Yamaha e60hwd Manuals

Manuals and User Guides for Yamaha e60hwd. We have 3 Yamaha e60hwd manuals available for free PDF download: Service Manual, Rigging Manual

Yamaha e60hwd Service Manual (489 pages)

Brand: Yamaha | Category: Outboard Motor | Size: 9.16 MB

How to Use this Manual
4
Symbols
16
Contents
18
Table of Contents
20
General Information
20
Identification Serial Number
22
Starting Serial Numbers
22
Safety While Working

24
- Fire Prevention
  24
- Ventilation
  24
- Self-Protection
  24
- Oils, Greases and Sealing Fluids
  24
- Good Working Practices
  26
- Safe Disassembly and Assembly
  28
Special Tools

30
- Measuring
  30
- Removing and Installing
  34
Features and Benefits

40
Technical Tips

60
- Shifting System
  60
  - Reverse
    64
  - Specifications
    68
  - General Specifications
    70
Identification

73
- Chapter 1 Chapter 2
  
  74
  - Power Unit
    74
    
    Lower Unit Specifications
    78
    
    Electrical Specifications
    80
    
    Outboard Dimensions
    84
    
    Bracket Dimensions
    92
    
    Tightening Torques
    100
    
    Specified Torques
    100
    
    Periodic Checks and Adjustments
    104
Maintenance Specifications

74
- Chapter 3
  
  106
Maintenance Interval Chart

106
- Checking the Top Cowling Fit
  108
Fuel System

110
- Checking the Fuel Line
  110
- Checking the Fuel Filter
  112
Control System

114
Lower Unit

146
- Checking the Lower Unit (for Air Leaks)
  148
- Checking the Anode
  150
- Checking the Battery
  150
General

150
Travail

151
- Checking the Spark Plugs
  152
- Lubrication Points
  156
- Chapter 4
  
  162
Fuel Line

162
- Fuel Joint, Fuel Filter and Fuel Pump Removing/Installing
  164
Fuel Joint, Fuel Filter and Fuel Pump

166
- Fuel Pump
  166
- Checking the Fuel Joint
  168
  - Disassembling/Assembling the Fuel Filter
    170
  - Fuel Filter Disassembly/Assembly
    170
  - Checking the Fuel Filter
    172
  - Disassembling/Assembling the Fuel Pump
    174
  - Fuel Pump Disassembly/Assembly
    174
  - Checking the Fuel Pump
    176
  - Carburetor Removal/Installation
    178
  - Removing/Installing the Carburetor
    178
  - Carburetor Disassembly/Assembly
    182
  - Disassembling/Assembling the Carburetor
    182
  - Checking the Carburetor
    188
  - Disassembling the Carburetor
    188
  - Assembling the Carburetor
    190
- Power Unit
  192
- D'etancheite
  195
- Recoil Starter Assembly Removing/Installing
  196
Recoil Starter Assembly

198
- Recoil Starter Assembly Disassembly/Assembly
  200
- Chapter 5
  
  200
  - Disassembling/Assembling the Recoil Starter Assembly
    200
    
    Disassembling the Recoil Starter Assembly
    206
    
    Recoil Starter Assembly Disassembly
    206
    
    Checking the Recoil Starter Assembly
    208
    
    Assembling the Recoil Starter Assembly
    210
    
    Checking the Recoil Starter
    212
    
    Removing/Installing the Starter Pulley and Flywheel Magnet Assembly
    214
    
    Starter Pulley and Flywheel Magnet Assembly Removal/Installation
    214
    
    Removing the Flywheel Magnet Assembly
    216
    
    Installing the Flywheel Magnet Assembly
    218
  - Removing/Installing the Electrical Units and Related Parts
    220
Power Unit

226
- Removing/Installing the Power Unit
  232
- Mesures
  245
- Crankshaft Assembly and Cylinder Body Removal and Installation
  268
- Ausbau und Einbau
  269
  - Checking the Cylinder Body
    270
  - Calculating the Piston-To-Cylinder Clearance
    272
  - Checking the Piston Pins and Small-End Bearings
    272
  - Checking the Piston Rings
    274
  - Installing the Crankshaft and Piston
    276
  - Installing the Piston and Piston Ring
    276
  - Checking the Crankshaft
    278
  - Lower Unit
    280
  - Removing/Installing the Lower Unit
    284
  - Checking the Propeller
    288
  - Checking the Trim Tab
    288
  - Installing the Propeller
    288
  - Removing the Propeller
    288
  - Water Pump Removal/Installation
    290
  - Checking the Impeller and Insert Cartridge
    294
  - Checking the Water Pump Housing
    294
  - Installing the Insert Cartridge and Water Pump Housing
    294
  - Installing the Water Pump Lower Housing
    294
  - Shift Rod Assembly Removal/Installation
    296
  - Installing the Shift Cam
    300
  - Installing the Shift Cam and Shifter
    300
  - Shift Rod Assembly Removal
    300
  - Installing the Shift Rod
    302
  - Propeller Shaft Housing Assembly Removal/Installation
    304
  - Propeller Shaft Housing Assembly Removal
    308
  - Propeller Shaft Housing Removal
    308
  - Installing the Propeller Shaft Housing Assembly
    310
  - Propeller Shaft Housing Assembly Disassembly/Assembly
    312
  - Disassembling the Propeller Shaft Housing Assembly
    314
  - Assembling the Propeller Shaft Housing Assembly
    316
  - Checking the Propeller Shaft Housing
    316
  - Propeller Shaft Assembly Disassembly/Assembly
    320
  - Assembling the Propeller Shaft Assembly
    326
  - Drive Shaft Removal/Installation
    328
  - Disassembling the Forward Gear Assembly
    330
  - Removing the Drive Shaft
    330
  - Removing the Drive Shaft Bearing
    330
  - Assembling the Forward Gear Assembly
    332
  - Installing the Drive Shaft Bearing
    332
  - Installing the Pinion Nut
    332
  - Lower Case Assembly Disassembly/Assembly
    334
  - Assembling the Lower Case Assembly
    338
  - Checking the Lower Case
    338
  - Shimming
    342
  - Selecting the Pinion Gear Shims
    344
  - Selecting the Forward Gear Shims
    348
  - Selecting the Reverse Gear Shims
    352
  - Backlash
    366
  - Measuring the Forward Gear Backlash
    366
  - Measuring the Reverse Gear Backlash
    370
  - Bracket Unit
    374
  - Steering Handle Assembly and Friction Bracket Removal/Installation
    376
  - Steering Handle Assembly Disassembly/Assembly
    384
  - Shift Handle Installation
    396
  - Throttle Cable Installation
    396
  - Bottom Cowling Removal/Installation
    398
  - Shift Actuator Assembly Disassembly/Assembly
    402
  - Upper Case Assembly Removal/Installation
    404
  - Steering Arm Removal/Installation
    414
  - Clamp Brackets Removal/Installation
    416
  - Checking the Shock Absorber
    422
  - Removing the Shock Absorber
    422
  - Electrical System
    424
  - Electrical Components View
    426
  - Digital Circuit Tester
    432
  - Electrical Components Analysis
    432
  - Measuring the Peak Voltage
    432
  - Peak Voltage Adaptor
    432
  - Measuring a Low Resistance
    434
- Correctos
  435
  - Ignition System Diagram
    436
  - Checking the Ignition Spark Gap
    438
  - Checking the Spark Plug Caps
    440
  - Checking the Charge Coil Peak Voltage
    442
  - Checking the Ignition Coil
    442
  - Checking the CDI Unit Peak Voltage
    444
  - Checking the Pulser Coil Peak Voltage
    444
  - Ignition Control System Wiring Diagram
    446
  - Checking the Engine Stop Switch
    448
  - Checking the Main Switch
    448
  - Checking over Heat Warning Lamp
    450
  - Checking the Thermo Switch
    450
  - Starting System Wiring Diagram
    452
  - Checking the Fuse
    454
  - Checking the Neutral Switch
    454
  - Starting System Checks
    454
  - Checking the Fuel Enrichment Valve
    456
  - Checking the Starter Relay
    456
  - Starter Motor Disassembly/Assembly
    458
- Desarmado y Armado
  459
  - Checking the Armature
    462
  - Checking the Pinion
    462
  - Removing the Pinion
    462
  - Checking the Brush Holder
    464
  - Checking the Cover
    464
  - Charging System Wiring Diagram
    466
  - Charging System Checks
    468
  - Checking the Lighting Coil
    468
  - Checking the Rectifier/Regulator
    468
  - Trouble Analysis Chart
    472
  - Troubleshooting for Peak Voltage
    480
  - Wiring Diagram
    484

Yamaha e60hwd Rigging Manual (329 pages)

Brand: Yamaha | Category: Outboard Motor | Size: 11.2 MB

Table of Contents

5
Propellers

65
Tiller Handles

139
- 6X4 Multi-Function Tiller Handle
  
  140
- Steering Friction Contents
  
  162
Conventional Gauge (6Y5 & 6Y7)

165
- Mounting the Meters
  
  168
  - Meter Mounting Procedure
    168
  - Analog Gauge Illumination (6Y7 Type)
    168
- Analog Tachometer
  
  169
  - Analog Tachometer Applications
    169
  - Analog Tachometer Dimensions
    170
  - Pole Number Set up
    170
- Digital Tachometer
  
  171
  - Digital Tachometer Applications
    171
  - Digital Tachometer Dimensions
    171
  - Pole Number Set up
    172
- Speedometer
  
  173
  - Speedometer Types and Applications
    173
  - Speedometer Dimensions
    174
  - Water Pressure Damper (Op)
    174
  - Speedometer Tube Routing
    175
  - Digital Speedometer Set up
    175
- Fuel Management Gauge
  
  176
  - Fuel Management Gauge Types and Applications
    176
  - Fuel Management Gauge Dimensions
    177
  - Fuel Sensor Installation
    178
  - Wiring Description
    179
  - Fuel Management Gauge Set up
    181
  - Fuel Mgt Gauge with Speedometer Set up
    181
- Analog Trim Meter
  
  182
  - Analog Trim Meter Applications
    182
  - Analog Trim Meter Dimensions
    182
  - Trim Sensor Adjustment
    182
- Coolant Pressure Meter
  
  183
- Coolant Temp. Meter
  
  184
- Hour Meter
  
  191
  - Hour Meter Applications
    191
  - Hour Meter Dimensions
    191
  - Wiring the Mechanical Hour Meter
    192
  - Wiring the Digital Hour Meter
    192
- Voltage Meter
  
  193
  - Voltage Meter Types and Applications
    193
  - Voltage Meter Dimensions
    193
  - Wiring the Voltage Meter
    193
- Fuel Meter
  
  194
  - Fuel Meter Types and Applications
    194
  - Fuel Meter Dimensions
    194
  - Wiring the Fuel Meter
    194
- Charge Warning Unit
  
  195
  - Charge Warning Unit Types and Applications
    195
  - Wiring the Charge Warning Unit
    195
- Wire Harnesses
  
  196
  - Remote-Oil Tank Harness
    196
  - Additional Accessory Lead
    196
  - Meter Harness
    197
  - Trim Meter Lead
    198
  - Trim and Oil Lead
    198
  - Combination Trim and Oil Lead
    198
  - Conversion Harness 1
    199
  - Fuel Management Gauge Harness
    199
  - Lighting Coil Extension Harness
    199
  - Rectifier Kit
    199
- Wiring Diagrams
  
  200
- Rigging Grommet Description
  
  211
Digital Network Gauge (6Y8)

215
- Digital Network Gauge Compatible Models
  
  216
- Digital Network Gauge Application
  
  216
  - Square Style Gauge Application
    216
- Digital Network Gauge Dimensions
  
  217
  - Round Style Gauge Application
    217
  - Square Style Gauge Dimensions
    217
  - Round Style Gauge Dimensions
    218
- Optional Equipment
  
  219
  - Multi-Sensor Application
    219
  - Fitting Plate
    219
  - Speed Sensor Kit
    220
  - Coolant Pressure Sensor Kit
    220
  - Speed/Coolant Pressure Sensors Kit
    221
- Wire Harness
  
  222
  - Main Bus Wire
    222
  - Pigtail Bus Wire
    222
  - System Power Supply Wire
    222
  - Immobilizer Power Distribution Wire 1
    222
- Network Hub
  
  223
  - Fuel Tank / Gps Wire
    223
- Optional Equipment
  
  224
  - Nmea2000 Gateway
    224
  - Analog Gauge Interface (If)
    224
- Immobilizer Unit
  
  225
- Network Wiring Diagrams
  
  226
  - FUEL INJECTED F30-F250 [Mechanical RC] & HPDI ENGINES
    226
- Initial Gauge Setup
  
  230
  - Setting for Gauge When 6Y9 Multi-Sensor Is Connected
    230
- Troubleshooting
  
  231
- Nmea0183 Compatible Equipment Connection
  
  232
- Basic Requirements
  
  232
- Digital Network Gauge (6Y8) Function Table
  
  233
Digital Network Premium Gauge (6Y9)

234
Battery

281
- Battery
  
  282
- Recommended Battery
  
  282
- Battery Cable Length
  
  284
- Battery Wiring
  
  286
Appendix

294

Yamaha e60hwd Service Manual (199 pages)

Brand: Yamaha | Category: Outboard Motor | Size: 20.95 MB

Table of Contents

3
- Important Information
  2
- General Information
  
  5
  - How to Use this Manual
    6
    
    Manual Format
    6
    
    Symbols
    7
- Contents
  
  7
  - Safety While Working
    8
    
    Fire Prevention
    8
    
    Parts, Lubricants, and Sealants
    8
    
    Self-Protection
    8
    
    Ventilation
    8
    
    Disassembly and Assembly
    9
    
    Good Working Practices
    9
  - Identification
    10
    
    Applicable Model
    10
    
    Serial Number
    10
  - Propeller Selection
    10
    
    Propeller Size
    10
    
    Selection
    11
  - Predelivery Checks
    11
    
    Checking the Battery (WHD, WD)
    11
    
    Checking the Fuel System
    11
    
    Checking the Gear Oil Level
    11
    
    Checking the Outboard Motor Mounting Height
    12
    
    Checking the Remote Control Cables (Remote Control Model)
    12
    
    Checking the Gear Shift and Throttle Operation
    13
    
    Checking the Steering System
    13
    
    Checking the Cooling Water Pilot Hole
    14
    
    Checking the Engine Start Switch, Engine Stop Lanyard Switch and Engine Stop Button
    14
    
    Test Run
    14
    
    After Test Run
    15
    
    Break-In
    15
Spec Specifications

17
- Specifications
  
  17
- General Specification
  
  18
- Maintenance Specification
  
  20
  - Power Unit
    20
  - Lower Unit
    22
  - Electrical
    22
  - Dimensions
    24
- Tightening Torques
  
  27
  - Specified Torques
    27
  - General Torques
    28
Chk Adj/Chk Adj

29
- Chk Adj
  
  30
- Special Service Tools
  
  30
- Periodic Checks and Adjustments
  
  30
- Maintenance Interval Chart
  
  31
- Periodic Checks and Adjustments
  
  32
- Top Cowling
  
  32
  - Checking the Top Cowling
    32
- Fuel System
  
  32
  - Checking the Fuel Joint and Fuel Hoses (Fuel Joint-To-Carburetors)
    32
  - Checking the Fuel Filter
    32
- Power Unit
  
  32
- Control System
  
  34
- Bracket
  
  40
  - Checking the Tilt Operation
    40
- Lower Unit
  
  41
  - Checking the Gear Oil Level
    41
  - Changing the Gear Oil
    41
  - Checking the Lower Unit for Air Leakage
    41
  - Chk Adj
    42
    
    Checking the Propeller
    42
- General
  
  42
  - Checking the Anode
    42
  - Checking the Battery
    42
  - Lubricating the Outboard Motor
    43
Fuel Fuel System

45
- Fuel
  45
- Fuel System
  
  46
- Special Service Tools
  
  46
- Hose Routing
  
  47
- Fuel Line
  
  48
- Carburetor
  
  51
- Fuel Pump
  
  55
  - Checking the Fuel Pump
    56
  - Disassembling the Fuel Pump
    56
  - Assembling the Fuel Pump
    57
  - Checking the Fuel Joint
    57
Powr Power Unit

59
- Powr
  59
- Special Service Tools
  
  60
- Power Unit
  
  60
- Power Unit
  
  64
- Reed Valves
  
  81
  - Removing the Reed Valve Assembly
    82
  - Checking the Reed Valves
    82
  - Cylinder Head
    85
    
    Checking the Cylinder Head
    85
    
    Checking the Exhaust Cover
    85
    
    Installing the Stud Bolt
    85
    
    Removing the Cylinder Head
    85
    
    Removing the Exhaust Cover
    85
    
    Installing the Thermoswitch
    86
- Crankcase
  
  87
  - Removing the Oil Seal Housing
    91
  - Removing the Crankcase
    91
  - Removing the Crankshaft Assembly
    91
  - Checking the Cylinder Bore
    91
  - Disassembling the Oil Seal Housing
    92
  - Checking the Oil Seal Housing
    92
  - Assembling the Oil Seal Housing
    92
  - Disassembling the Upper Bearing
    92
  - Assembling the Upper Bearing
    92
  - Checking the Piston Diameter
    93
  - Checking the Piston Clearance
    93
  - Checking the Piston Rings
    93
  - Checking the Piston Ring Side Clearance
    94
  - Checking the Piston Pin Boss Bore
    94
  - Checking the Piston Pin
    94
  - Checking the Internal Anodes
    94
  - Disassembling the Crankshaft
    95
  - Assembling the Crankshaft
    96
  - Checking the Crankshaft
    98
  - Assembling the Piston
    99
  - Assembling the Power Unit
    99
  - Installing the Power Unit
    102
Lowr Lower Unit

105
- Lowr
  105
- Special Service Tools
  
  106
- Lower Unit
  
  106
- Lower Unit
  
  110
  - Removing the Lower Unit
    114
  - Removing the Water Pump
    114
  - Removing the Oil Seal Housing and Shift Rod
    114
  - Checking the Water Pump and Shift Rod
    115
  - Disassembling the Oil Seal Housing
    115
  - Assembling the Oil Seal Housing
    115
- Propeller Shaft Housing
  
  116
- Drive Shaft and Lower Case
  
  121
  - Removing the Drive Shaft
    122
  - Disassembling the Drive Shaft
    122
  - Disassembling the Forward Gear
    122
  - Disassembling the Lower Case
    122
  - Checking the Pinion and Forward Gear
    123
  - Checking the Bearings
    123
  - Checking the Drive Shaft
    123
  - Checking the Lower Case
    123
  - Assembling the Lower Case
    123
  - Assembling the Forward Gear
    124
  - Assembling the Drive Shaft
    124
  - Installing the Drive Shaft
    124
  - Installing the Shift Rod and Oil Seal Housing
    125
  - Installing the Propeller Shaft Housing
    125
  - Installing the Water Pump
    126
  - Installing the Lower Unit
    127
- Shimming
  
  129
  - Selecting the Pinion Shims
    130
  - Selecting the Forward Gear Shims
    131
  - Selecting the Reverse Gear Shims
    132
- Backlash
  
  133
  - Measuring the Forward and Reverse Gear Backlash
    133
Brkt Bracket Unit

135
- Brkt
  135
- Tiller Handle (MHD, WHD)
  
  136
- Bracket Unit
  
  136
- Bottom Cowling
  
  141
- Upper Case, Pivot Shaft
  
  143
  - Removing the Pivot Shaft
    147
  - Installing the Pivot Shaft
    147
  - Disassembling the Upper Case
    148
  - Checking the Upper Case
    148
  - Assembling the Upper Case
    148
  - Installing the Upper Case
    149
- Clamp Brackets, Swivel Bracket (S, L-Transom)
  
  151
- Clamp Brackets, Swivel Bracket (X-Transom Model)
  
  154
  - Removing the Hydro Tilt Assembly
    157
  - Installing the Hydro Tilt Assembly
    158
  - Removing the Clamp Brackets
    158
  - Installing the Clamp Brackets
    158
Elec Electrical Systems

159
- Elec
  159
- Special Service Tools
  
  160
- Electrical Systems
  
  160
- Checking the Electrical Components
  
  161
  - Measuring the Peak Voltage
    161
  - Measuring Low Resistance
    161
- Electrical Components
  
  162
  - Top View
    162
  - Port View (WD)
    163
  - Starboard View (MHD)
    164
  - Starboard View (WHD, WD)
    165
- Ignition and Ignition Control System
  
  166
  - Checking the Ignition Spark Gap
    168
  - Checking the Ignition Coils
    168
  - Checking the Spark Plug Caps
    168
  - Checking the CDI Unit
    169
  - CDI Unit Resistance Chart (Reference)
    170
  - Checking the Pulser Coils
    171
  - Checking the Charge Coil
    171
  - Checking the Thermoswitch
    172
  - Checking the Warning Indicator
    172
  - Checking the Engine Stop Lanyard Switch (MHD, WHD)
    172
- Starting System (WHD, WD)
  
  173
- Starter Motor (WHD, WD)
  
  175
  - Removing the Starter Motor Pinion
    177
  - Checking the Starter Motor Pinion
    177
  - Checking the Armature
    177
  - Checking the Brushes
    178
  - Checking the Starter Motor Operation
    178
- Charging System
  
  179
  - Checking the Rectifier (WHD, WD)
    180
  - Checking the Lighting Coil
    180
  - Trbl Shtg
    182
    
    Ignition System
    182
    
    Power Unit
    182
    
    Troubleshooting
    182
    
    Fuel System
    184
    
    Compression Pressure
    185
    
    Lower Unit
    188
    
    Electrical System
    189
    
    Starting System
    189
    
    Charging System
    190

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Yamaha e60hwd Manuals

Yamaha e60hwd Service Manual (489 pages)

Table of Contents

Safety While Working

Special Tools

Features and Benefits

Technical Tips

Identification

Chapter 1 Chapter 2

Maintenance Specifications

Chapter 3

Maintenance Interval Chart

Fuel System

Control System

Lower Unit

General

Travail

Chapter 4

Fuel Line

Fuel Joint, Fuel Filter and Fuel Pump

Recoil Starter Assembly

Chapter 5

Power Unit

Yamaha e60hwd Rigging Manual (329 pages)

Table of Contents

Table of Contents

Propellers

Propeller Specifications

2014 Propeller Applications

Propeller Selection

Wot Operation Range Table

Remote Controls

Tiller Handles

6X4 Multi-Function Tiller Handle

Steering Friction Contents

Conventional Gauge (6Y5 & 6Y7)

Mounting the Meters

Analog Tachometer

Digital Tachometer

Speedometer

Fuel Management Gauge

Analog Trim Meter

Coolant Pressure Meter

Coolant Temp. Meter

Hour Meter

Voltage Meter

Fuel Meter

Charge Warning Unit

Wire Harnesses

Wiring Diagrams

Rigging Grommet Description

Digital Network Gauge (6Y8)

Digital Network Gauge Compatible Models

Digital Network Gauge Application

Digital Network Gauge Dimensions

Optional Equipment

Wire Harness

Network Hub

Optional Equipment

Immobilizer Unit

Network Wiring Diagrams

Initial Gauge Setup

Troubleshooting

Nmea0183 Compatible Equipment Connection

Basic Requirements

Digital Network Gauge (6Y8) Function Table

Digital Network Premium Gauge (6Y9)

Digital Network Premium Gauge Compatible Models

Digital Network Premium Gauge Application

Digital Network Premium Gauge Dimensions

Optional Equipment

Network Hub

Wire Harness

Network Wiring Diagrams

Battery

Battery

Recommended Battery

Battery Cable Length

Battery Wiring

Appendix