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Yamaha 50G, Service Manual

The Yamaha 50G Owner's Manual is a comprehensive guide for users of the Yamaha 50G product. This essential manual provides detailed instructions and information on how to operate and maintain the product efficiently. Download your free copy of the manual from our website, ensuring hassle-free access to valuable information.

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E

POWR

 

CHAPTER 5

POWER UNIT

 

EXPLODED DIAGRAM

 

................................................................................... 5-1

 

PREPARATION FOR OVERHAUL

 

.................................................................. 5-3

 

REMOVAL

 

....................................................................................................... 5-3

 

DISASSEMBLY

 

............................................................................................... 5-5

 

INSPECTION

 

................................................................................................... 5-6

CYLINDER HEAD...................................................................................... 5-6

CLEANING ......................................................................................... 5-6
INSPECTION ...................................................................................... 5-6

CYLINDER BLOCK.................................................................................... 5-7

CLEANING ......................................................................................... 5-7
INSPECTION ...................................................................................... 5-7

PISTON ..................................................................................................... 5-8

CLEANING ......................................................................................... 5-8
INSPECTION ...................................................................................... 5-8

PISTON RING ........................................................................................... 5-9

INSPECTION ...................................................................................... 5-9

PISTON PIN AND SMALL END BEARING ............................................ 5-10

CLEANING ....................................................................................... 5-10
INSPECTION .................................................................................... 5-10

CRANKSHAFT ........................................................................................ 5-10

INSPECTION .................................................................................... 5-10

REED VALVE........................................................................................... 5-11

INSPECTION .................................................................................... 5-11

THERMOSTAT........................................................................................ 5-12

CLEANING ....................................................................................... 5-12
INSPECTION .................................................................................... 5-12

CRANK MAIN BEARING ........................................................................ 5-12

CLEANING ....................................................................................... 5-12
INSPECTION .................................................................................... 5-12

DRIVE GEAR (OIL INJECTION PUMP DRIVE) ...................................... 5-13

INSPECTION .................................................................................... 5-13

DRIVEN GEAR (OIL INJECTION PUMP DRIVE).................................... 5-13

INSPECTION .................................................................................... 5-13

Summary of Contents for 50G

Page 1: ...6H2 28197 Z9 11 SERVICE MANUAL 50G 60F 70B 75C 90A ...

Page 2: ...ing its prod ucts models may differ in detail from the descriptions and illustrations given in this publica tion Use only the latest edition of this manual Authorized Yamaha dealers are notified periodically of modifications and significant changes in specifications and procedures and these are incorporated in successive editions of this manual A10001 0 50G 60F 70B 75C 90A SERVICE MANUAL 1999 Yama...

Page 3: ... to several models though only one may be illustrated The name of the model described will be mentioned in the description To help you identify components and understand the correct procedures of disassembly and assembly exploded diagrams are provided Steps in the procedures are numbered thus 1 2 3 Parts shown in the illustrations are identified thus 1 2 3 REFERENCES These have been kept to a mini...

Page 4: ...ander or a person inspecting or repairing the outboard motor CAUTION A CAUTION indicates special precautions that must be taken to avoid damage to the out board motor NOTE A NOTE provides key information to make procedures easier or clearer Model name 50GETO 60FEHTO 60FED 60FEDO 60FET 60FETO 70BEDO 70BETO USA and Canada name P60TH C60ER C60TR 70TR Control system Remote control Manual control Remot...

Page 5: ...tric current A Symbol G to J in an exploded diagram indicate grade of lubricant and location of lubrication point G Apply engine oil H Apply gear oil I Apply molybdenum disulfide oil J Apply water resistant grease Yamaha marine grease A Yamaha marine grease Symbols K to N in an exploded diagram indicate grade of sealing or locking agent and location of application point K Apply Gasket Maker L Appl...

Page 6: ......

Page 7: ...ATION 1 SPECIFICATIONS 2 SPEC PERIODIC INSPECTION AND ADJUSTMENT 3 FUEL SYSTEM 4 FUEL POWER UNIT 5 POWR LOWER UNIT 6 LOWR BRACKET UNIT 7 BRKT ELECTRICAL SYSTEMS 8 ELEC TROUBLE ANALYSIS 9 GEN INFO INSP ADJ TRBL ANLS A30000 0 ...

Page 8: ......

Page 9: ...SERIAL NUMBER 1 1 STARTING SERIAL NUMBERS 1 1 SAFETY WHILE WORKING 1 2 FIRE PREVENTION 1 2 VENTILATION 1 2 SELF PROTECTION 1 2 OILS GREASES AND SEALING FLUIDS 1 2 GOOD WORKING PRACTICES 1 3 DISASSEMBLY AND ASSEMBLY 1 4 SPECIAL TOOLS 1 5 MEASURING 1 6 REMOVAL AND INSTALLATION 1 8 ...

Page 10: ... 3 Transom height 4 Serial number STARTING SERIAL NUMBERS The starting serial number blocks are as fol lows Model Approved model No Serial number Model Approved model No Serial number World wide USA Canada World wide USA Canada 50GETO 62F L 400805 70BEDO 6H3 L 402029 60FEHTO P60TH P60TH 6H2 L 551924 70BETO 70TR 70TR L 491824 X 750186 X 731262 60FED C60ER S 001118 75CET C75TR C75TR 6H0 L 001251 L 3...

Page 11: ...r than air and if inhaled in large quantities will not support life Engine exhaust gases are harmful to breathe When test running an engine indoors maintain good ventilation SELF PROTECTION Protect your eyes with suitable safety glasses or safety goggles when using com pressed air when grinding or when doing any operation which may cause particles to fly off Protect hands and feet by wearing safet...

Page 12: ...soiled wiping rag in one s pocket 4 Hands and any other part of the body which have been in contact with lubri cants or lubricant contaminated cloth ing should be thoroughly washed with hot water and soap as soon as practica ble 5 To protect the skin the application of a suitable barrier cream to the hands before working is recommended 6 A supply of clean lint free cloths should be available for w...

Page 13: ...n parts with compressed air when disassembling them 2 Oil the contact surfaces of moving parts before assembly 3 After assembly check that moving parts operate normally 4 Install bearings with the manufacturer s markings on the side exposed to view and liberally oil the bearings 5 When installing oil seals apply a light coating of water resistant grease to the outside circumference ...

Page 14: ...tools recommended by Yamaha will aid the work and enable accu rate assembly and tune up Improvisations and use of improper tools can cause damage to the equipment NOTE For USA and Canada use part numbers starting with YB YM YU or YW For others use part numbers starting with 90890 ...

Page 15: ...auge N A 90890 06702 Pinion shimming 12 Digital caliper N A 90890 06704 Pinion shimming Forward shimming 13 Gauge block YB 34432 9 N A Pinion shimming 14 Adapter plate YB 34432 10 N A Pinion shimming 15 Gauge base YB 34432 11 N A Pinion shimming 16 Clamp YB 34432 17 N A Pinion shimming 17 Shimming plate N A 90890 06701 Forward shimming 18 Base plate YB 34446 1 N A Forward shimming 19 Compression s...

Page 16: ...1 7 GEN INFO E SPECIAL TOOLS ...

Page 17: ...sing oil seal Drive shaft outer bearing 7 Ring nut wrench YB 06048 YB 34447 90890 06510 90890 06511 Ring nut 8 Extension N A 90890 06513 Ring nut 9 Claw YB 06207 90890 06502 90890 06503 Propeller shaft housing 10 Universal puller YB 06117 N A Propeller shaft housing 11 Center bolt N A 90890 06504 Propeller shaft housing 12 Drive rod YB 06071 90890 06602 Propeller shaft housing oil seal Drive shaft...

Page 18: ...1 9 GEN INFO E SPECIAL TOOLS ...

Page 19: ...earing outer race attach ment YB 06156 90890 06626 90890 06627 Drive shaft outer bearing 26 Driver rod YB 06071 90890 06605 Forward gear outer bearing 27 Bearing outer race attach ment YB 06276 B 90890 06621 90890 06622 Forward gear outer bearing 28 Bearing inner race attach ment N A 90890 06640 90890 06662 Forward gear inner bearing 29 Shift rod wrench YB 06052 N A Shift rod 30 Cylinder end screw...

Page 20: ......

Page 21: ...SPEC 1 2 3 4 5 6 7 8 9 CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATION 2 1 MAINTENANCE SPECIFICATIONS 2 5 ENGINE 2 5 ELECTRICAL 2 7 DIMENSION 2 10 TIGHTENING TORQUE 2 12 GENERAL TORQUE SPECIFICATIONS 2 13 ...

Page 22: ... 5 521 20 5 X mm in 648 25 5 1 4 5 Weight Al S kg lb 94 207 2 95 5 211 3 104 229 4 103 5 228 5 L kg lb 102 225 97 5 215 3 105 5 233 5 112 247 1 96 212 2 106 234 4 X kg lb 115 254 1 109 240 4 108 5 239 5 Weight SUS S kg lb 97 5 215 3 105 5 233 5 L kg lb 99 5 219 3 107 5 237 5 X kg lb 110 5 244 5 Full throttle speed range r min 4 500 5 500 5 000 6 000 Output ISO kW hp r min 36 8 50 5 000 44 1 60 5 0...

Page 23: ...in 647 25 5 647 25 5 4 Weight Al S kg lb L kg lb 119 5 263 1 120 5 266 2 124 5 275 3 120 5 266 115 5 255 1 111 5 246 2 119 5 263 3 120 5 266 4 X kg lb 123 5 272 123 5 272 4 Weight SUS S kg lb L kg lb 121 5 268 1 122 5 270 2 122 5 270 113 5 250 2 121 5 268 3 122 5 270 4 X kg lb 125 5 277 125 5 277 4 Full throttle speed range r min 4 500 5 500 Output ISO kW hp r min 55 2 75 5 000 58 8 80 5 000 66 2 ...

Page 24: ... 10 Register plug cap standard Exhaust system Through prop boss Cooling system Water Lubrication system Pre mixed gasoline oil 2 Oil injection Fuel type P O N 3 Regular gasoline Fuel rating Min 86 Engine oil type grease TC W3 4 Gear oil type Hypoid gear oil SAE 90 5 Gear oil quantity cm3 US oz lmp oz 500 16 91 17 60 610 20 62 21 47 Engine oil tank capacity L US qt lmp qt 2 8 2 96 2 46 3 3 3 49 2 9...

Page 25: ... 3 13 5 8 13 3 13 17 3 13 19 3 13 21 3 13 23 3 13 25 3 13 1 2 14 3 13 1 2 16 P High performance propeller P type stainless in 3 14 20 3 14 24 3 14 28 Item Unit Model 75 80 90 hp Propeller K type aluminum K type stainless No of blades diameter pitch in 3 12 5 8 21 3 13 19 3 13 23 3 13 1 4 17 3 13 1 2 15 3 13 1 2 17 3 13 5 8 13 3 14 11 3 13 17 3 13 19 3 13 21 3 13 23 3 13 25 3 13 1 2 14 3 13 1 2 16 ...

Page 26: ... 0 0022 0 060 0 065 0 0024 0 0026 Limit mm in 0 105 0 0041 0 115 0 0045 Piston size D mm in 71 945 71 970 2 8325 2 8335 81 935 81 960 3 2258 3 2268 Measuring point H mm in 10 0 4 Oversize 1st mm in 72 25 2 844 82 25 3 238 2nd mm in 72 50 2 854 82 50 3 248 Offset mm in 0 5 0 0197 1 0 0 039 direction Exhaust side Exhaust side Piston ring Sectional sketch Top ring 2nd ring Type Keystone B mm in 2 0 0...

Page 27: ...ot jet P J 65 65 70 1 75 78 80 2 78 78 Pilot air jet P A J 70 75 80 1 70 80 75 2 80 70 Pilot screw P S Turns out 1 3 8 1 4 1 1 2 1 4 1 3 8 1 4 1 1 1 4 1 4 1 3 8 1 4 1 1 4 1 4 Float height F H mm in 15 0 1 0 0 59 0 04 14 0 1 0 0 55 0 04 14 0 2 0 0 55 0 08 1 19 5 3 0 0 77 0 12 2 Valve seat size ø 1 2 0 047 1 6 0 063 1 4 0 055 1 1 4 0 055 1 6 0 063 Idling speed r min 800 50 Oil injection pump Stamped...

Page 28: ...mm in 3 23 0 28 0 127 0 11 2 68 0 26 0 106 0 010 2 83 0 27 0 111 0 011 3 41 0 29 0 134 0 011 Charging coil resistance 20 C 68 F Ω 136 204 Brown Blue 64 96 Br R 191 288 B R Charge coil output peak voltage minimum color Br L R Br R L cranking open V 120 55 90 cranking connect V 150 60 100 1 500 r min V 160 170 135 3 500 r min V 120 150 135 Pulser coil resistance 20 C 68 F Ω 240 360 W R W B 241 362 W...

Page 29: ...0 0 035 0 039 CDI unit output peak voltage minimum color B W B B W B cranking open V cranking connect V 1 3 105 2 1 3 130 2 1 500 r min V 145 155 3 500 r min V 105 130 Lighting system Lighting coil resistance Ω 0 57 0 85 G W G 0 4 0 6 G W G STD 12V 80W 20 C 68 F Lighting coil output peak voltage minimum color G G W G G W cranking open V 8 5 10 cranking connect V 8 0 11 1 500 r min V 25 25 3 500 r ...

Page 30: ...imit mm in 29 1 14 31 1 22 Pinion ring gear gap mm in 3 0 5 0 0 12 0 20 Others Electrothermal valve resistance 20 C 68 F Ω 2 3 3 5 L B Fuel enrichment valve resistance 20 C 68 F Ω 3 4 4 0 L B Trim sensor resistance Ω 360 540 P B 800 1 200 B O Fuse A 20 Item Unit Model 50hp 60hp 70hp 75hp 80hp 90hp ...

Page 31: ... hp L6 S mm in 868 34 2 L 918 36 1 968 38 1 X 1 081 42 6 L7 S mm in 403 15 9 L X 411 16 2 457 18 0 H4 S mm in 400 15 7 L 520 20 5 X 648 25 5 647 25 5 H9 S mm in 719 28 3 L X 706 27 8 730 28 7 H12 S mm in 135 5 3 L 204 8 0 205 8 1 203 8 0 X 264 10 4 W5 mm in 321 12 6 331 13 0 A1 degree 35 30 A2 S degree 63 L X 67 62 1 A3 S degree 0 L X 4 T1 mm in 600 23 6 2 ...

Page 32: ...p 60 hp 70 hp 75 80 90 hp B1 mm in 125 4 4 9 B2 mm in 254 10 0 B3 mm in 163 5 6 4 B4 mm in 50 8 2 0 B5 mm in 180 7 1 B6 S mm in 329 13 0 L X 351 13 8 B7 mm in 138 1 5 4 B8 mm in 203 2 8 0 B9 mm in 18 5 0 7 D1 mm in 13 0 5 D2 mm in 55 5 2 2 D4 mm in 12 0 5 ...

Page 33: ... 0 8 5 8 12 12 1 2 8 7 Spark plug Bolt M14 3 3 25 2 5 18 Flywheel Nut M20 1 1 160 16 0 115 E Power unit mounting Bolt M8 8 11 21 2 1 15 Starter motor mounting Bolt M8 2 2 20 2 0 14 242 LT Straight screw plug Screw M12 1 1 23 2 3 1 7 UPPER CASE AND GEAR CASE Upper mount rubber Nut M10 2 2 24 2 4 17 271 LT Bracket bolt Nut M22 1 1 15 1 5 11 Upper case mounting Bolt M8 11 11 21 2 1 15 Exhaust guide B...

Page 34: ... 3 0 3 2 2 Main valve Screw 2 10 1 0 7 2 6H308 2 11 1 1 8 0 6H1 15 62F 02 Parts to be tightened Part name Thread size Q ty Tightening torque Remarks 50 60 70 hp 75 80 90 hp Nm m kg ft lb GENERAL TORQUE SPECIFICATIONS This chart specifies the torque for tighten ing standard fastners with standard fast ners with standard clean dry ISO threads at room temperature Torque specifications for special com...

Page 35: ...EL FILTER 3 4 FUEL TANK AND FUEL LINE 3 4 GEAR OIL 3 5 IDLE SPEED 3 5 IGNITION TIMING ADJUSTMENT 3 6 TIMING PLATE POSITION ADJUSTMENT 3 6 THROTTLE SENSOR CONTROL LINK ADJUSTMENT 3 7 IGNITION TIMING ADJUSTMENT 3 8 PICK UP TIMING ADJUSTMENT 3 9 OIL INJECTION PUMP 3 10 OPERATIONAL TEST 3 10 CHECKING THE OIL LEVEL WARNING SYSTEM 3 11 OIL PUMP LINK ADJUSTMENT 3 12 POWER TRIM AND TILT FLUID PTT model 3 ...

Page 36: ...l nut 3 4 Fuel filter 3 4 Fuel tank and fuel line Gear oil 3 5 Idle speed Ignition timing 3 6 Oil injection pump 3 10 Oil level warning system 3 11 Oil pump link 3 12 Power trim and tilt system Propeller 3 13 Spark plug D31000 0 ANODE Inspect the anode If it is worn out replace it with a new one If scaling of the surface is evident remove the anode clean it with a wire brush and remove all trace o...

Page 37: ...dical 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 mea sures Charge batteries in a well ventilated area Keep batteries away from fire sparks or open flames e g welding equipment lighted cigarettes DO NOT SMOKE wh...

Page 38: ...needle valve for wear and replace it if worn D31902 1 CARBURETOR LINK ADJUSTMENT 50 60 70 hp 1 Loosen the idle adjust screw and fully close the throttle valve 2 Loosen the throttle lever securing screws of upper and middle carburetors by turning clockwise 3 While lightly pushing the throttle lever of the lower carburetor in the direction of the arrow full closed tighten the throttle lever securing...

Page 39: ...rottle lever securing screw of the upper and lower carburetors by turning counterclockwise 1 Idle adjust screw 2 Throttle lever 3 Throttle lever securing screw D32000 0 CYLINDER HEAD BOLTS ENGINE MOUNTING BOLTS AND FLYWHEEL NUT 1 Retighten to specifications 2 Check other fixings and tighten if neces sary D32300 0 FUEL FILTER Clean the strainer of dust and impurities 1 Strainer body 2 Strainer 3 O ...

Page 40: ...utward to the specified setting 3 Start the motor and allow it to warm up for a few minutes Pilot screw stamped mark 62F00 6H210 6H007 6H015 1 3 8 1 4 turns out 6H20A 1 1 2 1 4 turns out 6H30A 6H107 1 1 4 1 4 turns out 4 Set the idle speed to the specified level by setting the throttle stop screw Use a tachometer for checking the speed when adjusting the motor speed NOTE Turning the throttle stop ...

Page 41: ...f No 1 cylinder NOTE For easy timing plate adjustment it is advisable to remove the spark plugs from all the cylinders 3 Slowly turn the flywheel CLOCKWISE and stop it when the piston is at TDC 4 If the end of the timing plate is not aligned with the TDC mark on the CDI magneto rotor loosen the timing plate set screw align the timing plate end with the TDC mark then tighten the screw 5 Remove the ...

Page 42: ...contacts the stopper the full retard indication on the CDI unit aligns with the timing indica tor 1 Timing indicator 2 Full retard indication 50 60 70 hp 3 Full retard indication 75 80 90 hp 4 Full retard adjusting screw NOTE The nut in the magneto control lever should be 2 mm 0 08 in off from the end of the magneto control lever 1 2 4 50 60 70 hp 3 Adjust the length of the full advance adjusting ...

Page 43: ...OTE Before adjusting be sure to warm up the engine 1 Attach the timing light and tachometer to the No 1 cylinder high tension code 2 While keeping the stopper in contact with the full retard adjusting screw measure the full retard ignition timing with the timing light If the timing is out of specification adjust it by turning the full retard adjusting screw NOTE When measuring the full retard igni...

Page 44: ...ne speed Full advance side engine speed 50 60 75 80 90 ph 5 000 500 rpm 70 hp 5 500 500 rpm Full advance side ignition timing 50 60 90 hp 22 1 BTDC 70 75 80 hp 20 1 BTDC PICK UP TIMING ADJUSTMENT NOTE Engine idle speed should be adjusted prop erly before adjusting the pick up timing 1 Turn the magneto control lever to the full retard position 2 Bring the throttle cam to lightly contact the throttl...

Page 45: ... C 50 86 F 1 Before measuring bleed the pump com pletely and ensure no air bubbles are present in the oil flowing out of the oil feed pipe 2 When measuring with the measuring cyl inder ensure that no oil clings to the cyl inder wall otherwise the measurement will be inaccurate 3 Use only genuine Yamaha oil If the vis cosity is too high or too low the mea surement of the discharge will be inaccurat...

Page 46: ...briefly for this will cause malfunc tion or engine seizure 50 60 70 hp Case Oil level Oil level warning lamp Warning buzzer Speed drop function 1 More than 770 cm3 0 81 US qt GREEN OFF OFF 2 770 cm3 0 31 Us qt 280 cm3 0 3 US qt YELLOW OFF OFF 3 280 cm3 or less 0 3 US qt RED ON ON 75 80 90 hp Case Oil level Oil level warning lamp Warning buzzer Speed drop function 1 More than 1 130 cm3 1 19 US qt G...

Page 47: ... FLUID PTT model 1 Tilt up the motor and lock it with the tilt lock lever 2 Remove the fluid level plug to check the fluid level With the motor tilted up the fluid level should be immediately below the fluid hole If the fluid level is low top up with the recommended fluid CAUTION When checking the fluid level with the unit removed from the engine hold the unit in the vertical position and set the ...

Page 48: ...heck the engine condition White color Lean fuel mixture Plugged filter jet Air leak Wrong settings Blackish color Electrical malfunction Defective spark plug 2 Clean the spark plug with spark plug cleaner or wire brush Use a wire gauge to adjust the plug gap a to specifica tion 3 If the electrode becomes too worn replace the spark plug Spark plug gap 0 9 1 0 mm 0 035 0 039 in Standard spark plugs ...

Page 49: ...y be on the surface of the plug and screw in the spark plug to the cor rect torque NOTE If a torque wrench is not available a good estimate of the correct torque is a further 1 4 to 1 2 turns b on finger tightened a spark plug T R Tightening torque 25 Nm 2 5 m kg 18 ft lb GREASING POINTS 1 Apply Water resistant grease ...

Page 50: ......

Page 51: ... EXPLODED DIAGRAM Except for C60ER C60TR C75TR 4 6 EXPLODED DIAGRAM For C60ER C60TR C75TR 4 7 REMOVAL AND DISASSEMBLY 4 8 INSPECTION 4 9 CARBURETOR BODY 4 9 NEEDLE VALVE 4 9 PILOT SCREW 4 9 COLLAR 4 9 FLOAT 4 9 ENRICHING FUEL PUMP 4 10 ELECTROTHERMAL VALVE 4 10 ASSEMBLY 4 11 INSTALLATION 4 13 OIL INJECTION SYSTEM Oil injection model 4 14 EXPLODED DIAGRAM 4 14 REMOVAL 4 16 CLEANING AND INSPECTION 4...

Page 52: ...E20000 1 FUEL SYSTEM EXPLODED DIAGRAM 1 Carburetor 2 Electrothermal valve 3 Fuel pump assembly 4 Fuel filter assembly 5 Fuel joint 6 Priming pump 7 Fuel meter assembly 8 Fuel tank cap 9 Fuel tank Except for C60ER C60TR C75TR ...

Page 53: ...LINE Check that the fuel line is correctly installed 50 60 70 hp 1 Oil tank 2 Oil injection pump 3 Carburetor 4 Fuel filter 5 Fuel pump 75 80 90 hp 1 Oil tank 2 Oil injection pump 3 Carburetor 4 Fuel filter 5 Fuel pump Oil injection model ...

Page 54: ...n good ventila tion 3 Spillage Remember that fuel remains in the fuel hose between the fuel joint and the car buretor Drain all remaining fuel out into a container or soak it up with a cloth so that the fuel does not spill onto the bot tom cowling 4 Leaks Failure to check for and correct fuel leaks may result in fire or explosion 1 Referring to the exploded diagram remove the fuel line E21010 0 CL...

Page 55: ...e rubber gasket to the fuel tank ensuring that there are no leaks between the fuel meter and the fuel tank 1 Fuel meter assembly 2 Suction pipe 3 Fuel strainer E21030 0 PRIMING PUMP 1 Visually inspect for cracks or breaks in the priming pump and fuel hoses and replace them if required 2 Check the operation of the check valve by blowing into the pump 1 Priming valve 2 Arrow mark 3 Check valve inlet...

Page 56: ...d replace as required E21060 0 FUEL PUMP 1 Using a screwdriver disassemble the fuel pump 2 Visually inspect the pump body for cracks and replace if required 3 Inspect the valves for cracks or distor tion and replace if required 4 Inspect the diaphragm for sign of dam age perforation or stretching and replace if required 5 Assemble the fuel pump with new gas kets E22000 0 INSTALLATION Referring to ...

Page 57: ...ARBURETOR EXPLODED DIAGRAM Except for C60ER C60TR C75TR 1 Pilot screw 2 Needle valve 3 Pilot jet 4 Main nozzle 5 Main jet 6 Float 7 Drain screw 8 Float chamber 9 Throttle stop screw 0 Collar A Electrothermal valve B Valve C Diaphragm ...

Page 58: ...4 7 FUEL E CARBURETOR EXPLODED DIAGRAM For C60ER C60TR C75TR 1 Pilot screw 2 Needle valve 3 Pilot jet 4 Main nozzle 5 Main jet 6 Float 7 Drain screw 8 Float chamber 9 Throttle stop screw 0 Collar ...

Page 59: ...iver to disassemble the carburetor 3 Using solvent clean the components thoroughly and blow dry them with compressed air WARNING Protect your eyes with suitable safety glasses or safety goggles when using com pressed air Protect your eyes and the eyes of others by directing the flow of com pressed air downward noting that solvent and small parts may be blown off CAUTION Do not use steel wire for c...

Page 60: ... if required PILOT SCREW 1 Inspect the pilot screw for wear and replace if required COLLAR 1 Inspect the collar at the end of the accel erator arm for wear and replace if required FLOAT 1 Visually inspect the float for damage or cracks and replace if required 2 Measure the float height a If it is more than 2 mm 0 08 in greater or less than the specified float height recheck the valve seat and need...

Page 61: ... replace if required 3 Inspect the valves for cracks or distor tion and replace if required 4 Inspect the diaphragm for any sign of damage perforation or stretching and replace if required ELECTROTHERMAL VALVE 1 Inspect the needle valve for any bend ing and wear and the piston valve for flow Inspect the body for cracks and the wire lead for defects 1 Needle valve 2 Piston valve 3 Body 4 Wire lead ...

Page 62: ...eads to a 12V bat tery c Measure the piston valve height b after several minutes d Compare the valve height a with b ASSEMBLY 1 Install a new O ring the valves on the body and secure with the screws 2 Install the diaphragm on the carburetor with new gaskets install the pump cover on the carburetor and secure with the screws 3 Install a new O ring to the electrother mal valve install it to the carb...

Page 63: ... body and secure with the screws 8 Install the plate with new packing and secure with the screws 9 Install the pilot screw with its spring screw it in until seated then screw it out the specified number of turns CAUTION Do not cause damage to the tip of the pilot screw by over tightening it Pilot screw stamped mark 62F00 6H210 6H007 6H015 1 3 8 1 4 turns out 6H20A 1 1 2 1 4 turns out 6H30A 6H107 1...

Page 64: ... screw 2 Connect the fuel hoses to the carbure tors and fit the hose clips over the recesses to ensure leak proof connec tions 3 Connect the electrothermal valve leads 4 Connect the oil pump link rod to the carburetor and oil injection pump 5 Install the silencer cover and tighten the bolt to the specified torque T R Bolt silencer cover 2 Nm 0 2 m kg 1 4 ft lb ...

Page 65: ... OIL INJECTION SYSTEM Oil injection model EXPLODED DIAGRAM 1 Oil level sensor 2 Oil strainer 3 Strainer cover gasket 4 Oil injection pump assembly 5 Check valve 6 Oil tank 7 Special washer 8 Oil tank cap assembly 9 Hook 0 Filler tube ...

Page 66: ...E OIL INJECTION SYSTEM 1 Check valve 2 Oil injection pump assembly 3 Drain screw 4 Oil tank 5 Strainer cover gasket 6 Oil strainer 7 Oil lever sensor 8 Special washer 9 Oil tank cap assembly 0 Hook A Filler tube ...

Page 67: ...and replace it if required OIL LEVER SENSOR Refer to OIL LEVEL SENSOR sec tion in chapter 8 OIL HOSES 1 Inspect the oil hoses for damage or cracks and replace them if required E43001 0 INSTALLATION 1 Connect the oil hoses to the oil pump and tighten the clips on the hoses 2 Install the driven gear 1 Driven gear 2 Washer 3 O ring 4 Distance collar 3 Install the oil pump to the power head NOTE Tight...

Page 68: ... the oil delivery hoses to the intake manifolds and tighten the clips on the hoses 6 Lead the wire of the oil level sensor to the port side of the engine and connect the cores 7 Bleed the air from the lines CAUTION After reinstalling the oil injection pump be sure to bleed the pump ...

Page 69: ......

Page 70: ...PISTON 5 8 CLEANING 5 8 INSPECTION 5 8 PISTON RING 5 9 INSPECTION 5 9 PISTON PIN AND SMALL END BEARING 5 10 CLEANING 5 10 INSPECTION 5 10 CRANKSHAFT 5 10 INSPECTION 5 10 REED VALVE 5 11 INSPECTION 5 11 THERMOSTAT 5 12 CLEANING 5 12 INSPECTION 5 12 CRANK MAIN BEARING 5 12 CLEANING 5 12 INSPECTION 5 12 DRIVE GEAR OIL INJECTION PUMP DRIVE 5 13 INSPECTION 5 13 DRIVEN GEAR OIL INJECTION PUMP DRIVE 5 13...

Page 71: ...EARINGS AND PISTON ASSEMBLY 5 15 CONNECTING ROD BIG END BEARING ASSEMBLY 75 80 90 hp 5 16 OIL SEAL HOUSING 5 17 CRANK CYLINDER ASSEMBLY 50 60 70 hp 5 17 CRANK CYLINDER ASSEMBLY 75 80 90 hp 5 18 CYLINDER HEAD AND EXHAUST COVER 5 19 DRAINAGE HOSE 5 20 INTAKE MANIFOLD 5 20 FUEL SYSTEM AND ELECTRICAL SYSTEM 5 20 INSTALLATION 5 21 ...

Page 72: ...der head gasket 5 Thermostat 6 Thermostat cover 7 Exhaust cover gasket 8 Exhaust inner cover 9 Exhaust outer cover 0 Piston pin clip A Piston pin B Drive gear C Bearing D Oil seal E O ring F Oil seal housing G Intake manifold H Valve seat packing I Reed valve plate J Reed valve assembly EXPLODED DIAGRAM ...

Page 73: ...r gasket 6 Cylinder head 7 Cylinder head gasket 8 Exhaust cover gasket 9 Exhaust inner cover 0 Exhaust outer cover A Piston pin clip B Piston pin C Bearing D Drive gear E Circlip F Oil seal G O ring H Oil seal housing I Intake manifold J Valve seat packing K Reed valve plate L Reed valve assembly B90TR 90AETO ...

Page 74: ...d up assembly and help ensure that all parts are correctly reinstalled NOTE When disassembling the engine keep mated parts together e g cylinder and pis ton and other parts that have been mated through normal wear Mated sets should be re used on reassembly or replaced com pletely G40003 0 REMOVAL 1 Remove the electrical system parts Refer to ELECTRICAL COMPONENTS section in chapter 8 1 Ground lead...

Page 75: ...nd then remove the power head from the upper casing 50 60 70 hp 8 bolts 75 80 90 hp 11 bolts NOTE The power head may be difficult to separate from the bottom cowling because of a stuck gasket holding them together If this is the case lever it off the bottom cowling with a piece of wood Use care not to damage the bottom cowling or power head with the wood 6 Remove the dowel pins from the bot tom co...

Page 76: ... one by one from the housing 5 Crankcase Remove the two dowel pins 6 Crankshaft and connecting rod 50 60 70 hp 7 Connecting rod caps needle bearings and crankshaft 75 80 90 hp 8 Piston and piston pin 9 Piston rings Note the following points 1 When disassembling the piston and pis ton pin place a tray under the connect ing rod to catch the needle bearings 2 Only carry out exchange of the crank shaf...

Page 77: ...combustion chamber 3 Using a soft brush clean the water jacket INSPECTION 1 Using a precision straight edge and thickness gauge measure the surface contacting the cylinder block for warping Å Lines indicate straight line measurement If the degree of warping exceeds this specification re surface the cylinder head as follows Place 400 600 grit wet or dry paper on the surface plate and resurface the ...

Page 78: ... or re bore it if necessary 2 Using a cylinder gauge measure the cylinder bore at three positions in the thrust and axial directions 1 Axial direction 2 Thrust direction A 10 mm 0 4 in below the cylinder top B 5 mm 0 2 in above the exhaust port C 5 mm 0 2 in below the scavenging port NOTE Do not place the cylinder gauge on the port hole If diameter is greater than the limit hone or rebore the cyli...

Page 79: ...ge 2 Using the measured cylinder bore diameter in thrust directions subtract the piston diameter measurement from the cylinder bore diameter measure ment If this clearance is not within the specifi cations replace the piston with stan dard or oversize and or rebore the cylinder Except for USA Piston diameter Standard 50 60 70 hp 71 945 71 970 mm 2 8325 2 8335 in 75 80 90 hp 81 935 81 960 mm 3 2258...

Page 80: ...avel to a depth of 20 mm 0 8 in from the top of the cylinder block CAUTION Take care not to scratch the piston Using a thickness gauge measure the end gap If the clearance is not within the specifi cations replace the piston ring NOTE If the clearance is greater than maximum even with a new piston ring rebore the cyl inder and use an over size piston and pis ton ring Side clearance 50 60 70 hp Top...

Page 81: ...ace the crankshaft on a crankshaft aligner or on V blocks 2 Using a dial gauge measure the con necting rod axial play If this axial play is greater than the max imum axial play replace the crankshaft assembly Maximum axial play 2 0 mm 0 08 in 3 Using feeler gauges measure the con necting rod side clearance 50 60 70 hp If this side clearance exceeds the speci fication replace the crankshaft assem b...

Page 82: ... REED VALVE INSPECTION 1 Visually inspect for warping of the reed valve If warped measure the distortion with feeler gauges If the amount of warping is greater than the specification replace the reed valve 2 Using a vernier caliper measure the valve stopper height If the valve stopper height is outside the specification adjust it by bending it 3 Visually inspect for cracks on the reed valve If cra...

Page 83: ...lve lift are not within the specifi cations replace the thermostat Water temperature Valve lift Below 48 52 C 118 126 F 0 mm Above 60 C 140 F Minimum 3 mm 0 12 in G65000 0 CRANK MAIN BEARING CLEANING 1 Using a soft brush and solvent thor oughly clean the bearing Dry it with air and sparingly lubricate it with 2 stroke outboard motor oil NOTE Do not spin bearing with air blower This can damage the ...

Page 84: ...IVE INSPECTION 1 Visually inspect drive gear teeth for cracks pitting or wear and replace the gear if any are found DRIVEN GEAR OIL INJECTION PUMP DRIVE INSPECTION 1 Visually inspect driven gear teeth for cracks pitting or wear and replace the gear if any are found ...

Page 85: ...Circlip 2 Oil injection pump drive gear 3 Crank lower bearing 2 Install the new oil seal in the needle bearing CAUTION The direction of the oil seal must be as shown in the illustration otherwise dam age will be caused 3 Install the new O ring 4 Lubricate the bearing with 2 stroke out board motor oil Apply water resistant grease or equivalent to the inside lip of the oil seal and to the O ring G72...

Page 86: ...ers on both sides CAUTION The washer should be placed with their convex sides facing the piston Number of needles per small end 28 pcs Small end bearing installer 50 60 70 hp YB 6287 90890 06527 75 80 90 hp YB 6107 90890 06527 3 Insert the piston pin into the piston 4 Align the UP mark on the piston crown towards the crankshaft s tapered end Install the piston in the connecting rod small end inser...

Page 87: ...upper middle and lower middle bearing pin holes with the pins on the cylinder and fit the crank shaft correctly to the cylinder 3 Install the bearing in the big end and install the cap The cap bolts should be tightened in the following manner a Lightly screw in the bolts by hand while making sure the cap and rod ends are aligned completely Then tighten the bolts to the 1st specified torque Next ti...

Page 88: ...fter installing the oil seal and O ring pack the oil seal lip and outer surface of the O ring with water resistant grease NOTE Avoid cutting or stretching the oil seal housing O ring 4 Install the oil seal housing onto the cyl inder and align the bolt holes T R Connecting rod big end 75 80 90 hp 1st step 12 Nm 1 2 m kg 8 7 ft lb 2nd step 35 Nm 3 5 m kg 25 ft lb G74000 0 CRANK CYLINDER ASSEMBLY 50 ...

Page 89: ...INDER ASSEMBLY 75 80 90 hp 1 Align each locating pin of the bearings and labyrinth seals with each cut on the cylinder block Then fit the crank assembly in place 2 Film coat the cylinder block mating sur face with Gasket Maker or equivalent 3 Install the dowel pins 4 Match the cylinder block and tighten the bolts to the specified torque in sequence and in two steps 5 Check that the crankshaft turn...

Page 90: ...0 60 70 hp 1st step 15 Nm 1 5 m kg 11 ft lb 2nd step 32 Nm 3 2 m kg 23 ft lb Cylinder head 75 80 90 hp 1st step 15 Nm 1 5 m kg 11 ft lb 2nd step 30 Nm 3 0 m kg 22 ft lb Å Å ı Tightening sequence ı Ç Tightening sequence 3 Install the thermostat gasket and cover T R Exhaust cover 50 60 70 hp 1st step 3 Nm 0 3 m kg 2 2 ft lb 2nd step 8 Nm 0 8 m kg 5 8 ft lb Exhaust cover 75 80 90 hp 1st step 9 Nm 0 9...

Page 91: ... to the intake manifold 2 Install the manifold assembly to the crankcase and tighten the bolts to the specified torque in sequence and in two steps T R Intake manifold 50 60 70 hp 1st step 4 Nm 0 4 m kg 2 9 ft lb 2nd step 8 Nm 0 8 m kg 5 8 ft lb Intake manifold 75 80 90 hp 1st step 4 Nm 0 4 m kg 2 9 ft lb 2nd step 12 Nm 1 2 m kg 8 7 ft lb G77000 0 FUEL SYSTEM AND ELECTRICAL SYSTEM 1 Install the fu...

Page 92: ...ace the gas ket on the bottom cowling 3 Install the power head onto the bottom cowling tighten the mounting bolts to the specified torque 4 Connect the hoses cables and wires 5 Install the apron 6 Check the fittings installation cable connections and functions before start ing the engine to check operation and to check for leaks T R Mounting bolts 21 Nm 2 1 m kg 15 ft lb ...

Page 93: ... HOUSING 6 9 CLAW WASHER 6 9 RING NUT 6 9 WATER PUMP HOUSING 6 10 IMPELLER 6 10 OIL SEAL HOUSING Water pump housing 6 10 GEAR 6 10 BEARING 6 10 CLUTCH DOG AND COMPONENTS 6 11 DRIVE AND PROPELLER SHAFT 6 11 DRIVE SHAFT SLEEVE 6 11 PROPELLER TRIM TAB ANODE 6 11 ASSEMBLY AND ADJUSTMENT 6 12 PROPELLER SHAFT HOUSING 6 12 GEAR CASE 6 13 SHIM SELECTION 6 17 FOR USA AND CANADA 6 17 EXCEPT FOR USA AND CANA...

Page 94: ...asket 5 Oil seal housing 6 Water pump gasket 7 Drive shaft 8 Woodruff key 9 Drive shaft sleeve 0 Needle bearing A Shifter B Shift slide C Forward gear D Clutch dog E Cross pin F Propeller shaft G Reverse gear H O ring I Bearing J Bearing housing K Needle bearing L Claw washer M Ring nut N Spacer O Propeller P Castle nut Q Trim tab R Pinion gear S Spacer 50GETO EXPLODED DIAGRAM ...

Page 95: ...te 4 Cartridge outer plate gasket 5 Oil seal housing 6 Water pump gasket 7 Drive shaft 8 Woodruff key 9 Drive shaft sleeve 0 Needle bearing A Shifter B Shift slide C Forward gear D Clutch dog E Cross pin F Propeller shaft G Reverse gear H O ring I Bearing J Bearing housing K Needle bearing L Claw washer M Ring nut N Spacer O Propeller P Castle nut Q Trim tab R Pinion gear ...

Page 96: ... lock it with the tilt lock lever 5 Remove the trim tab Before removing it put a mark indicating its position on the anticavitation plate 6 Remove the bolts 140007 0 DISASSEMBLY 1 Referring to the exploded diagram remove the following parts 1 Water pump housing and insert car tridge 2 Impeller and woodruff key 3 Oil seal housing Water pump housing Remove the oil seals if necessary Å For USA and Ca...

Page 97: ...nd turn it in the direction of the off mark using the special service tool Ring nut wrench YB 34447 3 90890 06511 4 Extension ring nut wrench 90890 06513 5 Å ı 4 5 6 Bearing housing Using special service tool Å For USA and Canada ı Except for USA and Canada Claw YB 6207 1 50 60 70 hp 90890 06503 2 75 80 90 hp 90890 06502 2 Flywheel puller YB 6117 3 Stopper guide plate 90890 06501 4 Center bolt 908...

Page 98: ...og 2 Cross pin 3 Cross pin ring 8 Shift slide Except for 50GETO C60ER C60TR 60FET Oceania C75TR 90AEHD 90AED C90TR 90AET Using a slotted screwdriver remove the shift slide balls 1 from the neu tral position and pull out the shift slide 2 and shifter 3 9 Reverse gear and bearing Å For USA and Canada ı Except for USA and Canada Slide hammer set YB 6096 1 Stopper guide plate 90890 06501 2 Bearing pul...

Page 99: ...0890 06538 4 Driver rod YB 6071 90890 06602 5 Needle bearing attachment YB 6153 90890 06612 6 Å ı 11 Pinion nut pinion and drive shaft bearing inner race Å For USA and Canada ı Except for USA and Canada NOTE For ease of reassembly and adjustment keep shim packs in their groups as removed Drive shaft holder 50 60 70 hp YB 6049 90890 06518 1 75 80 90 hp YB 6151 90890 06519 2 Pinion nut holder 90890 ...

Page 100: ...B 6096 1 Bearing outer race puller 90890 06523 2 Å 1 ı 2 13 Drive shaft bearing outer race Å For USA and Canada ı Except for USA and Canada Slide hammer set YB 6096 1 Stopper guide plate 90890 06501 2 Bearing puller 90890 06535 3 Stopper guide stand 90890 06538 4 Å 1 ı 2 3 4 14 Drive shaft sleeve 15 Drive shaft needle bearing Driver rod YB 6071 90890 06602 1 Needle bearing attachment YB 6155 90890...

Page 101: ... 8 E LOWR DISASSEMBLY 16 Reverse gear bearing and forward gear bearing NOTE Separate the bearing from the gear using special service tool and hydraulic press Bearing separator YB 6219 1 90890 06534 2 1 2 ...

Page 102: ...r clogging 151500 0 BEARING HOUSING 1 Using a soft brush and solvent clean the housing thoroughly 2 Visually inspect the housing for cracks and corrosion If any damage is found replace the bearing housing 152000 0 CLAW WASHER 1 Visually inspect the washer for cracks If a crack is found replace the claw washer 152500 0 RING NUT 1 Using a soft brush and solvent clean the thread of the ring nut 2 Vis...

Page 103: ...peller 154000 0 OIL SEAL HOUSING Water pump housing 1 Using a soft brush and solvent clean the oil seal housing 2 Visually inspect the housing for cracks or corrosion If a crack and or excessive corrosion is found replace the oil seal housing 154500 0 GEAR 1 Visually inspect the teeth and dogs on the gears for cracks peeling or distor tion due to gear crashing If damage is found on any of the gear...

Page 104: ...nd replace both if necessary 156000 0 DRIVE AND PROPELLER SHAFT 1 Visually inspect the shafts looking for grooved wear on the surface in contact with the bearings and oil seals and checking for wear on the splines Replace if worn or damaged 156300 0 DRIVE SHAFT SLEEVE 1 Visually inspect the sleeve for wear and cracks If any damage is found replace the sleeve 157000 0 PROPELLER TRIM TAB ANODE 1 Ref...

Page 105: ...plete into the bearing housing NOTE Install the needle bearing with its manufac ture s marks or numbers facing outward Å For USA and Canada ı Except for USA and Canada Depth a 50 hp 20 7 mm 1 06 in 60 90 hp 25 5 mm 1 00 in Drive rod YB 6071 90890 06604 1 Needle bearing attachment 50 hp 90890 06614 2 60 90 hp YB 6152 90890 06611 3 Bearing depth plate 90890 06603 4 Depth b 5 mm 0 20 in Driver rod YB...

Page 106: ...2 4 Bearing depth plate 90890 06603 5 Needle bearing attachment 50 hp 90890 06614 6 60 90 hp 90890 06611 6 Depth a 50 hp 198 3 198 8 mm 7 81 7 83 in 60 90 hp 187 6 188 6 mm 7 39 7 43 in Å ı 2 Align the drive shaft sleeve locating rib with the recess in the gear case and place the drive shaft sleeve into the gear case 3 Place the pinion gear shim pack 1 in position and install the taper roller bear...

Page 107: ... 90890 06621 4 Bearing inner race attachment 50 hp 90890 06640 1 60 90 hp 90890 06662 1 4 3 1 6 Place the drive shaft in the gear case and insert it into the pinion Tighten the pinion nut to the specified torque T R Pinion nut 50 hp 75 Nm 7 5 m kg 54 ft lb 60 90 hp 95 Nm 9 5 m kg 69 ft lb Drive shaft holder 50 60 70 hp YB 6049 90890 06518 1 75 80 90 hp YB 6151 90890 06519 1 Pinion nut holder 90890...

Page 108: ...shifter and stop pushing it when the balls move into the neu tral groove in the propeller shaft making a slick If the balls move into the reverse groove passing the neutral be sure to bring them back to neutral 5 Install the clutch dog so that its cross pin hole is aligned with the slot in the splined portion of the propeller shaft NOTE Install the clutch dog so that the F mark on the clutch dog i...

Page 109: ...C90TR 90AET 10 Place the reverse gear shim 1 in place then install the bearing housing 2 aligning the key way in the gear case with that in the bearing housing and insert the key 3 11 Place a claw washer in place install a ring nut with its embossed marks fac ing outward away from the bearing housing tighten the ring nut to the specified torque and bend the claw washer over the ring nut to lock it...

Page 110: ...d carry out the shim selection FOR USA AND CANADA Pinion gear shim NOTE Find pinion gear shim thickness T3 by selecting shims until the specified measure ment M with the special tool is obtained 1 Find the specified measurement M NOTE 1 P is the deviation of the lower case dimension from standard It is stamped on the trim tab mounting surface of the lower case in 0 01 mm units If the P mark is mis...

Page 111: ...on the drive shaft and tighten the nut to the specified torque 4 Using a thickness gauge at the specified measurement M established above check the fit between the shimming gauge and lower surface of the pinion as shown 5 If the thickness gauge at the M specifi cation will not fit then remove or add the shim s until the thickness gauge just fits between the tool surfaces Gauge block YB 34432 9 Ada...

Page 112: ...ash when the unit is assembled 2 If the F value is negative then sub tract the F value from the measurement Example If F mark is 5 then M 1 69 5 100 mm 1 69 0 05 mm 1 74mm If F mark is 3 then M 1 69 3 100 mm 1 69 0 03 mm 1 66 mm 2 Assemble the shimming gauge with the forward bearing and original shim s as shown in the illustration Tighten the nut four turns after contacting the spring NOTE If the ...

Page 113: ...15 0 18 0 30 0 40 and 0 50 mm Reverse gear shim NOTE Find the reverse gear shim thickness T2 by selecting shims until the specified measure ment M with the special tool is obtained 1 Find the specified measurement M NOTE 1 R is the deviation of the lower case dimension from standard It is stamped on the trim tab mounting surface of the lower case in 0 01 mm units If the R mark is missing or unread...

Page 114: ...on NOTE 1 If the original shim s is unavailable start with a 0 50 mm shim 2 Be sure to remove the O ring from under the thrust washer 3 Using a thickness gauge at the specified measurement M established above check the fit between the shimming gauge and the reverse gear Force the shimming gauge against the shims and thrust washer when checking the fit 4 If the thickness gauge at the M specifi cati...

Page 115: ... established above measure the distance between the pin ion height gauge and lower surface of the pinion as shown 5 P is the deviation of the lower case dimension from standard It is stamped on the trim tab mounting surface of the lower case in 0 01 mm units If the P mark is missing or unreadable assume a P mark of 0 and check the backlash when the unit is assembled Example If M is 32 10 mm P is 2...

Page 116: ... measurement M established above measure the bearing height 3 F is the deviation of the lower case dimension from standard It is stamped on the trim tab mounting surface of the lower case in 0 01 mm units If the F mark is missing or unreadable assume an F mark of 0 and check the backlash when the unit is assembled Example If M is 23 90 mm F is 5 then T1 24 50 5 100 23 90 0 65 Shim thickness T1 50 ...

Page 117: ...e thrust washer 2 Using a digital caliper at the specified measurement M established above measure the distance between the washer top and special tool top as shown Shim thickness T2 50 hp M 25 40 mm R 100 mm 60 70 hp M 28 00 mm R 100 mm 75 90 hp M 26 00 mm R 100 mm Shimming plate 90890 06701 Digital caliper 90890 06704 90890 06704 90890 06701 3 R is the deviation of the lower case dimension from ...

Page 118: ...the pinion may be too high If both forward and reverse gear back lashes are smaller than specified the pin ion may be too low If either of these conditions exists then check the pinion shim selection 1 Place the shift rod in neutral 2 Install a dial gauge on the gear case 3 Install a backlash indicator gauge spe cial service tool on the drive shaft 50 60 70 hp 18 mm in diameter 75 80 90 hp 20 mm i...

Page 119: ...shaft stops in each direction 3 Determine the shim size according to the chart 50 75 80 90 hp T R Center bolt 5 Nm 0 5 m kg 3 6 ft lb Claw YB 6207 90890 06503 50 60 70 hp 90890 06502 Universal puller YB 6117 Stopper guide plate 90890 06501 Center bolt 90890 06504 Forward gear backlash Decrease or increase Less than 0 08 mm 0 003 in Thickness of shim to be decreased mm 0 17 measurement 0 60 0 08 0 ...

Page 120: ...unnecessary More than 0 28 mm 0 011 in Thickness of shim to be increased mm mea surement 0 19 0 53 T R Nut propeller 5 Nm 0 5 m kg 3 6 ft lb Reverse gear backlash Decrease or increase Less than 0 84 mm 0 033 in Thickness of shim to be increased mm 1 01 measurement 0 60 0 84 1 17 mm 0 033 0 046 in Decrease or increase will be unnecessary More than 1 17 mm 0 046 in Thickness of shim to be decreased ...

Page 121: ... new gasket on the oil seal housing 4 Install a key in the keyway on the drive shaft and insert a impeller 5 Grease the impeller and install the water pump housing turning the drive shaft clockwise then tighten the bolts Reverse gear backlash Decrease or increase Less than 0 67 mm 0 026 in Thickness of shim to be increased mm 0 84 measurement 0 60 0 67 1 00 mm 0 026 0 039 in Decrease or increase w...

Page 122: ...nd shift into Neutral Shift rod wrench YB 6052 2 Align the mark on the shift lever with the arrow mark on the bottom cowling 3 Grease the spline of the drive shaft and the water tube outer face align the water tube and drive shaft install the lower unit and tighten the bolts to the specified torque T R Lower unit mounting bolts 40 Nm 4 0 m kg 29 ft lb ...

Page 123: ...er nut with the hole in the propeller shaft and insert the cotter pin into the hole Be sure to bend the cotter pin ends NOTE If the propeller nut does not align with the propeller shaft hole when the nut is tight ened to specification turn it in further so that they align T R Propeller nut 35 Nm 3 5 m kg 25 ft lb 7 Fill with fresh gear oil through the oil plug hole until oil flows out through the ...

Page 124: ... kPa 1 0 kg cm2 14 2 psi Then place the gear case in the water tank 3 Check that the pressure is held at 100 kPa 1 0 kg cm2 14 2 psi for 10 sec onds CAUTION Do not overpressurize NOTE If the pressure falls leakage from the lower unit is unacceptable requiring re inspection of its component parts Å For USA and Canada ı Except for USA and Canada Pressure tester YB 35956 90890 06762 Å ı ...

Page 125: ...IT 7 11 INSPECTION 7 11 POWER TRIM AND TILT UNIT 7 11 REMOVAL 7 11 EXPLODED DIAGRAM Short transom 6H308 7 12 DISASSEMBLY 7 14 INSPECTION 7 16 TILT ROD AND TRIM ROD 7 16 ASSEMBLY 7 16 EXPLODED DIAGRAM Long transom 6H1 15 62F 02 7 20 DISASSEMBLY 7 22 INSPECTION 7 24 TILT ROD AND TRIM ROD 7 24 ASSEMBLY 7 24 FILLING WITH HYDRAULIC FLUID AND AIR BLEEDING 7 28 HYDRAULIC FLUID PRESSURE TEST 7 28 INSTALLA...

Page 126: ...0TH 60FEHTO 1 P75TH 75CEHTO 90AEHD 2 1 Steering handle 2 Bracket 3 Main switch 4 Engine stop switch 5 Throttle cable 6 Link assembly 7 Shift cable 8 Cover 9 Grip 0 Battery cable A Main switch lead B Extension wire lead C PTT switch PTT model D Steering friction PTT model ...

Page 127: ...7 2 E BRKT BRACKET UNIT K15000 0 UPPER CASING 50 60 70 hp 1 Exhaust guide 2 Exhaust manifold 3 Muffler 4 Upper case 5 Apron 6 Seal 7 Bottom cowling ...

Page 128: ...7 3 E BRKT BRACKET UNIT 75 80 90 hp 1 Exhaust guide 2 Exhaust manifold 3 Muffler 4 Upper case 5 Apron 6 Seal 7 Bottom cowling ...

Page 129: ...BRACKET UNIT K 15300 0 BOTTOM COWLING 1 Power trim and tilt motor lead PTT model 2 Trim sender lead PTT model 3 Grommet 4 Flushing kit B90TR 90AETO 5 Clamp PTT model 6 Bottom cowling fitting plate 7 Shift actuator ...

Page 130: ...T K 15600 0 BRACKET UNIT 1 Upper mount rubber cover 2 Cap 3 Upper mount rubber nut 4 Screw 5 Low mount rubber cover 6 Ground lead 7 Bolt 8 Mount rubber housing 9 Lower mount rubber nut 0 Anode PTT model A Read wire PTT model ...

Page 131: ...7 6 E BRKT BRACKET UNIT BRACKET UNIT Manual tilt model 1 Tilt unit 2 Tilt lever 3 Clamp bracket spacer 4 Lower shock mount pin 5 Bushing ...

Page 132: ... 5 O ring 6 Bushing 7 Grease nipple 8 Ground lead 9 Tilt rod manual tilt model 0 Clamp bracket nut A Bolt 6 bolts B Clamp bracket bolt C Washer D Bushing E Clamp bracket F Trim sensor PTT model G Circlip H Pin I Bushing J Power trim and tilt unit PTT model K Cotter pin L Tilt lock lever M Bushing N Washer O Spring P Collar ...

Page 133: ... 4 Bushing 5 O ring 6 Bushing 7 Grease nipple 8 Ground lead 9 Tilt rod manual tilt model 0 Clamp bracket nut A Bolt 6 bolts B Clamp bracket bolt C Washer D Bushing E Clamp bracket F Trim sensor PTT model G Circlip H Pin I Bushing J Power trim and tilt unit PTT model K Tilt lock lever L Bushing M Spring N Collar ...

Page 134: ...t unit INSPECTION ANODE 1 Check anode and replace with new one when the size is less than 1 3 of original length BRACKET 1 Inspect the bracket and replace them if cracked TRIM SENSOR 1 Check resistance of the new trim sensor 2 Measure resistance between black and pink leads to check that the value changes gradually in the whole trim and tilt range If not replace trim sensor with new one Trim senso...

Page 135: ...the outboard motor Connect battery cables of the outboard motor to a battery and set the main switch to ON Adjust the trim sensor position by pushing a screw driver so that one segment on the trim indicator on the digital meter goes on Tilt up the outboard motor and tighten both installation bolts WARNING Be sure to support the engine with the tilt support lever while tightening the bolts to preve...

Page 136: ...ge it INSPECTION 1 Inspect the tilt cylinder assembly for scratches or corrosion If any scratches are found replace the tilt cylinder assembly POWER TRIM AND TILT UNIT REMOVAL 1 Disconnect the leads from the relay in the bottom cowling 2 Remove the tilt rod bolts and nut and the clamp bracket 3 Remove the circlip and the complete power trim and tilt unit ...

Page 137: ...piston assembly 6 Valve seat screw 7 Main valve assembly 8 Shuttle piston 9 Pipe 0 Down relief valve seat A Down relief spring B Gear pump assembly C Shaft connector D Filter 2 E Up relief valve lock screw F Up relief spring G Up relief valve seat H Filter 1 I Manual valve seat J Manual release spring K Adapter L Free piston M Back up ring 2 N Tilt cylinder assembly ...

Page 138: ...NIT 1 Power trim and tilt motor 2 Gear pump 3 Down relief valve 48 kg cm2 4 Main valve 5 2 way check valve 6 Reservoir 7 Up relief valve 40 kg cm2 8 Manual valve 9 Tilt cylinder 0 Absorber valve 80 kg cm2 A Free piston B Trim cylinder ...

Page 139: ...rt 1 Turn the manual valve fully towards the manual position 2 Remove the hydraulic fluid level plug and drain the hydraulic fluid 3 Remove the delivery pipes and drain the hydraulic fluid 4 Remove the hydraulic fluid reservoir and the tilt motor 5 Remove the shaft connector 6 Remove the filter and the gear pump 7 Remove the O rings and the complete down relief valve CAUTION Do not disassemble the...

Page 140: ...le piston and the free piston WARNING The free piston can be removed easily by blowing compressed air into the drain hole of the cylinder Be sure to cover the open end of the cylinder with a rag to prevent the free piston from being ejected which could cause injury or piston damage Cylinder end screw wrench YB 6175 2B 90890 06544 11 Remove the main valves and the shut tle piston 12 Remove the circ...

Page 141: ... replace the components 2 Clean all the parts thoroughly using a soft brush and solvent and dry them with compressed air 3 Inspect the tilt cylinder and pump unit and replace them if they are badly cor roded K54000 0 ASSEMBLY NOTE The components in this assembly are to be lightly coated with hydraulic fluid before assembly 1 Install the tilt cylinder and the delivery pipes 1 Bushing 2 Tilt cylinde...

Page 142: ... 0 3 m kg 2 2 ft lb 3 Install a new O ring on the shuttle pis ton insert the piston into the body then install the main valves with new O rings 1 O ring 2 Shuttle piston 3 O ring 4 O ring 5 Main valve T R Main valve 10 Nm 1 0 m kg 7 2 ft lb 4 Install the up relief valve with a new O ring and tighten the locking bolt to the specified torque 1 Filter 2 O ring 3 Up relief valve seat 4 Ball 5 Valve su...

Page 143: ...torque 1 O ring 2 Back up ring ATF automatic transmission fluid T R Trim cylinder end screw 70 Nm 7 0 m kg 50 ft lb Cylinder end screw wrench YB 6175 1A 90890 6548 6 Install the down relief valve and the complete gear pump with new O rings tighten the screws and fit the shaft con nector and filter then fill with hydraulic fluid 1 Down relief spring L 13 mm D 6 1 mm 2 Down relief valve seat 3 O rin...

Page 144: ...c fluid and tighten the end screw to the specified torque 1 O ring 2 Back up ring Cylinder end screw wrench YB 6175 2B 90890 06544 T R Tilt cylinder end screw 80 Nm 8 0 m kg 58 ft lb 9 Align the connector shaft keyway with the motor shaft projection and install the motor with new O ring 10 Install the hydraulic fluid reservoir with new O ring 1 O ring 11 Air bleeding Refer to page 7 28 T R Bolt ti...

Page 145: ...m piston assembly 6 Main valve assembly 7 Shuttle piston 8 Pipe 9 Main valve seal 0 Valve support pin A Down relief spring B Gear pump assembly C Shaft connector D Filter 1 E Valve lock screw F Trim spring G Up relief spring H Up relief valve seat I Filter 2 J Manual valve seat K Manual release spring L Adapter M Manual release screw N Free piston O Back up ring ...

Page 146: ...alve 0 2 kg cm2 2 Trim down valve 1 kg cm2 3 Reservoir 4 Up relief valve 100 kg cm2 5 Manual valve 6 Tilt cylinder 7 Absorber valve 180 kg cm2 8 Trim cylinder 9 Main valve 0 5 kg cm2 0 Down relief valve 30 kg cm2 A Gear pump B Power trim and tilt motor ...

Page 147: ...ly towards the manual position 2 Remove the delivery pipes and the hydraulic fluid level plug 3 Remove the hydraulic fluid reservoir and the tilt motor 4 Remove the shaft connector 5 Remove the filter and the gear pump 6 Remove the O rings and the complete down relief valve CAUTION Do not disassemble the gear pump unit which is factory adjusted but replace the complete gear pump unit if necessary ...

Page 148: ...6175 1A 90890 6548 10 Loosen the tilt cylinder end screw and pull out the tilt piston and the free pis ton WARNING The free piston can be removed easily by blowing compressed air into the drain hole of the cylinder Be sure to cover the open end of the cylinder with a rag to prevent the free piston from being ejected which could cause injury or piston damage Cylinder end screw wrench YB 6175 2B 908...

Page 149: ...h and solvent and inspect them carefully If there are light scratches on the surfaces these may be polished off using fine wet or dry sandpaper 440 600 grit but if there is excessive scratching replace the components 2 Clean all the parts thoroughly using a soft brush and solvent and dry them with compressed air 3 Inspect the tilt cylinder and pump unit and replace them if they are badly cor roded...

Page 150: ... ring 3 Manual release screw 4 O ring 5 Manual valve seat 6 Manual release spring ø0 6 mm 7 Adapter 1 8 Manual release spring ø1 2 mm T R Lock nut delivery pipe 15 Nm 1 5 m kg 11 ft lb T R Manual valve 3 Nm 0 3 m kg 2 2 ft lb 3 Install a new O ring on the shuttle pis ton and insert the piston into the body then install the main valves with new O rings 1 O ring 2 Shuttle piston 3 O ring 4 O ring 5 ...

Page 151: ... B Trim spring C Screw T R Valve lock screw 4 Nm 0 4 m kg 2 9 ft lb Screw 4 Nm 0 4 m kg 2 9 ft lb 5 Fit a new O ring and the back up ring on the trim piston fit new O rings and a new oil seal on the end screw and install the complete trim piston in the cylinder Fill the cylinder with hydraulic fluid and install and tighten the end screw to the specified torque 1 O ring 2 Back up ring ATF automatic...

Page 152: ...8 Fit a new O ring and the back up ring to the tilt piston and install the piston in the cylinder Fill the cylinder with hydraulic fluid and tighten the end screw to the specified torque 1 O ring 2 Back up ring 9 Align the connector shaft keyway with the motor shaft projection and install the motor with a new O ring 10 Install the hydraulic fluid reservoir with a new O ring 1 O ring T R End screw ...

Page 153: ...er tilt 3 Check the level of the hydraulic fluid at full tilt up top up with fluid if necessary Insert and tighten the fluid level plug 4 Connect the leads to a battery to check the function ATF automatic transmission fluid Trim and tilt up Blue Green Trim and tilt down Green Blue K55506 0 HYDRAULIC FLUID PRESSURE TEST Drive the motor to check trim and tilt up and down operation and fluid leakage ...

Page 154: ... to check the fluid discharge pressure during up operation NOTE The motor should not be operated for more than fourteen seconds after full tilt up oper ation Trim and tilt down Green Blue At the end of down operation Stamped mark 6H308 A 4 100 5 500 kPa 41 55 kg cm2 583 782 psi B 600 1 100 kPa 6 11 kg cm2 85 157 psi 6H1 15 A 2 200 3 800 kPa 22 38 kg cm2 313 540 psi B 600 1 100 kPa 6 11 kg cm2 85 1...

Page 155: ...kg cm2 0 psi 6H308 B 3 500 4 500 kPa 35 45 kg cm2 500 640 psi 6H1 15 B 9 000 11 000 kPa 90 110 kg cm2 1 280 1 565 psi 62F 02 B 5 690 6 570 kPa 57 66 kg cm2 299 526 psi 5 Remove the fluid pressure gauge and install the delivery pipes NOTE When the fluid pressure gauge has been removed be sure to bleed the air from the system K56000 0 INSTALLATION 1 Referring to the illustration install the power tr...

Page 156: ...breaker and the spring K62001 0 INSPECTION ARMATURE COIL 1 Visually inspect the commutator sur face and if it shows signs of roughness polish it with 600 grit wet or dry sand paper 2 Measure the outside diameter of the commutator by use of a vernier caliper If the diameter is less than the specified minimum outside diameter replace the whole armature Armature minimum outside diameter Standard 22 m...

Page 157: ...ontinuity discontinuity Commutator segments a Continuity Segment Laminations b Discontinuity Segment Shaft c Discontinuity Brush size a Standard 9 8 mm 0 39 in Minimum 4 8 mm 0 19 in BASE ASSEMBLY 1 Inspect the base assembly for cracks or burns and replace the base assembly if such are found 2 Check for continuity between the con nector and lead wire If there is disconti nuity replace the base ass...

Page 158: ... and install the yoke assembly then install the screws 3 Place the O ring on the motor assembly and align the grooves of the motor assembly and gear pump then install the bolts T R Screw 4 Nm 0 4 m kg 2 9 ft lb T R Power trim and tilt motor mounting bolt Stamped mark 6H308 6 Nm 0 6 m kg 4 3 ft lb 6H1 15 62F 02 7 Nm 0 7 m kg 5 1 ft lb ...

Page 159: ......

Page 160: ...K POSITION SENSOR 8 20 STARTER RELAY 8 21 POWER TRIM AND TILT RELAY 8 21 TRAILER SWITCH 8 22 RECTIFIER REGULATOR 8 23 FUSE 8 23 THERMO SWITCH 8 24 FUEL ENRICHMENT VALVE 8 24 OIL INJECTION SYSTEM Oil injection model 8 25 OIL LEVEL SENSOR 8 26 OIL LEVEL WARNING LAMP L E D 8 28 WIRING HARNESS 8 28 BRACKET 8 29 BATTERY 8 29 ENGINE STOP SWITCH P60TH 60FEHTO P75TH 75CEHTO 90AEHD 8 29 MAIN SWITCH P60TH 6...

Page 161: ...TO 8 30 STARTER MOTOR 8 31 REMOVAL 8 31 DISASSEMBLY 8 31 INSPECTION 8 32 PINION 8 32 STARTER CLUTCH 8 32 BRUSH 8 32 BRUSH HOLDER 8 32 ARMATURE 8 33 ASSEMBLY 50 60 70 hp 8 34 INSTALLATION 50 60 70 hp 8 35 ASSEMBLY 75 80 90 hp 8 35 INSTALLATION 75 80 90 hp 8 36 ...

Page 162: ...del 5 Trailer switch PTT model except for USA Canada and Oceania model 6 Neutral switch P60TH 60FEHTO 7 Starter relay 8 Oil warning lamp 50GETO 9 Charge coil 0 Crank position sensor A Lighting coil B Pulser coil C Wire harness D Fuse E CDI unit F Starter motor G Trim sensor PTT model H Rectifier regulator I Power trim and tilt connec tor assy P60TH 60FEHTO ...

Page 163: ...ch PTT model except for C75TR 75CET C90TR 90AET 5 Fuse 6 Wire harness 7 Neutral switch P75TH 75CEHTO 90AEHD 90TR 90AETO B90TR 90AETO 8 Pulser coil 9 Stator assembly 0 CDI unit A Rectifier regulator B Crank position sensor C Power trim and tilt relay PTT model D Starter relay E Starter motor F Trim sensor PTT model ...

Page 164: ...m sensor 2 Î To lighting coil 1 Except for C60ER C60TR 2 For PTT model 3 For PTT model except for USA Canada and Oceania model 4 For C60ER C60TR B Black L Blue Lg Light green R Red Sb Sky blue 1 Main switch 2 Engine stop switch 3 Neutral switch 4 Starter relay Å To battery ı To oil level sensor 1 Ç To trim sensor 1 Î To power trim and tilt motor 1 To power trim and tilt relay 1 Ï To thermo switch ...

Page 165: ...coupler 1 9 Charge coil coupler 0 Crank position sensor coupler Å To CDI unit ı To power trim and tilt motor 1 Ç To trim sensor 1 Î To oil level sensor 2 To meter Ï To electrothermal valve 5 Ì To fuel enrichment valve 6 Ó To trailer switch coupler 1 B Black Br Brown G Green Gy Gray L Blue Lg Light green O Orange P Pink R Red Sb Sky blue W White Y Yellow 1 For PTT model 2 For oil injection model 3 ...

Page 166: ...itch coupler 1 Å To electrothermal valve 2 ı To battery Ç To starter relay Î To lighting coil To wire harness Ï To meter Ì To trim sensor 1 Ó To power trim and tilt motor 1 1 For PTT model 2 Except for C75TR B Black L Blue Lg Light green R Red Sb Sky blue ...

Page 167: ...oupler C Power trim and tilt relay coupler 2 D Pulser coil coupler E Ground lead from starter relay F Ground lead from CDI unit Å To electrothermal valve 4 ı To trim sensor 2 Ç To power trim and tilt motor 2 Î To oil level sensor 3 To meter Ï To starter motor Ì To trailer switch 2 Ó To neutral switch 5 B Black Br Brown G Green Gy Gray L Blue Lg Light green O Orange P Pink R Red Sb Sky blue W White...

Page 168: ...el 9 Starter motor 0 Battery A Trim sensor PTT model B Power trim and tilt motor PTT model C Fuse 20A D CDI unit E Starter relay F Neutral switch P60TH 60FEHTO G Power trim and tilt relay PTT model H Oil warning lamp 50GETO I Trailer switch PTT model J Power trim and tilt switch P60TH 60FEHTO K Ignition coil Å To oil level gauge ı To trim gauge B Black Br Brown G Green Gy Gray L Blue O Orange P Pi...

Page 169: ...5 Charge coil 6 Lighting coil 7 Fuel enrichment valve 8 Starter motor 9 Battery 0 Fuse 20A A CDI unit B Starter relay C Ignition coil D Power trim and tilt relay For C60TR E Power trim and tilt motor For C60TR B Black Br Brown G Green Gy Gray L Blue O Orange P Pink R Red Sb Sky blue W White Y Yellow Lg Light green ...

Page 170: ...otor 0 Battery A Trim sensor PTT model B Power trim and tilt motor PTT model C Fuse 20A D Neutral switch P75TH 75CEHTO 90AEHD 90TR 90AETO B90TR 90AETO E CDI unit F Trailer switch PTT model G Power trim and tilt switch P75TH 75CEHTO H Power trim and tilt relay PTT model I Starter relay J Ignition coil Å To oil level gauge ı To trim gauge B Black Gr Brown G Green Gy Gray L Blue Lg Light green O Oran...

Page 171: ...coil 5 Charge coil 6 Pulser coil 7 CDI unit 8 Fuel enrichment valve 9 Starter motor 0 Battery A Trim sensor B Power trim and tilt motor C Fuse D Power trim and tilt relay E Ignition coil F Starter relay B Black Gr Brown G Green Gy Gray L Blue Lg Light green O Orange P Pink R Red Sb Sky blue W White Y Yellow ...

Page 172: ...ine stop switch Å To tachometer ı To power trim and tilt switch option Ç To trim sensor Î To oil level sensor To lamp switch option B Black Br Brown G Green Gy Gray G R Green Red L Blue O Orange P Pink R Red Sb Sky blue W White Y Yellow Lg Light green G W Green White P B Pink Black ...

Page 173: ...im and tilt switch Å To meter harness 1 Digital tachometer 2 Digital speedometer option 3 To fuel management meter option 4 Lamp switch option 5 Fuse 10A 6 Fuel sensor option Å To remote control box ı To trim sensor Ç To oil level gauge B Black Br Brown G Green Gy Gray L Blue Lg Light green O Orange P Pink R Red Sb Sky blue W White Y Yellow ...

Page 174: ... flywheel nut until it is flush with the crankshaft CAUTION The major load must be carried in the direc tion of the arrows If not the holder may easily slip off Flywheel holder YB 6139 90890 06522 CAUTION Keep the nut side flush with the crankshaft end until the flywheel comes off the tapered portion of the crankshaft ...

Page 175: ...agneto puller set bolts evenly and completely so that the puller plate is parallel to the flywheel 5 Remove the woodruff key from the crankshaft keyway using a screwdriver CAUTION Take special care not to damage the sur face of the crankshaft When removing the flywheel magneto lift it up while tilting it slightly Do not allow the magneto to con tact the timing plate ...

Page 176: ...ment NOTE The coil output varies greatly at cranking speed Cranking a cold engine with the plugs in and a weak battery does not enable proper readings Low resistance measurement When measuring a resistance of 10 Ω or less using the digital tester the correct measurement cannot be obtained because of the tester s internal resistance To obtain the correct value subtract this internal resistance from...

Page 177: ...rk plug cap to the spark gap tester 3 Remove the spark plugs from the engine 4 Crank the engine and check the sparks from the ignition system through the discharge window 5 Measure the ignition spark gap 6 If the output is out of specification measure the CDI SYSTEM PEAK VOLTAGE CDI SYSTEM PEAK VOLTAGE WARNING While taking CDI unit check be careful not to touch any connection of lead wires of the ...

Page 178: ... 3 500 Open Connect V 1 3 105 2 145 105 CDI unit Output peak voltage minimum B W B r min Cranking 1 500 3 500 Open Connect V 1 3 130 2 155 130 2 Charge coil output 1 Disconnect the charge coil coupler Connect the 2 3 pins test harness 2 Connect the tester to the measure ment terminal 3 Set the tester dial to specification 4 Crank or start the engine 5 Measure the charge coil output 6 If the output...

Page 179: ...t peak voltage minimum R L r min Cranking 1 500 3 500 Open Connect V 90 100 135 135 3 Pulser coil output 1 Disconnect the pulse coil couple Connect the 2 pins test harness 2 Connect the tester to the measure ment terminal 3 Set the tester dial to specification 4 Crank or start the engine 5 Measure the pulser coil output 6 If the output is beyond specification replace CDI unit 7 If the output is be...

Page 180: ...ect the tester to the lighting coil as shown 2 Set the tester dial to specification 3 Start the engine 4 Measure the lighting coil output 5 If the output is beyond specification replace rectifier regulator 6 If the output is below specification replace lighting coil 50 60 70 hp 75 80 90 hp Lighting coil Output peak voltage minimum G G W r min Cranking 1 500 3 500 Open Connect V 8 5 8 0 25 25 Light...

Page 181: ...nto the plug cap Distance a 5 mm 0 2 in Resistance specification type 1 Remove the spark plug cap by turning the cap 2 Install the spark plug cap onto the high tension cable CRANK POSITION SENSOR Measure the peak voltage of the crank posi tion sensor as shown 50 60 70 hp 75 80 90 hp Crank position sensor Output peak voltage minimum L R L W r min Cranking 1 500 3 500 Open Connect V 5 0 5 0 20 16 Cr...

Page 182: ...arter relay to a 12 V battery B Black Br Brown 4 Check that there is continuity between the starter relay terminals If the opera tion is not as specified replace the starter relay Brown lead Black lead Battery voltage 12V M51410 0 POWER TRIM AND TILT RELAY 1 Check the relay for terminal looseness and for wiring rust and corrosion Replace the relay if any of the three defects is found 2 Connect the...

Page 183: ...d 1 terminal to the tester and check the continuity 5 Connect the black terminal to the ter minal of the battery and the sky blue terminal to the terminal of the bat tery Then connect the terminal and 2 terminal to the tester and check the continuity M56100 0 TRAILER SWITCH 1 To see that there is continuity push the switch Unit Ω 2 Check rubber seal Replace the seal if it has any damage Checking l...

Page 184: ...to the battery to check continuity When testing disconnect the battery ter minals When resistance is measured at less than 100 Ω it can be said that there is continu ity Rectifier regulator check Green Green White Red Black Green Conti nuity Green White Conti nuity Conti nuity Conti nuity Red Black Conti nuity Conti nuity Conti nuity Tester Tester M57001 0 FUSE 1 Referring to the diagram check the...

Page 185: ...the specified temperature If continuity is not as specified replace the thermo switch 1 Discontinuity 2 Continuity 3 Discontinuity Å Temperature ı Time ON temperature a 84 90 C 183 194 F OFF temperature b 60 74 C 140 165 F FUEL ENRICHMENT VALVE 1 Measure the resistance of the fuel enrichment valve NOTE Refer to Low resistance measurement for this inspection Fuel enrichment valve resistance at 20 C...

Page 186: ...E ELECTRICAL ANALYSIS M57500 0 OIL INJECTION SYSTEM Oil injection model 1 Oil level sensor 2 Digital Meter Oil level warning lamps control unit 3 Lead wire 4 Lead wire 5 Lead wire assembly 50 60 70 hp 75 80 90 hp ...

Page 187: ...sistance 50 60 70 hp Marking 6H3 16 Unit Ω indicates that the pointer deflects once and returns to Discontinuity Oil level sensor resistance Float SW 1 ON A 79 5 82 5 mm 3 13 3 25 in Float SW 2 ON B 114 5 117 3 mm 4 51 4 62 in 1 Black 2 Green 1 Black 3 Green Red 1 Black 0 1 Black 2 Green 0 3 Green Red 640 Oil level sensor resistance Float SW 1 SW 2 both OFF 2 Green 2 Green 3 Green Red 1 Black 2 Gr...

Page 188: ...e the float with the magnet side upward Assemble the plate which has a hole at the bottom Oil level sensor resistance Float SW 1 ON A 5 8 8 8 mm 0 23 0 35 in Float SW 2 ON B 42 3 45 3 mm 1 67 1 78 in 1 Black 2 Green 1 Black 3 Green Red 1 Black 0 1 Black 2 Green 0 3 Green Red 640 Oil level sensor resistance Float SW 1 SW 2 both OFF 2 Green 2 Green 3 Green Red 1 Black 2 Green 3 Green Red Tester Test...

Page 189: ...capac ity type as this may damage the L E D We recommend using a pen light battery Battery voltage 1 5V M58300 0 WIRING HARNESS 1 Check the continuity between the cou pler side and each connector Cores and pins of identical colors must be con nected or a continuity test can not be made 2 If any of the cores is open circuit replace the wiring harness Lg Light green P Pink Br Brown B Black L Blue Sb...

Page 190: ...racked 50 60 70 hp 75 80 90 hp M58900 0 BATTERY Refer to PERIODIC SERVICE section in chapter 3 M59000 0 ENGINE STOP SWITCH P60TH 60FEHTO P75TH 75CEHTO 90AEHD 1 When removing and installing the lock plate check for continuity according to the chart below Lock plate Wire color W B Removed Installed ...

Page 191: ...he retainer plate 2 Install so that the woodruff key in the keyways fits in the crankshaft 3 Lock the flywheel rotor with the washer and nut Tighten the nut to the specified torque 4 Install the flywheel cover Checking leads White Black Red Yellow Red Yellow Brown Switch Position OFF Continuity Disconti nuity Disconti nuity ON Disconti nuity Continuity Disconti nuity START Disconti nuity Disconti ...

Page 192: ... with a plastic hammer if necessary 3 Using a piece of steel wire separate the brush springs and remove the brushes from the brush holders 4 Remove the yoke assembly by lightly tapping it with a plastic hammer and remove the armature 1 Clip 2 Pinion stopper 3 Spring 4 Pinion starter clutch 5 Front cover 6 O ring 7 Washer 50 60 70 hp t 1 0 mm 75 80 90 hp t 2 0 mm 8 Washer 50 60 70 hp t 0 15 mm 75 8...

Page 193: ...k that it turns freely Also try to rotate the pinion counterclockwise and confirm that it locks BRUSH 1 Measure the brushes for wear If the size is less than the minimum specification replace the complete brush holder assemblies Brush size a Standard 50 60 70 hp 12 5 mm 0 49 in 75 80 90 hp 16 0 mm 0 63 in Minimum 50 60 70 hp 9 0 mm 0 35 in 75 80 90 hp 12 0 mm 0 47 in BRUSH HOLDER 1 Check the insul...

Page 194: ...iameter of the commuta tor If the commutator diameter is out of specification replace the armature 4 Measure the commutator mica under cut depth If the undercut depth is less than the specified minimum scrape between the segments with a hacksaw blade then remove all particles of mica and metal with compressed air Maximum deflection 0 05 mm 0 0020 in Standard diameter 50 60 70 hp 30 mm 1 18 in 75 8...

Page 195: ... install the armature in the rear cover assembly NOTE Install by lifting the brushes and inserting the armature straight into the bushing tak ing care not to scratch the brush or contam inate it with grease 2 Install the yoke assembly aligning the recess on the rear cover with the projec tion on the stator and ensuring that the O ring fits correctly in the rear cover groove 3 Mount the two washers...

Page 196: ... Lift up the pinion stopper until its bottom contacts the cir clip INSTALLATION 50 60 70 hp 1 Place the starter motor on the starter motor stay and tighten the bolts to the specified torque 2 Secure the starter motor to the engine with the four starter motor mounting bolts 3 Connect the positive and negative wires to the starter motor T R Starter motor mounting bolt 20 Nm 2 0 m kg 14 ft lb ASSEMBL...

Page 197: ...lder with the gap in the brush holder so that the through bolt can be inserted 5 Install the rear cover onto the yoke assembly insert the through bolt into the rear cover and screw it into the front cover NOTE Apply a thin coat of grease anti freeze grease to the front and rear cover bear ings To seal out water the mating surfaces are coated with sealing compound INSTALLATION 75 80 90 hp 1 Place t...

Page 198: ......

Page 199: ...E 1 2 3 4 5 6 7 8 9 TRBL ANLS CHAPTER 9 TROUBLE ANALYSIS TROUBLE ANALYSIS 9 1 TROUBLE ANALYSIS CHART 9 1 ...

Page 200: ...g are obtained 8 Engine is free from any Hull problem TROUBLE ANALYSIS CHART Trouble mode Check elements ENGINE WILL NOT START ROUGH IDLING ENGINE STALLS ENGINE WILL NOT STOP POOR PERFORMANCE OVERHEATING LOOSE STEERING LOOSE TILT HOLDING TILT MOTOR WILL NOT RUN HARD SHIFTING IRREGULAR WARNING INDICATION POOR BATTERY CHARGING Relative part Reference Chapter FUEL SYSTEM Idle speed 3 Fuel hose 3 Fuel...

Page 201: ...r 7 PTT control system 7 ELECTRICAL Pulser coil 8 Charge coil 8 Lighting coil 8 Ignition coil 8 Spark plug cap 8 CDI unit 8 Crank position sensor 8 Starter relay 8 Power trim and tilt relay 8 Trailer switch 8 Rectifier regulator 8 Trouble mode Check elements ENGINE WILL NOT START ROUGH IDLING ENGINE STALLS ENGINE WILL NOT STOP POOR PERFORMANCE OVERHEATING LOOSE STEERING LOOSE TILT HOLDING TILT MOT...

Page 202: ... switch 8 Main switch 8 Neutral switch 8 Starter motor 8 Trouble mode Check elements ENGINE WILL NOT START ROUGH IDLING ENGINE STALLS ENGINE WILL NOT STOP POOR PERFORMANCE OVERHEATING LOOSE STEERING LOOSE TILT HOLDING TILT MOTOR WILL NOT RUN HARD SHIFTING IRREGULAR WARNING INDICATION POOR BATTERY CHARGING Relative part Reference Chapter ...

Page 203: ......

Page 204: ...Printed on recycled paper YAMAHA MOTOR CO LTD Printed in USA Feb 1999 1 CR 50GETO 60FEHTO 60FED 60FEDO 60FET 60FETO 70BEDO 70BETO 75CET 75CETO 75CEHTO 80AETO 90AEHD 90AED 90AET 90AETO ...

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