Yamaha 50G Service Manual
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Yamaha 50G Service Manual

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Download this manual See also: Owner's Manual
50G, 60F, 70B,
75C, 90A
SERVICE
MANUAL
6H2-28197-Z9-11

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Summary of Contents for Yamaha 50G

  • Page 1 50G, 60F, 70B, 75C, 90A SERVICE MANUAL 6H2-28197-Z9-11...

  • Page 2: Specifications

    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.

  • Page 3: How To Use This Manual

    A50000-0 HOW TO USE THIS MANUAL MANUAL FORMAT This manual provides the mechanic with descriptions of the operations of disassembly, repair, assembly, adjustment and inspection, each of which is presented in a sequential, step- by-step procedure. To assist you to find your way about this manual, the Section Title and Major Heading is given at the head of every page.
  • Page 4 SPECIFICATIONS These are given in bold type at each procedure. It is not necessary to leave the section deal- ing with the procedure in order to look up the specifications. It is important to note the differences in specifications of models. Where a procedure relates to more than one model, the main differences in specifications will be shown in the following table.

  • Page 5: Fuel System

    G Apply engine oil H Apply gear oil I Apply molybdenum disulfide oil J Apply water resistant grease (Yamaha marine grease A, Yamaha marine grease) Symbols K to N in an exploded diagram indicate grade of sealing or locking agent, and location of application point: ®...
  • Page 7 INDEX A30000-0 GENERAL INFORMATION INFO SPECIFICATIONS SPEC PERIODIC INSPECTION AND ADJUSTMENT INSP FUEL SYSTEM FUEL POWER UNIT POWR LOWER UNIT LOWR BRACKET UNIT BRKT – ELECTRICAL SYSTEMS ELEC TROUBLE ANALYSIS TRBL ANLS...

  • Page 9: Table Of Contents

    INFO CHAPTER 1 GENERAL INFORMATION IDENTIFICATION .................... 1-1 SERIAL NUMBER ..................1-1 STARTING SERIAL NUMBERS ............... 1-1 SAFETY WHILE WORKING ................1-2 FIRE PREVENTION ................... 1-2 VENTILATION................... 1-2 SELF-PROTECTION.................. 1-2 OILS, GREASES AND SEALING FLUIDS..........1-2 GOOD WORKING PRACTICES ..............1-3 DISASSEMBLY AND ASSEMBLY ............

  • Page 10: Identification

    IDENTIFICATION INFO A60000-1* IDENTIFICATION SERIAL NUMBER The serial number of the outboard motor is stamped on a plate attached to the port side of the clamp bracket. 1 Serial number NOTE: For USA model: As an anti-theft measure, a special label on which the outboard motor serial number is stamped is bonded to the port side of the clamp bracket.

  • Page 11: Safety While Working

    SAFETY WHILE WORKING INFO SAFETY WHILE WORKING The procedures given in this manual are those recommended by Yamaha to be fol- lowed Yamaha dealers their mechanics. FIRE PREVENTION Gasoline (petrol) is highly flammable. Petroleum vapor is explosive if ignited. Do not smoke while handling and keep it away from heat, sparks, and open flames.

  • Page 12: Good Working Practices

    SAFETY WHILE WORKING INFO Under normal conditions of use, there should be no hazards from the use of the lubricants mentioned in this manual. How- ever, safety is all-important and by adopt- ing good safety practices, any risk is minimized. A summary of the most important precau- tions is as follows: 1.

  • Page 13: Disassembly And Assembly

    SAFETY WHILE WORKING INFO 3. Non-reusable items When reassembling, always use new gaskets, packing, O-rings, oil seals, split-pins and circlips, etc. DISASSEMBLY AND ASSEMBLY 1. Clean parts with compressed-air when disassembling them. 2. Oil the contact surfaces of moving parts before assembly.

  • Page 14: Special Tools

    SPECIAL TOOLS INFO A80000-0* SPECIAL TOOLS The use of correct special tools recommended by Yamaha will aid the work and enable accu- rate assembly and tune-up. Improvisations and use of improper tools can cause damage to the equipment. NOTE: For USA and Canada, use part numbers starting with “YB-”, “YM-”, “YU-” or “YW-”.

  • Page 15: Measuring

    SPECIAL TOOLS INFO MEASURING Tool No. Except for Tool name Use for: USA and USA and Canada a Canada b Tachometer YU-08036-A 90890-06760 Idle speed Dynamic spark tester YM-34487 90890-06754 Ignition system CDI tester YU-91022-B N.A. Ignition system Mity Vac YB-35956 90890-06756 Fuel joint...
  • Page 16 SPECIAL TOOLS INFO...

  • Page 17: Removal And Installation

    SPECIAL TOOLS INFO REMOVAL AND INSTALLATION Tool No. Except for Tool name Use for: USA and USA and Canada a Canada b YB-06107 Small end bearing installer 90890-06527 Connecting rod YB-06287 Piston slider YU-33294 90890-06530 Cylinder piston Water pump housing oil seal Reverse gear bearing Slide hammer set YB-06096...
  • Page 18 SPECIAL TOOLS INFO...
  • Page 19 SPECIAL TOOLS INFO Tool No. Except for Tool name Use for: USA and USA and Canada a Canada b Propeller shaft needle bearing Bearing depth plate N.A. 90890-06603 Drive shaft needle bearing Oil seal attachment YB-06269 N.A. Propeller shaft oil seal Needle bearing depth stop YB-34473 N.A.
  • Page 21 SPEC CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATION ................2-1 MAINTENANCE SPECIFICATIONS..............2-5 ENGINE..................... 2-5 ELECTRICAL ..................... 2-7 DIMENSION.................... 2-10 TIGHTENING TORQUE ................2-12 GENERAL TORQUE SPECIFICATIONS ............2-13...

  • Page 22: General Specification

    SPEC GENERAL SPECIFICATION C20000-0* GENERAL SPECIFICATION Model Unit 50 hp 60 hp 70 hp Model 50GETO : P60TH/ : 70BEDO 60FEHTO : 70TR/70BETO : C60ER/60FED : 60FEDO : C60TR/60FET : 60FETO Approved model No. Overall Length mm (in) 698 (27.5) 713 (28.1) —...
  • Page 23 SPEC GENERAL SPECIFICATION Model Unit 75hp 80hp 90hp Model C75TR/75CET 80AETO 90AEHD 75TR/75CETO 90AED P75TH/75CEHTO C90TR/90AET 90TR/90AETO B90TR/90AETO Approved model No. *1,2 *2,3,4 Overall Length mm (in) 726 (28.6) 726 (28.6) 726 (28.6) 1,343 (52.9) — 1,343 (52.9) *1,2 *2,3,4 Overall Width mm (in) 374 (14.7)
  • Page 24 SPEC GENERAL SPECIFICATION Model Unit 50 hp 60 hp 70 hp 75 hp 80 hp 90 hp Scavenging system Loop charge Starting system Electric Ignition system Alternator output Carburetor starting system Choke valve /Prime start Advance type Micro computer Spark plug (NGK) BR8HS-10 B8HS-10 Spark plug with noise...
  • Page 25 SPEC GENERAL SPECIFICATION Model Item Unit 50 hp Propeller G type (aluminum) No. of blades × diameter 3 × 11-3/8 × 12 × pitch 3 × 11-1/8 × 13 Model Item Unit 60, 70 hp Propeller K type (aluminum) K type (stainless) No.

  • Page 26: Maintenance Specifications

    SPEC MAINTENANCE SPECIFICATIONS C31000-0* MAINTENANCE SPECIFICATIONS ENGINE Model Item Unit 50 hp 60 hp 70 hp 75 hp 80 hp 90 hp Cylinder head: Warpage limit mm (in) 0.1 (0.004) (Lines indicate straight measurement) Cylinder: Bore size mm (in) 72.00 ~ 72.02 82.00 ~ 82.02 (2.834 ~ 2.835) (3.228 ~ 3.229)
  • Page 27 SPEC MAINTENANCE SPECIFICATIONS Model Item Unit 50 hp 60 hp 70 hp 75 hp 80 hp 90 hp Crankshaft: Crank width “A” mm (in) 57.90 ~ 57.95 (2.280 ~ 2.281) — Crank width “B” mm (in) 151.7 ~ 152.0 (5.972 ~ 5.984) —...

  • Page 28: Electrical

    SPEC MAINTENANCE SPECIFICATIONS Model Item Unit 50 hp 60 hp 70 hp 75 hp 80 hp 90 hp Thermostat: °C (°F) Valve opening temper- 48 ~ 52 (118 ~ 126) ature °C (°F) Full-opening tempera- 60 (140) ture Valve lift mm (in) 3 (0.12) C32000-0*...
  • Page 29 SPEC MAINTENANCE SPECIFICATIONS Model Item Unit 50hp 60hp 70hp 75hp 80hp 90hp Ignition coil: Ω Primary coil resistance 0.18 ~ 0.24 (Black/White – Black) [20°C (68°F)] Secondary coil resis- kΩ 3.26 ~ 4.88 (Black/White – High tension cord) tance [20°C (68°F)] Ω...
  • Page 30 SPEC MAINTENANCE SPECIFICATIONS Model Item Unit 50hp 60hp 70hp 75hp 80hp 90hp Commutator outside mm (in) 30 (1.18) 33 (1.30) diameter <Repair limit> mm (in) 29 (1.14) 31 (1.22) Pinion/ring gear gap mm (in) 3.0 ~ 5.0 (0.12 ~ 0.20) Others: Ω...

  • Page 31: Dimension

    SPEC MAINTENANCE SPECIFICATIONS DIMENSION Model Item Unit 50 hp 60, 70 hp 75, 80, 90 hp mm (in) — 868 (34.2) — 918 (36.1) 968 (38.1) — 1,081 (42.6) mm (in) — 403 (15.9) — L, X 411 (16.2) 457 (18.0) mm (in) —...
  • Page 32 SPEC MAINTENANCE SPECIFICATIONS Model Unit 50 hp 60 hp 70 hp 75, 80, 90 hp mm (in) 125.4 (4.9) mm (in) 254 (10.0) mm (in) 163.5 (6.4) mm (in) 50.8 (2.0) mm (in) 180 (7.1) mm (in) — 329 (13.0) —...

  • Page 33: Tightening Torque

    SPEC TIGHTENING TORQUE C33000-0 TIGHTENING TORQUE Q’ty Tightening torque Part Thread Parts to be tightened Remarks 50, 60, 75, 80, name size Nm m • kg ft • lb 70 hp 90 hp ENGINE: Bolt — Crank case Bolt — Bolt Connecting rod Bolt...

  • Page 34: General Torque Specifications

    TIGHTENING TORQUE/ SPEC GENERAL TORQUE SPECIFICATIONS Q’ty Tightening torque Part Thread Parts to be tightened Remarks 50, 60, 75, 80, name size Nm m • kg ft • lb 70 hp 90 hp POWER TRIM AND TILT: — 6H308 Tilt cylinder end screw Screw —...
  • Page 35 INSP CHAPTER 3 PERIODIC INSPECTION AND ADJUSTMENT PERIODIC SERVICE ..................3-1 MAINTENANCE SCHEDULE ..............3-1 ANODE...................... 3-1 BATTERY ....................3-2 CARBURETOR ..................3-3 CARBURETOR LINK ADJUSTMENT............3-3 CYLINDER HEAD BOLTS, ENGINE MOUNTING BOLTS, AND FLYWHEEL NUT................3-4 FUEL FILTER..................... 3-4 FUEL TANK AND FUEL LINE..............

  • Page 36: Periodic Service

    INSP PERIODIC SERVICE D30000-1* PERIODIC SERVICE MAINTENANCE SCHEDULE The following chart may be taken as a helpful guide to the intervals between maintenance procedures. Initial Every Intervals Refer 10 hours 50 hours 100 hours 200 hours Item page (Break-in) (3 months) (6 months) (1 year) Anode...

  • Page 37: Battery

    INSP PERIODIC SERVICE D31305-0* BATTERY WARNING Battery electrolyte is dangerous; it contains sulfuric acid which is poisonous and highly caustic. Always follow these preventive measures: Avoid bodily contact with electrolyte as it can cause severe burns or permanent eye injury. Wear protective eye gear when handling or working near batteries.

  • Page 38: Carburetor

    INSP PERIODIC SERVICE D31600-1 CARBURETOR 1. Check the fuel passages and air pas- sages for fouling or clogging. Clean fouled parts with suitable cleaning sol- vent and blow out clogged passages with compressed air. WARNING Protect your eyes with suitable safety glasses or safety goggles when using com- pressed air.

  • Page 39: Cylinder Head Bolts, Engine Mounting Bolts, And Flywheel Nut

    INSP PERIODIC SERVICE (75, 80, 90 hp) 1. Loosen the idle adjust screw and fully close the throttle valve. 2. Loosen the throttle lever securing screws of upper and lower carburetors by turning clockwise. 3. While lightly pushing the throttle lever of the middle carburetor in the direction of the arrow (full-closed), tighten the throttle lever securing screw of the...

  • Page 40: Gear Oil

    INSP PERIODIC SERVICE D32900-0 GEAR OIL 1. Drain the gear oil thoroughly and pour in new oil. 2. Check for water or metallic sediment in the drained oil. NOTE: If the gear oil becomes “milky”, check the gear case oil seals and shift boot for water entry.

  • Page 41: Ignition Timing Adjustment

    INSP PERIODIC SERVICE D33304-0* IGNITION TIMING ADJUSTMENT TIMING PLATE POSITION ADJUSTMENT If the timing plate is moved even a little dur- ing inspection or repair operation, it should be set in the following way: This adjustment must be made before adjusting the ignition timing.

  • Page 42: Throttle Sensor Control Link Adjustment

    INSP PERIODIC SERVICE THROTTLE SENSOR CONTROL LINK 50, 60, 70 hp ADJUSTMENT 1. Adjust the lengths of the throttle sensor control link and throttle cam control link to specifications. Throttle sensor control link length a: 50, 60, 70 hp: 120 ± 0.5 mm (4.72 ±...

  • Page 43: Ignition Timing Adjustment

    INSP PERIODIC SERVICE 1 Timing indicator 2 Full-advance indication (75, 80 hp) 3 Full-advance indication (90 hp) 4 Full-advance adjusting screw IGNITION TIMING ADJUSTMENT CAUTION: When checking ignition timing using a tim- ing light, be sure to replace the propeller with the specified test propeller, and make tests with the machine placed in a test tank.

  • Page 44: Pick-Up Timing Adjustment

    INSP PERIODIC SERVICE 3. While keeping the stopper in contact with the full-advance adjusting screw, measure the full-retard ignition timing with the timing light. If the timing is out of specification, adjust it by turning the full-advance adjusting screw. NOTE: When measuring the full-advance ignition timing, keep the specified engine speed.

  • Page 45: Oil Injection Pump

    3. Use only genuine Yamaha oil. If the vis- cosity is too high or too low, the mea- surement of the discharge will be inaccurate.

  • Page 46: Checking The Oil Level Warning System

    INSP PERIODIC SERVICE D33900-0* CHECKING THE OIL LEVEL WARNING SYSTEM 1. Fill the oil-tank with oil. 2. Start the engine. 3. By letting the oil little by little out of the drain-hose, check that the oil-level warning system operates correctly. CAUTION: Do not allow the engine to operate without oil even briefly for this will cause malfunc-...

  • Page 47: Oil Pump Link Adjustment

    INSP PERIODIC SERVICE D34300-1 OIL PUMP LINK ADJUSTMENT 1. Fully-open the carburetor throttle valve. 2. Set the oil-pump lever 1 mm off full- open side stopper. With the lever in this position, adjust the length of the rod connecting the oil-pump to the carbure- tor and tighten the locknut.

  • Page 48: Propeller

    INSP PERIODIC SERVICE D34900-0 PROPELLER 1. Check the blades for wear, damage or cavitation erosion. 2. Check the spline for wear and damage. D35000-0* SPARK PLUG 1. Check the electrode 1 condition and state of wear, note the insulator 2 color and the electrode gap.

  • Page 49: Greasing Points

    INSP PERIODIC SERVICE 4. When installing the spark plug, clean the gasket surface, wipe off any grime that may be on the surface of the plug and screw in the spark plug to the cor- rect torque. Tightening torque: 25 Nm (2.5 m • kg, 18 ft • lb) NOTE: If a torque wrench is not available, a good estimate of the correct torque is a further 1/4...
  • Page 51 FUEL CHAPTER 4 FUEL SYSTEM FUEL SYSTEM ....................4-1 EXPLODED DIAGRAM ................4-1 FUEL LINE....................4-2 REMOVAL....................4-3 CLEANING AND INSPECTION ..............4-3 FUEL TANK ..................4-3 FUEL METER COMPLETE ..............4-4 PRIMING PUMP................. 4-4 FUEL FILTER ..................4-4 FUEL JOINTS..................4-5 FUEL PUMP ..................

  • Page 52: Fuel System

    FUEL FUEL SYSTEM E20000-1 FUEL SYSTEM EXPLODED DIAGRAM 1 Carburetor 8 Fuel tank cap 2 Electrothermal valve* 9 Fuel tank 3 Fuel pump assembly 4 Fuel filter assembly 5 Fuel joint 6 Priming pump 7 Fuel meter assembly * Except for C60ER, C60TR, C75TR...

  • Page 53: Fuel Line

    FUEL FUEL SYSTEM D22500-0 FUEL LINE Check that the fuel line is correctly installed. 50, 60, 70 hp 1 Oil tank* 2 Oil injection pump* 3 Carburetor 4 Fuel filter 5 Fuel pump 75, 80, 90 hp 1 Oil tank* 2 Oil injection pump* 3 Carburetor 4 Fuel filter...

  • Page 54: Removal

    FUEL FUEL SYSTEM REMOVAL WARNING 1. Fire prevention Gasoline (petrol) is highly flammable. Petroleum vapour is explosive if ignited. Do not smoke while handling and keep it away from heat, sparks and open flames. 2. Ventilation Petroleum vapour is heavier than air and if inhaled in large quantities will not sup- port life.

  • Page 55: Fuel Meter Complete

    FUEL FUEL SYSTEM E21020-0 FUEL METER COMPLETE 1. Using a soft brush and solvent, clean the strainer on the end of the suction pipe and blow-dry it with compressed air. 2. Visually inspect the strainer for damage and replace the fuel meter complete if required.

  • Page 56: Fuel Joints

    FUEL FUEL SYSTEM 3. Using a soft brush and solvent, clean the filter element thoroughly. Inspect the filter element for breakage or distor- tion and replace if required. 4. Using a soft brush and solvent, clean the filter-cup thoroughly. Inspect the fil- ter-cup for cracks or thread damage and replace if required.

  • Page 57: Carburetor

    FUEL CARBURETOR E31001-1 CARBURETOR EXPLODED DIAGRAM (Except for C60ER, C60TR, C75TR) 1 Pilot screw 8 Float chamber 2 Needle valve 9 Throttle stop screw 3 Pilot jet 0 Collar 4 Main nozzle A Electrothermal valve 5 Main jet B Valve 6 Float C Diaphragm 7 Drain screw...

  • Page 58: Exploded Diagram (For C60Er, C60Tr, C75Tr)

    FUEL CARBURETOR EXPLODED DIAGRAM (For C60ER, C60TR, C75TR) 1 Pilot screw 2 Needle valve 3 Pilot jet 4 Main nozzle 5 Main jet 6 Float 7 Drain screw 8 Float chamber 9 Throttle stop screw 0 Collar...

  • Page 59: Removal And Disassembly

    FUEL CARBURETOR REMOVAL AND DISASSEMBLY WARNING At this step, ensure there is no spillage of gasoline on removing the connections. 1. Remove the silencer cover, disconnect the fuel hose, then remove the carbure- tor. * Except for C60ER, C60TR, C75TR 2.

  • Page 60: Inspection

    FUEL CARBURETOR E32000-1* INSPECTION CARBURETOR BODY 1. Inspect the carburetor body for cracks or clogging of the passages. NEEDLE VALVE 1. Inspect the needle valve for free move- ment and wear and replace if required. PILOT SCREW 1. Inspect the pilot screw for wear and replace if required.

  • Page 61: Enriching Fuel Pump

    FUEL CARBURETOR Float height a [Stamped mark]: 62F00: 15.0 ± 1.0 mm (0.59 ± 0.04 in) 6H20A, 6H30A, 6H007, 6H107: 14.0 ± 1.0 mm (0.55 ± 0.04 in) 6H210: 14.0 ± 2.0 mm (0.55 ± 0.08 in) 6H015: 19.5 ± 3.0 mm (0.77 ± 0.12 in) E21060-0 ENRICHING FUEL PUMP 1.

  • Page 62: Assembly

    FUEL CARBURETOR NOTE: When measuring the resistance of 10 Ω or less using the digital tester, the correct measurement cannot be obtained. Refer to “Lower resistance measurement” (page 8- 15). 3. Check the piston valve height. If the piston valve height is not different from a to b, replace the electrothermal valve.
  • Page 63 FUEL CARBURETOR 6. Install the needle-valve on the float, attach the float to the carburetor body with the float-pin and tighten the screw. 7. Install a new O-ring to the float-cham- ber, install it to the carburetor body and secure with the screws. 8.

  • Page 64: Installation

    FUEL CARBURETOR E34004-1 INSTALLATION 1. Install the carburetors and plate with new gaskets. 1 Idle adjust screw 2 Throttle lever 3 Throttle lever securing screw 2. Connect the fuel hoses to the carbure- tors and fit the hose-clips over the recesses to ensure leak-proof connec- tions.

  • Page 65: Oil-Injection System (Oil Injection Model)

    FUEL OIL-INJECTION SYSTEM OIL-INJECTION SYSTEM (Oil injection model) EXPLODED DIAGRAM 1 Oil level sensor 8 Oil tank cap assembly 2 Oil strainer 9 Hook 3 Strainer cover gasket 0 Filler tube 4 Oil injection pump assembly 5 Check valve 6 Oil tank 7 Special washer 4-14...
  • Page 66 FUEL OIL-INJECTION SYSTEM 1 Check valve 8 Special washer 2 Oil injection pump assembly 9 Oil tank cap assembly 3 Drain screw 0 Hook 4 Oil tank A Filler tube 5 Strainer cover gasket 6 Oil strainer 7 Oil lever sensor 4-15...

  • Page 67: Removal

    FUEL OIL-INJECTION SYSTEM REMOVAL 1. Drain the oil from the oil-tank and remove the carburetor. 2. Disconnect the hoses and remove the oil-injection system. E42001-0* CLEANING AND INSPECTION OIL-TANK 1. Using solvent, clean the oil-tank. 2. Drain the solvent and dry the tank. 3.
  • Page 68 FUEL OIL-INJECTION SYSTEM 4. Assemble the oil-tank and install it. 5. Connect the oil delivery-hoses to the intake manifolds and tighten the clips on the hoses. 6. Lead the wire of the oil-level sensor to the port side of the engine and connect the cores.
  • Page 70 POWR CHAPTER 5 POWER UNIT EXPLODED DIAGRAM ................... 5-1 PREPARATION FOR OVERHAUL ..............5-3 REMOVAL ....................... 5-3 DISASSEMBLY ....................5-5 INSPECTION ....................5-6 CYLINDER HEAD..................5-6 CLEANING ..................5-6 INSPECTION ..................5-6 CYLINDER BLOCK..................5-7 CLEANING ..................5-7 INSPECTION ..................5-7 PISTON .....................
  • Page 71 POWR ASSEMBLY AND ADJUSTMENT ..............5-14 BEARING, OIL SEAL AND O-RING ............5-14 PISTON AND PISTON RING..............5-14 SMALL END BEARINGS AND PISTON ASSEMBLY......5-15 CONNECTING ROD BIG END BEARING ASSEMBLY (75, 80, 90 hp)..................5-16 OIL SEAL HOUSING ................5-17 CRANK CYLINDER ASSEMBLY (50, 60, 70 hp)........

  • Page 72: Exploded Diagram

    POWR EXPLODED DIAGRAM G20000-0 EXPLODED DIAGRAM 1 Cylinder head cover 8 Exhaust inner cover E O-ring 2 Head cover gasket 9 Exhaust outer cover F Oil seal housing 3 Cylinder head 0 Piston pin clip G Intake manifold 4 Cylinder head gasket A Piston pin H Valve seat packing 5 Thermostat...
  • Page 73 POWR EXPLODED DIAGRAM 1 Thermostat cover 0 Exhaust outer cover I Intake manifold 2 Thermostat A Piston pin clip J Valve seat packing 3 Thermo sensor B Piston pin K Reed valve plate 4 Cylinder head cover C Bearing L Reed valve assembly 5 Head cover gasket D Drive gear 6 Cylinder head...

  • Page 74: Preparation For Overhaul

    POWR PREPARATION FOR OVERHAUL/REMOVAL G30000-0 PREPARATION FOR OVERHAUL 1. Clean all dirt, mud, dust and foreign material from the engine before the engine is removed and disassembled. 2. To ensure that you can perform the work cleanly and efficiently, check that you have the proper tools and cleaning equipment before commencing engine removal and disassembly.
  • Page 75 POWR REMOVAL 3. Remove the throttle cable and the shift mechanism. 1 Throttle cable joint by removing the hair pin 2 Shift rod bracket bolt 3 Shift cable joint and bushing by removing the hair pin 4. Remove the front and rear aprons. 5.

  • Page 76: Disassembly

    POWR DISASSEMBLY G50003-0 DISASSEMBLY Referring to the exploded diagram, remove the following parts. 1. Cylinder head 2. Intake manifold 3. Exhaust cover and thermostat cover. 4. Oil seal housing Using the oil seal remover, remove the oil seal one by one from the housing. 5.

  • Page 77: Inspection

    POWR INSPECTION G61000-0* INSPECTION CYLINDER HEAD CLEANING 1. Using a gasket scraper, remove all traces of gasket material from the cylin- der head. 2. Using a round scraper, remove carbon deposits from the combustion chamber. CAUTION: Do not scratch the surfaces of the cylinder and combustion chamber.

  • Page 78: Cylinder Block

    POWR INSPECTION G61501-0* CYLINDER BLOCK CLEANING 1. Using a gasket-scraper, remove all traces of gasket material from the cylin- der-block surface. 2. Using a soft brush and solvent, clean the cylinder-block. INSPECTION 1. Visually inspect the cylinder sleeves for cracks and scratches. If cracks are found, replace the cylinder block.

  • Page 79: Piston

    POWR INSPECTION G62001-0* PISTON CLEANING 1. Using a gasket-scraper, remove the car- bon from the piston top. 2. Using a broken ring, clean the ring grooves. 3. Using a soft brush and solvent, thor- oughly clean the piston. If necessary, use 600 ~ 800 grit wet-or-dry sandpaper to remove score marks or varnish.

  • Page 80: Piston Ring

    POWR INSPECTION G62501-0* PISTON RING INSPECTION 1. Using a thickness gauge, measure the clearance between the piston ring and the groove land. Side clearance: 50, 60, 70 hp: Top/2nd ring: 0.03 ~ 0.07 mm (0.0012 ~ 0.0028 in) 75, 80, 90 hp: Top/2nd ring: 0.03 ~ 0.06 mm (0.0012 ~ 0.0024 in)

  • Page 81: Piston Pin And Small End Bearing

    POWR INSPECTION G63000-0 PISTON PIN AND SMALL END BEARING CLEANING 1. Use a soft brush and solvent to clean the parts. INSPECTION 1. Visually inspect for surface defects, breakage, scratches and pitting. If it is decided to replace the small end bear- ings, replace them all.

  • Page 82: Inspection

    POWR INSPECTION 4. Using dial gauges, measure the deflec- tion. Maximum deflection: 50, 60, 70 hp: 0.03 mm (0.0012 in) 75, 80, 90 hp: 0.05 mm (0.0020 in) If the deflection is greater than the spec- ified maximum, correct the alignment by use of a copper hammer and a wedge.

  • Page 83: Inspection

    POWR INSPECTION G64500-0* THERMOSTAT CLEANING 1. Using a soft brush and water, remove all traces of salt, dirt or corrosion. INSPECTION 1. Visually inspect the thermostat for dam- age. If the thermostat is damaged or if it opens when cold, replace it. 2.

  • Page 84: Inspection

    POWR INSPECTION G65500-0 DRIVE GEAR (OIL INJECTION PUMP DRIVE) INSPECTION 1. Visually inspect drive gear teeth for cracks, pitting or wear and replace the gear if any are found. DRIVEN GEAR (OIL INJECTION PUMP DRIVE) INSPECTION 1. Visually inspect driven gear teeth for cracks, pitting or wear and replace the gear if any are found.

  • Page 85: Assembly And Adjustment

    POWR ASSEMBLY AND ADJUSTMENT G71000-1 ASSEMBLY AND ADJUSTMENT BEARING, OIL SEAL AND O-RING 1. Press in the new bearing. CAUTION: When reassembling the lower crank bear- ing and/or the oil-pump drive gear, the tapered side of the drive gear and the seal- cap side of the bearing should be installed towards the crank side as shown in the illustration.

  • Page 86: Small End Bearings And Piston Assembly

    POWR ASSEMBLY AND ADJUSTMENT G73000-0* SMALL END BEARINGS AND PISTON ASSEMBLY 1. Count the small-end bearing needles. Number of needles per small end: 28-pcs. CAUTION: Do not use a mixture of new and used bear- ing needles in the same small end. 2.

  • Page 87: Connecting Rod Big End Bearing Assembly (75, 80, 90 Hp)

    POWR ASSEMBLY AND ADJUSTMENT G78000-0* CONNECTING ROD BIG END BEARING ASSEMBLY (75, 80, 90 hp) 1. Install the piston. Align the ring ends with locating pins in the grooves and using the piston slider, push the piston into the cylinder. Piston slider: YU-33294/90890-06530 NOTE:...

  • Page 88: Oil Seal Housing

    POWR ASSEMBLY AND ADJUSTMENT NOTE: Replace the cap bolts each time the con- necting rod is disassembled. Connecting rod big end: (75, 80, 90 hp) 1st step: 12 Nm (1.2 m • kg, 8.7 ft • lb) 2nd step: 35 Nm (3.5 m • kg, 25 ft • lb) G79000-1* OIL SEAL HOUSING 1.

  • Page 89: Crank Cylinder Assembly (75, 80, 90 Hp)

    POWR ASSEMBLY AND ADJUSTMENT 2. Lift the crank assembly a little in order to install a washer on the lower crank- case and align each location-pin of the bearings and labyrinth-seals with each cut on the cylinder-block. Then, fit the crank assembly in place.

  • Page 90: Cylinder Head And Exhaust Cover

    POWR ASSEMBLY AND ADJUSTMENT G75000-0* Å CYLINDER HEAD AND EXHAUST COVER 1. Install the gaskets cylinder-head cover and exhaust cover. 2. Tighten the bolts to the specified torque in sequence and in two steps. Å Tightening sequence Cylinder head (50, 60, 70 hp): Å...

  • Page 91: Drainage Hose

    POWR ASSEMBLY AND ADJUSTMENT G75500-0 DRAINAGE HOSE 1. Fit two clips around the drainage hose. 2. Connect one end of the hose to the delivery side of the check valve and the other end to the joint on the intake side and lock with the clips.

  • Page 92: Installation

    POWR INSTALLATION G8000-0* INSTALLATION 1. Install locating pins in position on the exhaust guide. 2. Align the locating-pin holes on the gas- ket with dowel pins and place the gas- ket on the bottom cowling. 3. Install the power head onto the bottom cowling, tighten the mounting-bolts to the specified torque.
  • Page 93 LOWR CHAPTER 6 LOWER UNIT EXPLODED DIAGRAM (FOR 50GETO, C60ER, C60TR/60FET (OCEANIA), C75TR, 90AEHD, 90AED, C90TR/90AET)..............6-1 EXPLODED DIAGRAM (EXCEPT FOR 50GETO, C60ER, C60TR/60FET (OCEANIA), C75TR, 90AEHD, 90AED, C90TR/90AET)..............6-2 PREPARATION FOR REMOVAL ..............6-3 DISASSEMBLY ....................6-3 INSPECTION ....................6-9 GEAR CASE ....................

  • Page 94: Exploded Diagram (For 50Geto, C60Er, C60Tr/60Fet (Oceania), C75Tr, 90Aehd, 90Aed, C90Tr/90Aet)

    LOWR EXPLODED DIAGRAM EXPLODED DIAGRAM (FOR 50GETO, C60ER, C60TR/60FET (OCEANIA), C75TR, 90AEHD, 90AED, C90TR/90AET) 1 Water pump housing A Shifter K Needle bearing 2 Impeller B Shift slide L Claw washer 3 Cartridge outer plate C Forward gear M Ring nut 4 Cartridge outer plate gasket D Clutch dog N Spacer...

  • Page 95: (Except For 50Geto, C60Er, C60Tr/60Fet (Oceania), C75Tr, 90Aehd, 90Aed, C90Tr/90Aet)

    LOWR EXPLODED DIAGRAM EXPLODED DIAGRAM (EXCEPT FOR 50GETO, C60ER, C60TR/60FET (OCEANIA), C75TR, 90AEHD, 90AED, C90TR/90AET) 1 Water pump housing A Shifter K Needle bearing 2 Impeller B Shift slide L Claw washer 3 Cartridge outer plate C Forward gear M Ring nut 4 Cartridge outer plate gasket D Clutch dog N Spacer...

  • Page 96: Preparation For Removal

    LOWR PREPARATION FOR REMOVAL/DISASSEMBLY 120001-0* PREPARATION FOR REMOVAL 1. Remove the nut, washer, propeller and spacer from the propeller shaft. 2. Drain the gear oil by removing the plugs from the oil-filling hole and the oil-level hole. Be sure to remove the oil filling plug first.
  • Page 97 LOWR DISASSEMBLY 4) Shift-rod 5) Ring-nut 1 and claw-washer 2 Å Ring nut wrench: YB-34447........ 3 90890-06511......4 Extension (ring nut wrench): 90890-06513......5 Å For USA and Canada ı Except for USA and Canada NOTE: ı To remove the ring-nut: straighten the lobe of the claw-washer by using a screwdriver, then attach and turn it in the direction of the off mark using the special service tool.
  • Page 98 LOWR DISASSEMBLY 7) Propeller shaft (For 50GETO, C60ER, C60TR/60FET (Oceania), C75TR, 90AEHD, 90AED, C90TR/90AET) 1 Clutch dog 2 Cross pin 3 Cross pin ring 7) Propeller shaft (Except for 50GETO, C60ER, C60TR/ 60FET (Oceania), C75TR, 90AEHD, 90AED, C90TR/90AET) 1 Clutch dog 2 Cross pin 3 Cross pin ring 8) Shift slide...
  • Page 99 LOWR DISASSEMBLY 10) Oil seals and needle bearing Å Slide hammer set: YB-6096........1 Stopper guide plate: 90890-06501......2 Bearing puller: 90890-06535......3 Stopper guide stand: 90890-06538......4 Driver rod: YB-6071/90890-06602 ... 5 ı Needle bearing attachment: YB-6153/90890-06612 ... 6 Å...
  • Page 100 LOWR DISASSEMBLY 12) Forward gear bearing outer race Å Slide hammer set: YB-6096........1 Bearing outer race puller: 90890-06523......2 Å For USA and Canada ı Except for USA and Canada NOTE: For ease of reassembly and adjustment, ı keep shim packs in their groups as removed.
  • Page 101 LOWR DISASSEMBLY 16) Reverse gear bearing and forward gear bearing Bearing separator: YB-6219........1 90890-06534......2 NOTE: Separate the bearing from the gear using special service tool and hydraulic press.

  • Page 102: Inspection

    LOWR INSPECTION 151001-0 INSPECTION GEAR CASE 1. Using a soft brush and solvent, clean the case and water passage. 2. Visually inspect the gear case for cracks, corrosion or distortion. If any crack or excessive corrosion is found, replace the gear case. 3.

  • Page 103: Water Pump Housing

    LOWR INSPECTION 153000-0 WATER PUMP HOUSING 1. Inspect the water pump housing for signs of twisting or scratches of the inner cartridge. If twisted or scratched excessively, replace the housing. 2. During the above operation, inspect the impeller plate and replace this if dam- aged.

  • Page 104: Clutch Dog And Components

    LOWR INSPECTION 15500-0 CLUTCH DOG AND COMPONENTS 1. Visually inspect the clutch dog, looking particularly for rounding of the dog edge, cracks and other signs of damage or wear. If the dog is excessively rounded, inspect the mating gear, and replace both if necessary.

  • Page 105: Assembly And Adjustment

    LOWR ASSEMBLY AND ADJUSTMENT 161009-0* ASSEMBLY AND ADJUSTMENT PROPELLER-SHAFT HOUSING 1. Install the thrust washer and press-fit a ball-bearing to the reverse gear. Å 50GETO 2. Install a needle-bearing and oil seals, Å and then press-fit the reverse gear com- plete into the bearing housing.

  • Page 106: Gear Case

    LOWR ASSEMBLY AND ADJUSTMENT GEAR CASE Å 1. Install a new needle-bearing in position. NOTE: The needle bearing should be installed with the mark facing the flange side of attach- ment. Driver rod: YB-6071........1 Needle bearing depth stop: YB-34473........ 2 Needle bearing attachment: YB-6155........
  • Page 107 LOWR ASSEMBLY AND ADJUSTMENT 4. Place the forward-gear shim-pack 1 in position and install the forward-gear outer race 2 on the shim-pack. Driver rod: YB-6071/90890-06605 ... 3 Bearing outer race attachment: 50 hp: 90890-06622 ....4 60 ~ 90 hp: YB-6276B/90890-06621..
  • Page 108 LOWR ASSEMBLY AND ADJUSTMENT 7. Assemble the propeller shaft. (Except for 50GETO, C60ER, C60TR/ 60FET (Oceania), C75TR, 90AEHD, 90AED, C90TR/90AET) 1) Insert the free shaft 1 into the shift slide 2. 2) Insert the two balls 3 and shifter 4 on the shift slide.
  • Page 109 LOWR ASSEMBLY AND ADJUSTMENT 8. Grease the lips of the oil-seals and insert the propeller shaft complete into the bearing housing. Then, place the bearing housing complete to the gear case. 9. Look into the gear case through the hole and align the shift rod hole in the gear case with the splined hole in the shift cam 1 and install the shift rod 2.

  • Page 110: Shim Selection

    LOWR SHIM SELECTION (FOR USA AND CANADA) SHIM SELECTION NOTE: 1. When reassembling the lower unit with the original gear case and inner parts, shim selection is not required. 2. When replacing the gear case only, read the numeral preceded by “F, R, P” and adjust the shims according to the differ- ence between numerals of the original gear-case and the new gear-case.
  • Page 111 LOWR SHIM SELECTION (FOR USA AND CANADA) Example: If P mark is “+5”, then M = 0.20 + (+5)/100 mm = 0.20 + 0.05 mm = 0.25 mm If P mark is “–3”, then M = 0.20 + (–3)/100 mm = 0.20 –...
  • Page 112 LOWR SHIM SELECTION (FOR USA AND CANADA) Forward gear shim NOTE: Find forward gear shim thickness (T1) by selecting shims until the specified measure- ment (M) with the special tool is obtained. 1. Find the specified measurement (M). Specified Measurement (M) = 1.69 mm + F/100 mm NOTE: 1.
  • Page 113 LOWR SHIM SELECTION (FOR USA AND CANADA) 3. Using a thickness gauge at the specified measurement (M) established above, check the fit between the shimming gauge and upper disc of the tool. Thickness gauge: YU-26900-8 YU-26900-9 4. If the thickness gauge at the M specifi- cation will not fit, then remove or add the shim(s) until the thickness gauge just fits between the tool surfaces.
  • Page 114 LOWR SHIM SELECTION (FOR USA AND CANADA) Example: (60, 70 hp) If R mark is “+5”, then M = 1.00 – (+5)/100 mm = 1.00 – 0.05 mm = 0.95 mm If R mark is “–3”, then M = 1.00 – (–3)/100 mm = 1.00 + 0.03 mm = 1.03 mm Example: (75, 90 hp)

  • Page 115: Except For Usa And Canada

    SHIM SELECTION LOWR (EXCEPT FOR USA AND CANADA) EXCEPT FOR USA AND CANADA Pinion gear shim 1. Find pinion gear shim thickness (T3) by selecting shims until the specified mea- surement (M) with the special tool is obtained. 2. Install the pinion on the drive shaft and tighten the nut to the specified torque.
  • Page 116 SHIM SELECTION LOWR (EXCEPT FOR USA AND CANADA) NOTE: Use a minimum number of shims to obtain the thickness equal or nearly equal to the calculation. Install the shims with the thicker one on the outer side. Forward gear shim 1.
  • Page 117 SHIM SELECTION LOWR (EXCEPT FOR USA AND CANADA) NOTE: Use a minimum number of shims to obtain the thickness equal or nearly equal to the calculation. Install the shims with the thicker one on the outer side. Reverse gear shim 1.

  • Page 118: Measuring The Backlash

    LOWR SHIM SELECTION Example: If M is “28.60 mm” R is “–1”, then T2 = 28.60 – 28.00 + 1/100 = 0.61 Available shim thickness: 0.10, 0.12, 0.15, 0.18, 0.30, 0.40 and 0.50 mm NOTE: Use a minimum number of shims to obtain the thickness equal or nearly equal to the calculation.
  • Page 119 LOWR SHIM SELECTION Forward gear 1. Install a bearing housing puller (special service tool) in the bearing housing so that it engages with the center bolt of the propeller shaft. NOTE: Tighten the center bolt while turning the propeller shaft a few times clockwise. Center bolt: 5 Nm (0.5 m •...
  • Page 120 LOWR SHIM SELECTION 60, 70 hp: Forward gear Decrease or increase backlash Thickness of shim to be Less than decreased (mm) = (0.19 0.09 mm (0.004 in) – measurement) × 0.53 0.09 – 0.28 mm Decrease or increase (0.004 – 0.011 in) will be unnecessary Thickness of shim to be More than...

  • Page 121: Water Pump Installation

    LOWR SHIM SELECTION 75, 80, 90 hp: Reverse gear Decrease or increase backlash Thickness of shim to be Less than increased (mm) = (0.84 – 0.67 mm (0.026 in) measurement) × 0.60 0.67 – 1.00 mm Decrease or increase will (0.026 –...

  • Page 122: Installation

    LOWR INSTALLATION 170003-0* INSTALLATION 1. Check that the clutch dog shifts to “For- ward”, “Neutral” and “Reverse” cor- rectly by turning the shift rod, and shift into “Neutral”. Shift rod wrench: YB-6052 2. Align the mark on the shift lever with the arrow mark on the bottom cowling.
  • Page 123 LOWR INSTALLATION 4. Install the trim tab on the gear case. Be sure to align the marks put on both of them when they were removed. Place the cap over the bolt hole. 5. Install the spacers, propeller, washer, and propeller nut over the propeller shaft.

  • Page 124: Lower Unit Leakage Check

    LOWR INSTALLATION 165000-0 Å LOWER UNIT LEAKAGE CHECK 1. Tighten the gear oil-drain screw and connect the tester to the oil-level hole. 2. Pump the tester, and apply a pressure of 100 kPa (1.0 kg/cm , 14.2 psi). Then, place the gear case in the water tank.
  • Page 125 BRKT CHAPTER 7 BRACKET UNIT BRACKET UNIT....................7-1 EXPLODED DIAGRAM ................7-1 MANUAL HANDLE ................7-1 UPPER CASING ................. 7-2 BOTTOM COWLING................7-4 BRACKET UNIT.................. 7-5 BRACKET UNIT (Manual tilt model) ..........7-6 BRACKET (Short transom) ............... 7-7 BRACKET (Long transom) ..............7-8 REMOVAL....................

  • Page 126: Bracket Unit

    BRKT BRACKET UNIT BRACKET UNIT EXPLODED DIAGRAM MANUAL HANDLE P60TH/60FEHTO , P75TH/75CEHTO, 90AEHD 1 Steering handle 6 Link assembly A Main switch lead 2 Bracket 7 Shift cable B Extension wire lead 3 Main switch 8 Cover C PTT switch (PTT model) 4 Engine stop switch 9 Grip D Steering friction...
  • Page 127 BRKT BRACKET UNIT K15000-0 UPPER CASING 50, 60, 70 hp 1 Exhaust guide 2 Exhaust manifold 3 Muffler 4 Upper case 5 Apron 6 Seal 7 Bottom cowling...
  • Page 128 BRKT BRACKET UNIT 75, 80, 90 hp 1 Exhaust guide 2 Exhaust manifold 3 Muffler 4 Upper case 5 Apron 6 Seal 7 Bottom cowling...
  • Page 129 BRKT BRACKET UNIT K-15300-0 BOTTOM COWLING 1 Power trim and tilt motor lead (PTT model) 2 Trim sender lead (PTT model) 3 Grommet 4 Flushing kit (B90TR/90AETO) 5 Clamp (PTT model) 6 Bottom cowling fitting plate 7 Shift actuator...
  • Page 130 BRKT BRACKET UNIT K-15600-0 BRACKET UNIT 1 Upper mount rubber cover 9 Lower mount rubber nut 2 Cap 0 Anode (PTT model) 3 Upper mount rubber nut A Read wire (PTT model) 4 Screw 5 Low mount rubber cover 6 Ground lead 7 Bolt 8 Mount rubber housing...
  • Page 131 BRKT BRACKET UNIT BRACKET UNIT (Manual tilt model) 1 Tilt unit 2 Tilt lever 3 Clamp bracket spacer 4 Lower shock mount pin 5 Bushing...

  • Page 132: Bracket (Short Transom)

    BRKT BRACKET UNIT K15900-0 BRACKET (Short transom) 1 Circlip 0 Clamp bracket nut I Bushing 2 Lower mounting housing A Bolt (6 bolts) J Power trim and tilt unit 3 Steering pivot shaft B Clamp bracket bolt (PTT model) 4 Bushing C Washer K Cotter pin 5 O-ring...

  • Page 133: Bracket (Long Transom)

    BRKT BRACKET UNIT K15900-0 BRACKET (Long transom) 1 Circlip 0 Clamp bracket nut I Bushing 2 Lower mounting housing A Bolt (6 bolts) J Power trim and tilt unit 3 Steering pivot shaft B Clamp bracket bolt (PTT model) 4 Bushing C Washer K Tilt lock lever 5 O-ring...

  • Page 134: Removal

    BRKT BRACKET UNIT K20002-0 REMOVAL 1. Remove the power-head. 2. Remove the swivel-bracket from the upper casing. CAUTION: Lay the outboard motor on the floor to carry out this removal. DISASSEMBLY 1. Referring to the exploded diagram, dis- assemble the bracket unit. INSPECTION ANODE 1.

  • Page 135: Assembly

    BRKT BRACKET UNIT Trim sensor adjustment Fully tilt up the outboard motor. Loosen the two bolts securing the trim sen- sor until it moves slightly. WARNING Be sure to support the engine with the tilt support lever while loosening the bolts to prevent the engine from tilting down due to lack of oil pressure.

  • Page 136: Hydraulic Tilt Unit

    HYDRAULIC TILT UNIT/ BRKT POWER TRIM AND TILT UNIT HYDRAULIC TILT UNIT WARNING This cylinder is highly pressurized. There- fore, never overhaul or damage it. INSPECTION 1. Inspect the tilt cylinder assembly for scratches or corrosion. If any scratches are found, replace the tilt cylinder assembly.

  • Page 137: Exploded Diagram (Short Transom [6H308])

    BRKT POWER TRIM AND TILT UNIT K51000-0 EXPLODED DIAGRAM (Short transom [6H308]) 1 Reservoir body 9 Pipe G Up relief valve seat 2 Reservoir plug 0 Down relief valve seat H Filter 1 3 Motor assembly A Down relief spring I Manual valve seat 4 Trim cylinder end screw B Gear pump assembly...
  • Page 138 BRKT POWER TRIM AND TILT UNIT 1 Power trim and tilt motor 0 Absorber valve (80 kg/cm 2 Gear pump A Free piston 3 Down-relief valve (48 kg/cm B Trim cylinder 4 Main valve 5 2-way check valve 6 Reservoir 7 Up-relief valve (40 kg/cm 8 Manual valve 9 Tilt cylinder...

  • Page 139: Disassembly

    BRKT POWER TRIM AND TILT UNIT K52002-0 DISASSEMBLY CAUTION: 1. Do not wipe components of the hydrau- lic system with rags or paper tissues, etc., as fibers entering the system will cause malfunction. 2. After removing the tilt-motor or oil-res- ervoir, do not depress the tilt-rod or trim-rod, since this may cause hydraulic fluid to be ejected from the port.
  • Page 140 BRKT POWER TRIM AND TILT UNIT 9. Using the special service tool, loosen the trim-cylinder end-screw and pull out the trim-piston and components. Cylinder end screw wrench: YB-6175-1A/90890-06542 10. Using the special service tool, loosen the tilt-cylinder end-screw and pull out the tile-piston and the free-piston.

  • Page 141: Inspection

    BRKT POWER TRIM AND TILT UNIT K53000-0 INSPECTION TILT-ROD AND TRIM-ROD 1. Clean these components using a soft brush and solvent and inspect them carefully. If there are light scratches on the surfaces, these may be polished off using fine wet-or-dry sandpaper (440 ~ 600 grit), but if there is excessive scratching, replace the components.
  • Page 142 BRKT POWER TRIM AND TILT UNIT 2. Install the manual-valve in the body with new O-rings. 1 O-ring (fitted into the body) 2 Manual valve seat 3 Manual release spring (L = 6.0 mm, D = 11.5 mm) 4 Adapter 1 5 O-ring 6 Manual valve (left-handed thread) 7 Circlip...
  • Page 143 BRKT POWER TRIM AND TILT UNIT Locking bolt: 13 Nm (1.3 m • kg, 9.4 ft • lb) 5. Fit a new O-ring and the back-up ring to the trim-piston, fit new O-rings and a new oil-seal to the end-screw and install the complete trim-piston in the cylinder.
  • Page 144 BRKT POWER TRIM AND TILT UNIT 7. Fit a new O-ring and the back-up ring on the free-piston and install it into the cyl- inder. 1 O-ring 2 Back-up ring 8. Fit a new O-ring and the back-up ring to the tilt-piston and install it into the cylin- der.

  • Page 145: Exploded Diagram (Long Transom [6H1-15], [62F-02])

    BRKT POWER TRIM AND TILT UNIT EXPLODED DIAGRAM (Long transom [6H1-15], [62F-02]) 1 Reservoir body A Down relief spring K Manual release spring 2 Reservoir plug B Gear pump assembly L Adapter 3 Motor assembly C Shaft connector M Manual release screw 4 Trim cylinder end screw D Filter 1 N Free piston...
  • Page 146 BRKT POWER TRIM AND TILT UNIT 1 Trim down valve (0.2 kg/cm 0 Down-relief valve (30 kg/cm 2 Trim down valve (1 kg/cm A Gear pump 3 Reservoir B Power trim and tilt motor 4 Up-relief valve (100 kg/cm 5 Manual valve 6 Tilt cylinder 7 Absorber valve (180 kg/cm 8 Trim cylinder...

  • Page 147: Disassembly

    BRKT POWER TRIM AND TILT UNIT K52002-0 DISASSEMBLY CAUTION: 1. Do not wipe components of the hydrau- lic system with rags or paper tissues, etc., as fibers entering the system will cause malfunction. 2. After removing the tilt-motor or oil-res- ervoir, do not depress the tilt-rod or trim-rod which may cause hydraulic fluid to be ejected from the port.
  • Page 148 BRKT POWER TRIM AND TILT UNIT 8. Remove the one-way valve and main valve seal. 9 Valve lock screw 0 O-ring A Ball B Washer C Main valve seal 9. Loosen the trim-cylinder end-screw and pull trim-piston components. Cylinder end screw wrench: YB-6175-1A/90890-6548 10.

  • Page 149: Inspection

    BRKT POWER TRIM AND TILT UNIT 12. Remove the circlip and the manual valve and components. 1 Snap ring 2 O-ring 3 Manual release screw 4 O-ring 5 Manual valve seat 6 Manual release spring 1 7 Adapter 1 8 Manual release spring 2 K53000-0 INSPECTION TILT-ROD AND TRIM-ROD...
  • Page 150 BRKT POWER TRIM AND TILT UNIT 1. Install the tilt-cylinder and the delivery pipes. 1 Bushing 2 Tilt-cylinder 3 Lower mount pin 4 Delivery pipe NOTE: Feed oil into each pipe. Lock nut (delivery pipe): 15 Nm (1.5 m • kg, 11 ft • lb) 2.
  • Page 151 BRKT POWER TRIM AND TILT UNIT 4. Install the up-relief valve and the valve lock screw with new O-rings and tighten the screw to the specified torque. 1 Main valve seal 2 Washer 3 Ball 4 O-ring 5 Valve lock screw 6 Filter 7 O-ring 8 Up relief valve seat...
  • Page 152 BRKT POWER TRIM AND TILT UNIT 6. Install the down relief-valve and the gear-pump complete with new O-rings, tighten the bolts, and fit the connector- shaft and filter, then fill with hydraulic fluid. 1 Down relief-valve assembly 2 Shaft-connector 3 O-ring 4 Bolt Bolt: 4 Nm (0.4 m •...

  • Page 153: Filling With Hydraulic Fluid And Air-Bleeding

    BRKT POWER TRIM AND TILT UNIT FILLING WITH HYDRAULIC FLUID AND AIR-BLEEDING 1. Pour in the fluid until it overflows from the fluid-level plug-hole and install the reservoir plug. (automatic transmission fluid) 2. Turn the manual-valve fully towards manual-tilt. Depress the tilt-rod fully, then close the manual valve.
  • Page 154 BRKT POWER TRIM AND TILT UNIT 3. Connect the leads to a battery to check the fluid discharge pressure during down-operation. Trim and tilt down ..Green (+) Blue (–) CAUTION: The motor should not be operated for more than three seconds after trim and tilt down is completed.

  • Page 155: Installation

    BRKT POWER TRIM AND TILT UNIT A: Tilt operating pressure B: Trim operating pressure During up operation pressure: A: 0 ~ 500 kPa (0 ~ 5 kg/cm , 0 ~ 71 psi) B: 0 ~ 500 kPa (0 ~ 5 kg/cm , 0 ~ 71 psi) At the end of up-operation pres- sure:...

  • Page 156: Power Trim And Tilt Motor

    BRKT POWER TRIM AND TILT MOTOR POWER TRIM AND TILT MOTOR DISASSEMBLY 1. Loosen the screws and remove the sta- tor, O-ring and the armature. 2. Disconnect the connector. 3. Loosen the screw and remove the brush, cover plate, circuit breaker and the spring.

  • Page 157: Brush

    BRKT POWER TRIM AND TILT MOTOR 3. Scrape between the segments with a hack-saw blade and then carefully remove all particles of metal and mica with compressed air. 4. Check for continuity or discontinuity of the armature coil. If it is out of specifica- tion, replace the armature.

  • Page 158: Assembly

    BRKT POWER TRIM AND TILT MOTOR K63000-0* ASSEMBLY 1. Install the armature into the frame-end. 2. Place the O-ring on the frame-end and install the yoke assembly, then install the screws. Screw: 4 Nm (0.4 m • kg, 2.9 ft • lb) 3.
  • Page 160 – ELEC CHAPTER 8 ELECTRICAL SYSTEMS ELECTRICAL COMPONENTS................. 8-1 ELECTRICAL WIRING ..................8-3 WIRING DIAGRAM ..................8-7 REMOTE CONTROL BOX ..............8-12 DIGITAL METER ................8-12 REMOVAL ..................... 8-13 MAGNETO BASE ................... 8-13 ELECTRICAL ANALYSIS ................8-15 INSPECTION................... 8-15 IGNITION SPARK GAP................8-16 CDI SYSTEM PEAK VOLTAGE ..............
  • Page 161 – ELEC INSTALLATION..................... 8-30 FLYWHEEL MAGNETO................8-30 STARTER MOTOR ..................8-31 REMOVAL....................8-31 DISASSEMBLY..................8-31 INSPECTION................... 8-32 PINION ..................... 8-32 STARTER CLUTCH ................8-32 BRUSH ..................... 8-32 BRUSH-HOLDER................8-32 ARMATURE ..................8-33 ASSEMBLY (50, 60, 70 hp) ..............8-34 INSTALLATION (50, 60, 70 hp) ............. 8-35 ASSEMBLY (75, 80, 90 hp) ..............

  • Page 162: Electrical Components

    – ELEC ELECTRICAL COMPONENTS M20000-0 ELECTRICAL COMPONENTS 50, 60, 70 hp 1 Ignition coil 6 Neutral switch (P60TH/60FEHTO) D Fuse 2 Spark-plug 7 Starter relay E CDI unit 3 Thermo switch 8 Oil warning lamp (50GETO) F Starter motor 4 Power trim and tilt replay 9 Charge coil G Trim sensor (PTT model) (PTT model)
  • Page 163 – ELEC ELECTRICAL COMPONENTS M20001-0 75, 80, 90 hp 1 Ignition coil 7 Neutral switch (P75TH/ C Power trim and tilt relay 2 Spark-plug 75CEHTO, 90AEHD, 90TR/ (PTT model) 3 Thermo switch 90AETO, B90TR/90AETO) D Starter relay 4 Trailer switch 8 Pulser coil E Starter motor (PTT model except for C75TR/...

  • Page 164: Electrical Wiring

    – ELEC ELECTRICAL WIRING D22000-0 ELECTRICAL WIRING Check that all leads and connectors are properly connected. 50, 60, 70 hp 1 Electrothermal valve 2 Clamp 3 Power trim and tilt motor lead 4 Trim sensor lead 5 Trailer switch coupler 6 Trailer switch 7 Fuel enrichment valve Å...
  • Page 165 – ELEC ELECTRICAL WIRING 50, 60, 70 hp : Black : Brown 1 Pulser coil coupler : Green 2 Trim sensor coupler Gy : Gray 3 Oil level sensor coupler : Blue 4 Wire harness coupler (7P /10P : Light green 5 Ground lead from rectifier/regulator : Orange 6 Ground lead from starter relay...
  • Page 166 – ELEC ELECTRICAL WIRING 75, 80, 90 hp : Black : Blue 1 Trailer switch coupler : Light green : Red Å To electrothermal valve Sb : Sky blue ı To battery Ç To starter relay Î To lighting coil ‰...
  • Page 167 – ELEC ELECTRICAL WIRING 75, 80, 90 hp : Black : Brown 1 Crank position sensor coupler : Green 2 Fuel enrichment valve Gy : Gray 3 Clamp : Blue 4 Clamp : Light green 5 Wire harness coupler : Orange 6 Trim sensor coupler : Pink 7 Oil level sensor coupler...

  • Page 168: Wiring Diagram

    – ELEC WIRING DIAGRAM M30000-0 WIRING DIAGRAM 50, 60, 70 hp...
  • Page 169 – ELEC WIRING DIAGRAM C60ER, C60TR...
  • Page 170 – ELEC WIRING DIAGRAM M30000-0 75, 80, 90 hp...
  • Page 171 – ELEC WIRING DIAGRAM C75TR 8-10...
  • Page 172 – ELEC WIRING DIAGRAM P60TH/60FEHTO 1 Buzzer 2 Fuse (10A) 3 Main switch 4 Engine stop switch Å To tachometer ı To power trim and tilt switch (option) Ç To trim sensor Î To oil level sensor ‰ To lamp switch (option) B ..Black Br..Brown G..Green...

  • Page 173: Remote Control Box

    – ELEC WIRING DIAGRAM M31000-0 REMOTE CONTROL BOX 1 Main switch 2 Buzzer 3 Neutral switch 4 Engine stop switch 5 Power trim and tilt switch Å To meter harness DIGITAL METER B ..Black Br ..Brown G ..Green Gy ..

  • Page 174: Removal

    – ELEC REMOVAL M40003-0 REMOVAL MAGNETO BASE 1. Remove the flywheel cover. 2. Remove the starter-pulley. 3. Loosen the flywheel nut until it is flush with the crankshaft. Flywheel holder: YB-6139/90890-06522 CAUTION: The major load must be carried in the direc- tion of the arrows.
  • Page 175 – ELEC REMOVAL 4. Remove the flywheel magneto. YB-6117 Flywheel puller: YB-6117/90890-06521 CAUTION: To prevent damage to the engine or tools, screw in the flywheel magneto-puller set- bolts evenly and completely so that the puller plate is parallel to the flywheel. 5.

  • Page 176: Electrical Analysis

    – ELEC ELECTRICAL ANALYSIS ELECTRICAL ANALYSIS INSPECTION CAUTION: All measuring instruments should be han- dled with special care or the correct mea- surement is impossible. On an instrument powered by dry batter- ies, the latter should be checked for voltage periodically and replaced, if necessary.

  • Page 177: Ignition Spark Gap

    – ELEC ELECTRICAL ANALYSIS IGNITION SPARK GAP WARNING While checking the spark be careful not to touch any connection of lead wires of the “Ignition spark gap tester”. When doing the spark test, take special care not to allow leakage from the plug cap which has been removed.
  • Page 178 – ELEC ELECTRICAL ANALYSIS 1. CDI unit output: 1) Connect the tester to the CDI unit as shown. 2) Set the tester dial to specification. 3) Crank or start the engine. 4) Measure all the CDI unit output. 5) If the output is beyond specification, replace the ignition coil.
  • Page 179 – ELEC ELECTRICAL ANALYSIS 50, 60, 70 hp Charge coil Output peak voltage (minimum) Br – L Cranking r/min 1,500 3,500 Open Connect 75, 80, 90 hp Charge coil Output peak voltage (minimum) R – Br Cranking r/min 1,500 3,500 Open Connect Charge coil...
  • Page 180 – ELEC ELECTRICAL ANALYSIS 50, 60, 70 hp Pulser coil Output peak voltage (minimum) W/R – W/B Cranking r/min 1,500 3,500 Open Connect 75, 80, 90 hp Pulser coil Output peak voltage (minimum) W/R – W/B Cranking r/min 1,500 3,500 Open Connect 4.

  • Page 181: Replacement Of Spark-Plug Cap

    – ELEC ELECTRICAL ANALYSIS M53005-0 REPLACEMENT OF SPARK-PLUG CAP [Standard type] 1. Remove the spark-plug cap by pulling the cap and remove the plug-cap spring from the high-tension cable. 2. Cut an amount of about a off the end of the high-tension cable.

  • Page 182: Starter Relay

    – ELEC ELECTRICAL ANALYSIS M55000-0 STARTER RELAY 1. Check for continuity between the termi- nals and the ends of the black and brown leads. 2. Test to ensure there is no continuity between terminals. 3. Check the relay operation. 1) Connect a tester between the termi- nals of the starter relay.

  • Page 183: Trailer Switch

    – ELEC ELECTRICAL ANALYSIS 3. Connect the (–) terminal and 1 terminal and the (–) terminal and 2 terminal to the tester and check the continuity in each case. Sb : Sky blue : Light green : Black 4. Connect the black terminal to the (–) ter- minal of the battery and the light green terminal to the (+) terminal of the bat- tery.

  • Page 184: Rectifier/Regulator

    – ELEC ELECTRICAL ANALYSIS M56501-0 RECTIFIER/REGULATOR 1. Check the continuity of the rectifier/reg- ulator. Rectifier/regulator check Tester + Green/ Green Black White Tester - Conti- ∞ ∞ Green nuity Green/ Conti- Conti- Conti- White nuity nuity nuity ∞ ∞ ∞ Conti- Conti- Conti-...

  • Page 185: Thermo Switch

    – ELEC ELECTRICAL ANALYSIS M57300-0 THERMO SWITCH 1. Immerse the thermo switch in water. While heating the water, check the con- tinuity at the specified temperature. 2. While cooling the water, check the con- tinuity at the specified temperature. If continuity is not as specified, replace the thermo switch.

  • Page 186: Oil Injection System (Oil Injection Model)

    – ELEC ELECTRICAL ANALYSIS M57500-0 OIL INJECTION SYSTEM (Oil injection model) 1 Oil level sensor 2 Digital Meter (Oil level warning lamps/control unit) 3 Lead wire 4 Lead wire 5 Lead wire assembly 50, 60, 70 hp 75, 80, 90 hp 8-25...

  • Page 187: Oil-Level Sensor

    – ELEC ELECTRICAL ANALYSIS M58004-0 50, 60, 70 hp 75, 80, 90 hp OIL-LEVEL SENSOR 1. Remove the circlip and disassemble the oil-level sensor. 1 Oil-level sensor 2 Strainer cover 3 Gasket 2. Referring to the illustrations and tables, check the continuity and resistance. 50, 60, 70 hp Unit: Ω...
  • Page 188 – ELEC ELECTRICAL ANALYSIS 75, 80, 90 hp Unit: Ω Marking: 6H1-15 Oil level sensor resistance Float SW.1 ON Float SW. 2 ON A 5.8 ~ 8.8 mm B 42.3 ~ 45.3 mm (0.23 ~ 0.35 in) (1.67 ~ 1.78 in) Tester Tester Green/...

  • Page 189: Oil-Level Warning Lamp (L.e.d.)

    – ELEC ELECTRICAL ANALYSIS M57602-0 OIL-LEVEL WARNING LAMP (L.E.D.) (50GETO) Test the Light Emitting Diode (L.E.D.) using a 1.5-V dry-cell battery. If no light is emitted, replace the warning lamp. Battery voltage: 1.5V CAUTION: Do not use a 12-V battery or a larger capac- ity type, as this may damage the L.E.D.

  • Page 190: Bracket

    – ELEC ELECTRICAL ANALYSIS M58800-0 50, 60, 70 hp 75, 80, 90 hp BRACKET 1. Inspect the bracket and replace it if it’s cracked. M58900-0* BATTERY Refer to “PERIODIC SERVICE” section in chapter 3. M59000-0 ENGINE STOP SWITCH (P60TH/60FEHTO, P75TH/75CEHTO, 90AEHD) 1.

  • Page 191: Main Switch (P60Th/60Fehto, P75Th/75Cehto, 90Aehd)

    – ELEC ELECTRICAL ANALYSIS/INSTALLATION MAIN SWITCH (P60TH/60FEHTO, P75TH/75CEHTO, 90AEHD) 1. Check the continuity of the main switch. Replace if continuity is not as specified. Checking leads White Yellow Black Yellow Brown Disconti- Disconti- Continuity nuity nuity Disconti- Disconti- Continuity nuity nuity Disconti- Disconti-...

  • Page 192: Starter Motor

    – ELEC STARTER MOTOR M71001-0* STARTER MOTOR REMOVAL 1. Disconnect the cables and remove the starter-motor. DISASSEMBLY 1. Remove the starter-clutch. Using a screw-driver, pry off the clip. 1 Clip 2 Pinion Stopper 3 Pinion (starter clutch) NOTE: Push the pinion stopper by hand toward the pinion and remove the clip.

  • Page 193: Inspection

    – ELEC STARTER MOTOR INSPECTION PINION 1. Inspect the pinion and inner teeth for wear or damage and check ease of pin- ion sliding motion and replace, if dam- aged. 2. Inspect the flywheel gear and replace, if worn or damaged. STARTER CLUTCH 1.

  • Page 194: Armature

    – ELEC STARTER MOTOR ARMATURE 1. Inspect the commutator surfaces and if these are dirty or burnt, clean with 400- grit wet-or-dry sandpaper. 2. Inspect the commutator deflection with a dial gauge and block and replace the armature if the deflection is out of spec- ification.

  • Page 195: Assembly (50, 60, 70 Hp)

    – ELEC STARTER MOTOR 5. Check the insulation between the shaft or laminations and ground. If there is any continuity, replace the armature. 6. Inspect that the commutator is an open circuit checking continuity between segments. If any segment is not continuous, replace the armature.

  • Page 196: Installation (50, 60, 70 Hp)

    – ELEC STARTER MOTOR 4. Insert the through-bolts into the rear cover and screw them into the front cover. 5. Mount the pinion, spring and pinion- stopper on the armature shaft. 6. Hold down the pinion-stopper and fit the circlip into the groove in the shaft. Use a socket-wrench that fits properly over the armature shaft.

  • Page 197: Installation (75, 80, 90 Hp)

    – ELEC STARTER MOTOR 2. Install the positive brush (on the stator coil side) in the brush holder and hold it with the spring. NOTE: Use care not to scratch the brushes when installing. 1 Positive brush 2 Spring 3. Mount the two steel washers and resin washer, in that order, on the armature shaft and install the front cover onto the yoke assembly.
  • Page 199 TRBL ANLS CHAPTER 9 TROUBLE ANALYSIS TROUBLE ANALYSIS ..................9-1 TROUBLE ANALYSIS CHART ..............9-1...

  • Page 200: Trouble Analysis

    TRBL TROUBLE ANALYSIS ANLS TROUBLE ANALYSIS NOTE: The following items should be obtained before “trouble analysis”. 1. Battery is charged and its specified gravity is in specification. 2. There is no incorrect wiring connection. 3. Wiring connections are surely engaged and without any rust. 4.
  • Page 201 TRBL TROUBLE ANALYSIS ANLS Trouble mode Check elements Reference Relative part Chapter LOWER UNIT Neutral position Clutch Gear Water inlet Water pump Propeller shaft Shift rod Shift slider Shift cam Lower case Shim adjustment BRACKET UNIT Bracket Mount rubber Shift actuator PTT UNIT Fluid level Relief valve...
  • Page 202 TRBL TROUBLE ANALYSIS ANLS Trouble mode Check elements Reference Relative part Chapter Fuse Thermo switch Oil level sensor Oil level warning lamp Wire harness Battery Engine stop switch Main switch Neutral switch Starter motor...
  • Page 204 YAMAHA MOTOR CO., LTD. Printed in USA × 1 CR Feb. 1999 – (50GETO, 60FEHTO, 60FED, 60FEDO, 60FET, 60FETO, 70BEDO, 70BETO, 75CET, 75CETO, 75CEHTO, 80AETO, 90AEHD, 90AED, 90AET, 90AETO) Printed on recycled paper...

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