Yamaha F100C Service Manual
  1. Manuals
  2. Brands
  3. Yamaha Manuals
  4. Engine
  5. F100C
  6. Service manual

Yamaha F100C Service Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

F100B
F100C
SERVICE MANUAL
290429
60C-28197-5D-11

Advertisement

Table of Contents
loading

Related Manuals for Yamaha F100C

Summary of Contents for Yamaha F100C

  • Page 1 F100B F100C SERVICE MANUAL 290429 60C-28197-5D-11...

  • Page 2: Important Information

    NOTICE This manual has been prepared by Yamaha primarily for use by Yamaha dealers and their trained mechanics when performing maintenance procedures and repairs to Yamaha equipment. It has been written to suit the needs of persons who have a basic understanding of the mechanical and electrical concepts and procedures inherent in the work, for without such knowledge attempted repairs or service to the equipment could render it unsafe or unfit for use.
  • Page 3 Contents General information INFO Specifications SPEC Periodic checks and adjustments Fuel system FUEL Power unit POWR Lower unit LOWR Bracket unit BRKT – Electrical systems ELEC Troubleshooting TRBL SHTG Index...

  • Page 4: Table Of Contents

    Acceleration pump...................1-17 Ignition system..................1-18 Ignition timing control................1-18 Lubrication system...................1-20 Cooling system ..................1-21 PTT (power trim and tilt) unit (F100B) .............1-22 PTT (power trim and tilt) unit (F100C) .............1-24 Propeller selection ..................1-25 Propeller size................... 1-25 Selection....................1-25 60C5D11...
  • Page 5 Predelivery checks ..................1-25 Checking the fuel system ................1-25 Checking the gear oil................1-26 Checking the engine oil ................1-26 Checking the battery................1-26 Checking the outboard motor mounting position ........1-26 Checking the remote control cables ............1-27 Checking the steering system ..............1-27 Checking the gearshift and throttle operation..........1-27 Checking the tilt system................1-28 Checking the engine start switch and engine stop switch/...

  • Page 6: How To Use This Manual

    INFO General information How to use this manual Manual format The format of this manual has been designed to make service procedures clear and easy to under- stand. Use the information below as a guide for effective and quality service. 1 Parts are shown and detailed in an exploded diagram and are listed in the components list.

  • Page 7: Symbols

    Symbols 7 to A in an exploded diagram indicate the grade of lubricant and the lubrication point. 7 Apply Yamaha 4-stroke motor oil 0 Apply corrosion resistant grease 8 Apply water resistant grease (Yamaha grease A) (Yamaha grease D) 9 Apply molybdenum disulfide grease...

  • Page 8: Safety While Working

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

  • Page 9: Good Working Practices

    Safety while working 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

    X: 200101– stamped on a label attached to the port L: 000101– clamp bracket. F100CET X: 200101– S60C1090 È F100B É F100C 1 Model name 2 Approved model code 3 Transom height 4 Serial number 60C5D11...

  • Page 11: Features And Benefits

    Features and benefits Power unit The F100B and F100C have been developed on the bases of the F100A, which has been recog- nized as being environmentally friendly, with established emission control, and which has received high marks as an efficiently superior model with a high fuel economy.
  • Page 12 The hollow volume at the top of the pistons has been made larger and the compression ration has been lowered to increase reliability and durability. F100B, F100C F100A S60C1270 1 Top ring...
  • Page 13 Features and benefits New plastic-region tightening bolts To tighten the plastic-region tightening bolts, tighten them to the specified torque, and then tighten them to the specified angle. By tightening the bolts to the specified angle, they are contracted to a more accurate torque, making periodic maintenance checks and adjustments to, as well as addi- tional tightening of the bolt unnecessary.
  • Page 14 INFO General information Fuel pump and fuel filter The fuel pump found in the F115A has been adopted. Although the quantity of parts has been reduced and the necessary servicing time has been decreased as well, the ability of the fuel pump to supply sufficient fuel has been retained.
  • Page 15 Features and benefits Hour meter A newly developed hour meter is incorporated on the F100B and F100C. The hour meter makes it possible to check the hours of operation of the outboard motor, which can be used to keep track of periodic checks and adjustments.

  • Page 16: Ignition System

    INFO General information Ignition system A CDI system has been incorporated. The CDI unit uses three signals (i.e., crankshaft position, engine revolution, and throttle position) to determine the optimum ignition timing. Engine speed is controlled by the CDI unit to prevent damage to the engine when the engine tem- perature sensor detects that the engine temperature (i.e., water temperature) is too high, or when the oil pressure switch detects that the oil pressure is too low, or when the engine idle speed is too high.
  • Page 17 Features and benefits At low speeds, the exhaust gas flows into the water wall through a hole on the side of the exhaust guide. S60C1330 È Exhaust gas flow at low speeds É Exhaust gas flow at high speeds An identification mark has been stamped on the exhaust manifold and exhaust chamber. 1 Identification mark “C”...

  • Page 18: Bracket Unit And The Ptt Unit

    The PTT unit of the F100C has been adopted from the proven F100A. This PTT unit consists of a single cylinder for both tilt and trim functions, making the unit compact and lightweight.

  • Page 19: Cooling System

    Features and benefits Cooling system A high capacity water pump and a large cylinder head water jacket have been incorporated to enable better cooling. A pressure control valve (PCV) has also been incorporated to control the cooling water pressure, which in turn helps prevent water leakage from the power unit. When the cooling water pressure becomes too high, the PCV opens and the cooling water flows through a bypass passage to the upper case.

  • Page 20: Lower Unit

    F100C S60C1390 1 Blue identification paint Lower unit The lower unit of the F100C does not contain a reverse gear shim. Therefore, it is not necessary to set the position of a shim for the reverse gear. Gear ratio F100A 2.31 (30/13)

  • Page 21: 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 F100B and F100C. In the Prime Start system, the thermo heater plunger is in a position that fully opens the fuel enrichment valve while the engine is being started.

  • Page 22: 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 23: Ignition System

    Technical tips Ignition system The computer controlled CDI system has three basic modes of operation: starting, warm-up, and normal operation. Ignition timing control Starting mode Ignition timing is fixed at 10° BTDC. The starting mode cuts off when the engine has been started and the engine speed is over 600 r/min.
  • Page 24 INFO General information • Low oil pressure control Three seconds after starting the engine this mode does not operate. When the oil pressure switch turns on oil pressure is 150 kPa (1.5 kg/cm , 21.3 psi) or below, this mode starts. The buzzer will sound and the warning light will turn on. Ignition to cylinders #1 and #4 will cut off and the engine speed will gradually lower to approximately 2,000 r/min.

  • Page 25: Lubrication System

    Technical tips Lubrication system Pressure fed Splash Return Cylinder head Crankcase Sleeve Intake and exhaust valves Camshaft Piston Crankshaft pin Camshaft journal Crankshaft journal Main gallery Oil pressure switch • Low oil pressure warning Oil filter • Filtration of foreign objects •...

  • Page 26: Cooling System

    INFO General information Cooling system Cooling water inlet Water pump Discharge Oil pan Pilot water Exhaust cover Flushing device outlet Cylinder Cylinder head Exhaust Pressure control pipe valve (PCV) Thermostat Upper case (water wall) Discharge Trim tab water inlet Propeller boss Discharge S60C1460 1-21...

  • Page 27: Ptt (Power Trim And Tilt) Unit (F100B)

    Technical tips PTT (power trim and tilt) unit (F100B) The circuit of the PTT unit and the location of its major components are shown in the illustration below. 1 Lower chamber shuttle valve E Passage to upper chamber of trim cylinders 2 Up-relief valve F Passage to lower chambers of tilt cylinder and 3 Pump chamber...
  • Page 28 INFO General information Component identification Description Notes Up-relief valve PTT fluid flows upward above 10.8 MPa (110 kg/cm 1,500 psi). Down-check valve PTT fluid flows easily to the left while some fluid flows to the right through a small restriction. Lower chamber check valve PTT fluid flows easily downward.

  • Page 29: Ptt (Power Trim And Tilt) Unit (F100C)

    Technical tips PTT (power trim and tilt) unit (F100C) The circuit of the PTT unit and the location of its major components are shown in the illustration below. S60C1480 1 PTT cylinder 9 Main valve 2 Free piston 0 Up-flow side...

  • Page 30: Propeller Selection

    INFO General information a Propeller diameter (in inches) Propeller selection b Propeller pitch (in inches) The performance of a boat and outboard c Propeller type (propeller mark) motor will be critically affected by the size and type of propeller you choose. Propellers Selection greatly affect boat speed, acceleration, When the engine speed is at the full throttle...

  • Page 31: Checking The Gear Oil

    Propeller selection / Predelivery checks NOTE: • If the engine oil is above the maximum level mark a, drain sufficient oil until the level is between a and b. • If the engine oil is below the minimum level mark b, add sufficient oil until the level is between a and b.

  • Page 32: Checking The Remote Control Cables

    INFO General information Checking the remote control cables Checking the steering system 1. Set the remote control lever to the neu- 1. Check the steering friction for proper tral position and fully close the throttle adjustment. lever/throttle grip. 2. Check that the throttle control lever 1 touches the fully closed stopper a.

  • Page 33: Checking The Tilt System

    Predelivery checks 2. Check that the throttle operates smoothly 3. Check that the engine turns off when the when the remote control lever or throttle engine stop switch is pushed or the grip is shifted from the fully closed posi- engine shut-off cord is pulled from the tion to the fully open position a.

  • Page 34: Break-In

    INFO General information 4. Run the outboard motor for one hour at 2,000 r/min or at half throttle, then for another hour at 3,000 r/min or at 3/4 throttle. 5. Check that the outboard motor does not tilt up when shifting into reverse and that water does not flow in over the transom.
  • Page 35 SPEC Specifications General specifications................... 2-1 Maintenance specifications ................2-3 Power unit....................2-3 Lower unit ....................2-6 Electrical ....................2-7 Dimensions....................2-9 Tightening torques..................2-14 Specified torques..................2-14 General torques..................2-16 60C5D11...

  • Page 36: General Specifications

    SPEC Specifications General specifications Model Item Unit F100BET F100CET Dimension Overall length mm (in) 825 (32.5) Overall width mm (in) 486 (19.1) Overall height mm (in) 1,595 (62.8) 1,582 (62.3) mm (in) 1,722 (67.8) 1,710 (67.3) Boat transom height mm (in) 508 (20.0) mm (in) 635 (25.0)
  • Page 37 General specifications Model Item Unit F100BET F100CET Fuel and oil Fuel type Unleaded gasoline/leaded gasoline Fuel rating RON* Engine oil type 4-stroke motor oil Engine oil grade SE, SF, SG, or SH 10W-30 or 10W-40 Engine oil quantity (with oil filter replacement) 4.7 (5.0, 4.1) (US qt, lmp qt) (without oil filter replacement)

  • Page 38: Specifications

    SPEC Specifications Maintenance specifications Power unit Model Item Unit F100BET F100CET Power unit Minimum compression 670 (6.7, 95) pressure* (kgf/cm , psi) Lubrication oil pressure kPa (kgf/cm 520 (5.2, 74) (reference data) psi) at 850 r/min Cylinder heads Warpage limit mm (in) 0.1 (0.04) (lines indicate straightedge...
  • Page 39 Maintenance specifications Model Item Unit F100BET F100CET 2nd ring Dimension B mm (in) 1.47–1.49 (0.0579–0.0586) Dimension T mm (in) 3.00–3.20 (0.1182–0.1259) End gap mm (in) 0.70–0.90 (0.0276–0.0354) Side clearance mm (in) 0.03–0.07 (0.0012–0.0027) Oil ring Dimension B mm (in) 2.38–2.48 (0.0938–0.0976) Dimension T mm (in) 2.40 (0.0945)
  • Page 40 SPEC Specifications Model Item Unit F100BET F100CET Valve springs Free length mm (in) 53.20 (2.0945) Minimum free length mm (in) 52.25 (2.0570) Tilt limit mm (in) 2.6 (0.10) Connecting rods Small-end inside diameter mm (in) 17.97–17.98 (0.7075–0.7078) Big-end inside diameter mm (in) 47.03–47.04 (1.8514–1.8518) Crank pin oil clearance...

  • Page 41: Lower Unit

    Maintenance specifications Model Item Unit F100BET F100CET Oil pump Discharge L (US gal, 5.9 (1.56, 1.30) at 100 °C (212 °F) with Imp gal)/min 10W-30 engine oil at 1,000 r/min Thermostats Opening temperature °C (°F) 50 (122) Fully open temperature °C (°F) 60 (140) Valve open lower limit...

  • Page 42: Electrical

    SPEC Specifications Electrical Model Item Unit F100BET F100CET Ignition system Ignition timing ATDC ± 5 (engine idle speed) Degree Pulser coil output peak voltage (W/R – B) (*1) at cranking 1 (*1) at cranking 2 at 1,500 r/min at 3,500 r/min 14.0 Ω...
  • Page 43 Maintenance specifications Model Item Unit F100BET F100CET Charging system Fuse 20, 30 Lighting coil output peak voltage (W – W) (*1) at cranking (*1) at 1,500 r/min (*1) at 3,500 r/min Ω (*2) Lighting coil resistance 0.32–0.48 (W – W) Rectifier Regulator output peak voltage (R –...

  • Page 44: Dimensions

    SPEC Specifications Dimensions Exterior S60C2150 60C5D11...
  • Page 45 Maintenance specifications Model Symbol Unit F100BET F100CET mm (in) 664 (26.1) 647 (25.5) mm (in) 161 (6.3) 171 (6.7) mm (in) — mm (in) 631 (24.8) 574 (22.6) mm (in) 69 (2.7) 65 (2.6) mm (in) 76 (3.0) mm (in) 1,005 (39.6) 998 (39.3) mm (in)
  • Page 46 SPEC Specifications Exterior (Tiller handle model) S60C2160 2-11 60C5D11...
  • Page 47 Maintenance specifications Model Symbol Unit F100BET F100CET mm (in) 664 (26.1) 651 (25.6) mm (in) 316 (12.4) 268.3 (10.5) mm (in) 832 (32.8) 792.7 (31.2) mm (in) 631 (24.8) 574 (22.6) mm (in) 69 (2.7) 65 (2.6) mm (in) 76 (3.0) mm (in) 1,005 (39.6) 998 (39.3)
  • Page 48 SPEC Specifications Clamp bracket Model Symbol Unit F100BET F100CET mm (in) 125.4 (4.9) mm (in) 254 (10.0) mm (in) 163.5 (6.4) mm (in) 50.8 (2.0) mm (in) 180 (7.1) mm (in) 367 (14.4) 347 (13.7) mm (in) — mm (in) —...
  • Page 49 Tightening torques Tightening torques Specified torques Tightening torques Part to be tightened Thread size N·m kgf·m ft·lb Power unit Flywheel magnet nut — 18.6 Negative battery lead bolt Positive battery lead nut — Power unit bolt Apron bolt Drive sprocket nut —...
  • Page 50 — Propeller nut — Trim tab bolt Ring nut — 10.3 Pinion nut — Water inlet cover screw — Lower unit (F100C) Check screw — Lower unit bolt Drain screw — Propeller nut — Ring nut — 10.3 Pinion nut —...

  • Page 51: Tightening Torques

    Gear pump assembly bolt Gear pump bolt Tilt cylinder end screw — Tilt piston nut — Trim cylinder end screw — Power trim and tilt unit (F100C) Tilt cylinder end screw — Reservoir cap — Pump housing assembly — Trim cylinder end screw —...
  • Page 52 SPEC Specifications — MEMO — 2-17 60C5D11...
  • Page 53 Periodic checks and adjustments Special service tools ..................3-1 Maintenance interval chart................3-2 Top cowling ....................3-4 Checking the top cowling................3-4 Checking the hour meter ................3-4 Fuel system ....................3-4 Checking the fuel joint and fuel hoses (fuel joint-to-carburetor) ....3-4 Checking the fuel filter ................3-4 Power unit.......................

  • Page 54: Chk Adj

    Periodic checks and adjustments Special service tools Oil filter wrench 90890-01426 Digital tachometer 90890-06760 Timing light 90890-03141 Leakage tester 90890-06762 60C5D11...

  • Page 55: Maintenance Interval Chart

    Special service tools / Maintenance interval chart Maintenance interval chart Use the following chart as a guideline for general maintenance. Adjust the maintenance intervals according to the operating conditions of the outboard motor. Initial Every Refer to Item Remarks page Top cowling Top cowling fit Check/adjust...
  • Page 56 Periodic checks and adjustments Initial Every Refer to Item Remarks page Lower unit Gear oil Change 3-13 Impeller/Woodruff key Check/replace 6-8, 6-36 Oil seals Check/replace — Drive shaft Check/replace 6-18, 6-46 Propeller Check 3-14 General Anodes/Trim tab Check/replace 3-14 Battery Check/charge 3-15 Wiring and connectors...

  • Page 57: Top Cowling

    Maintenance interval chart / Top cowling / Fuel system Top cowling Checking the top cowling 1. Check the fitting by pushing the cowling with both hands. Adjust if necessary. S60C3730 Fuel system Checking the fuel joint and fuel hoses (fuel joint-to-carburetor) S60C3010 1.

  • Page 58: Power Unit

    Periodic checks and adjustments NOTE: • Change the oil if it appears milky or black. • If the engine oil is above the maximum level mark a, drain sufficient oil until the level is between a and b. • If the engine oil is below the minimum level mark b, add sufficient oil until the level is between a and b.
  • Page 59 Fuel system / Power unit NOTE: To extract and change the oil through the dip- stick hole a, you can use an oil changer 3 S60C3090 like the one shown in the illustration. 3. Place a rag under the oil filter, and then remove the filter.

  • Page 60: Checking The Timing Belt

    Periodic checks and adjustments 7. Pour the specified amount of the recom- Checking the valve clearance mended engine oil into the oil filler hole. NOTE: For checking procedures, see Chapter 5, Recommended engine oil: “Checking the valve clearance”. 4-stroke motor oil API: SE, SF, SG, or SH SAE: 10W-30, 10W-40, or 20W-40 Checking the spark plugs...

  • Page 61: Checking The Thermostat

    Power unit 6. Install the spark plug, tighten it finger tight b, then to the specified torque with a spark plug wrench c. S60C3330 5. Check the thermostat valve opening at specified water temperatures. Replace if out of specification. Spark plug: 25 N·m (2.5 kgf·m, 18 ft·lb) Checking the thermostat 1.

  • Page 62: Control System

    2. Loosen the locknut 2, remove the clip 3, and then disconnect the throttle cable joint 4. S60C3360 È F100B É F100C S60C3400 2. Place the lower unit in water, and then 3. Contact the throttle control lever 1 with start the engine.

  • Page 63: Checking The Gearshift Operation

    Power unit / Control system S60C3440 S60C3420 CAUTION: 5. Adjust the position of the shift cable joint until its hole is aligned with the set pin. The throttle cable joint must be screwed in a minimum of 8.0 mm (0.31 in) c. 5.

  • Page 64: Checking The Ignition Timing

    Periodic checks and adjustments 3. Attach the special service tool to high- tension cord #1 1. S60C3450 S60C3470 Digital tachometer: 90890-06760 Engine idle speed: 800–900 r/min 3. Turn the throttle stop screw 2 in direc- tion a or b until the specified engine idle speed is obtained.

  • Page 65: Power Trim And Tilt Unit

    1 to check the lock mechanism of the lever. S60C3520 S60C3510 È F100B É F100C Checking the power trim and tilt fluid level S60C3530 È F100B 1. Fully tilt the outboard motor up, and then É...

  • Page 66: Lower Unit

    Periodic checks and adjustments 4. Install the reservoir cap, and then tighten 2. Place a drain pan under the drain screw 1, remove the drain screw, then the it to the specified torque. check screw 2 to drain the oil. Reservoir cap: 7 N·m (0.7 kgf·m, 5.1 ft·lb) Lower unit...

  • Page 67: Checking The Lower Unit (For Air Leakage)

    1. Check the propeller blades and splines 0.785 L (0.83 US qt, 0.69 Imp qt) for cracks, damage, or wear. Replace if F100C: necessary. 0.670 L (0.71 US qt, 0.59 Imp qt) 5. Install the check screw, quickly install the drain screw, and then tighten them to the specified torque.

  • Page 68: Checking The Battery

    Fully charge the battery if out of S60C3620 specification. S60C3630 S60C3640 È F100B É F100C CAUTION: Do not oil, grease, or paint the anodes, otherwise they will be ineffective. 2. Replace the anodes and trim tab if excessively eroded.

  • Page 69: Lubrication

    General Lubrication WARNING 1. Apply water resistant grease to the areas Battery electrolyte is dangerous; it con- shown. tains sulfuric acid which is poisonous and highly caustic. Always follow these preventive measures: • Avoid bodily contact with electrolyte as it can cause severe burns or permanent eye injury.
  • Page 70 Periodic checks and adjustments 2. Apply corrosion resistant grease to the areas shown. S60C3695 S60C3700 S60C3710 È F100B É F100C NOTE: Apply grease to the grease nipple until it flows from the bushings a. 3-17 60C5D11...
  • Page 71 FUEL Fuel system Special service tools ..................4-1 Hose routing ....................4-2 Fuel, blowby, and cooling water hoses............4-2 Fuel line and fuel filter ................... 4-3 Fuel pump ....................... 4-5 Checking the fuel pump................4-7 Disassembling the fuel pump ..............4-8 Checking the diaphragm and valves ............4-8 Assembling the fuel pump .................

  • Page 72: Fuel System

    FUEL Fuel system Special service tools Vacuum/pressure pump gauge set Vacuum gauge (digital) 90890-06756 (commercially obtainable) Digital tachometer Vacuum gauge (4 analog meters) 90890-06760 (commercially obtainable) Vacuum gauge Vacuum gauge adaptor 90890-03159 (commercially obtainable) Test harness (3 pins) 90890-06757 Digital circuit tester 90890-03174 60C5D11...

  • Page 73: Hose Routing

    Special service tools / Hose routing Hose routing Fuel, blowby, and cooling water hoses S60C4010 1 Blowby hose 9 Pilot water hose 2 Fuel hose (fuel pump-to-carburetor) 3 Fuel hose (fuel filter-to-fuel pump) 4 Fuel hose (fuel joint-to-fuel filter) 5 Fuel hose (carburetor-to-carburetor) 6 Hose (acceleration pump-to-carburetor) 7 Hose (carburetor-to-carburetor) 8 Cooling water hose...

  • Page 74: Fuel Line And Fuel Filter

    FUEL Fuel system Fuel line and fuel filter 10 N m (1.0 kgf m, 7.2 ft • • • S60C4030 60C5D11...
  • Page 75 Fuel line and fuel filter Part name Q’ty Remarks Fuel pump Body Fuel filter element Float O-ring Not reusable 2 × 36.2 mm Fuel filter cup Clip Fuel joint M6 × 12 mm Bolt Washer Clamp Clamp Fuel hose Fuel joint-to-fuel joint Fuel hose Fuel pump-to-fuel joint Plastic tie...

  • Page 76: Fuel Pump

    FUEL Fuel system Fuel pump m (0.4 kgf m, 2.9 ft • • • S60C4040 60C5D11...
  • Page 77 Fuel pump Part name Q’ty Remarks M6 × 35 mm Screw Cover Fuel pump body 2 Fuel pump body 1 Plunger Spring Spring Diaphragm Spring Valve Screw Gasket Not reusable 60C5D11...

  • Page 78: 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 79: Disassembling The Fuel Pump

    Fuel pump Disassembling the fuel pump Checking the diaphragm and valves 1. Check the diaphragm 1 for tears and the 1. Disassemble the fuel pump as shown. valves 2 for cracks. Replace if neces- sary. S60C4090 Assembling the fuel pump S60C4060 1.

  • Page 80: Throttle Control

    FUEL Fuel system Throttle control 15 16 S60C4120 60C5D11...
  • Page 81 Throttle control Part name Q’ty Remarks Throttle cam Throttle link rod Throttle position sensor Bracket Throttle control lever Bracket Washer Spring Washer Wave washer Collar M6 × 35 mm Bolt M6 × 12 mm Bolt Washer Wave washer Washer Collar M6 ×...
  • Page 82 FUEL Fuel system 16 17 19 20 S60C4130 4-11 60C5D11...
  • Page 83 Throttle control Part name Q’ty Remarks Silencer Carburetor assembly Intake manifold Acceleration pump Blowby hose M6 × 20 mm Bolt M8 × 60 mm Bolt O-ring Not reusable 3.5 × 47.7 mm Gasket M6 × 120 mm Bolt Spacer O-ring Not reusable Fuel hose Carburetor-to-carburetor...

  • Page 84: Carburetor

    FUEL Fuel system Carburetor S60C4140 4-13 60C5D11...
  • Page 85 Carburetor Part name Q’ty Remarks Carburetor body M4 × 10 mm Screw Cover Gasket Not reusable Spring O-ring Not reusable Pilot screw Prime Start M4 × 10 mm Screw Bracket O-ring Not reusable Body M5 × 16 mm Screw O-ring Not reusable O-ring Not reusable...

  • Page 86: Checking The Check Valve

    FUEL Fuel system Checking the check valve Checking the carburetor 1. Install the special service tool onto the 1. Check the air and fuel passages, and jets check valve. for dirt and foreign matter. Clean the car- buretor body with a petroleum based sol- vent if necessary.

  • Page 87: Checking The Prime Start

    Carburetor 4. Check the pilot screw and needle valve NOTE: for bends or wear. Replace if necessary. • The float should be resting on the needle valve 5, but not compressing it. • Take measurements at the end of the float opposite its pivoted side.

  • Page 88: Assembling The Carburetor

    FUEL Fuel system Assembling the carburetor 1. Install the main nozzle 1, main jet 2, pilot jet 3, plug 4, and valve seat 5 to the carburetor body as shown. S60C4240 Pilot screw setting: 1 1/2–2 1/2 turns out Adjusting the throttle link rod 1.

  • Page 89: Adjusting The Throttle Position Sensor

    Carburetor 4. Loosen the screws 2. NOTE: Make sure that there is complete clearance between the throttle cam roller 4 and the cam surface. 5. Adjust the length of the throttle link rod 5, and then tighten the nut 6 securely. 6.

  • Page 90: Adjusting The Pilot Screw

    FUEL Fuel system 4. Turn the throttle stop screw 3 in direc- Adjusting the pilot screw tion c or d until the specified engine 1. Start the engine and warm it up for 5 min- idle speed is obtained. utes to check the stability of the engine. Adjust the pilot screw if necessary.

  • Page 91: Synchronizing The Carburetors

    Carburetor 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 high- tension cord #1 1. S60C4290 S60C4330 Digital tachometer: 90890-06760 Vacuum gauge (digital) 3.
  • Page 92 FUEL Fuel system 6. Turn the throttle valve adjusting screws 6 to adjust the vacuum pressure of car- buretors #1, #2, and #3 to the same vac- uum variation as carburetor #4. S60C4350 7. Adjust the engine idle speed to specifica- tion.
  • Page 93 POWR Power unit Special service tools ..................5-1 Power unit....................... 5-3 Checking the valve clearance..............5-6 Checking the compression pressure ............5-9 Checking the oil pressure ................5-9 Removing the power unit.................5-10 Timing belt and sprockets................5-12 Removing the timing belt and sprockets..........5-17 Checking the timing belt and sprockets...........5-18 Installing the timing belt and sprockets............5-18 Cylinder head ....................5-21...

  • Page 94: Power Unit

    POWR Power unit Special service tools Compression gauge Valve spring compressor 90890-03160 90890-04019 Compression gauge adaptor Valve spring compressor attachment 90890-06563 90890-06320 Flywheel holder Valve guide remover/installer 90890-06522 90890-04064 Flywheel puller Valve guide reamer 90890-06521 90890-04066 Crankshaft holder 20 Valve seat cutter holder 90890-06552 90890-06553 60C5D11...
  • Page 95 Special service tools Valve seat cutter 90890-06315, 90890-06324, 90890-06326, 90890-06328, 90890-06555 Crank stand alignment 90890-03107 Oil filter wrench 90890-01426 Piston slider 90890-06530 60C5D11...

  • Page 96: Power Unit

    POWR Power unit Power unit 186 N m (18.6 kgf m, 135 ft • • • m (0.9 kgf m, 6.5 ft • • • S60C5010 60C5D11...
  • Page 97 Power unit Part name Q’ty Remarks Flywheel magnet M8 × 20 mm Bolt Cover Washer Woodruff key Engine oil dipstick M6 × 25 mm Bolt Plate Cover Plastic tie Not reusable 10 × 330 mm Pilot water hose M8 × 16 mm Bolt Negative battery lead Washer...
  • Page 98 POWR Power unit 42 N m (4.2 kgf m, 30 ft • • • m (0.4 kgf m, 2.9 ft • • • S60C5030 Part name Q’ty Remarks Power unit Gasket Dowel pin M6 × 16 mm Bolt Apron M8 × 35 mm Bolt M6 ×...

  • Page 99: Checking The Valve Clearance

    Power unit 3. Loosen the tensioner bolt 5, and then Checking the valve clearance remove the timing belt 6, driven sprock- 1. Remove the flywheel magnet cover 1, ets 7, and cylinder head cover 8. cover 2, disconnect the high-tension cords 3 and fuel hoses 4, and then remove the spark plugs.
  • Page 100 POWR Power unit 6. Turn the flywheel magnet 360° clock- Valve clearance: wise. Intake e: 0.20 ± 0.03 mm (0.008 ± 0.001 in) CAUTION: Exhaust f: Do not turn the flywheel magnet counter- 0.34 ± 0.03 mm (0.013 ± 0.001 in) clockwise, otherwise the valve system may be damaged.

  • Page 101: Power Unit

    Power unit 10. Measure the valve pad thickness with a micrometer. Select the necessary valve pad by calcu- lating its thickness with the following for- mula. Necessary valve pad thickness = Removed valve pad thickness + Measured valve clearance – Specified valve clearance Example: If the “Removed valve pad thickness”...

  • Page 102: Checking The Compression Pressure

    POWR Power unit 21. Install the cover and flywheel magnet 5. If the compression pressure is below cover. specification and the compression pres- sure for each cylinder is unbalanced, add Checking the compression pressure a small amount of engine oil to the cylin- 1.

  • Page 103: Removing The Power Unit

    Power unit Removing the power unit NOTE: 1. Remove the flywheel magnet cover and Apply force to the crankshaft end until the fly- flywheel magnet. wheel magnet comes off the tapered portion of the crankshaft. Flywheel holder 1: 90890-06522 Flywheel puller 2: 90890-06521 2.
  • Page 104 POWR Power unit 3. Disconnect the pilot water hose 7 and remove the engine oil dipstick 8 and cover 9. S60C5100 4. Disconnect the battery leads 0, wiring harness A, and PTT motor leads B. S60C5120 S60C5110 5. Remove the apron C and power unit by removing the bolts D.

  • Page 105: Timing Belt And Sprockets

    Power unit / Timing belt and sprockets Timing belt and sprockets · · · m (0.2 kgf m, 1.4 ft · · · m (0.4 kgf m, 2.9 ft S60C5130 Part name Q’ty Remarks M4 × 10 mm Screw M6 × 30 mm Bolt Lighting coil M6 ×...
  • Page 106 POWR Power unit · · · 60 N m (6.0 kgf m, 43 ft · · · 265 N m (26.5 kgf m, 192 ft · · · 39 N m (3.9 kgf m, 28 ft (B/W) · · · ·...
  • Page 107 Timing belt and sprockets Part name Q’ty Remarks Starter motor Ignition coil Starter motor lead Black/white Starter motor lead Black Washer M8 × 45 mm Bolt M6 × 20 mm Bolt Ground lead Ignition coil lead M6 × 30 mm Bolt Spark plug cap Screw...
  • Page 108 POWR Power unit m (0.8 kgf m, 5.8 ft ¥ ¥ ¥ m (0.2 kgf m, 1.4 ft ¥ ¥ ¥ S60C5150 5-15 60C5D11...
  • Page 109 Timing belt and sprockets Part name Q’ty Remarks Cover Starter relay Power trim and tilt relay CDI unit Rectifier Regulator Wiring harness Oil pressure switch M4 × 8 mm Bolt Oil pressure switch lead M6 × 12 mm Bolt Thermo sensor coupler Ground lead Starter relay lead PTT relay lead...

  • Page 110: Removing The Timing Belt And Sprockets

    POWR Power unit Removing the timing belt and NOTE: sprockets • Use a deep socket 2 (M46) for this proce- 1. Set the cylinder #1 piston position to dure. TDC of the compression stroke by align- • Do not turn the camshaft when loosening ing “...

  • Page 111: Checking The Timing Belt And Sprockets

    Timing belt and sprockets 2. Check the drive sprocket 1 and driven NOTE: sprockets 2 for cracks, damage, or Do not turn the camshaft when loosening the wear. Replace if necessary. driven sprocket bolt. Flywheel holder: 90890-06522 6. Remove the nut 1, drive sprocket A, retaining plate B, and Woodruff key C.
  • Page 112 POWR Power unit CAUTION: • Do not twist, turn inside out, or bend the timing belt beyond the maximum limit of 25 mm (1.0 in) e, otherwise it may be damaged. • Do not get oil or grease on the timing belt.
  • Page 113 Timing belt and sprockets 7. Tighten the tensioner bolts to the speci- fied torque. Flywheel holder: 90890-06522 Driven sprocket bolt 2: 60 N·m (6.0 kgf·m, 43 ft·lb) 10. Tighten the drive sprocket nut 6 to the specified torque, and then install the breather hose.

  • Page 114: Cylinder Head

    POWR Power unit Cylinder head 1st 8 N m (0.8 kgf m, 5.8 ft • • • 2nd 17 N m (1.7 kgf m, 12 ft • • • m (0.2 kgf m, 1.4 ft • • • 17 N m (1.7 kgf m, 12 ft •...
  • Page 115 Cylinder head Part name Q’ty Remarks Cylinder head cover Camshaft Camshaft cap Camshaft cap Fuel pump bracket Oil filler cap 3.1 × 30.6 mm O-ring M6 × 30 mm Bolt Gasket Not reusable Breather cover M4 × 8 mm Screw M7 ×...
  • Page 116 POWR Power unit 1st 15 N m (1.5 kgf m, 11 ft • • • 2nd 30 N m (3.0 kgf m, 22 ft • • • 3nd 90° 25 N m (2.5 kgf m, 18 ft • • • 1st 14 N m (1.4 kgf m, 10 ft...
  • Page 117 Cylinder head Part name Q’ty Remarks Cylinder head Exhaust valve Intake valve Cylinder head gasket Not reusable Dowel pin M8 × 55 mm Bolt M6 × 25 mm Bolt Cover Thermostat M10 × 143 mm Bolt Spark plug M8 × 25 mm Bolt M6 ×...

  • Page 118: Removing The Cylinder Head

    POWR Power unit Removing the cylinder head 1. Check that the camshaft dowel pin holes a are in the position shown in the illus- tration. Adjust if necessary. S60C5360 S60C5340 5. Remove the cylinder head bolts in the 2. Remove the cylinder head cover. sequence shown.

  • Page 119: Checking The Valve Springs

    Cylinder head Checking the valve springs 1. Measure the valve spring free length a. Replace if out of specification. S60C5380 NOTE: Do not mix the valve train parts. Keep them organized in their proper groups. Valve spring free length limit a: 52.25 mm (2.057 in) 7.

  • Page 120: Checking The Valve Guides

    POWR Power unit Checking the valve guides Valve margin thickness a: NOTE: Intake: • Use the valve guide clearance calculation 0.8–1.2 mm (0.031–0.047 in) method or the valve runout measurement Exhaust: method to check the valve guides. 1.0–1.4 mm (0.039–0.055 in) •...

  • Page 121: Replacing The Valve Guides

    Cylinder head Replacing the valve guides 1. Remove the valve guide 1 by striking the special service tool from the combus- tion chamber side. NOTE: • Turn the valve guide reamer clockwise to ream the valve guide. • Do not turn the reamer counterclockwise when removing the reamer.

  • Page 122: Refacing The Valve Seat

    POWR Power unit 4. Measure the valve seat contact width a Refacing the valve seat where the blueing dye is adhered to the 1. Reface the valve seat with the valve seat valve face. Reface the valve seat if the cutter.
  • Page 123 Cylinder head 6. If the valve seat contact area is too wide CAUTION: and situated in the center of the valve face, use a 30° cutter to cut the top edge Do not over cut the valve seat. Be sure to turn the cutter evenly downward at a pres- of the valve seat, a 60°...

  • Page 124: Checking The Camshaft

    POWR Power unit 8. If the valve seat contact area is too nar- Checking the camshaft row and situated near the bottom edge of 1. Measure the cam lobe. Replace if out of the valve face, use a 60° cutter to cut the specification.

  • Page 125: Checking The Cylinder Head

    Cylinder head Checking the cylinder head 3. Measure the camshaft journal diameter c and cylinder head journal inside diam- 1. Eliminate carbon deposits from the com- eter d. Replace the camshaft and cylin- bustion chambers and check for deterio- der head if out of specification. ration.

  • Page 126: Installing The Valves

    POWR Power unit Installing the valves 1. Install the new valve stem seal 1 to the valve guide. S60C5660 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 127: Installing The Cylinder Head

    Cylinder head 2. Install the camshaft (intake) 1 and cam- Installing the cylinder head shaft (exhaust) 2 with the new oil seals 1. Tighten the cylinder head bolts to the specified torques, in the specified stages, and in the sequence detailed in the spec- ification box.
  • Page 128 POWR Power unit 4. Install the camshaft caps in the proper position as shown and with the stamped numbers facing upside down. S60C5730 5. Tighten the camshaft cap bolts to the specified torques in two stages and in the sequence shown. NOTE: Apply engine oil to the camshaft cap bolts before installation.

  • Page 129: Cylinder Body

    Cylinder body Cylinder body 1st 19 N m (1.9 kgf m, 14 ft • • • 2nd 60° 1st 14 N m (1.4 kgf m, 10 ft • • • 2nd 28 N m (2.8 kgf m, 20 ft • •...
  • Page 130 POWR Power unit 23 N m (2.3 kgf m, 17 ft • • • 10 11 18 N m (1.8 kgf m, 13 ft • • • 1st 6 N m (0.6 kgf m, 4.3 ft • • • 2nd 12 N m (1.2 kgf m, 8.7 ft •...
  • Page 131 Cylinder body Part name Q’ty Remarks Exhaust cover Oil filter Gasket Not reusable Bolt Gasket Not reusable Gasket Not reusable Thermo sensor Retainer M6 × 16 mm Bolt Clamp M6 × 10 mm Bolt Gasket Not reusable Grommet Pressure control valve Spring Cover Bolt...

  • Page 132: 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 Oil filter: 18 N·m (1.8 kgf·m, 13 ft·lb) remove the filter. Disassembling the cylinder body 1. Remove the exhaust cover bolts in the sequence shown.

  • Page 133: Checking The Piston Diameter

    Cylinder body Checking the cylinder bore NOTE: 1. Measure the cylinder bore (D –D ) at Do not remove the ignition timing pointer measuring points a, b, and c, and in from the crankcase. direction d (D ), which is parallel to the crankshaft, and direction e (D ), which is at a right angle to the 3.

  • Page 134: Checking The Piston Clearance

    POWR Power unit Checking the piston clearance 1. Rebore the cylinder or replace the piston and piston rings as a set, or the cylinder body, or all parts if out of specification. Piston clearance: 0.07–0.08 mm (0.0028–0.0031 in) Checking the piston rings 1.

  • Page 135: 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 (0.0016–0.0031 in) Second ring b: 0.03–0.07 mm (0.0012–0.0027 in) Oil ring c: 0.03–0.15 mm (0.0012–0.0059 in) Checking the crankshaft...

  • Page 136: Checking The Crankshaft Pin Oil Clearance

    POWR Power unit ® 2. Measure the crankshaft runout. Replace 3. Put a piece of Plastigauge (PG-1) onto the crankshaft if out of specification. the crank pin, parallel to the crankshaft. S60C5900 NOTE: Crank stand alignment: Be sure not to put the Plastigauge (PG-1) 90890-03107 over the oil hole in the crank pin of the crank- shaft.

  • Page 137: Selecting The Connecting Rod Big End Bearing

    Cylinder body 5. Tighten the connecting rod bolts to the Crank pin oil clearance: specified torques in two stages. 0.023–0.035 mm (0.0010–0.0013 in) Selecting the connecting rod big end bearing 1. When replacing the connecting rod bear- ing, select the suitable bearing as fol- lows.

  • Page 138: Checking The Crankshaft Main Journal Oil Clearance

    POWR Power unit 3. Check the crank pin mark on the crank- Connecting rod bearing selection table shaft 2. (20 °C [68 °F]) 4. Select the suitable color b for the con- Connecting rod big necting rod bearing from the table. end diameters –...
  • Page 139 Cylinder body 3. Install half of the bearings (grooved bear- 5. Install the remaining half of the bearings ings) 1 and the crankshaft into the cylin- (plain bearings) 3 into the crankcase. der body 2. S60C5925 6. Install the crankcase onto the cylinder body and apply engine oil onto the threads of the crankcase bolts.

  • Page 140: Selecting The Crankshaft Main Journal Bearing

    POWR Power unit 3. Select the suitable color a for the main Crankcase bolt (M10): bearing from the table. 1st: 19 N·m (1.9 kgf·m, 14 ft·lb) 2nd: 60° (#1) (#2) (#3) (#4) (#5) Crankcase bolt (M8): 1st: 14 N·m (1.4 kgf·m, 10 ft·lb) 2nd: 28 N·m (2.8 kgf·m, 20 ft·lb) 8.

  • Page 141: Assembling The Cylinder Body

    Cylinder body Assembling the cylinder body 5. Select the suitable bearing from the table 1. Install the oil ring 1, second ring 2, and below according to the calculated values. top ring 3 to the piston with the “T” mark Crankshaft bearing selection table a on the piston rings facing upward.
  • Page 142 POWR Power unit 6. Set the crankshaft 8, and oil seals 9 CAUTION: and 0 into the cylinder body as shown. Install the bearings in their original posi- tion. 4. Install the piston with the “UP” mark on the piston crown facing towards the fly- wheel magnet.
  • Page 143 Cylinder body 10. Install the crankcase bolts, and then NOTE: tighten them to the specified torques in • Make sure that the large, flat side c of the two stages and in the sequence shown. connecting rod faces towards the flywheel magnet side of the crankshaft.

  • Page 144: Installing The Power Unit

    POWR Power unit 11. Install the new gasket and exhaust cover, and then tighten the bolts to the specified torques in two stages and in the sequence shown. S60C5B50 Exhaust cover bolt: 1st: 6 N·m (0.6 kgf·m, 4.3 ft·lb) 2nd: 12 N·m (1.2 kgf·m, 8.7 ft·lb) Installing the power unit 1.
  • Page 145 Cylinder body 5. Connect the pilot water hose 0 and 9. Install the Woodruff key G. install the engine oil dipstick A. S60C5C10 10. Install the flywheel magnet and flywheel magnet cover. S60C5B80 6. Connect the shift cable B and throttle cable C, and then adjust their lengths.
  • Page 146 Selecting the reverse gear shims ............6-28 Backlash (F100B) ..................6-29 Measuring the forward and reverse gear backlash .........6-29 Lower unit (F100C)..................6-31 Removing the lower unit ................6-35 Removing the water pump and shift rod..........6-36 Checking the water pump and shift rod ...........6-36...
  • Page 147 Checking the propeller shaft housing ............6-40 Checking the propeller shaft..............6-40 Assembling the propeller shaft assembly ..........6-41 Assembling the propeller shaft housing...........6-41 Drive shaft and lower case (F100C)............6-43 Removing the drive shaft.................6-45 Disassembling the drive shaft..............6-45 Disassembling the forward gear ..............6-45 Disassembling the lower case ..............6-46...

  • Page 148: Special Service Tools

    LOWR Lower unit Special service tools Ring nut wrench 3 Bearing separator 90890-06511 90890-06534 Ring nut wrench extension Stopper guide stand 90890-06513 90890-06538 Bearing housing puller claw L Bearing puller 90890-06502 90890-06535 Bearing puller claw 1 90890-06536 Bearing puller claw 2 90890-06537 Stopper guide plate 90890-06501...
  • Page 149 Special service tools Driver rod LL Pinion nut holder 90890-06605 90890-06505 Driver rod L3 90890-06652 Socket adapter 2 90890-06507 Driver rod SS 90890-06604 Bearing outer race puller 90890-06523 Bearing depth plate 90890-06603 Driver rod SL 90890-06602 Bearing inner race attachment 90890-06639, 90890-06641, 90890-06643, 90890-06661, 90890-06662 Bearing outer race attachment...
  • Page 150 LOWR Lower unit Driver rod LS Backlash indicator 90890-06606 90890-06706 Pinion height gauge Magnet base plate 90890-06702 90890-07003 Digital caliper Dial gauge set 90890-06704 90890-01252 Shimming plate Magnet base 90890-06701 90890-06705 Shift rod push arm 90890-06052 60C5D11...

  • Page 151: Lower Unit (F100B)

    Special service tools / Lower unit (F100B) Lower unit (F100B) 42 N m (4.2 kgf m, 30 ft • • • m (0.7 kgf m, 5.1 ft • • • 55 N m (5.5 kgf m, 40 ft • • •...
  • Page 152 LOWR Lower unit S60C6025 60C5D11...
  • Page 153 Lower unit (F100B) Part name Q’ty Remarks Shift rod assembly Oil seal Not reusable Oil seal housing O-ring Not reusable 3.1 × 64.6 mm Spring Circlip Shift rod M6 × 20 mm Bolt Woodruff key M8 × 45 mm Bolt Cover Seal Water pump housing...

  • Page 154: Removing The Lower Unit

    LOWR Lower unit Removing the lower unit 1. Drain the gear oil. For draining proce- dures, see Chapter 3, “Changing 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 155: Removing The Water Pump And Shift Rod

    Lower unit (F100B) 2. Check the impeller 1 and insert car- Removing the water pump and shift tridge 2 for cracks or wear. Replace if necessary. 1. Remove the water pump assembly and shift rod assembly 1. S60C6040 3. Check the Woodruff key 3 and the groove a on the drive shaft for wear.

  • Page 156: Propeller Shaft Housing (F100B)

    LOWR Lower unit Propeller shaft housing (F100B) 13 11 16 11 12 103 N m (10.3 kgf m, 74 ft • • • S60C6085 60C5D11...
  • Page 157 Propeller shaft housing (F100B) Part name Q’ty Remarks Propeller shaft assembly Propeller shaft housing assembly Reverse gear shim — As required Washer Straight key Claw washer Ring nut Shift rod joint Ball Slider Ball Ball Spring Dog clutch Cross pin Spring Propeller shaft Reverse gear...

  • Page 158: Removing The Propeller Shaft Housing Assembly

    LOWR Lower unit Removing the propeller shaft Disassembling the propeller shaft housing assembly housing 1. Straighten the claw washer tabs a, and 1. Remove the reverse gear and thrust then remove the ring nut and claw washer. washer. Ring nut wrench 3 1: 90890-06511 Ring nut wrench extension 2: 90890-06513 Bearing separator 1: 90890-06534...

  • Page 159: Disassembling The Propeller Shaft Assembly

    Propeller shaft housing (F100B) Disassembling the propeller shaft 2. Remove the ball bearing. assembly 1. Remove the spring 1, and then remove the cross pin 2, dog clutch 3, slider, and spring. Stopper guide plate 6: 90890-06501 Stopper guide stand 7: 90890-06538 Bearing puller 8: 90890-06535 Bearing puller claw 1 9:...

  • Page 160: Checking The Propeller Shaft

    LOWR Lower unit 3. Check the bearings for pitting or rum- Assembling the propeller shaft bling. Replace if necessary. assembly 1. Install the dog clutch 1 as shown. S60C6130 Checking the propeller shaft 1. Check the propeller shaft for bends or wear.
  • Page 161 Propeller shaft housing (F100B) NOTE: Depth c: Install the ball bearing with the manufacture 24.75–25.25 mm (0.97–0.99 in) identification mark e facing outward (propel- ler side). 2. Apply grease to the new oil seals, and then install them into the propeller shaft housing to the specified depth.

  • Page 162: Drive Shaft And Lower Case (F100B)

    LOWR Lower unit Drive shaft and lower case (F100B) 6-15 60C5D11...
  • Page 163 Drive shaft and lower case (F100B) Part name Q’ty Remarks Drive shaft Sleeve Cover Oil seal Not reusable M8 × 25 mm Bolt Drive shaft housing Needle bearing O-ring Not reusable 3 × 60.5 mm Pinion shim — As required Thrust bearing Seal Plate...

  • Page 164: Removing The Drive Shaft

    LOWR Lower unit Removing the drive shaft Disassembling the forward gear 1. Remove the drive shaft assembly and 1. Remove the taper roller bearing from the pinion, and then pull out the forward forward gear using a press. gear. S60C6200 S60C6190 CAUTION: Drive shaft holder 5 1: 90890-06519...

  • Page 165: Disassembling The Lower Case

    Drive shaft and lower case (F100B) Disassembling the lower case Checking the pinion and forward 1. Remove the taper roller bearing outer gear race and shim(s). 1. Check the teeth of the pinion, and the teeth and dogs of the forward gear for cracks or wear.

  • Page 166: Checking The Lower Case

    LOWR Lower unit Checking the lower case 2. Install the original shim(s) and taper roller bearing outer race. 1. Check the skeg and torpedo for cracks or damage. Replace if necessary. S60C6235 CAUTION: Assembling the lower case Add or remove shims, if necessary, when replacing the forward gear or lower case.

  • Page 167: Assembling The Drive Shaft Housing

    Drive shaft and lower case (F100B) 2. Install the new taper roller bearing into 2. Apply grease to the new oil seals, and the forward gear using a press. then install them into the drive shaft housing to the specified depth. Bearing inner race attachment 3: NOTE: 90890-06661...

  • Page 168: Installing The Propeller Shaft Housing

    LOWR Lower unit 3. Install the original shim(s) 4 and propel- ler shaft housing assembly 5 into the lower case, and then install the straight key 6, claw washer 7, and ring nut 8. 4. Tighten the nut to the specified torque. S60C6270 NOTE: Install the drive shaft by lifting it up slightly,...

  • Page 169: Installing The Water Pump And Shift Rod

    Drive shaft and lower case (F100B) Installing the water pump and shift 3. Install the Woodruff key into the drive shaft. 1. Install the shift rod assembly 1. 4. Align the groove on the impeller 5 with the Woodruff key 6, and then install it to the drive shaft.

  • Page 170: Installing The Lower Unit

    LOWR Lower unit 6. Install the O-ring A and insert cartridge NOTE: B into the pump housing C. • 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 171 Drive shaft and lower case (F100B) 5. Install the propeller and propeller nut, and then tighten the nut finger tight. Place a block of wood between the anti- cavitation plate and propeller to keep the propeller from turning, and then tighten the nut to the specified torque.

  • Page 172: Shimming (F100B)

    LOWR Lower unit Shimming (F100B) 59.0 34.0 15.8 S60C6305 6-25 60C5D11...

  • Page 173: Shimming

    Shimming (F100B) Shimming Pinion nut: NOTE: 93 N·m (9.3 kgf·m, 67 ft·lb) • Shimming is not required when assembling the original lower case and inner parts. 3. Measure the distance (M4) between the • Shimming is required when assembling the shimming tool and the pinion as shown.

  • Page 174: Selecting The Forward Gear Shims

    LOWR Lower unit NOTE: “P” is the deviation of the lower case dimen- sion from standard. The “P” mark a is stamped on the trim tab mounting surface of the lower case in 0.01 mm units. If the “P” mark is unreadable, assume that “P” is zero and check the backlash when the unit is assembled.

  • Page 175: Selecting The Reverse Gear Shims

    Shimming (F100B) NOTE: Calculation formula: • Select the shim thickness (T2) by using the Forward gear shim thickness (T1) = specified measurement(s) and the calcula- 24.60 + F/100 – M1 tion formula. • Measure the reverse gear at three points to Example: find the height average.

  • Page 176: Backlash (F100B)

    LOWR Lower unit 3. Select the reverse gear shim(s) (T2) as 3. Install the special service tool so that it follows. pushes against the propeller shaft. Calculated numeral Rounded numeral at 1/100 place 1, 2 3, 4, 5 6, 7, 8 9, 10 Available shim thicknesses: 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, and...
  • Page 177 Shimming (F100B) / Backlash (F100B) Backlash indicator 4: 90890-06706 NOTE: Tighten the propeller nut B while turning the Magnet base plate 5: 90890-07003 drive shaft until the drive shaft can no longer Dial gauge set 6: 90890-01252 be turned. Magnet base 7: 90890-06705 6.

  • Page 178: Lower Unit (F100C)

    LOWR Lower unit Lower unit (F100C) m (0.7 kgf m, 5.1 ft • • • 34 N m (3.4 kgf m, 25 ft • • • m (0.7 kgf m, 5.1 ft • • • 39 N m (3.9 kgf m, 28 ft •...
  • Page 179 Lower unit (F100C) Part name Q’ty Remarks Lower unit Plastic tie Not reusable 7 × 200 mm Hose Check screw Gasket Not reusable M10 × 40 mm Bolt Drain screw Dowel pin Grommet M8 × 45 mm Bolt Trim tab M8 ×...
  • Page 180 LOWR Lower unit S60C6400 6-33 60C5D11...
  • Page 181 Lower unit (F100C) Part name Q’ty Remarks Shift rod O-ring Not reusable 1.9 × 10.6 mm Oil seal Not reusable M6 × 16 mm Bolt Oil seal housing O-ring Not reusable 3.1 × 55.6 mm Circlip Screw Cover M8 × 75 mm Bolt M8 ×...

  • Page 182: Removing The Lower Unit

    LOWR Lower unit Removing the lower unit 1. Drain the gear oil. For draining proce- dures, see Chapter 3, “Changing 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 183: Removing The Water Pump And Shift Rod

    Lower unit (F100C) 2. Check the impeller 1, inner plate car- Removing the water pump and shift tridge 2 and insert plate cartridge 3 for cracks or wear. Replace if necessary. 1. Remove the water pump assembly and shift rod assembly 1.

  • Page 184: Propeller Shaft Housing (F100C)

    LOWR Lower unit Propeller shaft housing (F100C) 103 N m (10.3 kgf m, 74 ft • • • S60C6460 6-37 60C5D11...
  • Page 185 Propeller shaft housing (F100C) Part name Q’ty Remarks Propeller shaft assembly Propeller shaft housing assembly Ball Slider Shift plunger Cross pin Dog clutch Spring Propeller shaft Washer Straight key Claw washer Ring nut Reverse gear Thrust washer Ball bearing O-ring Not reusable 5.5 ×...

  • Page 186: Removing The Propeller Shaft Housing Assembly

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

  • Page 187: Disassembling The Propeller Shaft Assembly

    Propeller shaft housing (F100C) 2. Check the teeth and dogs of the reverse gear for cracks or wear. Replace the gear if necessary. S60C6125 3. Check the bearings for pitting or rum- Needle bearing attachment 0: bling. Replace if necessary.

  • Page 188: Assembling The Propeller Shaft Assembly

    LOWR Lower unit 2. Check the dog clutch and shift slider for cracks or wear. Replace if necessary. Assembling the propeller shaft assembly NOTE: 1. Install the dog clutch as shown. • Install the needle bearing with the manufac- ture identification mark a facing toward the oil seal (propeller side).
  • Page 189 Propeller shaft housing (F100C) 4. Install the reverse gear assembly to the NOTE: propeller shaft housing using a press. Install an oil seal halfway into the propeller shaft housing, then the other oil seal. Ball bearing attachment 4: 90890-06633 Driver rod LS 5: 90890-06606 Depth d: 4.5–5.5 mm (0.18–0.22 in)

  • Page 190: Drive Shaft And Lower Case (F100C)

    LOWR Lower unit Drive shaft and lower case (F100C) 6-43 60C5D11...
  • Page 191 Drive shaft and lower case (F100C) Part name Q’ty Remarks Drive shaft Taper roller bearing Not reusable Bearing outer race Not reusable Pinion shim — As required Sleeve 7 × 300 mm Hose Plastic tie Not reusable Joint Water inlet cover...

  • Page 192: Removing The Drive Shaft

    LOWR Lower unit Removing the drive shaft Disassembling the forward gear 1. Remove the drive shaft assembly and 1. Remove the taper roller bearing from the pinion, and then pull out the forward forward gear using a press. gear. S60C6525 S60C6190 CAUTION: Drive shaft holder 5 1: 90890-06519...

  • Page 193: Disassembling The Lower Case

    Drive shaft and lower case (F100C) Disassembling the lower case 3. Remove the needle bearing. 1. Remove the taper roller bearing outer race and shim(s). Needle bearing attachment 7: 90890-06611 Driver rod L3 8: 90890-06652 NOTE: Install the claws as shown.

  • Page 194: Checking The Lower Case

    LOWR Lower unit Depth c: 187.6–188.6 mm (7.39–7.43 in) 2. Install the sleeve, original shim(s), and drive shaft bearing outer race. Checking the lower case 1. Check the skeg and torpedo for cracks or damage. Replace if necessary. CAUTION: Add or remove shims, if necessary, when replacing the pinion or lower case.

  • Page 195: Assembling The Forward Gear

    Drive shaft and lower case (F100C) Assembling the drive shaft CAUTION: 1. Install the new drive shaft bearing into Add or remove shims, if necessary, when the drive shaft using a press. replacing the forward gear or lower case. Bearing outer race attachment 6:...

  • Page 196: Installing The Propeller Shaft Housing

    LOWR Lower unit Installing the propeller shaft housing 1. Install the washer 1, propeller shaft assembly 2, into the propeller shaft housing assembly 3. 2. Apply grease to the new O-rings. NOTE: Secure the ring nut by bending one tab a into the slot in the ring nut and the other tabs toward the propeller shaft housing assembly.
  • Page 197 Drive shaft and lower case (F100C) NOTE: Install the shift rod assembly into the lower case, turn it counterclockwise 90° a, and then push it down b to connect it to the shift slider 2. 2. Install the new oil seals into the oil seal housing as shown.

  • Page 198: Installing The Lower Unit

    LOWR Lower unit 7. Install the insert cartridge B and inner Installing the lower unit plate cartridge C into the pump housing 1. Set the gearshift to the neutral position at the power unit and lower unit. S60C6450 NOTE: Align the insert cartridge projections c with the holes d in the pump housing.
  • Page 199 Drive shaft and lower case (F100C) 5. Install the propeller and propeller nut, and then tighten the nut finger tight. Place a block of wood between the anti- cavitation plate and propeller to keep the propeller from turning, and then tighten the nut to the specified torque.

  • Page 200: Shimming (F100C)

    LOWR Lower unit Shimming (F100C) 6-53 60C5D11...

  • Page 201: Shimming

    Shimming (F100C) Shimming 2. Install the pinion and pinion nut, and then tighten the nut to the specified torque. NOTE: • Shimming is not required when assembling Pinion nut: the original lower case and inner parts. 93 N·m (9.3 kgf·m, 67 ft·lb) •...

  • Page 202: Selecting The Forward Gear Shims

    LOWR Lower unit Calculation formula: Pinion shim thickness (T3) = M – 31.50 mm – P/100 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”...

  • Page 203: Selecting The Reverse Gear Shims

    Selecting the reverse gear shims shaft can no longer be turned. NOTE: The F100C does not contain reverse gear Bearing housing puller claw L 1: shims, therefore shimming is not necessary. 90890-06502...
  • Page 204 LOWR Lower unit 4. Install the backlash indicator onto the 6. Add or remove shims if out of specifica- drive shaft (20 mm [0.79 in] in diameter), tion. then the dial gauge onto the lower unit. Forward gear Shim thickness backlash To be decreased by Less than...
  • Page 205 BRKT Bracket unit Special service tools ..................7-1 Tiller handle ....................7-3 Bottom cowling ....................7-9 Upper case (F100B)..................7-11 Disassembling the oil pump..............7-17 Checking the oil pump ................7-17 Assembling the oil pump .................7-17 Disassembling the oil pan................7-18 Checking the oil strainer ................7-18 Assembling the oil pan ................7-18 Installing the upper case................7-20 Swivel bracket and steering arm (F100B) ..........
  • Page 206 Disassembling the oil pan................7-60 Checking the oil strainer ................7-60 Assembling the oil pan ................7-60 Installing the upper case................7-62 Swivel bracket and clamp brackets (F100C) ..........7-63 Removing the steering arm ..............7-64 Installing the steering arm ............... 7-64 Clamp brackets (F100C) ................7-65 Removing the clamp brackets ..............7-67...
  • Page 207 Power trim and tilt motor (F100C) ..............7-86 Checking the power trim and tilt motor ............7-87 Assembling the power trim and tilt motor ..........7-87 Bleeding the power trim and tilt unit (F100C)..........7-88 Not installed..................... 7-88 Built-in...................... 7-89 Power trim and tilt electrical system............7-90 Checking the fuse..................7-91...

  • Page 208: Bracket Unit

    BRKT Bracket unit Special service tools Bearing inner race attachment Cylinder-end screw wrench 90890-06662 90890-06544 Up relief fitting Digital circuit tester 90890-06773 90890-03174 Down relief fitting 90890-06774 Hydraulic pressure gauge 90890-06776 Trim & tilt wrench 90890-06548 60C5D11...
  • Page 209 Special service tools — MEMO — 60C5D11...

  • Page 210: Tiller Handle

    BRKT Bracket unit Tiller handle 60C5D11...
  • Page 211 Tiller handle Part name Q’ty Remarks Tiller handle assembly Wiring harness extension Engine start switch lead PTT switch coupler Throttle cable M6 × 20 mm Bolt Clamp Shift cable Clip Cover M6 × 25 mm Bolt Plate M6 × 25 mm Bolt Retaining plate M6 ×...
  • Page 212 BRKT Bracket unit 60C5D11...
  • Page 213 Tiller handle Part name Q’ty Remarks 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 Bracket Collar Wave washer Washer M10 × 80 mm Bolt Connector Engine start switch housing...
  • Page 214 BRKT Bracket unit 60C5D11...
  • Page 215 Tiller handle Part name Q’ty Remarks Tiller handle Cotter pin Not reusable Friction adjusting knob Grommet Plastic tie Not reusable Cable clamp Stay M6 × 14 mm Bolt Throttle cable Short Clip Throttle arm Throttle arm shaft Shift cable Long Shift cable bracket M6 ×...

  • Page 216: Bottom Cowling

    BRKT Bracket unit Bottom cowling 25 26 S60C7030 60C5D11...
  • Page 217 Bottom cowling Part name Q’ty Remarks Shift rod Bottom cowling Shift rod bracket Bolt Spring Ball Cotter pin Not reusable Washer Bushing M6 × 25 mm Bolt Grommet Clip Shift rod lever Washer Shift bracket Bushing M6 × 40 mm Bolt M6 ×...

  • Page 218: Upper Case (F100B)

    BRKT Bracket unit Upper case (F100B) m (0.4 kgf m, 2.9 ft • • • 11 N m (1.1 kgf m, 8.0 ft • • • 53 N m (5.3 kgf m, 38 ft • • • 73 N m (7.3 kgf m, 53 ft •...
  • Page 219 Upper case (F100B) Part name Q’ty Remarks Upper case assembly Oil pump body Oil seal Not reusable Oil seal Not reusable M6 × 45 mm Bolt M6 × 10 mm Screw Cover Gasket Not reusable Shaft O-ring Not reusable Oil seal Not reusable Dowel pin O-ring...
  • Page 220 BRKT Bracket unit 26 N m (2.6 kgf m, 19 ft • • • 20 N m (2.0 kgf m, 14 ft • • • m (0.4 kgf m, 2.9 ft • • • S60C7045 7-13 60C5D11...
  • Page 221 Upper case (F100B) Part name Q’ty Remarks Muffler assembly Upper case M12 × 193 mm Bolt Washer Plate Upper mount M8 × 45 mm Bolt Grommet M8 × 40 mm Bolt Muffler seal Rubber seal Gasket Not reusable M6 × 15 mm Screw Baffle plate Damper...
  • Page 222 BRKT Bracket unit 11 N m (1.1 kgf m, 8.0 ft • • • 11 N m (1.1 kgf m, 8.0 ft • • • S60C7050 7-15 60C5D11...
  • Page 223 Upper case (F100B) Part name Q’ty Remarks Exhaust guide Dowel pin Gasket Not reusable Gasket Not reusable Oil strainer Collar M6 × 25 mm Bolt M6 × 25 mm Bolt Oil pan Gasket Not reusable Exhaust manifold M6 × 70 mm Bolt Exhaust seal Gasket...

  • Page 224: Disassembling The Oil Pump

    BRKT Bracket unit Disassembling the oil pump 1. Remove oil seals 1 and 2, the cover 3, gasket 4, shaft 5, and O-rings 6. S60C7060 Bearing inner race attachment: 90890-06662 2. Install the new oil seal 3 into the oil pump body 4.

  • Page 225: Disassembling The Oil Pan

    Upper case (F100B) 3. Install the O-rings 6 into the shaft 7. 4. Install the gasket 8 and the cover 2, and then tighten the screws to the speci- fied torque. S60C7070 Oil pump cover screw: 4 N·m (0.4 kgf·m, 2.9 ft·lb) S60C7075 Disassembling the oil pan Checking the oil strainer...
  • Page 226 BRKT Bracket unit 7. Install the water pipe 9. S60C7080 Oil strainer bolt: 11 N·m (1.1 kgf·m, 8.0 ft·lb) 3. Install the oil pan 3 and then tighten the bolts finger tight. 4. Install the exhaust manifold 4 and bolts, and then tighten the bolts finger tight.

  • Page 227: Installing The Upper Case

    Upper case (F100B) 6. Install the upper mounting nut 7 and Muffler assembly bolt B: lower mounting nut 8, and then tighten 20 N·m (2.0 kgf·m, 14 ft·lb) them to the specified torques. NOTE: Installing the upper case Before tightening the lower mounting nut, be 1.

  • Page 228: Swivel Bracket And Steering Arm (F100B)

    BRKT Bracket unit Swivel bracket and steering arm (F100B) S60C7115 7-21 60C5D11...
  • Page 229 Swivel bracket and steering arm (F100B) Part name Q’ty Remarks Steering arm Washer Bushing Swivel bracket O-ring Not reusable 5.6 × 48.2 mm Bushing Washer Steering yoke Circlip Steering hook Starboard tilt stop lever Bushing Port tilt stop lever M10 × 27 mm Trim stopper Tilt stop lever joint Bushing...

  • Page 230: Removing The Steering Arm

    BRKT Bracket unit 3. Install the bushing 5, O-ring 6, bushing Removing the steering arm 7, and washer 8 onto the swivel 1. Remove the circlip 1. bracket. 2. Remove the steering yoke 2 by striking it with a plastic hammer. S60C7120 3.
  • Page 231 Swivel bracket and steering arm (F100B) 4. Install the steering arm 3 into the steer- ing yoke 9 by aligning the center a of the yoke with the center b of the steer- ing arm. 5. Install the circlip 0. S60C7145 6.

  • Page 232: Clamp Brackets (F100B)

    BRKT Bracket unit Clamp brackets (F100B) 15 N m (1.5 kgf m, 11 ft • • • m (0.2 kgf m, 1.4 ft • • • S60C7150 7-25 60C5D11...
  • Page 233 Clamp brackets (F100B) Part name Q’ty Remarks Swivel bracket assembly Starboard clamp bracket Port clamp bracket Self-locking nut Grease nipple Ground lead Washer M6 × 11 mm Screw Washer Bushing Trim sensor M6 × 15 mm Screw Trim sensor cam M6 ×...

  • Page 234: Removing The Clamp Brackets

    BRKT Bracket unit Removing the clamp brackets 1. Remove the power trim and tilt unit. For removal procedures, see “Removing the power trim and tilt unit” in this chapter. 2. Remove the anode 1. 3. Loosen the self-locking nuts 2, bolt 3, cap 4, and then remove clamp brackets 5 and 6.

  • Page 235: Adjusting The Trim Sensor Cam

    Clamp brackets (F100B) Self-locking nut 4: Trim sensor resistance: 15 N·m (1.5 kgf·m, 11 ft·lb) Pink (P) – Black (B) 9–11 Ω at 20 °C (68 °F) 3. Install the power trim and tilt unit. For 4. Tighten the screw 1. installation procedures, see “Installing the power trim and tilt unit”...

  • Page 236: Power Trim And Tilt Unit (F100B)

    BRKT Bracket unit Power trim and tilt unit (F100B) Part name Q’ty Remarks Power trim and tilt unit PTT motor lead Shaft Plastic tie Not reusable Circlip M8 × 16 mm Bolt Washer Shaft Bushing M6 × 10 mm Bolt Ground lead 7-29 60C5D11...

  • Page 237: Removing The Power Trim And Tilt Unit

    Power trim and tilt unit (F100B) Removing the power trim and tilt unit 1. Fully tilt the outboard motor up, and then support it with the tilt stop lever 1. WARNING After tilting up the outboard motor, be sure to support it with the tilt stop lever. Otherwise, the outboard motor could sud- denly lower if the power trim and tilt unit NOTE:...
  • Page 238 BRKT Bracket unit Tilt cylinder and trim cylinder (F100B) 130 N m (13 kgf m, 94 ft • • • 100 N m (10 kgf m, 72 ft • • • 80 N m (8.0 kgf m, 58 ft • •...

  • Page 239: Tilt Cylinder And Trim Cylinder (F100B)

    Tilt cylinder and trim cylinder (F100B) Disassembling the tilt cylinder and trim cylinders 1. Hold the power trim and tilt unit 1 in a vise using aluminum plates a on both sides. S60C7435 Trim & tilt wrench: 90890-06548 5. Drain the power trim and tilt fluid. S60C7425 6.

  • Page 240: Checking The Reservoir

    BRKT Bracket unit NOTE: To remove the free piston, blow compressed air through the hole a while holding down the cloth. 8. Remove the trim piston assemblies. Checking the reservoir 1. Check the reservoir for cracks. Replace if necessary. 4. Check the trim and tilt rams for bends or excessive corrosion.

  • Page 241: Installing The Trim Rams

    Tilt cylinder and trim cylinder (F100B) 5. Fill the trim cylinders c with the recom- Installing the trim rams 1. Hold the cylinder body 1 in a vise using mended fluid to the correct level as aluminum plates a on both sides. shown.

  • Page 242: Assembling The Tilt Ram

    BRKT Bracket unit 4. Install new O-rings 6 and 7 into the tilt WARNING piston 8. Do not push the trim rams down while 5. Install the balls 9, absorber valve pins installing them into the trim cylinders. 0, and spring A as shown. Otherwise, the power trim and tilt fluid may spurt out from the unit.

  • Page 243: Installing The Tilt Ram

    Tilt cylinder and trim cylinder (F100B) Installing the tilt ram WARNING 1. Fill the tilt cylinder a with the recom- To prevent the power trim and tilt fluid mended fluid to the correct level as from spurting out due to internal pres- shown.

  • Page 244: Gear Pump (F100B)

    BRKT Bracket unit Gear pump (F100B) 7-37 60C5D11...
  • Page 245 Gear pump (F100B) Part name Q’ty Remarks Manual valve M5 × 16 mm Bolt Ball Shuttle piston O-ring Not reusable Main valve Ball M8 × 85 mm Bolt M8 × 24 mm Bolt Circlip O-ring Not reusable O-ring Not reusable Backup ring Spring Absorber valve pin...

  • Page 246: Disassembling The Gear Pump

    BRKT Bracket unit 2. Check the valve seat 1, down-relief Disassembling the gear pump valve 2, and valve pin 3 for dirt or resi- 1. Remove the main valves 1. due. Clean if necessary. S60C7470 3. Check the shuttle pistons 4, main valves 5, and up-relief valve seat 6 for dirt or S60C7420 residue.

  • Page 247: Checking The Gear Pump

    Gear pump (F100B) 4. Install the balls (3.18 mm [0.125 in]) 9, Checking the gear pump shuttle pistons 0, and balls (4.76 mm 1. Check the gear pump assembly for dam- [0.187 in]) A into the gear pump. age or excessive wear. Replace if neces- sary.

  • Page 248: Installing The Pump Housing

    BRKT Bracket unit 6. Install the new O-ring D to the down- 5. Install the manual valve A to the pump relief valve E. housing, tighten it to the specified torque, and then install the circlip B. 7. Install the filters F and down-relief valve E into the pump housing as shown.
  • Page 249 Gear pump (F100B) / Power trim and tilt motor (F100B) Power trim and tilt motor (F100B) Part name Q’ty Remarks Power trim and tilt motor Reservoir Reservoir cap O-ring Not reusable O-ring Not reusable M6 × 13 mm Bolt M6 × 35 mm Bolt O-ring Not reusable...
  • Page 250 BRKT Bracket unit Part name Q’ty Remarks M4 × 15 mm Screw Yoke Armature O-ring Not reusable M4 × 10 mm Screw Brush holder Brush 2 Brush 1 Brush holder Brush spring PTT motor base Oil seal Not reusable 7-43 60C5D11...

  • Page 251: Disassembling The Power Trim And Tilt Motor

    Power trim and tilt motor (F100B) Disassembling the power trim and tilt motor 1. Remove the PTT motor screws. 2. Remove the lead holder 1 and spacer 2 from the yoke 3, and then slide them towards the leads. CAUTION: Do not touch the bimetal a, otherwise the operation of the breaker may be affected.

  • Page 252: Checking The Power Trim And Tilt Motor

    BRKT Bracket unit Checking the power trim and tilt 4. Check the armature coil for continuity. Replace if out of specifications. motor 1. Check the commutator for dirt or foreign substances. Clean with #600 grit sand- paper if necessary. 2. Check the commutator undercut for dirt or foreign substances.

  • Page 253: Assembling The Power Trim And Tilt Motor

    Power trim and tilt motor (F100B) Assembling the power trim and tilt 6. Measure the brush length. Replace if out of specification. motor 1. Install the oil seal 1 into the motor base 2 as shown. Brush length limit f: 4.8 mm (0.19 in) 2.

  • Page 254: Installing The Power Trim And Tilt Motor

    BRKT Bracket unit 3. Remove all of the air bubbles with a syringe or suitable tool. NOTE: Turn the joint with a screwdriver, and then remove any air between the pump gear teeth. 4. Install the new O-ring 3, power trim and tilt motor 4, and then tighten the bolts 5 to the specified torque.

  • Page 255: Bleeding The Power Trim And Tilt Unit (F100B)

    Power trim and tilt motor (F100B) / Bleeding the power trim and tilt unit (F100B) 7. Install the reservoir cap, and then tighten 2. Place the power trim and tilt unit in an it to the specified torque. upright position. Reservoir cap: 3.

  • Page 256: Checking The Hydraulic Pressure

    BRKT Bracket unit 4. Remove the manual valve 2, and install 7. Reverse the PTT motor leads between the up relief fitting 3 and hydraulic pres- the battery terminals to fully extend the sure gauge 4, and then tighten them to tilt ram and trim rams, and then reverse them again to fully retract the rams.
  • Page 257 Bleeding the power trim and tilt unit (F100B) 5. Connect the PTT motor leads to the bat- 7. After measuring the hydraulic pressure, tery terminals to fully retract the trim and remove the special tools and quickly attach the down relief fitting 5. tilt rams.

  • Page 258: Installing The Power Trim And Tilt Unit

    BRKT Bracket unit 10. Remove the special tools. Installing the power trim and tilt unit 1. Fully tilt the outboard motor up, and then 11. Install the manual valve and circlip. support it with the tilt stop lever 1. S60C7705 12.

  • Page 259: Built-In

    Bleeding the power trim and tilt unit (F100B) Built-in 8. If necessary, add sufficient fluid of the recommended type to the correct level. 1. Loosen the manual valve by turning it counterclockwise until it cannot be turned further. S60C7715 NOTE: The fluid level should be at the brim of the filler hole.

  • Page 260: Upper Case (F100C)

    BRKT Bracket unit Upper case (F100C) 11 N m (1.1 kgf m, 8.0 ft • • • m (0.4 kgf m, 2.9 ft • • • 53 N m (5.3 kgf m, 38 ft • • • 16 17 53 N m (5.3 kgf...
  • Page 261 Upper case (F100C) Part name Q’ty Remarks Upper case assembly Oil pump body Oil seal Not reusable Oil seal Not reusable M6 × 45 mm Bolt M6 × 10 mm Screw Cover Gasket Not reusable Shaft O-ring Not reusable Oil seal...
  • Page 262 BRKT Bracket unit 26 N m (2.6 kgf m, 19 ft • • • 20 N m (2.0 kgf m, 14 ft • • • m (0.4 kgf m, 2.9 ft • • • S60C7195 7-55 60C5D11...
  • Page 263 Upper case (F100C) Part name Q’ty Remarks Muffler assembly Upper case M12 × 194 mm Bolt Washer Plate Upper mount M8 × 45 mm Bolt Grommet M8 × 40 mm Bolt Muffler seal Rubber seal Gasket Not reusable M6 × 15 mm...
  • Page 264 BRKT Bracket unit 11 N m (1.1 kgf m, 8.0 ft • • • 11 N m (1.1 kgf m, 8.0 ft • • • 11 N m (1.1 kgf m, 8.0 ft • • • S60C7200 7-57 60C5D11...
  • Page 265 Upper case (F100C) Part name Q’ty Remarks Exhaust guide Dowel pin Gasket Not reusable Gasket Not reusable Oil strainer Collar M6 × 25 mm Bolt M6 × 25 mm Bolt Oil pan Gasket Not reusable Exhaust manifold M6 × 70 mm...

  • Page 266: Disassembling The Oil Pump

    BRKT Bracket unit Disassembling the oil pump 1. Remove oil seals 1 and 2, the cover 3, gasket 4, shaft 5, and O-rings 6. S60C7060 Bearing inner race attachment: 90890-06662 2. Install the new oil seal 3 into the oil pump body 4.

  • Page 267: Disassembling The Oil Pan

    Upper case (F100C) 3. Install the O-rings 6 into the shaft 7. 4. Install the gasket 8 and cover 2, and then tighten the cover screws to the specified torque. S60C7205 Checking the oil strainer 1. Check the oil strainer for dirt and residue.
  • Page 268 BRKT Bracket unit 3. Install the oil pan 3 and then tighten the bolts finger tight. 4. Install the exhaust manifold 4 and bolts, and then tighten the bolts finger tight. 5. Tighten the exhaust manifold bolts 5, then the oil pan bolts 6. 6.

  • Page 269: Installing The Upper Case

    Upper case (F100C) 6. Install the upper mounting nut 7 and Installing the upper case lower mounting nut 8, and then tighten 1. Install the upper mount 1 and bolts 2 them to the specified torques. into the upper case.
  • Page 270 BRKT Bracket unit Swivel bracket and clamp brackets (F100C) 3 mm (0.12 in) S60C7230 Part name Q’ty Remarks Steering arm Washer Bushing O-ring Not reusable 3.8 × 36.5 mm Bushing Swivel bracket Washer Steering yoke Circlip Steering hook Tilt stop lever joint...

  • Page 271: Swivel Bracket And Clamp Brackets (F100C)

    Swivel bracket and clamp brackets (F100C) Removing the steering arm 1. Remove the circlip 1. 2. Remove the steering yoke 2 by striking it with a plastic hammer. S60C7245 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 272: Clamp Brackets (F100C)

    BRKT Bracket unit Clamp brackets (F100C) 15 N m (1.5 kgf m, 11 ft • • • m (0.3 kgf m, 2.2 ft • • • m (0.2 kgf m, 1.4 ft • • • S60C7260 7-65 60C5D11...
  • Page 273 Clamp brackets (F100C) Part name Q’ty Remarks Swivel bracket assembly Starboard clamp bracket Port clamp bracket Self-locking nut Ground lead M6 × 12 mm Screw Washer Bushing M6 × 16 mm Screw Trim sensor Grease nipple Trim sensor cam M6 × 25 mm...

  • Page 274: Removing The Clamp Brackets

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

  • Page 275: Adjusting The Trim Sensor Cam

    Clamp brackets (F100C) 4. Inject grease into both grease nipples 5. Fully tilt the outboard motor up, and then until grease comes out from the bushings support it with the tilt stop lever. WARNING After tilting up the outboard motor, be sure to support it with the tilt stop lever.

  • Page 276: Power Trim And Tilt Unit (F100C)

    BRKT Bracket unit Power trim and tilt unit (F100C) S60C7720 Part name Q’ty Remarks Power trim and tilt unit Plastic tie Not reusable PTT motor lead Circlip Shaft Shaft Bushing Bushing Ground lead M6 × 10 mm Bolt Bushing Bushing...

  • Page 277: Removing The Power Trim And Tilt Unit

    Power trim and tilt unit (F100C) Removing the power trim and tilt unit NOTE: 1. Fully tilt the outboard motor up, and then To remove the power trim and tilt unit, lower support it with the tilt stop lever 1.

  • Page 278: Tilt Cylinder And Trim Cylinder (F100C)

    BRKT Bracket unit Tilt cylinder and trim cylinder (F100C) 90 N m (9.0 kgf m, 65 ft • • • m (0.7 kgf m, 5.1 ft • • • m (0.7 kgf m, 5.1 ft • • • m (0.9 kgf m, 6.5 ft...
  • Page 279 Tilt cylinder and trim cylinder (F100C) Part name Q’ty Remarks Power trim and tilt motor Pump housing assembly Tilt cylinder end screw Trim cylinder assembly Tilt cylinder assembly M6 × 20 mm Bolt O-ring Not reusable Joint M6 × 75 mm...
  • Page 280 BRKT Bracket unit 80 N m (8.0 kgf m, 58 ft • • • 85 N m (8.5 kgf m, 61 ft • • • S60C7730 7-73 60C5D11...
  • Page 281 Tilt cylinder and trim cylinder (F100C) Part name Q’ty Remarks Trim cylinder Tilt ram Dust seal Not reusable Backup ring O-ring Not reusable 2.4 × 22.6 mm Tilt cylinder end screw O-ring Not reusable Backup ring O-ring Not reusable 2.4 × 22.6 mm...

  • Page 282: Disassembling The Tilt Cylinder

    BRKT Bracket unit Disassembling the tilt cylinder 1. Hold the power trim and tilt unit 1 in a vise using aluminum plates a on both sides. NOTE: Place the trim cylinder in the vise horizon- tally. S60C7760 2. Loosen the tilt cylinder end screw 2, and 2.

  • Page 283: Assembling The Trim Cylinder

    Tilt cylinder and trim cylinder (F100C) 4. Install the backup ring 5 and O-rings 6 3. Check the outer surface of the tilt piston and 7 into the trim cylinder end screw and free piston for scratches. Replace if necessary.
  • Page 284 BRKT Bracket unit 8. Install the filter H and plate I to the trim Tilt piston T: cylinder. 85 N·m (8.5 kgf·m, 61 ft·lb) 13. Install the trim cylinder onto the tilt ram. 14. Hold the trim cylinder G in a vise using aluminum plates a on both sides.

  • Page 285: Assembling The Tilt Cylinder

    Tilt cylinder and trim cylinder (F100C) Trim cylinder end screw 8: 80 N·m (8.0 kgf·m, 58 ft·lb) Assembling the tilt cylinder 1. Install the valve seal 1 and the circlip 2 into the free piston 3 as shown. 2. Install the free piston into the trim cylin- der 4 by installing the circlip 5.
  • Page 286 BRKT Bracket unit 10. Install the balls I into the trim cylinder, 7. Fill the reservoir with the recommended fluid to the correct level as shown. and then insert the trim cylinder into the tilt cylinder B. Recommended power trim and tilt NOTE: fluid: Apply grease to the balls to prevent them...

  • Page 287: Gear Pump (F100C)

    Tilt cylinder and trim cylinder (F100C) / Gear pump (F100C) Gear pump (F100C) m (0.8 kgf m, 5.8 ft • • • 2.2 mm (0.087 in) S60C7735 Part name Q’ty Remarks Gear pump M6 × 35 mm Bolt Down-relief spring...
  • Page 288 BRKT Bracket unit 11 N m (1.1 kgf m, 8.0 ft • • • m (0.4 kgf m, 2.9 ft • • • m (0.2 kgf m, 1.4 ft • • • 11 N m (1.1 kgf m, 8.0 ft •...
  • Page 289 Gear pump (F100C) Part name Q’ty Remarks Circlip Manual valve O-ring Not reusable 2.4 × 22.6 mm Manual release spring Manual release pin Circlip Ball Manual valve seat O-ring Not reusable 1.5 × 8.5 mm Pump housing Main valve O-ring...

  • Page 290: Disassembling The Gear Pump

    BRKT Bracket unit Disassembling the gear pump 1. Remove the gear pump 1. 2. Remove the relief valve seat 2 and relief valve seal 3. S60C7790 Checking the valves 1. Check the operation of the check valve a of the trim cylinder end screw and the valve for dirt or residue.

  • Page 291: Checking The Filters

    Gear pump (F100C) Checking the gear pump 1. Check the gear pump for damage. Replace if necessary. 3. Check main valves 3 and 4 for dirt or residue. Clean if necessary. S60C7835 4. Check the manual valve seat 5 and Assembling the gear pump relief valve seat 6 for dirt or residue.
  • Page 292 BRKT Bracket unit 3. Install the manual valve seat 6, and then tighten it to the specified torque. Depth a: 2.2 mm (0.087 in) 4. Install the manual valve 7, and then 7. Install the gear pump B by installing the tightening it to the specified torque.

  • Page 293: Power Trim And Tilt Motor (F100C)

    Gear pump (F100C) / Power trim and tilt motor (F100C) Power trim and tilt motor (F100C) S60C7945 Part name Q’ty Remarks M5 × 12 mm Screw Washer Yoke O-ring Not reusable Armature M4 × 10 mm Screw Washer M4 × 10 mm...

  • Page 294: Power Trim And Tilt Motor (F100C)

    BRKT Bracket unit Checking the power trim and tilt 4. Check the circuit breaker for continuity. Replace if there is no continuity. motor 1. Check the commutator for dirt or foreign substances. Clean with #600 grit sand- paper if necessary. S60C7950 5.

  • Page 295: Bleeding The Power Trim And Tilt Unit (F100C)

    Power trim and tilt motor (F100C) / Bleeding the power trim and tilt unit (F100C) 3. Install the armature 7, O-ring 8, and NOTE: yoke 9. The fluid level should be at the brim of the filler hole. 4. If necessary, add sufficient fluid of the recommended type to the correct level.

  • Page 296: Built-In

    BRKT Bracket unit NOTE: WARNING • Repeat this procedure so that the tilt ram After tilting up the outboard motor, be goes up and down four to five times (be sure to support it with the tilt stop lever. sure to wait a few seconds before switching Otherwise, the outboard motor could sud- the leads).

  • Page 297: Power Trim And Tilt Electrical System

    Bleeding the power trim and tilt unit (F100C) / Power trim and tilt electrical system Power trim and tilt electrical system S60C7990 1 Power trim and tilt motor È Tiller handle model 2 Power trim and tilt relay 3 Trailer switch...

  • Page 298: Checking The Fuse

    BRKT Bracket unit Checking the fuse Checking the power trim and tilt 1. Check the fuse for continuity. Replace if switch/trailer switch there is no continuity. 1. Check power trim tilt switch/trailer switch continuity. Replace if out of specification. Lead color Switch Sky blue Light green...
  • Page 299 – ELEC Electrical systems Special service tools ..................8-1 Checking the electrical components............8-2 Measuring the peak voltage ..............8-2 Measuring the lower resistance..............8-2 Electrical components................... 8-3 Starboard and port views................8-3 Front and rear views.................. 8-4 Tiller handle model ..................8-5 Wiring harness ....................

  • Page 300: Electrical Systems

    – ELEC Electrical systems Special service tools Ignition tester Test harness (3 pins) 90890-06754 90890-06757 Digital circuit tester Vacuum/pressure pump gauge set 90890-03174 90890-06756 Peak voltage adaptor 90890-03172 Test harness (6 pins) 90890-06772 Test harness (3 pins) 90890-06770 60C5D11...

  • Page 301: 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 internal resistance of the tester.

  • Page 302: Electrical Components

    – ELEC Electrical systems Electrical components Starboard and port views S60C8020 1 Ignition coils 9 Throttle position sensor 2 Thermo sensor 3 Starter motor 4 Fuse 5 Starter relay 6 Power trim and tilt relays 7 Oil pressure switch 8 Prime Start 60C5D11...

  • Page 303: Front And Rear Views

    Electrical components Front and rear views S60C8030 1 CDI unit È Tiller handle model 2 Starter relay 3 Power trim and tilt relays 4 Rectifier Regulator 5 Neutral switch (tiller handle model) 6 Spark plug 7 High-tension cords 8 Ignition coils 60C5D11...

  • Page 304: Tiller Handle Model

    – ELEC Electrical systems Tiller handle model S60C8040 1 Engine start switch 2 Engine start switch harness 3 Engine shut-off switch 4 Engine shut-off switch connector 5 Power trim and tilt switch 6 PTT switch lead 7 Neutral switch 8 Wiring harness extension 9 Connector assembly 60C5D11...

  • Page 305: Wiring Harness

    Electrical components / Wiring harness Wiring harness B B B S60C8050 A Trailer switch or power trim Connect to: : Black 1 Oil pressure switch and tilt switch : Brown B Starter relay 2 Throttle position sensor : Green C Power trim and tilt relays 3 Ground : Blue D Thermo sensor...

  • Page 306: Ignition System And Ignition Control System

    – ELEC Electrical systems Ignition system and ignition control system S60C8060 1 Spark plugs 0 Fuse (30 A) : Black : Black/yellow 2 Ignition coils A Oil pressure switch : Brown G/W : Green/white 3 Throttle position B Thermo sensor : Green P/W : Pink/white C Engine start switch...

  • Page 307: Checking The Ignition Spark Gap

    Ignition system and ignition control system Checking the ignition spark gap WARNING 1. Remove the cover and disconnect the • Do not touch any of the connections of spark plug caps from the spark plugs. the spark gap tester leads. 2.

  • Page 308: Checking The Ignition Coil

    – ELEC Electrical systems Checking the ignition coil Checking the CDI unit 1. Remove the high-tension cords from the 1. Measure the CDI unit output peak volt- ignition coil. age. If below specification, measure the Rectifier Regulator output peak voltage 2.

  • Page 309: Checking The Pulser Coil

    Ignition system and ignition control system Checking the pulser coil Pulser coil output peak voltage: 1. Measure the pulser coil output peak volt- White/red (W/R) – Black (B) age. Replace the pulser coil if below White/black (W/B) – Black (B) specification.

  • Page 310: Checking The Thermo Sensor

    – ELEC Electrical systems Checking the oil pressure switch Throttle position sensor input 1. Connect the special service tool to the oil voltage: pressure switch. Red (R) – Orange (O) 2. Slowly operate the special service tool. Throttle position sensor output voltage: Pink (P) –...

  • Page 311: Checking The Engine Start Switch

    Ignition system and ignition control system Checking the engine start switch Lead color 1. Check the engine start switch for continu- White (W) Black (B) ity. Replace if there is no continuity. Remove the lock plate a Install the lock plate b Push the button c Lead color...

  • Page 312: Electrical Systems

    – ELEC Electrical systems Starting system 1 Fuse (30 A) : Black 2 Fuse (20 A) : Brown 3 Starter motor : Red 4 Starter relay : White 5 Battery : Yellow 6 10-pin coupler B/W : Black/white 7 Neutral switch 8 Engine start switch È...

  • Page 313: Checking The Fuse

    Starting system Checking the fuse Checking the neutral switch 1. Check the fuse for continuity. Replace if 1. Check the neutral switch for continuity. there is no continuity. Replace if there is no continuity. S60C8220 Lead color Checking the wiring harness (10 pins) Brown (Br) Brown (Br)

  • Page 314: Starter Motor

    – ELEC Electrical systems Starter motor S60C8250 8-15 60C5D11...
  • Page 315 Starter motor Part name Q’ty Remarks Clip Pinion stopper Starter motor pinion Spring M6 × 52 mm Bolt Housing Rubber seal Bearing Clutch assembly E-clip Not reusable Thrust washer Center bracket Pinion shaft Planetary gear Outer gear Plate Armature Stator Brush assembly Brush holder assembly Plate...

  • Page 316: Removing The Starter Motor Pinion

    – ELEC Electrical systems Removing the starter motor pinion Checking the armature 1. Slide the pinion stopper 1 down as 1. Check the commutator for dirt. Clean shown, and then remove the clip 2. with #600 grid sandpaper and com- pressed air if necessary.

  • Page 317: Checking The Brushes

    Starter motor 3. Measure the commutator undercut a. Checking the brushes Replace the armature if out of specifica- 1. Measure the brush length. Replace the tion. brush assembly if out of specification. Commutator undercut limit a: Brush length limit a: 0.2 mm (0.01 in) 9.5 mm (0.37 in) 4.

  • Page 318: Checking The Relay Assembly

    – ELEC Electrical systems Checking the relay assembly 1. Connect the tester leads between the relay terminals as shown. 2. Connect the positive battery terminal to the black and white (B/W) lead. 3. Connect the negative battery terminal to the starter motor body. S60C8350 CAUTION: •...

  • Page 319: Charging System

    Starter motor / Charging system Charging system G G G/W G/W G G G/W G/W S60C8360 1 Lighting coil : Black 2 Rectifier Regulator : Green 3 Fuse (30 A) : Red 4 Battery : White 5 Starter motor G/W : Green/white 6 Starter relay 8-20 60C5D11...

  • Page 320: Checking The Lighting Coil

    – ELEC Electrical systems Checking the lighting coil Checking the Rectifier Regulator 1. Measure the lighting coil output peak 1. Measure the Rectifier Regulator output voltage. Replace the lighting coil if below peak voltage. If below specification, mea- specification. sure the lighting coil output peak voltage. Replace the Rectifier Regulator if the out- put peak voltage of the lighting coil is above specification.
  • Page 321 TRBL SHTG Troubleshooting Power unit....................... 9-1 Bracket unit ....................9-11 Electrical systems..................9-15 62Y5A11...
  • Page 322 TRBL SHTG Troubleshooting NOTE: • To diagnose a mechanical malfunction, use the troubleshooting charts pertaining to the trouble located in this chapter. Also, when checking and maintaining the outboard motor, see Chapters 4– 8, to check the part necessary to carry out safety maintenance. •...
  • Page 323 Power unit Is there conti- Replace the engine shut-off nuity? switch. Check the fuse for continuity. Is there conti- Replace the fuse. nuity? Check the wiring harnesses for continuity. Is there conti- Replace the wiring harnesses. nuity? Listen for the operation sound of the starter relay.
  • Page 324 TRBL SHTG Troubleshooting Symptom: Engine cranks, but will not start. • Check the ignition system. • Check the fuel system. • Check the compression pressure of the power unit. WARNING Check that the spark plugs pro- • Do not touch any of the connections of duce sparks.
  • Page 325 Power unit Does the Check the compression pres- engine start? sure of the combustion chamber. Out of specifi- cation? Check the condition of the spark Failure in starting operation plugs again. Check the valve Wet spark plugs? Failure in starting operation clearance.
  • Page 326 TRBL SHTG Troubleshooting Symptom: Engine can be started, but does not remain on. • Check the fuel system. • Check the ignition system. • Check the compression pressure of the power unit. (Fuel system) Check that the fuel vent screw of the fuel tank is open. Is the vent Open the fuel vent screw.
  • Page 327 Power unit (Ignition system) Check the ignition spark gap using the spark gap tester. Out of specifi- Check the ignition system out- cation? put peak voltage. Replace the spark plug. (Compression pressure) Check that there is no secondary air intake on the contact surfaces of the intake manifold and crankcase.
  • Page 328 TRBL SHTG 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 throttle cable and link rods. Good operat- Adjust the throttle cable and link ing condition?
  • Page 329 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 330 TRBL SHTG 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. (Cooling system) Check the water inlet for clogs or debris.
  • Page 331 Power unit (Lubricating system) Check the engine oil level. At specified Add engine oil to the correct level? level. Check the oil pressure. Out of specifi- Check the oil pump for debris or cation? oil leaks. Check the oil pas- Debris or leaks? sage.
  • Page 332 TRBL SHTG Troubleshooting Bracket unit Symptom: Power trim and tilt unit does not operate. Listen for the operation sound of the power trim and tilt relay. Can the oper- Check the voltage between each terminal. ation sound • Between the sky blue (Sb) lead and black (B) lead. be heard? •...
  • Page 333 Bracket unit At specified Add fluid to the correct level. level? Measure the hydraulic pressure. (for F100B) Out of specifi- Check the power trim and tilt cation? unit for leaks. Disassemble the power trim and tilt unit, and then check the filter for debris or dirt.
  • Page 334 TRBL SHTG Troubleshooting Symptom: Power trim and tilt unit does not hold the outboard motor up. Check that the manual valve is closed. Is it closed? Close the valve. Check the power trim and tilt fluid level. At specified Add fluid to the correct level. level? Disassemble the power trim and tilt unit, and then check the fil-...
  • Page 335 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 336 TRBL SHTG Troubleshooting Electrical systems Symptom: Battery becomes weaker quickly. • Check the charging system. Measure the output peak voltage of the lighting coil. Out of specifi- Replace the lighting coil. cation? Measure the Rectifier Regulator output peak voltage. Out of specifi- Replace the Rectifier Regulator.
  • Page 337 Checking the fuel system ......1-25 Checking the fuse......7-91 8-14 Backlash (F100B) ........6-29 Checking the gear oil........ 1-26 Backlash (F100C) ........6-56 Checking the gear oil level ....... 3-13 Bleeding the power trim and tilt unit Checking the gear pump ....7-40 7-84 (F100B) ...........7-48...
  • Page 338 Checking the spark plugs......3-7 Drive shaft and lower case (F100B) ..6-15 Checking the starter motor operation..8-19 Drive shaft and lower case (F100C) ..6-43 Checking the starter motor pinion .....8-17 Checking the starter relay ......8-14 Checking the steering system....1-27 Electrical .............
  • Page 339 PTT (power trim and tilt) unit (F100B) ..1-22 Installing the drive shaft ....6-20 6-48 PTT (power trim and tilt) unit (F100C) ..1-24 Installing the lower unit ....6-23 6-51 Installing the power trim and tilt motor ..7-47 Installing the power trim and tilt unit ..........
  • Page 340 Throttle control ..........4-9 Tightening torques ........2-14 Tiller handle ..........7-3 Tiller handle model........8-5 Tilt cylinder and trim cylinder (F100B) ..7-31 Tilt cylinder and trim cylinder (F100C) ..7-71 Timing belt and sprockets ......5-12 Top cowling..........3-4 Upper case (F100B)........7-11 Upper case (F100C) .........7-53 Ventilation ...........1-3...
  • Page 342 Wiring diagram F100BET, F100CET 1 Battery Color code 2 Power trim and tilt motor : Black 3 Starter motor : Brown 4 Starter relay : Green 5 Power trim and tilt relay : Gray 6 Rectifier Regulator : Blue 7 Lighting coil : Light green 8 Pulser coil : Orange...
  • Page 344 YAMAHA MOTOR CO., LTD. Printed in the Netherlands Jun. 2001 – 0.5 × 1 CR (F100BET, F100CET)
  • Page 345 F100BET, F100CET W/R B O P R START FREE DOWN FREE DOWN S60CWD01...

This manual is also suitable for:

F100b

Table of Contents