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Yamaha 200A Service Manual

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200A
L200A
SER VIC E MANUAL
290446
60H-28197-5E-11

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Summary of Contents for Yamaha 200A

  • Page 1 200A L200A SER VIC E MANUAL 290446 60H-28197-5E-11...

  • Page 2: Important Information

    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.

  • Page 3: General Information

    Contents General information INFO Specifications SPEC Periodic checks and adjustments Fuel system FUEL Power unit POWR Lower unit LOWR Bracket unit BRKT – Electrical systems ELEC Troubleshooting TRBL SHTG Index...

  • Page 4: Table Of Contents

    INFO INFO General information General information 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 ....................
  • Page 5 Checking the remote control cables ................ 1-15 Checking the steering system ................. 1-15 Checking the gearshift and throttle operation ............1-15 Checking the tilt sytem .................... 1-15 Checking the engine start switch and engine stop switch, engine shut-off switch ..1-16 Checking the pilot water outlet ................

  • Page 6: How To Use This Manual

    INFO General information How to use this manual Manual format The format of this manual has been designed to make service procedures clear and easy to under- stand. 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.

  • Page 7: Symbols

    Symbols 7 to B in an exploded diagram indicate the grade of lubricant and the lubrication point. 7 Apply Yamaha 4-stroke motor oil A Apply low temperature resistant grease 8 Apply water resistant grease (Yamaha grease A) (Yamaha grease C) 9 Apply molybdenum disulfide grease...

  • Page 8: Safety While Working

    Gasoline is highly flammable. Keep gasoline and all flammable products away from heat, sparks, and open flames. Parts, lubricants, and sealants Use only genuine Yamaha parts, lubricants, and sealants or those recommended by Yamaha, when servicing or repairing the outboard motor.

  • Page 9: Good Working Practices

    Safety while working 6. Keep a supply of clean, lint-free cloths for Disassembly and assembly wiping up spills, etc. 1. Use compressed air to remove dust and dirt during disassembly. Good working practices 2. Apply engine oil to the contact surfaces of Special tools moving parts before assembly.

  • Page 10: Identification

    INFO General information Identification Applicable models This manual covers the following models. Applicable models 200AET,L200AET Serial number The outboard motor serial number is stamped on a label attached to the port clamp bracket. 60H10000 1 Model name 2 Approved model code 3 Transom height 4 Serial number NOTE:...

  • Page 11: Features And Benefits

    Identification / Features and benefits Features and benefits Hour meter A hour meter is incorporated for easier control of interval time for the periodic maintenance. As the main switch is turned on, all segments light up for 2 seconds to check that the Light Emitting Diode is not failed.

  • Page 12: Exhaust Components (Factory Option)

    INFO General information Exhaust components (Factory option) The cylindrical components have been painted externally and internally after the anodic oxide coating to make a film for additional corrosion-resistance. Muffler Exhaust guide plate Exhaust manifold extension (Muffler 2) Exhaust manifold For X transom 60H10030 60H5E11...

  • Page 13: Piston And Cylinder

    Features and benefits Piston and cylinder Following items have been given to improve the durability for the piston and cylinder. A hard anodic oxide coating has been given to the piston pin boss and piston ring groove of the #1 and #2 piston.

  • Page 14: Connecting Rod

    INFO General information Connecting rod A process of the carburizing and quenching has been given to the inside of the small end to increase the strength. The small end bearing has been given 18 rollers, adding one roller from the previous model, to increase the durability.

  • Page 15: Gasket

    Features and benefits Gasket The intake manifold gasket has been given a silicon bead to increase more sealer. Silicon bead Silicon bead Gasket with silicon bead 60H10060 1-10 60H5E11...

  • Page 16: Reduction Gear And Clutch

    INFO General information Reduction gear and clutch The process of the double shot-peening has been given to the surface of the teeth portion of the pinion gear, forward gear and dog clutch to increase the durability. Dog clutch Forward gear Pinion gear 60H10070 1-11...

  • Page 17: Power Unit Mount Bolt

    Features and benefits Power unit mount bolt A fully threaded bolt coated with a sealing material to the thread portion has been adopted for mount- ing the power unit. This gives a sealing function to the bolt, which will help prevent the bolt from sticking by the salt water entering into the thread hole and crystallizing .

  • Page 18: Propeller Selection

    INFO General information Propeller selection Selection When the engine speed is at the full throttle The performance of a boat and outboard mo- operating range (4,500 – 5,500 r/min), the ideal tor will be critically affected by the size and type propeller for the boat is one that provides maxi- of propeller you choose.

  • Page 19: Predelivery Checks

    Features and benefits / Propeller selection Predelivery checks Checking the battery 1. Check the capacity, electrolyte level, and To make the delivery process smooth and effi- specified gravity of the battery. cient, the predelivery checks should be com- pleted as explained below. Recommend battery: Checking the fuel system CCA / SAE (Minimum) : 380 (A)

  • Page 20: Checking The Remote Control Cables

    INFO General information Checking the remote control cables Checking the steering system 1. Set the remote control lever to the neutral 1. Check that the steering operates smoothly. position and fully close the throttle lever. 2. Check that the basic ignition timing adjust- ing screw 1 on the magnet control lever is in contact with the stopper 2 on the crank- case when the throttle lever is in the fully...

  • Page 21: Checking The Engine Start Switch And Engine Stop Switch, Engine Shut-Off Switch

    Predelivery checks 2. Check that there is no abnormal noise pro- Checking the pilot water outlet duced when the outboard motor is tilted up 1. Start the engine, and check that cooling wa- or down. ter is discharged from the pilot water outlet. 3.

  • Page 22: Break-In

    INFO General information Break-in After test run Perform the break-in operation in the following 1. Check for water in the gear oil. four stages. 1. Keep the engine running at idle for the ini- 2. Check for fuel leakage in the cowling. tial ten minutes.
  • Page 23 SPEC Specifications Genral Specifications ....................2-1 Maintenance specifications ..................2-3 Power Unit......................... 2-3 Lower Unit ......................... 2-4 Electrical ........................2-5 Dimentions ........................ 2-7 Tightening torques ......................2-9 Specified torques ...................... 2-9 General torques ...................... 2-10 60H5E11...

  • Page 24: Genral Specifications

    SPEC General Information Genral Specifications Model Item Unit 200AET L200AET Dimension Overall length mm (in) 828(32.6) Overall width mm (in) 600(23.6) Overall height mm (in) 1,577(62.1) – mm (in) 1,703(67.0) Transom height mm (in) 516(20.3) – mm (in) 642(25.3) Weight(*1) kg (lb) 180(396) –...
  • Page 25 Genral Specifications Model Item Unit 200AET L200AET Fuel and oil Fuel type Regular unleaded gasoline Fuel rating RON(*4) Engin oil type 2-stroke outboard motor oil Engin oil grade NMMA-certified TCW-3 Gear oil type Hypoid gear oil Gear oil grade GL-4 Gear oil quantity (oz) 980(34.5)

  • Page 26: Maintenance Specifications

    SPEC General Information Maintenance specifications Power unit Model Item Unit 200AET L200AET Power unit Compression pressure* 700 (7.0, 101.5) (reference data) (kgf/cm , psi) Compression pressure* 520 (5.2, 75.4) (minimum) (kgf/cm , psi) Cylinder heads Warpage limit mm (in) 0.1 (0.04) (lines indicate straightedge po- sition) Cylinders...
  • Page 27 Maintenance specifications Model Item Unit 200AET L200AET Connecting rods Small-end inside diameter mm (in) 28.070 - 28.082 (1.1051 - 1.1056) Big-end inside diameter mm (in) 46.010 - 46.025 (1.8114 - 1.8120) Big-end side clearance mm (in) 0.12 - 0.26 (0.0047 - 0.0102) Small-end axial play limit mm (in) 2.0 (0.08)
  • Page 28 SPEC General Information Electrical Model Item Unit 200AET L200AET Ignition system Ignition timing (standard ignition timing) Degree ATDC 7 (full advance) Degree BTDC 18 Piston position (full advance) mm (in) 2.05 (0.0807) Pulser coil output peak voltage (W/B - W/L, W/Br - W/Y, W/G - W/R) at cranking 1(*1) at cranking 2(*1) at 1,500 r/min...
  • Page 29 Maintenance specifications Model Item Unit 200AET L200AET Starter motor Type Bendix Output Cranking time limit Second Brushes Standard length mm (in) 17 (0.67) Wear limit mm (in) 10 (0.39) Commutator Standard diameter mm (in) 33 (1.30) Wear limit mm (in) 32 (1.26) Mica Standard undercut...
  • Page 30 SPEC General Information Dimensions Exterior mm(in) 426(16.8) 660(26.0) 300(11.8) L: 1,032(40.6) 569(22.4) X: 1,144(45.0) 188(7.4) 543(21.4) 74(2.9) 173(6.8) L: 48(1.9) X: 61(2.4) L: 54(2.1) X: 62(2.4) 634(25.0) 60H5E11...
  • Page 31 Maintenance specifications Clamp bracket Model Item Unit 200AET L200AET 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) 367 (14.5) mm (in) 18.5 (0.7) mm (in) 82 (3.2) mm (in) 13 (0.5) mm (in)

  • Page 32: Lower Unit

    SPEC General Information Tightening torques Specified torques Tightening torques Part to be tightened Thread size N • m kgf • m ft • lb POWER UNIT Flywheel nut Crankcase bolt Intake manifold Cylinder head Cylinder head cover Thermostat cover Connecting rod cap Loosen completely Exhaust outer cover PCV cover...

  • Page 33: General Torques

    Tightening torques Tightening torques Part to be tightened Thread size N • m kgf • m ft • lb BRACKET UNIT Upper rubber mount nut Lower rubber mount nut Through tube nut 7/8'' Trim sender cam screw Trim rod reciever nut Reserver cap 0.07 Reserver mount bolt...
  • Page 34 Periodic checks and adjustments Periodic checks and adjustments Special service tools ..................... 3-1 Maintenance interval chart ................... 3-2 Top cowling ........................3-3 Checking the top cowling ..................3-3 Hour meter ........................3-3 Checking the hour meter................... 3-3 Fuel system........................3-3 Checking the fuel joint and fuel hoses (fuel joint - to - carburetor) ......
  • Page 35 Lower unit ........................3-19 Checking the gear oil level ..................3-19 Changing the gear oil ....................3-19 Checking the lower unit (for air leakage)..............3-20 Checking the propeller .................... 3-21 General ......................... 3-21 Checking the anodes ....................3-21 Checking the battery ....................3-21 Lubrication ......................

  • Page 36: Periodic Checks And Adjustments

    Periodic checks and adjustments Special service tools Timing light 90890-03141 Dial gauge set 90890-01252 Digital tachometer 90890-06760 Leakage tester 90890-06840 60H5E11...

  • Page 37: Maintenance Interval Chart

    Special service tools / Maintenance interval chart Maintenance interval chart Use the following chart as a guideline for general maintenance. Adjust the maintenance intervals according to the operating conditions of the outboard motor. Initial Every Refer 10 hours 50 hours 100 hours 200 hours Item...

  • Page 38: Top Cowling

    Periodic checks and adjustments Top cowling Hour meter Checking the top cowling Checking the hour meter 1. Check the fitting by pushing the cowling 1. Turn the ignition switch to ON. with both hands. Adjust if necessary. 2. Check that the total hour of operation is dis- played after the entire Light Emitting Diode has been illuminated for two seconds.

  • Page 39: Checking The Fuel Filter

    Top cowling / Hour meter / Fuel system / Power unit Power unit Checking the fuel filter 1. Check that the float 1 is in the appropriate Checking the spark plugs position. If water is accumulated, drain it 1. Disconnect the spark plug wire before re- by loosening the drain screw 2.

  • Page 40: Checking The Thermostat

    Periodic checks and adjustments 4. Check the thermostat valve lift A at the 5. Install the spark plug, tighten it finger-tight to the position B, then apply the specified specified water temperature. Replace the torque with a spark plug wrench to the po- thermostat if the valve lift is out of specifi- sition C.

  • Page 41: Control System

    Power unit / Control system 3. Check the water flowing out of the cooling Checking the throttle cable operation water pilot hole. If there is no water flow, 1. Check that the standard ignition timing ad- check the cooling water passage inside the justing screw 1 touches the fully closed outboard motor.

  • Page 42: Checking The Ignition Timing

    Periodic checks and adjustments Checking the ignition timing 2. Check the ignition timing while engine is running at idle speed. 1. Disconnect the throttle cable. 2. Remove the intake silencer and flywheel cover. 3. Turn the flywheel clockwise until the igni- tion timing mark on the flywheel magnet is aligned with the pointer mark A on the tim- ing plate at the full advance.

  • Page 43: Adjusting The Ignition Timing

    Control system 5. Check that the mark B on flywheel mag- 8. Check that the mark B on flywheel mag- net is aligned with the mark C on base as- net is aligned with the mark C on base as- sembly.
  • Page 44 Periodic checks and adjustments 5. Mount the dial gauge in the spark plug hole 8. Slowly turn the flywheel clockwise until the on #1 cylinder. #1 cylinder piston comes to the specified position. 60H30210 60H30235 NOTE: Secure the dial gauge after retracting it by ap- NOTE: proximately 3mm (0.118 in).
  • Page 45 Control system 10. Secure the timing plate 5 at the adjusted position and mark the position with paint. 11. Adjust the fully advanced stop screw 2 so that the stopper B has the specified length. 60H30260 Magnet control link length E : 65mm(2.56in) (reference) 14.
  • Page 46 Periodic checks and adjustments 16. Adjust the length of standard ignition tim- 22. Check the ignition timing by means of the ing adjusting screw 3 so that the timing timing light. mark D on the flywheel aligns with the mark C on the base assembly.

  • Page 47: Checking The Carburetor Synchronization

    Control system Checking the carburetor synchroniza- 5. Visually check that the throttle valves are all closed. tion 1. Disconnect the throttle cable. NOTE: Move the throttle lever slightly to help the vi- 2. Remove the intake silencer and flywheel sual check. cover.

  • Page 48: Adjusting The Carburetor Synchronization

    Periodic checks and adjustments Adjusting the carburetor synchroniza- 5. Loosen the throttle lever tightening screw 4 clockwise on the upper and lower car- tion buretors. NOTE: NOTE: Make sure the ignition timing is properly ad- The throttle lever tightening screw 4 has left justed before synchronizing the carburetor.

  • Page 49: Adjusting The Engine Idle Speed

    Control system 7. On the central carburetor, tighten the NOTE: throttle lever tightening screw 1 counter- The throttle lever tightening screw 1 has left clockwise to make the accelerator cam 6 hand threads. aligned with the centerline of the roller 7. 3.

  • Page 50: Adjusting The Carburetor Pickup Timing

    Periodic checks and adjustments 5. Install the tachometer onto the spark plug 7. Tighten the throttle lever tightening screw 1 counterclockwise on the central carbu- wire of #1 cylinder, and start the engine. retor, to make the accelerator cam 6 aligned with the centerline of the roller 7.

  • Page 51: Adjusting The Choke Solenoid

    Control system 3. Check that the accelerator cam 3 is Adjusting the throttle link and the aligned with the centerline of the roller 4. throttle cable operation NOTE: Complete the ignition timing adjustment, throttle valves synchronization, engine idle speed adjustment, and carburetor pickup tim- ing adjustment prior to the throttle link adjust- ment.

  • Page 52: Checking The Gearshift Operation

    Periodic checks and adjustments 5. Adjust the length B of the shift cable joint 3. Connect the cable joint, install the clip 2, and tighten the locknut 1. 2 so that its hole is aligned with the set pin. 4. Check the throttle cable for smooth opera- tion, and repeat steps 1-3 if necessary.

  • Page 53: Checking The Power Trim And Tilt Fluid Level

    Control system / Power trim and tilt unit / Lower unit Checking the power trim and tilt fluid 3. If the fluid level is low, add sufficient fluid of the recommended type until it overflows out level of the filler hole. 1.

  • Page 54: Lower Unit

    Periodic checks and adjustments Lower unit Changing the gear oil 1. Fully tilt up the outboard motor. Checking the gear oil level 2. Place a drain pan under the drain screw 1. Fully tilt down the outboard motor. 1, remove the drain screw 1 and the check screw 2 to drain the oil.

  • Page 55: Checking The Lower Unit (For Air Leakage)

    Lower unit / General 4. Insert the gear oil tube or gear oil pump Checking the lower unit (for air leak- into the drain hole and slowly fill the gear age) oil until oil flows out of the check hole and 1.

  • Page 56: Checking The Propeller

    Periodic checks and adjustments Checking the propeller Checking the battery 1. Check the propeller blades and splines for 1. Check the battery electrolyte level. If the cracks, damage, or wear. level is at or below the minimum level mark A, add distilled water until it reaches to the level between the maximum and minimum level marks.

  • Page 57: Lubrication

    Disconnect the black (–) battery cable first, then the red (+) battery cable. Electrolyte specific gravity: 1.280 at 20°C (68°F) 60H30550 Lubrication 1. Apply Yamaha grease A to the areas shown. 60H30560 60H30520 60H30570 60H30530 60H30580...
  • Page 58 Periodic checks and adjustments 3. Apply Yamaha grease D to the areas shown. 60H30610 60H30590 NOTE: Apply grease to the grease nipples until it over- flows from the bushings A . 2. Apply Yamaha grease C to the areas shown.
  • Page 59 FUEL Fuel system Fuel system Special service tools ..................... 4-1 Hose routing ........................4-2 Fuel hoses ........................ 4-2 Fuel filter, fuel pump, fuel joint ..................4-3 Checking the fuel joint....................4-6 Checking the fuel filter ....................4-6 Checking the fuel pump .................... 4-7 Disassembling the fuel pump ..................

  • Page 60: Fuel Fuel System

    FUEL Fuel system Special service tools Vacuum/pressure pump gauge set 90890-06756 60H5E11...

  • Page 61: Hose Routing

    Special service tools / Hose routing Hose routing Fuel hoses 60H40010 1 Fuel hose(fuel joint-to-fuel filter) 2 Fuel hose(fuel filter-to-fuel pump) 3 Fuel hose(fuel pump-to-carburetor) 60H5E11...

  • Page 62: Fuel Filter, Fuel Pump, Fuel Joint

    FUEL Fuel system Fuel filter, fuel pump, fuel joint 60H40020 Part name Q’ty Remarks Bolt M6 x 28 mm Fuel joint Bolt M6 x 50 mm Fuel pump Gasket Fuel filter bracket Fuel filter Bolt M6 x 16mm Fuel hose Fuel joint-to-Fuel filter Fuel hose Fuel filter-to-Joint...
  • Page 63 Fuel filter, fuel pump, fuel hose connector 60H40030 Part name Q’ty Remarks Bolt M6 x 16 mm Washer Fuel filter nut holder Bolt M6 x 14 mm Fuel filter bracket Fuel filter cap O-ring O-ring Fuel filter element Spring Red ring Fuel filter cup Fuel filter nut O-ring...
  • Page 64 FUEL Fuel system 60H40070 Part name Q’ty Remarks Fuel pump base Diaphragm Spring seat Spring Fuel pump body Fuel pump valve Screw M5 x 6 mm Gasket Diaphragm Diaphragm body Screw M5 x 35 mm 60H5E11...

  • Page 65: Checking The Fuel Joint

    Fuel filter, fuel pump, fuel hose connector 2. Check the fuel filter element 3 for clogging, Checking the fuel joint contamination, or foreign substances, and 1. Visually check the fuel hose connector for check the fuel filter cap 4 for crack or leak- cracks or damage.

  • Page 66: Checking The Fuel Pump

    FUEL Fuel system Checking the fuel pump 5. Mount the special service tool at the fuel pump outlet. 1. Disconnect the fuel hoses. 6. Apply the specified positive pressure to NOTE: make sure that no air leakage is detected. To disconnect the fuel hoses, place a drain pan Perform disassembly inspection, if neces- below the pump-hose connection so as not to sary.

  • Page 67: Disassembling The Fuel Pump

    Fuel filter, fuel pump, fuel hose connector Disassembling the fuel pump 2. Mount the spring. 1. Remove and disassemble the fuel pump to check the diaphragm for damage or break- age. 2. Check the seat valve for bending or dam- age.

  • Page 68: Carburetor

    FUEL Fuel system Carburetor 14 15 60H40130 Part name Q’ty Remarks Gasket Carburetor 1 Carburetor 2 Carburetor 3 Accelerator lever rod Choke rod Joint Choke nob Gasket Intake silencer Screw M5 x 55 mm Hose Bolt M6 x 15 mm Choke solenoid O-ring Grommet...
  • Page 69 Carburetor 60H40140 Part name Q’ty Remarks Plug Gasket Screw Plate Pilot screw Spring Screw Gasket Air bleed plug Slow air jet Carburetor body Needle valve Clip Float Gasket Screw drain 4-10 60H5E11...
  • Page 70 FUEL Fuel system 60H40140 Part name Q’ty Remarks Gasket Main jet No. 1,3 : 150 / No. 2,4 : 154 / No. 5 : 152 / No. 6 : 158 Plug Gasket Slow jet Screw M5 x 16 mm Idle adjusting screw Spring Carburetor 2 Carburetor 3...

  • Page 71: Disassembling The Carburetor

    Carburetor Disassembling the carburetor 4. Check the main jet, pilot jet, main air jet, pilot air jet, and main nozzle for clogging and contamination. Clean or replace them NOTE: whenever appropriate. • Write down how many turns you have actu- ally turned out the pilot screw.

  • Page 72: Assembling The Carburetor

    FUEL Fuel system Assembling the carburetor • Do not apply the excessive force to push- in the needle valve. • Do not apply the excessive force to screw- in the pilot screw. NOTE: Install the pilot screw 1, turn-in until it is lightly seated, and then turn out by the specified num- ber of turns.
  • Page 73 POWR Power unit Power unit Special service tools ..................... 5-1 Power unit ........................5-2 Checking the compression pressure................. 5-2 Removing the power unit ................... 5-14 Removing the flywheel magnet ................5-15 Removing the electrical components ..............5-15 Intake manifold ......................5-17 Removing the intake manifold .................

  • Page 74: Special Service Tools

    POWR Power unit Special service tools Compression gauge Needl bearing attachment 90890-03160 90890-06654 Flywheel holder Driver rod L3 90890-06522 90890-06652 Flywheel puller Bearing Separator 90890-06521 90890-06534 Ball bearing attachment Bearing outer race attachment 90890-06663, 90890-06637 90890-06626,90890-06624 Driver rod LS Piston ring compressor 90890-06606 90890-05158 Bearing inner race attachment...

  • Page 75: Checking The Compression Pressure

    Special service tools / Power unit Power unit 5. If the measured compression pressure is below specification, or it varies among the Checking the compression pressure cylinders, add a small amount of engine oil 1. Start the engine, warm it up for 5 minutes, to the cylinder, and check the pressure and then turn it off.
  • Page 76 POWR Power unit 60H50020 Part name Q’ty Remarks Flywheel cover Intake silencer Screw M5 x 55 mm Bolt M6 x 20 mm Retaining plate Grommet Air vent hose Dowel pin Gasket Bolt M6 x 30 mm Bolt M8 x 135 mm Bolt M6 x 20 mm Apron...
  • Page 77 Power unit 60H50020 Part name Q’ty Remarks Grommet Collar Grommet Washer Washer Washer 60H5E11...
  • Page 78 POWR Power unit 60H50030 Part name Q’ty Remarks : 30 mm Washer Flywheel magnet assembly Bolt M6 x 60 mm Stator assembly Pulser coil assembly Screw M6 x 18 mm Stopper Base Timing plate Screw M6 x 10 mm Woodruff key 60H5E11...
  • Page 79 Power unit 60H50035 Part name Q’ty Remarks Joint Magnet control rod Accelerator link Bolt M6 x 25 mm Collar Wave washer Accelerator cam Fully advanced stop screw Spring Standard ignition timing adjusting screw Bolt M8 x 45 mm Washer Collar Bush 60H5E11...
  • Page 80 POWR Power unit 60H50035 Part name Q’ty Remarks Bush Spring Magnet control lever Washer Washer Shift bracket Bolt M8 x 30 mm Bush Clamp Cable joint Clip Magnet control lever 60H5E11...
  • Page 81 Power unit 60H50040 Part name Q’ty Remarks Bolt M8 x 45 mm Starter motor Shim Washer Bolt M8 x 35 mm Wire lead Washer Bolt M8 x 16 mm Negative battery lead Wiring harness Bolt M6 x 16 mm Washer Bracket PTT relay PTT relay...
  • Page 82 POWR Power unit 60H50040 Part name Q’ty Remarks Holder Wire lead Connector Washer Cover Positive battery lead Fuse Fuse holder Plastic tie Tube 60H5E11...
  • Page 83 Power unit 60H50050 Part name Q’ty Remarks Bracket Grommet Washer Bolt M6 x 30 mm Bolt M6 x 12 mm Screw M6 x 19 mm CDI unit cover Screw M6 x 15 mm Ignition coil Bolt M6 x 20 mm Bolt M6 x 12 mm CDI unit...
  • Page 84 POWR Power unit 60H50050 Part name Q’ty Remarks Grommet Collar Plug cap 5-11 60H5E11...
  • Page 85 Power unit 60H50045 Part name Q’ty Remarks Wiring harness Wiring harness Wiring harness Wiring harness Bolt M6 x 12 mm Wire lead Rectifier Regulator (G/W) Wire lead Rectifier Regulator (G) Rectifier Regulator Bolt M6 x 20 mm Spring washer Washer Spring washer Washer Cover...
  • Page 86 POWR Power unit 60H50045 Part name Q’ty Remarks Hour meter Screw Bolt M6 x 25 mm Collar Grommet Bracket Bolt M6 x 12 mm Clamp Plastic tie Choke solenoid O-ring Bolt M6 x 15 mm 5-13 60H5E11...

  • Page 87: Removing The Power Unit

    Power unit / Removing the power unit Removing the power unit 5. Disconnect the wiring for power trim and tilt system, the pilot jet hose, and water pressure control valve hose. Remove the NOTE: mounting bracket bolts 5 for shift rod as- If the power unit is to be disassembled, it is sembly.

  • Page 88: Removing The Flywheel Magnet

    POWR Power unit Removing the flywheel magnet NOTE: Screw-in the flywheel puller set bolt until the 1. Remove the nut on the flywheel magnet. flywheel magnet comes off completely. Flywheel puller : 90890-06521 3. Remove the Woodruff key. Removing the electrical components 1.
  • Page 89 Removing the power unit 4. Remove the starter relay, and the power 7. Remove the CDI unit. trim and tilt relay assembly. 60H50183 8. Remove the bracket. 60H50160 5. Remove the Rectifier Regulator, hour meter, and magnet control lever. 60H50184 60H50170 6.

  • Page 90: Intake Manifold

    POWR Power unit Intake manifold 60H50185 Part name Q’ty Remarks Gasket Reed valve Gasket Clamp Bolt M6 x 25mm Bolt M5 x 15mm Hose Hose Hose Hose Clamp Hose Bolt M6 x 20 mm Bushing Damper bracket 5-17 60H5E11...

  • Page 91: Removing The Intake Manifold

    Intake manifold Removing the intake manifold 1. Remove the carburetor and the fuel hoses. 60H50215 NOTE: 60H50190 Loosen the bolts in the sequence shown. 2. Remove the intake manifold, and the reed 3. Remove the reed valve assembly. valve plate assembly. 60H50210 60H50200 4.
  • Page 92 POWR Power unit 5. Check the reed valves for bending. Replace 7. Install the reed valves. them if the bending exceeds the specified limit. 60H50220 Valve bending limit : 0.2 mm(0.08in) 6. Measure the valve stopper height. Replace the stopper if the height exceeds the speci- 60H50240 fied limit.

  • Page 93: Exhaust

    Intake manifold / Exhaust Exhaust 60H50255 Part name Q’ty Remarks Bolt M6 x 20mm Cylinder cover Gasket Gasket Exhaust inner cover Exhaust outer cover Bolt M6 x 35mm Gasket Pressure control valve cover Bolt M6 x 20mm Pressure control valve seat Pressure control valve Spring Clamp...

  • Page 94: Removing The Exhaust Cover

    POWR Power unit Removing the exhaust cover 1. Remove the pressure control valve. 60H50265 NOTE: Loosen the bolts in the sequence shown. 60H50250 3. Remove the cylinder block exhaust inner 2. Remove the exhaust outer cover, and the cover. exhaust inner cover. 4.

  • Page 95: Cylinder Head

    Exhaust / Cylinder head Cylinder head 60H50280 Part name Q’ty Remarks Gasket Cylinder head Thermoswitch Gasket Cylinder head cover Gasket Thermostat Thermostat cover Bolt M6 x 40 mm Bolt M6 x 30 mm Bolt M8 x 60 mm Clamp Bolt M8 x 20 mm Engine hanger Spark plug...

  • Page 96: Removing The Cylinder Head

    POWR Power unit Removing the cylinder head 1. Remove the spark plugs. 2. Remove the thermostat cover and the ther- mostat. 60H50300 60H50320 NOTE: NOTE: Loosen the bolts in the sequence shown. Loosen the bolts in the sequence shown. 3. Remove the cylinder head cover. 6.
  • Page 97 Cylinder head 9. Check the cylinder head warpage. Replace the cylinder head if measured warpage exceeds the specified limit. 60H50340 Warpage limit: 0.1mm(0.04in) NOTE: Check the warpage in the directious shown, using a straightedge and a thickness gauge. 5-24 60H5E11...

  • Page 98: Cylinder Block

    POWR Power unit Cylinder block 14 15 60H50350 Part name Q’ty Remarks Bolt M6 x 20mm Oil seal Upper bearing housing O-ring Needle bearing Crankcase Dowel Bolt M10 x 60mm Bolt M8 x 30mm Oil seal housing Oil seal Oil seal Bolt M6 x 20mm Gasket...
  • Page 99 Cylinder block 60H50360 Part name Q’ty Remarks Crankshaft Big-end bearing Connecting rod cap Connecting rod bolt Circlip Main journal bearing Cylinder block Anode Screw Piston/connecting rod assembly Gasket Accessory plug Seal ring Bearing Cir clip 5-26 60H5E11...

  • Page 100: Removing The Crankcase

    POWR Power unit Removing the crankcase 4. Install a new O-ring and a new oil seal into the bearing housing. 1. Remove the bearing housing. 2. Remove the O-ring, oil seal, and needle bearing from the bearing housing. 60H50390 Needle bearing attachment 1: 90890-06654 Driver rod L3 : 90890-06652...

  • Page 101: Removing The Piston, Connecting Rod Assembly, And The Crankshaft

    Cylinder block 8. Remove the crankcase. Removing the piston, connecting rod assembly, and the crankshaft 1. Loosen the connecting rod bolts to pull out the piston toward the cylinder head. • Take precautions not to scratch the cyl- inder sleeve surface with the connecting rod big end when pulling out the piston.

  • Page 102: Piston, Connecting Rod

    POWR Power unit Piston, Connecting rod 60H50450 Part name Q’ty Remarks Connecting rod Piston Starboard Washer Needle bearing Piston pin clip Piston pin Piston ring set Piston Port 5-29 60H5E11...

  • Page 103: Disassembling The Piston, And The Connecting Rod Assembly

    Piston, Connecting rod Disassembling the piston, and the 3. Check the anode. Clean the anode's sur- face, and replace if it has been eroded into connecting rod assembly half or smaller. 1. Remove the piston pin clip, and then re- move the piston pin.

  • Page 104: Checking The Piston

    POWR Power unit Checking the piston 5. Measure the cylinder bore with cylinder gauge. Calculate the cylinder bore diam- 1. Check the piston outside diameter. Re- eter (D), taper (T), and roundness (R). If place the piston if the diameter is out of the results exceeded the specified limit, specification.
  • Page 105 Piston, Connecting rod 4. Check the piston ring side clearance. Re- NOTE: place the piston and the piston rings as a Push-in the piston ring with the piston crown to the specified measuring position H in the set if the measurement is out of specifica- tion.

  • Page 106: Checking The Connecting Rod

    POWR Power unit Checking the connecting rod Crankshaft journal diameter: 1. Check the internal surfaces of big end and 53.975 - 53.991 mm small end for scratch. Replace if neces- (2.1250 - 2.1256 in) sary. at 20°C (68 °F) 2. Check the bearings at the small end and 6.

  • Page 107: Installing The Crankshaft

    Piston, Connecting rod 8. Install bearings and connecting rods to the 11. Check the crankshaft journal bearings. Re- crankshaft. place the bearings if necessary. Connecting rod: Installing the crankshaft 1st : 19N • m (1.9kgf • m, 14 ft • lb) 1.

  • Page 108: Assembling The Piston And Connecting Rod

    5. Install the bearing housing and the oil seal housing, and temporarily tighten the bolts. 60H50670 NOTE: • As assembled, "YAMAHA" marking on the connecting rod A shall be aligned with the marking on the piston B. 60H650665 • Make sure that piston and piston pin bear- ings are installed in the original combination.

  • Page 109: Installing The Piston And Connecting Rod

    Piston, Connecting rod Installing the piston and the connect- NOTE: • Make sure that the split face of the connect- ing rod. ing rod caps are mated correctly to the origi- nal position. 1. Insert the piston and connecting rod as- •...

  • Page 110: Installing The Cylinder Head

    POWR Power unit 6. Tighten the crankcase bolts. Installing the cylinder head 1. Check the anode on the cylinder block. 60H50735 NOTE: Replace the anode if it has been eroded into 60H50720 NOTE: half or smaller. Tighten the bolts to the specified torques in two stages and in the sequence shown.
  • Page 111 Piston, Connecting rod 3. Install the cylinder head cover. 5. Install the thermoswitch. 60H50770 6. Install the spark plugs. Spark plug : 25N • m(2.5kgf • m, 18 ft • lb) 60H50750 NOTE: Tighten the cylinder head cover bolts to the specified torque in two stages and in the se- quence shown.

  • Page 112: Mounting The Exhaust Cover

    POWR Power unit Mounting the exhaust cover 3. Install the pressure control valve. 1. Install the cylinder block exhaust cover. 2. Install the exhaust outer cover, and the ex- haust inner cover. 60H50810 Pressure control valve cover bolt: 1st : 4 N • m (0.4 kgf • m, 3 ft • lb) 2nd : 8 N •...

  • Page 113: Mounting The Coils

    Piston, Connecting rod Mounting the coils Power unit mounting bolt : 1. Install the pulser coil assembly, and the sta- 21 N • m (2.1 kgf • m, 15 ft • lb) tor assembly. 3. Tighten the flywheel magnet. 2. Mount the Woodruff key, and then install the flywheel magnet.
  • Page 114 POWR Power unit 5. Install the Rectifier Regulator, hour meter, 8. Install the upper case cover and the apron. and the magnet control lever. 60H50930 60H50850 9. Install the mounting bracket for the shift rod 6. Install the starter relay, and the power trim assembly.
  • Page 115 Piston, Connecting rod 12. Connect the fuel hoses. 16. Connect the battery cable. 60H50950 60H50970 13. Connect the shift cable, and the throttle cable. Positive terminal nut 1: 4 N • m (0.4 kgf • m, 3 ft • lb) Negative terminal bolt 2: 6 N •...
  • Page 116 LOWR Lower unit Lower unit Special service tools ..................... 6-1 Lower unit (regular rotation model) ................6-4 Removing the lower unit ................... 6-7 Removing the water pump and shift rod ..............6-8 Checking the water pump and shift rod ..............6-8 Propeller shaft, Propeller shaft housing (regular rotation model) ......
  • Page 117 Lower unit (counter rotation model) ................6-34 Removing the lower unit ..................6-37 Removing the water pump and shift rod ..............6-38 Checking the water pump and shift rod ..............6-38 Propeller shaft, Propeller shaft housing (counter rotation model) ......6-40 Removing the propeller shaft housing assembly and propeller shaft .....

  • Page 118: Lower Unit

    LOWR Lower unit Special service tools Stopper guide stand Ring nut wrench 4 90890-06538 90890-06512 Bearing puller assembly Ring nut wrench extension 90890-06535 90890-06513 Driver rod L3 Bearing housing puller claw L 90890-06652 90890-06502 Needle bearing attachment Stopper guide plate 90890-06653, 90890-06610, 90890-06612 90890-06501 Driver rod SS...
  • Page 119 Special service tools Bearing inner race attachment Driver rod LS 90890-06642, 90890-06661, 90890-06639, 90890-06606 90890-06660, 90890-06662 Drive shaft holder 6 Bearing outer race attachment 90890-06520 90890-06619 Pinion nut holder Shift rod push arm 90890-06505 90890-06052 Bearing outer race puller assembly Pinion height gauge 90890-06523 90890-06710...

  • Page 120: Lower Unit (Regular Rotation Model)

    LOWR Lower unit Backlash indicator 90890-06706 Magnet base 90890-06705 Magnet base plate 90890-07003 Dial gauge set 90890-01252 Ring nut wrench 90890-06578 60H5E11...

  • Page 121: Lower Unit (Regular Rotation Model)

    Special service tools / Lower unit (regular rotation model) Lower unit (regular rotation model) 11 12 60h60010 Part name Q’ty Remarks Lower unit Check screw Gasket Dowel Bolt M10 x 45mm Drain screw Bolt M10 x 45mm Bolt M10 x 70mm Spacer Propeller Washer...
  • Page 122 LOWR Lower unit 26 27 60h60020 Part name Q’ty Remarks Bolt M6 x 20mm Oil seal Oil seal housing O-ring Spring Circlip Shift rod Joint Plastic tie Hose Joint Bolt M8 x 45mm Cover Water seal damper Water pump housing O-ring Insert cartridge 60H5E11...
  • Page 123 Lower unit (regular rotation model) 26 27 60h60020 Part name Q’ty Remarks O-ring Impeller Outer plate cartridge Gasket Dowel Woodruff key Seal damper Guide Cooling water inlet cover Cooling water inlet cover Bolt M5 x 45 mm Washer Washer 60H5E11...

  • Page 124: Removing The Lower Unit

    LOWR Lower unit Removing the lower unit 1. Disconnect the battery cable. • Place a block of wood between the anti- cavitation plate and the propeller. Do not 2. Remove the lock plate for the engine stop touch the propeller with your hands. switch.

  • Page 125: Removing The Water Pump And Shift Rod

    Lower unit (regular rotation model) Removing the water pump and shift 2. When the insert cartridge is removed, al- ways replace the O-ring 3 with a new one, and insert the projection on the insert car- 1. Remove the water pump 1 and the shift tridge into the water pump housing hole at rod 2.
  • Page 126 LOWR Lower unit 4. Check the Woodruff key 4 and the groove A for wear. Replace if necessary. 60h60090 5. Check the shift rod for deformation or wear. Replace if necessary. 60h60100 60H5E11...

  • Page 127: Propeller Shaft, Propeller Shaft Housing (Regular Rotation Model)

    Lower unit / Propeller shaft, Propeller shaft housing (regular rotation model) Propeller shaft, Propeller shaft housing (regular rotation model) 60h60110 Part name Q’ty Remarks Slide shift Ball Slider Ball Ball Spring Dog clutch Cross pin Cross pin ring Propeller shaft Washer Reverse gear Reverse gear shim...
  • Page 128 LOWR Lower unit 60h60110 Part name Q’ty Remarks Needle bearing Oil seal Claw washer Ring nut 6-11 60H5E11...

  • Page 129: Removing The Propeller Shaft Housing Assembly

    Propeller shaft, Propeller shaft housing (regular rotation model) Removing the propeller shaft housing Disassembling the propeller shaft assembly. housing assembly 1. Pull up the claw washer tabs, and remove 1. Remove the reverse gear. the ring nut. 60h60140 60h60120 Bearing separator 1: 90890-06534 Ring nut wrench 4: Stopper guide stand 2:...

  • Page 130: Checking The Propeller Shaft Housing Assembly

    LOWR Lower unit Checking the propeller shaft housing 2. Remove the ball bearing. assembly 1. Clean the propeller shaft housing, and check it for cracks, corrosion, or damages. Replace if necessary. 60h60150 Stopper guide stand 2: 90890-06538 Bearing puller assembly 3: 60h60170 90890-06535 Bearing puller claw 1 4:...

  • Page 131: Assembling The Propeller Shaft Housing Assembly

    Propeller shaft, Propeller shaft housing (regular rotation model) Assembling the propeller shaft 3. Install the ball bearing onto the reverse gear. housing assembly 1. Install a new needle bearing into the pro- peller shaft housing to the specified depth using a press. 60h60220 Place an appropriate plate on the dogs be- 60h60200...

  • Page 132: Disassembling The Propeller Shaft Assembly

    LOWR Lower unit Disassembling the propeller shaft as- 2. Measure the propeller shaft run-out. sembly 1. Remove the slide shift 1. 2. Remove the cross pin ring 2, pull out the cross pin 3, and remove the dog clutch NOTE: Mark the dog clutch so that it will be reinstalled in correct orientation.

  • Page 133: Assembling The Propeller Shaft Assembly

    Propeller shaft, Propeller shaft housing (regular rotation model) Assembling the propeller shaft assem- 1. Assemble the slider assembly. 60h60290 NOTE: It is recommended to apply grease or the like to the balls to make the assembling work easier. 2. Insert the slider assembly 1 into the pro- peller shaft 2.

  • Page 134: Drive Shaft And Lower Case (Regular Rotation Model)

    LOWR Lower unit Drive shaft and lower case (regular rotation model) 16 17 60h60300 Part name Q’ty Remarks Drive shaft Drive shaft sleeve Cover Oil seal Bolt 8 x 25mm Drive shaft housing Needle bearing O-ring Pinion shim As required Thrust bearing Needle bearing Pinion...

  • Page 135: Removing The Drive Shaft And Forward Gear

    Drive shaft and lower case (regular rotation model) Removing the drive shaft and forward Disassembling the lower case gear 1. Remove the taper roller bearing outer race. NOTE: Shimming is required when the forward gear or taper roller bearing is replaced. 1.

  • Page 136: Checking The Drive Shaft Housing

    LOWR Lower unit Checking the drive shaft housing Driver rod SS 1: 1. Check the drive shaft housing for cracks or 90890-06604 damage. Also check the needle bearing Needle bearing attachment 2: for run-out and roughness, and the oil seals 90890-06610 for damage.

  • Page 137: Checking The Forward Gear

    Drive shaft and lower case (regular rotation model) Checking the forward gear Assembling the forward gear 1. Check the teeth and dogs of the forward 1. Install the needle bearing. gear for cracks or wear. Also check the bearing for run-out or roughness. Disas- semble them if necessary.

  • Page 138: Checking The Drive Shaft

    LOWR Lower unit Checking the drive shaft Assembling the lower unit (regu- 1. Check the drive shaft for bends or wear. lar rotation model) Replace the shaft if necessary. Installing the lower case 1. Install the shims and the taper roller bear- ing outer race.
  • Page 139 Drive shaft and lower case / Assembling the lower unit (regular rotation model) 3. Install the needle bearing rollers. 7. Tighten the pinion nut. NOTE: Apply some grease on the needle bearing roll- ers so that they will not fall off. 4.
  • Page 140 LOWR Lower unit 10. Install the shift rod 7 assembly, and tighten Ring nut wrench 8: the bolt. 90890-06512 Ring nut wrench extension 9: 90890-06513 Ring nut: 145 N • m (14.5 kgf • m, 105 lb • ft) 14. Make sure that the shifting mechanism works properly.

  • Page 141: Installing The Water Pump

    3. 60h60540 NOTE: To install the water pump housing, apply Yamaha grease A to the inner face of the wa- 60h60520 ter pump housing assembly, and then turn the drive shaft clockwise while pushing down the 2.

  • Page 142: Installing The Lower Unit

    LOWR Lower unit Installing the lower unit 1. Install the dowels to the lower case. 60h60580 60h60560 2. Make sure that the shift rod is in neutral position. Install the lower unit to the upper case, and tighten the lower case bolts to the specified torque.
  • Page 143 Assembling the lower unit (regular rotation model) 5. Insert the gear oil tube or gear oil pump into the drain hole and fill the gear oil until it flows out of the check hole and no air bubbles are visible. 60h30470 Recommended gear oil: Hypoid gear oil...

  • Page 144: Shimming (Regular Rotation Model)

    LOWR Lower unit Shimming (regular rotation model) 61.0 B1 37.0 17.2 69h60600 69h60605 6-27 60H5E11...

  • Page 145: Shimming

    Shimming (regular rotation model) Shimming NOTE: • Shimming is not required when the original lower case and inner parts are reused for the lower unit reassembly. • Shimming is required if either the lower case or the assembly parts are replaced for the lower unit reassembly.

  • Page 146: Selecting The Forward Gear Shims

    LOWR Lower unit 5. Calculate the lower case standard(P/100). Available shim thickness: 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50 Example: If "T3" is 0.58mm, then the pinion shim is 0.55 mm. If “T3” is 0.70mm, then the pinion shim is 0.68 mm.

  • Page 147: Selecting The Reverse Gear Shims

    Shimming (regular rotation model) 2. Calculate the lower case standard(F/100). Selecting the reverse gear shims NOTE: Obtain the reverse gear shim thickness (T2) by using the specified measurement(s) and the calculation formula. Calculation formula: Reverse gear shim thickness (T2) = M2 - 29.00 - R/100 S69J6570 1.

  • Page 148: Backlash (Regular Rotation Model)

    LOWR Lower unit Backlash (regular rotation model) 2. Calculate the lower case standard(R/100). NOTE: • Measure the backlash before installing the water pump. • Set the gear shift in neutral position for the measurement. • Measure the backlash for both forward and reverse gears.
  • Page 149 Shimming / Backlash (regular rotation model) 3. Install the backlash indicator onto the drive 6. Slowly turn the drive shaft clockwise and shaft. counterclockwise, and measure the back- lash based on the dial gauge readings NOTE: taken at the points where the drive shaft Backlash indicator shall be installed at practi- stops in each direction.

  • Page 150: Lower Unit (Counter Rotation Model)

    LOWR Lower unit 7. Remove the special service tools, and se- Reverse gear backlash: cure the propeller shaft by pulling it by the 0.74-1.29 mm (0.0291 - 0.0508 in) propeller. Reverse gear backlash M Shim thickness(mm) Less than To be decreased by 0.74 mm (0.0291 in) (1.02-M) x 0.72 More than...

  • Page 151: Lower Unit (Counter Rotation Model)

    Backlash / Lower unit (counter rotation model) Lower unit (counter rotation model) 60h61010 Part name Q’ty Remarks Lower unit Check screw Gasket Dowel Bolt M10 x 45mm Drain screw Bolt M10 x 45mm Bolt M10 x 70mm Spacer Propeller Washer Washer Propeller nut Cotter pin...
  • Page 152 LOWR Lower unit 26 27 60h61020 Part name Q’ty Remarks Bolt M6 x 20mm Oil seal Oil seal housing O-ring Spring Circlip Shift rod Joint Plastic tie Hose Joint Bolt M8 x 45mm Cover Seal Water pump housing O-ring Insert cartridge 6-35 60H5E11...
  • Page 153 Lower unit (counter rotation model) 26 27 60h61020 Part name Q’ty Remarks O-ring Impeller Outer plate cartridge Gasket Dowel Woodruff key Seal damper Guide Cooling water inlet cover Cooling water inlet cover Bolt M5 x 45 mm Washer Washer 6-36 60H5E11...

  • Page 154: Removing The Lower Unit

    LOWR Lower unit Removing the lower unit 1. Disconnect the battery cable. • Place a block of wood between the anti- cavitation plate and the propeller. Do not 2. Remove the lock plate for the engine stop touch the propeller with your hands. switch.

  • Page 155: Removing The Water Pump And Shift Rod

    Lower unit (counter rotation model) Removing the water pump and shift 2. When the insert cartridge is removed, al- ways replace the O-ring 3 with a new one, and insert the projection on the insert car- 1. Remove the water pump 1 and the shift tridge into the water pump housing hole at rod 2.
  • Page 156 LOWR Lower unit 4. Check the Woodruff key 4 and the groove A for wear. Replace if necessary. 60h60090 5. Check the shift rod for deformation or wear. Replace if necessary. 60h61100 6-39 60H5E11...

  • Page 157: Propeller Shaft, Propeller Shaft Housing (Counter Rotation Model)

    Lower unit / Propeller shaft, Propeller shaft housing (counter rotation model) Propeller shaft, Propeller shaft housing (counter rotation model) 12 13 60h61110 Part name Q’ty Remarks Slide shift Ball Slider Ball Ball Spring Dog clutch Cross pin Cross pin ring Forward gear Forward gear shim As required...
  • Page 158 LOWR Lower unit 12 13 60h61110 Part name Q’ty Remarks Propeller shaft housing Needle bearing Oil seal Claw washer Ring nut 6-41 60H5E11...

  • Page 159: Removing The Propeller Shaft Housing Assembly And Propeller Shaft

    Propeller shaft, Propeller shaft housing (counter rotation model) Removing the propeller shaft housing NOTE: Make sure that the shims left in the lower case assembly and propeller shaft have been removed. 1. Pull up the claw washer tabs. 2. Remove the ring nut. Bearing housing puller claw L 1: 90890-06502 Center bolt 2:...

  • Page 160: Checking The Propeller Shaft Assembly

    LOWR Lower unit 8. Remove the taper roller bearing from the 2. Measure the propeller shaft run-out. forward gear. 60h61265 Run-out limit: 0.05 mm (0.0020 in) 60h61625 3. Check the dog clutch for breakage or wear. Bearing inner race attachment: Replace if necessary.

  • Page 161: Disassembling The Propeller Shaft Housing Assembly

    Propeller shaft, Propeller shaft housing (counter rotation model) 5. Check the teeth and dogs of the forward Assembling the propeller shaft and gear for cracks or wear. Replace the gear propeller shaft assembly if necessary. 1. Install a new needle bearing into the pro- peller shaft housing to the specified depth using a press.
  • Page 162 LOWR Lower unit 3. Install the propeller shaft shim, the thrust 6. Assemble the slider assembly. bearing and the propeller shaft to the pro- peller shaft housing. 4. Install the taper roller bearing 56 and the thrust bearing to the propeller shaft hous- ing.

  • Page 163: Drive Shaft And Lower Case (Counter Rotation Model)

    Propeller shaft, Propeller shaft housing / Drive shaft and lower case (counter rotation model) Drive shaft and lower case (counter rotation model) 60h61300 Part name Q’ty Remarks Drive shaft Drive shaft sleeve Cover Oil seal Bolt 8 x 25mm Drive shaft housing Needle bearing O-ring Pinion shim...

  • Page 164: Removing The Drive Shaft And Reverse Gear

    LOWR Lower unit Removing the drive shaft and reverse 5. Remove the reverse gear. gear NOTE: Shimming is required when the reverse gear or taper roller bearing is replaced. 1. Loosen the pinion nut. 60h61323 SST Bearing puller assembly: 90890-06535 Disassembling the lower case 60h60310 NOTE:...

  • Page 165: Checking The Drive Shaft Housing

    Drive shaft and lower case (counter rotation model) 2. Remove the needle bearing outer race. Assembling the drive shaft housing 1. Install the needle bearing. 60h60330 Drover rod LL 2: 90890-06605 Ball bearing attachment 3: 90890-06636 60h60350 Checking the drive shaft housing Driver rod SS 1: 90890-06604 1.

  • Page 166: Checking The Reverse Gear

    LOWR Lower unit Checking the reverse gear Checking the drive shaft 1. Check the teeth and dogs of the reverse 1. Check the drive shaft for bends or wear. gear for cracks or wear. Also check the Replace if necessary. bearing for run-out and roughness.

  • Page 167: Assembling The Lower Unit (Counter Rotation Model)

    Drive shaft and lower case / Assembling the lower unit (counter rotation model) Assembling the lower unit 3. Install the needle bearing rollers. (counter rotation model) NOTE: Installing the lower case Apply some grease on the needle bearing roll- 1. Install the shims and the roller bearing. ers so that they will not fall off.
  • Page 168 LOWR Lower unit 9. Tighten the pinion nut. 12. Install the shift rod assembly, and tighten the bolt. 60h60460 60h61480 Drive shaft holder 6 5: 90890-06520 Pinion nut holder 6: 90890-06505 Socket adapter 3 6: 90890-06508 13. Align the key way, and install the key. 14.

  • Page 169: Installing The Water Pump

    16. Bend one of the claw washer tabs toward the woodruff key. yourself. 60h60530 60h60515 NOTE: • Align the groove on the impeller with the Woo- druff key. • Apply Yamaha grease A on the sliding face between the impeller and the outer plate car- tridge. 6-52 60H5E11...

  • Page 170: Installing The Speedometer Hose

    60h60540 specified torque. NOTE: To install the water pump housing, apply Yamaha grease A to the inner face of the wa- ter pump housing assembly, and then turn the drive shaft clockwise while pushing down the pump housing. Installing the speedometer hose 1.
  • Page 171 Assembling the lower unit (counter rotation model) 4. Install the propeller and the propeller nut. 5. Insert the gear oil tube or gear oil pump into Place a block of wood between the anti- the drain hole and fill the gear oil until it cavitation plate and the propeller to keep flows out of the check hole and no air the propeller from turning.

  • Page 172: Shimming (Counter Rotation Model)

    LOWR Lower unit Shimming (counter rotation model) 61.0 B1 36.5 16.8 60h61600 60h61607 6-55 60H5E11...

  • Page 173: Shimming

    Shimming (counter rotation model) Shimming NOTE: • Shimming is not required when the original lower case and inner parts are reused for the lower unit reassembly. • Shimming is required if either the lower case or the assembly parts are replaced for the lower unit reassembly.

  • Page 174: Selecting The Reverse Gear Shims

    LOWR Lower unit 5. Calculate the lower case standard(P/100). 7. Select the pinion shim(s) as follows. Calculated numeral Rounded numeral at 1/100 place 3,4,5 6,7,8 9,10 Available shim thickness: 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50 S69j6555 Example: NOTE: If "T3" is 0.58mm, then the pinion shim is •...

  • Page 175: Selecting The Forward Gear Shims

    Shimming (counter rotation model) NOTE: Example: • Set the thrust bearing and the race on the If "T1" is 0.45 mm, then the reverse gear roller bearing, and turn them two or three shim is 0.42 mm. times to make them seated properly. If "T1"...

  • Page 176: Selecting The Propeller Shaft Shims

    LOWR Lower unit Selecting the propeller shaft shims 2. Calculate the lower case standard(R/100). NOTE: Obtain the propeller shaft shim thickness(T4)by using the specified measurement(s) and the calculation formula. Calculation formula: Propeller shaft shim thickness (T4) = 29.00 - A/100 + B/100 - M5 - M6 S69j6585 NOTE:...
  • Page 177 Shimming (counter rotation model) NOTE: 5. Select the propeller shaft shim(s) as fol- Turn the thrust bearing two or three times to lows. make it seated properly. Calculated numeral Rounded numeral Measure the flange and bearing thickness at at 1/100 place three points, and obtain the average.

  • Page 178: Backlash (Counter Rotation Model)

    LOWR Lower unit Backlash (counter rotation model) Bearing housing puller claw L 1: 90890-6502 NOTE: Center bolt 2: 90890-06504 • Measure the backlash after removing the wa- Stopper guide plate 3: 90890-6501 ter pump. • Set the gear shift in neutral position for the 3.
  • Page 179 Backlash (counter rotation model) 10. Turn the shift rod to the neutral position D Forward gear backlash: with the shift rod push arm. 0.21 - 0.43 mm (0.0083 - 0.0169 in) 11. Turn the drive shaft counterclockwise by approximately 30°. Forward gear backlash M Shim thickness(mm) Less than...
  • Page 180 LOWR Lower unit NOTE: When measuring the reverse gear backlash, turn the shift rod push arm towards the reverse position C with force. 14. Add or remove shim(s) if out of specifica- tion. Reverse gear backlash M Shim thickness(mm) Less than To be decreased by 0.98 mm (0.0386 in) (1.14-M) x 0.72...
  • Page 181 BRKT Bracket unit Bracket unit Special service tools ..................... 7-1 Bottom Cowling ......................7-2 Upper case ........................7-6 Removing the upper case ..................7-10 Disassembling the upper case ................7-10 Checking the upper case ..................7-12 Assembling the upper case..................7-12 Power trim and tilt unit ....................

  • Page 182: Brkt Bracket Unit

    BRKT Bracket unit Special service tools Hydraulic pressure gauge: 90890-06776 Up-relief fitting: 90890-06773 Down-relief fitting: 90890-06774 Trim & tilt wrench: 90890-06548 60H5E11...

  • Page 183: Bottom Cowling

    Special service tools / Bottom Cowling Bottom Cowling 60h70010 Part name Q’ty Remarks Clip Shift rod Bush Washer Shift rod lever Washer Bush Shift rod bracket Grease nipple Washer Circlip Rubber seal Ball Spring Bushing Bolt M8 x 30 mm O-ring 60H5E11...
  • Page 184 BRKT Bracket unit 12 13 11 12 13 14 60h70020 Part name Q’ty Remarks Wire harness clamp Bolt M6 x 20 mm Plate Bolt M8 x 20 mm Bracket Clamp Grommet Holder Bolt Washer Hook Washer Bushing Grommet Bolt M6 x 10 mm Lever 60H5E11...
  • Page 185 Bottom Cowling 12 13 11 12 13 14 60h70020 Part name Q’ty Remarks Bushing Trailer switch holder Bolt M6 x 28 mm Trailer switch Grommet Rubber seal Screw Clamp Bolt M6 x 20 mm Clamp Pilot jet Hose Bolt M8 x 35 mm Read Grommet Collar...
  • Page 186 BRKT Bracket unit 12 13 11 12 13 14 60h70020 Part name Q’ty Remarks Grommet Bolt M6 x 15 mm Retaining plate Clamp 60H5E11...

  • Page 187: Upper Case

    Bottom Cowling / Upper case Upper case 60h70030 Part name Q’ty Remarks Washer Upper mount Bracket Washer Washer Washer Bolt M12 x 190 mm Bushing Washer Bolt M10 x 45 mm Mount housing Spring Washer Lower mount Washer 60H5E11...
  • Page 188 BRKT Bracket unit 60h70030 Part name Q’ty Remarks Washer Ground lead Bolt M14 x 180 mm Upper case assembly Ground lead Hose Bolt M10 x 45 mm Washer Bolt M6 x 10 mm Bolt M6 x 30 mm Plastic tie 60h70040 60H5E11...
  • Page 189 Upper case 60h70040 Part name Q’ty Remarks Bolt M8 x 45 mm Gasket Union joint Upper exhaust guide Gasket Lower exhaust guide Bolt M8 x 30 mm Gasket Exhaust manifold Bolt M8 x 45 mm Gasket Muffler Bolt M8 x 45 mm Rubber damper Clip Rubber seal...
  • Page 190 BRKT Bracket unit 60h70040 Part name Q’ty Remarks Upper case Rubber seal Pipe Rubber seal X transom Muffler 2 X transom Rubber seal X transom Bushing X transom Circlip X transom Grommet Rubber seal 60H5E11...

  • Page 191: Removing The Upper Case

    Upper case Removing the upper case 2. Remove the upper mount bracket. 1. Disconnect the ground lead. 2. Remove the lower mount cover. 60h70060 NOTE: Cover may pop up by the spring force. Hold it down by hand when loosening the screw. 60h70070 3.
  • Page 192 BRKT Bracket unit 5. Remove the muffler assembly, the rubber 7. Remove the exhaust manifold. seal and dowels. 60h70110 60h70090 8. Remove the lower exhaust guide. NOTE: In addition, remove the muffler 2 for X transom model. Muffler 2 is to be removed downward. 5.

  • Page 193: Checking The Upper Case

    Upper case 9. Remove the pressure control valve union 4. Check the exhaust guide, exhaust mani- joint from the upper exhaust guide. fold, and muffler for damage or corrosion. Replace if necessary. 60h70130 Checking the upper case 1. Check the union joint and hose for dam- age.
  • Page 194 BRKT Bracket unit 2. Install a new gasket and the lower exhaust 4. Install the rubber damper and spring nut guide onto the upper exhaust guide. Tem- on the muffler. Also install the water seal porarily tighten the bolts. and water tube. NOTE: Install the water tube so that it fits in the water pump.
  • Page 195 60h70230 NOTE: 10. Install the pressure control valve union joint Apply Yamaha grease A at the tip of water and hose, exhaust rubber seal, and upper pump tube, and positively fit it into the hole on exhaust guide rubber seal.

  • Page 196: Power Trim And Tilt Unit

    BRKT Bracket unit Power trim and tilt unit 6. Lock the outboard motor with the tilt stop lever 1. Bleeding the power trim and tilt unit (Built-in) NOTE: Check the fluid level before bleeding if the power trim and tilt unit does not operate while PTT motor is working.
  • Page 197 Power trim and tilt unit 60h70290 Part name Q’ty Remarks Power trim and tilt unit PTT motor lead Shaft Plastic tie Circlip Bolt M8 x 16 mm Washer Shaft Bushing Bolt M6 x 10 mm Ground lead 7-16 60H5E11...

  • Page 198: Removing The Power Trim And Tilt Unit

    BRKT Bracket unit Removing the power trim and tilt unit 2. Disconnect the ground lead under the power trim and tilt unit. 1. Fully tilt up the outboard motor, and lock it with the tilt stop lever 1. 3. Remove the plastic tie, and pull out the PTT motor lead.

  • Page 199: Checking The Hydraulic Pressure Of The Power Trim And Tilt Unit

    Power trim and tilt unit 5. Remove the circlip, and pull out the upper Reservoir cap: mount shaft. 0.7 N • m(0.07kgf • m, 0.5 ft • lb) Recommended power trim and tilt fluid: ATF Dexron II 2. Fully extend the power trim and tilt rods. 3.
  • Page 200 BRKT Bracket unit 5. Connect the power trim and tilt motor leads 7. Replace the up-relief fitting with the down- relief fitting 5. to the battery terminals, and fully retract the trim and tilt rods. 60h70400 60h70380 Hydraulic pressure gauge: Battery 90890-06776 Rods...
  • Page 201 Power trim and tilt unit 10. Connect the power trim and tilt motor leads to the battery terminals, and fully retract the trim and tilt rods. Measure the hydraulic pressure while keeping the rods at fully re- tracted position. 60h70380 Battery Rods PTT motor leads...

  • Page 202: Ptt Motor And Reservoir

    BRKT Bracket unit PTT motor and Reservoir 60h70440 Part name Q’ty Remarks Power trim and tilt motor Reservoir Reservoir cap O-ring O-ring Bolt 1/4 x 35 mm Bolt 1/4 x 35 mm O-ring Filter Joint 7-21 60H5E11...
  • Page 203 PTT motor and Reservoir 60H70445 Part name Q’ty Remarks Screw M4 x 15 mm Stator Armature O-ring Screw M4 x 10 mm Brush holder Brush 2 Brush 1 Brush holder Brush spring PTT motor base Oil seal Bearing Screw M4 x 15 mm 7-22 60H5E11...

  • Page 204: Disassembling The Ptt Motor

    BRKT Bracket unit Disassembling the PTT motor 4. Remove the armature. 1. Remove the PTT motor, O-ring, filter, and drive pin. Do not allow grease or oil to contact the commutator while working on it. 5. Disconnect the blue(L) lead 4. 60H70470 60h70470 60h70450...

  • Page 205: Checking The Ptt Motor

    PTT motor and Reservoir Checking the PTT motor Commutator diameter limit C: 1. Check the blush length A. Replace the 21 mm (0.83 in) blush if it is shorter than the specified limit. 4. Check the armature coil for continuity. Re- place it if the continuity is out of specifica- tion.

  • Page 206: Assembling The Ptt Motor

    BRKT Bracket unit NOTE: When the bearings and oil seals are removed, always replace them with new ones. Assembling the PTT motor 1. Connect the leads 1, and tighten up the screw 2. 60h70560 2. Push the brush 3 into the brush holder while installing the armature 4.
  • Page 207 PTT motor and Reservoir 60h70590 Part name Q’ty Remarks Bolt M5 x 16 mm Pump filter Gear Ball Shuttle piston O-ring Main valve Ball Bolt M8 x 85 mm Bolt M8 x 24 mm Pump housing Circlip Manual valve O-ring O-ring Backup ring Spring...
  • Page 208 BRKT Bracket unit 60h70590 Part name Q’ty Remarks Absorber valve pin Ball Up-relief valve seat O-ring Filter O-ring Down-relief valve Valve pin O-ring Valve seat Ball O-ring 7-27 60H5E11...

  • Page 209: Disassembling The Reservoir

    PTT motor and Reservoir Disassembling the reservoir 2. Drain the fluid from the reservoir to check any damage. Also check the cap and O- ring. Replace if necessary. Disassembling the gear pump unit 1. Remove the gear pump unit. 60h70600 NOTE: •...
  • Page 210 BRKT Bracket unit 3. Remove the gear pump cover and gear 5. Remove the main valves. pump. 60h70660 NOTE: To remove the main valves, cover the pump housing with a clean cloth, and blow com- pressed air through holes A and B. 60h70640 NOTE: Make sure that the shuttle piston and ball are...

  • Page 211: Checking The Reservoir And Gear Pump Unit

    PTT motor and Reservoir 2. Install new O-rings 6 on the main valves Checking the reservoir and gear pump 7. Then, attach them on the pump hous- unit ing. 1. Clean all the valves, pistons, balls, and fil- ters. Check them for damages or wear. Check the gear pump for damages or wear.
  • Page 212 BRKT Bracket unit 5. Install the gear pump cover B on the pump housing, and temporarily tighten the mount- ing bolts. 60h70730 6. Make sure that the gear pump turns smoothly by hands. Then, tighten the mounting bolts to the specified torque. Gear pump cover bolts: 6 N •...

  • Page 213: Tilt Cylinder And Trim Cylinder

    PTT motor and Reservoir / Tilt cylinder and trim cylinder Tilt cylinder and trim cylinder 60h70750 Part name Q’ty Remarks Tilt rod Trim piston assembly Cylinder body Free piston Backup ring O-ring Dust seal Seal Trim cylinder end screw O-ring Backup ring O-ring Dust seal...
  • Page 214 BRKT Bracket unit 60h70750 Part name Q’ty Remarks O-ring O-ring Washer Ball Valve Spring 7-33 60H5E11...

  • Page 215: Tilt Cylinder And Trim Cylinder

    Tilt cylinder and trim cylinder Disassembling the tilt cylinder and 6. Cover the tilt cylinder opening with a clean cloth 5, and blow compressed air through trim cylinder hole A to remove the free piston 6. 1. Loosen the tilt cylinder end cap 1, and re- move the tilt piston assembly 2.
  • Page 216 BRKT Bracket unit 2. Check the tilt piston and free piston for scratches. Replace if necessary. 60h70830 6. Remove the filter plug and filter from the 60h70800 tilt cylinder, and check them. 3. Air blow the contamination on the tilt pis- 7.

  • Page 217: Assembling The Power Trim And Tilt Unit

    Tilt cylinder and trim cylinder 10. Install the tilt cylinder end cap 4 on the tilt rod 5. 60h70870 11. Install a new O-ring 67 on the tilt piston 60h70900 8. Also install the ball 9, absorber pin 0, Assembling the power trim and tilt unit and spring A in this order.
  • Page 218 BRKT Bracket unit 3. Fill in the trim cylinders with fluid. Trim rod end cap: 78 N • m(7.8 kgf • m, 57 ft • lb) 6. Install new O-ring, valve pin, and check valve assembly on the tilt cylinder. 60h70980 NOTE: Refer to the illustration for the correct orienta-...
  • Page 219 Tilt cylinder and trim cylinder 9. Fill the tilt cylinder with the fluid. Trim & tilt wrench: 90890-06548 Trim rod end cap: 130 N • m(13 kgf • m, 94 ft • lb) 12. Install the joint 4 and filter 3 on the gear pump unit.

  • Page 220: Bleeding The Power Trim And Tilt Unit

    BRKT Bracket unit 14. Install a new O-ring 5 and the PTT motor Bleeding the power trim and tilt unit 6. Tighten up the bolts 7. NOTE: • Make sure that the manual valve 1 is tight- ened up. • Fix the power trim and tilt unit in the upright position, and check the fluid level.

  • Page 221: Installing The Power Trim And Tilt Unit

    Tilt cylinder and trim cylinder 2. Connect the power trim and tilt motor leads to the battery terminals, and fully extend the trim and tilt rods. After tilting up the outboard motor, be sure to support it with the tilt stop lever. Other- wise, the outboard motor could suddenly lower if the power trim and tilt unit should lose fluid pressure.
  • Page 222 BRKT Bracket unit Steering arm 60h70035 Part name Q’ty Remarks Steering arm Washer Bushing Swivel bracket O-ring Bushing Washer Steering yoke Circlip Thrust receiver Damper Clamp bracket Starboard Clamp bracket Port 7-41 60H5E11...

  • Page 223: Removing The Steering Arm

    Steering arm Removing the steering arm 3. Install the bushing, O-ring, and washer. Also install the steering yoke. 1. Remove the circlip 1. 2. Remove the steering yoke 2 by striking it with a plastic hammer or the like. 60h71190 60h71170 3.
  • Page 224 BRKT Bracket unit 5. Inject Yamaha grease A through the grease nipple. 60h71200 NOTE: Inject the grease until it comes out from both the upper bushing C. 7-43 60H5E11...
  • Page 225 Steering arm / Clamp brackets Clamp brackets 60h71210 Part name Q’ty Remarks Swivel brcket assembly Clamp bracket Starboard Clamp bracket Port Self-locking nut Grease nipple Ground lead Washer Bolt M6 x 11 mm Washer Bushing Trim sensor Screw M6 x 25 mm Trim sensor cam Screw M6 x 25 mm...
  • Page 226 BRKT Bracket unit 60h71210 Part name Q’ty Remarks Anode Through tube Bolt M8 x 20 mm Tilt stop lever Bush Collar Distance collar Spring pin Spring Spring hook Bolt M6 x 10 mm Tilt stop lever Ground lead Washer Bolt M6 x 10 mm 7-45 60H5E11...

  • Page 227: Clamp Brackets

    7. Install the ground lead between the clamp 6. Remove the trim sensor. brackets and the swivel bracket. 7. Disassemble the tilt stop lever, and remove 8. Apply Yamaha grease A through the grease the trim rod receiver. nipples. Assembling the clamp brackets 1.

  • Page 228: Install The Upper Case

    BRKT Bracket unit Install the upper case Adjusting the trim sensor cam 1. Install the upper cace and tighten the up- 1. Fully retract the power trim and tilt unit. per mount and lower mount nuts. 2. Loosen the trim sensor cam screw 1. 3.
  • Page 229 Clamp brackets 5. Check the trim sensor resistance. If the resistance is out of specification, adjust the trim sensor cam position, and check the trims sensor. Trim sensor resistance: Pink (P) - Black (B) 238.8-378.8 at 20°C (68°F) 7-48 60H5E11...
  • Page 230 ELEC ELEC Electrical systems Electrical systems Electrical systems Special service tools ..................... 8-1 Checking the electrical components ................8-2 Measuring the peak voltage ..................8-2 Measuring the lower resistance ................8-2 Electrical components ....................8-3 Starboard view ......................8-3 Port view ........................8-4 Top view ........................
  • Page 231 Choke solenoid ......................8-19 Checking the choke solenoid .................. 8-19 Charging system ......................8-20 Checking the lighting coil ..................8-21 Checking the Rectifier Regulator ................8-21 Power trim and tilt ....................... 8-22 Checking the power trim and tilt relay ..............8-23 Checking the power trim and tilt switch / trailer switch ..........

  • Page 232: Electrical Systems

    ELEC Electrical systems Special service tools Ignition tester 90890-06754 Digital circuit tester 90890-03174 Peak voltage adaptor B 90890-03172 Test harness (FWY-4) 90890-06771 Test harness (FWY-6) 90890-06772 60H5E11...

  • Page 233: Checking The Electrical Components

    Special service tools / Checking the electrical components Checking the electrical compo- Measuring the lower resistance When measuring a resistance of 10 or less nents with the digital circuit tester, the correct mea- Measuring the peak voltage surement cannot be obtained because of the internal resistance of the tester.

  • Page 234: Electrical Components

    ELEC Electrical systems Electrical components Starboard view 60h80030 1 Thermoswitch 2 Hour meter 3 Rectifier Regulator 4 Choke solenoid 60H5E11...

  • Page 235: Port View

    Electrical components Port view 60h80040 1 Starter motor 2 Starter relay 3 Power trim and tilt relay 60H5E11...

  • Page 236: Top View

    ELEC Electrical systems Top view 60h80050 1 Spark plug 2 Thermoswitch 3 Rectifier Regulator 4 Starter motor 5 Starter coil 6 Pulser coil 60H5E11...

  • Page 237: Rear View

    Electrical components Rear view 60h80045 1 Ignition coil 2 Spark plug 3 CDI unit 60H5E11...

  • Page 238: Wiring Harness

    ELEC Electrical systems Wiring harness Sb Lg SbLg R 60h80060 Connect to: 8 Ground lead Lg : Light green 1 Battery 9 Rectifier Regulator R : Red 2 Starter relay 0 Hour meter P : Pink 3 Power trim and tilt relay A Choke solenoid W : White 4 Power trim and tilt switch...

  • Page 239: Ignition System

    Electrical components / Ignition system Ignition system 60h80070 1 Spark plug L : Blue : Black/Red : White/Blue 2 Ignition coil B : Black B/W : Black/White W/Br : White/Brown 3 Pulser coil Br : Brown W/B : White/Black 4 Stator coil P : Pink W/G : White/Green 5 CDI unit...

  • Page 240: Checking The Ignition Spark Gap

    ELEC Electrical systems Checking the ignition spark gap 4. Crank the engine and observe the spark through the discharge window of the spark 1. Disconnect the spark plug caps from the gap tester. If it does not work properly, check spark plugs.

  • Page 241: Checking The Plug Cap (With Resister Type)

    Ignition system 2. Remove the spark plug cap 1, and remove Checking the plug cap the plug cap spring 3 from the spark plug (with resister type) wire 2. 1. Remove the spark plug cap 1 from the spark plug wire 2 by turning the cap coun- terclockwise.

  • Page 242: Checking The Ignition Coil

    ELEC Electrical systems Checking the ignition coil Checking the pulser coil 1. Remove the spark plug cap from the spark 1. Remove the CDI unit cover. plug. 2. Connect the pulser coil coupler and the CDI 2. Disconnect the ignition coil lead. unit with the test harness (6 pins) .

  • Page 243: Checking The Charge Coil

    Ignition system Digital circuit tester : 90890-03174 Peak voltage adapter B : 90890-03172 Test harness (FWY-4) : 90890-06771 Charge coil output peak voltage : Brown(Br) – Red(R) Unloaded Loaded r/min Cranking 1,500 3,500 DC V Charge coil peak voltage : Blue(L) –...

  • Page 244: Checking The Cdi Unit

    ELEC Electrical systems Checking the CDI unit Checking the thermoswitch 1. Place the thermoswitch 1 in a container 1. Connect the digital circuit tester lead to the ignition coil lead and the ground lead. with water and slowly heat the water. 2.

  • Page 245: Starting System

    Ignition system / Starting system Starting system START 60h80200 B :Black 1 Battery (12 volts) R :Red 2 Starter motor Br :Brown 3 Starter relay L :Blue 4 PTT down relay 5 Fuse (20 amps) Y :Yellow 6 Choke solenoid 7 Key switch panel 8-14 60H5E11...

  • Page 246: Checking The Fuse

    ELEC Electrical systems Checking the fuse 1. Check the fuse for continuity. Replace if there is no continuity. 60h80210 Checking the wiring harness (10 pins) 1. Check the wiring harness for continuity. Replace if there is no continuity. Checking the starter relay 1.

  • Page 247: Starter Motor

    Starting system Starter motor Starter motor 60h80260 Part name Q’ty Remarks Bolt M8 x 25 mm Starter motor cover Clip Pinion stopper Spring Pinion Housing Washer Armature Stator Spring Brush holder Washer Washer Washer Washer 8-16 60H5E11...
  • Page 248 ELEC Electrical systems 60h80260 Part name Q’ty Remarks Lower bracket Bolt M8 x 25 mm Bolt M6 x 115 mm 8-17 60H5E11...

  • Page 249: Removing The Starter Motor Pinion

    Starter motor Removing the starter motor pinion Checking the armature 1. Remove the starter motor cover. 1. Check the commutator for dirt. Clean with 2. Remove the adhesive. #600 grid sandpaper or by blowing the com- pressed air. Attach with adhesive after reassembly. 3.

  • Page 250: Checking The Brushes

    ELEC Electrical systems 4. Check the armature for continuity. Replace 2. Check the brush holder assembly for con- if out of specification. tinuity. Replace if out of specification. 60h80310 60h80330 Armature continuity: Brush continuity Commutator segments B Continuity Brush 1 – Brush 2 No continuity Segment B - Armature core C No continuity Segment B - Armature shaft D No continuity...

  • Page 251: Charging System

    Starter motor / Charging system Charging system 60h80230 1 Battery : Black 2 Fuse (20 amps) : Red 3 Lighting coil : Green 4 Rectifier Regulator : Yellow 5 Hour meter G/W : Green/White 8-20 60H5E11...

  • Page 252: Checking The Lighting Coil

    ELEC Electrical systems Checking the lighting coil Checking the Rectifier Regulator 1. Remove the Rectifier Regulator cover, and 1. Remove the Rectifier Regulator cover, and connect the digital circuit tester lead to the connect the digital circuit tester lead to the lighting coil.

  • Page 253: Power Trim And Tilt

    Charging system / Power trim and tilt Power trim and tilt 60h80365 1 Battery (12 volts) B : Black 2 Fuse (20 amps) R : Red 3 PTT up relay Sb : Sky blue 4 PTT down relay Lg : Light green 5 Trailer switch Gy : Gray 6 PTT motor...

  • Page 254: Checking The Power Trim And Tilt Relay

    ELEC Electrical systems Checking the power trim and tilt relay Checking the power trim and tilt 1. Connect the digital circuit tester between switch / trailer switch power trim and tilt relay terminals 1 and 1. Check the power trim and tilt switch/trailer switch for continuity.
  • Page 255 TRBL SHTG Troubleshooting Troubleshooting Power unit ........................9-1 Starting system ......................9-1 Ignition system ......................9-3 Fuel system ......................9-4 Compression pressure ....................9-5 Fuel system ......................9-6 Ignition system ......................9-7 Power unit ......................... 9-8 Air intake system....................... 9-9 Fuel system ......................

  • Page 256: Power Unit

    TRBL SHTG Troubleshooting NOTE: • To diagnose a mechanical malfunction, use the troubleshooting charts pertaining to the trouble located in this chapter. Also, when checking and maintaining the outboard motor, see Chapters 4–8, to check the part necessary to carry out safety maintenance. •...
  • Page 257 Power unit Is there Replace the fuse. continuity? Check the wiring harnesses for continuity. Is there Replace the wiring harnesses. continuity? Check the starter relay operation. Good operating Replace the starter relay. condition? Check the starter motor operation. Good operating Replace the starter motor.

  • Page 258: Ignition System

    TRBL SHTG Troubleshooting Symptom: Engine cranks, but will not start. • Check the ignition system. • Do not touch any of the connections of • Check the fuel system. the spark gap tester leads. • Check the compression pressure of the •...

  • Page 259: Fuel System

    Power unit Replace the pulser Is measured voltage exceeds the coil. specified value? Measure the charge coil output voltage. Is measured Replace the charge voltage exceeds the specified value? coil. Measure the CDI unit output peak voltage. Is measured Replace the CDI voltage exceeds the unit.

  • Page 260: Compression Pressure

    TRBL SHTG Troubleshooting Check the water accumulation or clogging of the fuel filter. Is there water Clean the fuel system from the or residue? fuel tank to the fuel filter. Check the fuel hose for kinks or fuel leakage. Correct or replace the faulty Is there any kinks parts.

  • Page 261: Fuel System

    Power unit Symptom: Engine starts but does not remain on. • Check the fuel system. • Do not touch any of the connections of • Check the ignition system. the spark gap tester leads. • Check the compression pressure of the power •...

  • Page 262: Ignition System

    TRBL SHTG Troubleshooting Ignition system Check that the spark plugs produce sparks. Are there Check the spark plugs, and clean sparks? or replace them as required. Check the ignition spark using the spark gap tester. Check the spark plug wire and Good ignition spark condition? spark plug cap for deterioration.

  • Page 263: Power Unit

    Power unit Measure the CDI unit output peak voltage. Is measured Replace the CDI voltage exceeds the unit. specified value? Check each component again. Check the ignition timing. Is ignition Adjust the ignition timing. timing correct? Check the power unit. Power unit Measure the compression pressure.

  • Page 264: Air Intake System

    TRBL SHTG Troubleshooting Symptom: The engine idle speed is not steady, but increases or decreases. • Check the air intake system. • Check the ignition system. • Check the intake manifold. Air intake system Check the operation of the throttle cable and throttle link. Adjust the throttle cable and Good operating throttle link.

  • Page 265: Fuel System

    Power unit Symptom: Engine does not accelerate when the throttle is opened quickly. The engine turns off when the throttle is opened quickly. Hesitation or stumble is observed in the course of acceleration. • Check the fuel system • Check the ignition system •...

  • Page 266: Ignition System

    TRBL SHTG Troubleshooting Ignition system Check that the spark plugs produce sparks. Check the spark plugs, and clean Are there or replace them as required. sparks? Check the ignition spark using the spark gap tester. Check the spark plug wire and Good ignition spark plug cap for deterioration.
  • Page 267 Power unit Is measured Replace the charge voltage exceeds the coil. specified value? Measure the CDI unit output peak voltage. Is measured Replace the CDI voltage exceeds the unit. specified value? Check the ignition timing. Check each component again. Is ignition Adjust the ignition timing.

  • Page 268: Cooling System

    TRBL SHTG Troubleshooting Symptom: Engine starts, but engine speed does not increase. Overheat warning buzzer is on. • Check the cooling system. Cooling system Check the cooling water inlet for clogs or damages Clean the cooling water inlet or Clogs or replace it.

  • Page 269: Bracket Unit

    Power unit / Bracket unit Bracket unit Symptom: Power trim and tilt unit does not operate. Listen to the operating sound of the power trim and tilt relay. Keep activating the trim switch, and check the voltage Can the between each terminal. operating sound Between the sky blue (Sb) lead and the ground lead.
  • Page 270 TRBL SHTG Troubleshooting Check the power trim and tilt fluid level. Is the fluid at Add fluid to the correct level. specified level? Bleed the power trim and tilt fluid. Restored to the Check the fluid leakage again. normal condition? Measure the hydraulic pressure of the power trim and tilt.
  • Page 271 Bracket unit Symptom: Power trim and tilt unit does not hold the outboard motor up. Check that the manual valve is closed. Is it closed? Close the valve. Check the possible oil leakage from the power trim and tilt unit. Oil leakage Repair the oil leakage.

  • Page 272: Lower Unit

    TRBL SHTG Troubleshooting Lower unit Symptom: Shift mechanism of the forward gear and reverse gear does not operate properly. Check the shift cable operation. Check the shift cables and links Good operating of the remote control box. condition? Check the operation of the shift rod.

  • Page 273: Electrical System

    Lower unit / Electrical system Electrical system Symptom: Battery discharges quickly. • Check the charging system. Measure the output peak voltage of the lighting coil. Is measured voltage above Replace the lighting coil. specification? Measure the Rectifier Regulator output peak voltage. Is measured voltage above Replace the Rectifier Regulator.
  • Page 274 Index Checking and replacing the spark plug caps (Standard type) ........8-9 Adjusting the carburetor pickup timing ..3-15 Checking the anodes ....... 3-21 Adjusting the carburetor Checking the armature ......8-18 synchronization ........3-13 Checking the battery ....... 1-14, 3-21 Adjusting the choke solenoid ....
  • Page 275 Checking the power trim and tilt fluid Disassembling the propeller shaft level ............3-18 assembly ..........6-15 Checking the power trim and tilt Disassembling the propeller shaft housing operation ..........3-17 assembly ........6-12, 6-44 Checking the power trim and tilt relay ..8-23 Disassembling the PTT motor ....
  • Page 276 Installing the power unit ......5-40 Removing the exhaust cover ....5-21 Installing the speedometer hose ..6-24, 6-53 Removing the flywheel magnet ....5-15 Installing the steering arm ......7-42 Removing the intake manifold ....5-18 Installing the water pump ....6-24, 6-52 Removing the lower unit ....
  • Page 277 Wiring harness ........... 8-7 60H5E11...

  • Page 278: Wiring Diagram

    WIRING DIAGRAM 200AET,L200AET Starter motor Starter relay Color code PTT up relay PTT down relay :Black Trailer switch :Brown PTT motor :Green Battery (12 volts) :Gray Thermoswitch :Blue Ignition coil :Light green CDI unit :Pink Charge coil :Red Lighting coil :Sky blue Purser coil :White...
  • Page 279 200AET, L200AET...
  • Page 281 YAMAHA MOTOR CO., LTD. Printed in Japan Feb.2002 - 0.9 1 (200AET,L200AET) Printed on recycled paper...

This manual is also suitable for:

L200a

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