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2-70

[6]

FUEL TUBE HOLDER

[5] 14 mm FUEL TUBE

CLIP

[1] WATER SEPARATOR

with WATER LEVEL

SENSOR

[4] FUEL TUBE A

[6]

FUEL TUBE HOLDER

[5]

14 mm FUEL TUBE

CLIP

[4] FUEL TUBE A

[3]

FUEL TUBE C

[2] TUBE CLIP B12

[2]

TUBE CLIP B12

Table of Contents

Default Chapter2
- Table of Contents2
Specifications6
- Dimensional Drawings9
Service Information11
- The Importance of Proper Servicing11
- Important Safety Precautions11
- Service Rules12
- Symbols Used in this Manual12
- Serial Number Locations12
- Maintenance Standards13
- Torque Values17
- Special Tools20
- Troubleshooting24
  - Engine24
- Cable/Harness Routing55
- Tube Routing76
- Lubrication87
Maintenance90
- Maintenance Schedule90
- Engine Oil91
- Oil Filter92
- Gear Case Oil93
- Spark Plugs95
- Valve Clearance98
- Fuel Strainer (Low Pressure Side)104
- Fuel Strainer (High Pressure Side)107
- WATER SEPARATOR with WATER LEVEL SENSOR108
- Idling111
- Shift Control Cable113
- Throttle Control Cable/ Throttle Link115
- Remote Control Lever Friction117
- Alternator Belt117
Engine Cover/Cover Lock120
- Engine Cover121
- Front Separate Cover126
- L./R. Engine under Covers128
  - Under Cover Front Bracket/ L./R. Side Cover Brackets139
Programmed-Fuel Injection154
- Service Precautions155
- Circuit Diagram156
- Vacuum Connections158
- Parts Location/Ecm Terminal Layout159
- Troubleshooting164
- Troubleshooting with Hds Tester166
  - Troubleshooting Guide by Dtc168
  - Troubleshooting171
- Troubleshooting Without Hds Tester210
  - Troubleshooting Guide212
  - Troubleshooting214
- Idle Control System246
- Fuel Supply System249
- Iab (Intake Air Bypass) Control262
  - System262
- Vapor Separator/Fuel Pump (High Pressure Side)264
Alternator312
- Silencer Duct313
- Alternator316
Engine Removal/Installation336
- Removal337
- Installation341
Thermostat/Relief Valve/Flush Valve344
- Thermostat345
- Water Relief Tube/Relief Valve348
- Flush Valve353
Crankshaft Pulley/Cam Chain355
- Disassembly356
- Assembly363
Cylinder Head/Valves374
- Cylinder Head Cover Removal375
- Cylinder Head Cover Disassembly377
- Camshaft/Rocker Arm Disassembly378
- Camshaft/Rocker Arm Inspection386
- Cylinder Head Assembly Removal392
- Cylinder Head Assembly Disassembly393
- Cylinder Head Assembly Inspection396
- Valve Guide Replacement399
- Valve Seat Reconditioning401
- Cylinder Head Assembly Assembly403
- Cylinder Head Assembly Installation405
- Camshaft/Rocker Arm Assembly407
- Cylinder Head Cover Assembly411
- Cylinder Head Cover Installation413
Oil Pump/Flywheel416
- Eop Switch/Oil Filter Flange417
- Oil Pump421
Crankcase/Balancer430
- Crankcase/Balancer Case Assembly Removal431
- Balancer Case Assembly Disassembly434
- Inspection435
- Balancer Case Assembly Assembly436
- Crankcase/Balancer Case Assembly Installation437
Cylinder Block/Crankshaft/Pistons442
- Disassembly443
- Inspection449
- Bearing Selection456
- Assembly460
Propeller/Gear Case/Extension Case/Oil Case468
- Propeller469
- Gear Case Assembly [*1]470
- Water Pump/Shift Rod [*1]474
- Propeller Shaft Holder Assembly [*1]484
- Propeller Shaft/Propeller Shaft Holder [*1]485
- Vertical Shaft/Bevel Gear [*1]494
- Shim Selection [*1]502
- Shim Position [*1]507
- Backlash Adjustment [*1]508
- Gear Case Assembly [*2]509
- Water Pump/Shift Rod [*2]513
- Propeller Shaft Holder Assembly [*2]523
- Propeller Shaft/Propeller Shaft Holder [*2]524
- Vertical Shaft/Bevel Gear [*2]535
- Shim Selection [*2]544
- Shim Position [*2]551
- Backlash Adjustment [*2]552
- Anode Metal/Water Screen555
- Extension Case/Lower Rubber Mount561
- Oil Case563
Mounting Case/Stern Bracket/Swivel Case/Power Trim/Tilt Assembly564
- Mounting Case565
- Stern Bracket/Swivel Case Removal/Installation573
- Stern Bracket/Swivel Case/ Power Trim/Tilt Assembly577
- Power Trim/Tilt Assembly599
- Air Bleeding611
- Blow Pressure Inspection613
- Power Tilt Motor Assembly616
Steering Rod/Remote Control Box622
- Steering Rod622
- Remote Control Box (Optional Part)623
- Control Panel (Optional Part)628
- Inspection630
Cables/Shift Link Bracket/Shift Arm/Neutral Switch632
- Remote Control Cable/Grommet633
- Shift Link Bracket/Neutral Switch642
- Seal Holder651
Electrical Equipment655
- Starter Motor655
- Starter Cable669
- Ecm/Pgm-Fi Main Relay/Fuse Box673
- Power Tilt Relay/Connector Bracket a681
Operation685
- Dohc (Swing Arm Type) + Vtec685
- Chain Drive Cam Drive System686
- Independent Cylinder Head/Cylinder Block Cooling System687
- Air/Fuel Ratio O688
- Feedback Control by A/F Sensor688

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