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60H5E11

Power unit

POWR

Oversize piston:

1st : 90.145 - 90.165mm

(3.5490 - 3.5498 in)

2nd : 90.395 - 90.415 mm

(3.5589 - 3.5596 in)

Piston ring dimensions
(Top ring, Second ring):

B:1.97 - 1.99mm
(0.0776 - 0.0783 in)
T: 2.7-2.9mm (0.1063 - 0.1142 in)
at 20°C (68 °F)

5-31

5. Measure the cylinder bore with cylinder

gauge. Calculate the cylinder bore diam-
eter (D), taper (T), and roundness (R). If
the results exceeded the specified limit,
rebore the cylinder sleeve, or replace the
cylinder block.

60H50480

A:

10mm (0.039 in) to the cylinder head top
surface

B:

5mm (0.20 in) above the exhaust port up-
per edge

C:

5mm (0.20 in) below the scavenging port
lower edge

NOTE:
• Measure the cylinder bore diameter at 6 po-

sitions shown.

• To obtain the cylinder bore diameter(D), cal-

culate the largest of D1-D6 measurements.

• Taper(T) is obtained by subtracting D5 from

D1, and D6 from D2 and selecting the maxi-
mum value.

• To obtain the out of round(R), calculate the

difference between D1 and D2, D3 and D4,
and D5 and D6 respectively. The largest dif-
ference of the three shall apply.

• Oversize pistons is available in two sizes.

Checking the piston

1. Check the piston outside diameter. Re-

place the piston if the diameter is out of
specification.

60H50490

2. Check the piston clearance. Replace the

piston and the piston ring, or the cylinder
block if out of specification.

3. Check the piston ring dimensions of B and

T. Replace the piston ring if the dimension
is out of specification.

60H50500

Specified limits
Cylinder bore diameter(D) :

90.10mm(3.5472in)
at 20 °C (68 °F)

Taper(T) : 0.08mm(0.0031in)
Out of round(R) : 0.05mm(0.0020in)

at 20 °C (68 °F)

Piston outside diameter:

89.895 - 89.915mm
(3.5392 - 3.5400 in)
at 20°C (68 °F)

A

: 10 mm (0.39 in)

Piston clearance:

0.100 - 0.106mm (0.0039 - 0.0042 in)
at 20°C (68 °F)

T

B

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Summary of Contents for 200A

Page 1: ...200A L200A 60H 28197 5E 11 290446 SERVICE MANUAL ...

Page 2: ...ally of modifications and significant changes in specifications and procedures and these are incorporated in successive editions of this manual Important information Particularly important information is distinguished in this manual by the following notations The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED 200A L200A SERVICE MANUAL 2002 by Yamaha Motor Co Ltd 1st Editi...

Page 3: ...General information GEN INFO Specifications SPEC Periodic checks and adjustments CHK ADJ Fuel system FUEL Power unit POWR Lower unit LOWR Bracket unit BRKT Electrical systems ELEC Troubleshooting TRBL SHTG Index ...

Page 4: ...ification 1 5 Applicable models 1 5 Serial number 1 5 Features and benefits 1 6 Hour meter 1 6 Exhaust components Factory option 1 7 Piston and cylinder 1 8 Connecting rod 1 9 Gasket 1 10 Reduction gear and clutch 1 11 Power unit mount bolt 1 12 Propeller selection 1 13 Propeller size 1 13 Selection 1 13 Predelivery checks 1 14 Checking the fuel system 1 14 Checking the gear oil 1 14 Checking the ...

Page 5: ...eering system 1 15 Checking the gearshift and throttle operation 1 15 Checking the tilt sytem 1 15 Checking the engine start switch and engine stop switch engine shut off switch 1 16 Checking the pilot water outlet 1 16 Test run 1 16 Break in 1 17 After test run 1 17 ...

Page 6: ...y 60H50270 5 Check the spring for fatigue or deforma tion Replace it if necessary 6 Check the exhaust cover for distortion or corrosion Replace it if necessary 60H50275 How to use this manual Manual format The format of this manual has been designed to make service procedures clear and easy to under stand Use the information below as a guide for effective and quality service 1 Parts are shown and ...

Page 7: ... SHTG 4 Specified tightening torque 5 Specified measurement 6 Specified electrical value Resistance Voltage Electric current 1 2 3 4 5 6 7 Apply Yamaha 4 stroke motor oil 8 Apply water resistant grease Yamaha grease A 9 Apply molybdenum disulfide grease 0 Apply corrosion resistant grease Yamaha grease D A Apply low temperature resistant grease Yamaha grease C B Apply injector grease Symbols C to H...

Page 8: ...nt soiled clothing has been made 5 To protect your skin apply a protective cream to your hands before working on the outboard motor Safety while working To prevent an accident or injury and to ensure quality service follow the safety procedures provided below Fire prevention Gasoline is highly flammable Keep gasoline and all flammable products away from heat sparks and open flames Ventilation Gaso...

Page 9: ...l seal be fore installation 5 Check that moving parts operate normally after assembly Tightening torques Follow the tightening torque specifications provided throughout the manual When tight ening nuts bolts and screws tighten the large sizes first and tighten fasteners starting in the center and moving outward Non reusable parts Always use new gaskets seals O rings cot ter pins circlips etc when ...

Page 10: ...mber The outboard motor serial number is stamped on a label attached to the port clamp bracket 1 Model name 2 Approved model code 3 Transom height 4 Serial number NOTE If the serial number label is removed VOID marks will appear on the label Model name 200AET L200AET Approved model code 60H 60J Starting serial No L 800101 X 850101 X 800101 60H10000 1 5 ...

Page 11: ...indicates the total of hours which the engine has been run since manufacture The indicated hour is the accumulated time detected by the pulse signal from the lighting coil The accumulated hour is held forever and cannot reset Identification Features and benefits 60H10010 1 6 Hour meter Rectifier Regulator Battery Fuse Main switch Power source Y Grand B Pulse G W Lighting coil Flywheel magnet G B H...

Page 12: ...ption The cylindrical components have been painted externally and internally after the anodic oxide coating to make a film for additional corrosion resistance 60H10030 1 7 For X transom Exhaust guide plate Exhaust manifold Muffler Exhaust manifold extension Muffler 2 ...

Page 13: ...ton ring The cylinder sleeve without the exhaust slit has been adopted not to accumulate some deposits which can prevent the piston rings from entwining Also the shape of the exhaust port has been given the gradual curve design to obtain the best engine performance and avoid scuffing of the piston ring 60H10040 1 8 Piston Hard anodic oxide coating Exhaust slit Cylinder sleeve Exhaust port Scavengi...

Page 14: ...the inside of the small end to increase the strength The small end bearing has been given 18 rollers adding one roller from the previous model to increase the durability The mating face of the big end bearing has been given a large area to increase the rigidity after assembling the bearing cap which increases the rigidty Also a silver plating 30 40µ has been given to the outside portion of the big...

Page 15: ...60H5E11 1 Silicon bead Silicon bead Gasket with silicon bead Gasket The intake manifold gasket has been given a silicon bead to increase more sealer 60H10060 1 10 Features and benefits ...

Page 16: ...Reduction gear and clutch The process of the double shot peening has been given to the surface of the teeth portion of the pinion gear forward gear and dog clutch to increase the durability 60H10070 1 11 Dog clutch Forward gear Pinion gear ...

Page 17: ... will help prevent the bolt from sticking by the salt water entering into the thread hole and crystallizing Also the bolt can come out by turning due to the full thread structure and the sealing material having a function as an insulator even if the bolt hole has been choked with corroded particles Therefore an easier servicing such as removing the power unit can be obtained NOTE Apply a sealing m...

Page 18: ...L 13 3 4 x 21 ML Stainless steel 13 3 8 x 23 ML 14 1 2 x 17 ML Propeller selection The performance of a boat and outboard mo tor will be critically affected by the size and type of propeller you choose Propellers greatly af fect boat speed acceleration engine life fuel economy and even boating and steering ca pabilities An incorrect choice could adversely affect performance and could also seriousl...

Page 19: ...ation of the boat and the outboard motor To determine the optimum mounting height test run the outboard motor at different heights 2 Check that the clamp brackets are secured with the mounting bolts Recommend battery CCA SAE Minimum 380 A CCA EN Minimum 430 A RC Minimum 124 Minute 20HR Minimum 70 AH JIS 65D31 95E41 Electrolyte specified gravity 1 280 at 20 C 68 F 1 14 Predelivery checks To make th...

Page 20: ...osition to the fully open position A S60C1210 Checking the tilt system 1 Check that the outboard motor tilts up and down smoothly when operating the power trim and tilt unit 60H10095 1 15 Checking the remote control cables 1 Set the remote control lever to the neutral position and fully close the throttle lever 2 Check that the basic ignition timing adjust ing screw 1 on the magnet control lever i...

Page 21: ...turns off when the engine start switch is turned to OFF 3 Check that the engine turns off when the engine shut off cord is pulled from the en gine shut off switch S60C1220 Checking the pilot water outlet 1 Start the engine and check that cooling wa ter is discharged from the pilot water outlet 60H30100 Test run 1 Start the engine and then check the en gine idle speed after the engine has been warm...

Page 22: ... less 60H10110 3 One hour at 4 000 r min or less 60H10120 4 For another eight hours run at 5 000 r min or less with repeated wide open throttle op eration that lasts five minutes or less 60H10130 1 17 After test run 1 Check for water in the gear oil 2 Check for fuel leakage in the cowling 3 After a test run and while the engine is at idle flush the cooling water passage with fresh water using the ...

Page 23: ...11 2 Specifications Genral Specifications 2 1 Maintenance specifications 2 3 Power Unit 2 3 Lower Unit 2 4 Electrical 2 5 Dimentions 2 7 Tightening torques 2 9 Specified torques 2 9 General torques 2 10 SPEC ...

Page 24: ...ing system Exhaust system Lubrication system mm in mm in mm in mm in mm in mm in kg lb kg lb kW HP r min L US gal Imp gal hr r min cm3 cu in mm in kPa kg cm2 Degree Degree V A 828 32 6 600 23 6 1 577 62 1 1 703 67 0 516 20 3 642 25 3 180 396 184 405 186 410 147 1 200 5 000 r min 4 500 5 500 81 21 4 17 8 5 500 r min 700 2 stroke 90 V6 2 596 158 4 90 0 3 54 x 68 0 2 68 5 9 520 5 2 Remote control Ele...

Page 25: ...ler direction Rear view Propeller ID mark Electrical Recommend battery CCA SAE Minimum CCA EN Minimum RC Minimum 20HR Minimum JIS RON 4 NMMA certified API SAE cm3 oz Degree Degree Degree A A Minute AH Regular unleaded gasoline 84 2 stroke outboard motor oil TCW 3 Hypoid gear oil GL 4 90 980 34 5 870 30 6 4 16 70 35 35 F N R 1 86 14 26 Spiral bevel gear Dog clutch Spline Clocklwise Counterclockwise...

Page 26: ... 3 0 4 0 0118 0 0157 20 0 79 0 02 0 06 0 0008 0 0024 Model 200AET L200AET Measuring conditions Ambient temperature 20 C 68 F wide open the throttle valve and the choke valve with plugs disconnected from all cylinders The figures are for reference only 2 3 Power unit Compression pressure reference data Compression pressure minimum Cylinder heads Warpage limit lines indicate straightedge po sition C...

Page 27: ...7 0 0102 2 0 0 08 53 975 53 991 2 1250 2 1256 35 985 36 000 1 4167 1 4173 0 03 0 0012 50 122 60 140 3 0 0 12 64E01 No 1 3 150 No 2 4 154 No 5 152 No 6 158 270 84 60 1 1 8 1 4 7 8 1 3 8 15 5 16 5 0 61 0 65 675 725 6 5 0 26 0 2 0 08 Lower unit Item Unit Gear backlash Pinion to forward gear Pinion to reverse gear Pinion shims Forward gear shims Reverse gear shims Propeller shaft shims Drive shaft Run...

Page 28: ...il resistance 2 Br R L B R CDI unit output peak voltage B W B at cranking loaded at 1 500 r min at 3 500 r min Spark plug gap Ignition spark gap Spark plug cap resistance Ignition coil resistance Primary coil B W B Secondary coil LEAD B Thermoswitch ON OFF Choke solenoid Resistance Degree Degree mm in V V V V Ω V V V V V V V V Ω Ω V V V mm in mm in Ω Ω at 20 C 68 F Ω at 20 C 68 F C F C F Ω ATDC 7 ...

Page 29: ...rent Power trim and tilt system Trim sensor Setting resistance Resistance P B Fluid type Brushes Standard length Wear limit Commutator Standard diameter Wear limit Hydraulic pressure UP DOWN kW Second mm in mm in mm in mm in mm in mm in A V V V Ω V V V A at 6 000 r min Ω Ω mm in mm in mm in mm in MPa kgf cm2 MPa kgf cm2 Bendix 1 1 30 17 0 67 10 0 39 33 1 30 32 1 26 0 8 0 031 0 2 0 008 20 3 20 0 50...

Page 30: ...8 569 22 4 L 1 032 40 6 X 1 144 45 0 543 21 4 188 7 4 74 2 9 788 31 0 L 946 37 2 X 1 072 42 2 631 24 8 L 516 20 3 X 642 25 3 210 8 3 205 8 1 26 1 0 45 1 8 L 762 30 0 X 837 33 0 L 54 2 1 X 62 2 4 L 48 1 9 X 61 2 4 173 6 8 31 1 2 70 12 4 634 25 0 Dimensions Exterior 2 7 ...

Page 31: ...Item Unit B1 B2 B3 B4 B5 B6 B9 C3 D1 D2 mm in mm in mm in mm in mm in mm in mm in mm in mm in mm in 125 4 4 9 254 10 0 163 5 6 4 50 8 2 0 180 7 1 367 14 5 18 5 0 7 82 3 2 13 0 5 55 5 2 2 Model 200AET L200AET Clamp bracket Maintenance specifications 2 8 ...

Page 32: ... 6 PCV cover 1st M6 4 0 4 3 2nd 8 0 8 6 Cylinder head accessory plug M14 23 2 3 17 Power unit mount bolt M8 21 2 1 15 Spark plug M14 25 2 5 18 Electric relay terminal nut M6 4 0 4 3 Starting motor mount bolt M8 29 2 9 22 Starting motor terminal nut M8 9 0 9 6 Ignition coil M6 8 0 8 6 Battery cable terminal nut M6 4 0 4 3 M8 6 0 6 5 Hour meter M5 2 0 2 2 LOWER UNIT Pinion nut M16 93 9 3 69 Propelle...

Page 33: ... size Tightening torques N m kgf m ft lb General torques This chart specifies tightening torques for stan dard fasteners with a standard ISO thread pitch Tightening torque specifications for spe cial components or assemblies are provided in applicable sections of this manual To avoid warpage tighten multi fastener assemblies in a crisscross fashion and progressive stages until the specified tighte...

Page 34: ...ater passage 3 5 Control system 3 6 Checking the throttle cable operation 3 6 Checking the ignition timing with timing light 3 6 Checking the ignition timing 3 7 Adjusting the ignition timing 3 8 Checking the carburetor synchronization 3 12 Adjusting the carburetor synchronization 3 13 Adjusting the engine idle speed 3 14 Adjusting the carburetor pickup timing 3 15 Adjusting the choke solenoid 3 1...

Page 35: ...t 3 19 Checking the gear oil level 3 19 Changing the gear oil 3 19 Checking the lower unit for air leakage 3 20 Checking the propeller 3 21 General 3 21 Checking the anodes 3 21 Checking the battery 3 21 Lubrication 3 22 ...

Page 36: ...60H5E11 CHK ADJ Periodic checks and adjustments 3 1 Special service tools Timing light 90890 03141 Dial gauge set 90890 01252 Digital tachometer 90890 06760 Leakage tester 90890 06840 ...

Page 37: ... seals Check replace Drive shaft Check replace 6 21 49 Propeller Check 3 21 General Anodes Trim tab Check replace 3 21 Battery Check charge 3 21 every month Wiring and connectors Adjust reconnect Nuts and bolts 4 Tighten Lubrication points Lubricate 3 22 Exhaust system Check replace deterioration Maintenance interval chart Use the following chart as a guideline for general maintenance Adjust the m...

Page 38: ...eck the fitting again and repeat steps 2 4 until the proper fitting is obtained 6 Check the rubber seal for cracks or dam age Replace if necessary Hour meter Checking the hour meter 1 Turn the ignition switch to ON 2 Check that the total hour of operation is dis played after the entire Light Emitting Diode has been illuminated for two seconds 60H30030 Fuel system Checking the fuel joint and fuel h...

Page 39: ...ain screw 2 60H30040 2 Check the filter element 3 for dirt and ac cumulated residue and check the filter cup 4 for foreign substances and cracks Clean with straight gasoline and replace the fuel filter element if necessary 60H30050 Power unit Checking the spark plugs 1 Disconnect the spark plug wire before re moving the spark plugs 2 Clean the electrodes 1 with a spark plug cleaner or wire brush R...

Page 40: ...0 2 Place the lower unit in water and then start the engine 60H30070 5 Install the spark plug tighten it finger tight to the position B then apply the specified torque with a spark plug wrench to the po sition C Spark plug 25 N m 2 5 kgf m 18 ft lb NOTE Clean the spark plug gasket and the seating face before installing the spark plug T R 4 Check the thermostat valve lift A at the specified water t...

Page 41: ...throttle cable 6 Adjusting the choke valve Checking the throttle cable operation 1 Check that the standard ignition timing ad justing screw 1 touches the fully closed stopper 2 on the cylinder block when the remote control lever is in neutral 60H30110 2 Check that magnet control lever 3 and ac celerator cam 4 move smoothly as the re mote control lever is moved 60H30120 3 If adjustment is required ...

Page 42: ...e that the shift lever is in neutral position Checking the ignition timing 1 Disconnect the throttle cable 2 Remove the intake silencer and flywheel cover 3 Turn the flywheel clockwise until the igni tion timing mark on the flywheel magnet is aligned with the pointer mark A on the tim ing plate at the full advance NOTE Turn the flywheel clockwise Turning it to the opposite direction will damage th...

Page 43: ... flywheel magnet is aligned with the pointer mark A on the timing plate at the standard ignition timing 60H30180 8 Check that the mark B on flywheel mag net is aligned with the mark C on base as sembly 60H30200 9 Adjust the ignition timing when the align ment of the marks BC could not be at tained for either or both of the fully ad vanced ignition timing and standard igni tion timing Adjusting the...

Page 44: ... Turn the flywheel clockwise Turning it to the opposite direction will damage the water pump impeller 7 Adjust the gauge so that the indicator points at zero at the top dead center identified above 60H30230 8 Slowly turn the flywheel clockwise until the 1 cylinder piston comes to the specified position 60H30235 NOTE To move the piston to the specified position flywheel should be turned almost one ...

Page 45: ...0250 12 Move the magnet control lever 1 until it touches the fully advanced stop screw 2 60H30160 13 Adjust the length of magnet control link so that the timing mark C on the flywheel aligns with the mark D on the base assem bly 60H30260 14 Turn the flywheel clockwise to align the pointer mark A on the timing plate with standard ignition angle on the flywheel scale 60H30180 15 Move the magnet cont...

Page 46: ...Timing light 90890 03141 3 11 16 Adjust the length of standard ignition tim ing adjusting screw 3 so that the timing mark D on the flywheel aligns with the mark C on the base assembly 60H30270 17 Make sure that the carburetor pick up tim ing is correct 18 Install the spark plugs 19 Install the intake silencer and flywheel cover 20 Connect the throttle cable 21 Start the engine and check the engine...

Page 47: ...the throttle cable 8 Install the intake silencer and the flywheel cover 9 Start the engine and adjust the engine idle speed by turning the idle adjusting screw Checking the carburetor synchroniza tion 1 Disconnect the throttle cable 2 Remove the intake silencer and flywheel cover 3 Loosen the throttle lever tightening screw 1 clockwise on the central carburetor 60H30290 NOTE The throttle lever tig...

Page 48: ...The throttle lever tightening screw 1 has left hand threads 4 Loosen the idle adjusting screw 2 on the central carburetor to make a gap between the screw tip and the throttle arm stopper 3 60H30300 5 Loosen the throttle lever tightening screw 4 clockwise on the upper and lower car buretors NOTE The throttle lever tightening screw 4 has left hand threads 60H30320 6 On the upper and lower carburetor...

Page 49: ... Adjusting the engine idle speed 1 Start the engine warm it up for 5 minutes and shut it off 2 Loosen the throttle lever tightening screw 1 clockwise on the central carburetor 60H30290 NOTE The throttle lever tightening screw 1 has left hand threads 3 Loosen the idle adjusting screw 2 to make a gap between the screw tip and the throttle arm stopper 3 60H30300 4 Turn in the pilot screws 4 until the...

Page 50: ...of A To decrease the idle speed turn the idle ad justing screw 5 in the direction of B 7 Tighten the throttle lever tightening screw 1 counterclockwise on the central carbu retor to make the accelerator cam 6 aligned with the centerline of the roller 7 60H30370 8 Check the engine idle speed after opening and closing the throttle for several times Adjusting the carburetor pickup timing 1 Disconnect...

Page 51: ...silencer 2 Make sure that the choke valve is fully open 3 Check that the choke solenoid face A is between the marking B on the plunger Adjust the position of the choke solenoid if necessary 60H30400 Adjusting the throttle link and the throttle cable operation NOTE Complete the ignition timing adjustment throttle valves synchronization engine idle speed adjustment and carburetor pickup tim ing adju...

Page 52: ...0427 5 Adjust the length B of the shift cable joint 2 so that its hole is aligned with the set pin 60H30428 The shift cable joint 2 2 2 2 2 must be screwed in a minimum of 8 0mm 0 31in B B B B B 6 Connect the shift cable joint 2 install the clip 3 and tighten the locknut 1 7 Check the shift cable for smooth operation and repeat steps 3 6 if necessary Power trim and tilt unit Checking the power tri...

Page 53: ... with the tilt stop lever 1 60H30430 After tilting up the outboard motor be sure to support it with the tilt stop lever 1 1 1 1 1 Oth erwise the outboard motor could suddenly lower if the power trim and tilt unit should lose fluid pressure 2 Remove the reservoir cap 2 and check the fluid level in the reservoir 60H30440 NOTE If the fluid is at the correct level the fluid should overflow out of the ...

Page 54: ...internal parts of the lower case if necessary Recommended gear oil Hypoid gear oil SAE 90 Lower unit Checking the gear oil level 1 Fully tilt down the outboard motor 2 Remove the check screw 1 and check the gear oil level in the lower case 60H30450 NOTE If the oil is at the correct level the oil should overflow out of the check hole when the check screw 1 is removed 3 If the oil level is low add s...

Page 55: ...nd no air bubbles are visible 60H30470 5 Install the check screw 2 and quickly in stall the drain screw 1 Checking the lower unit for air leak age 1 Remove the check screw 1 and install the leakage tester 60H30480 2 Apply the specified pressure to the lower unit to check whether the pressure is re tained for 10 seconds Do not over pressurize the lower unit oth erwise the oil seals may be damaged N...

Page 56: ...with water for 15 minutes and get immediate medical attention Antidote INTERNAL Drink large quantities of water or milk fol lowed with milk of magnesia beaten egg or vegetable oil Get immediate medical attention Batteries generate explosive hydrogen gas Always follow these preventive measures Charge batteries in a well ventilated area Keep batteries away from fire sparks or open flame e g welding ...

Page 57: ...er The proce dures mentioned in this manual may not al ways apply therefore consult the instruction manual of the battery Disconnect the black battery cable first then the red battery cable Lubrication 1 Apply Yamaha grease A to the areas shown 60H30520 60H30530 60H30540 60H30550 60H30560 60H30570 60H30580 ...

Page 58: ...cks and adjustments 3 23 3 Apply Yamaha grease D to the areas shown 60H30610 C 60H30590 NOTE Apply grease to the grease nipples until it over flows from the bushings A 2 Apply Yamaha grease C to the areas shown 60H30600 60H30605 C ...

Page 59: ...uel pump fuel joint 4 3 Checking the fuel joint 4 6 Checking the fuel filter 4 6 Checking the fuel pump 4 7 Disassembling the fuel pump 4 8 Assembling the fuel pump 4 8 Carburetor 4 9 Disassembling the carburetor 4 12 Checking the carburetor 4 12 Assembling the carburetor 4 13 Fuel system FUEL ...

Page 60: ...60H5E11 Fuel system FUEL 4 1 Special service tools Vacuum pressure pump gauge set 90890 06756 ...

Page 61: ...60H5E11 4 Hose routing Fuel hoses 60H40010 4 2 Special service tools Hose routing 1 Fuel hose fuel joint to fuel filter 2 Fuel hose fuel filter to fuel pump 3 Fuel hose fuel pump to carburetor ...

Page 62: ...6mm 9 Fuel hose 1 Fuel joint to Fuel filter 10 Fuel hose 1 Fuel filter to Joint 11 Fuel hose 1 Joint to Fuel pump 12 Fuel hose 2 Fuel pump to Joint 13 Fuel hose 1 Joint to Joint 14 Fuel hose 2 Joint to Carburetor 15 Fuel hose 1 Joint to Carburetor 16 Joint 3 17 Plastic tie 20 No Part name Q ty Remarks 1 2 3 4 4 5 6 7 8 9 10 11 12 13 14 15 16 16 16 17 17 17 17 17 17 17 17 17 17 17 17 17 17 17 17 17...

Page 63: ...ector No Part name Q ty Remarks 1 Bolt 1 M6 x 16 mm 2 Washer 1 3 Fuel filter nut holder 1 4 Bolt 1 M6 x 14 mm 5 Fuel filter bracket 1 6 Fuel filter cap 1 7 O ring 1 8 O ring 1 9 Fuel filter element 1 10 Spring 1 11 Red ring 1 12 Fuel filter cup 1 13 Fuel filter nut 1 14 O ring 1 15 Drain screw 1 ...

Page 64: ...ame Q ty Remarks 1 Fuel pump base 2 2 Diaphragm 2 3 Spring seat 2 4 Spring 2 5 Nut 8 6 Fuel pump body 2 7 Fuel pump valve 8 8 Screw 8 M5 x 6 mm 9 Gasket 2 10 Diaphragm 2 11 Diaphragm body 2 12 Screw 6 M5 x 35 mm 1 2 3 4 5 6 7 8 9 10 11 12 5 7 8 7 8 ...

Page 65: ...the fuel hose connector if neces sary 60H40040 Checking the fuel filter 1 Check that the float 1 is in the appropriate position If water is accumulated drain it by loosening the drain screw 2 60H40050 2 Check the fuel filter element 3 for clogging contamination or foreign substances and check the fuel filter cap 4 for crack or leak age Clean with straight gasoline or replace them if necessary 60H4...

Page 66: ...mp outlet with a finger Make sure no air leakage is detected 60H40080 4 Apply the specified negative pressure to make sure that no air leakage is detected 60H40090 5 Mount the special service tool at the fuel pump outlet 6 Apply the specified positive pressure to make sure that no air leakage is detected Perform disassembly inspection if neces sary 60H40100 NOTE Duly assemble the fuel pump valve t...

Page 67: ...for damage 60H40110 3 Clean out the fouling on the fuel pump body Assembling the fuel pump NOTE Clean the parts and keep the seat valve and the diaphragm in the gasoline before assem bly to obtain prompt operation of the pump at the engine start 1 Mount the seat valve on the pump body 60H40115 2 Mount the spring 60H40125 3 Mount the gasket diaphragm and cover 60H40127 NOTE Make sure that the gaske...

Page 68: ... 5 Carburetor 3 1 6 Accelerator lever rod 1 7 Choke rod 2 8 Joint 5 9 Choke nob 1 10 Gasket 3 11 Intake silencer 1 12 Screw 12 M5 x 55 mm 13 Hose 1 14 Bolt 2 M6 x 15 mm 15 Choke solenoid 1 16 O ring 1 17 Grommet 1 No Part name Q ty Remarks Carburetor 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 ...

Page 69: ...ilot screw 6 6 Spring 6 7 Screw 3 8 Gasket 3 9 Air bleed plug 6 10 Slow air jet 6 11 Carburetor body 3 12 Needle valve 6 13 Clip 6 14 Pin 6 15 Float 6 16 Gasket 3 17 Screw drain 6 No Part name Q ty Remarks 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 ...

Page 70: ...o 2 4 154 No 5 152 No 6 158 20 Plug 6 21 Gasket 6 22 Slow jet 6 23 Screw 12 M5 x 16 mm 24 Idle adjusting screw 1 25 Spring 1 26 Carburetor 2 1 27 Carburetor 3 1 28 Choke joint 1 No Part name Q ty Remarks 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 ...

Page 71: ...essive force may impair the performance in the serious way NOTE Clean the needle valve main jet and pilot jet afrer removal 2 Check the carburetor body for cracks or damage Replace it if necessary 3 Check the pilot screws and needle valves for bending or stepped wear Replace them if necessary 60H40150 4 Check the main jet pilot jet main air jet pilot air jet and main nozzle for clogging and contam...

Page 72: ...excessive force to push in the needle valve Do not apply the excessive force to screw in the pilot screw NOTE Install the pilot screw 1 turn in until it is lightly seated and then turn out by the specified num ber of turns 60H40170 Pilot screw 1 turn out 1 1 8 1 4 7 8 1 3 8 ...

Page 73: ...e crankcase 5 27 Removing the piston connecting rod assembly and the crankshaft 5 28 Piston Connecting rod 5 29 Disassembling the piston and the connecting rod assembly 5 30 Checking the cylinder block 5 30 Checking the piston 5 31 Checking the connecting rod 5 33 Checking the crankshaft 5 33 Installing the crankshaft 5 34 Assembling the piston and connecting rod 5 35 Installing the piston and con...

Page 74: ...r 90890 06521 Ball bearing attachment 90890 06663 90890 06637 Driver rod LS 90890 06606 Bearing inner race attachment 90890 06661 90890 06662 Needl bearing attachment 90890 06654 Driver rod L3 90890 06652 Bearing Separator 90890 06534 Bearing outer race attachment 90890 06626 90890 06624 Piston ring compressor 90890 05158 ...

Page 75: ...until the reading on the compression gauge stabi lizes and then check the compression pressure 60H50010 Compression gauge 90890 03160 Minimum compression pressure reference data 520 kPa 5 2 kgf cm2 75 4 psi 5 If the measured compression pressure is below specification or it varies among the cylinders add a small amount of engine oil to the cylinder and check the pressure again NOTE If the compress...

Page 76: ...etaining plate 1 6 Grommet 1 7 Air vent hose 1 8 Dowel pin 2 9 Gasket 1 10 Bolt 2 M6 x 30 mm 11 Bolt 6 M8 x 135 mm 12 Bolt 2 M6 x 20 mm 13 Apron 1 14 Bolt 2 M6 x 20 mm 15 Bolt 2 M6 x 20 mm 16 Upper case cover 1 17 Bolt 4 M8 x 30 mm No Part name Q ty Remarks 11 12 9 10 1 4 5 6 8 3 2 7 19 20 13 14 15 16 17 17 18 21 22 23 24 ...

Page 77: ...5E11 5 18 Nut 2 19 Grommet 2 20 Collar 2 21 Grommet 2 22 Washer 2 23 Washer 2 24 Washer 2 No Part name Q ty Remarks Power unit 60H50020 5 4 11 12 9 10 1 4 5 6 8 3 2 7 19 20 13 14 15 16 17 17 18 21 22 23 24 ...

Page 78: ... Flywheel magnet assembly 1 4 Bolt 3 M6 x 60 mm 5 Stator assembly 1 6 Pulser coil assembly 1 7 Screw 4 M6 x 18 mm 8 Stopper 4 9 Base 1 10 Timing plate 1 11 Screw 1 M6 x 10 mm 12 Woodruff key 1 No Part name Q ty Remarks C 572 LT E 1 2 3 4 5 6 8 9 10 11 7 12 5 5 ...

Page 79: ...H50035 1 Joint 2 2 Nut 2 3 Magnet control rod 1 4 Accelerator link 1 5 Bolt 1 M6 x 25 mm 6 Collar 1 7 Wave washer 1 8 Accelerator cam 1 9 Cap 2 10 Nut 2 11 Fully advanced stop screw 1 12 Spring 1 13 Standard ignition timing adjusting screw 1 14 Bolt 1 M8 x 45 mm 15 Washer 1 16 Collar 1 17 Bush 1 No Part name Q ty Remarks ...

Page 80: ...ontrol lever 1 21 Washer 1 22 Washer 1 23 Shift bracket 1 24 Bolt 2 M8 x 30 mm 25 Bush 1 26 Clamp 1 27 Cable joint 1 28 Clip 1 29 Magnet control lever 1 No Part name Q ty Remarks A 1 8 17 19 27 9 21 22 23 24 25 10 29 7 6 5 4 18 9 14 26 15 16 1 28 2 2 20 13 10 11 3 A A A A ...

Page 81: ...40 1 Bolt 2 M8 x 45 mm 2 Starter motor 1 3 Shim 1 4 Washer 1 5 Bolt 1 M8 x 35 mm 6 Wire lead 1 7 Nut 1 8 Washer 2 9 Bolt 1 M8 x 16 mm 10 Negative battery lead 1 11 Wiring harness 1 12 Bolt 2 M6 x 16 mm 13 Washer 2 14 Bracket 1 15 PTT relay 1 Sb 16 PTT relay 1 Lg 17 Starter relay 1 No Part name Q ty Remarks 5 8 Power unit ...

Page 82: ...3 14 15 16 17 18 19 20 21 21 22 24 25 26 27 28 22 23 572 LT 572 LT 1 60H50040 18 Holder 1 19 Wire lead 1 20 Connector 1 21 Washer 6 22 Nut 6 23 Cover 2 24 Positive battery lead 1 25 Fuse 1 26 Fuse holder 1 27 Plastic tie 1 28 Tube 1 No Part name Q ty Remarks 5 9 ...

Page 83: ...ommet 3 3 Washer 3 4 Bolt 3 M6 x 30 mm 5 Bolt 2 M6 x 12 mm 6 Screw 4 M6 x 19 mm 7 CDI unit cover 1 8 Screw 4 M6 x 15 mm 9 Ignition coil 6 10 Bolt 6 M6 x 20 mm 11 Bolt 2 M6 x 12 mm 12 CDI unit 1 13 Wire 1 14 Wire 1 15 Wire 1 Charge coil 16 Wire 1 Pulser coil 17 Wiring harness 1 No Part name Q ty Remarks ...

Page 84: ...60H5E11 Power unit POWR 5 11 60H50050 18 Grommet 1 19 Collar 3 20 Plug cap 6 No Part name Q ty Remarks 1 2 3 4 5 6 7 8 9 10 11 12 13 15 14 17 16 18 19 20 ...

Page 85: ...or G W 7 Wire lead 1 Rectifier Regulator G 8 Rectifier Regulator 1 9 Bolt 2 M6 x 20 mm 10 Nut 3 11 Spring washer 3 12 Washer 3 13 Nut 1 14 Spring washer 1 15 Washer 1 16 Cover 1 17 Screw 2 M6 x 24 mm No Part name Q ty Remarks 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 10 10 11 11 12 12 29 60H50045 5 12 Power unit ...

Page 86: ...1 Collar 2 22 Grommet 2 23 Bracket 1 24 Bolt 1 M6 x 12 mm 25 Clamp 1 26 Plastic tie 1 27 Choke solenoid 1 28 O ring 1 29 Bolt 2 M6 x 15 mm No Part name Q ty Remarks 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 10 10 11 11 12 12 29 60H50045 5 13 ...

Page 87: ...Remove the dowels 60H50100 Removing the power unit NOTE If the power unit is to be disassembled it is recommended to loosen the nut on flywheel magnet assembly before removing the power unit to improve working efficiency 1 Disconnect the battery cable 1 60H50070 2 Disengage the remote control connector Remove the shift cable 2 and the throttle cable 3 60H50075 3 Remove the flywheel magnet cover an...

Page 88: ...r motor 60h50150 Flywheel holder 90890 06522 Flywheel puller 90890 06521 5 15 Removing the flywheel magnet 1 Remove the nut on the flywheel magnet 60H50110 30 mm Apply force in the direction of the arrows shown While working take precautions against the slipping off of the flywheel holder 2 Remove the flywheel magnet 60H50120 Screw in the flywheel puller set bolts evenly to the full extent Make su...

Page 89: ...ove the bracket 60H50184 Removing the power unit 5 16 4 Remove the starter relay and the power trim and tilt relay assembly 60H50160 5 Remove the Rectifier Regulator hour meter and magnet control lever 60H50170 6 Remove the CDI unit cover 60H50180 ...

Page 90: ...4 15 13 14 15 60H50185 Intake manifold 1 Gasket 1 2 Reed valve 6 3 Gasket 6 4 Clamp 2 5 Bolt 16 M6 x 25mm 6 Bolt 12 M5 x 15mm 7 Hose 3 8 Hose 1 9 Hose 1 10 Hose 1 11 Clamp 2 12 Hose 6 13 Bolt 4 M6 x 20 mm 14 Bushing 2 15 Damper bracket 2 No Part name Q ty Remarks 5 17 ...

Page 91: ...arburetor and the fuel hoses 60H50190 2 Remove the intake manifold and the reed valve plate assembly 60H50200 60H50215 NOTE Loosen the bolts in the sequence shown 3 Remove the reed valve assembly 60H50210 4 Check the reed valves for cracks or dam age Replace them if necessary ...

Page 92: ... 5 mm 0 26in 5 19 5 Check the reed valves for bending Replace them if the bending exceeds the specified limit 60H50220 6 Measure the valve stopper height Replace the stopper if the height exceeds the speci fied limit 60H50230 7 Install the reed valves 60H50240 NOTE Use new gaskets ...

Page 93: ... 1 4 Gasket 2 5 Exhaust inner cover 1 6 Exhaust outer cover 1 7 Bolt 29 M6 x 35mm 8 Gasket 1 9 Pressure control valve cover 1 10 Bolt 2 M6 x 20mm 11 Pressure control valve seat 1 12 Pressure control valve 1 13 Spring 1 14 Clamp 1 15 Bolt 1 M6 x 12 mm 16 Clamp 1 No Part name Q ty Remarks Intake manifold Exhaust 5 20 ...

Page 94: ...en the bolts in the sequence shown 3 Remove the cylinder block exhaust inner cover 4 Check the pressure control valve for cracks or damage Also check the pressure con trol valve seat for deformation Replace them if necessary 60H50270 5 Check the spring for fatigue or deforma tion Replace it if necessary 6 Check the exhaust cover for distortion or corrosion Replace it if necessary 60H50275 ...

Page 95: ...ermoswitch 2 4 Gasket 2 5 Cylinder head cover 2 6 Gasket 2 7 Thermostat 2 8 Thermostat cover 2 9 Bolt 8 M6 x 40 mm 10 Bolt 36 M6 x 30 mm 11 Bolt 24 M8 x 60 mm 12 Clamp 1 13 Bolt 2 M8 x 20 mm 14 Engine hanger 1 15 Spark plug 6 No Part name Q ty Remarks Exhaust Cylinder head 5 22 Cylinder head ...

Page 96: ...e sequence shown 6 Check the anodes on the cylinder block Clean the anode s surface and replace if it has been eroded into half or smaller 60H50330 Do not oil grease or paint the anodes oth erwise they will not be able to prevent the galvanic corrosion effectively 7 Clean out the mineral deposits and con tamination on the cylinder head Also check the possible corrosion on the cylinder head Replace...

Page 97: ...0 04in Cylinder head 5 24 9 Check the cylinder head warpage Replace the cylinder head if measured warpage exceeds the specified limit 60H50340 NOTE Check the warpage in the directious shown using a straightedge and a thickness gauge ...

Page 98: ...dle bearing 1 6 Crankcase 1 7 Dowel 2 8 Bolt 8 M10 x 60mm 9 Bolt 12 M8 x 30mm 10 Oil seal housing 1 11 Oil seal 1 12 Oil seal 1 13 Bolt 4 M6 x 20mm 14 Gasket 1 15 Cover 1 16 Bolt 2 M6 x 16 mm 17 O ring 1 No Part name Q ty Remarks 5 25 Cylinder block E E 1 2 3 4 5 6 7 8 10 11 12 13 9 3 10 A A A A 14 15 16 17 ...

Page 99: ...od bolt 12 5 Circlip 2 6 Main journal bearing 2 7 Cylinder block 1 8 Anode 8 9 Screw 8 10 Piston connecting rod assembly 6 11 Gasket 2 12 Accessory plug 2 13 Seal ring 9 14 Bearing 1 15 Cir clip 1 No Part name Q ty Remarks Cylinder block 5 26 E E E 1 2 3 4 5 6 10 12 13 14 15 E 11 5 6 9 7 8 8 ...

Page 100: ...H50380 A A A A E Ball bearing attachment 90890 06663 Driver rod LS 90890 06606 Bearing inner race attachment 90890 06661 Needle bearing attachment 1 90890 06654 Driver rod L3 90890 06652 2 5 27 Ball bearing attachment 3 90890 06637 Bearing outer race attachment 4 90890 06624 Driver rod LS 90890 06606 3 4 4 Install a new O ring and a new oil seal into the bearing housing 60H50390 5 Remove the oil s...

Page 101: ...n toward the cylinder head Take precautions not to scratch the cyl inder sleeve surface with the connecting rod big end when pulling out the piston On the plane of the connecting rod con necting rod cap mating area mark the cyl inder number from which they came with a permanent marker so that the original condition of the mating face can be re stored Removed bearings must be sorted out and kept in...

Page 102: ...1 4 5 6 3 2 7 E E 5 3 8 60H50450 1 Connecting rod 6 2 Piston 3 Starboard 3 Washer 12 4 Needle bearing 6 5 Piston pin clip 12 6 Piston pin 6 7 Piston ring set 6 8 Piston 3 Port No Part name Q ty Remarks 5 29 Piston Connecting rod ...

Page 103: ...inder block 1 Check the cylinder sleeve for cracks or damage 2 Remove any rust or deposits on the cool ing water passage wall and check it for cor rosion Clean or replace if necessary 60H50460 Do not scratch the contacting surfece of the cylinder head and cylinder block 3 Check the anode Clean the anode s sur face and replace if it has been eroded into half or smaller 60H50470 Do not oil grease or...

Page 104: ...ments Taper T is obtained by subtracting D5 from D1 and D6 from D2 and selecting the maxi mum value To obtain the out of round R calculate the difference between D1 and D2 D3 and D4 and D5 and D6 respectively The largest dif ference of the three shall apply Oversize pistons is available in two sizes Checking the piston 1 Check the piston outside diameter Re place the piston if the diameter is out ...

Page 105: ...ion 60H50520 NOTE Push in the piston ring with the piston crown to the specified measuring position H in the cylinder Make sure that the cylinder sleeve bore diam eter falls within the specified limit 6 Measure the piston pin boss inside diam eter Replace the piston if the measure ment is out of specification 60H50530 7 Measure the piston pin outside diameter Replace the piston pin if the measurem...

Page 106: ... the small end and at the big end Replace the bearings if nec essary Checking the crankshaft 1 Remove the cir clip and the crankshaft lower bearing 60H50580 NOTE Use a commercially available bearing puller 2 Check the bearing for run out or roughness Replace the bearing if necessary 3 Remove the seal ring 4 Check the seal ring for cranks or damage 5 Measure the crankshaft journal diameter Replace ...

Page 107: ...od small end in parallel to the crank shaft 10 Measure the connecting rod side clearance Replace the connecting rod if the measure ment is out of specification 60H50630 Connecting rod side clearance 0 12 0 26 mm 0 0047 0 0102 in at 20 C 68 F Bearing inner race attachment 90890 06662 11 Check the crankshaft journal bearings Re place the bearings if necessary Installing the crankshaft 1 Install the ...

Page 108: ...ith the marking on the piston B Make sure that piston and piston pin bear ings are installed in the original combination 4 Assemble the crankshaft and the cylinder block 60H50655 NOTE The dowels on the cylinder block shall be fit ted into the dowel holes on the roller bear ings Align the seal ring end gap with the crank case center line 5 Install the bearing housing and the oil seal housing and te...

Page 109: ...d on the port side 2 Install the connecting rod caps 60H50690 Connecting rod 1st 19 N m 1 9 kgf m 14 ft lb 2nd 36 N m 3 6 kgf m 27 ft lb 3rd Loosen completely 4th 19 N m 1 9 kgf m 14 ft lb 5th 36 N m 3 6 kgf m 27 ft lb T R E NOTE Make sure that the split face of the connect ing rod caps are mated correctly to the origi nal position Apply oil on the bolts seating face and the threaded area 3 Tighte...

Page 110: ...anode if it has been eroded into half or smaller 2 Install the cylinder head 60H50740 NOTE Tighten the cylinder head bolts in the se quence shown Apply some oil on the bolts seating face and the threaded area 5 37 6 Tighten the crankcase bolts 60H50720 NOTE Tighten the bolts to the specified torques in two stages and in the sequence shown Apply some oil on the bolt s seating face and the threaded ...

Page 111: ...t cover 60H50760 NOTE Tighten the thermostat cover bolts to the speci fied torques in two stages and in the sequence shown Spark plug 25N m 2 5kgf m 18 ft lb T R Cylinder head cover bolt 1st 4 N m 0 4 kgf m 3 ft lb 2nd 8 N m 0 8 kgf m 6 ft lb T R Thermostat cover bolt 1st 4 N m 0 4 kgf m 3 ft lb 2nd 8 N m 0 8 kgf m 6 ft lb T R 5 Install the thermoswitch 60H50770 6 Install the spark plugs Piston Co...

Page 112: ... cover 1 Install the cylinder block exhaust cover 2 Install the exhaust outer cover and the ex haust inner cover 60H50790 60H50800 NOTE Tighten the exhaust outer cover bolts to the specified torque in two stages and in the se quence shown 3 Install the pressure control valve 60H50810 Mounting the intake manifold 1 Install the reed valve plate assembly and the intake manifold 60H50825 NOTE Tighten ...

Page 113: ...stall the power unit and tighten the bolts and nuts 60H50910 Flywheel holder 90890 06522 Flywheel magnet nut 160 N m 16 kgf m 116 ft lb T R Power unit mounting bolt 21 N m 2 1 kgf m 15 ft lb T R Ignition coil 8 N m 0 8 kgf m 6 ft lb T R 3 Tighten the flywheel magnet 60H50920 30 mm NOTE Apply some engine oil on the nut before tight ening Apply force in the direction of the arrows shown While workin...

Page 114: ...ilot jet hose and water pressure control valve hose 11 Install the carburetor 60H50940 Terminal nut 4 N m 0 4 kgf m 3 ft lb T R Mounting bolt 29N m 2 9 kgf m 21 ft lb Terminal nut 9N m 0 9 kgf m 6 ft lb T R 5 Install the Rectifier Regulator hour meter and the magnet control lever 60H50850 6 Install the starter relay and the power trim and tilt relay assembly 60H50860 7 Install the starter motor 60...

Page 115: ... 6 N m 0 6 kgf m 5 ft lb T R 16 Connect the battery cable 60H50970 12 Connect the fuel hoses 60H50950 13 Connect the shift cable and the throttle cable 60H50960 NOTE Adjust the shift cable and the throttle cable 14 Install the flywheel magnet cover and the intake silencer 15 Connect the remote control connector ...

Page 116: ...ropeller shaft assembly 6 16 Drive shaft and lower case regular rotation model 6 17 Removing the drive shaft and forward gear 6 18 Disassembling the lower case 6 18 Checking the drive shaft housing 6 19 Assembling the drive shaft housing 6 19 Checking the forward gear 6 20 Assembling the forward gear 6 20 Checking the drive shaft 6 21 Checking the pinion gear 6 21 Assembling the lower unit regular...

Page 117: ...del 6 46 Removing the drive shaft and reverse gear 6 47 Disassembling the lower case 6 47 Checking the drive shaft housing 6 48 Assembling the drive shaft housing 6 48 Checking the reverse gear 6 49 Assembling the reverse gear 6 49 Checking the drive shaft 6 49 Checking the pinion gear 6 49 Assembling the lower unit counter rotation model 6 50 Installing the lower case 6 50 Installing the water pu...

Page 118: ...sing puller claw L 90890 06502 Stopper guide plate 90890 06501 Center bolt 90890 06504 Bearing separator 90890 06534 Stopper guide stand 90890 06538 Bearing puller assembly 90890 06535 Driver rod L3 90890 06652 Needle bearing attachment 90890 06653 90890 06610 90890 06612 Driver rod SS 90890 06604 Bearing depth plate 90890 06603 ...

Page 119: ...06520 Pinion nut holder 90890 06505 Bearing outer race puller assembly 90890 06523 Ball bearing attachment 90890 06636 90890 06633 90890 06629 Driver rod LL 90890 06605 Driver rod LS 90890 06606 Bearing outer race attachment 90890 06619 Shift rod push arm 90890 06052 Pinion height gauge 90890 06710 Digital caliper 90890 06704 Shimming plate 90890 06701 ...

Page 120: ...60H5E11 Lower unit LOWR 6 3 Backlash indicator 90890 06706 Magnet base 90890 06705 Magnet base plate 90890 07003 Dial gauge set 90890 01252 Ring nut wrench 90890 06578 ...

Page 121: ...ion model 1 Lower unit 1 2 Check screw 1 3 Gasket 2 4 Dowel 2 5 Bolt 6 M10 x 45mm 6 Drain screw 1 7 Bolt 1 M10 x 45mm 8 Bolt 1 M10 x 70mm 9 Spacer 1 10 Propeller 1 11 Washer 1 12 Washer 1 13 Propeller nut 1 14 Cotter pin 1 15 Trim tab 1 16 Cap 1 No Part name Q ty Remarks 6 4 Lower unit regular rotation model ...

Page 122: ...9 22 28 29 30 31 1 Bolt 3 M6 x 20mm 2 Oil seal 1 3 Oil seal housing 1 4 O ring 1 5 Spring 1 6 Circlip 1 7 Shift rod 1 8 Joint 1 9 Plastic tie 3 10 Hose 1 11 Joint 1 12 Bolt 4 M8 x 45mm 13 Cover 1 14 Water seal damper 1 15 Water pump housing 1 16 O ring 1 17 Insert cartridge 1 No Part name Q ty Remarks 6 5 ...

Page 123: ...24 Seal damper 1 25 Guide 1 26 Nut 1 27 Cooling water inlet cover 1 28 Cooling water inlet cover 1 29 Bolt 1 M5 x 45 mm 30 Washer 3 31 Washer 4 No Part name Q ty Remarks 11 12 13 14 15 16 17 18 20 19 10 1 4 5 6 3 2 7 24 23 22 21 4 25 26 27 8 9 22 28 29 30 31 60h60020 Lower unit regular rotation model 6 6 ...

Page 124: ...ve it Remove the lower unit from the upper case after loosening and removing the bolts 60h60040 NOTE Mounting bolt appears when the trim tab is removed Make sure that the mounting bolt is removed as well Removing the lower unit 1 Disconnect the battery cable 2 Remove the lock plate for the engine stop switch 3 Set the gear shift in neutral position 4 Remove the drain screw and the check screw to d...

Page 125: ...ater pump housing 1 for de formation Also check the insert cartridge 2 for wear or deformation 60h60060 2 When the insert cartridge is removed al ways replace the O ring 3 with a new one and insert the projection on the insert car tridge into the water pump housing hole at the time of reassembly 60h60070 NOTE When mounting the insert cartridge apply small amount of Yamabond 4 to it and insert the ...

Page 126: ...60H5E11 Lower unit LOWR 6 9 4 Check the Woodruff key 4 and the groove A for wear Replace if necessary 60h60090 5 Check the shift rod for deformation or wear Replace if necessary 60h60100 ...

Page 127: ...1 8 Cross pin 1 9 Cross pin ring 1 10 Propeller shaft 1 11 Washer 1 12 Reverse gear 1 13 Reverse gear shim As required 14 Thrust washer 1 15 Ball bearing 1 16 O ring 1 17 Propeller shaft housing 1 No Part name Q ty Remarks Lower unit Propeller shaft Propeller shaft housing regular rotation model 6 10 Propeller shaft Propeller shaft housing regular rotation model ...

Page 128: ...60H5E11 Lower unit LOWR A A 11 12 13 14 15 16 17 18 20 19 9 10 1 4 5 6 8 3 2 7 21 22 4 2 60h60110 18 Key 1 19 Needle bearing 1 20 Oil seal 2 21 Claw washer 1 22 Ring nut 1 No Part name Q ty Remarks 6 11 ...

Page 129: ... tabs and remove the ring nut 60h60120 2 Remove the propeller shaft housing assem bly and the straight key 60h60130 NOTE Make sure that the shims left in the lower case have been removed Disassembling the propeller shaft housing assembly 1 Remove the reverse gear 60h60140 NOTE To remove the reverse gear squeeze in the bearing separator between the washer plate and the reverse gear Bearing separato...

Page 130: ...new ones Shimming is required when the reverse gear ball bearing or propeller shaft hous ing is replaced Checking the propeller shaft housing assembly 1 Clean the propeller shaft housing and check it for cracks corrosion or damages Replace if necessary 60h60170 2 Check the teeth and dogs of the reverse gear for cracks or wear Replace the gear if necessary 60h60180 Stopper guide stand 2 90890 06538...

Page 131: ...revent any damage to the gear teeth 4 Install the reverse gear assembly to the pro peller shaft housing 60h60230 NOTE Shimming is required when reverse gear or ball bearing is replaced Place an appropriate plate on the dogs be fore using a press to prevent any damage to the gear teeth Assembling the propeller shaft housing assembly 1 Install a new needle bearing into the pro peller shaft housing t...

Page 132: ... out the slider assembly 5 60h60250 NOTE Take precautions so that the balls will not jump out while pulling out the slider Checking the propeller shaft assem bly 1 Check the propeller shaft for bends for wear Replace if necessary 60h60260 2 Measure the propeller shaft run out 60h60265 3 Check the dog clutch for breakage or wear Replace if necessary 60h60270 4 Check the slide shift and the slider f...

Page 133: ...to make the assembling work easier 2 Insert the slider assembly 1 into the pro peller shaft 2 NOTE Make sure that the cross pin holes are aligned when inserting the slider assembly 3 Install the dog clutch 3 in the marked ori entation and fit in the cross pin 4 60h60295 NOTE A new dog clutch may be installed in either ways 4 Install the cross pin ring NOTE Make sure that the spring is not twisted ...

Page 134: ...eal 2 5 Bolt 4 8 x 25mm 6 Drive shaft housing 1 7 Needle bearing 1 8 O ring 1 9 Pinion shim As required 10 Thrust bearing 1 11 Needle bearing 1 12 Pinion 1 13 Nut 1 14 Forward gear shim 1 15 Taper roller bearing 1 16 Needle bearing 2 17 Forward gear 1 No Part name Q ty Remarks 6 17 Drive shaft and lower case regular rotation model ...

Page 135: ...ter race puller assembly 1 90890 06523 Ball bearing attachment 2 90890 06636 Driver rod LL 3 90890 06605 Drive shaft and lower case regular rotation model Removing the drive shaft and forward gear NOTE Shimming is required when the forward gear or taper roller bearing is replaced 1 Loosen the pinion nut 60h60310 2 Remove the drive shaft housing 3 Remove the drive shaft and then the pin ion gear 4 ...

Page 136: ...6 25 mm 0 2264 0 2460 in Installation depth B 0 25 0 75 mm 0 0098 0 0295 in Checking the drive shaft housing 1 Check the drive shaft housing for cracks or damage Also check the needle bearing for run out and roughness and the oil seals for damage Disassemble them if neces sary 2 Remove the cover and the oil seals 3 Remove the needle bearing 60h60340 NOTE When the needle bearing and oil seals are r...

Page 137: ...r run out or roughness Disas semble them if necessary 2 Remove the bearing 60h60370 NOTE When the taper roller bearing is removed al ways replace it with a new one 3 Remove the needle bearing 60h60380 NOTE When the needle bearing is removed always replace it with a new one Assembling the forward gear 1 Install the needle bearing 60h60390 2 Install a new taper roller bearing 60h60400 NOTE Shimming ...

Page 138: ...nd the thrust bearing for run out or roughness Replace if necessary Shimming is required when the thrust bear ing is replaced Checking the pinion gear 1 Check the pinion gear teeth for cracks or wear 60h60420 Assembling the lower unit regu lar rotation model Installing the lower case 1 Install the shims and the taper roller bear ing outer race 60h60430 Shimming is required when the forward gear th...

Page 139: ...fting it up slightly then aligning its splines with the pinion gear 6 Insert the thrust bearing into the drive shaft and install the drive shaft housing 60h60450 NOTE Shimming is required when the thrust bearing is replaced 7 Tighten the pinion nut 60h60460 8 Install the slid shift to the propeller shaft 9 Install the propeller shaft assembly 60h60475 NOTE Set the dog clutch in neutral position Se...

Page 140: ... and tighten the ring nut 60h60500 14 Make sure that the shifting mechanism works properly 60h60510 NOTE Change the shift rod position to forward to re verse and to neutral Make sure that propel ler shaft rotating direction is correct in forward and in reverse Also make sure that the posi tion is correct in neutral 15 Bend one of the claw washer tabs toward yourself 60h60515 Ring nut wrench 8 9089...

Page 141: ...on the sliding face between the impeller and the outer plate car tridge 4 Install the O ring into the water pump hous ing assembly 6 and install the water pump housing on the lower case 60h60540 NOTE To install the water pump housing apply Yamaha grease A to the inner face of the wa ter pump housing assembly and then turn the drive shaft clockwise while pushing down the pump housing Installing the...

Page 142: ...nd the propeller nut Place a block of wood between the anti cavitation plate and the propeller to keep the propeller from turning Then tighten the nut to the specified torque 60h60580 60h60590 Place a block of wood between the anti cavitation plate and the propeller Do not touch the propeller with your hands Disconnect the battery cable and remove the lock plate for the engine stop switch to preve...

Page 143: ...ear oil until it flows out of the check hole and no air bubbles are visible 60h30470 6 Install the check screw and quickly install the drain screw Assembling the lower unit regular rotation model Recommended gear oil Hypoid gear oil SAE 90 Oil quantity Regular rotation model 980 cm3 34 5 lmp oz ...

Page 144: ...60H5E11 Lower unit LOWR 69h60600 A B B3 T3 B4 61 0 T1 B1 37 0 17 2 A1 A3 B2 T2 A2 F R P 69h60605 6 27 Shimming regular rotation model ...

Page 145: ...and inner parts are reused for the lower unit reassembly Shimming is required if either the lower case or the assembly parts are replaced for the lower unit reassembly Selecting the pinion shims NOTE Obtain the pinion shim thickness T3 by us ing the specified measurement s and the cal culation formula Calculation formula Pinion shim thickness T3 80 00 P 100 M3 M4 1 Measure the drive shaft housing ...

Page 146: ...h when the unit is assembled Readjustment shall be wade if the measured backlash is out of specifica tion 6 Calculate the pinion shim thickness S69j6565 Calculation formula Pinion shim thickness T3 80 00 P 100 M3 M4 Example If M3 46 85 M4 32 52 and P 5 then T3 80 00 5 100 46 85 32 52 80 00 0 05 46 85 32 52 0 58 7 Select the pinion shim s as follows Selecting the forward gear shims NOTE Obtain the ...

Page 147: ... check the backlash when the unit is assembled Readjustment shall be made if the backlash is out of specification 3 Calculate the forward gear shim thickness Calculation formula Forward gear shim thickness T1 28 60 F 100 M1 Example If M1 28 00 and F 5 then T1 28 60 5 100 28 00 28 60 0 05 28 00 0 55 4 Select the forward gear shim s as follows Selecting the reverse gear shims NOTE Obtain the reverse...

Page 148: ... if the backlash is out of specification 3 Calculate the reverse gear shim thickness Calculation formula Reverse gear shim thickness T2 M2 29 00 R 100 Example If M2 30 50 and R 5 then T2 30 50 29 00 5 100 30 50 29 00 0 05 1 45 4 Select the reverse gear shim s as follows Backlash regular rotation model NOTE Measure the backlash before installing the water pump Set the gear shift in neutral position...

Page 149: ...ator onto the drive shaft NOTE Backlash indicator shall be installed at practi cably the closest position to the lower hous ing 6 Slowly turn the drive shaft clockwise and counterclockwise and measure the back lash based on the dial gauge readings taken at the points where the drive shaft stops in each direction S69J6655 NOTE While checking turn the drive shaft lightly with out applying too much f...

Page 150: ...ls and se cure the propeller shaft by pulling it by the propeller S69j6660 NOTE Install a spacer at the back of the propeller and tighten the propeller nut until the drive shaft does not turn any further Do not install the washer 8 Slowly turn the drive shaft clockwise and counterclockwise and measure the back lash based on the dial gauge readings taken at the points where the drive shaft stops in...

Page 151: ...2 4 Dowel 2 5 Bolt 6 M10 x 45mm 6 Drain screw 1 7 Bolt 1 M10 x 45mm 8 Bolt 1 M10 x 70mm 9 Spacer 1 10 Propeller 1 11 Washer 1 12 Washer 1 13 Propeller nut 1 14 Cotter pin 1 15 Trim tab 1 16 Cap 1 No Part name Q ty Remarks 6 34 Lower unit counter rotation model Backlash Lower unit counter rotation model ...

Page 152: ... 28 29 B 30 31 60h61020 1 Bolt 3 M6 x 20mm 2 Oil seal 1 3 Oil seal housing 1 4 O ring 1 5 Spring 1 6 Circlip 1 7 Shift rod 1 8 Joint 1 9 Plastic tie 3 10 Hose 1 11 Joint 1 12 Bolt 4 M8 x 45mm 13 Cover 1 14 Seal 1 15 Water pump housing 1 16 O ring 1 17 Insert cartridge 1 No Part name Q ty Remarks 6 35 ...

Page 153: ...f key 1 24 Seal damper 1 25 Guide 1 26 Nut 1 27 Cooling water inlet cover 1 28 Cooling water inlet cover 1 29 Bolt 1 M5 x 45 mm 30 Washer 3 31 Washer 4 No Part name Q ty Remarks 6 36 Lower unit counter rotation model 11 12 13 14 15 16 17 18 20 19 10 1 4 5 6 3 2 7 24 23 22 21 4 25 26 27 8 9 22 28 29 B 30 31 ...

Page 154: ...ve it Remove the lower unit from the upper case after loosening and removing the bolts 60h60040 NOTE Mounting bolt appears when the trim tab is removed Make sure that the mounting bolt is removed as well Removing the lower unit 1 Disconnect the battery cable 2 Remove the lock plate for the engine stop switch 3 Set the gear shift in neutral position 4 Remove the drain screw and the check screw to d...

Page 155: ... Also check the insert cartridge 2 for wear or deformation 60h60060 2 When the insert cartridge is removed al ways replace the O ring 3 with a new one and insert the projection on the insert car tridge into the water pump housing hole at the time of reassembly 60h60070 NOTE When mounting the insert cartridge apply small amount of Yamahabond 4 to it and in sert the projection on the insert cartridg...

Page 156: ...60H5E11 Lower unit LOWR B 6 39 4 Check the Woodruff key 4 and the groove A for wear Replace if necessary 60h60090 5 Check the shift rod for deformation or wear Replace if necessary 60h61100 ...

Page 157: ... pin 1 9 Cross pin ring 1 10 Forward gear 1 11 Forward gear shim As required 12 Thrust washer 1 13 Taper roller bearing 1 14 Propeller shaft 1 15 Thrust bearing 1 16 Propeller shaft shim As required 17 O ring 1 No Part name Q ty Remarks 6 40 Propeller shaft Propeller shaft housing counter rotation model Lower unit Propeller shaft Propeller shaft housing counter rotation model ...

Page 158: ...t LOWR E A A 11 12 13 14 15 16 17 18 20 19 9 10 1 4 5 6 8 3 2 7 21 22 23 4 2 60h61110 No Part name Q ty Remarks 18 Propeller shaft housing 1 19 Key 1 20 Needle bearing 1 21 Oil seal 2 22 Claw washer 1 23 Ring nut 1 6 41 ...

Page 159: ...ave been removed 4 Remove the propeller shaft 5 Remove the slide shift 4 6 Remove the spring 5 pull out the cross pin 6 and remove the dog clutch 7 NOTE Mark the dog clutch so that it will be reinstalled in correct orientation 7 Pull out the slider assembly 8 60h61250 NOTE Take precautions so that the ball will not jump out while pulling out the slider Propeller shaft Propeller shaft housing count...

Page 160: ... or wear Replace if necessary 60h61260 2 Measure the propeller shaft run out 60h61265 3 Check the dog clutch for breakage or wear Replace if necessary 60h60270 4 Check the slide shift and the slider for wear Replace if necessary 60h61280 Bearing inner race attachment 90890 06662 Bearing separator 90890 06534 8 Remove the taper roller bearing from the forward gear 60h61625 Run out limit 0 05 mm 0 0...

Page 161: ...o the propeller shaft housing and then drive in the outer oil seal to the specified depth Propeller shaft Propeller shaft housing counter rotation model Driver rod L3 90890 06652 Needle bearing attachment 90890 06653 5 Check the teeth and dogs of the forward gear for cracks or wear Replace the gear if necessary 60h60180 Disassembling the propeller shaft housing assembly 1 Remove the oil seal Also ...

Page 162: ...mming is required when forward gear or taper roller bearing is replaced 6 Assemble the slider assembly 60h60290 NOTE It is recommended to apply grease or the like to the balls to make the assembling work easier 7 Insert the slider assembly 1 into the pro peller shaft 2 NOTE Make sure that the cross pin holes are aligned when inserting the slider assembly 8 Install the dog clutch 3 in the marked or...

Page 163: ... Needle bearing 1 8 O ring 1 9 Pinion shim As required 10 Thrust bearing 1 11 Needle bearing 1 12 Pinion 1 13 Reverse gear shim 1 14 Roller bearing 1 15 Needle bearing 2 16 Thrust bearing 1 17 Reverse gear 1 No Part name Q ty Remarks Drive shaft and lower case counter rotation model Propeller shaft Propeller shaft housing Drive shaft and lower case counter rotation model ...

Page 164: ...n the pinion nut 60h60310 2 Remove the drive shaft housing NOTE Note that the pinion gear shims may be stuck on the drive shaft housing 3 Pull out the drive shaft and remove the pin ion gear 4 Remove the drive shaft sleeve NOTE Make sure that none of the needles of the drive shaft needle bearing is missing 5 Remove the reverse gear 60h61323 Disassembling the lower case NOTE Remove the lower case o...

Page 165: ... always replace them with new ones Assembling the drive shaft housing 1 Install the needle bearing 60h60350 2 First drive in the inner oil seal halfway into the drive shaft housing and then drive in the outer oil seal to the specified depth 60h60360 3 Install the cover Drive shaft and lower case counter rotation model Drover rod LL 2 90890 06605 Ball bearing attachment 3 90890 06636 Installation d...

Page 166: ...m with a new one Assembling the reverse gear 1 Install the needle bearing 60h60390 Checking the drive shaft 1 Check the drive shaft for bends or wear Replace if necessary 60h60410 2 Measure the drive shaft run out 60h60415 3 Check the thrust bearing for run out or roughness Replace if necessary NOTE Shimming is required when the thrust bearing is replaced Checking the pinion gear 1 Check the pinio...

Page 167: ...OTE Apply some grease on the needle bearing roll ers so that they will not fall off 4 Install the drive shaft sleeve 5 Install the reverse gear and the thrust bear ing on the lower case 6 Install the drive shaft and the pinion gear Then temporarily tighten the nut NOTE Shimming is required when the drive shaft housing or the drive shaft is replaced Install the drive shaft by lifting it up slightly...

Page 168: ...06512 Ring nut wrench extension 8 90890 06513 12 Install the shift rod assembly and tighten the bolt 60h61480 13 Align the key way and install the key 14 Install the claw washer and tighten the ring nut 60h61500 9 Tighten the pinion nut 60h60460 10 Install the slide shift to the propeller shaft 11 Install the shim s the propeller shaft and the propeller shaft housing assembly 60h61470 NOTE Set the...

Page 169: ...one of the claw washer tabs toward yourself 60h60515 Installing the water pump 1 Install the gasket 1 the dowels 2 and the outer plate cartridge 3 60h60520 2 Install the Woodruff key 4 into the drive shaft 3 Install the impeller 5 after aligning it with the woodruff key 60h60530 NOTE Align the groove on the impeller with theWoo druff key Apply Yamaha grease A on the sliding face between the impell...

Page 170: ...he pump housing Installing the speedometer hose 1 Apply Yamabond 4 to the speedometer hose and tighten it 60h60550 Installing the lower unit 1 Install the dowels to the lower case 60h60560 2 Make sure that the shift rod is in neutral position Install the lower unit to the upper case and tighten the bolts to the specified torque 3 Install the trim tab 1 to its original posi tion and tighten the tri...

Page 171: ...unit counter rotation model 4 Install the propeller and the propeller nut Place a block of wood between the anti cavitation plate and the propeller to keep the propeller from turning Then tighten the nut to the specified torque 60h61540 60h61550 Place a block of wood between the anti cavitation plate and the propeller Do not touch the propeller with your hands Disconnect the battery cable and remo...

Page 172: ...60H5E11 Lower unit LOWR A B B4 T3 B3 61 0 A3 T1 B1 36 5 A1 B7 B5 T4 B6 16 8 B2 T2 A2 A4 A5 60h61600 F R P 60h61607 6 55 Shimming counter rotation model ...

Page 173: ... NOTE Set the thrust washer on the drive shaft hous ing and turn it two or three times to make it seated properly Take measurements at three points on the thrust bearing and obtain the average 2 Measure the datum distance on the drive shaft Initially install the pinion height gauge to the drive shaft 60h60620 NOTE Install the drive shaft in the center of the pin ion height gauge Tighten the wing n...

Page 174: ... the measured backlash is out of specifica tion 6 Calculate the pinion shim thickness S69j6565 Calculation formula Pinion shim thickness T3 80 00 P 100 M3 M4 Example If M3 46 85 M4 32 52 and P 5 then T3 80 00 5 100 46 85 32 52 80 00 0 05 46 85 32 52 0 58 7 Select the pinion shim s as follows Example If T3 is 0 58mm then the pinion shim is 0 55 mm If T3 is 0 70mm then the pinion shim is 0 68 mm Sel...

Page 175: ...adjustment shall be made if the backlash is out of specification 3 Calculate the reverse gear shim thickness Calculation formula Reverse gear shim thickness T1 29 10 F 100 M1 Example If M1 27 95 and F 5 then T1 29 10 5 100 27 95 29 10 0 05 27 95 1 10 4 Select the reverse gear shim s as follows Example If T1 is 0 45 mm then the reverse gear shim is 0 42 mm If T1 is 0 60 mm then the reverse gear shi...

Page 176: ...ear shim thickness T2 M2 29 50 R 100 Example If M2 30 5 and R 5 then T2 30 5 29 50 5 100 30 5 29 50 0 05 1 05 4 Select the forward gear shim s as follows Example If T2 is 1 16mm then the reverse gear shim is 1 15 mm If T2 is 1 20mm then the reverse gear shims is 1 18 mm Selecting the propeller shaft shims NOTE Obtain the propeller shaft shim thickness T4 by using the specified measurement s and th...

Page 177: ...are zero and mea sure the end play when the unit is assembled Shimming shall be readjusted if the end play is out of specification 4 Calculate the propeller shaft shim thick ness Calculation formula Reverse gear shim thickness T4 29 00 A 100 B 100 M5 M6 Example If M5 15 15 M6 13 15 A 5 and B 5 then T4 29 00 5 100 5 100 15 15 13 15 29 00 0 05 0 05 15 15 13 15 0 70 Shimming counter rotation model 5 ...

Page 178: ...acklash indicator onto the drive shaft NOTE Backlash indicator shall be installed at practi cably the closest position to the lower hous ing having 22 4mm of outer diameter 4 Set the dial gauge onto the lower unit and fix it where the dial gauge plunger contact the mark B on the backlash indicator A 69j6655 5 Set the lower unit upside down 6 Slowly turn the drive shaft clockwise and counterclockwi...

Page 179: ... reverse position C with the shift rod push arm 9 Turn the drive shaft clockwise until the dog clutch is fully engaged 60h61710 10 Turn the shift rod to the neutral position D with the shift rod push arm 11 Turn the drive shaft counterclockwise by approximately 30 60h61720 12 Turn the shift rod to the reverse position C with the shift rod push arm 13 Slowly turn the drive shaft clockwise and count...

Page 180: ...ove shim s if out of specifica tion 15 Remove the special service tools and then install the water pump assembly Available shim thickness 0 10 0 12 0 15 0 18 0 30 0 40 0 50 Reverse gear backlash M Shim thickness mm Less than To be decreased by 0 98 mm 0 0386 in 1 14 M x 0 72 More than To be increased by 1 30 mm 0 0512 in M 1 14 x 0 72 M Measurement 6 63 ...

Page 181: ... motor 7 25 Disassembling the reservoir 7 28 Disassembling the gear pump unit 7 28 Checking the reservoir and gear pump unit 7 30 Assembling the reservoir and gear pump unit 7 30 Tilt cylinder and trim cylinder 7 32 Disassembling the tilt cylinder and trim cylinder 7 34 Checking the tilt cylinder and trim cylinder 7 34 Assembling the power trim and tilt unit 7 36 Bleeding the power trim and tilt u...

Page 182: ...60H5E11 Bracket unit BRKT 7 1 Special service tools Hydraulic pressure gauge 90890 06776 Up relief fitting 90890 06773 Down relief fitting 90890 06774 Trim tilt wrench 90890 06548 ...

Page 183: ...4 Washer 1 5 Shift rod lever 1 6 Washer 1 7 Bush 1 8 Shift rod bracket 1 9 Grease nipple 1 10 Washer 1 11 Circlip 1 12 Rubber seal 1 13 Ball 1 14 Spring 1 15 Bushing 1 16 Bolt 2 M8 x 30 mm 17 O ring 1 No Part name Q ty Remarks 7 2 Bottom Cowling 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 17 ...

Page 184: ...13 14 10 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 23 7 60h70020 1 Wire harness clamp 1 2 Bolt 1 M6 x 20 mm 3 Plate 1 4 Bolt 1 M8 x 20 mm 5 Bracket 1 6 Clamp 2 7 Pin 2 8 Grommet 1 9 Holder 2 10 Bolt 3 11 Washer 3 12 Hook 3 13 Washer 3 14 Bushing 3 15 Grommet 1 16 Bolt 2 M6 x 10 mm 17 Lever 3 No Part name Q ty Remarks 7 3 ...

Page 185: ...1 32 33 34 35 36 37 38 23 7 60h70020 18 Bushing 3 19 Trailer switch holder 1 20 Bolt 1 M6 x 28 mm 21 Trailer switch 1 22 Grommet 1 23 Rubber seal 1 24 Screw 2 25 Clamp 2 26 Bolt 1 M6 x 20 mm 27 Clamp 1 28 Pilot jet 1 29 Hose 1 30 Bolt 4 M8 x 35 mm 31 Read 1 32 Grommet 4 33 Collar 4 34 Grommet 1 No Part name Q ty Remarks Bottom Cowling 7 4 ...

Page 186: ... 17 17 17 18 18 18 20 19 21 22 24 9 10 11 12 13 14 10 1 4 5 6 8 3 2 7 25 9 11 12 13 14 10 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 23 7 7 5 35 Grommet 1 36 Bolt 2 M6 x 15 mm 37 Retaining plate 1 38 Clamp 1 No Part name Q ty Remarks 60h70020 ...

Page 187: ...er case 60h70030 1 Nut 2 2 Washer 2 3 Upper mount 2 4 Bracket 1 5 Washer 2 6 Washer 2 7 Washer 2 8 Bolt 2 M12 x 190 mm 9 Bushing 2 10 Nut 2 11 Washer 2 12 Bolt 4 M10 x 45 mm 13 Mount housing 2 14 Spring 4 15 Washer 2 16 Lower mount 2 17 Washer 2 No Part name Q ty Remarks 7 6 Bottom Cowling Upper case ...

Page 188: ...21 22 23 24 23 22 27 25 26 25 9 28 7 7 60h70040 60h70030 18 Washer 2 19 Ground lead 1 20 Bolt 2 M14 x 180 mm 21 Upper case assembly 1 22 Ground lead 1 23 Hose 1 24 Bolt 3 M10 x 45 mm 25 Washer 2 26 Bolt 1 M6 x 10 mm 27 Bolt 4 M6 x 30 mm 28 Plastic tie 1 No Part name Q ty Remarks ...

Page 189: ...x 45 mm 2 Gasket 1 3 Union joint 1 4 Upper exhaust guide 1 5 Gasket 1 6 Lower exhaust guide 1 7 Bolt 7 M8 x 30 mm 8 Gasket 1 9 Exhaust manifold 1 10 Bolt 4 M8 x 45 mm 11 Gasket 1 12 Muffler 1 13 Bolt 4 M8 x 45 mm 14 Rubber damper 2 15 Clip 2 16 Rubber seal 1 17 Dowel 2 No Part name Q ty Remarks Upper case 7 8 ...

Page 190: ...21 22 23 24 25 17 26 28 17 27 7 9 60h70040 18 Upper case 1 19 Rubber seal 1 20 Pipe 1 21 Rubber seal 1 X transom 22 Muffler 2 1 X transom 23 Rubber seal 1 X transom 24 Bushing 1 X transom 25 Circlip 1 X transom 26 Cap 1 27 Grommet 1 28 Rubber seal 1 No Part name Q ty Remarks ...

Page 191: ... the screw 3 Remove the lower case by loosening the upper mount and lower mount nuts 60h70065 Disassembling the upper case 1 Remove the pressure control valve hose exhaust rubber seal and upper exhaust guide rubber seal NOTE Upper exhaust guide rubber seal is attached with adhesive 2 Remove the upper mount bracket 60h70070 3 Remove the lower mount bracket 60h70080 Upper case 7 10 ...

Page 192: ...ower exhaust guide 60h70120 7 11 5 Remove the muffler assembly the rubber seal and dowels 60h70090 NOTE In addition remove the muffler 2 for X transom model Muffler 2 is to be removed downward 5 Remove the muffler 6 Remove the water tube and rubber damper from the muffler 60h70100 ...

Page 193: ...0 2 Check the rubber damper for deterioration Replace if necessary 60h70150 3 Check the water tube for deformation or corrosion Replace if necessary 60h70160 4 Check the exhaust guide exhaust mani fold and muffler for damage or corrosion Replace if necessary 60h70170 Assembling the upper case 1 Install the pressure control valve union joint to the upper exhaust guide 60h70175 Upper case 7 12 ...

Page 194: ... components specified above 6 Install a new rubber seal on the muffler as sembly Also install the dowels and a new rubber seal on the upper case 60h70210 NOTE Install the muffler 2 first for X transom model 572 LT 572 LT Exhaust manifold bolts 18 N m 1 8 kgf m 13 ft lb T R 2 Install a new gasket and the lower exhaust guide onto the upper exhaust guide Tem porarily tighten the bolts 60h70180 3 Inst...

Page 195: ...union joint and hose exhaust rubber seal and upper exhaust guide rubber seal NOTE Attach the upper exhaust guide rubber seal with adhesive Upper case bolts 21 N m 2 1 kgf m 5 ft lb T R A 572 LT A Upper case 7 14 7 Install the muffler assembly to the upper case 60h70230 NOTE Apply Yamaha grease A at the tip of water pump tube and positively fit it into the hole on the upper case 8 Install the upper...

Page 196: ...op lever 1 60h30430 60H70310 Power trim and tilt unit Bleeding the power trim and tilt unit Built in NOTE Check the fluid level before bleeding if the power trim and tilt unit does not operate while PTT motor is working 1 Turn the manual valve counterclockwise to the full extent 60h70310 2 Fully tilt up the outboard motor and release it to let it down by its own weight Repeat this operation four o...

Page 197: ... 2 PTT motor lead 2 3 Shaft 1 4 Plastic tie 3 5 Circlip 1 6 Bolt 2 M8 x 16 mm 7 Washer 2 8 Shaft 1 9 Bushing 6 10 Bolt 1 M6 x 10 mm 11 Ground lead 1 No Part name Q ty Remarks Power trim and tilt unit 7 16 1 2 3 4 5 6 6 7 7 8 9 9 9 9 10 11 A A A A A ...

Page 198: ...e tilt stop lever Other wise the outboard motor could suddenly lower if the power trim and tilt unit should lose fluid pressure NOTE If the power trim and tilt does not operate loosen the manual valve and tilt up the out board motor by hands Tighten the manual valve 60h70310 2 Disconnect the ground lead under the power trim and tilt unit 3 Remove the plastic tie and pull out the PTT motor lead 60h...

Page 199: ... shaft 60h70350 NOTE Pull out the upper mount pins downwardly at an angle while holding the power trim and tilt unit with a hand 6 Remove the collar Checking the hydraulic pressure of the power trim and tilt unit 1 Check the fluid level If it is lower than the correct level add sufficient fluid of the rec ommended type Install the reservoir cap after checking the fluid level 60h70365 NOTE If the f...

Page 200: ...ded position 60h70390 7 Replace the up relief fitting with the down relief fitting 5 60h70400 8 Tighten up the hydraulic pressure gauge and down relief fitting 9 Check the fluid level If it is lower than the correct level add sufficient fluid of the rec ommended type Install the reservoir cap after checking the fluid level NOTE If the fluid is at the correct level the fluid should overflow out of ...

Page 201: ...d fully extend the trim and tilt rods 60h70390 12 If the hydraulic pressure falls within the specification remove the hydraulic pres sure gauge and down relief fitting and re install the manual valve and circlip If the hydraulic pressure is out of specifica tion overhaul the power trim and tilt unit Power trim and tilt unit 7 20 Rods PTT motor leads Battery terminal Green G DOWN Blue L Hydraulic p...

Page 202: ...70440 1 2 3 4 5 6 7 8 9 10 1 Power trim and tilt motor 1 2 Reservoir 1 3 Reservoir cap 1 4 O ring 1 5 O ring 1 6 Bolt 3 1 4 x 35 mm 7 Bolt 4 1 4 x 35 mm 8 O ring 1 9 Filter 1 10 Joint 1 No Part name Q ty Remarks PTT motor and Reservoir ...

Page 203: ...Armature 1 4 O ring 1 5 Screw 2 M4 x 10 mm 6 Brush holder 1 7 Brush 2 1 8 Brush 1 1 9 Brush holder 1 10 Brush spring 2 11 PTT motor base 1 12 Oil seal 1 13 Bearing 1 14 Screw 2 M4 x 15 mm No Part name Q ty Remarks 60H70445 PTT motor and Reservoir 7 22 ...

Page 204: ...the filter if it is damaged 3 Slide out the lead holder 1 and rubber spacer 2 Then slide out the stator 3 Remove the stator 3 60h70460 NOTE Place a clean cloth over the end of the arma ture shaft and hold it with a pair of pliers while pulling out the stator 3 carefully 4 Remove the armature Do not allow grease or oil to contact the commutator while working on it 5 Disconnect the blue L lead 4 60h...

Page 205: ...0 2 Check the brush and circuit breaker for con tinuity Replace them if there is no conti nuity 60h70500 Do not touch the bimetal B B B B B otherwise the operation of the circuit breaker may be af fected 3 Check the commutator diameter Replace it if the diameter is smaller than the limit 60h70510 4 Check the armature coil for continuity Re place it if the continuity is out of specifica tion PTT mo...

Page 206: ...Assembling the PTT motor 1 Connect the leads 1 and tighten up the screw 2 60h70560 2 Push the brush 3 into the brush holder while installing the armature 4 60h70570 3 Install the stator 60h70580 NOTE Place a clean cloth over the end of the arma ture shaft and hold it with a pair of pliers while pushing in the stator carefully 1 2 ...

Page 207: ...Bolt 2 M5 x 16 mm 2 Pump filter 1 3 Gear 2 4 Ball 2 5 Shuttle piston 2 6 O ring 2 7 Main valve 2 8 Ball 2 9 Bolt 1 M8 x 85 mm 10 Bolt 2 M8 x 24 mm 11 Pump housing 1 12 Circlip 1 13 Manual valve 1 14 O ring 1 15 O ring 1 16 Backup ring 1 17 Spring 1 No Part name Q ty Remarks PTT motor and Reservoir 7 26 ...

Page 208: ... 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 18 Absorber valve pin 1 19 Ball 1 20 Up relief valve seat 1 21 O ring 1 22 Filter 2 23 O ring 1 24 Down relief valve 1 25 Valve pin 1 26 O ring 4 27 Valve seat 1 28 Pin 1 29 Ball 1 30 O ring 1 No Part name Q ty Remarks ...

Page 209: ...r to clean the hy draulic system components Small pieces of fibers remaining on them may cause mal function of the system Fluid may flow out while overhauling the power trim and tilt unit Place an appropri ate tray to prevent the fluid from spilling out on the floor Hold the power trim and tilt unit in a vise to work on it Put an aluminum plates A on both sides of the unit 1 Remove the reservoir a...

Page 210: ...d since they would be stuck on the gear pump cover 4 Remove the up relief valve assembly 60h70650 5 Remove the main valves 60h70660 NOTE To remove the main valves cover the pump housing with a clean cloth and blow com pressed air through holes A and B Never look into the openings while remov ing the main valves 6 Remove the manual valve 60h70670 ...

Page 211: ...iginal direction and position 1 Install a new O ring 1 the up relief valve seat 2 balls 3 and absorber valve pin 4 and spring 5 on the pump housing 60h70690 2 Install new O rings 6 on the main valves 7 Then attach them on the pump hous ing 60h70700 3 Install the gear pump 8 60h70710 4 Install the balls 9 shuttle pistons 0 and balls A into the gear pump cover 60h70720 NOTE Apply grease to the balls...

Page 212: ...rarily tighten the mount ing bolts 60h70730 6 Make sure that the gear pump turns smoothly by hands Then tighten the mounting bolts to the specified torque 7 Install a new O ring on the down relief valve 8 Install the filter down relief valve and filter to the pump housing 60h70740 9 Install a new O ring to the manual valve 10 Install the manual valve and circlip on the pump housing ...

Page 213: ... Cylinder body 1 4 Free piston 1 5 Backup ring 1 6 O ring 1 7 Dust seal 2 8 Seal 2 9 Trim cylinder end screw 2 10 O ring 2 11 Backup ring 2 12 O ring 2 13 Dust seal 1 14 Tilt cylinder end screw 1 15 O ring 1 16 O ring 1 17 Tilt piston 1 No Part name Q ty Remarks Tilt cylinder and trim cylinder PTT motor and Reservoir Tilt cylinder and trim cylinder 7 32 ...

Page 214: ...t BRKT 1 2 3 4 5 5 6 6 7 7 8 8 9 10 11 11 12 12 13 13 14 15 15 16 16 17 18 18 19 19 20 21 22 23 24 A A 7 33 60h70750 18 O ring 1 19 O ring 1 20 Washer 1 21 Nut 1 22 Ball 1 23 Valve 1 24 Spring 1 No Part name Q ty Remarks ...

Page 215: ...end cap 3 and remove the trim piston assembly 4 4 Drain the fluid 5 Install the trim piston assembly and tem porarily tighten the trim cylinder end cap finger tight Tilt cylinder and trim cylinder 7 34 6 Cover the tilt cylinder opening with a clean cloth 5 and blow compressed air through hole A to remove the free piston 6 60h70780 Never look into the openings while remov ing the free piston 7 Loos...

Page 216: ...lt rod for bends or corrosion Replace if necessary 60h70820 5 Check the trim piston for scratches Re place if necessary Check the trim rods for bends or corrosion Replace if necessary 60h70830 6 Remove the filter plug and filter from the tilt cylinder and check them 7 Check the inner walls of tilt cylinder and trim cylinder for scratches Replace if nec essary 60h70850 8 Install the filter and filt...

Page 217: ...6 N m 9 6 kgf m 71 ft lb T R 60H70880 60H70890 14 15 16 A 60H70930 1 10 Install the tilt cylinder end cap 4 on the tilt rod 5 60h70870 11 Install a new O ring 67 on the tilt piston 8 Also install the ball 9 absorber pin 0 and spring A in this order 12 Install the tilt piston sub assembly and washer B on the tilt rod 5 and tighten the nuts C 60h70880 13 Install new backup ring E and the O ring F on...

Page 218: ...illed with the fluid 4 Install the trim rods Make sure that the trim rods are fully ex tended when they are installed Once installed never push down the trim rods It is dangerous since the fluid may spurt out from the unit 5 Tighten up the trim rod end caps 2 60h70970 6 Install new O ring valve pin and check valve assembly on the tilt cylinder 60h70980 NOTE Refer to the illustration for the correc...

Page 219: ...p 130 N m 13 kgf m 94 ft lb T R 9 Fill the tilt cylinder with the fluid 60h71010 NOTE Pour the recommended fluid through the hole E until gear pump unit top is filled up with the fluid 10 Install the tilt piston assembly 60h71020 Make sure that the tilt rod are fully ex tended when they are installed Once installed never push down the tilt rod It is dangerous since the fluid may spurt out from the...

Page 220: ...7 39 PTT motor mounting bolts 5 N m 0 5 kgf m 4 ft lb T R Recommended power trim and tilt fluid ATF Dexron II 14 Install a new O ring 5 and the PTT motor 6 Tighten up the bolts 7 60h71060 NOTE Align the joint and armature shaft 15 Fill the reservoir with the recommended fluid to the specified level NOTE If the fluid is at the correct level the fluid should overflow out of the check hole when the c...

Page 221: ...lt up the outboard motor and lock it with the tilt stop lever 1 60h30430 After tilting up the outboard motor be sure to support it with the tilt stop lever Other wise the outboard motor could suddenly lower if the power trim and tilt unit should lose fluid pressure 2 Install the collar 3 Insert the upper mount pins while support ing the power trim and tilt unit by hands 4 Install the circlip 5 Ins...

Page 222: ... 1 3 Bushing 2 4 Swivel bracket 1 5 O ring 1 6 Bushing 1 7 Washer 1 8 Steering yoke 1 9 Circlip 1 10 Nut 2 11 Thrust receiver 2 12 Damper 1 13 Clamp bracket 1 Starboard 14 Clamp bracket 1 Port No Part name Q ty Remarks Steering arm 1 5 6 7 8 9 2 3 4 3 11 10 13 14 12 ...

Page 223: ...he steering arm 1 Install the washer and bushing onto the steering arm 2 Place the swivel bracket in the upright po sition and insert the steering arm into the swivel bracket 60h71180 3 Install the bushing O ring and washer Also install the steering yoke 60h71190 60h71200 NOTE Make sure that the orientation of steering yoke A and steering arm B is consistent at the time of installation 4 Install t...

Page 224: ...60H5E11 Bracket unit BRKT 7 43 5 InjectYamaha grease A through the grease nipple 60h71200 NOTE Inject the grease until it comes out from both the upper bushing C ...

Page 225: ... 2 Clamp bracket 1 Starboard 3 Clamp bracket 1 Port 4 Self locking nut 1 5 Grease nipple 5 6 Ground lead 1 7 Washer 2 8 Bolt 2 M6 x 11 mm 9 Washer 2 10 Bushing 6 11 Trim sensor 1 12 Screw 2 M6 x 25 mm 13 Trim sensor cam 1 14 Screw 1 M6 x 25 mm 15 Clamp 1 16 Bolt 4 M6 x 30 mm 17 Bracket 2 No Part name Q ty Remarks Clamp brackets Steering arm Clamp brackets 7 44 ...

Page 226: ... 29 22 30 10 31 32 33 7 45 60h71210 18 Anode 1 19 Through tube 1 20 Bolt 1 M8 x 20 mm 21 Tilt stop lever 1 22 Bush 4 23 Collar 1 24 Distance collar 2 25 Spring pin 2 26 Pin 1 27 Spring 1 28 Spring hook 1 29 Bolt 1 M6 x 10 mm 30 Tilt stop lever 1 31 Ground lead 1 32 Washer 1 33 Bolt 1 M6 x 10 mm No Part name Q ty Remarks ...

Page 227: ...top lever on the swivel bracket 3 Install the trim sensor 1 and bushing on the swivel bracket 60h71230 4 Install the through tube to go through the clamp brackets washer and swivel bracket in this order NOTE Make sure that the trim sensor cam is in stalled between the swivel bracket holes Adjust the trim sensor cam after assembly 5 Install the bolts on the through tube and tighten up the self lock...

Page 228: ...am 1 Fully retract the power trim and tilt unit 2 Loosen the trim sensor cam screw 1 3 Fix the trims sensor 2 cam where the speci fied trim sensor resistance is obtained 60h71270 4 Fully tilt up the outboard motor and lock it with the tilt stop lever 3 60h71290 After tilting up the outboard motor be sure to support it with the tilt stop lever Other wise the outboard motor could suddenly lower if t...

Page 229: ...sensor resistance Pink P Black B 238 8 378 8 at 20 C 68 F 7 48 5 Check the trim sensor resistance If the resistance is out of specification adjust the trim sensor cam position and check the trims sensor Clamp brackets ...

Page 230: ...hecking and replacing the spark plug caps Standard type 8 9 Checking the plug cap with resister type 8 10 Checking the ignition coil 8 11 Checking the pulser coil 8 11 Checking the charge coil 8 12 Checking the CDI unit 8 13 Checking the thermoswitch 8 13 Starting system 8 14 Checking the fuse 8 15 Checking the wiring harness 10 pins 8 15 Checking the starter relay 8 15 Starter motor 8 16 Removing...

Page 231: ...id 8 19 Charging system 8 20 Checking the lighting coil 8 21 Checking the Rectifier Regulator 8 21 Power trim and tilt 8 22 Checking the power trim and tilt relay 8 23 Checking the power trim and tilt switch trailer switch 8 23 Checking the trim sender 8 23 ...

Page 232: ...Electrical systems ELEC 8 1 Special service tools Ignition tester 90890 06754 Digital circuit tester 90890 03174 Peak voltage adaptor B 90890 03172 Test harness FWY 4 90890 06771 Test harness FWY 6 90890 06772 ...

Page 233: ...y 60h80010 Measuring the lower resistance When measuring a resistance of 10 or less with the digital circuit tester the correct mea surement cannot be obtained because of the internal resistance of the tester To obtain the correct value subtract the internal resistance from the displayed measurement Correct value displayed measurement internal resistance NOTE Obtain the internal resistance of the ...

Page 234: ...60H5E11 Electrical systems ELEC Electrical components Starboard view 60h80030 1 Thermoswitch 2 Hour meter 3 Rectifier Regulator 4 Choke solenoid 8 3 ...

Page 235: ...60H5E11 8 Port view 1 Starter motor 2 Starter relay 3 Power trim and tilt relay 60h80040 Electrical components 8 4 2 3 1 ...

Page 236: ...60H5E11 Electrical systems ELEC Top view 60h80050 1 Spark plug 2 Thermoswitch 3 Rectifier Regulator 4 Starter motor 5 Starter coil 6 Pulser coil 8 5 ...

Page 237: ...60H5E11 8 Rear view 60h80045 1 Ignition coil 2 Spark plug 3 CDI unit 1 2 3 8 6 Electrical components ...

Page 238: ... Thermoswitch 60h80060 8 Ground lead 9 Rectifier Regulator 0 Hour meter A Choke solenoid B Remote control Br Brown Sb Sky blue Lg Light green R Red P Pink W White B Black Y Yellow G Green L Blue 8 7 Sb Lg G R Y W Br P B L Y B G W Lg R Sb L Br Sb Lg P B B R R B B B G G B B B P P B P Sb Lg Y R Br G W P L B L Y G G G B B B B B B B B R R P B B P P W P B SbLg R Sb Lg Br B ...

Page 239: ...3 Pulser coil 4 Stator coil 5 CDI unit 6 Thermoswitche L Blue B Black Br Brown P Pink R Red W White B R Black Red B W Black White W B White Black W G White Green W R White Red W Y White Yellow W L White Blue W Br White Brown 8 8 Electrical components Ignition system ...

Page 240: ...k the engine and observe the spark through the discharge window of the spark gap tester If it does not work properly check the plug cap ignition coil or the specified peak voltages 60h80110 Do not touch any of the connections of the spark gap tester leads Do not let sparks leak out of the removed spark plug caps Keep flammable gas or liquids away since this test can produce sparks Checking and rep...

Page 241: ...60h80125 4 Press in the plug cap spring 3 until it touches the spark plug wire 2 conductor Then bent B as shown 60h80127 Checking the plug cap with resister type 1 Remove the spark plug cap 1 from the spark plug wire 2 by turning the cap coun terclockwise 60h80130 2 Measure the spark plug cap 1 resistance 60h80135 3 Replace the plug cap 1 if the resistance is out of specification 4 Install the spa...

Page 242: ...0890 06772 r min Unloaded Loaded Cranking 1 500 3 500 DC V 2 5 2 0 9 5 16 0 8 11 Checking the ignition coil 1 Remove the spark plug cap from the spark plug 2 Disconnect the ignition coil lead 3 Measure the ignition coil resistance Re place if out of specification 60h80140 60h80140 Checking the pulser coil 1 Remove the CDI unit cover 2 Connect the pulser coil coupler and the CDI unit with the test ...

Page 243: ... 96 6 Ω at 20 C 68 F Charge coil output peak voltage Brown Br Red R r min Unloaded Loaded Cranking 1 500 3 500 DC V 80 90 165 165 Charge coil peak voltage Blue L Black red B R r min Unloaded Loaded Cranking 1 500 3 500 DC V 30 30 160 165 8 12 Ignition system Checking the charge coil 1 Remove the CDI unit cover 2 Connect the charge coil and CDI unit with the test harness 4 pins 3 Measure the charge...

Page 244: ...ng 1 500 3 500 DC V 65 140 135 8 13 Checking the CDI unit 1 Connect the digital circuit tester lead to the ignition coil lead and the ground lead 2 Measure the CDI unit output peak voltage If the measurement is below specification check the lead and measure the peak out put voltages of pulser coil and charge coil 60h80150 Checking the thermoswitch 1 Place the thermoswitch 1 in a container with wat...

Page 245: ...ry 12 volts 2 Starter motor 3 Starter relay 4 PTT down relay 5 Fuse 20 amps 6 Choke solenoid 7 Key switch panel B Black R Red Br Brown L Blue Y Yellow 8 14 Ignition system Starting system Starting system OFF ON START W B R Y Br ...

Page 246: ...ay 1 Connect the digital circuit tester leads to the starter relay terminals 2 Connect the brown Br lead A to the posi tive battery terminal 3 Connect the black B lead B to the nega tive battery terminal 4 Check continuity between the starter relay terminals Replace if there is no continuity 60h80220 5 Check that there is no continuity between the starter relay terminals after disconnect ing the b...

Page 247: ...5 mm 2 Starter motor cover 1 3 Clip 2 4 Pinion stopper 1 5 Spring 1 6 Pinion 1 7 Housing 1 8 Washer 2 9 Armature 1 10 Stator 1 11 Spring 4 12 Brush holder 1 13 Washer 1 14 Washer 1 15 Washer 1 16 Nut 1 17 Washer 2 No Part name Q ty Remarks 8 16 Starting system Starter motor Starter motor ...

Page 248: ...60H5E11 Electrical systems ELEC 11 12 13 14 15 16 17 18 20 19 9 10 1 4 5 6 8 3 2 7 C 60h80260 18 Lower bracket 1 19 Bolt 1 M8 x 25 mm 20 Bolt 1 M6 x 115 mm No Part name Q ty Remarks 8 17 ...

Page 249: ...acks or wear Replace if necessary 60h80280 2 Check the pinion for smooth operation Re place if necessary NOTE Turn the pinion clockwise to check that it oper ates smoothly and turn it counterclockwise to check that it locks in place Checking the armature 1 Check the commutator for dirt Clean with 600 grid sandpaper or by blowing the com pressed air 60h80285 2 Measure the commutator diameter Re pla...

Page 250: ...he length is shorter than the specified limit 60h80320 2 Check the brush holder assembly for con tinuity Replace if out of specification 60h80330 Choke solenoid Checking the choke solenoid 1 Disengage the choke solenoid bullet con nector and measure the choke solenoid re sistance 60h80340 2 Connect the battery to the choke solenoid and check if the plunger is pulled in 60h80350 Armature continuity...

Page 251: ...60H5E11 8 Charging system 60h80230 1 Battery 2 Fuse 20 amps 3 Lighting coil 4 Rectifier Regulator 5 Hour meter B Black R Red G Green Y Yellow G W Green White 8 20 Starter motor Charging system ...

Page 252: ...e Replace the Rectifier Regu lator if the lighting coil output peak voltage is on or above specification and the Recti fier Regulator output peak voltage is be low specification 60h80250 NOTE Disconnect the output lead Red R Black B of the Rectifier Regulator when measuring the output peak voltage Lighting coil output peak voltage Green G Green white G W Lighting coil resistance use as reference G...

Page 253: ... 60h80365 1 Battery 12 volts 2 Fuse 20 amps 3 PTT up relay 4 PTT down relay 5 Trailer switch 6 PTT motor 7 Trim sender B Black R Red Sb Sky blue Lg Light green Gy Gray P Pink G Green L Blue 8 22 Charging system Power trim and tilt ...

Page 254: ...he black B lead to 4 the nega tive battery terminal as shown 3 Check the continuity between the terminals 1 and 2 Replace if there is no continu ity 4 Disconnect the black B lead 4 Check for cintinuity between terminals 1 and 2 Replace if there is no continuity 60h80370 Checking the power trim and tilt switch trailer switch 1 Check the power trim and tilt switch trailer switch for continuity Repla...

Page 255: ...on system 9 3 Fuel system 9 4 Compression pressure 9 5 Fuel system 9 6 Ignition system 9 7 Power unit 9 8 Air intake system 9 9 Fuel system 9 10 Ignition system 9 11 Cooling system 9 13 Bracket unit 9 14 Lower unit 9 17 Electrical system 9 18 Troubleshooting TRBL SHTG ...

Page 256: ...osion and that the battery is fully charged to 12 V Power unit Symptom Engine does not crank Check the starting system Check the power unit Starting system Yes No Yes No Yes No Check that the gear shift is in the neutral position Is the gear shift in neutral Set it to the neutral position Check the neutral switch inside remote control box for continuity Is there continuity Replace the neutral swit...

Page 257: ...Check the wiring harnesses for continuity Replace the wiring harnesses Is there continuity Check the starter relay operation Good operating condition Replace the starter relay Check the starter motor operation Replace the starter motor Good operating condition Check the power unit 9 2 ...

Page 258: ...est can produce sparks Ignition system Check the engine stop switch for continuity Is there continuity Replace the engine stop switch Check that the spark plugs produce sparks Are there sparks Check the spark plugs and clean or replace them as required Check the ignition spark using the spark gap tester Good ignition spark condition Check the spark plug wire and spark plug cap for deterioration No...

Page 259: ...coil Is measured voltage exceeds the specified value Is measured voltage exceeds the specified value Measure the CDI unit output peak voltage Replace the CDI unit Check the ignition timing Check each component again Is ignition timing correct Adjust the ignition timing Check the fuel system Fuel system Check that the fuel vent screw of the fuel tank is open Is the vent screw open Open the fuel ven...

Page 260: ...or replace the faulty parts Check the fuel pump for leaks from the valve by applying the specified pressure to the pump Is there any leakage Replace the fuel pump Check the carburetor operation Good operating condition Adjust or replace the carburetor Check the compression pressure Compression pressure Measure the compression pressure Does the measured pressure exceed the specified value Check the...

Page 261: ...hat the fuel vent screw of the fuel tank is open Is the vent screw open Open the fuel vent screw Check the water accumulation or clogging of the fuel filter Is there water or residue Clean the fuel system from the fuel tank to the fuel filter Check the fuel hose for kinks or fuel leakage Is there any kinks or fuel leakage Correct or replace the faulty parts Check the fuel pump for leaks from the v...

Page 262: ...er Good ignition spark condition Check the spark plug wire and spark plug cap for deterioration No deterioration Replace the spark plug wire or spark plug cap Measure the ignition coil resistance Is the measured resistance fall within the specification Replace the ignition coil Measure he pulser coil output peak voltage Is measured voltage exceeds the specified value Replace the pulser coil Measur...

Page 263: ...I unit Check the ignition timing Check each component again Is ignition timing correct Adjust the ignition timing Check the power unit Power unit Measure the compression pressure Does the measured pressure exceed the specified value Check the cylinder head cylinder head gasket piston piston rings and cylinder block Check each component again 9 8 ...

Page 264: ...throttle cable and throttle link Good operating condition Adjust the throttle cable and throttle link Check the carburetor operation Check the ignition system Check the intake manifold gasket and the reed valve to verify the integrity of the air intake system Are there sparks Check the ignition spark using the spark gap tester Good operating condition Adjust the carburetor Check the ignition timin...

Page 265: ... this test can produce sparks Check that the fuel vent screw of the fuel tank is open Is the vent screw open Open the fuel vent screw Check the water accumulation or clogging of the fuel filter Is there water or residue Clean the fuel system from the fuel tank to the fuel filter Check the fuel hose for kinks or fuel leakage Is there any kinks or fuel leakage Correct or replace the faulty parts Che...

Page 266: ... spark using the spark gap tester Good ignition spark condition Check the spark plug wire and spark plug cap for deterioration No deterioration Replace the spark plug wire or spark plug cap Measure the ignition coil resistance Is the measured resistance fall within the specification Replace the ignition coil Measure the pulser coil output peak voltage Is measured voltage exceeds the specified valu...

Page 267: ...ds the specified value Is measured voltage exceeds the specified value Measure the CDI unit output peak voltage Replace the CDI unit Check the ignition timing Check each component again Is ignition timing correct Adjust the ignition timing Check each component again Power unit 9 12 ...

Page 268: ...the cooling water inlet or replace it Check that cooling water is discharged from the cooling water pilot hole Is water discharged Check the water pump impeller Good condition Replace the impeller Check the cooling water passage Replace the thermostat Check the thermostat operation Good operating condition Check the thermoswitch Replace the thermoswitch Check the CDI unit Replace the CDI unit Chec...

Page 269: ...obtained Check for continuity through the battery relays and power trim and tilt switch Listen to the operating sound of the power trim and tilt motor Replace the power trim and tilt relay Activate the power trim and tilt switch and check the voltage between the blue L lead and green G lead Replace the power trim and tilt relay Check that the manual valve is closed Check the power trim and tilt mo...

Page 270: ...n Measure the hydraulic pressure of the power trim and tilt Measured hydraulic pressure within the specification Check the inner parts valves pistons gears etc Disassemble the power trim and tilt unit and check the filter for clogs or debris Is the filter clogged or contaminated Clean or replace the filter Check the fluid passage for clogs or stuck foreign substances Clogs or stuck foreign substan...

Page 271: ... inner parts valves pistons gears etc Check that the manual valve is closed Is it closed Close the valve Check the possible oil leakage from the power trim and tilt unit Oil leakage detected Repair the oil leakage Check the power trim and tilt fluid level Is the fluid at specified level Add fluid to the correct level 9 16 ...

Page 272: ...cables and links of the remote control box Check the operation of the shift rod Good operating condition Check the operation of detent mechanism in the bottom cowling and the function of the components in the lower case Check the condition of the shift rod connection between the lower case and the upper case Connected properly Replace the shift rod Disassemble the lower case and check or replace t...

Page 273: ...ge of the lighting coil Is measured voltage above specification Replace the lighting coil Measure the Rectifier Regulator output peak voltage Is measured voltage above specification Replace the Rectifier Regulator Replace the battery and check the power consumption of all electrical equipment aboard Lower unit Electrical system 9 18 ...

Page 274: ...lug caps Standard type 8 9 Checking the anodes 3 21 Checking the armature 8 18 Checking the battery 1 14 3 21 Checking the brushes 8 19 Checking the carburetor 4 12 Checking the carburetor synchronization 3 12 Checking the CDI unit 8 13 Checking the charge coil 8 12 Checking the choke solenoid 8 19 Checking the compression pressure 5 2 Checking the connecting rod 5 33 Checking the cooling water pa...

Page 275: ...nder head 5 22 D Dimentions 2 7 Disassembling the carburetor 4 12 Disassembling the clamp brackets 7 46 Disassembling the fuel pump 4 8 Disassembling the gear pump unit 7 28 Disassembling the lower case 6 18 6 47 Disassembling the piston and the connecting rod assembly 5 30 Disassembling the propeller shaft assembly 6 15 Disassembling the propeller shaft housing assembly 6 12 6 44 Disassembling th...

Page 276: ...linder head 5 23 Removing the drive shaft and forward gear 6 18 Removing the drive shaft and reverse gear 6 47 Removing the electrical components 5 15 Removing the exhaust cover 5 21 Removing the flywheel magnet 5 15 Removing the intake manifold 5 18 Removing the lower unit 6 7 6 37 Removing the piston connecting rod assembly and the crankshaft 5 28 Removing the power trim and tilt unit 7 17 Remov...

Page 277: ...60H5E11 W Wiring harness 8 7 i 4 ...

Page 278: ...ender Fuse 20 amps Spark plug A To remote control box switch panel B To trim meter C Cylinder head D Cylinder body E CDI magnet Color code B Black Br Brown G Green Gy Gray L Blue Lg Light green P Pink R Red Sb Sky blue W White Y Yellow B R Black Red B W Black White G W Green White W B White Black W Br White Brown W R White Red W G White Green W Y White Yellow W L White Blue Starter motor PTT up re...

Page 279: ...200AET L200AET ...

Page 280: ......

Page 281: ...Printed on recycled paper Printed in Japan Feb 2002 0 9 1 200AET L200AET E YAMAHA MOTOR CO LTD ...

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