Yamaha F200C, LF200C, F225C, LF225C, F200TR Service Manual
...
F200C
LF200C
F225C
LF225C
SERVICE MANUAL
69J-28197-1F-11LIT-18616-02-76
*LIT186160276*
NOTICE
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 a basic understanding of the mechanical and
electrical concepts and procedures inherent in the work, for without such knowledge attempted
repairs or service to the equipment could render it unsafe or unfit for use.
Because 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.
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.
F200C, LF200C, F225C, LF225C
SERVICE MANUAL
©2003 by Yamaha Motor Corporation, USA
1st Edition, September 2003
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Corporation, USA
is expressly prohibited.
Printed in USA
LIT-18616-02-76
Contents
General information
1
GEN
INFO
Specifications
2
SPEC
Periodic checks and adjustments
3
CHK
ADJ
Fuel system
4
FUEL
Power unit
5
POWR
Lower unit
6
LOWR
Bracket unit
7
BRKT
Electrical systems
8
ELEC
Troubleshooting
9
TRBL
SHTG
Index
–+
GEN
INFO
69J1D11
General information
How to use this manual.................................................................................1-1
Manual format............................................................................................1-1
Symbols.....................................................................................................1-2
Safety while working......................................................................................1-3
Fire prevention...........................................................................................1-3
Ventilation..................................................................................................1-3
Self-protection ...........................................................................................1-3
Parts, lubricants, and sealants ..................................................................1-3
Good working practices .............................................................................1-4
Disassembly and assembly .......................................................................1-4
Identification...................................................................................................1-4
Applicable models .....................................................................................1-4
Serial number ............................................................................................1-4
Features and benefits....................................................................................1-6
Newly developed V6 4-stroke engine........................................................1-6
Valve train system .....................................................................................1-9
Intake system ..........................................................................................1-11
Exhaust system .......................................................................................1-11
Fuel system .............................................................................................1-13
PTT (Power trim and tilt) unit...................................................................1-17
Technical tips ...............................................................................................1-18
Fuel injection control................................................................................1-18
Fail-safe function table ............................................................................1-20
PTT (Power trim and tilt) unit...................................................................1-21
Cooling system ........................................................................................1-26
Lubrication system...................................................................................1-26
Propeller selection.......................................................................................1-27
Propeller size...........................................................................................1-27
Selection..................................................................................................1-27
69J1D11
1
2
3
4
5
6
7
8
9
Predelivery checks ......................................................................................1-28
Checking the fuel system ........................................................................1-28
Checking the gear oil...............................................................................1-28
Checking the engine oil ...........................................................................1-28
Checking the battery................................................................................1-28
Checking the outboard motor mounting height........................................1-29
Checking the remote control cables ........................................................1-29
Checking the steering wheel ...................................................................1-30
Checking the gearshift and throttle operation..........................................1-30
Checking the tilt system...........................................................................1-30
Checking the engine start switch and engine stop lanyard switch ..........1-30
Checking the cooling water pilot hole ......................................................1-31
Test run ...................................................................................................1-31
Break-in ...................................................................................................1-31
After test run ............................................................................................1-31
GEN
INFO
General information
1-1
69J1D11
How to use this manual
1
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 parts and part quantities, as well as bolt, screw, O-ring, and hose
dimensions.
5
Service points regarding removal, checking, and installation are shown in individual illustrations
to explain the relevant procedure.
NOTE:
For troubleshooting procedures, see Chapter 9, “Troubleshooting.”
69J1D11
1-2
1
2
3
4
5
6
7
8
9
Symbols
The symbols below are designed to indicate the content of a chapter.
General information
Specifications
Periodic checks and adjustments
Fuel system
Power unit
Lower unit
Bracket unit
Electrical systems
Troubleshooting
GEN
INFO
SPEC
CHK
ADJ
FUEL
POWR
LOWR
BRKT
ELEC
TRBL
SHTG
– +
Symbols 1 to 6 indicate specific data.
1
Special tool
2
Specified oil or fluid
3
Specified engine speed
4
Specified tightening torque
5
Specified measurement
6
Specified electrical value
(resistance, voltage, electric current)
Symbols 7 to A in an exploded diagram indicate the grade of lubricant and the lubrication point.
7
Apply Yamaha 4-stroke motor oil
8
Apply water resistant grease (Yamaha grease A)
9
Apply molybdenum disulfide grease
0
Apply corrosion resistant grease
(Yamaha grease D)
A
Apply low temperature resistant grease
(Yamaha grease C)
Symbols B to G in an exploded diagram indicate the type of sealant or locking agent and the application point.
B
Apply Gasket Maker
®
C
Apply Yamabond No. 4
D
Apply LOCTITE
®
No. 271 (Red)
E
Apply LOCTITE
®
No. 242 (Blue)
F
Apply LOCTITE
®
No. 572
G
Apply silicon sealant
123456
T
R
.
.
7890A
E
A M
D C
BCDEFG
GM
4
271
LT
242
LT
572
LT
SS
How to use this manual
GEN
INFO
General information
1-3
69J1D11
Safety while working
1
To prevent an accident or injury and to
ensure quality service, follow the safety procedures provided below.
Fire prevention
Gasoline is highly flammable.
Keep gasoline and all flammable products
away from heat, sparks, and open flames.
Ventilation
Gasoline vapor and exhaust gas are heavier
than air and extremely poisonous. If inhaled
in large quantities they may cause loss of
consciousness and death within a short time.
When test running an engine indoors (e.g., in
a water tank) be sure to do so where adequate ventilation can be maintained.
Self-protection
Protect your eyes by wearing safety glasses
or safety goggles during all operations involving drilling and grinding, or when using an air
compressor.
Protect your hands and feet by wearing protective gloves and safety shoes when necessary.
Parts, lubricants, and sealants
Use only genuine Yamaha
parts, lubricants,
and sealants or those recommended by
Yamaha, when servicing or repairing the
outboard motor.
Under normal conditions, the lubricants mentioned in this manual should not harm or be
hazardous to your skin. However, you should
follow these precautions to minimize any risk
when working with lubricants.
1. Maintain good standards of personal and
industrial hygiene.
2. Change and wash clothing as soon as
possible if soiled with lubricants.
3. Avoid contact with skin. Do not, for
example, place a soiled rag in your
pocket.
4. Wash hands and any other part of the
body thoroughly with soap and hot water
after contact with a lubricant or lubricant
soiled clothing has been made.
5. To protect your skin, apply a protective
cream to your hands before working on
the outboard motor.
69J1D11
1-4
1
2
3
4
5
6
7
8
9
6. Keep a supply of clean, lint-free cloths for
wiping up spills, etc.
Good working practices
Special tools
Use the recommended special tools to protect parts from damage. Use the right tool in
the right manner—do not improvise.
Tightening torques
Follow the tightening torque specifications
provided throughout the manual. When tightening nuts, bolts, and screws, tighten the
large sizes first, and tighten fasteners starting
in the center and moving outward.
Non-reusable parts
Always use new gaskets, seals, O-rings, cotter pins, circlips, etc., when installing or
assembling parts.
Disassembly and assembly
1. Use compressed air to remove dust and
dirt during disassembly.
2. Apply engine oil to the contact surfaces
of moving parts before assembly.
3. Install bearings with the manufacture
identification mark in the direction indicated in the installation procedure. In
addition, be sure to lubricate the bearings
liberally.
4. Apply a thin coat of water-resistant
grease to the lip and periphery of an oil
seal before installation.
5. Check that moving parts operate normally after assembly.
Identification
1
Applicable models
This manual covers the following models.
Serial number
The outboard motor serial number is
stamped on a label attached to the port
clamp bracket.
Applicable models
F200TR, LF200TR, F225TR, LF225TR
Safety while working / Identification
GEN
INFO
General information
1-5
69J1D11
1
Model name
2
Approved model code
3
Transom height
4
Serial number
Model name
Approved
model code
Starting
serial No.
F200TR 60L 1001799–
LF200TR 60M 1000373–
F225TR 69J 1007259–
LF225TR 69K 1002513–
69J1D11
1-6
1
2
3
4
5
6
7
8
9
Features and benefits
1
Newly developed V6 4-stroke engine
The F225 is a newly developed 60-degree V6 4-stroke engine with a very compact and lightweight
design. Its size and weight are almost the same as the V6 2-stroke engines that are in current use.
This F225 offers numerous advantages of a 4-stroke engine. Compared to conventional 2-stroke
models, it emits much cleaner exhaust gases, offers a better fuel economy, and realizes lower noise
levels at idle and full throttle.
Through the newly developed “In-bank exhaust system,” which discharges exhaust gases from the
center of both banks, the engine block and the surrounding equipment have been made compact. In
addition, the six independent intake passages help to achieve a high level of driveability and power
output.
1
Electronic Fuel Injection
2
In-bank exhaust system
3
Pulse tuned long intake tracks
4
Individual inside track fuel injectors
S69J1250
60˚
Identification / Features and benefits
GEN
INFO
General information
1-7
69J1D11
Crankcase
The crankcase is made of cast aluminum, however steel has been cast into the areas for the crankshaft bearings. By distinguishing the area that requires strength from the area that allows the use of
a lighter material, both weight reduction and a stronger construction have been achieved.
The caps for the crankshaft bearings are secured with four bolts to ensure a high level of assembled
rigidity.
1
Casted aluminum
2
Steel
3
Crankcase
4
Cylinder block
Crankshaft
The crankshaft has been forged to realize a high-strength and high-rigidity construction. In the 60degree V6 cylinder configuration, the crankshaft pins are staggered 60 degrees from each other.
1
Crankpin #1
2
Crankpin #2
3
Crankpin #3
4
Crankpin #4
5
Crankpin #5
6
Crankpin #6
S69J1260
60˚
60˚
60˚
60˚
60˚
60˚
S69J1270
69J1D11
1-8
1
2
3
4
5
6
7
8
9
Piston
The piston has been carved out of a forged stock. To prevent the valves from coming in contact with
the piston, the piston is provided with a valve recess. If the engine goes out of timing and a valve
opens when the piston is at top-dead-center, this recess prevents the valve from coming in contact
with the piston, thus preventing engine damage.
1
Valve spring
2
Valve seal
3
Piston
4
Valve stem
5
Intake valve
6
Intake camshaft
7
Valve lifter
8
Valve recess
S69J1280
Features and benefits
GEN
INFO
General information
1-9
69J1D11
Valve train system
The valve train consists of a total of four camshafts, with two in each bank.
The camshafts are driven with the combination of a belt and chains. The crankshaft turns the belt to
drive the exhaust camshafts in both banks. Chains connect the exhaust camshafts to the intake
camshafts in the cylinder heads to drive the intake camshafts.
In addition, the timing belt offers quieter operation, and the cam chains help to achieve a compact
configuration through the use of individual driven sprockets.
Timing belt
The timing belt, which is driven by the drive sprocket that is attached to the crankshaft, rotates the
driven sprockets that are attached to the exhaust camshafts of both banks. The drive sprocket for
the timing belt is secured to the crankshaft by four bolts, and it can be removed easily for servicing.
In addition, the material of the driven sprockets has been changed from the previous metal to plastic
for weight reduction.
1
Driven sprocket
2
Timing chain
3
Intake camshaft
4
Crankshaft
5
Drive sprocket
6
Timing belt
7
Exhaust camshaft
8
Hydraulic timing belt tensioner
S69J1290
69J1D11
1-10
1
2
3
4
5
6
7
8
9
Tensioner
A timing chain tensioner is provided at the mid-span of the timing chain, between both camshafts.
The timing chain tensioner uses the force of a spring to maintain its tension. After the engine is
started, oil is pumped into the tensioner, and the resulting pressure causes the tension to increase.
A total of three tensioners are used, one for the timing belt, and one for each timing chain of both
banks, to maintain proper tension and to ensure the reliability of the valve train.
1
Intake camshaft
2
Exhaust camshaft
3
Timing chain
4
Timing chain tensioner
5
Hydraulic timing belt tensioner
S69J1300
Features and benefits
GEN
INFO
General information
1-11
69J1D11
Intake system
Throttle valve
A total of six intake throttle valves are provided, one for each cylinder. Together with the intake
silencer that offers enhanced intake efficiency and the injectors that are provided at each throttle
body, the throttle valves help to improve the intake efficiency of the engine. As a result, this engine
produces a higher power output and realizes better driveability.
1
Throttle valve
Exhaust system
In-bank exhaust system
The exhaust passage of the F225 is located in the V bank, a layout that is the opposite of conventional V6 engines. By providing the exhaust passage in the V bank, the engine has been made considerably more compact.
1
Exhaust gas
S69J1310
S69J1320
69J1D11
1-12
1
2
3
4
5
6
7
8
9
Exhaust passage during idle
To reduce noise when the engine is idling, the exhaust gas passage of the F225 has adopted a labyrinth construction. During idling, the exhaust gas passes through the passage on the side of the
exhaust guide, and enters the upper case through a hole in the upper case gasket. When it fills the
upper case, the exhaust gas enters another passage on the side of the exhaust guide through
another hole in the upper case gasket. Then, it is discharged through the idle port that is provided in
the upper case.
The exhaust manifold and muffler in the upper case are surrounded by the water jackets to reduce
exhaust noise. The water jackets also help prevent corrosion by preventing the exterior of the
exhaust manifold and muffler from coming in direct contact with the exhaust gas.
1
Idle port
2
Oil pan
3
Exhaust manifold
4
Muffler
È
Exhaust gas
É
Water
S69J1330
Features and benefits
GEN
INFO
General information
1-13
69J1D11
Fuel system
The fuel flows in the following order: fuel filter, low-pressure fuel pump, vapor separator, high-pressure fuel pump, and injectors. The excess fuel at the injectors passes through the pressure regulator and fuel cooler, and returns to the vapor separator.
When the engine start switch is turned on, the injectors of all cylinders operate before the pump
relay is actuated to prevent the injectors from sticking.
1
Fuel filter
2
Low-pressure fuel pump
3
Vapor separator
4
High-pressure fuel pump
5
Fuel injector
6
Pressure regulator
7
Fuel cooler
S69J1340
69J1D11
1-14
1
2
3
4
5
6
7
8
9
Low-pressure fuel pump
The F225 has adopted a newly developed, low-pressure electrical fuel pump, in place of the lowpressure mechanical fuel pump used in the previous electronic fuel injection system. With the adoption of the electric pump, the routing of the fuel system has been made more compact. To prevent
the over-pumping of fuel, this pump operates for 10 seconds, and stops for 20 seconds when the
engine is operating at low speeds.
The pump operates constantly if the engine speed is 1,200 r/min or higher, or for several seconds
(which vary by ambient temperature) after the engine is started. At other times, it operates for 10
seconds, and stops for 20 seconds to prevent over-pumping.
1
Vapor separator
2
Low-pressure fuel pump
3
Fuel filter
4
On
5
Off
6
10 seconds
7
20 seconds
S69J1350
Features and benefits
GEN
INFO
General information
1-15
69J1D11
Electronic control system
The ECM controls the ignition timing, the fuel injection timing, the fuel injection volume, and the ISC
and it maintains a stoichiometric air-fuel ratio in all operating conditions, including starting and idling.
Also, the ECM converts the signals from the input sensors and sends instructions to each part.
B Z
T
P
P
~
S60L1180
Injector #1,4
40
ISC motor A
ISC motor B
ISC motor C
ISC motor D
Oil pressure warning lamp
Overheat warning lamp
Engine warning lamp
Buzzer
Tachometer
25
High-pressure fuel pump
Low-pressure fuel pump
Battery power source
Main relay
Connector pin position
Main relay
Battery
Rectifire/Regulator
Main switch
28
Power source
for diagnosis
lamp
36
Diagnosis signal
26
Personal
computer
Starboard bank
Port bank
Ground for power source
42
Ground for unit
32
Thermo switch
37
Neutral switch
31
6
Emergency engine stop switch
4
Shift cutoff switch
9
Oil pressure sensor
29
Power source for oil pressure sensor
10
Intake air temperature sensor
7
Engine temperature sensor
35
Ground for sensors
8
Intake air presssure sensor
33
TPS
34
Power source for intake air pressure sensor
11
Power source for TPS
12
Pulser coil #3
13
Pulser coil #2
14
Pulser coil #1
15
Vacancy
DES switch
Vacancy
Ignition coil #1,4
ECM
Ignition coil #2,5
Ignition coil #3,6
Injector #2,5
39
Injector #3,6
20
18
21
19
24
23
27
3
1
17
16
44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23
22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
30
2
22
44
43
38
69J1D11
1-16
1
2
3
4
5
6
7
8
9
Ignition and fuel injection timing
This engine adopted the group injection system that the fuel required for one combustion is injected
twice per one cycle.
Therefore, the injector driving circuits can be integrated to 3 circuits and a simpler electrical structure is obtained.
Firing order : #1, #2, #3, #4, #5, #6
Injection order : #1 and #4 → #2 and #5 → #3 and #6 (group injection)
TDC
720˚
180˚
120˚
TDC
TDC
TDC
TDC
Crankshaft angle
Cylinder
Cylinder #1
Cylinder #2
Cylinder #3
Cylinder #4
Cylinder #5
Cylinder #6
Ignition
Injection
Ignition
Injection
Ignition
Injection
Ignition
Injection
Ignition
Injection
Ignition
Injection
Compression
Compression
Compression
Compression
Compression
Compression
Intake
Intake
Intake
Intake
Intake
Intake
Combustion Exhaust
Combustion Exhaust
Combustion Exhaust
Combustion
Exhaust
Combustion Exhaust
Combustion Exhaust
: Ignition spark
: Wasted spark
S60L1190
Features and benefits
GEN
INFO
General information
1-17
69J1D11
PTT (Power trim and tilt) unit
The PTT unit has been newly developed for the F225. Based on the field-proven 61A type, its PTT
fluid passage and internal valve construction have been changed for this application. Although the
valves of the 61A type have been distributed to the various areas of the gear pump housing, the
valves of the new PTT unit have been concentrated in the vicinity of the gear pump to improve their
serviceability. In addition, the material of the gear pump housing has been changed to enhance its
corrosion resistance.
1
Gear pump
2
Main valve
3
Relief valve
4
Manual valve
È
61A type
É
F225 type
C
C
B
B
A
A
DD
(A)
(B)
(C)
(D)
S69J1380
69J1D11
1-18
1
2
3
4
5
6
7
8
9
Technical tips
1
Fuel injection control
The F200/F225 injects fuel simultaneously to the following cylinder pairs: #1 and #4, #2 and #5, and
#3 and #6. Optimal injection timing is provided in accordance with the operating conditions of the
engine.
Starting fuel injection volume and injection timing
The injectors are actuated in sync with the standard crankshaft position signals (BTDC 70°) for cylinder pairs #1 and #4, #2 and #5, and #3 and #6, respectively.
Normal fuel injection volume and injection timing
To control the actuation timing of the injectors, the injection ending timing is established by using the
top-dead-center of the intake stroke as the standard, for cylinder pairs #1 and #4, #2 and #5, and #3
and #6, respectively.
#6
B70
#1 #2 #3 #4 #5 #6 #1 #2
CYLINDER #1
CYLINDER #2
CYLINDER #3
CYLINDER #4
CYLINDER #5
CYLINDER #6
SIGNAL #1/4
SIGNAL #2/5
SIGNAL #3/6
INJECTION #1/4
INJECTION #2/5
INJECTION #3/6
B10 B70 B10
B70 B10
B70 B10
B70 B10B10 B70 B10
B70 B10
B70 B10
(Compression TDC)
Compression Combustion Exhaust Intake Compression Expansion
Compression Combustion Exhaust Intake Compression
Intake
Compression
Combustion Exhaust Intake Compression
Compression Combustion Exhaust
Intake
Compression Combustion Exhaust
Compression Combustion Exhaust
Intake
Intake
Intake
Intake
Combustion Exhaust
Exhaust
Combustion Exhaust
Starting injection start timing
(standard position BTDC 70
˚)
S60L1200
#6
B70
#1 #2 #3 #4
#5 #6 #1 #2
CYLINDER #1
CYLINDER #2
CYLINDER #3
CYLINDER #4
CYLINDER #5
CYLINDER #6
SIGNAL #1/4
SIGNAL #2/5
SIGNAL #3/6
INJECTION #1/4
INJECTION #2/5
INJECTION #3/6
B10 B70 B10
B70 B10B70 B10
B70 B10
B10 B70 B10
B70 B10
B70 B10
Compression Combustion Exhaust Intake Compression Expansion
Compression Combustion Exhaust Intake Compression
Intake
Compression
Combustion Exhaust Intake Compression
Compression Combustion Exhaust Intake
Compression Combustion Exhaust
Compression Combustion Exhaust
Intake
Intake
Intake
Intake
Combustion Exhaust
Exhaust
Combustion Exhaust
(Compression TDC)
Synchronous injection completion timing
#1/4 synchronous injection start/completion
timing setting range
S60L1210
Features and benefits / Technical tips
GEN
INFO
General information
1-19
69J1D11
Over-revolution control
If the engine speed exceeds 4,500 r/min, while the shift is in neutral, ignition is stopped. The various
stages of ignition cutoff are shown in the table below.
Ignition cutoff cylinder in neutral
: Indicates a misfire at either cylinder (once, due to simultaneously firing).
: Indicates a misfire at both cylinders (twice continuous).
If the engine speed exceeds 6,200 r/min, while the shift is in forward or reverse, the ignition is
stopped. The various stages of ignition cutoff are shown in the table below.
Ignition cutoff cylinder in forward or reverse
: Indicates a misfire at either cylinder (once, due to simultaneously firing).
: Indicates a misfire at both cylinders (twice continuous).
Dual-engine control
When two outboard engines are used, if one of the engines enters any one of the control modes, the
other engine will also control its ignition. This control is activated with the same engine speeds as
with other control modes.
Shift cutoff control
If the shift cut switch is activated with the engine operating under 2,000 r/min, the system causes
one or two cylinders to misfire in order to facilitate shifting. The system causes cylinders #1 and #2,
or #4 and #5 to misfire when the engine speed is over 850 r/min, and cylinder #1 or #4 to misfire
when the engine speed is under 850 r/min.
Set speed (r/min) #1 #2 #3 #4 #5 #6
4,500
4,750
Set speed (r/min) #1 #2 #3 #4 #5 #6
6,200
6,250
6,300
6,350
6,400
6,450
69J1D11
1-20
1
2
3
4
5
6
7
8
9
Fail-safe function table
Symptom
FAIL-SAFE FUNCTION
DIAGNOSIS
CODE
Ignition Injection ISC
Engine
condition
Incorrect pulser
coil signal
Engine starting:
Only the cylinders
outputting normal
signal ignite at
BTDC10°, and all
cylinders thereafter.
All cylinders inject
simultaneously
based on the cylinder that is outputting a normal signal.
Only in neutral:
900 r/min
Idle speed
increases
13
Incorrect engine
temperature sensor signal
Normal control
Engine temperature
sensor is fixed to
40 °C to activate
normal control.
Only in neutral:
900 r/min
Idle speed
increases
15
Incorrect throttle
position sensor
signal
Ignition timing is
fixed to BTDC10°.
Correction is made
to the basic injection map.
Opening angle
is fixed to 60%.
Idle speed
increases
18
Incorrect intake air
temperature sensor signal
Normal control
Intake air temperature sensor is fixed
to 40 °C in order to
activate normal
control.
Only in neutral:
900 r/min
Idle speed
increases
23
Incorrect neutral
switch signal
Normal control Normal control Normal control Normal control
28
Incorrect intake air
pressure sensor
signal
Normal control
Correction is made
to the basic injection map.
Only in neutral:
900 r/min
Idle speed
increases
29
Incorrect oil pressure sensor signal
Normal control Normal control
Only in neutral:
900 r/min
Idle speed
increases
39
Incorrect shift cut
switch signal
Normal control Normal control
In neutral:
900 r/min
In gear:
850 r/min
Idle speed
increases
45
Incorrect thermoswitch signal
Normal control Normal control
Only in neutral:
900 r/min
Idle speed
increases
46
Technical tips
GEN
INFO
General information
1-21
69J1D11
PTT (Power trim and tilt) unit
In the newly designed PTT unit, the up-main valve, down-main valve, up-relief valve, and downrelief valve have been concentrated in the gear pump housing in order to improve the serviceability
of the engine and ensure reliable operation.
1
Tilt cylinder
2
Trim cylinder
3
Manual valve
4
Up-main valve
5
Down-main valve
6
Up-relief valve
7
Down-relief valve
8
Gear pump
9
Reservoir
0
Tilt ram
A
Tilt piston
B
Tilt piston absorber
C
Free piston
D
Shock return valve
E
Trim ram
F
Trim piston
G
Power trim and tilt motor
H
Up-shuttle piston
I
Down-shuttle piston
S69J1410
69J1D11
1-22
1
2
3
4
5
6
7
8
9
Trim-up and tilt-up function
When the PTT switch is pressed to “UP,” the power trim and tilt motor operates the gear pump and
fluid pressure is generated. As a result, the fluid pressure pushes the up-shuttle piston upward,
enters the trim cylinder and tilt cylinder lower chambers through the up-main valve, and then pushes
the tilt ram and trim ram upward.
In addition, the fluid pushes the down-shuttle piston downward, opens the down-main valve, and
returns the PTT fluid from the tilt cylinder upper chamber to the gear pump.
The fluid from the trim cylinder upper chamber then returns to the reservoir.
The tilt ram and the trim ram extend simultaneously, and after the trim ram has extended completely, the tilt ram operates to tilt up.
1
Tilt ram
2
Tilt cylinder
3
Trim ram
4
Trim cylinder
5
Power trim and tilt motor
6
Reservoir
7
Gear pump
8
Up-shuttle piston
9
Up-main valve
0
Down-shuttle piston
A
Down-main valve
È
Return
É
Send
:
:
S69J1420
Technical tips
GEN
INFO
General information
1-23
69J1D11
Trim ram retraction function
When the outboard motor is tilted up and held in place with the tilt stop lever and the PTT switch is
pressed to “DN,” the trim ram will be retracted.
Although the gear pump attempts to draw oil from the tilt cylinder and trim cylinder lower chambers,
after the PTT switch has been pressed, fluid cannot be drawn from the tilt cylinder lower chamber
because the tilt ram is secured in place by the tilt stop lever. Only the PTT fluid from the trim cylinder
lower chamber can be drawn, and as the fluid pressure decreases, the trim ram retracts into the trim
cylinder. Since the tilt ram is secured in place, the PTT fluid pumped by the gear pump flows into the
tilt cylinder upper chamber to increase fluid pressure. As a result, the down-relief valve opens, and
the PTT fluid is released into the reservoir.
1
Tilt ram
2
Tilt cylinder
3
Trim ram
4
Trim cylinder
5
Gear pump
6
Reservoir
7
Down-relief valve
È
Return
É
Send
:
:
S69J1430
69J1D11
1-24
1
2
3
4
5
6
7
8
9
Trim-down and tilt-down function
When the PTT switch is pressed to “DN,” the power trim and tilt motor operates the gear pump and
fluid pressure is generated. As a result, the fluid pressure pushes the down-shuttle piston upward,
enters the tilt cylinder upper chamber through the down-main valve, and then pushes the tilt ram
downward.
In addition, the fluid pushes the up-shuttle piston downward to open the up-main valve.
The gear pump draws the PTT fluid from the tilt cylinder and trim cylinder lower chambers, and then
retracts the tilt ram and the trim ram.
Since the fluid pressure from the gear pump is applied to the tilt cylinder upper chamber, the tilt ram
moves downward first.
The hydraulic oil flows into the trim cylinder upper chamber from the reservoir.
When the outboard motor comes in contact with the trim ram, the trim ram moves downward simultaneously with the tilt ram, due to its own weight and the suction of the PTT fluid by the trim cylinder
lower chamber.
1
Tilt ram
2
Tilt cylinder
3
Trim ram
4
Trim cylinder
5
Power trim and tilt motor
6
Reservoir
7
Gear pump
8
Up-shuttle piston
9
Up-main valve
0
Down-shuttle piston
A
Down-main valve
È
Return
É
Send
:
:
S69J1440
Technical tips
GEN
INFO
General information
1-25
69J1D11
Stationary condition
When the PTT switch is not pressed, the gear pump will not pump the fluid, the up-main valve and
the down-main valve will remain closed, and the PTT unit in the system remains constant. This will
allow the tilt ram and the trim ram to maintain their positions until the PTT fluid flows through the
system again.
When the outboard hits something in the water
If the lower casing comes in contact with an obstacle while the boat is in operation, a sudden extension force becomes applied to the tilt ram. This force causes the fluid pressure in the tilt cylinder
upper chamber to increase, and the tilt piston absorber to open and release the fluid pressure into
the space between the tilt piston and the free piston. As a result, the dampening effect of the tilt piston absorber and the oil lock mechanism prevent the PTT unit from damage, before the tilt piston
comes in contact with the top of the tilt cylinder.
After the collision, a force to return the outboard motor to its original position is generated due to the
weight of the outboard and the thrust of the propeller.
The PTT fluid passes through the shock return valve of the tilt piston, via the free piston, and into
the tilt cylinder upper chamber.
When the tilt piston comes in contact with the free piston, the tilt piston stops.
1
Tilt ram
2
Tilt cylinder
3
Tilt piston absorber
4
Tilt piston
5
Shock return valve
6
Free piston
S69J1450
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