Yamaha FT50C Service Manual
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Yamaha FT50C Service Manual

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FT50C
SERVICE MANUAL
290418
62Y-28197-5A-11

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Summary of Contents for Yamaha FT50C

  • Page 1 FT50C SERVICE MANUAL 290418 62Y-28197-5A-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: Table Of Contents

    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: General Information

    INFO General information How to use this manual ................. 1-1 Manual format.................... 1-1 Symbols..................... 1-2 Safety while working..................1-3 Fire prevention................... 1-3 Ventilation....................1-3 Self-protection ................... 1-3 Parts, lubricants, and sealants ..............1-3 Good working practices ................1-4 Disassembly and assembly ............... 1-4 Identification....................1-4 Applicable models ..................1-4 Serial number ....................
  • Page 5 Predelivery checks ..................1-26 Checking the fuel system ................1-26 Checking the gear oil................1-27 Checking the engine oil ................1-27 Checking the battery................1-27 Checking the outboard motor mounting position ........1-27 Checking the remote control cables ............1-27 Checking the steering system ..............1-28 Checking the gearshift and throttle operation..........1-28 Checking the tilt system................1-28 Checking the engine start switch and engine stop switch/...

  • 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 A in an exploded diagram indicate the grade of lubricant and the lubrication point. 7 Apply Yamaha 4-stroke motor oil 0 Apply anti-corrosion grease (Yamaha grease D) 8 Apply water resistant grease (Yamaha grease A) A Apply low temperature resistant grease 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 / Identification 6. Keep a supply of clean, lint-free cloths for wiping up spills, etc. Good working practices Special tools Use the recommended special tools to pro- tect parts from damage. Use the right tool in the right manner—do not improvise. 3.

  • Page 10: Features And Benefits

    L: 450101– Features and benefits Use of leaded gasoline New FT50C/F50D is designed for pleasure/light commercial use for all over the world. Therefore, engine components anti-corrosion and reliability has been increased while regular leaded gasoline is used. However, always use regular unleaded gasoline for longer engine life.

  • Page 11: Cdi Unit With Microcomputer

    Identification / Features and benefits CDI unit with microcomputer The ignition system consists of a flywheel, stator, pulser coil, thermoswitch, oil pressure switch, CDI unit, and ignition coil. The CDI unit contains a built-in microcomputer that determines the ignition timing separately for acceleration and for normal operation, based on signals received from the pulser coil, thermoswitch, and oil pressure switch.

  • Page 12: Lower Unit

    Higher class pinion and gears The lower unit of the new FT50C uses the same type of large gears that are used in the F100. The use of the same type of gears that are used in a higher class model provides ample durability, mak- ing it possible to accommodate a wider range of applications throughout the market.

  • Page 13: Technical Tips

    To facilitate the starting of a cold engine, an air-fuel mixture that is richer than normal is required. For this reason, the Prime Start system has been adopted in the FT50C. In the Prime Start system, the thermo heater plunger is in a position that fully opens the fuel enrichment valve while the engine is being started.
  • Page 14 INFO General information S62Y1240K 1 Prime Start 6 Carburetor 2 Intake manifold of the engine 7 Intake silencer È Air 3 Thermo heater plunger É Fuel 4 Fuel enrichment valve Ê Plunger movement 5 To carburetor #2 or #4 É The enriched air-fuel mixture is delivered to 1 Prime Start È...
  • Page 15 Technical tips Carburetor operation 1. Idle and low-speed operation Since the vacuum at the venturi is low when the throttle valve is opened slightly, the main nozzle does not supply any air-fuel mixture to the engine. When the engine is operating at idle, the fuel that passes through the pilot jet and the air that passes through the pilot air jet mix, enabling the air-fuel mixture that has been regulated by the pilot screw to be fed through the pilot outlet.
  • Page 16 INFO General information 2. Medium speed operation When the throttle valve opens further, air-fuel mixture is fed from the pilot outlet and all the bypass holes. In addition, air-fuel mixture is also supplied from the main nozzle in accordance with the opening angle of the throttle valve.
  • Page 17 Technical tips 3. High-speed operation When the throttle valve approaches its fully open position, the fuel that has been regulated by the main jet and the air that has been regulated by the main air jet are mixed in the main nozzle. The resultant mixture is then sprayed by the main nozzle into the venturi.

  • Page 18: Acceleration Pump

    INFO General information Acceleration pump The function of the acceleration pump is to ensure a smooth acceleration by preventing the air-fuel mixture from becoming temporarily lean in case the throttle valve is opened suddenly. When the throttle valve is opened suddenly, a large volume of air is introduced into the engine. However, because fuel is heavier than air, it is not possible to supply the volume of fuel that is necessary for the large volume of air that has been introduced.
  • Page 19 Technical tips Operation When the throttle is opened suddenly, diaphragm 1 (via the link that is connected to the throttle lever) operates to pressurize the air in the pump chamber. The pressurized air opens diaphragm 2, and becomes distributed to the carburetors by passing through the pipes that are connected to the carburetors.

  • Page 20: Ignition System

    INFO General information Ignition system In order to determine the optimal ignition timing that is necessary for the proper operation of the engine, the built-in microcomputer in the CDI unit detects the signals from various types of sensors and controls the ignition timing in accordance with a control map that is based on those signals. The microcomputer also effects controls to protect the engine against overheating, over-revolution, and oil pressure drops, as well as to control warning devices.
  • Page 21 Technical tips Pulser coil The pulser coil transmits the pulser signals, which are generated in the pulser coil in accordance with the rotation of the flywheel, to the CDI unit. Among the two protrusions that are provided for generating signals, one is used for cylinders #1 and #4, and the other for cylinders #2 and #3, thus enabling the pulser coil to simultaneously ignite two cylinders.

  • Page 22: Ignition Timing Control

    INFO General information Ignition timing control Control circuit diagram Operation Detection Microcomputer Ignition timing control Positive start Engine start Engine temperature (optimized ignition timing) Quick acceleration Acceleration Engine speed Engine speed control Over-revolution Warning buzzer (in remote-control Damage prevention Low oil pressure Oil pressure unit) Warning lamp...
  • Page 23 Technical tips Starting control When starting the engine, the timing is set to 5° BTDC until the crankshaft speed maintains 600 r/min for two seconds or longer. S62Y1350 1 Cylinder identification protrusion 7 Starting signal (5° BTDC) for cylinders #1 and 2 Protrusion for cylinders #1 and #4 3 Pulser coil 8 Starting signal (5°...

  • Page 24: Power Trim And Tilt

    INFO General information Acceleration control This control is activated when the throttle valve is opened suddenly. If the engine speed increases more than the specified figures, the control of the ignition timing transfers to the acceleration map. Thereafter, the control of the ignition timing transfers gradually to the control map before accelera- tion.
  • Page 25 Technical tips Hydraulic system diagram 1 Power trim and tilt cylinder 2 Ram 3 Reservoir 4 Manual valve 5 Down-main valve 6 Down-relief valve 7 Hydraulic pump 8 Up-relief valve 9 Up-main valve S62Y1370 Power trim and tilt components S62Y1380K 1 Cylinder 9 Reservoir 2 Ram...
  • Page 26 INFO General information Trim-up function The gear pump pumps power trim and tilt fluid to the up-main valve. As a result, the fluid pressure opens the up-shuttle piston causing the fluid to flow into the lower part of the power trim and tilt cyl- inder.
  • Page 27 Technical tips Trim-down function When the power trim and tilt switch is pressed to “Down”, the motor turns the gear pump counter- clockwise and the power trim and tilt fluid flows in the opposite direction to that of the trim-up func- tion.
  • Page 28 INFO General information Circular flow S62Y1410 1 Power trim and tilt cylinder 7 Gear pump 2 Ram 8 Free piston 3 Trim cylinder 9 Tilt piston È Return 4 Motor É Send 5 Reservoir 6 Up-relief valve 1-23 62Y5A11...
  • Page 29 Technical tips Tilt-down function When the power trim and tilt switch is pressed to “Down”, the motor turns the gear pump counter- clockwise, thus pumping the power trim and tilt fluid to the down-main valve. As a result, fluid pres- sure opens the down-main valve and the down-shuttle piston, which causes fluid to flow into the upper part of the trim cylinder and forces the tilt piston down.
  • Page 30 INFO General information Stopping condition When the power trim and tilt switch is not pushed (released), the gear pump does not pump the fluid, the up-main valve and the down-main valve are closed, and the power trim and tilt fluid pres- sure in the system remains constant.

  • Page 31: Propeller Selection

    Technical tips / Propeller selection / Predelivery checks Propeller selection Propeller size (in) Material The performance of a boat and outboard 12 5/8 × 21 - K Aluminum motor will be critically affected by the size 13 × 19 - K Aluminum and type of propeller you choose.

  • Page 32: Checking The Gear Oil

    INFO General information Checking the gear oil Battery capacity: 70–100 Ah 1. Check the gear oil level. Minimum cold cranking performance: 380 A Electrolyte specific gravity: 1.28 at 20 °C (68 °F) 2. Check that the positive and negative bat- tery leads are securely connected.

  • Page 33: Checking The Steering System

    Predelivery checks 3. Check that the alignment mark c is aligned with the mark d. Adjust if neces- sary. 3. Check that there is no interference with wires or hoses when the outboard motor is steered. Checking the gearshift and throttle operation 1.

  • Page 34: Checking The Engine Start Switch And Engine Stop Switch/Engine Shut-Off Switch

    INFO General information 4. Check that the trim meter points down 4. Run the outboard motor for one hour at when the outboard motor is tilted all the 2,000 r/min or at half throttle, then for way down. another hour at 3,000 r/min or at 3/4 throttle.

  • Page 35: Specifications

    SPEC Specifications General specifications................... 2-1 Maintenance specifications ................2-3 Power unit....................2-3 Lower unit ....................2-6 Electrical ....................2-6 Dimensions....................2-9 Tightening torques..................2-14 Specified torques..................2-14 General torques..................2-15 62Y5A11...

  • Page 36: General Specifications

    SPEC Specifications General specifications Model Item Unit FT50CEHD FT50CED FT50CET Dimension Overall length mm (in) 1,384 (54.5) 718 (28.3) Overall width mm (in) 361 (14.2) Overall height mm (in) 1,436 (56.5) Boat transom height mm (in) 508 (20.0) Weight (with aluminum propeller) kg (lb) 111.5 (246) 108 (238)
  • Page 37 General specifications Model Item Unit FT50CEHD FT50CED FT50CET Fuel and oil Fuel type Unleaded gasoline/leaded gasoline Fuel rating RON* Engine oil type 4-stroke motor oil Engine oil grade SE, SF, SG, SH 10W-30, 10W-40, or 20W-40 Engine oil quantity (with oil filter replacement) 2.2 (2.3, 1.9) (US qt, lmp qt) (without oil filter replacement)

  • Page 38: Maintenance Specifications

    SPEC Specifications Maintenance specifications Power unit Model Item Unit FT50CEHD FT50CED FT50CET Power unit Minimum compression 840 (8.4, 122) pressure* (kgf/cm , psi) Lubrication oil pressure 100 (1.0, 14) at 55 °C (131 °F), with (kgf/cm , psi) 10W-30 engine oil @ 900 r/min Cylinder heads Warpage limit...
  • Page 39 Maintenance specifications Model Item Unit FT50CEHD FT50CED FT50CET 2nd ring Dimension B mm (in) 1.47–1.49 (0.058–0.059) Dimension T mm (in) 2.49–2.51 (0.098–0.099) End gap mm (in) 0.30–0.50 (0.012–0.020) Side clearance mm (in) 0.03–0.07 (0.001–0.003) Oil ring Dimension B mm (in) 2.34–2.46 (0.092–0.097) Dimension T mm (in)
  • Page 40 SPEC Specifications Model Item Unit FT50CEHD FT50CED FT50CET Margin thickness (D) Intake mm (in) 0.6–1.0 (0.024–0.039) Exhaust mm (in) 0.7–1.1 (0.028–0.043) Stem diameter Intake mm (in) 5.48–5.49 (0.2157–0.2161) Exhaust mm (in) 5.46–5.47 (0.2150–0.2153) Guide inside diameter Intake and exhaust mm (in) 5.50–5.51 (0.2165–0.2169) Stem-to-guide clearance Intake...

  • Page 41: Lower Unit

    Maintenance specifications Model Item Unit FT50CEHD FT50CED FT50CET Fuel pump Discharge L (US gal, 70 (18.5, 15.4) Imp gal)/hr @ 6,000 r/min Pressure 49 (0.49, 7.0) (kgf/cm , psi) Plunger stroke mm (in) 5.85–9.05 (0.23–0.35) Carburetor ID mark 62Y30, 62Y50 (for Brazil) Main jet #1: 124, #2: 126, #3: 116, #4: 114 Pilot jet...
  • Page 42 SPEC Specifications Model Item Unit FT50CEHD FT50CED FT50CET Pulser coil output peak voltage (W/R – W/B) (*1) @ cranking 1 (*1) @ cranking 2 @ 1,500 r/min @ 3,500 r/min 11.2 Ω (*2) Pulser coil resistance 396–594 (W/R – W/B) CDI unit output peak voltage (B/O –...
  • Page 43 Maintenance specifications Model Item Unit FT50CEHD FT50CED FT50CET Charging system Fuse Lighting coil output peak voltage (G – G) (*1) @ cranking 11.9 (*1) @ 1,500 r/min (*1) @ 3,500 r/min Ω (*2) Lighting coil resistance 1.2–1.8 (G – G) Rectifier Regulator output peak voltage (R –...
  • Page 44 SPEC Specifications Dimensions Exterior C1 L5 S62Y2230 62Y5A11...
  • Page 45 Maintenance specifications Model Symbol Unit FT50CEHD mm (in) 576 (22.7) mm (in) 272 (10.7) mm (in) 797 (31.4) mm (in) 560 (22.0) mm (in) 97 (3.8) mm (in) — mm (in) 990 (39.0) mm (in) — mm (in) 397 (15.6) mm (in) 189 (7.4) mm (in)
  • Page 46 SPEC Specifications Exterior 2-11 62Y5A11...
  • Page 47 Maintenance specifications Model Symbol Unit FT50CED FT50CET mm (in) 576 (22.7) mm (in) 142 (5.6) mm (in) — mm (in) 560 (22.0) mm (in) 97 (3.8) mm (in) — mm (in) 990 (39.0) mm (in) — mm (in) 397 (15.6) mm (in) 149 (5.9) mm (in)
  • Page 48 SPEC Specifications Clamp bracket Model Symbol Unit FT50CEHD FT50CED FT50CET mm (in) 126 (5.0) mm (in) 254 (10.0) mm (in) 163.5 (6.4) mm (in) 50.8 (2.0) mm (in) 180 (7.1) mm (in) 355 (14.0) mm (in) — mm (in) 139 (5.5) mm (in) 18.5 (0.7) mm (in)
  • Page 49 Maintenance specifications / Tightening torques Tightening torques Specified torques Tightening torques Part to be tightened Thread size N·m kgf·m ft·lb Power unit Flywheel magnet nut — Stator base screw Cover screw Negative battery lead bolt Positive battery lead nut — Oil pressure switch —...
  • Page 50 SPEC Specifications Tightening torques Part to be tightened Thread size N·m kgf·m ft·lb Bracket unit Tiller handle assembly nut — Throttle cable (short) locknut — Upper mount nut — Lower mount nut — Trim sensor screw Clamp bracket self-locking nut —...
  • Page 51 Periodic checks and adjustments Special service tools ..................3-1 Maintenance interval chart................3-2 Top cowling ....................3-3 Checking the top cowling................3-3 Fuel system ....................3-3 Checking the fuel joint and fuel hoses (fuel joint-to-carburetor) ....3-3 Checking the fuel filter ................3-3 Power unit.......................

  • Page 52: Chk Adj

    Periodic checks and adjustments Special service tools Oil filter wrench 90890-01426 Digital tachometer 90890-06760 Timing light 90890-03141 Leakage tester 90890-06762 62Y5A11...

  • Page 53: 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 to Item Remarks 10 hours 50 hours 100 hours 200 hours...

  • Page 54: Top Cowling

    Periodic checks and adjustments Top cowling Fuel system Checking the top cowling Checking the fuel joint and fuel 1. Check the fitting by pushing the cowling hoses (fuel joint-to-carburetor) with both hands. Adjust if necessary. 1. Remove the plate 1, and then check the fuel hose connections and fuel joint 2 for leaks.

  • Page 55: Power Unit

    Top cowling / Fuel system / Power unit Power unit 2. Place a drain pan under the drain hole, and then remove the drain bolt 2 and let Checking the engine oil the oil drain completely. 1. Place the outboard motor in an upright position.

  • Page 56: Checking The Timing Belt

    Periodic checks and adjustments 4. Apply a thin coat of the new engine oil to 7. Fill the specified engine oil into the oil the O-ring of the new oil filter. filler hole. 5. Install the oil filter, and then tighten it to Recommended engine oil: the specified torque.
  • Page 57 Power unit 2. Remove the spark plugs, fuel pump 2, and cylinder head cover 3. CAUTION: Do not turn the flywheel counterclock- wise, otherwise the valve system may be damaged. 6. Check the intake valve clearance for cyl- inders #3 and #4, and the exhaust valve clearance for cylinders #2 and #4.

  • Page 58: Checking The Spark Plugs

    Periodic checks and adjustments Valve clearance: Intake d: 0.20 ± 0.05 mm (0.008 ± 0.002 in) Exhaust e: 0.30 ± 0.05 mm (0.012 ± 0.002 in) 7. Loosen the locknut 4, and then turn the adjusting screw 5 until the specified valve clearance is obtained.

  • Page 59: Checking The Thermostat

    Power unit Checking the thermostat 1. Remove the cover 1, thermostat cover 2, and thermostat 3. Water Valve lift a temperature below 0 mm (0 in) 60 °C (140 °F) above more than 70 °C (158 °F) 3 mm (0.12 in) 5.

  • Page 60: Control System

    Periodic checks and adjustments 3. Check for water flow at the cooling water 4. Adjust the position of the throttle cable outlet. If there is no water flow, check the joint until its hole is aligned with the set pin d on the throttle cam. cooling water passage inside the out- board motor.

  • Page 61: Checking The Engine Idle Speed

    Power unit / Control system 1. Start the engine and warm it up for 5 min- utes. 2. Attach the special service tool to high- tension cord #1 1, and then check the engine idle speed. Adjust if out of specifi- cation.

  • Page 62: Checking The Ignition Timing

    Periodic checks and adjustments 4. Check that the TDC “T” mark a on the Checking the ignition timing flywheel magnet is aligned with the mag- 1. Start the engine and warm it up for 5 min- net base pointer b. utes.

  • Page 63: Checking The Power Trim And Tilt Fluid Level

    Control system / Power trim and tilt unit / Lower unit Checking the power trim and tilt fluid NOTE: level The fluid level should be at the brim of the 1. Fully tilt the outboard motor up, and then filler hole. support it with the tilt stop lever 1.

  • Page 64: Chk Adj

    Periodic checks and adjustments 4. Install the check screw, and then tighten 4. Insert the gear oil tube or gear oil pump it to the specified torque. into the drain hole and slowly fill the gear oil until oil flows out of the check hole and Check screw: no air bubbles are visible.

  • Page 65: Checking The Lower Unit (For Air Leakage)

    Lower unit / General Checking the lower unit Checking the propeller (for air leakage) 1. Check the propeller blades and splines for cracks, damage, or wear. Replace if 1. Remove the check screw 1, and then necessary. install the special service tool. S62Y3585 General Leakage tester: 90890-06762...

  • Page 66: Checking The Battery

    Periodic checks and adjustments S62Y3650 2. Check the specific gravity of the electro- lyte. Fully charge the battery if out of specification. WARNING Battery electrolyte is dangerous; it con- tains sulfuric acid which is poisonous and highly caustic. Always follow these preventive measures: È...

  • Page 67: Lubrication

    General NOTE: • Batteries vary per manufacturer. The pro- cedures mentioned in this manual may not always apply, therefore, consult the instruc- tion manual of the battery. • Disconnect the negative lead first, then the positive lead. Electrolyte specific gravity: 1.280 at 20 °C (68 °F) Lubrication 1.
  • Page 68 Periodic checks and adjustments 2. Apply anti-corrosion grease to the areas shown. 3-17 62Y5A11...

  • Page 69: Fuel

    FUEL Fuel system Special service tools ..................4-1 Hose routing ....................4-2 Fuel and blowby hoses................4-2 Fuel filter and fuel pump ................4-3 Checking the fuel pump................4-5 Disassembling the fuel pump ..............4-5 Checking the diaphragm and valves ............4-6 Assembling the fuel pump ................. 4-6 Carburetor unit ....................

  • Page 70: Fuel System

    FUEL Fuel system Special service tools Vacuum/pressure pump gauge set Vacuum gauge adaptor 90890-06756 (commercially obtainable) Digital tachometer 90890-06760 Vacuum gauge 90890-03159 Vacuum gauge (digital) (commercially obtainable) Vacuum gauge (4 analog meters) (commercially obtainable) 62Y5A11...

  • Page 71: Hose Routing

    Special service tools / Hose routing Hose routing Fuel and blowby hoses 1 Blowby hose 2 Hose (acceleration pump-to-carburetor) 3 Fuel hose (fuel joint-to-fuel filter) 4 Fuel hose (fuel filter-to-fuel pump) 5 Fuel hose (fuel pump-to-carburetor) 6 Hose (carburetor-to-carburetor) 62Y5A11...

  • Page 72: Fuel Filter And Fuel Pump

    FUEL Fuel system Fuel filter and fuel pump 62Y5A11...
  • Page 73 Fuel filter and fuel pump Part name Q’ty Remarks Fuel joint Fuel filter Fuel pump M6 × 25 mm Bolt Seal Fuel hose Fuel joint-to-fuel filter Clip M8 × 14 mm Bolt Bracket Fuel hose Fuel filter-to-fuel pump 205.0 mm (8.1 in) Fuel hose Fuel pump-to-carburetor Clip...

  • Page 74: Checking The Fuel Pump

    FUEL Fuel system Checking the fuel pump • To eliminate any gaps between the fuel pump valves and the fuel pump body 2, and 1. Install the special service tool onto the to ensure a better seal, make sure that the fuel pump as shown.

  • Page 75: Checking The Diaphragm And Valves

    Fuel filter and fuel pump 4. Assemble the cover 3, gasket 4, and 3. Slowly let up on the plunger and dia- seal 5 with the screws 6, and then phragm, and then remove them. install the fuel pump. Checking the diaphragm and valves 1.

  • Page 76: Carburetor Unit

    FUEL Fuel system Carburetor unit 62Y5A11...
  • Page 77 Carburetor unit Part name Q’ty Remarks Carburetor assembly Joint-to-silencer Clip Blowby hose Prime Start coupler M6 × 30 mm Bolt Collar Throttle link rod O-ring Not reusable 34.5 × 1.9 mm Insulator Dowel pin M6 × 25 mm Bolt Fuel hose Fuel pump-to-carburetor Clip Rivet...

  • Page 78: Carburetor

    FUEL Fuel system Carburetor 62Y5A11...
  • Page 79 Carburetor Part name Q’ty Remarks Carburetor body M4 × 13 mm Screw Cover Seal Not reusable Pilot jet Main jet Needle valve Main nozzle O-ring Not reusable Plug Float M4 × 6 mm Screw Float pin Gasket Not reusable Float chamber Drain screw O-ring Not reusable...

  • Page 80: Checking The Carburetor

    FUEL Fuel system Checking the carburetor 1. Check the air and fuel passages and jets, for dirt and foreign matter. Clean the car- buretor body with a petroleum based sol- vent if necessary. 2. Blow compressed air into all passages and jets.

  • Page 81: Checking The Prime Start

    Carburetor NOTE: • The float should be resting on the needle valve 4, but not compressing it. • Take measurements at the top of the float flange opposite its pivoted side. Float height a: 9.5–10.5 mm (0.37–0.41 in) Checking the Prime Start 1.

  • Page 82: Adjusting The Throttle Link Rod

    FUEL Fuel system 3. Install the pilot screw 9, turn it in until it is lightly seated, then out the specified number of turns. Throttle link rod length b: 144 mm (5.67 in) 4. Push the throttle control lever 1 to the fully open position as shown.

  • Page 83: Synchronizing The Carburetors

    Carburetor 5. After adjusting the idle speed, rev the engine a few times and let it idle for at Digital tachometer: 90890-06760 least 15 seconds to check the stability of the engine. Adjust the carburetor syn- 3. Turn the pilot screws 2 in direction a chronization if necessary.

  • Page 84: Adjusting The Dash-Pot (Acceleration Pump)

    FUEL Fuel system 6. Turn the throttle valve adjusting screws 5 to adjust the vacuum pressure of car- buretors #1, #2, and #3 to the same vac- uum variation as carburetor #4. 7. Adjust the engine idle speed to specifica- Vacuum gauge (digital) (commercially obtainable) 3: tion.
  • Page 85 Carburetor Digital tachometer: 90890-06760 3. Open the throttle cam 2 slowly, and check the engine speed when the accel- eration pump stopper 3 comes into con- tact with point a. 7. Open and close the throttle cam a few times, and check the engine speed at the operation point of dash-pot again.

  • Page 86: Powr

    POWR Power unit Special service tools ..................5-1 Power unit....................... 5-3 Checking the compression pressure ............5-13 Checking the oil pressure ................5-13 Removing the power unit.................5-13 Timing belt and sprockets................5-16 Removing the timing belt and sprockets..........5-17 Checking the timing belt and sprockets...........5-18 Installing the sprockets and timing belt............5-18 Cylinder head ....................5-21 Removing the cylinder head ..............
  • Page 87 Cylinder body ....................5-35 Removing and installing the oil filter ............5-37 Disassembling the cylinder body ............. 5-37 Checking the piston diameter ..............5-38 Checking the cylinder bore ..............5-38 Checking the piston clearance ..............5-39 Checking the piston rings ................5-39 Checking the piston ring grooves ............5-40 Checking the piston ring side clearance..........

  • Page 88: Special Service Tools

    POWR Power unit Special service tools Compression gauge Valve spring compressor attachment 90890-03160 90890-06320 Flywheel holder Valve guide remover/installer 90890-06522 90890-06801 Flywheel puller Valve guide reamer 90890-06521 90890-06804 Crankshaft holder 18 Valve seat cutter holder 90890-06562 90890-06316 Valve spring compressor Valve seat cutter 90890-04019 90890-06315, 90890-06323, 90890-06326,...
  • Page 89 Special service tools Bearing outer race attachment 90890-06626 Oil filter wrench 90890-01426 Piston slider 90890-06529 62Y5A11...

  • Page 90: Power Unit

    POWR Power unit Power unit 62Y5A11...
  • Page 91 Power unit Part name Q’ty Remarks Flywheel magnet Stator coil Cover Grommet Washer M6 × 25 mm Bolt Lighting coil coupler Charge coil coupler Stator base Pulser coil coupler M6 × 24 mm Screw Dowel pin Woodruff key Cover M6 × 35 mm Screw 62Y5A11...
  • Page 92 POWR Power unit 62Y5A11...
  • Page 93 Power unit Part name Q’ty Remarks Throttle cable Shift cable Fuel pump Fuel filter assembly Carburetor assembly M6 × 20 mm Bolt Plate Clip Clip Grommet Holder Bolt O-ring Not reusable 24.4 × 3.1 mm Clip Fuel hose Fuel pump-to-carburetor Bolt Clip Fuel hose...
  • Page 94 POWR Power unit 62Y5A11...
  • Page 95 Power unit Part name Q’ty Remarks Power trim and tilt relay ET model M8 × 16 mm Bolt Negative battery lead Wiring harness extension Grommet Spring washer Positive battery lead PTT relay positive lead ET model Fuse holder lead Clip Warning indicator coupler EHD model Trailer switch coupler...
  • Page 96 POWR Power unit 62Y5A11...
  • Page 97 Power unit Part name Q’ty Remarks Bracket Starter motor Spark plug cap Ignition coil Wiring harness Thermoswitch Holder M6 × 12 mm Bolt Ground lead M6 × 12 mm Bolt Oil pressure switch Oil pressure switch lead Screw Ignition coil lead M6 ×...
  • Page 98 POWR Power unit Part name Q’ty Remarks Power unit Engine oil dipstick Gasket Not reusable Dowel pin M6 × 16 mm Bolt M8 × 80 mm Bolt Apron M6 × 24 mm Screw 5-11 62Y5A11...
  • Page 99 Power unit Part name Q’ty Remarks Throttle link rod Throttle cam Throttle control lever Clip Bushing M6 × 20 mm Bolt Spring Collar Bracket M6 × 30 mm Bolt Shift rod M6 × 30 mm Bolt Bracket Spring Bolt 5-12 62Y5A11...

  • Page 100: Checking The Compression Pressure

    POWR Power unit Checking the compression pressure • If the compression pressure does not increase, check the valve clearance, valve, 1. Start the engine, warm it up for 5 min- valve seat, cylinder sleeve, cylinder head utes, and then turn it off. gasket, and cylinder head.
  • Page 101 Power unit 3. Disconnect the fuel hose 3 and throttle link rod 4. CAUTION: • Apply force in the direction of the arrows shown, to prevent the flywheel holder from slipping off easily. • To prevent damage to the engine or tools, screw in the flywheel puller set bolts evenly and completely so that the flywheel puller plate is parallel to the fly-...
  • Page 102 POWR Power unit 4. Disconnect the battery leads 5, 10-pin coupler 6, PTT relay leads 7 (ET), PTT motor leads 8 (ET), ground lead 9 (ET), warning indicator coupler 0 (EHD), trailer switch coupler A (ET), pilot water hose B. 5.

  • Page 103: Timing Belt And Sprockets

    Power unit / Timing belt and sprockets Timing belt and sprockets Part name Q’ty Remarks Timing belt Drive sprocket Driven sprocket Bolt M8 × 20 mm Bolt Tensioner Spring Retaining plate Woodruff key M10 × 40 mm Bolt Washer M6 × 20 mm Bolt Blowby hose Clip...

  • Page 104: Removing The Timing Belt And Sprockets

    POWR Power unit 3. Remove the tensioner 4 and timing belt Removing the timing belt and 5 from the driven sprocket side. sprockets 1. Set the cylinder #1 piston position to TDC of the compression stroke by align- ing the “1” mark a on the driven sprocket with the “...

  • Page 105: Checking The Timing Belt And Sprockets

    Timing belt and sprockets Installing the sprockets and timing belt 1. Check that the “1” mark a on the driven sprocket 1 is aligned with the “ ” mark b on the cylinder head, and then tighten the bolt 2. 2.
  • Page 106 POWR Power unit 3. Check that the “ ” mark c on the retain- 5. Install the tensioner 8 and bolts, and ing plate is aligned with the “ ” mark d then tighten the bolts finger tight. on the cylinder body. 4.
  • Page 107 Timing belt and sprockets CAUTION: Crankshaft holder 18 B: 90890-06562 Do not turn the sprockets counterclock- wise, otherwise the valve system may be damaged. Drive sprocket nut 6: 140 N·m (14 kgf·m, 100 ft·lb) 9. Tighten the driven sprocket bolt 2 to the specified torque.

  • Page 108: Cylinder Head

    POWR Power unit Cylinder head 5-21 62Y5A11...
  • Page 109 Cylinder head Part name Q’ty Remarks Cylinder head Oil pump Cylinder head cover M6 × 20 mm Bolt Cylinder head cover gasket Not reusable M9 × 95 mm Bolt Spark plug M6 × 25 mm Bolt Dowel pin Cylinder head gasket Not reusable Grommet Anode...
  • Page 110 POWR Power unit Part name Q’ty Remarks Rocker arm assembly Rocker arm shaft Exhaust valve Intake valve Camshaft Valve cotter Spring retainer Valve spring Spring seat Stem seal Not reusable Valve guide Not reusable Retaining bolt Gasket Not reusable Oil seal Not reusable M8 ×...

  • Page 111: Removing The Cylinder Head

    Cylinder head Removing the cylinder head 1. Check that the camshaft dowel pin hole a is in the position shown in the illustra- tion. Adjust if necessary. S62Y5260 CAUTION: 2. Remove the cylinder head cover bolts in the sequence shown. Do not scratch or damage the mating sur- faces of the cylinder head and cylinder body.

  • Page 112: Checking The Valve Springs

    POWR Power unit 5. Remove the retaining bolt 4, then the • When replacing the valve, also replace the camshaft 5 by pulling it downward. valve guide and stem seal. Valve spring compressor 6: 90890-04019 Valve spring compressor attachment 90890-06320 Checking the valve springs 1.

  • Page 113: Checking The Valve Guides

    Cylinder head Valve stem runout: Intake: 0.03 mm (0.0012 in) Exhaust: 0.03 mm (0.0012 in) Checking the valve guides 1. Measure the valve guide inside diameter a. Replace if out of specification. Valve margin thickness a: Intake: 0.6–1.0 mm (0.024–0.039 in) Exhaust: 0.7–1.1 mm (0.028–0.043 in) 3.

  • Page 114: Checking The Valve Seat

    POWR Power unit 2. Install the new valve guide 2 by striking 4. Measure the valve guide inside diameter. the special service tool from the cam- Replace the valve guide if out of specifi- shaft side until the valve guide clip 3 cation.

  • Page 115: Refacing The Valve Seat

    Cylinder head 2. Cut the surface of the valve seat with a 45° cutter by turning the cutter clockwise until the valve seat face has become smooth. Valve seat contact width a: Intake: 0.9–1.1 mm (0.035–0.043 in) Exhaust: 0.9–1.1 mm (0.035–0.043 in) a Slag or rough surface Refacing the valve seat CAUTION:...
  • Page 116 POWR Power unit 60° S62Y5461 b Previous contact width b Previous contact width 5. Use a 45° cutter to adjust the contact 8. If the valve seat contact area is too nar- width of the valve seat to specification. row and situated near the bottom edge of the valve face, use a 60°...

  • Page 117: Checking The Rocker Arms And Rocker Arm Shaft

    Cylinder head 10. After every lapping procedure, be sure to Cam lobe a: clean off any remaining lapping com- Intake: pound from the cylinder head and the 30.89–30.99 mm valve. (1.2161–1.2200 in) 11. Check the valve seat contact area of the Exhaust: valve again.

  • Page 118: Checking The Cylinder Head

    POWR Power unit Camshaft journal diameter c: 36.93–36.94 mm (1.4539–1.4543 in) #2, #3, #4: 36.94–36.95 mm (1.4543–1.4547 in) Cylinder head journal inside diameter d: 37.00–37.02 mm (1.4567–1.4575 in) 4. Calculate the camshaft oil clearance e as follows. Replace the camshaft and cylinder head as a set if out of specifica- tion.

  • Page 119: Installing The Valves

    Cylinder head Installing the valves 3. Compress the valve spring, and then install the valve cotter 8 using a thin 1. Install the new valve stem seal 1 to the screwdriver with a small amount of valve guide, and then apply engine oil to grease applied to it.

  • Page 120: Installing The Camshaft

    POWR Power unit Installing the camshaft 1. Install the new oil seal 1. S62Y5650 2. Assembly the rocker arm 1 and rocker arm shaft 2, and the tensioner 3, rocker arm retainer 4 by installing the bolts. S62Y5630J Bearing outer race attachment: 90890-06626 2.

  • Page 121: Installing The Cylinder Head

    Cylinder head 3. Install the rocker arm shaft assembly to the cylinder head by installing the bolts, and then tighten them to the specified torque and in the sequence shown. CAUTION: Do not reuse the cylinder head gasket, always replace it with a new one. Bolt: 18 N·m (1.8 kgf·m, 13 ft·lb) NOTE: Apply engine oil to the cylinder head bolts...

  • Page 122: Cylinder Body

    POWR Power unit Cylinder body 5-35 62Y5A11...
  • Page 123 Cylinder body Part name Q’ty Remarks Oil filter Crankshaft M8 × 82 mm Bolt M6 × 35 mm Bolt Crankcase Oil seal Not reusable Main bearing Oil seal Not reusable Connecting rod bearing Connecting rod cap Bolt Dowel pin Cylinder body Connecting rod Piston pin clip Not reusable...

  • Page 124: Removing And Installing The Oil Filter

    POWR Power unit Removing and installing the oil filter 1. Place a rag under the oil filter, and then remove the filter. S62Y5710 Oil filter wrench: 90890-01426 S62Y5690 Oil filter wrench: 90890-01426 Oil filter: 18 N·m (1.8 kgf·m, 13 ft·lb) NOTE: Disassembling the cylinder body Be sure to clean up any oil spills.

  • Page 125: Checking The Piston Diameter

    Cylinder body Piston diameter a: 62.95–62.96 mm (2.478–2.479 in) Measuring point b: 5 mm (0.2 in) up from the bottom of the piston skirt Oversize piston diameter: Oversize 1: +0.25 mm (0.01 in) Oversize 2: +0.50 mm (0.02 in) CAUTION: Checking the cylinder bore Do not scratch or damage the mating sur- ) a at...

  • Page 126: Checking The Piston Clearance

    POWR Power unit 2. Level the piston ring 1 in the cylinder 2. Calculate the taper limit. Replace or rebore the cylinder body if out of specifi- with the piston crown of an inverted pis- cation. ton. 3. Check the piston ring end gap d at the Taper limit = maximum of D or D –...

  • Page 127: Checking The Piston Ring Grooves

    Cylinder body Checking the piston ring grooves Piston ring side clearance: 1. Measure piston ring grooves. Top ring a: Replace the piston if out of specification. 0.04–0.08 mm (0.002–0.003 in) Second ring b: 0.03–0.07 mm (0.001–0.003 in) Oil ring c: 0.05–0.19 mm (0.002–0.007 in) Checking the piston pin boss bore 1.

  • Page 128: Checking The Connecting Rod Small End Inside Diameter

    POWR Power unit Checking the connecting rod small end inside diameter 1. Measure the connecting rod small end 5 mm (0.2 in) inside diameter a. Replace the connect- ing rod if out of specification. 10 mm (0.4 in) S62Y5850 Connecting rod bolt thread diameter limit (difference between a and b): 0–0.1 mm (0–0.004 in) Checking the crankshaft...

  • Page 129: Checking The Crankshaft Main Journal Oil Clearance

    Cylinder body Crankshaft journal diameter a: CAUTION: 42.984–43.000 mm Install the bearings in their original posi- (1.6923–1.6929 in) tions. Crank pin diameter b: 32.984–33.000 mm NOTE: (1.2986–1.2992 in) Insert the projection a of the bearing into the Crank pin width c: notch in the cylinder body.

  • Page 130: Checking The Crankshaft Pin Oil Clearance

    POWR Power unit 7. Tighten the crankcase bolts to the speci- Crankshaft main journal oil fied torques in two stages and in the clearance: sequence shown. 0.012–0.036 mm (0.0005–0.0014 in) Checking the crankshaft pin oil clearance 1. Clean the bearings and the connecting rod.
  • Page 131 Cylinder body NOTE: NOTE: Be sure not to put the Plastigauge (PG-1) Do not turn the connecting rod until the crank over the oil hole in the crank pin of the crank- pin oil clearance measurement has been shaft. completed. 4.

  • Page 132: Selecting The Crankshaft Main Journal Bearing

    POWR Power unit Selecting the crankshaft main 4. When installing the main bearing, insert the projection of the main bearing into journal bearing the slot on the cylinder body. 1. When replacing the main bearing, select the suitable bearing as follows. CAUTION: Remove any small metal particles and oil 2.

  • Page 133: Assembling The Cylinder Body

    Cylinder body 3. Select the suitable color a for the con- Crank pin oil clearance: necting rod bearing from the table. 0.016–0.040 mm (0.0006–0.0015 in) 6. If the oil clearance is below specification, check the connecting rod bearing color and clean the contact surface of the con- necting rod and the connecting rod bear- ing, and then check the crank pin oil clearance again.
  • Page 134 POWR Power unit NOTE: • Face the embossed “Y11” mark a on the connecting rod in the same direction as the “UP” mark b on the piston. • Always use new piston pin clips, and do not allow the piston pin clip end to align with the piston pin slot c.
  • Page 135 Cylinder body 6. Install half of the bearings 9 into the cyl- inder body 0. NOTE: Insert the projection f of the bearing into the notch in the cylinder body. S62Y5A80 7. Set the crankshaft A, and oil seals B and C into the cylinder body as shown.

  • Page 136: Installing The Power Unit

    POWR Power unit ® 10. Apply Gasket Maker to the mating sur- NOTE: face of the crankcase. Apply engine oil to the crankcase bolt (M8) before installation. Crankcase bolt (M8): 1st: 15 N·m (1.5 kgf·m, 11 ft·lb) 2nd: 30 N·m (3.0 kgf·m, 22 ft·lb) Crankcase bolt (M6): 1st: 6 N·m (0.6 kgf·m, 4.3 ft·lb) 2nd: 12 N·m (1.2 kgf·m, 8.7 ft·lb)
  • Page 137 Cylinder body Mounting bolt 4: 6. Connect the throttle link rod G and fuel hose H. 21 N·m (2.1 kgf·m, 15 ft·lb) 4. Install the shift rod bolts 6, shift rod 7 and power trim and tilt relay 8. 5. Connect the pilot water hose 9, trailer switch coupler 0 (ET), warning indicator coupler A (EHD), ground lead B (ET), PTT motor leads C (ET), PTT relay...
  • Page 138 POWR Power unit NOTE: Apply engine oil to the flywheel magnet nut before installation. Flywheel holder: 90890-06522 Flywheel magnet nut: 160 N·m (16 kgf·m, 116 ft·lb) 8. Install the Woodruff key. 9. Install the flywheel magnet and flywheel magnet cover. CAUTION: Apply force in the direction of the arrows shown, to prevent the flywheel holder...

  • Page 139: Lowr

    LOWR Lower unit Special service tools ..................6-1 Lower unit ....................... 6-5 Removing the lower unit ................6-6 Water pump and shift rod................6-7 Removing the water pump and shift rod............ 6-9 Checking the water pump and shift rod .............6-9 Installing the water pump and shift rod............6-9 Propeller shaft housing ................

  • Page 140: Lower Unit

    LOWR Lower unit Special service tools Stopper guide plate Bearing puller claw 1 90890-06501 90890-06536 Center bolt Needle bearing attachment 90890-06504 90890-06610, 90890-06611, 90890-06612, 90890-06614 Bearing separator 90890-06534 Driver rod L3 90890-06652 Stopper guide stand 90890-06538 Driver rod SS 90890-06604 Bearing puller 90890-06535 Bearing depth plate...
  • Page 141 Special service tools Bearing inner race attachment Driver rod SL 90890-06639, 90890-06643, 90890-06661, 90890-06602 90890-06662 Bearing outer race attachment Drive shaft holder 4 90890-06621, 90890-06626 90890-06518 Driver rod LS Pinion nut holder 90890-06606 90890-06505 Driver rod LL Bearing outer race puller 90890-06605 90890-06523 Pinion height gauge...

  • Page 142: Lower Unit

    LOWR Lower unit Digital caliper Dial gauge set 90890-06704 90890-01252 Shimming plate Magnet base 90890-06701 90890-06705 Shift rod push arm Ring nut wrench 3 90890-06052 90890-06511 Backlash indicator Ring nut wrench extension 90890-06706 90890-06513 Magnet base plate Bearing housing puller claw L 90890-07003 90890-06502 62Y5A11...
  • Page 143 Special service tools Ball bearing attachment 90890-06655 Socket adapter 2 90890-06507 62Y5A11...
  • Page 144 LOWR Lower unit Lower unit Part name Q’ty Remarks Lower unit Plastic tie Not reusable Hose Check screw Gasket Not reusable Dowel pin M10 × 40 mm Bolt Drain screw Grommet M10 × 45 mm Bolt M8 × 60 mm Bolt Thrust washer Propeller...

  • Page 145: Removing The Lower Unit

    Lower unit Removing the lower unit 1. Drain the gear oil. For draining proce- dures, see Chapter 3, “Replacing the gear oil.” 2. Set the gearshift to the neutral position, and place a block of wood between the anti-cavitation plate and propeller to keep the propeller from turning, and then remove the propeller nut and propeller.

  • Page 146: Water Pump And Shift Rod

    LOWR Lower unit Water pump and shift rod 62Y5A11...
  • Page 147 Water pump and shift rod Part name Q’ty Remarks Shift rod assembly Oil seal Not reusable Oil seal housing O-ring Not reusable 49.4 × 3.1 mm Circlip Shift rod O-ring Not reusable 6.8 × 1.9 mm M6 × 16 mm Bolt Woodruff key M8 ×...

  • Page 148: Removing The Water Pump And Shift Rod

    LOWR Lower unit Removing the water pump and shift 1. Remove the water pump assembly and shift rod assembly 1. NOTE: Pull up the shift rod assembly a little a to dis- connect it from the shift slider 2, turn it coun- terclockwise 90°...
  • Page 149 Water pump and shift rod S62Y6580K NOTE: Align the insert plate cartridge projection c with the hole d in the pump housing. 8. Install the new gasket E, pump housing assembly D, and dowel pins F to the lower case. 9.

  • Page 150: Propeller Shaft Housing

    LOWR Lower unit Propeller shaft housing 6-11 62Y5A11...
  • Page 151 Propeller shaft housing Part name Q’ty Remarks Propeller shaft assembly Propeller shaft housing assembly Ball Slider Shift plunger Cross pin Dog clutch Spring Propeller shaft Washer Straight key Claw washer Ring nut Reverse gear Thrust washer Ball bearing O-ring Not reusable 86.8 ×...

  • Page 152: Removing The Propeller Shaft Housing Assembly

    LOWR Lower unit Removing the propeller shaft housing assembly 1. Straighten the claw washer tabs a, and then remove the ring nut and claw washer. Bearing separator 1: 90890-06534 Stopper guide plate 2: 90890-06501 Ring nut wrench 3 1: 90890-06511 Stopper guide stand 3: Ring nut wrench extension 2: 90890-06538...

  • Page 153: Disassembling The Propeller Shaft Assembly

    Propeller shaft housing S62Y6640 Needle bearing attachment 0: 3. Check the bearings for pitting or rum- 90890-06612 bling. Replace if necessary. Driver rod L3 A: 90890-06652 Disassembling the propeller shaft assembly 1. Remove the spring 1, and then remove the cross pin 2, dog clutch 3, slider and shift plunger.

  • Page 154: Assembling The Propeller Shaft Assembly

    LOWR Lower unit Assembling the propeller shaft 2. Apply grease to the new oil seals, and then install them into the propeller shaft assembly housing to the specified depth. 1. Install the dog clutch as shown. NOTE: NOTE: Install an oil seal halfway into the propeller Install the dog clutch 1 with the “F”...

  • Page 155: Installing The Propeller Shaft Housing

    Propeller shaft housing 4. Install the reverse gear assembly to the 3. Install the propeller shaft housing assem- bly 4 into the lower case, and then propeller shaft housing using a press. install the straight key 5, claw washer 6, and ring nut 7. 4.

  • Page 156: Drive Shaft And Lower Case

    LOWR Lower unit Drive shaft and lower case 6-17 62Y5A11...
  • Page 157 Drive shaft and lower case Part name Q’ty Remarks Drive shaft Taper roller bearing Not reusable Bearing outer race Not reusable Pinion shim — As required Sleeve Hose 200.0 mm (7.9 in) Plastic tie Not reusable Joint Water inlet cover Screw Seal Plate...

  • Page 158: Removing The Drive Shaft

    LOWR Lower unit Removing the drive shaft 1. Remove the drive shaft assembly and pinion, and then pull out the forward gear. S62Y6740K CAUTION: Do not reuse the bearing, always replace it with a new one. S62Y6850K Drive shaft holder 4 1: 90890-06518 Pinion nut holder 2: 90890-06505 Bearing separator 1: 90890-06534 Socket adapter 2 3: 90890-06507...

  • Page 159: Disassembling The Lower Case

    Drive shaft and lower case Disassembling the lower case 1. Remove the taper roller bearing outer race and shim(s). Needle bearing attachment 7: 90890-06611 Driver rod L3 8: 90890-06652 NOTE: Install the claws as shown. Checking the pinion and forward gear 1.

  • Page 160: Checking The Lower Case

    LOWR Lower unit Checking the lower case CAUTION: 1. Check the skeg and torpedo for cracks or Add or remove shims, if necessary, when damage. Replace if necessary. replacing the pinion or lower case. Assembling the lower case 1. Install the needle bearing into the lower NOTE: case to the specified depth.

  • Page 161: Assembling The Drive Shaft

    Drive shaft and lower case NOTE: Use the special service tool or a general pipe with the specified measurements. Bearing inner race attachment 1: 90890-06643 Installing the pinion 1. Install the forward gear, then the drive shaft assembly, pinion, and pinion nut, Bearing inner race attachment 1: and then tighten the nut to the specified 90890-06662...
  • Page 162 LOWR Lower unit 2. Install the two dowel pins 1 to the lower 5. Install the propeller and propeller nut, unit. tighten the nut finger tight. Place a block of wood between the anti-cavitation plate 3. Install the lower unit to the upper case, and propeller to keep the propeller from and then tighten the bolts to the specified turning, and then tighten the nut to the...

  • Page 163: Shimming

    Drive shaft and lower case / Shimming Shimming 6-24 62Y5A11...

  • Page 164: Selecting The Pinion Shims

    LOWR Lower unit Shimming Pinion nut: NOTE: 95 N·m (9.5 kgf·m, 69 ft·lb) • Shimming is not required when assembling the original lower case and inner parts. 3. Measure the distance (M) between the • Shimming is required when assembling the shimming tool and the pinion as shown.

  • Page 165: Selecting The Forward Gear Shims

    Shimming Example: If “M” is “32.10 mm” and “P” is “+5”, then T3 = 32.10 – 31.50 – (+5)/100 mm = 0.60 – 0.05 mm = 0.55 mm If “M” is “32.10 mm” and “P” is “–5”, then T3 = 32.10 – 31.50 – (–5)/100 mm = 0.60 + 0.05 mm = 0.65 mm 5.

  • Page 166: Selecting The Reverse Gear Shims

    LOWR Lower unit Example: If “M” is “24.00 mm” and “F” is “+5”, then Shift rod push arm: 90890-06052 T1 = 24.50 + (+5)/100 – 24.00 mm = 0.50 + 0.05 mm = 0.55 mm If “M” is “24.00 mm” and “F” is “–5”, then 3.
  • Page 167 Shimming / Backlash NOTE: Install the dial gauge so that the plunger a contacts the mark b on the backlash indica- tor. Backlash indicator 4: 90890-06706 Magnet base plate 5: 90890-07003 Dial gauge set 6: 90890-01252 Magnet base 7: 90890-06705 5.

  • Page 168: Brkt

    BRKT Bracket unit Special service tools ..................7-1 Tiller handle ....................7-2 Bottom cowling ....................7-7 Checking the throttle cable and shift rod ........... 7-9 Assembling the tiller handle............... 7-9 Lubricating the throttle gear..............7-10 Checking the shift rod assembly operation..........7-10 Upper case....................
  • Page 169 Power trim and tilt motor................7-43 Checking the power trim and tilt motor ............7-44 Assembling the power trim and tilt motor ..........7-45 Installing the power trim and tilt ...............7-45 Power trim and tilt electrical system............7-47 Checking the fuse..................7-48 Checking the power trim and tilt relay .............7-48 Checking the trailer switch...............

  • Page 170: Special Service Tools

    BRKT Bracket unit Special service tools Cylinder-end screw wrench 90890-06544 Digital circuit tester 90890-03174 62Y5A11...

  • Page 171: Tiller Handle

    Special service tools / Tiller handle Tiller handle Part name Q’ty Remarks M8 × 30 mm Bolt Wing nut Friction piece M6 × 35 mm Bolt Friction rod Washer Washer Link rod Plate M6 × 20 mm Bolt Grommet Cable guide Grommet Plastic tie Battery lead...
  • Page 172 BRKT Bracket unit 62Y5A11...
  • Page 173 Tiller handle Part name Q’ty Remarks Tiller handle Tiller handle wiring harness Clip Shift rod Bushing M12 × 70 mm Bolt Clip Throttle cable Plastic washer Metal washer Wave washer Gear Throttle shaft M6 × 25 mm Bolt Friction piece Wing nut M6 ×...
  • Page 174 BRKT Bracket unit 62Y5A11...
  • Page 175 Tiller handle Part name Q’ty Remarks Bracket M6 × 16 mm Bolt M6 × 16 mm Bolt Shift arm guide Washer Washer Bushing Tiller handle bracket Bushing Engine stop switch M6 × 20 mm Bolt Engine start switch housing M6 × 12 mm Screw Connector Black...

  • Page 176: Bottom Cowling

    BRKT Bracket unit Bottom cowling 62Y5A11...
  • Page 177 Bottom cowling Part name Q’ty Remarks Shift rod assembly Bottom cowling Bolt Spring Ball Shift rod bracket Cotter pin Not reusable Washer Bushing Bushing Shift rod Grommet Rubber seal M6 × 30 mm Bolt Grommet M6 × 14 mm EHD model Screw Warning indicator EHD model...

  • Page 178: Checking The Throttle Cable And Shift Rod

    BRKT Bracket unit 2. Install the throttle cable 3 into the gear Checking the throttle cable and shift 4 until the inner cable is engaged with the gear. 1. Check the operation of the throttle cable and shift rod. 3. Turn the throttle shaft 1 clockwise to wind the inner cable around the gear 4.

  • Page 179: Lubricating The Throttle Gear

    Bottom cowling Lubricating the throttle gear 1. Inject grease into the grease nipple until grease comes out from the screw hole Checking the shift rod assembly operation 1. Check the shift rod assembly and detent for smooth operation. 7-10 62Y5A11...

  • Page 180: Upper Case

    BRKT Bracket unit Upper case 7-11 62Y5A11...
  • Page 181 Upper case Part name Q’ty Remarks Upper case Washer M8 × 30 mm Bolt Upper mount Plate M8 × 175 mm Bolt M12 × 160 mm Bolt Grommet Ground lead Screw Mount cover M8 × 25 mm Bolt Mount housing Spring Washer Rubber washer...
  • Page 182 BRKT Bracket unit 7-13 62Y5A11...
  • Page 183 Upper case Part name Q’ty Remarks Oil seal Not reusable Exhaust guide Grommet Grommet Anode Cover Bolt Cover Bolt Gasket Not reusable Dowel pin M6 × 25 mm Bolt Oil pan Gasket Not reusable Exhaust manifold M6 × 45 mm Bolt Gasket Not reusable...

  • Page 184: Disassembling The Oil Pan

    BRKT Bracket unit Disassembling the oil pan 1. Check the oil strainer and relief valve for dirt and residue. Clean if necessary. 1. Remove the muffler 1 from the oil pan Assembling the oil pan 2. Remove the exhaust manifold 3 from 1.
  • Page 185 Upper case 9. Install the muffler assembly 0 by insert- ing the tip of the water pipe 4 into the joint hole a of the upper case. 7. Tighten the exhaust manifold bolts 7, then the oil pan bolts 8. 8.

  • Page 186: Installing The Upper Case

    BRKT Bracket unit Installing the upper case NOTE: 1. Install the upper mount 1 and bolts 2 Be sure to install the ground lead 8 into the into the upper case, and then tighten the mount housing 6. bolts 3. 4.

  • Page 187: Clamp Brackets

    Upper case / Clamp brackets Clamp brackets Part name Q’ty Remarks Swivel bracket assembly M6 × 15 mm ET model Screw Trim sensor ET model Trim sensor coupler ET model Plastic tie Not reusable Self-locking nut M6 × 25 mm Bolt Anode Port clamp bracket...

  • Page 188: Removing The Clamp Brackets

    BRKT Bracket unit Removing the clamp brackets NOTE: 1. Remove the power trim and tilt or hydro Adjust the trim sensor after installing the tilt. removing procedures, power trim and tilt. “Removing the power trim and tilt/hydro tilt” in this chapter. 2.

  • Page 189: Adjusting The Trim Sensor

    Clamp brackets 5. Measure the trim sensor resistance. Repeat steps 1–5 if out of specification. Adjusting the trim sensor 1. Fully tilt the outboard motor up, and then Trim sensor setting resistance: support it with the tilt stop lever 1. Pink (P) –...

  • Page 190: Swivel Bracket And Steering Arm

    BRKT Bracket unit Swivel bracket and steering arm 7-21 62Y5A11...
  • Page 191 Swivel bracket and steering arm Part name Q’ty Remarks Steering arm Washer Bushing O-ring Not reusable 28.9 × 3.8 mm Bushing Swivel bracket Bushing Port tilt stop lever Circlip Steering yoke Bushing Bushing Tilt stop lever joint Spring holder M6 × 10 mm Bolt Spring Bushing...

  • Page 192: Removing The Steering Arm

    BRKT Bracket unit Removing the steering arm 1. Remove the circlip 1. 2. Remove the steering yoke 2 by striking it with a plastic hammer. 4. Install the steering arm 5 into the steer- ing yoke 0 by aligning the center a of the yoke with the center b of the steer- ing arm.
  • Page 193 Swivel bracket and steering arm 6. Inject grease into the grease nipple until grease comes out from both the upper and lower bushings c. 7-24 62Y5A11...

  • Page 194: Power Trim And Tilt Unit

    BRKT Bracket unit Power trim and tilt unit Part name Q’ty Remarks Power trim and tilt ET model Hydro tilt EHD/ED models Plastic tie Not reusable PTT motor lead Washer M8 × 16 mm Bolt Circlip ET model Shaft ET model Bushing ET model Collar...

  • Page 195: Removing The Power Trim And Tilt/Hydro Tilt

    Power trim and tilt unit Removing the power trim and tilt/hydro tilt 1. Fully tilt the outboard motor up, and then support it with the tilt stop lever 1. WARNING After tilting up the outboard motor, be sure to support it with the tilt stop lever. Otherwise, the outboard motor could sud- denly lower if the power trim and tilt unit should lose fluid pressure.

  • Page 196: Tilt Cylinder And Trim Cylinder

    BRKT Bracket unit Tilt cylinder and trim cylinder 7-27 62Y5A11...
  • Page 197 Tilt cylinder and trim cylinder Part name Q’ty Remarks Power trim and tilt motor Tilt cylinder end screw M5 × 20 mm Bolt O-ring Not reusable Joint O-ring Not reusable Ball O-ring Not reusable 28.7 × 3.5 mm Free piston Valve seal Circlip Circlip...

  • Page 198: Trim Cylinder

    BRKT Bracket unit Trim cylinder 7-29 62Y5A11...
  • Page 199 Trim cylinder Part name Q’ty Remarks Tilt ram Dust seal Not reusable Backup ring O-ring Not reusable 16.8 × 2.4 mm Tilt cylinder end screw O-ring Not reusable Backup ring O-ring Not reusable 16.8 × 2.4 mm Trim cylinder end screw O-ring Not reusable O-ring...

  • Page 200: Gear Pump

    BRKT Bracket unit Gear pump 7-31 62Y5A11...
  • Page 201 Gear pump Part name Q’ty Remarks M5 × 8 mm Bolt Relief valve bracket M6 × 45 mm Bolt Adapter Up-relief spring 17.5 mm (0.69 in) Valve support pin Relief valve seal Down-relief spring 14.2 mm (0.56 in) Valve support pin Relief valve seal Filter Gear pump...
  • Page 202 BRKT Bracket unit 7-33 62Y5A11...
  • Page 203 Gear pump Part name Q’ty Remarks M5 × 20 mm Bolt Washer Gear pump bracket O-ring Not reusable 5.8 × 1.9 mm Spring Spacer Down-shuttle piston Up-shuttle piston Manual release spring Ball Gear pump cover Down-main valve O-ring Not reusable Valve seal Circlip Drive gear...

  • Page 204: Disassembling The Tilt Cylinder

    BRKT Bracket unit Disassembling the tilt cylinder NOTE: 1. Hold the power trim and tilt 1 in a vise Place the trim cylinder in the vise horizon- using aluminum plates a on both sides. tally. 2. Loosen the trim cylinder end screw 2, and then remove it.

  • Page 205: Checking The Tilt Cylinder And Trim Cylinder

    Gear pump 1. Check the power trim and tilt/hydro tilt for cracks or corrosion. Replace if neces- sary. 2. Check the inner walls of the trim cylinder and tilt cylinder for scratches. Replace if necessary. 3. Check the outer surface of the tilt piston and free piston for scratches.

  • Page 206: Checking The Filters

    BRKT Bracket unit 4. Check the down-relief valve 3, up-relief 2. Install the balls 6 into the gear pump valve 4, and shuttle pistons 5 for dirt or housing 5. residue. Clean if necessary. 3. Install the down-main valve 7 and up- main valve 8.

  • Page 207: Assembling The Trim Cylinder

    Gear pump 9. Install the relief valve bracket H by Gear pump bolt L: installing the bolts I, then tightening 6.5 N·m (0.65 kgf·m, 4.7 ft·lb) them to the specified torque. 12. Fill the reservoir with the recommended fluid to the correct level as shown. Recommended power trim and tilt fluid: ATF Dexron II...
  • Page 208 BRKT Bracket unit 2. Install the O-ring 3 to the end screw. 8. Install balls F and G, absorber valve pin H, spring I, pins J and K, and washer 3. Install the tilt ram 4 into the end screw. L into the tilt piston.

  • Page 209: Assembling The Tilt Cylinder

    Gear pump 4. Hold the power trim 0 and in a vise using aluminum plates a on both sides. CAUTION: Do not damage the check valve b when tightening the end screw. Cylinder-end screw wrench: 90890-06544 Trim cylinder end screw N: 5.

  • Page 210: Bleeding The Power Trim And Tilt (Not Installed)

    BRKT Bracket unit 7. Install the tilt cylinder end screw C, and then tighten it to the specified torque. Cylinder-end screw wrench: 90890-06544 Tilt cylinder end screw C: 90 N·m (9.0 kgf·m, 65 ft·lb) 2. Place the power trim and tilt in an upright 8.

  • Page 211: Bleeding The Power Trim And Tilt (Built-In)

    Gear pump 3. Tighten the manual valve by turning it Battery clockwise. Tilt rod PTT motor lead terminal 4. Let the fluid settle for 5 minutes. Blue (L) Green (G) 5. Push and hold the power trim and tilt Green (G) switch in the up position until the out- Down Blue (L)

  • Page 212: Power Trim And Tilt Motor

    BRKT Bracket unit Power trim and tilt motor Part name Q’ty Remarks M5 × 20 mm Screw Yoke O-ring Not reusable 52.0 × 1.9 mm Armature Bushing M4 × 12 mm Screw Wire lead Brush 2 Brush 1 Brush holder Circuit breaker Brush spring PTT motor base...

  • Page 213: Checking The Power Trim And Tilt Motor

    Power trim and tilt motor Checking the power trim and tilt motor 1. Check the commutator for dirt or foreign substances. Clean with #600 grit sand- paper if necessary. Armature coil continuity Commutator segments b Continuity Segment-laminations c No continuity Segment-shaft d No continuity 2.

  • Page 214: Assembling The Power Trim And Tilt Motor

    BRKT Bracket unit 4. Install the armature 9, O-ring 0, and 7. Check the base for cracks or damage. yoke A. Replace if necessary. 8. Check the bushing 1 for damage or wear. Replace if necessary. Assembling the power trim and tilt motor 1.
  • Page 215 Power trim and tilt motor 2. Install the shaft 2 and bolts 3 onto both clamp brackets together with the power trim and tilt/hydro tilt 4. 3. Install the tilt ram upper end into the swivel bracket with the shaft 5 and cir- clip(s) 6.

  • Page 216: Power Trim And Tilt Electrical System

    BRKT Bracket unit Power trim and tilt electrical system 1 Power trim and tilt motor : Black 2 Power trim and tilt relay : Green 3 Trailer switch : Gray 4 Fuse : Blue 5 Battery : Light green 6 Trim sensor : Pink : Red : Sky blue...

  • Page 217: Checking The Fuse

    Power trim and tilt electrical system Checking the fuse 3. Connect the light green (Lg) lead to the positive battery terminal and the black 1. Check the fuse and fuse holder for conti- (B) lead to the negative battery terminal nuity.

  • Page 218: Checking The Trailer Switch

    BRKT Bracket unit Checking the trailer switch 1. Check the trailer switch for continuity. Replace if out of specification. Lead color Switch Sky blue Light green Red (R) position (Sb) (Lg) Free Down Checking the trim sensor 1. Measure the trim sensor resistance. Replace if out of specification.

  • Page 219: Elec

    – ELEC 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 and port views................8-3 Front view ....................8-4 Top view ....................8-5 Tiller handle model ..................8-6 Wiring harness ....................

  • Page 220: Electrical Systems

    – ELEC Electrical systems Special service tools Ignition tester Dial gauge set 90890-06754 90890-01252 Digital circuit tester Magnet base 90890-03174 90890-06705 Peak voltage adaptor Test harness (3 pins) 90890-03172 90890-06770 Test harness (2 pins) Test harness (4 pins) 90890-06767 90890-06771 Vacuum/pressure pump gauge set 90890-06756 62Y5A11...

  • Page 221: Checking The Electrical Components

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

  • Page 222: Electrical Components

    – ELEC Electrical systems Electrical components Starboard and port views 1 Stator 9 Starter relay 2 Pulser coil 0 Starter motor 3 CDI unit 4 Ignition coil 5 Oil pressure switch 6 Thermoswitch 7 Prime Start 8 Rectifier Regulator 62Y5A11...

  • Page 223: Front View

    Electrical components Front view È Tiller handle model 1 Stator 2 Pulser coil 3 CDI unit 4 Fuse 5 Neutral switch (tiller handle model) 6 Starter relay 7 Starter motor 8 Power trim and tilt relay (power trim and tilt model) 62Y5A11...

  • Page 224: Top View

    – ELEC Electrical systems Top view 1 Stator 2 Pulser coil 3 CDI unit 4 Ignition coil 5 Starter motor 6 Trailer switch 62Y5A11...

  • Page 225: Tiller Handle Model

    Electrical components Tiller handle model 1 Engine start switch 2 Engine start switch harness 3 Engine shut-off switch 4 Engine shut-off switch connector 5 Neutral switch 6 Battery lead 62Y5A11...

  • Page 226: Wiring Harness

    – ELEC Electrical systems Wiring harness È Power trim and tilt 7 Warning indicator or Connect to: : White digital tachometer model : Black/orange 1 Tiller handle main 8 CDI unit B/W : Black/white switch or remote 9 Trailer switch : Black : Pink/black control box or wiring...

  • Page 227: Ignition System And Ignition Control System

    Wiring harness / Ignition system and Ignition control system Ignition system and Ignition control system 1 Spark plug : Black 2 Ignition coil : Brown 3 Charge coil : Blue 4 Pulser coil : White 5 Engine start switch : Black/orange 6 Engine shut-off switch B/W : Black/white 7 10-pin coupler...
  • Page 228 – ELEC Electrical systems È Remote control model 1 Thermoswitch : Black É Tiller handle model 2 Oil pressure switch : Green 3 CDI unit : Red 4 Digital tachometer : Yellow 5 Oil pressure warning indicator Gy/B : Gray/black 6 Overheat warning indicator : Pink/black 7 Remote control box...

  • Page 229: Checking The Ignition Spark Gap

    Ignition system and Ignition control system Checking the ignition spark gap WARNING 1. Disconnect the spark plug caps from the • Do not touch any of the connections of spark plugs. the spark gap tester leads. 2. Connect a spark plug cap to the special •...

  • Page 230: Checking The Ignition Coil

    – ELEC Electrical systems Checking the ignition coil 1. Remove the spark plug caps from the high-tension cords by turning the caps counterclockwise. 2. Measure the ignition coil resistance. Replace if out of specification. WARNING When checking the peak voltage do not touch any of the connections of the digital tester leads.

  • Page 231: Checking The Pulser Coil

    Ignition system and Ignition control system Checking the pulser coil 1. Measure the pulser coil output peak volt- age. Replace the pulser coil if below specification. WARNING When checking the peak voltage do not touch any of the connections of the digital tester leads.

  • Page 232: Checking The Pulser Coil Air Gap

    – ELEC Electrical systems 6. Tighten the pulser coil screws and fly- Pulser coil resistance (use as wheel magnet nut to the specified reference): torques. White/red (W/R) – White/black (W/B) Pulser coil screw: 396–594 Ω at 20 °C (68 °F) 4 N·m (0.4 kgf·m, 2.9 ft·lb) Flywheel magnet nut: 160 N·m (16 kgf·m, 116 ft·lb)

  • Page 233: Checking The Thermoswitch

    Ignition system and Ignition control system a Temperature b Time c No continuity d Continuity Thermoswitch continuity temperature: Pink (P) – Black (B) e: 76–84 °C (164–183 °F) f: 63–77 °C (145–170 °F) Checking the oil pressure switch 1. Connect the special service tool to the oil pressure switch.

  • Page 234: Starting System

    – ELEC Electrical systems Starting system 1 Fuse : Black 2 10-pin coupler : Brown 3 Engine start switch : Red 4 Starter motor 5 Battery 6 Neutral switch 7 Starter relay È Tiller handle model 8-15 62Y5A11...

  • Page 235: Checking The Fuse

    Starting system Checking the fuse 4. Check for continuity between the starter relay terminals. Replace if there is no 1. Check the fuse and fuse holder for conti- continuity. nuity. Replace if there is no continuity. 5. Check that there is no continuity between the starter relay terminals after discon- necting the brown or black lead.

  • Page 236: Starter Motor

    – ELEC Electrical systems Starter motor 8-17 62Y5A11...
  • Page 237 Starter motor Part name Q’ty Remarks Clip Pinion stopper Spring Starter motor pinion Upper bracket O-ring Not reusable Washer 1 Shim — As required Washer 2 Armature Stator O-ring Not reusable Brush holder assembly Brush set O-ring Not reusable Washer Spring washer Lower bracket M4 ×...

  • Page 238: Removing The Starter Motor Pinion

    – ELEC Electrical systems Removing the starter motor pinion 1. Slide the pinion stopper 1 down as shown, and then remove the clip 2. Dial gauge set 1: 90890-01252 Magnet base 2: 90890-06705 Checking the starter motor pinion Free play limit: 0.6 mm (0.024 in) 1.

  • Page 239: Checking The Brushes

    Starter motor 4. Measure the commutator undercut a. Replace the armature if out of specifica- tion. Brush length limit a: 12.0 mm (0.47 in) Commutator undercut limit: 2. Check the brush holder for continuity. 0.2 mm (0.01 in) Replace if out of specifications. 5.

  • Page 240: Charging System

    – ELEC Electrical systems Charging system 1 Lighting coil : Black 2 Rectifier Regulator : Green 3 Fuse : Red 4 Battery G/W : Green/white 8-21 62Y5A11...

  • Page 241: Checking The Lighting Coil

    Charging system Checking the lighting coil Lighting coil resistance (use as 1. Measure the lighting coil output peak reference): voltage. Replace the stator coil if below Green (G) – Green (G) specification. 1.2–1.8 Ω at 20 °C (68 °F) WARNING When checking the peak voltage do not touch any of the connections of the digital tester leads.

  • Page 242: Checking The Rectifier Regulator

    – ELEC Electrical systems Checking the Rectifier Regulator NOTE: 1. Measure the Rectifier Regulator output After starting the engine, disconnect the out- peak voltage. If below specification, mea- put lead (red lead) of the Rectifier Regulator sure the lighting coil output peak voltage. when measuring the output peak voltage.

  • Page 243: Trbl Shtg

    TRBL SHTG Troubleshooting Power unit....................... 9-1 Bracket unit ....................9-10 Electrical systems..................9-13 62Y5A11...
  • Page 244 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 Chapter 4– 8, to check the part necessary to carry out safety maintenance. •...
  • Page 245 Power unit Is there conti- Replace the engine shut-off nuity? switch. Check the fuse for continuity. Is there conti- Replace the fuse. nuity? Check the wiring harnesses for continuity. Is there conti- Replace the wiring harnesses. nuity? Check operation of the starter motor pinion.
  • Page 246 TRBL SHTG Troubleshooting Symptom: Engine cranks, but will not start. • Check the ignition system. • Check the fuel system. • Check the compression pressure of power unit. WARNING Check the ignition spark using the spark gap tester. • Do not touch any of the connections of the spark gap tester leads.
  • Page 247 Power unit Symptom: Engine can be started, but does not remain on. • Check the fuel system. • Check the ignition system. • Check the compression pressure of power unit. (Fuel system) Check that the fuel vent screw of the fuel tank is open. Is the vent Open the fuel vent screw.
  • Page 248 TRBL SHTG Troubleshooting (Ignition system) Check the ignition spark gap using the spark gap tester. Out of specifi- Check the ignition system out- cation? put peak voltage. Replace the spark plug. (Compression pressure) Check that there is no secondary air intake on the contact surfaces of the intake manifold and crankcase.
  • Page 249 Power unit Symptom: The engine idle speed is not steady, but increases or decreases. • Check the carburetors. • Check the air intake system. • Check the ignition system. Check the operation of the car- buretor throttle valves. Do the valves close simul- Check the ignition timing.
  • Page 250 TRBL SHTG Troubleshooting Symptom: Engine does not accelerate when the throttle is opened quickly. The engine turns off when the throttle is opened quickly. Acceleration is tardy and the engine is likely to stop at any moment. • Check the carburetors. •...
  • Page 251 Power unit Symptom: Engine can run, but engine speed will not increase. Overheat warning indicator is on. Oil pressure warning indicator is on. Warning indicator is on and buzzer is sounding. • Check the water cooling system. • Check the lubricating system. (Cooling system) Check the water inlet for clogs or debris.
  • Page 252 TRBL SHTG Troubleshooting (Lubricating system) Check the engine oil level. At specified Add engine oil to the correct level? level. Check the oil pressure. Out of specifi- Check the oil pump for debris or cation? wear. Check the oil pas- Debris or sage.
  • Page 253 Power unit / Bracket unit Bracket unit Symptom: Power trim and tilt unit does not operate. Listen for the operation sound of the power trim and tilt relay. Can the oper- Check the voltage between each terminal. ation sound • Between the sky blue (Sb) lead and black (B) lead. be heard? •...
  • Page 254 TRBL SHTG Troubleshooting 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 power trim and tilt fluid level. At specified Add fluid to the correct level. level? Disassemble the power trim and tilt unit, and then check it.
  • Page 255 Bracket unit Symptom: Shift mechanism of the forward gear and reverse gear does not operate properly. Check the shift cable operation. Good operat- Check the shift cables and links ing condition? of the remote control box. Check the operation of the shift rod.
  • Page 256 TRBL SHTG Troubleshooting Electrical systems Symptom: Battery becomes weaker quickly. • Check the charging system. Measure the output peak voltage of the lighting coil. Out of specifi- Replace the lighting coil. cation? Measure the Rectifier Regulator output peak voltage. Out of specifi- Replace the Rectifier Regulator.
  • Page 257 Checking the connecting rod bolt ..... 5-41 Checking the connecting rod small end Acceleration pump ........1-13 inside diameter ........5-41 Adjusting the dash-pot Checking the cooling water passage..3-8 (acceleration pump) ........4-15 Checking the crankshaft ......5-41 Adjusting the pilot screw ......4-13 Checking the crankshaft main journal oil Adjusting the throttle link rod.....4-13 clearance ..........
  • Page 258 Index Checking the piston pin boss bore....5-40 Checking the piston ring grooves....5-40 Dimensions..........2-9 Checking the piston ring side clearance ...5-40 Disassembling the cylinder body ....5-37 Checking the piston rings......5-39 Disassembling the drive shaft....6-19 Checking the power trim and tilt Disassembling the forward gear ....
  • Page 259 Installing the lower unit ......6-22 Removing the propeller shaft housing Installing the pinion ........6-22 assembly ..........6-13 Installing the power trim and tilt ....7-45 Removing the starter motor pinion ... 8-19 Installing the power unit ......5-49 Removing the steering arm ...... 7-23 Installing the propeller shaft housing ..6-16 Removing the timing belt and sprockets...
  • Page 260 Index Water pump and shift rod......6-7 Wiring harness ..........8-7 62Y5A11...
  • Page 262 Wiring diagram FT50CEHD, FT50CED 1 Battery Color code 2 Engine start switch : Black 3 Engine shut-off switch : Brown 4 Starter motor : Green 5 Starter relay : Blue 6 Neutral switch : Orange 7 Fuse (20A) : Pink 8 Prime Start : Red 9 Warning indicator...
  • Page 263 Wiring diagram FT50CET 1 Battery Color code 2 Power trim and tilt motor : Black 3 Power trim and tilt relay : Brown 4 Starter motor : Green 5 Fuse (20A) : Gray 6 Trim sensor : Blue 7 Prime Start : Light green 8 Starter relay : Orange...
  • Page 265 YAMAHA MOTOR CO., LTD. Printed in the Netherlands Jun. 2001 – 0.4 × 1 CR (FT50CEHD, FT50CED, FT50CET)
  • Page 266 FT50CEHD, FT50CED Gy/B G/W G/W Gy/B Gy/B Gy/B B B B S62YWD01K...
  • Page 267 FT50CET Gy/B G/W G/W Gy/B Gy/B Gy/B B B B Sb R Sb R FREE DOWN R Sb S62YWD04K...

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