAR STAMPED
NUT SURFACE

5) Set both tools on both sides of the flange of the vertical

[1] MEASUREMENT SURFACE
shaft with the side of the special tool, where is stamped
with the tool number, and the tapered part facing the
opposite side from the pinion gear as shown. Tighten the
bolts by hand.
[2]
NOTICE TOOL NO.
• Do not tighten the bolts with a tool. STAMPED
• There must be no wobbling in the special tool. It must SURFACE
securely set on the pinion gear.
[3]
TAPERED
[4] SURFACE
BOLTS

14-77
6) Hold the vertical shaft upright (with the pinion gear toward
up) and secure the vertical shaft. [1]
DEPTH GAUGE
7) Set the commercially available depth gauge at the gauge (Commercially available)
adapter of the pinion gear side as shown. Measure the
vertical shaft length (distance D) and record it.
[2]
PINION GEAR

[3]
GAUGE ADAPTER,
110 mm
070PJ-ZY30100

8) Assemble the outer race and the inner race of the 30 x 62 x

[1] OUTER RACE
40 mm taper roller bearing, and turn the outer race two or
three turns.

9) Measure the bearing height from the outer race end to the [2]
inner race end as shown, and record the measurement. INNER RACE

10) Measure the height of the taper roller bearing outer race
[1] OUTER RACE
and record it.

14-78
11) Calculate the gap (distance E) between the outer race and
inner race using the measurements obtained in step 9 and
10 and the following formula.

Formula:
Bearing height – Outer race height = Gap (distance E)

Example:
When, bearing height from the outer race end to the inner
race end is 34.9 mm (1.37 in),
And, outer race height is 29.7 mm (1.17 in):

34.9 – 29.7 = 5.2

Therefore, the gap (distance E) is 5.2 mm (0.20 in).

12) Determine the calculation value using the vertical shaft

length (distance D) obtained in step 7 and the gap (distance
E) obtained in step 11 and the following formula.

Formula:
Vertical shaft length (distance D) + Gap (distance E) – 147.2
= Calculation value

Example:
When, vertical shaft length (distance D) is 141.8 mm (5.58
in),
And, gap (distance E) is 5.2 mm (0.20 in):

141.8 + 5.2 – 147.2 = –0.20

Therefore, the calculation value is –0.20 mm (–0.008 in). [1]

GEAR CASE
13) Cross reference the calculation value and the engagement
mark located on the trim tab installation part of the gear
case, and select the shim of the appropriate thickness from
the shim selection table accordingly.

• Shim type table

[1] Shim type [2] Thickness
[3] Pinion gear shim A 0.10 mm (0.004 in) [2]
[4] Pinion gear shim B 0.15 mm (0.006 in) ENGAGEMENT
MARK
[5] Pinion gear shim C 0.30 mm (0.012 in)
[6] Pinion gear shim D 0.50 mm (0.020 in)

14-79
• Pinion gear shim selection table [3] Unit: mm (in)
[2] Calculation value
+0.41 (+0.0161) +0.35 (+0.014) +0.30 (+0.0118) +0.25 (+0.010) +0.20 (+0.008) +0.15 (+0.006) +0.10 (+0.004)
– – – – – – –
+0.35 (+0.014) +0.30 (+0.0118) +0.25 (+0.010) +0.20 (+0.008) +0.15 (+0.006) +0.10 (+0.004) +0.05 (+0.002)
F 0.30 (0.0118) 0.35 (0.014) 0.40 (0.0157) 0.45 (0.018) 0.50 (0.020) 0.55 (0.022) 0.60 (0.024)
[1] Engagement
mark on the

E 0.25 (0.010) 0.30 (0.0118) 0.35 (0.014) 0.40 (0.0157) 0.45 (0.018) 0.50 (0.020) 0.55 (0.022)
gear case

D 0.20 (0.008) 0.25 (0.010) 0.30 (0.0118) 0.35 (0.014) 0.40 (0.0157) 0.45 (0.018) 0.50 (0.020)
C 0.15 (0.006) 0.20 (0.008) 0.25 (0.010) 0.30 (0.0118) 0.35 (0.014) 0.40 (0.0157) 0.45 (0.018)
B 0.10 (0.004) 0.15 (0.006) 0.20 (0.008) 0.25 (0.010) 0.30 (0.0118) 0.35 (0.014) 0.40 (0.0157)
A 0.10 (0.004) 0.15 (0.006) 0.20 (0.008) 0.25 (0.010) 0.30 (0.0118) 0.35 (0.014)

[3] Unit: mm (in)

[2] Calculation value
+0.05 (+0.002) ±0 (±0.000) –0.05 (–0.002) –0.10 (–0.004) –0.15 (–0.006) –0.20 (–0.008) –0.25 (–0.010)
– – – – – – –
±0 (±0.000) –0.05 (–0.002) –0.10 (–0.004) –0.15 (–0.006) –0.20 (–0.008) –0.25 (–0.010) –0.31 (–0.0122)
F 0.65 (0.026) 0.70 (0.028) 0.75 (0.030) 0.80 (0.031) 0.85 (0.033) 0.90 (0.035) 0.95 (0.037)
[1] Engagement
mark on the

E 0.60 (0.024) 0.65 (0.026) 0.70 (0.028) 0.75 (0.030) 0.80 (0.031) 0.85 (0.033) 0.90 (0.035)
gear case

D 0.55 (0.022) 0.60 (0.024) 0.65 (0.026) 0.70 (0.028) 0.75 (0.030) 0.80 (0.031) 0.85 (0.033)
C 0.50 (0.020) 0.55 (0.022) 0.60 (0.024) 0.65 (0.026) 0.70 (0.028) 0.75 (0.030) 0.80 (0.031)
B 0.45 (0.018) 0.50 (0.020) 0.55 (0.022) 0.60 (0.024) 0.65 (0.026) 0.70 (0.028) 0.75 (0.030)
A 0.40 (0.0157) 0.45 (0.018) 0.50 (0.020) 0.55 (0.022) 0.60 (0.024) 0.65 (0.026) 0.70 (0.028)

• How to read shim selection table

When the engagement mark on the gear case is E and the calculation value is –0.20 mm (–0.008 in) or more, the shim
thickness is 0.80 mm (0.031 in).
When the calculation value is less than –0.20 mm (–0.008 in), the shim thickness is 0.85 mm (0.033 in). (See Shim
selection table above.)
[3] Unit: mm (in)
[2] Calculation value
+0.05 (+0.002) ±0 (±0.000) –0.05 (–0.002) –0.10 (–0.004) –0.15 (–0.006) –0.20 (–0.008) –0.25 (–0.010)
– – – – – – –
±0 (±0.000) –0.05 (–0.002) –0.10 (–0.004) –0.15 (–0.006) –0.20 (–0.008) –0.25 (–0.010) –0.31 (–0.0122)
F 0.65 (0.026) 0.70 (0.028) 0.75 (0.030) 0.80 (0.031) 0.85 (0.033) 0.90 (0.035) 0.95 (0.037)
[1] Engagement
mark on the

E 0.60 (0.024) 0.65 (0.026) 0.70 (0.028) 0.75 (0.030) 0.80 (0.031) 0.85 (0.033) 0.90 (0.035)
gear case

D 0.55 (0.022) 0.60 (0.024) 0.65 (0.026) 0.70 (0.028) 0.75 (0.030) 0.80 (0.031) 0.85 (0.033)
C 0.50 (0.020) 0.55 (0.022) 0.60 (0.024) 0.65 (0.026) 0.70 (0.028) 0.75 (0.030) 0.80 (0.031)
B 0.45 (0.018) 0.50 (0.020) 0.55 (0.022) 0.60 (0.024) 0.65 (0.026) 0.70 (0.028) 0.75 (0.030)
A 0.40 (0.0157) 0.45 (0.018) 0.50 (0.020) 0.55 (0.022) 0.60 (0.024) 0.65 (0.026) 0.70 (0.028)

• Shim combination
To obtain 0.75 mm (0.030 in) of shim thickness, combine three gear shim As and one gear shim B and one gear shim C,
or combine one gear shim A, one gear shim B and one gear shim D by referring to the shim type table.

14-80
b. FORWARD BEVEL GEAR SHIM
1) Assemble the outer race and the inner race of the 50 x 90 x [1]
28 mm taper bearing, and turn the outer race two or three OUTER RACE
turns.
[2]
2) Measure the bearing height (distance F) from the outer race INNER RACE
end to the inner race end as shown, and record the
measurement.

3) Measure the inner race height (distance K) as shown, and

record the measurement.

4) Determine the calculation value using the bearing height

(distance F), inner race height (distance K) and the
following formula.

Formula:
Bearing height (distance F) – Inner race height (distance K)
= Calculation value

Example:
When, bearing height (distance F) is 28.05 mm (1.104 in),
And, inner race height (distance K) is 28.00 mm (1.102 in):

28.05 – 28.00 = 0.05

Therefore, the calculation value is 0.05 mm (0.002 in).

5) Check the calculation value and select the shim of the

appropriate thickness from the shim selection table
accordingly.

• Shim type table

[1] Shim type [2] Thickness
[1]
[3] Forward bevel gear shim A 0.10 mm (0.004 in) 50 x 90 x 28 mm
[4] Forward bevel gear shim B 0.15 mm (0.006 in) TAPER BEARING
[5] Forward bevel gear shim C 0.30 mm (0.012 in) (INNER RACE)

[6] Forward bevel gear shim D 0.50 mm (0.020 in)

• Forward bevel gear shim selection table [3] Unit: mm (in)

[1] Calculation value [2] Shim thickness
+0.15 – +0.10 (+0.006 – +0.004) 0.35 (0.014)
+0.10 – +0.05 (+0.004 – +0.002) 0.40 (0.016)
+0.05 – ±0 (+0.002 – ±0.000) 0.45 (0.018)

Refer to page 14-80 for information on shim combination.

14-81
c. REVERSE BEVEL GEAR SHIM
1) Measure the bearing height (distance H) of the new 50 x 90
x 20 mm radial ball bearing as shown, and record the
measurement.

2) Determine the calculation value using the bearing height

(distance H) and the following formula.

Formula:
Bearing height (distance H) – 20 = Calculation value

Example:
When, bearing height (distance H) is 19.95 mm (0.785 in):

19.95 – 20 = –0.05

Therefore, the calculation value is –0.05 mm (–0.002 in).

3) Cross reference the calculation value and the engagement

mark located on the trim tab installation part of the gear
case, and select the shim of the appropriate thickness from
the shim selection table accordingly.
[1]
• Shim type table GEAR CASE
[1] Shim type [2] Thickness
[3] Forward bevel gear shim A 0.10 mm (0.004 in)
[4] Forward bevel gear shim B 0.15 mm (0.006 in)
[5] Forward bevel gear shim C 0.30 mm (0.012 in)
[6] Forward bevel gear shim D 0.50 mm (0.020 in)

• Reverse bevel gear shim selection table [3] Unit: mm (in)

[2]
[2] Calculation value ENGAGEMENT
±0 (±0.000) –0.05 (–0.002) MARK
– –
–0.05 (–0.002) –0.12 (–0.005)
1 0.60 (0.024) 0.65 (0.026)
[1] Engagement
mark on the

2 0.55 (0.022) 0.60 (0.024)

gear case

3 0.50 (0.020) 0.55 (0.022)

4 0.45 (0.018) 0.50 (0.020)
5 0.40 (0.016) 0.45 (0.018)
6 0.35 (0.014) 0.40 (0.016)

Refer to page 14-80 for the information on how to read the

shim selection table and shim combination.

14-82
d. THRUST SHIM
1) Assemble the outer race and inner race of the 50 x 90 x 28 [1]
mm taper bearing, and turn the outer race two or three OUTER RACE
turns.
[2]
2) Measure the bearing height (distance F) from the outer race INNER RACE
end to the inner race end as shown, and record the
measurement.

3) Measure the inner race height (distance K) as shown, and

record the measurement.

4) Determine the calculation value using the bearing height

(distance F), inner race height (distance K) and the
following formula.

Formula:
Bearing height (distance F) – Inner race height (distance K)
= Calculation value

Example:
When, bearing height (distance F) is 28.05 mm (1.104 in),
And, inner race height (distance K) is 28.00 mm (1.102 in):

28.05 – 28.00 = 0.05

Therefore, the calculation value is 0.05 mm (0.002 in).

5) Check the calculation value and the bearing height, and

select the shim of the appropriate thickness from the shim
selection table accordingly.

• Shim type table

[1] Shim type [2] Thickness
[1]
[3] Thrust shim A 0.10 mm (0.004 in) 50 x 90 x 28 mm
[4] Thrust shim B 0.15 mm (0.006 in) TAPER BEARING
[5] Thrust shim C 0.30 mm (0.012 in) (INNER RACE)

[6] Thrust shim D 0.50 mm (0.020 in)

• Thrust shim selection table [3] Unit: mm (in)

[2] Calculation value
+0.15 (+0.006) +0.10 (+0.004) +0.05 (+0.002)
– – –
+0.10 (+0.004) +0.05 (+0.002) ±0 (±0.000)
28.00
(1.102)
[1] Bearing height

– 0.65 (0.026) 0.70 (0.028) 0.75 (0.030)

28.05
(1.104)
28.05
(1.104)
– 0.60 (0.024) 0.65 (0.026) 0.70 (0.028)
28.10
(1.106)

Refer to page 14-80 for the information on how to read the

shim selection table and shim combination.

14-83
16. SHIM POSITION [*2]

[1]
30 x 62 x 40 mm
TAPER ROLLER
BEARING
(INNER RACE)

[14]
30 x 62 x 40 mm
TAPER ROLLER
BEARING
(OUTER RACE)

[13]
PINION GEAR SHIM
SELECTION: P. 14-77

[12]
VERTICAL SHAFT

[11]
PINION GEAR

[10]
PINION GEAR NUT
142 N.m (14.5 kgf.m, 105 lbf.ft)
[2]
50 x 90 x 20 mm
RADIAL BALL
BEARING

[9]
THRUST SHIM
[3]
SELECTION: P. 14-83 REVERSE BEVEL
ADJUSTMENT: P. 14-87 GEAR SHIM
[8] SELECTION: P. 14-82
50 x 90 x 28 mm [5] FORWARD ADJUSTMENT: P. 14-86
TAPER BEARING BEVEL GEAR
(INNER RACE) [4]
[6] REVERSE BEVEL GEAR
[7] FORWARD BEVEL
50 x 90 x 28 mm GEAR SHIM
TAPER BEARING
(OUTER RACE) SELECTION: P. 14-81
ADJUSTMENT: P. 14-85

14-84
17. BACKLASH ADJUSTMENT [*2]
[1]
a. FORWARD BEVEL GEAR BACKLASH PULLER BOLT
Backlash adjustment must be made after adjustment of each 07SPC-ZW0011Z
gear shim (P. 14-77).
Install the parts except the water pump in the gear case (P. 14-
51, 56 and 73).
1) Hold the propeller shaft securely with the special tool as
shown, and tighten the puller bolt to the specified torque.

TOOLS: [2]
Puller jaws 07SPC-ZW0010Z PULLER JAWS
Puller bolt 07SPC-ZW0011Z 07SPC-ZW0010Z

TORQUE: 5 N.m (0.5 kgf.m, 3.6 lbf.ft)

Turn the vertical shaft five to ten turns clockwise to fit the
bevel gear bearing. [1]
BACKLASH [2]
INDICATOR BACKLASH
2) Attach the special tool to the vertical shaft as shown, and
ATTACHMENT INDICATOR TOOL
adjust the dial indicator so its needle is at the line “2” of the 07SPJ-ZW0030Z
07SPK-ZW10100
special tool (backlash indicator tool).

TOOLS: 90˚ 90˚

Backlash indicator tool 07SPJ-ZW0030Z
Backlash indicator attachment 07SPK-ZW10100
90˚ 90˚
3) Turn the vertical shaft lightly right and left and record the
dial indicator reading.
Measure the backlash at the four points (by turning the
vertical shaft 90˚) in the same manner.

NOTICE
Do not turn the propeller shaft when turning the vertical
shaft.

4) Obtain the forward bevel gear backlash using the dial

indicator runout and the following formula. [3]
[4]
VERTICAL DIAL INDICATOR
Formula: SHAFT Adjust the dial indicator needle at
Dial indicator runout ÷ 0.86 = Backlash line “2” of the backlash indicator
tool.
Example:
When dial indicator runout is 0.195 mm (0.0077 in):
0.195 ÷ 0.86 = 0.23
Therefore, the backlash is 0.23 mm (0.009 in).

0.10 – 0.30 mm
Standard value
(0.004 – 0.012 in)

5) If the backlash is too large, reduce the forward bevel gear

shim thickness and recheck the backlash.
If the backlash is too small, increase the forward bevel gear
shim thickness and recheck the backlash.

NOTICE
Use the special tool when 50 x 90 x 28 mm taper bearing
outer race is removed to adjust the backlash again (P. 14-
60).

14-85
b. REVERSE BEVEL GEAR BACKLASH
1) Turn the vertical shaft five to ten turns clockwise for snug
seat of the bevel gear taper roller bearing.

2) Using the wrench, turn the shift rod in the direction shown
with the arrow and fix the propeller shaft.

NOTICE
If it is hard to fix the propeller shaft, turn the propeller shaft
to change the phase of the shaft and fix it.

3) Attach the special tool to the vertical shaft as shown, and

adjust the dial indicator so its needle is at the line “2” of the
special tool (backlash indicator tool). [1]
BACKLASH [2]
TOOLS: INDICATOR BACKLASH
Backlash indicator tool 07SPJ-ZW0030Z ATTACHMENT INDICATOR TOOL
Backlash indicator attachment 07SPK-ZW10100 07SPK-ZW10100 07SPJ-ZW0030Z

4) Turn the vertical shaft lightly right and left and record the
90˚ 90˚
dial indicator reading.
Measure the backlash at the four points (by turning the
vertical shaft 90˚) in the same manner.
90˚ 90˚
NOTICE
Do not turn the propeller shaft when turning the vertical
shaft.

5) Obtain the reverse bevel gear backlash using the dial

indicator runout and the following formula.

Formula:
Dial indicator runout ÷ 0.86 = Backlash

Example: [4] [3]

When dial indicator runout is 0.195 mm (0.0077 in): VERTICAL DIAL INDICATOR
SHAFT Adjust the dial indicator needle at
0.195 ÷ 0.86 = 0.23 line “2” of the backlash indicator
tool.
Therefore, the backlash is 0.23 mm (0.009 in).

0.10 – 0.35 mm
Standard value
(0.004 – 0.014 in)

6) If the backlash is too large, increase the reverse bevel gear

shim thickness and recheck the backlash.
If the backlash is too small, reduce the reverse bevel gear
shim thickness and recheck the backlash.

NOTICE
Use the special tool when 50 x 90 x 20 mm radial ball
bearing is removed to adjust the backlash again (P. 14-69).

7) Adjust the thrust clearance after replacement of the

forward bevel gear shim (P. 14-87).

14-86
c. THRUST CLEARANCE ADJUSTMENT
Adjust the thrust clearance after replacement of the forward [1]
bevel gear shim. DIAL INDICATOR

1) Check that the bearing holder assembly is securely

tightened to the specified torque on the propeller shaft
holder (P. 14-65).
Check that the clutch shifter and the shift slider are not [2]
installed (P. 14-57). PROPELLER SHAFT
HOLDER ASSEMBLY
2) Fix the propeller shaft holder assembly on the fixing tool
securely using the bolt as shown (P. 14-59).

3) Set the dial indicator perpendicularly so that its tip contacts

the end of the propeller shaft.

4) Move the propeller shaft up and down and read the runout
of the dial indicator. It must be within the specified range.

0.2 – 0.4 mm
Standard value
(0.01 – 0.02 in)

5) If the thrust clearance exceeds the specification, increase

the thrust shim thickness and recheck the thrust clearance.
If the thrust clearance is less than the specification, reduce
[3]
the thrust shim thickness and recheck the thrust clearance.
FIXING TOOL

14-87
18. ANODE METAL/WATER SCREEN
a. REMOVAL/INSTALLATION
Anode metal/water screen removal/installation can be made with the gear case mounted on the outboard motor.

[3]
ANODE METAL (2) [4]
[1] 5.5 x 1.5 mm O-RING
5 x 50 mm OVAL SCREW INSPECTION:
Replace the anode metal if Do not reuse.
1 N.m (0.1 kgf.m, 0.7 lbf.ft)
it is corroded excessively. [5]
[2] OIL LEVEL BOLT
6 x 50 mm HEX. BOLT
3.4 N.m (0.35 kgf.m, 2.5 lbf.ft)

[6]
5 mm SELF-
LOCKING NUT
[11]
L. WATER SCREEN
INSPECTION: [8]
Check for the clogged 6 mm SELF-
water through hole LOCKING NUT
before installation.
[7]
R. WATER SCREEN
[4] INSPECTION:
5.5 x 1.5 mm O-RING Check for the clogged
Do not reuse. water through hole
[10] before installation.
GEAR CASE ASSEMBLY [9]
OIL DRAIN BOLT
3.4 N.m (0.35 kgf.m, 2.5 lbf.ft)

14-88
19. EXTENSION CASE/LOWER [1]
LOWER MOUNT
RUBBER MOUNT HOUSING
6 x 12

a. DISASSEMBY
Remove the following parts.
– Engine cover (P. 4-2)
– L./R. engine under cover (P. 4-9)
– Gear case assembly (P. 14-3 and 42) [2]
1) Tilt up the outboard motor and hold it in the position by GROUND
hooking the hoist hook on each of the three engine [4] CABLE
hangers. 8 x 30 mm [3] 8 mm
HEX. BOLT (3) WASHER (3)
2) Remove the three 8 x 30 mm hex. bolts and the three 8 mm
washers, then remove the lower mount housing from the
extension case.
3) Remove the 6 x 12 mm flange bolt from the extension case
and disconnect the ground cable.
[1]
4) Holding the 12 mm self-locking nut with a wrench, remove 12 x 225 mm
the 12 x 225 mm hex. bolt, 12 mm self-locking nut and the HEX. BOLT
two 12 mm washers.

5) Remove the lower rubber mount and the lower mount [2]
collar from the extension case. LOWER MOUNT
COLLAR
[3] [4] [5]
LOWER RUBBER 12 mm 12 mm SELF-
MOUNT WASHER (2) LOCKING NUT

6) Remove the eight 10 x 40 mm flange bolts and remove the

extension case from the outboard motor.
Remove the two dowel pins.

NOTICE
Remove the extension case with care not to drop it. [1]
UNDER COVER
7) Remove the under cover seal B and the extension case SEAL B
grommet from the extension case. [2]
EXTENSION
8) Remove the circlip, and then remove the 26 mm washer CASE GROMMET
and the vertical shaft bushing from the extension case (XC,
XCC, XD and XCD types only).

[1] [3]
XC, XCC, XD and XCD types only 6 x 10 mm
DOWEL PIN (2)

[2]
EXTENSION CASE

[3]
VERTICAL SHAFT
BUSHING
[4]
26 mm WASHER 10 x 40 (8) [4]
[5] EXTENSION CASE
CIRCLIP

14-89
9) Remove the 6 x 12 mm flange bolt, and remove the water
tube setting plate, water tube and the water tube grommet.

[1]
WATER TUBE
GROMMET
[2]
WATER TUBE
SETTING PLATE
6 x 12

[3]
WATER TUBE

b. COMPONENTS DRAWING
[1]
12 x 225 mm HEX. BOLT (2) [4]
83 N.m (8.5 kgf.m, 61 lbf.ft) LOWER MOUNT
[3] COLLAR (2)
UNDER COVER [5]
[2] SEAL B LOWER RUBBER
WATER TUBE MOUNT (2)
GROMMET [6]
12 mm
WASHER (4)

[7]
[19] 12 mm SELF-
WATER TUBE [8] LOCKING NUT
6 x 10 mm (2)
DOWEL PIN (2)
[18]
EXTENSION CASE
GROMMET

[17] 6 x 12
WATER TUBE
SETTING PLATE

[16] [14]
8 x 30 mm LOWER MOUNT
HEX. BOLT (6) HOUSING (2)
[15] [13] [12]
8 mm EXTENSION VERTICAL SHAFT
WASHER (6) CASE BUSHING
[11] [9]
10 x 40 (8) 26 mm CIRCLIP
39 N.m (4.0 kgf.m, 29 lbf.ft) WASHER
[10]
XC, XCC, XD and XCD types only

14-90
c. ASSEMBLY
1) Apply grease to the circumference of the water tube
grommet and install it on the water tube.

2) Connect the water tube to the oil case noting the

installation direction as shown. [1]
PROJECTION
3) Install the water tube set plate aligning the stopper hole of
the water tube set plate with the projection on the oil case, [2]
and then tighten the 6 x 12 mm flange bolt. [5] STOPPER
WATER TUBE HOLE
GROMMET
[3]
WATER TUBE
6 x 12 SETTING PLATE

[4]
WATER TUBE

4) Install the under cover seal B, extension case grommet and

[1] [2]
the two dowel pins on the extension case. UNDER COVER
EXTENSION CASE
GROMMET SEAL B
NOTICE
Install the under cover seal B underside the projections of
the extension case securely.

5) Apply grease to the inner wall of the vertical shaft bushing.

Install the vertical shaft bushing, 26 mm washer and the
circlip in the extension case (XC, XCC, XD and XCD types [3] 6 x 10 mm
only). DOWEL PIN (2)

[1] XC, XCC, XD and XCD types only

[2]
EXTENSION CASE

[3]
[4]
VERTICAL SHAFT
EXTENSION CASE
BUSHING
[4]
26 mmWASHER

[5]
CIRCLIP

[5]
PROJECTION
[2]
UNDER COVER
SEAL B

14-91
6) Clean the extension case and oil case mating surfaces with
a degreasing cleaning solvent and a shop towel.
[1]
7) Apply sealant to the entire sealing surface of the oil case EXTENSION CASE
side of the extension case (ThreeBond® #5222B or
equivalent).

[2]
Sealant (ThreeBond®
#5222B) application
area

8) Apply grease to the water tube end. Install the extension

case on the outboard motor aligning the water tube with
[1]
the extension case grommet.
WATER TUBE
9) Tighten the eight 10 x 40 mm flange bolts to the specified
torque.

TORQUE: 39 N.m (4.0 kgf.m, 29 lbf.ft)

10 x 40 (8) [2]
[3] EXTENSION CASE
EXTENSION GROMMET
CASE

14-92
10) Install the lower mount collar and the lower rubber mount
on the extension case.

NOTICE [1]
12 x 225 mm HEX. BOLT
• Install the lower mount collar with the smaller diameter
side toward the lower rubber mount.
• Install the lower rubber mount with the “OUT” mark
toward out.

11) Install the 12 x 225 mm hex. bolt, two 12 mm washers and

the 12 mm self-locking nut. Holding the 12 mm self-locking
nut with a wrench, tighten the 12 x 225 mm hex. bolt to the
specified torque.

TORQUE: 83 N.m (8.5 kgf.m, 61 lbf.ft)

[6]
LOWER MOUNT
COLLAR

[5] [2]
“OUT” MARK 12 mm SELF-
LOCKING NUT
[4] [3]
LOWER RUBBER 12 mm
MOUNT WASHER (2)

12) Connect the ground cable with the 6 x 12 mm flange bolt.

13) Install the lower mount housing on the extension case, and
tighten the three 8 mm washers and the three 8 x 30 mm [1]
hex. bolts. LOWR MOUNT
HOUSING
14) Remove the hoist hooks from the engine hangers and 6 x 12
lower the outboard motor to the lowermost position.

15) Install the following pars.

– Gear case assembly (P. 14-5 and 44)
– L./R. engine under cover (P. 4-14)
– Engine cover (P. 4-2)

[2]
GROUND CABLE
[3]
[4] 8 mm WASHER (3)
8 x 30 mm
HEX. BOLT (3)

14-93
20. OIL CASE
a. REMOVAL
Remove the following parts.
– Engine cover (P. 4-2)
– L./R. engine under cover (P. 4-9)
– Gear case assembly (P. 14-3 and 42)
– Extension case/lower rubber mount (P. 14-89)
1) Drain the engine oil from the oil case (P. 3-2).

2) Remove the sixteen 10 x 40 mm flange bolts and remove the oil case from the mount case.

[1]
OIL LEVEL PIPE 6 x 12

[2]
OIL LEVEL GAUGE

[3]
[10] 11.5 x 3.5 mm O-RING
OIL PAN GASKET
Do not reuse.

[4]
6 x 10 mm DOWEL PIN (2)

[5]
20.6 x 2.6 mm O-RING
Do not reuse.

6 x 18 (2)
[9]
OIL CASE [6]
OIL STRAINER

[7]
OIL DRAIN PLUG BOLT
23 N.m (2.3 kgf.m, 17 lbf.ft)

[8]
10 x 40 (16)
12 mm DRAIN
34 N.m (3.5 kgf.m, 25 lbf.ft) PLUG WASHER
Do not reuse.

14-94
b. INSTALLATION
1) Clean the oil case and mount case mating surfaces and the
both sides of the oil pan gasket with a cleaning solvent and
a shop towel.
[2]
2) Apply bead [ø1.0 – 5.0 mm (ø0.04 – 0.20 in)] of the liquid [1] OIL PAN GASKET
gasket (ThreeBond® #1211 or equivalent) to the indicated Liquid gasket
area of the oil pan gasket. application area

NOTICE
• Assemble within 90 minutes after application of the liquid
gasket. If the parts have been left unassembled for 90
minutes, remove the old gasket and apply a new gasket
again.
• Do not fill in the oil case with the engine oil for 15 minutes
after assembly.

[3]
LIQUID GASKET
(Apply to both sides.)

[4]
OIL PAN GASKE

3) Apply engine oil to the circumference of the new 20.6 x 2.6

mm O-ring, and install it on the oil strainer. [1]
MOUNT CASE
4) Install the oil pan gasket on the mount case. Install the oil
strainer and tighten the two 6 x 18 mm flange bolts.

[4]
OIL PAN GASKET

[2]
20.6 x 2.6 mm
O-RING

6 x 8 (2)

[3]
OIL STRAINER

14-95
5) Apply the engine oil to the threads and seat of the sixteen
10 x 40 mm flange bolts. [2]
Install the two dowel pins and the oil case on the mount OIL LEVEL GAUGE
case, then loosely tighten the sixteen 10 x 40 mm flange
bolts. 6 x 12
[1]
OIL LEVEL PIPE
6) Apply engine oil to the new 11.5 x 3.5 mm O-ring, and
install it on the oil level pipe.

7) Install the oil level pipe on the mount case and tighten the
6 x 12 mm flange bolts.
Install the oil level gauge.

[3]
11.5 x 3.5 mm
O-RING

[4]
6 x 10 mm
DOWEL PIN (2)

[5]
OIL CASE

10 x 40 (16)

8) Tighten the 10 x 40 mm flange bolts to the specified torque

in the numbered sequence in two or three steps.

TORQUE: 34 N.m (3.5 kgf.m, 25 lbf.ft) ⑫ ⑥

9) Tighten the 12 mm drain plug washer and the oil drain plug
⑪ ⑬
bolt on the oil case. Tighten them to the specified torque
and add the engine oil.
⑩ ⑤ ④ ⑭
TORQUE: 23 N.m (2.3 kgf.m, 17 lbf.ft)
①
10) Install the following parts.
– Extension case/lower rubber mount (P. 14-91) ②
⑨ ⑮
– Gear case assembly (P. 14-5 and 44)
– L./R. engine under cover (P. 4-14) ③
– Engine cover (P. 4-2)
⑧ ⑯

14-96
15. MOUNTING CASE/STERN BRACKET/SWIVEL
CASE/POWER TRIM/TILT ASSEMBLY
1. MOUNTING CASE 4. POWER TRIM/TILT ASSEMBLY
2. STERN BRACKET/SWIVEL CASE 5. AIR BLEEDING
REMOVAL/INSTALLATION 6. BLOW PRESSURE INSPECTION
3. STERN BRACKET/SWIVEL 7. POWER TILT MOTOR ASSEMBLY
CASE/POWER TRIM/TILT ASSEMBLY

83 N.m (8.5 kgf.m,

61 lbf.ft)

34 N.m (3.5 kgf.m,

34 N.m (3.5 kgf.m, 25 lbf.ft)
25 lbf.ft)

34 N.m (3.5 kgf.m,

25 lbf.ft)

15-1
1. MOUNTING CASE
a. REMOVAL

Remove the following parts.

– Engine cover (P. 4-2)
– L./R. engine under covers (P. 4-9)
– Under cover front bracket (P. 4-20)
– Water relief tube C (P. 8-6)
– Engine assembly (P. 7-2)

Remove the two 12 mm self-locking nuts and remove the mounting case assembly.

[2]
MOUNTING CASE
ASSEMBLY

[1]
12 mm SELF-LOCKING
NUT (2)

15-2
b. MOUNTING CASE DISASSEMBLY
1) Remove the under cover seal A and the mounting case rubber seal from the mounting case.
Remove the shift shaft B and the shift shaft washer.
2) Remove the three 6 x 25 mm flange bolts and remove the idle exhaust port and the idle exhaust port gasket.
Replace the gasket with a new one on assembly.
3) Check the 22 x 35 x 7 mm water seal lips for cut and replace if necessary before removal.
Remove the two 22 x 35 x 7 mm water seals using a commercially available oil seal remover. Replace the oil seals
with the new ones on assembly.
4) Remove the 12 mm E-ring from the shift shaft A and remove the 14 mm washer and the shift shaft A.
Check the 14 x 26 x 8 mm water seal lip for cut and replace if necessary before removal. Remove the 14 x 26 x 8 mm
water seal using a commercially available oil seal remover. Replace with a new one on assembly.
5) Remove the two 12 x 145 mm stud bolts from the upper rubber mount.
6) Remove the six 8 x 35 mm flange bolts and remove the upper mount holder, upper mount holder gasket and the
upper rubber mount. Replace the gasket with a new one on assembly.
Check the upper rubber mount for deterioration and cracks. Replace with a new one if necessary.

[5] 22 x 35 x 7 mm 8 x 35 (6)
WATER SEAL (2)

[4] SHIFT SHAFT B [6] UPPER MOUNT

HOLDER

[7] UPPER MOUNT

[3] SHIFT SHAFT A
HOLDER GASKET

[8] UPPER RUBBER

[2] 20 x 28 x 13 mm
MOUNT
NEEDLE BEARING

6 x 25 (3)

[1] SHIFT SHAFT

WASHER
[9] IDLE EXHAUST
PORT

[17]
14 x 26 x 8 mm
WATER SEAL

[10] IDLE EXHAUST

PORT GASKET
[16] 14 mm WASHER

[11] MOUNTING
[15] 12 mm E-RING CASE

[12] UNDER COVER

SEAL A

[14] 12 x 145 mm
STUD BOLT (2) [13] MOUNTING CASE
RUBBER SEAL

15-3
c. 20 x 28 x 13 mm NEEDLE BEARING REMOVAL
[1] 20 x 28 x 13 mm
NEEDLE BEARING
1) Remove all parts from the mounting case.

2) Warm up the 20 x 28 x 13 mm needle bearing of the

mounting case and remove the needle bearing.

Replace the 20 x 28 x 13 mm needle bearing with a new one

on assembly.

NOTICE
Take care not to get burned during operation.

[2] MOUNTING CASE

d. 20 x 28 x 13 mm NEEDLE BEARING
INSTALLATION
[1]
1) Apply engine oil to the circumference of the new 20 x 28 x DRIVER
13 mm needle bearing. 07749-0010000

2) Install the 20 x 28 x 13 mm needle bearing in the mounting

case using the special tools and the hydraulic press as
shown. [2]
ATTACHMENT,
TOOLS: 28 x 30 mm
Driver 07749-0010000 07946-1870100
Attachment, 28 x 30 mm 07946-1870100
Pilot, 20 mm 07746-0040500

[3]
PILOT, 20 mm
07746-0040500

e. MOUNTING CASE ASSEMBLY

[1] UPPER RUBBER [2]
MOUNT “UP” MARK
1) Install the upper rubber mount in the mounting case with
the “UP” mark on the upper rubber mount toward up and
the white paint mark toward the opposite side from the [3] WHITE
water seal installation part. PAINT
MARK
Note the installation direction of the upper rubber mount.

[4] WATER SEAL INSTALLATION PART

15-4
2) Install the new upper mount holder gasket and the upper
mount holder on the upper rubber mount with the cutouts 8 x 35 (6)
in the upper mount holder gasket and in the upper mount
holder toward the opposite side from the water seal
installation part.
[1]
Note the installation direction. UPPER
MOUNT
3) Tighten the upper rubber mount securely with the six 8 x 35 HOLDER
mm flange bolts.

[4] [2] CUTOUTS

WATER SEAL
INSTALLATION
[3] UPPER MOUNT
PART
HOLDER GASKET

4) Tighten the two 12 x 145 mm stud bolts on the upper

rubber mount securely with the longer threads of the stud
bolts toward the upper rubber mount side. [1] UPPER RUBBER
MOUNT

[2] 12 x 145 mm
STUD BOLT (2)

[3] <12 x 145 mm STUD BOLT>

[4] SHORT [5] LONG [6]
UPPER
RUBBER
MOUNT
SIDE

15-5
5) Apply grease to the circumference and the mating surfaces
of the two new 22 x 35 x 7 mm water seals. [1] <Water seal
installation direction>
6) Install the 22 x 35 x 7 mm water seals one by one in the
[3]
mounting case using the special tools as shown. Note the DRIVER
installation direction of the water seals. 07749-0010000

7) After installing the water seals, apply 2 – 4 g (0.07 – 0.14 oz)

of grease to the lip and the area around the lip of the water
seals. [2]
(Apply grease to the
• Note the installation direction of the water seals. circumference and mating
surfaces of the seals.)
TOOLS:
Driver 07749-0010000
Attachment, 32 x 35 mm 07746-0010100
Pilot, 22 mm 07746-0041000
[4] ATTACHMENT,
32 x 35 mm
07746-0010100

[5]
PILOT, 22 mm
07746-0041000

8) Apply grease to the circumference of the new 14 x 26 x 8

[1] <Water seal installation
mm water seal. direction>
9) Install the water seal with the special tools as shown. Note [3]
the installation direction. DRIVER
07749-0010000
10) After installing the water seal, apply 2 – 4 g (0.07 – 0.14 oz)
of grease to the lip and the area around the lip of the water
seal.

• Note the installation direction of the water seal. [2] (Apply grease to the
circumference and
TOOLS: the lip of the seal.)
Driver 07749-0010000
Attachment, 24 x 26 mm 07746-0010700
Pilot, 12 mm 07746-0040100
[4]
ATTACHMENT,
24 x 26 mm
07746-0010700

[5]
14 x 26 x 8 mm
WATER SEAL

[6] PILOT, 12 mm
07746-0040100

15-6
11) Apply grease to the shift shaft A installation part in the
mounting case.
[1] SHIFT
SHAFT A
12) Set the shift shaft A on the mounting case and install the 14
mm washer and the 12 mm E-ring on the shift shaft A.

[2] 14 mm
[3] 12 mm WASHER
E-RING

13) Install the shift shaft washer on the mounting case.

14) Apply grease to the shift shaft B installation part in the [1]
mounting case. SHIFT
SHAFT B
Install the shift shaft B on the mounting case aligning the
punch mark on the shift shaft B with the punch mark on the
shift shaft A as shown.
[2]
SHIFT SHAFT
WASHER

[3] [1]
SHIFT SHAFT A SHIFT SHAFT B

[4] PUNCH MARKS

15-7
15) Clean the mounting case/idle exhaust port mating surfaces
and the both sides of the idle exhaust port gasket [2] LIQUID GASKET
thoroughly with a degreasing cleaning solvent and shop (Apply to both sides.)
towel. [1]
LIQUID GASKET
APPLICATION
16) Apply a bead [ø1.0 – 5.0 mm (ø0.04 –0.20 in)] of the liquid
AREA
gasket (ThreeBond® #1211 or equivalent) to the indicated
area of the both sides of the idle exhaust port gasket.
[3] GASKET
NOTICE
• Install the idle exhaust gasket within 90 minutes after
application of the liquid gasket. [4]
IDLE EXHAUST
• If it has been left for 90 minutes or longer, remove the old PORT GASKET
gasket and apply a liquid gasket again before installation.
6 x 25 (3)
17) Install the idle exhaust port gasket on the mounting case
and tighten the three 6 x 25 mm flange bolts securely.
[5]
IDLE EXHAUST
PORT

[4]
IDLE EXHAUST
PORT GASKET

18) Install the mounting case rubber seal on the mounting case
with the cut side to your side.

19) Install the under cover seal A on the mounting case (P. 15-
3).

[1]
[2] Install with
MOUNTING CASE
the cut side
RUBBER SEAL
to your side.

15-8
f. INSTALLATION

1) Set the mounting case assembly on the mount frame and tighten the two 12 mm self-locking nut to the specified
torque.

TORQUE: 83 N.m (8.5 kgf.m, 61 lbf.ft)

2) Remove the following parts.

– Engine assembly (P. 7-6)
– Water relief tube C (P. 8-7)
– Under cover front bracket (P. 4-31)
– L./R. engine under covers (P. 4-14)
– Engine cover (P. 4-2)

[2]
MOUNTING CASE
ASSEMBLY

[1]
12 mm SELF-LOCKING
NUT (2)
83 N.m (8.5 kgf.m,
61 lbf.ft)

15-9
2. STERN BRACKET/SWIVEL CASE [1] POWER TILT MOTOR [2] TRIM ANGLE
2P CONNECTOR SENSOR
REMOVAL/INSTALLATION 3P CONNECTOR

a. REMOVAL
Remove the following parts.
– Engine cover (P. 4-2)
– L./R. engine under covers (P. 4-9)
– Gear case assembly (P. 14-3 and 42)
– Remote control cable/grommet (P. 17-2)
– Starter cable (P. 18-15)
1) Place the outboard on a level surface (i.e. outboard motor
in the vertical position).
2) Remove the trim angle sensor 3P connector and the power
tilt motor 2P connector from the connector bracket A. [3]
CONNECTOR
Disconnect the trim angle sensor 3P connector and the BRACKET A
power tilt motor 2P connector.

3) Remove the undercase grommet C outside the under cover

front bracket. [1] UNDER COVER [2]
FRONT BRACKET WIRES [3]
TUBE
Pull off the tube and wires through the hole in the under
cover front bracket.

[5]
HOLE [4]
UNDERCASE
GROMMET C

4) Hook the hoist hook on each of the three engine hangers.

[2] HOIST CHAIN
Remove the following part.
– Lower rubber mount (P. 14-89)
[3]
[1] ENGINE ENGINE
NOTICE HANGER B HANGER (2)
Check that the outboard motor is not lifted off.

15-10
5) Swing the outboard motor right and left and remove the
two 12 mm self-locking nuts.

6) Check that the engine assembly/mounting case mating

surfaces are level to the ground.
Holding the outboard motor with the hoist, remove the
stern bracket/swivel case assembly mounted on the
outboard motor stand from the outboard motor.
If it is hard to remove the stern bracket/swivel case
assembly, remove by raising and lowering the outboard
motor slowly with the hoist.

NOTICE
• Do not raise the outboard motor stand off the ground
while raising the outboard motor with the hoist. [1] 12 mm SELF-
LOCKING NUT
• Remove the stern bracket/swivel case assembly with care
not to damage the threads of the two 12 x 145 mm stud
bolts.
7) After removing the stern bracket/swivel case assembly,
lower the outboard motor slowly.
Store the outboard motor with the extension case set on
the ground.

NOTICE
• If it is necessary to store the outboard motor by laying it
on its side, install the L./R. engine under covers (P. 4-14), [1]
12 mm SELF-
drain the engine oil (P. 3-2) and drain the gasoline from
LOCKING NUT
the vapor separator.
• Then, lay the outboard motor on a urethane foam sheet
or blanket with the intake manifold toward down.

[1]
12 mm SELF-LOCKING
NUT (2)

[2]
STERN BRACKET/SWIVEL
CASE ASSEMBLY

15-11
b. INSTALLATION
1) Lift up the outboard motor until the 12 x 145 mm stud bolts are flush with the holes in the mount frame of the stern
bracket/swivel case assembly.
2) Holding the outboard motor with the hoist, move the stern bracket/swivel case assembly, that are attached to the
outboard motor stand, slowly toward the outboard motor.
Insert the 12 x 145 mm stud bolts into the mount frame and tighten the two 12 mm self-locking nuts to the specified
torque.
TORQUE: 83 N.m (8.5 kgf.m, 61 lbf.ft)

[1]
12 mm SELF-LOCKING
NUT (2)
83 N.m (8.5 kgf.m,
61 lbf.ft)

[2] STERN BRACKET/SWIVEL

CASE ASSEMBLY

3) Install the lower rubber mount (P. 14-93).

[2] HOIST CHAIN
4) Detach the hoist hooks from the three engine hangers.

[3]
[1] ENGINE ENGINE
HANGER B HANGER (2)

15-12
5) Pass the tube and wires through the hole in the under cover
front bracket. [1] UNDER COVER [2]
FRONT BRACKET WIRES [3]
TUBE
Check that the taped ends of the power tilt motor wire and
trim angle sensor wire are in alignment with the end of the
undercase grommet C.

Install the undercase grommet C on the under cover front

bracket so they engage securely in the groove of the
undercase grommet C.

Move the front lock with a hand and check that the wires
and tube do not interfere with the front lock.

[5]
HOLE [4] UNDERCASE
GROMMET C

[7] Wires and tube must

not interfere with the
lock lever.
[6]
FRONT LOCK

[8]
TAPED
[4] PARTS
UNDERCASE
GROMMET C

[9] POWER
[11] SPEED TILT
[10]
SENSOR MOTOR
TRIM ANGLE
TUBE A WIRE
SENSOR WIRE

6) Connect the trim angle sensor 3P connector and the power

[1] POWER TILT MOTOR [2] TRIM ANGLE
tilt motor 2P connector. SENSOR
2P CONNECTOR
3P CONNECTOR
Install the power tilt motor 2P connector on the lower side
of the connector bracket A and the trim angle sensor 3P
connector on the upper side of the connector bracket A.

7) Install the following parts.

– Starter cable (P. 18-17)
– Remote control cable/grommet (P. 17-5)
– Gear case assembly (P. 14-5 and 44)
– L./R. engine under covers (P. 4-14)
– Engine cover (P. 4-2)

[3]
CONNECTOR
BRACKET A

15-13
3. STERN BRACKET/SWIVEL CASE/
POWER TRIM/TILT ASSEMBLY
a. STERN BRACKET/SWIVEL CASE/POWER TRIM/
TILT ASSEMBLY REMOVAL
Remove the following parts.
– Engine cover (P. 4-2)
– L./R. engine under covers (P. 4-9)
– Gear case assembly (P. 14-3 and 42)
– Stern bracket/swivel case (P. 15-10)
1) Loosen the manual valve fully and set the swivel case
assembly in the uppermost position.
After raising the swivel case assembly to the uppermost
[1] MANUAL VALVE
position, secure it in the position with the tilt stopper.
Tighten the manual valve.

2) Open the wire harness clip and release the trim angle
sensor wire, power tilt motor wire and the speed sensor [1] WIRE HARNESS
tube A. CLIP

Remove the spiral tube from the trim angle sensor wire,
power tilt motor wire and the speed sensor tube A.

[2]
SPIRAL TUBE

[3] WIRE/TUBE

3) Remove the wire band from the undercase grommet C and

release the trim angle sensor wire, power tilt motor wire
and the speed sensor tube A.
[1] WIRE BAND
Replace the tie wire with a new one on assembly.

[2] UNDERCASE
GROMMET C

15-14
4) Open the two wire bands that secure the speed sensor tube
A and B and disconnect the speed sensor tube A and B [1] SPEED SENSOR
from the joint A. TUBE A

Replace the wire bands with the new ones on assembly.

Check the speed sensor tube A for deterioration and cracks.

Replace if necessary.

[4]
WIRE
BAND (2)

[2] SPEED SENSOR

[3] JOINT A TUBE B

5) Remove the motor wire bushing from the L. stern bracket.

[1] [2]
L. STERN MOTOR WIRE
BRACKET BUSHING

6) Remove the two 6 x 25 mm hex. bolts and the two 6 mm

washers, and remove the anode metal.

Check the anode metal for corrosion. If it is corroded

excessively, replace with a new one.

[2]
6 mm
WASHER (2)

[1] ANODE METAL [3] 6 x 25 mm

HEX. BOLT (2)

15-15
7) Remove the speed sensor tube plates that secure the speed
sensor tube B.

Remove the speed sensor tube B.

[1] SPEED SENSOR
Check the speed sensor tube B for deterioration and cracks. TUBE B
Replace if necessary.

[2] 6 x 8 mm
SCREW (2)
[3] SPEED SENSOR
TUBE PLATE (2)

8) Remove the 10 mm self-locking nut and 10 mm washer,

and remove the 10 x 235 mm hex. bolt.
[1]
10 mm SELF-LOCKING
NUT

[2] 10 mm
WASHER
[3] 10 x 235 mm
HEX. BOLT

15-16
9) Remove the 15 mm E-ring from the upper cylinder pin. Remove the upper cylinder pin and the piston rod of the
power trim/tilt assembly from the swivel case assembly.
Check the upper cylinder bushing mounted on the piston rod of the power trim/tilt assembly. If it is damaged, replace
with a new one.
10) Remove the upper cylinder bushing.
Replace with a new one on assembly.

[3]
SWIVEL CASE
ASSEMBLY

[2] UPPER CYLINDER PIN

[1] 15 mm E-RING (2)

[5] UPPER CYLINDER [4] PISTON ROD

BUSHING (2)

11) Remove the two 6 x 20 mm hex. bolts and the two 6 mm

washers from the trim angle sensor, and remove the trim
angle sensor.
[1]
TRIM ANGLE
SENSOR

[3]
6 mm WASHER (2) [2]
6 x 20 mm HEX.
BOLT (2)

15-17
12) Remove the tilting bolt cap and loosen the 25 x 2.0 mm self-
locking nut or the 7/8-14 UNF self-locking nut. [1] TILTING BOLT
CAP

13) Holding the power trim/tilt assembly with the hands,

extend the L./R. stern brackets to the right and left and
remove the lower cylinder collar and the two 32 mm wave
washers.

14) Pull off the wires and tube through the hole in the L. stern
bracket and remove the power trim/tilt assembly.
[3]
Check the lower cylinder bushings mounted on the power [2] 7/8-14 UNF SELF-
25 x 2.0 mm SELF-
trim/tilt assembly for damage. Replace the bushings with LOCKING NUT
LOCKING NUT
the new ones if necessary.

15) Remove the lower cylinder bushings.

Replace the lower cylinder bushings with the new ones on

assembly.

NOTICE
• Do not push in the piston rod after removing the power
trim/tilt assembly.

If the piston rod is pushed down, extend the piston rod

fully and hold it in the position.

• Store the power trim/tilt assembly vertically with the

upper cylinder pin installation part facing up after
removal. Never store the power trim/tilt assembly by
laying it on its side or with the lower cylinder collar [1] R. STERN
installation part facing up. BRACKET

• If it is hard to remove the lower cylinder collar, loosen the

25 x 2.0 mm self-locking nut again. [2] LOWER
CYLINDER
COLLAR
[7]
UPPER CYLINDER
PIN INSTALLATION
PART

[6]
L. STERN
BRACKET

[3] POWER TRIM/TILT

[5] ASSEMBLY
[8]
LOWER CYLINDER 32 mm WAVE
PIN INSTALLATION WASHER (2)
PART [4] LOWER CYLINDER
BUSHING (2)

15-18
16) Remove the 25 x 2.0 mm self-locking nut or 7/8-14 UNF self-locking nut from the tilting shaft.
Replace the 25 x 2.0 mm self-locking nut or 7/8-14 UNF self-locking nut with a new one on assembly.
17) Remove the tilting shaft and remove the L./R. stern brackets, two 26 mm wave washers and the swivel case assembly.
Check the swivel case bushing that is mounted on the swivel case assembly.
Replace the swivel case bushing if it is damaged.
18) Remove the swivel case bushing.
Replace the swivel case bushing with a new one on assembly.
19) Remove the 15.54 x 2.26 mm O-ring from the tilting shaft.
Replace the O-ring with a new one on assembly.
Remove the wire harness clip from the L. stern bracket.

[1] SWIVEL CASE ASSEMBLY

[2]
7/8-14 UNF SELF-
LOCKING NUT
[11] SWIVEL CASE
BUSHING

[3] TILTING BOLT

CAP
[10] 26 mm WAVE
WASHER (2)

[4] TILTING SHAFT

[9]
25 x 2.0 mm SELF-
LOCKING NUT
[5] 15.54 x 2.26 mm
O-RING

[8] WIRE HARNESS

CLIP

[6] R. STERN
[7] L. STERN BRACKET
BRACKET

b. INSPECTION
[1] TRIM ANGLE SENSOR
3P CONNECTOR
• TRIM ANGLE SENSOR

Attach the tester leads to the trim angle sensor connector and
measure the resistance.

Resistance between
4–6Ω
Light green/black and Black
Resistance between
2.7 – 4.3 kΩ
Yellow/blue and Black

15-19
c. COMPONENTS DRAWING

[1] TILTING BOLT

CAP

[16]
SPEED SENSOR
TUBE PLATE (2)

[15] 6 x 8 mm SCREW (2)

[2]
SPEED SENSOR
TUBE B
[14] WIRE HARNESS
CLIP

[3] 10 mm
[13]
WASHER
SPEED SENSOR
TUBE A

[12]
WIRE BAND (2)

[11] JOINT A
[4]
10 mm SELF-LOCKING
[10] SPEED SENSOR NUT
TUBE B 34 N.m (3.5 kgf.m,
25 lbf.ft)
[5] MOTOR WIRE
BUSHING

[9] 10 x 235 mm
HEX. BOLT [6] ANODE METAL

[8] 6 mm WASHER (2) [7] 6 x 25 mm

HEX. BOLT (2)

15-20
 [3]
15 mm E-RING (2)
[2] SWIVEL CASE [4] SWIVEL CASE
ASSEMBLY BUSHING (2)

[6]
[1] UPPER CYLINDER [5] 7/8-14 UNF SELF-
PIN TILTING LOCKING NUT
SHAFT
34 N.m (3.5 kgf.m,
25 lbf.ft)

[19] 6 x 20 mm
HEX. NUT (2)

[18] 6 mm WASHER (2)

[17] TRIM ANGLE [7]

SENSOR 15.54 x 2.26 mm
O-RING
[16] 25 x 2.5 mm SELF-
LOCKING NUT
34 N.m (3.5 kgf.m, [8]
26 mm WAVE
25 lbf.ft)
WASHER (2)

[9]
R. STERN
BRACKET

[10] UPPER CYLINDER

BUSHING (2)
[15] L. STERN
BRACKET
[11] LOWER CYLINDER
COLLAR

[12] POWER TRIM/TILT

[13] ASSEMBLY
LOWER CYLINDER
BUSHING (2)

[14] 32 mm WAVE
WASHER (2)

15-21
d. SWIVEL CASE ASSEMBLY DISASSEMBLY

1) Remove the 6 x 8 mm screw and the ground cable.

[1] 6 x 8 mm
Remove the 39 mm external circlip. SCREW

[3]
39 mm [2]
EXTERNAL GROUND
CIRCLIP CABLE

2) Put a mark on the mount frame so it aligns with the

“ ”mark on the lower mount center housing. [1] “ ” MARK [2] MOUNT
FRAME

[4] LOWER MOUNT [3] MARK

CENTER HOUSING

3) Remove the lower mount center housing using a hydraulic

press and the special tools as shown.
[2]
PRESS
TOOLS: [1]
Driver 07749-0010000 DRIVER
Attachment, 32 x 35 mm 07746-0010100 07749-0010000
Pilot, 30 mm 07746-0040700

[3]
PILOT, 30 mm
[5] 07746-0040700
ATTACHMENT,
32 x 35 mm
07746-0010100

[4] LOWER MOUNT

CENTER HOUSING

15-22
4) Remove the mount frame and the 34 mm thrust washer
from the swivel case. [1]
MOUNT FRAME
Remove the 40 mm wave washer.
[2]
SWIVEL CASE

[4]
34 mm THRUST [3]
WASHER 40 mm WAVE
WASHER

5) Check the 39.5 x 52 x 6 mm oil seal lip for cut and replace
if necessary before removing the oil seal. [1] SWIVEL CASE
LINER (2)
Remove the 39.5 x 52 x 6 mm oil seal from the swivel case
using a commercially available oil seal remover.

Replace the oil seal with a new one on assembly.

6) Remove the two swivel case liners from the swivel case.

[2]
SWIVEL
CASE

[3]
39.5 x 52 x 6 mm
OIL SEAL

15-23
7) Remove the three grease fittings from the swivel case.
[2] SWIVEL CASE
8) Remove the two 10 mm self-locking nuts and the two 10
mm washers, then remove the two thrust receivers. [3] 10 mm
SELF-
LOCKING
NUT (2)
[1] GREASE
FITTING (3)

[4] 10 mm
WASHER
(2)
[5]
THRUST
RECEIVER (2)

9) Remove the 6 x 14 mm hex. bolt, and remove the detent

assisted spring and the detent spring.

10) Using a commercially available 2.5 mm pin driver, drive out

the 2.5 x 20 mm spring pin to the position where it does not [1]
interfere with the swivel case as shown. 2.5 mm PIN
DRIVER
Remove the driven-out 2.5 x 20 mm spring pin using the (Commercially
available)
cutting pliers or equivalent tool.

Remove the spring pin on the other side in the same

manner.

11) Remove the two tilt stoppers and the tilting bracket. [2]
2.5 x 20 mm
SPRING PIN
Check the tilt arm bushings mounted on the swivel case.
(2)
Replace them with the new ones if they are damaged. [4]
2.5 x 20 mm
12) Remove the tilt arm bushings. HEX. BOLT [5]
[3]
DETENT ASSISTED
DETENT
Replace the tilt arm bushings with the new ones on SPRING
SPRING
assembly.
[2] 2.5 x 20 mm
SPRING PIN (2)
[9]
SWIVEL [6]
CASE TILTING
BRACKET

[8] TILT ARM [7]

BUSHING (2) TILT STOPPER (2)

15-24
e. COMPONENTS DRAWING

[2] 6 x 14 mm [3]
HEX. BOLT DETENT ASSISTED
SPRING [4]
[1] DETENT SWIVEL CASE
SPRING LINER (2)

[5] 2.5 x 20 mm
SPRING PIN (2)

[6] TILTING
[21] BRACKET
GREASE FITTING (3)
3 N.m (0.3 kgf.m,
2.2 lbf.ft) [7]
TILT
STOPPER (2)

[8] TILT ARM

BUSHING (2)
[20]
MOUNT FRAME

[9] 10 mm SELF-
LOCKING NUT (2)

[10] 10 mm
[19] WASHER (2)
34 mm THRUST
WASHER

[11] SWIVEL CASE

[18] THRUST
RECEIVER (2)

[12]
[17] 39.5 x 52 x 6 mm LOWER MOUNT
OIL SEAL CENTER HOUSING

[16] 40 mm WAVE [13]

WASHER 6 x 8 mm
SCREW

[15] 39 mm EXTERNAL
CIRCLIP [14] GROUND CABLE

15-25
f. SWIVEL CASE ASSEMBLY ASSEMBLY
[1] [2] PROJECTION
2.5 mm PIN
1) Apply grease to the circumference of the new tilt stopper DRIVER
bushings and install them on the swivel case. (Commercially
available)
2) Install the two tilt stoppers and the tilting bracket on the
swivel case.

Install the tilt stopper in the position shown.

[4]
Check that the projection on the tilting bracket is in the 2.5 x 20 mm
position shown. SPRING PIN [3] DRIVE-IN
(2) DIRECTION
3) Drive the 2.5 x 20 mm spring pins into the tilting bracket
using a commercially available 2.5 mm pin driver as
shown. 1 – 2 mm
[6] (0.04 – 0.08 in)
6 x 14 mm
Check that 1 – 2 mm (0.04 – 0.08 in) of the spring pin end is HEX. BOLT [7]
[5]
out of the tilting bracket at the opposite side from the DETENT ASSISTED
DETENT
driving side. SPRING SPRING

• Do not drive in the spring pins excessively. The tilt

[4] 2.5 x 20 mm
stopper cannot operate properly if the extrusion length of
SPRING PIN
the pin is more than 1 – 2 mm (0.04 – 0.08 in). (2)
[11]
4) Apply grease to the cam of the tilting bracket. SWIVEL
CASE [8] TILTING
BRACKET
5) Apply grease to the detent spring roller. Secure the detent
spring and the detent assisted spring with the 6 x 14 mm
hex. bolt.

[9]
TILT
[10] TILT ARM STOPPER
BUSHING (2) (2)

6) Install the two thrust receivers on the swivel case, then

install the two 10 mm washers and the two 10 mm self- [2] SWIVEL CASE
locking nuts.
[3] 10 mm
Tighten the 10 mm self-locking nuts securely. SELF-
LOCKING
Apply grease to the sliding surface of the thrust receiver. [1] NUT (2)
GREASE
7) Set the three grease fittings on the swivel case, and tighten FITTING (3)
them to the specified torque.

TORQUE: 3 N.m (0.3 kgf.m, 2.2 lbf.ft)

[4] 10 mm
WASHER
(2)
[5]
THRUST
RECEIVER (2)

15-26
8) Apply grease to the outer surface of the swivel case liner.
[3] PROJECTION [4] SWIVEL
CASE
Install the swivel case liner aligning the projection on the
[2] LINER
swivel case liner with the concave in the swivel case.
SWIVEL CASE
9) Apply grease the circumference of the new 39.5 x 52 x 6
[1]
mm oil seal and install it in the bottom of the swivel case.
CONCAVE
Note the installation direction of the oil seal.

Apply grease to the oil seal lip.

[2]
SWIVEL
CASE [1]
CONCAVE

[4] SWIVEL CASE

LINER
[3]
PROJECTION

[5]
39.5 x 52 x 6 mm
OIL SEAL

10) Apply grease to the surface of the 34 mm thrust washer and

install it on the mount frame.
[1] MOUNT FRAME
Apply grease to the entire surface of the mount frame shaft
and install the mount frame on the swivel case.
[2] SWIVEL CASE
• Install the mount frame with care not to push the swivel
case liner out of the swivel case.

11) Apply grease to the surface of the 40 mm wave washer and

install it on the mount frame.

[4]
34 mm
THRUST
WASHER [3] 40 mm WAVE
WASHER

15-27
12) Apply grease to the spline of the lower mount center
housing.
[1] “ ” MARK [2] MOUNT
FRAME
Install the lower mount center housing on the mount frame
aligning the “ ” mark on the lower center housing with
the mark on the mount frame that had been put during
disassembly.

[3] MARK
[4] LOWER MOUNT
CENTER HOUSING

13) Position the swivel case/mount frame on the hydraulic

press as shown.

14) Position the special tool on the lower mount center housing
as shown. [1]
DRIVER, 40 mm I.D.
Press fit the lower mount center housing until it contacts 07746-0030100
the swivel case (i.e. hydraulic pressure of the hydraulic
press rises slightly).
[2]
TOOL: LOWER MOUNT
Driver, 40 mm I.D. 07746-0030100 CENTER HOUSING

15-28
15) Remove the swivel case assembly and the special tool from
the hydraulic press. [1] 39 mm EXTERNAL [2]
CIRCLIP PART “A”
16) Check that the mount frame turns smoothly.
Check that the 39 mm external circlip sets in position
smoothly.

<Mount frame turns smoothly and circlip can be installed>

Install the 39 mm external circlip and apply grease to the

part “A” shown in the drawing.
[4] PRESS
<Circlip can be installed but the mount frame does not turn
smoothly>
[3]
(1) Attach the special tools to the lower mount center DRIVER [5]
housing. 07749-0010000 ATTACHMENT,
32 x 35 mm
07746-0010100
TOOLS:
Driver 07749-0010000
Attachment, 32 x 35 mm 07746-0010100
Pilot, 30 mm 07746-0040700 [7]
PILOT, 30 mm
(2) Tighten the puller bolt and align the surface of the lower 07746-0040700
mount center housing with the circlip installation
groove in the mount frame.
Remove the puller and the special tool.

(3) Install the 39 mm external circlip and apply grease to the

part “A” shown in the drawing.
[6] LOWER MOUNT
CENTER HOUSING

[8] CIRCLIP INSTALLATION

GROOVE

[9]
ENLARGED VIEW
OF MOUNT FRAME

17) Tighten the 6 x 8 mm screw while pushing the ground cable

against the projection of the lower mount center housing. [1] Push against [2] 6 x 8 mm SCREW
the projection.
18) After assembling the swivel case, fill the grease fittings
with the grease using a grease gun.

[4] [3]
GROUND LOWER MOUNT
CABLE CENTER HOUSING

15-29
g. STERN BRACKET/SWIVEL CASE/POWER TRIM/ [1] [2] SWIVEL CASE
TILT ASSEMBLY INSTALLATION SWIVEL ASSEMBLY
CASE
• Check that the piston rod of the power trim/tilt assembly is in BUSHING
[3]
the fully extended position. (2)
TILTING SHAFT
1) Apply grease to the inner wall and circumference of the
new swivel case bushings. Install the new swivel case
[4]
bushings on the swivel case. TILTING
2) Apply grease to the new 15.54 x 2.26 mm O-ring and install BOLT CAP
it in the groove in the tilting shaft.
Apply grease to the threads and bearing of the tilting shaft.
Apply grease to the shaft installation parts of the swivel
case assembly and of the L./R. stern brackets. [5] 7/8-14 UNF
SELF-LOCKING
3) Tighten the new 25 x 2.5 mm self-locking nut or the 7/8-14 NUT
UNF self-locking nut on the threads at either the right or left
end of the tilting shaft. [6]
15.54 x 2.26 mm
4) Apply grease to the entire surface of the 26 mm wave O-RING
washer. Install the stern bracket and the 26 mm wave
washer on the end of the tilting shaft where the self-locking [7] R. STERN
nut has been mounted. [11] BRACKET
WIRE
• When the 7/8-14 UNF self-locking nut has been tightened HARNESS [8] 26 mm WAVE
on the tilting shaft, insert the tilting shaft into the R. stern CLIP WASHER (2)
bracket.
[10] [9] 25 x 2.0 mm SELF-
5) Pass the tilting shaft through the swivel case assembly and L. STERN BRACKET LOCKING NUT
install the 26 mm wave washer and the stern bracket.
6) Loosely tighten the new 25 x 2.0 mm self-locking nut or the
7/8-24 UNF self-locking nut on the tilting shaft. Move the
L./R. stern brackets to the self-locking nut side.
Raise the swivel case assembly to the uppermost position
and hold it in the position with the tilt stopper.
Install the wire harness clip on the L. stern bracket.

7) Apply grease to the inner wall and circumference of the

new lower cylinder bushings and install them on the power
trim/tilt assembly. [1] POWER TRIM/TILT
ASSEMBLY
Apply grease to the circumference of the lower cylinder
collar and install it in the power trim/tilt assembly.
[2]
LOWER CYLINDER
Apply grease to the entire surface of the 26 mm wave COLLAR
washers and install them on the power trim/tilt assembly.

8) Pass the trim angle sensor wire, power tilt motor wire and
the speed sensor tube B through the hole in the L. stern
bracket.

9) Install the lower cylinder collar, that has been mounted in

the power trim/tilt assembly, on the L./R. stern brackets.
[4]
LOWER CYLINDER [3]
BUSHING (2) 32 mm WAVE
WASHER (2)

15-30
10) Tighten the 25 x 2.0 mm self-locking nut or the 7/8-14 UNF
self-locking nut to the specified torque. [1]
TILTING BOLT CAP
TORQUE: 34 N.m (3.5 kgf.m, 25 lbf.ft)

Tighten the 25 x 2.0 mm self-locking nut or the 7/8-14 UNF

self-locking nut of the other side to the specified torque.

TORQUE: 34 N.m (3.5 kgf.m, 25 lbf.ft)

Tighten the tilting bolt cap on the 7/8-14 UNF self-locking

nut.

[3] 25 x 2.0 mm SELF- [2] 7/8-14 UNF SELF-

LOCKING NUT LOCKING NUT

11) Set the two 6 x 20 mm hex. bolts and the two 6 mm

washers on the trim angle sensor.

Tighten the two 6 x 20 mm hex. bolts securely. [1]

TRIM ANGLE
SENSOR

12) Pass the trim angle sensor wire, power tilt motor wire and
the speed sensor tube B through the motor wire bushing.
Install the motor wire bushing in the L. stern bracket [3] 6 mm [2] 6 x 20 mm
aligning the projection on the motor wire bushing with the WASHER (2) HEX. BOLT (2)
concave in the L. stern bracket.

• Check that the speed sensor tube B is at the rear side in

the motor wire bushing, compared with the position of [2] CONCAVE [3]
the trim angle sensor wire and the power tilt motor wire, PROJECTION
by viewing the L. stern bracket from the reverse side. [1]
L. STERN
[5] <Viewing L. stern bracket from reverse side> BRACKET

[7] UP (ENGINE SIDE)

[8] TRIM ANGLE

SENSOR WIRE

[6]
REARWARD

[10] [9] POWER TILT

SPEED SENSOR MOTOR WIRE
TUBE B [4] MOTOR WIRE BUSHING

15-31
13) Check that the corrugated tube on the power tilt motor wire
stands erect as shown. [1] CORRUGATED TUBE
(It must stand erect.)

[2] POWER TILT

MOTOR WIRE

14) Clamp the speed sensor tube B with the two speed sensor
tube plates and loosely tighten the two 6 x 8 mm screws. [3] SPEED SENSOR
[2] 6 x 8 mm TUBE PLATE (2)
SCREW (2)
15) Tighten the 6 x 8 mm screw securely so that the distance
from the gear case side speed sensor tube end to the end
of the speed sensor tube plate is 15 – 20 mm (0.6 – 0.8 in)
as shown.
[1] SPEED
Route the speed sensor tube B on the L. stern bracket and SENSOR
tighten the 6 x 8 mm screw of the upper speed sensor tube TUBE B
plate securely.

15 – 20 mm
(0.6 – 0.8 in)

16) Connect the speed sensor tube A to the joint A and fasten
[1] [3] SPEED
the new wire band on the speed sensor tube A.
MOTOR [2] SENSOR
WIRE WIRE TUBE A
Connect the speed sensor tube B to the joint A and fasten BANDS
BUSHING
the new wire band on the speed sensor tube B.

17) Adjust the distance from the end of the motor wire bushing
to the end of the speed sensor tube B so that it is
10 – 15 mm (0.4 – 0.6 in) as shown.

[4] JOINT A

[5] SPEED 10 – 15 mm
SENSOR (0.4 – 0.6 in)
TUBE B

15-32
18) Wind the spiral tube around the trim angle sensor wire,
power tilt motor wire and the speed sensor tube A.
[1]
19) Align the taped end of the power tilt motor wire with the SPIRAL TUBE
end of the motor wire bushing and install.

Clamp the trim angle sensor wire, power tilt motor wire
and the speed sensor tube A with the wire harness clip. [8]
Avoid clamping on the spiral tube. WIRE HARNESS [2]
CLIP TRIM ANGLE
SENSOR WIRE

[3]
[7] MOTOR WIRE
SPEED SENSOR BUSHING
TUBE A

[6] POWER TILT

MOTOR WIRE
[4] L. STERN
BRACKET
[5] TAPE

20) Pass the trim angle sensor wire, power tilt motor wire and
the speed sensor tube A through the undercase grommet
C. [3] POWER TILT
[2] TRIM ANGLE MOTOR WIRE
SENSOR WIRE
21) Align the taped ends of the trim angle sensor wire and the
power tilt motor wire with the end of the undercase
grommet C, and fasten the new wire band as shown.

After fastening the wire band, cut the excess of the wire
[1] SPEED
band so that the projected length is 5 – 10 mm (0.2 – 0.4 in)
SENSOR
(P. 2-44). TUBE A
[4]
TAPED PARTS

[5] WIRE BAND

[6] UNDERCASE
GROMMET C

15-33
22) Apply grease to the inner wall and circumference of the new upper cylinder bushings and install them on the piston
rod of the power trim/tilt assembly.
23) Apply grease to the circumference of the upper cylinder pin.
24) Align the hole in the piston rod with the hole in the swivel case assembly and insert the upper cylinder pin into the
swivel case assembly.
Install the two 15 mm E-rings on the upper cylinder pin.

[3] SWIVEL CASE

ASSEMBLY

[2] UPPER CYLINDER PIN

[1]
15 mm E-RING (2)

[5] UPPER CYLINDER [4] PISTON ROD

BUSHING (2)

25) Insert the 10 x 235 mm hex. bolt from the L. stern bracket
side and set the 10 mm washer.

Tighten the 10 mm self-locking nut to the specified torque. [1]

10 mm SELF-
TORQUE: 34 N.m (3.5 kgf.m, 25 lbf.ft) LOCKING NUT

[2] 10 mm WASHER
[3] 10 x 235 mm
HEX. BOLT

15-34
26) Check the anode metal for corrosion and replace with a
new one if necessary.

Tighten the anode metal with the two 6 x 25 mm hex. bolts

securely.

[2]
6 mm
WASHER (2)

[1] ANODE [3]

METAL 6 x 25 mm
HEX. BOLT (2)

27) If the manual valve is tightened, loosen it fully.

Raise the swivel case assembly a little, unlock the tilt

stopper and lower the swivel case assembly to the
lowermost position.

28) Remove the following parts.

– Stern bracket/swivel case (P. 15-12)
– Gear case assembly (P. 14-5 and 44)
– L./R. engine under covers (P. 4-14)
– Engine cover (P. 4-2)

[1] MANUAL VALVE

15-35
4. POWER TRIM/TILT ASSEMBLY
a. REMOVAL
Remove the stern bracket, swivel case and the power trim/tilt assembly (P. 15-14).

b. DISASSEMBLY
• Do not reuse the O-rings.
• Do not try to disassemble the pump assembly. Replace the pump assembly as an assembly if it is faulty.
• Do not use a shop towel or equivalent cloth, and do not wear the gloves during this operation.
• Do not reuse the drained Automatic Transmission Fluid (ATF).
• When the operation is made by holding the cylinder comp. in a vice, do not tighten the vice excessively. It can damage
the cylinder comp.
• Clean the disassembled parts with the fresh Automatic Transmission Fluid (ATF) and blow the parts with compressed
air to remove dust and dirt. Store the parts neatly keeping them off dust, dirt, oil/grease, etc.
• Remove the piston rod comp. and the piston rod B with care not to damage the sliding surface of the parts.

With the power trim/tilt assembly removed from the outboard

motor, connect the power tilt motor 2P connector and operate [1] OIL TANK CAP
the power tilt motor until the piston rod comp. and the piston
rod B reach the fully extended position.

1) Remove the oil tank cap.

Drain the Automatic Transmission Fluid (ATF) from the oil

tank.

• Do not drain the Automatic Transmission Fluid (ATF) by

pushing the piston rod comp. in.

2) Loosely tighten the oil tank cap on the oil tank.

[2]
Remove the three hex. bolts and remove the oil tank from OIL TANK
the cylinder comp.
[1] O-RING
Drain the Automatic Transmission Fluid (ATF) from the oil
tank.

3) Remove the O-ring from the cylinder comp.

Replace the O-ring with a new one on assembly.

[3]
HEX. BOLT (3)

15-36
4) Remove the four hex. bolts and remove the power tilt
motor assembly from the pump assembly. [1] HEX. BOLT (4)

Drain the Automatic Transmission Fluid (ATF) from the

pump assembly.

[2] POWER TILT

MOTOR
ASSEMBLY

[3]
PUMP ASSEMBLY

5) Remove the O-ring from the power tilt motor assembly.

Replace the O-ring with a new one on assembly. [1] O-RING

[2] POWER TILT

MOTOR
ASSEMBLY

6) Remove the drive joint and the filter B from the pump
assembly.
[1] DRIVE JOINT
Check the mesh of the filter B for blockage and tear. If it is
torn, replace the filter B with a new one. If it is clogged with
dust and dirt, blow the mesh with air to remove the [2] FILTER B
blockage. Take care not to damage the mesh.

Drain the residual Automatic Transmission Fluid (ATF) from

the pump assembly.
[3]
PUMP
ASSEMBLY

7) Remove the socket bolt A and Bs, and remove the pump
assembly from the cylinder comp. [3] O-RING (5)
[2] PUMP ASSEMBLY
Remove the five O-rings and orifice collar from the cylinder
comp. [1]
SOCKET
Replace the O-rings with the new ones on assembly. BOLT B (2)

[4]
[5] SOCKET BOLT A ORIFICE COLLAR

15-37
8) Remove the internal circlip and remove the manual valve
from the pump assembly. [3] PUMP ASSEMBLY

Check the manual valve and the O-ring for deterioration, [1] INTERNAL
wear and damage. Replace them if necessary. CIRCLIP

[2]
Replace the manual valve with a new one on assembly.
MANUAL
VALVE

9) Set the cylinder comp. in a vice as shown.

[2]
NOTICE CYLINDER COMP.
Do not tighten the vice excessively, as it can damage the
cylinder comp.
[1] VICE

10) Check that the left and right piston rods are in the fully
extended position. [1]
ROD GUIDE
COMP.
11) Loosen the rod guide comp. fully using the special tool as
shown.

TOOL:
Pin wrench, 4 mm 07SPA-ZW10200

[2] PIN WRENCH, 4 mm

07SPA-ZW10200

12) Remove the rod guide comp. and the piston rod Bs from
the trim cylinders slowly.

• Do not push the piston rod Bs into the trim cylinders.

13) Drain the Automatic Transmission Fluid (ATF) from the trim
[1]
cylinders.
ROD GUIDE
COMP. (2)
Remove the rod guide comps from the piston rod B.

[2] PISTON
ROD B (2)

15-38
14) Remove the O-ring from the rod guide comp.
[1] DUST
Replace the O-ring with a new one on assembly. SEAL
[2]
15) Insert a sharp-end screwdriver into the gap between the OIL SEAL
dust seal and the rod guide comp. Raise the dust seal and
remove it from the rod guide comp. [4]
ROD GUIDE
Remove the oil seal in the rod guide comp. in the same COMP.
manner.

Replace the dust seal and the oil seal with the new ones on [3]
assembly. O-RING

• Take care not to damage inside the rod guide comp. [3]
during this operation. O-RING [5]
SHARP-END
SCREWDRIVER [6]
Raise the
[1] DUST SEAL seal.

[2]
[4] ROD GUIDE OIL SEAL
COMP.

16) Remove the backup ring and the O-ring from the piston rod
B.
[1]
PISTON ROD B
Replace the backup ring and the O-ring with the new ones
as a set on assembly.

17) Check the piston rod B. If it is scored or scratched, or if the

rod is bent, replace the piston rod B with a new one. [2]
BACKUP RING

[3]
O-RING

18) Hold the cylinder comp. in a vice (P. 15-38).

19) Check that the piston rod comp. is in the fully extended
position.

20) Using the special tool, loosen the cylinder cap fully as
shown. [1]
PIN WRENCH,
6 mm
TOOL:
07SPA-ZW10100
Pin wrench, 6 mm 07SPA-ZW10100

[2] CYLINDER CAP

15-39
21) Remove the piston rod comp. from the cylinder comp.
[1]
[2]
CYLINDER COMP.
22) Remove the O-rings from the cylinder cap and the piston PISTON ROD
rod comp. COMP.

Replace the O-rings with the new ones on assembly.

[3]
CYLINDER
CAP

[4]
O-RINGS

23) Remove the free piston from the cylinder comp.

[1] FREE
Check the sliding surface of the free piston for wear and PISTON
damage. Replace the free piston if necessary. [2]
BACKUP
RING
24) Remove the backup ring and the O-ring from the free
piston. [4]
O-RING
Replace the backup ring and the O-ring as a set on
assembly.
[3]
Drain the residual Automatic Transmission Fluid (ATF) from CYLINDER
the cylinder comp. COMP.

c. INSPECTION [1] POWER TILT MOTOR

2P CONNECTOR
• POWER TILT MOTOR

Check for continuity between the terminals.

15-40
d. COMPONENTS DRAWING

[3]
PISTON ROD COMP.

[5] CYLINDER CAP

162 N.m (16.5kgf.m,
[2] 119 lbf.ft)
POWER TILT MOTOR
ASSEMBLY

[6] FREE PISTON

[1] HEX. BOLT (4)
[4]
5 N.m (0.5 kgf.m, O-RINGS [7] BACKUP RING
3.6 lbf.ft)
[10] HEX. BOLT (3)
[8] 5 N.m (0.5 kgf.m,
O-RING
3.6 lbf.ft)

[8] O-RING [9] OIL [11] OIL TANK CAP

TANK 2.5 N.m (0.25 kgf.m,
1.8 lbf.ft)

[26] DRIVE JOINT [12] DUST SEAL (2)

[27]
FILTER B
[25] PUMP
ASSEMBLY
[13]
OIL SEAL
(2)
[24] MANUAL VALVE
3.5 N.m (0.35 kgf.m,
2.5 lbf.ft) [14] ROD GUIDE
COMP. (2)
78 N.m (8.0 kgf.m,
58 lbf.ft)

[15] O-RING (2)

[23]
INTERNAL
CIRCLIP [20]
ORIFICE [16] PISTON ROD B (2)
COLLAR

[22] SOCKET BOLT A

[17] BACKUP RING (2)
8.5 N.m (0.85 kgf.m, [19] O-RING (5)
6.1 lbf.ft)
[18] CYLINDER
COMP. [15] O-RING (2)
[21] SOCKET BOLT B (2)
8.5 N.m (0.85 kgf.m,
6.1 lbf.ft)

15-41
e. ASSEMBLY

• Do not reuse the O-rings.

• Do not use a shop towel or equivalent cloth, and do not wear the gloves during this operation.
• Do not reuse the drained Automatic Transmission Fluid (ATF).
• When the operation is made by holding the cylinder comp. in a vice, do not tighten the vice excessively. It can damage
the cylinder comp.
• Add the Automatic Transmission Fluid (ATF) slowly.
• Assemble the power trim/tilt assembly with the piston rod comp. and the piston rod B fully extended. Do not push in
the piston rod comp. and the piston rod B.
• Do not allow the dust, dirt and other foreign material enter the cylinder comp. and the pump assembly during
assembly.
• Clean the parts with the fresh Automatic Transmission Fluid (ATF) and blow each port with compressed air to remove
dust and dirt. Check that the parts are clean before assembly.
• After assembly, coat the joints or mating sections of the parts and the sections where the paint came off with rust
preventive paint of the same color.

1) Hold the cylinder comp. in a vice as shown.

NOTICE
Do not tighten the vice excessively as it can damage the [2]
cylinder comp. CYLINDER
COMP.
2) Pour approximately 30 cm3(1.0 fl oz.) of the Automatic
Transmission Fluid (ATF) in the piston rod chamber of the
cylinder comp.
[1] VICE
Genuine Honda Automatic
Recommended oil Transmission Fluid (ATF)
DEXRON® or equivalent.

3) Apply Automatic Transmission Fluid (ATF) to the new O-

ring and the backup ring. Install the O-ring and backup ring [1] FREE PISTON
on the free piston.

4) Apply Automatic Transmission Fluid (ATF) to the [2] BACKUP

RING
circumference of the free piston and push it in the piston
rod chamber slowly until it bottoms out.

NOTICE (ATF)
[3] O-RING
Install the backup ring on the free piston with care not to
break it.
[4]
CYLINDER
COMP.

15-42
5) After installing the free piston, pour the fresh Automatic
Transmission Fluid (ATF) slowly up to the top of the piston
rod chamber of the cylinder comp. [1] Pour slowly
up to the top
of the piston
rod chamber.

6) Apply Automatic Transmission Fluid (ATF) to the new O-

ring and install it on the piston rod comp. [1] CYLINDER [2] PISTON
COMP. ROD
7) Apply Automatic Transmission Fluid (ATF) to the new O- COMP.
ring and install it on the cylinder cap.
[3]
8) With the piston rod comp. fully extended, install the piston CYLINDER
rod comp. slowly in the piston rod chamber of the cylinder CAP
comp.

Loosely tighten the cylinder cap.

• Do not install the piston rod comp. by pushing it in the [4] O-RINGS
(ATF)
piston rod chamber.

9) Tighten the cylinder cap to the specified torque using the

special tool as shown.

TOOL:
Pin wrench, 6 mm 07SPA-ZW10100

TORQUE: 162 N.m (16.5 kgf.m, 119 lbf.ft)

[1] PIN WRENCH,
6 mm
07SPA-ZW10100

[2] CYLINDER
CAP

10) Pour the fresh Automatic Transmission Fluid (ATF) in the

right and left trim cylinder chambers up to the top of the [1]
trim cylinder chamber. Pour slowly up to the
top of the trim cylinder
chamber.

15-43
11) Apply Automatic Transmission Fluid (ATF) to the new O-
ring and the backup ring and install them on the piston rod
comp. [1] PISTON
ROD B
• Install the backup ring on the free piston with care not to
break it.
[2]
BACKUP
RING
(ATF)

[3] O-RING

12) Apply Automatic Transmission Fluid (ATF) to the new oil

seal. [1] DUST SEAL

Holding the oil seal in the shape of “U” with your fingers,
install it in the lower groove in the rod guide comp. [2] OIL SEAL

13) Apply Automatic Transmission Fluid (ATF) to the new dust

seal. [3] ROD
GUIDE (ATF)
Holding the dust seal in the shape of “U” with your fingers, COMP.
install it in the upper groove in the rod guide comp.

14) Apply Automatic Transmission Fluid (ATF) to the new O- [4] O-RING
ring and install it on the rod guide comp.

[3]
[2] OIL SEAL ROD GUIDE COMP.

[4] O-RING [1] DUST SEAL

15) Install the rod guide comp. on the piston rod B.

Extend the piston rod fully and hold it in the position.

16) Holding the piston rod Bs aslant a little, set each of piston
rod Bs in the left and right trim cylinder chambers.
[1]
• Do not install the piston rod Bs by pushing them into ROD GUIDE
respective trim cylinders. COMP. (2)

17) Install the piston rod B in the trim cylinder chamber slowly.
[2]
PISTON
ROD B (2)

15-44
18) Holding the piston rod B in place, loosely tighten the rod
guide comp. on the cylinder comp. [1]
ROD GUIDE
COMP.
• Do not install the piston rod Bs by pushing them into
respective trim cylinders.

19) Using the special tool, tighten the left and right rod guide
comps. to the specified torque as shown.

TOOL:
Pin wrench, 4 mm 07SPA-ZW10200
[2] PIN WRENCH,
4 mm
TORQUE: 78 N.m (8.0 kgf.m, 58 lbf.ft)
07SPA-ZW10200

20) Check the manual valve and the O-ring for deterioration,
wear and damage. Replace the manual valve with a new [1] PUMP
one if necessary. ASSEMBLY

21) Apply Automatic Transmission Fluid (ATF) to the manual [2]MANUAL

valve O-ring. VALVE

Set the manual valve on the pump assembly and tighten it

to the specified torque.

TORQUE: 3.5 N.m (0.35 kgf.m, 2.5 lbf.ft)

[3]INTERNAL
CIRCLIP
22) Install the internal circlip securely in the groove in the (ATF)
pump assembly.

23) Apply Automatic Transmission Fluid (ATF) to the five new

O-rings and the orifice collar. [2]
PUMP ASSEMBLY
Set the five O-rings and the orifice collar in the indicated
(ATF)
position of the cylinder comp. [1]
SOCKET
24) Install the pump assembly on the cylinder comp. with the BOLT B (2)
socket bolt A and B.

Tighten the socket bolt A and B to the specified torque.

TORQUE: 8.5 N.m (0.85 kgf.m, 6.1 lbf.ft) [3]

[4] ORIFICE O-RING (5)
[5] SOCKET BOLT A COLLAR

25) Fill the pump assembly with the fresh Automatic

Transmission Fluid (ATF).
[1]
PUMP ASSEMBLY
• Do not fill up the pump assembly quickly. Pour the
Automatic Transmission Fluid (ATF) in the pump
assembly slowly.

15-45
26) Check the filter B for blockage and damage. Replace the
filter B if it is damaged. [1]
DRIVE JOINT
Blow air through the filter B if it is clogged. Clean the filter
B carefully to avoid damage.
[2]
FILTER B
Install the filter B and the drive joint on the pump assembly.

[3]
PUMP
ASSEMBLY

27) After installation, check the filter B for bubbles. Remove the
bubbles with the oil bottle or equivalent tool if necessary. [1] OIL BOTTLE

• Be sure to remove the air bubbles, or it will cause air in

the system.

28) After removing the air bubbles, fill the pump assembly fully
with the Automatic Transmission Fluid (ATF) again.

29) Apply Automatic Transmission Fluid (ATF) to the new O-

ring and install it on the power tilt motor assembly.
[1] O-RING

(ATF)

[2] POWER TILT

MOTOR
ASSEMBLY

30) Install the power tilt motor assembly on the pump

assembly aligning the projection on the power tilt motor [1] MOTOR
assembly with the recess in the drive joint and with the [2]
WIRE RECESS
motor wire of the power tilt motor assembly at the manual
IN DRIVE
valve side.
JOINT

[3] PROJECTION

15-46
31) Set the four hex. bolts on the power tilt motor assembly
and tighten the bolts to the specified torque. [1] HEX. BOLT (4)

TORQUE: 5 N.m (0.5 kgf.m, 3.6 lbf.ft)

[2]
POWER TILT
MOTOR
ASSEMBLY

[3] PUMP
ASSEMBLY

32) Apply Automatic Transmission Fluid (ATF) to the new O-

ring and install it on the cylinder comp. [1] OIL TANK

33) Install the oil tank on the cylinder comp. and tighten the
three hex. bolts to the specified torque. (ATF)
[2]
TORQUE: 5 N.m (0.5 kgf.m, 3.6 lbf.ft) HEX. BOLT
(3)

[3] O-RING

34) Remove the oil tank cap. Pour fresh Automatic

Transmission Fluid (ATF) to the upper limit of the oil tank
filler port.

Oil capacity 0.68R (0.72 US qt, 0.60 Imp qt)

NOTICE
Do not overfill with Automatic Transmission Fluid (ATF).
Pouring the Automatic Transmission Fluid (ATF) while it is
flowing out of the filler port will overfill the tank, and that [1]
will damage the oil seal of the motor when each rod is OIL TANK CAP
compressed.

35) After filling the oil tank with Automatic Transmission Fluid
(ATF), bleed air from the power trim/tilt assembly <without
mounting on the outboard motor> (P. 15-48).

36) Tighten the oil tank cap to the specified torque.

[2]
TORQUE: 2.5 N.m (0.25 kgf.m, 1.8 lbf.ft) UPPER
LIMIT

15-47
5. AIR BLEEDING
<Power trim/tilt assembly not mounted on the
outboard motor>

• Bleed air from the unit whenever the power trim/tilt assembly
is disassembled.

• Be sure to perform air bleeding in the following order.

Air bleeding without mounting the unit on the outboard
[1]
motor; Check on blow pressure; Air bleeding after mounting POWER TILT MOTOR
the unit on the outboard motor. 2P CONNECTOR

Connect each cable to operate the power trim/tilt assembly.

– Connect the positive (+) and negative (–) starter cables.

– Connect the power tilt motor 2P connector to the power tilt

relay.
[1]
– Be sure that the starter cables are connected to the battery. UPPER
LIMIT
1) Hold the power trim/tilt assembly vertically.

2) Push the “DN” side of the power tilt switch to compress

each rod fully.

3) Push the “UP” side of the power tilt switch to extend each
rod fully.

4) Remove the oil tank cap with each rod extended fully.
[2] POWER TILT
Check whether the Automatic Transmission Fluid (ATF) is at SWITCH
the upper limit of the oil tank filler port.

If Automatic Transmission Fluid (ATF) does not flow out of

the filler port, add Automatic Transmission Fluid (ATF) up
to the upper limit of the filler port using a syringe or
equivalent tool.

• Check the fluid level with the rods fully extended.

Note that Automatic Transmission Fluid (ATF) will spurt
out when the oil tank cap is removed with the rods fully
compressed.

5) After adding Automatic Transmission Fluid (ATF), repeat

the procedure from step 2 through 4 two or three times to
bleed air from the unit.

6) Be sure that the rods extend and compress during the step
5 operation.

• When the rods extend and compress fully, perform the

blow pressure check (P. 15-50) and air bleeding with the
unit mounted on the outboard motor (P. 15-49).

• When the rods do not compress fully, perform the

procedure explained under <when the rods do not
compress fully> (P. 15-49).

15-48
<When the rods do not compress fully>

1) With the rods extended fully, push the “UP” side of the
power tilt switch until the unit blows again. Push the “DN”
side of the power tilt switch, and be sure that the rods
compress.

If the rods compress fully, go to the blow pressure

inspection (P. 15-50).
[1] POWER TILT
2) If the rods do not compress after the step 1 operation, push SWITCH
the “DN” side of the power tilt switch while pushing the
piston rod B, and check whether the rods compress.

If the rods compress fully, go to the blow pressure

inspection (P. 15-50).

3) If the rods still do not compress after the step 2 operation,

loosen the manual valve and compress each rod. Tighten
the manual valve securely again. Push the “UP” side of the
power tilt switch to extend the rods fully, then push the
“DN” side of the switch and check whether the rods
compress fully.
[2]
If the rods compress fully, go to the blow pressure PISTON RODS B
inspection (P. 15-50).

4) If the rods do not compress fully after the above operation,

disassemble (P. 15-36) and reassemble (P. 15-42) the power
trim/tilt assembly and bleed air with the power trim/tilt
assembly not mounted on the outboard motor (P. 15-48).

<Air bleeding with power trim/tilt assembly

mounted on the outboard motor>

Perform the following procedure after bleeding air without [3] MANUAL VALVE
mounting the power trim/tilt assembly on the outboard motor
(P. 15-48) and after blow pressure inspection (P. 15-50).

1) Install the power trim/tilt assembly on the outboard motor

securely (P. 15-30).

2) Push the “UP” side of the power tilt switch and raise the [2]
outboard motor to the uppermost position. UPPER
LIMIT
Remove the oil tank cap, and check whether the Automatic
Transmission Fluid (ATF) is at the upper limit of the oil filler
port of the oil tank.

If the Automatic Transmission Fluid (ATF) does not flow out

of the oil filler port, add the Automatic Transmission Fluid [1] OIL TANK CAP
(ATF) up to the upper limit of the oil filler port using a
syringe or equivalent tool.

15-49
3) Lower the outboard motor slowly to the lowermost
[1] MANUAL VALVE
position by loosening the manual valve.

4) Tighten the manual valve securely.

5) Hold the outboard motor in the lowermost position for five

minutes.

6) Then, push the “UP” side of the power tilt switch and raise
the outboard motor to the uppermost position. Hold the
outboard motor in this position for five minutes. After five
minutes, check the fluid level in the oil tank (P. 15-47).
[3] TO LOOSEN [2] TO TIGHTEN
7) Repeat the procedure from step 3 through 6 five times.

6. BLOW PRESSURE INSPECTION

After bleeding air from the power trim/tilt assembly without [1]
mounting on the outboard motor and checking each rod for INTERNAL
proper compression, perform the following operation in the CIRCLIP
same manner as bleeding air without mounting on the
outboard motor.

1) Operate each rod of the power trim/tilt assembly (i.e. move

them up and down) several times and set the rods in the
full extended position.

2) Check that the Automatic Transmission Fluid (ATF) is at the [2] MANUAL VALVE
upper level in the oil tank (P. 15-47).

3) Using the special tools, check the blow pressure at the

upper and lower chambers of the cylinder.
[1] OIL PRESSURE GAUGE
a. LOWER CHAMBER BLOW PRESSURE JOINT B (Lower chamber)
07SPJ-ZW10200
1) Remove the internal circlip and manual valve from the
power trim/tilt assembly.

• Note that Automatic Transmission Fluid (ATF) will spurt

out when the manual valve is removed without the rods
fully extended. Move each rod to the fully extended
[2]
position before removing the manual valve. OIL PRESSURE GAUGE
• A small amount of the Automatic Transmission Fluid JOINT A (Upper chamber)
07SPJ-ZW10100
(ATF) will flow out when the manual valve is removed.
Attach the special tools quickly.
[3]
2) Attach the special tool (oil pressure gauge joint B) for PRESSURE GAUGE
measurement of lower chamber blow pressure to the (Commercially available)
manual valve installation section as shown.

Tighten the special tool to the specified torque.

TOOL:
Oil pressure gauge joint B 07SPJ-ZW10200

TORQUE: 9 N.m (0.9 kgf.m, 6.5 lbf.ft)

3) Attach a commercially available pressure gauge [P/T 1/4] [2] OIL PRESSURE GAUGE
which measures 14,710 kPa (150 kgf/cm2, 2,133 psi) or JOINT B (Lower chamber)
above to the special tool (oil pressure gauge joint B). 07SPJ-ZW10200

15-50
4) Remove the oil tank cap. Check that Automatic
Transmission Fluid (ATF) is at the upper limit of the filler
port (P. 15-47).

5) Push the “DN” side of the power tilt switch to compress

each rod fully.

6) Push the “UP” side of the power tilt switch to extend each
rod fully again. Read the pressure gauge to measure the
lower chamber blow pressure.

Lower chamber 8,826 – 11,768 kPa (90 – 120 kgf/cm2,

blow pressure 1,280 – 1,707 psi)

7) If the blow pressure is lower than the specified pressure,

check each part of the power trim/tilt assembly for oil
leakage (P. 15-54).

8) If there is no oil leakage but the pressure dropped sharp

below the specification, check the power tilt motor
assembly for the damaged oil seal. Disassemble the power [1] POWER TILT
tilt motor assembly (P. 15-53) and inspect (P. 15-55), and SWITCH
measure the lower chamber blow pressure again (P. 15-50).

9) Measure the upper chamber blow pressure.

b. UPPER CHAMBER BLOW PRESSURE

1) After measuring the lower chamber blow pressure, remove

the special tool (oil pressure gauge joint B) and the
pressure gauge from the pump assembly with each rod full
extended.

• Note that Automatic Transmission Fluid (ATF) will spurt

[1]
out when the special tool is removed without the rods
PRESSURE GAUGE
fully extended. Move each rod to the fully extended (Commercially
position before removing the special tool. available)

• A small amount of the Automatic Transmission Fluid

(ATF) will flow out when the special tool (oil pressure
gauge joint B) is removed. Attach the special tool (oil
pressure gauge joint A) quickly.

2) Attach the special tool (oil pressure gauge joint A) for

measurement of upper chamber blow pressure to the
manual valve installation section as shown.

Tighten the special tool to the specified torque.

TOOL: [2]
Oil pressure gauge joint A 07SPJ-ZW10100 OIL PRESSURE GAUGE
JOINT A (Upper chamber)
TORQUE: 9 N.m (0.9 kgf.m, 6.5 lbf.ft) 07SPJ-ZW10100

3) Attach a commercially available pressure gauge [P/T 1/4]

which measures 14,710 kPa (150 kgf/cm2, 2,133 psi) or
above to the special tool (oil pressure gauge joint B).

15-51
4) Remove the oil tank cap. Check that Automatic
Transmission Fluid (ATF) is at the upper limit of the filler
port (P. 15-47).

5) Push the “DN” side of the power tilt switch to compress

each rod fully. Read the pressure gauge to measure the
upper chamber blow pressure.

Upper chamber 3,923 – 7.355 kPa (40 – 75 kgf/cm2,

blow pressure 569 – 1,067 psi)

6) If the blow pressure is lower than the specified pressure,

check each part of the power trim/tilt assembly for oil
leakage.

7) If there is no oil leakage but the pressure dropped sharp

below the specification, check the power tilt motor
assembly for the damaged oil seal. Disassemble the power
tilt motor assembly (P. 15-53) and inspect (P. 15-55), and
measure the upper chamber blow pressure again (P. 15-50). [1] POWER TILT
SWITCH

8) After checking, push the “UP” side of the power tilt switch
and move each rod to the fully extended position.

9) Remove the special tool (oil pressure gauge joint A) and the [1]
INTERNAL
pressure gauge.
CIRCLIP
10) Tighten the manual valve to the specified torque.

TORQUE: 3.5 N.m (0.35 kgf.m, 2.5 lbf.ft)

11) With each rod in the fully extended position, remove the oil
tank cap and check that the Automatic Transmission Fluid [2] MANUAL
(ATF) is at the upper limit of the oil filler port (P. 15-47). VALVE

If the Automatic Transmission Fluid (ATF) does not flow out

of the oil filler port, add the Automatic Transmission Fluid
(ATF) up to the upper limit of the oil tank using a syringe or
equivalent tool (P. 15-47).

15-52
7. POWER TILT MOTOR ASSEMBLY [1] CORRUGATED [2] 4 x 16 mm SCREW
TUBE (Stainless steel)
a. DISASSEMBLY

1) Untape the corrugated tube and pull the tube to the

connector side. [5]
WIRE [3]
2) Remove the 4 x 16 mm screw. Pull out the wire holder and HOLDER YOKE
the two grommets from the yoke assembly and move them ASSEMBLY
to the corrugated tube side.

NOTICE
Pull out the grommets with care not to damage them.

3) Remove the two 4 x 16 mm screws.

[4]
GROMMETS

4) Wrap the armature shaft with a shop towel or equivalent

material to protect, and hold the shaft with pliers.

Pushing the two motor wires toward the yoke assembly,

remove the armature/front bracket assembly from the yoke
assembly.

5) Remove the armature from the front bracket.

[2] ARMATURE
• Do not allow the commutator to become contaminated
with oil or grease. [1] SHOP
TOWEL
6) Remove the two brush springs (P. 15-54).

7) Disconnect the motor wire (blue wire) terminal from the

breaker assembly while holding the breaker assembly with [3] MOTOR
a screwdriver. WIRES

NOTICE [4]
Do not disconnect the blue wire terminal without holding [5] PLIERS YOKE ASSEMBLY
the breaker assembly, or it can cause damage to the brush
holder B. Be sure to disconnect the terminal while holding
the breaker assembly.
[1] [2]
FRONT BRUSH
8) Remove the 4 x 10 mm screw from the brush holder A and ASSEMBLY
BRACKET
remove the brush assembly.
ASSEMBLY
[3]
• Take care not to touch the bimetal part of the breaker BRUSH
assembly during removal. HOLDER A

9) Remove the oil seal from the front bracket assembly (P. 15- [7]
BLUE [4]
54).
WIRE 4 x 10 mm
SCREW
Check the metal part of the front bracket assembly for
damage and wear. Replace the front bracket assembly if [6] TERMINAL
[5] GREEN WIRE
necessary.

15-53
b. COMPONENTS DRAWING
[3]
4 x 16 mm SCREW
[2] (Stainless steel)
CORRUGATED TUBE
1.4 N.m (0.14 kgf.m,
1.0 lbf.ft)

[1] ARMATURE
[4]
YOKE ASSEMBLY

[15
MOTOR WIRE
(Blue wire)

[14]
MOTOR WIRE
(Green wire) [5]
4 x 10 mm SCREW (2)

[13] [6]
BRUSH ASSEMBLY BREAKER ASSEMBLY

[12]
BRUSH SPRING (2)

[7] O-RING

[11]
FRONT BRACKET

[8]
4 x 16 mm
SCREW (2)

[10]
FRONT BRACKET
ASSEMBLY
[9] OIL SEAL

15-54
c. INSPECTION

• BRUSH LENGTH

Measure the brush length.

If the brush length is less than the service limit, replace the
front bracket assembly.

STANDARD SERVICE LIMIT

9.8 mm (0.39 in) 4.8 mm (0.19 in)

• BREAKER ASSEMBLY
[2] ARMATURE
[1]
1) Install the armature on the front bracket assembly. BRACKET
HOLDER
2) Connect the motor 2P connector to the outboard motor.

3) Operate the power tilt switch and check the breaker

assembly for operation sound. The breaker is normal if
there is operation sound from the breaker assembly.

Replace the front bracket assembly if there is no operation

[3]
sound from the breaker assembly. BREAKER
ASSEMBLY

• MICA DEPTH
If the grooves are clogged or mica depth is less than the
service limit, recut the groove using a hacksaw blade or a small
file.

If the mica depth is still less than the service limit, replace the
armature. 0.5 mm
(0.020 in)
SERVICE LIMIT 0.5 mm (0.020 in)

• ARMATURE

Use the armature tester if it is available.

• CONTINUITY CHECK – SEGMENTS

Check for continuity between the segments. If an open circuit

exists between any two segments, replace the armature.

15-55
• SHORT CIRCUIT TEST – CORE-TO-COMMUTATOR

Check for continuity between the commutator and armature

coil core.

If continuity exists, replace the armature.

• SHORT CIRCUIT TEST – SHAFT-TO-COMMUTATOR

Check for continuity between the commutator and armature

shaft.

If there is continuity, replace the armature.

• SHORT CIRCUIT TEST – ARMATURE

Place the armature on an armature tester.

Hold a hacksaw blade close to the armature core. If the blade is

attracted to the core or vibrates when the core is turned, the
armature is shorted. Replace the armature.

15-56
d. ASSEMBLY

• When the front bracket assembly is replaced with the new [3]
one, remove the 4 x 10 mm screw that secures the brush BRUSH
[1]
holder B. ASSEMBLY
FRONT
BRACKET [2]
1) Install the new O-ring and the oil seal on the front bracket ASSEMBLY BRUSH [4]
assembly (P. 15-54). SPRINGS PROJECTION

Apply heat resisting grease to the oil seal lip.

2) Connect the motor wire (blue wire) terminal to the breaker

assembly terminal. [10]
BREAKER
3) Check the magnet in the yoke assembly for washer and ASSEMBLY
other foreign material. There must be no washer, etc. on
the magnet.

Set the brush assembly terminal above the motor wire [9]
(green wire) terminal and loosely tighten the 4 x 10 mm BLUE [5]
WIRE BRUSH
screw. Be sure that the motor wire (green wire) terminal
HOLDER A
and the brush assembly wire terminal contact the
respective projections on the brush holder A, then tighten [8] [6]
the 4 x 10 mm screw securely. TERMINAL 4 x 16 mm
SCREW
[4]
PROJECTION [7]
GREEN WIRE

4) Check that the commutator surface is not contaminated

with oil and grease. Set the two brush springs on the front
bracket assembly and install the armature on the front
bracket with the brush terminal pushed in the holder.
[3]
5) Wrap the armature shaft with a shop towel or equivalent [2] YOKE ASSEMBLY
material and hold the shaft with the pliers. ARMATURE

6) Pulling the two motor wires of the yoke assembly side [1]
slowly, install the armature/front bracket assembly on the SHOP
yoke assembly. TOWEL

If it is hard to install the armature/front bracket assembly on

the yoke assembly, check whether the metal of yoke
assembly (i.e. where the armature shaft is installed) is out
of position and repeat the procedure from step 4.
[4]
MOTOR
7) Check that the armature turns smoothly and tighten the WIRES
two 4 x 16 mm screws.

After tightening the two 4 x 16 mm screws, connect the

power tilt motor 2P connector and check whether the motor [6] PLIERS [5] FRONT BRACKET
turns. ASSEMBLY
If the motor does not turn, disassemble the power tilt
motor assembly again, and check whether the motor wire
(blue wire) terminal is disconnected.

15-57
8) Install the two grommets and the wire holder on the yoke
assembly. [1] [2] 4 x 16 mm SCREW
CORRUGATED (Stainless steel)
Tighten the 4 x 16 mm screw (stainless steel screw) to the TUBE
specified torque. Take care not to overtighten it.

TORQUE: 1.4 N.m (0.14 kgf.m, 1.0 lbf.ft)

[3]
9) Tape the corrugated tube with the heat resisting tape so GROMMET (2)
that the distance from the wire holder end to the
corrugated tube end is 30 mm (1.2 in) or less as shown.
[4] WIRE
10) Install the power tilt motor assembly on the power trim/tilt
HOLDER
assembly (P. 15-46).

Coat the joints or mating sections of the parts and the

sections where the paint came off with rust preventive
paint of the same color.

11) Bleed air from the power trim/tilt assembly without

mounting on the outboard motor (P. 15-48).

[5]
HEAT RESISTING TAPE
(Wrap by two or three
winds.)

[1]
CORRUGATED
TUBE

[6]
30 mm
(1.2 in)
or below

15-58
16. STEERING ROD/REMOTE CONTROL
BOX

1. STEERING ROD 3. CONTROL PANEL (OPTIONAL PART)

2. REMOTE CONTROL BOX 4. INSPECTION
(OPTIONAL PART)

1. STEERING ROD
a. REMOVAL/INSTALLATION

[3]
3/8-24 UNF BOLT
[2] 22 N.m (2.2 kgf.m, 16 lbf.ft)
[1] TILTING BOLT CAP
STEERING CABLE

[8]
STEERING ROD COLLAR

[4]
MOUNT FRAME

[7]
10 mm WASHER (4)

[6]
STEERING ROD

[5]
3/8-24 UNF SELF-
LOCKING NUT (2)
22 N.m (2.2 kgf.m, 16 lbf.ft)

16-1
2. REMOTE CONTROL BOX (OPTIONAL PART)
a. DISASSEMBLY/ASSEMBLY
• REMOTE CONTROL CABLE

[1]
SHIFT PIVOT (2)
INSTALLATION:
Screw in the shift pivot 8 mm or more onto the
threaded end of the cable.
[1]-1
8 mm or more

[2] [3]
[10]
10-32 UNF 5 x 25 mm SELF-
REMOTE CONTROL
LOCK NUT TAPPING SCREW (7)
BOX COVER C
[9]
[4]
5 x 12 mm OVAL
REMOTE CONTOL CABLE
SCREW (2)
(Throttle side)
ADJUSTMENT: P. 3-26
[8]
FAST IDLE LEVER

[5]
CABLE CLAMP
SPACER

[7] [6]
REMOTE CONTOL REMOTE CONTROL CABLE
BOX COVER B (Shift side)
ADJUSTMENT: P. 3-24

16-2
• ELECTRIC COMPONENTS [2]
EMERGENCY STOP SWITCH
INSPECTION: P. 16-9

[1]
WARNING BUZZER
INSPECTION: P. 16-10
[3]
IGNITION SWITCH
[11] INSPECTION: P. 16-9
5 x 8 mm SELF-
TAPPING SCREW (2)

[10]
POWER TILT
CORD CLAMP

[9]
SPARE EMERGENCY [4]
STOP SWITCH CLIP 16 mm HEX. NUT
1.5 N.m (0.15 kgf.m, 1.1 lbf.ft)

[8]
22 mm NUT
4.8 N.m (0.49 kgf.m, 3.5 lbf.ft)
[7]
INDICATOR LIGHT
[OIL PRESSURE LIGHT/
OVERHEAT LIGHT] [5]
SOLENOID SWITCH
INSPECTION: P. 16-9

[6]
20 mm HEX. NUT

16-3
• SLIDING PLATE
[4] [7]
[3] 5 x 10 mm [5] 7 mm E-CLIP
5 mm WASHER SCREW 4 mm E-CLIP [8]
8 mm WASHER
[2] [6] [9]
FAST IDLE WHEEL 6 mm WASHER (2) 5 mm HEX. NUT
[1]
FAST IDLE SPRING [10]
5 x 16 mm
HEX. BOLT
[25]
13 x 13 mm FAST IDLE
DETENT ROLLER [11]
6 x 10 mm
SCREW
[24] 5 x 10 mm SELF-
TAPPING SCREW [12]
[23] LINK JOINT
SPRING SETTING PLATE BRACKET

[3] [13]
5 mm WASHER LINK JOINT ARM

[22] 4 x 10 mm SELF- [14]

TAPPING SCREW LINK JOINT
COLLAR (2)
[21] 4 mm WASHER
[15]
SLIDING PLATE
[20] SWITCH START CAM

[16]
SLIDING PLATE
[19] COLLAR
6 x 6 mm PIN
INSTALLATION: [17]
Install in the concave area of 12.7 x 23.9 mm FAST IDLE
the control wheel as shown. DETENT SPRING

[18]
CONTROL WHEEL

• SLIDING PLATE/COLLAR
[1] SLIDING PLATE [2]
INSTALLATION:
COLLAR “UP” MARK
Install the sliding plate with the “UP” mark facing up.
Attach the sliding plate collar to the sliding plate with its
wider side toward the “UP” mark of the sliding plate.

[3]
SLIDING PLATE

16-4
• REMOTE CONTROL LEVER ASSEMBLY/CONTROL WHEEL
[4]
[2] 6 mm HEX. NUT [5]
8 x 35 mm HEX. BOLT 5 x 10 mm SELF-TAPPING SCREW
[3]
[1] 4 mm WASHER (2) [6]
8 mm WASHER 5 mm WASHER
[7]
NEUTRAL SWITCH
SPACER
[21] [8]
CONTROL WHEEL FRICTION
ADJUSTING BOLT
[20]
28 mm WASHER
[9]
THROTTLE
[19] FRICTION BLOCK
SHIFT LINK
ARM

[18]
9.8 x 27.1 mm SHIFT
DETENT SPRING [10]
3 mm E-RING

[17] [5]
9 x 10 mm SHIFT 5 x 10 mm SELF-
DETENT ROLLER TAPPING SCREW

[11]
[16] SPRING SETTING PLATE
REMOTE CONTROL
BOX HOUSING A [12]
6 mm WASHER

[15] [13]
NEUTRAL 6 x 16 mm SELF-
LOCK BLOCK TAPPING SCREW (2)

[14]
REMOTE CONTROL
LEVER ASSEMBLY

16-5
• REMOTE CONTROL LEVER

[2]
REMOTE CONTROL [3] [4]
LEVER SPRING NEUTRAL 5 x 10 mm SCREW
RELEASE LEVER

[1]
REMOTE CONTROL
LEVER GRIP
[5]
LEVER SETTING
PLATE

[10]
5 x 12 mm SELF-
TAPPING SCREW
[11]
POWER TRIM/TILT SWITCH [9]
INSPECTION: P. 16-10 REMOTE CONTROL
LEVER

[8]
WIRE HARNESS CLIP

[7]
5 x 12 mm
OVAL SCREW

[6]
LEVER CAP

16-6
3. CONTROL PANEL (OPTIONAL PART)
a. DISASSEMBLY/ASSEMBLY

[5]
[1] [3] SWITCH PANEL HARNESS
INDICATOR LIGHT IGNITION SWITCH CONNECTION: P. 16-8
[MIL/ALTERNATOR
INSPECTION: P. 16-9
INDICATOR LIGHT]
[4] [6]
INSPECTION: P. 16-9 SWITCH PANEL
WIRE HARNESS
BAND CABLE
[2]
BUZZER
BRACKET
[18]
CONTROL PANEL

[17]
22 mm NUT
4.9 N.m (0.49 kgf.m,
3.5 lbf.ft)

[16]
16 mm HEX. NUT
1.5 N.m (0.15 kgf.m,
1.1 lbf.ft)
[7]
[8] TIE CABLE (2)
[15] WARNING BUZZER Do not reuse.
SPARE EMERGENCY INSPECTION: P. 16-10
STOP SWITCH CLIP
[9]
[14] EMERGENCY STOP SWITCH
EMERGENCY CORD INSPECTION: P. 16-9

[13]
5 x 40 mm SCREW (4)
[10]
[12] 5 mm FLANGE NUT (4)
5 mm WASHER (4)
[11]
5 mm SPRING WASHER (4)

16-7
b. SWITCH PANEL HARNESS
CONNECTION:
Connect the switch panel harnesses to the respective switches as shown.

[1]
To SWITCH [2]
PANEL CABLE To POWER [3]
TRIM/TILT To EMERGENCY
SWITCH STOP SWITCH

[4]
To METER HARNESS

[5]
SWITCH PANEL
HARNESS SIDE

[6]
CONTROL
PANEL SIDE

[10] [9]
INDICATOR IGNITION
LIGHT SWITCH
[8] EMERGENCY [7] WARNING
STOP SWITCH BUZZER

16-8
4. INSPECTION Bl/W
• IGNITION SWITCH Bl/R
Check for continuity between the terminals with the switch in
Bl/Y
each position.
Bl
Wire E IG BAT LO ST
Position (Bl) (Bl/R) (W/Bl) (Bl/Y) (Bl/W) W/Bl
OFF (Stop)
ON (Run)
START (Start)
: Continuity Bl: Black R: Red W: White Y: Yellow

• INDICATOR LIGHT [OIL PRESSURE LIGHT/

OVERHEAT LIGHT]
[1] SWITCH 1
NOTICE
[2] SWITCH 2
Use a known-good battery.
[3] SWITCH 3
Connect the black, red and yellow terminals to the switch 1, 2
and 3 respectively, and apply 12V battery voltage to the
black/yellow [gray] terminal. [Gr]
[4]
When the switch 1 is ON: Green light is ON. 12V BATTERY
When the switch 2 and 3 are ON: Green light is ON. [5]
When the switch 2 is ON: Red light is ON. COLOR IN BRACKETS [ ]:
Color in the brackets [ ] is for the side mount remote control SIDE MOUNT REMOTE CONTROL TYPE ONLY
type only.

• INDICTOR LIGHT [MIL/ALTERNATOR INDICATOR

LIGHT]
[1]
NOTICE ALTERNATOR
INDICTOR
Use a known-good battery.
LIGHT
Connect the white/blue terminal to the switch 1, red/blue R/Bu [2] SWITCH 1

terminal to the switch 2, and apply 12V battery voltage as [3] SWITCH 2
shown. W/Bu
When the switch 1 is ON: Alternator indictor light is ON.
When the switch 2 is ON: MIL is ON. Y/Bu
[4]
12V
[5] MIL BATTERY

• EMERGENCY STOP SWITCH

Attach the tester leads to the terminals and check for
continuity.

Switch clip position Continuity

Set No
Not set Yes
Switch is pushed with switch
Yes
clip being set

[1]
SWITCH CLIP

16-9
• WARNING BUZZER
NOTICE
Use a known-good battery.

Connect the black/yellow terminal of the warning buzzer to the

battery positive (+) terminal, and the yellow/green terminal to
the battery negative (–) terminal as shown. Check that the
buzzer sounds this time.

12 V

• POWER TRIM/TILT SWITCH (Side mount remote

control type only) [1] UP W/Bl Lg
Check for continuity between the terminals with the switch in
each position.
Lb
Lb W/Bl Lg
UP
DN (DOWN)
: Continuity
Lb: Light blue W: White Bl: Black Lg: Light green
[2]
DN (DOWN)

16-10
17. CABLES/SHIFT LINK BRACKET/SHIFT
ARM/NEUTRAL SWITCH

1. REMOTE CONTROL CABLE/ 2. SHIFT LINK BRACKET/NEUTRAL

GROMMET SWITCH
3. SEAL HOLDER

2.5 N.m (0.25 kgf.m, 1.8 lbf.ft)

17-1
1. REMOTE CONTROL CABLE/GROMMET
a. REMOVAL
Remove the following parts.
– Engine cover (P. 4-2)
– Front separate cover (P. 4-7).
1) Remove the remote control cable (shift side) shift pivot from the shift arm shift link pin.
2) Remove the remote control cable (throttle side) shift pivot from the throttle arm link pin.
3) Remove the remote control cables (shift and throttle sides) from the remote control cable plate and the remote
control cable grommet.

[1]
SHIFT PIVOT (2)

[9]
THROTTLE ARM
[2]
REMOTE
CONTROL CABLE
[8] (Throttle side)
LINK PIN

[7]
SHIFT LINK PIN

[6]
SHIFT ARM

[3]
[5] [4] REMOTE CONTROL
REMOTE CONTROL REMOTE CONTROL CABLE
CABLE PLATE CABLE GROMMET (Shift side)

4) Release the indicator light 6P connector and the remote [1] INDICATOR LIGHT [2] REMOTE CONTROL
control cable 14P connector from the neutral switch 6P CONNECTOR CABLE 14P CONNECTOR
bracket.

Disconnect the indicator light 6P connector and the remote

control cable 14P connector.

[3]
NEUTRAL SWITCH BRACKET

17-2
5) Remove the 6 x 16 mm hex. bolt and the 6 mm washer from the remote control cable plate, then remove the remote
control cable plate.
Release the starter cable from the cable bracket A and remove the remote control cable grommet from the under
cover front bracket.

[1]
6 x 16 mm HEX. BOLT [2]
REMOTE CONTROL
CABLE PLATE
[7]
6 mm WASHER

[3]
REMOTE CONTROL
CABLE GROMMET

[6]
STARTER CABLE

[5]
CABLE
BRACKET A
[4]
UNDER COVER FRONT
BRACKET

6) Remove the speed sensor tube A, remote control cable, indicator light wire, starter cable and the fuel tube A from
the remote control cable grommet. Remove the remote control cable grommet.

[1]
INDICATOR
LIGHT WIRE [2]
REMOTE CONTROL
CABLE

[3]
SPEED SENSOR
TUBE A

[4]
FUEL TUBE A

[5]
STARTER CABLE

[6]
REMOTE CONTROL
CABLE GROMMET

17-3
b. COMPONENTS DRAWING

[1]
SHIFT PIVOT (2)
[2]
LOCK NUT (2)

[3]
REMOTE CONTROL
CABLE
(Throttle side)
[4]
REMOTE CONTROL
CABLE
[17] (Shift side)
6 x 16 mm HEX. BOLT

[16]
6 mm WASHER
[15]
REMOTE CONTROL
CABLE PLATE
[5]
[14] SPEED
REMOTE CONTROL SENSOR
CABLE GROMMET TUBE A

[6]
REMOTE
CONTROL
CABLE
[7]
[9] INDICATOR
STARTER LIGHT WIRE
CABLE
[8]
FUEL TUBE A

[10]
6 x 17 mm
SPECIAL BOLT

[13]
FRONT SEPARATE
COVER

[12]
6 x 25 mm
SCREW (3) [11]
UNDERCASE
GROMMET BAND

17-4
c. INSTALLATION [1]
UNDER COVER
1) Set the indicator light wire and the remote control cable in FRONT BRACKET [2]
the specified positions in the remote control cable WHITE TAPE
grommet. Be sure that the tie wires on the indicator light
wire and the remote control cable are set against the
remote control cable grommet.

2) Set the starter cable in the specified position in the remote

control cable grommet by aligning the end of the white
tape on the starter cable with the end of the under cover
front bracket as shown. [3]
STARTER CABLE
3) Set the fuel tube A and the speed sensor tube A in the
specified positions of the remote control cable grommet.

[4] TIE WIRES

[5]
REMOTE
CONTROL CABLE

[6]
INDICATOR [7] REMOTE CONTROL
LIGHT WIRE CABLE GROMMET

[1]
INDICATOR LIGHT WIRE [2]
REMOTE CONTROL
CABLE

[3]
SPEED SENSOR
TUBE A

[4]
FUEL TUBE A

[1] [2]
INDICATOR REMOTE
[5] LIGHT WIRE CONTROL
STARTER CABLE
CABLE

[3]
SPEED
SENSOR
TUBE A

[6] [5] [4]

REMOTE CONTROL STARTER FUEL
CABLE GROMMET CABLE TUBE A

17-5
4) Install the remote control cable plate on the flat surface of the remote control cable grommet by aligning the
projection on the remote control cable plate with the groove in the under cover front bracket. Take care not to move
the alignments described in step 1 and 2 this time. Secure the remote control cable plate with the 6 x 16 mm hex.
bolt.
Secure the starter cable with the cable bracket A.
[1] [2]
6 x 16 mm HEX. BOLT REMOTE CONTROL
CABLE PLATE
[10]
6 mm WASHER
[3]
[9] PROJECTION
FLAT SURFACE
[4]
REMOTE CONTROL
CABLE GROMMET

[8]
STARTER CABLE
[5]
GROOVE IN UNDER
COVER FRONT BRACKET
[7]
CABLE
BRACKET A
[6]
UNDER COVER FRONT
BRACKET

5) Connect the indicator light 6P connector and the remote control cable 14P connector.
Install the indicator light 6P connector and the remote control cable 14P connector on the neutral switch bracket.

[1] INDICATOR LIGHT [2] REMOTE CONTROL

6P CONNECTOR CABLE 14P CONNECTOR

[3]
NEUTRAL SWITCH
BRACKET

17-6
6) Install the lock nut and the shift pivot on each of the remote control cables.
Align the groove in each of the remote control cables (shift and throttle sides) with the cutouts in the remote control
cable plate, and install the remote control cables on the remote control cable plate.
Fasten the undercase grommet band securely (P. 4-8).

[1]
[2]
SHIFT PIVOT (2)
GROOVES

[3]
REMOTE
CONTROL CABLE
(Throttle side)

[4]
REMOTE
CONTROL
CABLE
(Shift side)
[5]
CUTOUTS
[7] [6]
REMOTE CONTROL REMOTE CONTROL
CABLE PLATE CABLE GROMMET

d. REMOTE CONTROL CABLE (SHIFT SIDE) [2] Align.

[1] FLAT PART OF
INSTALLATION DETENT ARM

Check the following before installing the remote control cables

on the outboard motor.
– Remote control cables are securely connected to the remote
control box (P. 16-2).
– Shift arm is in the “N” (Neutral) position.
[3]
– Center of the neutral switch end is in line with the center of
NEUTRAL
the flat part of the detent arm, and the detent arm roller is in SWITCH END
the groove of the shift arm.
If the detent arm roller is in the groove of the shift arm but the
center of the neutral switch end is not in line with the center
of the flat part of the detent arm, check the detent arm.
Replace the detent arm with a new one if it is deformed or
damaged. [1] [3] “N” (NEUTRAL)
INNER [2]
1) Install the shift pivot on the remove control cable (shift CABLE CABLE OUTER
side).
SEAL
Apply marine grease to the mounting part of the shift link
pin on the shift pivot and to the shift link pin.
2) Check that the remote control cable (shift side) is detached
from the shift link pin.
Move the remote control lever fully to “F” (Forward) [4]
[6]
position, then return it slowly to the “N” (Neutral) position. “F” (FORWARD)
MARK (A)
[5]
3) With the remote control lever in the position described in [7] (MARINE REMOTE CONTROL
step 2, mark (A) at the end of the cable outer seal of the GREASE) BOX
inner cable.

17-7
4) Move the remove control lever fully to the “R” (Reverse)
position, then return it slowly to the “N” (Neutral) position. [2] “N” (NEUTRAL)
[1]
5) With the remote control lever in the position described in “R” (REVERSE)
step 4, mark (B) at the end of the cable outer seal of the
inner cable.

[3]
MARK (B)

6) Mark (C) at the midpoint between the mark (A) and the
mark (B). [1]
MARK (B)

[2] [3]
MARK (A) MARK (C)

7) Align the mark (C), marked in step 6, with the end of the
cable outer seal.

[1]
MARK (C)

8) Move the shift link pin end lightly right and left. If the shift
link pin has a free play, set the shift link pin at the center of
the free play.

[1]
SHIFT LINK
PIN

17-8
9) With the remote control cable (shift side) in the position
described in step 7 (i.e. the mark (C) aligns with the cable [1]
outer seal end), adjust the shift side remote control cable REMOTE CONTROL CABLE
length by turning the shift pivot so that the shift pivot sets (Shift side)
on the shift link pin smoothly.

NOTICE
Take care not to move the mark (C) out of alignment. Set
the shift pivot on the shift link pin with care not to move the
shift link pin from the center of the free play. [2]
SHIFT PIVOT
[2] [3]
SHIFT PIVOT SHIFT LINK PIN

[1]
REMOTE CONTROL CABLE
(Shift side)

10) After connecting the cable, move the remote control lever
back and forth and check for shift.

NOTICE [1]
ADJUSTMENT RANGE
When it is hard to put the remote control lever in the “F”
(Forward) or “R” (Reverse) position with the engine
stopped, shift the gear while turning the propeller or
propeller shaft. Do not shift the gear with force, or damage
to the shift system can result.

11) If the gear is not in neutral by moving the remote control [2] [3]
lever from the “F” (Forward) to the “N” (Neutral) position, MARK (A) MARK (C)
remove the shift side remote control cable from the shift
link pin and move the inner cable toward the mark (A).
Repeat the procedure from the step 8 (P. 17-8).

12) If the gear is not in neutral by moving the remote control

lever from the “R” (Reverse) to the “N” (Neutral) position,
remove the shift side remote control cable from the shift [1]
link pin and move the inner cable toward the mark (B). ADJUSTMENT RANGE
Repeat the procedure from the step 8 (P. 17-8).

13) After adjustment, set the remote control lever in each

position and check for operation. If the gear is not in neutral
securely, perform the step 11 or 12 again.
[2] [3]
14) Adjust the shift side remote control cable after connection MARK (C) MARK (B)
(P. 3-24).
Tighten the shift pivot lock nut securely.

17-9
e. REMOTE CONTROL CABLE (THROTTLE SIDE)
INSTALLATION

1) Apply marine grease to the link pin and the mounting part
[1]
of the link pin on the shift pivot. LINK PIN

2) Set the remote control cable (throttle side) shift pivot on the
[2] (MARINE
throttle arm link pin.
GREASE)
3) Adjust the throttle control cable/throttle link (P. 3-26).
Tighten the shift pivot lock nut securely.

4) Install the following parts.

– Front separate cover (P. 4-7)
– Engine cover (P. 4-2)

[4]
SHIFT PIVOT
[3]
REMOTE CONTROL CABLE
(Throttle side)

17-10
2. SHIFT LINK BRACKET/NEUTRAL SWITCH
a. REMOVAL
Remove the following parts.
– Engine cover (P. 4-2)
– Front separate cover (P. 4-7)
– L./R. engine under cover (P. 4-9)
– Remote control cable/grommet (P. 17-2)
1) Remove the throttle rod linkage pivot from the throttle plate.
2) Remove the two 6 x 18 mm flange bolts from the shift link bracket assembly.
Remove the link pin of the shift link bracket assembly from the shift arm, and remove the shift link bracket assembly.

[1]
THROTTLE PLATE
[2]
THROTTLE ROD

6 x 18 (2)

[3]
SHIFT LINK BRACKET
ASSEMBLY
[4]
LINK PIN
[5]
SHIFT ARM

3) Move the shift arm to the “N” (Neutral) position. Remove [1]
the 12 mm snap ring and the 12 mm washer from the shift 12 mm SNAP
shaft B. RING

[2]
12 mm WASHER

[3]
SHIFT ARM
[Move to “N”
(Neutral) position.]

17-11
4) Remove the shift arm from the shift shaft B while pulling
[2]
the detent arm to your side.
SHIFT ARM
[1]
DETENT
ARM [3]
SHIFT
SHAFT B

[4]
Pull to your side.

5) Remove the 6 x 14 mm flange bolt from the neutral switch [1]

bracket while pulling the detent arm toward you, then 6 x 14 (Pull in the direction
remove the neutral switch bracket. of the arrow.)

[3] [2]
DETENT ARM NEUTRAL SWITCH
BRACKET

6) Release the fuel tube A from the fuel tube holder. [2]
NEUTRAL SWITCH [3]
7) Remove the fuel tube holder from the neutral switch 2P CONNECTOR CONNECTOR
bracket. [1] BRACKET A
FUEL TUBE HOLDER
8) Remove the neutral switch 2P connector from the
connector bracket A, then disconnect the connector.
[7]
9) Remove the harness band clip that secures the alternator NEUTRAL
fuse cable from the neutral switch bracket. SWITCH
BRACKET
10) Remove the clip A from the neutral switch wire.

[4]
CLIP A
[5]
HARNESS
[6] BAND CLIP
ALTERNATOR
FUSE CABLE

17-12
11) Remove the 20 mm hex. nut from the neutral switch, then
[1] [2]
remove the neutral switch from the neutral switch bracket. 20 mm HEX. NUT NEUTRAL SWITCH
BRACKET

[3]
NEUTRAL
SWITCH

12) Remove the 6 x 12 mm flange bolt from the detent arm,

then remove the 6 mm washer, detent arm and the detent 6 x 12
spring.
[1]
Check the detent arm bushing on the detent arm. Replace 6 mm WASHER
the detent arm bushing if necessary.
[2]
13) Remove the detent arm bushing from the detent arm. DETENT
Replace the bushing with a new one on assembly. ARM
Check the detent arm for deformation or damage, and
replace if necessary.
[3]
DETENT ARM
BUSHING

[4]
DETENT
SPRING

b. INSPECTION

• NEUTRAL SWITCH
[1]
Connect the tester between the terminals and push the switch NEUTRAL SWITCH
knob. There must be continuity when the switch knob is
pushed, and no continuity when the knob is released.

17-13
c. COMPONENTS DRAWING
[1]
THROTTLE ROD

6 x 18 (2)

[18]
12 mm SNAP RING

[17]
12 mm
WASHER
[2]
SHIFT LINK BRACKET
ASSEMBLY

[3]
CONNECTOR
BRACKET A
[16]
SHIFT ARM [4]
FUEL TUBE A

[5]
FUEL TUBE
HOLDER

6 x 12 6 x 14

[15] [6]
6 mm WASHER CLIP A

[14]
DETENT ARM

[7]
[13] NEUTRAL
DETENT SPRING SWITCH

[8]
HARNESS BAND
[10] CLIP
[12]
NEUTRAL SWITCH
DETENT ARM
[11] BRACKET [9]
BUSHING
20 mm HEX. NUT ALTERNATOR
FUSE CABLE
2.5 N.m (0.25 kgf.m, 1.8 lbf.ft)

17-14
d. DISASSEMBLY OF SHIFT LINK BRACKET ASSEMBLY

1) Remove the throttle link.

2) Remove the throttle arm and remove the link pin.

3) Remove the shift link pin, link pin, shift slide pivot and the shift pivot plate.

4) Remove the throttle plate.

5) Check the two bushing As from the shift link bracket. If they are damaged, remove them and replace with the new
ones.

[3]
THROTTLE
PLATE

[4]
[2] BUSHING A (2)
[1] THROTTLE ARM
THROTTLE LINK

[15] [5]
6 mm WASHER SHIFT LINK
BRACKET

6 x 12

[6]
[14]
8 mm WASHER
4 mm E-RING (3) [13]
LINK PIN
[7]
6 mm E-RING
[12]
PIVOT WASHER [8]
SHIFT PIVOT
PLATE

[9]
SHIFT SLIDE
PIVOT
[11]
SHIFT LINK PIN
[10]
LINK PIN

17-15
e. ASSEMBLY OF SHIFT LINK BRACKET ASSEMBLY

1) Apply marine grease to the outer surface of the two bushing As and the inner wall at the mounting part of the bushing
A in the link bracket. Install the two bushing As in the shift link bracket.
2) Apply marine grease to the outer surface of the throttle plate shaft. Install the throttle plate on the shift link bracket.
Set the 8 mm washer on the throttle plate, and set the 6 mm E-ring in the groove in the throttle plate securely.
3) Apply marine grease to the outer surface of the throttle arm link pin. Set the link pin on the throttle arm and secure
with the pivot washer and the 4 mm E-ring.
4) Apply marine grease to the inner wall at the mounting part of the shift link bracket in the throttle arm.
Apply marine grease to the throttle arm mating surfaces on the shift link bracket, and install the throttle arm on the
shift link bracket.
5) Apply marine grease to the 6 mm washer and the throttle arm mating surfaces. Set the 6 mm washer on the throttle
arm and tighten the 6 x 12 mm flange bolt securely.
6) Apply marine grease to the mounting part of the throttle arm and the mounting part of the throttle plate in the throttle
link, then install the throttle link.
7) Apply marine grease to the shift slide pivot and the outer surface of the shift link pin. Apply marine grease to the
entire surface of the link pin. Apply marine grease to the chamfered side of the shift pivot plate.
8) Set the shift link pin and the link pin on the shift slide pivot. Install the shift slide pivot on the shift link bracket.
9) Install the shift pivot plate with its chamfer toward the shift link bracket. Set the 4 mm E-rings in the grooves in the
shift link pin and the link pin securely.

[4]
THROTTLE
[2] (MARINE PLATE
[1] GREASE)
THROTTLE LINK [3] [5]
[18] LINK PIN BUSHING A (2)
[2] (MARINE
THROTTLE ARM GREASE)

[17] [2] (MARINE

6 mm WASHER GREASE)

[16] [6]
(Apply marine grease SHIFT LINK
to the reverse side of BRACKET
the washer.)
6 x 12
[2] (MARINE
GREASE)
[2] (MARINE
GREASE) [7]
[15] 8 mm WASHER
PIVOT WASHER
[14]
4 mm E-RING (3) [8]
6 mm E-RING

[9]
SHIFT PIVOT PLATE
[13] [12]
CHAMFER SHIFT LINK [10]
PIN [11] SHIFT SLIDE PIVOT
[2] (MARINE LINK PIN
GREASE) [2] (MARINE
GREASE)

17-16
f. INSTALLATION
6 x 12
1) Apply marine grease to the inner wall of a new detent arm
bushing. Set the detent arm bushing on the detent arm.
[1]
2) Apply marine grease to the seal holder shaft. 6 mm WASHER
Apply marine grease to the roller area of the detent arm.
[2]
3) Align the hook (A) of the detent spring with the concave in [9] CONCAVE
the detent arm as shown. DETENT
Align the other hook (B) with the seal holder hole and ARM
install the detent spring.
[8]
4) Set the 6 mm washer on the detent arm and tighten the 6 x DETENT ARM
12 mm flange bolt securely. BUSHING

[7]
HOOK (A) [3] (MARINE
GREASE)

[6]
HOOK (B)

[4]
DETENT
[5] SPRING
HOLE

[3] (MARINE
GREASE)

5) Set the neutral switch on the neutral switch bracket and

tighten the 20 mm hex. nut to the specified torque. [2]
[1] NEUTRAL SWITCH
TORQUE: 2.5 N.m (0.25 kgf.m, 1.8 lbf.ft) 20 mm HEX. NUT BRACKET

[3]
NEUTRAL
SWITCH

17-17
6) Clamp the neutral switch wire with the clip A and set the
[2]
clip A on the neutral switch bracket.
NEUTRAL SWITCH [3]
2P CONNECTOR CONNECTOR
7) Connect the neutral switch 2P connector and set the neutral BRACKET A
switch 2P connector on the connector bracket A. [1]
FUEL TUBE HOLDER
8) Set the fuel tube holder on the connector bracket A.
[7]
9) Clamp the fuel tube A on the connector bracket A. NEUTRAL
SWITCH
10) Set the harness band clip that clamps the alternator fuse BRACKET
cable on the neutral switch bracket.

[4]
CLIP A
[5]
HARNESS
[6] BAND CLIP
ALTERNATOR
FUSE CABLE

11) Install the neutral switch bracket by aligning a small hole in

the neutral switch bracket with the boss on the seal holder 6 x 14 [1] (Pull in the direction
while pulling the detent arm to your side. Tighten the 6 x 14 of the arrow.)
mm flange bolt securely.
[2]
HOLE

[5] [4] [3]

DETENT BOSS NEUTRAL SWITCH
ARM BRACKET

12) Apply marine grease to the concave in the shift arm and to
[2]
the shift shaft B.
SHIFT ARM
Pulling the detent arm to your side, install the shift arm on [1]
the shift shaft B. DETENT
ARM [3]
SHIFT
SHAFT B

[5]
Pull to your side.

[4] (MARINE
GREASE)

17-18
13) Set the 12 mm washer on the shift shaft B and secure with
[1]
the 12 mm snap ring. 12 mm SNAP
RING

[2]
12 mm WASHER

[3]
SHIFT ARM
[Set in the “N”
(Neutral) position.]

14) Apply marine grease to the outer surface of the link pin of the shift link bracket and to the long hole in the shift arm.
Set the link pin aligning with the long hole in the shift arm.

15) Tighten the shift link bracket assembly with the two 6 x 18 mm flange bolts securely.

16) Apply marine grease to the mounting part of the linkage pivot on the throttle plate and to the linkage pivot. Install
the linkage pivot on the throttle plate.

17) Apply marine grease to the outer surface of the shift link pin and install the remote control cable (shift side) (P. 17-7).

18) Apply marine grease to the outer surface of the link pin and install the remote control cable (throttle side) (P.17-10).

19) Remove the following parts.

– Remote control cable/grommet (P. 17-5)
– L./R. engine under covers (P. 4-14)
– Front separate cover (P. 4-7)
– Engine cover (P. 4-2)

[2] THROTTLE [3]

PLATE THROTTLE ROD

[1] 6 x 18 (2)
SHIFT ARM

[4] (MARINE
GREASE)

[5]
SHIFT LINK BRACKET
ASSEMBLY

[6]
[4] (MARINE [4] (MARINE LINK PIN
GREASE) GREASE)

17-19
3. SEAL HOLDER 6 x 20 (2)

a. REMOVAL [1]
SEAL HOLDER
Remove the following pars.
– Engine cover (P. 4-2)
– Front separate cover (P. 4-7)
– R. engine under cover (P. 4-9)
– Remote control cable/bracket (P. 17-2)
– Shift link bracket/neutral switch (P. 17-11)

1) Remove the 6 x 14 mm flange bolt from the cable bracket

A, and remove the cable bracket A.
Remove the starter cable and the alternator fuse cable from
the cable bracket A.

2) Remove the two 6 x 20 mm flange bolts from the seal

holder, and remove the seal holder.
[4]
NOTICE CABLE
• Remove the seal holder with care not to raise the shift BRACKET A
shaft B. [2]
STARTER
6 x 14 CABLE
• Correct the shift shaft B if it is raised or if it is disengaged [3]
from the shift shaft A in the mounting case (P. 17-21). ALTERNATOR
FUSE CABLE
• Note that assembly with the shift shaft A and B out of
alignment will prevent proper shifting.

b. DISASSEMBLY
[1]
1) Before removing the 12 x 26 x 7 mm oil seal, check the oil 12 x 26 x 7 mm
seal lip for cut or other damage. Replace if necessary. OIL SEAL

2) Remove the 12 x 26 x 7 mm oil seal from the seal holder

[2]
using a commercially available oil seal remover. SEAL HOLDER
Replace the oil seal with a new one on assembly.

3) Remove the 25 x 2.4 mm O-ring from the seal holder.

Replace the O-ring with a new one on assembly.

[3]
25 x 2.4
mm O-RING

17-20
c. COMPONENTS DRAWING

[1]
12 x 26 x 7 mm
OIL SEAL

6 x 20 (2)

[7]
SEAL HOLDER [2]
SHIFT SHAFT B

[6]
25 x 2.4
mm O-RING
[3]
ALTERNATOR FUSE
CABLE

[5]
CABLE BRACKET A

[4]
STARTER CABLE
6 x 14

17-21
d. SHIFT SHAFT B CORRECTION [1] [1] STOPPER
STOPPER
Correct the shift shaft B with the seal holder removed.
Correct the shift shaft B only when the shift shaft B is raised or
when it is disengaged from the shift shaft A in the mounting
case.
[3]
Remove the following pars before correction. SHIFT
– Gear case assembly (P. 14-3, 42) SHAFT A
[2]
SHIFT SHAFT B
1) Turn the shift shaft B clockwise until the shift shaft A comes (Raise the shift shaft B
in contact with the stopper in the mounting case as shown. and turn it clockwise.)

NOTICE [4]
SHIFT SHAFT B
If the shift shaft B comes in contact with the stopper before (If the shift shaft B comes in contact with the
the shift shaft A does, raise the shift shaft B and turn it stopper before the shift shaft A does, raise the
counterclockwise until it engages with the shift shaft A. shift shaft B and turn it counterclockwise.)
Then turn the shift shaft B clockwise until the shift shaft A
comes in contact with the stopper.
[3]
SHIFT
SHAFT A

2) Raise the shift shaft B slowly while holding the shift shaft A
in contact with the stopper in the mounting case. [1]
STOPPER
3) With the raised shift shaft B pushed against the stopper in
the mounting case, lower the shift shaft B slowly and
engage it with the shift shaft A.

NOTICE
Hold the shift shaft A not to move when engaging it with [3]
the shift shaft B. SHIFT [2]
SHAFT A SHIFT SHAFT B
4) After correction, check for proper shifting of the gear. (Turn clockwise.)

5) Install the seal holder (P. 17-23) and the gear case assembly
(P. 14-5, 44). [4]
SHIFT SHAFT B
(Lower slowly and engage
with the shift shaft A)

[3]
SHIFT
SHAFT A

17-22
e. ASSEMBLY [1]
12 x 26 x 7 mm
1) Apply marine grease to a new 25 x 2.4 mm O-ring. OIL SEAL [2]
Apply soapy water to the outer surface of the 12 x 26 x 7 (Apply soapy
mm oil seal. water to the
outer surface.)
Apply marine grease to the mounting part of the O-ring on
the seal holder. [3]
SEAL
2) Install the 12 x 26 x 7 mm oil seal and 25 x 2.4 mm O-ring HOLDER
on the seal holder.

[5]
(MARINE
GREASE)

[4]
25 x 2.4 mm
O-RING
f. INSTALLATION
1) Tighten the cable bracket A with the 6 x 14 mm flange bolt
securely.
6 x 20 (2)
[1]
2) Protect the shift shaft B by taping around the stepped part
(Apply marine
of the shift shaft B. grease to the lip.)
3) Apply marine grease to the 12 x 26 x 7 mm oil seal lip [2] Tape around the
mounted on the seal holder. [5] stepped part.
SEAL
4) Install the seal holder over the shift shaft B slowly and HOLDER
tighten the seal holder with the two 6 x 20 mm flange bolts
securely.

NOTICE
• Install the seal holder with care not to raise the shift shaft
B.

• Correct the shift shaft B if it is raised or if it is disengaged [4]

from the shift shaft A in the mounting case (P. 17-22). CABLE
BRACKET A
• Note that assembly with the shift shaft A and B out of [3] SHIFT
alignment will prevent proper shifting. 6 x 14 SHAFT B

5) Remove the tape from the shift shaft B.

NOTICE [1] [2]

STARTER CABLE ALTERNATOR
Check that the oil seal lip is not turned up during removal
FUSE CABLE
of the tape.

6) Set the starter cable and the alternator fuse cable in the
cable bracket A as shown.

7) Install the following parts.

– Shift link bracket/neutral switch (P. 17-17)
– Remote control cable/grommet (P. 17-5)
– R. engine under covers (P. 4-15) [3]
– Front separate cover (P. 4-7) CABLE BRACKET A
– Engine cover (P. 4-2)

17-23
18. ELECTRICAL EQUIPMENT
1. STARTER MOTOR 4. POWER TILT RELAY/CONNECTOR
2. STARTER CABLE BRACKET A
3. ECM/PGM-FI MAIN RELAY/FUSE BOX

1. STARTER MOTOR
a. REMOVAL
1) Disconnect the negative (–) cable from the battery negative terminal.

2) Disconnect the main relay (White) terminal from the magnetic switch.

3) Move the terminal cover aside and remove the 8 mm washer-nuts and the 8 mm washer. Disconnect the alternator
fuse cable and the starter cable from the starter magnetic switch.

4) Loosen the 10 x 90 mm flange bolt fully.

5) Remove the starter motor together with the 10 x 90 mm flange bolt.

6) Remove the O-ring from the starter motor.

• Replace the O-ring.

[1] [2]
8 mm WASHER-NUT (2) ALTERNATOR FUSE CABLE

[9]
8 mm WASHER
[8]
STARTER MOTOR
[3]
STARTER CABLE

[4]
MAIN RELAY
TERMINAL (W)

[5]
10 x 90
Loosen fully and remove
together with the starter
motor.

[6]
STARTER MAGNETIC
SWITCH

[7]
O-RING
Do not reuse.

18-1
b. DISASSEMBLY [1] 8 mm WASHER-NUT
1) Move the terminal cover aside. Remove the 8 mm washer-
nut and disconnect the motor wire from the S terminal.

[2]
MOTOR WIRE
[3]
S TERMINAL
[4] STARTER
MAGNETIC
SWITCH

2) Remove the 6 x 22 mm washer screws and the O-rings.

[1] STARTER MAGNETIC
Remove the magnetic switch, spring and the plunger.
SWITCH

[2]
SPRING

[3]
PLUNGER

[5]
6 x 22 mm
SCREW (2)
[4]
O-RING (2)
Do not reuse.

3) Remove the two through bolts and remove the yoke/rear

bracket assembly. [1] THROUGH BOLT (2)
[5]
4) Remove the gasket and plate. YOKE/REAR
BRACKET
ASSEMBLY

[2]
GASKET

[4] [3]
FRONT BRACKET PLATE
ASSEMBLY

18-2
5) Remove the yoke from the armature/rear bracket assembly.
[1]
ARMATURE/REAR
BRACKET
ASSEMBLY

[2]
YOKE

6) Remove the two 5 x 8 mm screws and remove the rear

[1]
bracket. 5 x 8 mm
SCREW (2)

[2]
REAR BRACKET

7) Remove the brush holder.

[1]
BRUSH HOLDER

8) Remove the steel ball and planetary gear. [2]

[1]
PLANETARY STEEL BALL
GEAR (3)

18-3
9) Remove the gasket.

[1]
GASKET

10) Remove the overrunning clutch.

[2]
CLUTCH FORK
11) Remove the clutch fork.

[1]
OVERRUNNING
CLUTCH

• OVERRUNNING CLUTCH DISASSEMBLY [1] PIPE

1) Secure the gear shaft by placing a wood block under the [I.D.: approx. 11mm (0.4 in),
gear shaft assembly. O.D.: approx. 15 mm (0.6 in),
LENGTH: approx. 22 mm (0.8 in)]
NOTICE
Secure the gear shaft assembly with care not to contact the
internal gear.

2) Prepare a pipe of the following dimensions. [2]

• I.D.: approx. 11 mm (0.4 in), O.D.: approx. 15 mm (0.6 in), GEAR SHAFT
LENGTH: approx. 20 mm (0.8 in)

3) Set the pipe on the gear shaft stopper and drop the gear
shaft stopper by tapping on the pipe. [4]
SNAP RING
4) Remove the snap ring using a screwdriver or equivalent
tool.

[3]
WOOD BLOCK
[5]
GEAR SHAFT
STOPPER

18-4
5) Remove the gear shaft and the gear shaft stopper. Remove [1] GEAR SHAFT STOPPER
the internal gear and the overrunning clutch.
[2]
ONE-WAY CLUTCH

[4]
INTERNAL GEAR
[3]
GEAR SHAFT

• BRUSH HOLDER DISASSEMBLY

1) Remove the clip and the plate. [1]
PLATE
2) Remove the brush sets and the brush springs.

[4]
BRUSH
SPRING (4)

[2] BRUSH SET

[3]
BRUSH HOLDER

c. INSPECTION
• BRUSH LENGTH
Measure the brush length. Replace the brushes as a set if the
measurement is less than the service limit.

STANDARD SERVICE LIMIT

12.3 mm (0.48 in) 7.0 mm (0.28 in)

18-5
• MICA DEPTH
Measure the mica depth. If the grooves are clogged or mica
depth is less than the service limit, recut the grooves using a
hacksaw blade or a small file.

STANDARD SERVICE LIMIT

0.4 – 0.5 mm 0.2 mm
(0.016 – 0.020 in) (0.008 in)

• COMMUTATOR
1) Measure the commutator O.D. If the measurement is less
than the service limit, replace the armature with a new one.

2) Measure the commutator runout using a dial gauge.

If the measurement is more than the service limit, replace
the armature with a new one.

STANDARD SERVICE LIMIT

29.4 mm (1.16 in) 28.8 mm (1.13 in)

3) Check the commutator (insulaor) for damage, dust, dirt and

metal particles.
If there is stain, irregularity and/or evidence of burning,
clean with an emery paper #500 or #600.

STANDARD 0.1 mm (0.004 in)

18-6
• ARMATURE
Check the armature and shaft gear for wear and damage.

• ARMATURE SHORT-CIRCUIT TEST

Place the armature in an armature tester (commercially
available).
Hold a hacksaw blade close to the armature core. If the blade is
attracted to the core or vibrates when the core is turned, the
armature is shorted. Replace the armature.

• CONTINUITY CHECK – SEGMENTS

Check for continuity between each segment.If an open circuit
exists between any two segments, replace the armature.

• SHORT-CIRCUIT TEST – SHAFT-TO-

COMMUTATOR
Check for continuity between the commutator and armature
shaft. If there is continuity, replace the armature.

18-7
• SHORT-CIRCUIT TEST — CORE-TO-
COMMUTATOR
Check for continuity between the commutator and armature
coil core. If continuity exists, replace the armature.

• SHORT-CIRCUIT TEST — SHAFT-TO-ARMATURE

Check for continuity between the armature and armature shaft.
If there is continuity, replace the armature.

• OVERRUNNING CLUTCH
1) Check the overrunning clutch for smooth axial movement.
If the overrunning clutch does not move smoothly, clean
the spline and coat it with grease before recheck.
If the overrunning clutch does not move smoothly after
cleaning or coated with grease, replace the overrunning
clutch assembly.

2) Turn the gear shaft assembly by holding the overrunning

clutch. The gear shaft assembly should turn only clockwise.
If the clutch turns freely in both directions or if it does not
turn at all, replace the overrunning clutch.

3) Check the pinion gear teeth for wear and damage and
replace if necessary.

NOTICE
If the pinion gear is worn or damaged, the flywheel ring
gear must be inspected.

18-8
• MAGNETIC SWITCH [1] S TERMINAL
After assembly, check for continuity between the S terminal
and the yoke (ground). Check for continuity between the S
terminal and the M terminal.

[2]
d. ASSEMBLY M TERMINAL
NOTICE
After assembling the starter motor, apply sufficient amount of
the water resisting sealant (Sumitomo 3M Padding Sealer
#8533 or equivalent) to the mating sections of each part (P. 17-
19). [4]
BRUSH SET
Replace as a set.
[5] [6]
[1] PLATE REAR BRACKET
BRUSH HOLDER
[7]
[2]
5 x 8 mm SCREW (2)
BRUSH SPRING (4)
2.5 N.m (0.25 kgf.m, 1.8 lbf.ft)
[3]
[27] GASKET
YOKE
ASSEMBLY:
Check the inner wall of the
magnetic part for the foreign
material (nut, washer, etc.) [8]
before assembly. ARMATURE

[26]
6 x 22 mm SCREW (2)
6 N.m (0.6 kgf.m,, 4.3 lbf.ft) [25] [9]
SNAP RING THROUGH BOLT (2)
[24] 5 N.m (0.5 kgf.m, 3.6 lbf.ft)
GEAR SHAFT
STOPPER [10]
[23] OVERRUNNING
O-RING (2) CLUTCH
Do not reuse. [11]
INTERNAL GEAR
[22] [12]
FRONT BRACKET GEAR SHAFT
[13]
[21] STEEL BALL
CLUTCH FORK
[20]
PLUNGER
[14]
[19] PLATE PLANETARY
[16] GEAR (3)
[18] SPRING
GASKET
[17]
STARTER MAGNETIC [15]
SWITCH 8 mm WASHER-NUT

18-9
• OVERRUNNING CLUTCH ASSEMBLY [1] GEAR SHAFT STOPPER
1) Apply grease to the internal gear, inner wall of the
overrunning clutch, gear shaft sliding surface and the [2]
ONE-WAY
surface of the gear shaft stopper.
CLUTCH
2) Assemble the overrunning clutch, gear shaft and the gear
shaft stopper with the internal gear.

3) Install the new snap ring.

4) Holding the overrunning clutch, push the gear shaft into [4]
the overrunning clutch. Push the gear shaft stopper up to INTERNAL GEAR
set the snap ring in the groove of the gear shaft stopper [3]
GEAR SHAFT
securely.
[6]
[5]
GEAR SHAFT
SNAP RING
STOPPER

• BRUSH HOLDER ASSEMBLY

1) Install the brush springs and brushes on the brush holder. [1] PLATE
Install the plate on the brush holder.

2) Secure the plate with the clip. [4]

BRUSH SPRING

[2] BRUSH SET

[3]
BRUSH HOLDER

[5] CLIP

18-10
• FRONT BRACKET ASSEMBLY
1) Apply grease to the sliding surface of the clutch fork.

2) Set the clutch fork in the indicated position of the

overrunning clutch.

[2]
[1] OVERRUNNING
CLUTCH FORK CLUTCH

3) Install the overrunning clutch assembly on the front [2]

[1] [3] OVERRUNNING
bracket. GROOVE PROJECTION CLUTCH
• Install by aligning the projection on the outer surface of
the ring gear with the groove in the front bracket.

[4]
CLUTCH
FORK
[5]
FRONT BRACKET

4) Install the gasket.

• Install by aligning the projections on the gasket with the [1] GASKET
grooves in the front bracket.

[4]
PROJECTION
[2]
FRONT
BRACKET
[3]
GROOVE

5) Apply grease to the planetary gears, steel ball and the

[2]
internal gear.
STEEL BALL
6) Install the planetary gears, steel ball and the internal gear.
[1]
PLANETARY
GEAR (3)

18-11
• REAR BRACKET/YOKE ASSEMBLY [1]
1) Install the brush holder on the armature. 5 x 8 mm SCREW (2)
2.5 N.m (0.25 kgf.m, 1.8 lbf.ft)
2) Apply grease to the armature shaft and install the gear
bracket as shown.

3) Apply the water resisting sealant (Sumitomo 3M Padding [4]

Sealer #8533 or equivalent) to the seat of each 5 x 8 mm REAR
screw. BRACKET
Tighten the 5 x 8 mm screws to the specified torque.

TORQUE: 2.5 N.m (0.25 kgf.m, 1.8 lbf.ft)

[3]
ARMATURE [2]
BRUSH
HOLDER

4) Check the inner wall of the yoke for foreign material and
install the rear bracket/armature assembly.
• Install the rear bracket/armature assembly by aligning the
grommet with the cutout in the yoke. [1]
ARMATURE/REAR
BRACKET ASSEMBLY

[2]
YOKE

5) Install the plate and gasket on the front bracket.

[2] THROUGH BOLT (2)
6) Install the yoke/rear bracket assembly. [1] YOKE/REAR BRACKET
• Install by aligning the projection on the yoke with the ASSEMBLY
cutout in the front bracket.

7) Apply the water resisting sealant (Sumitomo 3M Padding

Sealer #8533 or equivalent) to the seat of each through bolt.
Tighten the through bolts to the specified torque.
[3]
TORQUE: 5 N.m (0.5 kgf.m, 3.6 lbf.ft) GASKET

[5] [4]
FRONT BRACKET PLATE
ASSEMBLY

18-12
8) Apply the engine oil to the new O-rings and install the O-
[1] 8 mm WASHER-NUT
rings on the 6 x 22 mm screws.

9) Install the plunger, spring and the starter magnetic switch. [2]
• Assemble the plunger and the clutch fork as shown. STARTER MAGNETIC
SWITCH
10) Tighten the 6 x 22 mm screws to the specified torque.

TORQUE: 6 N.m (0.6 kgf.m, 4.3 lbf.ft)

11) Connect the brush terminal (M terminal) to the starter

magnetic switch and tighten the 8 mm washer-nut securely.
[3]
SPRING

[4]
PLUNGER

[4]
PLUNGER
[7]
O-RING (2)
Do not reuse.
[6]
6 x 22 mm SCREW (2)
12) After assembling the starter motor, apply sufficient amount
of the water resisting sealant (Sumitomo 3M Padding 6 N.m (0.6 kgf.m, [5]
Sealer #8533 or equivalent) to the following mating 4.3 lbf.ft) CLUTCH FORK
sections.

[3]
SWITCH ASSEMBLY/FRONT
BRACKET MATING SECTION
[1] [2] [4]
MAGNETIC SWITCH CASE WIRE, GROMMET AND SWITCH MOUNTING
CAULKING SECTION REAR BRACKET SCREW

[5]
O-RING
INSTALLATION
PART

[6]
[8] [7] GASKET/FRONT BRACKET
SCREW/THROUGH BOLT AND ENGAGEMENT MATING SECTION
REAR BRACKET MATING SECTIONS SECTIONS WITH YOKE

18-13
e. INSTALLATION
1) Apply the engine oil to the new O-ring.

2) Set the two 10 x 90 mm flange bolts on the starter motor, and install both the starter motor and the two 10 x 90 mm
flange bolts on the engine.

3) Tighten the two 10 x 90 mm flange bolts to the specified torque.

TORQUE: 44 N.m (4.5 kgf.m, 33 lbf.ft)

4) Connect the starter cable to the starter magnetic switch and tighten the 8 mm washer-nut to the specified torque.

TORQUE: 11 N.m (1.1 kgf.m, 8 lbf.ft)

5) Install the 8 mm washer and the alternator fuse cable on the starter magnetic switch and tighten the 8 mm washer-
nut to the specified torque.

TORQUE: 11 N.m (1.1 kgf.m, 8 lbf.ft)

6) Connect the main relay (White) terminal to the starter magnetic switch.

7) Install the terminal cover securely.

[1]
8 mm WASHER-NUT
[3]
8 mm WASHER 11 N.m (1.1 kgf.m, 8 lbf.ft)
[1] [4]
8 mm WASHER-NUT ALTERNATOR FUSE CABLE
11 N.m (1.1 kgf.m, 8 lbf.ft)

[2]
STARTER MOTOR

[5]
STARTER CABLE

[6]
MAIN RELAY
TERMINAL (W)

[7]
10 x 90 (2)
Install on the engine together
with the starter motor.
TORQUE:
44 N.m (4.5 kgf.m, 33 lbf.ft)

[8]
STARTER MAGNETIC
SWITCH

[9]
O-RING
Do not reuse.

18-14
2. STARTER CABLE
a. REMOVAL
Remove the following parts.
– Engine cover (P. 4-2) [1]
– Front separate cover (P. 4-7) STARTER
CABLE 1P
NOTICE CONNECTOR
Disconnect the starter cable from the battery before (W WIRE)
disconnecting and connecting the starter cable.

1) Release the starter cable from the two harness clips.

[2]
2) Release the starter cable 1P connector (White wire) from CONNECTOR
the connector bracket C. BRACKET C
[4] HARNESS [3]
3) Disconnect the starter cable 1P connector (White wire). CLIP (2) STARTER CABLE

4) Remove and disconnect the two 8 mm washer-nuts,

alternator fuse cable, 8 mm washer and the positive (+) [1] 8 mm WASHER-
starter cable from the magnetic switch B terminal. NUT (2)

[2] ALTERNATOR
FUSE CABLE

[3] 8 mm WASHER

[4]
STARTER
CABLE (+)

[5]
B TERMINAL

5) Remove the 8 x 18 mm flange bolt from the crankcase, then

[1] CABLE BRACKET B [2]
disconnect the negative (–) starter cable. STARTER
CABLE (–)
6) Remove the harness band clip that secures the starter cable
from the cable bracket B.
Remove the wire harness clip.

[4] [3]
HARNESS WIRE HARNESS CLIP 8 x 18
BAND CLIP

18-15
7) Release the starter cable from the cable bracket A.

[1]
CABLE BRACKET A

[2]
STARTER CABLE

b. COMPONENTS LOCATION
[2]
ALTERNATOR FUSE CABLE
[1]
8 mm WASHER-NUT (2)
11 N.m (1.1 kgf.m, 8 lbf.ft)

[3]
[13] STARTER CABLE
8 mm WASHER 1P CONNECTOR
(W WIRE)

[12]
STARTER CABLE (+) [4]
CABLE
BRACKET A

[11]
WIRE HARNESS
CLIP (2)
[10]
CONNECTOR
BRACKET C

[9]
HARNESS CLIP (2)

[8] [5]
CABLE BRACKET B STARTER CABLE

[7]
[6]
HARNESS BAND 8 x 18
STARTER CABLE (–)
CLIP
26 N.m (2.7 kgf.m, 20 lbf.ft)

18-16
c. INSTALLATION
1) Secure the alternator fuse cable and the starter cable with
the cable bracket A as shown.

[1]
CABLE BRACKET A

[2]
STARTER CABLE

[2]
STARTER CABLE [3]
ALTERNATOR
FUSE CABLE

[1]
CABLE BRACKET A

2) Tighten the 8 x 18 mm flange bolt to the specified torque

[1] CABLE BRACKET B [2]
while pushing the negative (–) starter cable against the
projection on the crankcase. STARTER
CABLE (–)
TORQUE: 26 N.m (2.7 kgf.m, 20 lbf.ft)

3) Install the harness band clip, that clamps the starter cable,
on the cable bracket B.

4) Clamp the alternator fuse cable and the starter cable with
the wire harness clamp.

NOTICE
Check that the cables are not interfering with the shift arm.

[3]
[4] WIRE HARNESS CLIP 8 x 18
HARNESS
BAND CLIP [5]
PROJECTION

[6]
STARTER CABLE
(–) TERMINAL

18-17
5) Install the positive (+) starter cable on the magnetic switch
[1] 8 mm WASHER- [2]
B terminal at right angles to the vertical center line of the TERMINAL COVER
magnetic switch as shown. Tighten the 8 mm washer-nut to NUT
the specified torque. [6] ALTERNATOR
FUSE CABLE
TORQUE: 11 N.m (1.1 kgf.m, 8 lbf.ft)
[5] 8 mm WASHER
After tightening, set the 8 mm washer on the magnetic
switch B terminal. [1]
8 mm WASHER-
NUT
6) Install the alternator fuse cable on the magnetic switch B
terminal at right angles to the vertical center line of the [4]
magnetic switch as shown. Tighten the 8 mm washer-nut to STARTER
the specified torque. CABLE (+)

TORQUE: 11 N.m (1.1 kgf.m, 8 lbf.ft) [3]

B TERMINAL
After tightening, set the terminal cover on the magnetic
switch B terminal.

[6]
ALTERNATOR
FUSE CABLE
90˚

[4]
STARTER CABLE (+)

7) Connect the starter cable 1P connector (White wire).

8) Set the starter cable 1P connector (White wire) on the

connector bracket C.

9) Secure the starter cable with the two harness clips. [1]
STARTER
10) Install the following parts. CABLE 1P
CONNECTOR
– Front separate cover (P. 4-7)
(W WIRE)
– Engine cover (P. 4-2)

[2]
CONNECTOR
BRACKET C
[4] HARNESS [3]
CLIP (2) STARTER CABLE

18-18
3. ECM/PGM-FI MAIN RELAY/FUSE BOX
a. ELECTRIC PART COVER/ECM REMOVAL/INSTALLATON
Remove the following parts.
– Engine cover (P. 4-2)
– R. engine under cover (P. 4-9)

On installation, position each connector and harness in the proper position (P. 2-48).

[2] [1]
ECM CONNECTOR ELECTRIC
C (6P CONNECTOR) PART COVER

[3]
ECM CONNECTOR A
(26P CONNECTOR)

[5]
ECM (ELECTRONIC
CONTROL MODULE) [4]
ECM CONNECTOR B
6 x 20 (2) (34P CONNECTOR)

18-19
b. PGM-FI MAIN RELAY/CONNECTOR BRACKET B REMOVAL/INSTALLATION
Remove the following parts.
– Engine cover (P. 4-2)
– R. engine under cover (P. 4-9)
– Electric part cover/ECM (P. 18-19)
Disconnect the PGM-FI main relay connector wire and the alternator fuse cable from the starter motor.

On installation, position each connector and harness in the proper position (P. 2-48 through P. 2-51).

[1] [2]
PGM-FI MAIN RELAY UNIT SUSPENSION (2)
6 x 16 (2) INSPECTION: P. 18-24
5 N.m (0.5 kgf.m, 3.6 lbf.ft)

[3]
[9] RELAY
CONNECTOR SUSPENSION
BRACKET B

6 x 10

[8]
HARNESS BAND
CLIP (4)

[7]
PGM-FI MAIN RELAY
CONNECTOR WIRE [4]
LAF RELAY
[6] INSPECTION: P. 18-25
ALTERNATOR
FUSE CABLE
[5]
POWER TILT SWITCH
INSPECTION: P. 4-12

18-20
c. FUSE BOX/ALLTERNATOR FUSE BOX (90A) REMOVAL/INSTALLATION
Remove the following parts.
– Engine cover (P. 4-2)
– R. engine under cover (P. 4-9)
– Electric part cover/ECM (P. 18-19)
– PGM-FI main relay/connector bracket B (P. 18-20)

On installation, position each connector and harness in the proper position (P. 2-48 through P. 2-51).

[1] [2]
ALTERNATOR FUSE 6 mm WASHER-NUT (2)
BOX B TERMINAL 8 N.m (0.8 kgf.m, 5.8 lbf.ft)
INSTALLATION: P. 2-48
[14]
RELAY GROMMET (2)
[13] [3]
90A FUSE FUSE BOX
INSPECTION: COLLAR (2)
Check for the blown fuse.

[12]
5 x 12 mm SCREW-
WASHER (2)

[11]
ALTERNATOR FUSE BOX
INSPECTION: P. 18-25
ASSEMBLY: P. 18-23

[10]
6 mm WASHER (2)
6 x 25 (2)
5 N.m (0.5 kgf.m,
3.6 lbf.ft)

[9] 6 x 16 mm BOLT-
WASHER (2)
[8]
ALTERNATOR
FUSE COVER

[7]
90A SPARE FUSE

[6]
3 x 7 mm SCREW-
WASHER (2)

[4] To STARTER MOTOR

B TERMINAL

[5] To ALTERNATOR
B TERMINAL

18-21
 [2]
[1] COLLAR (4)
CASE GROMMET (4)

[11]
6 mm WASHER (4)

6 x 25 (4)

[10]
FUSE BOX
BRACKET

[9]
CONNECTOR
HOLDER CLIP B

6 x 10
5 N.m (0.5 kgf.m, 3.6 lbf.ft)

[8]
FUSE BOX COVER

[3] CONNECTOR
[7] BRACKET C
FUSE BOX
[4]
INSPECTION: P. 18-26 [6] HARNESS CLIP (3)
REMOVAL: P. 18-23 BLADE FUSE [5]
HARNESS BAND
CLIP (3)

18-22
• FUSE BOX
1) Insert a screwdriver or equivalent tool into the locking lugs
on the top and underside of the fuse box, and unlock.

2) With the lock unlocked, pull the fuse box toward you and
remove the fuse box from the fuse box bracket.

• ALTERNATOR FUSE BOX

ASSEMBLY: [1]
ALTERNATOR
Connect the alternator fuse cable (White wire) to the alternator
FUSE BOX
fuse box from the reverse side. Connect so that the “ ” marks
face the directions shown.

[2]
“ ” MARKS

18-23
d. INSPECTION
NOTICE
• Use a known-good battery.
• Do not connect the battery for more than 30 seconds. Wait for
one minute or more before connecting the battery again.

• PGM-FI MAIN RELAY

1) Connect the battery positive (+) terminal to the Black/Yellow
terminal of the PGM-FI main relay 6P connector and the
battery negative (–) terminal to the Black terminal. There
must be the continuity between the following terminals of
the 4P connector. [1]
• Between White/Yellow and White/Green terminals CONNECTORS VIEWED
• Between White/Yellow and White/Red terminals FROM THE FRONT SIDE
• Between White/Yellow and White/Black terminals W/G W/R
W/Bl Bu/R
2) Connect the battery positive (+) terminal to the PGM-FI
main relay terminal and the battery negative (–) terminal to
the Light green/Red terminal. There must be the continuity
between the White/Black and the Blue/Red terminals of the
2P connector. W/Bl W/Y
Bl/Y
3) Connect the battery positive (+) terminal to the Black/White
terminal of the PGM-FI main relay 6P connector and the Lg/R
battery negative (–) terminal to the Black/Blue terminal.
There must be continuity between the terminal and the Bl/Bu
White/Yellow terminal of the 4P connector. Bl
Bl/W
4) Connect the battery positive (+) terminal to the White/
Green terminal of the PGM-FI main relay 4P connector and
[1] [2]
the battery negative (–) terminal to the 6P connector Light
4P CONNECTOR PGM-FI MAIN RELAY
green/Red terminal. There must be continuity between the
White/Black and the Blue/Red terminals of the 2P W/G
connector. W/R

5) If there is no continuity, replace the PGM-FI main relay. W/Bl

W/Y

[3]
2P CONNECTOR

W/Bl
Bu/R

[4]
6P CONNECTOR

Bl/Bu
Bl/W

Lg/R
Bl/Y
Bl

[5] TERMINAL

18-24
• LAF RRELAY
Connect the battery positive (+) terminal to the LAF relay No.3
terminal and the battery negative (–) terminal to the No.4 [1]
LAF RELAY
terminal. There must be continuity between the No.1 and No.2
terminal of the LAF relay.

[2]
CONNECTOR VIEWED FROM
THE FRONT SIDE [4]
[3] NO.3 TERMINAL No. 1 TERMINAL

[6] No. 4 TERMINAL [5] No. 2 TERMINAL

• ALTERNATOR FUSE BOX/FUSE

NOTICE [1]
ALTERNATOR
Disconnect the positive (+) and negative (–) starter cables from FUSE BOX
the battery before inspection and replacement of the alternator
fuse box/fuse.

1) Check the 90A fuse for continuity.

– If there is no continuity, replace the 90A fuse with the
spare fuse.
– If there is continuity, install the 90A fuse on the alternator [4]
To STARTER [2]
fuse box and check for continuity between the cable
MOTOR B To ALTERNATOR
terminals. B TERMINAL
TERMINAL
2) When installing the spare fuse on the reverse side of the
cover, install so that the stamp of “90A” is at your side.

[3]
RED TAPE

18-25
• FUSE BOX/FUSE [2]
[1] ALTERNATOR
NOTICE TERMINAL FUSE BOX
Disconnect the positive (+) and negative (–) starter cables from
the battery before inspection and replacement of the fuse
box/fuse.

1) Remove the fuses from the fuse box and check for blown
[3]
fuse. FUSE BOX
2) If the fuses are normal, install them in the fuse box and
check for continuity between the terminals shown below.

Fuse No. Check point

Between the terminal and the No.3 terminal
1
of the C connector
Between the terminal and the No.2 terminal
2
of the C connector
Between the terminal and the No.1 terminal
3
of the C connector
Between the A connector No.3 terminal and
4
the B connector No.4 terminal
[6] [5]
Between the A connector No.2 terminal and
5 A CONNECTOR B CONNECTOR
the B connector No.1 terminal (3P) [4]
(4P) C CONNECTOR
Between the A connector No.1 terminal and
6 [7] CONNECTORS VIEWED (4P)
the B connector No.2 terminal
FROM THE FRONT SIDE
Between the terminal and the No.3 terminal
7
of the B connector

18-26
4. POWER TILT RELAY/CONNECTOR BRACKET A
a. REMOVAL/INSTALLATION
Remove the following parts.
– Engine cover (P 4-2)
– L./R. engine under covers (P. 4-9)
– Under cover front bracket (P. 4-20)
Remove each connector from the connector bracket A, then remove the connector bracket A and the power tilt relay.

On installation, position the connectors and harnesses in the proper position (P. 2-53 through P. 2-56).

[2] [3]
HARNESS BAND TP SENSOR 3P
CLIP (3) CONNECTOR
[4]
HARNESS CLIP
[1]
MAIN WIRE INSTALLATION:
HARNESS Clamp the taped part of
the water level sensor
wire and clamp the main
wire harness.

[5]
WATER LEVEL SENSOR
2P CONNECTOR
INSTALLATION: P. 3-21
INSPECTION: P. 3-19,20

[6]
POWER TILT RELAY
[12] 3P CONNECTOR
NEUTRAL
SWITCH 2P
CONNECTOR
[7]
TRIM ANGLE SENSOR
2P CONNECTOR

[8]
POWER TILT MOTOR
[11] 2P CONNECTOR
ALTERNATOR
FUSE CABLE
[10]
FUEL TUBE A [9]
INSPECTION: POWER TILT RELAY
Check for deterioration and 1P CONNECTOR
cracks. Replace if necessary.

18-27
 [2]
WIRE HARNESS CLIP
[1]
FRAME GROUND INSTALLATION:
6 x 12 (2) Clamp the power tilt
INSTALLATION: P. 18-29 relay ground cable.

[3]
RELAY BRACKET

6 x 14 (4)

[4]
[12] WIRE HARNESS CLIP
POWER TILT RELAY
GROUND CABLE 6 x 12 [5]
INSTALLATION: P. 18-29 WIRE HARNESS CLIP
INSTALLATION:
Clamp the power tilt
relay 3P connector wire,
2P connector wire and
the 1P connector wire.

[11]
COLLAR (2)

[10]
RELAY
GROMMET (2)

[9] [4]
POWER TILT RELAY WIRE HARNESS
INSPECTION: P. 18-29 CLIP
6 x 22 (2)

[6]
CONNECTOR
BRACKET A

[7]
[8] 14 mm FUEL
HARNESS CLIP TUBE CLIP

18-28
• FRAME GROUND
INSTALLATION:
[2]
Tighten the 6 x 12 mm flange bolts while pushing each ground
FRAME GROUND
terminal against the projection on the crankcase as shown. TERMINAL
[1] [3]
PROJECTIONS POWER TILT RELAY
• POWER TILT RELAY GROUND CABLE GROUND TERMINAL
INSTALLATION:
1) Connect the Black, Blue, Green/White wire side of the
ground terminal to the upper connection, and the Green,
Green/Black, Blue, Black/White wire side of the ground
terminal to the lower connection as shown.

2) Tighten the 6 x 12 mm flange bolt while pushing each

frame ground terminal against the projection on the
crankcase.

[4]
PROJECTION

[5]
FRAME GROUND
TERMINAL

b. INSPECTION
• POWER TILT RELAY
Note that the power tilt relay inspection must be made on
single unit of the power tilt relay.
[1]
1) Check for continuity between the terminals. GROUND WIRE

Green to Black terminals Continuity

Blue to Black terminals Continuity
Green to White terminals No continuity
Blue to White terminals No continuity

Bu
Bl

Lb Lg W G

18-29
 NOTICE
Use a known-good battery.

2) Connect the wires as shown, and check for continuity

between the following terminals.

• Connecting positive (+) battery terminal to Light green

terminal:
Green to Black terminals No continuity
Blue to Black terminals Continuity
Green to White terminals Continuity
Blue to White terminals No continuity Bu Lb Lg

• Connecting positive (+) battery terminal to Light blue

terminal:
Green to Black terminals Continuity [1]
Blue to Black terminals No continuity Connect
W Bl the (+)
Green to White terminals No continuity G
battery
Blue to White terminals Continuity terminal.

18-30
19. OPERATION
1. DOHC (SWING ARM TYPE) + VTEC 4. AIR/FUEL RATIO O2 FEEDBACK
2. CHAIN DRIVE CAM DRIVE SYSTEM CONTROL BY A/F SENSOR
3. INDEPENDENT CYLINDER HEAD/
CYLINDER BLOCK COOLING SYSTEM

1. DOHC (SWING ARM TYPE) + VTEC

STRUCTURE AND FEATURES
VTEC (BF150A only)
• The VTEC adapted on the BF150A outboard motors features the two cam profiles (for low and high engine speeds) and
the corresponding three rocker arms to drive the intake valve.
• Receiving the signal from the ECM, the VTEC solenoid valve turns the hydraulic pressure ON and OFF, moving the
rocker arm pistons built in the rocker arms and thereby combining and separating the three rocker arms to select either
of the two modes and two valve timings that are suitable for the running conditions (e.g. engine speed, load, etc.).

– When the engine speed is low [engine rpm is approx. 4,300 min–1 (rpm) or below], the rocker arm piston is retracted
in the rocker arm. Each rocker arm is separate from the other making the independent movement. The center rocker
arm, designed for the high engine speed, turns idle and the right and left rocker arms trace to the low engine speed
cams. Therefore, the two intake side valves are driven in the low engine speed cam profile.
Thus, improvement of the torque in full throttle low speed range was realized compared to the conventional fixed
valve timing method.
– When the engine speed is high [engine rpm is higher than approx. 4,300 min–1 (rpm)], the VTEC solenoid valve
functions according to the signal from the ECM, extruding the rocker arm pistons from the rocker arm and combining
the three rocker arms. As the center rocker arm, which is designed for the high engine speed, traces to the high speed
cam, the two intake side valves are driven in the high engine speed cam profile.
Thus, the two valves function in the valve timing that is specially designed for the high speed range, which assures
improvement in engine horsepower.

DOHC
• The DOHC engine is adopted on these models, which realized center plug layout designed to contribute to improved
fuel consumption efficiency.
• Though the engine is the DOHC type, it also adopted the swing arm rocker arm, which allows valve clearance
adjustment with the adjusting screw and eliminated shim engagement that is poor in operationability.

EXHAUST CAMSHAFT
INTAKE CAMSHAFT

EXHAUST ROCKER ARM

INTAKE ROCKER ARM
(SWING ARM TYPE)
Built in VTEC system
VALVE ADJUSTING
SCREW
VALVE ADJUSTING SCREW

CENTER PLUG ADOPTED

19-1
2. CHAIN DRIVE CAM DRIVE SYSTEM
STRUCTURE AND FEATURES
The intake/exhaust cam drive method was changed from the existing cogged belt drive to the silent chain drive type.
The chain tensioner was changed to the hydraulic type to make it maintenance free.

Structure:
As the basic structure of this chain drive cam drive system, the balancer is laid out in front of the crankshaft and the drive
valve system is laid out behind the crankshaft.
• The balancer and intake/exhaust cam drive were changed from the two-cogged belt type (BF115A•130A) to the two-
silent chain type.
• Cam chain tension adjustment was changed from the existing manual adjustment with spring to the automatic
adjustment by drawing the main gallery oil pressure. This system is the same in structure as the system adopted on
car.
• As the unique feature of these outboard motors, the dedicated chain lubrication oil jets are provided on the crankshaft
sprocket, intake/exhaust camshaft sprocket and the driven sprocket. These oil jets feature the unique rib shape to collect
the lubrication oil around the respective sprockets.

Effects:
• The chain guide is provided regulating 80% or more of the chain line. It thereby regulates deflection of the chain and
eliminates wind noise of the chain.
• The existing spring type chain tensioner needs chain tension adjustment regularly (when chain sound was produced).
These outboard motors are equipped on the hydraulic tensioner that has the adjustment mechanism (one-way lock
mechanism) to maintain constant chain tension by means of the hydraulic pressure. It also adopted the unique
lubrication system. Maintenance free during the service life of the chain tension was realized by adoption of these new
features.

INTAKE CAMSHAFT
SPROCKET
OIL JET

CRANKSHAFT
SPROCKET

DRIVEN SPROCKET
EXHAUST CAMSHAFT HYDRAULIC CHAIN
SPROCKET TENSIONER

19-2
3. INDEPENDENT CYLINDER HEAD/CYLINDER BLOCK COOLING SYSTEM
STRUCTURE AND FEATURES
The cylinder head and cylinder block cooling passages are laid out independently from each other, each of which is
equipped with the thermostat to control the cooling water temperature of each passage.

Structure:
• The cooling water supplied from the water pump with force flows through the water tube and oil case, then it is drawn
into the mounting case.
In the mounting case, the cooling water separates into the two independent flows; one that goes to the cylinder head
and the other that goes to the cylinder block.
The cooling water temperature of each flow is regulated by the thermostat located at the outlet port of each passage.
• The thermostat valve open temperature for the cylinder head cooling water and for the cylinder block cooling water are
set at different temperature from each other.
At the cylinder block side, the thermostat valve open temperature is set at the optimum temperature (60˚C) to prevent
oil dilution (over-cooling) during cruising at low speeds with extremely low load.
At the cylinder head side, the thermostat valve open temperature is set at the temperature (50˚C) that can enhance the
knocking limit by flushing the water more. Setting the valve open temperature in this way realized improvement in
engine horsepower as well as toughness of the cylinder head against overheating.

COOLING CIRCUIT DIAGRAM

THERMOSTAT A (50˚C)
(FOR HEAD)

THERMOSTAT B (60˚C)
(FOR BLOCK)

HEAD COOLING
PASSAGE

OIL FILTER
FLANGE

BRANCHING
CHAMBER

VAPOR
SEPARATOR

INLET WATER
BLOCK COOLING
RETURN
PASSAGES
WATER
WATER
RELIEF VALVE CHECK HOLE

WATER WATER TUBE

PUMP

19-3
4. AIR/FUEL RATIO O2 FEEDBACK CONTROL BY A/F SENSOR
Receiving the current value signal from the A/F (Air Fuel Ratio) sensor, the ECM controls the fuel injection duration (fuel
amount) so that the engine’s suction air fuel mixture is at or near the target air/fuel ratio determined by the main CPU.

ECM

MAP SENSOR
DECISION OF BASIC DECISION OF TARGET
INJECTION AMOUNT A/F RATIO
CKP SENSOR

CMP SENSOR

BASIC INJECTION AMOUNT

IAT SENSOR
ENVIRONMENT COPENSATION
ECT SENSOR

BARO SENSOR

TARGET A/F RATIO DECISION OF ACTUAL

A/F SENSOR INJECTOR
COMPENSATION INJECTION AMOUNT

A/F (AIR FUEL RATIO) SENSOR

The A/F sensor, mounted on the exhaust manifold, detects the oxygen density in the exhaust gas. The A/F sensor has the
built-in zirconia element coated with the platinum on the inner and outer surfaces and wrapped with the coarse diffused
resistance layer. The sensor is structured so that its inner surface is exposed to the atmosphere and the outer surface to
the exhaust gas.
When a given voltage is applied between the platinum electrodes, the current does not change by applying further
voltage between the electrodes. However, the current value changes in accordance with the oxygen density in the
exhaust gas that passed through the diffusion resistance layer. Utilizing this characteristic, the A/F sensor detects the
change in oxygen density in the exhaust gas linearly, and thereby it realized very precise control of the air/fuel ratio.

EXHAUST GAS A/F SENSOR AIR FUEL RATIO/CURRENT

CHARACTERISTIC CHART

TIP OF THE ZIRCONIA ELEMENT 10

SENSOR
ATMOSPHERE
5
CERAMIC HEATER i
0 A/F
PLATINUM ELECTRODES (mA) 10 15 20

DIFFUSED RESISTANCE –5
LAYER
–10

19-4
BF135A•BF150A
Side Mount Remote Control Type
Top Mount Remote Control Type/Panel Mount Remote Control Type

20-2
BF135A•BF150A
PGM-FI System Diagram 1 VAPOR SEPARATOR
2 FUEL PUMP (HIGH PRESSURE SIDE)
3 FUEL STRAINER (HIGH PRESSURE SIDE)
4 VAPOR FILTER
5 BATTERY
6 IGNITION SWITCH
7 STARTER MOTOR
8 NEUTRAL SWITCH
9 TRIM METER (OPTION)
10 TRIM ANGLE SENSOR
11 A/F HEATER RELAY
12 PGM-FI MAIN RELAY
13 ECU
14 CMP SENSOR
15 ACG WARNING LIGHT
16 MIL
17 IC REGULATOR AC GENERATOR
18 OVERHEAT WARNING LIGHT
19 OIL INDICATOR LIGHT
20 WARNING BUZZER
21 TACHOMETER (OPTION)
22 EMERGENCY STOP SWITCH
23 DATA LINK CONNECTOR
24 TACHOMETER PULSE CHECK CONNECTOR
25 FUEL CONSUMPTION METER
26 BARO SENSOR
27 VTEC SOLENOID VALVE
28 SILENCER CASE
29 IAT SENSOR
30 TP SENSOR
31 MAP SENSOR
32 EACV
33 IAC VALVE
34 IAB CONTROL VALVE
35 DIAPHRAGM
36 IGNITION COIL
37 FUEL INJECTOR
38 PRESSURE REGULATOR
39 FUEL PUMP (HIGH PRESSURE SIDE
40 ECT SENSOR 2
41 ECT SENSOR 4
42 KNOCK SENSOR
43 CKP SENSOR
44 OIL PRESSURE SWITCH (LOW PRESSURE SIDE)
45 OIL PRESSURE SWITCH (HIGH PRESSURE SIDE)
46 ECT SENSOR 1
47 ECT SENSOR 3
48 A/F SENSOR
49 FUEL FILTER (LOW PRESSURE SIDE)
50 WATER LEVEL SWITCH
51 WATER SEPARATOR
1. Specifications 6 - 10
2. Service Information 11 - 89
3. Maintenance 90 - 119
4. Engine cover/Cover Lock 120 - 153
5. Programmed Fuel Injection 154 - 311
6. Alternator 312 - 335
7. Engine removal/Installation 336 - 343
8. Thermostat/Relief valve/Flush valve 344 - 354
9. Crankshaft pulley/Cam chain 355 - 373
10. Cylinder head/Valves 374 - 415
11. Oil pump/Flywheel 416 - 429
12. Crankcase/Balancer 430 - 441
13. Cylinder block/Crankshaft/Pistons 442 - 467
14. Propeller/Gear case/Extension case/
Oil case 468 - 563
15. Mounting case/Stern bracket/Swivel
case/Power trim/Tilt assembly 564 - 621
16. Steering rod/Remote Control box 622 - 631
17. Cables/Shift link bracket/Shift arm/
Neutral switch 632 - 654
18. Electrical equipment 655 - 684
19. Operation 685 - 688
20. System diagram/Wiring diagram 689 - 691
Note: Make sure to select √ Shrink to fit in the
printer dialog box when printing wiring diagrams.