F60A SUPPLEMENTARY SERVICE MANUAL 292098 69W-28197-3D-1X
NOTICE This Supplementary Service Manual has been prepared to introduce new service and new data information for the F60 which is based on the F50. For complete information on service procedures, it is necessary to use this Supplementary Service Manual together with the following manual.
Contents General information Specifications Periodic checks and adjustments Fuel system Power unit Lower unit Bracket unit GEN INFO SPEC CHK ADJ FUEL POWR LOWR BRKT – Electrical systems Troubleshooting Index + ELEC TRBL SHTG 1 2 3 4 5 6 7 8 9
General information How to use this manual .................................................................................... 1 Manual format............................................................................................... 1 Symbols........................................................................................................ 2 Identification...................................................................................................... 3 Applicable models ....................
Specifications General specifications.................................................................................... 18 Maintenance specifications ........................................................................... 20 Power unit................................................................................................... 20 Lower unit ................................................................................................... 24 Electrical ...........................................
Power unit Power unit........................................................................................................ 45 Checking the compression pressure .......................................................... 55 Checking the oil pressure ........................................................................... 55 Checking the cylinder bore ......................................................................... 56 Checking the piston ring grooves .............................................
Electrical systems Wiring harness ................................................................................................ 85 Ignition and ignition control system ............................................................. 86 Checking the spark plug caps .................................................................... 88 Checking the pulser coil air gap ................................................................. 88 Checking the engine start switch.........................................
GEN INFO General information How to use this manual 1 Manual format The format of this manual has been designed to make service procedures clear and easy to understand. 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. 2 Tightening torque specifications are provided in the exploded diagrams and after a numbered step with tightening instructions.
How to use this manual Symbols The symbols below are designed to indicate the content of a chapter. General information Fuel system GEN INFO Bracket unit FUEL Specifications BRKT Power unit SPEC Electrical systems POWR ELEC Periodic checks and adjustments Lower unit CHK ADJ – + Troubleshooting TRBL SHTG LOWR Symbols 1 to 6 indicate specific data. 1 2 3 4 5 6 T. R.
GEN INFO General information Identification 1 Applicable models This manual covers the following models. Applicable models F60AEHT F60AET Serial number The outboard motor serial number is stamped on a label attached to the port clamp bracket. 1 2 3 4 Model name Approved model code Transom height Serial number Model name F60AEHT F60AET 3 Approved model code 69W Starting serial No.
Identification / Features and benefits Features and benefits 1 Power unit Based on the power unit of the field-proven F50, newly designed parts have been adopted in the various areas to attain 60 horsepower. The newly designed parts include the intake valves, exhaust valves, cylinder head, pistons, and the intake silencer. Cylinder head The shape of the combustion chamber has been changed to increase its capacity. The diameter of the intake and exhaust valves have been enlarged to increase output.
GEN INFO General information Oil pump The size of the oil pump rotor has been enlarged to increase the oil discharge volume. As a result, reliable lubrication has been realized. 22 mm (0.87 in) 24 mm (0.94 in) F50 F60 S69W1210 1 Rotor 2 Embossed letters for identification Oil discharge volume F50 21.5 L (5.68 US gal, 0.22 Imp gal)/min F60 23.5 L (6.21 US gal, 5.
Features and benefits Although the main jet specification numbers of the F50 differed between cylinders, the F60 uses main jets with the same specification number for all four cylinders due to the change in shape of the intake silencer. F50 : F60 S69W1230 È Air Comparison chart of main jet diameters Cylinder #1 #2 #3 #4 F50 #124 #126 #116 #114 F60 #124 #124 #124 #124 Power nozzle The F60 uses a power nozzle in its carburetors.
GEN INFO General information Lower unit Drive shaft The drive shaft has been machined to accommodate the high power output. The portion that mounts to the pinion gear has been machined with involute splines to increase durability. A section of the midspan of the drive shaft has been reduced to 14.4 mm (0.57 in) to prevent the drive shaft from breaking under impact loads. In addition, two grooves are provided on the drive shaft for identification purposes. Ø14.4 95.5 mm (3.
Features and benefits Forward gear bearing The size of the forward gear bearing has been increased to accommodate the high power output of the F60. With this increase, the coupling length of the forward gear has been extended as well. In addition, two grooves are provided on the forward gear for identification purposes. 26.0 mm (1.02 in) 23.2 mm (0.91 in) S69W1260 1 Forward gear bearing 2 Grooves for identification 3 Forward gear Bearing comparison chart Forward gear bearing Forward gear F50 22.
GEN INFO General information Bracket unit 69W-00 PTT (Power trim and tilt) unit Based on the 62Y type PTT unit of the F50, the internal valve and power trim and tilt motor have been changed. The construction of the valves has been changed to increase the shut-off pressure. The unit limits the movement of the outboard motor, which has increased in size with the increase in its power output, and secures it in place.
Features and benefits Steering friction The F60 tiller handle models use a newly developed, compact steering friction. S69W1280 1 Steering friction Electrical unit Starter motor The starter motor uses six magnets and four brushes to enhance its operating torque. F50 F60 S69W1290 1 2 3 4 5 6 7 8 Bearing Starter relay Neutral switch Engine start switch Magnet Brush Starter motor Battery Operating torque F50 2.74 N·m (0.27 kgf·m, 2.0 ft·lb) F60 3.50 N·m (0.35 kgf·m, 2.
GEN INFO General information Technical tips 1 Carburetor Power nozzle The power nozzle is activated when the engine is operating at high speeds. To reduce the fuel consumption rate and the pollution of the exhaust gases, the carburetors of the F60 are set lean. Therefore, the air-fuel mixture becomes lean at high engine speeds, when greater output is needed. The power nozzle supplies a richer fuel mixture at high engine speed to realize the optimal air-fuel ratio to produce output.
Technical tips PTT (Power Trim and Tilt) unit Shuttle piston A ball type shut-off construction is used for both the up-shuttle and down-shuttle pistons. The ball type realizes a reliable shut-off operation and high shut-off pressure.
GEN INFO General information Propeller selection 1 The performance of a boat and outboard motor will be critically affected by the size and type of propeller you choose. Propellers greatly affect boat speed, acceleration, engine life, fuel economy, and even boating and steering capabilities. An incorrect choice could adversely affect performance and could also seriously damage the engine.
Propeller selection / Predelivery checks Predelivery checks 1 To make the delivery process smooth and efficient, the predelivery checks should be completed as explained below. Checking the engine oil 1. Check the oil level. Checking the fuel system 1. Check that the fuel hoses are securely connected and that the fuel tank is full with fuel. NOTE: • If the engine oil is above the maximum level mark a, drain sufficient oil until the level is between a and b.
GEN INFO General information S69W1110 NOTE: The optimum mounting height is affected by the combination of the boat and the outboard motor. To determine the optimum mounting height, test run the outboard motor at different heights. CAUTION: The shift/throttle cable joint must be screwed in a minimum of 8.0 mm (0.31 in) e. Checking the steering system 2. Check that the clamp brackets are secured with the clamp bolts. Checking the shift/throttle cables 1.
Predelivery checks Checking the gearshift and throttle operation 1. Check that the gearshift operates smoothly when the remote control lever or shift lever is shifted from neutral into forward or reverse. 2. Check that the throttle operates smoothly when the remote control lever or throttle grip is shifted from the fully closed position to the fully open position a. È Checking the engine start switch and engine stop switch/engine shut-off switch 1.
GEN INFO General information Checking the cooling watger pilot hole 1. Start the engine, and then check that cooling water is discharged from the cooling water pilot hole. 0 1 2 10 S69W1190 È Hour After test run 1. Check for water in the gear oil. 2. Check for fuel leakage in the cowling. Test run 1. Start the engine, and then check that the gearshift operates smoothly. 3. After a test run and while the engine is at idle, flush the cooling water passage with fresh water using the flushing kit. 2.
Predelivery checks / General specifications General specifications Item Dimension Overall length Overall width Overall height (L) Boat transom height (L) Weight (with aluminum propeller) (L) Performance Maximum output Full throttle operating range Maximum fuel consumption Power unit Type Cylinder quantity Displacement Bore × stroke Compression ratio Carburetor quantity Control system Starting system Ignition control system Ignition timing Alternator output Enrichment system Spark plugs Cooling system Exhau
SPEC Specifications Item Fuel and oil Fuel type Fuel rating Engine oil type Engine oil grade Engine oil quantity (with oil filter replacement) Unit PON* RON API SAE L (US qt, lmp qt) (without oil filter replacement) L (US qt, lmp qt) Gear oil type Gear oil grade API SAE Gear oil quantity L (US qt, lmp qt) Bracket Trim angle Degree (at 12 degree boat transom) Tilt-up angle Degree Steering angle Degree Drive unit Gearshift positions Gear ratio Reduction gear type Clutch type Propeller shaft type Propelle
General specifications / Maintenance specifications Maintenance specifications 2 Power unit Item Power unit Minimum compression pressure* Lubrication oil pressure (reference data) Cylinder heads Warpage limit (lines indicate straightedge position) Cylinder head journal inside diameter Cylinders Bore size Taper limit Out-of-round limit Pistons Piston diameter (D) Measuring point (H) Piston-to-cylinder clearance Piston pin boss bore size Oversize piston 1st 2nd Oversize piston diameter 1st 2nd Piston pins
SPEC Specifications Item Piston rings Top ring Dimension B Dimension T End gap Side clearance 2nd ring Dimension B Dimension T End gap Side clearance Oil ring Dimension B Dimension T End gap Side clearance Camshafts Intake (A) Exhaust (A) Intake and exhaust (B) Camshaft journal diameter #1 #2, #3, #4 Camshaft journal oil clearance #1 #2, #3, #4 Maximum camshaft runout Rocker arm shafts Outside diameter Rocker arms Inside diameter Valves Valve clearance (cold) Intake Exhaust Head diameter (A) Intake Exhaus
Maintenance specifications Item Face width (B) Intake Exhaust Seat contact width (C) Intake Exhaust Margin thickness (D) Intake Exhaust Stem diameter Intake Exhaust Guide inside diameter Intake and exhaust Stem-to-guide clearance Intake Exhaust Stem runout limit Intake Exhaust Valve springs Free length Minimum free length Tilt limit Connecting rods Small-end inside diameter Big-end inside diameter Crankpin oil clearance Big-end bearing thickness Yellow Red Pink Green Crankshaft Crankshaft journal Diameter C
SPEC Specifications Item Crankcase main journal bearing thickness Yellow Red Pink Green Oil pump Type Outer rotor-to-housing clearance Outer rotor-to-inner rotor clearance limit Rotor-to-cover clearance Thermostat Opening temperature Fully open temperature Valve open lower limit Fuel pump Discharge Pressure Plunger stroke Carburetor ID mark Main jet Pilot jet Pilot screw Float height Engine idle speed 23 Unit Model F60AEHT F60AET mm (in) mm (in) mm (in) mm (in) 1.502–1.506 (0.0591–0.0593) 1.498–1.
Maintenance specifications Lower unit Item Gear backlash Pinion-to-forward gear Pinion-to-reverse gear Pinion shims Forward gear shims Reverse gear shims Unit mm (in) mm (in) mm mm mm Model F60AEHT F60AET 0.18–0.54 (0.0071–0.0212) 0.71–1.07 (0.0280–0.0421) 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.
SPEC Specifications Item Ignition control system Oil pressure switch ON ↔ OFF Thermoswitch (Gy/B – B) OFF → ON ON → OFF Starter motor Type Output Cranking time limit Brushes Standard length Wear limit Commutator Standard diameter Wear limit Mica Standard undercut Wear limit Charging system Fuse Lighting coil output peak voltage (G – G) at cranking (unloaded) at 1,500 r/min (unloaded) at 3,500 r/min (unloaded) Lighting coil resistance(*1) (G – G) Rectifier Regulator output peak voltage (R – B) at 1,500 r/m
Maintenance specifications Item Power trim and tilt system Trim sensor Setting resistance Resistance (P – B) Fluid type Brushes Standard length Wear limit Commutator Standard diameter Wear limit Mica Standard undercut 69W3D1X Unit Model F60AEHT F60AET Ω Ω 9–11 9–288.3 ATF Dexron II mm (in) mm (in) 10 (0.39) 3.5 (0.14) mm (in) mm (in) 22.0 (0.87) 21.0 (0.83) mm (in) 1.5 (0.
SPEC Specifications Dimensions Exterior L3 A1 W5 W2 W1 W6 L7 L6 L2 L1 L10 H9 H5 H2 H7 H10 H8 B6 H4 H1 C1 H3 L5 L8 H6 A2 H11 A3 L9 L4 S69W2150 27 69W3D1X
Maintenance specifications Symbol L1 L2 L3 L4 L5 L6 L7 L8 L9 L10 H1 H2 H3 H4 H5 H6 H7 H8 H9 H10 H11 W1 W2 W3 W4 W5 W6 A1 A2 A3 T1 69W3D1X Unit (L) (X) (L) (X) (L) (X) (L) (X) (L) (X) (L) (X) (L) (X) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) Degree Degree Degree mm (in) Mode
SPEC Specifications Exterior A1 W5 W1 L7 L6 L8 L1 L10 L2 H9 H2 H7 H10 H8 B6 H4 H1 C1 H3 L5 H6 A2 H11 A3 L9 29 L4 S69W2160 69W3D1X
Maintenance specifications Symbol L1 L2 L3 L4 L5 L6 L7 L8 L9 L10 H1 H2 H3 H4 H5 H6 H7 H8 H9 H10 H11 W1 W2 W3 W4 W5 W6 A1 A2 A3 T1 69W3D1X Unit (L) (X) (L) (X) (L) (X) (L) (X) (L) (X) (L) (X) (L) (X) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) Degree Degree Degree mm (in) Mode
SPEC Specifications Clamp bracket B5 B3 B4 B9 B9 B9 B2 C1 D1 B6 D2 B1 D1 B8 S69W2170 Symbol B1 B2 B3 B4 B5 B6 B7 B8 B9 C1 C2 D1 D2 31 Unit mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) Model F60AEHT F60AET 126 (5.0) 249 (10.0) 163.5 (6.4) 50.8 (2.0) 180 (7.1) 350 (13.8) — — 18.5 (0.7) 69 (2.7) — 13 (0.5) 60.5 (2.
Maintenance specifications / Tightening torques Tightening torques 2 Specified torques Part to be tightened Thread size Power unit Flywheel magnet nut Stator base screw Cover screw Red battery cable nut Oil pressure switch Oil pressure switch lead screw Ignition coil bolt Starter motor bolt Starter motor terminal nut Power unit bolt Tensioner bolt Tensioner adjusting bolt Drive sprocket nut Driven sprocket bolt Spark plug Cylinder head bolt — M6 M6 — — — M6 M8 — M8 — M8 — M10 — 1st 2nd 1st 2nd Oil pum
SPEC Specifications Part to be tightened Bracket unit Tiller handle assembly nut Engine shut-off switch nut Tiller handle bracket nut Engine start switch nut Tiller handle bracket bolt Friction plate bolt Friction plate self-locking nut Upper mount nut Lower mount nut Clamp bracket self-locking nut Power trim and tilt Tilt cylinder end screw PTT motor bolt Reservoir cap Trim cylinder end screw Tilt piston bolt Relief valve bracket bolt Gear pump assembly bolt Gear pump bracket bolt Electrical unit Pulser
Tightening torques / Special service tools Special service tools 3 Digital tachometer 90890-06760 Bearing separator 90890-06534 Compression gauge 90890-03160 Bearing inner race attachment 90890-06643 Drive shaft holder 4 90890-06518 Shimming plate 90890-06701 Pinion nut holder 90890-06505 Digital caliper 90890-06704 Socket adapter 1 90890-06506 Digital circuit tester 90890-03174 69W3D1X 1 2 3 4 5 6 7 8 9 34
CHK ADJ Periodic checks and adjustments Dial gauge set 90890-01252 Magnet base 90890-06705 35 69W3D1X
Special service tools / Maintenance interval chart Maintenance interval chart 3 Use the following chart as a guideline for general maintenance. Adjust the maintenance intervals according to the operating conditions of the outboard motor.
CHK ADJ Periodic checks and adjustments Top cowling 3 Checking the top cowling 1. Check the fitting by pushing the cowling with both hands. Adjust if necessary. NOTE: Be sure not to spill any fuel when removing the fuel filter cup. S69W3010 2. Loosen the nuts 1. Power unit 3. Move the hook 2 up or down slightly to adjust its position. Checking the thermostat 3 1. Remove the cover 1, thermostat cover 2, and thermostat 3. 3 2 S69W3020 NOTE: • To loosen the fitting, move the hook in direction a.
Top cowling / Fuel system / Power unit / General S69W3050 4. Check the thermostat valve opening at the specified water temperatures. Replace if out of specification. Water temperature Valve lift a 60 °C (140 °F) Valve begins to lift above 70 °C (158 °F) more than 3.0 mm (0.12 in) 5. Install the thermostat, new gasket, thermostat cover, and cover. General 3 Checking the anodes 1. Check the anodes and trim tab for scales, grease, or oil. Clean if necessary.
CHK ADJ Periodic checks and adjustments Lubrication 1. Apply water resistant grease to the areas shown. A A S69W3120 S69W3150 NOTE: Apply grease to the grease nipple until it flows from the bushings a. 2. Apply corrosion resistant grease to the areas shown.
General / Hose routing Hose routing 4 Fuel and blowby hoses 1 2 3 4 5 6 7 1 2 3 4 5 6 7 8 9 Blowby hose Hose (acceleration pump-to-carburetor) Fuel hose (fuel joint-to-fuel filter) Fuel hose (fuel filter-to-fuel pump) Fuel hose (fuel pump-to-carburetor) Hose (carburetor-to-carburetor) Hose (acceleration pump-to-acceleration pump) 69W3D1X 40
FUEL Fuel system Cooling water hose S69W4020 1 Pilot water hose 2 Flushing hose È Flushing device model É View in direction of arrow 41 69W3D1X
Hose routing / Fuel line and fuel filter Fuel line and fuel filter No.
FUEL Fuel system Carburetor unit No.
Carburetor unit Adjusting the dashpot (acceleration pump) 1. Start the engine and warm it up for 5 minutes. 2. Check that the engine speed at the operation point of the dashpot is within specification. 3. Attach the special service tool to spark plug wire #1 1. 5. If out of specification, adjust the dashpot until the specified engine speed is obtained. 6. Open the throttle cam 2 slowly, and check that the acceleration pump stopper 3 comes in contact with point a. 7.
POWR Power unit 45 Power unit 5 69W3D1X
Power unit No.
POWR 47 Power unit 69W3D1X
Power unit No.
POWR 49 Power unit 69W3D1X
Power unit No. Part name Q’ty Remarks 1 Cylinder head 1 2 Plate 1 3 Cylinder head cover 1 4 Bolt 7 M6 × 20 mm 5 Cylinder head cover gasket 1 Not reusable 6 Bolt 10 M9 × 95 mm 7 Spark plug 4 8 Bolt 5 9 Dowel pin 2 10 Cylinder head gasket 1 11 Grommet 4 12 Anode 4 13 Cover 4 14 Bolt 4 15 Cover 4 16 Bolt 4 17 O-ring 1 M6 × 25 mm Not reusable Not reusable 1.9 × 36.8 mm 18 O-ring 1 Not reusable 1.8 × 17.
POWR 51 Power unit 69W3D1X
Power unit No.
POWR 53 Power unit 69W3D1X
Power unit No.
POWR Power unit Checking the compression pressure 1. Start the engine, warm it up for 5 minutes, and then turn it off. 2. Remove the lock plate from the engine shut-off switch on the remote control box or tiller handle. 3. Remove all spark plugs, and then install the special service tools to each spark plug hole. NOTE: • If the compression pressure increases, check the piston and piston rings for wear. Replace if necessary.
Power unit Checking the cylinder bore 1. Measure the cylinder bore (D1–D6) at measuring points a, b, and c, and in direction d (D1, D3, D5), which is parallel to the crankshaft, and direction e (D2, D4, D6), which is at a right angle to the crankshaft. D2 D1 D4 D3 D6 D5 S69W5080 a 20 mm (0.8 in) b 60 mm (2.4 in) c 100 mm (3.9 in) Cylinder bore (D1–D6): 65.00–65.01 mm (2.5591–2.5594 in) Piston ring groove: Top ring a: 1.21–1.23 mm (0.0476–0.0484 in) Second ring b: 1.51–1.53 mm (0.0594–0.
LOWR Lower unit Drive shaft and lower case 57 6 69W3D1X
Drive shaft and lower case No.
LOWR Lower unit Removing the drive shaft 1. Remove the drive shaft assembly and pinion, and then pull out the forward gear. Bearing inner race attachment 1: 90890-06643 S69W6020 Drive shaft holder 4 1: 90890-06518 Pinion nut holder 2: 90890-06505 Socket adapter 1 3: 90890-06506 Installing the drive shaft 1. Install the forward gear, then the drive shaft assembly, pinion, and pinion nut, and then tighten the nut to the specified torque. Disassembling the forward gear 1.
Drive shaft and lower case / Shimming Shimming 69W3D1X 6 60
LOWR Lower unit Shimming NOTE: • Shimming is not required when assembling the original lower case and inner parts. • Shimming is required when assembling the original inner parts and a new lower case. • Shimming is required when replacing the inner part(s). Selecting the forward gear shims 1. Turn the taper roller bearing outer race 1 two or three times to seat the rollers, and then measure the bearing height (M) as shown. NOTE: “F” is the deviation of the lower case dimension from standard.
Shimming Example: If “T1” is 0.45 mm, then the forward gear shim is 0.42 mm. If “T1” is 0.60 mm, then the forward gear shim is 0.58 mm.
BRKT Tiller handle 63 Bracket unit 7 69W3D1X
Tiller handle No.
BRKT Bottom cowling 65 Bracket unit 7 69W3D1X
Bottom cowling No.
BRKT Upper case 67 Bracket unit 7 69W3D1X
Upper case No.
BRKT 69 Bracket unit 69W3D1X
Upper case No.
BRKT Bracket unit Disassembling the oil pan 1. Remove the muffler 1, plate 2, and exhaust manifold 3 from the oil pan 4. 3. Install the oil strainer 3 by installing the bolts. 2. Remove the oil pan 4 and the exhaust guide 5. 3. Remove the oil strainer 6 and the relief valve housing 7. 4. Install the water pipe 4. 5. Install the oil pan 5 and bolts, and then tighten the bolts finger tight. 6. Install the exhaust manifold 6 and bolts, and then tighten the bolts finger tight. Assembling the oil pan 1.
Upper case 10. Tighten the upper case bolts B, and then tighten them to the specified torque. 7. Tighten the oil pan bolts 7 then exhaust manifold bolts 8, and then tighten them to the specified torque. T. R. T. R. Exhaust manifold bolt 8: 10 N·m (1.0 kgf·m, 7.2 ft·lb) Upper case bolt B: 21 N·m (2.1 kgf·m, 15 ft·lb) Installing the upper case 8. Install the plate 9 and the muffler 0 to the oil pan. 1. Install the upper mount 1 and bolts 2 into the upper case. 2.
BRKT Bracket unit T. R. Upper mounting nut 7: 24 N·m (2.4 kgf·m, 17 ft·lb) Lower mounting nut 8: 42 N·m (4.2 kgf·m, 30 ft·lb) 4. Install the upper and lower mounting bolts into the swivel bracket 6 simultaneously. 5. Install the upper mounting nut 7 and lower mounting nut 8, and then tighten them to the specified torque. 6. Install the cover 9.
Upper case / Clamp brackets Clamp brackets No.
BRKT Bracket unit Adjusting the trim sensor 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 suddenly lower if the power trim and tilt unit should lose fluid pressure. 8. Measure the trim sensor resistance. Check the trim sensor if out of specification.
Clamp brackets / Swivel bracket and steering arm Swivel bracket and steering arm No.
BRKT Bracket unit Power trim and tilt unit No.
Power trim and tilt unit No.
BRKT No.
Power trim and tilt unit No.
BRKT No.
Power trim and tilt unit Disassembling the gear pump 1. Remove the manual valve 1 and gear pump 2. 5. Remove the drive gear A and driven gear B. Checking the valves 1. Check the operation of the check valve a of the trim cylinder end screw and check the valve for dirt or residue. Clean if necessary. 2. Remove the relief valve bracket 3, then the relief valve seal 4 and ball 5. 3. Remove the bracket 6, then the balls 7. 4. Remove the gear pump cover 8, then the shuttle pistons 9 and balls 0. 69W3D1X 2.
BRKT Bracket unit S69W7280 4. Check the main valves for dirt or residue. Clean if necessary. 4. Install the balls 9, manual release spring 0 and bracket A by installing the bolts B, then tightening them to the specified torque. S69W7290 5. Check the absorber valves for dirt or residue. Clean if necessary. T. R. S69W7300 Assembling the gear pump 1. Install the drive gear 1, driven gear 2, shaft 3, and pins 4 into the gear pump housing 5. Gear pump bracket bolt B: 5 N·m (0.5 kgf·m, 3.6 ft·lb) 5.
Power trim and tilt unit T. R. Relief valve bracket bolt G: 5 N·m (0.5 kgf·m, 3.6 ft·lb) 10. Install the joint M and power trim and tilt motor N by installing the bolts O, then tightening them to the specified torque. 7. Install the filters H and gear pump I by installing the bolts J, then tightening them to the specified torque. 8. Install the manual valve K and reservoir cap L. T. R. PTT motor bolt O: 4 N·m (0.4 kgf·m, 2.9 ft·lb) Checking the trim sensor 1. Measure the trim sensor resistance.
– ELEC + Electrical systems Wiring harness 8 B R B G L L P B B/W B/O B B B Y Y L Y/B P Y/R P/B P/W W P G G Y Y R G Y Lg W B/W P Sb B/O Br B B BB R Lg Br R Sb Sb Lg Lg Sb Sb R P/W P/B Y/R Y/B Y/B Y/R P/B P/W R P/W P/B Y/R Y/B R Lg P/B P/W L B B/O Y/B Y/R P W B/W R Lg Sb R G B B B B Br Sb Lg Lg Sb L Y P Y Y G G R B B B P B B/O B/W Lg Sb R Br P G W B Y S69W8010 7 1 Engine start switch or 8 9 remote control box extension 2 Power trim and tilt relay
Wiring harness / Ignition and ignition control system Ignition and ignition control system 1 2 3 4 5 6 7 8 Spark plug Ignition coil Charge coil Pulser coil Engine start switch Engine shut-off switch 10-pin coupler CDI unit 8 B Br L O W B/O B/W W/B W/R 1 2 3 4 5 6 7 8 9 : Black : Brown : Blue : Orange : White : Black/orange : Black/white : White/black : White/red È Tiller handle model 69W3D1X 86
ELEC 1 2 3 4 5 6 – + Electrical systems Thermoswitch Oil pressure switch CDI unit Oil pressure warning indicator Overheat warning indicator Warning indicator B P Gy/B P/B P/W Y/B Y/R : Black : Pink : Gray/black : Pink/black : Pink/white : Yellow/black : Yellow/red È Tiller handle model 87 69W3D1X
Ignition and ignition control system Checking the spark plug caps Pulser coil air gap a: 0.5–1.0 mm (0.020–0.039 in) 1. Remove the spark plug caps from the spark plug wires by turning the caps counterclockwise. 3. Remove the flywheel magnet nut and flywheel magnet. 4. Loosen the pulser coil screws, adjust the pulser coil 1 position, and then tighten the screws finger tight. 2. Measure the spark plug cap resistance. Replace if out of specification. 5.
ELEC – + Electrical systems Starting system 8 W B R P Br OFF ON R R START R Br Br R R Br R Br R N B M S B B B B B B Br Br S69W8090E 1 2 3 4 5 6 7 Fuse 10-pin coupler Engine start switch Starter motor Battery Neutral switch Starter relay B Br R : Black : Brown : Red È Tiller handle model 89 69W3D1X
Starting system / Starter motor Starter motor 8 1 2 3 4 5 11 6 7 8 12 14 13 T. 15 R. 9 7 N • m (0.7 kgf • m, 5.1 ft • Ib) 16 17 10 18 S69W8100 No.
ELEC – + Electrical systems Checking the armature 1. Check the armature axial free play. Replace the washers and shim(s) 3 if out of specification. Diameter limit: 32.0 mm (1.26 in) 4. Measure the commutator undercut a. Replace the armature if out of specification. Dial gauge set 1: 90890-01252 Magnet base 2: 90890-06705 Free play limit: 0.6 mm (0.024 in) 2. Check the commutator for dirt. Clean with #600 grid sandpaper and compressed air if necessary. Commutator undercut limit: 0.2 mm (0.01 in) 5.
Starter motor Brush length limit a: 10.0 mm (0.39 in) 2. Check the brush holder for continuity. Replace if out of specifications.
F60AEHT B Br B B G Gy Y L Y L L L Br G B B W/R Sb Br Y/R P/B W B/W Gy/B W/R Br B W/B L Y/B P/W O B/O P R G Lg G O W/B P G R Y R G L Br L W/B W/R G L Y L Br Sb B B/O Y/R L Br R G Y B/O Y L Br P/B O P G/W W/R W/B G G G/W W W P/W P/B Y/R B/O L R Br Y R G Lg P L Y/B P/W Y/R P/B W B/O B/W Y/B Y/R B B R B R B G Y W P Sb Br P W/R B R W B P L G/W G L P P/W W/B B/W Gy/B Lg Lg Sb Sb P/B B R L Sb Lg Gy/B Y/B B B B/W G/W Y B
Wiring diagram F60AEHT 1 2 3 4 5 6 7 8 9 0 A B C D E F G H I J K L Battery Engine start switch Starter motor Power trim and tilt motor Power trim and tilt relay Engine shut-off switch Starter relay Neutral switch Fuse (20 A) Warning indicator Power trim and tilt switch Prime Start Oil pressure switch CDI unit Thermoswitch Charge coil Pulser coil Lighting coil Rectifier Regulator Ignition coil Spark plug Trim sensor Color code B Br G Gy L Lg O P R Sb W Y B/O B/W G/W Gy/B P/B P/W W/B W/R Y/B Y/R : Black :
F60AET B Br B B G Gy Y L Y L Br L L G B B W/R Sb Y/R P/B W B/W Gy/B W/R Br B W/B L Y/B P/W O B/O P R G Lg G O W/B P G R Y R Br G L Br L W/B W/R G L Y L Sb B B/O Y/R L G Y B/O Y Br P/B O P Y L G/W W/R W/B G G G/W W W P/W P/B Y/R B/O L R Br Y Lg Lg Sb Sb G Lg L Y/B P/W Y/R P/B W B/O B/W W/R Y/B Y/R B B R B R B G B R Y W P Sb Br P L G/W G L P P/W W/B B/W Gy/B P P/B B R L Sb Lg Gy/B Y/B B B B/W G/W B B W Y/B P/W B Sb G
Wiring diagram F60AET 1 2 3 4 5 6 7 8 9 0 A B C D E F G H Battery Starter motor Power trim and tilt motor Power trim and tilt relay Starter relay Fuse (20 A) Trim sensor Prime Start Oil pressure switch CDI unit Thermoswitch Charge coil Pulser coil Lighting coil Rectifier Regulator Power trim and tilt switch Ignition coil Spark plug È To remote control É To warning indicator Ê To trim meter Color code B Br G Gy L Lg O P R Sb W Y B/O B/W G/W Gy/B P/B P/W W/B W/R Y/B Y/R : Black : Brown : Green : Gray : Bl
YAMAHA MOTOR CO., LTD. Printed in the Netherlands Jul. 2001 – 1.
