INDEX 1. SPECIFICATIONS ........................................................ 1-1 1.SPECIFICATIONS .................................................. 1-1 2.DIMENSIONAL DRAWINGS.................................. 1-4 3. MAINTENANCE ............................................................ 3-1 1.MAINTENANCE SCHEDULE ................................ 3-1 2.ENGINE OIL............................................................ 3-2 3.OIL FILTER .............................................................. 3-3 4.GEAR CASE OIL .................................................... 3-4 5.SPARK PLUGS ......................................................
3-6 6.VALVE CLEARANCE .............................................. 3-9 7.FUEL STRAINER (LOW PRESSURE SIDE) ........ 3-15 8.FUEL STRAINER (HIGH PRESSURE SIDE) ........ 3-18 9.WATER SEPARATOR with WATER LEVEL SENSOR .............................................................. 3-19 10. IDLING .................................................................. 3-22 11. SHIFT CONTROL CABLE .................................... 3-24 12. THROTTLE CONTROL CABLE/ THROTTLE LINK .................................................. 3-26 13. REMOTE CONTROL LEVER FRICTION .............. 3-28 14. ALTERNATOR BELT ............................................ 3-28 2.
SERVICE INFORMATION ............................................ 2-1 1.THE IMPORTANCE OF PROPER SERVICING ...... 2-1 2.IMPORTANT SAFETY PRECAUTIONS ................ 2-1 3.SERVICE RULES .................................................... 2-2 4.SYMBOLS USED IN THIS MANUAL .................... 2-2 5.SERIAL NUMBER LOCATIONS ............................ 2-2 6.MAINTENANCE STANDARDS .............................. 2-3 7.TORQUE VALUES .................................................. 2-7 8.SPECIAL TOOLS .................................................. 2-10 9.TROUBLESHOOTING .......................................... 2-14 a.
ENGINE····························································· 2-14 HARD STARTING ············································· 2-14 CYLINDER COMPRESSION TEST··················· 2-15 ENGINE DOES NOT RUN SMOOTHLY ·········· 2-16 b. IGNITION (POWER) SYSTEM ························· 2-20 ENGINE DOES NOT START ···························· 2-20 FUSE LOAD CHART········································· 2-21 FUSE BOX CONNECTION TABLE··················· 2-22 c. STARTER SYSTEM ·········································· 2-23 ENGINE DOES NOT START ·····························2-23 d.
IGNITION SYSTEM·········································· 2-25 ENGINE IS HARD TO START ·························· 2-25 e. FUEL SYSTEM ················································· 2-28 ENGINE IS HARD TO START ·························· 2-28 f. CHARGING SYSTEM······································· 2-30 BATTERY UNDER CHARGED·························· 2-30 ACG INDICATOR LINE INSPECTION ·············· 2-31 g.
ALERT SYSTEM ··············································· 2-32 OIL ALERT SYSTEM ········································ 2-32 OVERHEAT ALERT SYSTEM··························· 2-32 ALTERNATOR WARNING SYSTEM················ 2-32 FULL WATER (IN WATER SEPARATOR) WARNING SYSTEM········································· 2-32 MIL WARNING SYSTEM ································· 2-32 WARNING SYSTEM········································· 2-32 WARNING BUZZER SOUNDS CONTINUOUSLY·············································· 2-33 OIL PRESSURE INSPECTION·························· 2-35 INTERMITTENT PROLONGED SOUND OF WARNING BUZZER KEEPS SOUNDING········ 2-37 INTERMITTENT SHORT SOUND OF WARNING BUZZER KEEPS SOUNDING········ 2-38 h.
SHIFT MECHANISM ········································ 2-39 i. POWER TRIM/TILT ASSEMBLY ······················ 2-40 POWER TRIM/TILT ASSEMBLY DOES NOT MOVE························································2-40 POWER TRIM/TILT ASSEMBLY DOES NOT HOLD························································ 2-41 POWER TRIM/TILT MOTOR DOES NOT MOVE······················································· 2-42 POWER TRIM/TILT ASSEMBLY QUICK REFERENCE CHART········································· 2-43 CHECK POINT ·················································· 2-44 10. CABLE/HARNESS ROUTING .............................. 2-45 11.
TUBE ROUTING .................................................. 2-66 12. LUBRICATION ...................................................... 2-77 4. ENGINE COVER/COVER LOCK .................................. 4-1 1.ENGINE COVER .................................................... 4-2 2.FRONT SEPARATE COVER.................................... 4-7 3.L./R. ENGINE UNDER COVERS ............................ 4-9 4.UNDER COVER FRONT BRACKET/ L./R. SIDE COVER BRACKETS ............................ 4-20 5. PROGRAMMED-FUEL INJECTION ............................ 5-1 1.SERVICE PRECAUTIONS ...................................... 5-2 2.CIRCUIT DIAGRAM................................................
5-3 3.VACUUM CONNECTIONS .................................... 5-5 4.PARTS LOCATION/ ECM TERMINAL LAYOUT .................................... 5-6 5.TROUBLESHOOTING .......................................... 5-11 6.TROUBLESHOOTING WITH HDS TESTER ........................................................ 5-13 a. TROUBLESHOOTING GUIDE BY DTC············ 5-15 b.
TROUBLESHOOTING ······································ 5-18 MIL DOES NOT COME ON······························ 5-18 MIL COMES ON BUT DTC CODE DOES NOT APPEAR ···························································· 5-21 ALERT SYSTEM INITIAL OPERATION IS FAULTY····························································· 5-23 NEUTRAL SWITCH MALFUNCTION ·············· 5-26 TACHOMETER MALFUNCTION······················ 5-27 ECM TROUBLESHOOTING ····························· 5-28 MAP SENSOR TROUBLESHOOTING············· 5-28 CKP SENSOR TROUBLESHOOTING ·············· 5-30 ECT SENSOR 1 TROUBLESHOOTING ··········· 5-33 TP SENSOR TROUBLESHOOTING················· 5-34 CMP SENSOR TROUBLESHOOTING ············· 5-36 IAT SENSOR TROUBLESHOOTING················ 5-38 BARO SENSOR TROUBLESHOOTING··········· 5-39 IAC VALVE TROUBLESHOOTING ··················· 5-41 VTEC SOLENOID VALVE TROUBLESHOOTING ······································ 5-42 KNOCK SENSOR TROUBLESHOOTING ········ 5-43 A/F SENSOR HEATER TROUBLE- SHOOTING ······················································· 5-44 A/F SENSOR TROUBLESHOOTING················ 5-49 ECT SENSOR 2 TROUBLESHOOTING ··········· 5-51 ECT SENSOR 3 TROUBLESHOOTING ··········· 5-52