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Yamaha F50F Service Manual

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F50F
FT50G
F60C
FT60D
SERVICE MANUAL
290551
6C1-28197-3G-11

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Summary of Contents for Yamaha F50F

  • Page 1 F50F FT50G F60C FT60D SERVICE MANUAL 290551 6C1-28197-3G-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 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 5: Table Of Contents

    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 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

    7 Apply Yamaha 4-stroke motor oil A Apply corrosion resistant grease 8 Apply gear oil (Yamaha grease D) 9 Apply water resistant grease (Yamaha grease A) B Apply low temperature resistant grease 0 Apply molybdenum disulfide grease (Yamaha grease C)

  • Page 8: Safety While Working

    Parts, lubricants, and sealants Use only genuine Yamaha parts, lubricants, and sealants or those recommended by Yamaha, when servicing or repairing the out- board motor. Ventilation Gasoline vapor and exhaust gas are heavier than air and extremely poisonous.

  • 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 service tools Use the recommended special service tools to protect parts from damage. Use the right tool in the right manner—do not improvise. 3.

  • Page 10: Serial Number

    INFO General information Serial number outboard motor serial number stamped on a label attached to the port clamp bracket. S6C11010 1 Model name 2 Approved model code 3 Transom height 4 Serial number Approved Starting Model name model code serial No. F50FED F50FEHT 1000001–...

  • Page 11: Outline Of Features

    • Solenoid valve • Fuel cooler • Aluminum rocker arm Electrical • Compact electronic fuel injection system • Self-diagnosis system and Yamaha Diagnostic System • Variable trolling RPM switch (optional for tiller handle model) • Throttle position sensor with learning function (adjustment free) •...

  • Page 12: Features And Benefits

    INFO General information Features and benefits Fuel system A pressure regulator is built into the vapor separator to obtain compact and simple fuel delivery structure. A plastic fuel rail is used to prevent it from corrosion and for light weight. Fuel discharged from the pressure regulator returns to the vapor separator after cooling down through the fuel cooler.

  • Page 13: Solenoid Valve

    Features and benefits Solenoid valve Just after the engine is stopped, the cooling water supply is also stopped and the heat is conducted to the vapor separator from the engine, causing birth of many fuel vapor gases. The vapor gases are fed into the intake silencer to reburn them. However, many vapor gases are sucked into the combustion chambers, causing a rich air and fuel mixture, which is difficult to restart the engine.

  • Page 14: Electronic Control System

    INFO General information Electronic control system The electronic control system is built up by the sensors and the ECM (Electric control Module). The ECM receives signals from the sensors and determines the air and fuel mixture (A/F), and igni- tion timing. Under various condition, the ECM gives the best-suitable engine operation.

  • Page 15: Ecm (Electric Control Module)

    Features and benefits ECM (Electric Control Module) This engine is controlled by the ECM to obtain precision combustion under various operations, and can realize high power output, low fuel consumption, and low emission. The ECM controls the ignition timing, fuel injection timing, and the fuel injection volume, and ensures that the optimum ignition timing and air and fuel ratio can be achieved in all operating con- ditions such as engine starting, normal operation, and quick acceleration.

  • Page 16: Variable Trolling Rpm Switch (Optional)

    INFO General information Variable trolling RPM switch (optional) This device is an optional equipment for tiller handle model. The idling and/or trolling rpm can be controlled in the range of 620 through 900 r/min with 50 r/min interval. Especially for 620 through 700 r/min, the engine rpm is controlled with 40 r/min interval. Pushing and holding the switch changes rpm continuously at 50 r/min interval.

  • Page 17: Propeller Selection

    Features and benefits / Propeller selection Propeller selection Selection When the engine speed is at the full throttle The performance of a boat and outboard operating range (5,000–6,000 r/min), the motor will be critically affected by the size ideal propeller for the boat is one that pro- and type of propeller you choose.

  • Page 18: Predelivery Checks

    INFO General information Predelivery checks NOTE: To make the delivery process smooth and If the engine oil is below the minimum level efficient, the predelivery checks should be mark b, add sufficient oil until the level is completed as explained below. between a and b.

  • Page 19: Checking The Outboard Motor Mounting Height

    Predelivery checks Checking the outboard motor mounting height 1. Check that the anti-cavitation plate is aligned with the bottom of the boat. If the mounting height is too high, cavitation will occur and propulsion will be reduced. Also, the engine speed will increase abnormally and cause the engine to overheat.

  • Page 20: Checking The Gear Shift And Throttle Operation

    INFO General information 2. Check that steering operates È smoothly. È É É S69J1210 È Tiller handle model É Remote control model È Tiller handle model Checking the power trim and tilt É Remote control model system 3. Check that there is no interference with 1.

  • Page 21: Checking The Engine Start Switch And Engine Stop Lanyard Switch

    Predelivery checks È S6C11100 Checking the engine start switch and engine stop lanyard switch 1. Check that the engine starts when the engine start switch is turned to START. 2. Check that the engine turns off when the engine start switch is turned to OFF. È...

  • Page 22: Test Run

    INFO General information Test run After test run 1. Start the engine, and then check that the 1. Check for water in the gear oil. gear shift operates smoothly. 2. Check for fuel leakage in the cowling. 2. Check the engine idle speed after the 3.
  • Page 23 SPEC Specifications General specifications................... 2-1 Maintenance specification ................2-5 Power unit....................2-5 Lower unit ....................2-8 Electrical ....................2-9 Power unit....................2-11 Lower unit ....................2-14 Electrical ....................2-15 Dimensions....................2-17 Tightening torques..................2-21 Specified torques..................2-21 General torques..................2-24 6C13G11...

  • Page 24: Specifications

    SPEC Specifications General specifications Model Item Unit F50FED F50FEHT F50FET FT50GET Dimension Overall length mm (in) 1,339 706 (27.8) (27.8) (52.7) Overall width mm (in) 384 (15.1) Overall height mm (in) 1,415 (55.7) 1,455 (57.3) (*1) mm (in) — 1,569 (61.8) Boat transom height mm (in)
  • Page 25 General specifications Model Item Unit F50FED F50FEHT F50FET FT50GET Fuel and oil Fuel type Regular unleaded gasoline (*1) Fuel minimum rating Engine oil 4-stroke motor oil Engine oil grade SE, SF, SG, SH, or SJ 10W-30 or 10W-40 Engine oil quantity (without oil filter replacement) L (US qt, 2.5 (2.64, 2.20)
  • Page 26 SPEC Specifications Model Item Unit F60CEHT F60CET FT60DET Dimension Overall length mm (in) 1,339 (52.7) 706 (27.8) Overall width mm (in) 384 (15.1) Overall height mm (in) 1,415 (55.7) 1,455 (57.3) (*1) mm (in) — 1,569 (61.8) Boat transom height mm (in) 508 (20.0) (*1)
  • Page 27 General specifications Model Item Unit F60CEHT F60CET FT60DET Fuel and oil Fuel type Regular unleaded gasoline (*1) Fuel minimum rating Engine oil 4-stroke motor oil Engine oil grade SE, SF, SG, SH, or SJ 10W-30 or 10W-40 Engine oil quantity (without oil filter replacement) L (US qt, 2.5 (2.64, 2.20)

  • Page 28: Maintenance Specification

    SPEC Specifications Maintenance specification Power unit Model Item Unit F50FED F50FEHT F50FET FT50GET Power unit Minimum compression 960 (9.6, 139.2) (*1) pressure (kgf/cm , psi) (*2) Oil pressure 125 (1.25, 18.1) at engine idle speed (kgf/cm , psi) Cylinder head Warpage limit mm (in) 0.10 (0.0039)
  • Page 29 Maintenance specification Model Item Unit F50FED F50FEHT F50FET FT50GET 2nd piston ring Dimension B mm (in) 1.47–1.49 (0.0579–0.0587) Dimension T mm (in) 2.60–2.80 (0.1024–0.1102) End gap mm (in) 0.30–0.50 (0.0118–0.0197) Side clearance mm (in) 0.02–0.06 (0.0008–0.0024) Oil ring Dimension B mm (in) 2.36–2.48 (0.0929–0.0976) (*1)
  • Page 30 SPEC Specifications Model Item Unit F50FED F50FEHT F50FET FT50GET Stem diameter Intake mm (in) 5.475–5.490 (0.2156–0.2161) Exhaust mm (in) 5.460–5.475 (0.2150–0.2156) Guide inside diameter Intake and exhaust mm (in) 5.500–5.512 (0.2165–0.2170) Stem-to-guide clearance Intake and exhaust mm (in) 0.025–0.052 (0.0010–0.0020) Stem runout limit Intake mm (in)

  • Page 31: Lower Unit

    Maintenance specification Model Item Unit F50FED F50FEHT F50FET FT50GET Oil pump Type Trochoid Outer rotor-to-housing mm (in) 0.09–0.15 (0.0035–0.0059) clearance Outer rotor-to-inner rotor mm (in) 0.12 (0.0047) clearance limit Rotor-to-cover clearance mm (in) 0.03–0.08 (0.0012–0.0031) Relief valve operating 350–450 (3.5–4.5, 50.8–62.3) pressure (kgf/cm , psi)

  • Page 32: Electrical

    SPEC Specifications Electrical Model Item Unit F50FED F50FEHT F50FET FT50GET Ignition and ignition control system (*1) Ignition timing range Degree ATDC 10-BTDC 25 Spark plug gap mm (in) 0.8–0.9 (0.031–0.035) Ignition coil resistance Primary coil (R – B/W) Ω at 20 °C (68 °F) 1.53–2.07 Secondary coil at 20 °C (68 °F)
  • Page 33 Maintenance specification Model Item Unit F50FED F50FEHT F50FET FT50GET Starter motor Type Sliding gear Output Cranking time limit Second Brushes Standard length mm (in) 15.5 (0.61) Wear limit mm (in) 9.5 (0.37) Commutator Standard diameter mm (in) 29.0 (1.14) Wear limit mm (in) 28.0 (1.10) Mica...

  • Page 34: Power Unit

    SPEC Specifications Power unit Model Item Unit F60CEHT F60CET FT60DET Power unit Minimum compression 960 (9.6, 139.2) (*1) pressure (kgf/cm , psi) (*2) Oil pressure 125 (1.25, 18.1) at engine idle speed (kgf/cm , psi) Cylinder head Warpage limit mm (in) 0.10 (0.0039) (lines indicate straightedge position)
  • Page 35 Maintenance specification Model Item Unit F60CEHT F60CET FT60DET 2nd piston ring Dimension B mm (in) 1.47–1.49 (0.0579–0.0587) Dimension T mm (in) 2.60–2.80 (0.1024–0.1102) End gap mm (in) 0.30–0.50 (0.0118–0.0197) Side clearance mm (in) 0.02–0.06 (0.0008–0.0024) Oil ring Dimension B mm (in) 2.36–2.48 (0.0929–0.0976) (*1) Dimension T...
  • Page 36 SPEC Specifications Model Item Unit F60CEHT F60CET FT60DET Stem diameter Intake mm (in) 5.475–5.490 (0.2156–0.2161) Exhaust mm (in) 5.460–5.475 (0.2150–0.2156) Guide inside diameter Intake and exhaust mm (in) 5.500–5.512 (0.2165–0.2170) Stem-to-guide clearance Intake and exhaust mm (in) 0.025–0.052 (0.0010–0.0020) Stem runout limit Intake mm (in) 0.05 (0.0020)

  • Page 37: Lower Unit

    Maintenance specification Model Item Unit F60CEHT F60CET FT60DET Oil pump Type Trochoid Outer rotor-to-housing mm (in) 0.09–0.15 (0.0035–0.0059) clearance Outer rotor-to-inner rotor mm (in) 0.12 (0.0047) clearance limit Rotor-to-cover clearance mm (in) 0.03–0.08 (0.0012–0.0031) Relief valve operating 350–450 (3.5–4.5, 50.8–62.3) pressure (kgf/cm , psi)

  • Page 38: Electrical

    SPEC Specifications Electrical Model Item Unit F60CEHT F60CET FT60DET Ignition and ignition control system (*1) Ignition timing range Degree ATDC 10-BTDC 24 Spark plug gap mm (in) 0.8–0.9 (0.031–0.035) Ignition coil resistance Primary coil (R – B/W) Ω at 20 °C (68 °F) 1.53–2.07 Secondary coil at 20 °C (68 °F)
  • Page 39 Maintenance specification Model Item Unit F60CEHT F60CET FT60DET Starter motor Type Sliding gear Output Cranking time limit Second Brushes Standard length mm (in) 15.5 (0.61) Wear limit mm (in) 9.5 (0.37) Commutator Standard diameter mm (in) 29.0 (1.14) Wear limit mm (in) 28.0 (1.10) Mica...

  • Page 40: Dimensions

    SPEC Specifications Dimensions Exterior F50, F60 (Remote control model) mm (in) A: 930 (36.6) A: 406 (16.0) B: 932 (36.7) B: 417 (16.4) A: 148 (5.8) B: 147 (5.8) 122 (4.8) 584 (23.0) 62 (2.4) 533 (21.0) S6C12030 A: Hydro tilt model (For Europe) B: Power trim and tilt model 2-17 6C13G11...
  • Page 41 Maintenance specification (*1) F50, F60 (Tiller handle model) mm (in) 755 (29.7) 417 (16.4) 932 (36.7) 226 (8.9) 584 (23.0) 164 (6.5) 62 (2.4) 533 (21.0) S6C12020E Power trim and tilt model (*1) For Oceania 2-18 6C13G11...
  • Page 42 SPEC Specifications FT50, FT60 mm (in) L : 996 (39.2) 417 (16.4) X: 1,099 (43.3) 147 (5.8) 122 (4.8) 584 (23.0) 62 (2.4) 12˚ 561 (22.1) S6C12010 X: For Oceania 2-19 6C13G11...
  • Page 43 Maintenance specification Clamp bracket mm (in) 180 (7.1) 180 (7.1) 163.5 (6.4) 163.5 (6.4) 70.5 (2.78) 13 (0.5) 13 (0.5) 126 (5.0) 126 (5.0) S6C12070 2-20 6C13G11...

  • Page 44: Tightening Torques

    SPEC Specifications Tightening torques Specified torques Tightening torques Part to be tightened Thread size N·m kgf·m ft·lb Fuel system Fuel filter cup — Fuel pump screw Fuel pump valve screw 0.05 0.36 Idle speed control screw Sensor assembly screw Fuel cooler screw Fuel rail mounting bolt Throttle body mounting bolt Pressure regulator bolt...
  • Page 45 Tightening torques Tightening torques Part to be tightened Thread size N·m kgf·m ft·lb Cylinder head bolt 17.0 90° Spark plug — 12.5 Cooling water temperature sensor — 17.0 Oil pressure switch — Oil pressure switch lead bolt Exhaust cover bolt 17.0 Exhaust cover plug 40.6...
  • Page 46 SPEC Specifications Tightening torques Part to be tightened Thread size N·m kgf·m ft·lb Bracket unit Retaining plate bolt Tiller handle nut — 27.3 Self-locking nut — Engine stop lanyard switch nut — Tiller handle bracket nut — 27.3 Tiller handle bracket bolt 27.3 Engine start switch nut —...

  • Page 47: General Torques

    Tightening torques General torques This chart specifies tightening torques for standard fasteners with a standard ISO thread pitch. Tightening torque specifications for special components or assemblies are provided in applicable sections of this man- ual. To avoid warpage, tighten multi-fastener assemblies in a crisscross fashion and pro- gressive stages until the specified torque is reached.
  • Page 48 SPEC Specifications — MEMO — 2-25 6C13G11...
  • Page 49 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-fuel injector) ....3-3 Checking the fuel filter ................3-3 Power unit.......................

  • Page 50: Chk Adj

    Periodic checks and adjustments Special service tools Digital tachometer 90890-06760 Leakage tester 90890-06840 Oil filter wrench 90890-01426 Flywheel holder 90890-06522 Flywheel puller 90890-06521 6C13G11...

  • Page 51: Maintenance Interval Chart

    3-10 Top cowling Check Fuel filter Check/replace (can be disassembled) Fuel system Check Fuel tank Check/clean — (Yamaha portable tank) Gear oil Change 3-14 Lubrication points Lubricate 3-18 Engine idle speed Check/adjust 3-10 (EFI models) Power trim and tilt unit...

  • Page 52: Top Cowling

    Periodic checks and adjustments Top cowling 2. Check the low-pressure fuel hose con- nections and fuel joint for leaks. Replace Checking the top cowling if necessary. Also, check the fuel filter 1, 1. Check the fitting by pushing the cowling fuel pump 2, strainer 3, and fuel cooler with both hands.

  • Page 53: Changing The Engine Oil Using An Oil Changer

    Top cowling / Fuel system / Power unit 2. Remove the oil dipstick, wipe it clean, and then insert it back into the dipstick hole. 3. Remove the oil dipstick again to check the oil level and to check the oil for dis- coloration and its viscosity.

  • Page 54: Replacing The Oil Filter

    Periodic checks and adjustments 2. Remove the oil dipstick and oil filler cap 7. Turn the engine off, and then check the oil level and correct it if necessary. Replacing the oil filter 1. Extract the engine oil with an oil changer or drain it.

  • Page 55: Checking The Timing Belt

    Power unit 5. Pour the specified amount of the recom- mended engine oil into the oil filler hole. Recommended engine oil: 4-stroke motor oil API: SE, SF, SG, SH, or SJ SAE: 10W-30 or 10W-40 Engine oil quantity: With oil filter replacement: S6C13090 2.7 L (2.85 US qt, 2.38 Imp qt) Timing belt slack a:...
  • Page 56 Periodic checks and adjustments 3. Loosen the flywheel magnet nut. NOTE: Apply force to the crankshaft end until the fly- wheel magnet comes off the tapered portion of the crankshaft. Flywheel puller: 90890-06521 5. Disconnect the stator coil coupler and pulser coil coupler, and remove the stator coil assembly 1.

  • Page 57: Checking The Spark Plugs

    Power unit 10. Install the solenoid valve and stator coil assembly, and connect the stator coil coupler and pulser coil coupler. 11. Install the Woodruff key, then the fly- wheel magnet. CAUTION: Apply force in the direction of the arrows 8.

  • Page 58: Checking The Thermostat

    Periodic checks and adjustments 2. Clean the electrodes 1 with a spark plug cleaner or wire brush. Replace the spark plug if necessary. 2. Suspend the thermostat in a container of water. 3. Place a thermometer in the water and 3.

  • Page 59: Checking The Cooling Water Passage

    Power unit / Control system Water Valve lift a temperature 0.05 mm 58–62 °C (0.0020 in) (136–144 °F) (valve begins to lift) above more than 70 °C (158 °F) 3.0 mm (0.12 in) 5. Install the thermostat, gasket, and cover. Control system Checking the cooling water passage Checking the engine idle speed...
  • Page 60 Periodic checks and adjustments 3. Loosen the locknut 1, and then adjust 6. Contact the cam roller 2 on the throttle the throttle link rod length a. control lever to the throttle cam as shown, and then adjust the position of the throttle link rod until the joint 3 of the throttle link rod is aligned with the joint 4 of the control lever.

  • Page 61: Checking The Gear Shift Operation

    Control system 12. Operate the throttle to check that the throttle valves fully close and fully open, and check that the throttle cam contacts the fully closed stopper when the throttle is in the fully closed position. 13. Check the throttle cable for smooth oper- ation and, if necessary, repeat steps 1–...

  • Page 62: Bracket Unit

    Periodic checks and adjustments 5. Adjust the position of the shift cable joint NOTE: until its hole is aligned with the set pin. Be sure to listen to the winding sound of the power trim and tilt motor for smooth opera- tion.

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

    Control system / Bracket unit / Lower unit NOTE: If the fluid is at the correct level, the fluid should overflow out of the filler hole when the reservoir cap is removed. 3. If necessary, add sufficient fluid of the recommended type until it overflows out of the filler hole.

  • Page 64: Changing The Gear Oil

    Periodic checks and adjustments 3. If necessary, add sufficient gear oil of the recommended type until it overflows out of the check hole. Recommended gear oil: Hypoid gear oil API: GL-4 SAE: 90 4. Install the check screw, and then tighten it to the specified torque.

  • Page 65: Checking The Propeller

    Lower unit / General General Checking the anodes 1. Check the anodes and trim tab for scales, grease, or oil. Clean if necessary. Leakage tester: 90890-06840 2. Apply the specified pressure to check È that the pressure is maintained in the lower unit for at least 10 seconds.

  • Page 66: Checking The Battery

    Periodic checks and adjustments Ë WARNING Battery electrolyte is dangerous; it con- tains sulfuric acid which is poisonous and highly caustic. Always follow these preventive measures: • Avoid bodily contact with electrolyte as it can cause severe burns or permanent eye injury.

  • Page 67: Lubricating The Outboard Motor

    General Lubricating the outboard motor 1. Apply water resistant grease to the areas shown. S6C13270 É S6C13290 S6C17540 NOTE: Apply grease to the grease nipple until it flows from the bushings a. S6C17360 3-18 6C13G11...
  • Page 68 Periodic checks and adjustments 2. Apply low temperature resistant grease to the area shown. S6C13280 3. Apply corrosion resistant grease to the area shown. 3-19 6C13G11...
  • Page 69 FUEL Fuel system Special service tools ..................4-1 Hose routing ....................4-2 Fuel and blowby hoses................4-2 Cooling water pilot hoses ................4-3 Fuel filter and fuel pump ................4-4 Checking the fuel pump................4-6 Disassembling the fuel pump ..............4-6 Checking the diaphragm and valves ............4-7 Assembling the fuel pump .................

  • Page 70: Fuel System

    FUEL Fuel system Special service tools Vacuum/pressure pump gauge set 90890-06756 Fuel pressure gauge 90890-06786 Fuel pressure gauge adapter B 90890-06942 6C13G11...

  • Page 71: Hose Routing

    Special service tools / Hose routing Hose routing Fuel and blowby hoses S6C14010 1 Blowby hose 2 Fuel hose (fuel joint-to-fuel filter) 3 Fuel hose (fuel filter-to-fuel pump) 4 Fuel hose (fuel pump-to-strainer) 5 Fuel hose (strainer-to-vapor separator) 6 High-pressure fuel hose (vapor separator-to-fuel rail) 7 Fuel hose (pressure regulator-to-fuel cooler) 8 Fuel hose (fuel cooler-to-vapor separator) 6C13G11...

  • Page 72: Cooling Water Pilot Hoses

    FUEL Fuel system Cooling water pilot hoses S6C14340 1 Cooling water pilot hose (fuel cooler to fuel cooler) 2 Cooling water pilot hose (fuel cooler to fuel joint) 3 Cooling water pilot hose (fuel joint to upper case) 4 Flushing hose (hose joint to fuel joint) 5 Cooling water pilot hose (fuel joint to water outlet joint) 6 Cooling water pilot hose (fuel cooler to fuel joint) 7 Cooling water pilot hose (water outlet joint to water outlet)

  • Page 73: Fuel Filter And Fuel Pump

    Hose routing / Fuel filter and fuel pump Fuel filter and fuel pump · · · m (0.3 kgf m, 2.2 ft S6C14320 Part name Q’ty Remarks Fuel pump assembly M6 × 30 mm Bolt Fuel hose Holder Strainer O-ring Not reusable ø6 ×...
  • Page 74 FUEL Fuel system Part name Q’ty Remarks ø5 × 43 mm Screw Cover Seal Not reusable Fuel pump body 2 assembly Diaphragm Spring Fuel pump body 1 Spring Plunger Spring washer 6C13G11...

  • Page 75: Checking The Fuel Pump

    Fuel filter and fuel pump Checking the fuel pump 1. Disconnect the fuel hoses from the fuel pump. 2. Connect the special service tool to the fuel pump inlet. 3. Cover the fuel pump outlet with a finger, and then apply the specified positive pressure.

  • Page 76: Checking The Diaphragm And Valves

    FUEL Fuel system Checking the diaphragm and valves Checking the fuel joint 1. Check the diaphragm for tears and the 1. Check the fuel hose connector for cracks valves for cracks. Replace if necessary. or damage. Assembling the fuel pump 2.

  • Page 77: Intake Manifold

    Fuel filter and fuel pump / Intake manifold Intake manifold S6C14100 Part name Q’ty Remarks Blowby hose Holder Hose M6 × 35 mm Bolt M6 × 45 mm Bolt M8 × 40 mm Bolt Intake manifold assembly Cooling water pilot hose Pressure regulator hose Dowel Plastic tie...
  • Page 78 FUEL Fuel system · · · m (0.4 kgf m, 3.0 ft · · · m (0.4 kgf m, 3.0 ft · · · m (0.9 kgf m, 6.6 ft · · · m (0.9 kgf m, 6.6 ft S6C14110 Part name Q’ty Remarks...
  • Page 79 Intake manifold · · · m (0.4 kgf m, 3.0 ft · · · m (0.4 kgf m, 3.0 ft · · · m (0.9 kgf m, 6.6 ft · · · m (0.9 kgf m, 6.6 ft S6C14110 Part name Q’ty Remarks Link rod...

  • Page 80: Checking The Throttle Position Sensor

    System. If the output voltage is out of • Measure the throttle position sensor output specification, replace the throttle posi- voltage using the Yamaha Diagnostic Sys- tion sensor. tem. • Do not turn the throttle stop screw a.
  • Page 81 Intake manifold / Vapor separator Vapor separator S6C14130 Part name Q’ty Remarks Vapor separator Collar Grommet M6 × 30 mm Bolt Cooling water pilot hose M6 × 15 mm Bolt Corrugated tube 4-12 6C13G11...
  • Page 82 FUEL Fuel system · · · m (0.3 kgf m, 2.2 ft · · · m (0.3 kgf m, 2.2 ft · · · · · · 1.5 N m (0.15 kgf m, 1.1 ft m (0.4 kgf m, 3.0 ft S6C14140 Part name Q’ty...

  • Page 83: Vapor Separator

    Vapor separator · · · m (0.3 kgf m, 2.2 ft · · · m (0.3 kgf m, 2.2 ft · · · · · · 1.5 N m (0.15 kgf m, 1.1 ft m (0.4 kgf m, 3.0 ft S6C14140 Part name Q’ty...
  • Page 84 FUEL Fuel system · · · m (0.5 kgf m, 3.7 ft · · · m (0.2 kgf m, 1.5 ft · · · m (0.4 kgf m, 3.0 ft · · · m (0.2 kgf m, 1.5 ft S6C14360 Part name Q’ty Remarks...

  • Page 85: Disconnecting The Quick Connector

    Vapor separator Disconnecting the quick connector WARNING 1. Wrap the quick connector with a rag, and then rotate the quick connector tab 1 to Always reduce the fuel pressure in the the stopper position a. fuel line before servicing the line or the fuel pipe.

  • Page 86: Checking The Pressure Regulator

    FUEL Fuel system 3. Turn the engine start switch to ON, and NOTE: then measure the fuel pressure within 3 Before disconnecting the quick connector, seconds. release the fuel pressure. WARNING Before measuring the fuel pressure, make 3. Connect the special service tools as sure that the drain screw is tightened shown.

  • Page 87: Draining The Fuel

    Vapor separator 4. Drain the fuel from the vapor separator WARNING drain hose by pressing the valve using a thin screwdriver. • Before measuring the fuel pressure, make sure that the drain screw is tight- ened securely. • Do not loosen the drain screw while measuring the fuel pressure.

  • Page 88: Checking The Vapor Separator

    FUEL Fuel system 5. Remove the needle valve and other com- ponents. Checking the vapor separator 1. Check the needle valve for bends or wear. Replace if necessary. Float height c: 46.6 ± 1.0 mm (1.83 ± 0.04 in) 6. Check the float height d as shown.

  • Page 89: Assembling The Vapor Separator

    Vapor separator Float height b: 46.6 ± 1.0 mm (1.83 ± 0.04 in) 2. Adjust the lever c of the float by bending it until the float height d is within specifi- cation. NOTE: When adjusting the float height, do not bend the lever e.
  • Page 90 POWR Power unit Special service tools ..................5-1 Power unit....................... 5-3 Checking the compression pressure ............5-3 Checking the oil pressure ................5-3 Checking the valve clearance..............5-4 Removing the power unit.................5-14 Removing the timing belt and sprockets..........5-15 Checking the timing belt and sprockets...........5-16 Installing the timing belt and sprockets............5-17 Cylinder head ....................5-19 Removing the cylinder head ..............
  • Page 91 Cylinder block ....................5-37 Disassembling the cylinder block ............5-38 Checking the piston diameter ..............5-39 Checking the cylinder bore ..............5-39 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..........5-41 Checking the piston pin boss bore ............

  • Page 92: Power Unit

    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 installer 90890-06521 90890-06810 Crankshaft holder 18 Valve guide reamer 90890-06562 90890-06804 Valve spring compressor Valve seat cutter holder 90890-04019 90890-06316 6C13G11...
  • Page 93 Special service tools Valve seat cutter 90890-06312, 90890-06315, 90890-06323, 90890-06327, 90890-06328, 90890-06555 Bearing outer race attachment 90890-06626 Oil filter wrench 90890-01426 Piston slider 90890-06529 6C13G11...

  • Page 94: Power Unit

    POWR Power unit Power unit NOTE: Checking the compression pressure • If the compression pressure increases, 1. Start the engine, warm it up for 5 min- check the pistons and piston rings for wear. utes, and then turn it off. Replace if necessary.

  • Page 95: Checking The Valve Clearance

    Power unit Relief valve opening pressure (reference data): 350–450 kPa (3.5–4.5 kgf/cm , 50.8–62.3 psi) Checking the valve clearance CAUTION: Do not turn the flywheel magnet counter- clockwise, otherwise the valve system may be damaged. 1. Remove the flywheel magnet cover, and then remove the blowby hose 1.
  • Page 96 POWR Power unit 7. Check the intake valve clearance for cyl- NOTE: inders #3 and #4, and the exhaust valve • To decrease the valve clearance, turn the clearance for cylinders #2 and #4. Adjust adjusting screw clockwise. if out of specification. •...
  • Page 97 Power unit Part name Q’ty Remarks Power unit Oil dipstick Gasket Not reusable Dowel M6 × 16 mm Bolt M8 × 80 mm Bolt Apron ø6 × 24 mm Screw Flywheel magnet cover Grommet Neutral switch Tiller handle model Shift position switch M6 ×...
  • Page 98 POWR Power unit Part name Q’ty Remarks Washer Flywheel magnet M6 × 30 mm Bolt Stator coil Stator coil bracket M6 × 30 mm Bolt Collar Pulser coil M5 × 12 mm Bolt Woodruff key M6 × 20 mm Bolt 6C13G11...
  • Page 99 Power unit Part name Q’ty Remarks Timing belt Width across flats: 41 mm (1.6 in) Retaining plate Drive sprocket M10 × 35 mm Bolt Washer Driven sprocket Dowel Woodruff key 6C13G11...
  • Page 100 POWR Power unit · · · m (0.7 kgf m, 5.2 ft · · · 17 N m (1.7 kgf m, 12.5 ft S6C15050 Part name Q’ty Remarks Rectifier Regulator M6 × 25 mm Bolt Spark plug Spark plug wire Holder Ignition coil M6 ×...
  • Page 101 Power unit · · · 29 N m (2.9 kgf m, 21.4 ft · · · m (0.2 kgf m, 1.5 ft · · · m (0.9 kgf m, 6.6 ft · · · m (0.4 kgf m, 3.0 ft ·...
  • Page 102 POWR Power unit 9 10 · · · m (0.3 kgf m, 2.2 ft · · · · · · m (0.3 kgf m, 2.2 ft m (0.4 kgf m, 3.0 ft S6C15060 Part name Q’ty Remarks Bracket Junction box Main and fuel pump relay Power trim and tilt relay Cover...
  • Page 103 Power unit 9 10 · · · m (0.3 kgf m, 2.2 ft · · · · · · m (0.3 kgf m, 2.2 ft m (0.4 kgf m, 3.0 ft S6C15060 Part name Q’ty Remarks M6 × 20 mm Bolt Holder M6 ×...
  • Page 104 POWR Power unit S6C15070 Part name Q’ty Remarks Throttle cam Throttle control lever Bracket Lever Washer Bushing Clip M6 × 25 mm Bolt M6 × 35 mm Bolt Collar Wave washer Cotter pin Not reusable Throttle cam roller M6 × 35 mm Bolt Spring Collar...

  • Page 105: Removing The Power Unit

    Power unit 6. Remove the oil dipstick 9. Removing the power unit NOTE: It is recommended to loosen the flywheel magnet nut before removing the power unit to improve working efficiency. 1. Remove the flywheel magnet cover. 2. Disconnect the battery leads, PTT motor leads 1, and main switch coupler 2.

  • Page 106: Removing The Timing Belt And Sprockets

    POWR Power unit 10. Remove the power unit by removing the Removing the timing belt and bolts B. sprockets CAUTION: Do not turn the drive sprocket counter- clockwise, otherwise the valve system may be damaged. 1. Turn the drive sprocket clockwise and align the “...

  • Page 107: Checking The Timing Belt And Sprockets

    Power unit NOTE: NOTE: • Use a deep socket 2 for this procedure. Make sure that the camshaft does not crank • Make sure that the camshaft does not turn when loosening the driven sprocket bolt. when loosening the drive sprocket nut. Flywheel holder: 90890-06522 Crankshaft holder 18 3: 90890-06562...

  • Page 108: Installing The Timing Belt And Sprockets

    POWR Power unit Installing the timing belt and sprockets CAUTION: Do not turn the drive sprocket or the driven sprocket when the timing belt is not installed. Otherwise the piston and valves will interfere with each other and be damaged. 1.
  • Page 109 Power unit CAUTION: • Do not damage the timing belt during installation. • Do not twist, turn inside out, or bend the timing belt beyond the maximum limit of 25 mm (1.0 in), otherwise it can be dam- aged. • Do not get oil or grease on the timing belt.

  • Page 110: Cylinder Head

    POWR Power unit Cylinder head Part name Q’ty Remarks Cylinder head ø4 × 20 mm Screw Plate Engine hanger M6 × 20 mm Bolt Gasket Not reusable Cylinder head cover M6 × 20 mm Bolt O-ring Oil filler cap M9 × 93 mm Bolt Grommet Anode...
  • Page 111 Cylinder head Part name Q’ty Remarks Dowel Gasket Not reusable Grommet M6 × 25 mm Bolt Oil pump assembly M6 × 45 mm Bolt 5-20 6C13G11...
  • Page 112 POWR Power unit Part name Q’ty Remarks Camshaft Oil seal Not reusable Gasket Not reusable Retaining bolt Washer Rocker arm assembly Rocker arm assembly Valve cotter Valve spring retainer Valve spring Valve spring seat Valve seal Not reusable Valve guide Exhaust valve Intake valve Rocker arm shaft...
  • Page 113 Cylinder head Part name Q’ty Remarks Stopper guide Tensioner Stopper guide Tensioner 5-22 6C13G11...

  • Page 114: Removing The Cylinder Head

    POWR Power unit 4. Remove the rocker arm assembly 2 Removing the cylinder head and rocker arm shaft 3. 1. Remove the cylinder head cover. 2. Remove the cylinder head bolts in the sequence shown. S6C15410 5. Remove the retaining bolt 4, then the camshaft 5.

  • Page 115: Checking The Valve Springs

    Cylinder head 2. Measure the valve spring tilt b. Replace 6. Remove the intake and exhaust valves. if above specification. Valve spring tilt limit b: 1.7 mm (0.07 in) Checking the valves 1. Check the valve face for pitting or wear. Replace if necessary.

  • Page 116: Checking The Valve Guides

    POWR Power unit 3. Measure the valve stem diameter b. Replace if out of specification. Valve guide inside diameter a: Intake and exhaust: Valve stem diameter b: 5.500–5.512 mm Intake: (0.2165–0.2170 in) 5.475–5.490 mm (0.2156–0.2161 in) 2. Calculate the valve stem-to-valve guide Exhaust: clearance as follows.

  • Page 117: Checking The Valve Seat

    Cylinder head 4. Measure the valve guide inside diameter. Valve guide inside diameter: Intake and exhaust: 5.500–5.512 mm (0.2165–0.2170 in) Checking the valve seat 1. Eliminate carbon deposits from the valve with a scraper. 2. Apply a thin, even layer of Mechanic’s blueing dye (Dykem) onto the valve seat.

  • Page 118: Refacing The Valve Seat

    POWR Power unit 4. Measure the valve seat contact width a Valve seat cutter holder: where the blueing dye is adhered to the 90890-06316 valve face. Reface the valve seat if the Valve seat cutter: valve is not seated properly or if the valve 30°...
  • Page 119 Cylinder head 30˚ S69J5880 b Previous contact width b Previous contact width 4. Use a 60° cutter to adjust the contact 7. If the valve seat contact area is too nar- width of the bottom edge of the valve row and situated near the top edge of the seat.

  • Page 120: Checking The Rocker Arms And Rocker Arm Shaft

    POWR Power unit 9. Apply a thin, even layer of lapping com- Rocker arm inside diameter b: pound onto the valve seat, and then lap 16.000–16.018 mm the valve using a valve lapper (commer- (0.6299–0.6306 in) cially available). Rocker arm shaft outside diameter c: 15.971–15.991 mm (0.6288–0.6296 in)

  • Page 121: Checking The Cylinder Head

    Cylinder head 3. Measure the camshaft journal diameters c and d, and cylinder head journal inside diameter e. Replace the camshaft and cylinder head if out of specification. Cylinder head warpage limit: 0.10 mm (0.0039 in) Camshaft journal diameter c: 36.925–36.945 mm (1.4537–1.4545 in) Camshaft journal diameter d:...

  • Page 122: Checking The Oil Pump

    POWR Power unit Checking the oil pump 1. Measure the oil pump rotor clearances as shown. Replace if out of specification. S62Y5590 2. Install the valve 2, valve spring seat 3, valve spring 4, and valve spring retainer 5 in the sequence shown, and then attach the special service tools.

  • Page 123: Installing The Camshaft

    Cylinder head 2. Install the camshaft 2 in the direction shown, then the retaining bolt 3. 4. Lightly tap the valve spring retainer with a plastic hammer to set the valve cotter securely. Installing the rocker arm shaft assembly 1. Check that the camshaft dowel hole a is in the position shown in the illustration.

  • Page 124: Installing The Oil Pump

    POWR Power unit 2. Assemble the rocker arm assemblies 1 and rocker arm shaft 2, and then install the tensioners 3 and stopper guides 4 to the rocker arm shaft by installing the bolts 5. S6C15610 CAUTION: Be sure not to damage the washers 6 when installing the rocker arm shaft assembly to the cylinder head.

  • Page 125: Installing The Cylinder Head

    Cylinder head Installing the cylinder head CAUTION: 1. Install the driven sprocket, and then check that the “ 1” mark a on the • Do not reuse the cylinder head gasket, driven sprocket 1 is aligned with the “ ” always replace it with a new one.

  • Page 126: Exhaust Cover

    POWR Power unit Exhaust cover Part name Q’ty Remarks Cooling water temperature sensor Gasket Not reusable M6 × 14 mm Bolt Holder M6 × 14 mm Bolt M14 × 12 mm Plug Gasket Not reusable M8 × 17 mm Plug Gasket Not reusable Thermostat...
  • Page 127 Exhaust cover Part name Q’ty Remarks Cover M5 × 12 mm Bolt Plate M6 × 20 mm Bolt Joint Hose Hose Joint Hose Holder M4 × 8 mm Bolt Oil pressure switch lead Oil pressure switch Oil filter Joint Gasket Not reusable M14 ×...

  • Page 128: Cylinder Block

    POWR Power unit Cylinder block Part name Q’ty Remarks M8 × 82 mm Bolt M6 × 35 mm Bolt Crankcase Main bearing M6 × 30 mm Bolt Connecting rod assembly Connecting rod bearing Crankshaft Oil seal Not reusable Oil seal Not reusable Cylinder block M6 ×...

  • Page 129: Disassembling The Cylinder Block

    Cylinder block Disassembling the cylinder block 4. Remove the connecting rod bolts and the connecting rod caps, and then remove 1. Remove thermostat cover the crankshaft and oil seals. exhaust cover by removing the bolts in the sequence shown. S6C15620 2.

  • Page 130: Checking The Piston Diameter

    POWR Power unit Checking the piston diameter Cylinder bore (D –D 1. Measure the piston outside diameter at 65.000–65.015 mm the specified measuring point. Replace if (2.5591–2.5596 in) out of specification. 2. Calculate the taper limit. Replace the cyl- inder block if above specification. Taper limit: (direction d) –D...

  • Page 131: Checking The Piston Ring Grooves

    Cylinder block Piston ring end gap d: Piston ring dimensions: Top ring a: Top ring: B: 1.17–1.19 mm 0.15–0.30 mm (0.0461–0.0469 in) (0.0059–0.0118 in) T: 2.30–2.50 mm 2nd ring: (0.0905–0.0984 in) 0.30–0.50 mm 2nd ring b: (0.0118–0.0197 in) B: 1.47–1.49 mm Oil ring: (0.0579–0.0587 in) 0.20–0.70 mm...

  • Page 132: Checking The Piston Ring Side Clearance

    POWR Power unit Checking the piston ring side clearance 1. Measure the piston ring side clearance. Replace the piston and piston rings as a set if out of specification. Piston pin outside diameter: 15.965–15.970 mm (0.6285–0.6287 in) Checking the connecting rod small Piston ring side clearance: end inside diameter Top ring a:...

  • Page 133: Checking The Crankshaft

    Cylinder block 2. Measure the crankshaft runout. Replace the crankshaft if above specification. S6D55800 Connecting rod big end side clearance a: 0.05–0.22 mm (0.0020–0.0087 in) Crankshaft runout limit: 0.03 mm (0.0012 in) Checking the crankshaft Checking the crankpin oil clearance 1.

  • Page 134: Selecting The Connecting Rod Bearing

    POWR Power unit 3. Put a piece of Plastigauge (PG-1) onto the crankpin, parallel to the crankshaft. NOTE: Do not turn the connecting rod until the crankpin oil clearance measurement has NOTE: Be sure not to put the Plastigauge (PG-1) been completed.

  • Page 135: Checking The Crankshaft Journal Oil Clearance

    Cylinder block 2. Place the cylinder block upside down on a bench. 3. Install half of the bearings 1 and the crankshaft 2 into the cylinder block 3. NOTE: • Install the main bearings in their original positions. • Insert the projection a of each bearing into the slots in the cylinder block.

  • Page 136: Selecting The Main Bearings

    POWR Power unit 6. Install the crankcase onto the cylinder Crankshaft main journal oil block. clearance: 7. Apply engine oil to the threads of the 0.012–0.036 mm crankcase bolts, and then tighten them to (0.0005–0.0014 in) the specified torques in two stages and in the sequence shown.

  • Page 137: Assembling The Power Unit

    Cylinder block Cylinder body Crankshaft Bearing 45˚ 45˚ mark journal mark color Yellow #1,#4 Pink Green Assembling the power unit 1. Assemble the piston 1, connecting rod S6D55900 2, piston pin 3, and piston pin clips 4. CAUTION: Do not scratch the pistons or break the piston rings.
  • Page 138 POWR Power unit 5. Install the piston with the “UP” mark on the piston crown facing towards the fly- wheel magnet. NOTE: Apply engine oil to the side of the pistons and piston rings before installation. Piston slider: 90890-06529 NOTE: Apply engine oil to the inner oil seals before installation.
  • Page 139 Cylinder block NOTE: • Align the alignment marks g on the con- necting rod cap and connecting rod. • Apply engine oil to the connecting rod bolts before installation. Connecting rod cap bolt: 1st: 6 N·m (0.6 kgf·m, 4.4 ft·lb) 2nd: 17 N·m (1.7 kgf·m, 12.5 ft·lb) 9.

  • Page 140: Installing The Power Unit

    POWR Power unit 14. Install the oil filter, and then tighten it to 17. Install the cylinder head. the specified torque using the oil filter NOTE: wrench. For installation procedure, see “Installing the cylinder head.” Installing the power unit 1. Clean the power unit mating surface, and install the dowels 1 and a new gasket 2.
  • Page 141 Cylinder block 7. Install the PTT switch coupler, PTT motor NOTE: leads, and battery leads. Apply engine oil to the flywheel magnet nut before installation. Positive battery lead nut: 9 N·m (0.9 kgf·m, 6.6 ft·lb) PTT motor lead bolt: Flywheel holder: 90890-06522 4 N·m (0.4 kgf·m, 3.0 ft·lb) 8.
  • Page 142 LOWR Lower unit Special service tools ..................6-1 Lower unit (F50, F60) ..................6-5 Removing the lower unit ................6-7 Removing the water pump................. 6-7 Checking the water pump................6-7 Propeller shaft housing (F50, F60) ............... 6-8 Removing the propeller shaft housing assembly........6-9 Disassembling the propeller shaft assembly ..........6-9 Disassembling the propeller shaft housing..........
  • Page 143 Lower unit (FT50, FT60)................6-28 Removing the lower unit ................6-31 Removing the water pump and shift rod..........6-31 Checking the water pump and shift rod ...........6-32 Propeller shaft housing (FT50, FT60)............6-33 Removing the propeller shaft housing assembly........6-34 Disassembling the propeller shaft assembly ...........6-34 Disassembling the propeller shaft housing..........

  • Page 144: Lower Unit

    LOWR Lower unit Special service tools Bearing housing puller claw L Bearing puller assembly 90890-06502 90890-06535 Bearing housing puller claw S Needle bearing attachment 90890-06564 90890-06607, 90890-06608, 90890-06610, 90890-06611, 90890-06612, 90890-06614, 90890-06653 Stopper guide plate 90890-06501 Driver rod L3 90890-06652 Bearing separator 90890-06534 Ball bearing attachment...
  • Page 145 Special service tools Ball bearing attachment Bearing outer race puller assembly 90890-06655 90890-06523 Driver rod LS Driver rod SL 90890-06606 90890-06602 Bearing inner race attachment Bearing depth plate 90890-06639, 90890-06641, 90890-06643, 90890-06603 90890-06644, 90890-06661 Bearing outer race attachment Drive shaft holder 4 90890-06621, 90890-06622, 90890-06626, 90890-06518 90890-06627...
  • Page 146 LOWR Lower unit Shift rod push arm Backlash indicator 90890-06052 90890-06706 Pinion height gauge Magnet base plate 90890-06710 90890-07003 Pinion height gauge plate B Dial gauge set 90890-06712 90890-01252 Digital caliper Magnet base B 90890-06704 90890-06844 Shimming plate Center bolt 90890-06701 90890-06504 6C13G11...
  • Page 147 Special service tools Ring nut wrench 3 90890-06511 Ring nut wrench extension 90890-06513 6C13G11...

  • Page 148: Lower Unit (F50, F60)

    LOWR Lower unit Lower unit (F50, F60) Part name Q’ty Remarks Lower unit Check screw Gasket Not reusable Drain screw M10 × 40 mm Bolt Dowel M8 × 35 mm Bolt Anode Spacer Propeller Washer Washer Propeller nut Cotter pin Not reusable Trim tab M8 ×...
  • Page 149 Lower unit (F50, F60) Part name Q’ty Remarks Cover Seal M8 × 30 mm Bolt Water pump housing Insert cartridge Impeller O-ring Not reusable Dowel Outer plate cartridge Gasket Not reusable Seal Plate Woodruff key 6C13G11...

  • Page 150: Removing The Lower Unit

    LOWR Lower unit Removing the lower unit 5. Loosen the bolts, and then remove the lower unit from the upper case. 1. Drain the gear oil. 2. Set the gear shift 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 Removing the water pump...

  • Page 151: Propeller Shaft Housing (F50, F60)

    Lower unit (F50, F60) / Propeller shaft housing (F50, F60) Propeller shaft housing (F50, F60) Part name Q’ty Remarks Shift plunger Dog clutch Cross pin Spring Shift slider Spring Propeller shaft Reverse gear Reverse gear shim — O-ring Not reusable Ball bearing Not reusable O-ring...

  • Page 152: Removing The Propeller Shaft Housing Assembly

    LOWR Lower unit Removing the propeller shaft housing assembly 1. Remove the bolts, and then pull out the propeller shaft housing assembly. Bearing separator 1: 90890-06534 Bearing housing puller claw S 1: Stopper guide plate 2: 90890-06501 90890-06564 Stopper guide stand 3: Stopper guide plate 2: 90890-06501 Center bolt 3: 90890-06504 90890-06538...

  • Page 153: Checking The Propeller Shaft Housing

    Propeller shaft housing (F50, F60) Assembling the propeller shaft assembly 1. Install the dog clutch as shown. Needle bearing attachment 8: 90890-06614 Driver rod L3 9: 90890-06652 NOTE: Install the dog clutch 1 with the “F” mark a Checking the propeller shaft housing facing toward the shift plunger.
  • Page 154 LOWR Lower unit 2. Apply grease to new oil seals, and then 4. Install the reverse gear assembly into the install them into the propeller shaft hous- propeller shaft housing using a press. ing to the specified depth. NOTE: Install an oil seal halfway into the propeller shaft housing, then the other oil seal.
  • Page 155 Propeller shaft housing (F50, F60) / Drive shaft and lower case (F50, F60) Drive shaft and lower case (F50, F60) Part name Q’ty Remarks Seal Oil seal housing O-ring Not reusable Oil seal Not reusable Washer Drive shaft Forward gear Taper roller bearing assembly Not reusable Forward gear shim...
  • Page 156 LOWR Lower unit Part name Q’ty Remarks ø5 × 28 mm Screw Cooling water inlet cover Joint Plastic tie Not reusable Hose Shift rod Circlip O-ring Not reusable Shift rod housing Oil seal Not reusable 6-13 6C13G11...

  • Page 157: Drive Shaft And Lower Case (F50, F60)

    Drive shaft and lower case (F50, F60) Removing the drive shaft 1. Remove the drive shaft assembly and pinion, and then pull out the forward gear. CAUTION: Do not reuse the bearing, always replace it with a new one. S68S6360J Drive shaft holder 4 1: 90890-06518 Pinion nut holder 2: Bearing separator 1: 90890-06534...

  • Page 158: Disassembling The Lower Case

    LOWR Lower unit Disassembling the lower case 1. Remove the taper roller bearing outer race and shim(s). Needle bearing attachment 6: 90890-06614 Driver rod L3 7: 90890-06652 NOTE: Install the claws as shown. Checking the shift rod and shift cam 1.

  • Page 159: Checking The Lower Case

    Drive shaft and lower case (F50, F60) Checking the lower case 2. Install the needle bearing into the lower case to the specified depth. 1. Check the skeg and torpedo for cracks or damage. Replace the lower case if nec- essary.

  • Page 160: Assembling The Forward Gear

    LOWR Lower unit 3. Install the sleeve, original shim(s), and CAUTION: taper roller bearing outer race. Add or remove shim(s), if necessary, if replacing the taper roller bearing or lower case. Bearing outer race attachment 8: 90890-06622 Driver rod LL 9: 90890-06605 Assembling the forward gear 1.

  • Page 161: Installing The Oil Seal Housing

    Drive shaft and lower case (F50, F60) S68S6400 Drive shaft holder 4 1: 90890-06518 Pinion nut holder 2: New: 90890-06715 Current: 90890-06505 3. Install the propeller shaft housing assem- bly 4 into the lower case, and then Pinion nut: tighten the bolts 5 to the specified 74 N·m (7.4 kgf·m, 54.6 ft·lb) torque.

  • Page 162: Installing The Water Pump

    LOWR Lower unit Installing the water pump 1. Install a new gasket 1, the outer plate cartridge 2, and dowels 3. NOTE: Align the insert cartridge projection a with the hole b in the pump housing. 5. Install the new O-ring 8 and pump hous- ing assembly 9 into the lower case, tighten the bolts 0, and then install the seal A and cover B.
  • Page 163 Drive shaft and lower case (F50, F60) 2. Align the center of the set pin a with the alignment mark b on the bracket. S6C16310 Lower case mounting bolt 2: 39 N·m (3.9 kgf·m, 28.8 ft·lb) Shift rod push arm: 90890-06052 3.
  • Page 164 LOWR Lower unit 6. Install the propeller and propeller nut, and then tighten the nut finger tight. Place a block of wood between the anti- cavitation plate and propeller to keep the propeller from turning, and then tighten the nut to the specified torque. WARNING •...

  • Page 165: Shimming (F50, F60)

    Drive shaft and lower case (F50, F60) / Shimming (F50, F60) Shimming (F50, F60) 6-22 6C13G11...

  • Page 166: Shimming

    LOWR Lower unit Shimming 2. Install the pinion and pinion nut, and then tighten the nut to the specified torque. NOTE: • Shimming is not required when assembling Pinion nut: the original lower case and inner parts. 74 N·m (7.4 kgf·m, 54.6 ft·lb) •...

  • Page 167: Selecting The Forward Gear Shims

    Shimming (F50, F60) Calculation formula: Pinion shim thickness (T3) = M3 – 11.30 – P/100 Example: If “M3” is 11.70 mm and “P” is (+5), then T3 = 11.70 – 11.30 – (+5)/100 mm = 0.40 – 0.05 mm = 0.35 mm 5.

  • Page 168: Selecting The Reverse Gear Shims

    LOWR Lower unit 2. Calculate the forward gear shim thick- Example: ness (T1) as shown in the examples If “T1” is 0.49 mm, then the forward gear below. shim is 0.48 mm. If “T1” is 0.58 mm, then the forward gear shim is 0.55 mm.
  • Page 169 Shimming (F50, F60) / Backlash (F50, F60) NOTE: Shift rod push arm: 90890-06052 Install the dial gauge so that the plunger a contacts the mark b on the backlash indica- tor. 3. Install the special service tools so that it pushes against the propeller shaft.

  • Page 170: Lower Unit (Ft50, Ft60)

    LOWR Lower unit 8. Apply a load to the reverse gear by Reverse gear installing the propeller 8 (without the Shim thickness backlash washer 9 and 0), then the spacer A as Less than To be decreased by shown. (1.12 – M) × 0.56 0.89 mm (0.0350 in) More than To be increased by...
  • Page 171 Backlash (F50, F60) / Lower unit (FT50, FT60) Lower unit (FT50, FT60) Part name Q’ty Remarks Lower unit Hose Check screw Gasket Not reusable Dowel M10 × 40 mm/L-transom model Bolt Drain screw Grommet M10 × 45 mm Bolt M8 × 60 mm/L-transom model Bolt Spacer Propeller...
  • Page 172 LOWR Lower unit Part name Q’ty Remarks Stud bolt X-transom model M8 × 185 mm/X-transom model Bolt Dowel X-transom model Extension X-transom model Washer X-transom model Spring washer X-transom model X-transom model 6-29 6C13G11...
  • Page 173 Lower unit (FT50, FT60) Part name Q’ty Remarks O-ring Not reusable M6 × 16 mm Bolt Oil seal Not reusable Oil seal housing O-ring Not reusable Shift rod Woodruff key M8 × 55 mm Bolt M8 × 45 mm Bolt Water pump housing Seal Gasket...

  • Page 174: Removing The Lower Unit

    LOWR Lower unit Removing the lower unit 1. Drain the gear oil. 2. Set the gear shift to the neutral position, and place a block of wood between the 5. Loosen the bolts (nuts), and then remove anti-cavitation plate and propeller to keep the lower unit from the upper case.

  • Page 175: Checking The Water Pump And Shift Rod

    Lower unit (FT50, FT60) NOTE: Pull up the shift rod assembly a little a to dis- connect it from the shift slider 2, turn it coun- terclockwise 90° b, and then remove it. 2. Remove the Woodruff key, and then remove the outer plate cartridge.
  • Page 176 LOWR Lower unit Propeller shaft housing (FT50, FT60) Part name Q’ty Remarks Slider Shift plunger Cross pin Dog clutch Spring Propeller shaft Washer Reverse gear Thrust washer Ball bearing Not reusable O-ring Not reusable Propeller shaft housing Straight key Needle bearing Oil seal Not reusable Claw washer...

  • Page 177: Propeller Shaft Housing (Ft50, Ft60)

    Propeller shaft housing (FT50, FT60) Removing the propeller shaft housing assembly 1. Straighten the claw washer tabs a, and then remove the ring nut and claw washer. Disassembling the propeller shaft housing 1. Remove the reverse gear and thrust washer. Ring nut wrench 3 1: 90890-06511 Ring nut wrench extension 2: 90890-06513...

  • Page 178: Checking The Propeller Shaft Housing

    LOWR Lower unit 2. Remove the ball bearing. 3. Check the bearings for pitting or rum- bling. Replace if necessary. Checking the propeller shaft 1. Check the propeller shaft for bends or wear. Replace if necessary. 2. Measure the propeller shaft runout. CAUTION: Do not reuse the bearing, always replace it with a new one.
  • Page 179 Propeller shaft housing (FT50, FT60) Depth d: 5.0 ± 0.5 mm (0.200 ± 0.020 in) 3. Install the thrust washer 6 and new ball bearing 7 to the reverse gear 8 using a press. NOTE: • Install the needle bearing with the manufac- ture identification mark a facing toward the oil seal (propeller side).

  • Page 180: Drive Shaft And Lower Case (Ft50, Ft60)

    LOWR Lower unit Drive shaft and lower case (FT50, FT60) Part name Q’ty Remarks Drive shaft Taper roller bearing Not reusable Pinion shim — Sleeve Hose Plastic tie Not reusable Joint Cooling water inlet cover ø5 × 41 mm Screw Seal Plate Forward gear shim...
  • Page 181 Drive shaft and lower case (FT50, FT60) Part name Q’ty Remarks Pinion Lower case Oil seal housing O-ring Not reusable Oil seal Not reusable 6-38 6C13G11...

  • Page 182: 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. CAUTION: Do not reuse the bearing, always replace it with a new one. S68S6360J Drive shaft holder 4 1: 90890-06518 Pinion nut holder 2: Bearing separator 1: 90890-06534 New: 90890-06715...

  • Page 183: Disassembling The Lower Case

    Drive shaft and lower case (FT50, FT60) Disassembling the lower case 1. Remove the taper roller bearing outer race and shim(s). Needle bearing attachment 5: 90890-06611 Driver rod L3 6: 90890-06652 NOTE: Install the claws as shown. Checking the pinion and forward gear 1.

  • Page 184: Assembling The Lower Case

    LOWR Lower unit Assembling the lower case CAUTION: 1. Install the needle bearing into the lower Add or remove shim(s), if necessary, if case to the specified depth. replacing the taper roller bearing or lower case. NOTE: • Apply the gear oil to the inside and outside of the sleeve before installation.

  • Page 185: Assembling The Drive Shaft

    Drive shaft and lower case (FT50, FT60) Bearing inner race attachment 1: 90890-06643 Installing the pinion 1. Install the forward gear, then the drive shaft assembly, pinion, and pinion nut, and then tighten the nut to the specified torque. Needle bearing attachment 1: 90890-06607 2.

  • Page 186: Installing The Water Pump And Shift Rod

    LOWR Lower unit 3. Install the propeller shaft housing assem- bly 4 into the lower case, and then install the straight key 5, claw washer 6, and ring nut 7. 4. Tighten the ring nut to the specified torque. NOTE: Install the shift rod assembly into the lower case, turn it clockwise 90°...

  • Page 187: Installing The Lower Unit

    Drive shaft and lower case (FT50, FT60) 3. Install a new O-ring 5, onto the oil seal housing 7. 4. Install a new gasket 6, the oil seal hous- ing 7, a new gasket 8, and the outer plate cartridge 9. S6C16580 NOTE: Align the insert cartridge projection d with...
  • Page 188 LOWR Lower unit 2. Align the alignment mark a on the bush- ing with the alignment mark b on the bracket. S6C16310 È X-transom model Lower case mounting bolt (nut): 39 N·m (3.9 kgf·m, 28.8 ft·lb) 5. Install the trim tab 2 to its original posi- tion, and then connect the speedometer Shift rod push arm: 90890-06052 hose 3.
  • Page 189 Drive shaft and lower case (FT50, FT60) 6. Install the propeller and propeller nut, 7. Fill the gear oil to the correct level. and then tighten the nut finger tight. Place a block of wood between the anti- cavitation plate and propeller to keep the propeller from turning, and then tighten the nut to the specified torque.

  • Page 190: Shimming (Ft50, Ft60)

    LOWR Lower unit Shimming (FT50, FT60) 6-47 6C13G11...

  • Page 191: Shimming

    Shimming (FT50, FT60) Shimming 2. Install the pinion and pinion nut, and then tighten the nut to the specified torque. NOTE: • Shimming is not required when assembling Pinion nut: the original lower case and inner parts. 93 N·m (9.3 kgf·m, 68.6 ft·lb) •...

  • Page 192: Selecting The Forward Gear Shims

    LOWR Lower unit 4. Calculate the pinion shim thickness (T3) Example: as shown in the examples below. If “T3” is “0.55 mm”, then the pinion shim is 0.58 mm. If “T3” is “0.64 mm”, then the pinion shim is 0.65 mm. Selecting the forward gear shims 1.

  • Page 193: Backlash (Ft50, Ft60)

    Shimming (FT50, FT60) / Backlash (FT50, FT60) If “T1” is “0.50 mm”, then the forward gear shim is 0.48 mm. Backlash (FT50, FT60) Measuring the forward gear backlash 1. Remove the water pump assembly. 2. Set the gear shift to the neutral position at the lower unit.
  • Page 194 LOWR Lower unit 4. Install the backlash indicator onto the Available shim thicknesses: drive shaft (18 mm [0.71 in] in diameter), 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, and then the dial gauge onto the lower unit. 0.50 mm 7. Remove the special service tools from the propeller shaft, and then install the water pump assembly.
  • Page 195 Backlash (FT50, FT60) — MEMO — 6-52 6C13G11...
  • Page 196 BRKT Bracket unit Special service tools ..................7-1 Tiller handle ....................7-2 Checking the throttle cable and shift cable..........7-8 Assembling the tiller handle............... 7-8 Lubricating the tiller handle bracket............7-8 Adjusting the friction plate ................. 7-8 Bottom cowling ....................7-9 Upper case....................
  • Page 197 Tilt cylinder and trim cylinder ..............7-40 Disassembling the trim cylinder...............7-42 Disassembling the tilt cylinder ..............7-42 Checking the tilt cylinder and trim cylinder ..........7-43 Checking the valves ................7-43 Assembling the tilt cylinder ..............7-43 Assembling the power trim and tilt unit............7-45 Bleeding the power trim and tilt unit ............

  • Page 198: Bracket Unit

    BRKT Bracket unit Special service tools Bearing puller assembly Ball bearing attachment 90890-06535 90890-06637 Bearing puller claw 1 Cylinder-end screw wrench 90890-06536 90890-06588 Stopper guide stand Cylinder-end screw wrench 90890-06538 New: 90890-06568 Current: 90890-06544 Stopper guide plate 90890-06501 Driver rod LS 90890-06605 6C13G11...

  • Page 199: Tiller Handle

    Special service tools / Tiller handle Tiller handle · · · 10 N m (1.0 kgf m, 7.4 ft · · · m (0.7 kgf m, 5.2 ft · · · 37 N m (3.7 kgf m, 27.3 ft 27 26 ·...
  • Page 200 BRKT Bracket unit · · · 10 N m (1.0 kgf m, 7.4 ft · · · m (0.7 kgf m, 5.2 ft · · · 37 N m (3.7 kgf m, 27.3 ft 27 26 · · · m (0.4 kgf m, 3.0 ft S6C17010 Part name...
  • Page 201 Tiller handle · · · m (0.2 kgf m, 1.5 ft · · · 37 N m (3.7 kgf m, 27.3 ft · · · 37 N m (3.7 kgf m, 27.3 ft · · · m (0.3 kgf m, 2.2 ft ·...
  • Page 202 BRKT Bracket unit · · · m (0.2 kgf m, 1.5 ft · · · 37 N m (3.7 kgf m, 27.3 ft · · · 37 N m (3.7 kgf m, 27.3 ft · · · m (0.3 kgf m, 2.2 ft ·...
  • Page 203 Tiller handle 27 26 Part name Q’ty Remarks Tiller handle Cotter pin Not reusable Friction adjusting knob Grommet Plastic tie Not reusable Cable clamp Stay M6 × 14 mm Bolt Throttle cable Short Clip Throttle arm Throttle arm shaft Shift cable Long Shift cable bracket M6 ×...
  • Page 204 BRKT Bracket unit 27 26 Part name Q’ty Remarks ø5 × 10 mm Screw M6 × 14 mm Bolt Spring housing Spring Actuator Roller Bushing Shift arm Gear Holder M6 × 30 mm Bolt Throttle shaft Friction piece 6C13G11...

  • Page 205: Checking The Throttle Cable And Shift Cable

    Tiller handle Checking the throttle cable and shift Lubricating the tiller handle bracket cable 1. Inject grease into the grease nipple until grease comes out from the bushing a. 1. Check the operation of the throttle cable and shift cable. 2.

  • Page 206: Bottom Cowling

    BRKT Bracket unit Bottom cowling · · · 18 N m (1.8 kgf m, 13.3 ft · · · m (0.2 kgf m, 1.5 ft S6C17060 Part name Q’ty Remarks Washer Bushing Bracket Bushing M5 × 14 mm Bolt Shift rod Bushing Cotter pin Not reusable...
  • Page 207 Bottom cowling · · · 18 N m (1.8 kgf m, 13.3 ft · · · m (0.2 kgf m, 1.5 ft S6C17060 Part name Q’ty Remarks M6 × 25 mm Bolt Fuel joint Seal Bottom cowling assembly M6 × 20 mm Bolt Holder Washer...
  • Page 208 BRKT Bracket unit · · · 10 N m (1.0 kgf m, 7.4 ft S6C17070 Part name Q’ty Remarks Seal Tiller handle model Warning indicator Tiller handle model Collar Tiller handle model M6 × 35 mm, Tiller handle model Bolt M6 ×...
  • Page 209 Bottom cowling · · · 10 N m (1.0 kgf m, 7.4 ft S6C17070 Part name Q’ty Remarks Cowling lock lever Washer Wave washer Bushing M6 × 30 mm Bolt Grommet Collar Grommet Grommet Remote control model PTT motor lead Power trim and tilt model M6 ×...

  • Page 210: Upper Case

    BRKT Bracket unit Upper case · · · 24 N m (2.4 kgf m, 17.7 ft S6C17080 Part name Q’ty Remarks Upper case assembly M12 × 170 mm Bolt Washer M8 × 30 mm Bolt Upper mount Plate M8 × 175 mm Bolt Mount cover Washer...
  • Page 211 Upper case · · · 24 N m (2.4 kgf m, 17.7 ft S6C17080 Part name Q’ty Remarks M8 × 30 mm Bolt ø6 × 7 mm Screw Cover High thrust model M8 × 20 mm, High thrust model Bolt 7-14 6C13G11...
  • Page 212 BRKT Bracket unit · · · 17 N m (1.7 kgf m, 12.5 ft S6C17090 Part name Q’ty Remarks Muffler assembly Rubber seal Grommet Dowel Upper case Drive shaft bushing Circlip M10 × 45 mm Bolt Gasket Not reusable M14 × 12 mm Drain bolt 7-15 6C13G11...
  • Page 213 Upper case · · · 27 N m (2.7 kgf m, 20.0 ft · · · 10 N m (1.0 kgf m, 7.4 ft · · · 10 N m (1.0 kgf m, 7.4 ft S6C17100 Part name Q’ty Remarks Exhaust guide Oil seal Not reusable...
  • Page 214 BRKT Bracket unit · · · 27 N m (2.7 kgf m, 20.0 ft · · · 10 N m (1.0 kgf m, 7.4 ft · · · 10 N m (1.0 kgf m, 7.4 ft S6C17100 Part name Q’ty Remarks Rubber seal Gasket...

  • Page 215: Removing The Upper Case

    Upper case Removing the upper case Disassembling the oil pan 1. Remove the muffler 1, plate 2, and 1. Place a drain pan under the drain hole, exhaust manifold 3 from the oil pan 4. and then remove the drain bolt and let the oil drain completely.

  • Page 216: Assembling The Oil Pan

    BRKT Bracket unit Assembling the oil pan Oil strainer bolt: 1. Install a new gasket 1 onto the exhaust 10 N·m (1.0 kgf·m, 7.4 ft·lb) guide 2. 3. Install the oil pan 4, and then tighten the bolts finger tight. 4.

  • Page 217: Assembling The Upper Case

    Upper case S6C17180 S6C17200 Muffler bolt: Assembling the upper case 10 N·m (1.0 kgf·m, 7.4 ft·lb) 1. Install the drive shaft bushing into the upper case. 8. Install the muffler assembly A by insert- ing the tip of the cooling water pipe B into the joint hole b of the upper case.

  • Page 218: Installing The Upper Case

    BRKT Bracket unit Installing the upper case 1. Install the upper and lower mounting bolts into the swivel bracket 1 simulta- neously. 2. Install the upper mounting nuts 2, and then tighten the nuts to the specified torque. 3. Install and tighten the lower mounting nuts 3.

  • Page 219: Steering Arm

    Upper case / Steering arm Steering arm Part name Q’ty Remarks Steering arm Washer Bushing O-ring Not reusable Bushing Swivel bracket assembly Bushing Circlip Steering yoke Steering yoke High thrust model 7-22 6C13G11...

  • Page 220: 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 yoke 0 onto the steering arm 5 by aligning the center a of the yoke with the center b of the steering arm.
  • Page 221 Steering arm 7-24 6C13G11...

  • Page 222: Clamp Brackets And Swivel Bracket

    BRKT Bracket unit Clamp brackets and swivel bracket · · · 22 N m (2.2 kgf m, 16.2 ft · · · m (0.3 kgf m, 2.2 ft · · · 22 N m (2.2 kgf m, 16.2 ft S6C17320 Part name Q’ty Remarks...
  • Page 223 Clamp brackets and swivel bracket S6C17390 Part name Q’ty Remarks Swivel bracket Bushing Tilt stop lever Bushing Distance a: 30.3–30.4 mm (1.19–1.20 in) Collar Bushing Spring Spring holder M6 × 10 mm Bolt Bushing Tilt stop lever 7-26 6C13G11...

  • Page 224: Removing The Clamp Brackets

    BRKT Bracket unit Removing the clamp brackets 2. Assemble the clamp brackets and the swivel bracket by installing the self-lock- 1. Remove the power trim and tilt or hydro ing nuts 2, then tightening them to the tilt. For removal procedure, see “Remov- specified torque.
  • Page 225 Clamp brackets and swivel bracket Trim sensor setting resistance: Pink (P) – Black (B) 9–11 Ω at 20 °C (68 °F) 6. Fully tilt the outboard motor up, and then support it with the tilt stop lever. WARNING S6C17370 After tilting up the outboard motor, be sure to support it with the tilt stop lever.

  • Page 226: Power Trim And Tilt Unit

    BRKT Bracket unit Power trim and tilt unit Part name Q’ty Remarks Power trim and tilt unit Power trim and tilt model Hydro tilt unit Hydro tilt model Plastic tie Not reusable Power trim and tilt model Washer M8 × 19 mm Bolt Circlip Power trim and tilt model...

  • Page 227: Removing The Power Trim And Tilt Unit/Hydro Tilt Unit

    Power trim and tilt unit 3. Remove the plastic tie 2, and then pull Removing the power trim and tilt out the PTT motor leads. unit/hydro tilt unit 1. Fully tilt the outboard motor up, and then 4. Remove the bolts 3, then the lower support it with the tilt stop lever 1.

  • Page 228: Power Trim And Tilt Motor

    BRKT Bracket unit Power trim and tilt motor · · · m (0.4 kgf m, 3.0 ft · · · m (0.7 kgf m, 5.2 ft S6C17430 Part name Q’ty Remarks Stator ø5 × 20 mm Screw O-ring Not reusable Bearing Not reusable Armature...

  • Page 229: Disassembling The Power Trim And Tilt Motor

    Power trim and tilt motor Disassembling the power trim and 3. Remove the armature from the PTT motor base. tilt motor 1. Remove the power trim and tilt motor, O- CAUTION: ring, and joint from the power trim and tilt Do not allow grease or oil to contact the unit.

  • Page 230: Assembling The Power Trim And Tilt Motor

    BRKT Bracket unit 3. Measure commutator diameter. 6. Check the bearings and oil seal for dam- Replace if below specification. age or wear. Replace if necessary. NOTE: If the bearings and oil seal are removed, always replace them with new ones. Assembling the power trim and tilt motor 1.
  • Page 231 Power trim and tilt motor S6C17520 6. Install the stator onto the motor base. NOTE: Place a clean cloth over the end of the arma- ture shaft, hold it with a pair of pliers, and then carefully slide the stator over the arma- ture.

  • Page 232: Gear Pump

    BRKT Bracket unit Gear pump · · · m (0.5 kgf m, 3.7 ft · · · m (0.3 kgf m, 2.2 ft · · · m (0.5 kgf m, 3.7 ft · · · m (0.4 kgf m, 3.0 ft ·...
  • Page 233 Gear pump · · · m (0.5 kgf m, 3.7 ft · · · m (0.3 kgf m, 2.2 ft · · · m (0.5 kgf m, 3.7 ft · · · m (0.4 kgf m, 3.0 ft · · ·...
  • Page 234 BRKT Bracket unit · · · · · · m (0.3 kgf m, 2.2 ft m (0.4 kgf m, 3.0 ft S6C17450 Part name Q’ty Remarks Manual release spring Ball Bracket M3 × 5 mm Bolt M5 × 6 mm Bolt Washer O-ring...

  • Page 235: Disassembling The Gear Pump

    Gear pump Disassembling the gear pump 1. Remove the manual valve, then the gear pump and filters. S6C17600 Checking the gear pump 1. Clean all the pistons and balls, and then S6C17580 check them for damage or wear. Replace 2. Remove the relief valve seat caps, then if necessary.
  • Page 236 BRKT Bracket unit 3. Install the gear pump cover 4, then the pins 5. S6C17640 Lever bolt (M3) B, C: S6C17620 3 N·m (0.3 kgf·m, 2.2 ft·lb) 4. Install the adapters 6 into the gear pump 9. Install the up-relief valve seat D and cover.

  • Page 237: Tilt Cylinder And Trim Cylinder

    Gear pump / Tilt cylinder and trim cylinder Tilt cylinder and trim cylinder Part name Q’ty Remarks Tilt piston assembly Oil seal Not reusable Dust seal Not reusable O-ring Not reusable Trim cylinder end screw O-ring Not reusable O-ring Not reusable O-ring Not reusable Backup ring...
  • Page 238 BRKT Bracket unit Part name Q’ty Remarks Free piston O-ring Not reusable Ball Tilt cylinder 7-41 6C13G11...

  • Page 239: Disassembling The Trim Cylinder

    Tilt cylinder and trim cylinder Disassembling the trim cylinder 1. Hold the power trim and tilt unit 1 in a vise using aluminum plates a on both sides. NOTE: Place the tilt cylinder in the vise horizontally. 2. Loosen the tilt cylinder end screw 2, and 2.

  • Page 240: Checking The Tilt Cylinder And Trim Cylinder

    BRKT Bracket unit Assembling the tilt cylinder 1. Install new O-ring 1 into the trim cylinder end screw 2. 2. Install a new dust seal 3 and new oil seal 4 into the trim cylinder end screw 3. Install the tilt ram 5 into the trim cylinder end screw 2.
  • Page 241 Tilt cylinder and trim cylinder 6. Install the backup ring and new O-ring into the tilt piston 7. 7. Install balls 8 and 9, absorber valve pin, spring, pins, plate, and washer into the tilt piston. 8. Hold the tilt ram end in a vise using alu- minum plates on both sides.

  • Page 242: Assembling The Power Trim And Tilt Unit

    BRKT Bracket unit Assembling the power trim and tilt Recommended power trim and tilt fluid: unit ATF Dexron II 1. Hold the trim cylinder in a vise using alu- minum plates on both sides. 5. Install the new O-ring, joint, and power trim and tilt motor 5 by installing the 2.

  • Page 243: Bleeding The Power Trim And Tilt Unit

    Tilt cylinder and trim cylinder 7. Install the balls 6 into the tilt cylinder, and then insert the tilt cylinder into the trim cylinder 7. Bleeding the power trim and tilt unit 1. Tighten the manual valve 1 by turning it clockwise.

  • Page 244: Installing The Power Trim And Tilt Unit/Hydro Unit

    BRKT Bracket unit Battery Recommended power trim and tilt PTT motor lead terminal fluid: ATF Dexron II Sky blue (Sb) Light green (Lg) 5. Install the reservoir cap, and then tighten it to the specified torque. NOTE: • Repeat this procedure so that the tilt ram Reservoir cap: goes up and down four or five time (be sure 7 N·m (0.7 kgf·m, 5.2 ft·lb)

  • Page 245: Bleeding The Power Trim And Tilt Unit (Built-In)

    Tilt cylinder and trim cylinder 6. Route the PTT motor leads through the Manual valve: hole, and then install the plastic tie. 2 N·m (0.2 kgf·m, 1.5 ft·lb) 7. Connect the ground lead to the bottom of the power trim and tilt unit, and then 4.

  • Page 246: Power Trim And Tilt Electrical System

    BRKT Bracket unit 7. Remove the reservoir cap 2, and then Power trim and tilt electrical check the fluid level in the reservoir. system Checking the fuse 1. Check the fuse for continuity. Replace if there is no continuity. Checking the power trim and tilt relay 1.

  • Page 247: Checking The Power Trim And Tilt Switch

    Tilt cylinder and trim cylinder / Power trim and tilt electrical system Checking the power trim and tilt 2. Connect the digital circuit tester between power trim and tilt relay terminals 2 and switch 1. Check the power trim and tilt switch for continuity.

  • Page 248: Checking The Trim Sensor

    BRKT Bracket unit Checking the trim sensor 1. Measure the trim sensor resistance. Replace if out of specification. NOTE: Turn the lever 1 and measure the resistance as it gradually changes. Trim sensor resistance: Pink (P) – Black (B) 168.3–288.3 Ω at 20 °C (68 °F) a 9–11 Ω...
  • Page 249 Power trim and tilt electrical system — MEMO — 7-52 6C13G11...
  • Page 250 – 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 Port view....................8-3 Bow view ....................8-4 Starboard view................... 8-5 Top view ....................8-6 Tiller handle model ..................8-7 Ignition and ignition control system ............
  • Page 251 Starting system .................... 8-15 Checking the fuses .................. 8-15 Checking the starter relay................8-15 Starter motor ....................8-16 Disassembling the starter motor..............8-18 Checking the starter motor pinion............8-18 Checking the armature ................8-18 Checking the brushes................8-19 Checking the magnet switch..............8-19 Checking the starter motor operation ............8-19 Charging system ..................

  • Page 252: Electrical Systems

    – ELEC Electrical systems Special service tools Ignition tester Vacuum/pressure pump gauge set 90890-06754 90890-06756 Digital circuit tester Test harness (6 pins) 90890-03174 90890-06848 Peak voltage adapter B 90890-03172 Test harness (2 pins) 90890-06792 Test harness (2 pins) New: 90890-06867 Current: 90890-06767 6C13G11...

  • Page 253: Checking The Electrical Components

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

  • Page 254: Electrical Components

    – ELEC Electrical systems Electrical components Port view S6C18160 1 Power trim and tilt relay 2 Starter motor 3 Oil pressure switch 4 Cooling water temperature sensor 5 Rectifier Regulator 6 Ignition coil 7 Starter relay 8 Fuse (30 A) (starter relay) 6C13G11...

  • Page 255: Bow View

    Electrical components Bow view S6C18170 1 Sensor assembly (intake air temperature and 7 Main and fuel pump relay 8 Power trim and tilt relay intake air pressure) 2 ECM 9 Neutral switch (tiller handle model) 3 Fuse (20 A) (ECM, ignition coil, electric fuel 0 Shift position switch A Throttle position sensor pump, fuel injector, idle speed control, and...

  • Page 256: Starboard View

    – ELEC Electrical systems Starboard view S6C18180 1 Fuel injector 2 ECM 3 Throttle position sensor 4 Idle speed control 5 Sensor assembly (intake air temperature and intake air pressure) 6C13G11...

  • Page 257: Top View

    Electrical components Top view S6C18190 1 Solenoid valve 0 Fuse (20 A) (Rectifier Regulator) 2 Rectifier Regulator A Fuse (20 A) (main switch and power trim and 3 Spark plug tilt switch) 4 Ignition coil B Fuse (20 A) (ECM, ignition coil, electric fuel 5 Power trim and tilt switch pump, fuel injection, idle speed control, and (remote control model)

  • Page 258: Tiller Handle Model

    – ELEC Electrical systems Tiller handle model S6C18200 1 Shift position switch 2 Neutral switch (tiller handle model) 3 Warning indicator (tiller handle model) 4 Power trim and tilt switch 5 Engine stop lanyard switch 6 Variable trolling RPM switch (optional) 6C13G11...

  • Page 259: Ignition And Ignition Control System

    Ignition and ignition control NOTE: system The ignition spark can also be checked using Checking the ignition spark the “Stationary test” of the Yamaha Diagnos- 1. Disconnect the spark plug caps from the tic System. spark plugs. Checking the spark plug wires 2.

  • Page 260: Checking The Ecm

    – ELEC Electrical systems 3. Measure the ignition coil resistance. ECM output peak voltage: Replace if out of specification. Black/red (B/R) – Ground Black/white (B/W) – Ground Loaded r/min Cranking 1,500 3,500 DC V Checking the pulser coil 1. Remove the flywheel magnet cover and disconnect the pulser coil coupler.

  • Page 261: Checking The Pulser Coil Air Gap

    Pulser coil bolt: 4 N·m (0.4 kgf·m, 3.0 ft·lb) Checking the sensor assembly 1. Measure the ambient temperature. 2. Connect a computer to the outboard motor and use the Yamaha Diagnostic System to display the intake air tempera- ture. 8-10 6C13G11...

  • Page 262: Checking The Cooling Water Temperature Sensor

    – ELEC Electrical systems 4. Check the switch for no continuity at the specified pressure. Replace if there is continuity. Vacuum/pressure pump gauge set: 90890-06756 Specified oil pressure: 29.4–58.8 kPa S69J8270 (0.29–0.59 kgf/cm , 4.26–8.53 psi) Lead color Switch Checking the cooling water Blue/green position Black (B)

  • Page 263: Checking The Engine Start Switch (Tiller Handle Model)

    Ignition and ignition control system S6C18090 Lead color 2. Connect the digital circuit tester leads to Switch the relay terminals 2 and 3. White Black Pink Brown position (Br) 3. Connect the positive battery terminal to the main and fuel pump relay terminal 4. 4.

  • Page 264: Checking The Warning Indicators (Tiller Handle Model)

    NOTE: nal (1.5 V) to the yellow (Y) lead. Check the operation of the fuel injectors using the “Stationary test” of the Yamaha 5. Connect a negative penlight battery ter- Diagnostic System. minal (1.5 V) to the pink and black (P/B) lead.

  • Page 265: Checking The Main And Fuel Pump Relay (Fuel Control)

    Ignition and ignition control system / Fuel control system S6C18120 NOTE: After the engine start switch is turned to ON, the electric fuel pump will operate for 3 sec- S6D88120 onds. Checking the solenoid valve 1. Connect the special service tool to the Checking the main and fuel pump solenoid valve.

  • Page 266: Starting System

    – ELEC Electrical systems Starting system Checking the fuses 1. Check the fuses for continuity. Replace if there is no continuity. Checking the starter relay 1. Connect the digital circuit tester leads to the starter relay terminals. 2. Connect the positive battery terminal to the brown (Br) lead.
  • Page 267 Starting system / Starter motor Starter motor S63P8050 Part name Q’ty Remarks Clip Pinion stopper Starter motor pinion Spring M6 × 35 mm Bolt Housing Bearing Clutch assembly E-clip Not reusable Washer Bracket Pinion shaft Planetary gear Outer gear Plate Armature Stator 8-16...
  • Page 268 – ELEC Electrical systems S63P8050 Part name Q’ty Remarks Brush assembly Brush spring Brush holder Plate Washer Bracket ø4 × 15 mm Screw M6 × 120 mm Bolt Rubber seal Shift lever Spring Magnet switch assembly Washer 8-17 6C13G11...

  • Page 269: Starter Motor

    Starter motor Disassembling the starter motor 2. Measure commutator diameter. 1. Slide the pinion stopper 1 down as Replace the armature if below specifica- shown, and then remove the clip 2. tion. NOTE: Commutator diameter limit: Remove the clip with a thin screwdriver. 28.0 mm (1.10 in) 3.

  • Page 270: Checking The Brushes

    – ELEC Electrical systems 4. Check armature continuity. Replace if out of specifications. Brush continuity Brush 1 – Brush 2 No continuity Checking the magnet switch 1. Connect the tester leads between the magnet switch terminals as shown. 2. Connect the positive battery lead to the brown (Br) lead.

  • Page 271: Charging System

    Starter motor / Charging system 3. Disconnect the test harness coupler 1, Charging system and then measure the Rectifier Regulator Checking the stator coil output peak voltage at the coupler. If 1. Disconnect the stator coil coupler. below specification, measure the stator coil output peak voltage.
  • Page 272 – ELEC Electrical systems — MEMO — 8-21 6C13G11...
  • Page 273 TRBL SHTG Troubleshooting Special service tools ..................9-1 Yamaha Diagnostic System ................9-2 Introduction....................9-2 Self-diagnosis....................9-5 Diagnosing the electronic control system ..........9-5 Power unit....................... 9-7 Power trim and tilt unit ................9-22 6C13G11...

  • Page 274: Trbl Shtg

    TRBL SHTG Troubleshooting Special service tools Yamaha Diagnostic System 60V-85300-02 YAMAHA DIAGNOSTIC SYSTEM INSTALLATION MANUAL Yamaha Diagnostic System 60V-WS853-02 Diagnostic flash indicator B 90890-06865 6C13G11...
  • Page 275 Yamaha Diagnostic System Introduction Features The newly developed Yamaha Diagnostic System provides quicker detection and analysis of engine malfunctions for quicker troubleshooting procedures than traditional methods. By connecting your computer to the ECM (Electronic Control Module) of an outboard motor using the communication cable, this software can be used to display sensor data and data stored in the ECM on a computer’s monitor.
  • Page 276 • Windows XP is a multiuser operating system, therefore, be sure to end this program if the login user is changed. • The USB adapter cannot be used with Windows 95. For operating instructions of the Yamaha Diagnostic System, refer to the “Yamaha Diagnostic Sys- tem Instruction Manual.” 6C13G11...
  • Page 277 Yamaha Diagnostic System Connecting the communication cable to the outboard motor Bow view 3-pin communication coupler S6C19010 6C13G11...

  • Page 278: Self-Diagnosis

    TRBL SHTG Troubleshooting Self-diagnosis • Trouble code indication Example: The illustration indicates Diagnosing the electronic control code number 23. system a: Light on, 0.33 second 1. Connect the special service tool to the b: Light off, 4.95 seconds outboard motor as shown. c: Light off, 0.33 second d: Light off, 1.65 seconds S6C19030...
  • Page 279 Self-diagnosis Code Symptom Normal Incorrect cooling water temperature sensor signal Incorrect throttle position sensor signal Incorrect battery voltage Incorrect sensor assembly (intake air temperature sensor) signal Incorrect neutral switch signal Incorrect sensor assembly (intake air pressure sensor) signal Incorrect idle speed control signal Incorrect engine stop lanyard switch signal...

  • Page 280: Power Unit

    TRBL SHTG Troubleshooting NOTE: • Before troubleshooting the outboard motor, check the mounting and rigging of the outboard motor. Also, make sure that the specified fuel has been used and that the battery is fully charged. • To diagnose a mechanical malfunction, use the troubleshooting charts for each trouble located in this chapter.
  • Page 281 Power unit Repair or replace the defective Good condition? parts. Check the starter relay for conti- nuity. Is there continuity? Replace the starter relay. Check the neutral switch (tiller handle model) for continuity. Replace the neutral switch. Is there continuity? Check the engine start switch for continuity.
  • Page 282 TRBL SHTG Troubleshooting Ignition system Check the condition of the spark plugs. Clean, adjust, or replace the Good condition? spark plugs. Check the ignition spark using the ignition tester. WARNING • Do not touch any of the connections of the ignition tester leads. •...
  • Page 283 Power unit Good condition? Replace the ignition coils. Check the resistance of each spark plug wire and check the spark plug caps for salt buildup. Repair or replace the spark plug Good condition? wire. Check the main and fuel pump relay (main control) for continu- ity.
  • Page 284 TRBL SHTG Troubleshooting Fuel system Check the electric fuel pump operation. Can the opera- Check the fuse and wiring har- tion sound be ness for continuity. heard? Repair or replace Is there continuity? the defective parts. Check the main and fuel pump relay (fuel control) for continuity.
  • Page 285 Power unit Good condition? Replace the pressure regulator. Check the fuel rail for leaks or damage. Good condition? Replace the fuel rail. Check the fuel filters for clogs, dirt, or water and the hoses for leaks. Repair, clean, or replace the Good condition? defective parts.
  • Page 286 TRBL SHTG Troubleshooting Symptom 2: Engine speed at wide open throttle is low, engine speed decreases, or engine stalls (poor acceleration or poor deceleration). Check the battery lead connec- tions and check that the ground lead bolt is not loose or that it has not come off.
  • Page 287 Power unit Check the valve clearances or Out of specification? disassemble and check the engine. Check the ignition system, fuel system, lubrication system, or cooling system. Ignition system Check the condition of the spark plugs. Clean, adjust, or replace the Good condition? spark plugs.
  • Page 288 TRBL SHTG Troubleshooting Replace the engine stop lan- Is there continuity? yard switch. Check the resistance of each ignition coil. Good condition? Replace the ignition coils. Check the resistance of each spark plug wire and check the spark plug caps for salt buildup. Repair or replace the spark plug Good condition? wire.
  • Page 289 Power unit Fuel system Check the fuel filters for clogs, dirt, or water and the hoses for leaks. Repair or replace the defective Good condition? parts. Check the fuel pressure. Check the resistance of each Out of specification? injector and check the injectors for clogs.
  • Page 290 TRBL SHTG Troubleshooting Cracks or damage? Replace the diaphragm. Check the vapor separator nee- dle valve. Is the needle valve Replace the needle valve. bent or worn? Check the ignition system, lubri- cation system, or cooling sys- tem. Lubrication system Check the engine oil level.
  • Page 291 Power unit Check the oil pump for debris or Out of specification? oil leaks. Check the oil Debris or leaks? passage. Check the ignition system, fuel Clean or replace the defective system, or cooling system. parts. Cooling system Check the cooling water pas- sage for debris or leaks.
  • Page 292 TRBL SHTG Troubleshooting Replace the cooling water tem- Out of specification? perature sensor. Check the water pump. Good condition? Replace the water pump. Check the ignition system, fuel system, or lubrication system. Symptom 3: Engine speed not stable at low speeds or hunting occurs. Check the throttle position sen- sor and idle speed control and check that the connectors are...
  • Page 293 Power unit Ignition system Check the condition of the spark plugs. Clean, adjust, or replace the Good condition? spark plugs. Check the ignition spark using the ignition tester. WARNING • Do not touch any of the connections of the ignition tester leads. •...
  • Page 294 TRBL SHTG Troubleshooting Fuel system Check the fuel pump dia- phragm. Cracks or damage? Replace the diaphragm. Check the vapor separator nee- dle valve. Is the needle valve Replace the needle valve. bent or worn? Check the resistance of each injector and check the injectors for clogs.

  • Page 295: Power Trim And Tilt Unit

    Power unit / Power trim and tilt unit Power trim and tilt unit Symptom 1: Power trim and tilt unit does not operate. Check the power trim and tilt motor operation. Can the opera- tion sound be Check the battery and fuse. heard? Repair or replace Good condition?
  • Page 296 TRBL SHTG Troubleshooting Is it closed? Close the manual valve. Check the power trim and tilt fluid level. At specified level? Add fluid to the correct level. Disassemble and check the power trim and tilt unit. Symptom 2: Power trim and tilt unit does not hold the outboard motor up. Check that the manual valve is closed.
  • Page 297 Index Checking the connecting rod big end side clearance ......... 5-41 Adjusting the float ........4-19 Checking the connecting rod small Adjusting the friction plate......7-8 end inside diameter ........ 5-41 Adjusting the throttle link Checking the cooling water passage..3-10 and throttle cable ........3-10 Checking the cooling water pilot hole ..
  • Page 298 Index Checking the main and fuel pump relay Checking the tilt cylinder (main control) ..........8-11 and trim cylinder ........7-43 Checking the neutral switch Checking the timing belt ......3-6 (tiller handle model) ........8-11 Checking the timing belt and sprockets..5-16 Checking the oil pressure ......5-3 Checking the top cowling......
  • Page 299 Index ECM (Electric Control Module) ....1-10 Lower unit ........ 2-8 2-14 3-14 Electrical ........... 2-9 2-15 Lower unit (F50, F60) ......... 6-5 Electrical components.........8-3 Lower unit (FT50, FT60)......6-28 Electronic control system ......1-9 Lubricating the outboard motor....3-18 Exhaust cover ...........5-35 Lubricating the tiller handle bracket....
  • Page 300 Symbols ............1-2 Test run.............1-17 Tightening torques ........2-21 Tiller handle ..........7-2 Tiller handle model........8-7 Tilt cylinder and trim cylinder ....7-40 Top cowling..........3-3 Top view............8-6 Upper case..........7-13 Vapor separator ........4-12 Variable trolling RPM switch (optional) ..1-11 Ventilation ...........1-3 Yamaha Diagnostic System......9-2 6C13G11...
  • Page 301 Index — MEMO — 6C13G11...
  • Page 302 È To warning indicator (tiller handle model) W/B : White/black É To remote control or tiller handle : White/blue Ê To diagnostic flash indicator or Yamaha Diag- W/R : White/red nostic System : Yellow/green Ë To diagnostic flash indicator (special service tool) Ì...
  • Page 304 YAMAHA MOTOR CO., LTD. Printed in the Netherlands Jul. 2004 – 1.2 × 1 CR (E_2)
  • Page 305 F50FED, F50FEHT, F50FET, FT50GET, F60CEHT F60CET, FT60DET 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 Pu/R...

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