2011 YAMAHA F250CA 4-STROKE OUTBOARD Service Repair Manual SN：1000001 and up by 1632410

(L)F225 (L)F250 (L)F300

SERVICE MANUAL

LIT-18616-03-23

6CE-28197-1N-11

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 outboard motor or other property.

TIP: A TIP provides key information to make procedures easier or clearer.

(L)F225, (L)F250, (L)F300 SERVICE MANUAL ÂŠ2010 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

Contents General information

GEN INFO

Specification

SPEC

Technical features and description

TECH FEA

Rigging information

RIG GING

Troubleshooting

TRBL SHTG

Electrical system

ELEC

Fuel system

FUEL

Power unit

POWR

Lower unit

LOWR

Bracket unit

BRKT

Maintenance

MNT

Index Appendix

GEN INFO

General information 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

0 1 2 3 4 5 6 7 8 9 10

GEN INFO

General information

Safety while working

Handling of gasoline

To prevent an accident or injury and to provide quality service, observe the following safety procedures.

• Gasoline is highly flammable. Keep gasoline 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.

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 cowling removed according to the specific instructions in the manual. Keep hands, feet, hair, jewelry, clothing, personal flotation 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 starting 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.

0-1

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 consciousness 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 maintained.

Safety while working

Self-protection

Handling of gas torch

• 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.

• Improper handling of a gas torch may result in burns. For information on the proper handling 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.

0 1 2 3 4

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.

Part, lubricant, and sealant Use only genuine Yamaha parts, lubricants, and sealants, or those recommended by Yamaha, when servicing or repairing the outboard motor.

5 6 7 8 9 10

A 0-2

GEN INFO

General information

Handling of sealant

Non-reusable part

• 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.

Always use new gaskets, seals, O-rings, cotter pins, and so on, when installing or assembling parts.

Disassembly and assembly Special service tool Use the recommended special service tools to work safely, and to protect parts from damage.

Tightening torque When tightening nuts, bolts, and screws, follow 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.

0-3

• 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 identification mark is facing in the direction indicated in the installation procedure. In addition, make sure to lubricate the bearings 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.

Safety while working / How to use this manual

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 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 figure), 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:

0 1 2 3 4

For troubleshooting procedures, see Chapter 4, “Troubleshooting.”

5 6 7 8 9 10

A 0-4

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

Down side

DOHC

Double Over Head Camshaft

ECM

Electronic Control Module

EPA

Environmental Protection Agency

ETV

Electronic Throttle Valve

ENG

Engine

Exhaust

EXH

Exhaust

Forward

GPS

Global Positioning System

Identification

Intake

INT

Intake

ISO

International Organization for Standardization

LPS

Lever Position Sensor

MCA

Marine Cranking Ampere

Neutral

OCV

Oil Control Valve

PCV

Pressure Control Valve

PON

Pump Octane Number

PORT

Port side

PTT

Power Trim and Tilt

Reverse

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

0-5

How to use this manual Abbreviation

Description

TDC

Top Dead Center

TPS

Throttle Position Sensor

Up side

VCT

Variable Camshaft Timing

W/F

Water in Fuel

Y-COP

Yamaha Customer Outboard Protection

YDIS

Yamaha Diagnostic System

0 1 2 3 4 5 6 7 8 9 10

A 0-6

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. Symbol

Name Yamaha 4-stroke motor oil

Application 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

Symbols in an exploded diagram or illustration indicate the type of sealant or thread locking agent and the application points. Symbol

Name Gasket Maker

ThreeBond 1280B

0-7

Application Sealant

Sealant

ThreeBond 1303

Thread locking agent

ThreeBond 1303N

Thread locking agent

ThreeBond 1322

Thread locking agent

ThreeBond 1377B

Thread locking agent

Lubricant, sealant, and thread locking agent Symbol

Name ThreeBond 1386B

Application 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

6 7 8 9 10

A 0-8

GEN INFO

General information

Special service tool For U.S.A. and Canada Special service tools numbered â&#x20AC;&#x153;YB-*****â&#x20AC;? are distributed by K & L. Special service tools with Yamaha part numbers (90890-*****) are distributed by the Parts Division. Engine lifting eye 90890-06820

Peak volt adapter YU-39991

Drilling plate 90890-06783

Test harness (3 pins) YB-06869

YDIS (CD-ROM, Ver. 1.33) 60V-WS853-06

Pressure/vacuum tester YB-35956-A

YDIS USB adapter and cable 60V-WS850-00

Test harness (1 pin) YB-06888

Digital multimeter YU-34899-A

Test harness (2 pins) YB-06887

0-9

Special service tool Spark checker YM-34487

Vacuum/pressure pump gauge set 90890-06756

0 1 Test harness (2 pins) YB-06867

Compression gauge YU-33223

2 3 Test harness (3 pins) YB-06791

Balance hanger 90890-06822

4 5

Fuel pressure gauge adapter YW-06842

Universal magneto and rotor holder YU-01235

7 8 Fuel pressure gauge YB-06766

Primary sheave holder YS-01880-A

9 10

A 0-10

GEN INFO

General information

Valve spring compressor YM-04019

Neway valve seat kit YB-91044

Valve attachment YB-06320

Oil filter wrench 90890-06830

Valve guide remover YB-06801

Driver handle (large) YB-06071

Valve guide reamer YM-01196

Roller bearing installer/remover YB-06432

Valve lapper YM-A8998

Needle bearing installer YB-06111

0-11

Special service tool Piston ring compressor YM-08037

Ring nut wrench 6 90890-06677

0 1 Driveshaft needle bearing installer and remover YB-06196

Universal puller YB-06117

2 3

Shift rod socket 90890-06679

Bearing housing puller YB-06207

4 5

Bearing housing bearing/oil seal remover YB-06112

Bearing cup installer YB-06167

7 8

Ring nut wrench extension 90890-06513

Driveshaft bearing installer YB-06155

9 10

A 0-12

GEN INFO

General information

Bearing inner race attachment 90890-06661

Pinion nut holder 90890-06715

Forward gear needle bearing installer YB-06261

Driver rod L3 90890-06652

Driveshaft bearing installer YB-06246

Needle bearing attachment 90890-06680

Drive shaft ring nut wrench 90890-06674

Bearing inner race attachment 90890-06640

Drive shaft holder YB-06520

Driveshaft bearing installer YB-06246

0-13

Special service tool Pinion gear bushing installer YB-06029-2

Backlash adjustment plate YB-07003

0 1 Roller bearing installer/remover YB-06432-2

Magnetic base stand YU-A8438

2 3 Bearing installer YB-06016

Pinion shimming gauge 90890-06675

4 5

Backlash indicator 90890-06836

Pinion shimming gauge rod 90890-06676

7 8 Dial indicator gauge YU-03097

Slide hammer YB-06096

9 10

A 0-14

GEN INFO Propeller shaft remover YB-06335

General information and

bearing

Needle bearing attachment 90890-06607

Gland nut wrench YB-06578

Prop shaft/bearing installer YB-42225

Forward gear bearing installer YB-06345

0-15

housing

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

Special service tool Tilt rod wrench YB-06569

0 1 2 3 4 5 6 7 8 9 10

A 0-16

SPEC

Specification 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

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

0 1 2

4 5 6 7 8 9 10

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 emissions 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 timing 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

1-1

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 bearing • Propeller shaft with 3 bearings (regular rotation model) • Propeller damper cooling system • Patented shift damper system

a b

c d

Model feature

Model designation

F 300 X a

Model description

Model name

Transom height

d e f

CA d

F: 4-stroke regular rotation LF: 4-stroke counter rotation 300: 225/250/300 X: UL (25 in) U: SUL (30 in) Blank: PTT and electric starter C: Command Link Control A: A and later

Functions Product generation

Serial number The outboard motor serial number is indicated on a label affixed to the port clamp bracket.

Model name F225CA LF225CA F250CA LF250CA F300CA LF300CA

2 3 Approved model code 6CL 6CM 6CG 6CH 6CE 6CF

Starting serial No. 1000001– 1000001– 1000001– 1000001– 1000001– 1000001–

4 5 6 7

b YAMAHA MOTOR CO., LTD. MADE IN JAPAN PAYS D'ORIGINE JAPON

10 a Model name b Approved model code c Transom height d Serial number e Model year code

A 1-2

SPEC

Specification

Model data Dimension and weight Item Overall length Overall width Overall height X U

Unit

mm (in)

1890.0 (74.4)

Overall length Overall width Overall height X U Boat transom height X U Weight (without propeller) X U

2017.0 (79.4)

—

mm (in)

Unit

LF250CA

2017.0 (79.4)

643 (25.3) 770.0 (30.3)

—

kg (lb) kg (lb)

Item

F250CA

958.0 (37.7) 634.0 (25.0)

mm (in)

Weight (without propeller) X

LF225CA

mm (in) mm (in)

mm (in)

Boat transom height X

Model F225CA

770.0 (30.3)

260.0 (573) 268.0 (591)

—

268.0 (591) Model

F300CA

LF300CA

mm (in) mm (in)

958.0 (37.7) 634.0 (25.0)

mm (in) mm (in)

1890.0 (74.4) 2017.0 (79.4)

mm (in) mm (in)

643.0 (25.3) 770.0 (30.3)

kg (lb) kg (lb)

260.0 (573) 268.0 (591)

Performance Item Maximum output At 5500 r/min Full throttle operating range Maximum fuel consumption At 5500 r/min Engine idle speed Item Maximum output At 5500 r/min Full throttle operating range

1-3

Unit kW (HP) r/min L (US gal, Imp gal)/hr r/min Unit kW (HP) r/min

Model F225CA

LF225CA

F250CA

165.5 (225)

LF250CA

183.8 (250) 5000–6000

81.0 (21.4, 17.8)

91.0 (24.0, 20.0)

650–750 Model F300CA

LF300CA 220.6 (300) 5000–6000

Model data Item

Unit

Model F300CA

LF300CA

Maximum fuel consumption At 5500 r/min Engine idle speed

L (US gal, Imp gal)/hr r/min

97.0 (25.6, 21.3) 650–750

Power unit Item Type Cylinder quantity Total displacement Bore stroke Compression ratio Control system Starting system Fuel system Ignition control system Advance type Maximum generator output Spark plug Firing order Cooling system Exhaust system Lubrication system Item Type Cylinder quantity Total displacement Bore stroke Compression ratio Control system Starting system Fuel system Ignition control system Advance type Maximum generator output Spark plug Firing order Cooling system Exhaust system Lubrication system

Unit

cm3 (cu. in) mm (in)

V, A

Unit

cm³ (cu. in) mm (in)

V, A

Model F225CA

LF225CA

F250CA

LF250CA

4-stroke, DOHC V6 4169.0 (254.4) 96.0 96.0 (3.78 3.78) 10.3:1 Digital Electronic Control Electric Fuel injection TCI Microcomputer 12.0, 70.0 LFR6A-11 (NGK) 1–2–3–4–5–6 (normal operation) Water Propeller boss Wet sump

2 3 4 5 6

Model F300CA

LF300CA 4-stroke, DOHC V6 4169.0 (254.4) 96.0 96.0 (3.78 3.78) 10.3:1 Digital Electronic Control Electric Fuel injection TCI Microcomputer 12.0, 70.0 LFR6A-11 (NGK) 1–2–3–4–5–6 (normal operation) Water Propeller boss Wet sump

7 8 9 10

A 1-4

SPEC

Specification

Lower unit Item

Unit

Model F225CA

LF225CA

F250CA

LF250CA

Clockwise T

F–N–R 1.75 (21/12) Spiral bevel gear Dog clutch Spline Counter Clockclockwise wise TL T

Counter clockwise TL

Gear shift positions Gear ratio Reduction gear type Clutch type Propeller shaft type Propeller direction (rear view) Propeller mark Item

Unit

Gear shift positions Gear ratio Reduction gear type Clutch type Propeller shaft type Propeller direction (rear view) Propeller mark

Model F300CA

LF300CA

F–N–R 1.75 (21/12) Spiral bevel gear Dog clutch Spline Clockwise Counter clockwise T TL

Bracket unit Item Trim angle At 12º boat transom Tilt-up angle Steering angle Trim and tilt system Item Trim angle At 12º boat transom Tilt-up angle Steering angle Trim and tilt system

1-5

Unit

Model F225CA

LF225CA

degree degree degree

Unit degree degree degree

F250CA

LF250CA

–3 to 16 67 32 + 32 PTT Model F300CA

LF300CA –3 to 16 67 32 + 32 PTT

Model data

Fuel and oil requirement Item Fuel type Minimum fuel octane number

Unit PON

Engine oil Engine oil grade (*1) Total engine oil quantity (oil pan capacity) Gear oil type Gear oil grade (*2) Gear oil quantity

API SAE L (US qt, Imp qt) API SAE L (US qt, Imp qt)

Model F225CA

LF225CA

F250CA

LF250CA

Regular unleaded gasoline 87 YAMALUBE 4-M FC-W oil or 4-stroke motor oil with combination of the following SAE and API oil classifications SE, SF, SG, SH, SJ, SL 5W-30, 10W-30, 10W-40

Fuel type Minimum fuel octane number

Unit PON

Engine oil Engine oil grade (*1) Total engine oil quantity (oil pan capacity) Gear oil type Gear oil grade (*2) Gear oil quantity

API SAE L (US qt, Imp qt) API SAE L (US qt, Imp qt)

1 2

7.1 (7.50, 6.25) Hypoid gear oil GL-5 90, 80W-90

1.040 (1.10, 0.92)

(*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

Model F300CA LF300CA Premium unleaded gasoline 89 YAMALUBE 4-M FC-W oil or 4-stroke motor oil with combination of the following SAE and API oil classifications SE, SF, SG, SH, SJ, SL 5W-30, 10W-30, 10W-40 7.1 (7.50, 6.25) Hypoid gear oil GL-5 90, 80W-90

4 5 6 7 8

1.040 (1.10, 0.92)

9 10

A 1-6

SPEC

Specification

Battery requirement Item

Unit

Minimum cold cranking amps CCA/SAE Minimum marine cranking amps MCA/ABYC Minimum reserve capacity RC/SAE Item

Unit

Minimum cold cranking amps CCA/SAE Minimum marine cranking amps MCA/ABYC Minimum reserve capacity RC/SAE

Model F225FET

FL225FET

F250DET

680.0

770.0

minutes

160

FL250DET

Model F300CA

LF300CA

680.0

770.0

minutes

160

PTT fluid requirement Item

Unit

Model F225CA

LF225CA

Fluid type

1-7

LF250CA

ATF DEXRON II Item

Fluid type

F250CA

Unit

Model F300CA

LF300CA ATF DEXRON II

Model data / Electrical system technical data

Electrical system technical data Ignition timing control system Item Spark plug Gap Cam position sensor Input voltage Ignition coil Input voltage Pulser coil Air gap Output peak voltage At cranking (unloaded) At cranking (loaded) At 1500 r/min (loaded) At 3500 r/min (loaded) Resistance At 20 °C (68 °F) Air temperature sensor Input voltage Resistance (*1) At 20 °C (68 °F) At 80 °C (176 °F) Air pressure sensor Input voltage Output voltage (*1) At –20.0 kPa (–0.20 kgf/ cm2, –2.9 psi) At –46.7 kPa (–0.467 kgf/ cm2, –6.8 psi) Engine temperature sensor Input voltage Resistance (*1) At 5 °C (41 °F) At 25 °C (77 °F) At 100 °C (212 °F) Thermoswitch Input voltage Temperature Switch ON Switch OFF Knock sensor Resistance At 20 °C (68 °F)

Unit

Model F225CA

LF225CA

F250CA

mm (in)

1.0–1.1 (0.039–0.043)

12.0

mm (in)

0.4–1.1 (0.016–0.043)

V V V V

7.6 6.9 23.9 25.1

Ω

396.0–594.0

4.75–5.25

kΩ kΩ

2.21–2.69 0.32

4.75–5.25

3.21

2.16

4.75–5.25

kΩ kΩ kΩ

4.2–4.9 1.9–2.1 0.166–0.204

4.75–5.25

°C (°F) °C (°F)

84–90 (183–194) 68–82 (154–180)

kΩ

504.0–616.0

LF250CA

0 1 2 3 4 5 6 7 8 9 10

(*1) The figures are for reference only.

A 1-8

SPEC

Specification Item

Spark plug Gap Cam position sensor Input voltage Ignition coil Input voltage Pulser coil Air gap Output peak voltage At cranking (unloaded) At cranking (loaded) At 1500 r/min (loaded) At 3500 r/min (loaded) Resistance At 20 °C (68 °F) Air temperature sensor Input voltage Resistance (*1) At 20 °C (68 °F) At 80 °C (176 °F) Air pressure sensor Input voltage Output voltage (*1) At –20.0 kPa (–0.20 kgf/ cm2, –2.9 psi) At –46.7 kPa (–0.467 kgf/ cm2, –6.8 psi) Engine temperature sensor Input voltage Resistance (*1) At 5 °C (41 °F) At 25 °C (77 °F) At 100 °C (212 °F) Thermoswitch Input voltage Temperature Switch ON Switch OFF Knock sensor Resistance At 20 °C (68 °F) (*1) The figures are for reference only.

1-9

Unit

Model F300CA

LF300CA

mm (in)

1.0–1.1 (0.039–0.043)

12.0

mm (in)

0.4–1.1 (0.016–0.043)

V V V V

7.6 6.9 23.9 25.1

Ω

396.0–594.0

4.75–5.25

kΩ kΩ

2.21–2.69 0.32

4.75–5.25

3.21

2.16

4.75–5.25

kΩ kΩ kΩ

4.2–4.9 1.9–2.1 0.166–0.204

4.75–5.25

°C (°F) °C (°F)

84–90 (183–194) 68–82 (154–180)

kΩ

504.0–616.0

Electrical system technical data

Fuel injection control system Item Fuel line Pressure (*1) Within 5 seconds after engine start switch turned to ON At 700 r/min Water detection switch Input voltage Float height (*1) Fuel injector Input voltage Resistance (*1) At 20 °C (68 °F) Low-pressure fuel pump Input voltage Resistance (*1) At 20 °C (68 °F) High-pressure fuel pump Input voltage Resistance (*1) At 20 °C (68 °F) Vapor shut-off valve Input voltage Resistance At 20 °C (68 °F)

Unit

Model F225CA

LF225CA

F250CA

LF250CA

0 kPa (kgf/ cm2, psi)

330.0 (3.30, 47.9)

kPa (kgf/ cm2, psi)

280.0 (2.80, 40.6)

V mm (in)

4.75–5.25 53.0 (2.10)

12.0

Ω

11.5–12.5

12.0

Ω

0.5–4.0

12.0

Ω

0.2–3.0

12.0

Ω

30.0–34.0

1 2 3 4 5 6 7

(*1) The figures are for reference only. Item Fuel line Pressure (*1) Within 5 seconds after engine start switch turned to ON At 700 r/min Water detection switch Input voltage Float height (*1) Fuel injector Input voltage Resistance (*1) At 20 °C (68 °F)

Unit

Model F300CA

LF300CA

kPa (kgf/ cm2, psi)

330.0 (3.30, 47.9)

kPa (kgf/ cm2, psi)

280.0 (2.80, 40.6)

V mm (in)

4.75–5.25 53.0 (2.10)

12.0

Ω

11.5–12.5

8 9 10

A 1-10

SPEC

Specification Item

Low-pressure fuel pump Input voltage Resistance (*1) At 20 °C (68 °F) High-pressure fuel pump Input voltage Resistance (*1) At 20 °C (68 °F) Vapor shut-off valve Input voltage Resistance At 20 °C (68 °F)

Unit

Model F300CA

LF300CA

12.0

Ω

0.5–4.0

12.0

Ω

0.2–3.0

12.0

Ω

30.0–34.0

(*1) The figures are for reference only.

Engine speed control system Item TPS Output voltage (*1) With throttle valve fully closed TPS1 TPS2 Throttle valve opening angle (*1) With throttle valve fully closed Input voltage SPS Output voltage F N R Input voltage Oil pressure sensor Input voltage Output voltage (*1) At 392.0 kPa (3.92 kgf/cm2, 56.8 psi) At 784.0 kPa (7.84 kgf/cm2, 113.7 psi) (*1) The figures are for reference only.

1-11

Unit

Model F225CA

LF225CA

F250CA

V V

0.37–0.63 2.5–3.5

degree

4.5

4.75–5.25

V V V V

0.2–1.5 2.412–2.588 3.5–4.8 4.75–5.25

4.75–5.25

2.5

4.5

LF250CA

Electrical system technical data Item TPS Output voltage (*1) With throttle valve fully closed TPS1 TPS2 Throttle valve opening angle (*1) With throttle valve fully closed Input voltage SPS Output voltage F N R Input voltage Oil pressure sensor Input voltage Output voltage (*1) At 392.0 kPa (3.92 kgf/cm2, 56.8 psi) At 784.0 kPa (7.84 kgf/cm2, 113.7 psi)

Unit

Model F300CA

LF300CA

0 V V

0.37–0.63 2.5–3.5

degree

4.5

4.75–5.25

V V V V

0.2–1.5 2.412–2.588 3.5–4.8 4.75–5.25

4.75–5.25

2.5

4.5

1 2 3 4 5 6

(*1) The figures are for reference only.

VCT system Item OCV Input voltage Resistance At 20 °C (68 °F) Item OCV Input voltage Resistance At 20 °C (68 °F)

Unit

F225CA

LF225CA

F250CA

12.0

Ω

6.7–7.7

Unit

Model LF250CA

8 9

Model F300CA

LF300CA

12.0

Ω

6.7–7.7

A 1-12

SPEC

Specification

Shift actuator Item Shift actuator Rod stroke (*1) F N R Motor resistance (*1) At 20 °C (68 °F)

Unit

Model F225CA

LF225CA

F250CA

mm (in) mm (in) mm (in)

78.2 (3.08) 59.2 (2.33) 41.1 (1.62)

Ω

1.7

LF250CA

(*1) The figures are for reference only. Item Shift actuator Rod stroke (*1) F N R Motor resistance (*1) At 20 °C (68 °F)

Unit

Model F300CA

LF300CA

mm (in) mm (in) mm (in)

78.2 (3.08) 59.2 (2.33) 41.1 (1.62)

Ω

1.7

(*1) The figures are for reference only.

PTT system Item Trim sensor Free position resistance Setting resistance Item Trim sensor Free position resistance Setting resistance

1-13

Unit

Model F225CA

LF225CA

Ω Ω Unit Ω Ω

F250CA

LF250CA

247.6–387.6 9.0–11.0 Model F300CA

LF300CA 247.6–387.6 9.0–11.0

Electrical system technical data

Charging system Item Lighting coil Output peak voltage At cranking (unloaded) At 1500 r/min (unloaded) At 3500 r/min (unloaded) Resistance (*1) At 20 °C (68 °F) Fuse Rectifier Regulator Output peak voltage At 1500 r/min (loaded) At 3500 r/min (loaded) Item Lighting coil Output peak voltage At cranking (unloaded) At 1500 r/min (unloaded) At 3500 r/min (unloaded) Resistance (*1) At 20 °C (68 °F) Fuse Rectifier Regulator Output peak voltage At 1500 r/min (loaded) At 3500 r/min (loaded)

Unit

Model F225CA

LF225CA

F250CA

LF250CA

0 V V V

6.9 38.0 83.2

Ω A

0.1056–0.1584 100

V V

13.0 13.0

Unit

1 2 3

Model F300CA

LF300CA

V V V

6.9 38.0 83.2

Ω A

0.1056–0.1584 100

V V

13.0 13.0

4 5 6 7

(*1) The figures are for reference only.

Starting system Item Y-COP Input voltage Starter motor Type Output Cranking time limit Commutator Standard diameter Wear limit Standard undercut Wear limit

Unit

Model F225CA

LF225CA

F250CA

12.0

kW second

Sliding gear 1.70 30

mm (in) mm (in) mm (in) mm (in)

29.0 (1.14) 28.0 (1.10) 0.5–0.8 (0.02–0.03) 0.2 (0.01)

LF250CA

9 10

A 1-14

SPEC

Specification Item

Brush Standard length Wear limit Item Y-COP Input voltage Starter motor Type Output Cranking time limit Commutator Standard diameter Wear limit Standard undercut Wear limit Brush Standard length Wear limit

Unit

Model F225CA

LF225CA

mm (in) mm (in) Unit

F250CA

LF250CA

15.5 (0.61) 9.5 (0.37) Model F300CA

LF300CA 12.0

kW second

Sliding gear 1.70 30

mm (in) mm (in) mm (in) mm (in)

29.0 (1.14) 28.0 (1.10) 0.5–0.8 (0.02–0.03) 0.2 (0.01)

mm (in) mm (in)

15.5 (0.61) 9.5 (0.37)

Gauge/sensor Item Water pressure sensor Input voltage Output voltage (*1) At 392.0 kPa (3.92 kgf/cm2, 56.8 psi) At 784.0 kPa (7.84 kgf/cm2, 113.7 psi) Speed sensor Input voltage Output voltage (*1) At 392.0 kPa (3.92 kgf/cm2, 56.8 psi) At 784.0 kPa (7.84 kgf/cm2, 113.7 psi) (*1) The figures are for reference only.

1-15

Unit

Model F225CA

LF225CA

F250CA

4.75–5.25

2.5

4.5

4.75–5.25

2.5

4.5

LF250CA

Electrical system technical data Item Water pressure sensor Input voltage Output voltage (*1) At 392.0 kPa (3.92 kgf/cm2, 56.8 psi) At 784.0 kPa (7.84 kgf/cm2, 113.7 psi) Speed sensor Input voltage Output voltage (*1) At 392.0 kPa (3.92 kgf/cm2, 56.8 psi) At 784.0 kPa (7.84 kgf/cm2, 113.7 psi)

Unit

Model F300CA

LF300CA

4.75–5.25

2.5

4.5

4.75–5.25

2.5

4.5

0 1 2 3

(*1) The figures are for reference only.

4 5 6 7 8 9 10

A 1-16

SPEC

Specification

Fuel system technical data Fuel system Item

Unit

Model F225CA

LF225CA

F250CA

LF250CA

Fuel filter assembly Holding pressure Positive pressure Negative pressure

kPa (kgf/ cm2, psi) kPa (kgf/ cm2, psi)

200.0 (2.00, 29.0) 80.0 (0.80, 11.6)

Canister Holding pressure Positive pressure

kPa (kgf/ cm2, psi)

19.6 (0.196, 2.8)

kPa (kgf/ cm2, psi)

170.0 (1.70, 24.7)

mm (in)

67.5 ± 2.5 (2.66 ± 0.10)

Primer pump Holding pressure Positive pressure Vapor separator tank Float height Item

Unit

Model F300CA

LF300CA

Fuel filter assembly Holding pressure Positive pressure Negative pressure

kPa (kgf/ cm2, psi) kPa (kgf/ cm2, psi)

200.0 (2.00, 29.0) 80.0 (0.80, 11.6)

Canister Holding pressure Positive pressure

kPa (kgf/ cm2, psi)

19.6 (0.196, 2.8)

kPa (kgf/ cm2, psi)

170.0 (1.70, 24.7)

mm (in)

67.5 ± 2.5 (2.66 ± 0.10)

Primer pump Holding pressure Positive pressure Vapor separator tank Float height

1-17

Fuel system technical data / Power unit technical data

Power unit technical data Power unit Item

Unit

Model F225CA

LF225CA

F250CA

LF250CA

Compression pressure Minimum (*1) Engine oil Oil pressure (*2) At 60 °C (140 °F) with SL 10W-30 engine oil and at 750 r/min At 68 °C (154 °F) with SL 10W-30 engine oil and at 3000 r/min Timing belt Installation height Thermostat Valve opening temperature Fully open temperature Fully open stroke Replacement engine oil quantity (at periodic maintenance) Without oil filter replacement With oil filter replacement

kPa (kgf/ cm2, psi)

700.0 (7.00, 101.5)

kPa (kgf/ cm2, psi)

350.0 (3.50, 50.8)

kPa (kgf/ cm2, psi)

590.0 (5.90, 85.6)

mm (in)

2.5 (0.10)

°C (°F) °C (°F) mm (in)

50.0–54.0 (122.0–129.0) 62.0 (144.0) 4.3 (0.17)

1 2 3 4 5

L (US qt, Imp qt) L (US qt, Imp qt)

6.0 (6.34, 5.28)

6.3 (6.66, 5.54)

(*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 F300CA

Engine oil Oil pressure (*2) At 60 °C (140 °F) with SL 10W-30 engine oil and at 750 r/min At 68 °C (154 °F) with SL 10W-30 engine oil and at 3000 r/min Timing belt Installation height

kPa (kgf/ cm2, psi)

700.0 (7.00, 101.5)

kPa (kgf/ cm2, psi)

350.0 (3.50, 50.8)

kPa (kgf/ cm2, psi)

590.0 (5.90, 85.6)

mm (in)

2.5 (0.10)

7 8

LF300CA

Compression pressure Minimum (*1)

9 10

A 1-18

SPEC

Specification Item

Thermostat Valve opening temperature Fully open temperature Fully open stroke Replacement engine oil quantity (at periodic maintenance) Without oil filter replacement With oil filter replacement

Unit

Model F300CA

°C (°F) °C (°F) mm (in)

LF300CA

50.0–54.0 (122.0–129.0) 62.0 (144.0) 4.3 (0.17)

L (US qt, Imp qt) L (US qt, Imp qt)

6.0 (6.34, 5.28) 6.3 (6.66, 5.54)

Cylinder head assembly Item Valve lifter Outside diameter Valve lifter clearance Camshaft Cam lobe height Intake Exhaust Cam lobe width Intake and exhaust Journal diameter Runout Cylinder head Warpage limit Journal inside diameter Valve spring Free length Tilt limit Valve Clearance Intake Exhaust Seat contact width Intake Exhaust Margin thickness Intake Exhaust

1-19

Unit

Model F225CA

LF225CA

F250CA

LF250CA

mm (in) mm (in)

30.970–30.980 (1.2193–1.2197) 0.020–0.055 (0.0008–0.0022)

mm (in) mm (in)

46.661–46.761 (1.8370–1.8410) 46.960–47.060 (1.8488–1.8528)

mm (in) mm (in) mm (in)

35.950–36.050 (1.4154–1.4193) 24.960–24.980 (0.9827–0.9835) 0.030 (0.0012)

mm (in) mm (in)

0.10 (0.0039) 25.000–25.021 (0.9843–0.9851)

mm (in) mm (in)

48.1 (1.89) 1.7 (0.07)

mm (in) mm (in)

0.205 ± 0.035 (0.0081 ± 0.0014) 0.345 ± 0.035 (0.0136 ± 0.0014)

mm (in) mm (in)

1.100–1.400 (0.0433–0.0551) 1.400–1.700 (0.0551–0.0669)

mm (in) mm (in)

0.750–1.150 (0.0295–0.0453) 0.900–1.300 (0.0354–0.0512)

Power unit technical data Item Valve stem Diameter Intake Exhaust Runout Intake and exhaust Valve guide Inside diameter Intake and exhaust Valve guide clearance Intake Exhaust Installation height Item Valve lifter Outside diameter Valve lifter clearance Camshaft Cam lobe height Intake Exhaust Cam lobe width Intake and exhaust Journal diameter Runout Cylinder head Warpage limit Journal inside diameter Valve spring Free length Tilt limit Valve Clearance Intake Exhaust Seat contact width Intake Exhaust Margin thickness Intake Exhaust

Unit

Model F225CA

LF225CA

F250CA

LF250CA

mm (in) mm (in)

5.477–5.492 (0.2156–0.2162) 5.464–5.479 (0.2151–0.2157)

mm (in)

0.01 (0.0004)

mm (in)

5.504–5.522 (0.2167–0.2174)

mm (in) mm (in) mm (in)

0.012–0.045 (0.0005–0.0018) 0.025–0.058 (0.0010–0.0023) 11.300–11.700 (0.4449–0.4606)

Unit

0 1 2 3

Model F300CA

LF300CA

mm (in) mm (in)

30.970–30.980 (1.2193–1.2197) 0.020–0.055 (0.0008–0.0022)

mm (in) mm (in)

46.661–46.761 (1.8370–1.8410) 46.960–47.060 (1.8488–1.8528)

mm (in) mm (in) mm (in)

35.950–36.050 (1.4154–1.4193) 24.960–24.980 (0.9827–0.9835) 0.030 (0.0012)

mm (in) mm (in)

0.10 (0.0039) 25.000–25.021 (0.9843–0.9851)

mm (in) mm (in)

48.1 (1.89) 1.7 (0.07)

mm (in) mm (in)

0.205 ± 0.035 (0.0081 ± 0.0014) 0.345 ± 0.035 (0.0136 ± 0.0014)

mm (in) mm (in)

1.100–1.400 (0.0433–0.0551) 1.400–1.700 (0.0551–0.0669)

mm (in) mm (in)

0.750–1.150 (0.0295–0.0453) 0.900–1.300 (0.0354–0.0512)

4 5 6 7 8 9 10

A 1-20

SPEC

Specification Item

Valve stem Diameter Intake Exhaust Runout Intake and exhaust Valve guide Inside diameter Intake and exhaust Valve guide clearance Intake Exhaust Installation height

Unit

Model F300CA

LF300CA

mm (in) mm (in)

5.477–5.492 (0.2156–0.2162) 5.464–5.479 (0.2151–0.2157)

mm (in)

0.01 (0.0004)

mm (in)

5.504–5.522 (0.2167–0.2174)

mm (in) mm (in) mm (in)

0.012–0.045 (0.0005–0.0018) 0.025–0.058 (0.0010–0.0023) 11.300–11.700 (0.4449–0.4606)

Crankcase assembly Item Piston Diameter Measuring point Piston clearance Ring groove (top) Ring groove (2nd) Ring groove (oil) Pin boss inside diameter Pin outside diameter Cylinder Bore Piston ring Top ring Type Dimension height (B) Dimension width (T) End gap (*1) Side clearance 2nd ring Type Dimension height (B) Dimension width (T) End gap (*1) Side clearance Oil ring Dimension height (B) Dimension width (T) End gap (*1) Side clearance

1-21

Unit

Model F225CA

LF225CA

F250CA

LF250CA

mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in)

95.945–95.960 (3.7774–3.7779) 13.500 (0.5315) 0.040–0.067 (0.0016–0.0026) 1.230–1.250 (0.0484–0.0492) 1.220–1.240 (0.0480–0.0488) 2.510–2.530 (0.0988–0.0996) 22.011–22.018 (0.8666–0.8668) 21.996–22.005 (0.8660–0.8663)

mm (in)

96.000–96.012 (3.7795–3.7800)

mm (in) mm (in) mm (in) mm (in)

Barrel 1.200 (0.0472) 2.800–3.000 (0.1102–0.1181) 0.200–0.300 (0.0079–0.0118) 0.030–0.050 (0.0012–0.0020)

mm (in) mm (in) mm (in) mm (in)

Taper 1.170–1.190 (0.0461–0.0469) 3.800–4.000 (0.1496–0.1575) 0.600–0.750 (0.0236–0.0295) 0.030–0.070 (0.0012–0.0028)

mm (in) mm (in) mm (in) mm (in)

2.400–2.470 (0.0945–0.0972) 2.350–2.750 (0.0925–0.1083) 0.150–0.600 (0.0059–0.0236) 0.040–0.130 (0.0016–0.0051)

Power unit technical data Item Connecting rod Small end inside diameter Big end inside diameter Big end side clearance Oil clearance (*1) Crankshaft Journal diameter Crankpin diameter Runout Crankpin width Crankcase Oil clearance (*1)

Unit

Model F225CA

LF225CA

F250CA

LF250CA

mm (in) mm (in) mm (in) mm (in)

22.010–22.024 (0.8665–0.8671) 55.990–56.010 (2.2043–2.2051) 0.140–0.310 (0.0055–0.0122) 0.025–0.050 (0.0010–0.0020)

mm (in) mm (in) mm (in) mm (in)

72.976–72.996 (2.8731–2.8739) 52.980–53.000 (2.0858–2.0866) 0.030 (0.0012) 21.000–21.100 (0.8268–0.8307)

mm (in)

0.029–0.045 (0.0011–0.0018)

0 1 2 3

(*1) The figures are for reference only. Item Piston Diameter Measuring point Piston clearance Ring groove (top) Ring groove (2nd) Ring groove (oil) Pin boss inside diameter Pin outside diameter Cylinder Bore Piston ring Top ring Type Dimension height (B) Dimension width (T) End gap (*1) Side clearance 2nd ring Type Dimension height (B) Dimension width (T) End gap (*1) Side clearance Oil ring Dimension height (B) Dimension width (T) End gap (*1) Side clearance

Unit

Model F300CA

LF300CA

mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in)

mm (in)

96.000–96.012 (3.7795–3.7800)

4 5 6 7

mm (in) mm (in) mm (in) mm (in)

Barrel 1.200 (0.0472) 2.800–3.000 (0.1102–0.1181) 0.200–0.300 (0.0079–0.0118) 0.030–0.050 (0.0012–0.0020)

mm (in) mm (in) mm (in) mm (in)

Taper 1.170–1.190 (0.0461–0.0469) 3.800–4.000 (0.1496–0.1575) 0.600–0.750 (0.0236–0.0295) 0.030–0.070 (0.0012–0.0028)

mm (in) mm (in) mm (in) mm (in)

2.400–2.470 (0.0945–0.0972) 2.350–2.750 (0.0925–0.1083) 0.150–0.600 (0.0059–0.0236) 0.040–0.130 (0.0016–0.0051)

8 9 10

A 1-22

SPEC

Specification Item

Connecting rod Small end inside diameter Big end inside diameter Big end side clearance Oil clearance (*1) Crankshaft Journal diameter Crankpin diameter Runout Crankpin width Crankcase Oil clearance (*1) (*1) The figures are for reference only.

1-23

Unit

Model F300CA

LF300CA

mm (in) mm (in) mm (in) mm (in)

22.010–22.024 (0.8665–0.8671) 55.990–56.010 (2.2043–2.2051) 0.140–0.310 (0.0055–0.0122) 0.025–0.050 (0.0010–0.0020)

mm (in) mm (in) mm (in) mm (in)

72.976–72.996 (2.8731–2.8739) 52.980–53.000 (2.0858–2.0866) 0.030 (0.0012) 21.000–21.100 (0.8268–0.8307)

mm (in)

0.029–0.045 (0.0011–0.0018)

Power unit technical data / Lower unit technical data

Lower unit technical data Lower unit assembly (regular rotation model) Item

Unit

Model F225CA

F250CA

F300CA

Lower unit Holding pressure Forward gear backlash (*1) Reverse gear backlash (*1) Pinion shim (T3) Forward gear shim (T1) Reverse gear shim (T2) Propeller shaft shim (T4) Propeller shaft Motive torque Runout Drive shaft Motive torque Runout

kPa (kgf/ cm2, psi) mm (in) mm (in) mm mm mm mm

68.6 (0.686, 9.9)

N·m (kgf·m, ft·lb) mm (in)

0.04–0.59 (0.0016–0.0232) 0.15–0.88 (0.0059–0.0346) 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50 2.00, 2.03, 2.06, 2.09, 2.12, 2.15 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50 0.7, 0.8, 0.9, 1.0, 1.1, 1.2

N·m (kgf·m, ft·lb) mm (in)

2 3

0.44–1.32 (0.04–0.13, 0.32–0.97) 0.02 (0.0008)

0.27–1.94 (0.03–0.20, 0.20–1.43) 1.0 (0.0394)

(*1) Figures obtained using the special service tools.

Lower unit assembly (counter rotation model) Item

Unit

Model LF225CA

LF250CA

LF300CA

Lower unit Holding pressure Forward gear backlash (*1) Reverse gear backlash (*1) Pinion shim (T3) Forward gear shim (T2) Reverse gear shim (T1) Propeller shaft shim (T4) Propeller shaft Free play Runout Drive shaft Motive torque Runout

kPa (kgf/ cm2, psi) mm (in) mm (in) mm mm mm mm

0.18–0.76 (0.0071–0.0299) 0.19–0.84 (0.0075–0.0331) 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50 2.00, 2.03, 2.06, 2.09, 2.12, 2.15 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50

mm (in) mm (in)

0.25–0.35 (0.0098–0.0138) 0.02 (0.0008)

N·m (kgf·m, ft·lb) mm (in)

68.6 (0.686, 9.9)

7 8 9 10

0.27–1.94 (0.03–0.20, 0.20–1.43) 1.0 (0.0394)

(*1) Figures obtained using the special service tools.

A 1-24

SPEC

Specification

Bracket unit technical data PTT system Item

Unit

Model F225CA

LF225CA

F250CA

LF250CA

PTT Hydraulic pressure MPa (kgf/ cm2, psi) MPa (kgf/ cm2, psi)

Down Up Motor commutator Standard diameter Wear limit Standard undercut (*1) Wear limit Motor brush Standard length Wear limit

6.7–8.7 (67.0–87.0, 971.5–1261.5) 13.0–15.0 (130.0–150.0, 1885.0–2175.0)

mm (in) mm (in) mm (in) mm (in)

23.0 (0.91) 22.0 (0.87) 1.4 (0.06) 0.9 (0.04)

mm (in) mm (in)

11.5 (0.45) 4.5 (0.18)

(*1) The figures are for reference only. Item

Unit

Model F300CA

LF300CA

PTT Hydraulic pressure Down Up

MPa (kgf/ cm2, psi) MPa (kgf/ cm2, psi)

Motor commutator Standard diameter Wear limit Standard undercut (*1) Wear limit Motor brush Standard length Wear limit (*1) The figures are for reference only.

1-25

6.7–8.7 (67.0–87.0, 971.5–1261.5) 13.0–15.0 (130.0–150.0, 1885.0–2175.0)

mm (in) mm (in) mm (in) mm (in)

23.0 (0.91) 22.0 (0.87) 1.4 (0.06) 0.9 (0.04)

mm (in) mm (in)

11.5 (0.45) 4.5 (0.18)

Bracket unit technical data / Specified tightening torque

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 Part to be tightened

Screw size

Water pressure sensor adapter Water pressure sensor Receiver screw

— — M4

Tightening torques N·m kgf·m ft·lb 23 2.3 17.0 18 1.8 13.3 4 0.4 3.0

Fuel system Part to be tightened

Screw size

Fuel cup assembly Intake manifold bolt

— 1st 2nd 1st 2nd

Intake silencer bolt Surge tank bracket bolt Fuel pump cover bolt Vapor separator drain screw Needle valve assembly screw Float pin screw Float chamber cover screw Vapor separator cover bolt Pressure regulator screw Fuel cooler cover screw

M8 M6 M6 M6 M6 — M4 M4 M5 M4 M5 M5

N·m 5 24 24 11 11 7 11 5 2 2 2 2 2 4 4

Tightening torques kgf·m ft·lb 0.5 3.7 2.4 17.7 2.4 17.7 1.1 8.1 1.1 8.1 0.7 5.2 1.1 8.1 0.5 3.7 0.2 1.5 0.2 1.5 0.2 1.5 0.2 1.5 0.2 1.5 0.4 3.0 0.4 3.0

1 2 3 4 5 6 7

Power unit Part to be tightened

Screw size

Spark plug Power unit mounting bolts

— 1st 2nd

Apron screw PTT motor lead bolt Pulser coil bolt Flywheel magnet bolt Starter motor lead screw Fuse box screw Terminal bolt PTT relay nut Starter motor nut

M10 M6 M6 M5

1st 2nd

M10 M4 ø5 M8 — —

Tightening torques N·m kgf·m ft·lb 28 2.8 20.7 42 4.2 31.0 42 4.2 31.0 3 0.3 2.2 4 0.4 3.0 4 0.4 3.0 40 4.0 29.5 90° 2 0.2 1.5 2 0.2 1.5 25 2.5 18.4 5 0.5 3.7 9 0.9 6.6

1-26

8 9 10

SPEC

Specification Part to be tightened

Rectifier Regulator cover bolt

Screw size 1st 2nd

M8 M6 M8 M6 M6 — M10

Starter motor bracket bolt Starter motor bolt Engine ECM bolt Shift actuator bolt Timing belt tensioner bolt Pulley bolt Camshaft cap bolts

1st 2nd

Driven sprocket bolt VCT bolt VCT cap Exhaust plug Braided plug OCV bolt Cylinder head bolt

1st 2nd 1st 2nd

Connecting rod bolt

Crankcase bolt

M11 M8 M6

1st 2nd

Bracket bolt Oil filter union bolt Oil pressure sensor Oil filter Thermostat housing bolt Thermostat cover bolt Knock sensor Knock sensor bracket bolt Pulley bracket bolt

M7 M10 — — M18 M14 M6

Oil pump cover screw Oil cooler bolt

M6 M6 UNF — — M6 M6 — M6

1st 2nd 1st 2nd 1st 2nd 1st 2nd

M8 M9 M10 M8

Tightening torques N·m kgf·m ft·lb 6 0.6 4.4 12 1.2 8.9 25 2.5 18.4 12 1.2 8.9 30 3.0 22.1 7 0.7 5.2 19 1.9 14.0 39 3.9 28.8 39 3.9 28.8 8 0.8 5.9 17 1.7 12.5 60 6.0 44.3 60 6.0 44.3 32 3.2 23.6 56 5.6 41.3 23 2.3 17.0 7 0.7 5.2 39 3.9 28.8 180° 14 1.4 10.3 28 2.8 20.7 4 0.4 3.0 6 0.6 4.4 12 1.2 8.9 12 1.2 8.9 49 4.9 36.1 13 1.3 9.6 18 1.8 13.3 12 1.2 8.9 12 1.2 8.9 32 3.2 23.6 12 1.2 8.9 14 1.4 10.3 28 2.8 20.7 40 4.0 29.5 90° 55 5.5 40.6 90° 14 1.4 10.3 28 2.8 20.7

Lower unit (regular rotation model) Part to be tightened Water inlet cover bolt Drain screw Check screw

1-27

Screw size M5 — —

Tightening torques N·m kgf·m ft·lb 2 0.2 1.5 9 0.9 6.6 9 0.9 6.6

Specified tightening torque Part to be tightened Trim tab bolt Propeller nut Lower case mounting bolt (X-transom model) Lower case stud bolt (U-transom model) Lower case mounting nut (U-transom model) Lower case mounting bolt (U-transom model) Water inlet cover screw Propeller shaft housing ring nut Cover bolt Drive shaft nut Drive shaft ring nut Pinion nut

Screw size M10 — M10 — — M10 M5 — M8 — — —

Tightening torques N·m kgf·m ft·lb 42 4.2 31.0 54 5.4 39.8 47 4.7 34.7 23 2.3 17.0 47 4.7 34.7 47 4.7 34.7 1 0.1 0.7 155 15.5 114.3 8 0.8 5.9 40 4.0 29.5 177 17.7 130.5 143 14.3 105.5

Water inlet cover bolt Drain screw Check screw Trim tab bolt Propeller nut Lower case mounting bolt (X-transom model) Lower case stud bolt (U-transom model) Lower case mounting nut (U-transom model) Lower case mounting bolt (U-transom model) Water inlet cover screw Propeller shaft housing ring nut Cover bolt Drive shaft nut Drive shaft ring nut Pinion nut

Screw size M5 — — M10 — M10 — — M10 M5 — M8 — — —

Tightening torques N·m kgf·m ft·lb 2 0.2 1.5 9 0.9 6.6 9 0.9 6.6 42 4.2 31.0 54 5.4 39.8 47 4.7 34.7 23 2.3 17.0 47 4.7 34.7 47 4.7 34.7 1 0.1 0.7 155 15.5 114.3 8 0.8 5.9 40 4.0 29.5 177 17.7 130.5 143 14.3 105.5

Bracket unit Part to be tightened Speed sensor Adapter screw Upper mounting nut Lower mounting nut Upper mount bracket bolt Lower mount bracket bolt Upper case bolt Anode screw Drain bolt Oil strainer bolt Exhaust manifold bolt

1 2 3

Lower unit (counter rotation model) Part to be tightened

Screw size — ø6 — — M10 M10 M10 M8 M6 — M6 M8

N·m 18 4 72 72 55 55 42 20 4 27 12 20

Tightening torques kgf·m ft·lb 1.8 13.3 0.4 3.0 7.2 53.1 7.2 53.1 5.5 40.6 5.5 40.6 4.2 31.0 2.0 14.8 0.4 3.0 2.7 19.9 1.2 8.9 2.0 14.8

1-28

4 5 6 7 8 9 10

SPEC

Specification Part to be tightened

Oil pan bolt Muffler bolt Plate screw Self-locking nut Grease nipple Trim sensor screw

Screw size M8 M8 M6 — — M6

Tightening torques N·m kgf·m ft·lb 20 2.0 14.8 20 2.0 14.8 4 0.4 3.0 23 2.3 17.0 3 0.3 2.2 4 0.4 3.0

PTT unit Part to be tightened Reservoir mounting bolt Reservoir cap PTT motor mounting bolt Pump bracket bolt Gear pump bolt Manual valve Tilt ram Tilt piston screw Pipe joint Pipe joint adapter Trim cylinder end screw Tilt cylinder end screw

1-29

Screw size M8 — M8 M5 M5 — — M6 — — — —

N·m 19 7 19 7 7 2 65 7 15 20 160 90

Tightening torques kgf·m ft·lb 1.9 14.0 0.7 5.2 1.9 14.0 0.7 5.2 0.7 5.2 0.2 1.5 6.5 47.9 0.7 5.2 1.5 11.1 2.0 14.8 16.0 118.0 9.0 66.4

Specified tightening torque / General tightening torque

General tightening torque This chart indicates the tightening torques for standard fasteners with a standard ISO thread pitch. Width across flats (A) 8 mm 10 mm 12 mm 14 mm 17 mm

Screw size (B) M5 M6 M8 M10 M12

General torque specifications N·m kgf·m ft·lb 3.7 0.5 5 5.9 0.8 8 13.3 1.8 18 26.6 3.6 36 31.7 4.3 43

1 2 3 4 5 6 7 8 9 10

A 1-30

SPEC

Specification

— MEMO —

1-31

TECH FEA

Technical features and description 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

0 1 2 3 4 5 6 7

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

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 trouble codes on the YDIS. It is also equipped with Y-COP as an anti-theft measure (optional). Check valve Air Pressure regulator

Filter

Canister

Check valve High-pressure fuel pump

Low-pressure fuel pump Water separator Fuel Water detection switch

Vapor separator Fuel injector

OCV

Vapor shut-off valve

Ignition coil

TPS

LPS

ETV Air

Ignition coil

OCV

Shift actuator Fuel injector

Digital Electronic Control ECM

Shift control Valve control Fuel control Ignition control Command Link Plus Multifunction Color Gauge

Engine ECM Battery Hub

Y-COP (optional)

2-1

Cam position sensor Engine Pulser coil Air pressure sensor start switch Oil pressure sensor SPS Air temperature sensor Knock sensor Engine temperature sensor Thermoswitch Water pressure sensor (optional) Speed sensor (optional)

YDIS

Engine shut-off switch

Electronic control system

Engine ECM component e

b a

1 2

j p q

y o

l n m

5 6

x r

w v 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)

9 10

A 2-2

TECH FEA

Technical features and description

Sensor, switch, and actuator Engine ECM

Pulser coil

Cam position sensor (PORT EX)

Cam position sensor (PORT IN) Cam position sensor (STBD IN) TPS 1 TPS 2 SPS 1 SPS 2 ETV Shift actuator Air pressure sensor Air temperature sensor Engine temperature sensor Oil pressure sensor Thermoswitch Knock sensor Engine shut-off switch Fuel injector Ignition coil Vapor shut-off valve OCV

High-pressure fuel pump

2-3

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. 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). 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). Detects the advance angle on the port camshaft. Detects the advance angle on the starboard camshaft. 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 malfunctions. 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. Opens and closes the throttle valve using a motor. Drives the motor according to the engine ECM command for engaging or disengaging the gearshift. Detects the intake air pressure. Detects the intake air temperature. Detects the engine temperature. Detects the oil pressure. Detects engine overheating. Detects engine knocking. Stops the engine forcibly. Injects fuel. Activates the ignition. Controls the amount of vapor gas to be sent from the vapor separator to the intake system. 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. Pressurizes the fuel and sends the fuel to the fuel rails.

Electronic control system Low-pressure fuel pump

Sends the fuel from the fuel tank to the vapor separator.

0 1 2 3 4 5 6 7 8 9 10

A 2-4

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 injection. 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, various compensations are made to determine the actual fuel injection timing and fuel injection amount. Also, a fuel injector anti-sticking control has been adopted. Pulser coil Cam position sensor (PORT EX)

Fuel injector

Cam position sensor (PORT IN) Cam position sensor (STBD IN) High-pressure fuel pump

TPS SPS

Engine ECM

LPS Air pressure sensor

Low-pressure fuel pump

Air temperature sensor Engine temperature sensor Thermoswitch Engine shut-off switch

Battery

2-5

Vapor shut-off valve

Electronic control system 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. Fuel injection type Simultaneous fuel injection in the start-up mode Group fuel injection in the start-up mode

Group fuel injection in the normal operating mode

Sequential fuel injection in the normal operating mode

Fuel injection timing All cylinders according to the fuel injection setting data Each cylinder group (#1 and #4, #2 and #5, and #3 and #6) at BTDC 430° (BTDC 70° according to the exhaust TDC) Each cylinder group (#1 and #4, #2 and #5, and #3 and #6) according to the exhaust and compression TDCs 2 times for every 2 turns of the crankshaft Each cylinder according to the injection completion timing, which is set using the exhaust TDC

Fuel injection amount

Condition

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 Until engine starting is detected (500 r/min or more)

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)

After cylinder identification is completed by the cam position sensor (PORT EX)

1 2 3 4 5 6

Example: Group fuel injection in the start-up mode

#1 Compression Combustion Exhaust Intake Compression Intake Compression Combustion Exhaust Intake #2 Intake Intake Compression Combustion Exhaust #3 Exhaust Exhaust Intake Compression Combustion Exhaust #4 Combustion Exhaust Intake Compression Combustion #5 Combustion Exhaust Intake Compression #6 Compression Pulser coil signal Cam position sensor (EX) signal

7 8 9 10

Injection #1 Injection #2 Injection #3 Injection #4 Injection #5 Injection #6

A 2-6

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 simultaneously 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 â&#x20AC;&#x153;Engine speed controlâ&#x20AC;? (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. Compensation For changes in intake air pressure For changes in intake air temperature During warm-up After start-up For atmospheric pressure During dashpot function operation For changes in air and fuel ratio During acceleration For retarded ignition timing

Corresponding sensor Air pressure sensor Air temperature sensor Engine temperature sensor Engine temperature sensor Air pressure sensor Air pressure sensor, LPS, SPS, and pulser coil Air pressure sensor, engine temperature sensor, and pulser coil Air pressure sensor and TPS Engine temperature sensor and pulser coil

Fuel injector anti-sticking control After the engine start switch is turned to ON and before the high-pressure fuel pump starts operating, the engine ECM sends a signal once to actuate all of the fuel injectors simultaneously to prevent the fuel injector valves from sticking.

2-7

Electronic control system

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 â&#x20AC;&#x153;Knock controlâ&#x20AC;? (2-11).

0 1

Pulser coil Cam position sensor (PORT EX)

Cam position sensor (PORT IN)

Cam position sensor (STBD IN)

TPS LPS Engine ECM

Ignition coil

SPS

5 6

Air pressure sensor Engine temperature sensor

7 Knock sensor

Engine shut-off switch Battery

9 10

A 2-8

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. Basic ignition timing Engine starting ignition timing (BTDC 10°) Idling basic ignition timing Normal basic ignition timing

Criteria Engine is starting (less than 500 r/min) Engine speed is at engine idle speed Engine speed is more than engine idle speed

Ignition cylinder All cylinders simultaneously Each cylinder sequentially Each cylinder sequentially

Ignition timing restriction The advancing or retarding of the ignition timing is restricted according to the engine speed, engine temperature, and dashpot function. Restriction Engine speed restriction

Corresponding sensor Pulser coil

Engine temperature restriction

Engine temperature sensor

Dashpot function restriction (when the throttle valve is closed quickly)

Pulser coil and LPS

Details The ignition timing is restricted between BTDC 50° (advance angle) and ATDC 20° (retard angle) according to the engine speed. The ignition timing is restricted between BTDC 50° (advance angle) and ATDC 30° (retard angle) according to the engine temperature. The ignition timing is restricted to ATDC 20° when the dashpot function operates.

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. Compensation After start-up For stable idle speed During dashpot function operation For shift-cutout control During acceleration

2-9

Corresponding sensor Engine temperature sensor LPS and pulser coil LPS, SPS, and pulser coil Pulser coil and SPS Air pressure sensor and TPS

Electronic control system

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 operated and the VCT assemblies are advanced, retarded, or maintained in the current position to control the intake valve opening timing.

Pulser coil

Cam position sensor (PORT EX)

Cam position sensor (PORT IN) Cam position sensor (STBD IN)

TPS

OCV (PORT)

OCV (STBD)

Engine ECM

LPS

Air pressure sensor

Engine temperature sensor

7 8 9 10

A 2-10

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 damage. 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: Engine temperature Engine speed Less than 4500 r/min

4500 r/min or more

Less than 20 °C (68 °F) Knock control does not activate

20–25 °C (68–77 °F) Knock control activates if conditions continue for 0.5 seconds Knock control activates

More than 25 °C (77 °F) Knock control activates

The knock control also activates when the engine temperature sensor is malfunctioning regardless of the preceding conditions.

2-11

Electronic control system

Engine speed control In engine speed control, the engine ECM decreases the engine speed to protect the engine from damage.

Pulser coil

Air pressure sensor Cam position sensor (PORT EX)

Fuel injector

Cam position sensor (PORT IN) Cam position sensor (STBD IN)

Ignition coil

TPS Engine ECM

LPS ETV motor

SPS Engine temperature sensor

Digital Electronic Control ECM

Oil pressure sensor

Thermoswitch Engine shut-off switch

Command Link Plus Multifunction Color Gauge

7 8

Overheat control Criteria The thermoswitch is on.

Description The engine ECM controls the throttle valve opening. As a result, the engine speed cannot increase to more than 2000â&#x20AC;&#x201C; 3000 r/min. Also, the alert buzzer sounds and the overheat alert indicator comes on.

Low oil pressure control Criteria The pressure decreases to less than 250 kPa (2.5 kgf/cm2, 36.25 psi).

2-12

9 10

TECH FEA

Technical features and description

Skip-firing control Criteria 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.

Description 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. 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 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. Decreases the engine speed to less than 1500 r/min.

Engine is over revving.

Controls the engine speed when over revving is detected.

Engine is rotating in reverse.

Stops the engine if the engine reverse rotation is detected.

Engine speed is high when shifting gears.

Detects the activation of shift cutout control, and controls the engine speed. Cancels the fuel injection control and ignition control at all of the cylinders.

Engine shut-off switch is on.

2-13

Electronic control system

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 learning 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.

0 1

Pulser coil

LPS

TPS

Air pressure sensor Engine ECM

ETV motor

Engine temperature sensor

6 Thermoswitch

7 SPS

8 9 10

A 2-14

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.

Pulser coil

Shift actuator

Cam position sensor (PORT EX)

Fuel injector

Cam position sensor (PORT IN) Ignition coil Cam position sensor (STBD IN)

Engine ECM

ETV motor

TPS

SPS

2-15

Digital Electronic Control ECM

Electronic control system

Fail-safe control In fail-safe control, the engine ECM enters the fail-safe mode when an electrical component malfunctions. The fail-safe control system records the trouble codes according to the engine trouble conditions. Trouble code 13 15

17 23 24

29 39

73 74 86

Item Pulser coil Engine temperature sensor Knock sensor Air temperature sensor Cam position sensor (PORT EX) Air pressure sensor Oil pressure sensor Cam position sensor (PORT EX) Cam position sensor (PORT IN) OCV (STBD) OCV (PORT) Y-COP

LAN gauge display C/E C/E C/E C/E

No signal Open or short circuit in the engine temperature sensor circuit. Output voltage is less than 0.18 V or more than 4.90 V. Output voltage is less than 0.90 V or more than 4.00 V. Output voltage is less than 0.10 V or more than 4.60 V.

L (*1)

1 2 3

C/E Output voltage is less than 0.20 V or more than 4.50 V. 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. Signal error (irregular)

4 5

C/E

Signal error (irregular) C/E C/E C/E C/E

112, 113, 114, 115, 116, 117, 118, 119, 121, 122, 123, 129, 136, 137, 138, 139, 141, 142, 144, 145 124, 125, 126, 127, 128

Trouble conditions to be detected

Signal error (irregular)

C/E

ETV

Open or short circuit in the OCV circuit Open or short circuit in the OCV circuit Open or short circuit in the Y-COP circuit Communication error continues for more than 3 seconds. Open or short circuit in the ETV relay and ETV motor circuit

7 8 9

C/E

10 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.

A 2-16

TECH FEA

Technical features and description

Trouble code 146, 147, 148, 149, 150, 153, 154, 155 156, 157 160, 161, 162, 163, 164, 165, 166, 167, 168, 169, 170, 171, 172, 173, 174, 175, 176, 177, 178, 179, 180, 181

Item

LAN gauge display

SPS C/E Extension wiring harness LPS

C/E

(*1) Low oil pressure alert is displayed.

2-17

Trouble conditions to be detected Open or short circuit in the SPS circuit, and shift actuator does not operate.

Communication error between the engine ECM and Digital Electronic Control Open or short circuit in the LPS circuit

Electronic control system

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) battery. 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 connected, the regulator function of the Rectifier Regulator will be turned off by the engine ECM to increase the efficiency of charging the main battery.

0 1 2

Lighting coil (stator assembly)

3 Engine ECM

Fuse box Rectifier Regulator

5 Isolator lead (optional)

6 House battery (optional)

Main battery

8 9 10

A 2-18

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 succeeded. 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 signals. The electric controlled shift-in or shift-out provides smooth, reliable, and quiet gear shift engagement. The Command Link Plus Multifunction Color Gauge and the new engine start switch can be installed (optional).

2-19

Electronic control system

Command Link Plus Multifunction Color Gauge Command Link Plus Multifunction Color Gauge

SET

CANCEL

Hub

Control lever

Hub

Control lever

Main switch

Engine start/ stop button

LPS

Digital Electronic Control ECM (PORT)

LPS

Digital Electronic Control ECM (STBD)

Digital Electronic Control ECM (center)

Y-COP (optional)

LPS

Engine shut-off switch

Digital Electronic Control ECM (PORT)

Station selector switch

LPS

Digital Electronic Control ECM (center)

Engine ECM

Engine start/stop button

Digital Electronic Control ECM (STBD)

5 Station selector switch

6 7

Engine ECM

8 9 10

A 2-20

TECH FEA

Technical features and description

Digital Electronic Control component

f c

a e

b g

d e

j B

f c

k e l

A B C D

Single type (6X6) Twin type (6X6) Triple type (6X6) Single type (6X7)

a Control lever b PTT switch c LPS d Free throttle switch e Digital Electronic Control ECM f Active indicator

2-21

e m

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

Electronic control system

Sensor, switch Digital Electronic Control ECM

LPS

Free throttle switch Active indicator Active indicator Engine selector switch Engine start/stop button Engine start switch Main switch PTT switch Station selector switch Command Link Plus Multifunction Color Gauge

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. 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. Enables engine speed to be increased while in neutral using the control lever. Displays operational conditions of the Digital Electronic Control. Comes on when communication error occurs between the 6Y9 Digital Electronic Control and the engine ECM. Selects the outboard motor to be operated. Starts and stops the engine while the system is activated. Activates and deactivates the system. Starts and stops the engine. Activates (with the engine start switch ON) and deactivates the system. Operates the PTT unit to adjust the trim/tilt angle of the outboard motor. Switches between the main station and substation. Displays engine status and boat status on a single display.

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A 2-22

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