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Z300A LZ300A SUPPLEMENTARY SERVICE MANUAL 292211 6D0-28197-3F-1X NOTICE This Supplementary Service Manual has been prepared to introduce new service and new data information for the Z300 and LZ300 which are based on the Z250 and LZ250. For complete information on service procedures, it is necessary to use this Supplementary Service Manual together with the following manual. Z250D, LZ250D SERVICE MANUAL: 60V-28197-3E-11 Important information 1 Particularly important information is distinguished in this manual by the following notations: The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! WARNING Failure to follow WARNING instructions could result in severe injury or death to the machine operator, a bystander, or a person inspecting or repairing the outboard motor. CAUTION: A CAUTION indicates special precautions that must be taken to avoid damage to the outboard motor. NOTE: A NOTE provides key information to make procedures easier or clearer. CAUTION: USE UNLEADED STRAIGHT GASOLINE ONLY • Gasoline containing lead can cause performance loss and engine damage. • Do not use gasoline mixed with oil during the break-in period or anytime thereafter. YAMALUBE 2-STROKE OUTBOARD OIL IS RECOMMENDED. Z300A, LZ300A SUPPLEMENTARY SERVICE MANUAL ©2003 by Yamaha Motor Co., Ltd. 1st Edition, July 2003 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited. Printed in the Netherlands Contents General information Specifications Periodic checks and adjustments Fuel system Power unit Lower unit Bracket unit GEN INFO SPEC CHK ADJ FUEL POWR LOWR BRKT – Electrical systems Troubleshooting Index + ELEC TRBL SHTG 1 2 3 4 5 6 7 8 9 General information How to use this manual .................................................................................... 1 Manual format............................................................................................... 1 Symbols........................................................................................................ 2 Identification...................................................................................................... 3 Applicable models ........................................................................................ 3 Serial number ............................................................................................... 3 Features and benefits ....................................................................................... 4 Crankcase and cylinders .............................................................................. 4 Intake system ............................................................................................... 6 Upper case ................................................................................................... 8 Lower case ................................................................................................... 9 ECM (Electronic Control Module) ............................................................... 10 Wiring harness connector holder................................................................ 10 Propeller selection .......................................................................................... 11 Propeller size.............................................................................................. 11 Selection..................................................................................................... 11 Predelivery checks ......................................................................................... 12 Checking the fuel system ........................................................................... 12 Checking the gear oil level ......................................................................... 12 Checking the engine oil level...................................................................... 12 Checking the battery................................................................................... 12 Checking the outboard motor mounting height........................................... 13 Checking the remote control cables ........................................................... 13 Checking the steering system .................................................................... 14 Checking the gear shift and throttle operation............................................ 14 Checking the power trim and tilt system..................................................... 14 Checking the engine start switch and engine stop lanyard switch ............. 14 Checking the cooling water pilot hole ......................................................... 15 Test run ...................................................................................................... 15 Break-in ...................................................................................................... 15 After test run ............................................................................................... 15 6D03F1X Specifications General specifications.................................................................................... 16 Maintenance specifications ........................................................................... 18 Power unit................................................................................................... 18 Lower unit ................................................................................................... 20 Electrical ..................................................................................................... 20 Dimensions................................................................................................. 23 Tightening torques.......................................................................................... 25 Specified torques........................................................................................ 25 General torques.......................................................................................... 27 Periodic checks and adjustments Special service tools ...................................................................................... 28 Maintenance interval chart............................................................................. 31 Oil injection system ........................................................................................ 32 Adjusting the oil pump link rod.................................................................... 32 Lower unit ........................................................................................................ 32 Checking the lower unit for air leakage ...................................................... 32 General............................................................................................................. 33 Lubricating the outboard motor................................................................... 33 Fuel system Fuel filter .......................................................................................................... 35 6D03F1X Power unit Power unit........................................................................................................ 36 Removing the power unit............................................................................ 37 Crankcase ........................................................................................................ 39 Removing the crankcase covers ................................................................ 40 Installing the crankcase covers .................................................................. 40 Installing the power unit.............................................................................. 40 Lower unit Propeller shaft housing (regular rotation model) ........................................ 43 Shimming (regular rotation model) ............................................................... 45 Selecting the pinion shims.......................................................................... 46 Backlash (regular rotation model)................................................................. 47 Measuring the forward and reverse gear backlash .................................... 47 Propeller shaft housing (counter rotation model) ....................................... 50 Drive shaft and lower case (counter rotation model) .................................. 52 Disassembling the reverse gear ................................................................. 54 Assembling the lower case......................................................................... 54 Shimming (counter rotation model) .............................................................. 56 Selecting the pinion shims.......................................................................... 57 Backlash (counter rotation model)................................................................ 58 Measuring the forward and reverse gear backlash .................................... 58 Bracket unit Bottom cowling ............................................................................................... 61 Upper case, steering arm, swivel bracket, and clamp brackets ................. 64 Power trim and tilt unit ................................................................................... 69 Checking the hydraulic pressure ................................................................ 69 6D03F1X Electrical systems Electrical components.................................................................................... 72 Port view..................................................................................................... 72 Top view ..................................................................................................... 73 Troubleshooting Self-diagnosis.................................................................................................. 74 Diagnosing the electronic control system ................................................... 74 Wiring diagram 6D03F1X GEN INFO General information How to use this manual 1 Only chapters containing revisions or additional items in the base manual have been included in this manual. All special service tools introduced in this manual are mentioned in Chapter 3. 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. 1 Parts are shown and detailed in an exploded diagram and are listed in the components list. 2 Tightening torque specifications are provided in the exploded diagrams and after a numbered step with tightening instructions. 3 Symbols are used to indicate important aspects of a procedure, such as the grade of lubricant and lubrication point. 4 The components list consists of part names and part quantities, as well as bolt and screw dimensions. 5 Service points regarding removal, checking, and installation are shown in individual illustrations to explain the relevant procedure. LOWR 3 Lower unit 2 1 Lower unit LOWR Lower unit Removing the drive shaft 1. Remove the drive shaft assembly and pinion, and then pull out the forward gear. S62Y6740K CAUTION: S62Y6850K No. Part name Q’ty 1 Lower unit 1 2 Plastic tie 1 3 Hose 1 4 Check screw 1 5 Gasket 2 6 Dowel pin 2 7 Bolt 4 8 Drain screw 1 Not reusable Disassembling the drive shaft M10 9 Grommet 1 Bolt 1 M10 11 Bolt 1 M8 Thrust washer 1 13 Propeller 1 14 Washer 1 15 Washer 16 Cotter pin 1 17 Propeller nut 1 18 Trim tab 1 1. Install the pinion nut 1, tighten it finger tight, and then remove the drive shaft bearing 2 using a press. Not reusable 10 12 Drive shaft holder 4 1: 90890-06518 Pinion nut holder 2: 90890-06505 Socket adapter 2 3: 90890-06507 Remarks Bearing separator 1: 90890-06534 2. Remove the needle bearing from the forward gear. 40 mm 45 mm 60 mm CAUTION: CAUTION: 1 6-5 Do not reuse the bearing, always replace it with a new one. • Do not press the drive shaft threads a directly. • Do not reuse the bearing, always replace it with a new one. Not reusable Bearing inner race attachment 3: 90890-06639 62Y5A11 Do not reuse the bearing, always replace it with a new one. Stopper guide plate 2: 90890-06501 Stopper guide stand 3: 90890-06538 Bearing puller 4: 90890-06535 Bearing puller claw 1 5: 90890-06536 Disassembling the forward gear 1. Remove the taper roller bearing from the forward gear using a press. 4 6-19 62Y5A11 5 1 6D03F1X How to use this manual Symbols The symbols below are designed to indicate the content of a chapter. General information Fuel system GEN INFO Bracket unit FUEL Specifications BRKT Power unit SPEC Electrical systems POWR Periodic checks and adjustments Lower unit CHK ADJ – ELEC + Troubleshooting TRBL SHTG LOWR Symbols 1 to 6 indicate specific data. 1 2 3 4 5 6 T. R. 1 2 3 4 5 Specified measurement 6 Specified electrical value (resistance, voltage, electric current) Special tool Specified oil or fluid Specified engine speed Specified tightening torque Symbols 7 to C in an exploded diagram indicate the grade of lubricant and the lubrication point. 7 8 9 0 A E 7 8 9 0 A M B D C C I G Apply 2-stroke outboard motor oil Apply gear oil Apply water resistant grease (Yamaha grease A) Apply molybdenum disulfide grease A Apply corrosion resistant grease (Yamaha grease D) B Apply low temperature resistant grease (Yamaha grease C) C Apply injector grease Symbols D to I in an exploded diagram indicate the type of sealant or locking agent and the application point. D E GM F 4 D Apply Gasket Maker E Apply Yamabond No. 4 F Apply LOCTITE 271 (red) 6D03F1X G H I LT LT LT 271 242 572 SS G Apply LOCTITE 242 (blue) H Apply LOCTITE 572 I Apply silicon sealant 2 1 2 3 4 5 6 7 8 9 GEN INFO General information Identification 1 Applicable models This manual covers the following models. Applicable models Z300AETO, LZ300AETO Serial number The outboard motor serial number is stamped on a label attached to the port clamp bracket. 1 2 3 4 Model name Approved model code Transom height Serial number Model name Approved model code Z300AETO 6D0 LZ300AETO 6D1 3 Starting serial No. X: 1000001– U: 1000001– X: 1000001– 6D03F1X Identification / Features and benefits Features and benefits 1 Crankcase and cylinders The following modifications have been adopted to increase the output as compared to the Z250 power unit. • The material of the crankshaft has been changed to a high-grade clean steel(*1) to increase durability against stress. • Wider exhaust ports with planed-off edges have been adopted and the exhaust timing has been changed to reduce the exchange loss of the exhaust gas. • Cooling water jackets have been incorporated to the crankcase to increase engine-cooling ability. *1: Steel with decreased nonmetallic inclusion content 1 Crankshaft identification Identification mark: 2 mm (0.079 in) punch mark 2 Exhaust port 3 Crankcase water jackets È Water flow 6D03F1X 4 GEN INFO General information • Newly-forged lightweight pistons with a hard anodic coating on the piston pin boss have been adopted to increase durability and reduce the inertia mass of the pistons. • The top piston rings are made of steel and are ion-plated to increase durability. • The heat treatments for the piston pins and connecting rods have been changed so that there is multiphase carbonization to increase durability. 1 2 3 4 5 6 5 Ion plating (chromium) Identification mark: R Identification mark: 6D0 Oil groove Hard anodic coating Identification mark È Top ring É Second ring 6D03F1X Features and benefits • The anti-corrosion anodes in the cooling water passages of the cylinder block are larger to increase reliability and performance. 1 Anodes Intake system The openings in the throttle bodies were enlarged to a 46 mm (1.81 in) diameter to increase power output. 6D03F1X 6 GEN INFO General information An oil groove has been added to each reed valve seat. Oil in the groove helps to reduce impact when the reed valve contacts the reed valve seat. The dimensions of the reed valve assembly are the same as those for the Z250. 1 Oil groove 2 Identification mark: 6D0 The oil pump has been newly designed to obtain optimal oil supply. È Model É Identification mark 7 6D03F1X Features and benefits Upper case Water jackets have been incorporated to both sides of the lower part of the upper case. This structure reduces the heat transfer to the upper case from the exhaust gas. The cooling water discharged from the water pump is supplied to the upper case around the muffler from the pipe connected to the exhaust guide, flows down into the water jacket, and then drains to the lower case. Water jackets have been incorporated to the exhaust manifold to protect it from the high-temperature exhaust gas. Fresh cooling water from the water pump accumulates in the water jacket, and then drains into the muffler. 1 2 3 4 5 6 7 8 9 0 Muffler Upper case Gasket Upper case water jacket Lower case Exhaust guide Hose Exhaust manifold Water Water pump 6D03F1X È Water flow É Exhaust passage 8 GEN INFO General information Lower case The propeller shaft housing and the ring are newly designed to reduce the exhaust back-pressure and cool the propeller damper. Cooling water is taken in from the front of the trim tab, flows through the pipe in the lower case and propeller shaft housing, and then is supplied directly to the propeller boss. This prevents the cooling water from mixing with the exhaust gas in the exhaust passage in the lower case and also prevents the cooling water from obstructing the exhaust gas. Therefore, the exhaust back-pressure can be reduced. A low gear ratio has been adopted to match the power output characteristics. 1 2 3 4 5 Water pipe (for cooling the propeller boss) Heli-sert bushing Ring Fluorine-coated oil seals Propeller shaft housing (with water passage) È Water flow É Pinion gear Ê Reduction gear Ë Model Gear ratio Z250 1.81 Z250F Z300 1.75 Ì Identification mark Model Z300 LZ300 60X1 Notes Same as Z250F Í Identification mark Model Z300 LZ300 9 Notes F 60X00 Same as Z250F R 69L00 Same as 250C F 6D100 New R 6D100 New 6D03F1X Features and benefits ECM (Electronic Control Module) ECMs have been adopted that are specific to each model to control the ignition and injection timing. NOTE: The diagnostic codes are the same as those for the Z250, and the latest version of the YDIS covers all previous models with fuel injection. È É VZ225 (Z250H) 60Y-01 VZ250 (Z250F) 60X-01 Z250 (Z250D) Z300 (Z300A) Ê 60V-01 60V-21 Ë 6D0-00 S6D01100 È Model É ECM identification Ê Note Ë For Brazil Wiring harness connector holder A wiring harness connector holder has been added to the side of bottom cowling to secure the 10pin main harness, remote oil tank harness, warning indicator harness, and trim meter harness. The wiring harness connector holder helps to organize the harnesses and hold them in place. 1 2 3 4 5 6 7 10-pin main harness Remote oil tank harness (Blue connector) Bottom cowling seal Holder Trim meter harness Warning indicator harness Isolator lead 6D03F1X 10 GEN INFO General information Propeller selection 1 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. An 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. Selection When the engine speed is at the full throttle operating range (4,500–5,500 r/min), the ideal propeller for the boat is one that provides maximum performance in relation to boat speed and fuel consumption. Regular rotation model Propeller size (in) Material 13 3/8 × 23 - M 13 3/8 × 25 - M 13 3/4 × 17 - M2 13 3/4 × 19 - M2 Propeller size The size of the propeller is indicated on the propeller boss end and on the side of the propeller boss. 13 3/4 × 21 - M 14 1/2 × 19 - T 14 1/2 × 21 - T 14 1/2 × 23 - M 14 3/4 × 25 - T × a - 14 7/8 × 21 - M b c 15 × 17 - T Stainless 15 1/8 × 27 - T 15 1/4 × 15 - M 15 1/4 × 17 - M S69J1100 15 1/4 × 19 - M 15 3/4 × 13 - M Counter rotation model Propeller size (in) - 13 3/8 × 23 - ML b c 13 3/4 × 17 - ML1 Material 13 3/4 × 19 - ML1 S60C1125 a Propeller diameter (in inches) b Propeller pitch (in inches) c Propeller type (propeller mark) 13 3/4 × 21 - ML 14 1/2 × 19 - TL Stainless 14 1/2 × 21 - TL 15 × 17 - TL 15 1/4 × 15 - ML 11 6D03F1X Propeller selection / Predelivery checks Predelivery checks 1 To make the delivery process smooth and efficient, the predelivery checks should be completed as explained below. Checking the gear oil level 1. Check the gear oil level. Checking the fuel system 1. Check that the fuel hoses are securely connected and that the fuel tank is full with fuel. S60V1290 Checking the engine oil level 1. Check that the engine oil level is between the maximum and minimum level marks. S60V3260 Recommended engine oil: YAMALUBE 2-stroke outboard motor oil Checking the battery 1. Check the capacity, electrolyte level, and specified gravity of the battery. Recommended battery capacity: CCA/EN: 711 A 20HR/IEC: 100 Ah Electrolyte specified gravity: 1.280 at 20 °C (68 °F) CAUTION: • Use unleaded straight gasoline only. • Do not use gasoline mixed with oil (premixed fuel). 6D03F1X 2. Check that the positive and negative battery leads are securely connected. 12 GEN INFO General information Checking the outboard motor mounting height 1. Check that the anti-cavitation plate is aligned with the bottom of the boat. If the mounting height is too high, cavitation will occur and propulsion will be reduced. Also, the engine speed will increase abnormally and cause the engine to overheat. If the mounting height is too low, water resistance will increase and reduce engine efficiency. 2 a 1 S60V1040 3. Check that the center of the set pin b is aligned with the alignment mark c on the bottom cowling. NOTE: 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. 2. Check that the clamp brackets are secured with the clamp bolts. d S60C1190 Checking the remote control cables 1. Set the remote control lever to the neutral position and fully close the throttle lever. 2. Check that the throttle cam 1 is in its fully closed position and align the center of the throttle cam roller 2 with the alignment mark a. 13 CAUTION: The shift/throttle cable joint must be screwed in a minimum of 8.0 mm (0.31 in) d. 6D03F1X Predelivery checks Checking the steering system 1. Check the steering friction for proper adjustment. 2. Check that smoothly. the steering operates Checking the power trim and tilt system 1. Check that the outboard motor tilts up and down smoothly when operating the power trim and tilt unit. 2. Check that there is no abnormal noise produced when the outboard motor is tilted up or down. 3. Check that there is no interference with wires or hoses when the tilted-up outboard motor is steered. S60V1060 3. Check that there is no interference with wires or hoses when the outboard motor is steered. Checking the gear shift and throttle operation 1. Check that the gear shift operates smoothly when the remote control lever is shifted from neutral to forward or reverse. 4. 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 1. Check that the engine starts when the engine start switch is turned to START. 2. Check that the engine turns off when the engine start switch is turned to OFF. 2. Check that the throttle operates smoothly when the remote control lever is shifted from the fully closed position to the fully open position a. N F S60V1070 R a 3. Check that the engine turns off when the engine stop lanyard is pulled from the engine stop lanyard switch. a S69J1210 6D03F1X 14 GEN INFO General information Checking the cooling water pilot hole 1. Check that cooling water is discharged from the cooling water pilot hole. a b È 0 c 1 d 2 10 S60V1120 È Hour After test run S60V3140 1. Check for water in the gear oil. Test run 2. Check for fuel leakage in the cowling. 1. Start the engine, and then check that the gear shift operates smoothly. 3. Flush the cooling water passage with fresh water using the flushing kit and with the engine running at idle. 2. Check the engine idle speed after the engine has been warmed up. 3. Operate at trolling speed. 4. Run the outboard motor for 1 hour at 3,000 r/min or at half throttle, then for another hour at 4,000 r/min or at 3/4 throttle. 5. Check that the outboard motor does not tilt up when shifting into reverse and that water does not flow in over the transom. NOTE: The test run is part of the break-in operation. Break-in During the test run, perform the break-in operation in the following four stages. 1. First 10 minutes a of operation at idle 2. Fifty minutes b at 3,000 r/min or less 3. One hour c at 4,000 r/min or less 4. Eight hours d at 5,000 r/min or less with repeated wide-open-throttle operation for 5 minutes or less 15 6D03F1X Predelivery checks / General specifications General specifications Item Dimension Overall length Overall width Overall height (X) (U) Boat transom height (X) (U) Weight (with stainless propeller) (X) (U) Performance Maximum output Full throttle operating range Maximum fuel consumption Engine idle speed Power unit Type Total displacement Bore × stroke Compression ratio Control system Starting system Enrichment system Ignition control system Maximum generator output Spark plug Cooling system Exhaust system Lubrication system 6D03F1X 2 Unit Model Z300AETO LZ300AETO mm (in) mm (in) 868 (34.2) 568 (22.4) mm (in) mm (in) 1,830 (72.0) mm (in) mm (in) kg (lb) kg (lb) kW (hp) r/min L (US gal, lmp gal)/hr r/min cm3 (cu. in) mm (in) V, A 1,957 (77.0) 1 2 3 4 5 6 7 8 9 — 635 (25.0) 762 (30.0) — 252 (556) 257 (567) — 220.7 (300) at 5,000 r/min 4,500–5,500 105.0 (27.7, 23.1) at 5,500 r/min 700–760 2-stroke, 76°, V6, HPDI 3,342 (203.9) 93.0 (3.66) × 82.0 (3.23) 6.2 Remote control Electric starter Fuel injection TCI 12, 50 BKR7EKU (NGK) Water Propeller boss Oil injection 16 SPEC Specifications Item Fuel and oil Fuel type Fuel minimum rating Engine oil(*2) Engine oil tank capacity Oil tank Remote oil tank Gear oil type Gear oil grade Gear oil quantity Bracket unit Trim angle (at 12° boat transom) Tilt-up angle Steering angle Drive unit Gear shift positions Gear ratio Reduction gear type Clutch type Propeller shaft type Propeller direction (rear view) Propeller mark Electrical Battery minimum capacity(*3) CCA/EN 20HR/IEC Unit RON(*1) PON L (US gal, lmp gal) L (US gal, lmp gal) SAE 3 cm (US oz, lmp oz) Model Z300AETO LZ300AETO Regular unleaded gasoline 90 86 YAMALUBE 2-stroke outboard motor oil 1.2 (0.32, 0.26) 10.5 (2.77, 2.31) Hypoid gear oil 90 1,150 (38.9, 40.6) 1,000 (33.8, 35.3) Degree –3 to 16 Degree Degree 70 30 + 30 F-N-R 1.75 (28/16) Spiral bevel gear Dog clutch Spline Clockwise Counterclockwise T, M TL, ML A Ah 711 100 (*1) RON: Research Octane Number PON: Pump Octane Number = (RON + Motor Octane Number)/2 (*2) If 2-stroke outboard motor oil is not available, a 2stroke NMMA-certified TC-W3 oil of equivalent quality must be used. (*3) CCA: Cold Cranking Ampere EN: European Norm (European standard) IEC: International Electrotechnical Commission 17 6D03F1X General specifications / Maintenance specifications Maintenance specifications 2 Power unit Item Power unit Minimum compression pressure* Cylinder heads Warpage limit (lines indicate straightedge position) Cylinders Bore size Bore size limit Taper limit Out-of-round limit Pistons Piston diameter (D) Measuring point (H) Piston-to-cylinder clearance Piston pin boss bore Oversize piston 1st 2nd Oversize piston diameter 1st 2nd Piston pins Outside diameter Unit Model Z300AETO LZ300AETO kPa (kgf/cm2, psi) 580 (5.8, 84) mm (in) 0.1 (0.004) mm (in) mm (in) mm (in) mm (in) 93.000–93.020 (3.6614–3.6622) 93.100 (3.6654) 0.08 (0.0031) 0.05 (0.0020) mm (in) mm (in) mm (in) mm (in) 92.830–92.850 (3.6547–3.6555) 10 (0.39) 0.165–0.171 (0.0065–0.0067) 26.004–26.015 (1.0238–1.0242) mm (in) mm (in) 0.25 (0.010) 0.50 (0.020) mm (in) mm (in) 93.080–93.100 (3.6646–3.6653) 93.330–93.350 (3.6744–3.6752) mm (in) 25.995–26.000 (1.0234–1.0236) * Measuring conditions: Ambient temperature 20 °C (68 °F), wide open throttle, with spark plugs removed from all cylinders. The figures are for reference only. 6D03F1X 18 SPEC Specifications Item Piston rings Top ring Dimension B Dimension T End gap Side clearance 2nd piston ring Dimension B Dimension T End gap Side clearance Connecting rods Small end inside diameter Big end side clearance Small end axial play limit Crankshaft Crankshaft journal diameter Crankpin diameter Runout limit Thermostats Opening temperature Fully open temperature Valve open lower limit Oil pump Identification mark Bleeding Reed valves Valve stopper height limit Valve bending limit 19 Unit Model Z300AETO LZ300AETO mm (in) mm (in) mm (in) mm (in) 2.05 (0.0807) 3.00–3.20 (0.118–0.126) 0.30–0.50 (0.0118–0.0197) 0.02–0.06 (0.0008–0.0024) mm (in) mm (in) mm (in) mm (in) 2.05 (0.0807) 2.70–2.90 (0.106–0.114) 0.30–0.45 (0.0118–0.0177) 0.02–0.06 (0.0008–0.0024) mm (in) mm (in) mm (in) 31.000–31.012 (1.2205–1.2209) 0.12–0.26 (0.0047–0.0102) 2.0 (0.08) mm (in) mm (in) mm (in) 58.975–58.991 (2.3219–2.3225) 40.485–40.500 (1.5939–1.5945) 0.02 (0.0008) °C (°F) °C (°F) mm (in) 48–52 (118–126) 60 (140) 4.3 (0.17) 6D000 Screw type mm (in) mm (in) 8 (0.31) 0.2 (0.008) 6D03F1X Maintenance specifications Lower unit Item Unit Gear backlash Pinion-to-forward gear mm (in) Pinion-to-reverse gear Pinion shims Forward gear shims Reverse gear shims Propeller shaft shims mm (in) mm mm mm mm Propeller shaft End play mm (in) Model Z300AETO LZ300AETO 0.12–0.44 0.30–0.62 (0.0047–0.0173) (0.0118–0.0244) 0.61–0.90 (0.0240–0.0354) 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 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 — 0.25–0.35 (0.0098–0.0138) Electrical Item Ignition and ignition control system Ignition timing (cylinder #1) Spark plug gap Ignition coil resistance Primary coil (R – B/W) at 20 °C (68 °F) Secondary coil (R – spark plug wire) at 20 °C (68 °F) ECM output peak voltage (R – B/W) at cranking (loaded) at 1,500 r/min (loaded) at 3,500 r/min (loaded) Pulser coil output peak voltage (W/R, W/B, W/Y, W/G, W/L, W/Br – B) at cranking (unloaded) at cranking (loaded) at 1,500 r/min (loaded) at 3,500 r/min (loaded) 6D03F1X Unit Model Z300AETO LZ300AETO Degree Degree mm (in) ATDC 7 at engine idle speed BTDC 14 at 5,500 r/min 1.5–1.6 (0.059–0.063) Ω 1.36–1.84 kΩ 7.31–9.89 V V V 265 240 240 V V V V 3.5 3.5 20.0 30.0 20 SPEC Specifications Item Unit (*1) Pulser coil resistance (W/R, W/B, W/Y, W/G, W/L, W/Br – B) Throttle position sensor Input voltage (O – R) Output voltage (P – O) Crank position sensor output peak voltage (G/L – G/W) at cranking (unloaded) at cranking (loaded) at 1,500 r/min (loaded) at 3,500 r/min (loaded) Crank position sensor resistance(*1) (G/L – G/W) Crank position sensor air gap Intake air temperature sensor resistance at 0 °C (32 °F) at 80 °C (176 °F) Engine temperature sensor resistance (B/Y – B/Y) at 20 °C (68 °F) at 100 °C (212 °F) Fuel control system Injector driver output peak voltage(*1) (Pu/R – O/R, Pu/B – O/B, Pu/Y – O/Y, Pu/G – O/G, Pu/L – O/L, Pu/W – O/W) at cranking (loaded) at 1,500 r/min (loaded) at 3,500 r/min (loaded) Fuel injector resistance(*1) at 20 °C (68 °F) Fuel pressure sensor output voltage(*1) (O – P) (*1) 21 Model Z300AETO LZ300AETO Ω 294–398 V V 5 0.58–0.62 at engine idle speed (0.48–0.52 at throttle valve full closed) V V V V Ω 1.5 1.5 8.0 10.0 178.5–241.5 mm (in) 0.5–1.5 (0.02–0.06) kΩ kΩ 5.4–6.6 0.3–0.4 kΩ kΩ 54.2–69.0 3.12–3.48 V V V 70 80 80 Ω V 0.9–1.1 3.2 at engine idle speed The figures are for reference only. 6D03F1X Maintenance specifications Item Starter motor Type Output Cranking time limit Brushes Standard length Wear limit Commutator Standard diameter Wear limit Mica Standard undercut Wear limit Charging system Fuse Stator coil output peak voltage (G – G) at cranking (unloaded) at 1,500 r/min (unloaded) at 3,500 r/min (unloaded) Stator coil resistance(*1) at 20 °C (68 °F) (G – G) Rectifier Regulator output peak voltage (R – ground) at 1,500 r/min (unloaded) at 3,500 r/min (unloaded) Power trim and tilt system Trim sensor Setting resistance Resistance (P – B) Fluid type (*1) Unit Model Z300AETO LZ300AETO kW Second Sliding gear 1.4 30 mm (in) mm (in) 15.5 (0.61) 9.5 (0.37) mm (in) mm (in) 29.0 (1.14) 28.0 (1.10) mm (in) mm (in) 0.5–0.8 (0.02–0.03) 0.2 (0.01) A 20, 30, 100 V V V 5.5 40 90 Ω 0.11–0.17 V V 14.5 14.5 Ω Ω 9–11 9–387.6 ATF Dexron II The figures are for reference only. 6D03F1X 22 SPEC Specifications Dimensions Exterior 284 (11.2) 30˚ 660 (26.0) 420 (16.5) mm (in) X: 1,152 (45.4) U: 1,270 (50.0) 628 (24.7) 211 (8.3) 645 (25.4) X: 67 (2 U: 86 .6) (3.4) ˚ 67 X: 848 (33.4) U: 925 (36.4) 45 (1.8) 404 (15.9) 32 (1.3) 757 (29.8) X: 640 (25.2) U: 766 (30.2) 245 (9.6) 216 (8.5) X: 1,074 (42.3) U: 1,201 (47.3) 907 (35.7) 75 (3.0) 25 (1.0) 1 2˚ 23 X: 48 (1.9) U: 55 (2.2) 3˚ 677 (26.7) S60V2010 6D03F1X Maintenance specifications Clamp bracket mm (in) 180 (7.1) 180 (7.1) 163.5 (6.4) 50.8 (2.0) 163.5 (6.4) 55.5 (2.2) 254 (10.0) 411 (16.2) 13 (0.5) 18.5 (0.7) 79 (3.1) 13 (0.5) 125.4 (4.9) 125.4 (4.9) S60V2020 6D03F1X 24 SPEC Specifications Tightening torques 2 Specified torques Part to be tightened Thread size Fuel system Fuel pump screw Emergency switch High pressure fuel pump bolt Power unit Negative battery terminal nut Drive belt tensioner bolt Starter motor bolt Intake air temperature sensor Rectifier Regulator bolt 1st 2nd PTT motor lead bolt Shift position switch screw Control lever stopper screw Connecting rod cap Crankshaft balancer nut Crankcase bolt Cylinder head cover bolt Exhaust outer cover bolt 1st 2nd 1st 2nd 25 (M8) M10 M8 — 12 39 29 8 6 12 4 3 2 28 45 M6 M9 M10 M6 M6 1st 2nd 1st 2nd 1st 2nd Flywheel magnet nut Fuel rail mounting bolt Fuel filter cup holder mounting bolt Injector holder bolt Intake silencer mounting screw Reed valve mounting screw Intake manifold bolt Oil pump mounting bolt Pressure control valve cover bolt 3 4 23 (M32) Crankcase cover bolt Cylinder head bolt M5 — M8 M6 M4 — 1st 2nd 3rd 4th 5th M8 M6 M6 (M24) M8 M6 M8 M6 M5 M6 M6 1st 2nd Tightening torques N·m kgf·m ft·lb M6 0.3 0.4 2.3 2.2 3.0 17.0 1.2 8.9 3.9 28.8 2.9 21.4 0.8 5.9 0.6 4.4 1.2 8.9 0.4 3.0 0.3 2.2 0.2 1.5 2.8 20.7 4.5 33.2 Loosen completely 28 2.8 20.7 45 4.5 33.2 100 10.0 73.8 17 1.7 12.5 34 3.4 25.1 4 0.4 3.0 9 0.9 6.6 11 1.1 8.1 15 1.5 11.1 30 3.0 22.1 5 0.5 3.7 11 1.1 8.1 5 0.5 3.7 11 1.1 8.1 190 19.0 140 23 2.3 17.0 8 0.8 5.9 26 2.6 19.2 3 0.3 2.2 3 0.3 2.2 13 1.3 9.6 7 0.7 5.2 5 0.5 3.7 11 1.1 8.1 6D03F1X Tightening torques Part to be tightened Thread size Shift cut switch mounting screw Spark plug Positive battery terminal nut Thermostat cover bolt Throttle body mounting bolt and nut Power unit mounting bolt Lower unit (regular rotation model) Exhaust guide bolt Gear oil check screw Lower case mounting bolt Pinion nut Propeller nut Propeller shaft housing bolt Trim tab mounting bolt Gear oil drain screw Grease nipple Lower unit (counter rotation model) Exhaust guide bolt Gear oil check screw Lower case mounting bolt Pinion nut Propeller nut Ring nut Propeller shaft housing bolt Trim tab mounting bolt Gear oil drain screw Grease nipple Bracket unit Flushing hose adapter screw Upper case mounting bolt Lower exhaust guide mounting bolt Exhaust manifold mounting bolt Muffler mounting bolt Lower rubber mount nut Through tube nut Trim rod stopper nut Upper rubber mount nut Friction plate screw 6D03F1X M4 M14 (M8) M6 1st 2nd M6 M8 Tightening torques N·m kgf·m ft·lb 3 0.3 2.2 25 2.5 18.4 9 0.9 6.6 11 1.1 8.1 4 0.4 3.0 10 1.0 7.4 32 3.2 23.6 M8 M8 M10 (M16) (M18) M8 M10 — — 32 9 47 142 54 30 42 9 6 3.2 0.9 4.7 14.2 5.4 3.0 4.2 0.9 0.6 23.6 6.6 34.7 104.7 39.8 22.1 31.0 6.6 4.4 M8 M8 M10 (M16) (M18) — M8 M10 — — 32 9 47 142 54 108 30 42 9 6 3.2 0.9 4.7 14.2 5.4 10.8 3.0 4.2 0.9 0.6 23.6 6.6 34.7 104.7 39.8 79.7 22.1 31.0 6.6 4.4 M5 M8 M8 M8 M8 (M14) (M22) (M10) (M14) M6 5 32 22 25 25 72 22 36 72 4 0.5 3.2 2.2 2.5 2.5 7.2 2.2 3.6 7.2 0.4 3.7 23.6 16.2 18.4 18.4 53.1 16.2 26.6 53.1 3.0 26 SPEC Specifications Part to be tightened Power trim and tilt unit Blind plug Gear pump housing mounting screw Gear pump housing bolt Trim down spring screw Main valve Manual valve PTT motor unit mounting bolt Oil pipe Relief valve cap screw Reservoir mounting bolt Reservoir cap Tilt cylinder end screw Tilt rod Trim cylinder end screw Trim rod Valve plate bolt PTT unit mounting bolt Thread size — M4 M5 M5 — — M8 — M5 M8 M12 — — — — M6 M10 Tightening torques N·m kgf·m ft·lb 7 2 4 4 11 2 19 15 4 19 7 90 55 160 38 7 42 0.7 0.2 0.4 0.4 1.1 0.2 1.9 1.5 0.4 1.9 0.7 9.0 5.5 16.0 3.8 0.7 4.2 5.2 1.5 3.0 3.0 8.1 1.5 14.0 11.1 3.0 14.0 5.2 66.4 40.6 118 28.0 5.2 31.0 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 (A) Bolt (B) 8 mm 10 mm 12 mm 14 mm 17 mm M5 M6 M8 M10 M12 27 General torque specifications N·m kgf·m ft·lb 5 0.5 3.6 8 0.8 5.8 18 1.8 13 36 3.6 25 43 4.3 31 6D03F1X Tightening torques / Special service tools Special service tools 3 Leakage tester 90890-06840 Shift rod push arm 90890-06052 Flywheel holder 90890-06522 Bearing housing puller claw L 90890-06502 Pinion height gauge 90890-06710 Stopper guide plate 90890-06501 Fixing plate 90890-06711 Center bolt 90890-06504 Digital caliper 90890-06704 Backlash indicator 90890-06706 6D03F1X 1 2 3 4 5 6 7 8 9 28 CHK ADJ Periodic checks and adjustments Magnet base plate 90890-07003 Ball bearing attachment 90890-06657 Dial gauge set 90890-01252 Driver rod LL 90890-06605 Magnet base B 90890-06844 Bearing outer race attachment 90890-06628 Needle bearing attachment 90890-06653, 90890-06654 Bearing outer race puller assembly 90890-06523 Driver rod L3 90890-06652 Driver rod SS 90890-06604 29 6D03F1X Special service tools PTT oil pressure gauge assembly 90890-06580 PTT oil pressure gauge adapter 90890-06581 Diagnostic flash indicator B 90890-06865 6D03F1X 30 CHK ADJ Periodic checks and adjustments Maintenance interval chart 3 Use the following chart as a guideline for general maintenance. Adjust the maintenance intervals according to the operating conditions of the outboard motor. Initial Item Anodes (external) Anodes (internal) Battery Cooling water passages Top cowling Fuel filter (can be disassembled) Fuel system Gear oil Lubrication points Engine idle speed (EFI models) PCV (Pressure Control Valve) Power trim and tilt unit Propeller and cotter pin Shift link/shift cable Thermostat Throttle link/throttle cable/throttle pick-up timing Water pump Spark plugs High pressure fuel pump drive belt High pressure fuel pump oil level Oil pump Oil tank water drain Throttle position sensor Remarks Every 10 hours 50 hours 100 hours 200 hours (1 month) (3 months) (6 months) (1 year) Check/replace Check/replace Check/charge Clean Check Check/replace Check Change Lubricate Check/adjust Check Check Check/replace Check/adjust Check Check/adjust Check Clean/adjust/replace Check/replace Check/fill Check/adjust Check/clean Check/adjust NOTE: When operating in salt water, turbid or muddy water, the engine should be flushed with clean water after each use. Item High pressure fuel pump drive belt Remarks Every 500 hours (2.5 years) 1,000 hours (5 years) Replace CAUTION: If the flywheel magnet cover is removed to service the outboard motor, be sure to check that the fuel hoses are routed correctly before installing it. 31 6D03F1X Maintenance interval chart / Oil injection system / Lower unit Oil injection system 3 Adjusting the oil pump link rod 1. Loosen the locknut 1 and then disconnect the oil pump link rod 2. Lower unit 3 Checking the lower unit for air leakage 1. Remove the check screw 1, and then install the special service tool. 2. Fully close the throttle valves. 3. Adjust the oil pump link rod so that there is a 0.5 mm (0.02 in) gap a between the oil pump lever 3 (in the fully closed position) and the stopper 4. 2 1 Leakage tester: 90890-06840 a 3 4 3 S60V3290 4. Connect the oil pump link rod. 5. Check that the oil pump lever 3 contacts the stopper 4 when the throttle valve is in the fully open position. CAUTION: Do not over pressurize the lower unit, otherwise the oil seals may be damaged. NOTE: Cover the check hole with a rag when removing the tester from the lower unit. 4 Lower unit holding pressure: 70 kPa (0.7 kgf/cm2, 10 psi) 3 S60V3300 6D03F1X 2. Apply the specified pressure to check that the pressure is maintained in the lower unit for at least 10 seconds. 3. If pressure drops below specification, check the drive shaft and propeller shaft oil seals for damage. 32 CHK ADJ Periodic checks and adjustments General 3 Lubricating the outboard motor 1. Apply water resistant grease to the areas shown. A S60V3430 33 6D03F1X General A S6D03010 NOTE: Apply grease to the grease nipple until it flows from the bushings a. 2. Apply low temperature resistant grease to the areas shown. A C S60V3440 3. Apply corrosion resistant grease to the areas shown. 4. Apply injector grease to the areas shown. 6D03F1X 34 FUEL Fuel system Fuel filter 4 9 T. R. 8 N · m (0.8 kgf · m, 5.9 ft · Ib) 12 11 13 14 10 1 2 5 15 4 3 6 16 8 7 S6D04010 No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 35 Part name Bolt Washer Holder Bolt Collar Grommet Bracket Bolt Cap Fuel hose Fuel hose O-ring O-ring Fuel filter element Cup Nut Q’ty 1 1 1 1 2 2 1 2 1 1 1 1 1 1 1 1 Remarks M6 × 16 mm M6 × 14 mm M6 × 25 mm Not reusable Not reusable 6D03F1X Fuel filter / Power unit Power unit 5 13 11 LT 12 572 10 9 6 LT 572 7 14 16 15 7 1 6 8 7 8 7 T. R. 32 N · m (3.2 kgf · m, 23.6 ft · Ib) 5 3 4 2 No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Part name Apron Bolt Screw grommet Screw Hose Hose Plastic tie Joint Joint Bolt Bracket Bolt Plate Bolt Bolt Bolt 6D03F1X S6D05010 Q’ty 1 4 1 1 2 2 6 2 1 3 1 4 1 2 8 4 Remarks M6 × 16 mm ø4 × 16 mm Not reusable M8 × 55 mm M6 × 20 mm M8 × 30 mm M8 × 135 mm M8 × 45 mm 36 1 2 3 4 5 6 7 8 9 POWR Power unit Removing the power unit NOTE: It is recommended to loosen the flywheel magnet nut before removing the power unit to improve working efficiency. 1. Disconnect the battery leads 1. 6. Remove the bracket 8 and disconnect the trim sensor coupler (or connector) 9. 8 9 2. Disconnect the shift cable 2 and the throttle cable 3. S6D05020 7. Disconnect the PTT switch coupler and the shift lever 0. 3. Disconnect the fuel hose 4 and the oil hose 5. 8. Disconnect the cooling water hose A. A 4. Remove the flywheel magnet cover. 5. Remove the junction box cover, and then disconnect the cooling water hose 6 and the PTT motor leads 7. 37 S6D05040 6D03F1X Power unit 9. Remove the apron B and the hose joint assembly C. 10. Remove the bolts D, then the power unit. 11. Remove the shift rod assembly E and gasket F. F E S6D05070 6D03F1X 38 POWR Power unit Crankcase 5 1 T. R. T. R. 11 N · m (1.1 kgf · m, 8.1 ft · Ib) 4 5 6 11 N · m (1.1 kgf · m, 8.1 ft · Ib) 13 13 2 4 3 1 T. R. 11 N · m (1.1 kgf · m, 8.1 ft · Ib) 7 8 1 13 9 14 1014 13 9 11 13 14 14 12 No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 39 Part name Bolt Crankcase cover Gasket Hose Crankcase cover Gasket Gasket Crankcase cover Hose Joint Hose Joint Clip Plastic tie 13 S6D05080 Q’ty 36 1 1 2 1 1 1 1 2 1 1 1 7 4 Remarks M6 × 25 mm Not reusable Not reusable Not reusable Not reusable 6D03F1X Crankcase Removing the crankcase covers Installing the power unit 1. Disconnect the hoses from the crankcase covers. 1. Clean the power unit mating surface, and then install new dowels 1, a new gasket 2, and the shift rod assembly 3. 2. Remove the crankcase cover bolts in the sequences shown. 4 1 1 1 6 2 0 3 3 8 D B F C F 7 A E B 8 9 C D 9 0 A E 4 3 5 6 4 5 4 A 3 7 2 D 9 3 5 1 4 1 5 9 8 4 3 8 7 C D B A C B S6D05100 T. R. Crankcase cover bolt: 11 N·m (1.1 kgf·m, 8.1 ft·lb) NOTE: Replace or reuse the power unit mounting bolts. If reusing the power unit mounting bolts, be sure to completely remove any LOCTITE remaining on the bolts. T. R. 2. Connect the hoses to the crankcase covers. 6D03F1X 2. Install the power unit 4, and then tighten the power unit mounting bolts 5 to the specified torque. F 0 6 2 6 2 Do not reuse the dowels, always replace them with new ones. E E 0 S60V5C20 S6D05090 1. Install the new gaskets and crankcase covers, and then tighten the crankcase cover bolts to the specified torque in the sequences shown. 1 3 CAUTION: Installing the crankcase covers F 2 2 2 7 1 Power unit mounting bolt 5: 32 N·m (3.2 kgf·m, 23.6 ft·lb) 40 POWR Power unit 3. Install the hose joint assembly 6 and the apron 7. T. R. PTT motor lead bolt: 4 N·m (0.4 kgf·m, 3.0 ft·lb) 8. Install the bracket B and connect the trim sensor coupler (or connector) C. 4. Connect the PTT switch coupler and the shift lever 8. B C S6D05130 9. Install the junction box cover. 10. Connect the fuel hose D and oil hose E. 5. Connect the cooling water hose 9. 9 S6D05110 6. Connect the cooling water hose 0 to the Rectifier Regulator. 7. Connect the PTT motor leads A, and then tighten the PTT motor lead bolts to the specified torque. 41 6D03F1X Crankcase 11. Connect the shift cable F and throttle cable G, and then adjust their lengths. 12. Install the Woodruff key and flywheel magnet. 13. Tighten the flywheel magnet nut to the specified torque. NOTE: Align the marks a on the pointer H, which you made during disassembly. 15. Install all removed parts. CAUTION: Apply force in the direction of the arrows shown to prevent the flywheel holder from slipping off easily. NOTE: Apply engine oil to the flywheel magnet nut before installation. Flywheel holder: 90890-06522 T. R. Flywheel magnet nut: 190 N·m (19.0 kgf·m, 140 ft·lb) 14. Install the pointer H. 6D03F1X 42 LOWR Lower unit Propeller shaft housing (regular rotation model) No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 43 Part name Water pipe Rubber seal Rubber seal Shift rod joint Ball Slider Shift plunger Dog clutch Cross pin Spring Propeller shaft Washer Reverse gear Reverse gear shim Ball bearing O-ring Propeller shaft housing Q’ty 1 1 1 1 2 1 1 1 1 1 1 1 1 — 1 1 1 6 Remarks Not reusable Not reusable 6D03F1X Propeller shaft housing (regular rotation model) 6 No. 18 19 20 21 22 23 24 25 26 27 28 29 Part name Dowel Grease nipple Rubber seal O-ring Needle bearing Oil seal Ring Bolt Bolt Cooling water inlet cover Nut Screw 6D03F1X Q’ty 1 1 1 1 1 2 1 2 2 2 1 1 1 2 3 4 5 6 7 8 9 Remarks Not reusable Not reusable M8 × 20 mm M8 × 33 mm 44 LOWR Lower unit Shimming (regular rotation model) 6 F P R B4 T3 B3 A3 65.0 A B B5 T1 T2 B1 39.4 41.0 A1 B2 A2 S6D06020 45 6D03F1X Shimming (regular rotation model) Selecting the pinion shims 1. Install the special service tools onto the drive shaft 1. Digital caliper 4: 90890-06704 4. Turn the thrust bearing 5 two or three times to seat the drive shaft housing 6, and then measure the housing height (M3) as shown. NOTE: • Select the shim thickness (T3) by using the specified measurement(s) and the calculation formula. • Install the special service tools onto the drive shaft so that the shaft is at the center of the hole. • Tighten the wing nuts another 1/4 of a turn after they contact the fixing plate 2. NOTE: Measure the thrust bearing at three points to find the height average. Pinion height gauge 3: 90890-06710 2. Install the pinion and pinion nut, and then tighten the nut to the specified torque. T. R. Pinion nut: 142 N·m (14.2 kgf·m, 104.7 ft·lb) 3. Measure the distance (M4) between the special service tool and the pinion as shown. 6D03F1X 46 LOWR Lower unit 5. Calculate the pinion shim thickness (T3) as shown in the examples below. Example: If “T3” is 0.68 mm, then the pinion shim is 0.65 mm. If “T3” is 0.70 mm, then the pinion shim is 0.68 mm. Backlash (regular rotation model) 6 Measuring the forward and reverse gear backlash 1. Remove the water pump assembly. NOTE: “P” is the deviation of the lower case dimension from standard. The “P” mark a is stamped on the trim tab mounting surface of the lower case in 0.01 mm units. If the “P” mark is unreadable, assume that “P” is zero and check the backlash when the unit is assembled. 2. Set the gear shift to the neutral position at the lower unit. Calculation formula: Pinion shim thickness (T3) = 82.00 + P/100 – M3 – M4 Example: If “M3” is 50.75 mm and “M4” is 30.52 mm and “P” is (–5), then T3 = 82.00 + (–5)/100 – 50.75 – 30.52 mm = 82.00 – 0.05 – 50.75 – 30.52 mm = 0.68 mm Shift rod push arm: 90890-06052 3. Install the special service tools so that it pushes against the propeller shaft. 6. Select the pinion shim(s) (T3) as follows. Calculated numeral at 1/100 place Rounded numeral 1, 2 0 3, 4, 5 2 6, 7, 8 5 9, 10 8 Available shim thicknesses: 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, and 0.50 mm 47 NOTE: Tighten the center bolt while turning the drive shaft until the drive shaft can no longer be turned. 6D03F1X Shimming (regular rotation model) / Backlash (regular rotation model) Bearing housing puller claw L 1: 90890-06502 Stopper guide plate 2: 90890-06501 Center bolt 3: 90890-06504 4. Install the backlash indicator onto the drive shaft (22.4 mm [0.88 in] in diameter), then the dial gauge onto the lower unit. 5. Set the lower unit upside down. Forward gear backlash Shim thickness Less than 0.12 mm (0.0047 in) To be decreased by (0.28 – M) × 0.81 More than 0.44 mm (0.0173 in) To be increased by (M – 0.28) × 0.81 M: Measurement Available shim thicknesses: 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, and 0.50 mm 8. Remove the special service tools from the propeller shaft. 9. Apply a load to the reverse gear by installing the propeller 8, the spacer 9 (without the washer 0), then the washer A as shown. NOTE: Install the dial gauge so that the plunger a contacts the mark b on the backlash indicator. Backlash indicator 4: 90890-06706 Magnet base plate 5: 90890-07003 Dial gauge set 6: 90890-01252 Magnet base B 7: 90890-06844 NOTE: Tighten the propeller nut B while turning the drive shaft until the drive shaft can no longer be turned. 6. Slowly turn the drive shaft clockwise and counterclockwise and measure the backlash when the drive shaft stops in each direction. Forward gear backlash: 0.12–0.44 mm (0.0047–0.0173 in) 7. Add or remove shim(s) if out of specification. 6D03F1X 48 LOWR Lower unit 10. Slowly turn the drive shaft clockwise and counterclockwise and measure the backlash when the drive shaft stops in each direction. Reverse gear backlash: 0.61–0.90 mm (0.0240–0.0354 in) 11. Add or remove shim(s) if out of specification. Reverse gear backlash Shim thickness Less than 0.61 mm (0.0240 in) To be decreased by (0.76 – M) × 0.81 More than 0.90 mm (0.0354 in) To be increased by (M – 0.76) × 0.81 M: Measurement Available shim thicknesses: 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, and 0.50 mm 12. Remove the special service tools, and then install the water pump assembly. 49 6D03F1X Backlash (regular rotation model) / Propeller shaft housing (counter rotation model) Propeller shaft housing (counter rotation model) No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Part name Water pipe Rubber seal Rubber seal Shift rod joint Ball Slider Shift plunger Dog clutch Cross pin Spring Forward gear Forward gear shim Ring nut Claw washer Taper roller bearing assembly Propeller shaft Thrust bearing 6D03F1X Q’ty 1 1 1 1 2 1 1 1 1 1 1 — 1 1 1 1 1 6 Remarks Not reusable 50 LOWR Lower unit 6 No. 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 51 Part name Propeller shaft shim O-ring Propeller shaft housing Dowel Grease nipple Rubber seal O-ring Needle bearing Oil seal Ring Bolt Bolt Cooling water inlet cover Nut Screw Q’ty — 1 1 1 1 1 1 1 2 1 2 2 2 1 1 Remarks Not reusable Not reusable Not reusable M8 × 20 mm M8 × 33 mm 6D03F1X Propeller shaft housing (counter rotation model) / Drive shaft and lower case (counter rotation model) Drive shaft and lower case (counter rotation model) No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Part name Drive shaft Cover Oil seal Bolt Drive shaft housing Needle bearing O-ring Pinion shim Thrust bearing Lower case Needle bearing Pinion Washer Nut Reverse gear shim Retainer Needle bearing 6D03F1X Q’ty 1 1 2 4 1 1 1 — 1 1 1 1 1 1 — 1 1 6 Remarks Not reusable M8 × 25 mm Not reusable 52 LOWR Lower unit 6 No. 18 19 20 53 Part name Thrust bearing Needle bearing Reverse gear Q’ty 1 1 1 Remarks Not reusable 6D03F1X Drive shaft and lower case (counter rotation model) Disassembling the reverse gear 1. Remove the needle bearing from the reverse gear using a chisel. CAUTION: Add or remove shim(s), if necessary, if replacing the forward gear or lower case. Ball bearing attachment 3: 90890-06657 Driver rod LL 4: 90890-06605 3. Install the needle bearing outer case into the lower case. Assembling the lower case 1. Install the needle bearing into the retainer to the specified depth. NOTE: Apply gear oil to the needle bearing outer case before installation. Needle bearing attachment 1: 90890-06654 Driver rod L3 2: 90890-06652 Depth a: –0.25–0.25 mm (–0.010–0.010 in) 2. Install the original shim(s) and retainer into the lower case. 6D03F1X Bearing outer race attachment 5: 90890-06628 Bearing outer race puller assembly 6: 90890-06523 4. Install the needle bearing into the needle bearing outer case. NOTE: Apply gear oil or grease to the needle bearing before installation. 54 LOWR Lower unit 5. Install the new needle bearing into the reverse gear to the specified depth. Needle bearing attachment 7: 90890-06653 Driver rod SS 8: 90890-06604 Depth b: 6.75–7.25 mm (0.266–0.285 in) 6. Install the thrust bearing and reverse gear into the lower case. 55 6D03F1X Drive shaft and lower case (counter rotation model) / Shimming (counter rotation model) Shimming (counter rotation model) 6 F P R B4 T3 A3 B3 65.0 A B B8 B5 A5 T1 T2 B1 38.4 47.5 A1 B7 B6 A4 A2 T´4 S6D06150 6D03F1X 56 LOWR Lower unit Selecting the pinion shims 1. Install the special service tools onto the drive shaft 1. Digital caliper 4: 90890-06704 4. Turn the thrust bearing 5 two or three times to seat the drive shaft housing 6, and then measure the housing height (M3) as shown. NOTE: • Select the shim thickness (T3) by using the specified measurement(s) and the calculation formula. • Install the special service tools onto the drive shaft so that the shaft is at the center of the hole. • Tighten the wing nuts another 1/4 of a turn after they contact the fixing plate 2. Pinion height gauge 3: 90890-06710 NOTE: Measure the thrust bearing at three points to find the height average. 5. Calculate the pinion shim thickness (T3) as shown in the examples below. 2. Install the pinion and pinion nut, and then tighten the nut to the specified torque. T. R. Pinion nut: 142 N·m (14.2 kgf·m, 104.7 ft·lb) 3. Measure the distance (M4) between the special service tool and the pinion as shown. 57 6D03F1X Shimming (counter rotation model) / Backlash (counter rotation model) NOTE: “P” is the deviation of the lower case dimension from standard. The “P” mark a is stamped on the trim tab mounting surface of the lower case in 0.01 mm units. If the “P” mark is unreadable, assume that “P” is zero and check the backlash when the unit is assembled. Backlash (counter rotation model) 6 Measuring the forward and reverse gear backlash 1. Remove the water pump assembly. 2. Set the gear shift to the neutral position at the lower unit. Calculation formula: Pinion shim thickness (T3) = 82.00 + P/100 – M3 – M4 Example: If “M3” is 50.75 mm and “M4” is 30.52 mm and “P” is (–5), then T3 = 82.00 + (–5)/100 – 50.75 – 30.52 mm = 82.00 – 0.05 – 50.75 – 30.52 mm = 0.68 mm Shift rod push arm: 90890-06052 6. Select the pinion shim(s) (T3) as follows. Calculated numeral at 1/100 place Rounded numeral 1, 2 0 3, 4, 5 2 6, 7, 8 5 9, 10 8 3. Install the special service tools so that it pushes against the propeller shaft. Available shim thicknesses: 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, and 0.50 mm Example: If “T3” is 0.68 mm, then the pinion shim is 0.65 mm. If “T3” is 0.70 mm, then the pinion shim is 0.68 mm. NOTE: Tighten the center bolt while turning the drive shaft until the drive shaft can no longer be turned. Bearing housing puller claw L 1: 90890-06502 Stopper guide plate 2: 90890-06501 Center bolt 3: 90890-06504 4. Install the backlash indicator onto the drive shaft (22.4 mm [0.88 in] in diameter), then the dial gauge onto the lower unit. 6D03F1X 58 LOWR Lower unit 5. Set the lower unit upside down. NOTE: Install the dial gauge so that the plunger a contacts the mark b on the backlash indicator. Backlash indicator 4: 90890-06706 Magnet base plate 5: 90890-07003 Dial gauge set 6: 90890-01252 Magnet base B 7: 90890-06844 8. Remove the special service tools from the propeller shaft. 9. Turn the shift rod to the reverse position c with the shift rod push arm. 10. Turn the drive shaft clockwise until the dog clutch 8 is fully engaged. 6. Slowly turn the drive shaft clockwise and counterclockwise and measure the backlash when the drive shaft stops in each direction. Forward gear backlash: 0.30–0.62 mm (0.0118–0.0244 in) 7. Add or remove shim(s) if out of specification. Forward gear backlash Shim thickness Less than 0.30 mm (0.0118 in) To be decreased by (0.46 – M) × 0.81 More than 0.62 mm (0.0244 in) To be increased by (M – 0.46) × 0.81 11. Turn the shift rod to the neutral position d with the shift rod push arm. 12. Turn the drive shaft counterclockwise approximately 30°. M: Measurement Available shim thicknesses: 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, and 0.50 mm 59 6D03F1X Backlash (counter rotation model) 13. Turn the shift rod to the reverse position c with the shift rod push arm. 14. Slowly turn the drive shaft clockwise and counterclockwise and measure the backlash when the drive shaft stops in each direction. NOTE: When measuring the reverse gear backlash, turn the shift rod push arm towards the reverse position c with force. Reverse gear backlash: 0.61–0.90 mm (0.0240–0.0354 in) 15. Add or remove shim(s) if out of specification. Reverse gear backlash Shim thickness Less than 0.61 mm (0.0240 in) To be decreased by (0.76 – M) × 0.81 More than 0.90 mm (0.0354 in) To be increased by (M – 0.76) × 0.81 M: Measurement Available shim thicknesses: 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, and 0.50 mm 16. Remove the special service tools, and then install the water pump assembly. 6D03F1X 60 BRKT Bracket unit Bottom cowling 7 36 37 28 37 35 29 A A A 39 34 30 5 26 24 40 33 27 32 25 7 16 15 14 6 33 32 5 23 4 22 20 19 18 28 31 21 38 26 1 A 13 12 9 1110 4 3 5 7 7 8 4 2 6 17 No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 61 Part name Bottom cowling Rubber seal Grommet Bolt Bracket Cowling lock lever Bushing Plate Bolt Wave washer Lever Washer Bolt Spring Hook Bolt Plastic tie 5 4 S6D07010 Q’ty 1 1 2 4 4 3 6 3 6 3 3 3 3 3 3 3 1 Remarks M6 × 16 mm M6 × 30 mm M6 × 16 mm M6 × 16 mm 6D03F1X Bottom cowling 7 36 37 28 37 35 29 A A A 39 34 30 5 26 24 40 33 27 32 25 7 16 15 14 6 33 32 5 23 4 22 20 19 18 28 31 21 38 26 1 A 13 12 9 1110 4 3 5 7 7 8 4 2 6 17 No. 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 Part name Holder Grommet Holder Bolt Retaining plate Bolt Bolt Cable holder Grommet Power trim and tilt switch Bolt Bracket Bracket Bracket Plate Bolt Grommet 6D03F1X 5 4 S6D07010 Q’ty 1 1 1 1 1 2 1 1 2 1 4 1 1 1 2 2 1 Remarks M6 × 25 mm M6 × 25 mm M6 × 16 mm M6 × 20 mm M6 × 20 mm 62 1 2 3 4 5 6 7 8 9 BRKT Bracket unit 7 36 37 28 37 35 29 A A A 39 34 30 5 26 24 40 33 27 32 25 7 16 15 14 6 33 32 5 23 4 22 20 19 18 28 31 21 38 26 1 A 13 12 9 1110 4 3 5 7 7 8 4 2 6 17 No. 35 36 37 38 39 40 63 Part name Gasket Cover Bolt Cover Ground lead Rubber trim 5 4 S6D07010 Q’ty 1 1 13 1 1 1 Remarks Not reusable M6 × 20 mm 6D03F1X Bottom cowling / Upper case, steering arm, swivel bracket, and clamp brackets Upper case, steering arm, swivel bracket, and clamp brackets No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Part name Upper case assembly Cover Ground lead Bolt Bolt Adapter Dowel Plastic tie Hose Circlip Nut Washer Nut Steering yoke Washer Bushing O-ring 6D03F1X Q’ty 1 2 1 1 1 1 1 1 1 1 2 4 2 1 2 1 1 7 Remarks M6 × 10 mm M6 × 25 mm Not reusable Not reusable 64 BRKT Bracket unit 7 No. 18 19 20 21 22 65 Part name Bushing Steering arm Washer Washer Grommet Q’ty 2 1 2 2 4 Remarks 6D03F1X Upper case, steering arm, swivel bracket, and clamp brackets 7 No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Part name Upper case Dowel Upper mount Washer Washer Washer Bolt Bracket Muffler assembly Gasket Mount housing Ground lead Washer Washer Lower mount Bolt Bolt 6D03F1X Q’ty 1 2 2 2 2 2 2 1 1 1 2 1 2 2 2 3 1 Remarks M14 × 190 mm Not reusable M10 × 45 mm M8 × 45 mm 66 BRKT Bracket unit 7 No. 18 19 Bolt Gasket Part name Q’ty 2 1 20 21 22 23 24 25 Muffler Bolt Bolt Bolt Circlip Bushing 1 2 4 2 1 1 Remarks M8 × 30 mm U-transom model Not reusable 67 U-transom model M6 × 35 mm / U-transom model M10 × 45 mm M14 × 205 mm 6D03F1X Upper case, steering arm, swivel bracket, and clamp brackets 7 No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Part name Muffler Exhaust manifold Gasket Lower exhaust guide Gasket Upper exhaust guide Flushing hose Plastic tie Joint Hose Rubber seal Pipe Rubber seal Bolt Bolt Bolt Hose 6D03F1X Q’ty 1 1 1 1 1 1 1 1 1 2 1 1 1 6 4 4 1 Remarks Not reusable Not reusable Not reusable M8 × 50 mm M8 × 50 mm M8 × 35 mm 68 BRKT Bracket unit Power trim and tilt unit 7 Checking the hydraulic pressure Ram 1. Check the hydraulic pressure. Check the internal parts if out of specification. Down PTT motor lead Battery terminal Light green (Lg) + Sky blue (Sb) - 2. Fully extend the power trim and tilt rams. Hydraulic pressure (down): 4.7–6.7 MPa (47–67 kgf/cm2) 3. Loosen the pipe joints 1, and then remove the pipe joint a. 4. Install the oil pressure gauge 2. 6. Reverse the PTT motor leads between the battery terminals to fully extend the trim and tilt rams. NOTE: Wrap the removed pipe joint a in a rag. Ram PTT oil pressure gauge assembly: 90890-06580 5. Connect the PTT motor leads to the battery terminals to retract the trim ram, and then measure the hydraulic pressure. Up PTT motor lead Battery terminal Sky blue (Sb) + Light green (Lg) - 7. Remove the oil pressure gauge 2. 8. Install the pipe joint a, and then tighten the pipe joints to the specified torque. T. R. Pipe joint 1: 15 N·m (1.5 kgf·m, 11.1 ft·lb) 9. Connect the PTT motor leads to the battery terminals to fully retract the trim and tilt rams. 10. Loosen the pipe joints 3, and then remove the pipe joint b. 11. Install the oil pressure gauge 2. 69 6D03F1X Power trim and tilt unit NOTE: Wrap the removed pipe joint b in a rag. PTT oil pressure gauge assembly: 90890-06580 14. Remove the oil pressure gauge 2. 15. Install the pipe joint b, and then tighten the pipe joints to the specified torque. T. R. 12. Connect the PTT motor leads to the battery terminals to extend the trim ram, and then measure the hydraulic pressure. Pipe joint 3: 15 N·m (1.5 kgf·m, 11.1 ft·lb) 16. After measuring the hydraulic pressure, connect the PTT motor leads to the battery terminals to fully extend the trim and tilt rams. Hydraulic pressure (up): 11.3–13.3 MPa (113–133 kgf/cm2) 13. Reverse the PTT motor leads between the battery terminals to fully retract the trim and tilt rams. 6D03F1X 17. Remove the reservoir cap, and then check the fluid level in the reservoir. 70 BRKT Bracket unit 18. If necessary, add fluid of the recommended type to the correct level. NOTE: If the fluid is at the correct level, the fluid should overflow out of the filler hole when the cap is removed. Recommended power trim and tilt fluid: ATF Dexron II 19. Install the reservoir cap. T. R. 71 Reservoir cap: 7 N·m (0.7 kgf·m, 5.2 ft·lb) 6D03F1X Power trim and tilt unit / Electrical components Electrical components 8 Port view 3 4 5 2 1 9 8 7 6 S6D08010 1 2 3 4 5 6 7 8 Throttle position sensor Emergency switch Pulser coil Oil level sensor Stator coil Water detection switch Atmospheric pressure sensor Electric oil pump 6D03F1X 9 Electric fuel pump 72 1 2 3 4 5 6 7 8 9 – ELEC + Electrical systems Top view 1 2 2 3 3 A 0 9 4 8 5 7 6 S6D08020 1 2 3 4 5 6 7 8 9 0 73 Ignition coil Fuel injector Spark plug Oil level sensor Emergency switch Throttle position sensor Power trim and tilt switch Shift position switch Shift cut switch Crank position sensor A Engine temperature sensor 6D03F1X Electrical components / Self-diagnosis Self-diagnosis 9 Diagnosing the electronic control system 1. Connect the special service tool to the outboard motor as shown. • Trouble code indication Example: The illustration code number 23. a: Light on, 0.33 second b: Light off, 4.95 seconds c: Light off, 0.33 second d: Light off, 1.65 seconds indicates NOTE: When performing this diagnosis, all of the electrical wires must be properly connected. Diagnostic flash indicator B: 90890-06865 2. Start the engine and let it idle. 3. Check the flash pattern of the diagnostic flash indicator to determine if there are any malfunctions. • Normal condition (no defective part or irregular processing is found) • Single flash is given every 4.95 seconds. a: Light on, 0.33 second b: Light off, 4.95 seconds 6D03F1X 74 1 2 3 4 5 6 7 8 9 TRBL SHTG Troubleshooting 4. If a flash pattern listed in the diagnostic code chart is displayed, check the malfunctioning part according to the flash pattern. NOTE: When more than one problem is detected, the light of the diagnostic flash indicator flashes in the pattern of the lowest numbered problem. After that problem is corrected, the light flashes in the pattern of the next lowest numbered problem. This continues until all of the problems are detected and corrected. Code 75 Symptom 1 Normal 13 Incorrect pulser coil signal 14 Incorrect crank position sensor signal 15 Incorrect engine temperature sensor signal 18 Incorrect throttle position sensor signal 19 Incorrect battery voltage 22 Incorrect atmospheric pressure sensor signal 23 Incorrect intake air temperature sensor signal 25 Incorrect fuel pressure signal 26 Incorrect injector signal 27 Incorrect water in fuel signal 28 Incorrect shift position switch signal 44 Incorrect engine stop lanyard switch signal 62 Low fuel pressure warning 6D03F1X Index A. G. Adjusting the oil pump link rod ..................... 32 After test run ................................................ 15 Applicable models.......................................... 3 Assembling the lower case .......................... 54 B. Backlash (counter rotation model) ............... 58 Backlash (regular rotation model) ................ 47 Bottom cowling............................................. 61 Break-in........................................................ 15 General........................................................ 33 General specifications ................................. 16 General torques........................................... 27 H. How to use this manual ................................. 1 I. Identification .................................................. 3 Installing the crankcase covers ................... 40 Installing the power unit............................... 40 Intake system ................................................ 6 C. Checking the battery .................................... 12 Checking the cooling water pilot hole .......... 15 Checking the engine oil level ....................... 12 Checking the engine start switch and engine stop lanyard switch......................... 14 Checking the fuel system............................. 12 Checking the gear oil level........................... 12 Checking the gear shift and throttle operation ........................................ 14 Checking the hydraulic pressure.................. 69 Checking the lower unit for air leakage........ 32 Checking the outboard motor mounting height ......................................... 13 Checking the power trim and tilt system ...... 14 Checking the remote control cables............. 13 Checking the steering system...................... 14 Crankcase.................................................... 39 Crankcase and cylinders................................ 4 D. Diagnosing the electronic control system .... 74 Dimensions .................................................. 23 Disassembling the reverse gear .................. 54 Drive shaft and lower case (counter rotation model)............................. 52 E. ECM (Electronic Control Module) ................ 10 Electrical ...................................................... 20 Electrical components.................................. 72 F. L. Lower case .................................................... 9 Lower unit .............................................. 20, 32 Lubricating the outboard motor.................... 33 M. Maintenance interval chart .......................... 31 Maintenance specifications ......................... 18 Manual format................................................ 1 Measuring the forward and reverse gear backlash ......................... 47, 58 O. Oil injection system...................................... 32 P. Port view...................................................... 72 Power trim and tilt unit ................................. 69 Power unit.............................................. 18, 36 Predelivery checks ...................................... 12 Propeller selection ....................................... 11 Propeller shaft housing (counter rotation model) ............................ 50 Propeller shaft housing (regular rotation model) ............................. 43 Propeller size............................................... 11 R. Removing the crankcase covers ................. 40 Removing the power unit............................. 37 Features and benefits .................................... 4 Fuel filter ...................................................... 35 6D03F1X 76 1 2 3 4 5 6 7 8 9 Index S. Selecting the pinion shims .....................46, 57 Selection ...................................................... 11 Self-diagnosis .............................................. 74 Serial number................................................. 3 Shimming (counter rotation model).............. 56 Shimming (regular rotation model)............... 45 Special service tools .................................... 28 Specified torques ......................................... 25 Symbols ......................................................... 2 T. Test run........................................................ 15 Tightening torques ....................................... 25 Top view....................................................... 73 U. Upper case..................................................... 8 Upper case, steering arm, swivel bracket, and clamp brackets.................................... 64 W. Wiring harness connector holder ................. 10 77 6D03F1X Index — MEMO — 6D03F1X 78 Wiring diagram Z300AETO, LZ300AETO 1 2 3 4 5 6 7 8 9 0 A B C D E F G H I J K L M N O P Q R S T U V W X Y Z [ \ ] _ Electric fuel pump Electric oil pump Oil level sensor Water detection switch Throttle position sensor Emergency switch Atmospheric pressure sensor Thermoswitch Power trim and tilt switch Fuel pressure sensor Pulser coil Stator coil Crank position sensor Fuel injector Fuel pump relay Injector driver Ignition coil Spark plug ECM Diode Engine temperature sensor Trim sensor Oil pump (remote oil tank) Oil level sensor (remote oil tank) Shift cut switch Shift position switch Power trim and tilt relay Power trim and tilt motor Intake air temperature sensor Starter relay Starter motor Starting battery Accessory battery Fuse holder Fuse (20 A) ECM main relay Injector driver relay Fuse (100 A) Fuse (30 A) Rectifier Regulator È É Ê Ë Ì To personal computer for diagnosis To remote control box/switch panel To warning indicator To trim meter To diagnostic flash indicator (special service tool) (*1) Isolator cable (optional) (*2) Negative cable (commercially available) Color code B Br G Gy L Lg O P R Sb W Y B/Br B/G B/L B/O B/R B/W B/Y G/L G/R G/W L/G L/R L/W L/Y O/B O/G O/L O/R O/W O/Y Pu/B Pu/G Pu/L Pu/R Pu/W Pu/Y R/L R/W R/Y W/B W/Br W/G W/L W/R W/Y Y/R : Black : Brown : Green : Gray : Blue : Light green : Orange : Pink : Red : Sky blue : White : Yellow : Black/brown : Black/green : Black/blue : Black/orange : Black/red : Black/white : Black/yellow : Green/blue : Green/red : Green/white : Blue/green : Blue/red : Blue/white : Blue/yellow : Orange/black : Orange/green : Orange/blue : Orange/red : Orange/white : Orange/yellow : Purple/black : Purple/green : Purple/blue : Purple/red : Purple/white : Purple/yellow : Red/blue : Red/white : Red/yellow : White/black : White/brown : White/green : White/blue : White/red : White/yellow : Yellow/red YAMAHA MOTOR CO., LTD. Printed in the Netherlands Jul. 2003 – 0.5 × 1 CR (E) Z300AETO, LZ300AETO 1 L G B W/Y W/B W/R W/B W/Y B R/Y L R W/Br W/L R W/G W/L W/Br G G G G G G G G/W C B B B R/Y G ` G A L 2L B W/R W/B W/Y W/G W/L W/Br B G Y3 R/Y 2 G G/L G/L G/W G 6 (*1) 4 3 2 (*2) B X B 3 E #2 D B L/R L/W L/R L/G L/W R/Y B R/Y D D F Pu/G Z \ B [ ] L/R 90ABCDE #6 B L/W F #3 Pu/Y O/Y B 12345678 NOPQRST IJK 0 7GH 56A 9 BCD N EFL M MLF EDCBAHG 7 65 9 KJI N0 1 2 3 4 V 8 U 12 8 34 R R R/W FGHIJKLM D D #5 Br/W R R Br R R R/W Pu/L Pu/W L/W B B S O/L O/W Ì O/L O/B L B R R/W O/R ! 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F G O/R O/R O/L Pu/L O/G O/B Pu/B 1 2 3 4 5 6 7 8 9 10 Pu/R Pu/Y O/Y Pu/W O/W Pu/G : : : : : : : : : : B R/W O/B Pu/B Pu/L Pu/W — O/W B R/W 11 12 13 14 15 16 17 18 19 20 : : : : : : : : : : Pu/B — Pu/W Pu/L G B R/W O/R Pu/R Pu/G 21 22 23 24 25 26 27 28 29 30 : : : : : : : : : : Pu/Y — O/Y B R/W Pu/R — Pu/Y Pu/G G : : : : : : : : : : : : : : : : : : : : L/W P — L/R L/R L/G G/R P B O P B/Y B/Y P P L/Y L/W L/G Y/R L 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 : : : : : : : : : : : : : : : : : : : : B/R G W Y Br — R/L W/Y G G Pu/L Pu/R B/O B/W B/Y R/L W/G L/Y Pu/W Pu/B 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 : : : : : : : : : : : : : : : : : : : : — Y B B W/L W/R G Pu/Y W/B — B B W/Br W/B L — Pu/G B/Br B/L B/G : : : : : : : : R R R R R/L R/L R/W R 9 10 11 12 13 14 15 16 : : : : : : : : L/Y L/Y R/Y R/Y R/Y R/Y R/Y R/Y 17 18 19 20 21 22 23 24 : : : : : : : : R R R/W R/W R/W R/W R/Y R/W Pu/R Pu/Y Pu/G Pu/W Pu/L Pu/B G B R/Y R/Y R/Y B B R/W R/W B B R/W R/W L/Y R/L R/L W/B B B R/Y R/Y R/Y R/Y R/Y R/Y G G Y R/Y R/Y L W/R W/B W/Y W/G W/L W/Br L B B B/W B/G B/Br B/O B/Y B/L I 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 X ± 1 2 3 4 5 6 7 8 # P L/W Y/R B/Y Br B B Lg Sb R Br B B/Y R/W L/R O L/G B/R L/W P P L/R L/W Y/R B P L Y Br W G L/Y P B/Y B/Y G/R L/G Lg Sb R/W B B Y B B B/R B/R L Y P B/Y B/Y W/R L/W Sb Lg Sb Lg Y W G P L/Y B L/G B B/R B/R W/R Y G/R Gy L B L/W S6D0WD04