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OWNER’S MANUAL

XT225R(C)

LIT-11626-16-22

5RK-28199-11

Related Manuals for Yamaha XT225R

Summary of Contents for Yamaha XT225R

Page 1
OWNER’S MANUAL XT225R(C) LIT-11626-16-22 5RK-28199-11…
Page 2
EAU03438…
Page 3
The design and manufacture of this Yamaha motorcycle fully comply with the emissions standards for clean air applicable at the date of manufacture. Yamaha has met these standards without reduc- ing the performance or economy of operation of the motorcycle. To maintain these high standards, it is important that you and your Yamaha dealer pay close attention to the recommended maintenance schedules and operating instructions contained within this manual.
Page 4: Important Manual Information

8 This manual should be considered a permanent part of this motorcycle and should remain with it even if the motorcycle is subsequently sold. 8 Yamaha continually seeks advancements in product design and quality. Therefore, while this manual contains the most current product information available at the time of printing, there may be minor discrepancies between your motorcycle and this manual.
Page 5
IMPORTANT MANUAL INFORMATION EW000000 PLEASE READ THIS MANUAL AND THE “YOU AND YOUR MOTORCYCLE: RIDING TIPS” BOOKLET CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE. DO NOT ATTEMPT TO OPERATE THIS MOTORCYCLE UNTIL YOU HAVE ATTAINED ADE- QUATE KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES AND UNTIL YOU HAVE BEEN TRAINED IN SAFE AND PROPER RIDING TECHNIQUES.
Page 6
AFFIX DEALER LABEL HERE EAU04247 XT225R(C) OWNER’S MANUAL ©2002 by Yamaha Motor Corporation, U.S.A. 1st edition, April 2002 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in Japan.
Page 7: Table Of Contents

EAU00009 TABLE OF CONTENTS SAFETY INFORMATION ……..1-1 Starter (choke) knob ……..3-8 Safe riding …………1-1 Seat …………..3-8 Protective apparel ………..1-3 Helmet holder ……….3-9 Modifications ………..1-3 Adjusting the shock absorber assembly ..3-9 Loading and accessories ……..1-3 Sidestand …………3-12 Gasoline and exhaust gas …….1-5 Ignition circuit cut-off system ……3-12 Location of important labels ……1-7 PRE-OPERATION CHECKS ……4-1…
Page 8
TABLE OF CONTENTS Removing and installing the cowling and Checking and lubricating the brake and panels …………6-7 shift pedals ……….6-30 Checking the spark plug ……..6-8 Checking and lubricating the brake and Canister (for California only) ……6-10 clutch levers ……….6-31 Engine oil and oil filter element …..6-10 Checking and lubricating the sidestand ..6-31 Cleaning the air filter element ……6-14 Lubricating the rear suspension ….6-31…
Page 9
CONSUMER INFORMATION ……9-1 Identification numbers ……..9-1 Key identification number ……..9-1 Vehicle identification number ……9-1 Model label …………9-2 Reporting safety defects ……..9-3 Motorcycle noise regulation ……9-4 Maintenance record ………9-6 Street and enduro motorcycle limited warranty ……….9-8 Yamaha extended service (Y.E.S.) ….9-10…
Page 10: Safety Information

EAU00017 Q SAFETY INFORMATION MOTORCYCLES ARE SINGLE TRACK VEHICLES. THEIR SAFE USE AND OPERATION ARE DEPENDENT UPON THE USE OF PROPER RIDING TECHNIQUES AS WELL AS THE EXPER- TISE OF THE OPERATOR. EVERY OPERATOR SHOULD KNOW THE FOLLOWING REQUIRE- MENTS BEFORE RIDING THIS MOTORCYCLE. HE OR SHE SHOULD: 1.
Page 11: Safety Information

Q SAFETY INFORMATION 4. Many accidents involve inexperienced operators. In fact, many operators who have been involved in accidents do not even have a current motorcycle license. a. Make sure that you are qualified and that you only lend your motorcycle to other qualified oper- ators.
Page 12: Protective Apparel

6. Passengers should also observe the precautions mentioned above. Modifications Modifications made to this motorcycle not approved by Yamaha, or the removal of original equipment, may render the motorcycle unsafe for use and may cause severe personal injury. Modifications may also make your motorcycle illegal to use.
Page 13
Genuine Yamaha accessories have been specifically designed for use on this motorcycle. Since Yamaha cannot test all other accessories that may be available, you must personally be responsible for the proper selection, installation and use of non-Yamaha accessories. Use extreme caution when selecting and installing any accessories.
Page 14: Gasoline And Exhaust Gas

Q SAFETY INFORMATION a. Accessories fitted to the handlebar or the front fork area can create instability due to improper weight distribution or aerodynamic changes. If accessories are added to the handlebar or front fork area, they must be as lightweight as possible and should be kept to a minimum. b.
Page 15
Q SAFETY INFORMATION a. The engine and exhaust system may be hot, therefore, park the motorcycle in a place where pedestrians or children are not likely to touch these hot areas. b. Do not park the motorcycle on a slope or soft ground, otherwise it may fall over. c.
Page 16: Location Of Important Labels

Q SAFETY INFORMATION EAU02977 Location of important labels Please read the following important labels carefully before operating this motorcycle.
Page 17
Q SAFETY INFORMATION WARNING BEFORE YOU OPERATE THIS VEHICLE, READ THE OWNER’S MANUAL AND ALL LABELS. ALWAYS WEAR AN APPROVED MOTORCYCLE HELMET, eye protection, and protective clothing. 5GK-2118K-00 3 California only EMISSION HOSE ROUTING CARB. FROM FUEL TANK CANISTER TO ATMOSPHERE 4YN-21686-00…
Page 18: Description

EAU00026 DESCRIPTION Left view 1. Headlight (page 6-36) 6. Shock absorber spring preload 2. Fuel cock (page 3-7) adjusting nut (page 3-10) 3. Air filter element (page 6-14) 7. Shock absorber rebound damping 4. Helmet holder (page 3-9) adjusting dial (page 3-11) 5.
Page 19: Right View

DESCRIPTION Right view 9 10 9. Battery (page 6-33) 14. Spark arrester (page 6-16) 10. Fuse (page 6-35) 11. Engine oil filter element (page 6-11) 12. Engine oil level check window (page 6-10) 13. Brake pedal (page 3-4, 6-23)
Page 20: Controls And Instruments

DESCRIPTION Controls and instruments 1. Clutch lever (page 3-3, 6-21) 6. Right handlebar switches (page 3-3) 2. Left handlebar switches (page 3-2) 7. Brake lever (page 3-4, 6-22) 3. Starter (choke) knob (page 3-8) 8. Throttle grip (page 6-17, 6-30) 4.
Page 21: Instrument And Control Functions

EAU00027 INSTRUMENT AND CONTROL FUNCTIONS To unlock the steering Insert the key and turn it to “OFF”. EW000017 Never turn the key to “LOCK” while the motorcycle is moving. LOCK a. Push. b. Release. EAU00029 c. Turn. Main switch/steering lock EAU00043 The main switch/steering lock con- LOCK…
Page 22: Indicator Lights

INSTRUMENT AND CONTROL FUNCTIONS 1. High beam indicator light “&” 1. Speedometer 1. Dimmer switch “&/%” 2. Turn signal indicator light “5” 2. Odometer 2. Turn signal switch “4/6” 3. Neutral indicator light “N” 3. Tripmeter 3. Horn switch “*” 4.
Page 23: Clutch Lever

INSTRUMENT AND CONTROL FUNCTIONS EAU00129 Horn switch “*” Press this switch to sound the horn. 1. Engine stop switch “#/$” 1. Clutch lever 2. Start switch “,” EAU00152 EAU03890 Clutch lever Engine stop switch “#/$” The clutch lever is located at the left Set this switch to “#”…
Page 24: Shift Pedal

INSTRUMENT AND CONTROL FUNCTIONS 1. Shift pedal 1. Brake lever 1. Brake pedal EAU00157 EAU00158 EAU00162 Shift pedal Brake lever Brake pedal The shift pedal is located on the left The brake lever is located at the right The brake pedal is on the right side side of the engine and is used in handlebar grip.
Page 25: Fuel Tank Cap

INSTRUMENT AND CONTROL FUNCTIONS To install the fuel tank cap 1. Insert the fuel tank cap into the tank opening with the key insert- ed in the lock, and then turn the cap 1/3 turn clockwise. 2. Turn the key 1/3 turn clockwise, and then remove it.
Page 26
INSTRUMENT AND CONTROL FUNCTIONS EAU00185 EAU04265 Your Yamaha engine has been designed to use regular unleaded Recommended fuel: Immediately wipe off spilled fuel gasoline with a pump octane number UNLEADED GASOLINE ONLY with a clean, dry, soft cloth, since [(R+M)/2] of 86 or higher, or a…
Page 27: Fuel Cock

INSTRUMENT AND CONTROL FUNCTIONS ON: Normal position OFF: Closed position RES: Reserve position 1. Arrow mark positioned over “OFF” 1. Arrow mark positioned over “ON” 1. Arrow mark positioned over “RES” EAU03050 Fuel cock With the lever in this position, fuel This indicates reserve.
Page 28: Starter (Choke) Knob

INSTRUMENT AND CONTROL FUNCTIONS EAU02949 Seat To remove the seat 1. Remove panels A and B. (See page 6-7 for panel removal and installation procedures.) 1. Starter (choke) knob “1” 1. Bolt (×2) EAU04038 2. Remove the bolts and pull the Starter (choke) knob “1”…
Page 29: Helmet Holder

INSTRUMENT AND CONTROL FUNCTIONS EAU04848 Adjusting the shock absorber assembly This shock absorber assembly is equipped with spring preload adjusting nut and a rebound damping force adjusting dial. EC000015 Never attempt to turn an adjusting 1. Projection 1. Helmet holder 2.
Page 30
INSTRUMENT AND CONTROL FUNCTIONS Spring preload: Minimum (soft): Distance A = 36.5 mm (1.4 in) Standard: Distance A = 43.5 mm (1.7 in) Maximum (hard): Distance A = 48.0 mm (1.8 in) 3. Tighten the locknut to the speci- 1. Spring preload adjusting nut a.
Page 31
1 click in direction b* Maximum (hard) this will result in poor damp- * With the adjusting dial fully turned in direction a ing performance. 8 Always have a Yamaha dealer service the shock absorber. 3-11…
Page 32: Sidestand

8 It cuts the running engine when regularly as described below and the transmission is in gear and have a Yamaha dealer repair it if it the sidestand is moved down. does not function properly. Periodically check the operation of the ignition circuit cut-off system according to the following procedure.
Page 33
5. Push the start switch. Does the engine start? The neutral switch may be defective. The motorcycle should not be ridden until checked by a Yamaha dealer. With the engine still running: 6. Move the sidestand up. 7. Keep the clutch lever pulled.
Page 34: Pre-Operation Checks

• If necessary, add recommended oil to specified level. 6-10–6-13 • Check vehicle for oil leakage. • Check operation. • If soft or spongy, have Yamaha dealer bleed hydraulic system. • Check lever free play. Front brake • Adjust if necessary.
Page 35
• Make sure that operation is smooth. • Check cable free play. Throttle grip 6-17, 6-30 • If necessary, have Yamaha dealer adjust cable free play and lubricate cable and grip housing. • Make sure that operation is smooth. Control cables 6-29–6-30…
Page 36
PRE-OPERATION CHECKS NOTE: Pre-operation checks should be made each time the motorcycle is used. Such an inspection can be accomplished in a very short time; and the added safety it assures is more than worth the time involved. EWA00033 If any item in the Pre-operation check list is not working properly, have it inspected and repaired before operat- ing the motorcycle.
Page 37: Operation And Important Riding Points

Consult Yamaha dealer be blocked and performance 8 The transmission is in the neutral regarding any control or func- will suffer.
Page 38
ECA00055 should be on, otherwise have a Yamaha dealer check the electrical For maximum engine life, always circuit. warm the engine up before starting off. Never accelerate hard when the engine is cold!
Page 39: Starting A Warm Engine

OPERATION AND IMPORTANT RIDING POINTS EAU01258 EC000048 Starting a warm engine Follow the same procedure as for 8 Even with the transmission in starting a cold engine with the excep- the neutral position, do not tion that the starter (choke) is not coast for long periods of time required when the engine is warm.
Page 40
OPERATION AND IMPORTANT RIDING POINTS EAU02988 EAU00427 NOTE: To start out and accelerate To decelerate Always shift gears at the recommend- 1. Pull the clutch lever to disengage 1. Apply both the front and the rear ed shift points. the clutch. brakes to slow the motorcycle.
Page 41: Recommended Shift Points

OPERATION AND IMPORTANT RIDING POINTS EAU02989 EAU01128 EAU04234 Recommended shift points Engine break-in 0–150 km (0–90 mi) 8 Avoid prolonged operation above The recommended shift points during There is never a more important peri- acceleration and deceleration are od in the life of your engine than the 1/3 throttle.
Page 42: Parking

If any engine trouble should occur 8 Do not park on a slope or on during the engine break-in period, soft ground, otherwise the immediately have a Yamaha dealer motorcycle may overturn. check the vehicle.
Page 43: Periodic Maintenance And Minor Repair

However, additional tools cycle maintenance work, have a GROUPED SEPARATELY. THESE such as a torque wrench may be nec- Yamaha dealer do it for you. SERVICES REQUIRE SPECIALIZED essary to perform certain mainte- DATA, KNOWLEDGE, AND EQUIP- nance work correctly.
Page 44
PERIODIC MAINTENANCE AND MINOR REPAIR NOTE: If you do not have the tools or experi- ence required for a particular job, have a Yamaha dealer perform it for you. EW000062 Modifications not approved by Yamaha may cause loss of perfor- mance, excessive emissions, and render the vehicle unsafe for use.
Page 45: Periodic Maintenance Chart For The Emission Control System

√ 8 * emission control 9 Replace if necessary. system** * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. ** For California. EAU03906 NOTE: From 16,000 mi (26,000 km) or 30 months, repeat the maintenance intervals starting from 4,000 mi (6,000 km) or…
Page 46: General Maintenance And Lubrication Chart

Every 500 km (300 mi) and after washing the 9 Adjust and lubricate Drive chain lubricant motorcycle or riding in the rain chain thoroughly. 9 Apply chain lube Control and Yamaha chain and cable √ √ √ √ √ meter cable throughly.
Page 47
15 * Wheel bearings — smooth rotation. 9 Check and clean or √ √ √ √ √ 16 * Sidestand switch — replace if necessary. Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.
Page 48
PERIODIC MAINTENANCE AND MINOR REPAIR EAU03906 NOTE: From 16,000 mi (26,000 km) or 30 months, repeat the maintenance intervals starting from 4,000 mi (6,000 km) or 6 months. EAU03057 NOTE: 8 The air filter needs more frequent service if you are riding in unusually wet or dusty areas. 8 Hydraulic brake system 9 When disassembling the master cylinder or caliper cylinder, always replace the brake fluid.
Page 49: Removing And Installing The Cowling And Panels

PERIODIC MAINTENANCE AND MINOR REPAIR 1. Cowling A 1. Screw 1. Panel A 2. Panel A 2. Screw EAU01145 3. Panel B EAU00488 Cowling A EAU03516 Panel A To remove the cowling Removing and installing the To remove the panel Remove the screw, and then pull the cowling and panels Remove the screw, and then pull the…
Page 50: Checking The Spark Plug

PERIODIC MAINTENANCE AND MINOR REPAIR 1. Panel B 1. Spark plug cap 1. Spark plug wrench 2. Screw EAU01833 2. Remove spark plug EAU00488 Checking the spark plug shown, with the spark plug Panel B The spark plug is an important wrench included in the owner’s To remove the panel engine component, which is easy to…
Page 51
Instead, tightened to the specified torque as 1. Measure the spark plug gap with have a Yamaha dealer check the soon as possible. a wire thickness gauge and, if motorcycle. necessary, adjust the gap to 4. Install the spark plug cap.
Page 52: Canister (For California Only)

PERIODIC MAINTENANCE AND MINOR REPAIR EAU04617 Engine oil and oil filter element The engine oil level should be checked before each ride. In addition, the oil must be changed and the oil filter element cleaned at the intervals specified in the General maintenance and lubrication chart.
Page 53
PERIODIC MAINTENANCE AND MINOR REPAIR 1. Engine oil level check window 1. Engine guard 1. Engine oil filler cap 2. Maximum level mark 2. Bolt 4. Remove the engine oil filler cap 3. Minimum level mark To change the engine oil (with or and drain bolt along with the O- 3.
Page 54
PERIODIC MAINTENANCE AND MINOR REPAIR 4 3 2 1 1. Engine oil drain bolt 1. Oil filter element drain bolt 1. Oil filter element 2. O-ring 2. Oil filter element cover 2. O-ring (×2) 3. Compression spring 3. Bolt (×2) 8.
Page 55
PERIODIC MAINTENANCE AND MINOR REPAIR ECA00133 13. Add the specified amount of the Tightening torques: recommended engine oil, and Oil filter element cover bolt: 8 In order to prevent clutch slip- then install and tighten the oil 10 Nm (1.0 m0kgf, 7.2 ft0lbf) page (since the engine oil also filler cap.
Page 56: Cleaning The Air Filter Element

PERIODIC MAINTENANCE AND MINOR REPAIR 1. Air filter case cover 1. Air filter element 1. Sponge material 2. Screw (×3) 2. Air filter element frame 3. Pull the air filter element out from EAU04221 4. Remove the sponge material the air filter case. Cleaning the air filter from the air filter element frame.
Page 57
NOTE: “UP” mark pointing as shown. The sponge material should be wet but not dripping. Recommended oil: Yamaha foam air filter oil or other quality air filter oil 6-15…
Page 58: Cleaning The Spark Arrester

PERIODIC MAINTENANCE AND MINOR REPAIR EAU01549 Cleaning the spark arrester The spark arrester should be cleaned at the intervals specified in the Periodic maintenance and lubrication chart. EWA00007 8 Always let the exhaust system cool prior to touching exhaust 1. Muffler 1.
Page 59: Adjusting The Carburetor

To prevent retor adjustments should be left to this from occurring, the valve clear- Yamaha dealer, who has the neces- ance must be adjusted by a Yamaha sary professional knowledge and dealer at the intervals specified in the experience.
Page 60: Tires

PERIODIC MAINTENANCE AND MINOR REPAIR EAU04836 EWA00012 Tire air pressure Tires (measured on cold tires) To maximize the performance, dura- Load* Front Rear Because loading has an enormous 150 kPa 125 kPa bility, and safe operation of your impact on the handling, braking, Up to 90 kg (198 lb) (1.25 kgf/cm (1.50 kgf/cm…
Page 61
Manufacturer Size Type or if the sidewall is cracked, have a BRIDGESTONE 2.75-21 45P TW27 Yamaha dealer replace the tire imme- CHENG SHIN 2.75-21 45P C-6006 diately. REAR Minimum tire tread depth Manufacturer…
Page 62: Spoke Wheels

If any damage is including the tires, should be found, have a Yamaha dealer left to a Yamaha dealer, who replace wheel. has the necessary profession- attempt even the smallest repair al knowledge and experience.
Page 63: Accessories And Replacement Parts

PERIODIC MAINTENANCE AND MINOR REPAIR EAU00691 manufactured by other companies, Accessories and Yamaha cannot be held liable for replacement parts any consequences caused by the use of items which have not been approved by Yamaha. This motorcycle is not designed to pull a trailer or to be attached to a sidecar.
Page 64: Adjusting The Brake Lever Free Play

If there is air 2. Adjusting nut 2. Adjusting bolt in the hydraulic system, have c. Free play 3. If the specified clutch lever free a Yamaha dealer bleed the EAU00696 play could obtained Adjusting the brake lever…
Page 65: Adjusting The Brake Pedal Position And Free Play

Periodically check the brake adjusting bolt in direction a. To pedal free play and, if necessary, lower the brake pedal, turn the It is advisable to have a Yamaha adjust it as follows. adjusting bolt in direction b. dealer make these adjustments.
Page 66: Adjusting The Rear Brake Light Switch

8 If proper adjustment cannot be obtained as described, have a 1. Brake pedal free play adjusting nut 1. Rear brake light switch Yamaha dealer make this 2. Adjusting nut adjustment. To increase the brake pedal free…
Page 67: Checking The Front Brake Pads And Rear Brake Shoes

Yamaha dealer wear indicator reaches the wear limit replace the brake pads as a set. line, have a Yamaha dealer replace the brake shoes as a set. 6-25…
Page 68: Checking The Brake Fluid Level

However, if ing leakage and poor braking the brake fluid level goes down performance. suddenly, have a Yamaha dealer 1. Minimum level mark check the cause. Recommended brake fluid: EAU03294 Checking the brake fluid…
Page 69: Changing The Brake Fluid

EAU03985 EAU00744 Changing the brake fluid Drive chain slack Have a Yamaha dealer change the The drive chain slack should be brake fluid at the intervals specified in checked before each ride and adjust- the NOTE after the periodic mainte- ed if necessary.
Page 70
PERIODIC MAINTENANCE AND MINOR REPAIR EW000103 NOTE: Make sure that both adjusting plates After adjusting the brake pedal are in the same position for proper free play, check the operation of wheel alignment. the brake light. EC000096 Improper drive chain slack will overload the engine as well as 1.
Page 71: Lubricating The Drive Chain

If ECA00053 a cable is damaged or does not move To prevent damaging the O-rings, smoothly, have a Yamaha dealer check or replace it. do not clean the drive chain with steam cleaners,…
Page 72: Checking And Lubricating The Throttle Grip And Cable

PERIODIC MAINTENANCE AND MINOR REPAIR EW000111 EAU04034 Checking and lubricating the throttle grip and cable Damage to the outer housing of The operation of the throttle grip cables may result in internal rust- should be checked before each ride. ing and cause interference with In addition, the cable should be lubri- cable movement.
Page 73: Checking And Lubricating The Brake And Clutch Levers

Yamaha dealer check or repair it. The operation of the brake and clutch The pivoting points of the rear sus- levers should be checked before pension must be lubricated at the Recommended lubricant:…
Page 74: Checking The Front Fork

EC000098 If any damage is found or the front fork does not operate smoothly, have a Yamaha dealer check or repair it. 6-32…
Page 75: Checking The Wheel Bearings

If there is play is no need to check the electrolyte or in the wheel hub or if the wheel does to add distilled water. not turn smoothly, have a Yamaha EC000101 dealer check the wheel bearings. Never attempt to remove the bat- tery cell seals, as this would per- 2.
Page 76
EW000116 8 KEEP THIS AND ALL BATTER- To charge the battery IES OUT OF THE REACH OF Have a Yamaha dealer charge the 8 Electrolyte is poisonous and CHILDREN. battery as soon as possible if it dangerous since it contains seems to have discharged.
Page 77: Replacing The Fuse

EAU01307 the battery. If you do not have 4. If the fuse immediately blows Replacing the fuse access to a sealed-type (MF) again, have a Yamaha dealer The fuse holder is located behind battery charger, have check the electrical system.
Page 78: Replacing The Headlight Bulb

PERIODIC MAINTENANCE AND MINOR REPAIR EAU01528 Replacing the headlight bulb This motorcycle is equipped with a quartz bulb headlight. If the headlight bulb burns out, replace it as follows. 1. Remove cowling A. (See page 6-7 for cowling removal and installation procedures.) 1.
Page 79
PERIODIC MAINTENANCE AND MINOR REPAIR 8. Install the cowling. 9. Have a Yamaha dealer adjust the headlight beam if necessary. 1. Headlight bulb holder a. Do not touch the glass part of the bulb. EC000105 4. Remove the headlight bulb hold-…
Page 80: Replacing A Turn Signal Light Bulb

PERIODIC MAINTENANCE AND MINOR REPAIR 1. Lens 1. Bulb 1. Lens 2. Screw 2. Screw (×2) 2. Remove the defective bulb by EAU03497 EAU01623 pushing it in and turning it coun- Replacing a turn signal light Replacing the tail/brake light terclockwise.
Page 81: Supporting The Motorcycle

PERIODIC MAINTENANCE AND MINOR REPAIR EAU01579 To service the rear wheel Supporting the motorcycle Raise the rear wheel off the ground Since this model is not equipped with by using a motorcycle stand or, if a a centerstand, follow these precau- motorcycle stand is not available, by tions when removing the front and placing a jack either under each side…
Page 82: Front Wheel

3. Remove the speedometer cable holder by removing the screw. 8 It is advisable to have a 4. Disconnect speedometer Yamaha dealer service the cable from the front wheel. wheel. 5. Remove the axle nut. 8 Securely support the motorcy- 6.
Page 83
PERIODIC MAINTENANCE AND MINOR REPAIR Tightening torque: Axle nut: 85 Nm (8.5 m0kgf, 62 ft0lbf) 6. Connect the speedometer cable, and then install the speedometer cable holder by installing the screw. 7. Install the brake disc cover by 1. Speedometer gear unit 1.
Page 84: Rear Wheel

8 It is advisable to have a 3. Loosen the axle nut. install the wheel. Yamaha dealer service the 4. Turn the drive chain adjusting wheel. plate on each side of the 8. Pull the wheel axle out, and then 8 Securely support the motorcy- swingarm fully in direction a.
Page 85
PERIODIC MAINTENANCE AND MINOR REPAIR EW000103 2. Install the drive chain onto the rear sprocket, and then adjust After adjusting the brake pedal the drive chain slack. (See page free play, check the operation of 6-28 for drive chain slack adjust- the brake light.
Page 86: Troubleshooting

Use only genuine Yamaha replace- ment parts. Imitation parts may look like Yamaha parts, but they are often inferior, have a shorter service life and can lead to expensive repair bills. 6-44…
Page 87: Troubleshooting Chart

There is compression. Check the ignition. Operate the electric starter. There is no compression. Have a Yamaha dealer check the vehicle. 3. Ignition Wipe off with a dry cloth and correct the Open throttle halfway and operate Remove the spark spark plug gap, or replace the spark plug.
Page 88: Motorcycle Care And Storage

EAU03521 MOTORCYCLE CARE AND STORAGE Before cleaning Cleaning Care 1. Cover the muffler outlet with a ECA00010 While the open design of a motorcy- plastic bag after the engine has cle reveals the attractiveness of the 8 Avoid cooled down. using strong acidic…
Page 89
MOTORCYCLE CARE AND STORAGE 8 Do not use any harsh chemical 8 For motorcycles equipped After riding in the rain, near the sea products on plastic parts. Be with a windshield: Do not use or on salt-sprayed roads sure to avoid using cloths or strong cleaners hard…
Page 90
NOTE: ior. 4. To prevent corrosion, it is recom- Consult a Yamaha dealer for advice mended to apply a corrosion pro- on what products to use. tection spray on all metal, includ- ing chrome- and nickel-plated, surfaces.
Page 91: Storage

MOTORCYCLE CARE AND STORAGE Long-term c. Install the spark plug cap onto Storage Before storing your motorcycle for the spark plug, and then place Short-term several months: the spark plug on the cylinder Always store your motorcycle in a 1. Follow all the instructions in the head so that the electrodes cool, dry place and, if necessary, pro- “Care”…
Page 92
MOTORCYCLE CARE AND STORAGE 7. Check and, if necessary, correct the tire air pressure, and then lift the motorcycle so that both of its wheels ground. Alternatively, turn the wheels a little every month in order to pre- vent the tires from becoming degraded in one spot.
Page 93: Specifications

EAU01038 SPECIFICATIONS Specifications Engine oil Model XT225R(C) 0° 10° 30° 50° 70° 90° 110° 130°F Dimensions Type Overall length 2,070 mm (81.5 in) YAMALUBE 4 (10W30) or SAE 10W30 Overall width 805 mm (31.7 in) Overall height 1,160 mm (45.7 in)
Page 94: Specifications

SPECIFICATIONS Fuel Gear ratio 3.090 Type UNLEADED GASOLINE ONLY 2.000 Fuel tank capacity 8.8 L (1.94 lmp qt, 2.32 US qt) 1.428 Reserve amount 2.0 L (0.44 lmp qt, 0.53 US qt) 1.125 Carburetor 0.925 Manufacturer MIKUNI 0.793 BST34 × 1 Model×quantity Chassis Spark plug…
Page 95
SPECIFICATIONS Maximum load* 183 kg (404 lb) Rear Tire air pressure Type Drum brake (measured on cold tires) Operation Right foot Up to 90 kg (198 lb) load* Suspension Front 125 kPa (1.25 kgf/cm , 18 psi) Front Rear 150 kPa (1.50 kgf/cm , 22 psi) Type Telescopic fork…
Page 96
SPECIFICATIONS Headlight type Quartz bulb (halogen) Bulb voltage, wattage × quantity 12V, 60/55W × 1 Headlight 12V, 8/27W × 1 Tail/brake light Front turn signal/ 12V, 27/8W × 2 position light 12V, 27W × 2 Rear turn signal light 12V, 3.4W × 1 Meter lighting 12V, 3.4W ×…
Page 97: Consumer Information

Record the key identification number, vehicle identification number and model label information in the spaces provided below for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehicle is stolen. 1. KEY IDENTIFICATION 1. Key identification number 1.
Page 98: Model Label

The model label is affixed to the frame under the seat. (See page 3-8 for seat removal and installation pro- cedures.) Record the information on this label in the space provided. This information will be needed when ordering spare parts from a Yamaha dealer.
Page 99: Reporting Safety Defects

If you believe that your vehicle has a defect which could cause a crash or could cause injury or death, you should imme- diately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying Yamaha Motor Corporation, U.S.A. If NHTSA receives similar complaints, it may open an investigation, and if it finds that a safety defect exists in a group of vehicles, it may order a recall and remedy campaign.
Page 100: Motorcycle Noise Regulation

CONSUMER INFORMATION EAU01053 Motorcycle noise regulation TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED: Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any per- son.
Page 101
CONSUMER INFORMATION…
Page 102: Maintenance Record

CONSUMER INFORMATION EAU03052 Maintenance record Copies of work orders and/or receipts for parts purchased and installed on your motorcycle will be required to document that maintenance has been completed in accordance with the emissions warranty. The chart below is printed only as a reminder that maintenance work is required.
Page 103
CONSUMER INFORMATION Maintenance Date of Servicing dealer Mileage Remarks interval service name and address 16,000 mi (26,000 km) or 30 months 19,000 mi (31,000 km) or 36 months 22,000 mi (36,000 km) or 42 months 25,000 mi (41,000 km) or 48 months 28,000 mi (46,000 km) or…
Page 104: Street And Enduro Motorcycle Limited Warranty

CONSUMER INFORMATION EAU02918 YAMAHA MOTOR CORPORATION, U.S.A. STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY…
Page 105
CONSUMER INFORMATION…
Page 106: Yamaha Extended Service (Y.e.s.)

CONSUMER INFORMATION EAU01063 YAMAHA EXTENDED SERVICE (Y.E.S.) 9-10…
Page 107
9-11…
Page 108
YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2002·5–0.7×1(E)

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Yamaha Serow 225 Service Repair Manuals on Motor Era

Motor Era offers service repair manuals for your Yamaha Serow 225 — DOWNLOAD your manual now! Yamaha Serow 225 service repair manuals

Complete list of Yamaha Serow 225 motorcycle service repair manuals:

Yamaha XT 225 Serow 1992-2007 Service Repair Workshop Manual 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006
DOWNLOAD Yamaha XT225 XT 225 Serow 1992-2007 Service Repair Workshop Manual

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The Cyclepedia Yamaha XT225 Serow motorcycle online service manual features detailed full-color photographs and wiring diagrams, complete specifications with step-by-step procedures performed and written by a veteran Yamaha motorcycle dealer trained technician.

Keep your Yamaha XT225 Serow dual-sport motorcycle running in top notch condition with the easy to use Cyclepedia Online Yamaha XT225 Serow Service Manual. This instantly available manual covers everything from piston and cylinder inspection, to wheel bearing replacement, and everything in between. If you ever have any questions on how to use the manual, or performing the procedures on your Yamaha XT225 Serow motorcycle, Cyclepedia.com provides expert tech support to assist you.

This Cyclepedia manual covers 1992 – 2007 Yamaha XT225 Serow motorcycles.

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Periodic Maintenance

Periodic Maintenance Chart, Clutch Cable Adjustment, Throttle Free Play, Brake Bleeding, Engine Idle Speed, Drive Chain Adjustment, Rear Brake Inspection, Front Brake Pads, Engine Oil, Spark Plug, Air Filter Servicing, Spark Arrestor, Tires, Valve Clearance, Compression Test

Quick Reference

XT225 Serow Specifications, VIN and Engine Number Location, Torque Specifications, General Torque Specifications

Fuel System

Carburetor Removal, Carburetor Installation, Carburetor Assembly, Carburetor Disassembly, Carburetor Specifications, Fuel Strainer, Airbox

External Components

Side Covers, Seat, Fuel Tank, Footpegs, Front Number Plate, Handlebar, Front Fender, Rear Fender, Exhaust System

Engine

Engine Specifications, Camshaft Removal, Camshaft Installation, Cylinder Head, Valves, Starter Motor, Cylinder and Piston, Clutch, Left Engine Components, Left Side Install, Right Engine Components, Oil Pump, Engine Removal, Engine Installation, Crankcase Splitting, Crankshaft, Crankcase Assembly, Transmission Removal, Transmission Assembly

Final Drive

Drive Chain, Engine Sprocket, Rear Wheel Sprocket

Front Brake

Brake Disc, Front Brake Specifications, Master Cylinder, Front Brake Caliper

Rear Brake

Rear Drum Brake, Brake Rod and Pedal

Wheels

Wheel and Axle Inspection, Front Wheel, Rear Wheel, Bearing Replacement

Steering

Removal, Bearing Replacement, Installation

Front Suspension

Fork Removal and Installation, Front Fork Assembly, Front Fork Disassembly

Rear Suspension

Shock Removal, Shock Installation, Specifications, Swing Arm

Electrical System

Electrical Specifications, Ignition System, Charging System, Starter System, Switches, Wiring Diagram, Lights

Online Parts Diagrams

Troubleshooting

Professional Tech Support

My Service Records – Online Maintenance Record Keeping Software

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Page 1
F225A FL225A SERVICE MANUAL 290435 69J-28197-3D-11…
Page 2: Important Information

NOTICE This manual has been prepared by Yamaha primarily for use by Yamaha dealers and their trained mechanics when performing maintenance procedures and repairs to Yamaha equipment. It has been written to suit the needs of persons who have a basic understanding of the mechanical and electrical concepts and procedures inherent in the work, for without such knowledge attempted repairs or service to the equipment could render it unsafe or unfit for use.
Page 3
Contents General information INFO Specifications SPEC Periodic checks and adjustments Fuel system FUEL Power unit POWR Lower unit LOWR Bracket unit BRKT – Electrical systems ELEC Troubleshooting TRBL SHTG Index…
Page 4: Table Of Contents

INFO General information How to use this manual …………….. 1-1 Manual format……………….. 1-1 Symbols………………… 1-2 Safety while working………………1-3 Fire prevention………………. 1-3 Ventilation………………..1-3 Self-protection ………………. 1-3 Parts, lubricants, and sealants …………..1-3 Good working practices …………….1-4 Disassembly and assembly …………… 1-4 Identification………………..1-5 Applicable models ………………1-5 Serial number ………………..
Page 5
Predelivery checks ………………1-28 Checking the fuel system …………….1-28 Checking the gear oil…………….1-28 Checking the engine oil …………….1-28 Checking the battery…………….1-28 Checking the outboard motor mounting height……..1-29 Checking the remote control cables …………1-29 Checking the steering wheel …………..1-30 Checking the gearshift and throttle operation……….1-30 Checking the tilt system…………….1-30 Checking the engine start switch and engine stop switch/…
Page 6: How To Use This Manual

INFO General information How to use this manual Manual format The format of this manual has been designed to make service procedures clear and easy to under- stand. Use the information below as a guide for effective and quality service. 1 Parts are shown and detailed in an exploded diagram and are listed in the components list.
Page 7: Symbols

Symbols 7 to A in an exploded diagram indicate the grade of lubricant and the lubrication point. 7 Apply Yamaha 4-stroke motor oil 0 Apply corrosion resistant grease 8 Apply water resistant grease (Yamaha grease A) (Yamaha grease D) 9 Apply molybdenum disulfide grease…
Page 8: Safety While Working

Gasoline is highly flammable. Keep gasoline and all flammable products away from heat, sparks, and open flames. Parts, lubricants, and sealants Use only genuine Yamaha parts, lubricants, and sealants or those recommended by Yamaha, when servicing or repairing the outboard motor.
Page 9: Good Working Practices

Safety while working Disassembly and assembly 6. Keep a supply of clean, lint-free cloths for wiping up spills, etc. 1. Use compressed air to remove dust and dirt during disassembly. Good working practices Special tools 2. Apply engine oil to the contact surfaces Use the recommended special tools to pro- of moving parts before assembly.
Page 10: Identification

INFO General information Identification Applicable models This manual covers the following models. Applicable models F225AET, FL225AET Serial number outboard motor serial number stamped on a label attached to the port clamp bracket. 1 Model name 2 Approved model code 3 Transom height 4 Serial number Approved Starting…
Page 11: Features And Benefits

Identification / Features and benefits Features and benefits Newly developed V6 4-stroke engine The F225 is a newly developed 60-degree V6 4-stroke engine with a very compact and lightweight design. Its size and weight are almost the same as the V6 2-stroke engines that are in current use. This F225 offers numerous advantages of a 4-stroke engine.
Page 12
INFO General information Crankcase The crankcase is made of cast aluminum, however steel has been cast into the areas for the crank- shaft bearings. By distinguishing the area that requires strength from the area that allows the use of a lighter material, both weight reduction and a stronger construction have been achieved. The caps for the crankshaft bearings are secured with four bolts to ensure a high level of assembled rigidity.
Page 13
Features and benefits Piston The piston has been carved out of a forged stock. To prevent the valves from coming in contact with the piston, the piston is provided with a valve recess. If the engine goes out of timing and a valve opens when the piston is at top-dead-center, this recess prevents the valve from coming in contact with the piston, thus preventing engine damage.
Page 14: Valve Train System

INFO General information Valve train system The valve train consists of a total of four camshafts, with two in each bank. The camshafts are driven with the combination of a belt and chains. The crankshaft turns the belt to drive the exhaust camshafts in both banks. Chains connect the exhaust camshafts to the intake camshafts in the cylinder heads to drive the intake camshafts.
Page 15
Features and benefits Tensioner A timing chain tensioner is provided at the mid-span of the timing chain, between both camshafts. The timing chain tensioner uses the force of a spring to maintain its tension. After the engine is started, oil is pumped into the tensioner, and the resulting pressure causes the tension to increase. A total of three tensioners are used, one for the timing belt, and one for each timing chain of both banks, to maintain proper tension and to ensure the reliability of the valve train.
Page 16: Intake System

INFO General information Intake system Throttle valve A total of six intake throttle valves are provided, one for each cylinder. Together with the intake silencer that offers enhanced intake efficiency and the injectors that are provided at each throttle body, the throttle valves help to improve the intake efficiency of the engine. As a result, this engine produces a higher power output and realizes better driveability.
Page 17
Features and benefits Exhaust passage during idle To reduce noise when the engine is idling, the exhaust gas passage of the F225 has adopted a lab- yrinth construction. During idling, the exhaust gas passes through the passage on the side of the exhaust guide, and enters the upper case through a hole in the upper case gasket.
Page 18: Fuel System

INFO General information Fuel system The fuel flows in the following order: fuel filter, low-pressure fuel pump, vapor separator, high-pres- sure fuel pump, and injectors. The excess fuel at the injectors passes through the pressure regula- tor and fuel cooler, and returns to the vapor separator. When the engine start switch is turned on, the injectors of all cylinders operate before the pump relay is actuated to prevent the injectors from sticking.
Page 19
Features and benefits Low-pressure fuel pump The F225 has adopted a newly developed, low-pressure electrical fuel pump, in place of the low- pressure mechanical fuel pump used in the previous electronic fuel injection system. With the adop- tion of the electric pump, the routing of the fuel system has been made more compact. To prevent the over-pumping of fuel, this pump operates for 10 seconds, and stops for 20 seconds when the engine is operating at low speeds.
Page 20
INFO General information Electronic control system The ECM of the F225 controls the ignition timing, the fuel injection timing, the fuel injection volume, and the ISC and it maintains a stoichiometric air-fuel ratio in all operating conditions, including start- ing and idling. Also, the ECM converts the signals from the input sensors and sends instructions to each part.
Page 21
Features and benefits Ignition and fuel injection timing Firing order : #1, #2, #3, #4, #5, #6 Injection order : #1 and #4 → #2 and #5 → #3 and #6 (group injection) : Ignition spark Crankshaft angle Wasted spark ˚…
Page 22: Ptt (Power Trim And Tilt) Unit

INFO General information PTT (Power trim and tilt) unit The PTT unit has been newly developed for the F225. Based on the field-proven 61A type, its PTT fluid passage and internal valve construction have been changed for this application. Although the valves of the 61A type have been distributed to the various areas of the gear pump housing, the valves of the new PTT unit have been concentrated in the vicinity of the gear pump to improve their serviceability.
Page 23: Technical Tips

Features and benefits / Technical tips Technical tips Fuel injection control The F225 injects fuel simultaneously to the following cylinder pairs: #1 and #4, #2 and #5, and #3 and #6. Optimal injection timing is provided in accordance with the operating conditions of the engine.
Page 24
INFO General information Over-revolution control If the engine speed exceeds 4,500 r/min, while the shift is in neutral, ignition is stopped. The various stages of ignition cutoff are shown in the table below. Ignition cutoff cylinder in neutral Set speed (r/min) 4,500 4,750 : Indicates a misfire at either cylinder (once, due to simultaneously firing).
Page 25: Fail-Safe Function Table

Technical tips Fail-safe function table FAIL-SAFE FUNCTION DIAGNOSIS Symptom Engine CODE Ignition Injection condition Engine starting: All cylinders inject Only the cylinders simultaneously Incorrect pulser outputting normal Only in neutral: Idle speed based on the cylin- coil signal signal ignite at 900 r/min increases der that is output-…
Page 26: Ptt (Power Trim And Tilt) Unit

INFO General information PTT (Power trim and tilt) unit In the newly designed PTT unit, the up-main valve, down-main valve, up-relief valve, and down- relief valve have been concentrated in the gear pump housing in order to improve the serviceability of the engine and ensure reliable operation.
Page 27
Technical tips Trim-up and tilt-up function When the PTT switch is pressed to “UP,” the power trim and tilt motor operates the gear pump and fluid pressure is generated. As a result, the fluid pressure pushes the up-shuttle piston upward, enters the trim cylinder and tilt cylinder lower chambers through the up-main valve, and then pushes the tilt ram and trim ram upward.
Page 28
INFO General information Trim ram retraction function When the outboard motor is tilted up and held in place with the tilt stop lever and the PTT switch is pressed to “DN,” the trim ram will be retracted. Although the gear pump attempts to draw oil from the tilt cylinder and trim cylinder lower chambers, after the PTT switch has been pressed, fluid cannot be drawn from the tilt cylinder lower chamber because the tilt ram is secured in place by the tilt stop lever.
Page 29
Technical tips Trim-down and tilt-down function When the PTT switch is pressed to “DN,” the power trim and tilt motor operates the gear pump and fluid pressure is generated. As a result, the fluid pressure pushes the down-shuttle piston upward, enters the tilt cylinder upper chamber through the down-main valve, and then pushes the tilt ram downward.
Page 30
INFO General information Stationary condition When the PTT switch is not pressed, the gear pump will not pump the fluid, the up-main valve and the down-main valve will remain closed, and the PTT unit in the system remains constant. This will allow the tilt ram and the trim ram to maintain their positions until the PTT fluid flows through the system again.
Page 31: Cooling System

Technical tips Cooling system S69J1460 1 Cooling water inlet 6 In-bank exhaust system 2 Water pump 7 Thermostat 3 Oil pan 8 Propeller boss 4 Exhaust pipe È Water 5 PCV (Pressure control valve) Lubrication system Cylinder head Crankcase Pressure feed Splash Sleeve Return…
Page 32: Propeller Selection

INFO General information a Propeller diameter (in inches) Propeller selection b Propeller pitch (in inches) The performance of a boat and outboard c Propeller type (propeller mark) motor will be critically affected by the size and type of propeller you choose. Propellers Selection greatly affect boat speed, acceleration, When the engine speed is at the full throttle…
Page 33: Predelivery Checks

Propeller selection / Predelivery checks Predelivery checks Checking the engine oil 1. Check the oil level. To make the delivery process smooth and efficient, the predelivery checks should be completed as explained below. Checking the fuel system 1. Check that the fuel hoses are securely connected and that the fuel tank is full with fuel.
Page 34: Checking The Outboard Motor Mounting Height

INFO General information Checking the outboard motor mounting height 1. Check that the anti-cavitation plate is aligned with the bottom of the boat. If the mounting height is too high, cavitation will occur and propulsion will be reduced. Also, the engine speed will increase abnormally and cause the engine to overheat.
Page 35: Checking The Steering Wheel

Predelivery checks Checking the steering wheel Checking the tilt system 1. Check the steering friction for proper 1. Check that the outboard motor tilts up adjustment. and down smoothly when operating the power trim and tilt unit. 2. Check that steering operates smoothly.
Page 36: Checking The Cooling Water Pilot Hole

INFO General information Checking the cooling water pilot hole 1. Check that cooling water is discharged from the cooling water pilot hole. S69J1240 È Hour After test run 1. Check for water in the gear oil. S69J1230 2. Check for fuel leakage in the cowling. Test run 1.
Page 37
SPEC Specifications General specifications………………. 2-1 Maintenance specifications …………….2-3 Power unit………………..2-3 Lower unit ………………..2-6 Electrical ………………..2-7 Dimensions………………..2-9 Tightening torques………………2-12 Specified torques………………2-12 General torques………………2-15 69J3D11…
Page 38: General Specifications

SPEC Specifications General specifications Model Item Unit F225AET FL225AET Dimension Overall length mm (in) 892 (35.1) Overall width mm (in) 634 (25.0) Overall height mm (in) 1,805 (71.1) mm (in) 1,932 (76.1) Boat transom height mm (in) 635 (25.0) mm (in) 762 (30.0) Weight (with stainless propeller)
Page 39
General specifications Model Item Unit F225AET FL225AET Fuel and oil Fuel type Regular unleaded gasoline Fuel rating PON* Engine oil type 4-stroke motor oil Engine oil grade SE, SF, SG, or SH 10W-30 or 10W-40 Engine oil quantity (with oil filter replacement) 6.0 (6.3, 5.3) (US qt, lmp qt) (without oil filter replacement)
Page 40: Specifications

SPEC Specifications Maintenance specifications Power unit Model Item Unit F225AET FL225AET Power unit Minimum compression 880 (8.8, 125) pressure* (kgf/cm , psi) Lubrication oil pressure kPa (kgf/cm 650 (6.5, 924) psi) at 700 r/min Cylinder heads Warpage limit mm (in) 0.1 (0.004) (lines indicate straightedge position)
Page 41
Maintenance specifications Model Item Unit F225AET FL225AET Oil ring Dimension B mm (in) 2.40–2.47 (0.0945–0.0972) Dimension T mm (in) 2.3–2.7 (0.091–0.106) End gap mm (in) 0.15–0.60 (0.0059–0.0236) Side clearance mm (in) 0.04–0.13 (0.0016–0.0051) Camshafts Intake (A) mm (in) 45.30–45.40 (1.7835–1.7874) Exhaust (A) mm (in) 45.35–45.45 (1.7854–1.7894)
Page 42
SPEC Specifications Model Item Unit F225AET FL225AET Valve lifters Valve lifter outside diameter mm (in) 32.98–33.00 (1.2984–1.2992) Valve lifter-to-cylinder head mm (in) 0.02–0.05 (0.0008–0.0020) clearance Valve shims Valve shim thickness mm (in) 2.320–2.960 (0.0913–0.1165) (in 0.020 mm increments) Connecting rods Small-end inside diameter mm (in) 21.00 (0.827)
Page 43: Lower Unit

Maintenance specifications Model Item Unit F225AET FL225AET Oil pump Discharge L (US gal, 8.8 (2.32, 1.94) at 97–103 °C (207–217 °F) Imp gal)/min with 10W-40 engine oil at 700 r/min Pressure 138 (1.38, 19.62) (kgf/cm , psi) Relief valve opening pressure 529–647 (5.29–6.47, 75.22–92.00) (kgf/cm , psi)
Page 44: Electrical

SPEC Specifications Electrical Model Item Unit F225AET FL225AET Ignition and ignition control system Ignition timing (engine idle speed) Degree Pulser coil output peak voltage (W/R – B, W/B – B, W/G – B) at cranking (unloaded) at cranking (loaded) at 1,500 r/min (loaded) at 3,500 r/min (loaded) Ω…
Page 45
Maintenance specifications Model Item Unit F225AET FL225AET Starter motor Type Sliding gear Output Cranking time limit Second Brushes Standard length mm (in) 15.5 (0.61) Wear limit mm (in) 9.5 (0.37) Commutator Standard diameter mm (in) 29.0 (1.14) Wear limit mm (in) 28.0 (1.10) Mica Standard undercut…
Page 46: Dimensions

SPEC Specifications Dimensions Exterior 12˚ S69J2130 69J3D11…
Page 47
Maintenance specifications Model Symbol Unit F225AET FL225AET mm (in) 651 (25.6) mm (in) 219 (8.6) mm (in) — mm (in) 673 (26.5) mm (in) 59 (2.3) mm (in) 59 (2.3) mm (in) 1,155 (45.5) mm (in) 1,272 (50.1) mm (in) 618 (24.3) mm (in) 230 (9.1)
Page 48
SPEC Specifications Clamp bracket S69J2140 Model Symbol Unit F225AET FL225AET mm (in) 125 (4.9) mm (in) 254 (10.0) mm (in) 163 (6.4) mm (in) 51 (2.0) mm (in) 180 (7.1) mm (in) 411 (16.2) mm (in) — mm (in) — mm (in) 19 (0.7) mm (in)
Page 49: Tightening Torques

Maintenance specifications / Tightening torques Tightening torques Specified torques Tightening torques Part to be tightened Thread size N·m kgf·m ft·lb Fuel system Fuel filter holder bolt Fuel filter bracket bolt Intake air temperature sensor — Low-pressure fuel pump bracket bolt Fuel cooler nut —…
Page 50
SPEC Specifications Tightening torques Part to be tightened Thread size N·m kgf·m ft·lb Timing chain tensioner bolt Spark plug — Cylinder head bolt 90° Engine hanger bolt Cooling water cover bolt Starboard cylinder head plug — Cylinder block plug — Engine temperature sensor —…
Page 51: Tightening Torques

Tightening torques Tightening torques Part to be tightened Thread size N·m kgf·m ft·lb Upper case mount nut — Engine oil drain bolt Apron stay — Pressure control valve — Upper exhaust guide bolt Oil strainer bolt Oil pan bolt Exhaust manifold bolt Muffler bolt Baffle plate screw Clamp bracket self-locking nut…
Page 52: General Torques

SPEC Specifications General torques This chart specifies tightening torques for standard fasteners with a standard ISO thread pitch. Tightening torque specifications for special components or assemblies are provided in applicable sections of this man- ual. To avoid warpage, tighten multi-fastener assemblies in a crisscross fashion and pro- gressive stages until the specified torque is reached.
Page 53
Periodic checks and adjustments Special service tools ………………3-1 Maintenance interval chart…………….3-2 Top cowling ………………..3-4 Checking the top cowling…………….3-4 Fuel system ………………..3-4 Checking the fuel joint and fuel hoses (fuel joint-to-fuel injector) ….3-4 Measuring the fuel pressure (high-pressure fuel line) ……. 3-5 Checking the fuel filter …………….
Page 54: Chk Adj

Periodic checks and adjustments Special service tools Fuel pressure gauge 90890-06786 Digital tachometer 90890-06760 Timing light 90890-03141 Leakage tester 90890-06762 69J3D11…
Page 55: Maintenance Interval Chart

Special service tools / Maintenance interval chart Maintenance interval chart Use the following chart as a guideline for general maintenance. Adjust the maintenance intervals according to the operating conditions of the outboard motor. Initial Every Refer to Item Remarks page Top cowling Top cowling fit Check…
Page 56
Periodic checks and adjustments Initial Every Refer to Item Remarks page Lower unit Gear oil Change 3-17 Impeller/Woodruff key Check/replace (500 hours 6-10, or 30 months) 6-38 Oil seals Check/replace — Propeller Check (before each use) 3-18 General Anodes/Trim tab Check/replace 3-18 Battery…
Page 57: Top Cowling

Maintenance interval chart / Top cowling / Fuel system Top cowling Checking the top cowling 1. Check the fitting by pushing the cowling with both hands. Adjust if necessary. Fuel system Checking the fuel joint and fuel hoses (fuel joint-to-fuel injector) 1.
Page 58: Measuring The Fuel Pressure (High-Pressure Fuel Line)

Periodic checks and adjustments Measuring the fuel pressure (high- pressure fuel line) 1. Remove the cap 1. 2. Install the fuel pressure gauge onto the pressure check valve. É NOTE: Be sure not to spill any fuel when removing the fuel filter cup. Power unit Checking the engine oil Fuel pressure gauge: 90890-06786…
Page 59: Changing The Engine Oil Using An Oil Changer

Fuel system / Power unit Changing the engine oil using an oil 6. Install the oil filler cap and dipstick, and then start the engine and warm it up for 5 changer minutes. 1. Start the engine and warm it up. 7.
Page 60: Replacing The Oil Filter

Periodic checks and adjustments S69J3140 Apron bolt: 8 N·m (0.8 kgf·m, 5.8 ft·lb) Replacing the oil filter NOTE: 1. Extract the engine oil with an oil changer Be sure to clean up any oil spills. or drain it. 2. Remove the oil filter cover 1. 5.
Page 61: Checking The Timing Belt

Power unit 5. Install the oil filter, and then tighten it to 3. Turn the crankshaft clockwise two turns the specified torque using a 72.5 mm to take up slack in the timing belt. (2.9 in) oil filter wrench. Replacing the timing belt NOTE: For replacement procedures, see Chapter 5, “Replacing the timing belt.”…
Page 62: Checking The Thermostat

Periodic checks and adjustments 5. Check the spark plug gap a. Adjust if out of specification. Specified spark plug: LFR5A-11 (NGK) Spark plug gap a: 1.1 mm (0.043 in) 6. Install the spark plug, tighten it finger S69J3220 tight b, then to the specified torque with a spark plug wrench c.
Page 63: Adjusting The Throttle Link And Throttle Cable Operation (With A Stop Bolt)

Power unit / Control system 4. Push the throttle control lever 8 against the stop bolt 7. Adjusting the throttle link and throttle cable operation (with a stop NOTE: bolt) Use a general bolt with the specified mea- surements. NOTE: •…
Page 64: Adjusting The Throttle Link And Throttle Cable Operation (Without A Stop Bolt)

Periodic checks and adjustments 12. Check the throttle cable for smooth oper- ation and adjust the cable length, if nec- essary, repeating steps 1–10. Adjusting the throttle link and throttle cable operation (without a stop bolt) NOTE: • Be sure to synchronize the throttle valves before adjusting the throttle link.
Page 65: Checking The Gearshift Operation

Control system 5. Check that the alignment mark a is between the alignment marks b. If not, repeat steps 2–4. S69J3340 CAUTION: The throttle cable joint must be screwed in a minimum of 8.0 mm (0.31 in) f. 8. Connect the cable joint, install the clip, and then tighten the locknut.
Page 66: Checking The Engine Idle Speed

Periodic checks and adjustments 5. Adjust the position of the shift cable joint Digital tachometer: 90890-06760 until its hole is aligned with the set pin. Engine idle speed: 650–750 r/min 4. Turn the engine off, loosen the locknut 2, and then disconnect the link rod 3 from the magnet control lever 4.
Page 67
Control system 10. Install the link rod 3, and then tighten the locknut 2. 11. Check that the alignment mark c is between the alignment marks d. If nec- essary, repeat steps 8–10. NOTE: • To increase the idle speed, turn the throttle stop screw in direction a.
Page 68: Checking The Ignition Timing

Periodic checks and adjustments 4. Attach the special service tool to spark plug wire #1. S69J3470 CAUTION: The throttle cable joint must be screwed in a minimum of 8.0 mm (0.31 in) h. 14. Connect the cable joint, install the clip, and then tighten the locknut.
Page 69: Checking The Power Trim And Tilt Fluid Level

Control system / Power trim and tilt unit / Lower unit NOTE: Be sure to listen to the winding sound of the power trim and tilt motor for smooth opera- tion. 2. Fully tilt the outboard motor up, and then support it with the tilt stop lever 1 to check the lock mechanism of the lever.
Page 70: Changing The Gear Oil

Periodic checks and adjustments NOTE: If the oil is at the correct level, the oil should overflow out of the check hole when the check screw is removed. 3. If necessary, add sufficient gear oil of the recommended type until it overflows out of the check hole.
Page 71: Checking The Lower Unit (For Air Leakage)

Lower unit / General Checking the lower unit Checking the propeller (for air leakage) 1. Check the propeller blades and splines 1. Remove the check screw 1, and then for cracks, damage, or wear. Replace if necessary. install the special service tool. É…
Page 72: Checking The Battery

Periodic checks and adjustments WARNING Battery electrolyte is dangerous; it con- tains sulfuric acid which is poisonous and highly caustic. Always follow these preventive measures: • Avoid bodily contact with electrolyte as it can cause severe burns or permanent eye injury. •…
Page 73: Lubrication

General Lubrication 1. Apply water resistant grease to the areas shown. 3-20 69J3D11…
Page 74
Periodic checks and adjustments NOTE: Apply grease to the grease nipple until it flows from the bushings a. 2. Apply corrosion resistant grease to the areas shown. 3-21 69J3D11…
Page 75
FUEL Fuel system Special service tools ………………4-1 Hose routing ………………..4-2 Fuel and blowby hoses…………….4-2 Intake silencer, fuel filter, and fuel pump ………… 4-3 Vapor separator………………..4-5 Removing the hose clamps …………… 4-7 Installing the hose clamps …………….. 4-7 Checking the check valve…………….4-7 Reducing the fuel pressure…………….
Page 76: Fuel System

FUEL Fuel system Special service tools Vacuum/pressure pump gauge set 90890-06756 Digital circuit tester 90890-03174 Test harness (3 pins) 90890-06793 Vacuum gauge 90890-03159 69J3D11…
Page 77: Hose Routing

Special service tools / Hose routing Hose routing Fuel and blowby hoses 1 Blowby hose 7 High-pressure fuel hose 2 Fuel hose (fuel joint-to-fuel filter) (starboard fuel rail-to-port fuel rail) 3 Fuel hose (fuel filter-to-fuel pump) 8 Fuel hose (pressure regulator-to-fuel cooler) 4 Fuel hose (fuel pump-to-vapor separator) 9 Fuel hose (fuel cooler-to-vapor separator) 5 Fuel hose (vapor separator-to-fuel pump)
Page 78: Intake Silencer, Fuel Filter, And Fuel Pump

FUEL Fuel system Intake silencer, fuel filter, and fuel pump 69J3D11…
Page 79: Intake Silencer, Fuel Filter, And Fuel Pump

Intake silencer, fuel filter, and fuel pump Part name Q’ty Remarks Cover M6 × 28 mm Bolt M6 × 16 mm Bolt Washer Holder M6 × 14 mm Bolt Bracket M6 × 19 mm Bolt Fuel hose Fuel joint O-ring Not reusable Fuel filter element Spring…
Page 80: Vapor Separator

FUEL Fuel system Vapor separator 69J3D11…
Page 81
Vapor separator Part name Q’ty Remarks Float chamber Cover High-pressure fuel pump Float Water hose Fuel hose Joint Fuel cooler Washer Water hose Bracket M8 × 16 mm Bolt Collar Bushing M8 × 16 mm Bolt Collar High-pressure fuel pump relay Washer Hose M4 ×…
Page 82: Removing The Hose Clamps

FUEL Fuel system Removing the hose clamps 1. Remove the hose clamps by cutting the joint. CAUTION: If the hose clamps are removed without cutting the joint first, the fuel hose will be damaged. Vacuum/pressure pump gauge set: Installing the hose clamps 90890-06756 1.
Page 83: Checking The Vapor Separator

Vapor separator WARNING Reduce the fuel pressure before removing the vapor separator drain screw, or pres- surized fuel will spray out and may result in serious injury. Checking the vapor separator 1. Check the needle valve for bends or wear. Replace if necessary. WARNING Always reduce the fuel pressure in the high-pressure fuel line before servicing…
Page 84: Intake Manifold And High-Pressure Fuel Line

FUEL Fuel system Intake manifold and high-pressure fuel line 69J3D11…
Page 85
Intake manifold and high-pressure fuel line Part name Q’ty Remarks Hose High-pressure fuel hose Clamp Joint Joint Screw Washer Throttle position sensor Screw Bracket Bracket M5 × 15 mm Screw Bracket Joint O-ring Not reusable Metal gasket Not reusable M5 × 15 mm Screw Intake air pressure sensor O-ring…
Page 86
FUEL Fuel system 4-11 69J3D11…
Page 87
Intake manifold and high-pressure fuel line Part name Q’ty Remarks Starboard intake manifold Throttle body #1 Throttle body #3 Throttle body #5 Starboard fuel rail Port intake manifold Throttle body #2 Throttle body #4 Throttle body #6 Port fuel rail Pressure regulator M8 ×…
Page 88: Throttle Control

FUEL Fuel system Throttle control 4-13 69J3D11…
Page 89
Throttle control Part name Q’ty Remarks Bracket Joint Magnet control lever Shaft Bracket M6 × 20 mm Bolt Washer Bushing Gear Throttle control lever Circlip Bolt Wave washer Washer Throttle cam Spring M6 × 14 mm Bolt Bracket M8 × 20 mm Bolt Terminal Starter motor lead…
Page 90: Removing The Pressure Regulator

Checking the idle speed control (ISC) 1. Check the operation of the idle speed control using the “Stationary test” or the “Active test” of the Yamaha Diagnostic System. S69J4130 Checking the fuel injector 1. Check the filter for dirt or residue. Clean if necessary.
Page 91: Synchronizing The Throttle Valve

Throttle control Synchronizing the throttle valve 1. Loosen the bank synchronizing screw 1. 2. Remove the port link rod 2 and star- board link rod 3. 6. Loosen the port throttle stop screw 8 until it separates from the throttle body lever 9.
Page 92
FUEL Fuel system Test harness (3 pins): 90890-06793 10. Turn the engine start switch to ON. 13. Tighten the starboard throttle stop screw 4 until the output voltage is adjusted to 11. Measure the throttle position sensor out- put voltage. Adjust the throttle position specification as mentioned in step 11, sensor B position if out of specification.
Page 93
Throttle control 15. Tighten the synchronizing screw 0 of É cylinder #4, and stop tightening when the throttle plate starts to move. Similarly, tighten and adjust the synchronizing screw A of cylinder #6. Vacuum gauge: 90890-03159 16. Tighten the port throttle stop screw 8 until it contacts the throttle body lever 9, and then turn it one additional turn.
Page 94
FUEL Fuel system 19. Measure the vacuum of cylinders #1, #3, and #5. Repeat step 12 if out of specifi- cation. Vacuum difference between cylinders: 20 mmHg (27 mbar, 0.79 inHg) 20. Measure the vacuum of cylinders #2, #4, and #6. Repeat step 12 if out of specifi- cation.
Page 95
Throttle control 25. Check that there is no clearance a between the port and starboard throttle stop screws 4 and 8, and the throttle body levers 5 and 9. If there is any clearance, repeat step 24. 26. Start the engine, and when the engine speed is at idle, check the average vac- uum difference between the port and starboard banks.
Page 96
POWR Power unit Special service tools ………………5-1 Power unit………………….. 5-3 Checking the compression pressure …………5-14 Checking the oil pressure …………….5-14 Checking the oil pressure sensor …………5-15 Checking the valve clearance…………..5-15 Replacing the timing belt ……………..5-21 Removing the power unit……………..5-23 Removing the oil filter …………….
Page 97
Cylinder block ………………..5-43 Disassembling the cylinder block …………5-47 Checking the piston diameter …………..5-47 Checking the cylinder bore …………..5-48 Checking the piston clearance …………..5-48 Checking the piston rings …………….5-48 Checking the piston ring grooves …………5-49 Checking the piston ring side clearance……….5-49 Checking the piston pin boss bore …………
Page 98: Special Service Tools

POWR Power unit Special service tools Compression gauge Valve spring compressor 90890-03160 90890-04019 Compression gauge adaptor Valve spring compressor attachment 90890-06563 90890-06320 Test harness (3 pins) Valve guide remover/installer 90890-06769 90890-06801 Flywheel holder Valve guide installer 90890-06522 90890-06810 Flywheel puller Valve guide reamer 90890-06521 90890-06804…
Page 99
Special service tools Valve seat cutter holder 90890-06316 Valve seat cutter 90890-06324, 90890-06325, 90890-06327 Crank stand alignment 90890-03107 Piston ring compressor 90890-05158 69J3D11…
Page 100: Power Unit

POWR Power unit Power unit 69J3D11…
Page 101
Power unit Part name Q’ty Remarks Power unit Screw Cover Dipstick M6 × 20 mm Bolt Dipstick guide O-ring Not reusable Plastic tie Not reusable Fuel hose M6 × 10 mm Bolt PTT motor lead Sky blue, light green Gasket Not reusable Clip Shift cable…
Page 102
POWR Power unit 69J3D11…
Page 103
Power unit Part name Q’ty Remarks Washer Flywheel magnet M6 × 30 mm Screw Stator coil M6 × 35 mm Bolt Blowby hose guide Blowby hose Blowby hose Stator coil bracket Collar Woodruff key Plastic tie Not reusable Wiring harness guide M6 ×…
Page 104
POWR Power unit 69J3D11…
Page 105
Power unit Part name Q’ty Remarks Wiring harness Rectifier Regulator coupler M6 × 20 mm Bolt Ground lead M6 × 16 mm Bolt Bracket M6 × 16 mm Bolt M6 × 25 mm Bolt Power trim and tilt relay Washer Spring washer Battery lead Screw…
Page 106
POWR Power unit Part name Q’ty Remarks Starter motor Spring washer Battery cable From terminal and power trim and tilt relay M8 × 45 mm Bolt M6 × 20 mm Bolt Ground lead M6 × 35 mm Bolt Rectifier Regulator Gasket Not reusable Cover…
Page 107
Power unit Part name Q’ty Remarks Ignition coil M6 × 20 mm Bolt M6 × 20 mm Bolt Bracket Clamp Clamp M6 × 20 mm Screw Plate Gasket Grommet Idle speed control hose 5-10 69J3D11…
Page 108
POWR Power unit 5-11 69J3D11…
Page 109
Power unit Part name Q’ty Remarks M6 × 30 mm Bolt Washer Link rod arm Plug O-ring Not reusable M6 × 20 mm Bolt Link rod Long Link rod Short Link rod Oil filler cap O-ring Not reusable Oil filler neck M6 ×…
Page 110
POWR Power unit Part name Q’ty Remarks Timing belt M5 × 45 mm Bolt Drive sprocket Plate Woodruff key Timing belt tensioner M10 × 35 mm Bolt Driven sprocket Dowel pin M6 × 30 mm Bolt Port cylinder head cover Gasket Not reusable Starboard cylinder head cover…
Page 111: Checking The Compression Pressure

Power unit Checking the compression pressure NOTE: 1. Start the engine, warm it up for 5 min- • If the compression pressure increases, utes, and then turn it off. check the piston and piston rings for wear. Replace if necessary. 2.
Page 112: Checking The Oil Pressure Sensor

POWR Power unit 5. Check the oil pressure. Check the oil Oil pressure sensor input voltage: pump, oil leakage, and oil strainer if out Pink/white (P/W) – Black (B) of specification. Oil pressure (reference data): Oil pressure sensor output voltage 650 kPa (6.5 kgf/cm , 92.4 psi) at (reference data):…
Page 113
Power unit 9. Similarly, check the valve clearance of cylinders #1, #2, and #3 in order, and be sure to turn the flywheel magnet 120° clockwise each time. Adjust if out of specification. NOTE: Do not turn the flywheel magnet counter- clockwise.
Page 114
POWR Power unit 10. Turn the flywheel magnet an additional NOTE: 120° clockwise and align the “1TDC” Apply force to the crankshaft end until the fly- mark on the flywheel magnet with the wheel magnet comes off the tapered portion pointer, and check that the “I”…
Page 115
Power unit 15. Remove the driven sprockets. 19. Measure the valve shim thickness with a micrometer, and then note the measure- ment. 20. Select the necessary valve shim by cal- culating its thickness with the following formula. Necessary valve shim thickness = Removed valve shim thickness + Measured valve clearance –…
Page 116
POWR Power unit NOTE: • Install the camshaft caps in the proper posi- tion as shown and with the stamped num- bers facing upside down. • Apply engine oil to the camshaft cap bolts before installation. Camshaft cap bolt: 1st: 8 N·m (0.8 kgf·m, 5.8 ft·lb) 2nd: 17 N·m (1.7 kgf·m, 12 ft·lb) Timing chain tensioner bolt: 12 N·m (1.2 kgf·m, 8.7 ft·lb)
Page 117
Power unit Flywheel magnet nut: 240 N·m (24 kgf·m, 174 ft·lb) 30. Turn the flywheel magnet clockwise two turns, and then check that all alignment marks are aligned. 28. Install the Woodruff key. 29. Install the flywheel magnet. É NOTE: Do not turn the flywheel magnet counter- clockwise.
Page 118: Replacing The Timing Belt

POWR Power unit 35. Install the ignition coil cover, wiring har- É ness guide, and flywheel magnet cover. Replacing the timing belt 1. Remove the flywheel magnet cover, igni- tion coil cover, and intake silencer. 2. Turn the flywheel magnet clockwise and align the “1TDC”…
Page 119
Power unit 5. Disconnect the stator coil couplers 3 and pulser coil coupler 4, and remove the blowby hose 5 and stator coil bracket 6. 9. Check that “I” marks c and d on the driven sprockets are aligned with marks e and f, and that the “…
Page 120: Removing The Power Unit

POWR Power unit É CAUTION: CAUTION: • Do not twist, turn inside out, or bend the Apply force in the direction of the arrows timing belt beyond the maximum limit of shown, to prevent the flywheel holder 25 mm (1.0 in) j, otherwise it may be from slipping off easily.
Page 121
Power unit 5. Remove the upper case cover 9 and aprons 0. 6. Remove the power unit by removing the bolts A. 3. Remove the dipstick guide 5, and dis- connect the fuel hose 6, PTT motor leads 7, and flushing device hose (flush- ing device model) 8.
Page 122: Removing The Oil Filter

POWR Power unit É NOTE: Be sure to clean up any oil spills. Removing the timing belt and sprockets 1. Turn the drive sprocket clockwise and align the “ ” mark a on the plate with the “ ” mark b on the cylinder block, and check that “I”…
Page 123: Checking The Timing Belt And Sprockets

Power unit Checking the timing belt and 2. Using a hexagon wrench, turn the timing belt tensioner 1 clockwise to push the sprockets timing belt, increase strength gradually, 1. Check the interior and exterior of the tim- and then insert a ø5.0 mm (0.2 in) pin 2 ing belt for cracks, damage, or wear.
Page 124: Installing The Sprockets And Timing Belt

POWR Power unit Installing the sprockets and timing belt 1. Install the driven sprockets 1, and then tighten the bolts to the specified torque. 2. Check that “I” marks a and b on the driven sprockets are aligned with marks c and d.
Page 125
Power unit 7. Install the timing belt 6 from the drive sprocket side with its part number in the upright position, turn the belt a half turn counterclockwise to align it, and then remove the pin 5. 8. Turn the drive sprocket clockwise two turns, and then check that the alignment marks are aligned.
Page 126: Cylinder Head

POWR Power unit Cylinder head 5-29 69J3D11…
Page 127
Cylinder head Part name Q’ty Remarks Timing chain tensioner M6 × 25 mm Bolt Timing chain tensioner M7 × 37 mm Bolt M7 × 48 mm Bolt Camshaft cap Camshaft cap Timing chain Oil seal Not reusable Camshaft 3 Camshaft 4 Camshaft 2 Camshaft 1 M6 ×…
Page 128
POWR Power unit 5-31 69J3D11…
Page 129
Cylinder head Part name Q’ty Remarks Spark plug M10 × 120 mm Bolt M8 × 55 mm Bolt M8 × 90 mm Bolt Port cylinder head M6 × 20 mm Bolt Engine hanger M6 × 12 mm Bolt Ground lead Gasket Not reusable Starboard cylinder head…
Page 130: Removing The Cylinder Head

POWR Power unit Removing the cylinder head CAUTION: 1. Remove the exhaust cover bolts in the Do not scratch or damage the mating sur- sequence shown. faces of the cylinder head and cylinder block. 5. Remove the valve shim 2 from the valve lifter 3 using compressed air.
Page 131: Checking The Valve Springs

Cylinder head Valve spring compressor 4: 90890-04019 Valve spring compressor attachment 90890-06320 Checking the valve springs 1. Measure the valve spring free length a. Replace if out of specification. Valve margin thickness a: Intake: 0.7 mm (0.028 in) Exhaust: 1.0 mm (0.039 in) 3.
Page 132: Checking The Valve Guides

POWR Power unit Valve stem runout: Intake: 0.01 mm (0.0004 in) Exhaust: 0.01 mm (0.0004 in) Checking the valve guides NOTE: Before checking the valve guide make sure that the valve stem diameter is within specifi- S69J5790 cation. Valve guide remover/installer: 1.
Page 133: Checking The Valve Seat

Cylinder head NOTE: • Turn the valve guide reamer clockwise to ream the valve guide. • Do not turn the reamer counterclockwise when removing the reamer. Valve guide reamer: 90890-06804 4. Measure the valve guide inside diameter. Replace the valve guide if out of specifi- cation.
Page 134
POWR Power unit Valve seat cutter holder: 90890-06316 Valve seat cutter: 30° (intake and exhaust): 90890-06327 45° (intake and exhaust): 90890-06325 30° 60° (intake and exhaust): S69J5880 90890-06324 b Previous contact width 2. Cut the surface of the valve seat with a 4.
Page 135: Checking The Camshaft

Cylinder head 9. Apply a thin, even layer of lapping com- pound onto the valve seat, and then lap the valve using a valve lapper (commer- cially obtainable). b Previous contact width 7. If the valve seat contact area is too nar- row and situated near the top edge of the valve face, use a 30°…
Page 136: Checking The Timing Chain Tensioner

POWR Power unit 4. Measure the camshaft journal diameter c and cylinder head journal inside diam- eter d. Replace the camshaft and cylin- der head if out of specification. Cam lobe a: Intake: 45.30–45.40 mm S69J5970 (1.7835–1.7874 in) Camshaft journal diameter c: Exhaust: 45.35–45.45 mm 24.96–24.98 mm…
Page 137: Checking The Timing Chain

Cylinder head Installing the valves Timing chain tensioner wear limit a: 1. Install the new valve seal 1 to the valve 1.0 mm (0.04 in) from standard guide. Checking the timing chain 1. Check the timing chain for damage or wear.
Page 138: Installing The Cylinder Head

POWR Power unit CAUTION: Do not reuse the cylinder head gaskets, always replace them with new ones. NOTE: • Apply engine oil to the cylinder head bolts before installation. • Tighten the M10 bolts to the specified torques in three stages first, and then tighten the M8 bolts to the specified torques 4.
Page 139
Cylinder head NOTE: • Install the camshaft caps in the proper posi- tion as shown and with the stamped num- bers facing upside down. • Apply engine oil to the camshaft cap bolts before installation. Camshaft cap bolt: 1st: 8 N·m (0.8 kgf·m, 5.8 ft·lb) 2nd: 17 N·m (1.7 kgf·m, 12 ft·lb) Timing chain tensioner bolt: 12 N·m (1.2 kgf·m, 8.7 ft·lb)
Page 140: Cylinder Block

POWR Power unit Cylinder block 5-43 69J3D11…
Page 141
Cylinder block Part name Q’ty Remarks Crankcase cover M8 × 45 mm Bolt M6 × 20 mm Bolt Engine hanger Plate M4 × 8 mm Screw Gasket Not reusable Baffle plate Dowel pin Bolt Not reusable Connecting rod cap Connecting rod bearing Connecting rod Piston Clip…
Page 142
POWR Power unit 5-45 69J3D11…
Page 143
Cylinder block Part name Q’ty Remarks Crankshaft Cylinder block Crankcase Oil seal Not reusable Thrust bearing Thrust bearing Main bearing Main bearing M8 × 95 mm Stud bolt M10 × 105 mm Bolt M8 × 95 mm Bolt M8 × 55 mm Bolt O-ring Not reusable…
Page 144: Disassembling The Cylinder Block

POWR Power unit Disassembling the cylinder block NOTE: 1. Remove the cooling water passage • Be sure to keep the bearings in the order as cover bolts in the sequence shown. they were removed, and to note the bearing color. •…
Page 145: Checking The Cylinder Bore

Cylinder block Checking the piston clearance Piston diameter a: 1. Rebore the cylinder or replace the piston 93.921–93.941 mm and piston rings as a set, or the cylinder (3.6977–3.6985 in) block, or all parts if out of specification. Measuring point b: 5 mm (0.2 in) up from the bottom of Piston clearance: the piston skirt…
Page 146: Checking The Piston Ring Grooves

POWR Power unit Checking the piston ring side clearance 1. Measure the piston ring side clearance. Replace the piston and piston rings as a set if out of specification. Piston ring end gap d: Top ring: Piston ring side clearance: 0.15–0.30 mm Top ring a: (0.0059–0.0118 in)
Page 147: Checking The Piston Pin

Cylinder block Checking the piston pin 1. Measure piston diameter. Replace if out of specification. Piston pin diameter: Connecting rod big end side 21.00 mm (0.827 in) clearance a: 0.20–0.25 mm (0.008–0.010 in) Checking the connecting rod small end inside diameter Checking the crankshaft 1.
Page 148: Checking The Crankpin Oil Clearance

POWR Power unit Crankshaft journal diameter a: 62.968–62.992 mm (2.4791–2.4800 in) Crankpin diameter b: 49.976–50.000 mm (1.9676–1.9685 in) Crankpin width c: 21.50–21.55 mm (0.8465–0.8484 in) NOTE: 2. Measure the crankshaft runout. Replace Install the connecting rod bearings in their the crankshaft if out of specification. original positions.
Page 149: Selecting The Connecting Rod Bearing

Cylinder block Connecting rod bolt: 1st: 23 N·m (2.3 kgf·m, 17 ft·lb) 2nd: 48 N·m (4.8 kgf·m, 35 ft·lb) 3rd: 90° 7. Remove the connecting rod cap and measure the width of the compressed Plastigauge (PG-1) on each crankpin. Replace the connecting rod bearing if out of specification.
Page 150: Checking The Crankshaft Main Journal Oil Clearance

POWR Power unit 4. Insert the projection a of the bearing into the notch in the cylinder block. NOTE: Install the main bearings in their original posi- tions. 5. Put a piece of Plastigauge (PG-1) on each main journal parallel to the crank- 3.
Page 151: Selecting The Crankshaft Main Bearing

Cylinder block 9. Tighten the crankcase bolts to the speci- 10. Remove the crankcase and measure the fied torques in two stages and in the width of the compressed Plastigauge sequence shown. (PG-1) on each main journal. Replace the main bearing if out of specification. Crankshaft main journal oil clearance: 0.025–0.050 mm…
Page 152: Disassembling The Oil Pump

POWR Power unit Disassembling the oil pump 1. Remove the screws 1 and disassemble the oil pump. 3. Select the suitable main bearing number c from the table. Checking the oil pump 1. Check the oil seals and gasket for tears. Replace if necessary.
Page 153: Assembling The Piston And Cylinder Block

Cylinder block NOTE: 45° 45° Install the oil seals using a general pipe of the proper size. Screw 3: #1,#4 4 N·m (0.4 kgf·m, 2.9 ft·lb) Assembling the piston and cylinder block 1. Assemble the piston 1, connecting rod 2, piston pin 3, and new piston pin clips S60C5E90 CAUTION: Do not scratch the piston or break the pis-…
Page 154
POWR Power unit 6. Install half of the bearings 9 into the cyl- ® 10. Apply Gasket Maker to the mating sur- inder block 0. face of the crankcase. 7. Insert the projection f of the bearing into 11. Insert the projection g of the bearing into the notch in the cylinder block.
Page 155
Cylinder block NOTE: • The oil seals must be installed before tight- ening the crankcase bolts. • Apply engine oil to the crankcase bolts before installation. • Tighten crankcase bolts 1–F to the speci- fied torques in two stages first, and then tighten crankcase bolts G–S to the speci- fied torques in two stages.
Page 156
POWR Power unit Crankcase cover bolt: 1st: 14 N·m (1.4 kgf·m, 10 ft·lb) 2nd: 28 N·m (2.8 kgf·m, 20 ft·lb) 18. Install the new gasket and cooling water passage cover, and then tighten the bolts to the specified torque in the sequence shown.
Page 157: Checking The Thermostat

Cylinder block 20. Install the oil filter, and then tighten it to 4. Check the thermostat valve opening at the specified torque using a 72.5 mm specified water temperatures. (2.9 in) oil filter wrench. Replace if out of specification. Water Valve lift a temperature 0 mm (0 in)
Page 158
POWR Power unit PTT motor lead bolt: 4 N·m (0.4 kgf·m, 2.9 ft·lb) 6. Connect the shift cable A and throttle cable B, and then adjust their lengths. For adjustment procedures, see Chapter 3, “Checking the throttle link and throttle cable operation,”…
Page 159
Cylinder block 7. Install the holders C and retaining plate NOTE: Apply engine oil to the flywheel magnet nut before installation. Flywheel holder: 90890-06522 Flywheel magnet nut: 240 N·m (24 kgf·m, 174 ft·lb) 11. Reinstall the all removed parts. 8. Install the stator coil bracket and stator coil.
Page 160
LOWR Lower unit Special service tools ………………6-1 Lower unit (regular rotation model) …………. 6-5 Removing the lower unit …………….6-9 Removing the water pump and shift rod………… 6-9 Checking the water pump and shift rod ………..6-10 Propeller shaft housing (regular rotation model) ……..6-11 Removing the propeller shaft housing assembly……..
Page 161
Propeller shaft housing (counter rotation model) ……..6-39 Removing the propeller shaft housing assembly……..6-41 Disassembling the propeller shaft housing……….6-41 Checking the propeller shaft housing …………6-42 Checking the propeller shaft…………..6-42 Assembling the propeller shaft housing………..6-43 Drive shaft and lower case (counter rotation model) …….6-45 Removing the drive shaft……………..6-47 Disassembling the drive shaft housing …………6-47 Disassembling the reverse gear …………..6-47…
Page 162: Special Service Tools

LOWR Lower unit Special service tools Bearing housing puller claw L Bearing puller 90890-06502 90890-06535 Stopper guide plate Bearing puller claw 1 90890-06501 90890-06536 Center bolt Slide hammer 90890-06504 90890-06531 Bearing separator Bearing outer race puller 90890-06534 90890-06523 Stopper guide stand Outer race puller claw A 90890-06538 90890-06532…
Page 163
Special service tools Needle bearing attachment Ball bearing attachment 90890-06610, 90890-06653, 90890-06654 90890-06636, 90890-06656, 90890-06657 Driver rod L3 Driver rod LS 90890-06652 90890-06606 Driver rod SS Bearing outer race attachment 90890-06604 90890-06622, 90890-06628, 90890-06658 Bearing depth plate Drive shaft holder 6 90890-06603 90890-06520 Bearing inner race attachment…
Page 164
LOWR Lower unit Socket adapter 3 Shimming plate 90890-06508 90890-06701 Driver rod LL Shift rod push arm 90890-06605 90890-06052 Pinion height gauge Backlash indicator 90890-06702 90890-06706 Fixing plate Magnet base plate 90890-06711 90890-07003 Digital caliper Dial gauge set 90890-06704 90890-01252 69J3D11…
Page 165
Special service tools Magnet base 90890-06705 Puller head 90890-06514 Ring nut wrench 90890-06578 Flywheel puller 90890-06521 69J3D11…
Page 166: Lower Unit (Regular Rotation Model)

LOWR Lower unit Lower unit (regular rotation model) 69J3D11…
Page 167
Lower unit (regular rotation model) Part name Q’ty Remarks Lower unit Plate Rubber seal Check screw Gasket Not reusable Dowel pin M10 × 45 mm Bolt Drain screw Grommet M10 × 44 mm Bolt M10 × 70 mm Bolt Spacer Washer Propeller Washer…
Page 168
LOWR Lower unit S69J6010 69J3D11…
Page 169
Lower unit (regular rotation model) Part name Q’ty Remarks Shift rod Oil seal Not reusable Oil seal housing O-ring Not reusable 3.1 × 70.6 mm Spring Circlip M6 × 20 mm Bolt Seal Woodruff key M8 × 45 mm Bolt Cover Seal Water pump housing…
Page 170: Removing The Lower Unit

LOWR Lower unit Removing the lower unit 1. Drain the gear oil. For draining proce- dures, see Chapter 3, “Changing the gear oil.” 2. Set the gearshift to the neutral position, and place a block of wood between the anti-cavitation plate and propeller to keep the propeller from turning, and then remove the propeller nut and propeller.
Page 171: Checking The Water Pump And Shift Rod

Lower unit (regular rotation model) Checking the water pump and shift 4. Check the shift rod for cracks or wear. Replace if necessary. 1. Check the water pump housing for defor- mation. Replace if necessary. S69J6045 S69J6030 2. Check the impeller 1 and insert car- tridge 2 for cracks or wear.
Page 172: Propeller Shaft Housing (Regular Rotation Model)

LOWR Lower unit Propeller shaft housing (regular rotation model) 6-11 69J3D11…
Page 173
Propeller shaft housing (regular rotation model) Part name Q’ty Remarks Shift rod joint Ball Slider Shift plunger Dog clutch Cross pin Spring Propeller shaft Washer Reverse gear Reverse gear shim — As required Ball bearing Not reusable O-ring Not reusable 3.1 ×…
Page 174: Removing The Propeller Shaft Housing Assembly

LOWR Lower unit Removing the propeller shaft Disassembling the propeller shaft housing assembly housing 1. Remove the bolts 1, ring 2, and bolts 1. Remove the reverse gear and reverse gear shim(s). É 2. Pull out the propeller shaft housing assembly.
Page 175: Checking The Propeller Shaft Housing

Propeller shaft housing (regular rotation model) 3. Remove the oil seals and needle bear- ing. É S69J6115 Checking the propeller shaft 1. Check the propeller shaft for bends or Needle bearing attachment 9: wear. Replace if necessary. 90890-06653 Driver rod L3 0: 90890-06652 Checking the propeller shaft housing 1.
Page 176: Assembling The Propeller Shaft Assembly

LOWR Lower unit Assembling the propeller shaft 2. Apply grease to the new oil seals, and then install them into the propeller shaft assembly housing to the specified depth. 1. Install the dog clutch 1 as shown. É NOTE: NOTE: Install an oil seal halfway into the propeller Install the dog clutch 1 with the “F”…
Page 177
Propeller shaft housing (regular rotation model) 4. Install the reverse gear 7 and original shim(s) 8 to the propeller shaft housing using a press. É CAUTION: Add or remove shim(s), if necessary, when replacing the reverse gear or ball bearing. Bearing outer race attachment 9: 90890-06622 6-16…
Page 178: Drive Shaft And Lower Case (Regular Rotation Model)

LOWR Lower unit Drive shaft and lower case (regular rotation model) 6-17 69J3D11…
Page 179
Drive shaft and lower case (regular rotation model) Part name Q’ty Remarks Drive shaft Cover Oil seal Not reusable M8 × 25 mm Bolt Drive shaft housing Needle bearing O-ring Not reusable 3 × 60.5 mm Pinion shim — As required Thrust bearing Lower case Needle bearing outer case…
Page 180: Removing The Drive Shaft

LOWR Lower unit Removing the drive shaft Disassembling the forward gear 1. Remove the drive shaft, drive shaft hous- 1. Remove the taper roller bearing from the ing, and pinion, and then pull out the for- forward gear using a press. ward gear.
Page 181: Checking The Pinion And Forward Gear

Drive shaft and lower case (regular rotation model) S69J6210 Ball bearing attachment 3: Checking the lower case 90890-06636 1. Check the skeg and torpedo for cracks or Driver rod LL 4: 90890-06605 damage. Replace if necessary. Checking the pinion and forward gear 1.
Page 182: Assembling The Forward Gear

LOWR Lower unit 2. Install the needle bearing outer case into the lower case. É Needle bearing attachment 1: 90890-06610 NOTE: Driver rod LS 2: 90890-06606 Apply engine oil to the needle bearing outer case before installation. Depth a: 4.25–4.75 mm (0.167–0.187 in) Bearing outer race attachment 3: 90890-06628 2.
Page 183: Installing The Propeller Shaft Housing

Drive shaft and lower case (regular rotation model) 2. Install the drive shaft housing 1, thrust Installing the propeller shaft housing bearing 2, and original shim(s) 3 to the 1. Install the washer 1 and propeller shaft drive shaft 4. assembly 2 into the propeller shaft housing assembly 3.
Page 184
LOWR Lower unit 5. Install the washers 7, wave washer 8, spacer 9, and collar 0 to the drive shaft. 2. Install the new gasket 2, outer plate car- NOTE: tridge 3, and dowel pins 4. • The collar and spacer should fit together firmly.
Page 185: Installing The Lower Unit

Drive shaft and lower case (regular rotation model) 7. Install the O-ring D and pump housing É assembly E into the lower case, tighten the bolts F, and then install the seal G and cover H. Shift rod push arm: 90890-06052 2.
Page 186
LOWR Lower unit 5. Install the propeller and propeller nut, and then tighten the nut finger tight. Place a block of wood between the anti- cavitation plate and propeller to keep the propeller from turning, and then tighten the nut to the specified torque. WARNING Do not hold the propeller with your hands when loosening or tightening it.
Page 187: Shimming (Regular Rotation Model)

Drive shaft and lower case (regular rotation model) / Shimming (regular rotation model) Shimming (regular rotation model) 65.0 B1 39.4 41.0 S69J6550 6-26 69J3D11…
Page 188: Shimming

LOWR Lower unit Shimming Pinion nut: NOTE: 142 N·m (14.2 kgf·m, 103 ft·lb) • Shimming is not required when assembling the original lower case and inner parts. 3. Measure the distance (M4) between the • Shimming is required when assembling the shimming tool and the pinion as shown.
Page 189: Selecting The Forward Gear Shims

Shimming (regular rotation model) 5. Calculate the pinion shim thickness (T3) Example: as shown in the examples below. If “T3” is 0.68 mm, then the pinion shim is 0.65 mm. If “T3” is 0.70 mm, then the pinion shim is 0.68 mm.
Page 190: Selecting The Reverse Gear Shims

LOWR Lower unit 2. Calculate the forward gear shim thickness Example: (T1) as shown in the examples below. If “T1” is 0.45 mm, then the forward gear shim is 0.42 mm. If “T1” is 0.60 mm, then the forward gear shim is 0.58 mm.
Page 191
Shimming (regular rotation model) / Backlash (regular rotation model) Calculated numeral Rounded numeral at 1/100 place 1, 2 3, 4, 5 6, 7, 8 9, 10 Available shim thicknesses: 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, and 0.50 mm Example: If “T2” is 1.16 mm, then the reverse gear shim is 1.15 mm.
Page 192
LOWR Lower unit É Backlash indicator 4: 90890-06706 Magnet base plate 5: 90890-07003 Dial gauge set 6: 90890-01252 Magnet base 7: 90890-06705 6. Slowly turn the drive shaft clockwise and counterclockwise and measure the back- lash when the drive shaft stops in each direction.
Page 193: Backlash (Regular Rotation Model)

Backlash (regular rotation model) NOTE: Tighten the propeller nut B while turning the drive shaft until the drive shaft can no longer be turned. 10. Slowly turn the drive shaft clockwise and counterclockwise and measure the back- lash when the drive shaft stops in each direction.
Page 194: Lower Unit (Counter Rotation Model)

LOWR Lower unit Lower unit (counter rotation model) 6-33 69J3D11…
Page 195
Lower unit (counter rotation model) Part name Q’ty Remarks Lower unit Plate Rubber seal Check screw Gasket Not reusable Dowel pin M10 × 45 mm Bolt Drain screw Grommet M10 × 44 mm Bolt M10 × 70 mm Bolt Spacer Washer Propeller Washer…
Page 196
LOWR Lower unit S69J6350 6-35 69J3D11…
Page 197
Lower unit (counter rotation model) Part name Q’ty Remarks Shift rod Oil seal Not reusable Oil seal housing O-ring Not reusable 3.1 × 70.6 mm Spring Circlip M6 × 20 mm Bolt Seal Woodruff key M8 × 45 mm Bolt Cover Seal Water pump housing…
Page 198: Removing The Lower Unit

LOWR Lower unit Removing the lower unit 1. Drain the gear oil. For draining proce- dures, see Chapter 3, “Changing the gear oil.” 2. Set the gearshift to the neutral position, and place a block of wood between the anti-cavitation plate and propeller to keep the propeller from turning, and then remove the propeller nut and propeller.
Page 199: Checking The Water Pump And Shift Rod

Lower unit (counter rotation model) Checking the water pump and shift 4. Check the shift rod for cracks or wear. Replace if necessary. 1. Check the water pump housing for defor- mation. Replace if necessary. S69J6360 S69J6030 2. Check the impeller 1 and insert car- tridge 2 for cracks or wear.
Page 200: Propeller Shaft Housing (Counter Rotation Model)

LOWR Lower unit Propeller shaft housing (counter rotation model) 6-39 69J3D11…
Page 201
Propeller shaft housing (counter rotation model) Part name Q’ty Remarks Shift rod joint Ball Slider Shift plunger Dog clutch Cross pin Spring Forward gear Forward gear shim — As required Ring nut Claw washer Bearing outer race Not reusable Taper roller bearing Not reusable Propeller shaft Thrust bearing…
Page 202: Removing The Propeller Shaft Housing Assembly

LOWR Lower unit Removing the propeller shaft housing assembly 1. Remove the bolts 1, ring 2, and bolts Bearing separator 4: 90890-06534 3. Install the propeller shaft assembly in the reverse direction into the lower case. 2. Pull out the propeller shaft housing assembly.
Page 203: Checking The Propeller Shaft Housing

Propeller shaft housing (counter rotation model) S69J6105 2. Check the teeth and dogs of the forward gear for cracks or wear. Replace the gear if necessary. CAUTION: • Do not press the propeller shaft threads a directly. • Do not reuse the taper roller bearing, S69J6110 always replace it with a new one.
Page 204: Assembling The Propeller Shaft Housing

LOWR Lower unit 2. Check the dog clutch, shift rod joint, and É shift slider for cracks or wear. Replace if necessary. NOTE: Install an oil seal halfway into the propeller shaft housing, then the other oil seal. Assembling the propeller shaft housing Bearing inner race attachment 4: 1.
Page 205
Propeller shaft housing (counter rotation model) Ring nut 0: 108 N·m (10.8 kgf·m, 78 ft·lb) 7. Install the forward gear B, original shim(s) C, and dog clutch D using a press. Ring nut wrench 9: 90890-06578 5. Install the propeller shaft assembly in the reverse direction into the lower case.
Page 206: Drive Shaft And Lower Case (Counter Rotation Model)

LOWR Lower unit Drive shaft and lower case (counter rotation model) 6-45 69J3D11…
Page 207
Drive shaft and lower case (counter rotation model) Part name Q’ty Remarks Drive shaft Cover Oil seal Not reusable M8 × 25 mm Bolt Drive shaft housing Needle bearing O-ring Not reusable 3 × 60.5 mm Pinion shim — As required Thrust bearing Lower case Needle bearing case…
Page 208: Removing The Drive Shaft

LOWR Lower unit Removing the drive shaft 1. Remove the drive shaft assembly and pinion, and then pull out the reverse gear and thrust bearing. É Disassembling the lower case 1. Remove the retainer and shim(s). S69J6180 É Drive shaft holder 6 1: 90890-06520 Pinion nut holder 2: 90890-06505 Socket adapter 3 3: 90890-06508 Disassembling the drive shaft…
Page 209: Checking The Pinion And Reverse Gear

Drive shaft and lower case (counter rotation model) S69J6210 Ball bearing attachment 5: Checking the lower case 90890-06636 1. Check the skeg and torpedo for cracks or Driver rod LL 6: 90890-06605 damage. Replace if necessary. Checking the pinion and reverse gear 1.
Page 210: Assembling The Drive Shaft Housing

LOWR Lower unit 5. Install the new needle bearings into the reverse gear to the specified depth. É CAUTION: Add or remove shim(s), if necessary, Needle bearing attachment 7: when replacing the forward gear or lower 90890-06653 case. Driver rod SS 8: 90890-06604 Bearing depth plate 9: 90890-06603 Ball bearing attachment 3: 90890-06657…
Page 211: Installing The Drive Shaft

Drive shaft and lower case (counter rotation model) 2. Apply grease to the new oil seals, and 3. Install the drive shaft, housing, pinion, then install them into the drive shaft and pinion nut, and then tighten the nut housing to the specified depth. to the specified torque.
Page 212: Installing The Water Pump And Shift Rod

LOWR Lower unit 2. Install the bolts 1, ring 2, and bolts 3, and then tighten the bolts 1 to the speci- fied torque. Propeller shaft housing bolt 1: 30 N·m (3.0 kgf·m, 22 ft·lb) Installing the water pump and shift 3.
Page 213: Installing The Lower Unit

Drive shaft and lower case (counter rotation model) 5. Install the washers 7, wave washer 8, spacer 9, and collar 0 to the drive shaft. NOTE: • The collar and spacer should fit together firmly. • While pulling the drive shaft up, install the collar with an appropriate tool a that fits over the drive shaft as shown.
Page 214
LOWR Lower unit 5. Install the propeller and propeller nut, É and then tighten the nut finger tight. Place a block of wood between the anti- cavitation plate and propeller to keep the propeller from turning, and then tighten the nut to the specified torque. Shift rod push arm: 90890-06052 2.
Page 215: Shimming (Counter Rotation Model)

Drive shaft and lower case (counter rotation model) / Shimming (counter rotation model) Shimming (counter rotation model) 65.0 B1 38.4 47.5 T´4 S69J6670 6-54 69J3D11…
Page 216: Shimming

LOWR Lower unit Shimming Pinion nut: NOTE: 142 N·m (14.2 kgf·m, 103 ft·lb) • Shimming is not required when assembling the original lower case and inner parts. 3. Measure the distance (M4) between the • Shimming is required when assembling the shimming tool and the pinion as shown.
Page 217: Selecting The Reverse Gear Shims

Shimming (counter rotation model) 5. Calculate the pinion shim thickness (T3) Example: as shown in the examples below. If “T3” is 0.68 mm, then the pinion shim is 0.65 mm. If “T3” is 0.70 mm, then the pinion shim is 0.68 mm.
Page 218: Selecting The Forward Gear Shims

LOWR Lower unit 2. Calculate the reverse gear shim thickness Example: (T1) as shown in the examples below. If “T1” is 0.75 mm, then the reverse gear shim is 0.72 mm. If “T1” is 0.80 mm, then the reverse gear shim is 0.78 mm.
Page 219: Selecting The Propeller Shaft Shims

Shimming (counter rotation model) Example: Shimming plate 2: 90890-06701 If “M5” is 22.95 mm and “M6” is 15.73 mm Digital caliper 3: 90890-06704 and “R” is (+1) and “A” is (+6), then T2 = 8.45 + (+1)/100 – (+6)/100 – 22.95 + 15.73 mm 2.
Page 220
LOWR Lower unit NOTE: “A” and “B” are the deviation of the propeller shaft housing dimension from standard. The “A” mark a and “B” mark b are stamped on the propeller shaft housing in 0.01 mm units. If the “A” mark or “B” mark is unreadable, assume that “A”…
Page 221
Shimming (counter rotation model) / Backlash (counter rotation model) Backlash Available shim thicknesses: (counter rotation model) 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, and Measuring the forward and reverse 0.50 mm gear backlash 1. Remove the water pump assembly. 6. If the “A” mark or “B” mark is unreadable, measure the propeller shaft free play as 2.
Page 222
LOWR Lower unit 5. Set the lower unit upside down. 8. Remove the special service tools from the propeller shaft. É NOTE: Install the dial gauge so that the plunger a 9. Turn the shift rod into the reverse posi- contacts the mark b on the backlash indica- tion c with the shift rod push arm.
Page 223: Backlash (Counter Rotation Model)

Backlash (counter rotation model) 13. Turn the shift rod to the reverse position c with the shift rod push arm. 14. Slowly turn the drive shaft clockwise and counterclockwise and measure the back- lash when the drive shaft stops in each direction.
Page 224
BRKT Bracket unit Special service tools ………………7-1 Bottom cowling ………………..7-3 Upper case, steering arm, swivel bracket and clamp brackets ….7-7 Draining the engine oil…………….7-13 Disassembling the oil pan…………….7-13 Checking the oil strainer …………….7-13 Assembling the oil pan …………….7-13 Removing the steering arm …………..
Page 225
Power trim and tilt electrical system…………7-43 Checking the fuse………………7-44 Checking the power trim and tilt relay ………….7-44 Checking the power trim and tilt switch ………..7-45 Checking the trim sensor……………..7-45 69J3D11…
Page 226: Special Service Tools

BRKT Bracket unit Special service tools PTT oil pressure gauge assembly 90890-06580 PTT oil pressure gauge adapter 90890-06581 Cylinder-end screw wrench 90890-06544 PTT piston vice attachment 90890-06572 Tilt rod wrench 90890-06569 69J3D11…
Page 227
Special service tools — MEMO — 69J3D11…
Page 228: Bottom Cowling

BRKT Bracket unit Bottom cowling 69J3D11…
Page 229
Bottom cowling Part name Q’ty Remarks Bracket Shift cut switch Bracket Neutral switch M4 × 16 mm Screw Plate Spring Bushing Grease nipple Bolt M6 × 35 mm Bolt Clamp M6 × 35 mm Bolt M4 × 16 mm Screw Plate Clip Bushing…
Page 230
BRKT Bracket unit 69J3D11…
Page 231
Bottom cowling Part name Q’ty Remarks Bottom cowling Rubber seal Cowling lock lever Bushing Plate M6 × 30 mm Bolt Wave washer Lever Washer M6 × 20 mm Bolt Spring Hook M6 × 20 mm Bolt Bracket M6 × 25 mm Bolt Plate Grommet…
Page 232: Upper Case, Steering Arm, Swivel Bracket And Clamp Brackets

BRKT Bracket unit Upper case, steering arm, swivel bracket and clamp brackets 69J3D11…
Page 233
Upper case, steering arm, swivel bracket and clamp brackets Part name Q’ty Remarks Upper case assembly Damper M14 × 190 mm Bolt Washer Upper mount Bracket M10 × 40 mm Bolt M10 × 40 mm Bolt Mount housing M14 × 205 mm Bolt Washer Rubber washer…
Page 234
BRKT Bracket unit 69J3D11…
Page 235
Upper case, steering arm, swivel bracket and clamp brackets Part name Q’ty Remarks Upper exhaust guide M8 × 35 mm Bolt Pressure control valve M6 × 20 mm Bolt Plate Collar M10 × 45 mm Bolt Gasket Not reusable Dowel pin Lower exhaust guide Gasket Not reusable…
Page 236
BRKT Bracket unit 7-11 69J3D11…
Page 237
Upper case, steering arm, swivel bracket and clamp brackets Part name Q’ty Remarks Through tube Port clamp bracket M10 × 45 mm Bolt Ground lead Screw Washer Bushing Friction plate M6 × 10 mm Screw M6 × 15 mm Screw Trim sensor Grease nipple M6 ×…
Page 238: Draining The Engine Oil

BRKT Bracket unit 2. Remove the oil pan 4 from the upper Draining the engine oil exhaust guide 5 and lower exhaust 1. Place a drain pan under the drain hole, guide 6. and then remove the drain bolt 1 and let the oil drain completely.
Page 239
Upper case, steering arm, swivel bracket and clamp brackets 2. Install the oil strainer 4 and bolts, and Exhaust manifold bolt 7: then tighten the bolts to the specified 20 N·m (2.0 kgf·m, 14 ft·lb) torque. Oil pan bolt 8: 20 N·m (2.0 kgf·m, 14 ft·lb) 6.
Page 240: Removing The Steering Arm

BRKT Bracket unit 13. Install the lower mounts I and mount housings J. Removing the steering arm 1. Remove the circlip 1. 2. Remove the steering yoke 2 by striking it with a plastic hammer. Muffler assembly bolt D: 20 N·m (2.0 kgf·m, 14 ft·lb) Muffler assembly bolt E: 42 N·m (4.2 kgf·m, 30 ft·lb) Pressure control valve F:…
Page 241: Installing The Steering Arm

Upper case, steering arm, swivel bracket and clamp brackets Installing the steering arm 1. Install the washer 1 and bushing 2 onto the steering arm 3. 2. Place the swivel bracket 4 in an upright position, and then install the steering arm onto the swivel bracket.
Page 242: Installing The Upper Case

BRKT Bracket unit Installing the upper case WARNING 1. Install the upper and lower mounting bolts into the swivel bracket 1 simulta- After tilting up the outboard motor, be sure to support it with the tilt stop lever. neously. Otherwise, the outboard motor could sud- 2.
Page 243: Removing The Clamp Brackets

Upper case, steering arm, swivel bracket and clamp brackets Removing the clamp brackets 2. Assemble the clamp brackets and the 1. Remove the self-locking nut 1 and swivel bracket by connecting the ground lead 2, installing the through tube 3, ground lead 2, then clamp brackets 3 then tightening the self-locking nut 4 fin- and 4.
Page 244: Adjusting The Trim Sensor

BRKT Bracket unit 3. Install the tilt ram upper end into the Adjusting the trim sensor swivel bracket with the shaft 4 and cir- 1. Fully tilt the outboard motor up, and then clip 5. support it with the tilt stop lever 1. 4.
Page 245
Upper case, steering arm, swivel bracket and clamp brackets 7. Fully tilt the outboard motor up, and then support it with the tilt stop lever. WARNING After tilting up the outboard motor, be sure to support it with the tilt stop lever. Otherwise, the outboard motor could sud- denly lower if the power trim and tilt unit should lose fluid pressure.
Page 246: Power Trim And Tilt Unit

BRKT Bracket unit Power trim and tilt unit 7-21 69J3D11…
Page 247
Power trim and tilt unit Part name Q’ty Remarks Cylinder block Reservoir M8 × 20 mm Bolt O-ring Not reusable 1.9 × 12.6 mm M12 × 10 mm Reservoir cap O-ring Not reusable Sheet Filter Spacer M8 × 20 mm Bolt O-ring Not reusable…
Page 248
BRKT Bracket unit 7-23 69J3D11…
Page 249
Power trim and tilt unit Part name Q’ty Remarks Circlip Dust seal Not reusable Trim cylinder end screw O-ring Not reusable Trim ram Trim piston Washer M8 × 20 mm Bolt Backup ring O-ring Not reusable Spring Adapter Circlip Tilt ram Dust seal Not reusable Tilt cylinder end screw…
Page 250
BRKT Bracket unit 7-25 69J3D11…
Page 251
Power trim and tilt unit Part name Q’ty Remarks Gear housing 1 M5 × 40 mm Bolt Plate Filter Valve lock screw Down-relief spring Valve support pin Relief valve seal Up-relief spring Valve support pin O-ring Not reusable 1.8 × 11.35 mm Ball Circlip Main valve seal…
Page 252: Disassembling The Power Trim And Tilt Motor

BRKT Bracket unit Disassembling the power trim and Checking the power trim and tilt tilt motor motor 1. Remove the PTT motor screws 1, then 1. Check the commutator for dirt or foreign the yoke 2. substances. Clean with #600 grit sand- paper if necessary.
Page 253: Assembling The Power Trim And Tilt Motor

Power trim and tilt unit 8. Check the bearing for damage or wear. Replace if necessary. Assembling the power trim and tilt motor 1. Install the new oil seal 1 and bearing 2 into the motor base 3 as shown. Armature coil continuity Commutator segments b Continuity…
Page 254: Checking The Hydraulic Pressure

BRKT Bracket unit 4. Install the PTT oil pressure gauge adapter set 2. 6. Install the wave washer A and washer B into the yoke C. NOTE: Cover the removed pipe joint a with a rag. PTT oil pressure gauge adapter set: 90890-06580 7.
Page 255
Power trim and tilt unit 6. Reverse the PTT motor leads between the battery terminals to fully extend the trim and tilt rams. NOTE: Cover the removed pipe joint b with a rag. Battery PTT motor lead PTT oil pressure gauge adapter set: terminal 90890-06580 Sky blue (Sb)
Page 256: Disassembling The Gear Pump

BRKT Bracket unit NOTE: If the fluid is at the correct level, the fluid should overflow out of the filler hole when the cap is removed. 14. Remove the PTT oil pressure gauge adapter set 2. Recommended power trim and tilt fluid: 15.
Page 257: Disassembling The Tilt Cylinder And Trim Cylinders

Power trim and tilt unit Disassembling the tilt cylinder and trim cylinders 1. Hold the tilt cylinder 1 in a vise using aluminum plates a on both sides. 2. Loosen the tilt cylinder end screw 2, and then remove the tilt piston assembly. 3.
Page 258
BRKT Bracket unit WARNING Never look into the tilt cylinder opening because the free piston and power trim and tilt fluid may be expelled out force- fully. 5. Hold the tilt piston in a vise using the special service tool 4 on both sides. 6.
Page 259: Checking The Reservoir

Power trim and tilt unit Checking the reservoir 1. Check the reservoir for cracks or corro- sion. Replace if necessary. 4. Check the trim and tilt rams for bends or excessive corrosion. Polish with #400– 600 grit sandpaper if there is light rust or replace if necessary.
Page 260: Checking The Filters

BRKT Bracket unit Checking the filters 1. Check gear pump filters 1 and 2, and shuttle piston filters 3 for dirt or residue. Clean if necessary. 2. Check the up-relief valve and down-relief valve for dirt or residue. Clean if neces- sary.
Page 261: Assembling The Tilt Ram

Power trim and tilt unit 3. Install the balls 7, manual release spring 5. Install the filters C and gear pump D by 8, and bracket 9 by installing the bolts installing the bolts E, then tightening 0, then tightening them to the specified them to the specified torque.
Page 262: Assembling The Trim Rams

BRKT Bracket unit Tilt ram 0: 55 N·m (5.5 kgf·m, 40 ft·lb) 5. Install the new O-ring C and backup ring D into the tilt piston 9. 6. Install the balls E, absorber valve pins F, and springs G as shown. 7.
Page 263: Installing The Tilt Cylinder

Power trim and tilt unit 3. Install the tilt cylinder 3 to the cylinder block 4. 4. Install pipes 5 and 6, and then tighten them to the specified torque. Trim piston bolt: 38 N·m (3.8 kgf·m, 27 ft·lb) 4. Install the new O-ring 3, backup ring 4, spring 5, adapter 6, and circlip 7 to the trim piston 1.
Page 264: Installing The Power Trim And Tilt Motor

BRKT Bracket unit Recommended power trim and tilt 2. Fill the pump housing with the recom- mended fluid to the correct level a as fluid: ATF Dexron II shown. 3. Install the trim piston assembly into the trim cylinder, and then tighten the trim cylinder end screw 2 to the specified torque.
Page 265: Installing The Reservoir

Power trim and tilt unit Reservoir bolt 6: 18 N·m (1.8 kgf·m, 13 ft·lb) Reservoir cap 7: 7 N·m (0.7 kgf·m, 5.1 ft·lb) Installing the tilt ram 1. Fill the tilt cylinder with the recommended fluid to the correct level a as shown. 2.
Page 266: Bleeding The Power Trim And Tilt Unit

BRKT Bracket unit WARNING Recommended power trim and tilt fluid: To prevent the power trim and tilt fluid ATF Dexron II from spurting out due to internal pres- sure, the tilt ram should be kept at full 5. Install the reservoir cap. length.
Page 267: Built-In

Power trim and tilt unit / Bleeding the power trim and tilt unit 6. Support the outboard motor with the tilt NOTE: stop lever, and then let the fluid settle for • Repeat this procedure so that the rams go 5 minutes.
Page 268: Power Trim And Tilt Electrical System

BRKT Bracket unit Power trim and tilt electrical system S69J7520 1 Fuse (30 A) : Black 2 Fuse (20 A) : Gray 3 Power trim and tilt relay : Light green 4 Power trim and tilt motor : Pink 5 10-pin coupler : Red 6 Battery : Sky blue…
Page 269: Checking The Fuse

Power trim and tilt electrical system Checking the fuse 1. Check the fuse for continuity. Replace if Power trim and tilt relay continuity there is no continuity. Sky blue (Sb) – Black (B) Continuity Light green (Lg) – Black (B) Terminal 1 –…
Page 270: Checking The Power Trim And Tilt Switch

BRKT Bracket unit NOTE: Turn the lever 1 and measure the resistance as it gradually changes. Trim sensor resistance: Pink (P) – Black (B) 9–11 Ω at 20 °C (68 °F) a 247.6–387.6 Ω at 20 °C (68 °F) b Checking the power trim and tilt switch 1.
Page 271
– ELEC Electrical systems Special service tools ………………8-1 Checking the electrical components…………8-2 Measuring the peak voltage …………..8-2 Measuring the lower resistance…………..8-2 Electrical components………………. 8-3 Starboard and rear views …………….8-3 Port view………………..8-4 Front view ………………..8-5 Top view ………………..8-6 Wiring harness ………………..
Page 272: Electrical Systems

– ELEC Electrical systems Special service tools Ignition tester Test harness (3 pins) 90890-06754 90890-06793 Digital circuit tester Test harness (3 pins) 90890-03174 90890-06770 Peak voltage adaptor Test harness (2 pins) 90890-03172 90890-06787 Test harness (2 pins) 90890-06792 Test harness (4 pins) 90890-06771 69J3D11…
Page 273: Checking The Electrical Components

Special service tools / Checking the electrical components Checking the electrical Measuring the lower resistance When measuring a resistance of 10 Ω or less components with the digital circuit tester, the correct mea- Measuring the peak voltage surement cannot be obtained because of the internal resistance of the tester.
Page 274: Electrical Components

– ELEC Electrical systems Electrical components Starboard and rear views S69J8030 1 Thermoswitch 2 Starter motor 3 Oil pressure sensor 4 Ignition coils 69J3D11…
Page 275: Port View

Electrical components Port view S69J8040 1 Fuel injectors 2 High-pressure fuel pump relay 3 Low-pressure fuel pump 4 ECM 5 High-pressure fuel pump 6 Fuses 69J3D11…
Page 276: Front View

– ELEC Electrical systems Front view S69J8050 1 Starter motor 2 Fuses 3 ECM 4 Main relay 5 Rectifier Regulator 6 Power trim and tilt relay 7 Starter relay 69J3D11…
Page 277: Top View

Electrical components Top view S69J8060 1 Spark plugs A Stator coil 2 Idle speed control B Throttle position sensor 3 Thermoswitches C Ignition coils 4 Intake air pressure sensor 5 Engine temperature sensor 6 Fuses 7 Rectifier Regulator 8 Intake air temperature sensor 9 Starter motor 0 Oil pressure sensor 69J3D11…
Page 278: Wiring Harness

– ELEC Electrical systems Wiring harness 1 : G 16 : B/W 31 : Br 2 : Y/G 17 : L/R 32 : B 3 : P 18 : G/B 33 : P/G 4 : W 19 : G 34 : P 5 : —…
Page 279
Wiring harness Connect to: 1 Neutral switch 2 Shift cut switch 3 Fuel injector 4 Throttle position sensor 5 Thermoswitch 6 Ignition coil 7 Intake air pressure sensor 8 Low-pressure fuel pump 9 Low-pressure fuel pump driver 0 High-pressure fuel pump relay A High-pressure fuel pump B Idle speed control C Engine temperature sensor…
Page 280
– ELEC Electrical systems S69J8090 Connect to: : Gray : Black/yellow : Orange/yellow 1 Starter motor : Blue Br/W : Brown/white : Pink/black 2 Wiring harness : Light green : Green/black : Pink/green 3 Rectifier Regulator : Orange : Green/red P/W : Pink/white 4 Starter relay : Pink…
Page 281: Ignition And Ignition Control System

Wiring harness / Ignition and ignition control system Ignition and ignition control system S69J8100 1 ECM 9 Pulser coil H Spark plug B/W : Black/white 2 Oil pressure sensor 0 Stator coil : Black/yellow 3 Intake air temperature A Rectifier Regulator : Black : Blue/yellow B Intake air pressure…
Page 282: Checking The Ignition Spark Gap

– ELEC Electrical systems Checking the ignition spark gap WARNING 1. Remove the ignition coil cover and dis- • Do not touch any of the connections of connect the spark plug caps from the the spark gap tester leads. spark plugs. •…
Page 283: Checking The Ecm

Ignition and ignition control system Checking the ECM 1. Remove the ignition coil cover and dis- connect the ignition coil coupler. 2. Connect the test harness (2 pins) to the ignition coil. 3. Measure the ECM output peak voltage. If below specification, measure the pulser coil output peak voltage.
Page 284: Checking The Intake Air Temperature Sensor

– ELEC Electrical systems Checking the engine temperature sensor 1. Place the engine temperature sensor in a container of water and slowly heat the water. Test harness (3 pins): 90890-06793 S69J8240 Throttle position sensor input voltage: 2. Measure the engine temperature sensor Orange (O) –…
Page 285: Checking The Thermoswitch

Ignition and ignition control system Checking the thermoswitch Checking the shift cut switch 1. Place the thermoswitch in a container of 1. Check the shift cut switch for continuity. water and slowly heat the water. Replace if there is no continuity. S69J8270 S69J8250 Lead color…
Page 286: Checking The Main Relay

– ELEC Electrical systems Checking the main relay 1. Connect the digital circuit tester leads to main relay terminals 1, 2, and 3. 2. Connect the terminal 4 to the positive battery terminal. 3. Connect the terminal 5 to the negative battery terminal.
Page 287: Fuel Control System

Ignition and ignition control system / Fuel control system Fuel control system L/R3 R/Y1 1 2 3 4 5 6 S69J8290 1 ECM A Stator coil K Low-pressure fuel pump 2 Oil pressure sensor B Rectifier Regulator L High-pressure fuel pump relay 3 Intake air temperature sensor C Intake air pressure sensor M Fuel injector…
Page 288
– ELEC Electrical systems L/R3 R/Y1 1 2 3 4 5 6 S69J8290 : Black : Green/black P/W : Pink/white : Brown : Green/red : Red/yellow : Green G/W : Green/white W/B : White/black : Blue : Green/yellow W/G : White/green : Orange : Blue/red W/R : White/red…
Page 289: Checking The Low-Pressure Fuel Pump And High-Pressure Fuel Pump

Fuel control system Checking the low-pressure fuel 4. Check for continuity between the high- pressure fuel pump relay terminals. pump and high-pressure fuel pump Replace if there is no continuity. 1. Disconnect the starter relay lead (brown lead) 1 to prevent the engine from start- 5.
Page 290: Starting System

– ELEC Electrical systems Starting system Br/W Br/W S69J8330 1 Fuse (30 A) : Black 2 Fuse (20 A) : Brown 3 Starter relay : Red 4 Starter motor Br/W : Brown/white 5 Battery 8-19 69J3D11…
Page 291: Checking The Fuse

Starting system Checking the fuse 1. Check the fuse for continuity. Replace if there is no continuity. S69J8340 Checking the wiring harness (10 pins) 1. Check the wiring harness for continuity. Replace if there is no continuity. Checking the starter relay 1.
Page 292: Starter Motor

– ELEC Electrical systems Starter motor 8-21 69J3D11…
Page 293
Starter motor Part name Q’ty Remarks Clip Pinion stopper Starter motor pinion Spring M6 × 35 mm Bolt Housing Rubber seal Bearing Clutch assembly E-clip Not reusable Thrust washer Center bracket Pinion shaft Planetary gear Outer gear Plate Armature Stator Brush holder assembly Plate Thrust washer…
Page 294: Removing The Starter Motor Pinion

– ELEC Electrical systems Removing the starter motor pinion 1. Slide the pinion stopper 1 down as shown, and then remove the clip 2. 2. Measure commutator diameter. Replace the armature if out of specifica- tion. NOTE: Remove the clip with a thin screwdriver. Checking the starter motor pinion 1.
Page 295: Checking The Brushes

Starter motor Brush continuity Brush 1 – Brush 2 No continuity Checking the magnet switch 1. Connect the tester leads between the magnet switch terminals as shown. 2. Connect the positive battery terminal to the black and white (B/W) lead. Armature continuity 3.
Page 296: Charging System

– ELEC Electrical systems Charging system S69J8460 1 Stator coil : Black 2 Rectifier Regulator : Green 3 Fuse (30 A) : Red 4 Battery G/W : Green/white : Red/yellow 8-25 69J3D11…
Page 297: Checking The Stator Coil

Charging system Checking the stator coil Stator coil resistance 1. Remove the intake silencer and discon- (use as reference): nect the stator coil coupler. Green (G) – Green (G) 0.24–0.41 Ω at 20 °C (68 °F) 2. Connect the test harness (3 pins) to the Green/white (G/W) –…
Page 298
– ELEC Electrical systems Digital circuit tester: 90890-03174 Peak voltage adaptor: 90890-03172 Test harness (2 pins): 90890-06787 Rectifier Regulator output peak voltage: Red (R) – Black (B) Red/yellow (R/Y) – Black (B) Unloaded r/min 1,500 3,500 DC V 8-27 69J3D11…
Page 299
TRBL SHTG Troubleshooting Special service tools ………………9-1 Yamaha Diagnostic System …………….9-2 Introduction………………..9-2 Operating………………..9-3 Troubleshooting………………9-46 Power unit………………… 9-47 Bracket unit ………………..9-56 Electrical systems………………9-60 Self-diagnosis………………..9-61 Diagnosing the electronic control system ……….9-61 69J3D11…
Page 300: Trbl Shtg

TRBL SHTG Troubleshooting Special service tools Yamaha Diagnostic System 68F-85300-01 Yamaha Diagnostic System (upgrade) 68F-2819K-10 Diagnostic flash indicator 4 90890-06795 Diagnostic flash adaptor 90890-06794 69J3D11…
Page 301
Yamaha Diagnostic System Introduction Features The newly developed Yamaha Diagnostic System provides quicker detection and analysis of engine malfunctions for quicker troubleshooting procedures than traditional methods. By connecting your laptop computer to the ECM (Electronic Control Module) of an outboard motor using the communication cable, this software can be used to display sensor data and data stored in the ECM on a laptop computer’s monitor.
Page 302: Operating

4. Connect the 12 V battery to the outboard motor. NOTE: The following items should be checked before starting the Yamaha Diagnostic System. • The battery is properly charged and its specific gravity is within specification. • There are no incorrect wiring connections.
Page 303
2. Turn on your computer and start up Windows 95, Windows 98, Windows Me, or Windows 2000. 3. From the taskbar at the bottom of your computer screen, click the Start button (Fig. 4), point to Programs, and then click Yamaha Diagnostic System. Fig. 4…
Page 304
TRBL SHTG Troubleshooting 4. Open the Yamaha Diagnostic System window. (Fig. 5) After about three seconds the display will automatically go to the first menu, or click or press any key to go to the first menu. (See fig. 6.) Fig.
Page 305
Yamaha Diagnostic System NOTE: • If an error message appears and the program stops operating, follow the error messages. • If the program doesn’t start, an error message will explain the problem. If the program doesn’t start and an error message is not displayed, the cause of the problem is most likely insufficient com- puter memory.
Page 306
TRBL SHTG Troubleshooting NOTE: If a diagnosis record is stored in the ECM, “Diagnosis record available,” appears as a confirmation message before the Main Menu is displayed. (Fig. Fig. 8 Selecting commands from the main menu Eight commands appear in the Main Menu. Select a command in any of the following three ways. Three ways to select command: •…
Page 307
Yamaha Diagnostic System Explanation of each command 1. Diagnosis The diagnosis codes, their corresponding part name, the diagnosing results, and the diagnostic cri- teria are listed. List of items: Condition of coils (pulser coil) Condition of sensors (throttle position sensor, intake air temperature sensor, intake air pressure…
Page 308
TRBL SHTG Troubleshooting 6. Data logger Two out of six items (engine speed, battery voltage, throttle position, intake air pressure, engine temperature, and oil pressure) are selected and 13 minutes of their recorded data are displayed on a graph. The operating time as compared to the engine speed and the total operating time are also displayed.
Page 309
Yamaha Diagnostic System Operating procedure: Select the code number that you wish to view a diagnosis record for by either clicking it or pressing the up or down arrow keys on your keyboard. To scroll the display and view other items, click in the scroll bar, or press the up or down arrow keys on your keyboard.
Page 310
TRBL SHTG Troubleshooting 2. Specify the printer, the printing range, and the number of copies to be printed. Fig. 12 3. Click the OK button to begin printing. To cancel printing, click the Cancel button. NOTE: The Print Screen function in Windows cannot be used since scroll data cannot be printed. 9-11 69J3D11…
Page 311
Yamaha Diagnostic System Save By selecting the Save command in the Diagnosis, Diagnosis record, Engine monitor, or Data logger mode, the corresponding data can be saved on a disk. Operating procedure: 1. Click the Save [F2] button or press the F2 key on your keyboard. The Save As dialog box is displayed.
Page 312
TRBL SHTG Troubleshooting 2. Select the disk and folder where the data will be saved and specify its file name. (Fig. 15) Fig. 15 3. Click the Save button to save the data. To cancel saving, click the Cancel button. (Fig. 15) 9-13 69J3D11…
Page 313
Yamaha Diagnostic System Diagnosis record The diagnosis codes of malfunctions that have been recorded in the outboard motor’s ECM, the diagnostic codes’ corresponding part name, and the time when the malfunctions occurred are listed. A maximum of six items can be displayed at one time. The latest occurrence appears on top. In addition, diagnosis codes stored in the ECM can be deleted.
Page 314
TRBL SHTG Troubleshooting NOTE: When a Diagnosis record is not available, “Diagnosis Record is unavailable” is displayed. (Fig. 17) Fig. 17 9-15 69J3D11…
Page 315
Yamaha Diagnostic System Deleting diagnosis record in the ECM: 1. Select the item that you wish to delete by either clicking it or pressing the up or down arrow keys on your keyboard. NOTE: The selected code is highlighted in light blue.
Page 316
TRBL SHTG Troubleshooting Engine monitor WARNING Do not use the Engine Monitor function to check the engine condition while operating a boat, otherwise you may become distracted, which could result in a collision. CAUTION: Be sure to avoid splashing water on the laptop computer, adapter, and communication cable, and to avoid damaging them with strong sudden jolts or vibration.
Page 317
Yamaha Diagnostic System Operating procedure: 1. To scroll the display and view other items, click in the scroll bar, or press the up or down arrow keys on your keyboard. 2. To change a displayed item, click the Select [F3] button or press the F3 key on your keyboard.
Page 318
TRBL SHTG Troubleshooting Stationary test Selecting this command displays a window where stationary tests (spark ignition coil #, operate injector #, operate electric fuel pump, operate electric fuel feed pump, and operate ISC valve) can be selected. WARNING Avoid clicking the Execute and Cancel buttons repeatedly, otherwise the ECM or PC may not work properly and they may be damaged.
Page 319
Yamaha Diagnostic System Sparking ignition coil procedure: A voltage is applied to the ignition coil of the selected cylinder, a spark is created in the spark gap tester, and then the ignition system is checked. Five sparks are created within five seconds.
Page 320
TRBL SHTG Troubleshooting 5. Click the Execute button or press the Enter key on your keyboard. (Fig. 24) Fig. 24 Fig. 25 9-21 69J3D11…
Page 321
Yamaha Diagnostic System NOTE: If the engine is running an error message is displayed. Follow the instructions that appear. (Fig. 26) Fig. 26 6. While checking the information that appears in the Test situation column, follow the test instructions in the messages that are displayed. (See fig. 25.) NOTE: If an error occurs while the test is being performed, an error message is displayed.
Page 322
TRBL SHTG Troubleshooting 9. To perform the test again to the same cylinder, click the Execute button or press the Enter key on your keyboard. To perform the test on a different cylinder, click the Return [ESC] button or press the Esc key on your keyboard to return to main menu where a different test can be selected.
Page 323
Yamaha Diagnostic System Operating injector procedure: A voltage is applied to the injector of the selected cylinder, the injector is activated, and then the fuel system is checked. The fuel is injected 20 times within two seconds. WARNING • Do not perform the test with the injector removed from the cylinder head or with any fuel system parts removed.
Page 324
TRBL SHTG Troubleshooting 3. Click the Execute button or press the Enter key on your keyboard. (Fig. 30) Fig. 30 NOTE: If an error occurs while the test is being performed, an error message is displayed. Follow the instructions that appear. 9-25 69J3D11…
Page 325
Yamaha Diagnostic System 4. Listen to the operating sound of the injector for the cylinder being tested. Fig. 31 WARNING Do not touch the injector connector. NOTE: Before activating the injector, operate the electric fuel pump for ten seconds in order to build up fuel pressure.
Page 326
TRBL SHTG Troubleshooting 5. To perform the test again on the same cylinder, click the Execute button or press the Enter key on your keyboard. To perform the test on a different cylinder, click the Return [ESC] button or press the Esc key on your keyboard to return to the window where a different test can be selected.
Page 327
Yamaha Diagnostic System Operating the electric fuel pump: A voltage is applied to the electric fuel pump, the electric fuel pump is operated, and then the fuel system is checked. The electric fuel pump is operated for ten seconds. WARNING •…
Page 328
TRBL SHTG Troubleshooting 2. Click the Execute button or press the Enter key on your keyboard. (Fig. 34) Fig. 34 NOTE: If an error occurs while the test is being performed, an error message is displayed. Follow the instructions that appear. 3.
Page 329
Yamaha Diagnostic System 4. To perform the test again click the Execute button or press the Enter key on your keyboard. To perform a different test, click the Return [ESC] button or press the Esc key on your keyboard to return to the window where a different test can be selected.
Page 330
TRBL SHTG Troubleshooting 1. Select the test to be performed, and then click the Select button or press the Enter key on your keyboard. (Fig. 36) Fig. 36 2. Click the Execute button or press the Enter key on your keyboard. (Fig. 37) Fig.
Page 331
Yamaha Diagnostic System 3. Listen to the operating sound of the fuel feed pump. Fig. 38 4. To test again, click the Execute button or press the Enter key on your keyboard. To perform a different test, click the Return button or return to the test selection menu or press the ESC key on your keyboard.
Page 332
TRBL SHTG Troubleshooting Operating the ISC valve: Operate the ISC valve and listen to its operating sound. The operating time is three seconds. 1. Select the test to be performed, and then click the Select button or press the Enter key on your keyboard.
Page 333
Yamaha Diagnostic System 3. Listen to the operating sound of the ISC valve. Fig. 42 4. To test again, click the Execute button or press the Enter key on your keyboard. To perform a different test, click the Return button to return to the test selection menu or press the ESC key on your keyboard.
Page 334
TRBL SHTG Troubleshooting Active test Selecting this command displays a window where active tests (fully open ISC valve and angle of ISC valve opening) can be selected. WARNING Avoid clicking the Execute and Cancel buttons repeatedly, otherwise the ECM or PC may not work properly and they may be damaged.
Page 335
Yamaha Diagnostic System 1. Select the test to be performed, and then click the Select button or press the Enter key on your keyboard. Fig. 45 2. Click the Execute button or press the Enter key on your keyboard. (Fig. 46) Fig.
Page 336
TRBL SHTG Troubleshooting 3. The ISC valve is fully open. Check that the engine speed revs up. Fig. 47 4. To test again, click the Execute button or press the Enter key on your keyboard. To perform a different test, click the Return button to return to the test selection menu or press the ESC key on your keyboard.
Page 337
Yamaha Diagnostic System Opening the ISC valve angle: Set the opening angle of the ISC valve, and adjust the air volume when the engine is idling. The operating time is 30 minutes. Before testing warm the engine up. 1. Select the test to be performed, and then click the Select button or press the Enter key on your keyboard.
Page 338
TRBL SHTG Troubleshooting 3. Check the opening angle of the ISC valve is set. Refer to the service manual for adjusting pro- cedures. After 30 minutes have passed, the test will end automatically. Fig. 51 4. To test again, click the Execute button or press the Enter key on your keyboard. To perform a different test, click the Return button to return to the test selection menu or press the ESC key on your keyboard.
Page 339
Yamaha Diagnostic System Data logger Monitor item selection A window that allows you to select the Data comparison graph or the Engine operating hours according to engine speed appears. Fig. 53 Operating procedure: 1. Select the desired item by either clicking it or pressing the up or down arrow keys on your key- board.
Page 340
TRBL SHTG Troubleshooting Data display item selection A window that allows you to select the items that will be graphed. No more than two items can be displayed. Fig. 54 Operating procedure: 1. Select the desired items by either clicking them or pressing the up or down arrow keys on your keyboard, and then press the space bar.
Page 341
Yamaha Diagnostic System Data comparison graph A line graph appears with the items selected in the Data display item selection window on the ver- tical axes and the Time before engine stop on the horizontal axis. (Fig. 55) Fig. 55 NOTE: •…
Page 342
TRBL SHTG Troubleshooting Engine operating hours according to engine speed The operating hours as compared to the engine speed and the total operating hours are displayed. (Fig. 56) Fig. 56 A window is displayed showing the amount of hours that the engine is operated at each engine speed range.
Page 343
Yamaha Diagnostic System ECM No. The ECM part number of the outboard motor is read from the ECM and is displayed. (Fig. 57) Fig. 57 9-44 69J3D11…
Page 344
TRBL SHTG Troubleshooting Exit The program is exited. Fig. 58 Operating procedure: Click the OK button or press the Enter key on your keyboard to exit the program. To cancel exiting the program, click the Cancel button or press the Esc key on your keyboard. (Fig.
Page 345
Yamaha Diagnostic System Troubleshooting Error content Cause Action Communication cable Engine start switch is turned Turn the engine start switch to related error occurs OFF. Communication cable is Connect communication cable disconnected. between the laptop computer’s communication port and 3-pin communication coupler of the outboard motor.
Page 346: Power Unit

TRBL SHTG Troubleshooting NOTE: • To diagnose a mechanical malfunction, use the troubleshooting charts pertaining to the trouble located in this chapter. Also, when checking and maintaining the outboard motor, see Chapters 4– 8 for safe maintenance procedures. • Check that all electrical connections are tight and free from corrosion, and that the battery is fully charged to 12 V.
Page 347
Power unit Is there Replace the engine shut-off continuity? switch. Check the fuse for continuity. Is there Replace the fuse. continuity? Check the wiring harnesses for continuity. Is there Replace the wiring harnesses. continuity? Listen for the operation sound of the starter relay. Can the oper- ation sound Replace the starter relay.
Page 348
TRBL SHTG Troubleshooting Symptom: Engine cranks, but will not start (engine shut-off switch is operating normally). • Check the ignition system. • Check the fuel system. • Check the compression pressure of the power unit. WARNING Check that the spark plugs pro- •…
Page 349
Power unit Does the Check the compression pres- engine start? sure of the combustion chamber. Out of specification? Check the condition of the spark Failure in starting operation plugs again. Check the valve Wet spark plugs? Failure in starting operation clearance.
Page 350
Check the fuel pressure. Check the fuel Out of Check the pressure regulator. injector resistance. specification? Check the fuel system using the Out of Yamaha Diagnostic System. specification? Continued on next page. Replace the fuel injector. 9-51 69J3D11…
Page 351
Is there Replace the high-pressure fuel continuity? pump relay. Check the fuel system using the Yamaha Diagnostic System. Ignition system Check the ignition spark gap using the spark gap tester. Out of Check the ignition system out- specification? put peak voltage.
Page 352
Check the second- ary air intake on the O-ring and manifold Out of Synchronize the throttle valves. plate, idle speed specification? control hose, and the gaskets of the vacuum check bolts. Check the engine using the Yamaha Diagnostic System. 9-53 69J3D11…
Page 353
The engine turns off when the throttle is opened quickly. Acceleration is tardy and the engine is likely to stop at any moment. • Check the engine using the diagnostic flash indicator or the Yamaha Diagnostic System. Symptom: Engine can run, but engine speed will not increase.
Page 354
Check the oil pump for debris or specification? oil leaks. Check the oil Debris or leaks? passage. Clean or replace the respective Check the oil pressure sensor. parts. Good condition? Replace the oil pressure sensor. Check the engine using the Yamaha Diagnostic System. 9-55 69J3D11…
Page 355: Bracket Unit

Power unit / Bracket unit Bracket unit Symptom: Power trim and tilt unit does not operate. Listen for the operation sound of the power trim and tilt relay. Can the oper- Check the voltage between each terminal. ation sound • Between the sky blue (Sb) lead and black (B) lead. be heard? •…
Page 356
TRBL SHTG Troubleshooting At specified Add fluid to the correct level. level? Measure the hydraulic pressure. Out of Check the power trim and tilt specification? unit for leaks. Disassemble the power trim and tilt unit, and then check the filter for debris or dirt.
Page 357
Bracket unit Symptom: Power trim and tilt unit does not hold the outboard motor up. Check that the manual valve is closed. Is it closed? Close the valve. Check the power trim and tilt fluid level. At specified Add fluid to the correct level. level? Disassemble the power trim and tilt unit, and then check the…
Page 358
TRBL SHTG Troubleshooting Symptom: Shift mechanism of the forward gear and reverse gear does not operate properly. Check the shift cable operation. Good operat- Check the shift cables and links ing condition? of the remote control box. Check the operation of the shift rod.
Page 359: Electrical Systems

Bracket unit / Electrical systems Electrical systems Symptom: Battery becomes weaker quickly. • Check the charging system. Measure the output peak voltage of the stator coil. Out of Replace the stator coil. specification? Measure the Rectifier Regulator output peak voltage. Out of Replace the Rectifier Regulator.
Page 360: Self-Diagnosis

TRBL SHTG Troubleshooting Self-diagnosis Diagnosing the electronic control system 1. Connect the special tools to the outboard motor as shown. É L/W, L/W • Trouble code indication Example: The illustration indicates code number 23. a: Light on, 0.33 second b: Light off, 4.95 seconds b: Light off, 0.33 second d: Light off, 1.65 seconds R/B, W/B, B…
Page 361
Self-diagnosis Code Symptom Normal Incorrect pulser coil signal Incorrect engine temperature sensor signal Incorrect throttle position sensor signal Incorrect battery voltage Incorrect intake air temperature sensor signal Incorrect neutral switch signal Incorrect intake air pressure sensor signal Incorrect idle speed control signal Incorrect oil pressure sensor signal…
Page 362
Index Checking the connecting rod small end inside diameter ……..5-50 Adjusting the throttle link and throttle Checking the cooling water passage..3-9 cable operation (with a stop bolt) ….3-10 Checking the cooling water pilot hole ..1-31 Adjusting the throttle link and throttle Checking the crankpin oil clearance..
Page 363
Checking the oil strainer ……7-13 Checking the vapor separator ….4-8 Checking the outboard motor mounting Checking the water pump and height …………1-29 shift rod……….6-10 6-38 Checking the pinion and forward gear ..6-20 Checking the wiring harness (10 pins) ..8-20 Checking the pinion and reverse gear ..6-48 Control system……….
Page 364
Index Fuel injection control ………1-18 Maintenance specifications ……2-3 Fuel system……..1-13 Manual format……….1-1 Measuring the forward and reverse gear backlash ….6-30 6-60 Measuring the fuel pressure General ………….3-18 (high-pressure fuel line)……3-5 General specifications………2-1 Measuring the lower resistance….8-2 General torques ……..2-15 Measuring the peak voltage …….
Page 365
Technical tips ……….1-18 Test run………….1-31 Throttle control ……….4-13 Tightening torques ……..2-12 Top cowling……….3-4 Top view…………8-6 Troubleshooting ……..9-46 Upper case, steering arm, swivel bracket and clamp brackets …7-7 Valve train system……..1-9 Vapor separator ……….4-5 Ventilation ………..1-3 Wiring harness ……….8-7 Yamaha Diagnostic System……9-2 69J3D11…
Page 366
WIRING DIAGRAM F225AET, FL225AET 1 Low-pressure fuel pump Color code 2 Low-pressure fuel pump driver : Black 3 High-pressure fuel pump relay : Brown 4 High-pressure fuel pump : Green 5 Idle speed control : Gray 6 Fuel injector : Blue 7 Spark plug : Light green 8 Ignition coil…
Page 368
YAMAHA MOTOR CO., LTD. Printed in the Netherlands Jun. 2001 – 1.3 × 1 CR (F225AET, FL225AET)
Page 369
F225AET, FL225AET — — — R/Y1 — L/R3 B B B B B B Y/G3 R/Y1 B B B B B B R/Y4 R/Y5 R/Y6 1 2 3 4 5 6 Lg R Sb Br/W Br/W Br/W S69JWD03…
Page 370
L/R3 R/Y1 Br/W S69JWD04…

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Summary of Contents for Yamaha XT225R

Page 4: Important Manual Information

Page 7: Table Of Contents

Page 10: Safety Information

Page 11: Safety Information

Page 12: Protective Apparel

Page 14: Gasoline And Exhaust Gas

Page 16: Location Of Important Labels

Page 18: Description

Page 19: Right View

Page 20: Controls And Instruments

Page 21: Instrument And Control Functions

Page 22: Indicator Lights

Page 23: Clutch Lever

Page 24: Shift Pedal

Page 25: Fuel Tank Cap

Page 27: Fuel Cock

Page 28: Starter (Choke) Knob

Page 29: Helmet Holder

Page 32: Sidestand

Page 34: Pre-Operation Checks

Page 37: Operation And Important Riding Points

Page 39: Starting A Warm Engine

Page 41: Recommended Shift Points

Page 42: Parking

Page 43: Periodic Maintenance And Minor Repair

Page 45: Periodic Maintenance Chart For The Emission Control System

Page 46: General Maintenance And Lubrication Chart

Page 49: Removing And Installing The Cowling And Panels

Page 50: Checking The Spark Plug

Page 52: Canister (For California Only)

Page 56: Cleaning The Air Filter Element

Page 58: Cleaning The Spark Arrester

Page 59: Adjusting The Carburetor

Page 60: Tires

Page 62: Spoke Wheels

Page 63: Accessories And Replacement Parts

Page 64: Adjusting The Brake Lever Free Play

Page 65: Adjusting The Brake Pedal Position And Free Play

Page 66: Adjusting The Rear Brake Light Switch

Page 67: Checking The Front Brake Pads And Rear Brake Shoes

Page 68: Checking The Brake Fluid Level

Page 69: Changing The Brake Fluid

Page 71: Lubricating The Drive Chain

Page 72: Checking And Lubricating The Throttle Grip And Cable

Page 73: Checking And Lubricating The Brake And Clutch Levers

Page 74: Checking The Front Fork

Page 75: Checking The Wheel Bearings

Page 77: Replacing The Fuse

Page 78: Replacing The Headlight Bulb

Page 80: Replacing A Turn Signal Light Bulb

Page 81: Supporting The Motorcycle

Page 82: Front Wheel

Page 84: Rear Wheel

Page 86: Troubleshooting

Page 87: Troubleshooting Chart

Page 88: Motorcycle Care And Storage

Page 91: Storage

Page 93: Specifications

Page 94: Specifications

Page 97: Consumer Information

Page 98: Model Label

Page 99: Reporting Safety Defects

Page 100: Motorcycle Noise Regulation

Page 102: Maintenance Record

Page 104: Street And Enduro Motorcycle Limited Warranty

Page 106: Yamaha Extended Service (Y.e.s.)

Yamaha Serow 225 Service Repair Manuals on Motor Era

This Cyclepedia manual covers 1992 – 2007 Yamaha XT225 Serow motorcycles.

Periodic Maintenance

Quick Reference

Fuel System

External Components

Engine

Final Drive

Front Brake

Rear Brake

Wheels