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Yamaha e60hwd, Service Manual

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NOTICE

This manual has been prepared by Yamaha primarily for use by Yamaha dealers and their trained
mechanics when performing maintenance procedures and repairs to Yamaha equipment. It has
been written to suit the needs of persons who have a basic understanding of the mechanical and
electrical concepts and procedures inherent in the work, for without such knowledge attempted
repairs or service to the equipment could render it unsafe or unfit for use.

Because Yamaha has a policy of continuously improving its products, models may differ in detail
from the descriptions and illustrations given in this publication. 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.

Important information

Particularly important information is distinguished in this manual by the following notations:

Q

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS
INVOLVED!

w

Failure to follow WARNING instructions could result in severe injury or death to the machine
operator, a bystander, or a person inspecting or repairing the outboard motor.

c

C

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.

E60H

SERVICE MANUAL

©2004 by Yamaha Motor Co., Ltd.

1st Edition, October 2004

All rights reserved.

Any reprinting or unauthorized use 

without the written permission of 

Yamaha Motor Co., Ltd. 
is expressly prohibited.

Printed in Japan

A4Cover  04.9.20 17:53  Page 2

Summary of Contents for e60hwd

Page 1: ...SERVICE MANUAL 69D 28197 5G 11 E60H ...

Page 2: ...lly 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 Q The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED w Failure to follow WARNING instructions could result in sever...

Page 3: ...eral information Periodic checks and adjustments Fuel system Power unit Bracket unit Electrical systems Troubleshooting Index Contents Lower unit 9 8 7 6 2 1 GEN INFO SPEC CHK ADJ FUEL POWR LOWR BRKT ELEC TRBL SHTG 3 4 5 ...

Page 4: ......

Page 5: ...er selection 1 5 Propeller size 1 5 Selection 1 6 Predelivery checks 1 6 Checking the fuel system 1 6 Checking the gear oil level 1 6 Checking the battery WHD WD 1 6 Checking the outboard motor mounting height 1 7 Checking the remote control cables remote control model 1 7 Checking the steering system 1 8 Checking the gear shift and throttle operation 1 8 Checking the engine start switch engine st...

Page 6: ... reusable 6 Dowel pin 2 7 Bolt 4 M10 40 mm 8 Drain screw 1 9 Grommet 1 10 Bolt 1 M10 45 mm 11 Bolt 1 M8 60 mm 12 Thrust washer 1 13 Propeller 1 14 Washer 1 15 Washer 1 16 Cotter pin 1 Not reusable 17 Propeller nut 1 18 Trim tab 1 LOWR Lower unit 6 19 62Y5A11 Removing the drive shaft 1 Remove the drive shaft assembly and pinion and then pull out the forward gear Disassembling the drive shaft 1 Inst...

Page 7: ...llustration indicate the grade of lubricant and the lubri cation point 7 Apply Yamaha 2 stroke motor oil 8 Apply gear oil 9 Apply water resistant grease Yamaha grease A 0 Apply molybdenum disulfide grease q Apply corrosion resistant grease Yamaha grease D w Apply low temperature resistant grease Yamaha grease C e Apply injector grease Symbols r to o in an exploded diagram or illustration indicate ...

Page 8: ...ing an air compressor Protect your hands and feet by wearing pro tective gloves and safety shoes when neces sary Parts lubricants and sealants Use only genuine Yamaha parts lubricants and sealants or those recommended by Yamaha when servicing or repairing the out board motor Under normal conditions the lubricants men tioned in this manual should not harm or be hazardous to your skin However you sh...

Page 9: ... center and moving outward Non reusable parts Always use new gaskets seals O rings cot ter pins circlips etc when installing or assembling parts Disassembly and assembly 1 Use compressed air to remove dust and dirt during disassembly 2 Apply engine oil to the contact surfaces of moving parts before assembly 3 Install bearings with the manufacture identification mark in the direction indicat ed in ...

Page 10: ...atly affect boat speed acceleration engine life fuel economy and even boating and steering capabilities An incorrect choice could adversely affect performance and could also seriously damage the engine Use the following information as a guide for selecting a propeller that meets the operating conditions of the boat and the outboard motor Propeller size The size of the propeller is indicated as sho...

Page 11: ... with fuel cC Use pre mixed fuel only Fuel and oil mixing ratio is 50 1 For break in period 25 1 mixture shall be used Checking the gear oil 1 Check the gear oil level Checking the battery WHD WD 1 Check the capacity electrolyte level and specified gravity of the battery 2 Check that the positive and negative bat tery leads are securely connected Propeller size in Material 14 11 K 13 5 8 13 K 13 1...

Page 12: ...y the combination of the boat and the outboard motor To determine the optimum mounting height test run the outboard motor at differ ent heights 2 Check that the clamp brackets are secured with the clamp screws Checking the remote control cables remote control model 1 Set the remote control lever to the neutral position and fully close the throttle lever 2 Check that the control lever 1 is in its f...

Page 13: ...es smooth ly 3 Check that there is no interference with wires or hoses when the outboard motor is steered Checking the gear shift and throttle operation 1 Check that the gear shift operates smoothly when the shift lever or remote control lever is shifted from neutral to for ward or reverse 2 Check that the throttle operates smoothly when the throttle grip tiller handle model is turned from the ful...

Page 14: ... switch Checking the cooling water pilot hole 1 Check that cooling water is discharged from the cooling water pilot hole Test run 1 Start the engine then check that the gear shift operates smoothly 2 Check the engine idle speed after the engine has been warmed up 3 Operate at trolling speed 4 Run the outboard motor for 1 hour at 3 000 r min or at half throttle then for another hour at 4 000 r min ...

Page 15: ...min Vary engine speed occa sionally Run at full throttle for 1 minute the allow about 10 minutes of operation at 3 4 throttle or less to let the engine cool 4 8 hours d at any speed but avoid oper ating at full throttle for more than 5 min utes at a time Let the engine cool between full throttle runs Vary engine speed occasionally 5 After the first 10hours Use standard pre mix ratio of fuel and oi...

Page 16: ...GEN INFO 1 11 69D5G11 MEMO ...

Page 17: ...6 5 4 3 2 1 SPEC Specifications General specification 2 1 Maintenance specification 2 3 Power unit 2 3 Lower unit 2 5 Electrical 2 5 Dimensions 2 7 Tightening torques 2 10 Specified torques 2 10 General torques 2 11 ...

Page 18: ...ating range r min 4 500 5 500 Maximum fuel consumption L US gal 25 5 6 7 5 6 at 5 500 r min lmp gal hr Engine idle speed r min 950 1 050 Power unit Engine type 2 stroke L Cylinder quantity 3 Total displacement cm3 cu in 849 0 51 81 Bore x stroke mm in 72 0 69 5 2 83 2 74 Compression ratio 6 10 Intake system Reed valve Scavenging system Loop charge Control system Tiller handle Tiller handle Remote ...

Page 19: ...et unit Trim angle Degree 8 12 16 20 24 at 12 boat transom Tilt up angle Degree 67 Steering angle Degree 35 35 Drive unit Gear shift positions F N R Gear ratio 2 33 28 12 Reduction gear type Spiral bevel gear Clutch type Dog clutch Propeller shaft type Spline Propeller direction rear view Clockwise Propeller ID mark K Electrical Battery minimum capacity 2 CCA EN 430 20HR IEC 70 1 Meeting both API ...

Page 20: ...020 Pistons Piston diameter D mm in 71 940 71 965 2 8323 2 8333 Measuring point H mm in 10 0 0 39 Piston to cylinder clearance mm in 0 055 0 060 0 0022 0 0024 limit 0 110 0 0043 Piston pin boss bore mm in 19 904 19 915 0 7836 0 7841 Oversize piston 1st mm in 0 25 0 010 2nd mm in 0 50 0 020 Oversize piston diameter 1st mm in 72 190 72 215 2 8421 2 8431 2nd mm in 72 440 72 465 2 8520 2 8529 Piston p...

Page 21: ...r 1st mm in 72 25 2 845 2nd mm in 72 50 2 854 Connecting rods Small end inside diameter mm in 24 900 24 912 0 9803 0 9808 Big end side clearance mm in 0 200 0 700 0 0079 0 0276 Small end axial play limit mm in 2 0 0 08 Crankshaft Crankshaft width A mm in 57 90 57 95 2 280 2 282 Crankshaft width B mm in 35 88 36 10 1 413 1 421 Crankpin diameter mm in 26 994 27 000 1 0628 1 0630 Runout limit mm in 0...

Page 22: ...t Cranking loaded V 100 at 1 500 r min loaded V 140 at 3 500 r min loaded V 100 SPEC 2 5 69D5G11 Specifications Item Unit Model E60HMHD E60HWHD E60HWD Carburetor ID mark 6K503 Main jet M J 135 Main air jet M A J 145 Main nozzle M N mm in 3 0 0 12 Pilot jet P J 70 Pilot air jet P A J 85 Pilot screw P S turns out 1 1 4 1 3 4 Valve seat size mm in 1 4 0 06 Float height mm in 12 0 16 0 0 47 0 63 Lower...

Page 23: ...ded V 120 at Cranking loaded V 110 at 1 500 r min loaded V 150 at 3 500 r min loaded V 110 Charge coil resistance Ω 149 182 Br Ground Starter motor Type Bendix Brushes Length limit mm in 9 0 0 35 Armature Commutator diameter mm in 30 0 1 18 Commutator diameter limit mm in 29 0 1 14 Commutator undercut limit mm in 0 2 0 01 Charging system Fuse A 20 Lighting coil output peak voltage G G at Cranking ...

Page 24: ... 67 2 6 640 25 2 635 25 0 556 21 9 561 22 1 4 0 0 16 6 0 0 24 264 10 4 248 9 8 208 8 2 229 9 0 40 1 6 85 3 4 68 2 7 722 24 8 737 29 0 954 37 6 831 32 7 574 22 6 450 17 7 191 7 5 553 21 8 753 29 7 670 26 4 20 0 8 28 1 1 111 4 4 97 3 8 322 12 7 553 21 8 182 7 2 159 6 3 69D2001M Dimensions Exterior mm in MHD WHD MHD S transom ...

Page 25: ... 7 6 5 4 3 2 1 Maintenance specification 180 7 1 180 7 1 163 5 6 4 163 5 6 4 126 5 0 126 5 0 13 0 5 69 2 7 18 5 0 7 355 14 0 327 5 12 9 50 8 2 0 13 0 5 55 5 2 2 254 10 0 Clamp bracket S L transom model mm in S transom ...

Page 26: ...SPEC 2 9 69D5G11 Specifications 180 7 1 180 7 1 163 5 6 4 163 5 6 4 126 5 0 126 5 0 13 0 5 69 2 7 18 5 0 7 355 14 0 50 8 2 0 13 0 5 55 5 2 2 254 10 0 Clamp bracket X transom model mm in ...

Page 27: ... 1st M6 3 0 3 2 2 2nd 8 0 8 5 8 1st M8 10 1 0 7 2 Crankcase bolt 2nd 20 2 0 15 1st M10 20 2 0 15 2nd 40 4 0 29 5 Spark plug M14 25 2 5 18 Lower unit Check screw 9 0 9 6 6 Drain screw 9 0 9 6 6 Lower case mounting nut M10 40 4 0 29 5 Cooling water inlet cover M5 4 5 0 45 3 3 Propeller nut M16 35 3 5 25 3 Propeller shaft housing ring nut 105 10 5 76 Pinion nut M16 95 9 5 68 Bracket unit Tiller handl...

Page 28: ...cable sections of this manu al To avoid warpage tighten multi fastener assemblies in a crisscross fashion and pro gressive stages until the specified torque is reached Unless otherwise specified torque specifications require clean dry threads Components should be at room temperature General torque Nut A Bolt B specifications N m kgf m ft lb 8 mm M5 5 0 5 3 6 10 mm M6 8 0 8 5 8 12 mm M8 18 1 8 13 1...

Page 29: ...g the start in gear protection 3 5 Synchronizing the carburetors 3 5 Checking the engine idle speed 3 6 Adjusting the throttle link position 3 6 Adjusting the pick up timing 3 7 Adjusting the throttle cable 3 7 Checking the gear shift operation 3 8 Checking the ignition timing 3 9 Adjusting the ignition timing 3 10 Bracket 3 11 Checking the tilt operation 3 11 Lower unit 3 12 Checking the gear oil...

Page 30: ...CHK ADJ 69D5G11 3 1 Special service tools Periodic checks and adjustments CHK ADJ Digital tachometer 90890 06760 Leakage tester 90890 06840 Timing light 90890 03141 Dial gauge set 90890 01252 ...

Page 31: ...3 13 Cooling water passages Clean 1 1 3 5 Cowling clamp Check 1 3 3 Fuel filter can be dis Check clean 1 1 1 3 3 assembled Fuel system Check 1 1 1 3 3 Fuel tank Yamaha por Check clean 1 table tank Gear oil Change 1 1 3 12 Lubrication points Lubricate 1 3 14 Idling speed carbure Check adjust 1 1 3 6 tor model Propeller and cotter pin Check replace 1 1 3 13 Shift link shift cable Check adjust 1 3 8 ...

Page 32: ...joint and fuel hoses fuel joint to carburetors 1 Check the fuel hose connections and fuel joint 1 for leaks Replace if necessary Also check the fuel filter 2 fuel pump 3 and carburetors 4 for leaks or deteri oration Replace if necessary Checking the fuel filter 1 Check the fuel filter element 1 for dirt and residue and check the fuel filter cup 2 for foreign substances and cracks Clean the cup wit...

Page 33: ...d excessive carbon or other deposits and the gasket for damage Replace the spark plug if necessary 4 Check the spark plug gap a Adjust if out of specification 5 Install the spark plug temporary tight and then tighten it to the specified torque with a spark plug wrench 69D5G11 3 4 9 8 7 6 5 4 3 2 1 Top cowling Fuel system Power unit 6B430030 a 6B430025 1 Specified spark plug B8HS 10 BR8HS 10 NGK Sp...

Page 34: ...f the carburetor 1 and carburetor 2 by turning the screws 3 clockwise NOTE The screw 3 is left hand thread CHK ADJ 3 5 69D5G11 Periodic checks and adjustments 1 2 69D30070 a b 5 Install the thermostat and thermostat cover and then tighten the cover bolts Checking the cooling water pas sages 1 Check the cooling water inlet cover 1 screw 2 and cooling water inlet for clog ging Clean if necessary 2 P...

Page 35: ... 3 Turn the throttle stop screw 2 in direction a or b until the specified engine idle speed is obtained NOTE 9 To increase the idle speed turn the throttle stop screw in direction a 9 To decrease the idle speed turn the throttle stop screw in direction b 4 If the specified engine idle speed cannot be obtained adjust the throttle cable Adjusting the throttle link position 1 Remove the link rod 1 fr...

Page 36: ...6 a Adjusting the pick up timing 1 Remove the link rod 1 from the control lever 2 and cam 3 2 Set the control lever 4 to fully retard position it contacts the stopper 5 3 Turn the cam 3 to lightly contact to the throttle lever roller 6 NOTE The throttle valve should not open 4 Adjust the length a of the link rod 1 until the holes align with the set pins on the control lever 2 and cam 3 and then in...

Page 37: ...ble length if nec essary repeat the steps 3 6 NOTE If the remote control cables cannot be prop erly adjusted at the engine side make adjust ments at the remote control side w The throttle cable end must be screwed in a minimum of 8 0 mm 0 31in a 5 Install the throttle cable joint 3 clip 2 and then tighten the lock nut 1 6 Check that the full advanced screw 8 contacts the stopper 9 when the throttl...

Page 38: ...rvice tool 2 to spark plug wire 1 and then check the engine ignition timing 4 Check that the ATDC 2 scale a on the flywheel magnet is aligned with the point er b on the timing plate Adjust if neces sary 5 Check that the scale c on the flywheel magnet is advances to BTDC 19 scale when the engine speed increased Adjust if necessary 6 7 69D30100 F N R 69D30155 a b 69D30156 c 69D30115 1 69D30150 2 Dig...

Page 39: ...zero position and then align the specified position to turn the flywheel magnet clockwise NOTE Turn the flywheel magnet to clockwise when to locate the piston TDC 5 Check that the scale a on the flywheel magnet with the timing plate b are spec ified position 6 When the piston at specified position set the control lever 2 to the full advanced position c it stop contacts the cap 3 to the stopper 4 7...

Page 40: ... 8 11 Turn the adjusting screw 9 so that the mark d on the flywheel magnet 6 aligned with the pointer e on the base assembly Bracket Checking the tilt operation 1 Fully tilt the outboard motor up and down a few times and check the entire tilt range for smooth operation Check the tilt mechanism if necessary 2 Fully tilt the outboard motor up then sup port it with the tilt stop lever 1 to check the ...

Page 41: ...se if necessary 4 Insert a gear oil tube or gear oil pump into the drain hole and slowly fill the gear oil until oil flows out of the check hole and no air bubbles are visible Checking the lower unit for air leak age cC Do not over pressurize the lower unit oth erwise the oil seals may be damaged 1 Remove the check screw 1 and then install the special service tool 69D30140 1 2 69D10055 1 Recommend...

Page 42: ...trim tab for scales grease and oil Clean if necessary CHK ADJ 3 13 69D5G11 Periodic checks and adjustments Lower unit holding pressure 100 kPa 1 0 kgf cm2 14 psi 69D30310 69D30320 cC Do not oil grease or paint the anodes or the trim tab otherwise they will be inef fective 2 Replace the anodes or trim tab if exces sively eroded NOTE For checking the cylinder anodes refer to the chapter 5 Checking t...

Page 43: ...ention Antidote INTERNAL 9 Drink large quantities of water or milk followed with milk of magnesia beaten egg or vegetable oil Get immediate medical attention 9 Charge batteries in a well ventilated area 9 Keep batteries away from fire sparks or open flames e g welding equipment lighted cigarettes 9 DO NOT SMOKE when charging or han dling batteries KEEP BATTERIES AND ELECTROLYTE OUT OF REACH OF CHI...

Page 44: ...CHK ADJ 3 15 69D5G11 Periodic checks and adjustments å Tiller handle model 2 Apply corrosion resistant grease to the area shown 69D30220 A A 69D30225 A 6B430300 å ...

Page 45: ...e 4 3 Carburetor 4 6 Disassembling the carburetor 4 8 Checking the carburetor 4 8 Assembling the carburetors 4 9 Adjusting the throttle stop screw 4 9 Fuel pump 4 10 Checking the fuel pump 4 11 Disassembling the fuel pump 4 11 Assembling the fuel pump 4 12 Checking the fuel joint 4 12 FUEL ...

Page 46: ...FUEL 4 1 69D5G11 Fuel system Special service tools Vacuum pressure pump gauge set 90890 06756 Digital caliper 90890 06704 ...

Page 47: ...7 6 5 4 3 2 1 Special service tools Hose routing Hose routing 1 Fuel hose Fuel joint to fuel filter 2 Fuel hose Fuel filter to fuel pump 3 Fuel hose Fuel pump to carburetors 4 Pilot water hose 69D4010E 1 2 3 4 3 1 2 3 ...

Page 48: ...e Q ty Remarks 1 Lock tie 4 2 Fuel hose 1 3 Bolt 1 M6 25 mm 4 Fuel joint 1 5 Clamp 10 6 Fuel hose 1 7 Fuel hose 1 8 Bolt 2 M6 40 mm 9 Fuel pump 1 10 Gasket 1 11 Bolt 3 M6 16 mm 12 Bolt 1 M6 14 mm 13 Bracket 1 14 Holder 1 15 Fuel filter assembly 1 16 Cup 1 17 Nut 1 Not reusable Not reusable ...

Page 49: ...art name Q ty Remarks 18 O ring 1 19 Fuel filter element 1 20 Spring 1 21 Float 1 22 Fuel hose 1 23 Fuel hose 1 24 Fuel hose 1 25 Fuel hose 1 26 Pipe 2 27 Screw 4 ø6 45 mm 28 Washer 4 29 Intake silencer 1 30 Bolt 6 M6 45 mm 31 Bracket 1 32 Link rod 1 33 Rod 2 34 Joint 4 Not reusable ...

Page 50: ...2 N m 0 2 kgf m 1 5 ft lb 69D4020E No Part name Q ty Remarks 35 Carburetor assembly 1 1 36 Carburetor assembly 2 1 37 Carburetor assembly 3 1 38 Gasket 1 39 Joint 1 40 Choke rod 1 41 Grommet 1 42 Choke solenoid 1 WD model Not reusable ...

Page 51: ...30 mm 2 Plate 3 3 Gasket 3 4 Plate 3 5 Main air jet 3 6 Gasket 3 7 Plate 3 8 Pilot air jet 3 9 O ring 3 10 Plate 3 11 Pilot air screw 3 12 Spring 3 13 Screw 3 1 and 2 carburetor 14 Washer 3 1 and 2 carburetor 15 Screw 12 ø4 14 mm 16 Float chamber 3 17 Gasket 3 Not reusable Not reusable Not reusable Not reusable ...

Page 52: ... Float 3 19 Float pin 3 20 Needle valve 3 21 Clip 3 22 Pin 3 23 Cap 3 24 Pilot jet 3 25 Main jet 3 26 Main nozzle 3 27 Drain screw 3 28 Gasket 3 29 Throttle stop screw 1 2 carburetor 30 Spring 1 2 carburetor 31 Cap 1 3 carburetor 32 Carburetor assembly 3 Not reusable ...

Page 53: ... that they can be re assembled in their orig inal positions Checking the carburetors 1 Check the air and fuel passages and jets for dirt and foreign matter Clean the car buretor body with a petroleum based sol vent if necessary 2 Blow compressed air into all passages and jets cC 9 Direct the compressed air downward otherwise cleaning solvent may be blown into your eyes or small parts of the carbur...

Page 54: ...p screw in direction b 3 If the specified engine idle speed cannot be obtained adjust the throttle cable FUEL 4 9 69D5G11 Fuel system Assembling the carburetors 1 Install the main air jet 1 and then install the plate 2 and a new gasket 3 into the carburetor body 2 Install the pilot air jet 4 and then install the plate 5 and a new gasket 6 into the carburetor body 3 Install a new O ring 7 to the pl...

Page 55: ...l pump Fuel pump 69D4040E No Part name Q ty Remarks 1 Screw 3 ø6 30 mm 2 Cover 1 3 Diaphragm 1 4 Gasket 1 5 Fuel pump body 1 6 Gasket 1 7 Diaphragm 1 8 Check valve 2 9 Gasket 1 10 Cover 1 11 Screw 2 10 Nut 2 Not reusable Not reusable Not reusable ...

Page 56: ...the specified positive pressure and check that there is no air leakage Disassemble the fuel pump if necessary NOTE Assemble the fuel pump valve to the fuel pump body and moisten the inside of fuel pump with gasoline to ensure a better seal Disassembling the fuel pump 1 Disassemble the fuel pump 2 Check the diaphragms for tears or dam age Replace if necessary 3 Check the valves for bends or damage ...

Page 57: ...g the fuel pump NOTE Clean the parts and soak the valves and the diaphragms in gasoline before assembly to obtain prompt operation of the fuel pump when starting the engine 1 Install the check valves 1 onto the fuel pump body 2 Install new gaskets 2 the diaphragms 3 and covers 4 NOTE Make sure that the gaskets and diaphragms are kept in place through the assembly process 4 3 2 2 3 4 69D40050 1 1 6...

Page 58: ...FUEL 4 13 69D5G11 MEMO ...

Page 59: ...cking the exhaust cover 5 26 Installing the stud bolt 5 26 Installing the thermoswitch 5 27 Crankcase 5 28 Removing the oil seal housing 5 32 Removing the crankcase 5 32 Removing the crankshaft assembly 5 32 Checking the cylinder bore 5 32 Disassembling the oil seal housing 5 33 Checking the oil seal housing 5 33 Assembling the oil seal housing 5 33 Disassembling the upper bearing 5 33 Assembling ...

Page 60: ...03160 Flywheel holder 90890 06522 Flywheel puller 90890 06521 Crankshaft aligner 90890 03107 Driver rod L3 90890 06652 Driver rod LS 90890 06606 Bearing Separator 90890 06534 Crank jig set 90890 02422 Needle bearing attachment 90890 06637 Needle bearing attachment 90890 06631 ...

Page 61: ...nge 90890 02351 Body 90890 02352 Bolt 90890 02353 Washer 90890 02354 Bushing 9 D30 90890 02363 B 9 Press body 90890 02385 Bearing pressure C 90890 02393 C Height ring H 11 90890 02377 H 11 Plate C 90890 02402 Crank separater kit set 02416 02417 90890 02418 ...

Page 62: ...nit Disassembling kit 90890 02416 Nut 90890 02407 Pressure plate 90890 02408 Pole 90890 02409 Plate A 90890 02410 Plate B 90890 02411 Assembling kit 90890 02417 Guide 90890 02412 Guide plate 90890 02413 Guide pole 90890 02414 ...

Page 63: ...69D5G11 5 4 9 8 7 6 5 4 3 2 1 Special service tools Base 90890 02415 Small end bearing installer 90890 06527 Cylinder gauge 90890 06759 Bearing inner race attachment 90890 06641 ...

Page 64: ...k the engine until the reading on the compres sion gauge stabilizes NOTE Do not pull the choke knob when checking the compression pressure 5 If the compression pressure is below specification and the compression pres sure for each cylinder is unbalanced add a small amount of engine oil to the cylin ders and then check the compression pressure again NOTE 9 If the compression pressure increases chec...

Page 65: ...ft lb 69D5010E No Part name Q ty Remarks 1 Power unit 1 2 Manual starter assembly 1 3 Collar 3 4 Grommet 6 5 Bolt 2 M8 30 mm 6 Bolt 1 M8 26 mm 7 Bolt 2 M8 30 mm 8 Grommet 2 9 Collar 2 10 Bolt 2 M6 20 mm 11 Bolt 2 M6 25 mm 12 Apron 1 13 Apron 1 14 Bolt 2 M8 35 mm 15 Bolt 6 M8 85 mm 16 Gasket 1 17 Dowel 2 Not reusable ...

Page 66: ... kgf m 15 5 ft lb 4 N m 0 4 kgf m 3 0 ft lb 8 N m 0 8 kgf m 5 8 ft lb 69D5010E No Part name Q ty Remarks 18 Bolt 1 M6 25 mm 19 Neutral switch assembly 1 20 Bolt 1 M6 12 mm 21 Bracket 1 22 Starter relay 1 23 Wireharness 1 24 Bolt 1 M6 16 mm ...

Page 67: ... 5 4 3 2 1 Power unit 160 N m 16 kgf m 115 ft lb WHD WD WD 69D5020E No Part name Q ty Remarks 1 Flywheel magnet 1 2 Bolt 3 M8 12 mm 3 Starter pulley 1 4 Nut 1 5 Washer 1 6 Bolt 1 M6 10 mm 7 Timing plate 1 8 Woodruff key 1 ...

Page 68: ... 1 3 Bolt 6 M6 25 mm 4 Ignition coil 3 5 Bolt 3 M6 16 mm 6 Screw 2 7 Bracket 1 8 Grommet 3 9 Collar 3 10 CDI unit 1 11 Screw 1 ø6 25 mm WHD and WD models 12 Rectifier 1 WHD and WD models 13 Bolt 2 M6 55 mm 14 Bracket 1 15 Bolt 2 M6 35 mm WHD and WD models 16 Bolt 1 M6 25 mm WHD and WD models 17 Bolt 2 M6 30 mm ...

Page 69: ...nit 20 N m 2 0 kgf m 15 ft lb MHD 69D5030E No Part name Q ty Remarks 18 Lighting coil 1 19 Screw 2 ø5 25 mm 20 Charge coil 1 21 Screw 3 ø6 12 mm 22 Retainer 3 23 Base assembly 1 24 Retainer 1 25 Washer 1 26 Starter motor 1 WHD and WD models ...

Page 70: ... name Q ty Remarks 1 Joint 1 2 Bolt 1 M6 16 mm 3 Collar 1 4 Bolt 1 M6 25 mm 5 Collar 1 6 Wave washer 1 7 Cam 1 8 Link rod 1 9 Joint 2 10 Nut 2 11 Bolt 1 M6 45 mm 12 Washer 1 13 Collar 1 14 Control lever 1 15 Spring 1 16 Control lever 1 17 Washer 1 ...

Page 71: ...69D5G11 5 12 9 8 7 6 5 4 3 2 1 Power unit 69D5040E No Part name Q ty Remarks 18 Control lever 1 19 Screw 2 20 Nut 2 21 Cap 2 ...

Page 72: ... Q ty Remarks 1 Manual starter case 1 2 Stay 5 3 Washer 2 4 Spiral spring 1 5 Collar 1 6 Sheave drum 1 7 Cover 1 8 Clip 1 9 Collar 1 10 Drive pawl 1 11 Spring 1 12 Spring 1 13 Drive plate 1 14 Washer 1 15 Bolt 1 M6 16 mm 16 Bolt 1 M6 25 mm 17 Washer 1 ...

Page 73: ...rks 18 Bushing 1 19 Roller 1 20 Bolt 2 M6 30 mm 21 Grommet 2 22 Collar 2 23 Cover 1 24 Manual starter handle 1 25 Damper 1 26 Starter rope guide 1 27 Starter rope 1 28 Bolt 1 M6 12 mm 29 Clip 1 30 Washer 1 31 Start in gear protection cable 1 32 Spring 1 33 Guide 1 34 Bolt 1 ...

Page 74: ...POWR 5 15 69D5G11 Power unit 69D5050E No Part name Q ty Remarks 35 Stopper 1 36 Spring 1 ...

Page 75: ...ave drum can pop out Hold the sheave drum with your hand then pull it out 3 Remove the sheave 0 drum from the manual starter case NOTE Insert a flat head screwdriver into the hole b in the sheave drum and push down on the spiral spring so that it release from the sheave drum w The spiral spring can pop out Cover the spiral spring with cloths then pull out the sheave drum 4 Remove the spiral spring...

Page 76: ...r rope as shown in the illustration 9 Be sure to leave 5 0 10 0 mm 0 2 0 4 in at the end a of the starter rope 4 Wind the starter rope 2 1 2 around the sheave drum in the direction of the arrow shown in the illustration NOTE After winding the starter rope around the sheave drum install the starter rope in the notch b 5 Install the washer and the spiral spring 4 into the starter case NOTE Install t...

Page 77: ...nec essary NOTE Align the mark on the stopper with guide and then turn the sheave drum 10 Pull the manual starter handle complete ly then measure the starter rope length Adjust if the starter rope length is out of specification Removing the power unit NOTE It is recommended to loosen the flywheel magnet nut before removing the power unit to improve working efficiency 1 Remove the carburetor assemb...

Page 78: ...ol model or throttle cable 5 and shift cable 6 tiller control cable 6 Disconnect the battery leads 7 WHD WD warning indicator leads engine stop lanyard switch lead MHD WHD and ground leads 8 7 Disconnect the starter relay leads 9 WHD WD and coupler 0 from the wire harness 8 Disconnect the pilot water hose 9 Remove the shift bracket q 10 Remove the apron and then remove the power unit by removing t...

Page 79: ... levers 1 Remove the control levers 69D5G11 5 20 9 8 7 6 5 4 3 2 1 Power unit 1 2 3 4 5 6 5 69D50220 69D50230 Flywheel puller 90890 06521 Removing the flywheel magnet 1 Remove the starter pulley and then loosen the flywheel magnet nut cC Apply force in the direction of the arrows shown While working do not allow the flywheel holder to slip off the flywheel 2 Remove the flywheel magnet cC To preven...

Page 80: ... the control lever 1 Install the spring into the control lever 1 and then install the control lever 2 NOTE Align the projection a on the control lever 2 with projection b on the control lever 1 to turn the direction 69D50240 2 1 69D50245 a b ...

Page 81: ...gf m 5 8 ft lb 69D5060E No Part name Q ty Remarks 1 Screw 1 2 Timing plate 1 3 Bolt 7 M6 25 mm 4 Intake manifold assembly 1 5 Screw 6 ø5 16 mm 6 Reed valve assembly 3 7 Gasket 1 8 Plate 1 9 Gasket 1 10 Intake manifold 1 11 Screw 18 ø3 7 mm 12 Valve stopper 6 13 Reed valve 6 14 Body 3 Not reusable Not reusable Reed valves ...

Page 82: ... 1 Remove the intake manifold bolts 1 and then remove the intake manifold cover 2 gasket and reed valve assembly Checking the reed valves 1 Check the reed valves for bends a Replace if above specification 69D50250 1 1 1 1 1 2 69D50265 a Valve bend limit a 0 20 mm 0 0079 in Valve stopper height b 2 8 3 2 mm 0 11 0 13 in 69D50270 b ...

Page 83: ...m 2 5 kgf m 18 ft lb 10 N m 1 0 kgf m 7 2 ft lb 69D5070E No Part name Q ty Remarks 1 Gasket 1 2 Plug 1 3 Gasket 1 4 Cylinder head 1 5 Thermoswitch 1 6 Bolt 13 M8 70 mm 7 Spark plug 3 8 Nut 1 9 Cylinder head cover 1 10 Gasket 1 11 Stud bolt 1 12 Thermostat 1 13 Gasket 1 14 Cover 1 15 Bolt 2 M6 25 mm 16 Bolt 16 M6 35 mm 17 Clamp 2 Not reusable Not reusable Not reusable Not reusable Cylinder head ...

Page 84: ... 23 ft lb 3 N m 0 3 kgf m 2 2 ft lb 8 N m 0 8 kgf m 5 8 ft lb 23 N m 2 3 kgf m 17 ft lb 25 N m 2 5 kgf m 18 ft lb 10 N m 1 0 kgf m 7 2 ft lb 69D5070E No Part name Q ty Remarks 18 Exhaust outer cover 1 19 Gasket 1 20 Exhaust inner cover 1 21 Gasket 1 Not reusable Not reusable ...

Page 85: ...om the com bustion chambers and check for deterio ration or corrosion 2 Check the cylinder head warpage using a straightedge 1 and thickness gauge 2 in four directions as shown Replace if above specification Removing the exhaust cover 1 Remove the exhaust cover bolts in the sequence shown Checking the exhaust cover 1 Check the exhaust cover for distortion or corrosion Replace if necessary Installi...

Page 86: ...hown 3 Tighten the nuts to specified torque 4 Remove the two nuts from the stud bolt Installing the thermoswitch 1 Install the thermoswitch 1 push into the bottom of the flange on the cylinder head cover 2 69D50283 69D50284 69D50320 1 2 69D50282 2 Stud bolt 10 N m 1 0 kgf m 7 2 ft lb ...

Page 87: ...ft lb 69D5080E No Part name Q ty Remarks 1 Crankshaft assembly 1 2 Cylinder Block 1 3 Dowel 2 4 Oil seal 1 5 Oil seal 1 6 O ring 1 7 Oil seal housing 1 8 Bolt 3 M6 25 mm 9 Bolt 8 M10 55 mm 10 Bolt 6 M8 40 mm 11 Crankcase 1 12 Bracket 1 13 Bolt 2 M6 25 mm 14 Bolt 2 M6 16 mm 15 Cover 2 16 Grommet 2 17 Anode 2 Not reusable Not reusable Not reusable Crankcase ...

Page 88: ... 29 69D5G11 Power unit 10 N m 1 0 kgf m 7 2 ft lb 20 N m 2 0 kgf m 15 ft lb 20 N m 2 0 kgf m 15 ft lb 40 N m 4 0 kgf m 29 5 ft lb 69D5080E No Part name Q ty Remarks 18 Bolt 2 M8 20 mm 19 Plate 1 20 Bracket 1 ...

Page 89: ... Clip 1 4 Oil seal 1 5 Circlip 6 6 Washer 6 7 Needle bearing 84 8 Piston ring set 3 9 Piston pin 3 10 Piston 3 11 Crank assembly 1 1 12 Roller bearing assembly 2 13 Labyrinth ring 2 14 Crank assembly 2 1 15 Crank assembly 3 1 16 Ball bearing 1 17 Crank 1 1 Not reusable Not reusable Not reusable Not reusable ...

Page 90: ...POWR 5 31 69D5G11 Power unit 69D5090E No Part name Q ty Remarks 18 Washer 6 19 Roller bearing 3 20 Connecting rod 3 21 Crank pin 3 22 Crank 2 2 23 Crank 3 2 24 Crank 4 1 ...

Page 91: ...d oil seal housing Checking the cylinder bore 1 Measure the cylinder bore D1 D6 at measuring points a b and c and in direction d D1 D3 D5 which is parallel to the crankshaft and direction e D2 D4 D6 which is at a right angle to the crankshaft a 10 0 mm 0 39 in from the cylinder head top surface b 5 0 mm 0 20 in above the exhaust port upper edge c 5 0 mm 0 20 in below the scavenging port lower edge...

Page 92: ...bore the cylinder block if above specification Disassembling the oil seal housing 1 Remove the O ring 1 and oil seals 2 Checking the oil seal housing 1 Check the oil seal housing for cracks damage or corrosion Replace if neces sary Assembling the oil seal housing 1 Apply grease to new oil seal then install them into the oil seal housing 69D50380 1 2 Taper limit D1 D5 direction d D2 D6 direction e ...

Page 93: ... of specification 2 Level the piston rings 1 in a cylinder with a piston crown 3 Check the piston ring end gap a at the specified measuring point Replace if out of specification T B 69D50410 Piston outside diameter 71 940 71 965 mm 2 8323 2 8333 in Measuring point a 10 0 mm 0 39 in up from the bottom of the piston skirt Oversize piston diameter 1st 72 190 7 215 mm 2 8421 2 8431 in 2nd 72 440 72 46...

Page 94: ... outside diameter Replace if out of specification Checking the internal anodes 1 Check the anodes on the cylinder block Clean the anode s surface and replace if it has been eroded into half size or small er cC Do not oil grease or the anodes other wise they will not be able to prevent gal vanic corrosion effectively Piston ring side clearance Top ring and 2nd ring 0 03 0 07 mm 0 0012 0 0028 in Pis...

Page 95: ...l service tools between 3 crank assembly 0 and 2 crank assembly 2 and then separate them using a press 4 Remove the roller bearing from the inner race of the 2 crank assembly same pro cedure as 1 crank assembly 5 Remove the lower bearing q 69D50420 7 1 2 4 5 6 3 3 69D50430 5 4 0 2 3 3 6 7 Nut 3 90890 02407 Pressure plate 4 90890 02408 Pole 5 90890 02409 Plate A 6 90890 02410 Plate B 7 90890 02411 ...

Page 96: ...ing a press and the bushing 3 Carefully press the inner race onto the shaft 2 Insert the pin 6 on the special service tool into the hole 7 on the 2 crank assembly 8 3 Insert the pin e on the special service tool y into the hole r on the 1 crank assembly t 6B450600 w 69D50450 69D50460 6 0 8 7 9 69D50465 0 q w 9 69D50470 t y e r 6F650560 1 4 5 3 2 Bearing separator 90890 06534 Bushing 9 D30 3 90890 ...

Page 97: ... remove the three guide and pull out the guide plate d 7 Insert the pin on the special service tool into the hole on the 2 crank assembly and insert the pin on the special service tool into the hole on the 3 crank assem bly as same procedure as 1 and 2 8 Install the labyrinth ring f onto 3 crank assembly g and install the roller bearing h onto 2 crank assembly 8 before assembling the 2 and 3 NOTE ...

Page 98: ...the crankshaft and connecting rods If it does not turn smoothly disassemble the crankshaft and adjust or replace any parts as necessary Checking the crankshaft 1 Measure the crankshaft widths a and b Repair or disassemble the crankshaft if out of specification 2 Measure the connecting rod small end axial play Replace the bearing and con necting rod if above specification Guide o 90890 02412 Press ...

Page 99: ...Install the crankshaft assembly into the cylinder block 3 Measure the crankshaft runout Repair or disassemble the crankshaft if above specification Assembling the piston 1 Install the 2nd piston ring 1 and top ring 2 onto the pistons NOTE Install the piston rings with the recess for the locating pin facing up toward the piston crown 69D5G11 5 40 9 8 7 6 5 4 3 2 1 Crankcase 69D50510 2 1 69D50520 3 ...

Page 100: ...e crankshaft jour nals POWR 5 41 69D5G11 Power unit 69D50540 1 1 1 1 2 2 2 3 Install the crankcase onto the cylinder block and then tighten the crankcase bolts to the specified torques in two stages and in the sequence shown NOTE Apply engine oil to the crankcase bolts before installation 4 Install the oil seal housing 69D50550 69D50590 69D50580 Crankcase bolt M8 1st 10 N m 1 0 kgf m 7 2 ft lb 2nd...

Page 101: ... m 2 2 ft lb 2nd 8 N m 0 8 kgf m 5 8 ft lb NOTE Apply engine oil to the cylinder head bolts nut before installation 7 Install the thermostat a new gasket and thermostat cover NOTE Apply LOCTITE 572 to the thermostat cover bolts before installation 8 Install the spark plugs tighten them tem porary tight then to the specified torque with a spark plug wrench 9 Install the intake manifold assembly 3 a...

Page 102: ...ontrol model or the throttle cable tiller handle model and then adjust their length For adjustment proce dures see Chapter 3 POWR 5 43 69D5G11 Power unit 1 2 3 5 4 69D50260 Power unit mounting bolt 4 21 N m 2 1 kgf m 15 5 ft lb 9 Install the bracket 6 and neutral switch bracket 7 WHD NOTE Set the shift position to the reverse when install the neutral switch bracket 10 Connect the neutral switch co...

Page 103: ...anual starter and start in gear protection cable 8 and then adjust it length For adjustment procedures see Chapter 3 15 Install all removed parts 16 Set the shift lever to the neutral position and check that the start in gear protec tion lever position WHD Adjust if neces sary 8 69D50165 ...

Page 104: ...POWR 5 45 69D5G11 MEMO ...

Page 105: ...ng the propeller shaft housing 6 15 Drive shaft and lower case 6 16 Removing the drive shaft 6 17 Disassembling the drive shaft 6 17 Disassembling the forward gear 6 17 Disassembling the lower case 6 17 Checking the pinion and forward gear 6 18 Checking the bearings 6 18 Checking the drive shaft 6 18 Checking the lower case 6 18 Assembling the lower case 6 18 Assembling the forward gear 6 19 Assem...

Page 106: ...late 90890 06501 Bearing puller assembly 90890 06535 Drive shaft holder 3 90890 06517 Bearing outer race puller assembly 90890 06523 Bearing Separator 90890 06534 Ring nut wrench extension 90890 06513 Bearing housing puller claw L 90890 06502 Center bolt 90890 06504 Ring nut wrench 90890 06511 ...

Page 107: ...tachment 90890 06608 Needle bearing attachment 90890 06611 90890 06612 Bearing outer race attachment 90890 06621 90890 06626 Shift rod push arm 90890 06052 Stopper guide stand 90890 06538 Driver rod SL 90890 06602 Bearing depth plate 90890 06603 Driver rod SS 90890 06604 Driver rod LL 90890 06605 ...

Page 108: ...712 Pinion nut holder New 90890 06715 Current 90890 06505 Magnet base B 90890 06844 Backlash indicator 90890 06706 Bearing inner race attachment 90890 06639 90890 06643 90890 06662 Ball bearing attachment 90890 06655 Driver rod L3 90890 06652 Shimming plate 90890 06701 Digital caliper 90890 06704 ...

Page 109: ...69D5G11 6 4 9 8 7 6 5 4 3 2 1 Special service tools Magnet base plate 90890 07003 ...

Page 110: ...b X 40 N m 4 0 kgf m 29 5 ft lb 69D6010E No Part name Q ty Remarks 1 Lower unit 1 2 Check screw 1 3 Gasket 3 4 Drain screw 1 5 Screw 1 6 Dowel 2 7 Cover 1 8 Bolt 1 M10 45 mm 9 Anode 1 10 Washer 1 11 Propeller 1 12 Washer 1 13 Washer 1 14 Propeller nut 1 15 Cotter pin 1 16 Bolt 1 M8 112 mm 17 Nut 4 Not reusable Not reusable ...

Page 111: ... Spring washer 4 19 Washer 4 20 Water inlet cover 2 21 Screw 1 ø5 42 mm 22 Nut 1 23 Seal 1 24 Guide 1 25 Dowel 2 26 Extension 1 S and L transom model 27 Bolt 1 M10 45 mm X transom model 28 Dowel 2 X transom model 29 Bolt 1 M8 190 mm X transom model 30 Nut 4 X transom model 31 Spring washer 4 X transom model 32 Washer 4 X transom model 33 Dowel 2 X transom model 34 Extension 1 X transom model ...

Page 112: ...ip 1 2 Shift rod 1 3 Circlip 1 4 O ring 1 5 Plate 1 6 Oil seal 1 7 O ring 1 8 Bolt 2 M6 45 mm 9 Cap 1 10 Screw 2 11 Grommet 1 12 Seal 1 13 Bolt 2 M8 70 mm 14 Bolt 2 M8 50 mm 15 Water pump housing 1 16 Insert cartridge 1 17 Impeller 1 Not reusable Not reusable Not reusable ...

Page 113: ...t 69D6020E No Part name Q ty Remarks 18 Dowel 2 19 Gasket 1 20 Outer plate cartridge 1 21 Gasket 1 22 Oil seal housing 1 23 Gasket 1 24 O ring 1 25 Oil seal 2 26 Woodruff key 1 Not reusable Not reusable Not reusable Not reusable Not reusable ...

Page 114: ...y leads from the battery and the clip from the engine stop lanyard switch 9 Put a block of wood between the anti cavitation plate and propeller to keep the propeller from turning 3 Mark the trim tab at the area shown 4 Remove the cover 1 then remove the trim tab bolt 2 and trim tab 3 5 Loosen the bolt 4 and nuts 5 and then remove the lower unit from the upper case åX transom model Removing the wat...

Page 115: ...ssary 3 Check the Woodruff key 1 and the key way a in the drive shaft for wear Replace if necessary 4 Check the shift rod for cracks or wear Replace if necessary Disassembling the oil seal housing 1 Remove the oil seals using a flat head screwdriver Assembling the oil seal housing 1 Apply grease to new oil seals and then install them into the oil seal housing 69D60040 a 1 69D60035 Shift rod push a...

Page 116: ... 5 kgf m 76 ft lb No Part name Q ty Remarks 1 Slider 1 2 Shifter 1 3 Shift slider 1 4 Shaft assembly 1 5 Ball 2 6 Pin 1 7 Cross pin 1 8 Spring 1 9 Spring 1 10 Dog clutch 1 11 Spring nut 2 12 Plunger 2 13 Spring 1 14 Washer 1 15 Shaft 1 16 Propeller shaft 1 17 Reverse gear 1 ...

Page 117: ...E 105 N m 10 5 kgf m 76 ft lb No Part name Q ty Remarks 18 Reverse gear shim 19 Washer 1 20 O ring 1 21 Bearing 1 22 Propeller shaft housing 1 23 Straight key 1 24 Needle bearing 1 25 Oil seal 2 26 Lock washer 1 27 Ring nut 1 Not reusable Not reusable Not reusable ...

Page 118: ... assembly 1 Remove the spring 1 then the cross pin 2 dog clutch 3 spring 4 slider 5 shifter 6 and shift slider assembly 7 Disassembling the propeller shaft housing 1 Remove the reverse gear 6F600060 1 1 2 3 4 5 6 7 69D60050 6F660070 2 3 6B460580 5 4 6 Ring nut wrench 2 90890 06511 Ring nut wrench extension 3 90890 06513 Stopper guide plate 4 90890 06501 Bearing housing puller claw L 5 90890 06502 ...

Page 119: ...f necessary Checking the propeller shaft 1 Check the propeller shaft for bends or wear Replace if necessary 2 Measure the propeller shaft runout 3 Check the dog clutch and shift slider for cracks or wear Replace if necessary Assembling the propeller shaft assembly 1 Install the dog clutch 1 and the slider 2 as shown NOTE 9 Install the dog clutch 1 with the F mark a facing toward the shift plunger ...

Page 120: ...e propeller shaft housing then the other oil seal 3 Install the washer 6 and new ball bear ing 7 onto the reverse gear 8 using a press 4 Install the reverse gear assembly into the propeller shaft housing using a press 6F660150 3 2 1 b a 6F660170 9 8 7 6 0 69D60080 6F660160 4 5 c Driver rod SS 1 90890 06604 Needle bearing attachment 2 90890 06612 Bearing depth plate 3 90890 06603 Bearing inner race...

Page 121: ...95 N m 9 5 kgf m 68 ft lb 69D6040E No Part name Q ty Remarks 1 Drive shaft 1 2 Forward gear 1 3 Taper roller bearing assembly 1 4 Forward gear shim 5 Nut 1 6 Pinion gear 1 7 Lower case 1 8 Needle bearing 1 9 Sleeve 1 10 Pinion gear shim 11 Taper roller bearing assembly 1 Not reusable Not reusable Not reusable ...

Page 122: ...ollar 4 9 Do not reuse the bearing always replace it with a new one Disassembling the forward gear 1 Remove the taper roller bearing from the forward gear using a press cC Do not reuse the bearing always replace it with a new one Disassembling the lower case 1 Remove the taper roller bearing outer race and shim s NOTE Install the claws a as shown 6F660190 1 2 6F660210 1 Drive shaft holder 3 1 9089...

Page 123: ...r case 1 Check the skeg and torpedo for cracks or damage Replace the lower case if nec essary Assembling the lower case 1 Install the needle bearing into the lower case to the specified depth NOTE 9 Install the needle bearing with the manufac ture identification mark a facing up 9 Be careful not to let the stopper b get out of position when using the driver rod SL 6 5 5 6 4 2 3 69D60110 Needle bea...

Page 124: ...lower case Assembling the forward gear 1 Install a new taper roller bearing into the forward gear using a press Assembling the drive shaft 1 Install a new drive shaft bearing onto the drive shaft using a press Installing the drive shaft 1 Install the forward gear then the drive shaft assembly spacer pinion and pin ion nut 2 Tighten the nut to the specified torque G 6B460350 7 6 5 4 5 4 d 6F660290 ...

Page 125: ...ginal shim s 1 and pro peller shaft assembly 2 into the propeller shaft housing assembly 3 2 Apply grease to new O rings cC Add or remove shim s if necessary if replacing the reverse gear propeller shaft housing or lower case 3 Install the propeller shaft housing assem bly 4 straight key 5 and lock washer 6 into the lower case and then tighten the ring nut 7 to the specified torque 1 3 2 69D60230 ...

Page 126: ...ft 3 Align the groove in the impeller 3 with the Woodruff key 4 and then install the impeller onto the drive shaft 4 Install the insert cartridge 5 into the pump housing 6 and then apply grease to the inside of the insert cartridge NOTE Align the insert cartridge projection a with the hole b in the pump housing Ring nut 105 N m 10 5 kgf m 76 ft lb Ring nut wrench 8 90890 06511 Ring nut wrench exte...

Page 127: ...osition at the lower unit and power unit Make sure that the shift rod is in the neutral position using a special service tool 2 Install the dowels 1 into the lower unit and extension 2 3 Install the lower unit into the upper case and then tighten the lower case mounting bolt and nuts 3 to the specified torque 4 Install the trim tab 4 to its original posi tion and then tighten the trim tab bolt 5 å...

Page 128: ...op lanyard switch 9 Put a block of wood between the anti cavitation plate and propeller to keep the propeller from turning NOTE If the grooves in the propeller nut 7 do not align with the cotter pin hole tighten the nut until they are aligned 7 Insert a gear oil tube or gear oil pump into the drain hole and slowly fill the gear oil until oil flows out of the check hole and no air bubbles are visib...

Page 129: ...69D5G11 6 24 9 8 7 6 5 4 3 2 1 Drive shaft and lower case Shimming Shimming T3 M3 M2 69D6050E T2 T1 M1 ...

Page 130: ...ing nuts another 1 4 of a turn after they contact the plate 2 2 Install the pinion and pinion nut and then tighten the nut to the specified torque 3 Measure the distance M3 between the special service tool and the pinion as shown 4 Calculate the pinion shim thickness T3 as shown in the examples below NOTE P is the deviation of the lower case dimen sion from standard The P mark a is stamped on the ...

Page 131: ...easurement s and the calcula tion formula 9 Measure the bearing outer race at three points to find the height average 2 Calculate the forward gear shim thick ness T1 as shown in the examples below NOTE F is the deviation of the lower case dimen sion from standard The F mark a is stamped on the trim tab mounting surface of the lower case in 0 01 mm units If the F mark is unreadable assume that F is...

Page 132: ...pecified measurement s and the calcula tion formula 9 Measure the bearing housing at three points to find the height average 3 Calculate the reverse gear shim thick ness T2 as shown in the examples below NOTE R is the deviation of the lower case dimen sion from standard The R mark a is stamped on the trim tab mounting surface of the lower case in 0 01 mm units If the R mark is unreadable assume th...

Page 133: ...enter bolt while turning the drive shaft until the drive shaft can no longer be turned 4 Install the backlash indicator onto the drive shaft 20 0 mm 0 78 in in diame ter then the dial gauge onto the lower unit NOTE Install the dial gauge so that the plunger a contacts the mark b on the backlash indica tor Calculation formula Reverse gear shim thickness T2 M2 28 00 R 100 Calculated numeral Rounded ...

Page 134: ...d measure the back lash when the drive shaft stops in each direction 10 Add or remove the shim s if out of spec ification M Measurement 11 Remove the special service tools and then install the water pump assembly Forward gear backlash 0 14 0 46 mm 0 0053 0 0182 in Reverse gear backlash 0 77 1 16 mm 0 0304 0 0456 in Forward gear Shim thickness backlash Less than To be decreased by 0 14 mm 0 0053 in...

Page 135: ...Removing the pivot shaft 7 12 Installing the pivot shaft 7 12 Disassembling the upper case 7 13 Checking the upper case 7 13 Assembling the upper case 7 13 Installing the upper case 7 14 Clamp brackets swivel bracket S L transom 7 16 Clamp brackets swivel bracket X transom model 7 19 Removing the hydro tilt assembly 7 22 Installing the hydro tilt assembly 7 23 Removing the clamp brackets 7 23 Inst...

Page 136: ...D No Part name Q ty Remarks 1 Clip 2 2 Joint 2 3 Nut 2 4 Throttle cable 1 5 Bolt 2 M6 16 mm 6 Cable clamp 1 7 Grommet 1 8 Nut 1 9 Tiller handle bracket 1 10 Plastic washer 2 11 Metal washer 2 12 Wave washer 1 13 Bolt 1 M7 70 mm 14 Collar 1 15 Engine stop lanyard switch 1 16 Bolt 2 M6 16 mm 17 Bracket 1 Tiller handle MHD WHD ...

Page 137: ...0 kgf m 29 5 ft lb 69D7010E WHD No Part name Q ty Remarks 18 Cotter pin 2 19 Washer 2 20 Collar 1 21 Shift rod 1 22 Shift rod 1 23 Nut 1 24 Washer 1 25 Collar 2 M5 10 mm 26 Holder 1 27 Ball 1 28 Spring 1 29 Shift lever 1 30 Bolt 1 M6 20 mm 31 Screw 1 ø6 26 mm 32 Bolt 1 M6 30 mm 33 Screw 1 ø6 10 mm 34 Switch holder 2 ...

Page 138: ...b 69D7010E WHD No Part name Q ty Remarks 35 Start switch 1 36 Nut 1 37 Screw 1 38 Throttle grip 1 39 Washer 1 40 Spring 1 41 Collar 1 42 Screw 4 ø5 12 mm 43 Screw 1 ø6 8 mm 44 Nipple 1 45 Gasket 1 46 Cover 1 47 Plate 1 48 Throttle shaft 1 49 Housing 1 50 Bolt 1 M6 25 mm 51 Friction control piece 1 Not reusable ...

Page 139: ...1 7 4 9 8 7 6 5 4 3 2 1 Tiller handle MHD WHD 40 N m 4 0 kgf m 29 5 ft lb 4 N m 0 4 kgf m 3 0 ft lb 40 N m 4 0 kgf m 29 5 ft lb 69D7010E WHD No Part name Q ty Remarks 52 Nut 2 53 Bracket 1 54 Bolt 1 M6 25 mm ...

Page 140: ...ller handle 2 by aligning the mark a of the tiller handle with the screw hole b of the throttle shaft 2 Install the throttle cable 3 into the gear 4 until the inner cable is engaged with the gear 3 Turn the throttle shaft 1 clockwise to wind the inner cable around the gear 4 NOTE Make sure that the throttle grip is fully closed when installing the throttle cable Lubricating the throttle gear 1 Inj...

Page 141: ...art name Q ty Remarks 1 Clip 2 2 Bushing 1 3 Cotter pin 1 4 Washer 1 5 Ball 1 6 Spring 1 7 Plug 1 8 Collar 1 9 Washer 1 10 Shift rod lever 1 11 Shift rod lever assembly 1 12 Bolt 2 M6 12 mm 13 Bracket 1 14 Wave washer 1 15 Collar 2 16 Collar 2 17 Cowling lock lever 1 Bottom cowling ...

Page 142: ...Q ty Remarks 18 Bracket 1 19 Washer 1 20 Cowling lock lever 1 21 Bolt 4 M6 30 mm 22 Grommet 4 23 Collar 4 24 Boot 1 25 Seal 1 26 Grommet 1 27 Damper 1 28 Warning indicator 1 29 Grommet 1 30 Clamp 1 WHD and WD models 31 Shift bracket 1 32 Bolt 2 M6 20 mm ...

Page 143: ... No Part name Q ty Remarks 1 Bolt 3 M8 35 mm 2 Upper mount housing 1 3 Cap 2 4 Bolt 2 M10 174 mm 5 Washer 2 6 Washer 2 7 Washer 2 8 Upper mount 2 9 Nut 2 10 Screw 2 11 Cover 2 12 Collar 2 13 Bolt 4 M8 25 mm 14 Ground lead 1 15 Nut 2 16 Washer 2 17 Washer 2 Upper case pivot shaft ...

Page 144: ...BRKT 7 9 69D5G11 Bracket unit X 69D7030E No Part name Q ty Remarks 18 Lower mount 2 19 Washer 2 20 Washer 2 21 Bolt 2 M8 155 mm 22 Cap 2 23 Lower mount housing 2 24 Spring 4 25 Upper case 1 ...

Page 145: ...D5G11 7 10 9 8 7 6 5 4 3 2 1 Upper case pivot shaft 69D7050E No Part name Q ty Remarks 1 Pivot shaft 1 2 Washer 1 3 Bushing 1 4 O ring 2 5 Bushing 2 6 Bushing 1 7 Mount housing 1 8 Circlip 1 Not reusable ...

Page 146: ... 15 5 ft lb F 69D7040E No Part name Q ty Remarks 1 Bolt 2 M8 30 mm 2 Exhaust guide 1 3 Gasket 1 4 Bolt 3 M8 30 mm 5 Exhaust manifold 1 6 Bolt 4 M8 30 mm 7 Rubber washer 1 8 Collar 1 9 Water pipe 1 10 Seal 1 11 Muffler 1 12 Seal 1 13 Seal 1 14 Damper 2 15 Dowel 2 16 Upper case 1 Not reusable Not reusable ...

Page 147: ...vel bracket by pulling the arm off the bracket Installing the pivot shaft 1 Installing the washer 1 bushing 2 a new O ring 3 and bushing 4 onto the pivot shaft 5 2 Place the swivel bracket 6 in an upright position and then install the pivot shaft onto the swivel bracket 3 Install the bushing 7 a new O ring 8 and bushing 9 onto the swivel bracket 69D70120 1 69D70190 6 5 1 2 3 4 69D70200 7 8 9 69D70...

Page 148: ... the water pipe 2 the exhaust manifold 3 the muffler 4 and the bolts and then tighten the bolts BRKT 7 13 69D5G11 Bracket unit 4 Install the pivot shaft 5 into the mount housing 0 by aligning the center a of the mount housing with the center b of the pivot shaft 5 Install the circlip q Disassembling the upper case 1 Remove the muffler assembly 1 from the upper case 2 69D70210 b 0 5 q a 69D70040 5 ...

Page 149: ...n tighten the bolts 3 2 Set the lower mount 4 and bolts 5 to the upper case 3 Install the end of the springs 6 into the groove of the lower mount housing 7 and then tighten the bolts 8 4 Install the upper and lower mounting bolts into the pivot shaft 9 simultaneous ly 5 Install the upper mounting nuts 0 and lower mounting nuts q and then tighten them 5 6 69D70035 4 5 6 7 8 69D70080 69D70090 0 9 q ...

Page 150: ...15 69D5G11 Bracket unit 6 Install the ground lead w into the mount housing 7 as shown and then install the cover e å S L transom models port side X transom model starboard side w 69D70110 7 e w 69D70100 7 e å ...

Page 151: ... lb 69D7060E No Part name Q ty Remarks 1 Tilt pin 1 2 Nut 2 3 Washer 2 4 Bolt 1 5 Spacer 1 6 Bolt 2 M6 25 mm 7 Anode 1 8 Bolt 1 M6 10 mm 9 Ground lead 2 10 Screw 1 ø6 8 mm 11 Circlip 2 12 Pin 1 13 Bushing 2 14 Hydro tilt assembly 1 15 Bushing 1 16 Bushing 2 17 Screw 1 Clamp brackets swivel bracket S L transom ...

Page 152: ... Part name Q ty Remarks 18 Anode 1 19 Bushing 2 20 Bolt 1 M6 10 mm 21 Tilt lever 1 22 Cap 1 23 Grease nipple 3 24 Ground lead 1 25 Cap 2 26 Self locking nut 2 27 Through tube 1 28 Swivel bracket 1 29 Washer 2 30 Bushing 2 31 Bolt 1 M6 10 mm 32 Plate 1 33 Spring 1 34 Pin 2 ...

Page 153: ...kets swivel bracket 22 N m 2 2 kgf m 16 2 ft lb 69D7060E No Part name Q ty Remarks 35 Collar 1 36 Bushing 4 37 Tilt stop lever 1 38 Tilt stop lever 1 39 Clamp bracket 1 40 Clamp bracket 1 41 Pin 2 42 Clamp handle 2 43 Pad pin 2 44 Clamp pad 2 ...

Page 154: ... Q ty Remarks 1 Tilt pin 1 2 Bolt 2 M6 16 mm 3 Bolt 2 M6 29 mm 4 Washer 2 5 Anode 1 6 Plate 1 7 Bolt 6 M10 45 mm 8 Pin 1 9 Bushing 6 10 Hydro tilt assembly 1 11 Spacer 1 12 Bushing 2 13 Bolt 1 M6 10 mm 14 Tilt lever 1 15 Cap 1 16 Reverse lock lever 1 17 Washer 1 Clamp brackets swivel bracket X transom model ...

Page 155: ... N m 0 8 kgf m 5 8 ft lb 69D7070E No Part name Q ty Remarks 18 Rod 1 19 Joint 1 20 Grease nipple 3 21 Cap 2 22 Self locking nut 1 23 Through tube 1 24 Washer 2 25 Bushing 2 26 Bolt 1 M6 10 mm 27 Plate 1 28 Spring 1 29 Pin 3 30 Bushing 4 31 Lever 1 32 Collar 1 33 Collar 1 34 Tilt stop lever 1 ...

Page 156: ...f m 11 1 ft lb 8 N m 0 8 kgf m 5 8 ft lb 69D7070E No Part name Q ty Remarks 35 Cap 2 36 Tilt stop lever 1 37 Clamp bracket 1 38 Clamp bracket 1 39 Pin 2 40 Clamp handle 2 41 Pad pin 2 42 Clamp pad 2 43 Screw 1 44 Ground lead 1 45 Swivel bracket 1 ...

Page 157: ...ve the bolt s 4 and spacer 5 5 Remove the circlip s 6 and pin 7 6 Remove the hydro tilt assembly 8 å S L transom models X transom model w 9 Do not tamper or attempt to open the hydro tilt assembly 9 Do not subject the hydro tilt assembly to an open flame or any other source of high heat High heat can cause an explo sion due to excessive gas pressure 9 Do not deform or damage the hydro tilt assembl...

Page 158: ...th tilt stop levers 4 Remove the through tube then disas semble the clamp brackets Installing the clamp brackets 1 Install the bushings 1 and tilt stop levers 2 to the swivel bracket 3 2 Assemble the clamp brackets 4 bush ings 5 washers 6 and swivel bracket 3 and then install the through tube 7 3 Tighten the self locking nuts 8 to the specified torque and then tighten the caps 9 4 Install the hydr...

Page 159: ...hecking the pulser coils 8 12 Checking the charge coil 8 12 Checking the thermoswitch 8 13 Checking the warning indicator 8 13 Checking the engine stop lanyard switch MHD WHD 8 13 Starting system WHD WD 8 14 Checking the fuse WHD WD 8 15 Checking the starter relay WHD WD 8 15 Checking the engine start switch WHD 8 15 Checking the neutral switch WHD WD if equipped 8 15 Checking the choke solenoid W...

Page 160: ...8 1 69D5G11 Electrical systems Special service tools Ignition tester 90890 06754 Digital circuit tester 90890 03174 Peak voltage adaptor B 90890 03172 Test harness 4 pins New 90890 06875 Current 90890 06775 ...

Page 161: ...voltage do not touch any of the connections of the digital circuit tester leads NOTE 9 Use the peak voltage adaptor with the digi tal circuit tester 9 When measuring the peak voltage set the selector on the digital circuit tester to the DC voltage mode 9 Connect the positive pin on the peak volt age adaptor to the positive terminal of the digital circuit tester Measuring low resistance When measur...

Page 162: ...1 2 3 6 7 8 9 0 q 4 5 69D80010 1 Starter motor WHD WD 2 Starter relay WHD WD 3 Ignition coil 4 Spark plug 5 Lighting coil 6 Charge coil 7 Pulser coil 8 Engine start switch WHD 9 Engine stop lanyard switch MHD WHD 0 Warning indicator q Neutral switch WHD WD If equipped ...

Page 163: ...69D5G11 8 4 9 8 7 6 5 4 3 2 1 Port view WD 69D80040 1 1 Choke solenoid Electrical components ...

Page 164: ...ELEC 8 5 69D5G11 Electrical systems Starboard view MHD 69D80020 1 2 3 4 5 1 Spark plug 2 Ignition coil 3 CDI unit 4 Warning indicator 5 Thermoswitch ...

Page 165: ...9 8 7 6 5 4 3 2 1 Electrical components Starboard view WHD WD 69D80030 1 2 3 4 5 6 7 8 9 1 Spark plug 2 Ignition coil 3 CDI unit 4 Starter motor 5 Warning indicator 6 Starter relay 7 Fuse 8 Rectifier 9 Thermoswitch ...

Page 166: ...G11 Electrical systems 69D80110 Ignition and ignition control system 1 Spark plug 2 Ignition coil 3 Charge coil 4 Pulser coil 5 CDI unit B Black Br Brown B W Black White W B White Black W R White Red W G White Green ...

Page 167: ... 6 5 4 3 2 1 Ignition and ignition control system 69D80115 1 Thermoswitch 2 CDI unit 3 Warning indicator 4 Engine stop lanyard switch MHD WHD 5 Engine start switch WHD å MHD WHD WHD B Black P Pink W White Y R Yellow Red ...

Page 168: ...ce this test can produce sparks Checking the ignition coils 1 Remove the spark plug cap from the spark plug 2 Disconnect the ignition coil connector 3 Measure the ignition coil resistance Replace if out of specification Checking the spark plug caps 1 Check the spark plug caps for cracks or damage Replace if necessary 2 Remove the spark plug cap 1 from the spark plug wire 2 3 Check the spark plug w...

Page 169: ...tage of the pulser coil is above specification NOTE Remove the all spark plug caps set the engine start switch to ON position and install the engine stop lanyard switch clip when measure the CDI unit peak voltage at the clanking to use the manual starter WHD 69D80060 Digital circuit tester 90890 3174 Peak voltage adaptor B 90890 03172 CDI unit output peak voltage Black and White B W Ground B r min...

Page 170: ...1 4 46 4 69 6 46 4 69 6 46 4 69 6 44 66 3 8 5 6 52 78 32 48 32 48 72 108 B 23 2 34 8 23 2 34 8 23 2 34 8 3 4 5 0 3 4 5 0 3 4 5 0 3 5 5 3 6 9 5 8 7 2 24 36 16 24 12 4 18 6 B W 1 B W 2 B W 3 Br 36 54 36 54 36 54 8 4 12 6 16 24 16 24 16 24 6 4 9 6 16 24 30 45 28 42 28 42 W 36 54 36 54 36 54 8 4 12 6 21 6 32 4 21 4 32 4 21 4 32 4 20 8 31 2 24 36 16 24 16 24 36 54 Y R P Gy Gy 800 1200 800 1200 800 1200...

Page 171: ...White Black W B Ground B White Green W G Ground B r min Unloaded Loaded Cranking 1 500 3 500 DC V 2 0 2 0 6 0 10 0 69D80070 Digital circuit tester 90890 3174 Peak voltage adaptor B 90890 03172 Test harness 4 pins New 90890 06875 Current 90890 06775 Pulser coil resistance reference data White red W R Ground B White Black W B Ground B White Green W G Ground B 117 143 Ω at 20 C 68 F 69D80070 Digital ...

Page 172: ...y Checking the thermoswitch 1 Place the thermoswitch in a container of water and slowly heat the water 2 Check the switch for continuity at the specified temperatures Replace if out of specification a Temperature b Time c No continuity d Continuity Checking the warning indicator 1 Disconnect the warning indicator connec tor 2 Check that the indicator for continuity 69D80090 Thermoswitch continuity...

Page 173: ...on control system Starting system 69D80140 Starting system WHD WD 1 Fuse 2 Engine start switch WHD 3 Neutral switch WHD WD if equipped 4 Starter motor 5 Battery 6 Starter relay 7 Choke solenoid WD å WHD WD B Black Br Brown B W Black White L Blue R Red ...

Page 174: ...own Br lead 3 Connect the negative battery terminal to the black B lead 4 Check for continuity between the starter relay terminals Replace if there is no continuity 5 Check that there is no continuity between the starter relay terminals after discon necting a battery terminal from the brown or black lead Replace if there is continu ity Checking the engine start switch WHD 1 Check the engine start ...

Page 175: ...1 Clip 1 2 Pinion stopper 1 3 Spring 1 4 Pinion assembly 1 5 Bolt 2 6 Washer 2 7 Washer 2 8 O ring 2 9 Front cover 1 10 O ring 1 11 Washer set 12 Armature assembly 1 13 Yoke assembly 1 14 Bracket 1 15 O ring 1 16 Nut 2 17 Spring washer 2 Not reusable Not reusable Not reusable Starter motor WHD WD ...

Page 176: ... 17 69D5G11 Electrical systems 69D8000E No Part name Q ty Remarks 18 Plate washer 1 19 Bushing 1 20 O ring 1 21 Bushing 1 22 Brush 2 23 Spring 2 24 Screw 2 25 Brush holder 1 26 Bolt 1 27 Washer 1 Not reusable ...

Page 177: ...ace if necessary NOTE Turn the pinion counterclockwise to check that it operates smoothly and turn it clockwise to check that it locks in place Checking the armature 1 Check the commutator for dirt Clean with 600 grit sandpaper and compressed air if necessary 2 Measure the commutator diameter a Replace the armature if below specifica tion 3 Measure the commutator undercut b Replace the armature if...

Page 178: ...mbly for continuity Replace if out of specifica tions Checking the starter motor operation 1 Check the operation of the starter motor after installing it onto the power unit a 6F680200 Brush length limit a 9 0 mm 0 35 in 6F680190 c d e 69D80160 1 2 Armature continuity Commutator segments c Continuity Segment Armature core d No continuity Segment Armature shaft e No continuity Brush continuity Brus...

Page 179: ... 20 9 8 7 6 5 4 3 2 1 Starter motor Charging system 69D80170 Charging system 1 Rectifier WHD WD 2 Lighting coil 3 Battery WHD WD 4 Fuse WHD WD å 1 Lighting coil model 2 Lighting coil model B Black G Green R Red ...

Page 180: ...ltage Checking the lighting coil 1 Measure the lighting coil output peak voltage Replace the lighting coil if below specification Digital circuit tester 90890 3174 Digital circuit tester 90890 3174 Peak voltage adaptor B 90890 03172 Rectifier output peak voltage Red R Black B r min Unloaded 1 500 3 500 DC V 20 40 69D80130 Lighting coil output peak voltage Green G Green G r min Unloaded Cranking 1 ...

Page 181: ...1 9 8 7 6 5 4 3 2 1 TRBL SHTG TRBL SHTG Troubleshooting Power unit 9 1 Ignition system 9 1 Fuel system 9 3 Compression pressure 9 4 Lower unit 9 7 Electrical system 9 8 Starting system 9 8 Charging system 9 9 ...

Page 182: ...th clip installed Check the condition of the spark plugs Check the ignition spark using the spark gap tester Replace the engine stop lanyard switch Is there correct continued on following page Yes Yes No Clean and replace as required No Check the spark plug wires or caps for deterioration and damage No Yes Are they in good condition Is a good spark being produced Measure the ignition coil resistan...

Page 183: ...unit Yes Replace the charge coil No Replace the pulser coil No Check the pulser coil output peak voltage No Yes Yes Does the out put peak voltage exceed specifi cation values Does the out put peak voltage exceed specifi cation values Does the out put peak voltage exceed specifi cation values Check the CDI unit output peak voltage Ignition system troubles are clear No Does the engine start Refer to...

Page 184: ...d check the internal parts Replace the diafragm gasket spring and or check valve as necessary No Are there any kinks or fuel leakage Check the fuel pump for leakage or internal damage No Is there any leakage or inter nal damage Check the operation of the carburetor Check the compression pressure Yes Does the carburetor set ting and throttle link operating correctly No Is there water or residue Dis...

Page 185: ...r bore for wear or damage Correct or replace if worn or damaged Check the cylinder head gasket and cylinder head for corrosion or damage Replace if corrosion or damaged Does the pressure exceed the specification values Yes Check ignition timing Adjust as necessary Does the compression pressure increase Yes No NOTE While restoring a damaged part it is also necessary to trace and solve the cause of ...

Page 186: ...perat ing correctly Check the pilot screw Yes Is the pilot screw setting correct Disassemble the carburetor and check the internal parts Check the throttle valve for smooth operation No Are the fuel or air passages clogged Yes Correct or replace the carburetor No Does the throttle valve stick No Check the ignition system or compression system Replace if foulty parts Check the carburetors synchro n...

Page 187: ... Replace the correct type of spark plug Are they correctly Check the spark plug heat range Yes Is it range correctly Check the ignition control system 9 Clean the all water passsages clogg and clean or replase the water inlet screen 9 Disassemble and clean the water pump Replace the impeller as necessary Check the cylinder head and gasket Yes Clean the cylinder head and replace the gasket Yes No I...

Page 188: ... correctly or replace the shift rod as necessary No Replace the spring shift cam shift slider and shift plunger as necessary Is it connected properly and in good condition Is it operating correctly Disassemble the lower case and check the dog clutch operation Yes Is it in good operating condition Check the dog clutch and forward and reverse gears and replace if necessary Yes Refer to page 1 8 Refe...

Page 189: ...ireharness or lead and replace or tighten the ground lead bolt Is there blown Check the engine start switch for continuity Yes Is there continuity Check the wireharness for connecting condition and battery positive lead terminal ground lead bolt for corrosion and loosen Yes Yes Is the battery fully charged Are they good condittion continued on following page Check the neutral switch for correctly ...

Page 190: ... condition 9 Be sure the wireharness couplers and connectores are good connection Charging system Check the lighting coil output peak voltage Check the rectifier output peak voltage Replace the battery and then check the all of the electrical equipment on the boat Replace the lighting coil Replace the rectifier No Does the out put peak voltage exceed specifi cation values Yes No Does the out put p...

Page 191: ...inder bore 5 32 Checking the cylinder head 5 26 Checking the drive pawl 5 17 Checking the drive shaft 6 18 Checking the electrical components 8 2 Checking the engine idle speed 3 6 Checking the engine start switch WHD 8 15 Checking the engine start switch engine stop lanyard switch and engine stop button 1 9 Checking the engine stop lanyard switch MHD WHD 8 13 Checking the exhaust cover 5 26 Check...

Page 192: ...bling the upper bearing 5 33 Disassembling the upper case 7 13 Disassembly and assembly 1 4 Drive shaft and lower case 6 16 E Electrical 2 5 Electrical syatem 9 8 Electrical components 8 3 F Fire prevention 1 3 Fuel line 4 3 Fuel pump 4 10 Fuel system 3 3 G General 3 13 General specification 2 1 General torques 2 11 Good working practices 1 4 H Hose routing 4 2 How to use this manual 1 1 I Identif...

Page 193: ...ving the pivot shaft 7 12 Removing the power unit 5 18 Removing the propeller shaft housing assembly 6 13 Removing the reed valve assembly 5 23 Removing the starter motor pinion 8 18 Removing the water pump 6 9 S Safety while working 1 3 Selecting the forward gear shims 6 26 Selecting the pinion shims 6 25 Selecting the reverse gear shims 6 27 Selection 1 6 Self protection 1 3 Serial number 1 5 Sh...

Page 194: ...tch 4 Charge coil 5 Pulser coil 6 Lighting coil 7 CDI unit 8 Engine stop lanyard switch 9 Warning indicator å 1 Lighting coil model 2 Lighting coil model Color code B Black Br Brown P Pink W White B W Black White W G White Green W B White Black W R White Red Y R Yellow Red ...

Page 195: ......

Page 196: ...YAMAHA MOTOR CO LTD Printed in Japan Oct 2004 0 9 1 E_2 Printed on recycled paper ...

Page 197: ...E60HMHD 1 2 3 B P B B B P P P B B P Br Br Br G B G G G G P W B W B W B W P Y R P Y R W B W W R W B W G W G W B W R B W B W B B B W B F M W G W R W G W R ...

Page 198: ... 9 Fuse 0 Starter motor q Starter relay w Neutral switch WD if equipped e Battery r Warning indicator t Engine start switch WHD y Engine stop lanyard switch å 1 Lighting coil model 2 Lighting coil model ç WHD Color code B Black Br Brown G Green P Pink R Red W White B W Black White W B White Black W G White Green W R White Red Y R Yellow Red ...

Page 199: ... P B P P Br Br Br B Br Br Br G B G G G G B W B W P P W R R R Y R B W R W R W B W G W G W B W R B W B W B B P P B P P B B W B 15B B G R R R P R G W B B Y R Br Br W R B Br Y R W W W B B B 15B 15B 15B 15B B W B F M W G W R W G W R Br W B R W R B ...

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