Service manual

ManualsBrandsYamaha ManualsAutomotiveT-60

6H2-28197-Z9-11

SERVICE

MANUAL

50G, 60F, 70B,

75C, 90A

Summary of content (204 pages)

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50G, 60F, 70B, 75C, 90A SERVICE MANUAL 6H2-28197-Z9-11
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E NOTICE This manual has been prepared by the Yamaha Motor Company Ltd. 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.
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E A50000-0 HOW TO USE THIS MANUAL MANUAL FORMAT This manual provides the mechanic with descriptions of the operations of disassembly, repair, assembly, adjustment and inspection, each of which is presented in a sequential, stepby-step procedure. To assist you to find your way about this manual, the Section Title and Major Heading is given at the head of every page. An Index to contents is provided on the first page of each section. MODEL INDICATION Multiple models are shown in this manual.
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E SPECIFICATIONS These are given in bold type at each procedure. It is not necessary to leave the section dealing with the procedure in order to look up the specifications. It is important to note the differences in specifications of models. Where a procedure relates to more than one model, the main differences in specifications will be shown in the following table.
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E 1 A50001-1-4 2 GEN INFO SYMBOLS Symbols 1 to 9 are designed as thumbtabs to indicate the content of a chapter.
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E A30000-0 INDEX GENERAL INFORMATION SPECIFICATIONS PERIODIC INSPECTION AND ADJUSTMENT FUEL SYSTEM POWER UNIT LOWER UNIT BRACKET UNIT GEN INFO SPEC INSP ADJ FUEL POWR LOWR BRKT – ELECTRICAL SYSTEMS TROUBLE ANALYSIS + ELEC TRBL ANLS 1 2 3 4 5 6 7 8 9
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GEN INFO E CHAPTER 1 GENERAL INFORMATION IDENTIFICATION ............................................................................................ 1-1 SERIAL NUMBER ..................................................................................... 1-1 STARTING SERIAL NUMBERS ............................................................... 1-1 SAFETY WHILE WORKING ............................................................................ 1-2 FIRE PREVENTION ...........................................
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GEN INFO IDENTIFICATION E A60000-1* IDENTIFICATION SERIAL NUMBER The serial number of the outboard motor is stamped on a plate attached to the port side of the clamp bracket. 1 Serial number NOTE: For USA model: As an anti-theft measure, a special label on which the outboard motor serial number is stamped is bonded to the port side of the clamp bracket. The label is specially treated so that peeling it off causes cracks across the serial number. 1 2 3 4 Model name Approved model No.
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GEN INFO SAFETY WHILE WORKING E SAFETY WHILE WORKING The procedures given in this manual are those recommended by Yamaha to be followed by Yamaha dealers and their mechanics. FIRE PREVENTION Gasoline (petrol) is highly flammable. Petroleum vapor is explosive if ignited. Do not smoke while handling and keep it away from heat, sparks, and open flames. VENTILATION Petroleum vapor is heavier than air and if inhaled in large quantities will not support life. Engine exhaust gases are harmful to breathe.
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GEN INFO SAFETY WHILE WORKING E Under normal conditions of use, there should be no hazards from the use of the lubricants mentioned in this manual. However, safety is all-important and by adopting good safety practices, any risk is minimized. A summary of the most important precautions is as follows: 1. While working, maintain good standards of personal and industrial hygiene. 2.
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GEN INFO SAFETY WHILE WORKING E 3. Non-reusable items When reassembling, always use new gaskets, packing, O-rings, oil seals, split-pins and circlips, etc. DISASSEMBLY AND ASSEMBLY 1. Clean parts with compressed-air when disassembling them. 2. Oil the contact surfaces of moving parts before assembly. 3. After assembly, check that moving parts operate normally. 4. Install bearings with the manufacturer’s markings on the side exposed to view and liberally oil the bearings. 5.
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GEN INFO SPECIAL TOOLS E A80000-0* SPECIAL TOOLS The use of correct special tools recommended by Yamaha will aid the work and enable accurate assembly and tune-up. Improvisations and use of improper tools can cause damage to the equipment. NOTE: ● For USA and Canada, use part numbers starting with “YB-”, “YM-”, “YU-” or “YW-”. ● For others, use part numbers starting with “90890-”.
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GEN INFO SPECIAL TOOLS E MEASURING Tool name 1 2 3 4 5 6 7 8 9 10 11 Tachometer Dynamic spark tester CDI tester Mity Vac Pressure tester Dial gauge Backlash indicator Magnet base Backlash adjusting plate Thickness gauge Pinion height gauge 12 Digital caliper 13 14 15 16 17 18 19 20 21 22 23 24 Gauge block Adapter plate Gauge base Clamp Shimming plate Base plate Compression spring Press plate Gauge pin Digital multimeter Pocket tester Pressure gauge 25 Shimming gauge 26 3 pins test harness Tool
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GEN INFO SPECIAL TOOLS E 1-7
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GEN INFO SPECIAL TOOLS E REMOVAL AND INSTALLATION 1 Small end bearing installer 2 Piston slider Tool No. Except for USA and USA and Canada a Canada b YB-06107 90890-06527 YB-06287 YU-33294 90890-06530 3 Slide hammer set YB-06096 N.A. 4 Stopper guide plate N.A. 90890-06501 5 Bearing puller N.A. 90890-06535 6 Stopper guide stand N.A. 90890-06538 7 Ring nut wrench 8 Extension YB-06048 YB-34447 N.A. 9 Claw YB-06207 10 11 Universal puller Center bolt YB-06117 N.A.
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GEN INFO SPECIAL TOOLS E 1-9
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GEN INFO SPECIAL TOOLS Tool name E Tool No. Except for USA and USA and Canada a Canada b 21 Bearing depth plate 22 23 24 29 30 Oil seal attachment Needle bearing depth stop Driver rod Bearing outer race attachment Driver rod Bearing outer race attachment Bearing inner race attachment Shift rod wrench Cylinder end screw wrench YB-06052 YB-06175-1A 31 Cylinder end screw wrench YB-06175-2B 32 33 Flywheel holder Flywheel puller 25 26 27 28 N.A. 90890-06603 YB-06269 YB-34473 YB-06071 N.A. N.
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SPEC E CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATION ............................................................................ 2-1 MAINTENANCE SPECIFICATIONS................................................................ 2-5 ENGINE..................................................................................................... 2-5 ELECTRICAL ............................................................................................. 2-7 DIMENSION..................................................
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SPEC GENERAL SPECIFICATION E C20000-0* GENERAL SPECIFICATION Unit Model Approved model No. Overall Length Overall width Overall height Boat transom height O/M transom height Weight (Al.) Weight (SUS.
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SPEC GENERAL SPECIFICATION Unit Model Approved model No. Overall Length mm (in) Overall Width mm (in) Overall Height mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) kg (lb) kg (lb) X S L kg (lb) kg (lb) kg (lb) X Full throttle speed range Output (ISO) Maximum fuel consumption kg (lb) r/min O/M transom height Weight (Al.) Weight (SUS.
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SPEC GENERAL SPECIFICATION Unit Scavenging system Starting system Ignition system Alternator output Carburetor starting system Advance type Spark plug (NGK) Spark plug with noise suppressor (NGK) Exhaust system Cooling system Lubrication system Fuel type Fuel rating Engine oil type/grease Gear oil type Gear oil quantity Engine oil tank capacity Tilt angle (Manual tilt model) Tilt-up angle S L, X Trim angle (PTT model) Steering angle *1: *2: *3: *4 : *5: *6: 60 hp Model 70 hp 75 hp Loop charge Electr
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SPEC GENERAL SPECIFICATION Item Unit Propeller No. of blades × diameter × pitch in Item Unit Propeller No.
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SPEC MAINTENANCE SPECIFICATIONS E C31000-0* MAINTENANCE SPECIFICATIONS ENGINE Item Unit Cylinder head: Warpage limit mm (in) (Lines indicate straight measurement) Cylinder: Bore size mm (in) Taper limit Out of round limit Piston: Piston to cylinder clearance Piston size “D” 50 hp 60 hp Model 70 hp 75 hp mm (in) mm (in) Measuring point “H” mm (in) Oversize mm (in) mm (in) mm (in) 1st 2nd Offset [direction] Piston ring: Sectional sketch Top ring & 2nd ring Type B T End gap [install
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SPEC MAINTENANCE SPECIFICATIONS Item Unit Crankshaft: Crank width “A” Crank width “B” Crank width “C” Maximum deflection “D” Connecting rod side clearance “E” Connecting rod maximum axial play “F” Carburetor: Stamp mark 60 hp Model 70 hp 75 hp 80 hp 90 hp mm (in) 57.90 ~ 57.95 (2.280 ~ 2.281) — mm (in) 151.7 ~ 152.0 (5.972 ~ 5.984) — mm (in) 245.5 ~ 246.1 (9.67 ~ 9.69) 284.2 ~ 284.8 (11.19 ~ 11.21) mm (in) 0.03 (0.0012) 0.05 (0.0020) mm (in) 0.20 ~ 0.70 (0.008 ~ 0.028) mm (in) 0.12 ~ 0.26 (0.
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SPEC MAINTENANCE SPECIFICATIONS Item Thermostat: Valve opening temperature Full-opening temperature Valve lift Unit 50 hp E Model 70 hp 75 hp 60 hp °C (°F) 48 ~ 52 (118 ~ 126) °C (°F) 60 (140) mm (in) 3 (0.
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SPEC MAINTENANCE SPECIFICATIONS Item Ignition coil: Primary coil resistance [20°C (68°F)] Secondary coil resistance [20°C (68°F)] Crank position sensor resistance [20°C (68°F)] Crank position sensor peak voltage: (minimum) color @ cranking (open) @ cranking (connect) @ 1,500 r/min @ 3,500 r/min Spark plug: Spark plug gap CDI unit output peak voltage: (minimum) color @ cranking (open) @ cranking (connect) @ 1,500 r/min @ 3,500 r/min Lighting system: Lighting coil resistance STD (12V 80W) [20°C (68°F)] Ligh
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SPEC MAINTENANCE SPECIFICATIONS Model 70hp 75hp E Item Unit Commutator outside diameter Pinion/ring gear gap Others: Electrothermal valve resistance [20°C (68°F)] Fuel enrichment valve resistance [20°C (68°F)] Trim sensor resistance mm (in) 60hp 30 (1.18) mm (in) mm (in) 29 (1.14) 31 (1.22) 3.0 ~ 5.0 (0.12 ~ 0.20) Ω 2.3 ~ 3.5 (L – B) Ω 3.4 ~ 4.0 (L – B) Ω 360 ~ 540 (P – B) 800 ~ 1,200 (B – O) 20 Fuse 50hp A 2-9 80hp 33 (1.
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SPEC MAINTENANCE SPECIFICATIONS E DIMENSION Item L6 L7 H4 H9 H12 W5 A1 A2 A3 T1 *1: For *2: Unit S L X S L, X S L X S L, X S L X S L, X S L, X mm (in) mm (in) Model 60, 70 hp 868 (34.2) 50 hp — 918 (36.1) — — 75, 80, 90 hp — 968 (38.1) 1,081 (42.6) 403 (15.9) — 457 (18.0) — 411 (16.2) mm (in) — mm (in) — — 400 (15.7) 520 (20.5) 648 (25.5) 719 (28.3) 647 (25.5) — 730 (28.7) — 203 (8.0) 706 (27.8) mm (in) — 204 (8.0) — mm (in) degree degree — degree — 135 (5.3) 205 (8.1) 264 (10.
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SPEC MAINTENANCE SPECIFICATIONS Unit B1 B2 B3 B4 B5 B6 B7 B8 B9 D1 D2 D4 S L, X mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) E Model 50 hp 60 hp 125.4 (4.9) 254 (10.0) 163.5 (6.4) 50.8 (2.0) 180 (7.1) 329 (13.0) 351 (13.8) 138.1 (5.4) 203.2 (8.0) 18.5 (0.7) 13 (0.5) 55.5 (2.2) 12 (0.
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SPEC TIGHTENING TORQUE E C33000-0 TIGHTENING TORQUE Parts to be tightened Q’ty Part Thread name size 50, 60, 75, 80, 70 hp 90 hp Tightening torque Nm m • kg ft • lb Remarks Pinion nut Lower case mounting Propeller Tiller handle mounting Handle bracket mounting — 6 Bolt M8 — 14 — 14 14 Bolt M6 16 — Bolt M8 — 18 Bolt M6 M14 M20 M8 M8 M12 M10 M22 M8 M8 M8 M8 8 Nut — Nut M12 1 — 75 7.5 54 Nut Bolt Nut Nut Nut M16 M10 M16 M10 M10 1 5 1 1 2 1 5 1 1 2 95 40 35 38 38 9.5 4.
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TIGHTENING TORQUE/ GENERAL TORQUE SPECIFICATIONS SPEC Parts to be tightened Q’ty Part Thread name size 50, 60, 75, 80, 70 hp 90 hp E Tightening torque Nm m • kg ft • lb Remarks POWER TRIM AND TILT: Tilt cylinder end screw Screw — 1 Trim cylinder end screw Screw — 2 Fluid-level plug Bolt — 1 Lock nut Nut — 6 Valve spring mounting Screw — 2 Valve lock screw Screw — 1 Bolt M6 3 Manual valve Screw — 1 Main valve Screw — 2 Gear pump mounting Nut (A) 8 mm 10 mm 12 mm 14
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INSP ADJ E CHAPTER 3 PERIODIC INSPECTION AND ADJUSTMENT PERIODIC SERVICE ........................................................................................ 3-1 MAINTENANCE SCHEDULE ................................................................... 3-1 ANODE...................................................................................................... 3-1 BATTERY .................................................................................................. 3-2 CARBURETOR .................
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INSP ADJ PERIODIC SERVICE E D30000-1* PERIODIC SERVICE MAINTENANCE SCHEDULE The following chart may be taken as a helpful guide to the intervals between maintenance procedures.
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INSP ADJ PERIODIC SERVICE E D31305-0* BATTERY WARNING Battery electrolyte is dangerous; it contains 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. ● Wear protective eye gear when handling or working near batteries. Antidote (EXTERNAL): ● SKIN - Wash with water. ● EYES - Flush with water for 15 minutes and get immediate medical attention.
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INSP ADJ PERIODIC SERVICE E D31600-1 CARBURETOR 1. Check the fuel passages and air passages for fouling or clogging. Clean fouled parts with suitable cleaning solvent and blow out clogged passages with compressed air. WARNING Protect your eyes with suitable safety glasses or safety goggles when using compressed air. 2. Check the needle-valve for wear and replace it if worn. D31902-1* CARBURETOR LINK ADJUSTMENT (50, 60, 70 hp) 1. Loosen the idle adjust screw and fully close the throttle valve. 2.
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INSP ADJ PERIODIC SERVICE E (75, 80, 90 hp) 1. Loosen the idle adjust screw and fully close the throttle valve. 2. Loosen the throttle lever securing screws of upper and lower carburetors by turning clockwise. 3. While lightly pushing the throttle lever of the middle carburetor in the direction of the arrow (full-closed), tighten the throttle lever securing screw of the upper and lower carburetors by turning counterclockwise.
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INSP ADJ PERIODIC SERVICE E D32900-0 GEAR OIL 1. Drain the gear oil thoroughly and pour in new oil. 2. Check for water or metallic sediment in the drained oil. NOTE: If the gear oil becomes “milky”, check the gear case oil seals and shift boot for water entry. D33000-0* IDLE-SPEED 1. Turn the pilot screw until it is lightly seated. 2. Turn the pilot screw outward to the specified setting.
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INSP ADJ PERIODIC SERVICE E D33304-0* IGNITION TIMING ADJUSTMENT TIMING PLATE POSITION ADJUSTMENT If the timing plate is moved even a little during inspection or repair operation, it should be set in the following way: This adjustment must be made before adjusting the ignition timing. 1. Remove the spark plugs from the cylinders. 2. Install a dial-gauge in the spark-plug hole of No. 1 cylinder. NOTE: For easy timing-plate adjustment, it is advisable to remove the spark plugs from all the cylinders. 3.
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INSP ADJ PERIODIC SERVICE THROTTLE SENSOR CONTROL LINK ADJUSTMENT 1. Adjust the lengths of the throttle sensor control link and throttle cam control link to specifications. 50, 60, 70 hp a E b Throttle sensor control link length a: 50, 60, 70 hp: 120 ± 0.5 mm (4.72 ± 0.02 in) 75, 80, 90 hp: 93.5 ± 0.5 mm (3.68 ± 0.02 in) Throttle cam link length b: 50, 60, 70 hp: 95 mm (3.74 in) 75, 80, 90 hp: 120.5 mm (4.74 in) 50, 60, 70 hp 2.
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INSP ADJ PERIODIC SERVICE E 1 2 3 4 Timing indicator Full-advance indication (75, 80 hp) Full-advance indication (90 hp) Full-advance adjusting screw IGNITION TIMING ADJUSTMENT CAUTION: When checking ignition timing using a timing light, be sure to replace the propeller with the specified test propeller, and make tests with the machine placed in a test tank. NOTE: Before adjusting, be sure to warm up the engine. 1. Attach the timing light and tachometer to the No. 1 cylinder high tension code. 2.
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INSP ADJ PERIODIC SERVICE E 3. While keeping the stopper in contact with the full-advance adjusting screw, measure the full-retard ignition timing with the timing light. If the timing is out of specification, adjust it by turning the full-advance adjusting screw. NOTE: When measuring the full-advance ignition timing, keep the specified engine speed.
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INSP ADJ PERIODIC SERVICE E D34000-0* OIL INJECTION PUMP OPERATIONAL TEST 1. Start the engine and set the idling speed at 1,500 rpm by adjusting the throttle-stop lever. CAUTION: Use only oil-mixed fuel (50:1) as malfunction or engine seizure may otherwise result. 2. Remove the oil-pump link-rod and fix the oil-pump lever in the full-throttle position. 3. Measure the oil discharge from each port for three minutes using a measuring cylinder graduated in steps of at least 0.
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INSP ADJ PERIODIC SERVICE E D33900-0* CHECKING THE OIL LEVEL WARNING SYSTEM 1. Fill the oil-tank with oil. 2. Start the engine. 3. By letting the oil little by little out of the drain-hose, check that the oil-level warning system operates correctly. CAUTION: Do not allow the engine to operate without oil even briefly for this will cause malfunction or engine seizure. 50, 60, 70 hp Oil level Speed Warning warning drop buzzer lamp function Case Oil level 1 More than 770 cm3 (0.
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INSP ADJ PERIODIC SERVICE E D34300-1 OIL PUMP LINK ADJUSTMENT 1. Fully-open the carburetor throttle valve. 2. Set the oil-pump lever 1 mm off fullopen side stopper. With the lever in this position, adjust the length of the rod connecting the oil-pump to the carburetor and tighten the locknut. 3. Install the connecting-rod. 4. By operating the carburetor, check that the throttle-valve opens fully. D34600-0 POWER TRIM AND TILT FLUID (PTT model) 1. Tilt-up the motor and lock it with the tiltlock lever. 2.
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INSP ADJ PERIODIC SERVICE E D34900-0 PROPELLER 1. Check the blades for wear, damage or cavitation erosion. 2. Check the spline for wear and damage. D35000-0* SPARK PLUG 1. Check the electrode 1 condition and state of wear, note the insulator 2 color and the electrode gap. Normal condition is a medium to light tan color. Distinctly different color → Check the engine condition.
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INSP ADJ PERIODIC SERVICE E 4. When installing the spark plug, clean the gasket surface, wipe off any grime that may be on the surface of the plug and screw in the spark plug to the correct torque. T. Tightening torque: 25 Nm (2.5 m • kg, 18 ft • lb) R. NOTE: If a torque wrench is not available, a good estimate of the correct torque is a further 1/4 to 1/2 turns b on finger-tightened a spark plug. GREASING POINTS 1.
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FUEL E CHAPTER 4 FUEL SYSTEM FUEL SYSTEM ................................................................................................ 4-1 EXPLODED DIAGRAM ............................................................................. 4-1 FUEL LINE................................................................................................. 4-2 REMOVAL................................................................................................. 4-3 CLEANING AND INSPECTION .........................
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FUEL FUEL SYSTEM E E20000-1 FUEL SYSTEM EXPLODED DIAGRAM 1 2 3 4 5 6 7 Carburetor Electrothermal valve* Fuel pump assembly Fuel filter assembly Fuel joint Priming pump Fuel meter assembly 8 Fuel tank cap 9 Fuel tank * Except for C60ER, C60TR, C75TR 4-1
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FUEL FUEL SYSTEM E D22500-0 FUEL LINE Check that the fuel line is correctly installed.
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FUEL FUEL SYSTEM E REMOVAL WARNING 1. Fire prevention Gasoline (petrol) is highly flammable. Petroleum vapour is explosive if ignited. Do not smoke while handling and keep it away from heat, sparks and open flames. 2. Ventilation Petroleum vapour is heavier than air and if inhaled in large quantities will not support life. Engine exhaust gases are harmful to breathe. When test-running an engine indoors, maintain good ventilation. 3.
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FUEL FUEL SYSTEM E E21020-0 FUEL METER COMPLETE 1. Using a soft brush and solvent, clean the strainer on the end of the suction pipe and blow-dry it with compressed air. 2. Visually inspect the strainer for damage and replace the fuel meter complete if required. 3. Inspect the fuel meter components for cracks and replace the fuel meter complete if required. 4.
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FUEL FUEL SYSTEM E 3. Using a soft brush and solvent, clean the filter element thoroughly. Inspect the filter element for breakage or distortion and replace if required. 4. Using a soft brush and solvent, clean the filter-cup thoroughly. Inspect the filter-cup for cracks or thread damage and replace if required. 5. Place the O-ring on the filter body, install the element and screw in the filter cup. E21050-0 FUEL JOINTS 1. Inspect the fuel joints for leaks and cracks and replace as required.
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FUEL CARBURETOR E E31001-1 CARBURETOR EXPLODED DIAGRAM (Except for C60ER, C60TR, C75TR) 1 2 3 4 5 6 7 Pilot screw Needle valve Pilot jet Main nozzle Main jet Float Drain screw 8 9 0 A B C Float chamber Throttle stop screw Collar Electrothermal valve Valve Diaphragm 4-6
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FUEL CARBURETOR E EXPLODED DIAGRAM (For C60ER, C60TR, C75TR) 1 2 3 4 5 6 7 8 9 0 Pilot screw Needle valve Pilot jet Main nozzle Main jet Float Drain screw Float chamber Throttle stop screw Collar 4-7
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FUEL CARBURETOR E REMOVAL AND DISASSEMBLY WARNING At this step, ensure there is no spillage of gasoline on removing the connections. 1. Remove the silencer cover, disconnect the fuel hose, then remove the carburetor. * Except for C60ER, C60TR, C75TR 2. Referring to the diagram, use a screwdriver to disassemble the carburetor. 3. Using solvent, clean the components thoroughly and blow-dry them with compressed air.
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FUEL CARBURETOR E E32000-1* INSPECTION CARBURETOR BODY 1. Inspect the carburetor body for cracks or clogging of the passages. NEEDLE VALVE 1. Inspect the needle valve for free movement and wear and replace if required. PILOT SCREW 1. Inspect the pilot screw for wear and replace if required. COLLAR 1. Inspect the collar at the end of the accelerator-arm for wear and replace if required. FLOAT 1. Visually inspect the float for damage or cracks and replace if required. 2. Measure the float height a.
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FUEL CARBURETOR E Float height a [Stamped mark]: 62F00: 15.0 ± 1.0 mm (0.59 ± 0.04 in) 6H20A, 6H30A, 6H007, 6H107: 14.0 ± 1.0 mm (0.55 ± 0.04 in) 6H210: 14.0 ± 2.0 mm (0.55 ± 0.08 in) 6H015: 19.5 ± 3.0 mm (0.77 ± 0.12 in) E21060-0 ENRICHING FUEL PUMP 1. Using a screwdriver, disassemble the fuel pump. 2. Visually inspect the pump body for cracks and replace if required. 3. Inspect the valves for cracks or distortion and replace if required. 4.
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FUEL CARBURETOR E NOTE: When measuring the resistance of 10 Ω or less using the digital tester, the correct measurement cannot be obtained. Refer to “Lower resistance measurement” (page 815). 3. Check the piston valve height. If the piston valve height is not different from a to b, replace the electrothermal valve. a) Measure the piston valve height a. b) Connect the wire leads to a 12V battery. c) Measure the piston valve height b after several minutes. d) Compare the valve height a with b. ASSEMBLY 1.
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FUEL CARBURETOR E 6. Install the needle-valve on the float, attach the float to the carburetor body with the float-pin and tighten the screw. 7. Install a new O-ring to the float-chamber, install it to the carburetor body and secure with the screws. 8. Install the plate with new packing and secure with the screws. 9. Install the pilot-screw with its spring, screw it in until seated then screw it out the specified number of turns.
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FUEL CARBURETOR E E34004-1 INSTALLATION 1. Install the carburetors and plate with new gaskets. 1 Idle adjust screw 2 Throttle lever 3 Throttle lever securing screw 2. Connect the fuel hoses to the carburetors and fit the hose-clips over the recesses to ensure leak-proof connections. 3. Connect the electrothermal valve leads. 4. Connect the oil-pump link-rod to the carburetor and oil-injection pump. 5. Install the silencer cover and tighten the bolt to the specified torque. T. R.
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FUEL OIL-INJECTION SYSTEM OIL-INJECTION SYSTEM (Oil injection model) EXPLODED DIAGRAM 1 2 3 4 5 6 7 Oil level sensor Oil strainer Strainer cover gasket Oil injection pump assembly Check valve Oil tank Special washer 8 Oil tank cap assembly 9 Hook 0 Filler tube 4-14 E
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FUEL 1 2 3 4 5 6 7 OIL-INJECTION SYSTEM Check valve Oil injection pump assembly Drain screw Oil tank Strainer cover gasket Oil strainer Oil lever sensor 8 9 0 A Special washer Oil tank cap assembly Hook Filler tube 4-15 E
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FUEL OIL-INJECTION SYSTEM E REMOVAL 1. Drain the oil from the oil-tank and remove the carburetor. 2. Disconnect the hoses and remove the oil-injection system. E42001-0* CLEANING AND INSPECTION OIL-TANK 1. Using solvent, clean the oil-tank. 2. Drain the solvent and dry the tank. 3. Inspect the oil-tank for cracks and replace it if required. OIL-LEVER SENSOR Refer to “OIL-LEVEL SENSOR” section in chapter 8. OIL-HOSES 1. Inspect the oil-hoses for damage or cracks and replace them if required.
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FUEL OIL-INJECTION SYSTEM E 4. Assemble the oil-tank and install it. 5. Connect the oil delivery-hoses to the intake manifolds and tighten the clips on the hoses. 6. Lead the wire of the oil-level sensor to the port side of the engine and connect the cores. 7. Bleed the air from the lines. CAUTION: After reinstalling the oil injection pump, be sure to bleed the pump.
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POWR E CHAPTER 5 POWER UNIT EXPLODED DIAGRAM ................................................................................... 5-1 PREPARATION FOR OVERHAUL .................................................................. 5-3 REMOVAL ....................................................................................................... 5-3 DISASSEMBLY ............................................................................................... 5-5 INSPECTION ..........................................
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POWR ASSEMBLY AND ADJUSTMENT ................................................................ 5-14 BEARING, OIL SEAL AND O-RING ....................................................... 5-14 PISTON AND PISTON RING.................................................................. 5-14 SMALL END BEARINGS AND PISTON ASSEMBLY............................ 5-15 CONNECTING ROD BIG END BEARING ASSEMBLY (75, 80, 90 hp)........................................................................................
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POWR EXPLODED DIAGRAM E G20000-0 EXPLODED DIAGRAM 1 2 3 4 5 6 7 Cylinder head cover Head cover gasket Cylinder head Cylinder head gasket Thermostat Thermostat cover Exhaust cover gasket 8 9 0 A B C D Exhaust inner cover Exhaust outer cover Piston pin clip Piston pin Drive gear Bearing Oil seal 5-1 E F G H I J O-ring Oil seal housing Intake manifold Valve seat packing Reed valve plate Reed valve assembly
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POWR 1 2 3 4 5 6 7 8 9 EXPLODED DIAGRAM Thermostat cover Thermostat Thermo sensor Cylinder head cover Head cover gasket Cylinder head Cylinder head gasket Exhaust cover gasket Exhaust inner cover 0 A B C D E F G H Exhaust outer cover Piston pin clip Piston pin Bearing Drive gear Circlip Oil seal O-ring Oil seal housing E I J K L Intake manifold Valve seat packing Reed valve plate Reed valve assembly *B90TR/90AETO 5-2
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POWR PREPARATION FOR OVERHAUL/REMOVAL E G30000-0 PREPARATION FOR OVERHAUL 1. Clean all dirt, mud, dust and foreign material from the engine before the engine is removed and disassembled. 2. To ensure that you can perform the work cleanly and efficiently, check that you have the proper tools and cleaning equipment before commencing engine removal and disassembly. 3. During engine disassembly, as parts are disassembled, clean them and place them in trays in their order of disassembly.
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POWR REMOVAL E 3. Remove the throttle cable and the shift mechanism. 1 Throttle cable joint by removing the hair pin 2 Shift rod bracket bolt 3 Shift cable joint and bushing by removing the hair pin 4. Remove the front and rear aprons. 5. Remove the power head installation bolts, and then remove the power head from the upper casing. 50, 60, 70 hp ..................................8 bolts 75, 80, 90 hp ................................
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POWR DISASSEMBLY E G50003-0 DISASSEMBLY Referring to the exploded diagram, remove the following parts. 1. Cylinder head 2. Intake manifold 3. Exhaust cover and thermostat cover. 4. Oil seal housing Using the oil seal remover, remove the oil seal one by one from the housing. 5. Crankcase Remove the two dowel pins. 6. Crankshaft and connecting rod. (50, 60, 70 hp) 7. Connecting rod caps, needle bearings and crankshaft. (75, 80, 90 hp) 8. Piston and piston pin 9.
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POWR INSPECTION E G61000-0* INSPECTION CYLINDER HEAD CLEANING 1. Using a gasket scraper, remove all traces of gasket material from the cylinder head. 2. Using a round scraper, remove carbon deposits from the combustion chamber. CAUTION: Do not scratch the surfaces of the cylinder and combustion chamber. 3. Using a soft brush, clean the water jacket. INSPECTION 1. Using a precision straight-edge and thickness gauge, measure the surface contacting the cylinder block for warping. Å Warpage limit: 0.
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POWR INSPECTION E G61501-0* CYLINDER BLOCK CLEANING 1. Using a gasket-scraper, remove all traces of gasket material from the cylinder-block surface. 2. Using a soft brush and solvent, clean the cylinder-block. INSPECTION 1. Visually inspect the cylinder sleeves for cracks and scratches. If cracks are found, replace the cylinder block. If scratches are found, check the degree of out-of-round, and then hone the cylinder or re-bore it if necessary. 2.
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POWR INSPECTION E G62001-0* PISTON CLEANING 1. Using a gasket-scraper, remove the carbon from the piston top. 2. Using a broken ring, clean the ring grooves. 3. Using a soft brush and solvent, thoroughly clean the piston. If necessary, use 600 ~ 800 grit wet-or-dry sandpaper to remove score marks or varnish. INSPECTION 1. Using a micrometer, measure the piston diameter at right angles to the piston-pin center line, 10 mm (0.4 in) above the bottom edge. Piston diameter: Standard: 50, 60, 70 hp:71.
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POWR INSPECTION E G62501-0* PISTON RING INSPECTION 1. Using a thickness gauge, measure the clearance between the piston ring and the groove land. Side clearance: 50, 60, 70 hp: Top/2nd ring: 0.03 ~ 0.07 mm (0.0012 ~ 0.0028 in) 75, 80, 90 hp: Top/2nd ring: 0.03 ~ 0.06 mm (0.0012 ~ 0.0024 in) If the clearance is not within the specifications, replace the piston. Å Top/2nd: Keystone type ı Piston marked with “W” (50, 60, 70 hp) Å ı 2. Insert the piston ring into the cylinder.
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POWR INSPECTION E G63000-0 PISTON PIN AND SMALL END BEARING CLEANING 1. Use a soft brush and solvent to clean the parts. INSPECTION 1. Visually inspect for surface defects, breakage, scratches and pitting. If it is decided to replace the small end bearings, replace them all. G63500-0* CRANKSHAFT INSPECTION 1. Place the crankshaft on a crankshaftaligner or on V-blocks. 2. Using a dial gauge, measure the connecting-rod axial play. Maximum axial play: 2.0 mm (0.
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POWR INSPECTION E 4. Using dial gauges, measure the deflection. Maximum deflection: 50, 60, 70 hp: 0.03 mm (0.0012 in) 75, 80, 90 hp: 0.05 mm (0.0020 in) If the deflection is greater than the specified maximum, correct the alignment by use of a copper hammer and a wedge. If the deflection is greater than the specified maximum, replace the crankshaft assembly. G64000-0* REED VALVE INSPECTION 1. Visually inspect for warping of the reed valve. If warped, measure the distortion with feeler gauges.
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POWR INSPECTION E G64500-0* THERMOSTAT CLEANING 1. Using a soft brush and water, remove all traces of salt, dirt or corrosion. INSPECTION 1. Visually inspect the thermostat for damage. If the thermostat is damaged or if it opens when cold, replace it. 2. Immerse the thermostat in water and heat the water gradually. Check the valve opening temperature and the valve lift. Water temperature Valve lift Below 48 ~ 52˚C (118 ~ 126˚F) 0 mm Above 60˚C (140˚F) Minimum 3 mm (0.
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POWR INSPECTION E G65500-0 DRIVE GEAR (OIL INJECTION PUMP DRIVE) INSPECTION 1. Visually inspect drive gear teeth for cracks, pitting or wear and replace the gear if any are found. DRIVEN GEAR (OIL INJECTION PUMP DRIVE) INSPECTION 1. Visually inspect driven gear teeth for cracks, pitting or wear and replace the gear if any are found.
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POWR ASSEMBLY AND ADJUSTMENT E G71000-1 ASSEMBLY AND ADJUSTMENT BEARING, OIL SEAL AND O-RING 1. Press in the new bearing. CAUTION: When reassembling the lower crank bearing and/or the oil-pump drive gear, the tapered side of the drive gear and the sealcap side of the bearing should be installed towards the crank side as shown in the illustration. 75, 80, 90 hp: Install the circlip 1 Circlip 2 Oil injection pump drive gear 3 Crank lower bearing 2. Install the new oil seal in the needle bearing.
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POWR ASSEMBLY AND ADJUSTMENT E G73000-0* SMALL END BEARINGS AND PISTON ASSEMBLY 1. Count the small-end bearing needles. Number of needles per small end: 28-pcs. CAUTION: Do not use a mixture of new and used bearing needles in the same small end. 2. Using the special service tool, install the bearings in the connecting-rod small end and place washers on both sides.
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POWR ASSEMBLY AND ADJUSTMENT E G78000-0* CONNECTING ROD BIG END BEARING ASSEMBLY (75, 80, 90 hp) 1. Install the piston. Align the ring ends with locating pins in the grooves and using the piston slider, push the piston into the cylinder. Piston slider: YU-33294/90890-06530 NOTE: The “UP” mark on the piston crown should be on the flywheel side. Be sure to apply oil to the piston and cylinder wall. 2.
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POWR ASSEMBLY AND ADJUSTMENT E NOTE: Replace the cap bolts each time the connecting rod is disassembled. T. R. Connecting rod big end: (75, 80, 90 hp) 1st step: 12 Nm (1.2 m • kg, 8.7 ft • lb) 2nd step: 35 Nm (3.5 m • kg, 25 ft • lb) G79000-1* OIL SEAL HOUSING 1. Press-fit the oil seals one by one. CAUTION: When press-fitting the oil seal, be sure that if faces in the correct direction. 2. Fit the new O-ring in the grooves in the oil seal housing outer surfaces. 3.
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POWR ASSEMBLY AND ADJUSTMENT E 2. Lift the crank assembly a little in order to install a washer on the lower crankcase and align each location-pin of the bearings and labyrinth-seals with each cut on the cylinder-block. Then, fit the crank assembly in place. 3. Film-coat the cylinder-block mating surface with Gasket Maker or equivalent. 4. Install the dowel-pins. 5. Match the cylinder-block and tighten the bolts to the specified torque in sequence and in two steps. T. R.
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POWR ASSEMBLY AND ADJUSTMENT E G75000-0* Å CYLINDER HEAD AND EXHAUST COVER 1. Install the gaskets cylinder-head cover and exhaust cover. 2. Tighten the bolts to the specified torque in sequence and in two steps. Å Tightening sequence T. Å R. Cylinder head (50, 60, 70 hp): 1st step: 15 Nm (1.5 m • kg, 11 ft • lb) 2nd step: 32 Nm (3.2 m • kg, 23 ft • lb) Cylinder-head (75, 80, 90 hp): 1st step: 15 Nm (1.5 m • kg, 11 ft • lb) 2nd step: 30 Nm (3.
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POWR ASSEMBLY AND ADJUSTMENT E G75500-0 DRAINAGE HOSE 1. Fit two clips around the drainage hose. 2. Connect one end of the hose to the delivery side of the check valve and the other end to the joint on the intake side and lock with the clips. G76000-0* INTAKE MANIFOLD 1. Install the reed-valve assembly and the gasket reed-valve plate to the intake manifold. 2. Install the manifold assembly to the crankcase and tighten the bolts to the specified torque in sequence and in two steps. T. R.
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POWR INSTALLATION E G8000-0* INSTALLATION 1. Install locating pins in position on the exhaust guide. 2. Align the locating-pin holes on the gasket with dowel pins and place the gasket on the bottom cowling. 3. Install the power head onto the bottom cowling, tighten the mounting-bolts to the specified torque. T. Mounting bolts: 21 Nm (2.1 m • kg, 15 ft • lb) R. 4. Connect the hoses, cables and wires. 5. Install the apron. 6.
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LOWR E CHAPTER 6 LOWER UNIT EXPLODED DIAGRAM (FOR 50GETO, C60ER, C60TR/60FET (OCEANIA), C75TR, 90AEHD, 90AED, C90TR/90AET).................................................................. 6-1 EXPLODED DIAGRAM (EXCEPT FOR 50GETO, C60ER, C60TR/60FET (OCEANIA), C75TR, 90AEHD, 90AED, C90TR/90AET).................................................................. 6-2 PREPARATION FOR REMOVAL .................................................................... 6-3 DISASSEMBLY ....................................
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LOWR EXPLODED DIAGRAM E EXPLODED DIAGRAM (FOR 50GETO, C60ER, C60TR/60FET (OCEANIA), C75TR, 90AEHD, 90AED, C90TR/90AET) 1 2 3 4 5 6 7 8 9 0 Water pump housing Impeller Cartridge outer plate Cartridge outer plate gasket Oil-seal housing Water pump gasket Drive shaft Woodruff key Drive shaft sleeve Needle bearing A B C D E F G H I J Shifter Shift slide Forward gear Clutch dog Cross pin Propeller shaft Reverse gear O-ring Bearing Bearing housing 6-1 K L M N O P Q R S Needle bearing Claw washer Ring nut
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LOWR EXPLODED DIAGRAM E EXPLODED DIAGRAM (EXCEPT FOR 50GETO, C60ER, C60TR/60FET (OCEANIA), C75TR, 90AEHD, 90AED, C90TR/90AET) 1 2 3 4 5 6 7 8 9 0 Water pump housing Impeller Cartridge outer plate Cartridge outer plate gasket Oil-seal housing Water pump gasket Drive shaft Woodruff key Drive shaft sleeve Needle bearing A B C D E F G H I J Shifter Shift slide Forward gear Clutch dog Cross pin Propeller shaft Reverse gear O-ring Bearing Bearing housing 6-2 K L M N O P Q R Needle bearing Claw washer Rin
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LOWR PREPARATION FOR REMOVAL/DISASSEMBLY E 120001-0* PREPARATION FOR REMOVAL 1. Remove the nut, washer, propeller and spacer from the propeller shaft. 2. Drain the gear oil by removing the plugs from the oil-filling hole and the oil-level hole. Be sure to remove the oil filling plug first. 3. Set the shift lever into neutral position. 4. Tilt up the lower unit and lock it with the tilt lock lever. 5. Remove the trim tab. Before removing it, put a mark indicating its position on the anticavitation plate.
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LOWR DISASSEMBLY E 4) Shift-rod 5) Ring-nut 1 and claw-washer 2 Å Ring nut wrench: YB-34447................................ 3 90890-06511........................... 4 Extension (ring nut wrench): 90890-06513........................... 5 Å For USA and Canada ı Except for USA and Canada ı NOTE: To remove the ring-nut: straighten the lobe of the claw-washer by using a screwdriver, then attach and turn it in the direction of the off mark using the special service tool.
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LOWR DISASSEMBLY E 7) Propeller shaft (For 50GETO, C60ER, C60TR/60FET (Oceania), C75TR, 90AEHD, 90AED, C90TR/90AET) 1 Clutch dog 2 Cross pin 3 Cross pin ring 7) Propeller shaft (Except for 50GETO, C60ER, C60TR/ 60FET (Oceania), C75TR, 90AEHD, 90AED, C90TR/90AET) 1 Clutch dog 2 Cross pin 3 Cross pin ring 8) Shift slide (Except for 50GETO, C60ER, C60TR/ 60FET (Oceania), C75TR, 90AEHD, 90AED, C90TR/90AET) Using a slotted screwdriver, remove the shift slide balls 1 from the neutral position and pull out the
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LOWR DISASSEMBLY E 10) Oil seals and needle bearing Å Slide hammer set: YB-6096.................................. 1 Stopper guide plate: 90890-06501........................... 2 Bearing puller: 90890-06535........................... 3 Stopper guide stand: 90890-06538........................... 4 Driver rod: YB-6071/90890-06602 ........... 5 Needle bearing attachment: YB-6153/90890-06612 ...........
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LOWR Å DISASSEMBLY E 12) Forward gear bearing outer race 1 Slide hammer set: YB-6096.................................. 1 Bearing outer race puller: 90890-06523........................... 2 Å For USA and Canada ı Except for USA and Canada ı Å NOTE: For ease of reassembly and adjustment, keep shim packs in their groups as removed. 2 13) Drive shaft bearing outer race 1 Slide hammer set: YB-6096.................................. 1 Stopper guide plate: 90890-06501...........................
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LOWR DISASSEMBLY E 16) Reverse gear bearing and forward gear bearing 1 Bearing separator: YB-6219.................................. 1 90890-06534........................... 2 2 NOTE: Separate the bearing from the gear using special service tool and hydraulic press.
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LOWR INSPECTION E 151001-0 INSPECTION GEAR CASE 1. Using a soft brush and solvent, clean the case and water passage. 2. Visually inspect the gear case for cracks, corrosion or distortion. If any crack or excessive corrosion is found, replace the gear case. 3. Check the water inlet cover and water passage for clogging. 151500-0 BEARING HOUSING 1. Using a soft brush and solvent, clean the housing thoroughly. 2. Visually inspect the housing for cracks and corrosion.
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LOWR INSPECTION E 153000-0 WATER PUMP HOUSING 1. Inspect the water pump housing for signs of twisting or scratches of the inner cartridge. If twisted or scratched excessively, replace the housing. 2. During the above operation, inspect the impeller plate and replace this if damaged. 153500-0 IMPELLER 1. Visually inspect the impeller for cracks, distortion or burning. If any damage is found, replace the impeller. 154000-0 OIL-SEAL HOUSING (Water pump housing) 1.
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LOWR INSPECTION E 15500-0 CLUTCH DOG AND COMPONENTS 1. Visually inspect the clutch dog, looking particularly for rounding of the dog edge, cracks and other signs of damage or wear. If the dog is excessively rounded, inspect the mating gear, and replace both if necessary. 156000-0 DRIVE AND PROPELLER SHAFT 1. Visually inspect the shafts, looking for grooved wear on the surface in contact with the bearings and oil-seals and checking for wear on the splines. Replace if worn or damaged.
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LOWR ASSEMBLY AND ADJUSTMENT E 161009-0* ASSEMBLY AND ADJUSTMENT PROPELLER-SHAFT HOUSING 1. Install the thrust washer and press-fit a ball-bearing to the reverse gear. Å 50GETO Å 2. Install a needle-bearing and oil seals, and then press-fit the reverse gear complete into the bearing housing. 1 NOTE: Install the needle bearing with its manufacture's marks or numbers facing outward. 2 ı Depth a: 50 hp : 20.7 mm (1.06 in) 60 ~ 90 hp: 25.5 mm (1.00 in) 1 Drive rod: YB-6071/90890-06604 ...........
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LOWR ASSEMBLY AND ADJUSTMENT E GEAR CASE Å 1. Install a new needle-bearing in position. NOTE: The needle bearing should be installed with the mark facing the flange side of attachment. Driver rod: YB-6071.................................. 1 Needle bearing depth stop: YB-34473................................ 2 Needle bearing attachment: YB-6155.................................. 3 Driver rod: 90890-06602........................... 4 Bearing depth plate: 90890-06603...........................
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LOWR ASSEMBLY AND ADJUSTMENT E 4. Place the forward-gear shim-pack 1 in position and install the forward-gear outer race 2 on the shim-pack. 3 Driver rod: YB-6071/90890-06605 ........... 3 Bearing outer race attachment: 50 hp: 90890-06622 ............... 4 60 ~ 90 hp: YB-6276B/90890-06621...... 4 4 5. Install the bearing inner race to the forward-gear, then place the forward-gear complete onto the outer race. 1 Bearing inner race attachment: 50 hp: 90890-06640 ...............
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LOWR ASSEMBLY AND ADJUSTMENT E 7. Assemble the propeller shaft. (Except for 50GETO, C60ER, C60TR/ 60FET (Oceania), C75TR, 90AEHD, 90AED, C90TR/90AET) 1) Insert the free shaft 1 into the shift slide 2. 2) Insert the two balls 3 and shifter 4 on the shift slide. NOTE: Grease the balls so that they will not come off easily from the shift slide, thus making your work easier.
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LOWR ASSEMBLY AND ADJUSTMENT E 8. Grease the lips of the oil-seals and insert the propeller shaft complete into the bearing housing. Then, place the bearing housing complete to the gear case. 9. Look into the gear case through the hole and align the shift rod hole in the gear case with the splined hole in the shift cam 1 and install the shift rod 2. (Except for 50GETO, C60ER, C60TR/ 60FET (Oceania), C75TR, 90AEHD, 90AED, C90TR/90AET) 10.
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LOWR SHIM SELECTION (FOR USA AND CANADA) E SHIM SELECTION NOTE: 1. When reassembling the lower unit with the original gear case and inner parts, shim selection is not required. 2. When replacing the gear case only, read the numeral preceded by “F, R, P” and adjust the shims according to the difference between numerals of the original gear-case and the new gear-case. 3. If the bearing(s) and/or gear(s) are replaced, carry out the shim selection.
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LOWR SHIM SELECTION (FOR USA AND CANADA) E Example: If P mark is “+5”, then M = 0.20 + (+5)/100 mm = 0.20 + 0.05 mm = 0.25 mm If P mark is “–3”, then M = 0.20 + (–3)/100 mm = 0.20 – 0.03 mm = 0.17 mm YB-34432-9 YB-34432-10 YB-34432-11 2. Assemble the shimming gauge with the drive shaft, bearing and shim(s) as shown in the illustration. YU-26900-8 YU-26900-9 NOTE: 1. Attach the adapter plate to the gauge base using 4 bolts with appropriate sizes. 2.
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LOWR SHIM SELECTION (FOR USA AND CANADA) E Forward gear shim NOTE: Find forward gear shim thickness (T1) by selecting shims until the specified measurement (M) with the special tool is obtained. 1. Find the specified measurement (M). Specified Measurement (M) = 1.69 mm + F/100 mm NOTE: 1. F is the deviation of the lower case dimension from standard. It is stamped on the trim tab mounting surface of the lower case in 0.01 mm units.
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LOWR SHIM SELECTION (FOR USA AND CANADA) E 3. Using a thickness gauge at the specified measurement (M) established above, check the fit between the shimming gauge and upper disc of the tool. Thickness gauge: YU-26900-8 YU-26900-9 4. If the thickness gauge at the M specification will not fit, then remove or add the shim(s) until the thickness gauge just fits between the tool surfaces. Available shim thicknesses: 0.10, 0.12, 0.15, 0.18, 0.30, 0.40 and 0.
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LOWR SHIM SELECTION (FOR USA AND CANADA) E Example: (60, 70 hp) If R mark is “+5”, then M = 1.00 – (+5)/100 mm = 1.00 – 0.05 mm = 0.95 mm If R mark is “–3”, then M = 1.00 – (–3)/100 mm = 1.00 + 0.03 mm = 1.03 mm Example: (75, 90 hp) If R mark is “+5”, then M =1.50 – (+5)/100 mm =1.50 – 0.05 mm =0.45 mm If R mark is “–3”, then M =1.50 – (–3)/100 mm =1.50 + 0.03 mm =1.53 mm 2.
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LOWR SHIM SELECTION (EXCEPT FOR USA AND CANADA) E EXCEPT FOR USA AND CANADA Pinion gear shim 1. Find pinion gear shim thickness (T3) by selecting shims until the specified measurement (M) with the special tool is obtained. 2. Install the pinion on the drive shaft and tighten the nut to the specified torque. T. R. Pinion nut: 50 hp: 75 Nm (7.5 m • kg, 54 ft • lb) 60 ~ 90 hp: 95 Nm (9.5 m • kg, 69 ft • lb) 3.
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LOWR SHIM SELECTION (EXCEPT FOR USA AND CANADA) E NOTE: ● Use a minimum number of shims to obtain the thickness equal or nearly equal to the calculation. ● Install the shims with the thicker one on the outer side. Forward gear shim 1. Find forward gear shim thickness (T1) by selecting shims until the specified measurement (M) with the special tool is obtained. 2. Using a digital caliper at the specified measurement (M) established above, measure the bearing height.
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LOWR SHIM SELECTION (EXCEPT FOR USA AND CANADA) E NOTE: ● Use a minimum number of shims to obtain the thickness equal or nearly equal to the calculation. ● Install the shims with the thicker one on the outer side. Reverse gear shim 1. Find reverse gear shim thickness (T2) by selecting shims until the specified measurement (M) with the special tool is obtained. NOTE: Be sure to remove the O-ring from under the thrust washer. 2.
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LOWR SHIM SELECTION E Example: If M is “28.60 mm” R is “–1”, then T2 = 28.60 – 28.00 + 1/100 = 0.61 Available shim thickness: 0.10, 0.12, 0.15, 0.18, 0.30, 0.40 and 0.50 mm NOTE: ● Use a minimum number of shims to obtain the thickness equal or nearly equal to the calculation. ● Install the shims with the thicker one on the outer side. 163015-0* MEASURING THE BACKLASH NOTE: ● Do not install the water pump components when measuring the backlash.
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LOWR SHIM SELECTION E Forward gear 1. Install a bearing housing puller (special service tool) in the bearing housing so that it engages with the center bolt of the propeller shaft. NOTE: Tighten the center bolt while turning the propeller shaft a few times clockwise. T. Center bolt: 5 Nm (0.5 m • kg, 3.6 ft • lb) R. Claw: YB-6207/90890-06503 50, 60, 70 hp: 90890-06502 Universal puller: YB-6117 Stopper guide plate: 90890-06501 Center bolt: 90890-06504 2.
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LOWR SHIM SELECTION E 60, 70 hp: Forward gear backlash Decrease or increase Less than 0.09 mm (0.004 in) Thickness of shim to be decreased (mm) = (0.19 – measurement) × 0.53 0.09 – 0.28 mm (0.004 – 0.011 in) Decrease or increase will be unnecessary More than 0.28 mm (0.011 in) Thickness of shim to be increased (mm) = (measurement – 0.19) × 0.53 Reverse gear 1. Install a propeller on the propeller shaft, with the front facing backward, fit the nut and tighten. T. Nut (propeller): 5 Nm (0.
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LOWR SHIM SELECTION E 75, 80, 90 hp: Reverse gear backlash Decrease or increase Less than 0.67 mm (0.026 in) Thickness of shim to be increased (mm) = (0.84 – measurement) × 0.60 0.67 – 1.00 mm (0.026 – 0.039 in) Decrease or increase will be unnecessary More than 1.00 mm (0.039 in) Thickness of shim to be decreased (mm) = (measurement – 0.84) × 0.60 1 164000-0 WATER PUMP INSTALLATION 1. Install a new oil seal in the oil-seal housing, and fit a new O-ring in the Oring groove.
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LOWR INSTALLATION E 170003-0* INSTALLATION 1. Check that the clutch dog shifts to “Forward”, “Neutral” and “Reverse” correctly by turning the shift rod, and shift into “Neutral”. Shift rod wrench: YB-6052 2. Align the mark on the shift lever with the arrow mark on the bottom cowling. 3. Grease the spline of the drive-shaft and the water-tube outer face, align the water-tube and drive-shaft, install the lower unit and tighten the bolts to the specified torque. T. R.
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LOWR INSTALLATION E 4. Install the trim tab on the gear case. Be sure to align the marks put on both of them when they were removed. Place the cap over the bolt hole. 5. Install the spacers, propeller, washer, and propeller nut over the propeller shaft. T. Propeller nut: 35 Nm (3.5 m • kg, 25 ft • lb) R. 6. Align the recess in the propeller nut with the hole in the propeller shaft and insert the cotter pin into the hole. Be sure to bend the cotter pin ends.
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LOWR INSTALLATION E 165000-0 Å LOWER UNIT LEAKAGE CHECK 1. Tighten the gear oil-drain screw and connect the tester to the oil-level hole. 2. Pump the tester, and apply a pressure of 100 kPa (1.0 kg/cm2, 14.2 psi). Then, place the gear case in the water tank. 3. Check that the pressure is held at 100 kPa (1.0 kg/cm2, 14.2 psi) for 10 seconds. ı CAUTION: Do not overpressurize. NOTE: If the pressure falls, leakage from the lower unit is unacceptable, requiring re-inspection of its component parts.
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BRKT E CHAPTER 7 BRACKET UNIT BRACKET UNIT............................................................................................... 7-1 EXPLODED DIAGRAM ............................................................................. 7-1 MANUAL HANDLE ............................................................................ 7-1 UPPER CASING ................................................................................. 7-2 BOTTOM COWLING.............................................................
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BRKT BRACKET UNIT E BRACKET UNIT EXPLODED DIAGRAM MANUAL HANDLE P60TH/60FEHTO*1, P75TH/75CEHTO, 90AEHD*2 1 2 3 4 5 Steering handle Bracket Main switch Engine stop switch Throttle cable 6 7 8 9 0 Link assembly Shift cable Cover Grip Battery cable 7-1 A B C D Main switch lead Extension wire lead PTT switch (PTT model) Steering friction (PTT model)
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BRKT BRACKET UNIT E K15000-0 UPPER CASING 50, 60, 70 hp 1 2 3 4 5 6 7 Exhaust guide Exhaust manifold Muffler Upper case Apron Seal Bottom cowling 7-2
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BRKT BRACKET UNIT E 75, 80, 90 hp 1 2 3 4 5 6 7 Exhaust guide Exhaust manifold Muffler Upper case Apron Seal Bottom cowling 7-3
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BRKT BRACKET UNIT E K-15300-0 BOTTOM COWLING 1 2 3 4 5 6 7 Power trim and tilt motor lead (PTT model) Trim sender lead (PTT model) Grommet Flushing kit (B90TR/90AETO) Clamp (PTT model) Bottom cowling fitting plate Shift actuator 7-4
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BRKT BRACKET UNIT E K-15600-0 BRACKET UNIT 1 2 3 4 5 6 7 8 Upper mount rubber cover Cap Upper mount rubber nut Screw Low mount rubber cover Ground lead Bolt Mount rubber housing 9 Lower mount rubber nut 0 Anode (PTT model) A Read wire (PTT model) 7-5
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BRKT BRACKET UNIT E BRACKET UNIT (Manual tilt model) 1 2 3 4 5 Tilt unit Tilt lever Clamp bracket spacer Lower shock mount pin Bushing 7-6
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BRKT BRACKET UNIT E K15900-0 BRACKET (Short transom) 1 2 3 4 5 6 7 8 9 Circlip Lower mounting housing Steering pivot shaft Bushing O-ring Bushing Grease nipple Ground lead Tilt rod (manual tilt model) 0 A B C D E F G H Clamp bracket nut Bolt (6 bolts) Clamp bracket bolt Washer Bushing Clamp bracket Trim sensor (PTT model) Circlip Pin 7-7 I Bushing J Power trim and tilt unit (PTT model) K Cotter pin L Tilt lock lever M Bushing N Washer O Spring P Collar
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BRKT BRACKET UNIT E K15900-0 BRACKET (Long transom) 1 2 3 4 5 6 7 8 9 Circlip Lower mounting housing Steering pivot shaft Bushing O-ring Bushing Grease nipple Ground lead Tilt rod (manual tilt model) 0 A B C D E F G H Clamp bracket nut Bolt (6 bolts) Clamp bracket bolt Washer Bushing Clamp bracket Trim sensor (PTT model) Circlip Pin 7-8 I Bushing J Power trim and tilt unit (PTT model) K Tilt lock lever L Bushing M Spring N Collar
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BRKT BRACKET UNIT E K20002-0 REMOVAL 1. Remove the power-head. 2. Remove the swivel-bracket from the upper casing. CAUTION: Lay the outboard motor on the floor to carry out this removal. DISASSEMBLY 1. Referring to the exploded diagram, disassemble the bracket unit. INSPECTION ANODE 1. Check anode and replace with new one when the size is less than 1/3 of original length. BRACKET 1. Inspect the bracket and replace them, if cracked. TRIM SENSOR 1. Check resistance of the new trim sensor.
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BRKT BRACKET UNIT E Trim sensor adjustment Fully tilt up the outboard motor. Loosen the two bolts securing the trim sensor until it moves slightly. WARNING Be sure to support the engine with the tilt support lever while loosening the bolts to prevent the engine from tilting down due to lack of oil pressure. Fully tilt down the outboard motor. Connect battery cables of the outboard motor to a battery and set the main switch to “ON”.
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BRKT HYDRAULIC TILT UNIT/ POWER TRIM AND TILT UNIT E HYDRAULIC TILT UNIT WARNING This cylinder is highly pressurized. Therefore, never overhaul or damage it. INSPECTION 1. Inspect the tilt cylinder assembly for scratches or corrosion. If any scratches are found, replace the tilt cylinder assembly. POWER TRIM AND TILT UNIT REMOVAL 1. Disconnect the leads from the relay in the bottom cowling. 2. Remove the tilt-rod, bolts and nut, and the clamp-bracket. 3.
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BRKT POWER TRIM AND TILT UNIT E K51000-0 EXPLODED DIAGRAM (Short transom [6H308]) 1 2 3 4 5 6 7 8 Reservoir body Reservoir plug Motor assembly Trim cylinder end screw Trim piston assembly Valve seat screw Main valve assembly Shuttle piston 9 0 A B C D E F Pipe Down relief valve seat Down relief spring Gear pump assembly Shaft connector Filter 2 Up relief valve lock screw Up relief spring 7-12 G H I J K L M N Up relief valve seat Filter 1 Manual valve seat Manual release spring Adapter Free piston
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BRKT 1 2 3 4 5 6 7 8 9 POWER TRIM AND TILT UNIT Power trim and tilt motor Gear pump Down-relief valve (48 kg/cm2) Main valve 2-way check valve Reservoir Up-relief valve (40 kg/cm2) Manual valve Tilt cylinder 0 Absorber valve (80 kg/cm2) A Free piston B Trim cylinder 7-13 E
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BRKT POWER TRIM AND TILT UNIT E K52002-0 DISASSEMBLY CAUTION: 1. Do not wipe components of the hydraulic system with rags or paper tissues, etc., as fibers entering the system will cause malfunction. 2. After removing the tilt-motor or oil-reservoir, do not depress the tilt-rod or trim-rod, since this may cause hydraulic fluid to be ejected from the port. 1. Turn the manual valve fully towards the manual position. 2. Remove the hydraulic-fluid level-plug and drain the hydraulic-fluid. 3.
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BRKT POWER TRIM AND TILT UNIT E 9. Using the special service tool, loosen the trim-cylinder end-screw and pull out the trim-piston and components. Cylinder end screw wrench: YB-6175-1A/90890-06542 10. Using the special service tool, loosen the tilt-cylinder end-screw and pull out the tile-piston and the free-piston. WARNING The free-piston can be removed easily by blowing compressed air into the drain-hole of the cylinder.
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BRKT POWER TRIM AND TILT UNIT E K53000-0 INSPECTION TILT-ROD AND TRIM-ROD 1. Clean these components using a soft brush and solvent and inspect them carefully. If there are light scratches on the surfaces, these may be polished off using fine wet-or-dry sandpaper (440 ~ 600 grit), but if there is excessive scratching, replace the components. 2. Clean all the parts thoroughly using a soft brush and solvent and dry them with compressed air. 3.
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BRKT POWER TRIM AND TILT UNIT E 2. Install the manual-valve in the body with new O-rings. 1 O-ring (fitted into the body) 2 Manual valve seat 3 Manual release spring (L = 6.0 mm, D = 11.5 mm) 4 Adapter 1 5 O-ring 6 Manual valve (left-handed thread) 7 Circlip T. Manual valve: 3 Nm (0.3 m • kg, 2.2 ft • lb) R. 3. Install a new O-ring on the shuttle-piston, insert the piston into the body, then install the main valves with new Orings. 1 2 3 4 5 O-ring Shuttle-piston O-ring O-ring Main valve T.
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BRKT POWER TRIM AND TILT UNIT E T. Locking bolt: 13 Nm (1.3 m • kg, 9.4 ft • lb) R. 5. Fit a new O-ring and the back-up ring to the trim-piston, fit new O-rings and a new oil-seal to the end-screw and install the complete trim-piston in the cylinder. Fill the cylinder with hydraulic fluid and install and tighten the end-screw to the specified torque. ATF (automatic transmission fluid) 1 O-ring 2 Back-up ring T. Trim cylinder end screw: 70 Nm (7.0 m • kg, 50 ft • lb) R.
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BRKT POWER TRIM AND TILT UNIT E 7. Fit a new O-ring and the back-up ring on the free-piston and install it into the cylinder. 1 O-ring 2 Back-up ring 8. Fit a new O-ring and the back-up ring to the tilt-piston and install it into the cylinder. Fill the cylinder with hydraulic fluid and tighten the end-screw to the specified torque. 1 O-ring 2 Back-up ring Cylinder end screw wrench: YB-6175-2B/90890-06544 T. Tilt cylinder end screw: 80 Nm (8.0 m • kg, 58 ft • lb) R. 9.
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BRKT POWER TRIM AND TILT UNIT E EXPLODED DIAGRAM (Long transom [6H1-15], [62F-02]) 1 2 3 4 5 6 7 8 9 0 Reservoir body Reservoir plug Motor assembly Trim cylinder end screw Trim piston assembly Main valve assembly Shuttle piston Pipe Main valve seal Valve support pin A B C D E F G H I J Down relief spring Gear pump assembly Shaft connector Filter 1 Valve lock screw Trim spring Up relief spring Up relief valve seat Filter 2 Manual valve seat 7-20 K L M N O Manual release spring Adapter Manual release
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BRKT 1 2 3 4 5 6 7 8 9 POWER TRIM AND TILT UNIT Trim down valve (0.2 kg/cm2) Trim down valve (1 kg/cm2) Reservoir Up-relief valve (100 kg/cm2) Manual valve Tilt cylinder Absorber valve (180 kg/cm2) Trim cylinder Main valve (0.
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BRKT POWER TRIM AND TILT UNIT E K52002-0 DISASSEMBLY CAUTION: 1. Do not wipe components of the hydraulic system with rags or paper tissues, etc., as fibers entering the system will cause malfunction. 2. After removing the tilt-motor or oil-reservoir, do not depress the tilt-rod or trim-rod which may cause hydraulic fluid to be ejected from the port. 1. Turn the manual valve fully towards the manual position. 2. Remove the delivery pipes and the hydraulic-fluid level-plug. 3.
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BRKT POWER TRIM AND TILT UNIT E 8. Remove the one-way valve and main valve seal. 9 0 A B C Valve lock screw O-ring Ball Washer Main valve seal 9. Loosen the trim-cylinder end-screw and pull out the trim-piston and components. Cylinder end screw wrench: YB-6175-1A/90890-6548 10. Loosen the tilt-cylinder end-screw and pull out the tilt-piston and the free-piston. WARNING The free-piston can be removed easily by blowing compressed air into the drain-hole of the cylinder.
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BRKT POWER TRIM AND TILT UNIT E 12. Remove the circlip and the manual valve and components. 1 2 3 4 5 6 7 8 Snap ring O-ring Manual release screw O-ring Manual valve seat Manual release spring 1 Adapter 1 Manual release spring 2 K53000-0 INSPECTION TILT-ROD AND TRIM-ROD 1. Clean these components using a soft brush and solvent and inspect them carefully.
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BRKT POWER TRIM AND TILT UNIT E 1. Install the tilt-cylinder and the delivery pipes. 1 2 3 4 Bushing Tilt-cylinder Lower mount pin Delivery pipe NOTE: Feed oil into each pipe. T. Lock nut (delivery pipe): 15 Nm (1.5 m • kg, 11 ft • lb) R. 2. Install the manual-valve in the body with new O-rings. 1 2 3 4 5 6 7 8 Snap ring O-ring Manual release screw O-ring Manual valve seat Manual release spring (ø0.6 mm) Adapter 1 Manual release spring (ø1.2 mm) T. Manual valve: 3 Nm (0.3 m • kg, 2.
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BRKT POWER TRIM AND TILT UNIT E 4. Install the up-relief valve and the valve lock screw with new O-rings and tighten the screw to the specified torque. 1 2 3 4 5 6 7 8 9 0 A B C Main valve seal Washer Ball O-ring Valve lock screw Filter O-ring Up relief valve seat Up relief valve seal Valve support pin Up relief spring Trim spring Screw T. R. Valve lock screw: 4 Nm (0.4 m • kg, 2.9 ft • lb) Screw: 4 Nm (0.4 m • kg, 2.9 ft • lb) 5.
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BRKT POWER TRIM AND TILT UNIT E 6. Install the down relief-valve and the gear-pump complete with new O-rings, tighten the bolts, and fit the connectorshaft and filter, then fill with hydraulic fluid. 1 2 3 4 Down relief-valve assembly Shaft-connector O-ring Bolt T. Bolt: 4 Nm (0.4 m • kg, 2.9 ft • lb) R. 7. Fit a new O-ring on the free-piston and install it into the cylinder. 1 O-ring 8. Fit a new O-ring and the back-up ring to the tilt-piston and install the piston in the cylinder.
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BRKT POWER TRIM AND TILT UNIT E FILLING WITH HYDRAULIC FLUID AND AIR-BLEEDING 1. Pour in the fluid until it overflows from the fluid-level plug-hole and install the reservoir plug. ATF (automatic transmission fluid) 2. Turn the manual-valve fully towards manual-tilt. Depress the tilt-rod fully, then close the manual valve. Use the motor to go fully up, check hydraulic and top if necessary. Open the manual valve and repeat these operations two or three times.
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BRKT POWER TRIM AND TILT UNIT E 3. Connect the leads to a battery to check the fluid discharge pressure during down-operation. Trim and tilt down ........ Green (+) Blue (–) CAUTION: The motor should not be operated for more than three seconds after trim and tilt down is completed.
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BRKT POWER TRIM AND TILT UNIT E A: Tilt operating pressure B: Trim operating pressure During up operation pressure: A: 0 ~ 500 kPa (0 ~ 5 kg/cm2, 0 ~ 71 psi) B: 0 ~ 500 kPa (0 ~ 5 kg/cm2, 0 ~ 71 psi) At the end of up-operation pressure: A: 0 kPa (0 kg/cm2, 0 psi) [6H308] B: 3,500 ~ 4,500 kPa (35 ~ 45 kg/cm2, 500 ~ 640 psi) [6H1-15] B: 9,000 ~ 11,000 kPa (90 ~ 110 kg/cm2, 1,280 ~ 1,565 psi) [62F-02] B: 5,690 ~ 6,570 kPa (57 ~ 66 kg/cm2, 299 ~ 526 psi) 5.
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BRKT POWER TRIM AND TILT MOTOR E POWER TRIM AND TILT MOTOR DISASSEMBLY 1. Loosen the screws and remove the stator, O-ring and the armature. 2. Disconnect the connector. 3. Loosen the screw and remove the brush, cover plate, circuit breaker and the spring. K62001-0* INSPECTION ARMATURE COIL 1. Visually inspect the commutator surface and if it shows signs of roughness, polish it with 600-grit wet-or-dry sandpaper. 2. Measure the outside diameter of the commutator by use of a vernier caliper.
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BRKT POWER TRIM AND TILT MOTOR E 3. Scrape between the segments with a hack-saw blade and then carefully remove all particles of metal and mica with compressed air. 4. Check for continuity or discontinuity of the armature coil. If it is out of specification, replace the armature. Armature coil continuity/ discontinuity Commutator segments a Continuity SegmentLaminations b Discontinuity Segment-Shaft c Discontinuity BRUSH 1. Measure the brushes for wear. Brush, size a: Standard: 9.8 mm (0.
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BRKT POWER TRIM AND TILT MOTOR E K63000-0* ASSEMBLY 1. Install the armature into the frame-end. 2. Place the O-ring on the frame-end and install the yoke assembly, then install the screws. T. Screw: 4 Nm (0.4 m • kg, 2.9 ft • lb) R. 3. Place the O-ring on the motor assembly and align the grooves of the motor assembly and gear pump, then install the bolts. T. R. 7-33 Power trim and tilt motor mounting bolt: [Stamped mark] [6H308] 6 Nm (0.6 m • kg, 4.3 ft • lb) [6H1-15], [62F-02] 7 Nm (0.
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ELEC – + E CHAPTER 8 ELECTRICAL SYSTEMS ELECTRICAL COMPONENTS......................................................................... 8-1 ELECTRICAL WIRING ..................................................................................... 8-3 WIRING DIAGRAM ......................................................................................... 8-7 REMOTE CONTROL BOX ...................................................................... 8-12 DIGITAL METER ...........................................
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ELEC – + E INSTALLATION............................................................................................. 8-30 FLYWHEEL MAGNETO.......................................................................... 8-30 STARTER MOTOR ........................................................................................ 8-31 REMOVAL............................................................................................... 8-31 DISASSEMBLY...............................................................
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ELEC – + ELECTRICAL COMPONENTS E M20000-0 ELECTRICAL COMPONENTS 50, 60, 70 hp Ignition coil Spark-plug Thermo switch Power trim and tilt replay (PTT model) 5 Trailer switch (PTT model except for USA, Canada and Oceania model) 1 2 3 4 6 7 8 9 0 A B C Neutral switch (P60TH/60FEHTO) Starter relay Oil warning lamp (50GETO) Charge coil Crank position sensor Lighting coil Pulser coil Wire harness 8-1 D E F G H I Fuse CDI unit Starter motor Trim sensor (PTT model) Rectifier/regulator Power trim and til
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ELEC – + ELECTRICAL COMPONENTS E M20001-0 75, 80, 90 hp Ignition coil Spark-plug Thermo switch Trailer switch (PTT model except for C75TR/ 75CET, C90TR/90AET) 5 Fuse 6 Wire harness 1 2 3 4 7 Neutral switch (P75TH/ 75CEHTO, 90AEHD, 90TR/ 90AETO, B90TR/90AETO) 8 Pulser coil 9 Stator assembly 0 CDI unit A Rectifier/regulator B Crank position sensor 8-2 C Power trim and tilt relay (PTT model) D Starter relay E Starter motor F Trim sensor (PTT model)
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ELEC – + ELECTRICAL WIRING E D22000-0 ELECTRICAL WIRING Check that all leads and connectors are properly connected.
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ELEC – + ELECTRICAL WIRING 50, 60, 70 hp E 1 2 3 4 5 6 7 8 9 0 Pulser coil coupler Trim sensor coupler*1 Oil level sensor coupler*2 Wire harness coupler (7P*3/10P*4) Ground lead from rectifier/regulator Ground lead from starter relay Ground lead from wire harness Power trim and tilt relay coupler*1 Charge coil coupler Crank position sensor coupler B Br G Gy L Lg O P R Sb W Y Å ı Ç Î ‰ Ï Ì Ó To CDI unit To power trim and tilt motor*1 To trim sensor*1 To oil level sensor*2 To meter To electrothermal
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ELEC – + ELECTRICAL WIRING 75, 80, 90 hp 1 Trailer switch E B L Lg R Sb coupler*1 Å To electrothermal valve*2 ı To battery Ç To starter relay Î To lighting coil ‰ To wire harness Ï To meter Ì To trim sensor*1 Ó To power trim and tilt motor*1 *1: For PTT model *2: Except for C75TR 8-5 : Black : Blue : Light green : Red : Sky blue
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ELEC – + ELECTRICAL WIRING 75, 80, 90 hp 1 2 3 4 5 6 7 8 9 0 A B C D E F E B Br G Gy L Lg O P R Sb W Y Crank position sensor coupler Fuel enrichment valve*1 Clamp Clamp Wire harness coupler Trim sensor coupler*2 Oil level sensor coupler*3 Clamp Ground lead from power trim and tilt relay *2 Ground lead from wire harness Ground lead from rectifier/regulator Charge coil coupler Power trim and tilt relay coupler*2 Pulser coil coupler Ground lead from starter relay Ground lead from CDI unit *1: *2: *3: *4
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8-7 Sb .......Sky blue W ........White Y .........Yellow Lg .......Light green WIRING DIAGRAM B .........Black Br ........Brown G .........Green Gy .......Gray L..........Blue O .........Orange P..........Pink R .........
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Thermo switch Rectifier/regulator Crank position sensor Pulser coil Charge coil Lighting coil Fuel enrichment valve Starter motor Battery Fuse (20A) CDI unit Starter relay Ignition coil Power trim and tilt relay (For C60TR) Power trim and tilt motor (For C60TR) – B......... Black Br ....... Brown G ........ Green Gy ...... Gray L ......... Blue O ........ Orange P......... Pink R......... Red Sb ...... Sky blue W ....... White Y......... Yellow Lg.......
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8-9 Sb ...... Sky blue W ....... White Y ........ Yellow WIRING DIAGRAM B......... Black Gr ....... Brown G ........ Green Gy ...... Gray L ......... Blue Lg ....... Light green O ........ Orange P ......... Pink R.........
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Thermo switch Rectifier/regulator Crank position sensor Lighting coil Charge coil Pulser coil CDI unit Fuel enrichment valve Starter motor Battery Trim sensor Power trim and tilt motor Fuse Power trim and tilt relay Ignition coil Starter relay – B......... Black Gr....... Brown G ........ Green Gy ...... Gray L ......... Blue Lg....... Light green O ........ Orange P......... Pink R......... Red Sb ...... Sky blue W ....... White Y.........
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ELEC – + WIRING DIAGRAM P60TH/60FEHTO 1 2 3 4 Buzzer Fuse (10A) Main switch Engine stop switch Å To tachometer ı To power trim and tilt switch (option) Ç To trim sensor Î To oil level sensor ‰ To lamp switch (option) B .........Black Br........Brown G.........Green Gy.......Gray G/R .....Green/Red L .........Blue O.........Orange P .........Pink R .........Red Sb .......Sky blue W ........White Y .........Yellow Lg .......Light green G/W ....Green/White P/B ......
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ELEC – + WIRING DIAGRAM E M31000-0 REMOTE CONTROL BOX 1 2 3 4 5 Å Main switch Buzzer Neutral switch Engine stop switch Power trim and tilt switch To meter harness DIGITAL METER 1 2 3 4 5 6 Digital tachometer Digital speedometer (option) To fuel management meter (option) Lamp switch (option) Fuse (10A) Fuel sensor (option) Å To remote control box ı To trim sensor Ç To oil level gauge 8-12 B ........ Black Br ....... Brown G ........ Green Gy ...... Gray L......... Blue Lg....... Light green O .
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ELEC – + REMOVAL E M40003-0 REMOVAL MAGNETO BASE 1. Remove the flywheel cover. 2. Remove the starter-pulley. 3. Loosen the flywheel nut until it is flush with the crankshaft. Flywheel holder: YB-6139/90890-06522 CAUTION: The major load must be carried in the direction of the arrows. If not, the holder may easily slip off. CAUTION: Keep the nut side flush with the crankshaft end until the flywheel comes off the tapered portion of the crankshaft.
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ELEC – + REMOVAL E 4. Remove the flywheel magneto. YB-6117 Flywheel puller: YB-6117/90890-06521 CAUTION: To prevent damage to the engine or tools, screw in the flywheel magneto-puller setbolts evenly and completely so that the puller plate is parallel to the flywheel. 5. Remove the woodruff key from the crankshaft keyway using a screwdriver. CAUTION: Take special care not to damage the surface of the crankshaft. When removing the flywheel magneto, lift it up while tilting it slightly.
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ELEC – + ELECTRICAL ANALYSIS E ELECTRICAL ANALYSIS INSPECTION CAUTION: All measuring instruments should be handled with special care or the correct measurement is impossible. On an instrument powered by dry batteries, the latter should be checked for voltage periodically and replaced, if necessary. NOTE: “ ” indicates the terminals between which there is a continuity of electricity; i.e., a closed circuit at the respective switch position.
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ELEC – + ELECTRICAL ANALYSIS E IGNITION SPARK GAP WARNING ● While checking the spark be careful not to touch any connection of lead wires of the “Ignition spark gap tester”. ● When doing the spark test, take special care not to allow leakage from the plug cap which has been removed. This check is likely to produce sparks, so be sure that no flammable gas or fluid is present. 1. Ignition spark gap: 1) Adjust the spark gap to specification by turning the adjusting knob.
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ELEC – + ELECTRICAL ANALYSIS E 1. CDI unit output: 1) Connect the tester to the CDI unit as shown. 2) Set the tester dial to specification. 3) Crank or start the engine. 4) Measure all the CDI unit output. 5) If the output is beyond specification, replace the ignition coil. 6) If the output is below specification, measure the charge coil output.
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ELEC – + ELECTRICAL ANALYSIS E 50, 60, 70 hp Charge coil Output peak voltage (minimum) Br – L r/min V Cranking Open Connect 120 150 1,500 3,500 160 120 75, 80, 90 hp Charge coil Output peak voltage (minimum) R – Br r/min V Cranking Open Connect 55 60 1,500 3,500 170 150 Charge coil Output peak voltage (minimum) R–L r/min V Cranking Open Connect 90 100 1,500 3,500 135 135 3. Pulser coil output: 1) Disconnect the pulse coil couple. Connect the 2 pins test harness.
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ELEC – + ELECTRICAL ANALYSIS E 50, 60, 70 hp Pulser coil Output peak voltage (minimum) W/R – W/B r/min V Cranking Open Connect 4.5 2.5 1,500 3,500 6.5 10 75, 80, 90 hp Pulser coil Output peak voltage (minimum) W/R – W/B r/min V Cranking Open Connect 7.0 5.0 1,500 3,500 14 20 4. Lighting coil output: 1) Connect the tester to the lighting coil as shown. 2) Set the tester dial to specification. 3) Start the engine. 4) Measure the lighting coil output.
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ELEC – + ELECTRICAL ANALYSIS E M53005-0 REPLACEMENT OF SPARK-PLUG CAP [Standard type] 1. Remove the spark-plug cap by pulling the cap and remove the plug-cap spring from the high-tension cable. 2. Cut an amount of about a off the end of the high-tension cable. Distance a: 5 mm (0.2 in) 3. Fit onto the plug cap-spring. 4. Push the cap-spring into the plug-cap. [Resistance specification type] 1. Remove the spark-plug cap by turning the cap. 2. Install the spark-plug cap onto the hightension cable.
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ELEC – + ELECTRICAL ANALYSIS E M55000-0 STARTER RELAY 1. Check for continuity between the terminals and the ends of the black and brown leads. 2. Test to ensure there is no continuity between terminals. 3. Check the relay operation. 1) Connect a tester between the terminals of the starter relay. Connect the leads of the starter-relay to a 12-V battery. Brown lead........................................ (+) Black lead ..........................................
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– + ELECTRICAL ANALYSIS E 3. Connect the (–) terminal and 1 terminal and the (–) terminal and 2 terminal to the tester and check the continuity in each case. Sb : Sky blue Lg : Light green B : Black 4. Connect the black terminal to the (–) terminal of the battery and the light green terminal to the (+) terminal of the battery. Then, connect the (+) terminal and 1 terminal to the tester and check the continuity. 5.
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ELEC – + ELECTRICAL ANALYSIS E M56501-0 RECTIFIER/REGULATOR 1. Check the continuity of the rectifier/regulator. Rectifier/regulator check Tester + Green Tester Green Green/ White Red Black ∞ Continuity ∞ Continuity Continuity Green/ White Continuity Red ∞ ∞ Black Continuity Continuity ∞ Continuity ∞ : Discontinuity If continuity is not as specified, replace the rectifier/regulator. NOTE: ● The digital tester cannot be used for this inspection.
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ELEC – + ELECTRICAL ANALYSIS E M57300-0 THERMO SWITCH 1. Immerse the thermo switch in water. While heating the water, check the continuity at the specified temperature. 2. While cooling the water, check the continuity at the specified temperature. If continuity is not as specified, replace the thermo switch. ON temperature a: 84 ~ 90˚C (183 ~ 194˚F) OFF temperature b: 60 ~ 74˚C (140 ~ 165˚F) 1 2 3 Å ı Discontinuity Continuity Discontinuity Temperature Time FUEL ENRICHMENT VALVE 1.
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ELEC – + ELECTRICAL ANALYSIS M57500-0 OIL INJECTION SYSTEM (Oil injection model) 1 Oil level sensor 2 Digital Meter (Oil level warning lamps/control unit) 3 Lead wire 4 Lead wire 5 Lead wire assembly 50, 60, 70 hp 75, 80, 90 hp 8-25 E
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ELEC – 50, 60, 70 hp + ELECTRICAL ANALYSIS E M58004-0 75, 80, 90 hp OIL-LEVEL SENSOR 1. Remove the circlip and disassemble the oil-level sensor. 1 Oil-level sensor 2 Strainer cover 3 Gasket 2. Referring to the illustrations and tables, check the continuity and resistance. 50, 60, 70 hp Marking: 6H3-16 Unit: Ω Oil level sensor resistance Float SW.1 ON A 79.5 ~ 82. 5 mm (3.13 ~ 3.25 in) Tester + Tester Tester + 1 Black 2 Green - Tester 1 Black 2 Green Float SW. 2 ON B 114.5 ~ 117.3 mm (4.
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ELEC – + ELECTRICAL ANALYSIS E 75, 80, 90 hp Marking: 6H1-15 Unit: Ω Oil level sensor resistance Float SW.1 ON A 5.8 ~ 8.8 mm (0.23 ~ 0.35 in) Tester + Tester Tester + 1 Black 2 Green - Tester 1 Black 2 Green Float SW. 2 ON B 42.3 ~ 45.3 mm (1.67 ~ 1.78 in) 0 1 Black 3 Green/ Red 0 1 Black 3 Green/ Red *∞ 640 Oil level sensor resistance Float SW. 1, SW.
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ELEC – + ELECTRICAL ANALYSIS E M57602-0 OIL-LEVEL WARNING LAMP (L.E.D.) (50GETO) Test the Light Emitting Diode (L.E.D.) using a 1.5-V dry-cell battery. If no light is emitted, replace the warning lamp. Battery voltage: 1.5V CAUTION: Do not use a 12-V battery or a larger capacity type, as this may damage the L.E.D. We recommend using a pen light battery. M58300-0 WIRING HARNESS 1. Check the continuity between the coupler side and each connector.
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ELEC – 50, 60, 70 hp + ELECTRICAL ANALYSIS E M58800-0 75, 80, 90 hp BRACKET 1. Inspect the bracket and replace it if it’s cracked. M58900-0* BATTERY Refer to “PERIODIC SERVICE” section in chapter 3. M59000-0 ENGINE STOP SWITCH (P60TH/60FEHTO, P75TH/75CEHTO, 90AEHD) 1. When removing and installing the lockplate, check for continuity according to the chart below.
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– + ELECTRICAL ANALYSIS/INSTALLATION E MAIN SWITCH (P60TH/60FEHTO, P75TH/75CEHTO, 90AEHD) 1. Check the continuity of the main switch. Replace if continuity is not as specified. Checking leads Red | Yellow | Brown Disconti- DiscontiContinuity nuity nuity DiscontiDiscontiContinuity nuity nuity White | Black Switch Position ELEC OFF ON START Discontinuity Red | Yellow DiscontiContinuity nuity NEUTRAL SWITCH (P60TH/60FEHTO, P75TH/75CEHTO, 90AEHD, 90TR/ 90AETO, B90TR/90AETO) 1.
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ELEC – + STARTER MOTOR E M71001-0* STARTER MOTOR REMOVAL 1. Disconnect the cables and remove the starter-motor. DISASSEMBLY 1. Remove the starter-clutch. Using a screw-driver, pry off the clip. 1 Clip 2 Pinion Stopper 3 Pinion (starter clutch) NOTE: Push the pinion stopper by hand toward the pinion and remove the clip. 50, 60, 70 hp 2. Remove the two through-bolts and pull out the front cover lightly tapping it with a plastic hammer, if necessary. 75, 80, 90 hp 3.
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ELEC – + STARTER MOTOR E INSPECTION PINION 1. Inspect the pinion and inner teeth for wear or damage and check ease of pinion sliding motion and replace, if damaged. 2. Inspect the flywheel gear and replace, if worn or damaged. STARTER CLUTCH 1. Check the clutch movement. Rotate the pinion clockwise and check that it turns freely. Also, try to rotate the pinion counterclockwise and confirm that it locks. BRUSH 1. Measure the brushes for wear. Brush size a: Standard: 50, 60, 70 hp: 12.5 mm (0.
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ELEC – + STARTER MOTOR E ARMATURE 1. Inspect the commutator surfaces and if these are dirty or burnt, clean with 400grit wet-or-dry sandpaper. 2. Inspect the commutator deflection with a dial gauge and block and replace the armature if the deflection is out of specification. Maximum deflection: 0.05 mm (0.0020 in) If the deflection is greater than the specified deflection, replace the armature. 3. Measure the diameter of the commutator. Standard diameter: 50, 60, 70 hp: 30 mm (1.
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ELEC – + STARTER MOTOR E 5. Check the insulation between the shaft or laminations and ground. If there is any continuity, replace the armature. 6. Inspect that the commutator is an open circuit by checking for continuity between segments. If any segment is not continuous, replace the armature. ASSEMBLY (50, 60, 70 hp) 1. Apply a thin coat of water resistant grease to the rear cover bushing and install the armature in the rear cover assembly.
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ELEC – + STARTER MOTOR E 4. Insert the through-bolts into the rear cover and screw them into the front cover. 5. Mount the pinion, spring and pinionstopper on the armature shaft. 6. Hold down the pinion-stopper and fit the circlip into the groove in the shaft. Use a socket-wrench that fits properly over the armature shaft. Reform the circlip by using pliers. Lift up the pinionstopper until its bottom contacts the circlip. INSTALLATION (50, 60, 70 hp) 1.
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ELEC – + STARTER MOTOR E 2. Install the positive brush (on the stator coil side) in the brush holder and hold it with the spring. NOTE: Use care not to scratch the brushes when installing. 1 Positive brush 2 Spring 3. Mount the two steel washers and resin washer, in that order, on the armature shaft and install the front cover onto the yoke assembly. 1 Front cover 4. Align the cut (for the through-bolt) in the brush holder with the gap in the brush holder so that the through-bolt can be inserted. 5.
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TRBL ANLS E CHAPTER 9 TROUBLE ANALYSIS TROUBLE ANALYSIS ..................................................................................... 9-1 TROUBLE ANALYSIS CHART .................................................................
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TRBL ANLS TROUBLE ANALYSIS E TROUBLE ANALYSIS NOTE: The following items should be obtained before “trouble analysis”. 1. Battery is charged and its specified gravity is in specification. 2. There is no incorrect wiring connection. 3. Wiring connections are surely engaged and without any rust. 4. Lanyard is installed to the engine stop switch. 5. Shift position is in neutral. 6. Fuel is coming to the carburetor. 7. Correct rigging and engine setting are obtained. 8. Engine is free from any “Hull problem”.
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TRBL ANLS TROUBLE ANALYSIS POOR BATTERY CHARGING IRREGULAR WARNING INDICATION HARD SHIFTING Check elements TILT MOTOR WILL NOT RUN LOOSE TILT HOLDING LOOSE STEERING OVERHEATING POOR PERFORMANCE ENGINE WILL NOT STOP ENGINE STALLS ROUGH IDLING ENGINE WILL NOT START Trouble mode E Relative part LOWER UNIT Neutral position Clutch Gear Water inlet Water pump Propeller shaft Shift rod Shift slider Shift cam Lower case Shim adjustment BRACKET UNIT Bracket Mount rubber Shift actuator PTT UNIT Flui
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TRBL ANLS TROUBLE ANALYSIS POOR BATTERY CHARGING IRREGULAR WARNING INDICATION HARD SHIFTING Check elements TILT MOTOR WILL NOT RUN LOOSE TILT HOLDING LOOSE STEERING OVERHEATING POOR PERFORMANCE ENGINE WILL NOT STOP ENGINE STALLS ROUGH IDLING ENGINE WILL NOT START Trouble mode E Relative part Fuse Thermo switch Oil level sensor Oil level warning lamp Wire harness Battery Engine stop switch Main switch Neutral switch Starter motor 9-3 Reference Chapter 8 8 8 8 8 3 8 8 8 8
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YAMAHA MOTOR CO., LTD. Printed in USA Feb. 1999 – ?.