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2011 YAMAHA LF300CA 4-STROKE OUTBOARD Service Repair Manual SN:1000001 and up

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This is the Highly Detailed factory service repair manual for the2011 YAMAHA LF300CA 4-STROKE OUTBOARD, this Service Manual has detailed illustrations as well as step by step instructions,It is 100 percents complete and intact. they are specifically written for the do-it-yourself-er as well as the experienced mechanic.2011 YAMAHA LF300CA 4-STROKE OUTBOARD Service Repair Workshop Manual provides step-by-step instructions based on the complete dis-assembly of the machine. It is this level of detail, along with hundreds of photos and illustrations, that guide the reader through each service and repair procedure. Complete download comes in pdf format which can work under all PC based windows operating system and Mac also, All pages are printable. Using this repair manual is an inexpensive way to keep your vehicle working properly.

Service Repair Manual Covers:
General Information
Specification
Technical Feature and Description
Rigging Information
Troubleshooting
Electrical System
Fuel System
Power Unit
Lower Unit
Bracket Unit
Maintenance
Index
Appendix
File Format: PDF
Compatible: All Versions of Windows & Mac
Language: English
Requirements: Adobe PDF Reader

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Published in: Automotive
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2011 YAMAHA LF300CA 4-STROKE OUTBOARD Service Repair Manual SN:1000001 and up

  1. 1. SERVICE MANUAL LIT-18616-03-23 6CE-28197-1N-11 (L)F225 (L)F250 (L)F300
  2. 2. Preface 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 the Bronze Technical Certificate of the YTA (Yamaha Technical Academy) marine or the equivalent basic understanding of the mechanical and electrical concepts and procedures inherent in the work, for without such knowledge attempted repairs or service to the equipment could render it unsafe or unfit for use. Because Yamaha has a policy of continuously improving its products, models may differ in detail from the descriptions and illustrations given in this publication. Use only the latest edition of this manual. Authorized Yamaha dealers are notified periodically of modifications and significant changes in specifications and procedures, and these are incorporated in successive editions of this manual. Also, up-to-date parts information is available on YDS (Yamaha Dealer System). Additional information and up-to-date information on Yamaha products and services are available on YDS (Yamaha Dealer System). Important information Particularly important information is distinguished in this manual by the following notations: The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! A WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury. A NOTICE indicates special precautions that must be taken to avoid damages to the out- board motor or other property. TIP: A TIP provides key information to make procedures easier or clearer. (L)F225, (L)F250, (L)F300 SERVICE MANUAL ©2010 by Yamaha Motor Corporation, U.S.A. 1st Edition, May 2010 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in U.S.A. LIT-18616-03-23
  3. 3. Contents General information GEN INFO 0 Specification SPEC 1 Technical features and description TECH FEA 2 Rigging information RIG GING 3 Troubleshooting TRBL SHTG 4 Electrical system ELEC 5 Fuel system FUEL 6 Power unit POWR 7 Lower unit LOWR 8 Bracket unit BRKT 9 Maintenance MNT 10 Index Appendix A
  4. 4. GEN INFO 0 1 2 3 4 5 6 7 8 9 10 A General information 0 Safety while working .................................................... 0-1 Rotating part .............................................................................. 0-1 Hot part ...................................................................................... 0-1 Electric shock ............................................................................ 0-1 Propeller .................................................................................... 0-1 Handling of gasoline .................................................................. 0-1 Ventilation .................................................................................. 0-1 Self-protection ........................................................................... 0-2 Working with crane .................................................................... 0-2 Handling of gas torch ................................................................ 0-2 Part, lubricant, and sealant ........................................................ 0-2 Handling of sealant .................................................................... 0-3 Special service tool ................................................................... 0-3 Tightening torque ...................................................................... 0-3 Non-reusable part ...................................................................... 0-3 Disassembly and assembly ....................................................... 0-3 How to use this manual .................................................... 0-4 Manual format ........................................................................... 0-4 Abbreviation .............................................................................. 0-5 Lubricant, sealant, and thread locking agent ................. 0-7 Symbol ...................................................................................... 0-7 Special service tool ........................................................... 0-9
  5. 5. 0-1 GEN INFO General information Safety while working To prevent an accident or injury and to pro- vide quality service, observe the following safety procedures. Rotating part • Hands, feet, hair, jewelry, clothing, personal flotation device straps, and so on, can become entangled with internal rotating parts of the engine, resulting in serious injury or death. • Keep the top cowling installed whenever possible. Do not remove or install the top cowling when the engine is running. • Only operate the engine with the top cowl- ing removed according to the specific instructions in the manual. Keep hands, feet, hair, jewelry, clothing, personal flota- tion device straps, and so on, away from any exposed moving parts. Hot part During and after operation, engine parts are hot enough to cause burns. Do not touch any parts under the top cowling until the engine has cooled. Electric shock Do not touch any electrical parts while start- ing or operating the engine. Otherwise, shock or electrocution could result. Propeller Do not hold the propeller with your hands when loosening or tightening the propeller nut. Handling of gasoline • Gasoline is highly flammable. Keep gaso- line and all flammable products away from heat, sparks, and open flames. • Gasoline is poisonous and can cause injury or death. Handle gasoline with care. Never siphon gasoline by mouth. If you swallow some gasoline, inhale a lot of gasoline vapor, or get some gasoline in your eyes, see your doctor immediately. If gasoline spills on your skin, wash with soap and water. If gasoline spills on your clothing, change your clothes. Ventilation • Gasoline vapor and exhaust gas are heavier than air and extremely poisonous. If gasoline vapor or exhaust gas is inhaled in large quantities, it may cause loss of con- sciousness and death within a short time. • When test running an engine indoors (for example, in a water tank) make sure to do so where adequate ventilation can be main- tained.
  6. 6. 0-2 Safety while working 0 1 2 3 4 5 6 7 8 9 10 A Self-protection • Protect your eyes by wearing safety glasses or safety goggles during all opera- tions involving drilling and grinding, or when using an air compressor. • Protect your hands and feet by wearing pro- tective gloves and safety shoes when nec- essary. Working with crane • Outboard motors weighing 18.0 kg (39.7 lb) and over must be carried by a crane. • Use the wire ropes of adequate strength, and lift up the outboard motor using the three-point suspension. • If the outboard motor does not have three or more points to be suspended, support it using additional ropes, or the like, so that the outboard motor can be lifted and carried in a stable manner. Handling of gas torch • Improper handling of a gas torch may result in burns. For information on the proper han- dling of the gas torch, see the operation manual issued by the manufacturer. • When using a gas torch, keep it away from the gasoline and oil, to prevent a fire. • Components become hot enough to cause burns. Do not touch any hot components directly. Part, lubricant, and sealant Use only genuine Yamaha parts, lubricants, and sealants, or those recommended by Yamaha, when servicing or repairing the out- board motor.
  7. 7. 0-3 GEN INFO General information Handling of sealant • Wear protective gloves to protect your skin, when using the sealants. • See the material safety data sheet issued by the manufacturer. Some of the sealants may be harmful to human health. Special service tool Use the recommended special service tools to work safely, and to protect parts from dam- age. Tightening torque When tightening nuts, bolts, and screws, fol- low the tightening instructions provided throughout the manual. If the tightening order is not specified, tighten the large sizes first, and then tighten the small sizes, starting from the center and moving outward. Non-reusable part Always use new gaskets, seals, O-rings, cot- ter pins, and so on, when installing or assem- bling parts. Disassembly and assembly • Use compressed air to remove dust and dirt during disassembly. • Apply engine oil to the contact surfaces of moving parts before assembly. • Install bearings so that the bearing identifi- cation mark is facing in the direction indi- cated in the installation procedure. In addition, make sure to lubricate the bear- ings liberally. • Apply a thin coat of water resistant grease to the lip and periphery of an oil seal before installation. • Check that moving parts operate normally after assembly.
  8. 8. 0-4 How to use this manual 0 1 2 3 4 5 6 7 8 9 10 A How to use this manual Manual format The format of this manual has been designed to make service procedures clear and easy to under- stand. Use the following information as a guide for effective and quality service. • Parts are shown and detailed in an exploded diagram and are listed in the component list (see a in the following figure for an example page). • The component list consists of part names and quantities, as well as bolt and screw dimensions (see b in the following figure). • Symbols are used to indicate important aspects of a procedure, such as the grade of lubricant and the lubrication points (see c in the following figure). • Tightening torque specifications are provided in the exploded diagrams (see d in the following fig- ure), and in the related detailed instructions. Some torque specifications are listed in stages as torque figures or angles in degrees. • Separate procedures and illustrations are used to explain the details of removal, checking, and installation where necessary (see e in the following figure for an example page). TIP: For troubleshooting procedures, see Chapter 4, “Troubleshooting.” Safety while working / How to use this manual
  9. 9. 0-5 GEN INFO General information Abbreviation The following abbreviations are used in this service manual. Abbreviation Description ABYC American Boat and Yacht Council API American Petroleum Institute ATDC After Top Dead Center ATF Automatic Transmission Fluid AWG American Wire Gauge BTDC Before Top Dead Center C/E Check Engine CARB California Air Resources Board CCA Cold Cranking Ampere DN Down side DOHC Double Over Head Camshaft ECM Electronic Control Module EPA Environmental Protection Agency ETV Electronic Throttle Valve ENG Engine EX Exhaust EXH Exhaust F Forward GPS Global Positioning System ID Identification IN Intake INT Intake ISO International Organization for Standardization LPS Lever Position Sensor MCA Marine Cranking Ampere N Neutral OCV Oil Control Valve PCV Pressure Control Valve PON Pump Octane Number PORT Port side PTT Power Trim and Tilt R Reverse RC Reserve Capacity R.C. Remote Control (Digital Electronic Control) SAE Society of Automotive Engineers SPS Shift Position Sensor STBD Starboard side TCI Transistor-Controlled Ignition
  10. 10. 0-6 How to use this manual 0 1 2 3 4 5 6 7 8 9 10 A TDC Top Dead Center TPS Throttle Position Sensor UP Up side VCT Variable Camshaft Timing W/F Water in Fuel Y-COP Yamaha Customer Outboard Protection YDIS Yamaha Diagnostic System Abbreviation Description
  11. 11. 0-7 GEN INFO General information Lubricant, sealant, and thread locking agent Symbol Symbols in an exploded diagram or illustration indicate the grade of lubricant and the lubrication points. Symbols in an exploded diagram or illustration indicate the type of sealant or thread locking agent and the application points. Symbol Name Application Yamaha 4-stroke motor oil Lubricant Gear oil Lubricant Water resistant grease (Yamaha grease A) Lubricant Molybdenum disulfide grease Lubricant Corrosion resistant grease (Yamaha grease D) Lubricant Low temperature resistant grease (Yamaha grease C) Lubricant WR-No.2 grease Lubricant Symbol Name Application Gasket Maker Sealant ThreeBond 1280B Sealant ThreeBond 1303 Thread locking agent ThreeBond 1303N Thread locking agent ThreeBond 1322 Thread locking agent ThreeBond 1377B Thread locking agent
  12. 12. 0-8 Lubricant, sealant, and thread locking agent 0 1 2 3 4 5 6 7 8 9 10 A ThreeBond 1386B Sealant ThreeBond 1530D Sealant LOCTITE 210 (red) Thread locking agent LOCTITE 242 (blue) Thread locking agent LOCTITE 271 (red) Thread locking agent LOCTITE 572 (white) Sealant Silicone sealant Sealant Symbol Name Application
  13. 13. 0-9 GEN INFO General information Special service tool For U.S.A. and Canada Special service tools numbered “YB-*****” are distributed by K & L. Special service tools with Yamaha part numbers (90890-*****) are distributed by the Parts Division. Engine lifting eye 90890-06820 Drilling plate 90890-06783 YDIS (CD-ROM, Ver. 1.33) 60V-WS853-06 YDIS USB adapter and cable 60V-WS850-00 Digital multimeter YU-34899-A Peak volt adapter YU-39991 Test harness (3 pins) YB-06869 Pressure/vacuum tester YB-35956-A Test harness (1 pin) YB-06888 Test harness (2 pins) YB-06887
  14. 14. 0-10 Special service tool 0 1 2 3 4 5 6 7 8 9 10 A Spark checker YM-34487 Test harness (2 pins) YB-06867 Test harness (3 pins) YB-06791 Fuel pressure gauge adapter YW-06842 Fuel pressure gauge YB-06766 Vacuum/pressure pump gauge set 90890-06756 Compression gauge YU-33223 Balance hanger 90890-06822 Universal magneto and rotor holder YU-01235 Primary sheave holder YS-01880-A
  15. 15. 0-11 GEN INFO General information Valve spring compressor YM-04019 Valve attachment YB-06320 Valve guide remover YB-06801 Valve guide reamer YM-01196 Valve lapper YM-A8998 Neway valve seat kit YB-91044 Oil filter wrench 90890-06830 Driver handle (large) YB-06071 Roller bearing installer/remover YB-06432 Needle bearing installer YB-06111
  16. 16. 0-12 Special service tool 0 1 2 3 4 5 6 7 8 9 10 A Piston ring compressor YM-08037 Driveshaft needle bearing installer and remover YB-06196 Shift rod socket 90890-06679 Bearing housing bearing/oil seal remover YB-06112 Ring nut wrench extension 90890-06513 Ring nut wrench 6 90890-06677 Universal puller YB-06117 Bearing housing puller YB-06207 Bearing cup installer YB-06167 Driveshaft bearing installer YB-06155
  17. 17. 0-13 GEN INFO General information Bearing inner race attachment 90890-06661 Forward gear needle bearing installer YB-06261 Driveshaft bearing installer YB-06246 Drive shaft ring nut wrench 90890-06674 Drive shaft holder YB-06520 Pinion nut holder 90890-06715 Driver rod L3 90890-06652 Needle bearing attachment 90890-06680 Bearing inner race attachment 90890-06640 Driveshaft bearing installer YB-06246
  18. 18. 0-14 Special service tool 0 1 2 3 4 5 6 7 8 9 10 A Pinion gear bushing installer YB-06029-2 Roller bearing installer/remover YB-06432-2 Bearing installer YB-06016 Backlash indicator 90890-06836 Dial indicator gauge YU-03097 Backlash adjustment plate YB-07003 Magnetic base stand YU-A8438 Pinion shimming gauge 90890-06675 Pinion shimming gauge rod 90890-06676 Slide hammer YB-06096
  19. 19. 0-15 GEN INFO General information Propeller shaft and bearing housing remover YB-06335 Needle bearing attachment 90890-06607 Gland nut wrench YB-06578 Prop shaft/bearing installer YB-42225 Forward gear bearing installer YB-06345 Drive handle (small) YB-06229 PTT pressure gauge YB-06580 Bearing splitter plates YU-35557 PTT cylinder wrench YB-06175-2B PTT piston vice tool YB-06572
  20. 20. 0-16 Special service tool 0 1 2 3 4 5 6 7 8 9 10 A Tilt rod wrench YB-06569
  21. 21. SPEC Specification 1 Model feature ..................................................................... 1-1 General feature ......................................................................... 1-1 Model designation ..................................................................... 1-2 Serial number ............................................................................ 1-2 Model data ......................................................................... 1-3 Dimension and weight ............................................................... 1-3 Performance .............................................................................. 1-3 Power unit ................................................................................. 1-4 Lower unit .................................................................................. 1-5 Bracket unit ............................................................................... 1-5 Fuel and oil requirement ............................................................ 1-6 Battery requirement ................................................................... 1-7 PTT fluid requirement ................................................................ 1-7 Electrical system technical data ...................................... 1-8 Ignition timing control system .................................................... 1-8 Fuel injection control system ................................................... 1-10 Engine speed control system .................................................. 1-11 VCT system ............................................................................. 1-12 Shift actuator ........................................................................... 1-13 PTT system ............................................................................. 1-13 Charging system ..................................................................... 1-14 Starting system ........................................................................ 1-14 Gauge/sensor .......................................................................... 1-15 Fuel system technical data ............................................ 1-17 Fuel system ............................................................................. 1-17 Power unit technical data ............................................... 1-18 Power unit ............................................................................... 1-18 Cylinder head assembly .......................................................... 1-19 Crankcase assembly ............................................................... 1-21 Lower unit technical data ............................................... 1-24 Lower unit assembly (regular rotation model) ......................... 1-24 Lower unit assembly (counter rotation model) ........................ 1-24 Bracket unit technical data ............................................ 1-25 PTT system ............................................................................. 1-25 Specified tightening torque ............................................ 1-26 Rigging information ................................................................. 1-26 Fuel system ............................................................................. 1-26 Power unit ............................................................................... 1-26
  22. 22. 0 1 2 4 5 6 7 8 9 10 A Lower unit (regular rotation model) ......................................... 1-27 Lower unit (counter rotation model) ......................................... 1-28 Bracket unit ............................................................................. 1-28 PTT unit ................................................................................... 1-29 General tightening torque .............................................. 1-30
  23. 23. 1-1 SPEC Specification Model feature General feature (L)F225CA, (L)F250CA, and (L)F300CA overall feature • Newly developed 60° V6, DOHC, 24-valve, 4-stroke 4169.0 cm3 (254.4 cu. in) engine • Low exhaust emissions conform to US EPA and CARB 3-STAR regulations, and permeation emis- sions from exterior fuel hoses conform to EPA regulations • All models can use Command Link Plus • Y-COP (optional) a Power unit • Plastic cylinder head covers • Shimless valve lifters • Large diameter intake valve heads • Cylinder heads with integrated exhaust cover • Crankcase and oil filter bracket with oil cooler • Crankshaft with integrated drive sprocket • Sleeveless cylinders • Compact VCT assemblies with narrow tim- ing belt • Blowby gas reburning system • Vapor gas treatment b Electrical • Electronic fuel injection control • Ignition timing control • VCT control • Knock control • Engine speed control • ETV control • Electronic shift control • Fail-safe control • New YDIS 1.33 version • Multi-engine system for alert mode and auto engine speed synchronization • Adjusting trolling speed function • High-output stator assembly • Isolator for house (accessory) battery • Water-cooled Rectifier Regulator c Bracket unit • Same type of bracket as F250 • Same type of PTT unit as F250 d Upper case • Lightweight bottom cowling • Vibration reduction mounting • Water-sealed outer wall e Lower unit • Dual water inlets • Drive shaft with a double taper roller bear- ing • Propeller shaft with 3 bearings (regular rotation model) • Propeller damper cooling system • Patented shift damper system a d b e c
  24. 24. 1-2 Model feature 0 1 2 3 4 5 6 7 8 9 10 A Model designation Serial number The outboard motor serial number is indi- cated on a label affixed to the port clamp bracket. a Model name b Approved model code c Transom height d Serial number e Model year code a Model description F: 4-stroke regular rotation LF: 4-stroke counter rotation b Model name 300: 225/250/300 c Transom height X: UL (25 in) U: SUL (30 in) d Functions Blank: PTT and electric starter e C: Command Link Control f Product generation A: A and later F 300 X C A ba c d e f YAMAHA MOTOR CO., LTD. MADE IN JAPAN PAYS D'ORIGINE JAPON a b c d e Model name Approved model code Starting serial No. F225CA 6CL 1000001– LF225CA 6CM 1000001– F250CA 6CG 1000001– LF250CA 6CH 1000001– F300CA 6CE 1000001– LF300CA 6CF 1000001–
  25. 25. 1-3 SPEC Specification Model data Dimension and weight Performance Item Unit Model F225CA LF225CA F250CA LF250CA Overall length mm (in) 958.0 (37.7) Overall width mm (in) 634.0 (25.0) Overall height X mm (in) 1890.0 (74.4) U mm (in) 2017.0 (79.4) — 2017.0 (79.4) Boat transom height X mm (in) 643 (25.3) U mm (in) 770.0 (30.3) — 770.0 (30.3) Weight (without propeller) X kg (lb) 260.0 (573) U kg (lb) 268.0 (591) — 268.0 (591) Item Unit Model F300CA LF300CA Overall length mm (in) 958.0 (37.7) Overall width mm (in) 634.0 (25.0) Overall height X mm (in) 1890.0 (74.4) U mm (in) 2017.0 (79.4) Boat transom height X mm (in) 643.0 (25.3) U mm (in) 770.0 (30.3) Weight (without propeller) X kg (lb) 260.0 (573) U kg (lb) 268.0 (591) Item Unit Model F225CA LF225CA F250CA LF250CA Maximum output At 5500 r/min kW (HP) 165.5 (225) 183.8 (250) Full throttle operating range r/min 5000–6000 Maximum fuel consumption At 5500 r/min L (US gal, Imp gal)/hr 81.0 (21.4, 17.8) 91.0 (24.0, 20.0) Engine idle speed r/min 650–750 Item Unit Model F300CA LF300CA Maximum output At 5500 r/min kW (HP) 220.6 (300) Full throttle operating range r/min 5000–6000
  26. 26. 1-4 Model data 0 1 2 3 4 5 6 7 8 9 10 A Power unit Maximum fuel consumption At 5500 r/min L (US gal, Imp gal)/hr 97.0 (25.6, 21.3) Engine idle speed r/min 650–750 Item Unit Model F225CA LF225CA F250CA LF250CA Type 4-stroke, DOHC Cylinder quantity V6 Total displacement cm3 (cu. in) 4169.0 (254.4) Bore stroke mm (in) 96.0 96.0 (3.78 3.78) Compression ratio 10.3:1 Control system Digital Electronic Control Starting system Electric Fuel system Fuel injection Ignition control system TCI Advance type Microcomputer Maximum generator output V, A 12.0, 70.0 Spark plug LFR6A-11 (NGK) Firing order 1–2–3–4–5–6 (normal operation) Cooling system Water Exhaust system Propeller boss Lubrication system Wet sump Item Unit Model F300CA LF300CA Type 4-stroke, DOHC Cylinder quantity V6 Total displacement cm³ (cu. in) 4169.0 (254.4) Bore stroke mm (in) 96.0 96.0 (3.78 3.78) Compression ratio 10.3:1 Control system Digital Electronic Control Starting system Electric Fuel system Fuel injection Ignition control system TCI Advance type Microcomputer Maximum generator output V, A 12.0, 70.0 Spark plug LFR6A-11 (NGK) Firing order 1–2–3–4–5–6 (normal operation) Cooling system Water Exhaust system Propeller boss Lubrication system Wet sump Item Unit Model F300CA LF300CA
  27. 27. 1-5 SPEC Specification Lower unit Bracket unit Item Unit Model F225CA LF225CA F250CA LF250CA Gear shift positions F–N–R Gear ratio 1.75 (21/12) Reduction gear type Spiral bevel gear Clutch type Dog clutch Propeller shaft type Spline Propeller direction (rear view) Clock- wise Counter clockwise Clock- wise Counter clockwise Propeller mark T TL T TL Item Unit Model F300CA LF300CA Gear shift positions F–N–R Gear ratio 1.75 (21/12) Reduction gear type Spiral bevel gear Clutch type Dog clutch Propeller shaft type Spline Propeller direction (rear view) Clockwise Counter clockwise Propeller mark T TL Item Unit Model F225CA LF225CA F250CA LF250CA Trim angle At 12º boat transom degree –3 to 16 Tilt-up angle degree 67 Steering angle degree 32 + 32 Trim and tilt system PTT Item Unit Model F300CA LF300CA Trim angle At 12º boat transom degree –3 to 16 Tilt-up angle degree 67 Steering angle degree 32 + 32 Trim and tilt system PTT
  28. 28. 1-6 Model data 0 1 2 3 4 5 6 7 8 9 10 A Fuel and oil requirement (*1) If the recommended engine oil grades are not available, use engine oil with an API classification of SH, SJ, or SL and an SAE classification of 15W-40, 20W-40, or 20W-50. (*2) Meeting both API and SAE requirements. (*1) If the recommended engine oil grades are not available, use engine oil with an API classification of SH, SJ, or SL and an SAE classification of 15W-40, 20W-40, or 20W-50. (*2) Meeting both API and SAE requirements. Item Unit Model F225CA LF225CA F250CA LF250CA Fuel type Regular unleaded gasoline Minimum fuel octane number PON 87 Engine oil YAMALUBE 4-M FC-W oil or 4-stroke motor oil with combination of the following SAE and API oil classifications Engine oil grade (*1) API SE, SF, SG, SH, SJ, SL SAE 5W-30, 10W-30, 10W-40 Total engine oil quantity (oil pan capacity) L (US qt, Imp qt) 7.1 (7.50, 6.25) Gear oil type Hypoid gear oil Gear oil grade (*2) API GL-5 SAE 90, 80W-90 Gear oil quantity L (US qt, Imp qt) 1.040 (1.10, 0.92) Item Unit Model F300CA LF300CA Fuel type Premium unleaded gasoline Minimum fuel octane number PON 89 Engine oil YAMALUBE 4-M FC-W oil or 4-stroke motor oil with combination of the following SAE and API oil classifications Engine oil grade (*1) API SE, SF, SG, SH, SJ, SL SAE 5W-30, 10W-30, 10W-40 Total engine oil quantity (oil pan capacity) L (US qt, Imp qt) 7.1 (7.50, 6.25) Gear oil type Hypoid gear oil Gear oil grade (*2) API GL-5 SAE 90, 80W-90 Gear oil quantity L (US qt, Imp qt) 1.040 (1.10, 0.92)
  29. 29. 1-7 SPEC Specification Battery requirement PTT fluid requirement Item Unit Model F225FET FL225FET F250DET FL250DET Minimum cold cranking amps CCA/SAE A 680.0 Minimum marine cranking amps MCA/ABYC A 770.0 Minimum reserve capacity RC/SAE minutes 160 Item Unit Model F300CA LF300CA Minimum cold cranking amps CCA/SAE A 680.0 Minimum marine cranking amps MCA/ABYC A 770.0 Minimum reserve capacity RC/SAE minutes 160 Item Unit Model F225CA LF225CA F250CA LF250CA Fluid type ATF DEXRON II Item Unit Model F300CA LF300CA Fluid type ATF DEXRON II
  30. 30. 1-8 Electrical system technical data 0 1 2 3 4 5 6 7 8 9 10 A Electrical system technical data Ignition timing control system (*1) The figures are for reference only. Item Unit Model F225CA LF225CA F250CA LF250CA Spark plug Gap mm (in) 1.0–1.1 (0.039–0.043) Cam position sensor Input voltage V 12.0 Ignition coil Input voltage V 12.0 Pulser coil Air gap mm (in) 0.4–1.1 (0.016–0.043) Output peak voltage At cranking (unloaded) V 7.6 At cranking (loaded) V 6.9 At 1500 r/min (loaded) V 23.9 At 3500 r/min (loaded) V 25.1 Resistance At 20 °C (68 °F) Ω 396.0–594.0 Air temperature sensor Input voltage V 4.75–5.25 Resistance (*1) At 20 °C (68 °F) kΩ 2.21–2.69 At 80 °C (176 °F) kΩ 0.32 Air pressure sensor Input voltage V 4.75–5.25 Output voltage (*1) At –20.0 kPa (–0.20 kgf/ cm2, –2.9 psi) V 3.21 At –46.7 kPa (–0.467 kgf/ cm2, –6.8 psi) V 2.16 Engine temperature sensor Input voltage V 4.75–5.25 Resistance (*1) At 5 °C (41 °F) kΩ 4.2–4.9 At 25 °C (77 °F) kΩ 1.9–2.1 At 100 °C (212 °F) kΩ 0.166–0.204 Thermoswitch Input voltage V 4.75–5.25 Temperature Switch ON °C (°F) 84–90 (183–194) Switch OFF °C (°F) 68–82 (154–180) Knock sensor Resistance At 20 °C (68 °F) kΩ 504.0–616.0 Model data / Electrical system technical data
  31. 31. 1-9 SPEC Specification (*1) The figures are for reference only. Item Unit Model F300CA LF300CA Spark plug Gap mm (in) 1.0–1.1 (0.039–0.043) Cam position sensor Input voltage V 12.0 Ignition coil Input voltage V 12.0 Pulser coil Air gap mm (in) 0.4–1.1 (0.016–0.043) Output peak voltage At cranking (unloaded) V 7.6 At cranking (loaded) V 6.9 At 1500 r/min (loaded) V 23.9 At 3500 r/min (loaded) V 25.1 Resistance At 20 °C (68 °F) Ω 396.0–594.0 Air temperature sensor Input voltage V 4.75–5.25 Resistance (*1) At 20 °C (68 °F) kΩ 2.21–2.69 At 80 °C (176 °F) kΩ 0.32 Air pressure sensor Input voltage V 4.75–5.25 Output voltage (*1) At –20.0 kPa (–0.20 kgf/ cm2, –2.9 psi) V 3.21 At –46.7 kPa (–0.467 kgf/ cm2, –6.8 psi) V 2.16 Engine temperature sensor Input voltage V 4.75–5.25 Resistance (*1) At 5 °C (41 °F) kΩ 4.2–4.9 At 25 °C (77 °F) kΩ 1.9–2.1 At 100 °C (212 °F) kΩ 0.166–0.204 Thermoswitch Input voltage V 4.75–5.25 Temperature Switch ON °C (°F) 84–90 (183–194) Switch OFF °C (°F) 68–82 (154–180) Knock sensor Resistance At 20 °C (68 °F) kΩ 504.0–616.0
  32. 32. 1-10 Electrical system technical data 0 1 2 3 4 5 6 7 8 9 10 A Fuel injection control system (*1) The figures are for reference only. Item Unit Model F225CA LF225CA F250CA LF250CA Fuel line Pressure (*1) Within 5 seconds after engine start switch turned to ON kPa (kgf/ cm2, psi) 330.0 (3.30, 47.9) At 700 r/min kPa (kgf/ cm2, psi) 280.0 (2.80, 40.6) Water detection switch Input voltage V 4.75–5.25 Float height (*1) mm (in) 53.0 (2.10) Fuel injector Input voltage V 12.0 Resistance (*1) At 20 °C (68 °F) Ω 11.5–12.5 Low-pressure fuel pump Input voltage V 12.0 Resistance (*1) At 20 °C (68 °F) Ω 0.5–4.0 High-pressure fuel pump Input voltage V 12.0 Resistance (*1) At 20 °C (68 °F) Ω 0.2–3.0 Vapor shut-off valve Input voltage V 12.0 Resistance At 20 °C (68 °F) Ω 30.0–34.0 Item Unit Model F300CA LF300CA Fuel line Pressure (*1) Within 5 seconds after engine start switch turned to ON kPa (kgf/ cm2, psi) 330.0 (3.30, 47.9) At 700 r/min kPa (kgf/ cm2, psi) 280.0 (2.80, 40.6) Water detection switch Input voltage V 4.75–5.25 Float height (*1) mm (in) 53.0 (2.10) Fuel injector Input voltage V 12.0 Resistance (*1) At 20 °C (68 °F) Ω 11.5–12.5
  33. 33. 1-11 SPEC Specification (*1) The figures are for reference only. Engine speed control system (*1) The figures are for reference only. Low-pressure fuel pump Input voltage V 12.0 Resistance (*1) At 20 °C (68 °F) Ω 0.5–4.0 High-pressure fuel pump Input voltage V 12.0 Resistance (*1) At 20 °C (68 °F) Ω 0.2–3.0 Vapor shut-off valve Input voltage V 12.0 Resistance At 20 °C (68 °F) Ω 30.0–34.0 Item Unit Model F225CA LF225CA F250CA LF250CA TPS Output voltage (*1) With throttle valve fully closed TPS1 V 0.37–0.63 TPS2 V 2.5–3.5 Throttle valve opening angle (*1) With throttle valve fully closed degree 4.5 Input voltage V 4.75–5.25 SPS Output voltage F V 0.2–1.5 N V 2.412–2.588 R V 3.5–4.8 Input voltage V 4.75–5.25 Oil pressure sensor Input voltage V 4.75–5.25 Output voltage (*1) At 392.0 kPa (3.92 kgf/cm2, 56.8 psi) V 2.5 At 784.0 kPa (7.84 kgf/cm2, 113.7 psi) V 4.5 Item Unit Model F300CA LF300CA
  34. 34. 1-12 Electrical system technical data 0 1 2 3 4 5 6 7 8 9 10 A (*1) The figures are for reference only. VCT system Item Unit Model F300CA LF300CA TPS Output voltage (*1) With throttle valve fully closed TPS1 V 0.37–0.63 TPS2 V 2.5–3.5 Throttle valve opening angle (*1) With throttle valve fully closed degree 4.5 Input voltage V 4.75–5.25 SPS Output voltage F V 0.2–1.5 N V 2.412–2.588 R V 3.5–4.8 Input voltage V 4.75–5.25 Oil pressure sensor Input voltage V 4.75–5.25 Output voltage (*1) At 392.0 kPa (3.92 kgf/cm2, 56.8 psi) V 2.5 At 784.0 kPa (7.84 kgf/cm2, 113.7 psi) V 4.5 Item Unit Model F225CA LF225CA F250CA LF250CA OCV Input voltage V 12.0 Resistance At 20 °C (68 °F) Ω 6.7–7.7 Item Unit Model F300CA LF300CA OCV Input voltage V 12.0 Resistance At 20 °C (68 °F) Ω 6.7–7.7
  35. 35. 1-13 SPEC Specification Shift actuator (*1) The figures are for reference only. (*1) The figures are for reference only. PTT system Item Unit Model F225CA LF225CA F250CA LF250CA Shift actuator Rod stroke (*1) F mm (in) 78.2 (3.08) N mm (in) 59.2 (2.33) R mm (in) 41.1 (1.62) Motor resistance (*1) At 20 °C (68 °F) Ω 1.7 Item Unit Model F300CA LF300CA Shift actuator Rod stroke (*1) F mm (in) 78.2 (3.08) N mm (in) 59.2 (2.33) R mm (in) 41.1 (1.62) Motor resistance (*1) At 20 °C (68 °F) Ω 1.7 Item Unit Model F225CA LF225CA F250CA LF250CA Trim sensor Free position resistance Ω 247.6–387.6 Setting resistance Ω 9.0–11.0 Item Unit Model F300CA LF300CA Trim sensor Free position resistance Ω 247.6–387.6 Setting resistance Ω 9.0–11.0
  36. 36. 1-14 Electrical system technical data 0 1 2 3 4 5 6 7 8 9 10 A Charging system (*1) The figures are for reference only. Starting system Item Unit Model F225CA LF225CA F250CA LF250CA Lighting coil Output peak voltage At cranking (unloaded) V 6.9 At 1500 r/min (unloaded) V 38.0 At 3500 r/min (unloaded) V 83.2 Resistance (*1) At 20 °C (68 °F) Ω 0.1056–0.1584 Fuse A 100 Rectifier Regulator Output peak voltage At 1500 r/min (loaded) V 13.0 At 3500 r/min (loaded) V 13.0 Item Unit Model F300CA LF300CA Lighting coil Output peak voltage At cranking (unloaded) V 6.9 At 1500 r/min (unloaded) V 38.0 At 3500 r/min (unloaded) V 83.2 Resistance (*1) At 20 °C (68 °F) Ω 0.1056–0.1584 Fuse A 100 Rectifier Regulator Output peak voltage At 1500 r/min (loaded) V 13.0 At 3500 r/min (loaded) V 13.0 Item Unit Model F225CA LF225CA F250CA LF250CA Y-COP Input voltage V 12.0 Starter motor Type Sliding gear Output kW 1.70 Cranking time limit second 30 Commutator Standard diameter mm (in) 29.0 (1.14) Wear limit mm (in) 28.0 (1.10) Standard undercut mm (in) 0.5–0.8 (0.02–0.03) Wear limit mm (in) 0.2 (0.01)
  37. 37. 1-15 SPEC Specification Gauge/sensor (*1) The figures are for reference only. Brush Standard length mm (in) 15.5 (0.61) Wear limit mm (in) 9.5 (0.37) Item Unit Model F300CA LF300CA Y-COP Input voltage 12.0 Starter motor Type Sliding gear Output kW 1.70 Cranking time limit second 30 Commutator Standard diameter mm (in) 29.0 (1.14) Wear limit mm (in) 28.0 (1.10) Standard undercut mm (in) 0.5–0.8 (0.02–0.03) Wear limit mm (in) 0.2 (0.01) Brush Standard length mm (in) 15.5 (0.61) Wear limit mm (in) 9.5 (0.37) Item Unit Model F225CA LF225CA F250CA LF250CA Water pressure sensor Input voltage V 4.75–5.25 Output voltage (*1) At 392.0 kPa (3.92 kgf/cm2, 56.8 psi) V 2.5 At 784.0 kPa (7.84 kgf/cm2, 113.7 psi) V 4.5 Speed sensor Input voltage V 4.75–5.25 Output voltage (*1) At 392.0 kPa (3.92 kgf/cm2, 56.8 psi) V 2.5 At 784.0 kPa (7.84 kgf/cm2, 113.7 psi) V 4.5 Item Unit Model F225CA LF225CA F250CA LF250CA
  38. 38. 1-16 Electrical system technical data 0 1 2 3 4 5 6 7 8 9 10 A (*1) The figures are for reference only. Item Unit Model F300CA LF300CA Water pressure sensor Input voltage V 4.75–5.25 Output voltage (*1) At 392.0 kPa (3.92 kgf/cm2, 56.8 psi) V 2.5 At 784.0 kPa (7.84 kgf/cm2, 113.7 psi) V 4.5 Speed sensor Input voltage V 4.75–5.25 Output voltage (*1) At 392.0 kPa (3.92 kgf/cm2, 56.8 psi) V 2.5 At 784.0 kPa (7.84 kgf/cm2, 113.7 psi) V 4.5
  39. 39. 1-17 SPEC Specification Fuel system technical data Fuel system Item Unit Model F225CA LF225CA F250CA LF250CA Fuel filter assembly Holding pressure Positive pressure kPa (kgf/ cm2, psi) 200.0 (2.00, 29.0) Negative pressure kPa (kgf/ cm2, psi) 80.0 (0.80, 11.6) Canister Holding pressure Positive pressure kPa (kgf/ cm2, psi) 19.6 (0.196, 2.8) Primer pump Holding pressure Positive pressure kPa (kgf/ cm2, psi) 170.0 (1.70, 24.7) Vapor separator tank Float height mm (in) 67.5 ± 2.5 (2.66 ± 0.10) Item Unit Model F300CA LF300CA Fuel filter assembly Holding pressure Positive pressure kPa (kgf/ cm2, psi) 200.0 (2.00, 29.0) Negative pressure kPa (kgf/ cm2, psi) 80.0 (0.80, 11.6) Canister Holding pressure Positive pressure kPa (kgf/ cm2, psi) 19.6 (0.196, 2.8) Primer pump Holding pressure Positive pressure kPa (kgf/ cm2, psi) 170.0 (1.70, 24.7) Vapor separator tank Float height mm (in) 67.5 ± 2.5 (2.66 ± 0.10)
  40. 40. 1-18 Power unit technical data 0 1 2 3 4 5 6 7 8 9 10 A Power unit technical data Power unit (*1) Measuring conditions: Ambient temperature 20 °C (68 °F), with spark plugs removed from all cylinders. The figures are for reference only. (*2) For the checking method, see “Checking the oil pressure” (7-1). The figures are for reference only. Item Unit Model F225CA LF225CA F250CA LF250CA Compression pressure Minimum (*1) kPa (kgf/ cm2, psi) 700.0 (7.00, 101.5) Engine oil Oil pressure (*2) At 60 °C (140 °F) with SL 10W-30 engine oil and at 750 r/min kPa (kgf/ cm2, psi) 350.0 (3.50, 50.8) At 68 °C (154 °F) with SL 10W-30 engine oil and at 3000 r/min kPa (kgf/ cm2, psi) 590.0 (5.90, 85.6) Timing belt Installation height mm (in) 2.5 (0.10) Thermostat Valve opening temperature °C (°F) 50.0–54.0 (122.0–129.0) Fully open temperature °C (°F) 62.0 (144.0) Fully open stroke mm (in) 4.3 (0.17) Replacement engine oil quan- tity (at periodic maintenance) Without oil filter replacement L (US qt, Imp qt) 6.0 (6.34, 5.28) With oil filter replacement L (US qt, Imp qt) 6.3 (6.66, 5.54) Item Unit Model F300CA LF300CA Compression pressure Minimum (*1) kPa (kgf/ cm2, psi) 700.0 (7.00, 101.5) Engine oil Oil pressure (*2) At 60 °C (140 °F) with SL 10W-30 engine oil and at 750 r/min kPa (kgf/ cm2, psi) 350.0 (3.50, 50.8) At 68 °C (154 °F) with SL 10W-30 engine oil and at 3000 r/min kPa (kgf/ cm2, psi) 590.0 (5.90, 85.6) Timing belt Installation height mm (in) 2.5 (0.10) Fuel system technical data / Power unit technical data
  41. 41. 1-19 SPEC Specification (*1) Measuring conditions: Ambient temperature 20 °C (68 °F), with spark plugs removed from all cylinders. The figures are for reference only. (*2) For the checking method, see “Checking the oil pressure” (7-1). The figures are for reference only. Cylinder head assembly Thermostat Valve opening temperature °C (°F) 50.0–54.0 (122.0–129.0) Fully open temperature °C (°F) 62.0 (144.0) Fully open stroke mm (in) 4.3 (0.17) Replacement engine oil quan- tity (at periodic maintenance) Without oil filter replacement L (US qt, Imp qt) 6.0 (6.34, 5.28) With oil filter replacement L (US qt, Imp qt) 6.3 (6.66, 5.54) Item Unit Model F225CA LF225CA F250CA LF250CA Valve lifter Outside diameter mm (in) 30.970–30.980 (1.2193–1.2197) Valve lifter clearance mm (in) 0.020–0.055 (0.0008–0.0022) Camshaft Cam lobe height Intake mm (in) 46.661–46.761 (1.8370–1.8410) Exhaust mm (in) 46.960–47.060 (1.8488–1.8528) Cam lobe width Intake and exhaust mm (in) 35.950–36.050 (1.4154–1.4193) Journal diameter mm (in) 24.960–24.980 (0.9827–0.9835) Runout mm (in) 0.030 (0.0012) Cylinder head Warpage limit mm (in) 0.10 (0.0039) Journal inside diameter mm (in) 25.000–25.021 (0.9843–0.9851) Valve spring Free length mm (in) 48.1 (1.89) Tilt limit mm (in) 1.7 (0.07) Valve Clearance Intake mm (in) 0.205 ± 0.035 (0.0081 ± 0.0014) Exhaust mm (in) 0.345 ± 0.035 (0.0136 ± 0.0014) Seat contact width Intake mm (in) 1.100–1.400 (0.0433–0.0551) Exhaust mm (in) 1.400–1.700 (0.0551–0.0669) Margin thickness Intake mm (in) 0.750–1.150 (0.0295–0.0453) Exhaust mm (in) 0.900–1.300 (0.0354–0.0512) Item Unit Model F300CA LF300CA
  42. 42. 1-20 Power unit technical data 0 1 2 3 4 5 6 7 8 9 10 A Valve stem Diameter Intake mm (in) 5.477–5.492 (0.2156–0.2162) Exhaust mm (in) 5.464–5.479 (0.2151–0.2157) Runout Intake and exhaust mm (in) 0.01 (0.0004) Valve guide Inside diameter Intake and exhaust mm (in) 5.504–5.522 (0.2167–0.2174) Valve guide clearance Intake mm (in) 0.012–0.045 (0.0005–0.0018) Exhaust mm (in) 0.025–0.058 (0.0010–0.0023) Installation height mm (in) 11.300–11.700 (0.4449–0.4606) Item Unit Model F300CA LF300CA Valve lifter Outside diameter mm (in) 30.970–30.980 (1.2193–1.2197) Valve lifter clearance mm (in) 0.020–0.055 (0.0008–0.0022) Camshaft Cam lobe height Intake mm (in) 46.661–46.761 (1.8370–1.8410) Exhaust mm (in) 46.960–47.060 (1.8488–1.8528) Cam lobe width Intake and exhaust mm (in) 35.950–36.050 (1.4154–1.4193) Journal diameter mm (in) 24.960–24.980 (0.9827–0.9835) Runout mm (in) 0.030 (0.0012) Cylinder head Warpage limit mm (in) 0.10 (0.0039) Journal inside diameter mm (in) 25.000–25.021 (0.9843–0.9851) Valve spring Free length mm (in) 48.1 (1.89) Tilt limit mm (in) 1.7 (0.07) Valve Clearance Intake mm (in) 0.205 ± 0.035 (0.0081 ± 0.0014) Exhaust mm (in) 0.345 ± 0.035 (0.0136 ± 0.0014) Seat contact width Intake mm (in) 1.100–1.400 (0.0433–0.0551) Exhaust mm (in) 1.400–1.700 (0.0551–0.0669) Margin thickness Intake mm (in) 0.750–1.150 (0.0295–0.0453) Exhaust mm (in) 0.900–1.300 (0.0354–0.0512) Item Unit Model F225CA LF225CA F250CA LF250CA
  43. 43. 1-21 SPEC Specification Crankcase assembly Valve stem Diameter Intake mm (in) 5.477–5.492 (0.2156–0.2162) Exhaust mm (in) 5.464–5.479 (0.2151–0.2157) Runout Intake and exhaust mm (in) 0.01 (0.0004) Valve guide Inside diameter Intake and exhaust mm (in) 5.504–5.522 (0.2167–0.2174) Valve guide clearance Intake mm (in) 0.012–0.045 (0.0005–0.0018) Exhaust mm (in) 0.025–0.058 (0.0010–0.0023) Installation height mm (in) 11.300–11.700 (0.4449–0.4606) Item Unit Model F225CA LF225CA F250CA LF250CA Piston Diameter mm (in) 95.945–95.960 (3.7774–3.7779) Measuring point mm (in) 13.500 (0.5315) Piston clearance mm (in) 0.040–0.067 (0.0016–0.0026) Ring groove (top) mm (in) 1.230–1.250 (0.0484–0.0492) Ring groove (2nd) mm (in) 1.220–1.240 (0.0480–0.0488) Ring groove (oil) mm (in) 2.510–2.530 (0.0988–0.0996) Pin boss inside diameter mm (in) 22.011–22.018 (0.8666–0.8668) Pin outside diameter mm (in) 21.996–22.005 (0.8660–0.8663) Cylinder Bore mm (in) 96.000–96.012 (3.7795–3.7800) Piston ring Top ring Type Barrel Dimension height (B) mm (in) 1.200 (0.0472) Dimension width (T) mm (in) 2.800–3.000 (0.1102–0.1181) End gap (*1) mm (in) 0.200–0.300 (0.0079–0.0118) Side clearance mm (in) 0.030–0.050 (0.0012–0.0020) 2nd ring Type Taper Dimension height (B) mm (in) 1.170–1.190 (0.0461–0.0469) Dimension width (T) mm (in) 3.800–4.000 (0.1496–0.1575) End gap (*1) mm (in) 0.600–0.750 (0.0236–0.0295) Side clearance mm (in) 0.030–0.070 (0.0012–0.0028) Oil ring Dimension height (B) mm (in) 2.400–2.470 (0.0945–0.0972) Dimension width (T) mm (in) 2.350–2.750 (0.0925–0.1083) End gap (*1) mm (in) 0.150–0.600 (0.0059–0.0236) Side clearance mm (in) 0.040–0.130 (0.0016–0.0051) Item Unit Model F300CA LF300CA
  44. 44. 1-22 Power unit technical data 0 1 2 3 4 5 6 7 8 9 10 A (*1) The figures are for reference only. Connecting rod Small end inside diameter mm (in) 22.010–22.024 (0.8665–0.8671) Big end inside diameter mm (in) 55.990–56.010 (2.2043–2.2051) Big end side clearance mm (in) 0.140–0.310 (0.0055–0.0122) Oil clearance (*1) mm (in) 0.025–0.050 (0.0010–0.0020) Crankshaft Journal diameter mm (in) 72.976–72.996 (2.8731–2.8739) Crankpin diameter mm (in) 52.980–53.000 (2.0858–2.0866) Runout mm (in) 0.030 (0.0012) Crankpin width mm (in) 21.000–21.100 (0.8268–0.8307) Crankcase Oil clearance (*1) mm (in) 0.029–0.045 (0.0011–0.0018) Item Unit Model F300CA LF300CA Piston Diameter mm (in) 95.945–95.960 (3.7774–3.7779) Measuring point mm (in) 13.500 (0.5315) Piston clearance mm (in) 0.040–0.067 (0.0016–0.0026) Ring groove (top) mm (in) 1.230–1.250 (0.0484–0.0492) Ring groove (2nd) mm (in) 1.220–1.240 (0.0480–0.0488) Ring groove (oil) mm (in) 2.510–2.530 (0.0988–0.0996) Pin boss inside diameter mm (in) 22.011–22.018 (0.8666–0.8668) Pin outside diameter mm (in) 21.996–22.005 (0.8660–0.8663) Cylinder Bore mm (in) 96.000–96.012 (3.7795–3.7800) Piston ring Top ring Type Barrel Dimension height (B) mm (in) 1.200 (0.0472) Dimension width (T) mm (in) 2.800–3.000 (0.1102–0.1181) End gap (*1) mm (in) 0.200–0.300 (0.0079–0.0118) Side clearance mm (in) 0.030–0.050 (0.0012–0.0020) 2nd ring Type Taper Dimension height (B) mm (in) 1.170–1.190 (0.0461–0.0469) Dimension width (T) mm (in) 3.800–4.000 (0.1496–0.1575) End gap (*1) mm (in) 0.600–0.750 (0.0236–0.0295) Side clearance mm (in) 0.030–0.070 (0.0012–0.0028) Oil ring Dimension height (B) mm (in) 2.400–2.470 (0.0945–0.0972) Dimension width (T) mm (in) 2.350–2.750 (0.0925–0.1083) End gap (*1) mm (in) 0.150–0.600 (0.0059–0.0236) Side clearance mm (in) 0.040–0.130 (0.0016–0.0051) Item Unit Model F225CA LF225CA F250CA LF250CA
  45. 45. 1-23 SPEC Specification (*1) The figures are for reference only. Connecting rod Small end inside diameter mm (in) 22.010–22.024 (0.8665–0.8671) Big end inside diameter mm (in) 55.990–56.010 (2.2043–2.2051) Big end side clearance mm (in) 0.140–0.310 (0.0055–0.0122) Oil clearance (*1) mm (in) 0.025–0.050 (0.0010–0.0020) Crankshaft Journal diameter mm (in) 72.976–72.996 (2.8731–2.8739) Crankpin diameter mm (in) 52.980–53.000 (2.0858–2.0866) Runout mm (in) 0.030 (0.0012) Crankpin width mm (in) 21.000–21.100 (0.8268–0.8307) Crankcase Oil clearance (*1) mm (in) 0.029–0.045 (0.0011–0.0018) Item Unit Model F300CA LF300CA
  46. 46. 1-24 Lower unit technical data 0 1 2 3 4 5 6 7 8 9 10 A Lower unit technical data Lower unit assembly (regular rotation model) (*1) Figures obtained using the special service tools. Lower unit assembly (counter rotation model) (*1) Figures obtained using the special service tools. Item Unit Model F225CA F250CA F300CA Lower unit Holding pressure kPa (kgf/ cm2, psi) 68.6 (0.686, 9.9) Forward gear backlash (*1) mm (in) 0.04–0.59 (0.0016–0.0232) Reverse gear backlash (*1) mm (in) 0.15–0.88 (0.0059–0.0346) Pinion shim (T3) mm 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50 Forward gear shim (T1) mm 2.00, 2.03, 2.06, 2.09, 2.12, 2.15 Reverse gear shim (T2) mm 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50 Propeller shaft shim (T4) mm 0.7, 0.8, 0.9, 1.0, 1.1, 1.2 Propeller shaft Motive torque N·m (kgf·m, ft·lb) 0.44–1.32 (0.04–0.13, 0.32–0.97) Runout mm (in) 0.02 (0.0008) Drive shaft Motive torque N·m (kgf·m, ft·lb) 0.27–1.94 (0.03–0.20, 0.20–1.43) Runout mm (in) 1.0 (0.0394) Item Unit Model LF225CA LF250CA LF300CA Lower unit Holding pressure kPa (kgf/ cm2, psi) 68.6 (0.686, 9.9) Forward gear backlash (*1) mm (in) 0.18–0.76 (0.0071–0.0299) Reverse gear backlash (*1) mm (in) 0.19–0.84 (0.0075–0.0331) Pinion shim (T3) mm 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50 Forward gear shim (T2) mm 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50 Reverse gear shim (T1) mm 2.00, 2.03, 2.06, 2.09, 2.12, 2.15 Propeller shaft shim (T4) mm 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50 Propeller shaft Free play mm (in) 0.25–0.35 (0.0098–0.0138) Runout mm (in) 0.02 (0.0008) Drive shaft Motive torque N·m (kgf·m, ft·lb) 0.27–1.94 (0.03–0.20, 0.20–1.43) Runout mm (in) 1.0 (0.0394) Power unit technical data / Lower unit technical data
  47. 47. 1-25 SPEC Specification Bracket unit technical data PTT system (*1) The figures are for reference only. (*1) The figures are for reference only. Item Unit Model F225CA LF225CA F250CA LF250CA PTT Hydraulic pressure Down MPa (kgf/ cm2, psi) 6.7–8.7 (67.0–87.0, 971.5–1261.5) Up MPa (kgf/ cm2, psi) 13.0–15.0 (130.0–150.0, 1885.0–2175.0) Motor commutator Standard diameter mm (in) 23.0 (0.91) Wear limit mm (in) 22.0 (0.87) Standard undercut (*1) mm (in) 1.4 (0.06) Wear limit mm (in) 0.9 (0.04) Motor brush Standard length mm (in) 11.5 (0.45) Wear limit mm (in) 4.5 (0.18) Item Unit Model F300CA LF300CA PTT Hydraulic pressure Down MPa (kgf/ cm2, psi) 6.7–8.7 (67.0–87.0, 971.5–1261.5) Up MPa (kgf/ cm2, psi) 13.0–15.0 (130.0–150.0, 1885.0–2175.0) Motor commutator Standard diameter mm (in) 23.0 (0.91) Wear limit mm (in) 22.0 (0.87) Standard undercut (*1) mm (in) 1.4 (0.06) Wear limit mm (in) 0.9 (0.04) Motor brush Standard length mm (in) 11.5 (0.45) Wear limit mm (in) 4.5 (0.18)
  48. 48. 1-26 Specified tightening torque 0 1 2 3 4 5 6 7 8 9 10 A Specified tightening torque Specified tightening torques are provided for specific nuts, bolts, and screws. When tightening these fasteners, follow the tightening torque specifications indicated throughout the manual to meet the design aims of the outboard motor. Rigging information Fuel system Power unit Part to be tightened Screw size Tightening torques N·m kgf·m ft·lb Water pressure sensor adapter — 23 2.3 17.0 Water pressure sensor — 18 1.8 13.3 Receiver screw M4 4 0.4 3.0 Part to be tightened Screw size Tightening torques N·m kgf·m ft·lb Fuel cup assembly — 5 0.5 3.7 Intake manifold bolt 1st M8 24 2.4 17.7 2nd 24 2.4 17.7 1st M6 11 1.1 8.1 2nd 11 1.1 8.1 Intake silencer bolt M6 7 0.7 5.2 Surge tank bracket bolt M6 11 1.1 8.1 Fuel pump cover bolt M6 5 0.5 3.7 Vapor separator drain screw — 2 0.2 1.5 Needle valve assembly screw M4 2 0.2 1.5 Float pin screw M4 2 0.2 1.5 Float chamber cover screw M5 2 0.2 1.5 Vapor separator cover bolt M4 2 0.2 1.5 Pressure regulator screw M5 4 0.4 3.0 Fuel cooler cover screw M5 4 0.4 3.0 Part to be tightened Screw size Tightening torques N·m kgf·m ft·lb Spark plug — 28 2.8 20.7 Power unit mounting bolts 1st M10 42 4.2 31.0 2nd 42 4.2 31.0 Apron screw M6 3 0.3 2.2 PTT motor lead bolt M6 4 0.4 3.0 Pulser coil bolt M5 4 0.4 3.0 Flywheel magnet bolt 1st M10 40 4.0 29.5 2nd 90° Starter motor lead screw M4 2 0.2 1.5 Fuse box screw ø5 2 0.2 1.5 Terminal bolt M8 25 2.5 18.4 PTT relay nut — 5 0.5 3.7 Starter motor nut — 9 0.9 6.6 Bracket unit technical data / Specified tightening torque
  49. 49. 1-27 SPEC Specification Lower unit (regular rotation model) Rectifier Regulator cover bolt 1st M6 6 0.6 4.4 2nd 12 1.2 8.9 Starter motor bracket bolt M8 25 2.5 18.4 M6 12 1.2 8.9 Starter motor bolt M8 30 3.0 22.1 Engine ECM bolt M6 7 0.7 5.2 Shift actuator bolt M6 19 1.9 14.0 Timing belt tensioner bolt — 39 3.9 28.8 Pulley bolt M10 39 3.9 28.8 Camshaft cap bolts 1st M7 8 0.8 5.9 2nd 17 1.7 12.5 Driven sprocket bolt M10 60 6.0 44.3 VCT bolt — 60 6.0 44.3 VCT cap — 32 3.2 23.6 Exhaust plug M18 56 5.6 41.3 Braided plug M14 23 2.3 17.0 OCV bolt M6 7 0.7 5.2 Cylinder head bolt 1st M11 39 3.9 28.8 2nd 180° 1st M8 14 1.4 10.3 2nd 28 2.8 20.7 Oil pump cover screw M6 4 0.4 3.0 Oil cooler bolt 1st M6 6 0.6 4.4 2nd 12 1.2 8.9 Bracket bolt M6 12 1.2 8.9 Oil filter union bolt UNF 49 4.9 36.1 Oil pressure sensor — 13 1.3 9.6 Oil filter — 18 1.8 13.3 Thermostat housing bolt M6 12 1.2 8.9 Thermostat cover bolt M6 12 1.2 8.9 Knock sensor — 32 3.2 23.6 Knock sensor bracket bolt M6 12 1.2 8.9 Pulley bracket bolt 1st M8 14 1.4 10.3 2nd 28 2.8 20.7 Connecting rod bolt 1st M9 40 4.0 29.5 2nd 90° Crankcase bolt 1st M10 55 5.5 40.6 2nd 90° 1st M8 14 1.4 10.3 2nd 28 2.8 20.7 Part to be tightened Screw size Tightening torques N·m kgf·m ft·lb Water inlet cover bolt M5 2 0.2 1.5 Drain screw — 9 0.9 6.6 Check screw — 9 0.9 6.6 Part to be tightened Screw size Tightening torques N·m kgf·m ft·lb
  50. 50. 1-28 Specified tightening torque 0 1 2 3 4 5 6 7 8 9 10 A Lower unit (counter rotation model) Bracket unit Trim tab bolt M10 42 4.2 31.0 Propeller nut — 54 5.4 39.8 Lower case mounting bolt (X-transom model) M10 47 4.7 34.7 Lower case stud bolt (U-transom model) — 23 2.3 17.0 Lower case mounting nut (U-transom model) — 47 4.7 34.7 Lower case mounting bolt (U-transom model) M10 47 4.7 34.7 Water inlet cover screw M5 1 0.1 0.7 Propeller shaft housing ring nut — 155 15.5 114.3 Cover bolt M8 8 0.8 5.9 Drive shaft nut — 40 4.0 29.5 Drive shaft ring nut — 177 17.7 130.5 Pinion nut — 143 14.3 105.5 Part to be tightened Screw size Tightening torques N·m kgf·m ft·lb Water inlet cover bolt M5 2 0.2 1.5 Drain screw — 9 0.9 6.6 Check screw — 9 0.9 6.6 Trim tab bolt M10 42 4.2 31.0 Propeller nut — 54 5.4 39.8 Lower case mounting bolt (X-transom model) M10 47 4.7 34.7 Lower case stud bolt (U-transom model) — 23 2.3 17.0 Lower case mounting nut (U-transom model) — 47 4.7 34.7 Lower case mounting bolt (U-transom model) M10 47 4.7 34.7 Water inlet cover screw M5 1 0.1 0.7 Propeller shaft housing ring nut — 155 15.5 114.3 Cover bolt M8 8 0.8 5.9 Drive shaft nut — 40 4.0 29.5 Drive shaft ring nut — 177 17.7 130.5 Pinion nut — 143 14.3 105.5 Part to be tightened Screw size Tightening torques N·m kgf·m ft·lb Speed sensor — 18 1.8 13.3 Adapter screw ø6 4 0.4 3.0 Upper mounting nut — 72 7.2 53.1 Lower mounting nut — 72 7.2 53.1 Upper mount bracket bolt M10 55 5.5 40.6 Lower mount bracket bolt M10 55 5.5 40.6 Upper case bolt M10 42 4.2 31.0 M8 20 2.0 14.8 Anode screw M6 4 0.4 3.0 Drain bolt — 27 2.7 19.9 Oil strainer bolt M6 12 1.2 8.9 Exhaust manifold bolt M8 20 2.0 14.8 Part to be tightened Screw size Tightening torques N·m kgf·m ft·lb
  51. 51. 1-29 SPEC Specification PTT unit Oil pan bolt M8 20 2.0 14.8 Muffler bolt M8 20 2.0 14.8 Plate screw M6 4 0.4 3.0 Self-locking nut — 23 2.3 17.0 Grease nipple — 3 0.3 2.2 Trim sensor screw M6 4 0.4 3.0 Part to be tightened Screw size Tightening torques N·m kgf·m ft·lb Reservoir mounting bolt M8 19 1.9 14.0 Reservoir cap — 7 0.7 5.2 PTT motor mounting bolt M8 19 1.9 14.0 Pump bracket bolt M5 7 0.7 5.2 Gear pump bolt M5 7 0.7 5.2 Manual valve — 2 0.2 1.5 Tilt ram — 65 6.5 47.9 Tilt piston screw M6 7 0.7 5.2 Pipe joint — 15 1.5 11.1 Pipe joint adapter — 20 2.0 14.8 Trim cylinder end screw — 160 16.0 118.0 Tilt cylinder end screw — 90 9.0 66.4 Part to be tightened Screw size Tightening torques N·m kgf·m ft·lb
  52. 52. 1-30 General tightening torque 0 1 2 3 4 5 6 7 8 9 10 A General tightening torque This chart indicates the tightening torques for standard fasteners with a standard ISO thread pitch. Width across flats (A) Screw size (B) General torque specifications N·m kgf·m ft·lb 8 mm 10 mm 12 mm 14 mm 17 mm M5 M6 M8 M10 M12 5 8 18 36 43 0.5 0.8 1.8 3.6 4.3 3.7 5.9 13.3 26.6 31.7 Specified tightening torque / General tightening torque
  53. 53. 1-31 SPEC Specification — MEMO —
  54. 54. TECH FEA 0 1 2 3 4 5 6 7 8 9 10 A Technical features and description 2 Electronic control system ................................................ 2-1 Engine ECM component ........................................................... 2-2 Sensor, switch, and actuator ..................................................... 2-3 Electronic fuel injection control .................................................. 2-5 Ignition timing control ................................................................ 2-8 VCT control ............................................................................. 2-10 Knock control ........................................................................... 2-11 Engine speed control ............................................................... 2-12 ETV control .............................................................................. 2-14 Electronic shift control system ................................................. 2-15 Fail-safe control ....................................................................... 2-16 Charging system ..................................................................... 2-18 Digital network control ............................................................. 2-19 Sensor, switch ......................................................................... 2-22 Y-COP ............................................................................... 2-23 Power unit system .......................................................... 2-24 Shimless valve lifter ................................................................. 2-25 Sleeveless cylinder .................................................................. 2-25 Oil cooler ................................................................................. 2-26 Fuel system ..................................................................... 2-27 Fuel diagram ........................................................................... 2-27 Lubrication system ......................................................... 2-29 Lubrication diagram ................................................................. 2-29 Cooling system ............................................................... 2-30 Cooling diagram ...................................................................... 2-30 Intake and exhaust system ............................................ 2-32 Intake and exhaust diagram .................................................... 2-32 Lower unit ........................................................................ 2-33 Double taper roller bearing ...................................................... 2-33 Propeller shaft bearing (regular rotation model) ...................... 2-33 Propeller .................................................................................. 2-34
  55. 55. 2-1 TECH FEA Technical features and description Electronic control system This model uses an electronic fuel injection control, ignition timing control, knock control, engine speed control, Digital Electronic Control, electronic shift control, ETV control, and fail-safe control. The engine ECM performs these controls based on data received from each sensor and switch. The engine ECM is equipped with a self-diagnosis function. This function can be used to check trou- ble codes on the YDIS. It is also equipped with Y-COP as an anti-theft measure (optional). LPS YDISY-COP TPS ETV OCV OCV SPS Check valve Air Pressure regulator Filter Check valve High-pressure fuel pump Vapor separator Fuel injector Ignition coil Canister Low-pressure fuel pump Water separator Fuel Water detection switch Vapor shut-off valve Air Shift actuator Ignition coil Fuel injector Shift control Valve control Fuel control Ignition control Command Link Plus Multifunction Color Gauge Battery Hub Engine shut-off switch Engine ECM Engine start switch Cam position sensor Pulser coil Air pressure sensor Oil pressure sensor Air temperature sensor Knock sensor Engine temperature sensor Thermoswitch Water pressure sensor (optional) Speed sensor (optional) Digital Electronic Control ECM (optional)
  56. 56. 2-2 Electronic control system 0 1 2 3 4 5 6 7 8 9 10 A Engine ECM component a ETV b Air pressure sensor c Air temperature sensor d Pulser coil e Engine temperature sensor f Vapor shut-off valve g Thermoswitch (PORT) h OCV (PORT) i Cam position sensor (PORT IN) j Fuel injector (PORT) k High-pressure fuel pump l Low-pressure fuel pump m TPS n SPS o Shift actuator p OCV (STBD) q Thermoswitch (STBD) r Cam position sensor (STBD IN) s Oil pressure sensor t Fuel injector (STBD) u Ignition coil (STBD) v Knock sensor w Engine ECM x Ignition coil (PORT) y Cam position sensor (PORT EX) a b c d e f g h i j k y x w v s p q r lmo n u t
  57. 57. 2-3 TECH FEA Technical features and description Sensor, switch, and actuator Engine ECM Determines the engine operating conditions according to the input signals from the sensors which are installed at various locations on the engine, and sends output signals to operate the actuators to perform the various control functions. Pulser coil Detects the engine speed. Detects the crankshaft angle and piston positions. Determines each group of cylinders (#1 and #4, #2 and #5, and #3 and #6). Cam position sen- sor (PORT EX) Determines the stroke. (For example, distinguishes the compression stroke TDC from the exhaust stroke TDC.) Determines each group of cylinders (#1 and #4, #2 and #5, and #3 and #6). Determines the stroke of each cylinder according to the signals from both the pulser coil and the cam position sensor (PORT EX). Cam position sen- sor (PORT IN) Detects the advance angle on the port camshaft. Cam position sen- sor (STBD IN) Detects the advance angle on the starboard camshaft. TPS 1 Detect the throttle valve opening. TPS 1 is the main sensor and TPS 2 is the sub sensor. TPS 1 and TPS 2 mutually monitor each other for malfunc- tions. TPS 2 SPS 1 Detect the shift position. SPS 1 is the main sensor and SPS 2 is the sub sensor. SPS 1 and SPS 2 mutually monitor each other for malfunctions.SPS 2 ETV Opens and closes the throttle valve using a motor. Shift actuator Drives the motor according to the engine ECM command for engaging or disengaging the gearshift. Air pressure sensor Detects the intake air pressure. Air temperature sensor Detects the intake air temperature. Engine tempera- ture sensor Detects the engine temperature. Oil pressure sensor Detects the oil pressure. Thermoswitch Detects engine overheating. Knock sensor Detects engine knocking. Engine shut-off switch Stops the engine forcibly. Fuel injector Injects fuel. Ignition coil Activates the ignition. Vapor shut-off valve Controls the amount of vapor gas to be sent from the vapor separator to the intake system. OCV Advances or retards the camshaft timing by switching the oil passages through which the engine oil is sent into the advance chamber or the retard chamber in the rotor vane housing. High-pressure fuel pump Pressurizes the fuel and sends the fuel to the fuel rails.
  58. 58. 2-4 Electronic control system 0 1 2 3 4 5 6 7 8 9 10 A Low-pressure fuel pump Sends the fuel from the fuel tank to the vapor separator.
  59. 59. 2-5 TECH FEA Technical features and description Electronic fuel injection control In electronic fuel injection control, the engine ECM determines the fuel injection timing and fuel injection amount according to the signals from the sensors and performs the appropriate fuel injec- tion. The fuel injection amount is controlled by the fuel injector actuation time. There are 2 types of fuel injection timing control: synchronous fuel injection and asynchronous fuel injection. According to the engine operating conditions during the control, the control mode switches automatically between the start-up mode, normal operating mode, and fuel injection cutoff mode. In addition, vari- ous compensations are made to determine the actual fuel injection timing and fuel injection amount. Also, a fuel injector anti-sticking control has been adopted. TPS SPS LPS Pulser coil Cam position sensor (PORT EX) Cam position sensor (PORT IN) Cam position sensor (STBD IN) Air pressure sensor Air temperature sensor Engine temperature sensor Thermoswitch Engine shut-off switch Battery Engine ECM Fuel injector Low-pressurefuel pump Vapor shut-off valve High-pressure fuel pump
  60. 60. 2-6 Electronic control system 0 1 2 3 4 5 6 7 8 9 10 A Synchronous fuel injection Synchronous fuel injection is fuel injection that occurs using a fixed timing, which is synchronized with the crankshaft angle set by the engine ECM according to the signals from the pulser coil. Example: Group fuel injection in the start-up mode Fuel injection type Fuel injection timing Fuel injection amount Condition Simultaneous fuel injection in the start-up mode All cylinders according to the fuel injection setting data According to the fuel injection setting data when the engine temperature is 78–80 °C (172–176 °F) or more and the fuel injection setting data when the engine temperature is less than 78–80 °C (172–176 °F) Until cylinder identification is completed by the pulser coil Group fuel injection in the start-up mode Each cylinder group (#1 and #4, #2 and #5, and #3 and #6) at BTDC 430° (BTDC 70° according to the exhaust TDC) Until engine starting is detected (500 r/min or more) Group fuel injection in the normal operating mode Each cylinder group (#1 and #4, #2 and #5, and #3 and #6) according to the exhaust and compression TDCs According to the fuel injection setting data for the fuel octane rating and the knock learning value, which are recorded in the engine ECM Until cylinder identification is completed by the cam position sensor (PORT EX) 2 times for every 2 turns of the crankshaft Sequential fuel injection in the normal operating mode Each cylinder according to the injection completion timing, which is set using the exhaust TDC After cylinder identification is completed by the cam position sensor (PORT EX) Compression Combustion Exhaust Intake Compression ExhaustIntake Compression Combustion Intake ExhaustCompression Combustion IntakeIntakeExhaust Compression CombustionIntakeExhaust Exhaust Compression CombustionIntakeExhaustCombustion CompressionIntakeExhaustCombustionCompression #1 Cam position sensor (EX) signal Injection #1 Injection #2 Injection #3 Injection #4 Injection #5 Injection #6 #2 #3 #4 #5 #6 Pulser coil signal
  61. 61. 2-7 TECH FEA Technical features and description Asynchronous fuel injection Asynchronous fuel injection is fuel injection that occurs using the timing determined necessary by the engine ECM according to the signals from the sensors, not synchronized with the crankshaft angle set by the engine ECM. At engine start-up or during acceleration, if the changes in the signals from the TPS or air pressure sensor exceed a predetermined level, fuel injection is performed simul- taneously for all of the cylinders. In the fuel injection cutoff mode, the fuel injection is cut off while the engine speed control is being performed. See “Engine speed control” (2-12). Fuel injection amount compensation The fuel injection control makes compensations to the fuel injection amount according to the engine operating conditions. The compensations are determined according to the signals from the following sensors. Fuel injector anti-sticking control After the engine start switch is turned to ON and before the high-pressure fuel pump starts operat- ing, the engine ECM sends a signal once to actuate all of the fuel injectors simultaneously to pre- vent the fuel injector valves from sticking. Compensation Corresponding sensor For changes in intake air pressure Air pressure sensor For changes in intake air temperature Air temperature sensor During warm-up Engine temperature sensor After start-up Engine temperature sensor For atmospheric pressure Air pressure sensor During dashpot function operation Air pressure sensor, LPS, SPS, and pulser coil For changes in air and fuel ratio Air pressure sensor, engine temperature sensor, and pulser coil During acceleration Air pressure sensor and TPS For retarded ignition timing Engine temperature sensor and pulser coil
  62. 62. 2-8 Electronic control system 0 1 2 3 4 5 6 7 8 9 10 A Ignition timing control In ignition timing control, the engine ECM uses signals from the sensors to assess engine operating conditions and determines the basic ignition timing and ignition coil energization time. The engine ECM also applies various restrictions and compensations to determine the actual ignition timing. The ignition timing is also controlled according to the knock control. See “Knock control” (2-11). TPS LPS SPS Pulser coil Cam position sensor (PORT EX) Cam position sensor (PORT IN) Cam position sensor (STBD IN) Air pressure sensor Engine temperature sensor Knock sensor Engine shut-off switch Battery Engine ECM Ignition coil
  63. 63. 2-9 TECH FEA Technical features and description Basic ignition timing The basic ignition timing is divided into 3 types: engine starting ignition timing, idling basic ignition timing, and normal basic ignition timing. Ignition timing restriction The advancing or retarding of the ignition timing is restricted according to the engine speed, engine temperature, and dashpot function. Ignition timing compensation The ignition timing control makes advance or retard compensations to the ignition timing according to the engine operating conditions. The compensations are determined according to the signals from the following sensors. Basic ignition timing Criteria Ignition cylinder Engine starting ignition timing (BTDC 10°) Engine is starting (less than 500 r/min) All cylinders simultaneously Idling basic ignition timing Engine speed is at engine idle speed Each cylinder sequentially Normal basic ignition timing Engine speed is more than engine idle speed Each cylinder sequentially Restriction Corresponding sensor Details Engine speed restriction Pulser coil The ignition timing is restricted between BTDC 50° (advance angle) and ATDC 20° (retard angle) according to the engine speed. Engine temperature restriction Engine temperature sensor The ignition timing is restricted between BTDC 50° (advance angle) and ATDC 30° (retard angle) according to the engine temperature. Dashpot function restriction (when the throttle valve is closed quickly) Pulser coil and LPS The ignition timing is restricted to ATDC 20° when the dashpot function operates. Compensation Corresponding sensor After start-up Engine temperature sensor For stable idle speed LPS and pulser coil During dashpot function operation LPS, SPS, and pulser coil For shift-cutout control Pulser coil and SPS During acceleration Air pressure sensor and TPS
  64. 64. 2-10 Electronic control system 0 1 2 3 4 5 6 7 8 9 10 A VCT control In VCT control, the engine ECM determines the appropriate intake valve opening timing according to the signals from the sensors. According to the engine operating conditions, the OCVs are oper- ated and the VCT assemblies are advanced, retarded, or maintained in the current position to con- trol the intake valve opening timing. TPS LPS Pulser coil Cam position sensor (PORT EX) Cam position sensor (PORT IN) Cam position sensor (STBD IN) Air pressure sensor Engine temperature sensor Engine ECM OCV (PORT) OCV (STBD)
  65. 65. 2-11 TECH FEA Technical features and description Knock control In knock control, the engine ECM receives the knock signal from the knock sensor which is installed on the cylinder block between the cylinder banks. The engine ECM retards the ignition timing and decreases the engine speed according to the amount of knocking to protect the engine from dam- age. If the knocking occurs frequently, the ignition timing is retarded until the knocking is no longer detected, and the retarded ignition timing is maintained, using the learning function. The knock control activates according to the following conditions: The knock control also activates when the engine temperature sensor is malfunctioning regardless of the preceding conditions. Engine temperature Less than 20 °C (68 °F) 20–25 °C (68–77 °F) More than 25 °C (77 °F) Engine speed Less than 4500 r/min Knock control does not activate Knock control activates if conditions continue for 0.5 seconds Knock control activates 4500 r/min or more Knock control activates
  66. 66. 2-12 Electronic control system 0 1 2 3 4 5 6 7 8 9 10 A Engine speed control In engine speed control, the engine ECM decreases the engine speed to protect the engine from damage. Overheat control Low oil pressure control Criteria Description The thermoswitch is on. The engine ECM controls the throttle valve opening. As a result, the engine speed cannot increase to more than 2000– 3000 r/min. Also, the alert buzzer sounds and the overheat alert indicator comes on. Criteria Description The pressure decreases to less than 250 kPa (2.5 kgf/cm2, 36.25 psi). The engine ECM controls the throttle valve opening. As a result, the engine speed cannot increase to more than 2000– 3000 r/min. Also, the alert buzzer sounds and the oil pressure alert indicator comes on. TPS LPS SPS Pulser coil Cam position sensor (PORT EX) Cam position sensor (PORT IN) Cam position sensor (STBD IN) Air pressure sensor Oil pressure sensor Engine temperature sensor Thermoswitch Engine shut-off switch Engine ECM Fuel injector Digital Electronic Control ECM Command Link Plus Multifunction Color Gauge Ignition coil ETV motor
  67. 67. 2-13 TECH FEA Technical features and description Skip-firing control Criteria Description ETV is locked in an open position. Controls the engine speed when it has been determined that the ETV is locked in an open position. Over 1501 r/min Firing and fuel injection will be skipped for all of the cylinders. 1399–1500 r/min Firing and fuel injection will be skipped for cylinders #1, #2, #3, #5, and #6. 1302–1398 r/min Firing and fuel injection will be skipped for cylinders #2, #3, #5, and #6. 1200–1301 r/min Firing and fuel injection will be skipped for cylinders #2, #3, and #5. 1103–1199 r/min Firing and fuel injection will be skipped for cylinders #2 and #5. 1001–1102 r/min Firing and fuel injection will be skipped for cylinder #2. Engine is over revving. Controls the engine speed when over revving is detected. Over 6450 r/min Firing and fuel injection will be skipped for all of the cylinders. 6399–6449 r/min Firing and fuel injection will be skipped for cylinders #1, #2, #3, #5, and #6. 6353–6398 r/min Firing and fuel injection will be skipped for cylinders #2, #3, #5, and #6. 6302–6352 r/min Firing and fuel injection will be skipped for cylinders #2, #3, and #5. 6251–6301 r/min Firing and fuel injection will be skipped for cylinders #2 and #5. 6200–6250 r/min Firing and fuel injection will be skipped for cylinder #2. Engine is rotating in reverse. Stops the engine if the engine reverse rotation is detected. Engine reverse rotation is determined using 2 parameters: presence or absence of the cam position sensor (PORT EX) signal, and the actual advance angle of the intake camshaft. If the reverse rotation is detected, the engine ECM cuts off the fuel injection and ignition to stop the engine. Engine speed is high when shifting gears. Detects the activation of shift cutout control, and controls the engine speed. Decreases the engine speed to less than 1500 r/min. Engine shut-off switch is on. Cancels the fuel injection control and ignition control at all of the cylinders.
  68. 68. 2-14 Electronic control system 0 1 2 3 4 5 6 7 8 9 10 A ETV control In ETV control, the engine ECM determines the appropriate throttle valve opening according to the signals from the sensors, and controls the throttle valve. The engine ECM is equipped with a learn- ing function that records all of the compensations made by the control to the throttle valve opening for the operating conditions up to that point. In addition, the engine idle speed is controlled using the ETV control. TPS LPS SPS Pulser coil Air pressure sensor Engine temperature sensor Thermoswitch Engine ECM ETV motor
  69. 69. 2-15 TECH FEA Technical features and description Electronic shift control system The electronic shift control system operates the shift actuator based on the Digital Electronic Control communication data transmitted by the Digital Electronic Control ECM. TPS SPS Pulser coil Cam position sensor (PORT EX) Cam position sensor (PORT IN) Cam position sensor (STBD IN) Digital Electronic Control ECM Engine ECM Fuel injector Ignition coil ETV motor Shift actuator
  70. 70. 2-16 Electronic control system 0 1 2 3 4 5 6 7 8 9 10 A Fail-safe control In fail-safe control, the engine ECM enters the fail-safe mode when an electrical component mal- functions. The fail-safe control system records the trouble codes according to the engine trouble conditions. Trouble code Item LAN gauge display Trouble conditions to be detected 13 Pulser coil C/E No signal 15 Engine temperature sensor C/E Open or short circuit in the engine temperature sensor circuit. Output voltage is less than 0.18 V or more than 4.90 V. 17 Knock sensor C/E Output voltage is less than 0.90 V or more than 4.00 V. 23 Air temperature sensor C/E Output voltage is less than 0.10 V or more than 4.60 V. 24 Cam position sensor (PORT EX) C/E Signal error (irregular) 29 Air pressure sensor C/E Output voltage is less than 0.20 V or more than 4.50 V. 39 Oil pressure sensor L (*1) Output voltage is less than 0.30 V, more than 4.80 V for 260 seconds, or more than 4.80 V when the engine is stopped. 71 Cam position sensor (PORT EX) C/E Signal error (irregular) 72 Cam position sensor (PORT IN) C/E Signal error (irregular) 73 OCV (STBD) C/E Open or short circuit in the OCV circuit 74 OCV (PORT) C/E Open or short circuit in the OCV circuit 86 Y-COP C/E Open or short circuit in the Y-COP circuit Communication error continues for more than 3 seconds. 112, 113, 114, 115, 116, 117, 118, 119, 121, 122, 123, 129, 136, 137, 138, 139, 141, 142, 144, 145 ETV C/E Open or short circuit in the ETV relay and ETV motor circuit 124, 125, 126, 127, 128 TPS C/E Output voltage is less than 0.35 V or more than 4.80 V, or the output voltage difference between TPS 1 and TPS 2 is 2.30 V or more.
  71. 71. 2-17 TECH FEA Technical features and description (*1) Low oil pressure alert is displayed. 146, 147, 148, 149, 150, 153, 154, 155 SPS C/E Open or short circuit in the SPS circuit, and shift actuator does not operate. 156, 157 Extension wiring harness C/E Communication error between the engine ECM and Digital Electronic Control 160, 161, 162, 163, 164, 165, 166, 167, 168, 169, 170, 171, 172, 173, 174, 175, 176, 177, 178, 179, 180, 181 LPS C/E Open or short circuit in the LPS circuit Trouble code Item LAN gauge display Trouble conditions to be detected
  72. 72. 2-18 Electronic control system 0 1 2 3 4 5 6 7 8 9 10 A Charging system This model features a high output charging system that provides up to 70 A. This charging system also functions as a battery isolator that will charge a house (accessory) bat- tery. The engine ECM senses the voltage of the main battery and house (accessory) battery based on the signals from the Rectifier Regulator. If the main battery voltage decreases below 13.5 V when the house (accessory) battery is con- nected, the regulator function of the Rectifier Regulator will be turned off by the engine ECM to increase the efficiency of charging the main battery. Lighting coil (stator assembly) Engine ECM Fuse box Rectifier Regulator Isolator lead (optional) Main battery House battery (optional)
  73. 73. 2-19 TECH FEA Technical features and description Digital network control This model features the newly developed Command Link Plus Digital Electronic Control that includes the Digital Electronic Control ECM. Mutual authentication is performed between the Digital Electronic Control ECM and the engine ECM. The Digital Electronic Control system operates only when the mutual authentication has suc- ceeded. The Digital Electronic Control ECM converts actions on the control lever related to the gear shift and the throttle opening or closing into the electrical signals and transmits the signals to the engine ECM. The engine ECM controls the operation of ETV and shift actuator based on the electrical sig- nals. The electric controlled shift-in or shift-out provides smooth, reliable, and quiet gear shift engage- ment. The Command Link Plus Multifunction Color Gauge and the new engine start switch can be installed (optional).
  74. 74. 2-20 Electronic control system 0 1 2 3 4 5 6 7 8 9 10 A SET MENU CANCEL SET MENU CANCEL Y-COP LPS LPS LPSLPS LPS LPS Command Link Plus Multifunction Color Gauge Command Link Plus Multifunction Color Gauge Hub Hub Engine start/ stop button Engine shut-off switch Station selector switch Control lever Control lever Digital Electronic Control ECM (PORT) Digital Electronic Control ECM (STBD) Digital Electronic Control ECM (center) Digital Electronic Control ECM (PORT) Digital Electronic Control ECM (STBD) Digital Electronic Control ECM (center) Control lever Control lever Station selector switch Engine start/stop button Main switch Engine ECM Engine ECM Engine ECM (optional)
  75. 75. 2-21 TECH FEA Technical features and description Digital Electronic Control component A Single type (6X6) B Twin type (6X6) C Triple type (6X6) D Single type (6X7) a Control lever b PTT switch c LPS d Free throttle switch e Digital Electronic Control ECM f Active indicator g Alert indicator h Engine selector switch i Engine start switch j Main switch k Command Link Plus Multifunction Color Gauge l Engine start/stop button (single type) m Engine start/stop button (twin type) n Engine start/stop button (triple type) o Engine start/stop button (all type) p Station selector switch a c d e f g a ab c d f g B e h b d f g C e D b c d e f g a bA i j k l m pon c
  76. 76. 2-22 Electronic control system 0 1 2 3 4 5 6 7 8 9 10 A Sensor, switch Digital Electronic Control ECM Converts actions on the control lever related to the gearshift and the throttle opening or closing into electrical signals and transmits the signals to the engine ECM. Receives digital signals transmitted from the engine ECM. Performs mutual authentication with the engine ECM to perform various controls. LPS Detects the control lever position. LPS 1 is the main sensor and LPS 2 is the sub sensor. LPS 1 and LPS 2 mutually monitor each other for malfunctions. Free throttle switch Enables engine speed to be increased while in neutral using the control lever. Active indicator Displays operational conditions of the Digital Electronic Control. Active indicator Comes on when communication error occurs between the 6Y9 Digital Electronic Control and the engine ECM. Engine selector switch Selects the outboard motor to be operated. Engine start/stop button Starts and stops the engine while the system is activated. Engine start switch Activates and deactivates the system. Starts and stops the engine. Main switch Activates (with the engine start switch ON) and deactivates the system. PTT switch Operates the PTT unit to adjust the trim/tilt angle of the outboard motor. Station selector switch Switches between the main station and substation. Command Link Plus Multifunction Color Gauge Displays engine status and boat status on a single display.
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