Page 1 F50A FT50B FT50C SERVICE MANUAL 290408 62Y-28197-3A-11...
Page 2: Important Information
NOTICE This manual has been prepared by Yamaha primarily for use by Yamaha dealers and their trained mechanics when performing maintenance procedures and repairs to Yamaha equipment. It has been written to suit the needs of persons who have a basic understanding of the mechanical and electrical concepts and procedures inherent in the work, for without such knowledge attempted repairs or service to the equipment could render it unsafe or unfit for use.
Page 3: Table Of Contents
Contents General information INFO Specifications SPEC Periodic checks and adjustments Fuel system FUEL Power unit POWR Lower unit LOWR Bracket unit BRKT – Electrical systems ELEC Index...
Page 5: General Information
INFO General information How to use this manual ................. 1-1 Manual format.................... 1-1 Symbols..................... 1-2 Safety while working..................1-3 Fire prevention................... 1-3 Ventilation....................1-3 Self-protection ................... 1-3 Parts, lubricants, and sealants ..............1-3 Good working practices ................1-4 Disassembly and assembly ............... 1-4 Identification....................1-5 Applicable models ..................1-5 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
Symbols 1 to 5 in an exploded diagram indicate the grade of lubricant and the lubrication point. 1 Apply Yamaha 4-stroke motor oil 2 Apply water resistant grease (Yamaha grease A, Yamaha marine grease) 3 Apply molybdenum disulfide grease 4 Apply anti-corrosion grease (Yamaha grease D)
Page 8: Safety While Working
Gasoline is highly flammable. Keep gasoline and all flammable products away from heat, sparks, and open flames. Parts, lubricants, and sealants Use only genuine Yamaha parts, lubricants, and sealants or those recommended by Yamaha, when servicing or repairing the outboard motor.
Page 9: Good Working Practices
Safety while working 6. Keep a supply of clean, lint-free cloths for wiping up spills, etc. Good working practices Special tools Use the recommended special tools to pro- tect parts from damage. Use the right tool in the right manner—do not improvise. 3.
Page 10: Identification
INFO General information Identification Approved Starting Applicable models Model name model code serial No. This manual covers the following models. USA, Canada Applicable models F50TH L: 451812– USA, Canada Worldwide F50TR L: 421732– — F50AEHD T50TR L: 406850– F50TH F50AEHT Worldwide —...
Page 11: Features And Benefits
Features and benefits Newly designed four carburetors Newly designed four carburetors have been based on the current F50A. Prime Start has been adopted for the starting system to further increase starting performance and serviceability. Further- more, the acceleration pump and the dashpot have been integrated to simplify construction and to ease serviceability.
Page 12: Cdi Unit With Microcomputer
INFO General information CDI unit with microcomputer The ignition system consists of a flywheel, stator, pulser coil, thermoswitch, oil pressure switch, CDI unit, and ignition coil. The CDI unit contains a built-in microcomputer that determines the ignition timing separately for acceleration and for normal operation, based on signals received from the pulser coil, thermoswitch, and oil pressure switch.
Page 13: Lower Unit
The lower unit of the new T50/FT50B, FT50C uses the same type of large gears that are used in the F100. The use of the same type of gears that are used in a higher class model provides ample dura- bility, making it possible to accommodate a wider range of applications throughout the market. F50/F50A T50/FT50B, FT50C S62Y1220...
Page 14 INFO General information Shift slider type shift mechanism The T50/FT50B, FT50C has adopted the shift slider type shift mechanism. This shift mechanism enables a prompt engagement of the dog clutch regardless of the operating speed of the shift lever. Thus, smooth and positive shift operation has been made possible. 1 Shift rod 2 Propeller shaft 3 Dog clutch...
Page 15: Technical Tips
To facilitate the starting of a cold engine, an air-fuel mixture that is richer than normal is required. For this reason, the Prime Start system has been adopted in the F50/F50A, T50/FT50B, FT50C. In the Prime Start system, the thermo heater plunger is in a position that fully opens the fuel enrich- ment valve while the engine is being started.
Page 16 INFO General information 1 Prime Start È The enriched air-fuel mixture is delivered to cylinders #1 and #2 by the Prime Start system attached to carburetor #1. É The enriched air-fuel mixture is delivered to cylinders #3 and #4 by the Prime Start system attached to carburetor #3.
Page 17: Technical Tips
Technical tips Carburetor operation 1. Idle and low-speed operation Since the vacuum at the venturi is low when the throttle valve is opened slightly, the main nozzle does not supply any air-fuel mixture to the engine. When the engine is operating at idle, the fuel that passes through the pilot jet and the air that passes through the pilot air jet mix, enabling the air-fuel mixture that has been regulated by the pilot screw to be fed through the pilot outlet.
Page 18 INFO General information 2. Medium speed operation When the throttle valve opens further, air-fuel mixture is fed from the pilot outlet and all the bypass holes. In addition, air-fuel mixture is also supplied from the main nozzle in accordance with the opening angle of the throttle valve.
Page 19 Technical tips 3. High-speed operation When the throttle valve approaches its fully open position, the fuel that has been regulated by the main jet and the air that has been regulated by the main air jet are mixed in the main nozzle. The resultant mixture is then sprayed by the main nozzle into the venturi.
Page 20: Acceleration Pump
INFO General information Acceleration pump The function of the acceleration pump is to ensure a smooth acceleration by preventing the air-fuel mixture from becoming temporarily lean in case the throttle valve is opened suddenly. When the throttle valve is opened suddenly, a large volume of air is introduced into the engine. However, because fuel is heavier than air, it is not possible to supply the volume of fuel that is necessary for the large volume of air that has been introduced.
Page 21 Technical tips Operation When the throttle is opened suddenly, diaphragm 1 (via the link that is connected to the throttle lever) operates to pressurize the air in the pump chamber. The pressurized air opens diaphragm 2, and becomes distributed to the carburetors by passing through the pipes that are connected to the carburetors.
Page 22: Ignition System
INFO General information Ignition system In order to determine the optimal ignition timing that is necessary for the proper operation of the engine, the built-in microcomputer in the CDI unit detects the signals from various types of sensors and controls the ignition timing in accordance with a control map that is based on those signals. The microcomputer also effects controls to protect the engine against overheating, over-revolution, and oil pressure drops, as well as to control warning devices.
Page 23 Technical tips Pulser coil The pulser coil transmits the pulser signals, which are generated in the pulser coil in accordance with the rotation of the flywheel, to the CDI unit. Among the two protrusions that are provided for generating signals, one is used for cylinders #1 and #4, and the other for cylinders #2 and #3, thus enabling the pulser coil to simultaneously ignite two cylinders.
Page 24: Ignition Timing Control
INFO General information Ignition timing control Control circuit diagram Operation Detection Microcomputer Ignition timing control Positive start Engine start Engine temperature (optimized ignition timing) Quick acceleration Acceleration Engine speed Engine speed control Over-revolution Warning buzzer (in remote-control Damage prevention Low oil pressure Oil pressure unit) Warning lamp...
Page 25 Technical tips Starting control When starting the engine, the timing is set to 5° BTDC until the crankshaft speed maintains 600 r/min for two seconds or longer. S62Y1350 1 Cylinder identification protrusion 7 Starting signal (5° BTDC) for cylinders #1 and 2 Protrusion for cylinders #1 and #4 3 Pulser coil 8 Starting signal (5°...
Page 26 INFO General information Acceleration control This control is activated when the throttle valve is opened suddenly. If the engine speed increases more than the specified figures, the control of the ignition timing transfers to the acceleration map. Thereafter, the control of the ignition timing transfers gradually to the control map before accelera- tion.
Page 27: Power Trim And Tilt
Technical tips Power trim and tilt The newly designed power trim and tilt consists of an up-main valve, a down-main valve, an up- relief valve, a single cylinder, and a single ram, which control both trim and tilt functions. The power trim and tilt cylinder has been integrated with the gear pump housing, the reservoir tank, and the power trim and tilt motor in order to achieve a smaller and more compact unit.
Page 28 INFO General information Power trim and tilt components S62Y1380 1 Cylinder A Up-relief valve 2 Ram B Up-shuttle piston 3 Check valve C Down-shuffle piston 4 Down-main valve D Trim cylinder base 5 Down-relief valve E Free piston 6 Motor F Tilt piston 7 Gear pump 8 Up-main valve...
Page 29 Technical tips Trim-up function The gear pump pumps power trim and tilt fluid to the up-main valve. As a result, the fluid pressure opens the up-shuttle piston causing the fluid to flow into the lower part of the power trim and tilt cyl- inder.
Page 30 INFO General information Trim-down function When the power trim and tilt switch is pressed to “Down”, the motor turns the gear pump counter- clockwise and the power trim and tilt fluid flows in the opposite direction to that of the trim-up func- tion.
Page 31 Technical tips Tilt-up function S62Y1400 1 Power trim and tilt cylinder 0 Up-shuttle piston 2 Ram A Down-shuttle piston 3 End screw B Trim cylinder base 4 Check valve C Free piston 5 Trim cylinder D Tilt piston 6 Reservoir E Balls 7 Down-main valve È...
Page 32 INFO General information Circular flow S62Y1410 1 Power trim and tilt cylinder 7 Gear pump 2 Ram 8 Free piston 3 Trim cylinder 9 Tilt piston 4 Motor È Return 5 Reservoir É Send 6 Up-relief valve 1-27 62Y3A11...
Page 33 Technical tips Tilt-down function When the power trim and tilt switch is pressed to “Down”, the motor turns the gear pump counter- clockwise, thus pumping the power trim and tilt fluid to the down-main valve. As a result, fluid pres- sure opens the down-main valve and the down-shuttle piston, which causes fluid to flow into the upper part of the trim cylinder and forces the tilt piston down.
Page 34 INFO General information Tilt-down function S62Y1420 1 Power trim and tilt cylinder A Down-shuttle piston 2 Ram B Ball 3 Trim cylinder C Trim cylinder base 4 Down-relief valve D Free piston 5 Down-main valve E Tilt piston 6 Gear pump F Balls 7 Reservoir È...
Page 35 Technical tips Stopping condition When the power trim and tilt switch is not pushed (released), the gear pump does not pump the fluid, the up-main valve and the down-main valve are closed, and the power trim and tilt fluid pres- sure in the system remains constant.
Page 36 INFO General information Damper function S62Y1430 1 Power trim and tilt cylinder 7 Check valve 2 Trim cylinder 8 Tilt piston absorber 3 Ram 9 Tilt piston 4 Tilt piston absorber È Send 5 Tilt piston É Moving direction 6 Free piston 1-31 62Y3A11...
Page 37: Propeller Selection
An incorrect choice F50/F50A could adversely affect performance and Propeller size (in) Material could also seriously damage the motor.
Page 38: Predelivery Checks
INFO General information Predelivery checks Checking the engine oil 1. Check the oil level. To make the delivery process smooth and efficient, the predelivery checks should be completed as explained below. Checking the fuel system 1. Check that the fuel hoses are securely connected and that the fuel tank is full with fuel.
Page 39: Checking The Outboard Motor Mounting Position
Predelivery checks Checking the outboard motor CAUTION: mounting position The shift/throttle cable joint must be 1. Check the position of the anti-cavitation screwed in a minimum of 8.0 mm (0.31 in) plate. 2. Check that the clamp brackets are secured with the clamp bolts. Checking the steering wheel/tiller handle 1.
Page 40: Checking The Tilt System
INFO General information 2. Check that the throttle control lever con- tacts the respective stoppers when the throttle control lever is closed or fully open. Checking the pilot water outlet 1. Check that cooling water is discharged from the pilot water outlet. Checking the tilt system 1.
Page 41: Break-In
Predelivery checks Break-in In the test run, the break-in operation is per- formed in the following three stages. 1. One hour a at 2,000 r/min or at approxi- mately half throttle. 2. One hour b at 3,000 r/min or 3/4 throttle and one minute out of every ten at full throttle.
Page 42 INFO General information — MEMO — 1-37 62Y3A11...
Page 43: Specifications
SPEC Specifications General specifications................... 2-1 Maintenance specifications ................2-5 Power unit....................2-5 Lower unit ....................2-9 Electrical ....................2-9 Power unit....................2-12 Lower unit ....................2-16 Electrical ....................2-16 Dimensions....................2-19 Tightening torques..................2-29 Specified torques..................2-29 General torques..................2-31 62Y3A11...
Page 44: General Specifications
SPEC Specifications General specifications Model — — — F50TR Item Unit Canada — F50TH — F50TR Worldwide F50AEHD F50AEHT F50AED F50AET Dimension Overall length mm (in) 1,329 (52.3) 718 (28.3) Overall width mm (in) 361 (14.2) Overall height mm (in) 1,397 (55.0) mm (in) —...
Page 45 General specifications Model — — — F50TR Item Unit Canada — F50TH — F50TR Worldwide F50AEHD F50AEHT F50AED F50AET Fuel and oil Fuel type Regular unleaded gasoline Fuel rating *PON Engine oil type 4-stroke motor oil Engine oil grade SE, SF, SG, SH 10W-30, 10W-40, or 20W-40 Engine oil quantity (with oil filter replacement)
Page 46 SPEC Specifications Model T50TR — — — Item Unit Canada T50TR — — — Worldwide FT50BET FT50CEHD FT50CED FT50CET Dimension Overall length mm (in) 1,384 718 (28.3) (28.3) (54.5) Overall width mm (in) 361 (14.2) Overall height mm (in) 1,436 (56.5) Boat transom height mm (in) 508 (20.0)
Page 47 General specifications Model T50TR — — — Item Unit Canada T50TR — — — Worldwide FT50BET FT50CEHD FT50CED FT50CET Fuel and oil Fuel type Regular unleaded gasoline Fuel rating *PON Engine oil type 4-stroke motor oil Engine oil grade SE, SF, SG, SH 10W-30, 10W-40, or 20W-40 Engine oil quantity (with oil filter replacement)
Page 48: Maintenance Specifications
SPEC Specifications Maintenance specifications Power unit Model — — — F50TR Item Unit Canada — F50TH — F50TR Worldwide F50AEHD F50AEHT F50AED F50AET Power unit Minimum compression 840 (8.4, 119) pressure* (kgf/cm , psi) Lubrication oil pressure 100 (1.0, 14) at 55 °C (131 °F), with (kgf/cm , psi)
Page 49 Maintenance specifications Model — — — F50TR Item Unit Canada — F50TH — F50TR Worldwide F50AEHD F50AEHT F50AED F50AET 2nd ring Dimension B mm (in) 1.47–1.49 (0.058–0.059) Dimension T mm (in) 2.49–2.51 (0.098–0.099) End gap mm (in) 0.30–0.50 (0.012–0.020) Side clearance mm (in) 0.03–0.07 (0.001–0.003) Oil ring...
Page 50 SPEC Specifications Model — — — F50TR Item Unit Canada — F50TH — F50TR Worldwide F50AEHD F50AEHT F50AED F50AET Margin thickness (D) Intake mm (in) 0.6–1.0 (0.024–0.039) Exhaust mm (in) 0.7–1.1 (0.028–0.043) Stem diameter Intake mm (in) 5.48–5.49 (0.2157–0.2161) Exhaust mm (in) 5.46–5.47 (0.2150–0.2153) Guide inside diameter...
Page 51 Maintenance specifications Model — — — F50TR Item Unit Canada — F50TH — F50TR Worldwide F50AEHD F50AEHT F50AED F50AET Oil pump Type Trochoid Outer rotor-to-housing mm (in) 0.09–0.15 (0.004–0.006) clearance Outer rotor-to-inner rotor mm (in) 0.01–0.10 (0.0004–0.0039) clearance limit Rotor-to-cover clearance mm (in) 0.03–0.08 (0.001–0.003) Thermostats...
Page 52: Lower Unit
SPEC Specifications Lower unit Model — — — F50TR Item Unit Canada — F50TH — F50TR Worldwide F50AEHD F50AEHT F50AED F50AET Gear backlash Pinion-to-forward gear mm (in) 0.18–0.54 (0.007–0.021) Pinion-to-reverse gear mm (in) 0.71–1.07 (0.028–0.042) Pinion shims 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50 Forward gear shims 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50 Reverse gear shims...
Page 53 Maintenance specifications Model — — — F50TR Item Unit Canada — F50TH — F50TR Worldwide F50AEHD F50AEHT F50AED F50AET Ignition control system Oil pressure switch 50 (0.5, 7.11) (kgf/cm , psi) Thermoswitch (Gy/B – B) OFF → ON °C (°F) 76–84 (169–183) ON →...
Page 54 SPEC Specifications Model — — — F50TR Item Unit Canada — F50TH — F50TR Worldwide F50AEHD F50AEHT F50AED F50AET Power trim and tilt system Trim sensor Ω Setting resistance 9−11 Ω Resistance (P – B) 10–288.3 Fluid type ATF Dexron II Brushes Standard length mm (in)
Page 55: Power Unit
Maintenance specifications Power unit Model T50TR — — — Item Unit Canada T50TR — — — Worldwide FT50BET FT50CEHD FT50CED FT50CET Power unit Minimum compression 840 (8.4, 119) pressure* (kgf/cm , psi) Lubrication oil pressure 100 (1.0, 14) at 55 °C (131 °F), with (kgf/cm , psi) 10W-30 engine oil...
Page 56 SPEC Specifications Model T50TR — — — Item Unit Canada T50TR — — — Worldwide FT50BET FT50CEHD FT50CED FT50CET 2nd ring Dimension B mm (in) 1.47–1.49 (0.058–0.059) Dimension T mm (in) 2.49–2.51 (0.098–0.099) End gap mm (in) 0.30–0.50 (0.012–0.020) Side clearance mm (in) 0.03–0.07 (0.001–0.003) Oil ring...
Page 57 Maintenance specifications Model T50TR — — — Item Unit Canada T50TR — — — Worldwide FT50BET FT50CEHD FT50CED FT50CET Margin thickness (D) Intake mm (in) 0.6–1.0 (0.024–0.039) Exhaust mm (in) 0.7–1.1 (0.028–0.043) Stem diameter Intake mm (in) 5.48–5.49 (0.2157–0.2161) Exhaust mm (in) 5.46–5.47 (0.2150–0.2153) Guide inside diameter...
Page 58 SPEC Specifications Model T50TR — — — Item Unit Canada T50TR — — — Worldwide FT50BET FT50CEHD FT50CED FT50CET Oil pump Type Trochoid Outer rotor-to-housing mm (in) 0.09–0.15 (0.004–0.006) clearance Outer rotor-to-inner rotor mm (in) 0.01–0.10 (0.0004–0.0039) clearance limit Rotor-to-cover clearance mm (in) 0.03–0.08 (0.001–0.003) Thermostats...
Page 59: Lower Unit
Maintenance specifications Lower unit Model T50TR — — — Item Unit Canada T50TR — — — Worldwide FT50BET FT50CEHD FT50CED FT50CET Gear backlash Pinion-to-forward gear mm (in) 0.12–0.45 (0.005–0.018) Pinion-to-reverse gear mm (in) 0.71–1.11 (0.028–0.044) Pinion shims 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50 Forward gear shims 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50 Electrical...
Page 60 SPEC Specifications Model T50TR — — — Item Unit Canada T50TR — — — Worldwide FT50BET FT50CEHD FT50CED FT50CET Ignition control system Oil pressure switch 50 (0.5, 7.11) (kgf/cm , psi) Thermoswitch (Gy/B – B) OFF → ON °C (°F) 76–84 (169–183) ON →...
Page 61 Maintenance specifications Model T50TR — — — Item Unit Canada T50TR — — — Worldwide FT50BET FT50CEHD FT50CED FT50CET Power trim and tilt system Trim sensor Ω Setting resistance 9−11 Ω Resistance (P – B) 10–288.3 Fluid type ATF Dexron II Brushes Standard length mm (in)
Page 62: Dimensions
SPEC Specifications Dimensions Exterior 2-19 62Y3A11...
Page 63 Maintenance specifications Model — — Symbol Unit Canada — F50TH Worldwide F50AEHD F50AEHT mm (in) 576 (22.7) mm (in) 223 (8.8) mm (in) 753 (29.6) mm (in) 532 (20.9) mm (in) 97 (3.8) mm (in) — 85 (3.3) mm (in) 930 (36.6) 932 (36.7) mm (in)
Page 64 SPEC Specifications Exterior 2-21 62Y3A11...
Page 65 Maintenance specifications Model — F50TR T50TR Symbol Unit Canada — F50TR T50TR Worldwide F50AED F50AET FT50BET mm (in) 576 (22.7) mm (in) 142 (5.6) mm (in) — mm (in) 532 (20.9) 560 (22.0) mm (in) 97 (3.8) mm (in) — 85 (3.3) —...
Page 66 SPEC Specifications Exterior C1 L5 S62Y2230 2-23 62Y3A11...
Page 67 Maintenance specifications Model — Symbol Unit Canada — Worldwide FT50CEHD mm (in) 576 (22.7) mm (in) 272 (10.7) mm (in) 797 (31.4) mm (in) 560 (22.0) mm (in) 97 (3.8) mm (in) — mm (in) 990 (39.0) mm (in) — mm (in) 397 (15.6) mm (in)
Page 68 SPEC Specifications Exterior 2-25 62Y3A11...
Page 69 Maintenance specifications Model — — Symbol Unit Canada — — Worldwide FT50CED FT50CET mm (in) 576 (22.7) mm (in) 142 (5.6) mm (in) — mm (in) 560 (22.0) mm (in) 97 (3.8) mm (in) — mm (in) 990 (39.0) mm (in) —...
Page 70 SPEC Specifications Clamp bracket Model — — — F50TR Symbol Unit Canada — F50TH — F50TR Worldwide F50AEHD F50AEHT F50AED F50AET mm (in) 126 (5.0) mm (in) 254 (10.0) mm (in) 163.5 (6.4) mm (in) 50.8 (2.0) mm (in) 180 (7.1) mm (in) 355 (14.0) mm (in)
Page 71 Maintenance specifications Clamp bracket Model T50TR — — — Symbol Unit Canada T50TR — — — Worldwide FT50BET FT50CEHD FT50CED FT50CET mm (in) 126 (5.0) mm (in) 254 (10.0) mm (in) 163.5 (6.4) mm (in) 50.8 (2.0) mm (in) 180 (7.1) mm (in) 355 (14.0) mm (in)
Page 72: Tightening Torques
Adjusting screw locknut — Oil filter — Drain bolt — Exhaust cover bolt Crankcase bolt Connecting rod cap bolt — Lower unit (F50/F50A) Check screw — Lower unit bolt Drain screw — Propeller nut — Water inlet cover screw —...
Page 73 — Ring nut — 10.5 Water inlet cover screw — Pinion nut Bracket unit Tiller handle assembly nut (F50/F50A) — Engine shut-off switch nut (F50/F50A) — Tiller handle bracket nut (F50/F50A) — Main switch nut (F50/F50A) — Friction wing nut (FT50C) —...
Page 74: General Torques
SPEC Specifications 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 75 Periodic checks and adjustments Special service tools ..................3-1 Maintenance interval chart................3-3 Top cowling ....................3-4 Checking the top cowling................3-4 Fuel system ....................3-4 Checking the fuel joint and fuel hoses (fuel joint-to-carburetor) ....3-4 Checking the fuel filter ................3-5 Power unit.......................
Page 76: Chk Adj
Periodic checks and adjustments Special service tools For USA and Canada Pressurfge/vacuum tester YB-35956-A Oil filter wrench For worldwide YU-38411 Flywheel magnet holder Oil filter wrench YB-06139 90890-01426 Universal puller Flywheel holder YB-06117 90890-06522 Inductive self-powered tachometer Flywheel puller YU-08036-B 90890-06521 Battery powered timing light Digital tachometer...
Page 77 Special service tools Timing light 90890-03141 Leakage tester 90890-06762 62Y3A11...
Page 78: Maintenance Interval Chart
Periodic checks and adjustments Maintenance interval chart Use the following chart as a guideline for general maintenance. Adjust the maintenance intervals according to the operating conditions of the outboard. Initial Every Refer to Item Remarks 10 hours 50 hours 100 hours 200 hours page (Break-in)
Page 79: Top Cowling
Maintenance interval chart / Top cowling / Fuel system Top cowling Fuel system Checking the top cowling Checking the fuel joint and fuel 1. Check the fitting by pushing the cowling hoses (fuel joint-to-carburetor) 1. Remove the plate 1, and then check the with both hands.
Page 80: Checking The Fuel Filter
Replacing the engine oil 1. Remove the engine oil dipstick and oil filler cap 1. È F50/F50A É T50/FT50B, FT50C NOTE: Be sure not to spill any fuel when removing the fuel filter cup.
Page 81 Fuel system / Power unit 2. Place a drain pan under the drain hole, and then remove the drain bolt 2 and let the oil drain completely. S62Y3110 S62Y3080 3. Place a rag under the oil filter, and then remove the filter. S62Y3115 Oil filter wrench: YU-38411 / 90890-01426 Oil filter: 18 N·m (1.8 kgf·m, 13 ft·lb)
Page 82: Checking The Timing Belt
Periodic checks and adjustments Oil quantity: With oil filter replacement: 2.2 L (2.3 US qt, 1.9 Imp qt) Without oil filter replacement: 2.0 L (2.1 US qt, 1.8 Imp qt) 8. Install the oil filler cap and dipstick, and then start the engine and warm it up for 5 minutes.
Page 83 Power unit Flywheel magnet holder 1: YB-06139 Flywheel holder 1: 90890-06522 Universal puller 2: YB-06117 Flywheel puller 2: 90890-06521 3. Disconnect the stator couplers 3, and then remove the stator 4. 4. Disconnect the pulser coil coupler 5, and then remove the stator base 6 with both collars 7.
Page 84 Periodic checks and adjustments 6. Check that the “1” mark a on the driven CAUTION: sprocket is aligned with the “ ” mark b on the cylinder head, and that the “ ” • Do not twist, turn inside out, or bend the mark c on the drive sprocket is aligned timing belt beyond the maximum limit of with the “...
Page 85: Checking The Valve Clearance
Power unit 2. Remove the spark plugs, fuel pump 2, 13. Install the flywheel magnet and flywheel and cylinder head cover 3. magnet cover. 3. Turn the flywheel clockwise and align the “1” mark a on the driven sprocket with the “...
Page 86: Checking The Spark Plugs
Periodic checks and adjustments 5. Turn the flywheel clockwise and align the NOTE: “4” mark c on the driven sprocket with Adjust the valve clearance when the engine the “ ” mark b on the cylinder head. is cold. Valve clearance: Intake d: 0.20 ±...
Page 87: Checking The Thermostat
Power unit 2. Clean the electrodes 1 with a spark plug Spark plug: 18 N·m (1.8 kgf·m, 13 ft·lb) cleaner or wire brush. Replace the spark plug if necessary. Checking the thermostat 1. Remove the cover 1, thermostat cover 2, and thermostat 3. 3.
Page 88: Checking The Cooling Water Passage
Periodic checks and adjustments 4. Check the thermostat valve opening at 3. Check for water flow at the cooling water specified water temperatures. outlet. If there is no water flow, check the Replace if out of specification. cooling water passage inside the out- board.
Page 89: Checking The Gearshift Operation
Power unit / Control system 3. Align the alignment mark b on the throt- tle cam 1 with the alignment mark c on the shift bracket. 4. Adjust the position of the throttle cable joint until its hole is aligned with the set pin d on the throttle cam.
Page 90: Checking The Engine Idle Speed
Periodic checks and adjustments Checking the engine idle speed Checking the ignition timing 1. Start the engine and warm it up for 5 min- 1. Start the engine and warm it up for 5 min- utes. utes. 2. Attach the special service tool to high- 2.
Page 91: Power Trim And Tilt Unit
Control system / Power trim and tilt unit 4. Check that the TDC “T” mark a on the flywheel magnet is aligned with the mag- net base pointer b. Checking the power trim and tilt fluid level 1. Fully tilt the outboard up, and then sup- Ignition timing: BTDC 5 ±...
Page 92: Chk Adj
Periodic checks and adjustments 3. Remove the reservoir cap 3, and then NOTE: check the fluid level in the reservoir. The gear oil level should be at the brim of the check hole. 3. If necessary, add sufficient gear oil of the recommended type to the correct level.
Page 93 Check the internal parts of the lower case if necessary. Oil quantity: F50/F50A: 6. Insert the gear oil tube or gear oil pump 0.43 L (0.45 US qt, 0.38 Imp qt) into the drain hole and slowly fill the gear...
Page 94: Checking The Lower Unit (For Air Leakage)
Periodic checks and adjustments Checking the lower unit Checking the propeller (for air leakage) 1. Check the propeller blades and splines 1. Remove the check screw 1, and then for cracks, damage, or wear. Replace if necessary. install the special service tool. S62Y3585 General Checking the anodes...
Page 95: Checking The Battery
• Avoid bodily contact with electrolyte as É EHD, ED models it can cause severe burns or permanent Ê EHT, ET models eye injury. Ë F50/F50A only • Wear protective eye gear when handling or working near batteries. Antidote (EXTERNAL): • SKIN – Wash with water.
Page 96: Lubrication
• Disconnect the negative lead first, then the positive lead. Electrolyte specific gravity: 1.280 at 20 °C (68 °F) Lubrication 1. Apply water resistant grease to the areas shown. S62Y3720 È F50/F50A, T50/FT50B É FT50C 3-21 62Y3A11...
Page 97 General NOTE: Apply grease to the grease nipple until it flows from the bushings a. 2. Apply anti-corrosion grease to the areas shown. 3-22 62Y3A11...
Page 98 Periodic checks and adjustments — MEMO — 3-23 62Y3A11...
Page 99: Fuel
FUEL Fuel system Special service tools ..................4-1 Hose routing ....................4-2 Fuel and blowby hoses................4-2 Cooling water hose..................4-3 Fuel line ......................4-5 Fuel filter and fuel pump ................4-7 Checking the fuel pump................4-9 Disassembling the fuel pump ..............4-9 Checking the diaphragm and valves ............4-10 Assembling the fuel pump ...............
Page 100: Fuel System
FUEL Fuel system Special service tools For USA and Canada Digital tachometer 90890-06760 Pressure/vacuum tester YB-35956-A Vacuum gauge 90890-03159 Inductive self-powered tachometer YU-08036-B Carburetor synchronizer YU-08030 For worldwide Vacuum/pressure pump gauge set 90890-06756 62Y3A11...
Page 101: Hose Routing
Special service tools / Hose routing Hose routing Fuel and blowby hoses 1 Blowby hose 2 Hose (acceleration pump-to-carburetor) 3 Fuel hose (fuel joint-to-fuel filter) 4 Fuel hose (fuel filter-to-fuel pump) 5 Fuel hose (fuel pump-to-carburetor) 6 Hose (carburetor-to-carburetor) 62Y3A11...
Page 102: Cooling Water Hose
FUEL Fuel system Cooling water hose È Models with flushing device 62Y3A11...
Page 103 Hose routing — MEMO — 62Y3A11...
Page 104: Fuel Line
FUEL Fuel system Fuel line 62Y3A11...
Page 105 Fuel line Tightening torques Part name Q’ty Remarks Stage N·m kgf·m ft·lb Fuel joint Fuel filter F50/F50A Fuel filter T50/FT50B, FT50C Fuel pump M6 × 25 mm Bolt Seal Fuel hose Fuel joint-to-fuel filter Clip M8 × 14 mm Bolt...
Page 106: Fuel Filter And Fuel Pump
FUEL Fuel system Fuel filter and fuel pump 62Y3A11...
Page 107 Fuel filter element Body Float M5 × 35 mm Screw Cover Fuel pump body 2 Fuel pump body 1 Plunger Spring Spring Diaphragm M3 × 6 mm Screw Valve Seal Not reusable Gasket Not reusable È F50/F50A É T50/FT50B, FT50C 62Y3A11...
Page 108: Checking The Fuel Pump
FUEL Fuel system Checking the fuel pump NOTE: 1. Install the special service tool onto the • Make sure that air does not escape from fuel pump as shown. the opposite side of the fuel pump. • To eliminate any gaps between the fuel pump valves and the fuel pump body 2, and to ensure a better seal, make sure that the inside of the fuel pump is moist with gaso-...
Page 109: Checking The Diaphragm And Valves
Fuel filter and fuel pump 2. Push down on the plunger and the dia- 2. Push down on the plunger and the dia- phragm, turn the fuel pump body 1 1 phragm, and then install the pin 1. approximately 90° to a position where the pin 2 can be removed easily, and then remove the pin.
Page 110: Carburetor Unit
FUEL Fuel system Carburetor unit 4-11 62Y3A11...
Page 111 Carburetor unit Tightening torques Part name Q’ty Remarks Stage N·m kgf·m ft·lb Carburetor assembly Joint-to-silencer Clip Blowby hose Prime Start coupler M6 × 30 mm Bolt Collar Throttle link rod O-ring Not reusable Insulator Dowel pin M6 × 25 mm Bolt Fuel hose Fuel pump-to-carburetor...
Page 112 FUEL Fuel system 4-13 62Y3A11...
Page 113 Carburetor unit Tightening torques Part name Q’ty Remarks Stage N·m kgf·m ft·lb Acceleration pump M5 × 9 mm Screw Link rod Hose Acceleration pump-to- acceleration pump Hose Acceleration pump-to- carburetor Link rod 4-14 62Y3A11...
Page 114 FUEL Fuel system 4-15 62Y3A11...
Page 115 Carburetor unit Tightening torques Part name Q’ty Remarks Stage N·m kgf·m ft·lb Carburetor Silencer Plastic tie Not reusable Blowby hose Silencer-to-joint M6 × 90 mm Bolt Collar O-ring Not reusable Plate O-ring Not reusable O-ring Not reusable Joint Plastic tie Not reusable Fuel hose Carburetor-to-carburetor...
Page 116: Carburetor
FUEL Fuel system Carburetor 4-17 62Y3A11...
Page 117 Carburetor Tightening torques Part name Q’ty Remarks Stage N·m kgf·m ft·lb Carburetor body M4 × 13 mm Screw Cover Seal Not reusable Pilot jet Main jet Needle valve Main nozzle O-ring Not reusable Plug Float M4 × 6 mm Screw Float pin Gasket Not reusable...
Page 118: Checking The Carburetor
FUEL Fuel system Checking the carburetor 1. Check the air and fuel passages and jets, for dirt and foreign matter. Clean the car- buretor body with a petroleum based sol- vent if necessary. 2. Blow compressed air into all passages and jets.
Page 119: Checking The Prime Start
Carburetor 5. Check the float for deterioration. Replace it necessary. Prime Start plunger extended length a: 24.6 mm (0.97 in) 6. Measure the float height a. Replace the float and needle valve, if out of specifica- Assembling the carburetor tion, as a set. 1.
Page 120: Adjusting The Throttle Link Rod
FUEL Fuel system 2. Install the needle valve 5, float 6, float Adjusting the throttle link rod pin 7, and screw 8 as shown, and then 1. Push the throttle control lever 1 to the the check the float for smooth operation. fully open position as shown, and then measure the gap between the carburetor throttle lever 2 and carburetor stopper...
Page 121: Adjusting The Pilot Screw
Carburetor 4. Push the throttle control lever 1 to the fully open position as shown. 5. While pushing the carburetor throttle lever 2 against the carburetor stopper 3, loosen, and then tighten the adjusting screw 5. Adjusting the pilot screw Engine idle speed: 900 ±...
Page 122: Synchronizing The Carburetors
FUEL Fuel system Synchronizing the carburetors 1. Start the engine and warm it up for 5 min- utes to check the stability of the engine. 2. Attach the special service tool to the high-tension cord #1 1. S62Y4380 Inductive self-powered tachometer: YU-08036-B Digital tachometer: 90890-06760 3.
Page 123: Adjusting The Dash-Pot (Acceleration Pump)
Carburetor 5. Measure the vacuum pressure of carbu- retor #4. 6. Turn the throttle valve adjusting screws 5 to adjust the vacuum pressure of car- buretors #1, #2, and #3 to the same vac- uum variation as carburetor #4. S62Y4430 Inductive self-powered tachometer: YU-08036-B Digital tachometer: 90890-06760...
Page 124 FUEL Fuel system 5. Open the throttle cam 2 slowly, and check that the acceleration pump stopper 3 comes in contact with point a. 6. Turn the adjusting screw 4 in or out until the specified engine speed is obtained. 7.
Page 125 — MEMO — 4-26 62Y3A11...
Page 126: Powr
POWR Power unit Troubleshooting..................... 5-1 Special service tools ...................5-10 Power unit..................... 5-13 Checking the compression pressure ............5-25 Checking the oil pressure ................5-25 Removing the power unit.................5-26 Timing belt and sprockets................5-29 Removing the timing belt and sprockets..........5-31 Checking the timing belt and sprockets...........5-32 Installing the timing belt and sprockets............5-32 Cylinder head ....................5-35 Removing the cylinder head ..............
Page 127 Cylinder body ....................5-51 Removing and installing the oil filter ............5-55 Disassembling the cylinder body ............. 5-55 Checking the piston diameter ..............5-56 Checking the cylinder bore ..............5-56 Checking the piston clearance ..............5-57 Checking the piston rings ................5-57 Checking the piston ring grooves ............5-58 Checking the piston ring side clearance..........
Page 128: Troubleshooting
POWR Power unit Troubleshooting Before troubleshooting the power unit, check that all electrical connections are tight and free from corrosion, and that the battery is fully charged to 12 V. Symptom: Engine does not crank. • Check the starting system. •...
Page 129 Troubleshooting Check the wiring harnesses for continuity. Is there conti- Replace the wiring harnesses. nuity? Check operation of the starter motor pinion. Does the pin- Listen for the operation sound ion rotate? of the starter relay. Can the oper- Replace the starter Remove all spark plugs, and ation sound relay.
Page 130 POWR Power unit Symptom: Engine cracks, but will not start. • Check the ignition system. • Check the fuel system. • Check the compression pressure of power unit. WARNING Check the ignition spark using the spark gap tester. • Do not touch any of the connections of the spark gap tester Below the...
Page 131 Troubleshooting Symptom: Engine can be started, but does not remain on. • Check the fuel system. • Check the ignition system. • Check the compression pressure of power unit. Check that the fuel vent screw of the fuel tank is open. Is the vent Open the fuel vent screw.
Page 132 POWR Power unit Check that there is no secondary air intake on the contact surfaces of the intake manifold and crankcase. Is there air Replace the respective seals. intake? Check the compression pres- sure of the combustion chamber. Check the ignition spark gap using the spark gap tester. Out of specifi- Check the ignition system out- cation?
Page 133 Troubleshooting Symptom: The engine idle speed is not steady, but increases or decreases. • Check the carburetors. • Check the air intake system. • Check the ignition system. Check the operation of the car- buretor throttle valves. Do the valves close simul- Check the ignition timing.
Page 134 POWR Power unit Symptom: Engine does not accelerate when the throttle is opened quickly. The engine turns off when the throttle is opened quickly. Acceleration is tardy and the engine is likely to stop at any moment. • Check the carburetors. •...
Page 135 Troubleshooting Symptom: Engine can run, but engine speed will not increase. Overheat warning indicator is on. Oil pressure warning indicator is on. Warning indicator is on and buzzer is sounding. • Check the water cooling system. • Check the lubricating system. Check the water inlet for clogs or debris.
Page 136 POWR Power unit Check the engine oil level. At specified Add engine oil to the correct level? level. Check the oil pressure. Out of specifi- Check the oil pump for debris or cation? wear. Check the oil pas- Debris or sage.
Page 137: Special Service Tools
Special service tools Special service tools For USA and Canada Valve guide remover YM-01122 Compression gauge YU-33223-1 Valve guide reamer YM-01196 Flywheel magnet holder YB-06139 Valve seat cutter set YM-91043-C Universal puller YB-06117 Drive shaft needle bearing depth stop YB-34473 Crankshaft holder YB-06562 Oil filter wrench...
Page 138: Power Unit
POWR Power unit Piston ring compressor Valve spring compressor YU-33294 90890-04019 For worldwide Valve spring compressor attachment 90890-06320 Compression gauge 90890-03160 Valve guide remover/installer 90890-06801 Flywheel holder 90890-06522 Valve guide reamer 90890-06804 Flywheel puller 90890-06521 Valve seat cutter holder 90890-06316 Crankshaft holder 18 90890-06562 5-11...
Page 139 Special service tools Valve seat cutter 90890-06315, 90890-06323, 90890-06326, 90890-06328, 90890-06555 Bearing outer race attachment 90890-06626 Oil filter wrench 90890-01426 Piston slider 90890-06529 5-12 62Y3A11...
Page 140 POWR Power unit Power unit 5-13 62Y3A11...
Page 141 Power unit Tightening torques Part name Q’ty Remarks Stage N·m kgf·m ft·lb Flywheel magnet Stator coil Cover Grommet Washer M6 × 25 mm Bolt Lighting coil coupler Charge coil coupler Stator base Pulser coil coupler M6 × 24 mm Screw Dowel pin Woodruff key Cover...
Page 142 POWR Power unit 5-15 62Y3A11...
Page 143 Power unit Tightening torques Part name Q’ty Remarks Stage N·m kgf·m ft·lb Throttle cable Shift cable F50/F50A, T50/FT50B Shift cable FT50C Fuel pump Fuel filter assembly F50/F50A Fuel filter assembly T50/FT50B, FT50C Carburetor assembly M6 × 20 mm Bolt Plate...
Page 144 POWR Power unit 5-17 62Y3A11...
Page 145 Power unit Tightening torques Part name Q’ty Remarks Stage N·m kgf·m ft·lb Power trim and tilt relay EHT/ET models M8 × 16 mm Bolt Negative battery lead Wiring harness extension Grommet Spring washer Positive battery lead PTT relay positive lead EHT/ET models Fuse holder lead Clip...
Page 146 POWR Power unit 5-19 62Y3A11...
Page 147 Power unit Tightening torques Part name Q’ty Remarks Stage N·m kgf·m ft·lb Bracket Starter motor Spark plug cap Ignition coil Wiring harness Thermoswitch Holder M6 × 12 mm Bolt Ground lead M6 × 12 mm Bolt Oil pressure switch Oil pressure switch lead Screw Ignition coil lead M6 ×...
Page 148 POWR Power unit 5-21 62Y3A11...
Page 149 Power unit Tightening torques Part name Q’ty Remarks Stage N·m kgf·m ft·lb Power unit Engine oil dipstick Gasket Not reusable Dowel pin M6 × 16 mm Bolt M8 × 80 mm Bolt Apron M6 × 24 mm Screw 5-22 62Y3A11...
Page 150 POWR Power unit 5-23 62Y3A11...
Page 151 Power unit Tightening torques Part name Q’ty Remarks Stage N·m kgf·m ft·lb Throttle link rod Throttle cam Throttle control lever Clip Bushing M6 × 20 mm Bolt Spring Collar Bracket M6 × 30 mm Bolt Shift rod M6 × 30 mm Bolt Bracket Spring...
Page 152: Checking The Compression Pressure
POWR Power unit Checking the compression pressure NOTE: 1. Start the engine, warm it up for 5 min- • If the compression pressure increases, utes, and then turn it off. check the piston and piston rings for wear. Replace if necessary. 2.
Page 153: Removing The Power Unit
Power unit Removing the power unit 1. Remove the flywheel magnet cover and flywheel magnet. CAUTION: • Apply force in the direction of the arrows shown, to prevent the flywheel holder from slipping off easily. • To prevent damage to the engine or tools, screw in the flywheel puller set bolts evenly and completely so that the flywheel puller plate is parallel to the fly-...
Page 154 POWR Power unit 2. Disconnect the throttle cable 1 and shift 5. Remove the power trim and tilt relay C, cable/shift rod 2. shift rod D and shift rod bolts E. 3. Disconnect the fuel hose 3 and throttle link rod 4. 6.
Page 155 Power unit 7. Remove the power unit by removing the bolts G. 5-28 62Y3A11...
Page 156: Timing Belt And Sprockets
POWR Power unit Timing belt and sprockets 5-29 62Y3A11...
Page 157 Timing belt and sprockets Tightening torques Part name Q’ty Remarks Stage N·m kgf·m ft·lb Timing belt Drive sprocket Driven sprocket Bolt M8 × 20 mm Bolt Tensioner Spring Retaining plate Woodruff key M10 × 40 mm Bolt Washer M6 × 20 mm Bolt Blowby hose Clip...
Page 158: Removing The Timing Belt And Sprockets
POWR Power unit 3. Remove the tensioner 4 and timing belt Removing the timing belt and 5 from the driven sprocket side. sprockets 1. Set the cylinder #1 piston position to TDC of the compression stroke by align- ing the “1” mark a on the driven sprocket with the “...
Page 159: Checking The Timing Belt And Sprockets
Timing belt and sprockets 5. Remove the nut 1, retaining plates 8, Installing the timing belt and drive sprocket 9, and Woodruff key 0. sprockets 1. Check that the “1” mark a on the driven sprocket 1 is aligned with the “ ” mark b on the cylinder head, and then tighten the bolt 2.
Page 160 POWR Power unit 5. Install the tensioner 8 and bolts, and 3. Check that the “ ” mark c on the retain- ing plate is aligned with the “ ” mark d then tighten the bolts finger tight. on the cylinder body. 4.
Page 161 Timing belt and sprockets Crankshaft holder B: YB-06562 CAUTION: Crankshaft holder 18 B: 90890-06562 Do not turn the sprockets counterclock- wise, otherwise the valve system may be damaged. Drive sprocket nut 6: 140 N·m (14 kgf·m, 100 ft·lb) 9. Tighten the driven sprocket bolt 2 to the specified torque.
Page 162: Cylinder Head
POWR Power unit Cylinder head 5-35 62Y3A11...
Page 163 Cylinder head Tightening torques Part name Q’ty Remarks Stage N·m kgf·m ft·lb Cylinder head Oil pump Cylinder head cover M6 × 20 mm Bolt Cylinder head cover Not reusable gasket M9 × 95 mm Bolt Spark plug M6 × 25 mm Bolt Dowel pin Cylinder head gasket...
Page 164 POWR Power unit 5-37 62Y3A11...
Page 165 Cylinder head Tightening torques Part name Q’ty Remarks Stage N·m kgf·m ft·lb Rocker arm assembly Rocker arm shaft Cylinder head Exhaust valve Intake valve Camshaft Valve cotter Spring retainer Valve spring Spring seat Stem seal Not reusable Valve guide Not reusable Retaining bolt Gasket Not reusable...
Page 166: Removing The Cylinder Head
POWR Power unit Removing the cylinder head 1. Check that the camshaft dowel pin hole a is in the position shown in the illustra- tion. Adjust if necessary. S62Y5260 2. Remove the cylinder head cover bolts in the sequence shown. 4.
Page 167: Checking The Valve Springs
Cylinder head 5. Remove the retaining bolt 4, then the Valve spring compressor 6: camshaft 5 by pulling it downward. YM-01253 / 90890-04019 Valve spring compressor attachment 7: 90890-06320 Checking the valve springs 1. Measure the valve spring free length a. Replace if out of specification.
Page 168: Checking The Valve Guides
POWR Power unit 2. Measure the valve margin thickness a. Valve stem runout: Replace if out of specification. Intake: 0.03 mm (0.0012 in) Exhaust: 0.03 mm (0.0012 in) Checking the valve guides 1. Measure the valve guide inside diameter a. Replace if out of specification. Valve margin thickness a: Intake: 0.6–1.0 mm (0.024–0.039 in) Exhaust: 0.7–1.1 mm (0.028–0.043 in)
Page 169: Checking The Valve Seat
Cylinder head 2. Install the new valve guide 2 by striking 4. Measure the valve guide inside diameter. the special service tool from the cam- Replace the valve guide if out of specifi- shaft side until the valve guide clip 3 cation.
Page 170: Refacing The Valve Seat
POWR Power unit Valve seat contact width a: a Slag or rough surface Intake: 0.9–1.1 mm (0.035–0.043 in) Exhaust: 0.9–1.1 mm (0.035–0.043 in) CAUTION: Do not over cut the valve seat. Make sure Refacing the valve seat to turn the cutter evenly downward at a 1.
Page 171 Cylinder head 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. valve face, use a 30° cutter to cut the top edge of the valve seat.
Page 172: Checking The Rocker Arms And Rocker Arm Shaft
POWR Power unit CAUTION: Do not get the lapping compound on the valve stem and valve guide. 10. After every lapping procedure, be sure to clean off any remaining lapping com- pound from the cylinder head and the valve. Cam lobe a: 11.
Page 173: Checking The Cylinder Head
Cylinder head 3. Measure the camshaft journal diameter c and cylinder head journal inside diam- eter d. Replace the camshaft and cylin- der head if out of specification. Camshaft journal diameter c: #1: 36.93–36.94 mm (1.4539–1.4543 in) #2, #3, #4: 36.94–36.95 mm (1.4543–1.4547 in) Cylinder head journal inside diameter d: 37.00–37.02 mm (1.4567–1.4575 in)
Page 174: 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, spring seat 3, valve spring 4, and spring retainer 5 in the sequence shown, and then attach the special service tool.
Page 175: Installing The Camshaft
Cylinder head Installing the camshaft 3. Compress the valve spring, and then install the valve cotter 8 using a thin 1. Install the new oil seal 1. screwdriver with a small amount of grease applied to it. S62Y5630 È For USA and Canada É...
Page 176: Installing The Rocker Arm Assembly
POWR Power unit Installing the rocker arm assembly 3. Install the rocker arm shaft assembly to the cylinder head by installing the bolts, 1. Check that the camshaft dowel pin hole a is in the position shown in the illustra- and then tighten them to the specified torque.
Page 177 Cylinder head 2. Tighten the cylinder head bolts to the specified torques in two stages and in the sequence shown. NOTE: Apply engine oil to the cylinder head bolts (M9) before installation. Cylinder head bolt (M9): 1st: 23 N·m (2.3 kgf·m, 17 ft·lb) 2nd: 47 N·m (4.7 kgf·m, 34 ft·lb) Cylinder head bolt (M6): 1st: 6 N·m (0.6 kgf·m, 4.3 ft·lb)
Page 178: Cylinder Body
POWR Power unit Cylinder body 5-51 62Y3A11...
Page 179 Cylinder body Tightening torques Part name Q’ty Remarks Stage N·m kgf·m ft·lb Oil filter Crankshaft M8 × 82 mm Bolt M6 × 35 mm Bolt Crankcase Oil seal Not reusable Main bearing Oil seal Not reusable Connecting rod bearing Connecting rod cap Bolt Dowel pin Cylinder body...
Page 180 POWR Power unit 5-53 62Y3A11...
Page 181 Cylinder body Tightening torques Part name Q’ty Remarks Stage N·m kgf·m ft·lb Anode Cover Cover M6 × 20 mm Bolt M5 × 12 mm Bolt M6 × 35 mm Bolt È Tightening sequence 5-54 62Y3A11...
Page 182: Removing And Installing The Oil Filter
POWR Power unit Removing and installing the oil filter 1. Place a rag under the oil filter, and then remove the filter. S62Y5710 Oil filter wrench: YU-38411 / 90890-01426 S62Y5690 Oil filter: 18 N·m (1.8 kgf·m, 13 ft·lb) Oil filter wrench: YU-38411 / 90890-01426 Disassembling the cylinder body NOTE: 1.
Page 183: Checking The Piston Diameter
Cylinder body 2. Remove the crankcase bolts in the sequence shown. Piston diameter a: 62.95–62.96 mm (2.478–2.479 in) Measuring point b: 5 mm (0.2 in) up from the bottom of the piston skirt Oversize piston diameter: Oversize 1: +0.25 mm (0.01 in) Oversize 2: +0.50 mm (0.02 in) Checking the cylinder bore 3.
Page 184: Checking The Piston Clearance
POWR Power unit 2. Calculate the taper limit. Replace or Piston ring dimensions: rebore the cylinder body if out of specifi- Top ring a: cation. B: 1.17–1.19 mm (0.046–0.047 in) Taper limit = maximum of D or D – T: 2.39–2.41 mm (0.094–0.095 in) Second ring b: minimum of D or D...
Page 185: Checking The Piston Ring Grooves
Cylinder body Checking the piston ring grooves Piston ring side clearance: 1. Measure piston ring grooves. Top ring a: Replace the piston if out of specification. 0.04–0.08 mm (0.002–0.003 in) Second ring b: 0.03–0.07 mm (0.001–0.003 in) Oil ring c: 0.05–0.19 mm (0.002–0.007 in) Checking the piston pin boss bore 1.
Page 186: Checking The Connecting Rod Small End Inside Diameter
POWR Power unit Checking the connecting rod small end inside diameter 1. Measure the connecting rod small end 5 mm (0.2 in) inside diameter a. Replace the connect- ing rod if out of specification. 10 mm (0.4 in) S62Y5850 Connecting rod bolt thread diameter limit (difference between a and b): 0–0.1 mm (0–0.004 in) Checking the crankshaft...
Page 187: Checking The Crankshaft Main Journal Oil Clearance
Cylinder body 2. Measure the crankshaft runout. Replace the crankshaft if out of specification. NOTE: Do not put the Plastigauge (PG-1) over the oil hole in the main journals of the crankshaft. Crankshaft runout limit: 0.04 mm (0.0016 in) 5. Install the remaining half of the bearings Checking the crankshaft main into the crankcase.
Page 188: Checking The Crankshaft Pin Oil Clearance
POWR Power unit NOTE: CAUTION: Do not move the crankshaft until the main Install the bearings in their original posi- journal oil clearance measurement has been tions. completed. NOTE: Crankcase bolt (M8): Insert the projection a of the bearing into the 1st: 15 N·m (1.5 kgf·m, 11 ft·lb) slot on the cap and connecting rod.
Page 189: Selecting The Crankshaft Main Journal Bearing
Cylinder body Selecting the crankshaft main NOTE: journal bearing • Align the alignment marks b on the con- 1. When replacing the main bearing, select necting rod cap and connecting rod. the suitable bearing as follows. • Face the embossed “Y” mark on the con- necting rod toward the flywheel side of the 2.
Page 190: Selecting The Connecting Rod Big End Bearing
POWR Power unit 4. When installing the main bearing, insert the projection of the main bearing into the slot on the cylinder body. CAUTION: Remove any small metal particles and oil from the contact surfaces of the cylinder body and the main bearing. 5.
Page 191: Assembling The Cylinder Body
Cylinder body 6. If the oil clearance is below specification, 3. Offset the piston ring end gaps as check the connecting rod bearing color shown. and clean the contact surface of the con- necting rod and the connecting rod bear- ing, and then check the crank pin oil clearance again.
Page 192 POWR Power unit 7. Set the crankshaft A, and oil seals B 5. Install the piston with the “UP” mark on and C into the cylinder body as shown. the piston crown facing towards the fly- wheel. Apply engine oil to the inner oil seal, jour- nal bearings, and connecting rod bear- ing.
Page 193 Cylinder body NOTE: Align the alignment marks g on the connect- ing rod cap and connecting rod. Connecting rod bolt: 1st: 6 N·m (0.6 kgf·m, 4.3 ft·lb) 2nd: 17 N·m (1.7 kgf·m, 12 ft·lb) 9. Install half of the bearings 9 into the crankcase, then dowel pins E.
Page 194: Installing The Power Unit
POWR Power unit 12. Install the new gasket and exhaust cover, and then tighten the bolts to the specified torques in two stages and in the sequence shown. Mounting bolt 4: Exhaust cover bolt: 1st: 6 N·m (0.6 kgf·m, 4.3 ft·lb) 21 N·m (2.1 kgf·m, 15 ft·lb) 2nd: 12 N·m (1.2 kgf·m, 8.7 ft·lb) 3.
Page 195 Cylinder body 4. Install the shift rod bolts 6, shift rod 7 6. Connect the throttle link rod G and fuel and power trim and tilt relay 8. hose H. 5. Connect the flushing hose (models with flushing device), pilot water hose 9, trailer switch coupler 0 (EHT, ET), warn- ing indicator coupler A (EHD, EHT), ground lead B (EHT, ET), PTT motor...
Page 196 POWR Power unit 8. Install the Woodruff key. Flywheel magnet holder: YB-06139 Flywheel holder: 90890-06522 Flywheel magnet nut: 160 N·m (16 kgf·m, 116 ft·lb) 9. Install the flywheel magnet and flywheel magnet cover. È For USA and Canada É For worldwide CAUTION: Apply force in the direction of the arrows shown, to prevent the flywheel holder...
Page 197 — MEMO — 5-70 62Y3A11...
Page 198: Lowr
Special service tools ..................6-1 Lower unit (F50/F50A)..................6-7 Removing the lower unit ................6-9 Water pump and propeller shaft housing (F50/F50A).......6-11 Removing the water pump and propeller shaft housing assembly ..6-13 Disassembling the propeller shaft housing..........6-13 Disassembling the propeller shaft assembly ...........6-14 Checking the water pump................6-14...
Page 199 Backlash (F50/F50A) ..................6-39 Measuring the forward and reverse gear backlash .........6-39 Lower unit (T50/FT50B, FT50C) ..............6-41 Removing the lower unit ................6-43 Water pump and shift rod (T50/FT50B, FT50C) .........6-45 Removing the water pump and shift rod..........6-47 Checking the water pump and shift rod ...........6-47 Installing the water pump and shift rod............6-48...
Page 200: Special Service Tools
LOWR Lower unit Special service tools For USA and Canada Bearing housing needle bearing installer YB-06111 Bearing housing puller YB-06207, YB-06234 Oil seal installer YB-06168 Universal puller YB-06117 Forward/reverse gear bearing installer YB-06270-A Slide hammer and adapters YB-06096 Bearing cup installer YB-06167 Bearing housing needle bearing remover YB-06112, YB-06153...
Page 201 Special service tools Bearing splitter plate Pinion shim selecting tools YB-06219 YB-34432-8, YB-34432-9, YB-34432-10A, YB-34432-11A, YB-34432-17 Drive shaft needle bearing remover and installer Forward gear shim selecting tools YB-06063, YB-06155 YB-34446-1, YB-34446-3, YB-34446-4, YB-34446-5, YB-34446-7, YB-34446-15 Drive shaft needle bearing depth stop YB-34473, YB-34474 Shift rod push arm YB-06052...
Page 202 LOWR Lower unit Dial gauge Forward gear needle bearing and tapered YU-03097 roller bearing installer YB-06200 For worldwide Magnetic flexible stand YU-34481 Bearing housing puller claw 90890-06564 Bearing housing oil seal installer YB-06269 Stopper guide plate 90890-06501 Gland nut wrench YB-34447 Center bolt 90890-06504...
Page 203 Special service tools Stopper guide stand Driver rod SS 90890-06538 90890-06604 Bearing puller Bearing depth plate 90890-06535 90890-06603 Bearing puller claw 1 Bearing inner race attachment 90890-06536 90890-06639, 90890-06641, 90890-06643, 90890-06644, 90890-06661, 90890-06662 Needle bearing attachment 90890-06607, 90890-06610, 90890-06611, Drive shaft holder 4 90890-06612, 90890-06614, 90890-06653 90890-06518 Driver rod L3...
Page 204 LOWR Lower unit Socket adapter 1 Driver rod LS 90890-06506 90890-06606 Bearing outer race puller Driver rod LL 90890-06523 90890-06605 Outer race puller claw A Pinion height gauge 90890-06532 90890-06702 Driver rod SL Digital caliper 90890-06602 90890-06704 Bearing outer race attachment Shimming plate 90890-06621, 90890-06622, 90890-06626, 90890-06701...
Page 205 Special service tools Shift rod push arm Ring nut wrench 3 90890-06052 90890-06511 Backlash indicator Ring nut wrench extension 90890-06706 90890-06513 Magnet base plate Bearing housing puller claw L 90890-07003 90890-06502 Dial gauge set Ball bearing attachment 90890-01252 90890-06655 Magnet base Socket adapter 90890-06705 90890-06507...
Page 206: Lower Unit (F50/F50A)
LOWR Lower unit Lower unit (F50/F50A) 62Y3A11...
Page 207 Lower unit (F50/F50A) Tightening torques Part name Q’ty Remarks Stage N·m kgf·m ft·lb Lower unit Plastic tie Not reusable Hose Check screw Gasket Not reusable M10 × 40 mm Bolt Drain screw Dowel pin M8 × 35 mm Bolt Anode M8 ×...
Page 208: Removing The Lower Unit
LOWR Lower unit Removing the lower unit 1. Drain the gear oil. For draining proce- dures, see Chapter 3, “Replacing the gear oil.” 2. Set the gearshift to the neutral position, and place a block of wood between the anti-cavitation plate and propeller to keep the propeller from turning, and then remove the propeller nut and propeller.
Page 209 Lower unit (F50/F50A) — MEMO — 6-10 62Y3A11...
Page 210: Water Pump And Propeller Shaft Housing (F50/F50A)
LOWR Lower unit Water pump and propeller shaft housing (F50/F50A) 6-11 62Y3A11...
Page 211 Water pump and propeller shaft housing (F50/F50A) Tightening torques Part name Q’ty Remarks Stage N·m kgf·m ft·lb Propeller shaft assembly Propeller shaft housing assembly Spacer Grommet M8 × 20 mm Bolt Water pump housing Insert plate cartridge Impeller O-ring Not reusable...
Page 212: Removing The Water Pump And Propeller Shaft Housing Assembly
LOWR Lower unit Removing the water pump and propeller shaft housing assembly 1. Remove the water pump assembly. 2. Remove the propeller shaft housing assembly by removing the bolts 1, then pulling the housing out. È For USA and Canada É...
Page 213: Disassembling The Propeller Shaft Assembly
Water pump and propeller shaft housing (F50/F50A) È For USA and Canada É For worldwide Checking the water pump 1. Check the pump housing for deforma- Slide hammer and adapters 7: YB-06096 tion. Replace if necessary. Stopper guide plate 8: 90890-06501...
Page 214: Checking The Propeller Shaft Housing
LOWR Lower unit 3. Check the Woodruff key 3 and the groove a on the drive shaft for wear. Replace if necessary. S62Y6120 Checking the propeller shaft 1. Check the propeller shaft for bends or S62Y6110 wear. Replace if necessary. Checking the propeller shaft housing 1.
Page 215: Assembling The Propeller Shaft Assembly
Water pump and propeller shaft housing (F50/F50A) Assembling the propeller shaft NOTE: assembly • Install the needle bearing with the manufac- 1. Install the dog clutch as shown. ture identification mark a facing toward the oil seal (propeller side). • Do not strike the driver rod in a manner that will force the stopper b out of place.
Page 216 LOWR Lower unit Oil seal installer 6: YB-06168 Forward/reverse gear bearing installer A: Driver handle 7: YB-06071 YB-06270-A Needle bearing attachment 8: Bearing inner race attachment B: 90890-06653 90890-06639 Driver rod L3 9: 90890-06652 4. Install the reverse gear assembly to the propeller shaft housing using a press.
Page 217: Installing The Propeller Shaft Housing
Water pump and propeller shaft housing (F50/F50A) Installing the propeller shaft housing 1. Install the washer 1, propeller shaft assembly 2, and shift plunger 3, into the propeller shaft housing assembly 4. 2. Apply grease to the new O-rings. 4. Install the insert plate cartridge 3 into the water pump housing 4.
Page 218 LOWR Lower unit 5. Install the O-ring 5, pump housing assembly 4, and dowel pins 6 into the lower case, tighten the bolts 7, and then install the grommet 8 and spacer 9. S62Y6200J NOTE: • When installing the pump housing, apply grease to the inside of the housing, and then turn the drive shaft clockwise while pushing down the pump housing.
Page 219 Water pump and propeller shaft housing (F50/F50A) — MEMO — 6-20 62Y3A11...
Page 220: Drive Shaft And Lower Case (F50/F50A)
LOWR Lower unit Drive shaft and lower case (F50/F50A) 6-21 62Y3A11...
Page 221 Drive shaft and lower case (F50/F50A) Tightening torques Part name Q’ty Remarks Stage N·m kgf·m ft·lb Shift rod assembly Drive shaft Oil seal Not reusable Oil seal housing O-ring Not reusable Circlip Shift rod O-ring Not reusable Taper roller bearing...
Page 222: 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. È For USA and Canada É For worldwide CAUTION: • Do not press the drive shaft threads a directly.
Page 223: Disassembling The Lower Case
Drive shaft and lower case (F50/F50A) Disassembling the lower case 1. Remove the taper roller bearing outer race and shim(s). S62Y6250 È For USA and Canada É For worldwide NOTE: Install the claw as shown. Slide hammer and adapters 5: YB-06096...
Page 224: Checking The Pinion And Forward Gear
LOWR Lower unit Checking the pinion and forward gear 1. Check the teeth of the pinion, and the teeth and dogs of the forward gear for cracks or wear. Replace the pinion or gear if necessary. Checking the lower case 1.
Page 225 Drive shaft and lower case (F50/F50A) 2. Install the needle bearing into the lower case to the specified depth. É CAUTION: Add or remove shims, if necessary, when replacing the pinion or lower case. NOTE: • Apply gear oil to the inside and outside of È...
Page 226: Assembling The Forward Gear
LOWR Lower unit 4. Install the forward gear original shim(s) Drive shaft taper roller bearing cup installer and taper roller bearing outer race. 1: YB-06110 Bearing inner race attachment 2: 90890-06639 Assembling the drive shaft 1. Install the new drive shaft bearing into the drive shaft using a press.
Page 227: Installing The Drive Shaft
Drive shaft and lower case (F50/F50A) 2. Install the new oil seals to the oil seal É housing as shown. S62Y6850R È For USA and Canada É For worldwide Drive shaft holder 1: YB-06049 Drive shaft holder 4 2: 90890-06518...
Page 228 LOWR Lower unit 2. Install the two dowel pins 1 to the lower unit. 3. Install the lower unit to the upper case, and then tighten the bolts to the specified torque. 5. Install the propeller and propeller nut, 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...
Page 229 Drive shaft and lower case (F50/F50A) WARNING Do not hold the propeller with your hands when loosening or tightening it. Be sure to remove the battery leads from the bat- teries and the engine shut-off switch. Put a block of wood between the cavitation plate and propeller to keep the propeller from turning.
Page 230: Shimming (F50) (For Usa And Canada)
LOWR Lower unit Shimming (F50) (for USA and Canada) 6-31 62Y3A11...
Page 231: Shimming
Shimming (F50) (for USA and Canada) Shimming NOTE: • Shimming is not required when assembling the original lower case and inner parts. • Shimming is required when assembling the original inner parts and a new lower case. • Shimming is required when replacing the inner parts.
Page 232: Selecting The Forward Gear Shims
LOWR Lower unit 5. Measure the clearance (M) between the Selecting the forward gear shims shim selecting tool and the pinion as 1. Calculate the specified value (M0) as shown. shown in the examples below. NOTE: NOTE: Measure the pinion at three points to find the “F”...
Page 233: Selecting The Reverse Gear Shims
Shimming (F50) (for USA and Canada) 2. Install the taper roller bearing 1 to the shim selecting tools. NOTE: The sum of T1 and M should not be more than M0. Forward gear shim thickness (T1) = M0 – M Available shim thicknesses: 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, and NOTE:...
Page 234: Shimming (F50A) (For Worldwide)
LOWR Lower unit Shimming (F50A) (for worldwide) 6-35 62Y3A11...
Page 235: Shimming
Shimming (F50A) (for worldwide) Shimming 3. Measure the distance (M) between the shimming tool and the pinion as shown. NOTE: • Shimming is not required when assembling the original lower case and inner parts. • Shimming is required when assembling the original inner parts and a new lower case.
Page 236: Selecting The Forward Gear Shims
LOWR Lower unit Example: If “M” 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 If “M” is “11.70 mm” and “P” is “–5”, then T3 = 11.70 –...
Page 237: Selecting The Reverse Gear Shims
Shimming (F50A) (for worldwide) Example: NOTE: If “M” is “22.45 mm” and “F” is “+5”, then Measure the backlash with the original T1 = 22.75 + (+5)/100 – 22.45mm shim(s). If the original shim(s) is unavailable, = 0.30 + 0.05 mm = 0.35 mm start with a 0.50 mm shim.
Page 238: Backlash (F50/F50A)
LOWR Lower unit Backlash (F50/F50A) NOTE: Measuring the forward and reverse Tighten the universal puller or center bolt gear backlash while turning the drive shaft until the drive 1. Remove the water pump assembly. shaft can no longer be turned.
Page 239 Backlash (F50/F50A) 5. Slowly turn the drive shaft clockwise and 9. Slowly turn the drive shaft clockwise and counterclockwise and measure the back- counterclockwise and measuring the lash when the drive shaft stops in each backlash when the drive shaft stops in direction.
Page 240: Lower Unit (T50/Ft50B, Ft50C)
LOWR Lower unit Lower unit (T50/FT50B, FT50C) 6-41 62Y3A11...
Page 241 Lower unit (T50/FT50B, FT50C) Tightening torques Part name Q’ty Remarks Stage N·m kgf·m ft·lb Lower unit Plastic tie Not reusable Hose Check screw Gasket Not reusable Dowel pin M10 × 40 mm Bolt Drain screw Grommet M10 × 45 mm, Bolt : 12 mm M8 ×...
Page 242: Removing The Lower Unit
LOWR Lower unit Removing the lower unit 1. Drain the gear oil. For draining proce- dures, see Chapter 3, “Replacing the gear oil.” 2. Set the gearshift to the neutral position, and place a block of wood between the anti-cavitation plate and propeller to keep the propeller from turning, and then remove the propeller nut and propeller.
Page 243 Lower unit (T50/FT50B, FT50C) — MEMO — 6-44 62Y3A11...
Page 244: Water Pump And Shift Rod (T50/Ft50B, Ft50C)
LOWR Lower unit Water pump and shift rod (T50/FT50B, FT50C) 6-45 62Y3A11...
Page 245 Water pump and shift rod (T50/FT50B, FT50C) Tightening torques Part name Q’ty Remarks Stage N·m kgf·m ft·lb Shift rod assembly Oil seal Not reusable Oil seal housing O-ring Not reusable Circlip Shift rod O-ring Not reusable M6 × 16 mm Bolt Woodruff key M8 ×...
Page 246: Removing The Water Pump And Shift Rod
LOWR Lower unit 2. Check the impeller 1 and insert plate Removing the water pump and shift cartridge 2 for cracks or wear. Replace if necessary. 1. Remove the water pump assembly and shift rod assembly 1. S62Y6540 3. Check the Woodruff key 3 and the groove a on the drive shaft for wear.
Page 247: Installing The Water Pump And Shift Rod
Water pump and shift rod (T50/FT50B, FT50C) Installing the water pump and shift 1. Install the shift rod assembly 1. È For USA and Canada É For worldwide Bearing housing oil seal installer 3: YB-06269 Driver handle 4: YB-06071 Needle bearing attachment 5: 90890-06610 Driver rod L3 6: 90890-06652 3.
Page 248 LOWR Lower unit 6. Align the groove on the impeller B with 8. Install the new gasket G, pump housing the Woodruff key C, and then install it to assembly F, and dowel pins H to the the drive shaft. lower case.
Page 249 Water pump and shift rod (T50/FT50B, FT50C) — MEMO — 6-50 62Y3A11...
Page 250: Propeller Shaft Housing (T50/Ft50B, Ft50C)
LOWR Lower unit Propeller shaft housing (T50/FT50B, FT50C) 6-51 62Y3A11...
Page 251 Propeller shaft housing (T50/FT50B, FT50C) Tightening torques Part name Q’ty Remarks Stage N·m kgf·m ft·lb Propeller shaft assembly Propeller shaft housing assembly Ball Slider Shift plunger Cross pin Dog clutch Spring Propeller shaft Washer Straight key Claw washer Ring nut 10.5 Reverse gear Thrust washer...
Page 252: Removing The Propeller Shaft Housing Assembly
LOWR Lower unit Removing the propeller shaft Bearing housing puller 3: YB-06207 housing assembly Universal puller 4: YB-06117 1. Straighten the claw washer tabs a, and Bearing housing puller claw L 5: then remove the ring nut and claw 90890-06502 washer.
Page 253: Disassembling The Propeller Shaft Assembly
Propeller shaft housing (T50/FT50B, FT50C) NOTE: Bearing housing needle bearing remover B: Install the bearing separator 2 between the YB-06153 reverse gear and thrust washer completely, Needle bearing attachment B: then the other special service tools. 90890-06612 Driver handle C: YB-06071 Driver rod L3 C: 90890-06652 2.
Page 254: Checking The Propeller Shaft
LOWR Lower unit 2. Check the teeth and dogs of the reverse gear for cracks or wear. Replace the gear if necessary. Assembling the propeller shaft assembly S62Y6640 1. Install the dog clutch as shown. 3. Check the bearings for pitting or rum- bling.
Page 255 Propeller shaft housing (T50/FT50B, FT50C) È For USA and Canada È For USA and Canada É For worldwide É For worldwide NOTE: NOTE: • Install the needle bearing with the manufac- Install an oil seal halfway into the propeller ture identification mark a facing toward the shaft housing, then the other oil seal.
Page 256: Installing The Propeller Shaft Housing
LOWR Lower unit NOTE: Install the ball bearing with the manufacture identification mark e facing outward (propel- ler side). Drive shaft needle bearing depth stop C: YB-34473 Bearing inner race attachment D: 90890-06639 4. Install the reverse gear assembly to the propeller shaft housing using a press.
Page 257 Propeller shaft housing (T50/FT50B, FT50C) Gland nut wrench 8: YB-34447 Ring nut wrench 3 8: 90890-06511 Ring nut wrench extension 9: 90890-06513 Ring nut 7: 105 N·m (10.5 kgf·m, 76 ft·lb) 6-58 62Y3A11...
Page 258: Drive Shaft And Lower Case (T50/Ft50B, Ft50C)
LOWR Lower unit Drive shaft and lower case (T50/FT50B, FT50C) 6-59 62Y3A11...
Page 259 Drive shaft and lower case (T50/FT50B, FT50C) Tightening torques Part name Q’ty Remarks Stage N·m kgf·m ft·lb Drive shaft Taper roller bearing Not reusable Bearing outer race Not reusable Pinion shim — As required Sleeve Hose Plastic tie Not reusable Joint Water inlet cover Screw...
Page 260: Removing The Drive Shaft
LOWR Lower unit Removing the drive shaft CAUTION: 1. Remove the drive shaft assembly and • Do not press the drive shaft threads a pinion, and then pull out the forward directly. gear. • Do not reuse the bearing, always replace it with a new one.
Page 261: Disassembling The Lower Case
Drive shaft and lower case (T50/FT50B, FT50C) NOTE: Install the claws as shown. Slide hammer and adapters 1: YB-06096 Bearing outer race puller 2: 90890-06523 Outer race puller claw A 3: 90890-06532 2. Remove the drive shaft bearing outer race, shim(s), and drive shaft sleeve. È...
Page 262: Checking The Pinion And Forward Gear
LOWR Lower unit 3. Remove the needle bearing. Checking the drive shaft 1. Check the drive shaft for bends or wear. Replace if necessary. Bearing housing needle bearing remover 9: YB-06153 Needle bearing attachment 9: Checking the lower case 90890-06611 1.
Page 263 Drive shaft and lower case (T50/FT50B, FT50C) È For USA and Canada É For worldwide NOTE: • Install the needle bearing with the manufac- È For USA and Canada ture identification mark a facing upward. É For worldwide • When using the driver rod, do not strike the special tool in a manner that will force the CAUTION: stopper b out of place.
Page 264: Assembling The Forward Gear
LOWR Lower unit 3. Install the original shim(s) and taper roller bearing outer race. È For USA and Canada É For worldwide Forward gear needle bearing and tapered roller bearing installer 1: YB-06200 Bearing inner race attachment 2: 90890-06662 2. Install the new needle bearing into the forward gear to the specified depth.
Page 265: Assembling The Drive Shaft
Drive shaft and lower case (T50/FT50B, FT50C) Assembling the drive shaft Drive shaft holder 1: YB-06049 1. Install the new drive shaft bearing into Drive shaft holder 4 1: 490890-06518 the drive shaft using a press. Pinion nut holder 2: 90890-06505 Socket adapter 2 3: 90890-06507 Pinion nut: 95 N·m (9.5 kgf·m, 68 ft·lb) Installing the lower unit...
Page 266 LOWR Lower unit 2. Install the two dowel pins 1 to the lower unit. 3. Install the lower unit to the upper case, and then tighten the bolts to the specified torque. 5. Install the propeller and propeller nut, 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...
Page 267 Drive shaft and lower case (T50/FT50B, FT50C) WARNING Do not hold the propeller with your hands when loosening or tightening it. Be sure to remove the battery leads from the bat- teries and the engine shut-off switch. Put a block of wood between the cavitation plate and propeller to keep the propeller from turning.
Page 268: Shimming (T50) (For Usa And Canada)
LOWR Lower unit Shimming (T50) (for USA and Canada) 6-69 62Y3A11...
Page 269: Shimming
Shimming (T50) (for USA and Canada) Shimming NOTE: • Shimming is not required when assembling the original lower case and inner parts. • Shimming is required when assembling the original inner parts and a new lower case. • Shimming is required when replacing the inner part(s).
Page 270: Selecting The Forward Gear Shims
LOWR Lower unit 5. Measure the clearance (M) between the Selecting the forward gear shims shim selecting tool and the pinion as 1. Calculate the specified value (M0) as shown. shown in the examples below. NOTE: NOTE: Measure the pinion at three points to find the “F”...
Page 271 Shimming (T50) (for USA and Canada) 2. Install the taper roller bearing 1 to the 4. Select the forward gear shims (T1). shim selecting tools. NOTE: The sum of T1 and M should not be more than M0. Forward gear shim thickness (T1) = M0 –...
Page 272: Shimming (Ft50B, Ft50C) (For Worldwide)
LOWR Lower unit Shimming (FT50B, FT50C) (for worldwide) 6-73 62Y3A11...
Page 273: Shimming
Shimming (FT50B, FT50C) (for worldwide) Shimming 3. Measure the distance (M) between the shimming tool and the pinion as shown. NOTE: • Shimming is not required when assembling the original lower case and inner parts. • Shimming is required when assembling the original inner parts and a new lower case.
Page 274: Selecting The Forward Gear Shims
LOWR Lower unit Example: If “M” is “32.10 mm” and “P” is “+5”, then T3 = 32.10 – 31.50 – (+5)/100 mm = 0.60 – 0.05 mm = 0.55 mm If “M” is “32.10 mm” and “P” is “–5”, then T3 = 32.10 –...
Page 275 Shimming (FT50B, FT50C) (for worldwide) Example: If “M” is “24.00 mm” and “F” is “+5”, then T1 = 24.50 + (+5)/100 – 24.00 mm = 0.50 + 0.05 mm = 0.55 mm If “M” is “24.00 mm” and “F” is “–5”, then T1 = 24.50 + (–5)/100 –...
Page 276: Backlash (T50/Ft50B, Ft50C)
LOWR Lower unit Backlash (T50/FT50B, FT50C) NOTE: Measuring the forward and reverse Tighten the universal puller or center bolt gear backlash while turning the drive shaft until the drive 1. Remove the water pump assembly. shaft can no longer be turned. 2.
Page 277 Backlash (T50/FT50B, FT50C) Backlash indicator gauge 6: YB-06265 NOTE: Tighten the propeller nut D while turning the Backlash indicator 6: 90890-06706 drive shaft until the drive shaft can no longer Magnetic plate 7: YB-07003 be turned. Magnet base plate 7: 90890-07003 Dial gauge 8: YU-03097 Dial gauge set 8: 90890-01252 9.
Page 278: Brkt
BRKT Bracket unit Troubleshooting..................... 7-1 Special service tools ..................7-4 Tiller handle (F50/F50A, T50/FT50B) ............7-5 Checking the throttle cable and shift cable..........7-15 Assembling the tiller handle..............7-15 Tiller handle (FT50C)..................7-17 Checking the throttle cable and shift rod ..........7-23 Assembling the tiller handle..............
Page 279 Gear pump ....................7-59 Disassembling the tilt cylinder ..............7-63 Disassembling the trim cylinder...............7-63 Disassembling the gear pump ..............7-64 Checking the tilt cylinder and trim cylinder ..........7-64 Check the valves ..................7-65 Checking the filters .................. 7-65 Checking the gear pump .................7-66 Assembling the gear pump..............
Page 280: Troubleshooting
BRKT Bracket unit Troubleshooting Before troubleshooting the power trim and tilt unit, check that all electrical connections are tight and free from corrosion, and that the battery is fully charged to 12 V. Symptom: Power trim and tilt unit does not operate. Listen for the operation sound of the power trim and tilt relay.
Page 281 Troubleshooting Symptom: Power trim and tilt unit does not hold the outboard motor up. Check that the manual release plug is closed. Is it closed? Close the plug. Check the power trim and tilt fluid level. At specified Add fluid to the correct level. level? Disassemble the power trim and tilt unit, and then check it.
Page 282 BRKT Bracket unit Symptom: Shift mechanism of the forward gear and reverse gear does not operate properly. Check the shift cable operation. Good operat- Check the shift cables and links ing condition? of the remote control box. Check the operation of the shift rod.
Page 283: Special Service Tools
Troubleshooting / Special service tools Special service tools For USA and Canada Trim and tilt cylinder wrench YB-06175-2B For worldwide Cylinder-end screw wrench 90890-06544 62Y3A11...
Page 284: Tiller Handle (F50/F50A, T50/Ft50B)
BRKT Bracket unit Tiller handle (F50/F50A, T50/FT50B) 62Y3A11...
Page 285 Tiller handle (F50/F50A, T50/FT50B) Tightening torques Part name Q’ty Remarks Stage N·m kgf·m ft·lb Tiller handle assembly Friction plate Tiller handle wiring harness Tiller handle wiring Models applicable for harness tachometer, trim meter or warning buzzer Grommet Clip Throttle cable Plate M6 ×...
Page 286 BRKT Bracket unit 62Y3A11...
Page 287 Tiller handle (F50/F50A, T50/FT50B) Tightening torques Part name Q’ty Remarks Stage N·m kgf·m ft·lb Collar M8 × 50 mm Bolt Self-locking nut Bracket Steering lock shaft Steering lock knob Friction plate Friction piece 62Y3A11...
Page 288 BRKT Bracket unit 62Y3A11...
Page 289 Tiller handle (F50/F50A, T50/FT50B) Tightening torques Part name Q’ty Remarks Stage N·m kgf·m ft·lb Tiller handle sub assembly M6 × 10 mm Screw Shift lever cover M8 × 40 mm Bolt Shift lever Bushing Washer Bushing Engine shut-off switch Washer...
Page 290 BRKT Bracket unit 7-11 62Y3A11...
Page 291 Tiller handle (F50/F50A, T50/FT50B) Tightening torques Part name Q’ty Remarks Stage N·m kgf·m ft·lb M6 × 40 mm Screw Throttle grip M5 × 25 mm Screw Washer Spring Bushing 7-12 62Y3A11...
Page 292 BRKT Bracket unit 7-13 62Y3A11...
Page 293 Tiller handle (F50/F50A, T50/FT50B) Tightening torques Part name Q’ty Remarks Stage N·m kgf·m ft·lb Tiller handle Cotter pin Not reusable Friction adjusting knob Grommet Plastic tie Cable clamp Stay M6 × 14 mm Bolt Throttle cable Short Clip Throttle arm...
Page 294: Checking The Throttle Cable And Shift Cable
BRKT Bracket unit Checking the throttle cable and shift cable 1. Check the operation of the throttle cable and shift cable. 2. Check the inner wire and outer wire of both cables for bends or damage, and the rubber seals for damage. Replace if necessary.
Page 295 Tiller handle (F50/F50A, T50/FT50B) — MEMO — 7-16 62Y3A11...
Page 296: Tiller Handle (Ft50C)
BRKT Bracket unit Tiller handle (FT50C) 7-17 62Y3A11...
Page 297 Tiller handle (FT50C) Tightening torques Part name Q’ty Remarks Stage N·m kgf·m ft·lb M8 × 30 mm Bolt Wing nut Friction piece M6 × 35 mm Bolt Friction rod Washer Washer Link rod Plate M6 × 20 mm Bolt Grommet Cable guide Grommet Plastic tie...
Page 298 BRKT Bracket unit 7-19 62Y3A11...
Page 299 Tiller handle (FT50C) Tightening torques Part name Q’ty Remarks Stage N·m kgf·m ft·lb Tiller handle Tiller handle wiring harness Clip Shift rod Bushing M12 × 70 mm Bolt Clip Throttle cable Plastic washer Metal washer Wave washer Gear Throttle shaft M6 ×...
Page 300 BRKT Bracket unit 7-21 62Y3A11...
Page 301 Tiller handle (FT50C) Tightening torques Part name Q’ty Remarks Stage N·m kgf·m ft·lb Bracket M6 × 16 mm Bolt M6 × 16 mm Bolt Shift arm guide Washer Washer Bushing Tiller handle bracket Bushing Engine stop switch M6 × 20 mm Bolt Engine start switch housing...
Page 302: Checking The Throttle Cable And Shift Rod
BRKT Bracket unit 2. Install the throttle cable 3 into the gear Checking the throttle cable and shift 4 until the inner cable is engaged with the gear. 1. Check the operation of the throttle cable and shift rod. 3. Turn the throttle shaft 1 clockwise to wind the inner cable around the gear 4.
Page 303 Tiller handle (FT50C) — MEMO — 7-24 62Y3A11...
Page 304: Bottom Cowling
BRKT Bracket unit Bottom cowling 7-25 62Y3A11...
Page 305 Bottom cowling Tightening torques Part name Q’ty Remarks Stage N·m kgf·m ft·lb Shift rod assembly Bottom cowling Bolt Spring Ball Shift rod bracket Cotter pin Not reusable Washer Bushing Bushing Shift rod Grommet Rubber seal M6 × 30 mm Bolt Grommet M6 ×...
Page 306 BRKT Bracket unit 7-27 62Y3A11...
Page 307 Bottom cowling Tightening torques Part name Q’ty Remarks Stage N·m kgf·m ft·lb Bolt Models with trailer switch Bracket Models with trailer switch Trailer switch Models with trailer switch PTT motor lead EHT/ET models Trim sensor coupler EHT/ET models M6 × 24 mm Screw EHT/ET models Grommet...
Page 308: Checking The Shift Rod Assembly Operation
BRKT Bracket unit Checking the shift rod assembly operation 1. Check the shift rod assembly and detent for smooth operation. È F50/F50A, T50/FT50B É FT50C 7-29 62Y3A11...
Page 309 Bottom cowling — MEMO — 7-30 62Y3A11...
Page 310: Upper Case
BRKT Bracket unit Upper case 7-31 62Y3A11...
Page 311 Upper case Tightening torques Part name Q’ty Remarks Stage N·m kgf·m ft·lb Upper case assembly Washer M8 × 30 mm Bolt Upper mount Plate M8 × 175 mm Bolt M12 × 160 mm Bolt Grommet Ground lead Screw Mount cover M8 ×...
Page 312 BRKT Bracket unit 7-33 62Y3A11...
Page 313 Upper case Tightening torques Part name Q’ty Remarks Stage N·m kgf·m ft·lb Muffler assembly Upper case Muffler seal Rubber seal Dowel pin Grommet Guide FT50C Damper M5 × 16 mm Screw Baffle plate M8 × 30 mm Bolt Drive shaft bushing Circlip 7-34 62Y3A11...
Page 314 BRKT Bracket unit (F50/F50A, T50/FT50B) 7-35 62Y3A11...
Page 315 Upper case Tightening torques Part name Q’ty Remarks Stage N·m kgf·m ft·lb Oil seal Not reusable Exhaust guide Grommet Gasket Not reusable Dowel pin M6 × 25 mm Bolt Oil pan Gasket Exhaust manifold M6 × 50 mm Bolt Gasket Not reusable M6 ×...
Page 316 BRKT Bracket unit (FT50C) 7-37 62Y3A11...
Page 317 Upper case Tightening torques Part name Q’ty Remarks Stage N·m kgf·m ft·lb Oil seal Not reusable Exhaust guide Grommet Grommet Anode Cover Bolt Cover Bolt Gasket Not reusable Dowel pin M6 × 25 mm Bolt Oil pan Gasket Not reusable Exhaust manifold M6 ×...
Page 318: Disassembling The Oil Pan
BRKT Bracket unit Disassembling the oil pan Assembling the oil pan 1. Remove the muffler 1 from the oil pan 1. Install the gaskets onto the exhaust guide 1. 2. Remove the exhaust manifold 3 from 2. Install the relief valve assembly 2 by the oil pan 2.
Page 319 Upper case 4. Install the water pipe 4. 5. Install the oil pan 5 and bolts, and then tighten the bolts finger tight. 6. Install the exhaust manifold 6 and bolts, and then tighten the bolts finger tight. S62Y7245 8. Install the muffler 9 into the oil pan. È...
Page 320: Installing The Upper Case
BRKT Bracket unit 9. Install the muffler assembly 0 by insert- ing the tip of the water pipe 4 into the joint hole a of the upper case. Installing the upper case NOTE: 1. Install the upper mount 1 and bolts 2 Be sure to install the ground lead 8 into the into the upper case, and then tighten the mount housing 6.
Page 321 Upper case 4. Install the upper and lower mounting bolts into the swivel bracket 9 simulta- neously. 5. Install the upper mounting nut 0 and lower mounting nut A, and then tighten them to the specified torques. 6. Install the cover B by installing the screw.
Page 322: Clamp Brackets
BRKT Bracket unit Clamp brackets 7-43 62Y3A11...
Page 323 Clamp brackets Tightening torques Part name Q’ty Remarks Stage N·m kgf·m ft·lb Swivel bracket assembly Screw EHT/ET models M6 × 15 mm Trim sensor EHT/ET models Trim sensor coupler EHT/ET models Plastic tie Not reusable Self-locking nut M6 × 25 mm Bolt Anode Port clamp bracket...
Page 324: Removing The Clamp Brackets
BRKT Bracket unit Removing the clamp brackets NOTE: 1. Remove the power trim and tilt or hydro Adjust the trim sensor after installing the tilt. removing procedures, power trim and tilt. “Removing the power trim and tilt/hydro tilt” in this chapter. 2.
Page 325: Adjusting The Trim Sensor
Clamp brackets 4. Inject grease into both grease nipples 4. Fully tilt the outboard down. until grease comes out from the bushings 5. Measure the trim sensor resistance. Repeat steps 1–5 if out of specification. Adjusting the trim sensor Trim sensor setting resistance: 1.
Page 326: Swivel Bracket And Steering Arm
BRKT Bracket unit Swivel bracket and steering arm 7-47 62Y3A11...
Page 327: Swivel Bracket And Steering Arm
Swivel bracket and steering arm Tightening torques Part name Q’ty Remarks Stage N·m kgf·m ft·lb Steering arm Washer Bushing O-ring Not reusable Bushing Swivel bracket Bushing Port tilt stop lever Circlip Steering yoke Bushing Bushing Tilt stop lever joint Spring holder M6 ×...
Page 328: Removing The Steering Arm
BRKT Bracket unit Removing the steering arm 1. Remove the circlip 1. 2. Remove the steering yoke 2 by striking it with a plastic hammer. 4. Install the steering arm 5 into the steer- ing yoke 0 by aligning the center a of the yoke with the center b of the steer- ing arm.
Page 329 Swivel bracket and steering arm 6. Inject grease into the grease nipple until grease comes out from both the upper and lower bushings c. 7-50 62Y3A11...
Page 330: Power Trim And Tilt Unit
BRKT Bracket unit Power trim and tilt unit 7-51 62Y3A11...
Page 331 Power trim and tilt unit Tightening torques Part name Q’ty Remarks Stage N·m kgf·m ft·lb Power trim and tilt EHT/ET models Hydro tilt EHD/ED models Plastic tie Not reusable PTT motor lead Washer M8 × 16 mm Bolt Circlip EHT/ET models Shaft EHT/ET models Bushing...
Page 332: Removing The Power Trim And Tilt/Hydro Tilt
BRKT Bracket unit Removing the power trim and tilt/hydro tilt 1. Fully tilt the outboard up, and then sup- port it with the tilt stop lever 1. WARNING After tilting up the outboard, be sure to support it with the tilt stop lever. Otherwise, the outboard could suddenly lower if the power trim and tilt unit should lose fluid pressure.
Page 333 Power trim and tilt unit — MEMO — 7-54 62Y3A11...
Page 334: Tilt Cylinder And Trim Cylinder
BRKT Bracket unit Tilt cylinder and trim cylinder 7-55 62Y3A11...
Page 335: Tilt Cylinder And Trim Cylinder
Tilt cylinder and trim cylinder Tightening torques Part name Q’ty Remarks Stage N·m kgf·m ft·lb Power trim and tilt motor Tilt cylinder end screw M5 × 20 mm Bolt O-ring Not reusable Joint O-ring Not reusable Ball O-ring Not reusable Free piston Circlip Trim cylinder base...
Page 336: Trim Cylinder
BRKT Bracket unit Trim cylinder 7-57 62Y3A11...
Page 337 Trim cylinder Tightening torques Part name Q’ty Remarks Stage N·m kgf·m ft·lb Tilt ram Dust seal Not reusable Backup ring O-ring Not reusable Tilt cylinder end screw O-ring Not reusable Backup ring O-ring Not reusable Trim cylinder end screw O-ring Not reusable O-ring Not reusable...
Page 338: Gear Pump
BRKT Bracket unit Gear pump 7-59 62Y3A11...
Page 339 Gear pump Tightening torques Part name Q’ty Remarks Stage N·m kgf·m ft·lb M5 × 8 mm Bolt Relief valve bracket M6 × 40 mm Bolt Valve lock screw Up-relief spring Valve support pin O-ring Not reusable Ball Down-relief spring Valve support pin Relief valve seal Filter O-ring...
Page 340 BRKT Bracket unit 7-61 62Y3A11...
Page 341 Gear pump Tightening torques Part name Q’ty Remarks Stage N·m kgf·m ft·lb M5 × 20 mm Bolt Washer Gear pump bracket O-ring Not reusable Spacer Spring Valve pin Ball Manual release spring Ball Gear pump cover Spring Shuttle piston O-ring Not reusable Valve seal Circlip...
Page 342: Disassembling The Tilt Cylinder
BRKT Bracket unit Disassembling the tilt cylinder NOTE: 1. Hold the power trim and tilt 1 in a vise Place the trim cylinder in the vise horizon- using aluminum plates a on both sides. tally. 2. Loosen the trim cylinder end screw 2, and then remove it.
Page 343: Disassembling The Gear Pump
Gear pump 4. Remove the gear pump cover 9, then Disassembling the gear pump the down-main valve 0 and up-main 1. Remove the manual release plug 1 and valve A. gear pump 2. 5. Remove the drive gear B and driven gear C.
Page 344: Check The Valves
BRKT Bracket unit 3. Check the outer surface of the tilt piston and free piston for scratches. Replace if necessary. 3. Check the down-main valve 1 and the up-main valve 2 for dirt or residue. Clean if necessary. 4. Check the tilt ram for bends or excessive 4.
Page 345: Checking The Gear Pump
Gear pump 7. Install the gear pump bracket C by Checking the gear pump installing the bolts D, then tightening 1. Check the drive gear 1, driven gear 2, and shaft 3 for damage or excessive them to the specified torque. wear.
Page 346: Assembling The Trim Cylinder
BRKT Bracket unit 10. Install the filters J and gear pump K by installing the bolts L, then tightening them to the specified torque. 11. Install the manual release plug M and reservoir cap N. PTT motor bolt Q: 4 N·m (0.4 kgf·m, 2.9 ft·lb) Assembling the trim cylinder 1.
Page 347 Gear pump 4. Install the backup ring 5 and O-rings 6 9. Hold the tilt ram end in a vise using alu- and 7 into the trim cylinder end screw minum plates on both sides. 10. Install the tilt piston to the tilt ram by installing the bolt, then tightening it to the specified torque.
Page 348: Assembling The Tilt Cylinder
BRKT Bracket unit 13. Install the trim cylinder end screw N, and then tighten it to the specified torque. 4. Hold the power trim 0 and in a vise using aluminum plates a on both sides. CAUTION: Do not damage the check valve b when tightening the end screw.
Page 349: Bleeding The Power Trim And Tilt (Not Installed)
Gear pump 7. Install the tilt cylinder end screw C, and then tighten it to the specified torque. Trim and tilt cylinder wrench: YB-06175-2B Cylinder-end screw wrench: 90890-06544 Tilt cylinder end screw C: 90 N·m (9.0 kgf·m, 65 ft·lb) 2. Place the power trim and tilt in an upright 8.
Page 350: Bleeding The Power Trim And Tilt (Built-In)
BRKT Bracket unit 6. Connect the PTT motor leads 2 to the Bleeding the power trim and tilt battery terminals. (built-in) 1. Loosen the manual release plug by turn- ing it counterclockwise until it cannot be turned further. 2. Fully tilt the outboard up, and then Battery release it and let it lower by its own Tilt rod...
Page 351 Gear pump 7. Remove the reservoir cap 1, and then check the fluid level in the reservoir. 8. If necessary, add sufficient fluid of the recommended type to the correct level. NOTE: The fluid level should be at the brim of the filler hole.
Page 352: Power Trim And Tilt Motor
BRKT Bracket unit Power trim and tilt motor 7-73 62Y3A11...
Page 353 Power trim and tilt motor Tightening torques Part name Q’ty Remarks Stage N·m kgf·m ft·lb M5 × 20 mm Screw Yoke O-ring Not reusable Armature Bushing M4 × 12 mm Screw Wire lead Brush 2 Brush 1 Brush holder Circuit breaker Brush spring PTT motor base Oil seal...
Page 354: Checking The Power Trim And Tilt Motor
BRKT Bracket unit Checking the power trim and tilt motor 1. Check the commutator for dirt or foreign substances. Clean with #600 grit sand- paper if necessary. Armature coil continuity Commutator segments b Continuity Segment-laminations c No continuity Segment-shaft d No continuity 2.
Page 355: Assembling The Power Trim And Tilt Motor
Power trim and tilt motor 8. Check the bushing 1 for damage or wear. Replace if necessary. Assembling the power trim and tilt motor 1. Install the oil seal 1 and the bushing 2 into the motor base 3 as shown. Installing the power trim and tilt 1.
Page 356 BRKT Bracket unit 2. Install the shaft 2 and bolts 3 onto both clamp brackets together with the power trim and tilt/hydro tilt 4. 3. Install the tilt ram upper end into the swivel bracket with the shaft 5 and cir- clip(s) 6.
Page 357: Power Trim And Tilt Electrical System
Power trim and tilt motor / Power trim and tilt electrical system Power trim and tilt electrical system 1 Power trim and tilt motor : Black 2 Power trim and tilt relay : Green 3 Trailer switch : Gray 4 Power trim and tilt switch : Blue 5 Fuse : Light green...
Page 358: Checking The Fuse
BRKT Bracket unit Checking the fuse 3. Connect the light green (Lg) lead to the positive battery terminal and the black 1. Check the fuse and fuse holder for conti- (B) lead to the negative battery terminal nuity. Replace if there is no continuity. as shown.
Page 359: Checking The Power Trim And Tilt Switch/Trailer Switch
Power trim and tilt electrical system Checking the power trim and tilt Trim sensor resistance: switch/trailer switch Pink (P) – Black (B) 1. Check power trim tilt 10–288.3 Ω at 20 °C (68 °F) switch/trailer switch continuity. Replace if out of specification. NOTE: Turn the lever 1 and measure the resistance as it gradually changes.
Page 360 BRKT Bracket unit — MEMO — 7-81 62Y3A11...
Page 361: Elec
Electrical components................... 8-5 Starboard and port views................8-5 Front view ....................8-6 Top view ....................8-7 Tiller handle model (F50/F50A, T50/FT50B) ..........8-8 Tiller handle model (FT50C)..............8-9 Wiring harness ..................... 8-10 Ignition system and Ignition control system..........8-11 Checking the ignition spark gap ..............8-13 Checking the spark plug caps ..............8-14...
Page 362: Electrical Systems
– ELEC Electrical systems Troubleshooting Before troubleshooting the charging system, check that all electrical connections are tight and free from corrosion, and that the battery is fully charged to 12 V. Symptom: Battery becomes weaker quickly. • Check the charging system. Measure the output peak voltage of the lighting coil.
Page 363: Special Service Tools
Troubleshooting / Special service tools Special service tools For USA and Canada Dial gauge YU-03097 Dynamic spark tester YM-34487 Magnetic flexible stand YU-34481 Digital multimeter YU-34899-A Test harness (3 pins) YB-06770 Peak voltage adaptor YU-39991 Test harness (4 pins) YB-06771 Test harness (2 pins) For worldwide YB-06767...
Page 364 – ELEC Electrical systems Digital circuit tester Magnet base 90890-03174 90890-06705 Peak voltage adaptor Test harness (3 pins) 90890-03172 90890-06770 Test harness (2 pins) Test harness (4 pins) 90890-06767 90890-06771 Vacuum/pressure pump gauge set 90890-06756 Dial gauge set 90890-01252 62Y3A11...
Page 365: 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 because of the The condition of the ignition system can be internal resistance of the tester.
Page 366: Electrical Components
– ELEC Electrical systems Electrical components Starboard and port views 1 Stator 9 Starter relay 2 Pulser coil 0 Starter motor 3 CDI unit A PTT switch coupler 4 Ignition coil 5 Oil pressure switch È Power trim and tilt model with tiller handle 6 Thermoswitch 7 Prime Start 8 Rectifier Regulator...
Page 367: Front View
Electrical components Front view 1 Stator È Tiller handle model 2 Pulser coil 3 CDI unit 4 Fuse 5 Neutral switch (tiller handle model) 6 Starter relay 7 Starter motor 8 Power trim and tilt relay (power trim and tilt model) 62Y3A11...
Page 368: Top View
– ELEC Electrical systems Top view 1 Stator 2 Pulser coil 3 CDI unit 4 Ignition coil 5 Starter motor 6 Trailer switch 62Y3A11...
Page 369: Tiller Handle Model (F50/F50A, T50/Ft50B)
Electrical components Tiller handle model (F50/F50A, T50/FT50B) 1 Engine start switch È Applicable for tachometer, trim meter or 2 Engine start switch harness warning buzzer model 3 Engine shut-off switch 4 Engine shut-off switch connector 5 Neutral switch 6 Battery lead...
Page 370: Tiller Handle Model (Ft50C)
– ELEC Electrical systems Tiller handle model (FT50C) 1 Engine start switch 2 Engine start switch harness 3 Engine shut-off switch 4 Engine shut-off switch connector 5 Neutral switch 6 Battery lead 62Y3A11...
Page 371: Wiring Harness
Electrical components / Wiring harness Wiring harness 7 Warning indicator or È Power trim and tilt Connect to: : White 1 Tiller handle main digital tachometer model : Black/orange 8 CDI unit B/W : Black/white switch or remote 9 Power trim and tilt : Black : Pink/black control box or wiring...
Page 372: Ignition System And Ignition Control System
– ELEC Electrical systems Ignition system and Ignition control system 1 Spark plug : Black 2 Ignition coil : Brown 3 Charge coil : Blue 4 Pulser coil : White 5 Engine start switch : Black/orange 6 Engine shut-off switch B/W : Black/white 7 10-pin coupler W/B : White/black...
Page 373 Ignition system and Ignition control system 1 Thermoswitch È Remote control model : Black 2 Oil pressure switch É Tiller handle model : Green 3 CDI unit : Red 4 Digital tachometer : Yellow 5 Oil pressure warning Gy/B : Green/black indicator : Pink/black 6 Overheat warning...
Page 374: Checking The Ignition Spark Gap
– ELEC Electrical systems Checking the ignition spark gap 1. Disconnect the spark plug caps from the spark plugs. 2. Connect a spark plug cap to the special service tool. È For USA and Canada É For worldwide 4. Crank the engine and observe the spark through the discharge window of the spark gap tester.
Page 375: Checking The Spark Plug Caps
Ignition system and Ignition control system Checking the spark plug caps 1. Remove the spark plug caps from the high-tension cords by turning the caps counterclockwise. 2. Measure the spark plug cap resistance. Replace if out of specification. Ignition coil resistance: Primary coil: Orange (O) –...
Page 376: Checking The Cdi Unit
– ELEC Electrical systems Checking the CDI unit CDI unit output peak voltage: 1. Measure the CDI unit output peak volt- Black/orange (B/O) – Black (B) age. If below specification, measure the Black/white (B/W) – Black (B) charge coil output peak voltage and the Unloaded Loaded pulser coil output peak voltage.
Page 377: Checking The Pulser Coil
Ignition system and Ignition control system NOTE: Digital multimeter: YU-34899-A • Use the peak voltage adaptor with the digi- Digital circuit tester: 90890-03174 tal circuit tester. Peak voltage adaptor: • When measuring the peak voltage, set the YU-39991 / 90890-03172 selector on the digital circuit tester to the Test harness (2 pins): DC voltage mode.
Page 378: Checking The Engine Start Switch
– ELEC Electrical systems 3. Remove the flywheel magnet nut and fly- Lead color wheel magnet. Switch White Black Pink Brown 4. Loosen the pulser coil screws, adjust the position (Br) pulser coil 2 position, and then tighten the screws finger tight. START Checking the engine shut-off switch 1.
Page 379: Checking The Thermoswitch
Ignition system and Ignition control system Checking the thermoswitch 1. Place the thermoswitch in a container of water and slowly heat the water. 3. Check the switch for continuity at the specified pressure. Replace if there is no continuity. 2. Check the switch for continuity at the Pressure/vacuum tester: YB-35956-A specified temperatures.
Page 380: Starting System
– ELEC Electrical systems Starting system 1 Fuse : Black 2 10-pin coupler : Brown 3 Engine start switch : Red 4 Starter motor 5 Battery 6 Neutral switch 7 Starter relay È Tiller handle model 8-19 62Y3A11...
Page 381: Checking The Fuse
Starting system Checking the fuse 4. Check for continuity between the starter relay terminals. Replace if there is no 1. Check the fuse and fuse holder for conti- continuity. nuity. Replace if there is no continuity. 5. Check that there is no continuity between the starter relay terminals after discon- necting the brown or black lead.
Page 382: Starter Motor
– ELEC Electrical systems Starter motor 8-21 62Y3A11...
Page 383 Starter motor Tightening torques Part name Q’ty Remarks Stage N·m kgf·m ft·lb Clip Pinion stopper Spring Starter motor pinion Upper bracket O-ring Not reusable Washer 1 Shim — As required Washer 2 Armature Stator O-ring Not reusable Brush holder assembly Brush set O-ring Not reusable...
Page 384: Removing The Starter Motor Pinion
– ELEC Electrical systems Removing the starter motor pinion 1. Slide the pinion stopper 1 down as shown, and then remove the clip 2. Dial gauge 1: YU-03097 Dial gauge set 1: 90890-01252 Magnetic flexible stand 2: YU-34481 Magnet base 2: 90890-06705 Checking the starter motor pinion 1.
Page 385: Checking The Brushes
Starter motor 4. Measure the commutator undercut a. Brush length limit a: 12.0 mm (0.47 in) Replace the armature if out of specifica- tion. 2. Check the brush holder for continuity. Replace if out of specifications. Commutator undercut limit: 0.2 mm (0.01 in) Brush assembly continuity Brush 1 –...
Page 386: Charging System
– ELEC Electrical systems Charging system 1 Lighting coil : Black 2 Rectifier Regulator : Green 3 Fuse : Red 4 Battery G/W : Green/white 8-25 62Y3A11...
Page 387: Checking The Lighting Coil
Charging system Checking the lighting coil Lighting coil resistance (use as reference): 1. Measure the lighting coil output peak Green (G) – Green (G) voltage. Replace the stator coil if below 1.2–1.8 Ω at 20 °C (68 °F) specification. Checking the Rectifier Regulator 1.
Page 388 – ELEC Electrical systems Rectifier Regulator output peak voltage: Red (R) – Black (B) Unloaded r/min 1,500 3,500 DC V 18.9 19.5 NOTE: After starting the engine, disconnect the out- put lead (red lead) of the Rectifier Regulator when measuring the output peak voltage. 8-27 62Y3A11...
Page 389 — MEMO — 8-28 62Y3A11...
Page 390 Checking the fuel joint and fuel hoses Assembling the trim cylinder .....7-67 (fuel joint-to-carburetor) ......3-4 Checking the fuel pump......4-9 Checking the fuel system ......1-33 Backlash (F50/F50A) ........6-39 Checking the fuse......7-79 8-20 Backlash (T50/FT50B, FT50C) ....6-77 Checking the gear oil........ 1-33 Bleeding the power trim and tilt (built-in)...7-71...
Page 391 Disassembling the trim cylinder....7-63 Checking the shift rod and shift cam..6-25 Disassembly and assembly ......1-4 Checking the shift rod assembly Drive shaft and lower case (F50/F50A) ..6-21 operation ..........7-29 Drive shaft and lower case Checking the spark plug caps....8-14 (T50/FT50B, FT50C) ......
Page 392 6-36 6-70 6-74 Newly designed four carburetors ....1-6 Shimming (F50) (for USA and Canada) ... 6-31 Shimming (F50A) (for worldwide) ..... 6-35 Shimming (FT50B, FT50C) Parts, lubricants, and sealants....1-3 (for worldwide) ........6-73 Power trim and tilt ........1-22 Shimming (T50) (for USA and Canada) ... 6-69 Power trim and tilt electrical system..7-78...
Page 393 Swivel bracket and steering arm....7-47 Symbols ............1-2 Synchronizing the carburetors ....4-23 Technical tips ..........1-10 Test run.............1-35 Tightening torques ........2-29 Tiller handle (F50/F50A, T50/FT50B) ..7-5 Tiller handle (FT50C) ........7-17 Tiller handle model (F50/F50A, T50/FT50B)......8-8 Tiller handle model (FT50C) .......8-9 Tilt cylinder and trim cylinder ....7-55 Timing belt and sprockets ......5-29...
Page 394 Wiring diagram F50AEHD, F50AED, FT50CEHD, FT50CED 1 Battery Color code 2 Engine start switch : Black 3 Engine shut-off switch : Brown 4 Starter motor : Green 5 Starter relay : Blue 6 Neutral switch : Orange 7 Fuse (20A) : Pink 8 Prime Start : Red...
Page 395 Wiring diagram F50TH/F50AEHT 1 Battery Color code 2 Power trim and tilt motor : Black 3 Engine start switch : Brown 4 Power trim and tilt relay : Green 5 Engine shut-off switch : Blue 6 Starter motor : Light green 7 Starter relay : Orange 8 Neutral switch...
Page 396 Wiring diagram (applicable for tachometer, trim meter or warning buzzer) F50TH/F50AEHT* 1 Battery Color code 2 Power trim and tilt motor : Black 3 Power trim and tilt relay : Brown 4 Starter motor : Green 5 Fuse (20A) : Blue 6 Neutral switch : Light green 7 Starter relay...
Page 397 Wiring diagram F50TR/F50AET, T50TR/FT50BET, FT50CET 1 Battery Color code 2 Power trim and tilt motor : Black 3 Power trim and tilt relay : Brown 4 Starter motor : Green 5 Fuse (20A) : Gray 6 Trim sensor : Blue 7 Prime Start : Light green 8 Starter relay...
Page 399 YAMAHA MOTOR CO., LTD. Printed in the Netherlands Nov. 2000 – 1.4 × 1 CR (F50AEHD, F50AEHT, F50AED, F50AET, FT50BET, FT50CEHD, FT50CED, FT50CET)
Page 400 F50AEHD, F50AED, FT50CEHD, FT50CED Gy/B G/W G/W È Gy/B Gy/B Gy/B È B B B É È S62YWD01R...
Page 401 F50TH/F50AEHT Gy/B G/W G/W Gy/B Gy/B Gy/B B B B Sb R È Sb R Sb R FREE FREE DOWN DOWN Lg Sb S62YWD02R...
Page 402 F50TH/F50AEHT ∗ Gy/B G/W G/W Gy/B B B B Gy/B Gy/B B B B Sb R R Sb Lg G P Sb R Sb R FREE FREE DOWN DOWN Lg Sb G/W G/R S62YWD03R...
Page 403 F50TR/F50AET, T50TR/FT50BET, FT50CET Gy/B G/W G/W Gy/B Gy/B Gy/B B B B È Sb R Sb R FREE DOWN R Sb S62YWD04R...

This manual is also suitable for:

Ft50c Ft50b

Yamaha F50A Service Manual

Table of Contents

Spec Specifications

General Specifications

Maintenance Specifications

Tightening Torques

Chk Adj/Chk Adj

Chk Adj

Special Service Tools

Periodic Checks and Adjustments

Maintenance Interval Chart

Top Cowling

Fuel System

Power Unit

Control System

Power Trim and Tilt Unit

Lower Unit

General

Fuel Fuel System

Special Service Tools

Fuel System

Hose Routing

Fuel Line

Fuel Filter and Fuel Pump

Carburetor Unit

Carburetor

Powr Power Unit

Troubleshooting

Special Service Tools

Power Unit

Timing Belt and Sprockets

Cylinder Head

Cylinder Body

Lowr Lower Unit

Special Service Tools

Lower Unit (F50/F50A)

Water Pump and Propeller Shaft Housing (F50/F50A)

Drive Shaft and Lower Case (F50/F50A)

Shimming (F50) (for USA and Canada)

Shimming (F50A) (for Worldwide)

Backlash (F50/F50A)

Lower Unit (T50/FT50B, FT50C)

Water Pump and Shift Rod (T50/FT50B, FT50C)

Propeller Shaft Housing (T50/FT50B, FT50C)

Drive Shaft and Lower Case (T50/FT50B, FT50C)

Shimming (T50) (for USA and Canada)

Shimming (FT50B, FT50C) (for Worldwide)

Backlash (T50/FT50B, FT50C)

Brkt Bracket Unit

Troubleshooting

Special Service Tools

Tiller Handle (F50/F50A, T50/FT50B)

Tiller Handle (FT50C)

Bottom Cowling

Upper Case

Clamp Brackets

Swivel Bracket and Steering Arm

Power Trim and Tilt Unit

Tilt Cylinder and Trim Cylinder

Trim Cylinder

Gear Pump

Power Trim and Tilt Motor

Power Trim and Tilt Electrical System

Quick Links

Chapters

Troubleshooting

Related Manuals for Yamaha F50A

Summary of Contents for Yamaha F50A