Marlin 100 EFI SERVICE MANUAL

Transcription

1 Marlin 00 EFI SERVICE MNUL

2 NOTICE This manual has been prepared by Selva primarily for use by Selva dealers and their trained mechanics when performing maintenance procedures and repairs to Selva equipment. It has been written to suit the needs of persons who have a basic understanding of the mechanical and electrical concepts and procedures inherent in the work, for without such knowledge attempted repairs or service to the equipment could render it unsafe or unfit for use. Because Selva 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. uthorized Selva dealers are notified periodically of modifications and significant changes in specifications and procedures, and these are incorporated in successive editions of this manual. Important information Particularly important information is distinguished in this manual by the following notations: The Safety lert Symbol means TTENTION! BECOME LERT! YOUR SFETY IS INVOLVED! WRNING Failure to follow WRNING instructions could result in severe injury or death to the machine operator, a bystander, or a person inspecting or repairing the outboard motor. CUTION: CUTION indicates special precautions that must be taken to avoid damage to the outboard motor. NOTE provides key information to make procedures easier or clearer.

3 Contents General information GEN INFO Specifications SPEC Periodic checks and adjustments CHK DJ Fuel system FUEL Power unit POWR Lower unit LOWR Bracket unit BRKT + Electrical systems ELEC Troubleshooting TRBL SHTG Index

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5 GEN INFO General information How to use this manual...- Manual format...- Symbols...- Safety while working...- Fire prevention...- Ventilation...- Self-protection...- Parts, lubricants, and sealants...- Good working practices...- Disassembly and assembly...- Identification...- pplicable model...- Serial number...- Propeller selection...- Propeller size...- Selection...- Predelivery checks...- Checking the fuel system...- Checking the engine oil level...- Checking the gear oil level...- Checking the battery...- Checking the outboard motor mounting height...- Checking the remote control cables...- Checking the steering system...- Checking the gear shift and throttle operation...- Checking the power trim and tilt system...- Checking the engine start switch and engine stop lanyard switch...- Checking the cooling water pilot hole...- Test run...- Break-in...- fter test run...- DG

6 GEN 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 understand. Use the information below as a guide for effective and quality service. Parts are shown and detailed in an exploded diagram and are listed in the components list. Tightening torque specifications are provided in the exploded diagrams and after a numbered step with tightening instructions. Symbols are used to indicate important aspects of a procedure, such as the grade of lubricant and lubrication point. The components list consists of part names and part quantities, as well as bolt and screw dimensions. Service points regarding removal, checking, and installation are shown in individual illustrations to explain the relevant procedure. For troubleshooting procedures, see Chapter, Troubleshooting. LOWR Lower unit Lower unit LOWR Lower unit Removing the drive shaft. Remove the drive shaft assembly and pinion, and then pull out the forward gear. SY0K SY0K CUTION: Do not reuse the bearing, always replace it with a new one. No. Part name Q ty Remarks Lower unit Plastic tie Not reusable Hose Check screw Gasket Not reusable Dowel pin Bolt M0 0 mm Drain screw Grommet 0 Bolt M0 mm Bolt M 0 mm Thrust washer Propeller Washer Washer Cotter pin Not reusable Propeller nut Trim tab - Y Drive shaft holder : 00-0 Pinion nut holder : Socket adapter : Disassembling the drive shaft. Install the pinion nut, tighten it finger tight, and then remove the drive shaft bearing using a press. CUTION: Do not press the drive shaft threads a directly. Do not reuse the bearing, always replace it with a new one. Bearing inner race attachment : 00-0 Bearing separator : Remove the needle bearing from the forward gear. CUTION: Do not reuse the bearing, always replace it with a new one. Stopper guide plate : Stopper guide stand : 00-0 Bearing puller : 00-0 Bearing puller claw : 00-0 Disassembling the forward gear. Remove the taper roller bearing from the forward gear using a press. - Y - DG

7 How to use this manual Symbols The symbols below are designed to indicate the content of a chapter. General information GEN INFO Fuel system FUEL Bracket unit BRKT Specifications Power unit Electrical systems SPEC POWR ELEC + Periodic checks and adjustments Lower unit Troubleshooting CHK DJ LOWR TRBL SHTG Symbols to indicate specific data. Special tool Specified oil or fluid Specified engine speed Specified tightening torque Specified measurement Specified electrical value (resistance, voltage, electric current) Symbols to C in an exploded diagram indicate the grade of lubricant and the lubrication point. 0 B C E G pply Selva -stroke motor oil pply gear oil pply water resistant grease (Selva grease ) 0 pply molybdenum disulfide grease M D C I pply corrosion resistant grease (Selva grease D) B pply low temperature resistant grease (Selva grease C) C pply injector grease Symbols D to H in an exploded diagram indicate the type of sealant or locking agent and the application point. D E F G H GM LT LT LT SS D pply Gasket Maker E pply LOCTITE (red) F pply LOCTITE (blue) G pply LOCTITE H pply silicon sealant DG -

8 GEN INFO General information Safety while working To prevent an accident or injury and to ensure quality service, follow the safety procedures provided below. Fire prevention Gasoline is highly flammable. Keep gasoline and all flammable products away from heat, sparks, and open flames. Parts, lubricants, and sealants Use only genuine Selva parts, lubricants, and sealants or those recommended by Selva, when servicing or repairing the outboard motor. Ventilation Gasoline vapor and exhaust gas are heavier than air and extremely poisonous. If inhaled in large quantities they may cause loss of consciousness and death within a short time. When test running an engine indoors (e.g., in a water tank) be sure to do so where adequate ventilation can be maintained. Under normal conditions, the lubricants mentioned in this manual should not harm or be hazardous to your skin. However, you should follow these precautions to minimize any risk when working with lubricants.. Maintain good standards of personal and industrial hygiene.. Change and wash clothing as soon as possible if soiled with lubricants. Self-protection Protect your eyes by wearing safety glasses or safety goggles during all operations involving drilling and grinding, or when using an air compressor. Protect your hands and feet by wearing protective gloves and safety shoes when necessary.. void contact with skin. Do not, for example, place a soiled rag in your pocket.. Wash hands and any other part of the body thoroughly with soap and hot water after contact with a lubricant or lubricant soiled clothing has been made.. To protect your skin, apply a protective cream to your hands before working on the outboard motor. - DG

9 . Keep a supply of clean, lint-free cloths for wiping up spills, etc. Good working practices Special service tools Use the recommended special service tools to protect parts from damage. Use the right tool in the right manner do not improvise. Tightening torques Follow the tightening torque specifications provided throughout the manual. When tightening nuts, bolts, and screws, tighten the large sizes first, and tighten fasteners starting in the center and moving outward. Non-reusable parts lways use new gaskets, seals, O-rings, cotter pins, circlips, etc., when installing or assembling parts. Safety while working Disassembly and assembly. Use compressed air to remove dust and dirt during disassembly.. pply engine oil to the contact surfaces of moving parts before assembly.. Install bearings with the manufacture identification mark in the direction indicated in the installation procedure. In addition, be sure to lubricate the bearings liberally.. pply 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. DG -

10 GEN INFO General information Identification pplicable model This manual covers the following model. pplicable model F0BET, F00DET Serial number The outboard motor serial number is stamped on a label attached to the port clamp bracket. Propeller selection The performance of a boat and outboard motor will be critically affected by the size and type of propeller you choose. Propellers greatly affect boat speed, acceleration, engine life, fuel economy, and even boating and steering capabilities. n incorrect choice could adversely affect performance and could also seriously damage the engine. Use the following information as a guide for selecting a propeller that meets the operating conditions of the boat and the outboard motor. Propeller size The size of the propeller is indicated on the propeller boss end, on the side of the propeller boss. SD00 a - b c SJ00 Model name pproved model code Transom height Serial number a - b c Model name pproved model code Starting serial No. F0BET D F00DET D a Propeller diameter (in inches) b Propeller pitch (in inches) c Propeller type (propeller mark) S0C0 - DG

11 Identification / Propeller selection / Predelivery checks Selection When the engine speed is at the full throttle operating range (,000,000 r/min), the ideal propeller for the boat is one that provides maximum performance in relation to boat speed and fuel consumption. Propeller size (in) Material / - K - K - K - K / - K / - K luminum / - K - K SD00 - K - K - K - K Stainless CUTION: This is a -stroke engine. Never use premixed fuel. - K / - K / - K Checking the engine oil level. Check the engine oil level. Predelivery checks To make the delivery process smooth and efficient, the predelivery checks should be completed as explained below. Checking the fuel system. Check that the fuel hoses are securely connected and that the fuel tank is full with fuel. a b S0C0 If the engine oil is below the minimum level mark b, add sufficient oil until the level is between a and b. Recommended engine oil: -stroke motor oil PI: SE, SF, SG, SH, or SJ SE: 0W-0 or 0W-0 Engine oil quantity: Without oil filter replacement:. L (. US qt,. Imp qt) DG -

12 GEN INFO General information Checking the gear oil level. Check the gear oil level. The optimum mounting height is affected by the combination of the boat and the outboard motor. To determine the optimum mounting height, test run the outboard motor at different heights.. Check that the clamp brackets are secured with the clamp bolts. Checking the battery. Check the capacity, electrolyte level, and specified gravity of the battery. Recommended battery capacity: CC/EN: 0 0HR/IEC: 0 h Electrolyte specified gravity:.0 at 0 C ( F) S0C0 Checking the remote control cables. Set the remote control lever to the neutral position and fully close the throttle lever.. Check that the stopper on the throttle cam contacts the fully closed stopper on the cylinder block.. Check that the positive and negative battery leads are securely connected. Checking the outboard motor mounting height. 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. lso, the engine speed will increase abnormally and cause the engine to overheat. If the mounting height is too low, water resistance will increase and reduce engine efficiency. SD00. Check that the alignment mark a on the bushing is aligned with the alignment mark b on the bracket. a b SD00 - DG

13 Predelivery checks F N R a WRNING c SJ0 The shift/throttle cable joint must be screwed in a minimum of.0 mm (0. in) c. Checking the steering system. Check the steering friction for proper adjustment.. Check that the steering operates smoothly. S0C00. Check that there is no interference with wires or hoses when the outboard motor is steered. Checking the gear shift and throttle operation. Check that the gear shift operates smoothly when the remote control lever is shifted from neutral to forward or reverse.. Check that the throttle operates smoothly when the remote control lever is shifted from forward or reverse to the fully open position a. a SJ0 Checking the power trim and tilt system. Check that the outboard motor tilts up and down smoothly when operating the power trim and tilt unit.. Check that there is no abnormal noise produced when the outboard motor is tilted up or down.. Check that there is no interference with wires or hoses when the tilted-up outboard motor is steered.. Check that the trim meter points down when the outboard motor is tilted all the way down. Checking the engine start switch and engine stop lanyard switch. Check that the engine starts when the engine start switch is turned to STRT.. Check that the engine turns off when the engine start switch is turned to OFF. S0V00 DG -

14 GEN INFO General information. Check that the engine turns off when the engine stop lanyard is pulled from the engine stop lanyard switch. Break-in During the test run, perform the break-in operation in the following three stages.. One hour a at,000 r/min or at approximately half throttle. One hour b at,000 r/min or / throttle and minute out of every 0 at full throttle. Eight hours c at any speed, however, avoid running at full speed for more than minutes Checking the cooling water pilot hole. Check that cooling water is discharged from the cooling water pilot hole. a b c È 0 0 È Hour SJ0 fter test run. Check for water in the gear oil. Test run. Start the engine, and then check that the gear shift operates smoothly.. Check the engine idle speed after the engine has been warmed up.. Check for fuel leakage in the cowling.. Flush the cooling water passage with fresh water using the flushing kit and with the engine running at idle.. Operate at trolling speed.. Run the outboard motor for hour at,000 r/min or at half throttle, then for another hour at,000 r/min or at / throttle.. Check that the outboard motor does not tilt up when shifting into reverse and that water does not flow in over the transom. The test run is part of the break-in operation. - DG

15 SPEC Specifications General specifications...- Maintenance specification...- Power unit...- Lower unit...- Electrical...- Dimensions...- Tightening torques...- Specified torques...- General torques...- DG

16 SPEC Specifications General specifications Item Unit Model Marlin 00 EFI Dimension Overall length mm (in) (.) Overall width mm (in) (.) Overall height (L) mm (in), (.) (X) mm (in),0 (.) Boat transom height (L) mm (in) 0 (0.0) (X) mm (in) (.0) Weight (with aluminum propeller) (L) kg (lb) 0 () (X) kg (lb) () (with stainless propeller) (L) kg (lb) () (X) kg (lb) () Performance Maximum output kw (hp). (0) at,00 r/min. (00) at,00 r/min Full throttle operating range r/min,000,000 Maximum fuel consumption L (US gal, Imp gal)/hr.0 (.0,.) at,000 r/min.0 (.,.) at,000 r/min Engine idle speed r/min 0 0 Power unit Type In-line, -stroke, DOHC, valves Cylinder quantity Total displacement cm (cu. in), (.) Bore stroke mm (in).0. (..0) Compression ratio. Control system Remote control Starting system Electric Fuel system Fuel injection Ignition control system TCI dvance type Micro computer Maximum generator output V,, Spark plug LFR- (NGK) Cooling system Water Exhaust system Propeller boss Lubrication system Wet sump - DG

17 General specifications Item Unit Model Marlin 00 EFI Fuel and oil Fuel type Regular unleaded gasoline Fuel minimum rating RON (*) PON Engine oil -stroke motor oil Engine oil grade PI SE SE, SF, SG, SH, or SJ 0W-0 or 0W-0 Engine oil quantity (without oil filter replacement) L (US qt,. (.,.) Imp qt) (with oil filter replacement) L (US qt,. (.,.) Imp qt) Gear oil type Hypoid gear oil Gear oil grade (*) PI GL- SE 0 Gear oil quantity cm (US oz, 0 (.,.) Imp oz) Bracket unit Trim angle Degree to (at boat transom) Tilt-up angle Degree 0 Steering angle Degree + Drive unit Gear shift positions F-N-R Gear ratio. (0/) Reduction gear type Spiral bevel gear Clutch type Dog clutch Propeller shaft type Spline Propeller direction (rear view) Clockwise Propeller mark K Electrical Battery minimum capacity (*) CC/EN 0 0HR/IEC h 0 (*) RON: Research Octane Number PON: Pump Octane Number = (RON + Motor Octane Number)/ (*) Meeting both PI and SE requirements (*) CC: Cold Cranking mpere EN: European Norm (European standard) IEC: International Electrotechnical Commission DG -

18 SPEC Specifications Maintenance specification Power unit Item Unit Model Marlin 00 EFI Power unit Minimum compression kpa 0 (.,.) pressure (*) (kgf/cm, psi) Oil pressure (*) kpa 0 (.,.0) at engine idle speed (kgf/cm, psi) Cylinder head Warpage limit mm (in) 0. (0.00) (lines indicate straightedge position) Camshaft cap inside diameter mm (in) (0. 0.) Cylinders Bore size mm (in) (.0.0) Taper limit mm (in) 0.0 (0.00) Out-of-round limit mm (in) 0.0 (0.000) Pistons Piston diameter (D) mm (in).. (.0.0) Measuring point (H) mm (in).0 (0.) Piston clearance mm (in) ( ) Over size piston diameter mm (in).. (..) Piston rings Top ring Dimension B mm (in).. ( ) Dimension T mm (in).0.00 (0.0 0.) End gap mm (in) ( ) Side clearance mm (in) ( ) nd piston ring Dimension B mm (in).. ( ) Dimension T mm (in).00.0 (0. 0.0) End gap mm (in) ( ) Side clearance mm (in) ( ) (*) Measuring conditions: mbient temperature 0 C ( F), wide open throttle, with spark plugs removed from all cylinders. The figures are for reference only. (*) The figures are for reference only. - DG

19 Maintenance specification Item Unit Model Marlin 00 EFI Oil ring Dimension B mm (in).. ( ) Dimension T (*) mm (in).0 (0.0) End gap mm (in) ( ) Side clearance mm (in) ( ) Camshafts Intake () mm (in).. (..0) Exhaust () mm (in).0.0 (..) Intake (B) mm (in). 0.0 (..) Exhaust (B) mm (in). 0.0 (.0.) Camshaft journal diameter mm (in).0.0 (0. 0.) Camshaft runout limit mm (in) 0.0 (0.00) Valves Valve clearance (cold) Intake mm (in) 0.0 ± 0.0 (0.00 ± 0.00) Exhaust mm (in) 0. ± 0.0 (0.0 ± 0.00) Head diameter () Intake mm (in).0. (..) Exhaust mm (in).0. (0. 0.) Face width (B) Intake mm (in).. ( ) Exhaust mm (in).. ( ) Seat contact width (C) Intake mm (in).0.0 ( ) Exhaust mm (in).0.0 ( ) Margin thickness (D) Intake mm (in) ( ) Exhaust mm (in).00.0 ( ) Stem diameter Intake mm (in)..0 (0. 0.) Exhaust mm (in).0. (0. 0.) Guide inside diameter Intake and exhaust mm (in) (0. 0.) Stem-to-guide clearance Intake mm (in) ( ) Exhaust mm (in) ( ) Stem runout limit mm (in) 0.0 (0.000) Valve springs Free length mm (in).0 (.0) Tilt limit mm (in). (0.0) (*) The figure is for reference only. DG -

20 SPEC Specifications Item Unit Model Marlin 00 EFI Valve lifters Valve lifter outside diameter mm (in)..0 (.00.0) Valve lifter-to-cylinder head mm (in) ( ) clearance Valve shims Valve shim thickness mm (in).0. (0.0 0.) (in 0.0 mm increments) Connecting rods Big end inside diameter mm (in).0.0 (..) Big end side clearance mm (in) ( ) Crankpin oil clearance mm (in) ( ) Big-end bearing thickness Yellow mm (in)..0 ( ) Green mm (in).0. ( ) Blue mm (in)..0 ( ) Red mm (in).0. ( ) Crankshaft Crankshaft journal diameter mm (in)..000 (..) Crankpin diameter mm (in)..000 (..) Crankpin width mm (in).00.0 (0. 0.) Runout limit mm (in) 0.0 (0.00) Crankcase Crankshaft journal oil mm (in) ( ) clearance Upper crankcase main bearing thickness Green mm (in).. (0. 0.) Blue mm (in)..00 (0. 0.) Red mm (in).00.0 (0. 0.) Upper crankcase main bearing # thickness Green mm (in).. (0. 0.) Blue mm (in)..00 (0. 0.) Red mm (in).00.0 (0. 0.) Lower crankcase main bearing thickness Yellow mm (in).00.0 (0. 0.) Green mm (in).0.0 (0. 0.) Blue mm (in).0.0 (0. 0.) Red mm (in).0.0 (0. 0.) - DG

21 Maintenance specification Oil pump Discharge at 0 C (0 F) with 0W-0 engine oil Pressure at 0 C (0 F) with 0W-0 engine oil Relief valve opening pressure Lower unit Electrical Item Unit L (US gal, Imp gal)/min kpa (kgf/cm, psi) kpa (kgf/cm, psi) Model. (.,.) at,000 r/min.0 (.,.) at,000 r/min (..,..) Thermostat Opening temperature C ( F) ( ) Fully open temperature C ( F) 0 () Valve open lower limit mm (in). (0.) Marlin 00 EFI Item Unit Model F0BET F00DET Gear backlash Pinion-to-forward gear mm (in) ( ) Pinion shims mm 0.0, 0., 0., 0., 0.0, 0.0, 0.0 Forward gear shims mm 0.0, 0., 0., 0., 0.0, 0.0, 0.0 Item Unit Model F0BET F00DET Ignition and ignition control system Spark plug gap mm (in).0. ( ) Ignition coil resistance at 0 C ( F) Primary coil (R B/W) Ω..0 Secondary coil kω..0 Spark plug wire resistance # kω. 0. # kω..0 # kω.. # kω. 0. DG -

22 SPEC Specifications Item Unit Model Marlin 00 EFI ECM output peak voltage (B/R, B/W Ground) at cranking (loaded) V 0 at,00 r/min (loaded) V 0 at,00 r/min (loaded) V 0 Pulser coil output peak voltage (W/R, W/B B) at cranking (unloaded) V. at cranking (loaded) V. at,00 r/min (loaded) V. at,00 r/min (loaded) V. Pulser coil resistance (*) Ω (W/R, W/B B) Throttle position sensor Output voltage (P B) V 0.. at engine idle speed Cooling water temperature sensor resistance at 0 C ( F) kω.. at 0 C ( F) kω Oil pressure switch Operating pressure kpa (kgf/cm, psi).. (..,..) Fuel control system Fuel injector resistance (*) at C (0 F) Ω.0 Starter motor Type Sliding gear Output kw.0 Cranking time limit Second 0 Brushes Standard length mm (in). (0.) Wear limit mm (in). (0.) Commutator Standard diameter mm (in).0 (.) Wear limit mm (in).0 (.0) Mica Standard undercut mm (in) 0. (0.0) Wear limit mm (in) 0. (0.0) (*) The figures are for reference only. - DG

23 Maintenance specification Item Unit Model Marlin 00 EFI Charging system Fuse 0 Stator coil output peak voltage (W W) at cranking (unloaded) V. at,00 r/min (unloaded) V. at,00 r/min (unloaded) V. Stator coil resistance (*) (W W) at 0 C ( F) Ω Rectifier Regulator output peak voltage (R Ground) at,00 r/min (unloaded) V.0 at,00 r/min (unloaded) V.0 Power trim and tilt system Trim sensor Setting resistance (P B) Ω 0 ± Resistance (P B) Ω. Fluid type TF Dexron II Brushes Standard length mm (in) 0.0 (0.) Wear limit mm (in). (0.) Commutator Standard diameter mm (in).0 (0.) Wear limit mm (in).0 (0.) Mica Standard undercut mm (in). (0.0) Wear limit mm (in).0 (0.0) (*) The figure is for reference only. DG -

24 SPEC Specifications Dimensions Exterior mm (in) (0.) (.) (.) (.) L: (.) X:,0 (.) L : (.) X: (.) (.) (.) (.) (.) (.) (.) 0 (.) 0 (.) L: (.) X:, (.) (.) (.) L: (0.) X: (.) L : (.0) X: (0.) (.) (.) SD00 - DG

25 Clamp bracket Maintenance specification mm (in) 0 (.) 0 (.). (.). (.) 0. (.0) 0 (.). (.) (0.). (0.) (0.0). (.). (.). (.) (0.) SD00 DG -0

26 SPEC Specifications Tightening torques Specified torques Part to be tightened Thread size Tightening torques N m kgf m ft lb Fuel system Fuel filter cup 0 Fuel pump mounting bolt M 0.0. Fuel pump screw M 00 Sensor assembly screw M. 0 Idle speed control screw M. 0 Fuel rail mounting bolt M 0 Throttle body mounting bolt M 0 Fuel cooler screw M 0 Float chamber screw M 0 Vapor separator drain screw. 0 Pressure regulator bolt M 0 Fuel hose joint 00 Plate screw M 0 Wiring harness holder screw M 0 Pressure check valve 0.0. Power unit Power unit mounting bolt st 0 M0 nd 0 pron screw M 00 Flywheel magnet nut M Starter motor bolt M Spark plug wire cover screw M 00 Starter relay lead bolt M 00 Starter relay holder screw M 0 Main and fuel pump relay screw M 0 Oil pressure switch 0 Oil pressure switch lead bolt M 0 PTT relay lead nut M 00 PTT motor lead bolt M 00 Positive battery lead nut M 0 Timing belt tensioner bolt M0 Drive sprocket nut M0 Driven sprocket bolt M Camshaft cap bolt st 0 M nd Cylinder head cover plate screw M 0 Cylinder head cover bolt st 0 M nd 0 - DG

27 Tightening torques Part to be tightened Thread size Tightening torques N m kgf m ft lb st. 0. M nd. 0. Cylinder head bolt st nd M rd 0 Spark plug Cylinder block plug M 0 Oil filter joint Oil filter Exhaust cover bolt st 0 M nd node screw M 0 Exhaust cover plug M. 0. Crankcase bolt st. 0. M nd. 0. st 0 M0 nd 0 Connecting rod cap bolt st M nd 0 Lower unit Gear oil drain screw 0 Gear oil check screw 0 Lower case mounting bolt (L-transom model) M0 Lower case mounting nut (X-transom model) Propeller nut M Ring nut 0 00 Cooling water inlet cover screw 0 Pinion nut M Bracket unit Shift rod detent bolt Shift position switch screw M Flushing hose adapter screw M 0 Oil pump bolt M 0.0. Upper mounting nut Lower mounting nut Grease nipple 0 Oil pump cover screw M 00 Oil seal housing screw M 00 Upper mount bolt M. 0. Baffle plate bolt M 00 Muffler assembly bolt M 0.0. Engine oil drain bolt M. 0.0 Oil strainer bolt M 0.0. Oil pan bolt M DG -

28 SPEC Specifications Part to be tightened Thread size Tightening torques N m kgf m ft lb Exhaust manifold bolt M Steering arm stud bolt M Self-locking nut Trim sensor cam screw M 0 Power trim and tilt unit Reservoir cap 0 PTT motor bolt M 00 Gear pump bolt M 0 Gear pump housing bolt M 0 Relief valve cap bolt M 00 M 0 Lever bolt M 0 Manual valve 0 Gear pump bracket bolt M 0 M 00 Trim cylinder end screw 0.0. Tilt cylinder end screw Tilt piston bolt M 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 manual. To avoid warpage, tighten multi-fastener assemblies in a crisscross fashion and progressive stages until the specified torque is reached. Unless otherwise specified, torque specifications require clean, dry threads. Components should be at room temperature. Nut () Bolt (B) General torque specifications N m kgf m ft lb mm M 0 0 mm M 0 mm M. mm M0. mm M. - DG

29 CHK DJ Periodic checks and adjustments Special service tools...- Maintenance interval chart...- Top cowling...- Checking the top cowling...- Fuel system...- Checking the fuel joint and fuel hoses (fuel joint-to-fuel injector)...- Checking the fuel filter...- Power unit...- Checking the engine oil...- Changing the engine oil using an oil changer...- Changing the engine oil by draining it...- Replacing the oil filter...- Checking the timing belt...- Checking the spark plugs...- Checking the thermostat...- Checking the cooling water passage...- Control system...- Checking the engine idle speed...- djusting the throttle link and throttle cable...- Checking the gear shift operation...-0 Bracket unit...- Checking the power trim and tilt operation...- Checking the power trim and tilt fluid level...- Lower unit...- Checking the gear oil level...- Changing the gear oil...- Checking the lower unit for air leakage...- Checking the propeller...- General...- Checking the anodes...- Checking the battery...- Lubricating the outboard motor...- DG

30 CHK DJ Periodic checks and adjustments Special service tools Digital tachometer Leakage tester Oil filter wrench DG

31 Special service tools / Maintenance interval chart Maintenance interval chart Use the following chart as a guideline for general maintenance. djust the maintenance intervals according to the operating conditions of the outboard motor. Item Remarks 0 hours ( month) Initial 0 hours ( months) Every 00 hours ( months) 00 hours ( year) Refer to page nodes (external) Check/replace - nodes (internal) Check/replace - Battery Check/charge - Cooling water passages Clean - Top cowling Check - Fuel filter Check/replace - (can be disassembled) Fuel system Check - Gear oil Change - Lubrication points Lubricate - Engine idle speed Check/adjust - (EFI models) PCV (Pressure Control Valve) Check - Power trim and tilt unit Check - Propeller and cotter pin Check/replace - Shift link/shift cable Check/adjust -0 Thermostat Check - Throttle link/throttle cable/ Check/adjust - throttle pick-up timing Water pump Check - Engine oil Check/change - Oil filter Change - Spark plugs Clean/adjust/ - replace Timing belt Check/replace - When operating in salt water, turbid or muddy water, the engine should be flushed with clean water after each use. Item Remarks 00 hours (. years) Every,000 hours ( years) Refer to page Timing belt Replace - Valve clearance (DOHC) Check/adjust -0 When using lead or high-sulfur gasoline, checking valve clearance may be required more frequently than every 00 hours. DG -

32 CHK DJ Periodic checks and adjustments Top cowling Checking the top cowling. Check the fitting by pushing the cowling with both hands. djust if necessary.. Check the low-pressure fuel hose connections and fuel joint for leaks. Replace if necessary. lso, check the fuel filter, fuel pump, strainer, and fuel cooler for leaks or deterioration. Replace if necessary.. Check the high-pressure fuel hose connections for leaks. Replace if necessary. lso, check the vapor separator, fuel rail, fuel injectors, and pressure regulator for leaks or deterioration. Replace if necessary.. Loosen the bolts. S0C00. Move the hook up or down slightly to adjust its position. a b SD00 To loosen the fitting, move the hook in direction a. To tighten the fitting, move the hook in direction b. SD00 Checking the fuel filter. Check the fuel filter element for dirt and residue and check the fuel filter cup for foreign substances and cracks. Clean the cup with straight gasoline and replace the element if necessary.. Tighten the bolts.. Check the fitting again and, if necessary, repeat steps. Fuel system Checking the fuel joint and fuel hoses (fuel joint-to-fuel injector). Remove the flywheel magnet cover. SD00 Be sure not to spill any fuel when removing the fuel filter cup. - DG

33 Top cowling / Fuel system / Power unit Power unit Checking the engine oil. Place the outboard motor in an upright position.. Remove the oil dipstick, wipe it clean, and then insert it back into the dipstick hole.. Remove the oil dipstick again to check the oil level and to check the oil for discoloration and its viscosity. a. Operate the oil changer to extract the oil. b S0C0 Be sure to clean up any oil spills.. Pour the specified amount of the recommended engine oil into the oil filler hole. Change the oil if it appears milky or dirty. If the engine oil is below the minimum level mark b, add sufficient oil until the level is between a and b. Changing the engine oil using an oil changer. Start the engine, warm it up, and then turn it off.. Remove the oil dipstick and oil filler cap. S0C00 Recommended engine oil: -stroke motor oil PI: SE, SF, SG, SH, or SJ SE: 0W-0 or 0W-0 Engine oil quantity: Without oil filter replacement:. L (. US qt,. Imp qt). Install the oil filler cap and oil dipstick, and then start the engine and warm it up for minutes.. Turn the engine off, and then check the oil level and correct it if necessary. Changing the engine oil by draining it. Start the engine, warm it up, and then turn it off.. Insert the tube of the oil changer into the dipstick hole. DG -

34 CHK DJ Periodic checks and adjustments. Remove the oil dipstick and oil filler cap.. Turn the engine off, and then check the oil level and correct it if necessary. Replacing the oil filter. Extract the engine oil with an oil changer or drain it.. Place a rag under the oil filter, and then remove the oil filter using the oil filter wrench. S0C00. Place a drain pan under the drain hole, and then remove the drain bolt and let the oil drain completely. SD00 Wait more than minutes after turning the engine off to replace the oil filter. Be sure to clean up any oil spills. Be sure to clean up any oil spills.. Install the drain bolt, and then tighten it to the specified torque. Engine oil drain bolt: N m (. kgf m, 0.0 ft lb) Oil filter wrench : pply a thin coat of engine oil to the O- ring of the new oil filter.. Install the oil filter, and then tighten it to the specified torque using the oil filter wrench.. Pour the specified amount of the recommended engine oil into the oil filler hole. Recommended engine oil: -stroke motor oil PI: SE, SF, SG, SH, or SJ SE: 0W-0 or 0W-0 Engine oil quantity: Without oil filter replacement:. L (. US qt,. Imp qt). Install the oil filler cap and oil dipstick, and then start the engine and warm it up for minutes. - DG

35 Power unit E. While turning the flywheel magnet clockwise, check the interior a and the exterior b of the timing belt for cracks, damage, or wear. Replace if necessary. a SD00 b SD00 For replacement procedures, see Chapter, Replacing the timing belt. Oil filter: N m (. kgf m,. ft lb) Checking the spark plugs. Remove the spark plug wire cover.. Pour the specified amount of the recommended engine oil into the oil filler hole. Recommended engine oil: -stroke motor oil PI: SE, SF, SG, SH, or SJ SE: 0W-0 or 0W-0 Engine oil quantity: With oil filter replacement:. L (. US qt,. Imp qt). Install the oil filler cap and oil dipstick, and then start the engine and warm it up for minutes.. Turn the engine off, and then check the oil level and correct it if necessary. Checking the timing belt CUTION: Do not turn the flywheel magnet counterclockwise, otherwise the valve system may be damaged.. Remove the flywheel magnet cover.. Disconnect the spark plug wires, and then remove the spark plugs.. Clean the electrodes with a spark plug cleaner or wire brush. Replace the spark plug if necessary.. Check the electrodes for erosion and excessive carbon or other deposits, and the gasket for damage. Replace the spark plug if necessary. DG -

36 CHK DJ Periodic checks and adjustments. Check the spark plug gap a. djust if out of specification. Specified spark plug: LFR- (NGK) Spark plug gap a:.0. mm ( in). Install the spark plugs, tighten them finger tight, then to the specified torque using a spark plug wrench. SD00. Suspend the thermostat in a container of water. Spark plug: N m (. kgf m,. ft lb). Place a thermometer in the water and slowly heat the water.. Install the spark plug wire cover. Spark plug wire cover screw: N m (0. kgf m,.0 ft lb) Checking the thermostat. Remove the flywheel magnet cover.. Disconnect the cooling water hose, and then remove the thermostat cover and thermostat. SJE0. Check the thermostat valve opening at the specified water temperatures. Replace if out of specification. - DG

37 Power unit / Control system Water temperature C ( F) above 0 C ( F) Valve lift a 0.0 mm (0.000 in) (valve begins to lift) more than. mm (0. in). Install the thermostat and cover.. Connect the cooling water hose, and then install the flywheel magnet cover. Checking the cooling water passage. Check the cooling water inlet cover and cooling water inlet for clogs. Clean if necessary. Control system Checking the engine idle speed. Start the engine and warm it up for minutes.. ttach the special service tool to spark plug wire #, and then check the engine idle speed. Digital tachometer: S0C0 Engine idle speed: 0 0 r/min SY0. Place the lower unit in water, and then start the engine.. Check for water flow at the cooling water pilot hole. If there is no water flow, check the cooling water passage inside the outboard motor. djusting the throttle link and throttle cable. Remove the intake silencer.. Set the remote control lever to the neutral position and fully close the throttle lever. DG -

38 CHK DJ Periodic checks and adjustments. Loosen the locknut, remove the clip, and then disconnect the throttle cable joint.. Loosen the locknut, and then disconnect the throttle link rod joint from the ball joint of the throttle body. a SD0. djust the throttle link rod joint to align its hole with the ball joint 0 on the throttle body. SD00. Check that the stopper on the throttle cam contacts the fully closed stopper on the cylinder block. 0 SD0. Connect the throttle link rod joint, and then tighten the locknut.. Check that the throttle valve fully close. Do not turn the throttle stop screw. SD00 0. Operate the throttle cam to check that the throttle valve fully closes and fully opens, and check that the gap b between the stopper on the throttle lever and fully open stopper B on the throttle body is less than mm (0.0 in) when the throttle cam is in the fully open position. B. Push the throttle link rod toward the cylinder head and check that the throttle cam roller contacts the side a of the throttle cam. b SD0. djust the position of the throttle cable joint until its hole is aligned with the set pin on the throttle cam. - DG

39 Control system WRNING c The throttle cable joint must be screwed in a minimum of.0 mm (0. in) c.. Connect the throttle cable joint, install the clip, and then tighten the locknut.. Check the throttle cable for smooth operation and, if necessary, repeat steps.. Install the intake silencer. Checking the gear shift operation. Check that the gear shift operates smoothly when shifting it from neutral to forward or reverse. djust the shift cable length if necessary.. Set the gear shift to the neutral position.. Loosen the locknut, remove the clip, and then disconnect the shift cable joint.. Remove the clip. SJ0. lign the alignment mark a on the bushing and alignment mark b on the bracket.. Install the clip.. djust the position of the shift cable joint until its hole is aligned with the set pin. c WRNING The shift cable joint must be screwed in a minimum of.0 mm (0. in) c. a b SD00 SJ0. Connect the cable joint, install the clip, and then tighten the locknut.. Check the gear shift for smooth operation and, if necessary, repeat steps. SD0 DG -0

40 CHK DJ Periodic checks and adjustments Bracket unit Checking the power trim and tilt operation. Fully tilt the outboard motor up and down a few times and check the entire trim and tilt range for smooth operation. Check the power trim and tilt fluid level if necessary. SD0 WRNING fter tilting up the outboard motor, be sure to support it with the tilt stop lever. Otherwise, the outboard motor could suddenly lower if the power trim and tilt unit should lose fluid pressure.. Remove the reservoir cap, and then check the fluid level in the reservoir. Be sure to listen to the winding sound of the power trim and tilt motor for smooth operation.. Fully tilt the outboard motor up, and then support it with the tilt stop lever to check the lock mechanism of the lever. SD0 Checking the power trim and tilt fluid level. Fully tilt the outboard motor up, and then support it with the tilt stop lever. SD0 If the fluid is at the correct level, the fluid should overflow out of the filler hole when the reservoir cap is removed.. If necessary, add sufficient fluid of the recommended type until it overflows out of the filler hole. Recommended power trim and tilt fluid: TF Dexron II. Install the reservoir cap, and then tighten it to the specified torque. Reservoir cap: N m (0. kgf m,. ft lb) - DG

41 Bracket unit / Lower unit Lower unit Checking the gear oil level. Fully tilt the outboard motor down.. Remove the check screw, and then check the gear oil level in the lower case. If the oil is at the correct level, the oil should overflow out of the check hole when the check screw is removed.. If necessary, add sufficient gear oil of the recommended type until it overflows out of the check hole.. Install the check screw, and then tighten it to the specified torque. Recommended gear oil: Hypoid gear oil PI: GL- SE: 0 Changing the gear oil. Tilt the outboard motor up slightly.. Place a drain pan under the drain screw, remove the drain screw, then the check screw and let the oil drain completely. Gear oil check screw: N m (0. kgf m,. ft lb) S0C0. Check the oil for metal and discoloration, and its viscosity. Check the internal parts of the lower case if necessary. DG -

42 CHK DJ Periodic checks and adjustments. Insert a gear oil tube or gear oil pump into the drain hole and slowly fill the gear oil until oil flows out of the check hole and no air bubbles are visible. Leakage tester: pply the specified pressure to check that the pressure is maintained in the lower unit for at least 0 seconds. CUTION: Do not over pressurize the lower unit, otherwise the oil seals can be damaged. Cover the check hole with a rag when removing the tester from the lower unit. Recommended gear oil: Hypoid gear oil PI: GL- SE: 0 Gear oil quantity: 0 cm (. US oz,. Imp oz). Install the check screw and quickly install the drain screw, and then tighten them to the specified torque. Lower unit holding pressure: 00 kpa (.0 kgf/cm,. psi). If pressure drops below specification, check the drive shaft and propeller shaft oil seals for damage. Checking the propeller. Check the propeller blades and splines for cracks, damage, or wear. Replace if necessary. Gear oil check screw and drain screw: N m (0. kgf m,. ft lb) Checking the lower unit for air leakage. Remove the check screw, and then install the special service tool. - DG

43 Lower unit / General General Checking the anodes. Check the anodes and trim tab for scales, grease, or oil. Clean if necessary. If it is necessary to disassemble the outboard motor to check an anode, refer to the applicable disassembly procedure in this manual.. Replace the anodes or trim tab if excessively eroded. Checking the battery. Check the battery electrolyte level. If the level is at or below the minimum level mark a, add distilled water until the level is between the maximum and minimum level marks. a SD0 SJ0 SD0 CUTION: SY0 Do not oil, grease, or paint the anodes or the trim tab, otherwise they will be ineffective. DG -

44 CHK DJ Periodic checks and adjustments. Check the specific gravity of the electrolyte. Fully charge the battery if out of specification. Lubricating the outboard motor. pply water resistant grease to the areas shown. WRNING Battery electrolyte is dangerous; it contains sulfuric acid which is poisonous and highly caustic. lways follow these preventive measures: void bodily contact with electrolyte as it can cause severe burns or permanent eye injury. Wear protective eye gear when handling or working near batteries. ntidote (EXTERNL): SKIN Wash with water. EYES Flush with water for minutes and get immediate medical attention. ntidote (INTERNL): Drink large quantities of water or milk followed with milk of magnesia, beaten egg, or vegetable oil. Get immediate medical attention. Batteries generate explosive, hydrogen gas. lways follow these preventive measures: Charge batteries in a well-ventilated area. Keep batteries away from fire, sparks or open flames (e.g., welding equipment, lighted cigarettes). DO NOT SMOKE when charging or handling batteries. KEEP BTTERIES ND ELECTROLYTE OUT OF RECH OF CHILDREN. a S0C0 S0C0 SD0 a Batteries vary per manufacturer. The procedures mentioned in this manual may not always apply, therefore, consult the instruction manual of the battery. Disconnect the negative battery lead first, then the positive battery lead. a S0C Electrolyte specific gravity:.0 at 0 C ( F) - DG

45 General a a S0C0 pply grease to the grease nipple until it flows from the bushings a.. pply low temperature resistant grease to the area shown. C SD0. pply corrosion resistant grease to the area shown. DG -

46 CHK DJ Periodic checks and adjustments MEMO - DG

47 FUEL Fuel system Special service tools...- Hose routing...- Fuel and blowby hoses...- Fuel filter and fuel pump...- Checking the fuel pump...- Disassembling the fuel pump...- Checking the diaphragm and valves...- ssembling the fuel pump...- Intake manifold...- Checking the throttle position sensor...- Installing the throttle position sensor...- Checking the idle speed control...- Vapor separator...-0 Reducing the fuel pressure...- Disconnecting the quick connector...- Measuring the fuel pressure...- Checking the pressure regulator...- Draining the fuel...- Removing the fuel hose clamp...- Installing the fuel hose clamp...- Disassembling the vapor separator...- Checking the vapor separator...- ssembling the vapor separator...- djusting the float...- Canister...- Checking the canister...-0 DG

48 FUEL Fuel system Special service tools Vacuum/pressure pump gauge set 00-0 Fuel pressure gauge 00-0 Fuel pressure gauge adapter B DG

49 Special service tools / Hose routing Hose routing Fuel and blowby hoses Blowby hose Fuel hose (primary pump-to-fuel filter) Fuel hose (fuel filter-to-fuel pump) Fuel hose (fuel pump-to-strainer) Fuel hose (strainer-to-vapor separator) High-pressure fuel hose (vapor separator-to-fuel rail) Fuel hose (pressure regulator-to-fuel cooler) Fuel hose (fuel cooler-to-vapor separator) Canister hose (vapor separator-to-canister) 0 Canister hose (canister-to-idle speed control) Canister hose (canister-to-filter) B Canister hose (filter-to-bottom cowling) DG -

50 FUEL Fuel system Fuel filter and fuel pump 0 N m (.0 kgf m,. ft Ib) 0 0 N m (0. kgf m,. ft Ib) SD00 No. Part name Q ty Remarks Nut Fuel filter assembly O-ring Not reusable Fuel filter element O-ring Not reusable Float Cup Fuel hose Fuel pump 0 Bolt M 0 mm Fuel hose Strainer Bolt M mm Bracket O-ring Not reusable - DG

51 Fuel filter and fuel pump N m (0. kgf m,.0 ft Ib) 0 No. Part name Q ty Remarks Screw ø mm Cover Gasket Not reusable Fuel pump body assembly Diaphragm Pin Spring Fuel pump body Spring 0 Plunger Nut SD00 DG -

52 FUEL Fuel system Checking the fuel pump. Place a drain pan under the fuel hose connections, and then disconnect the fuel hoses from the fuel pump.. pply the specified positive pressure and check that there is no air leakage. Disassemble the fuel pump if necessary.. Connect the special service tool to the fuel pump inlet.. Cover the fuel pump outlet with a finger, and then apply the specified positive pressure. Check that there is no air leakage. SP0 ssemble the fuel pump valve to the fuel pump body, and moisten the inside of the fuel pump with gasoline to ensure a good seal. Vacuum/pressure pump gauge set: 00-0 Specified pressure: 0 kpa (0. kgf/cm,. psi) SP00. pply the specified negative pressure and check that there is no air leakage. Specified pressure: 0 kpa (0. kgf/cm,. psi) Disassembling the fuel pump. Disassemble the fuel pump.. Push down on the plunger and the diaphragm, turn fuel pump body approximately 0 to a position where the pin can be removed easily, and then remove the pin. SP00 Specified pressure: 0 kpa (0. kgf/cm,. psi). Connect the special service tool to the fuel pump outlet. - DG

53 . Slowly let up on the plunger and diaphragm, and then remove them. Fuel filter and fuel pump Checking the diaphragm and valves. Check the diaphragm for tears and the valves for cracks. Replace if necessary. ssembling the fuel pump Clean the parts and soak the valves and the diaphragm in gasoline before assembly to obtain prompt operation of the fuel pump when starting the engine.. lign the plunger and diaphragm installation holes a, and then install the plunger into the diaphragm.. Push down on the plunger and the diaphragm, and then install the pin.. Turn fuel pump body approximately 0, and then push down on the plunger several times to make sure that the pin does not come out. Make sure that the gasket and diaphragm are kept in place through the assembly process. DG -

54 FUEL Fuel system Intake manifold 0 SD00 No. Part name Q ty Remarks Intake silencer F0BET Bolt M 0 mm Bushing Collar Intake manifold assembly Bolt M 0 mm Collar Bolt M 00 mm Spacer 0 Bolt M mm Collar Holder Gasket Not reusable Pin Joint Intake silencer Marlin 00 EFI - DG

55 Intake manifold. N m (0. kgf m,. ft lb) N m (0. kgf m,. ft Ib) 0 N m (0. kgf m,. ft Ib) SD00 No. Part name Q ty Remarks Intake manifold Sensor assembly Screw ø mm O-ring Not reusable Idle speed control O-ring Not reusable Throttle body assembly Bolt M mm Gasket Not reusable 0 Throttle position sensor Screw O-ring Not reusable Fuel injector O-ring set Not reusable Fuel rail Bolt M mm DG -

56 FUEL Fuel system Checking the throttle position sensor. Check the throttle position sensor output voltage using the Selva Diagnostic System. If the output voltage is out of specification, replace the throttle position sensor. Throttle position sensor output voltage at engine idle speed: 0.. V Installing the throttle position sensor. Install the throttle position sensor in a position where the output voltage is within specification. a SD0 If the throttle position sensor output voltage is out of specification, reinstall the throttle position sensor. Measure the throttle position sensor output voltage using the Selva Diagnostic System. Do not turn the throttle stop screw a. Throttle position sensor output voltage at engine idle speed: 0.. V Checking the idle speed control. Check the operation of the idle speed control using the Selva Diagnostic System. - DG

57 Intake manifold / Vapor separator Vapor separator 0 SD00 No. Part name Q ty Remarks Vapor separator Bolt M 0 mm Grommet Collar Fuel hose Fuel inlet hose Hose Joint Hose 0 Hose Hose Hose Clamp Clamp Quick connector Clamp Not reusable Plastic tie Not reusable DG -0

58 FUEL Fuel system N m (0. kgf m,. ft Ib). N m (0. kgf m,. ft lb) 0 N m (0. kgf m,. ft Ib) N m (0. kgf m,.0 ft Ib) SD00 No. Part name Q ty Remarks Screw ø mm Gasket Not reusable Float chamber Damper Drain screw O-ring Not reusable Joint screw O-ring Not reusable Fuel hose 0 Fuel cooler Screw ø mm Fuel hose Hose Hose Hose Plastic tie Not reusable - DG

59 Vapor separator N m (0. kgf m,. ft Ib) 0 N m (.0 kgf m,. ft Ib) N m (0. kgf m,. ft Ib) N m (0. kgf m,.0 ft Ib) LT N m (0. kgf m,. ft Ib) 0 SD00 No. Part name Q ty Remarks Cover Pressure regulator Bolt M mm O-ring Not reusable Joint screw O-ring Not reusable Electric fuel pump Grommet Collar 0 Filter Screw ø mm Wiring harness Float Needle valve Pin Not reusable Cap DG -