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Yamaha F100C, Service Manual

The Yamaha F100C service manual is a comprehensive guide for maintaining and repairing this exceptional outboard motor. It can be easily downloaded for free from manualshive.com, providing users with access to crucial information and instructions to ensure optimal performance and longevity for their Yamaha F100C.

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60C5D11

1-26

1
2
3
4
5
6
7
8
9

CAUTION:

This is a 4-stroke engine. Never use pre-
mixed fuel.

Checking the gear oil

1.

Check the gear oil level.

Checking the engine oil

1.

Check the oil level.

NOTE:

• If the engine oil is above the maximum level

mark 

a

, drain sufficient oil until the level is

between 

a

 and 

b

.

• If the engine oil is below the minimum level

mark 

b

, add sufficient oil until the level is

between 

a

 and 

b

.

Checking the battery

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. 

Checking the outboard motor 
mounting position

1.

Check the position of the anti-cavitation
plate.

2.

Check that the clamp brackets are
secured with the clamp bolts.

S60C1130

S60C1140

S60C1150

Recommended engine oil:

4-stroke motor oil

API: SE, SF, SG, or SH
SAE: 10W-30, 10W-40, or 
20W-40

Oil capacity:

Without oil filter replacement:

4.5 L (4.8 US qt, 4.0 Imp qt)

Battery capacity: 70–100 Ah
Minimum cold cranking performance:

380 A

Electrolyte specific gravity:

1.28 at 20 °C (68 °F)

Propeller selection / Predelivery checks

Summary of Contents for F100C

Page 1: ...SERVICE MANUAL 60C 28197 5D 11 290429 F100B F100C ...

Page 2: ...ications and significant changes in specifications and procedures and these are incorporated in successive editions of this manual Important information 1 Particularly important information is distinguished in this manual by the following notations The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED WARNING Failure to follow WARNING instructions could result in severe inju...

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

Page 4: ...ation 1 5 Applicable models 1 5 Serial number 1 5 Features and benefits 1 6 Power unit 1 6 Ignition system 1 11 Bracket unit and the PTT unit 1 13 Cooling system 1 14 Lower unit 1 15 Technical tips 1 16 Carburetor 1 16 Acceleration pump 1 17 Ignition system 1 18 Ignition timing control 1 18 Lubrication system 1 20 Cooling system 1 21 PTT power trim and tilt unit F100B 1 22 PTT power trim and tilt ...

Page 5: ...ing the outboard motor mounting position 1 26 Checking the remote control cables 1 27 Checking the steering system 1 27 Checking the gearshift and throttle operation 1 27 Checking the tilt system 1 28 Checking the engine start switch and engine stop switch engine shut off switch 1 28 Checking the pilot water outlet 1 28 Test run 1 28 Break in 1 29 After test run 1 29 ...

Page 6: ...ightening torque specifications are provided in the exploded diagrams and after a numbered step with tightening instructions 3 Symbols are used to indicate important aspects of a procedure such as the grade of lubricant and lubrication point 4 The components list consist of parts and part quantities as well as bolt screw O ring and hose dimensions 5 Service points regarding removal checking and in...

Page 7: ...ance Voltage Electric current Symbols 7 to A in an exploded diagram indicate the grade of lubricant and the lubrication point 7 Apply Yamaha 4 stroke motor oil 8 Apply water resistant grease Yamaha grease A 9 Apply molybdenum disulfide grease 0 Apply corrosion resistant grease Yamaha grease D A Apply low temperature resistant grease Yamaha grease C Symbols B to G in an exploded diagram indicate th...

Page 8: ...sing 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 s...

Page 9: ...r 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 indi cated in the in...

Page 10: ...tamped on a label attached to the port clamp bracket È F100B É F100C 1 Model name 2 Approved model code 3 Transom height 4 Serial number NOTE If the serial number label is removed VOID marks will appear on the label Applicable models F100BET F100CET S60C1090 Model name Approved model code Starting serial No F100BET 60C L 000101 X 200101 F100CET 60D L 000101 X 200101 ...

Page 11: ...tly superior model with a high fuel economy Blowby gas which is discharged from the engine is returned to the intake silencer and reburned to purify the exhaust gas The intake passage and exhaust passage have been arranged around the engine to make the entire engine compact When compared to a small 2 stroke V4 engine it is compact like an in line three cylinder engine 1 Silencer 2 Carburetor È Int...

Page 12: ...ng heat treated the single unit is struck and the connecting rod and end cap are split apart as shown in the illustration To increase accuracy during installation the connecting rod and end cap that were processed together are always installed as a set The hollow volume at the top of the pistons has been made larger and the compression ration has been lowered to increase reliability and durability...

Page 13: ...pecified angle they are contracted to a more accurate torque making periodic maintenance checks and adjustments to as well as addi tional tightening of the bolt unnecessary The cylinder head bolts connecting rod bolts and crankcase bolts have adopted this method to help better control torque accuracy 1 Specified torque 2 Specified angle 3 Connecting rod bolt 4 Cylinder head bolt 5 Crankcase journa...

Page 14: ...s been retained A water separation fuel filter has been adopted When water is mixed with fuel it is separated and precipitated at the bottom of the filter to prevent it from flowing to the carburetors As water gathers in the fuel cup the red float inside the cup begins to rise indicating that the accumulation of water is taking place After water has gathered in the fuel cup the fuel filter can be ...

Page 15: ...engine switch is turned to ON all LED on the display will illuminate for two seconds and then the hours of operation will be displayed A signal from the Rectifier Regulator via the green and white G W lead is sent to the hour meter as the hours of operation accumulation The hours of operation cannot be deleted 1 Hour meter 2 Grand B 3 Battery Y 4 Engine start switch 5 Starter motor 6 Fuse 7 Rectif...

Page 16: ...ture i e water temperature is too high or when the oil pressure switch detects that the oil pressure is too low or when the engine idle speed is too high In addition when the engine overheats or when there is low oil pressure the warning lamp flashes and the buzzer sounds If the throttle position sensor and engine temperature sensor malfunction the engine ignition timing is set by the CDI unit to ...

Page 17: ...e on the side of the exhaust guide È Exhaust gas flow at low speeds É Exhaust gas flow at high speeds An identification mark has been stamped on the exhaust manifold and exhaust chamber 1 Identification mark C 2 Exhaust manifold 3 Exhaust chamber 4 Identification mark D S60C1330 Features and benefits ...

Page 18: ...s PTT unit has been constructed to feature a single tilt cylinder and two trim cylinders The PTT unit of the F100C has been adopted from the proven F100A This PTT unit consists of a single cylinder for both tilt and trim functions making the unit compact and lightweight Oil pump The oil pump has been installed directly above the oil pan and to the exhaust guide In addition the oil pump is operated...

Page 19: ...the cooling water flows through a bypass passage to the upper case An additional water inlet located in front of the trim tab allows cooling water to flow into the exhaust passage in the lower unit during high speed operation This extra cooling water properly cools the high temperature exhaust gas before it exits through the propeller boss helping to prevent the rub ber parts in the propeller boss...

Page 20: ...lt the time necessary between part changes or maintenance has been extended 1 Blue identification paint Lower unit The lower unit of the F100C does not contain a reverse gear shim Therefore it is not necessary to set the position of a shim for the reverse gear Gear ratio 1 No reverse gear shim 2 Reverse gear shim F100B F100C 58ø 89ø S60C1390 F100A 2 31 30 13 F100B 2 15 28 13 F100C 2 31 30 13 F100C...

Page 21: ... while the engine is being warmed up Once the engine is started a signal is sent from the pulser coil to the CDI and from the CDI to the Prime Start to allow the wax to expand The expanded wax moves the thermo heater plunger in the direction to close the enrichment valve As a result the volume of fuel that passes through the fuel enrichment valve decreases A few min utes after the engine has start...

Page 22: ...he fuel volume in order to adjust the air fuel mixture to a ratio that is necessary for the engine in case the throttle valve is opened suddenly Operation When the throttle is opened suddenly diaphragm via the link that is connected to the throttle lever operates to pressurize the air in the dashpot The pressurized air distributed to the carburetors by passing through the in line one way valve tha...

Page 23: ...kshaft position and engine revolution The throttle position sensor also sends signals to the computer which then determines the throttle position The microcomputer uses these three signals to determine the proper ignition timing Fail safe controls When the engine start switch is turned on both low oil pressure and overheat warning lights will turn on After the engine is started and the engine oper...

Page 24: ...sed The buzzer will then stop and the warning light will turn off Throttle position sensor If the throttle position sensor is faulty the ignition timing will automatically be fixed at 10 BTDC Engine temperature sensor If the engine temperature sensor is faulty the ignition timing will automatically be fixed at 10 BTDC Dual engine control system This control system is used when two outboard motors ...

Page 25: ...l cooling Oil strainer Oil pump with relief valve Oil filter Main gallery Oil pressure switch Low oil pressure warning Filtration of foreign objects Suction pressure feeding of oil Prevention of air suction Filtration of large foreign objects Camshaft journal Intake and exhaust valves Camshaft Pressure fed Splash Return Crankcase Cylinder head S60C1450 Technical tips ...

Page 26: ...Cooling water inlet Oil pan Water pump Flushing device Pilot water outlet Pressure control valve PCV Discharge Trim tab water inlet Exhaust cover Cylinder Cylinder head Thermostat Upper case Propeller boss Discharge water wall Discharge Exhaust pipe S60C1460 ...

Page 27: ...Trim and tilt housing 8 Reservoir 9 Filter screen 0 Shock valve A Passage to reservoir B Free piston check valve C Trim ram D Shock return valve E Passage to upper chamber of trim cylinders F Passage to lower chambers of tilt cylinder and trim cylinders G Passage to upper chamber of tilt cylinder H Thermal valve I Manual valve J Lower chamber check valve K Upper chamber check valve L Upper chamber...

Page 28: ...amber check valve PTT fluid flows easily downward Upper chamber shuttle valve PTT fluid flows easily upward pressure on top causes valve to move down Manual valve Port side clockwise to release Free piston check valve PTT fluid flows easily downward Shock valve PTT fluid flows downward above 16 7 MPa 170 kg cm2 2 420 psi Shock return valve PTT fluid flows easily upward Check valve PTT fluid flows ...

Page 29: ... major components are shown in the illustration below 1 PTT cylinder 2 Free piston 3 Pressure release valves 4 Check valve 5 Tilt piston 6 Trim piston 7 Ram 8 Manual valve 9 Main valve 0 Up flow side A Shuttle piston B Down flow side C Gear pump D Up relief valve E Down relief valve F Reservoir S60C1480 Technical tips ...

Page 30: ...blade or outside of the propeller boss a Propeller diameter in inches b Propeller pitch in inches c Propeller type propeller mark Selection When the engine speed is at the full throttle operating range 5 000 6 000 r min the ideal propeller for the boat is one that pro vides maximum performance in relation to boat speed and fuel consumption Predelivery checks 1 To make the delivery process smooth a...

Page 31: ...apacity electrolyte level and specified gravity of the battery 2 Check that the positive and negative bat tery leads are securely connected Checking the outboard motor mounting position 1 Check the position of the anti cavitation plate 2 Check that the clamp brackets are secured with the clamp bolts S60C1130 S60C1140 S60C1150 Recommended engine oil 4 stroke motor oil API SE SF SG or SH SAE 10W 30 ...

Page 32: ...ment mark c on the bracket CAUTION The shift throttle cable joint must be screwed in a minimum of 8 0 mm 0 31 in d Checking the steering system 1 Check the steering friction for proper adjustment 2 Check that the steering operates smoothly 3 Check that there is no interference with wires or hoses when the outboard motor is steered Checking the gearshift and throttle operation 1 Check that the gear...

Page 33: ...he outboard motor is tilted all the way down Checking the engine start switch and engine stop switch engine shut off switch 1 Check that the engine starts when the engine start switch is turned to START 2 Check that the engine turns off when the engine start switch is turned to OFF 3 Check that the engine turns off when the engine stop switch is pushed or the engine shut off cord is pulled from th...

Page 34: ...n perform the break in operation in the following three stages 1 One hour a at 2 000 r min or at approxi mately half throttle 2 One hour b at 3 000 r min or 3 4 throttle and one minute out of every ten at full throttle 3 Eight hours c at any speed however avoid running at full speed for more than five minutes È Hour After test run 1 Check for water in the gear oil 2 Check for fuel leakage in the c...

Page 35: ...2 3 4 5 6 7 8 9 Specifications General specifications 2 1 Maintenance specifications 2 3 Power unit 2 3 Lower unit 2 6 Electrical 2 7 Dimensions 2 9 Tightening torques 2 14 Specified torques 2 14 General torques 2 16 ...

Page 36: ...ll throttle operating range r min 5 000 6 000 Maximum fuel consumption L US gal lmp gal hr at 6 000 r min 31 0 8 19 6 82 Power unit Type In line 4 stroke DOHC 16 valves Cylinder quantity 4 Displacement cm3 cu in 1 596 97 4 Bore stroke mm in 79 0 81 4 3 11 3 20 Compression ratio 8 90 Carburetor quantity 4 Control system Remote control Tiller handle Starting system Electric Ignition control system M...

Page 37: ...ear oil Gear oil grade API SAE GL 4 90 Gear oil quantity L US qt lmp qt 0 785 0 83 0 69 0 670 0 71 0 59 Bracket Trim angle at 12 degree boat transom Degree 4 16 Tilt up angle Degree 70 Steering angle Degree 30 30 35 35 Drive unit Gearshift positions F N R Gear ratio 2 15 28 13 2 31 30 13 Reduction gear type Spiral bevel gear Clutch type Dog clutch Propeller shaft type Spline Propeller direction re...

Page 38: ...31 Out of round limit mm in 0 08 0 0031 Pistons Piston diameter D mm in 78 93 78 94 3 1075 3 1078 Measuring point H mm in 13 0 5 Piston to cylinder clearance mm in 0 07 0 08 0 0028 0 0031 Oversize piston 1st mm in 0 25 0 0098 Oversize piston diameter mm in 79 18 79 19 3 1173 3 1177 Piston pins Outside diameter mm in 17 997 18 000 0 7085 0 7087 Piston rings Top ring Dimension B mm in 1 17 1 19 0 04...

Page 39: ...ximum camshaft runout mm in 0 1 0 004 Valves Valve clearance cold Intake mm in 0 20 0 03 0 008 0 001 Exhaust mm in 0 34 0 03 0 013 0 001 Head diameter A Intake mm in 29 0 29 2 1 142 1 150 Exhaust mm in 24 0 24 2 0 945 0 953 Face width B Intake mm in 2 00 2 43 0 0787 0 0957 Exhaust mm in 2 28 2 71 0 0898 0 1067 Seat contact width C Intake mm in 1 2 1 6 0 047 0 063 Exhaust mm in 1 2 1 6 0 047 0 063 ...

Page 40: ...eter mm in 47 984 48 000 1 8892 1 8897 Crank pin Diameter mm in 43 982 44 000 1 7315 1 7322 Runout limit mm in 0 03 0 0012 Crankcase Crankshaft main journal oil clearance mm in 0 024 0 044 0 0010 0 0017 Upper crankcase main journal bearing thickness Green mm in 2 992 2 999 0 1178 0 1181 Blue mm in 2 999 3 006 0 1181 0 1183 Red mm in 3 006 3 013 0 1183 0 1186 Lower crankcase main journal bearing th...

Page 41: ...or ID mark 60C00 Main jet 128 Main air jet 75 Pilot jet 42 Pilot air jet 85 Midrange jet 40 Pilot screw turns out 1 1 2 2 1 2 Float height mm in 12 5 15 5 0 49 0 61 Engine idle speed r min 800 900 Item Unit Model F100BET F100CET Gear backlash Pinion to forward gear mm in 0 19 0 53 0 007 0 021 0 13 0 47 0 005 0 019 Pinion to reverse gear mm in 0 86 1 26 0 034 0 050 Pinion shims mm 0 10 0 12 0 15 0 ...

Page 42: ...25 at 3 500 r min V 126 Spark plug gap mm in 11 0 4 Ignition control system Oil pressure switch kPa kgf cm2 psi 150 1 5 21 3 Thermo sensor resistance at 20 C 68 F kΩ 2 54 at 40 C 104 F kΩ 1 15 at 60 C 140 F kΩ 0 59 at 80 C 176 F kΩ 0 32 Starter motor Type Sliding gear Output kW 1 4 Cranking time limit Second 30 Brushes Standard length mm in 15 5 0 61 Wear limit mm in 9 5 0 37 Commutator Standard d...

Page 43: ... current V A at 6 000 r min 12 20 Enrichment control system Prime Start Plunger minimum length a mm in 15 0 0 59 Power trim and tilt system Trim sensor Setting resistance Ω 9 11 Resistance P B Ω 9 378 8 Fluid type ATF Dexron II Brushes Standard length mm in 9 8 0 39 Wear limit mm in 4 8 0 19 Commutator Standard diameter mm in 22 0 87 Wear limit mm in 21 0 83 Mica Standard undercut mm in 1 35 0 05 ...

Page 44: ...SPEC Specifications 2 9 60C5D11 Dimensions Exterior S60C2150 L7 L6 L1 L4 A3 L9 L5 C3 L2 H7 H10 H8 W5 W1 A1 H4 H1 H11 H9 H2 H3 H6 A2 T1 L10 L8 B6 ...

Page 45: ... 1 1 L10 mm in 75 3 0 62 2 4 H1 L mm in 929 36 6 917 36 1 X mm in 1 056 41 6 1 040 40 9 H2 mm in 667 26 3 666 26 2 H3 mm in 191 7 5 H4 L mm in 516 20 3 537 21 1 X mm in 643 25 3 664 26 1 H5 mm in H6 L mm in 776 30 6 767 30 2 X mm in 854 33 6 844 33 2 H7 mm in 388 15 3 366 14 4 H8 mm in 14 0 6 27 1 1 H9 mm in 877 34 5 856 33 7 H10 mm in 44 1 7 48 1 9 H11 mm in 25 1 0 24 0 9 W1 mm in 243 9 6 240 9 4...

Page 46: ...SPEC Specifications 2 11 60C5D11 Exterior Tiller handle model H9 H5 H2 H7 H10 H8 H4 H3 L8 L9 L4 A3 A2 H6 L5 C3 B6 H1 H11 L7 L6 L1 L2 L10 W6 W2 L3 A1 W5 W1 S60C2160 ...

Page 47: ...10 mm in 75 3 0 62 2 4 H1 L mm in 929 36 6 917 36 1 X mm in 1 056 41 6 1 040 40 9 H2 mm in 667 26 3 666 26 2 H3 mm in 191 7 5 H4 L mm in 516 20 3 537 21 1 X mm in 643 25 3 664 26 1 H5 mm in 748 29 4 743 2 29 3 H6 L mm in 776 30 6 767 30 2 X mm in 854 33 6 844 33 2 H7 mm in 388 15 3 366 14 4 H8 mm in 105 4 1 76 3 3 0 H9 mm in 877 34 5 856 33 7 H10 mm in 44 1 7 48 1 9 H11 mm in 25 1 0 24 0 9 W1 mm i...

Page 48: ...mbol Unit Model F100BET F100CET 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 mm in 367 14 4 347 13 7 B7 mm in B8 mm in B9 mm in 18 5 0 7 C2 mm in C3 mm in 82 3 2 80 3 1 D1 mm in 13 0 5 D2 mm in 55 5 2 2 ...

Page 49: ...0 2 1 4 Ignition coil bolt M6 8 0 8 5 8 Ground lead bolt M6 8 0 8 5 8 Oil pressure switch 8 0 8 5 8 Oil pressure switch lead bolt M4 2 0 2 1 4 Cylinder head cover bolt M6 8 0 8 5 8 Breather cover screw M4 2 0 2 1 4 Fuel pump bracket bolt M7 17 1 7 12 Camshaft cap bolt 1st M7 8 0 8 5 8 2nd 17 1 7 12 Spark plug 25 2 5 18 Cylinder head bolt 1st M8 14 1 4 10 2nd 28 2 8 20 1st M10 15 1 5 11 2nd 30 3 0 ...

Page 50: ... 6 Bracket unit Tiller handle assembly nut 37 3 7 27 Engine shut off switch nut 4 0 4 2 9 Engine start switch nut 4 0 4 2 9 Tiller handle bracket bolt M10 37 3 7 27 Oil pump assembly bolt M6 11 1 1 8 0 Oil pump cover screw M6 4 0 4 2 9 Upper mount nut 53 5 3 38 Lower mount nut F100B 73 7 3 53 F100C 53 5 3 38 Upper mount bolt M8 26 2 6 19 Muffler assembly bolt M8 20 2 0 14 Baffle plate screw M6 4 0...

Page 51: ...5 1 PTT motor bolt M6 5 0 5 3 6 Manual valve 3 0 3 2 2 Gear pump assembly bolt M8 9 0 9 6 5 Gear pump bolt M5 6 0 6 4 3 Tilt cylinder end screw 130 13 94 Tilt piston nut 100 10 72 Trim cylinder end screw 80 8 0 58 Power trim and tilt unit F100C Tilt cylinder end screw 90 9 0 65 Reservoir cap 7 0 7 5 1 Pump housing assembly 9 0 9 6 5 Trim cylinder end screw 80 8 0 58 Tilt piston bolt M12 85 8 5 61 ...

Page 52: ...SPEC Specifications 2 17 60C5D11 MEMO ...

Page 53: ...g the valve clearance 3 7 Checking the spark plugs 3 7 Checking the thermostat 3 8 Checking the cooling water passage 3 8 Control system 3 9 Checking the throttle cable operation 3 9 Checking the gearshift operation 3 10 Checking the engine idle speed 3 10 Checking the ignition timing 3 11 Power trim and tilt unit 3 12 Checking the power trim and tilt operation 3 12 Checking the power trim and til...

Page 54: ...CHK ADJ Periodic checks and adjustments 3 1 60C5D11 Special service tools 3 Oil filter wrench 90890 01426 Digital tachometer 90890 06760 Timing light 90890 03141 Leakage tester 90890 06762 ...

Page 55: ... 3 4 Fuel tank 1 Clean Power unit Ignition timing Check 3 11 Engine oil Check change 3 5 Oil filter Change 3 5 Oil pump Check 7 17 7 59 Timing belt 2 Check replace 3 7 Valve clearance Check adjust 5 6 Spark plugs Clean adjust replace 3 7 Piston rings Check replace 5 41 Thermostat Check 3 8 Pressure control valve Check Oil leakage Check replace Flywheel magnet nut Check Carburetor 3 Check Motor ext...

Page 56: ...case bolts Lower unit Gear oil Change 3 13 Impeller Woodruff key Check replace 6 8 6 36 Oil seals Check replace Drive shaft Check replace 6 18 6 46 Propeller Check 3 14 General Anodes Trim tab Check replace 3 14 Battery Check charge 3 15 Wiring and connectors Adjust reconnect Nuts and bolts 5 Tighten Lubrication points Lubricate 3 16 Rubber seals Replace Bearings Check replace Exhaust system deter...

Page 57: ...re displayed after the entire LED 1 has been illuminated for two seconds Replace if LED does not illuminate Fuel system 3 Checking the fuel joint and fuel hoses fuel joint to carburetor 1 Remove the plate 1 and then check the fuel hose connections and fuel joint 2 for leaks Replace if necessary Also check the fuel filter 3 fuel pump 4 and carbu retor 5 for leaks and the fuel hoses for leaks and de...

Page 58: ...ck the oil level and the oil for discoloration and its viscosity NOTE Change the oil if it appears milky or black If the engine oil is above the maximum level mark a drain sufficient oil until the level is between a and b If the engine oil is below the minimum level mark b add sufficient oil until the level is between a and b Changing the engine oil 1 Remove the engine oil dipstick and oil filler ...

Page 59: ...sure to clean up any oil spills 4 Apply a thin coat of engine oil to the O ring of the new oil filter 5 Install the oil filter and then tighten it to the specified torque 6 Install the drain bolt and then tighten it to the specified torque Oil filter wrench 90890 01426 S60C3080 Oil filter wrench 90890 01426 T R Oil filter 18 N m 1 8 kgf m 13 ft lb T R Drain bolt 28 N m 2 8 kgf m 20 ft lb S60C3090 ...

Page 60: ...ment procedures see Chapter 5 Removing the timing belt and sprockets Checking the valve clearance NOTE For checking procedures see Chapter 5 Checking the valve clearance Checking the spark plugs 1 Remove the cover 2 Disconnect the high tension cords and then remove the spark plugs 3 Clean the electrodes 1 with a spark plug cleaner or wire brush Replace the spark plug if necessary 4 Check the elect...

Page 61: ...lowly heat the water 5 Check the thermostat valve opening at the specified water temperatures Replace if out of specification 6 Install the thermostat new gasket ther mostat cover and then connect the cool ing water hose 7 Install the flywheel magnet cover Checking the cooling water passage 1 Check the cooling water inlet cover 1 and cooling water inlet 2 for clogs Clean if necessary T R Spark plu...

Page 62: ...the throttle control lever 1 touches the fully closed stopper a when the remote control lever is in neutral or the throttle grip is fully closed Adjust the throttle cable length if necessary as fol lows 2 Loosen the locknut 2 remove the clip 3 and then disconnect the throttle cable joint 4 3 Contact the throttle control lever 1 with the fully closed stopper a 4 Adjust the position of the throttle ...

Page 63: ...t 3 4 Align the set pin a in the center of the shift bracket and with the alignment mark b on the bracket 5 Adjust the position of the shift cable joint until its hole is aligned with the set pin CAUTION The shift cable joint must be screwed in a minimum of 8 0 mm 0 31 in c 6 Connect the cable joint install the clip and then tighten the locknut 7 Check the gearshift for smooth operation and adjust...

Page 64: ...s to check the stability of the engine Checking the ignition timing 1 Start the engine and warm it up for 5 min utes 2 Attach the special service tool to high tension cord 1 and then check the engine idle speed 3 Attach the special service tool to high tension cord 1 1 4 Check that the ignition timing mark 5 a on the flywheel magnet is aligned with the pointer b Check the ignition system and ignit...

Page 65: ...el 1 Fully tilt the outboard motor up and then support it with the tilt stop lever 1 È F100B É F100C WARNING After tilting up the outboard motor be sure to support it with the tilt stop lever Otherwise the outboard motor could sud denly lower if the power trim and tilt unit should lose fluid pressure 2 Remove the reservoir cap 2 and then check the fluid level in the reservoir È F100B É F100C NOTE ...

Page 66: ...of the check hole 4 Install the check screw and then tighten it to the specified torque Changing the gear oil 1 Tilt the outboard motor up slightly 2 Place a drain pan under the drain screw 1 remove the drain screw then the check screw 2 to drain the oil 3 Check the oil for metal discoloration and its viscosity Check the internal parts of the lower case if necessary 4 Insert the gear oil tube or g...

Page 67: ...ssure drops below specification check the drive shaft and propeller shaft oil seals for damage Checking the propeller 1 Check the propeller blades and splines for cracks damage or wear Replace if necessary General 3 Checking the anodes 1 Check the anodes and trim tab for scales grease or oil Clean if necessary Recommended gear oil Hypoid gear oil SAE 90 Oil quantity F100B 0 785 L 0 83 US qt 0 69 I...

Page 68: ...and trim tab if excessively eroded Checking the battery 1 Check the battery electrolyte level If the level is at or below the minimum level mark a add distilled water until the level is between the maximum and minimum level marks 2 Check the specific gravity of the electro lyte Fully charge the battery if out of specification S60C3610 S60C3620 S60C3630 S60C3640 S60C3650 ...

Page 69: ...e 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 when charging or han dling batteries KEEP BATTERIES AND ELECTROLYTE OUT OF REACH OF CHILDREN NOTE Batteries vary per manufacturer ...

Page 70: ... checks and adjustments 3 17 60C5D11 È F100B É F100C NOTE Apply grease to the grease nipple until it flows from the bushings a 2 Apply corrosion resistant grease to the areas shown S60C3695 A A S60C3700 A S60C3710 A A ...

Page 71: ... fuel pump 4 8 Checking the diaphragm and valves 4 8 Assembling the fuel pump 4 8 Throttle control 4 9 Carburetor 4 13 Checking the check valve 4 15 Checking the fuel filters 4 15 Checking the carburetor 4 15 Checking the Prime Start 4 16 Assembling the carburetor 4 17 Adjusting the throttle link rod 4 17 Adjusting the throttle position sensor 4 18 Adjusting the pilot screw 4 19 Synchronizing the ...

Page 72: ...set 90890 06756 Digital tachometer 90890 06760 Vacuum gauge 90890 03159 Test harness 3 pins 90890 06757 Digital circuit tester 90890 03174 Vacuum gauge digital commercially obtainable Vacuum gauge 4 analog meters commercially obtainable Vacuum gauge adaptor commercially obtainable ...

Page 73: ...uel hose fuel pump to carburetor 3 Fuel hose fuel filter to fuel pump 4 Fuel hose fuel joint to fuel filter 5 Fuel hose carburetor to carburetor 6 Hose acceleration pump to carburetor 7 Hose carburetor to carburetor 8 Cooling water hose 9 Pilot water hose S60C4010 Special service tools Hose routing ...

Page 74: ...EL Fuel system 4 3 60C5D11 Fuel line and fuel filter 4 S60C4030 8 8 11 10 9 7 7 14 15 7 7 13 8 7 7 13 11 10 9 16 12 26 27 25 24 23 29 28 15 2 19 20 17 1 15 18 21 22 3 4 5 6 T R 10 N m 1 0 kgf m 7 2 ft Ib ...

Page 75: ...el joint to fuel joint 14 Fuel hose 1 Fuel pump to fuel joint 15 Plastic tie 2 Not reusable 16 O ring 1 Not reusable 17 Bolt 2 M6 30 mm 18 Fuel hose 1 Fuel pump to fuel filter 12 5 300 mm 19 Plastic tie 2 Not reusable 20 Bolt 1 M6 16 mm 21 Bracket 1 22 Nut 1 23 Fuel hose 1 Fuel filter to fuel joint 12 5 950 mm 24 Plate 1 25 Bolt 1 M6 25 mm 26 Bolt 2 M6 25 mm 27 Grommet retaining plate 1 28 Plastic...

Page 76: ...FUEL Fuel system 4 5 60C5D11 Fuel pump 4 S60C4040 1 2 15 11 12 3 12 11 13 14 10 9 13 14 8 7 4 6 5 T R 4 N m 0 4 kgf m 2 9 ft Ib ...

Page 77: ...art name Q ty Remarks 1 Screw 3 M6 35 mm 2 Cover 1 3 Fuel pump body 2 1 4 Fuel pump body 1 1 5 Plunger 1 6 Spring 1 7 Nut 3 8 Spring 1 9 Pin 1 10 Diaphragm 1 11 Nut 2 12 Spring 2 13 Valve 2 14 Screw 2 15 Gasket 1 Not reusable Fuel pump ...

Page 78: ...over pressurize the fuel pump oth erwise excessive pressure may cause air leakage NOTE Make sure that air does not escape from the opposite side of the fuel pump To eliminate any gaps between the fuel pump valves and the fuel pump body 2 and to ensure a better seal make sure that the inside of the fuel pump is moist with gaso line Vacuum pressure pump gauge set 90890 06756 S60C4050 Fuel pump press...

Page 79: ... and then remove them Checking the diaphragm and valves 1 Check the diaphragm 1 for tears and the valves 2 for cracks Replace if neces sary Assembling the fuel pump 1 Align the plunger and diaphragm installa tion holes a and then install the plunger into the diaphragm 2 Push down on the plunger and the dia phragm and then install the pin 1 3 Turn the fuel pump body 1 2 approxi mately 90 and then p...

Page 80: ...FUEL Fuel system 4 9 60C5D11 Throttle control 4 S60C4120 7 8 1 12 11 10 9 21 20 13 14 1516 17 4 19 18 5 6 22 3 23 2 ...

Page 81: ...nsor 1 4 Bracket 1 5 Throttle control lever 1 6 Bracket 1 7 Washer 1 8 Spring 1 9 Washer 1 10 Wave washer 1 11 Collar 1 12 Bolt 1 M6 35 mm 13 Bolt 1 M6 12 mm 14 Washer 1 15 Wave washer 1 16 Washer 1 17 Collar 1 18 Bolt 2 M6 25 mm 19 Collar 1 20 Pin 1 21 Spacer 1 22 Screw 2 M5 25 mm 23 Screw 2 M5 10 mm Throttle control ...

Page 82: ...FUEL Fuel system 4 11 60C5D11 5 8 6 1 9 7 14 10 15 1617 24 4 11 12 3 1920 20 22 23 21 2 13 18 S60C4130 25 26 27 25 23 25 28 22 25 21 25 21 ...

Page 83: ...e 13 Fuel hose 2 Carburetor to carburetor 14 Link lever 1 15 O ring 4 Not reusable 16 Spacer 4 17 O ring 4 Not reusable 2 4 44 5 mm 18 Bolt 5 M8 35 mm 19 Fuel filter 4 20 Clip 8 21 Fuel hose 2 Carburetor to fuel pump 10 120 mm 22 Fuel hose 1 Carburetor to fuel pump 10 180 mm 23 Fuel hose 1 Carburetor to fuel pump 10 350 mm 24 Screw 2 M6 15 mm 25 Hose 7 Carburetor to carburetor 26 Hose 1 Carburetor...

Page 84: ...FUEL Fuel system 4 13 60C5D11 Carburetor 4 7 5 6 1 1 1 2 3 4 29 26 25 22 24 23 16 17 15 21 20 19 18 11 13 10 9 8 27 28 12 14 14 S60C4140 ...

Page 85: ... Pilot screw 1 8 Prime Start 1 9 Screw 1 M4 10 mm 10 Bracket 1 11 O ring 1 Not reusable 12 Body 1 13 Screw 3 M5 16 mm 14 O ring 4 Not reusable 15 O ring 1 Not reusable 16 Valve seat 1 17 Needle valve 1 18 Pilot jet 1 19 Plug 1 20 Main nozzle 1 21 Main jet 1 22 Screw 1 M4 8 mm 23 Float 1 24 Float pin 1 25 Gasket 1 Not reusable 26 Float chamber 1 27 O ring 1 Not reusable 28 Drain screw 1 29 Screw 4 ...

Page 86: ...assages 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 CAUTION Direct the compressed air downward otherwise cleaning solvent may be blown into your eyes or small parts of the carburetor may be blown off Do not use steel wire for cleaning the jets otherwise the jet diameters may be enlarge...

Page 87: ...eedle valve 5 but not compressing it Take measurements at the end of the float opposite its pivoted side Checking the Prime Start 1 Measure the length of the Prime Start plunger 2 Connect the positive Prime Start blue L lead and the negative Prime Start black B lead to a battery as shown 3 Measure the plunger length a after applying power for 5 minutes Replace if out of specification S60C4190 S60C...

Page 88: ...ure tor body and lock it with the screw 3 Install the pilot screw 0 turn it in until it is lightly seated then out the specified number of turns Adjusting the throttle link rod 1 Set the throttle control lever to the fully closed position 2 Check that the mark a on the throttle cam aligns with the center of the link lever b as shown 3 Contact the throttle control lever 1 with the fully closed stop...

Page 89: ... the center of the link lever b NOTE Make sure that there is no interference between the throttle control lever 1 and the throttle position sensor lead 7 Adjusting the throttle position sensor 1 Connect the test harness 3 pins and digital circuit tester 2 Start the engine and warm it up for 5 min utes to check the stability of the engine 3 Contact the throttle control lever 1 with the fully closed...

Page 90: ...in direction b 3 4 turn 4 Turn the throttle stop screw 3 in direc tion c or d until the specified engine idle speed is obtained NOTE To increase the idle speed turn the throttle stop screw in direction c To decrease the idle speed turn the throttle stop screw in direction d 5 After adjusting the idle speed rev the engine a few times and let it idle for at least 15 seconds to check the stability of...

Page 91: ... to 1 000 r min by turning the throttle stop screw 5 on car buretor 4 in direction a or b NOTE To increase idle speed turn the throttle stop screw in direction a To decrease idle speed turn the throttle stop screw in direction b 5 Measure the vacuum pressure of carbu retor 4 Digital tachometer 90890 06760 Vacuum gauge 90890 03159 S60C4290 1 2 3 4 S60C4320 Vacuum gauge digital commercially obtainab...

Page 92: ...carburetor 4 7 Adjust the engine idle speed to specifica tion 8 After adjusting the idle speed rev the engine a few times and let it idle for at least 15 seconds to check that the vac uum pressure of carburetors 1 2 and 3 stays within 50 mmHg 67 mbar 1 97 inHg of carburetor 4 and to check the stability of the engine Engine idle speed 800 900 r min 1 2 3 4 S60C4350 ...

Page 93: ...eat 5 28 Refacing the valve seat 5 29 Checking the camshaft 5 31 Checking the cylinder head 5 32 Installing the valves 5 33 Installing the cylinder head 5 34 Cylinder body 5 36 Removing and installing the oil filter 5 39 Disassembling the cylinder body 5 39 Checking the piston diameter 5 40 Checking the cylinder bore 5 40 Checking the piston clearance 5 41 Checking the piston rings 5 41 Checking t...

Page 94: ...adaptor 90890 06563 Flywheel holder 90890 06522 Flywheel puller 90890 06521 Crankshaft holder 20 90890 06552 Valve spring compressor 90890 04019 Valve spring compressor attachment 90890 06320 Valve guide remover installer 90890 04064 Valve guide reamer 90890 04066 Valve seat cutter holder 90890 06553 ...

Page 95: ... 2 1 2 3 4 5 6 7 8 9 Valve seat cutter 90890 06315 90890 06324 90890 06326 90890 06328 90890 06555 Crank stand alignment 90890 03107 Oil filter wrench 90890 01426 Piston slider 90890 06530 Special service tools ...

Page 96: ...ower unit 5 3 60C5D11 Power unit 5 S60C5010 2 3 5 1 4 14 17 21 13 15 20 19 18 16 18 19 7 8 9 12 11 10 6 E T R 186 N m 18 6 kgf m 135 ft lb T R 9 N m 0 9 kgf m 6 5 ft Ib 25 26 27 28 29 30 31 23 32 33 34 24 22 ...

Page 97: ...Pilot water hose 1 10 330 mm 13 Bolt 1 M8 16 mm 14 Negative battery lead 1 15 Nut 1 16 Washer 1 17 Positive battery lead 1 18 PTT motor lead 2 19 Washer 2 20 Nut 2 21 Wiring harness 1 22 Throttle cable 1 23 Shift cable 1 24 Fuel hose 1 Fuel filter to fuel joint 12 5 950 mm 25 Bolt 2 M6 25 mm 26 Retaining plate 1 27 Bolt 1 M6 20 mm 28 Plate 1 29 Grommet 1 30 Bolt 1 M6 20 mm 31 Clamp 1 32 Clip 2 33 ...

Page 98: ...s 1 Power unit 1 2 Gasket 1 3 Dowel pin 2 4 Bolt 5 M6 16 mm 5 Nut 2 6 Apron 1 7 Bolt 2 M8 35 mm 8 Bolt 2 M6 40 mm 9 Bolt 6 M10 130 mm S60C5030 1 2 3 5 6 4 9 8 7 LT 572 572 LT 572 572 3 7 9 3 9 9 T R 42 N m 4 2 kgf m 30 ft Ib T R 4 N m 0 4 kgf m 2 9 ft Ib ...

Page 99: ...on the driven sprockets are aligned CAUTION Do not turn the flywheel magnet counter clockwise otherwise the valve system may be damaged 3 Loosen the tensioner bolt 5 and then remove the timing belt 6 driven sprock ets 7 and cylinder head cover 8 4 Install the driven sprockets 7 and timing belt 6 and then tighten the tensioner bolt 5 5 Check the intake valve clearance for cyl inders 1 and 2 and the...

Page 100: ...eck the valve clearance when the engine is cold Note the measurement 8 Adjust the valve clearance if out of speci fication Loosen the tensioner bolt 5 and then remove the timing belt 6 driven sprockets 7 camshaft caps 9 and camshafts 0 NOTE Do not mix the valve train parts Keep them organized in their proper groups 9 Remove the valve pad A from the valve lifter B using a thin screwdriver S60C3250 ...

Page 101: ...y wheel magnet is aligned with the pointer b and that marks c and d on the driven sprockets are aligned Adjust if necessary CAUTION Do not turn the flywheel magnet coun terclockwise otherwise the valve sys tem may be damaged Do not remove the ignition timing pointer 17 Install the timing belt and then tighten the tensioner bolt finger tight 18 Turn the flywheel magnet clockwise two turns and then ...

Page 102: ... engine oil to the cylin der and then check the pressure again NOTE If the compression pressure increases check the piston and piston rings for wear Replace if necessary If the compression pressure does not increase check the valve clearance valve valve seat cylinder sleeve cylinder head gasket and cylinder head Adjust or replace if necessary Checking the oil pressure 1 Start the engine warm it up...

Page 103: ...ge to the engine or tools screw in the flywheel puller set bolts evenly and completely so that the flywheel puller plate is parallel to the fly wheel magnet NOTE Apply force to the crankshaft end until the fly wheel magnet comes off the tapered portion of the crankshaft 2 Remove the retaining plate 1 and clamp 2 and then disconnect the throttle cable 3 and shift cable 4 Remove the grom met 5 and d...

Page 104: ...onnect the pilot water hose 7 and remove the engine oil dipstick 8 and cover 9 4 Disconnect the battery leads 0 wiring harness A and PTT motor leads B 5 Remove the apron C and power unit by removing the bolts D S60C5100 S60C5110 S60C5120 ...

Page 105: ...ing coil base 1 6 Dowel pin 1 7 Cover 1 8 Screw 2 9 Screw 3 M6 20 mm 10 Neutral switch 1 Tiller handle model 11 Plate 1 Tiller handle model 12 Bracket 1 Tiller handle model 13 Bolt 2 M6 14 mm Tiller handle model 14 Hour meter 1 S60C5130 1 2 3 4 7 9 5 6 13 11 12 8 14 T R 2 N m 0 2 kgf m 1 4 ft Ib T R 4 N m 0 4 kgf m 2 9 ft Ib 10 Power unit Timing belt and sprockets ...

Page 106: ...18 29 28 31 26 27 22 15 20 16 30 23 21 24 25 17 T R 265 N m 26 5 kgf m 192 ft lb E E E T R 39 N m 3 9 kgf m 28 ft Ib T R 60 N m 6 0 kgf m 43 ft Ib 8 11 12 12 7 6 1 4 B R 4 5 3 10 9 2 9 13 14 3 B W T R 8 N m 0 8 kgf m 5 8 ft Ib T R 8 N m 0 8 kgf m 5 8 ft Ib ...

Page 107: ... Ground lead 3 10 Ignition coil lead 2 11 Bolt 4 M6 30 mm 12 Spark plug cap 4 13 Screw 5 14 Cover 1 15 Timing belt 1 16 Drive sprocket 1 17 Driven sprocket 2 18 Clip 1 19 Cooling water hose 1 20 Plastic tie 1 Not reusable 21 Bolt 2 M6 16 mm 22 Bracket 1 23 Bolt 2 M10 35 mm 24 Washer 2 25 Pin 2 26 Spring 1 27 Bolt 1 M10 45 mm 28 Tensioner 1 29 Nut 1 30 Retaining plate 1 31 Woodruff key 1 Timing bel...

Page 108: ...POWR Power unit 5 15 60C5D11 S60C5150 1 2 26 3 13 14 19 21 22 20 6 10 7 8 12 11 9 4 18 17 24 16 15 28 23 5 27 25 24 25 T R 8 N m 0 8 kgf m 5 8 ft Ib T R 2 N m 0 2 kgf m 1 4 ft Ib ...

Page 109: ...sure switch lead 1 10 Bolt 2 M6 12 mm 11 Thermo sensor coupler 1 12 Ground lead 3 13 Starter relay lead 1 14 PTT relay lead 2 15 Bolt 1 M6 12 mm 16 Bolt 1 M6 20 mm 17 Collar 4 18 Grommet 4 19 Bolt 4 M6 28 mm 20 CDI unit coupler 2 21 Bolt 1 M6 20 mm 22 Ground lead 2 23 Hour meter coupler 1 24 Bolt 2 M6 12 mm 25 Hour meter lead 2 26 Bolt 3 M6 16 mm 27 Rectifier Regulator lead 1 28 Bolt 2 M6 25 mm Ti...

Page 110: ...drive sprocket counter clockwise otherwise the valve system may be damaged 2 Loosen the drive sprocket nut 1 NOTE Use a deep socket 2 M46 for this proce dure Do not turn the camshaft when loosening the drive sprocket nut 3 Disconnect the cooling water hose 4 4 Remove the bracket 5 spring 6 ten sioner 7 and timing belt 8 from the driven sprocket side 5 Loosen the driven sprocket bolts 9 and remove ...

Page 111: ...lt for cracks damage or wear Replace if necessary 2 Check the drive sprocket 1 and driven sprockets 2 for cracks damage or wear Replace if necessary Installing the sprockets and timing belt 1 Check that marks a and b on the driven sprockets 1 are aligned and then tighten the bolts 2 2 Install the retaining plate 3 Woodruff key 4 drive sprocket 5 and nut 6 and then tighten the nut Flywheel holder 9...

Page 112: ... or bend the timing belt beyond the maximum limit of 25 mm 1 0 in e otherwise it may be damaged Do not get oil or grease on the timing belt 5 Install the tensioner 8 spring 9 and bolts and then tighten the bolts finger tight 6 Take up the timing belt slack by turning the drive sprocket clockwise at least two full turns CAUTION Do not turn the sprockets counterclock wise otherwise the valve system ...

Page 113: ...ve sprocket nut 6 to the specified torque and then install the breather hose NOTE Use a deep socket A M46 for this proce dure Install the timing belt and then tighten the drive sprocket nut 6 so that the drive sprocket and the driven sprocket do not move out of the TDC position T R Tensioner bolt 0 39 N m 3 9 kgf m 28 ft lb S60C5290 S60C5300 Flywheel holder 90890 06522 T R Driven sprocket bolt 2 6...

Page 114: ...2 3 3 14 4 4 4 5 15 T R 8 N m 0 8 kgf m 5 8 ft Ib LT 271 GM 4 E E E E E E T R 1st 8 N m 0 8 kgf m 5 8 ft lb 2nd 17 N m 1 7 kgf m 12 ft lb T R 2 N m 0 2 kgf m 1 4 ft Ib E T R 1st 8 N m 0 8 kgf m 5 8 ft lb 2nd 17 N m 1 7 kgf m 12 ft lb E M M M T R 17 N m 1 7 kgf m 12 ft Ib GM GM 4 ...

Page 115: ...over 1 2 Camshaft 2 3 Camshaft cap 2 4 Camshaft cap 8 5 Fuel pump bracket 1 6 Oil filler cap 1 7 O ring 1 3 1 30 6 mm 8 Bolt 14 M6 30 mm 9 Gasket 1 Not reusable 10 Breather cover 1 11 Screw 8 M4 8 mm 12 Bolt 4 M7 48 mm 13 Bolt 16 M7 37 mm 14 Oil seal 2 Not reusable 15 Bolt 2 M7 48 mm Cylinder head ...

Page 116: ...13 14 22 20 18 17 19 21 23 24 16 15 12 11 10 2 23 22 21 20 19 18 17 E E E E E E LT 271 A A T R 1st 14 N m 1 4 kgf m 10 ft lb 2nd 28 N m 2 8 kgf m 20 ft lb T R 1st 15 N m 1 5 kgf m 11 ft lb 2nd 30 N m 3 0 kgf m 22 ft lb 3nd 90 T R 25 N m 2 5 kgf m 18 ft Ib ...

Page 117: ...5 Dowel pin 2 6 Bolt 5 M8 55 mm 7 Bolt 2 M6 25 mm 8 Cover 1 9 Thermostat 1 10 Bolt 10 M10 143 mm 11 Spark plug 4 12 Bolt 4 M8 25 mm 13 Bolt 2 M6 20 mm 14 Cover 2 15 Anode 2 16 Grommet 2 17 Valve pad 16 18 Valve lifter 16 19 Valve cotter 32 20 Spring retainer 16 21 Valve spring 16 22 Spring seat 16 23 Stem seal 16 Not reusable 24 Valve guide 16 Not reusable Cylinder head ...

Page 118: ...p bolts in the sequence shown 4 Remove camshaft caps 1 and 2 cam shaft intake 3 camshaft exhaust 4 and fuel pump bracket 5 5 Remove the cylinder head bolts in the sequence shown CAUTION Do not scratch or damage the mating sur faces of the cylinder head and cylinder body NOTE Use a T type TORX socket T55 to remove the cylinder head bolts M10 6 Remove the valve pads 6 and valve lift ers 7 S60C5340 S...

Page 119: ...ecking the valve springs 1 Measure the valve spring free length a Replace if out of specification 2 Measure the valve spring tilt b Replace if out of specification Checking the valves 1 Check the valve face for pitting or wear Replace if necessary 2 Measure the valve margin thickness a Replace if out of specification Valve spring compressor 8 90890 04019 Valve spring compressor attachment 9 90890 ...

Page 120: ...uide inside diameter a 2 Calculate the valve stem to valve guide clearance as follows Replace the valve guide if out of specification Valve margin thickness a Intake 0 8 1 2 mm 0 031 0 047 in Exhaust 1 0 1 4 mm 0 039 0 055 in Valve stem diameter b Intake 5 97 5 99 mm 0 2350 0 2358 in Exhaust 5 96 5 97 mm 0 2347 0 2350 in Valve stem runout Intake 0 01 mm 0 0004 in Exhaust 0 01 mm 0 0004 in Valve gu...

Page 121: ...the valve guide reamer clockwise to ream the valve guide Do not turn the reamer counterclockwise when removing the reamer 4 Measure the valve guide inside diameter Replace the valve guide if out of specifi cation Checking the valve seat 1 Eliminate carbon deposits from the valve with a scraper 2 Apply a thin even layer of Mechanic s blueing dye Dykem onto the valve seat 3 Lap the valve slowly on t...

Page 122: ...ing the valve seat 1 Reface the valve seat with the valve seat cutter 2 Cut the surface of the valve seat with a 45 cutter by turning the cutter clockwise until the valve seat face has become smooth a Slag or rough surface Valve seat contact width a Intake 1 2 1 6 mm 0 047 0 063 in Exhaust 1 2 1 6 mm 0 047 0 063 in Valve seat cutter holder 90890 06553 Valve seat cutter 30 intake 90890 06326 30 exh...

Page 123: ...ontact width of the valve seat to specification b Previous contact width c Specified contact width 6 If the valve seat contact area is too wide and situated in the center of the valve face use a 30 cutter to cut the top edge of the valve seat a 60 cutter to cut the bottom edge to center the area and set its width b Previous contact width 7 If the valve seat contact area is too nar row and situated...

Page 124: ...AUTION Do not get the lapping compound on the valve stem and valve guide 10 After every lapping procedure be sure to clean off any remaining lapping com pound from the cylinder head and the valve 11 Check the valve seat contact area of the valve again Checking the camshaft 1 Measure the cam lobe Replace if out of specification 2 Measure the camshaft runout Replace if out of specification S60C5500 ...

Page 125: ...ifica tion Checking the cylinder head 1 Eliminate carbon deposits from the com bustion chambers and check for deterio ration 2 Check the cylinder head warpage using a straightedge 1 and thickness gauge 2 in five directions as shown Replace if out of specification Camshaft journal diameter c 24 96 24 98 mm 0 9827 0 9834 in Camshaft cap inside diameter d 25 00 25 02 mm 0 9843 0 9850 in e d c 0 02 0 ...

Page 126: ...ttach the special service tool 3 Compress the valve spring and then install the valve cotter 8 using a thin screwdriver with a small amount of grease applied to it 4 Lightly tap the spring retainer with a plas tic hammer to set the valve cotter securely 5 Install the valve pads and valve lifters Valve spring compressor 6 90890 04019 Valve spring compressor attachment 7 90890 06320 S60C5660 E S60C5...

Page 127: ...fore installation Use a T type TORX socket T55 to install the cylinder head bolts M10 2 Install the camshaft intake 1 and cam shaft exhaust 2 with the new oil seals 3 3 Check that the camshaft dowel pin holes a are in the position shown in the illus tration Adjust if necessary T R Cylinder head bolt M10 1st 1 0 15 N m 1 5 kgf m 11 ft lb 2nd A J 30 N m 3 0 kgf m 22 ft lb 3rd P Y 90 Cylinder head bo...

Page 128: ...nce shown NOTE Apply engine oil to the camshaft cap bolts before installation 6 Install the fuel pump bracket 7 Install the cylinder head cover T R Camshaft cap bolt 1st 8 N m 0 8 kgf m 5 8 ft lb 2nd 17 N m 1 7 kgf m 12 ft lb T R Fuel pump bracket 17 N m 1 7 kgf m 12 ft lb T R Cylinder head cover 8 N m 0 8 kgf m 5 8 ft lb S60C5730 5 2 A 1 1 A 7 2 A 2 2 A 3 2 A 4 2 A 5 2 A 8 2 A 9 2 A 10 2 A 6 1 A ...

Page 129: ...Oil ring 4 9 Second ring 4 10 Top ring 4 11 Main bearing 10 12 Oil seal 1 Not reusable 13 Oil seal 1 Not reusable 14 Bolt 4 M6 25 mm 15 Bracket 2 16 Bolt 10 M10 135 mm 17 Bolt 10 M8 55 mm S60C5760 UP E E E E E 16 2 17 11 13 4 7 6 12 3 1 11 11 11 11 E E 14 15 15 14 8 9 10 5 T R 1st 19 N m 1 9 kgf m 14 ft lb 2nd 60 T R 1st 18 N m 1 8 kgf m 13 ft lb 2nd 90 E T R 1st 14 N m 1 4 kgf m 10 ft lb 2nd 28 N...

Page 130: ...37 60C5D11 S60C5750 2 23 18 6 7 8 15 13 12 19 20 22 21 1 5 3 4 16 17 14 10 11 9 E E A A LT 572 T R 1st 6 N m 0 6 kgf m 4 3 ft lb 2nd 12 N m 1 2 kgf m 8 7 ft lb T R 18 N m 1 8 kgf m 13 ft Ib T R 23 N m 2 3 kgf m 17 ft Ib ...

Page 131: ...Bolt 1 5 Gasket 1 Not reusable 6 Gasket 1 Not reusable 7 Thermo sensor 1 8 Retainer 1 9 Bolt 2 M6 16 mm 10 Clamp 1 11 Bolt 1 M6 10 mm 12 Gasket 1 Not reusable 13 Grommet 1 14 Pressure control valve 1 15 Spring 1 16 Cover 1 17 Bolt 3 18 Grommet 1 19 Anode 1 20 Cover 1 21 Bolt 2 M8 25 mm 22 Bolt 1 M6 20 mm 23 Bolt 18 M6 30 mm Cylinder body ...

Page 132: ... engine oil to the O ring of the new oil filter 3 Install the oil filter and then tighten it to the specified torque Disassembling the cylinder body 1 Remove the exhaust cover bolts in the sequence shown 2 Remove the crankcase bolts in the sequence shown Oil filter wrench 90890 01426 Oil filter wrench 90890 01426 S60C5770 S60C5780 E T R Oil filter 18 N m 1 8 kgf m 13 ft lb S60C5800 S60C5810 ...

Page 133: ...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 20 mm 0 8 in b 70 mm 2 8 in c 120 mm 4 7 in 2 Calculate the taper limit Replace or rebore the cylinder body if out of specifi cation 3 Calculate the out of round limit Replace or rebore the cylinder body if out of spec ification Piston diameter a 78 93 78 9...

Page 134: ...heck the piston ring end gap e at the specified measuring point Replace if out of specification Piston clearance 0 07 0 08 mm 0 0028 0 0031 in Piston ring dimensions Top ring a B 1 17 1 19 mm 0 0461 0 0468 in T 2 8 3 0 mm 0 111 0 118 in Second ring b B 1 47 1 49 mm 0 0579 0 0586 in T 3 00 3 20 mm 0 1182 0 1259 in Oil ring c B 2 38 2 48 mm 0 0938 0 0976 in T 2 40 mm 0 0945 in Measuring point d 20 m...

Page 135: ...eter b and crank pin width c Replace the crankshaft if out of specification Piston ring groove Top ring a 1 23 1 25 mm 0 0485 0 0492 in Second ring b 1 52 1 54 mm 0 0599 0 0606 in Oil ring c 2 51 2 53 mm 0 0989 0 0996 in S60C5860 S60C5870 Piston ring side clearance Top ring a 0 04 0 08 mm 0 0016 0 0031 in Second ring b 0 03 0 07 mm 0 0012 0 0027 in Oil ring c 0 03 0 15 mm 0 0012 0 0059 in Cranksha...

Page 136: ...ap 2 CAUTION Install the bearings in their original posi tions 3 Put a piece of Plastigauge PG 1 onto the crank pin parallel to the crankshaft NOTE Be sure not to put the Plastigauge PG 1 over the oil hole in the crank pin of the crank shaft 4 Install the connecting rod to the crank pin 3 NOTE Make sure that the large flat side a on the connecting rod faces towards the flywheel side of the cranksh...

Page 137: ...bolts 6 Remove the connecting rod cap and measure the width of the compressed Plastigauge PG 1 on each crank pin Replace the connecting rod bearing if out of specification Selecting the connecting rod big end bearing 1 When replacing the connecting rod bear ing select the suitable bearing as fol lows 2 Measure the connecting rod big end inside diameter a NOTE Reuse the connecting rod bolts T R Con...

Page 138: ...TION The mark indicates that the color of the upper and lower bearings are different 7 If the measurement value is more than the maximum value 3 063 mm replace the crankshaft connecting rod or both Checking the crankshaft main journal oil clearance 1 Clean the bearings main journals and bearing portions of the crankcase and cylinder body 2 Place the cylinder body upside down on a bench 1 2 3 S60C5...

Page 139: ...he oil hole in the main journals of the crankshaft 5 Install the remaining half of the bearings plain bearings 3 into the crankcase 6 Install the crankcase onto the cylinder body and apply engine oil onto the threads of the crankcase bolts 7 Tighten the crankcase bolts to the speci fied torques in two stages and in the sequence shown NOTE Do not move the crankshaft until the main journal oil clear...

Page 140: ...aring from the table 4 Subtract crankshaft journal diameters 1 5 from cylinder body journal diame ters 1 5 NOTE Cylinder body journal diameters 1 5 and crankshaft journal diameters 1 5 can be determined by the stamped value as described below Crankshaft journal diameter 47 900 stamped value 1 000 Example 1 92 47 992 Cylinder body journal diameter 54 000 stamped value 1 000 Example 1 32 54 032 T R ...

Page 141: ...der body 1 Install the oil ring 1 second ring 2 and top ring 3 to the piston with the T mark a on the piston rings facing upward 2 Offset the piston ring end gaps as shown CAUTION Do not scratch the piston or break the pis ton rings NOTE After installing the piston rings check that they move smoothly 3 Install the upper half of the bearing into the connecting rod 4 and the lower half into the conn...

Page 142: ...oved bear ings 6 into the cylinder body 7 NOTE Install the unified thrust bearing at the posi tion b shown 6 Set the crankshaft 8 and oil seals 9 and 0 into the cylinder body as shown 7 Install the connecting rod cap 5 to the connecting rod and then tighten the new connecting rod bolts A to the specified torques in two stages CAUTION Do not reuse the connecting rod bolts always replace them with n...

Page 143: ...o not get any Gasket Maker on the journal bearings 10 Install the crankcase bolts and then tighten them to the specified torques in two stages and in the sequence shown CAUTION The oil seals must be installed before tightening the crankcase bolts NOTE Apply engine oil to the crankcase bolts before installation T R Connecting rod bolt A 1st 18 N m 1 8 kgf m 13 ft lb 2nd 90 S60C5B40 E GM GM T R Cran...

Page 144: ...all the dowel pins 1 and gasket 2 2 Install the power unit 3 by installing bolts 4 and 5 then tightening them to the specified torque 3 Install the apron 6 4 Connect the battery leads 7 wiring har ness 8 and PTT motor leads 9 T R Exhaust cover bolt 1st 6 N m 0 6 kgf m 4 3 ft lb 2nd 12 N m 1 2 kgf m 8 7 ft lb S60C5B50 T R Mounting bolt 4 5 42 N m 4 2 kgf m 30 ft lb S60C5B60 LT 572 LT 572 S60C5B70 ...

Page 145: ...arshift opera tion 7 Connect the fuel hose D 8 Install the grommet E and retaining plate F 9 Install the Woodruff key G 10 Install the flywheel magnet and flywheel magnet cover CAUTION Apply force in the direction of the arrows shown to prevent the flywheel holder from slipping off easily NOTE Apply engine oil to the flywheel magnet nut before installation S60C5B80 S60C5B90 Flywheel holder 90890 0...

Page 146: ...haft housing 6 17 Disassembling the forward gear 6 17 Disassembling the lower case 6 18 Checking the pinion and forward gear 6 18 Checking the bearings 6 18 Checking the drive shaft 6 18 Checking the lower case 6 19 Assembling the lower case 6 19 Assembling the forward gear 6 19 Assembling the drive shaft housing 6 20 Installing the drive shaft 6 20 Installing the propeller shaft housing 6 21 Inst...

Page 147: ...ve shaft 6 45 Disassembling the forward gear 6 45 Disassembling the lower case 6 46 Checking the pinion and forward gear 6 46 Checking the bearings 6 46 Checking the drive shaft 6 46 Checking the lower case 6 47 Assembling the lower case 6 47 Assembling the forward gear 6 48 Assembling the drive shaft 6 48 Installing the drive shaft 6 48 Installing the propeller shaft housing 6 49 Installing the w...

Page 148: ...02 Stopper guide plate 90890 06501 Center bolt 90890 06504 Bearing separator 90890 06534 Stopper guide stand 90890 06538 Bearing puller 90890 06535 Bearing puller claw 1 90890 06536 Bearing puller claw 2 90890 06537 Needle bearing attachment 90890 06609 90890 06610 90890 06611 90890 06612 90890 06653 Ball bearing attachment 90890 06631 90890 06633 90890 06636 ...

Page 149: ...inner race attachment 90890 06639 90890 06641 90890 06643 90890 06661 90890 06662 Drive shaft holder 5 90890 06519 Pinion nut holder 90890 06505 Socket adapter 2 90890 06507 Bearing outer race puller 90890 06523 Driver rod SL 90890 06602 Bearing outer race attachment 90890 06620 90890 06621 90890 06623 90890 06626 90890 06628 Special service tools ...

Page 150: ... 90890 06606 Pinion height gauge 90890 06702 Digital caliper 90890 06704 Shimming plate 90890 06701 Shift rod push arm 90890 06052 Backlash indicator 90890 06706 Magnet base plate 90890 07003 Dial gauge set 90890 01252 Magnet base 90890 06705 ...

Page 151: ...mmet 1 10 Bolt 1 M10 45 mm 11 Bolt 1 M10 70 mm 12 Spacer 1 13 Propeller 1 14 Washer 1 15 Washer 1 16 Cotter pin 1 Not reusable 17 Propeller nut 1 18 Trim tab 1 S60C6005 1 6 9 10 3 12 16 17 15 14 13 18 7 11 LT LT 572 LT LT 572 M D 5 4 6 5 8 2 A T R 42 N m 4 2 kgf m 30 ft Ib T R 55 N m 5 5 kgf m 40 ft Ib T R 39 N m 3 9 kgf m 28 ft Ib T R 39 N m 3 9 kgf m 28 ft Ib T R 7 N m 0 7 kgf m 5 1 ft Ib Specia...

Page 152: ...LOWR Lower unit 6 5 60C5D11 S60C6025 A A A A 11 12 13 14 15 16 17 18 20 19 21 22 23 24 24 9 10 1 2 3 4 5 6 7 8 LT 572 LT 572 A A ...

Page 153: ... 1 6 Circlip 1 7 Shift rod 1 8 Bolt 3 M6 20 mm 9 Woodruff key 1 10 Bolt 4 M8 45 mm 11 Cover 1 12 Seal 1 13 Water pump housing 1 14 O ring 1 Not reusable 2 5 42 mm 15 Insert cartridge 1 16 O ring 1 Not reusable 2 5 91 5 mm 17 Collar 1 18 Spacer 1 19 Washer 2 20 Wave washer 1 21 Impeller 1 22 Outer plate cartridge 1 23 Gasket 1 Not reusable 24 Dowel pin 2 Lower unit F100B ...

Page 154: ... hold the propeller with your hands when loosening or tightening it Be sure to remove the battery leads from the bat teries and the engine shut off switch Put a block of wood between the anti cavita tion plate and propeller to keep the pro peller from turning 3 Disconnect the speedometer hose 1 4 Mark the trim tab 2 at the area shown and then remove it 5 Loosen the bolts and then remove the lower ...

Page 155: ...rod 1 Check the pump housing for deforma tion Replace if necessary 2 Check the impeller 1 and insert car tridge 2 for cracks or wear Replace if necessary 3 Check the Woodruff key 3 and the groove a on the drive shaft for wear Replace if necessary 4 Check the shift rod for cracks or wear Replace if necessary S60C6035 S60C6040 S60C6045 S60C6050 Lower unit F100B ...

Page 156: ...R Lower unit 6 9 60C5D11 Propeller shaft housing F100B 6 S60C6085 24 E A A 23 21 20 19 18 E 22 D 3 1 2 6 7 5 4 D D T R 103 N m 10 3 kgf m 74 ft lb 8 9 10 11 12 13 9 13 11 16 14 17 15 12 10 12 8 14 15 16 17 ...

Page 157: ...ight key 1 6 Claw washer 1 7 Ring nut 1 8 Shift rod joint 1 9 Ball 2 10 Slider 1 11 Ball 2 12 Ball 2 13 Spring 1 14 Dog clutch 1 15 Cross pin 1 16 Spring 1 17 Propeller shaft 1 18 Reverse gear 1 19 Thrust washer 1 20 Ball bearing 1 21 O ring 1 Not reusable 5 5 97 8 mm 22 Propeller shaft housing 1 23 Needle bearing 1 24 Oil seal 2 Not reusable Propeller shaft housing F100B ...

Page 158: ...everse gear and thrust washer NOTE Install the bearing separator 1 between the reverse gear and thrust washer completely Ring nut wrench 3 1 90890 06511 Ring nut wrench extension 2 90890 06513 Bearing housing puller claw L 3 90890 06502 Stopper guide plate 4 90890 06501 Center bolt 5 90890 06504 Bearing separator 1 90890 06534 Stopper guide plate 2 90890 06501 Stopper guide stand 3 90890 06538 Bea...

Page 159: ...ng 1 Clean the propeller shaft housing using a soft brush and cleaning solvent and then check it for cracks Replace if necessary 2 Check the teeth and dogs of the reverse gear for cracks or wear Replace the gear if necessary Stopper guide plate 6 90890 06501 Stopper guide stand 7 90890 06538 Bearing puller 8 90890 06535 Bearing puller claw 1 9 90890 06536 Needle bearing attachment 0 90890 06653 Dr...

Page 160: ...haft assembly 1 Install the dog clutch 1 as shown Assembling the propeller shaft housing 1 Install the needle bearing into the propel ler shaft housing to the specified depth NOTE Install the needle bearing with the manufac ture identification mark a facing toward the oil seal propeller side When using the driver rod do not strike the special tool in a manner that will force the stopper b out of p...

Page 161: ... 7 to the reverse gear 8 using a press NOTE Install the ball bearing with the manufacture identification mark e facing outward propel ler side 4 Install the reverse gear assembly to the propeller shaft housing using a press Depth c 24 75 25 25 mm 0 97 0 99 in Bearing outer race attachment 4 90890 06628 Driver rod LS 5 90890 06606 Depth d 4 75 5 25 mm 0 19 0 21 in Bearing inner race attachment 9 90...

Page 162: ...LOWR Lower unit 6 15 60C5D11 Drive shaft and lower case F100B 6 ...

Page 163: ...9 Pinion shim As required 10 Thrust bearing 1 11 Seal 1 12 Plate 1 13 Joint 1 14 Plastic tie 2 Not reusable 7 80 mm 15 Hose 1 16 Joint 1 17 Nut 1 18 Water inlet cover 2 19 Lower case 1 20 Screw 1 21 Nut 1 22 Pinion 1 23 Needle bearing 1 24 Forward gear shim As required 25 Bearing outer race 1 Not reusable 26 Taper roller bearing 1 Not reusable 27 Needle bearing 1 28 Forward gear 1 Drive shaft and ...

Page 164: ...earing always replace it with a new one 2 Remove the needle bearing from the for ward gear CAUTION Do not reuse the bearing always replace it with a new one Drive shaft holder 5 1 90890 06519 Pinion nut holder 2 90890 06505 Socket adapter 2 3 90890 06507 Needle bearing attachment 1 90890 06610 Driver rod L3 2 90890 06652 S60C6190 Bearing separator 1 90890 06534 Bearing inner race attachment 2 9089...

Page 165: ...eeth and dogs of the forward gear for cracks or wear Replace if necessary Checking the bearings 1 Check the bearings for pitting or rum bling Replace if necessary Checking the drive shaft 1 Check the drive shaft for bends or wear Replace if necessary Bearing outer race puller 1 90890 06523 Outer race puller claw A 2 90890 06532 Ball bearing attachment 3 90890 06636 Driver rod LL 4 90890 06605 S60C...

Page 166: ...ce the stopper b out of place 2 Install the original shim s and taper roller bearing outer race CAUTION Add or remove shims if necessary when replacing the forward gear or lower case Assembling the forward gear 1 Install the new needle bearing into the forward gear to the specified depth Driver rod SL 1 90890 06602 Needle bearing attachment 2 90890 06609 Bearing depth plate 3 90890 06603 Depth c 1...

Page 167: ...ed depth NOTE Install an oil seal halfway into the drive shaft housing then the other oil seal Installing the drive shaft 1 Install the forward gear to the lower case 2 Install the drive shaft housing 1 to the drive shaft 2 3 Install the drive shaft assembly pinion and pinion nut and then tighten the nut to the specified torque Bearing inner race attachment 3 90890 06661 Needle bearing attachment ...

Page 168: ...im s 4 and propel ler shaft housing assembly 5 into the lower case and then install the straight key 6 claw washer 7 and ring nut 8 4 Tighten the nut to the specified torque NOTE Secure the ring nut by bending one tab a into the slot in the ring nut and the other tabs toward the propeller shaft housing assembly Drive shaft holder 5 3 490890 06519 Pinion nut holder 4 90890 06505 Socket adapter 2 5 ...

Page 169: ...ve shaft 4 Align the groove on the impeller 5 with the Woodruff key 6 and then install it to the drive shaft 5 Install the washers 7 wave washer 8 spacer 9 and collar 0 to the drive shaft NOTE The collar and spacer should fit together firmly While pulling the drive shaft up install the collar with some appropriate tool a that fits over the drive shaft as shown S60C6055 LT 572 A A Drive shaft and l...

Page 170: ... cover H NOTE When installing the pump housing apply grease to the inside of the housing and then turn the drive shaft clockwise while pushing down the pump housing Align the cover H projection d with the hole e in the pump housing Installing the lower unit 1 Set the gearshift to the neutral position at the lower unit 2 Install the two dowel pins 1 to the lower unit 3 Install the lower unit to the...

Page 171: ...ue WARNING Do not hold the propeller with your hands when loosening or tightening it Be sure to remove the battery leads from the bat teries and the engine shut off switch Put a block of wood between the anti cavita tion plate and propeller to keep the pro peller from turning NOTE If the grooves in the propeller nut 4 do not align with the cotter pin hole tighten the nut until they are aligned T R...

Page 172: ...LOWR Lower unit 6 25 60C5D11 Shimming F100B 6 T3 B4 59 0 A3 A1 B2 T2 15 8 A2 34 0 B1 T1 F R P B3 S60C6305 ...

Page 173: ... the shimming tool to the drive shaft so that the shaft is at the center of the hole Tighten the wing nuts another 1 4 of a turn after they contact the fixing plate 2 2 Install the pinion and pinion nut and then tighten the nut to the specified torque 3 Measure the distance M4 between the shimming tool and the pinion as shown 4 Install the thrust bearing 5 to the drive shaft housing 6 and then mea...

Page 174: ...eat the rollers and then measure the bearing height M1 as shown NOTE Select the shim thickness T1 by using the specified measurement s and the calcula tion formula Measure the bearing outer race at three points to find the height average 2 Calculate the forward gear shim thickness 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 s...

Page 175: ... measure ment 2 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 unreadable assume that R is zero and check the backlash when the unit is assembled Example If M2 is 27 95 mm and R is 2 then T2 27 95 ...

Page 176: ...n the center bolt while turning the drive shaft until the drive shaft can no longer be turned 4 Install the backlash indicator onto the drive shaft 22 4 mm 0 88 in in diame ter then the dial gauge onto the lower unit 5 Set the lower unit upside down NOTE Install the dial gauge so that the plunger a contacts the mark b on the backlash indica tor Calculated numeral at 1 100 place Rounded numeral 1 2...

Page 177: ...direction 11 Add or remove shims if out of specifica tion M Measurement 12 Remove the special service tools and then install the water pump assembly Backlash indicator 4 90890 06706 Magnet base plate 5 90890 07003 Dial gauge set 6 90890 01252 Magnet base 7 90890 06705 Forward gear backlash 0 19 0 53 mm 0 007 0 021 in Forward gear backlash Shim thickness Less than 0 19 mm 0 007 in To be decreased b...

Page 178: ...0C5D11 Lower unit F100C 6 S60C6385 18 17 16 15 14 13 9 10 8 11 6 3 8 1 4 5 5 7 12 2 D M T R 7 N m 0 7 kgf m 5 1 ft Ib A T R 7 N m 0 7 kgf m 5 1 ft Ib T R 34 N m 3 4 kgf m 25 ft Ib LT 572 T R 39 N m 3 9 kgf m 28 ft Ib LT 572 ...

Page 179: ...eusable 3 Hose 1 7 200 mm 4 Check screw 1 5 Gasket 2 Not reusable 6 Bolt 4 M10 40 mm 7 Drain screw 1 8 Dowel pin 2 9 Grommet 1 10 Bolt 1 M8 45 mm 11 Trim tab 1 12 Bolt 1 M8 60 mm 13 Spacer 1 14 Propeller 1 15 Washer 1 16 Spacer 1 17 Propeller nut 1 18 Cotter pin 1 Not reusable Lower unit F100C ...

Page 180: ...LOWR Lower unit 6 33 60C5D11 S60C6400 8 9 12 10 11 13 15 16 18 19 20 21 23 22 24 25 17 17 14 7 A A A A A LT 572 LT 572 LT 572 2 4 1 5 6 A 3 ...

Page 181: ...mm 7 Circlip 1 8 Screw 2 9 Cover 1 10 Bolt 2 M8 75 mm 11 Bolt 2 M8 50 mm 12 Seal 1 13 Water pump housing 1 14 Inner plate cartridge 1 15 Insert cartridge 1 16 Impeller 1 17 Dowel pin 2 18 Gasket 1 Not reusable 19 Outer plate cartridge 1 20 Gasket 1 Not reusable 21 Oil seal housing 1 22 O ring 1 Not reusable 3 1 52 4 mm 23 Gasket 1 Not reusable 24 Oil seal 2 Not reusable 25 Woodruff key 1 Lower uni...

Page 182: ...t hold the propeller with your hands when loosening or tightening it Be sure to remove the battery leads from the bat teries and the engine shut off switch Put a block of wood between the anti cavita tion plate and propeller to keep the pro peller from turning 3 Disconnect the speedometer hose 1 4 Mark the trim tab 2 at the area shown and then remove it 5 Loosen the bolts and then remove the lower...

Page 183: ...en remove it Checking the water pump and shift rod 1 Check the pump housing for deforma tion Replace if necessary 2 Check the impeller 1 inner plate car tridge 2 and insert plate cartridge 3 for cracks or wear Replace if necessary 3 Check the Woodruff key 4 and the groove a on the drive shaft for wear Replace if necessary 4 Check the shift rod for cracks or wear Replace if necessary S60C6405 S60C6...

Page 184: ...LOWR Lower unit 6 37 60C5D11 Propeller shaft housing F100C 6 S60C6460 13 12 2 11 10 1 14 15 16 17 20 20 19 18 5 6 6 7 3 7 8 9 8 3 3 4 9 5 4 D D A D A A E E T R 103 N m 10 3 kgf m 74 ft lb ...

Page 185: ...r 1 5 Shift plunger 1 6 Cross pin 1 7 Dog clutch 1 8 Spring 1 9 Propeller shaft 1 10 Washer 1 11 Straight key 1 12 Claw washer 1 13 Ring nut 1 14 Reverse gear 1 15 Thrust washer 1 16 Ball bearing 1 17 O ring 1 Not reusable 5 5 97 8 mm 18 Propeller shaft housing 1 19 Needle bearing 1 20 Oil seal 2 Not reusable Propeller shaft housing F100C ...

Page 186: ...t washer completely 2 Remove the ball bearing 3 Remove the oil seals and needle bear ing Ring nut wrench 3 1 90890 06511 Ring nut wrench extension 2 90890 06513 Bearing housing puller claw L 3 90890 06502 Stopper guide plate 4 90890 06501 Center bolt 5 90890 06504 Bearing separator 1 90890 06534 Stopper guide plate 2 90890 06501 Stopper guide stand 3 90890 06538 Bearing puller 4 90890 06535 Bearin...

Page 187: ...t brush and cleaning solvent and then check it for cracks Replace if necessary 2 Check the teeth and dogs of the reverse gear for cracks or wear Replace the gear if necessary 3 Check the bearings for pitting or rum bling Replace if necessary Checking the propeller shaft 1 Check the propeller shaft for bends or wear Replace if necessary Needle bearing attachment 0 90890 06612 Driver rod L3 A 90890 ...

Page 188: ...to the propel ler shaft housing to the specified depth NOTE Install the needle bearing with the manufac ture identification mark a facing toward the oil seal propeller side When using the driver rod do not strike the special tool in a manner that will force the stopper b out of place 2 Apply grease to the new oil seals and then install them into the propeller shaft housing to the specified depth D...

Page 189: ... press NOTE Install the ball bearing with the manufacture identification mark e facing outward propel ler side 4 Install the reverse gear assembly to the propeller shaft housing using a press Ball bearing attachment 4 90890 06633 Driver rod LS 5 90890 06606 Depth d 4 5 5 5 mm 0 18 0 22 in Ball bearing attachment 9 90890 06631 Bearing outer race attachment 0 90890 06623 Propeller shaft housing F100...

Page 190: ...LOWR Lower unit 6 43 60C5D11 Drive shaft and lower case F100C 6 ...

Page 191: ...red 5 Sleeve 1 6 Hose 1 7 300 mm 7 Plastic tie 1 Not reusable 8 Joint 1 9 Nut 1 10 Water inlet cover 2 11 Screw 1 12 Seal 1 13 Plate 1 14 Forward gear shim As required 15 Bearing outer race 1 Not reusable 16 Taper roller bearing 1 Not reusable 17 Needle bearing 1 18 Forward gear 1 19 Needle bearing 1 20 Pinion 1 21 Nut 1 22 Lower case 1 Drive shaft and lower case F100C ...

Page 192: ...ng the forward gear 1 Remove the taper roller bearing from the forward gear using a press CAUTION Do not reuse the bearing always replace it with a new one 2 Remove the needle bearing from the for ward gear CAUTION Do not reuse the bearing always replace it with a new one Drive shaft holder 5 1 90890 06519 Pinion nut holder 2 90890 06505 Socket adapter 2 3 90890 06507 Bearing inner race attachment...

Page 193: ...ogs of the forward gear for cracks or wear Replace if necessary Checking the bearings 1 Check the bearings for pitting or rum bling Replace if necessary Checking the drive shaft 1 Check the drive shaft for bends or wear Replace if necessary Bearing outer race puller 1 90890 06523 Outer race puller claw A 2 90890 06532 Stopper guide plate 3 90890 06501 Stopper guide stand 4 90890 06538 Bearing pull...

Page 194: ...t will force the stopper b out of place 2 Install the sleeve original shim s and drive shaft bearing outer race CAUTION Add or remove shims if necessary when replacing the pinion or lower case NOTE Apply the gear oil to the inside and outside of the sleeve Install the sleeve by facing the projection d forward 3 Install the original shim s and taper roller bearing outer race Driver rod SL 1 90890 0...

Page 195: ...r case 2 Install the drive shaft assembly pinion and pinion nut and then tighten the nut to the specified torque NOTE Install the drive shaft by lifting it up slightly then aligning it with the pinion and the spline of the drive shaft Bearing outer race attachment 6 90890 06621 Driver rod LL 7 90890 06605 Needle bearing attachment 1 90890 06609 Driver rod L3 2 90890 06652 Depth a 1 2 mm 0 05 in Be...

Page 196: ...r case and then install the straight key 5 claw washer 6 and ring nut 7 4 Tighten the nut to the specified torque NOTE Secure the ring nut by bending one tab a into the slot in the ring nut and the other tabs toward the propeller shaft housing assembly Installing the water pump and shift rod 1 Install the shift rod assembly 1 Ring nut wrench 3 8 90890 06511 Ring nut wrench extension 9 90890 06513 ...

Page 197: ...into the oil seal housing as shown 3 Install the new O ring 5 4 Install the new gasket 6 oil seal housing 7 new gasket 8 and outer plate car tridge 9 5 Install the Woodruff key into the drive shaft 6 Align the groove on the impeller 0 with the Woodruff key A and then install it to the drive shaft Ball bearing attachment 3 90890 06636 Driver rod LS 4 90890 06606 S60C6440 A Drive shaft and lower cas...

Page 198: ...9 Install and tighten the bolts H NOTE When installing the pump housing apply grease to the inside of the housing and then turn the drive shaft clockwise while pushing down the pump housing Installing the lower unit 1 Set the gearshift to the neutral position at the power unit and lower unit 2 Install the two dowel pins 1 to the lower unit 3 Install the lower unit to the upper case and then tighte...

Page 199: ...ue WARNING Do not hold the propeller with your hands when loosening or tightening it Be sure to remove the battery leads from the bat teries and the engine shut off switch Put a block of wood between the anti cavita tion plate and propeller to keep the pro peller from turning NOTE If the grooves in the propeller nut 4 do not align with the cotter pin hole tighten the nut until they are aligned T R...

Page 200: ...LOWR Lower unit 6 53 60C5D11 Shimming F100C 6 ...

Page 201: ...wing nuts another 1 4 of a turn after they contact the fixing plate 2 2 Install the pinion and pinion nut and then tighten the nut to the specified torque 3 Measure the distance M between the shimming tool and the pinion as shown NOTE Measure the pinion at three points to find the clearance average 4 Calculate the pinion shim thickness T3 as shown in the examples below NOTE P is the deviation of t...

Page 202: ...the specified measurement s and the calcula tion formula Measure the bearing outer race at three points to find height average 2 Calculate the forward gear shim thickness 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 unreadable assume that...

Page 203: ... Measuring the forward gear backlash 1 Remove the water pump assembly 2 Set the gearshift to the neutral position 3 Install the special service tool so that it pushes against the propeller shaft NOTE Tighten the universal puller or center bolt while turning the drive shaft until the drive shaft can no longer be turned Calculation formula Forward gear shim thickness T1 24 50 F 100 M Calculated nume...

Page 204: ...t stops in each direction 6 Add or remove shims if out of specifica tion M Measurement 7 Remove the special service tools and then install the water pump assembly Backlash indicator 4 90890 06706 Magnet base plate 5 90890 07003 Dial gauge set 6 90890 01252 Magnet base 7 90890 06705 Forward gear backlash 0 13 0 47 mm 0 005 0 019 in Forward gear backlash Shim thickness Less than 0 13 mm 0 005 in To ...

Page 205: ...emoving the clamp brackets 7 27 Installing the clamp brackets 7 27 Adjusting the trim sensor cam 7 28 Power trim and tilt unit F100B 7 29 Removing the power trim and tilt unit 7 30 Tilt cylinder and trim cylinder F100B 7 31 Disassembling the tilt cylinder and trim cylinders 7 32 Checking the reservoir 7 33 Checking the tilt cylinder and trim cylinder 7 33 Assembling the trim rams 7 33 Installing t...

Page 206: ...7 60 Installing the upper case 7 62 Swivel bracket and clamp brackets F100C 7 63 Removing the steering arm 7 64 Installing the steering arm 7 64 Clamp brackets F100C 7 65 Removing the clamp brackets 7 67 Installing the clamp brackets 7 67 Adjusting the trim sensor cam 7 68 Power trim and tilt unit F100C 7 69 Removing the power trim and tilt unit 7 70 Installing the power trim and tilt unit 7 70 Ti...

Page 207: ...g the power trim and tilt motor 7 87 Bleeding the power trim and tilt unit F100C 7 88 Not installed 7 88 Built in 7 89 Power trim and tilt electrical system 7 90 Checking the fuse 7 91 Checking the power trim and tilt relay 7 91 Checking the power trim and tilt switch trailer switch 7 91 Checking the trim sensor 7 91 ...

Page 208: ...ools 7 Bearing inner race attachment 90890 06662 Up relief fitting 90890 06773 Down relief fitting 90890 06774 Hydraulic pressure gauge 90890 06776 Trim tilt wrench 90890 06548 Cylinder end screw wrench 90890 06544 Digital circuit tester 90890 03174 ...

Page 209: ...60C5D11 7 2 1 2 3 4 5 6 7 8 9 MEMO Special service tools ...

Page 210: ...BRKT Bracket unit 7 3 60C5D11 Tiller handle 7 ...

Page 211: ...able 1 6 Bolt 1 M6 20 mm 7 Clamp 1 8 Shift cable 1 9 Clip 1 10 Nut 2 11 Cover 1 12 Bolt 1 M6 25 mm 13 Plate 1 14 Bolt 2 M6 25 mm 15 Retaining plate 1 16 Bolt 1 M6 25 mm 17 Plate 1 18 Friction plate 1 19 Friction piece 2 20 Nut 2 21 Collar 2 22 Bolt 2 23 Bolt 2 24 Nut 1 25 Washer 1 26 Bracket 1 27 Nut 2 28 Steering lock shaft 1 29 Steering lock knob 1 30 Washer 2 Tiller handle ...

Page 212: ...BRKT Bracket unit 7 5 60C5D11 ...

Page 213: ...shut off switch 1 11 Nut 1 12 Washer 1 13 Bracket 1 14 Collar 1 15 Wave washer 1 16 Washer 1 17 Bolt 1 M10 80 mm 18 Connector 2 19 Engine start switch housing 1 20 Engine start switch 1 21 Nut 1 22 Bolt 1 M6 25 mm 23 Screw 1 24 Bolt 1 M6 20 mm 25 Cover 1 26 Power trim and tilt switch 1 27 Screw 7 M6 16 mm 28 Screw 2 M6 40 mm 29 Throttle grip 1 30 Screw 1 M5 25 mm 31 Washer 1 32 Spring 1 33 Bushing...

Page 214: ...BRKT Bracket unit 7 7 60C5D11 ...

Page 215: ...ay 1 8 Bolt 1 M6 14 mm 9 Throttle cable 1 Short 10 Clip 1 11 Throttle arm 1 12 Throttle arm shaft 1 13 Shift cable 1 Long 14 Shift cable bracket 1 15 Bolt 1 M6 20 mm 16 Clip 1 17 Frame 1 18 Screw 2 M5 14 mm 19 Bolt 1 M6 14 mm 20 Spring housing 1 21 Spring 1 22 Actuator 1 23 Roller 1 24 Bushing 1 25 Shift arm 1 26 Bolt 2 M6 30 mm 27 Throttle shaft 1 28 Friction piece 1 29 Nut 1 Tiller handle ...

Page 216: ...RKT Bracket unit 7 9 60C5D11 Bottom cowling 7 S60C7030 29 18 22 23 25 26 27 28 31 32 30 18 19 20 33 37 36 2 24 21 4 5 6 7 8 9 10 3 9 1 11 12 13 14 15 16 12 17 34 34 35 38 A A A A A A A A A A A A A A A A ...

Page 217: ...ip 2 13 Shift rod lever 1 14 Washer 1 15 Shift bracket 1 16 Bushing 1 17 Bolt 2 M6 40 mm 18 Bolt 4 M6 20 mm 19 Bracket 1 20 Trailer switch 1 21 Pilot water hose 1 22 Hook 2 23 Spring 2 24 Bolt 2 M6 12 mm 25 Washer 2 26 Lever 2 27 Wave washer 2 28 Bushing 2 29 Bolt 4 M6 30 mm 30 Plate 2 31 Bushing 2 32 Cowling lock lever 2 33 Bolt 4 M8 35 mm 34 Grommet 2 35 Grommet 1 36 Clamp 1 37 Bolt 1 M6 30 mm 3...

Page 218: ...e F100B 7 S60C7040 13 12 12 15 16 17 20 19 21 1 22 23 18 14 13 LT LT 572 5 3 4 6 7 8 9 10 10 2 11 18 A A LT 572 E A A T R 73 N m 7 3 kgf m 53 ft lb T R 53 N m 5 3 kgf m 38 ft Ib T R 4 N m 0 4 kgf m 2 9 ft Ib T R 11 N m 1 1 kgf m 8 0 ft Ib A E ...

Page 219: ...le 5 Bolt 6 M6 45 mm 6 Screw 6 M6 10 mm 7 Cover 1 8 Gasket 1 Not reusable 9 Shaft 1 10 O ring 2 Not reusable 11 Oil seal 1 Not reusable 12 Dowel pin 2 13 O ring 2 Not reusable 1 9 22 9 mm 14 Damper 2 15 Nut 2 16 Nut 2 17 Washer 2 18 Ground lead 1 19 Grease nipple 1 20 Washer 2 21 Bolt 1 M6 10 mm 22 Mount cover 2 23 Bolt 4 M10 40 mm Upper case F100B ...

Page 220: ...nit 7 13 60C5D11 S60C7045 A A A A A A 6 8 3 5 18 19 20 22 21 9 11 10 1 13 15 16 23 24 2 14 LT 572 LT 572 7 4 12 17 A A 17 T R 26 N m 2 6 kgf m 19 ft Ib T R 20 N m 2 0 kgf m 14 ft Ib T R 4 N m 0 4 kgf m 2 9 ft Ib A A ...

Page 221: ... Upper mount 1 7 Bolt 3 M8 45 mm 8 Grommet 1 9 Bolt 4 M8 40 mm 10 Muffler seal 1 11 Rubber seal 1 12 Gasket 1 Not reusable 13 Screw 2 M6 15 mm 14 Baffle plate 1 15 Damper 1 16 Grommet 1 17 Dowel pin 2 18 Bolt 2 M14 235 mm 19 Washer 2 20 Rubber washer 2 21 Lower mount 2 22 Washer 2 23 Drive shaft bushing 1 24 Circlip 1 Upper case F100B ...

Page 222: ... 15 60C5D11 S60C7050 17 16 19 18 20 22 23 14 15 13 12 8 9 7 5 6 4 3 1 10 11 21 16 2 LT 572 LT 572 LT 572 LT 572 LT 572 LT 572 LT 572 LT 572 LT 572 LT 572 A A T R 11 N m 1 1 kgf m 8 0 ft Ib T R 11 N m 1 1 kgf m 8 0 ft Ib A ...

Page 223: ...ble 5 Oil strainer 1 6 Collar 3 7 Bolt 3 M6 25 mm 8 Bolt 12 M6 25 mm 9 Oil pan 1 10 Gasket 1 Not reusable 11 Exhaust manifold 1 12 Bolt 4 M6 70 mm 13 Exhaust seal 1 14 Gasket 2 Not reusable 15 Plate 1 16 Dowel pin 2 17 Bolt 6 M6 30 mm 18 Muffler 1 19 Bolt 1 M6 50 mm 20 Spacer 1 21 Grommet 1 22 Pipe 1 23 Rubber seal 1 Upper case F100B ...

Page 224: ...d O ring for tears Replace if necessary 3 Check the oil passage for dirt or residue Clean if necessary Assembling the oil pump 1 Install the new oil seal 1 into the cover 2 2 Install the new oil seal 3 into the oil pump body 4 NOTE Use a general pipe with the specified mea surements S60C7055 S60C7280 Bearing inner race attachment 90890 06662 General pipe 5 D 43 mm 1 69 in d 40 mm 1 57 in T 30 mm 1...

Page 225: ...xhaust manifold 4 from the oil pan 3 3 Remove the oil pan 3 from the exhaust guide 5 4 Remove the oil strainer 6 Checking the oil strainer 1 Check the oil strainer for dirt and residue Clean if necessary Assembling the oil pan 1 Install the gaskets onto the exhaust guide 1 2 Install the oil strainer 2 and bolts and then tighten the bolts to the specified torque T R Oil pump cover screw 4 N m 0 4 k...

Page 226: ...and the muffler 8 into the oil pan 7 Install the water pipe 9 8 Install the muffler assembly 0 by insert ing the tip of the water pipe A into the joint hole a of the upper case 9 Install the muffler assembly bolts B and then tighten them to the specified torque T R Oil strainer bolt 11 N m 1 1 kgf m 8 0 ft lb T R Exhaust manifold bolt 5 11 N m 1 1 kgf m 8 0 ft lb Oil pan bolt 6 11 N m 1 1 kgf m 8 ...

Page 227: ...e upper mounting nut 7 and lower mounting nut 8 and then tighten them to the specified torques NOTE Before tightening the lower mounting nut be sure to connect the ground lead to the lower mounting bolt 7 Install the oil pump assembly 9 T R Muffler assembly bolt B 20 N m 2 0 kgf m 14 ft lb T R Upper mount bolt 3 26 N m 2 6 kgf m 19 ft lb S60C7100 LT 572 LT 572 A S60C7105 LT 572 LT 572 A T R Upper ...

Page 228: ...BRKT Bracket unit 7 21 60C5D11 Swivel bracket and steering arm F100B 7 S60C7115 10 11 1 2 3 15 14 13 4 3 5 6 7 9 8 16 19 20 19 18 23 22 21 17 12 13 A A A A A A A A A A ...

Page 229: ... 48 2 mm 6 Bushing 1 7 Washer 1 8 Steering yoke 1 9 Circlip 1 10 Steering hook 1 11 Nut 2 12 Starboard tilt stop lever 1 13 Bushing 2 14 Port tilt stop lever 1 15 Nut 2 16 Trim stopper 2 M10 27 mm 17 Pin 2 18 Tilt stop lever joint 1 19 Bushing 2 20 Collar 1 21 Spring 1 22 Spring holder 1 23 Bolt 1 M6 10 mm Swivel bracket and steering arm F100B ...

Page 230: ... steering arm from the swivel bracket by pulling the arm off the bracket Installing the steering arm 1 Install the washer 1 and bushing 2 onto the steering arm 3 2 Place the swivel bracket 4 in an upright position and then install the steering arm onto the swivel bracket 3 Install the bushing 5 O ring 6 bushing 7 and washer 8 onto the swivel bracket S60C7120 ...

Page 231: ... ing yoke 9 by aligning the center a of the yoke with the center b of the steer ing arm 5 Install the circlip 0 6 Inject grease into the grease nipple until grease comes out from both the upper and lower bushings c A S60C7140 A A S60C7145 Swivel bracket and steering arm F100B ...

Page 232: ...BRKT Bracket unit 7 25 60C5D11 Clamp brackets F100B 7 S60C7150 24 T R 2 N m 0 2 kgf m 1 4 ft Ib T R 15 N m 1 5 kgf m 11 ft Ib ...

Page 233: ...ing nut 1 5 Grease nipple 6 6 Ground lead 1 7 Washer 1 8 Screw 1 M6 11 mm 9 Washer 2 10 Bushing 2 11 Trim sensor 1 12 Screw 2 M6 15 mm 13 Trim sensor cam 1 14 Screw 1 M6 24 mm 15 Clamp 1 16 Ground lead 1 17 Bolt 1 M6 20 mm 18 Anode 1 19 Bracket 2 20 Ground lead 1 21 Bolt 4 M6 30 mm 22 Through tube 1 23 Bolt 1 M8 20 mm 24 Cap 1 Clamp brackets F100B ...

Page 234: ...ng nuts 2 bolt 3 cap 4 and then remove clamp brackets 5 and 6 4 Remove the trim sensor 7 Installing the clamp brackets 1 Install the trim sensor 1 onto the swivel bracket assembly NOTE Adjust the trim sensor after installing the power trim and tilt unit 2 Assemble the clamp brackets and the swivel bracket by installing the anode 2 bolt 3 and self locking nuts 4 then tightening them to the specifie...

Page 235: ... tilt the outboard motor up and then support it with the tilt stop lever WARNING After tilting up the outboard motor be sure to support it with the tilt stop lever Otherwise the outboard motor could sud denly lower if the power trim and tilt unit should lose fluid pressure 6 Measure the trim sensor resistance Check the trim sensor if out of specifica tion T R Self locking nut 4 15 N m 1 5 kgf m 11...

Page 236: ...trim and tilt unit F100B 7 No Part name Q ty Remarks 1 Power trim and tilt unit 1 2 PTT motor lead 2 3 Shaft 1 4 Plastic tie 3 Not reusable 5 Circlip 1 6 Bolt 2 M8 16 mm 7 Washer 2 8 Shaft 1 9 Bushing 6 10 Bolt 1 M6 10 mm 11 Ground lead 1 ...

Page 237: ...rim and tilt unit should lose fluid pressure NOTE If the power trim and tilt does not operate loosen the manual valve and tilt the outboard motor up manually 2 Loosen the plastic ties 2 and then pull out the PTT motor lead 3 3 Remove the bolt 4 and disconnect the ground lead 5 4 Remove the circlip 6 then the shaft 7 5 Loosen the bolts 8 and then remove the shaft 9 6 Remove the power trim and tilt ...

Page 238: ...ble 9 Trim cylinder end screw 2 10 O ring 2 Not reusable 11 Backup ring 2 12 O ring 2 Not reusable 13 Dust seal 1 Not reusable 14 Tilt cylinder end screw 1 15 O ring 1 Not reusable 16 O ring 1 Not reusable 17 Tilt piston 1 18 O ring 1 Not reusable 19 O ring 1 Not reusable 1 18 19 16 15 13 A A A A T R 80 N m 8 0 kgf m 58 ft Ib T R 100 N m 10 kgf m 72 ft lb T R 130 N m 13 kgf m 94 ft lb 13 14 15 16 ...

Page 239: ... the fluid 4 Loosen the trim cylinder end screws 3 and then remove them 5 Drain the power trim and tilt fluid 6 Install the trim cylinder end screws 4 and tighten them finger tight NOTE Cover the tilt cylinder with a clean cloth 5 7 Remove the free piston 6 WARNING Never look into the tilt cylinder opening because the free piston and power trim and tilt fluid may be expelled out force fully Trim t...

Page 240: ...ck the inner walls of the cylinder body for scratches Replace if necessary 3 Check the outer surface of the tilt piston and free piston for scratches Replace if necessary 4 Check the trim and tilt rams for bends or excessive corrosion Polish with 400 600 grit sandpaper if there is light rust or replace if necessary Assembling the trim rams 1 Install the new seal 1 and dust seal 2 into the trim cyl...

Page 241: ...n der until it bottoms out 5 Fill the trim cylinders c with the recom mended fluid to the correct level as shown 6 Add a small amount of the recommended fluid though cylinder body holes d e and f 7 Install the trim piston assembly into the trim cylinder and then tighten the trim cylinder end screw 5 to the specified torque Recommended power trim and tilt fluid ATF Dexron II Fluid quantity 30 cm3 1...

Page 242: ...all the tilt cylinder end screw 4 to the tilt ram 5 3 Hold the tilt ram end in a vise using alu minum plates on both sides 4 Install new O rings 6 and 7 into the tilt piston 8 5 Install the balls 9 absorber valve pins 0 and spring A as shown 6 Install the tilt piston 8 washer B and nut C to the tilt ram 5 and then tighten the nut to the specified torque Trim tilt wrench 90890 06548 T R Trim cylind...

Page 243: ...n the tilt cylinder end screw 1 to the specified torque WARNING To prevent the power trim and tilt fluid from spurting out due to internal pres sure the tilt ram should be kept at full length NOTE Place the tilt cylinder end screw at the bottom of the tilt ram and install the tilt piston assem bly into the tilt cylinder Recommended power trim and tilt fluid ATF Dexron II S60C7590 Trim tilt wrench ...

Page 244: ...BRKT Bracket unit 7 37 60C5D11 Gear pump F100B 7 ...

Page 245: ... 2 8 Bolt 1 M8 85 mm 9 Bolt 2 M8 24 mm 10 Circlip 1 11 O ring 1 Not reusable 12 O ring 1 Not reusable 13 Backup ring 1 14 Spring 1 15 Absorber valve pin 1 16 Ball 1 17 Up relief valve seat 1 18 O ring 1 Not reusable 19 O ring 5 Not reusable 20 Ball 1 21 Pin 1 22 Valve seat 1 23 Down relief valve 1 24 O ring 1 Not reusable 25 Filter 2 26 Valve pin 1 Gear pump F100B ...

Page 246: ...s a and b while holding the cloth down Checking the valves 1 Check the operation of the tilt piston absorber valves and the valves for dirt or residue Clean if necessary 2 Check the valve seat 1 down relief valve 2 and valve pin 3 for dirt or resi due Clean if necessary 3 Check the shuttle pistons 4 main valves 5 and up relief valve seat 6 for dirt or residue Clean if necessary Checking the filter...

Page 247: ...rs 8 into the pump housing 4 Install the balls 3 18 mm 0 125 in 9 shuttle pistons 0 and balls 4 76 mm 0 187 in A into the gear pump CAUTION Install all components in their original direction and position for proper assem bly and operation NOTE Apply grease to the balls and shuttle pistons to prevent them from falling out of the gear pump 5 Install the gear pump B to the pump housing and then tight...

Page 248: ...sing 6 to the cylin der body and then tighten the bolts 7 to the specified torque 4 Install the new O rings 8 and 9 and backup ring 0 to the manual valve A 5 Install the manual valve A to the pump housing tighten it to the specified torque and then install the circlip B 6 Install the new O ring C and reservoir D to the cylinder body and then tighten the bolts E to the specified torque 7 Install th...

Page 249: ... No Part name Q ty Remarks 1 Power trim and tilt motor 1 2 Reservoir 1 3 Reservoir cap 1 4 O ring 1 Not reusable 5 O ring 1 Not reusable 6 Bolt 3 M6 13 mm 7 Bolt 4 M6 35 mm 8 O ring 1 Not reusable 9 Filter 1 10 Joint 1 Gear pump F100B Power trim and tilt motor F100B ...

Page 250: ...No Part name Q ty Remarks 1 Screw 3 M4 15 mm 2 Yoke 1 3 Armature 1 4 O ring 1 Not reusable 5 Screw 2 M4 10 mm 6 Brush holder 1 7 Brush 2 1 8 Brush 1 1 9 Brush holder 1 10 Brush spring 2 11 PTT motor base 1 12 Oil seal 1 Not reusable ...

Page 251: ...act the commutator NOTE Place a clean cloth over the end of the arma ture shaft and carefully pull the armature from the yoke with a pair of pliers as shown 3 Remove the screws 4 disconnect the PTT motor leads 5 and then remove the brush holders 6 and brushes 7 CAUTION Do not touch the bimetal a otherwise the operation of the breaker may be affected NOTE Hold the brush with a screwdriver as shown ...

Page 252: ...ary 3 Measure the commutator diameter a Replace if out of specification 4 Check the armature coil for continuity Replace if out of specifications 5 Check the brush for continuity Replace if there is no continuity CAUTION Do not touch the bimetal e otherwise the operation of the breaker may be affected Commutator diameter limit a 21 mm 0 83 in Armature coil continuity Commutator segments b Continui...

Page 253: ...Assembling the power trim and tilt motor 1 Install the oil seal 1 into the motor base 2 as shown 2 Install the brush holders 3 brushes 4 PTT motor leads 5 and screws 6 to the motor base as shown 3 Install the brush springs into the motor base and push the brushes 4 into the holders and then install the armature 7 4 Install the new O ring and yoke 8 to the motor base Brush length limit f 4 8 mm 0 1...

Page 254: ...ll of the air bubbles with a syringe or suitable tool NOTE Turn the joint with a screwdriver and then remove any air between the pump gear teeth 4 Install the new O ring 3 power trim and tilt motor 4 and then tighten the bolts 5 to the specified torque NOTE Align the armature shaft with the recess in the joint 5 Remove the reservoir cap 6 Fill the reservoir b with the recom mended fluid to the bri...

Page 255: ... in the reservoir NOTE The fluid level should be at the brim of the filler hole 4 If necessary add sufficient fluid of the recommended type to the correct level 5 Install the reservoir cap 6 Connect the PTT motor leads 2 to the battery terminals T R Reservoir cap 7 N m 0 7 kgf m 5 1 ft lb S60C7615 Recommended power trim and tilt fluid ATF Dexron II Ram PTT motor lead Battery terminal Up Blue L Gre...

Page 256: ...re fully extended Add sufficient fluid if necessary and then repeat step 7 NOTE Repeat this procedure until the fluid remains at the correct level Checking the hydraulic pressure 1 Check the hydraulic pressure Check the internal parts if out of specification 2 Fully extend the power trim and tilt rams 3 Remove the circlip 1 4 Remove the manual valve 2 and install the up relief fitting 3 and hydrau...

Page 257: ...attery terminals to fully retract the trim and tilt rams and then measure the hydraulic pressure 9 After measuring the hydraulic pressure connect the PTT motor leads to the bat tery terminals to fully extend the trim and tilt rams Ram PTT motor lead Battery terminal Up Blue L Green G Down Green G Blue L Hydraulic pressure up 7 9 9 8 MPa 80 100 kgf cm2 Hydraulic pressure gauge 4 90890 06776 Down re...

Page 258: ...lt unit 1 Fully tilt the outboard motor up and then support it with the tilt stop lever 1 WARNING After tilting up the outboard motor be sure to support it with the tilt stop lever Otherwise the outboard motor could sud denly lower if the power trim and tilt unit should lose fluid pressure 2 Install the shaft 2 and bolts 3 onto both clamp brackets together with the power trim and tilt unit 4 3 Ins...

Page 259: ...t stop lever and then let the fluid settle for 5 minutes WARNING After tilting up the outboard motor be sure to support it with the tilt stop lever Otherwise the outboard motor could sud denly lower if the power trim and tilt unit should lose fluid pressure 7 Remove the reservoir cap 1 and then check the fluid level in the reservoir 8 If necessary add sufficient fluid of the recommended type to th...

Page 260: ...pper case F100C 7 S60C7190 13 16 17 20 21 1 18 12 12 14 13 LT 572 T R 11 N m 1 1 kgf m 8 0 ft Ib A A 15 T R 53 N m 5 3 kgf m 38 ft Ib T R 53 N m 5 3 kgf m 38 ft Ib 19 18 A A 3 4 6 7 8 9 10 10 2 T R 4 N m 0 4 kgf m 2 9 ft Ib 5 11 E A E ...

Page 261: ... seal 1 Not reusable 5 Bolt 6 M6 45 mm 6 Screw 6 M6 10 mm 7 Cover 1 8 Gasket 1 Not reusable 9 Shaft 1 10 O ring 2 Not reusable 11 Oil seal 1 Not reusable 12 Dowel pin 2 13 O ring 2 Not reusable 1 9 22 9 mm 14 Damper 2 15 Nut 2 16 Nut 2 17 Washer 2 18 Ground lead 1 19 Grease nipple 1 20 Washer 2 21 Bolt 1 M6 10 mm Upper case F100C ...

Page 262: ...1 S60C7195 7 6 3 5 26 18 19 20 21 25 9 11 10 1 13 15 16 23 24 2 14 8 4 17 17 22 12 A LT 572 LT 572 LT 572 LT 572 A A LT 572 LT 572 T R 4 N m 0 4 kgf m 2 9 ft Ib A A A T R 20 N m 2 0 kgf m 14 ft Ib T R 26 N m 2 6 kgf m 19 ft Ib A A ...

Page 263: ...olt 3 M8 45 mm 8 Grommet 1 9 Bolt 4 M8 40 mm 10 Muffler seal 1 11 Rubber seal 1 12 Gasket 1 Not reusable 13 Screw 2 M6 15 mm 14 Baffle plate 1 15 Damper 1 16 Grommet 1 17 Dowel pin 2 18 Bolt 2 M12 200 mm 19 Washer 4 20 Rubber washer 2 21 Lower mount 2 22 Washer 2 23 Drive shaft bushing 1 24 Circlip 1 25 Mount cover 2 26 Bolt 4 M10 40 mm Upper case F100C ...

Page 264: ...C7200 17 19 18 20 21 22 14 15 13 12 8 9 7 4 10 11 2 1 3 5 6 16 16 A A LT 572 LT 572 LT 572 LT 572 LT 572 LT 572 LT 572 LT 572 LT 572 LT 572 T R 11 N m 1 1 kgf m 8 0 ft Ib T R 11 N m 1 1 kgf m 8 0 ft Ib T R 11 N m 1 1 kgf m 8 0 ft Ib A A ...

Page 265: ... reusable 5 Oil strainer 1 6 Collar 3 7 Bolt 3 M6 25 mm 8 Bolt 12 M6 25 mm 9 Oil pan 1 10 Gasket 1 Not reusable 11 Exhaust manifold 1 12 Bolt 4 M6 70 mm 13 Exhaust seal 1 14 Gasket 2 Not reusable 15 Plate 1 16 Dowel pin 2 17 Bolt 6 M6 30 mm 18 Muffler 1 19 Bolt 1 M6 50 mm 20 Grommet 1 21 Pipe 1 22 Rubber seal 1 Upper case F100C ...

Page 266: ...and O ring for tears Replace if necessary 3 Check the oil passage for dirt or residur Clean if necessary Assembling the oil pump 1 Install the new oil seal 1 into the cover 2 2 Install the new oil seal 3 into the oil pump body 4 NOTE Use a general pipe with the specified mea surements S60C7055 S60C7280 Bearing inner race attachment 90890 06662 General pipe 5 D 43 mm 1 69 in d 40 mm 1 57 in T 30 mm...

Page 267: ...il pan 3 3 Remove the oil pan 3 from the exhaust guide 5 4 Remove the oil strainer 6 Checking the oil strainer 1 Check the oil strainer for dirt and residue Clean if necessary Assembling the oil pan 1 Install the gaskets onto the exhaust guide 1 2 Install the oil strainer 2 and bolts and then tighten the bolts to the specified torque T R Oil pump cover screw 4 N m 0 4 kgf m 2 9 ft lb S60C7070 A A ...

Page 268: ...ts 6 6 Install the plate 7 and the muffler 8 into the oil pan 7 Install the water pipe 9 8 Install the muffler assembly 0 by insert ing the tip of the water pipe A into the joint hole a of the upper case 9 Install the muffler assembly bolts B and then tighten them to the specified torque S60C7085 LT 572 LT 572 LT 572 LT 572 A A T R Muffler assembly bolt B 20 N m 2 0 kgf m 14 ft lb S60C7210 LT 572 ...

Page 269: ... simulta neously 6 Install the upper mounting nut 7 and lower mounting nut 8 and then tighten them to the specified torques NOTE Before tightening the lower mounting nut be sure to connect the ground lead to the lower mounting bolt 7 Install the oil pump assembly 9 T R Upper mount bolt 3 26 N m 2 6 kgf m 19 ft lb S60C7100 LT 572 LT 572 A S60C7220 LT 572 LT 572 A T R Upper mounting nut 7 53 N m 5 3...

Page 270: ...O ring 2 Not reusable 3 8 36 5 mm 5 Bushing 2 6 Swivel bracket 1 7 Washer 1 8 Steering yoke 1 9 Circlip 1 10 Steering hook 1 11 Nut 2 12 Tilt stop lever joint 1 13 Pin 1 14 Bushing 2 15 Spring 1 16 Spring holder 1 17 Bolt 1 M6 10 mm 18 Tilt stop lever 1 S60C7230 11 10 9 8 7 4 5 5 4 3 2 1 15 17 16 13 12 18 15 14 3 mm 0 12 in 6 A A A A A A A A ...

Page 271: ...5 2 Place the swivel bracket 6 in an upright position and then install the steering arm onto the swivel bracket 3 Install the bushing 7 O ring 8 and washer 9 onto the swivel bracket 4 Install the steering arm 5 into the steer ing yoke 0 by aligning the center a of the yoke with the center b of the steer ing arm 5 Install the circlip A 6 Inject grease into the grease nipple until grease comes out f...

Page 272: ... 60C5D11 Clamp brackets F100C 7 S60C7260 4 22 21 12 13 7 7 8 8 6 5 2 3 11 9 10 15 14 1 16 17 18 19 20 5 LT 572 LT 572 A A A 11 T R 15 N m 1 5 kgf m 11 ft Ib T R 3 N m 0 3 kgf m 2 2 ft Ib T R 2 N m 0 2 kgf m 1 4 ft Ib A A A A ...

Page 273: ... Self locking nut 1 5 Ground lead 1 6 Screw 1 M6 12 mm 7 Washer 2 8 Bushing 2 9 Screw 2 M6 16 mm 10 Trim sensor 1 11 Grease nipple 2 12 Trim sensor cam 1 13 Screw 1 M6 25 mm 14 Clamp 2 15 Bolt 1 M6 10 mm 16 Plate 1 17 Anode 1 18 Ground lead 1 19 Bolt 2 M6 14 mm 20 Bolt 2 M6 16 mm 21 Through tube 1 22 Bolt 1 M8 20 mm Clamp brackets F100C ...

Page 274: ...ackets 1 Install the trim sensor 1 onto the swivel bracket assembly NOTE Adjust the trim sensor after installing the power trim and tilt unit 2 Assemble the clamp brackets and the swivel bracket by installing the anode 2 bolt 3 and self locking nuts 4 then tightening the nuts to the specified torque 3 Install the power trim and tilt unit For installation procedures see Installing the power trim an...

Page 275: ...d then support it with the tilt stop lever WARNING After tilting up the outboard motor be sure to support it with the tilt stop lever Otherwise the outboard motor could sud denly lower if the power trim and tilt unit should lose fluid pressure 6 Measure the trim sensor resistance Check the trim sensor if out of specifica tion Trim sensor resistance Pink P Black B 9 11 Ω at 20 C 68 F T R Trim senso...

Page 276: ...emarks 1 Power trim and tilt unit 1 2 Plastic tie 3 Not reusable 3 PTT motor lead 2 4 Circlip 3 5 Shaft 1 6 Shaft 1 7 Bushing 2 8 Bushing 2 9 Ground lead 1 10 Bolt 1 M6 10 mm 11 Bushing 2 12 Bushing 2 13 Spacer 1 S60C7720 4 5 7 7 8 8 4 4 6 11 11 12 12 13 1 2 3 9 10 A A A A A A A A A A ...

Page 277: ...ties 2 and then pull out the PTT motor lead 3 3 Remove the bolt 4 and disconnect the ground lead 5 4 Remove the circlips 6 then shafts 7 and 8 5 Remove the power trim and tilt unit 9 NOTE To remove the power trim and tilt unit lower the tilt ram slightly Installing the power trim and tilt unit 1 Fully tilt the outboard motor up and then support it with the tilt stop lever 1 2 Install the shaft 2 a...

Page 278: ...nder and trim cylinder F100C 7 S60C7725 10 9 12 11 6 1 7 3 4 13 14 15 15 16 17 16 17 18 8 2 21 19 20 20 22 5 T R 90 N m 9 0 kgf m 65 ft Ib T R 7 N m 0 7 kgf m 5 1 ft Ib LT 572 LT 572 T R 9 N m 0 9 kgf m 6 5 ft Ib T R 7 N m 0 7 kgf m 5 1 ft Ib ...

Page 279: ...der assembly 1 6 Bolt 4 M6 20 mm 7 O ring 1 Not reusable 8 Joint 1 9 Bolt 3 M6 75 mm 10 Reservoir cap 1 11 O ring 1 Not reusable 1 9 12 6 mm 12 O ring 4 Not reusable 1 5 8 5 mm 13 Ball 6 14 O ring 1 Not reusable 15 Free piston 1 16 Valve seal 1 17 Circlip 1 18 Circlip 1 Not reusable 19 Trim cylinder base 1 20 Spring 2 21 Plate 1 22 Circlip 1 Tilt cylinder and trim cylinder F100C ...

Page 280: ...nit 7 73 60C5D11 S60C7730 1 12 13 20 19 18 21 15 17 14 32 31 29 27 28 26 22 25 23 10 11 8 9 6 7 3 4 5 2 30 24 30 16 23 24 7 3 4 5 11 8 9 16 17 14 LT 271 A A T R 80 N m 8 0 kgf m 58 ft Ib T R 85 N m 8 5 kgf m 61 ft Ib ...

Page 281: ...eusable 2 4 22 6 mm 10 Trim cylinder end screw 1 11 O ring 1 Not reusable 12 Plate 1 13 Filter 1 14 O ring 1 Not reusable 15 Trim piston 1 16 Backup ring 1 17 O ring 1 Not reusable 18 Ball 5 19 Absorber valve pin 5 20 Spring 5 21 Plate 1 22 Ball 1 23 O ring 1 Not reusable 3 5 35 7 mm 24 Backup ring 1 25 Tilt piston 1 26 Ball 4 27 Absorber valve pin 4 28 Spring 4 29 Pin 4 30 Pin 2 31 Washer 1 32 Bo...

Page 282: ...linder 1 in a vise using aluminum plates a on both sides NOTE Place the trim cylinder in the vise horizon tally 2 Loosen the trim cylinder end screw 2 and then remove it CAUTION Do not damage the check valve b when loosening the end screw Checking the tilt cylinder and trim cylinder 1 Check the power trim and tilt unit for cracks or corrosion Replace if neces sary 2 Check the inner walls of the tr...

Page 283: ...1 into the tilt cylinder end screw 2 2 Install the O ring 3 onto the end screw 3 Install the tilt ram 4 into the end screw 4 Install the backup ring 5 and O rings 6 and 7 into the trim cylinder end screw 8 5 Install the trim cylinder end screw onto the tilt ram 6 Install O rings 9 and 0 and backup ring A onto the trim piston B 7 Install the balls C absorber valve pins D and springs E into the trim...

Page 284: ...2 Install the tilt piston to the tilt ram by installing the bolt T then tightening it to the specified torque 13 Install the trim cylinder onto the tilt ram 14 Hold the trim cylinder G in a vise using aluminum plates a on both sides NOTE Place the trim cylinder in the vise horizon tally 15 Install the trim cylinder end screw 8 and then tighten it to the specified torque CAUTION Do not damage the c...

Page 285: ...the circlip 9 4 Install the O rings 0 and pump housing assembly A to the tilt cylinder B by installing the bolts C then tightening them to the specified torque 5 Install the reservoir cap D to the speci fied torque 6 Hold the power trim E in a vise using aluminum plates a on both sides T R Trim cylinder end screw 8 80 N m 8 0 kgf m 58 ft lb T R Pump housing bolt C 9 N m 0 9 kgf m 6 5 ft lb Reservo...

Page 286: ... I into the trim cylinder and then insert the trim cylinder into the tilt cylinder B NOTE Apply grease to the balls to prevent them from falling out of the cylinder 11 Pull the tilt ram until it is fully extended install the tilt cylinder end screw J and then tighten it to the specified torque Recommended power trim and tilt fluid ATF Dexron II T R PTT motor bolt H 7 N m 0 7 kgf m 5 1 ft lb S60C79...

Page 287: ... 1 7 Relief valve seat 1 8 O ring 1 Not reusable 1 5 13 7 mm 9 Filter 1 10 Filter 2 11 O ring 2 Not reusable 12 Down relief spring 1 13 Valve support pin 1 14 Relief valve seal 1 15 O ring 2 Not reusable S60C7735 10 11 15 12 13 14 10 11 7 8 9 3 4 5 8 3 4 5 6 2 2 mm 0 087 in 7 6 9 2 1 T R 8 N m 0 8 kgf m 5 8 ft Ib Tilt cylinder and trim cylinder F100C Gear pump F100C ...

Page 288: ... 7 81 60C5D11 S60C7740 1 2 3 6 5 4 7 8 9 17 18 20 21 22 23 24 25 11 11 12 12 13 13 14 10 15 16 19 T R 11 N m 1 1 kgf m 8 0 ft Ib T R 2 N m 0 2 kgf m 1 4 ft Ib T R 4 N m 0 4 kgf m 2 9 ft Ib T R 11 N m 1 1 kgf m 8 0 ft Ib ...

Page 289: ... O ring 1 Not reusable 1 5 8 5 mm 10 Pump housing 1 11 Main valve 2 12 O ring 2 Not reusable 13 O ring 2 Not reusable 14 Shuttle piston 1 15 O ring 1 Not reusable 1 9 12 6 mm 16 Main valve 1 17 O ring 1 Not reusable 18 O ring 1 Not reusable 19 O ring 1 Not reusable 20 Valve seat 2 21 Spring 1 22 Relief valve seat 1 23 O ring 1 Not reusable 1 9 10 6 mm 24 Filter 1 25 O ring 1 Not reusable 1 9 9 6 m...

Page 290: ... valves 6 and shuttle piston 7 5 Remove the main valve 8 and relief valve seat 9 Checking the valves 1 Check the operation of the check valve a of the trim cylinder end screw and the valve for dirt or residue Clean if neces sary 2 Check the operation of the trim piston absorber valves 1 and tilt piston absorber valves 2 and the valves for dirt or residue Clean if necessary S60C7780 S60C7785 S60C77...

Page 291: ...residue Clean if necessary Checking the gear pump 1 Check the gear pump for damage Replace if necessary Assembling the gear pump 1 Install the shuttle piston 1 and main valves 2 and then tighten the valves to the specified torque 2 Install the relief valve seat 3 valve seats 4 and main valve 5 and then tighten the valve to the specified torque S60C7825 S60C7830 T R Main valve 2 and 5 11 N m 1 1 kg...

Page 292: ...e seal 8 relief valve seat 9 and absorber valve pin 0 6 Tighten the cap A into the relief valve seat to the specified depth a 7 Install the gear pump B by installing the bolts C then tightening them to the specified torque T R Manual valve seat 6 4 N m 0 4 kgf m 2 9 ft lb Manual valve 7 2 N m 0 2 kgf m 1 4 ft lb S60C7845 S60C7850 Depth a 2 2 mm 0 087 in T R Gear pump bolt C 8 N m 0 8 kgf m 5 8 ft ...

Page 293: ... 3 Yoke 1 4 O ring 1 Not reusable 5 Armature 1 6 Screw 1 M4 10 mm 7 Washer 1 8 Screw 3 M4 10 mm 9 Circuit breaker 1 10 Brush 2 11 Brush spring 2 12 Brush holder 1 13 PTT motor base 1 14 Oil seal 1 Not reusable S60C7945 1 3 4 5 6 8 8 10 10 11 11 9 12 13 8 14 7 2 A A A A A A Gear pump F100C Power trim and tilt motor F100C ...

Page 294: ...it breaker for continuity Replace if there is no continuity 5 Check the base for cracks or damage Replace if necessary 6 Check the oil seal 1 for damage or wear Replace if necessary Assembling the power trim and tilt motor 1 Install the oil seal 1 into the motor base 2 as shown 2 Install the springs 3 into the motor base 2 then the brush holder 4 into the motor base together with the brushes 5 and...

Page 295: ... hole 4 If necessary add sufficient fluid of the recommended type to the correct level 5 Install the reservoir cap 6 Connect the PTT motor leads 2 to the battery terminals 7 Reverse the PTT motor leads between the battery terminals to fully extend the tilt ram and then reverse them again to fully retract the ram S60C7970 A A A A S60C7935 Recommended power trim and tilt fluid ATF Dexron II Tilt ram...

Page 296: ... the manual valve by turning it clockwise 4 Let the fluid settle for 5 minutes 5 Push and hold the power trim and tilt switch in the up position until the out board motor is fully tilted up 6 Support the outboard motor with the tilt stop lever and then let the fluid settle for 5 minutes WARNING After tilting up the outboard motor be sure to support it with the tilt stop lever Otherwise the outboar...

Page 297: ...A 6 Fuse 20 A 7 10 P coupler 8 Trim sensor 9 Battery È Tiller handle model B Black G Green Gy Gray L Blue Lg Light green P Pink R Red Sb Sky blue S60C7990 B Gy P Sb Sb Sb L L Sb Lg Lg Lg Lg R R R R P B B Gy Gy B B B G G B B B Gy Gy P P Sb Sb Sb L L Sb Lg Lg Lg Lg R R R R R B B Gy Gy B B B G G B Sb R Lg Bleeding the power trim and tilt unit F100C Power trim and tilt electrical system ...

Page 298: ... Replace if there is no continu ity 4 Disconnect the black B lead 4 Check for continuity between terminals 1 and 2 Replace if there is continuity Checking the power trim and tilt switch trailer switch 1 Check the power trim and tilt switch trailer switch for continuity Replace if out of specification Checking the trim sensor 1 Measure the trim sensor resistance Replace if out of specification NOTE...

Page 299: ...ecking the pulser coil 8 10 Checking the throttle position sensor 8 10 Checking the thermo sensor 8 11 Checking the oil pressure switch 8 11 Checking the engine start switch 8 12 Checking the engine shut off switch 8 12 Starting system 8 13 Checking the fuse 8 14 Checking the wiring harness 10 pins 8 14 Checking the starter relay 8 14 Checking the neutral switch 8 14 Starter motor 8 15 Removing th...

Page 300: ...rvice tools 8 Ignition tester 90890 06754 Digital circuit tester 90890 03174 Peak voltage adaptor 90890 03172 Test harness 6 pins 90890 06772 Test harness 3 pins 90890 06770 Test harness 3 pins 90890 06757 Vacuum pressure pump gauge set 90890 06756 ...

Page 301: ... any of the connections of the digital tester leads NOTE Use the peak voltage adaptor with the digi tal circuit tester When measuring the peak voltage set the selector on the digital circuit tester to the DC voltage mode Connect the positive pin on the peak volt age adaptor to the positive terminal of the digital circuit tester Measuring the lower resistance When measuring a resistance of 10 Ω or ...

Page 302: ...60C5D11 Electrical components 8 Starboard and port views 1 Ignition coils 2 Thermo sensor 3 Starter motor 4 Fuse 5 Starter relay 6 Power trim and tilt relays 7 Oil pressure switch 8 Prime Start 9 Throttle position sensor S60C8020 ...

Page 303: ...t and rear views 1 CDI unit 2 Starter relay 3 Power trim and tilt relays 4 Rectifier Regulator 5 Neutral switch tiller handle model 6 Spark plug 7 High tension cords 8 Ignition coils È Tiller handle model S60C8030 Electrical components ...

Page 304: ...handle model 1 Engine start switch 2 Engine start switch harness 3 Engine shut off switch 4 Engine shut off switch connector 5 Power trim and tilt switch 6 PTT switch lead 7 Neutral switch 8 Wiring harness extension 9 Connector assembly S60C8040 ...

Page 305: ...switch B Starter relay C Power trim and tilt relays D Thermo sensor E Prime Start B Black Br Brown G Green L Blue Lg Light green O Orange P Pink R Red Sb Sky blue W White Y Yellow B Y Black yellow P B Pink black P W Pink white S60C8050 B P Y P P B B Y P R W L B O P W P W O B L B Y B Sb B B B B B R Y Y R Y Lg Lg Sb Br B B B B B L B B P O P W Y B Y P B P W P B L W R Y R Y B B Y Sb Sb Lg Br Y Sb Lg P...

Page 306: ...g coil 8 Rectifier Regulator 9 Battery 0 Fuse 30 A A Oil pressure switch B Thermo sensor C Engine start switch D Engine shut off switch È Tiller handle model B Black Br Brown G Green O Orange P Pink R Red W White Y Yellow B O Black orange B W Black white B Y Black yellow G W Green white P W Pink white W B White black W R White red S60C8060 G W B Y B B B Y P W P R W B O P W B Y P W B Y B B ...

Page 307: ...n WARNING Do not touch any of the connections of the spark gap tester leads Do not let sparks leak out of the removed spark plug caps Keep flammable gas or liquids away since this test can produce sparks Checking the high tension cords 1 Remove the high tension cords from the ignition coil 2 Measure the high tension cord resis tance Replace if out of specification Ignition tester 90890 06754 Ignit...

Page 308: ...nd pulser coil output peak voltage Replace the CDI unit if the output peak voltage of the Rectifier Regulator and pulser coil is above specification Ignition coil resistance Primary coil Black white B W Black B 0 08 0 11 Ω at 20 C 68 F Secondary coil 3 5 4 7 kΩ at 20 C 68 F S60C8110 B W B B W B Digital circuit tester 90890 03174 Peak voltage adaptor 90890 03172 Test harness 6 pins 90890 06772 CDI ...

Page 309: ... Measure the throttle position sensor input voltage Replace the CDI unit if out of specification 3 Measure the throttle position sensor out put voltage Replace the CDI unit if out of specification Digital circuit tester 90890 03174 Peak voltage adaptor 90890 03172 Test harness 6 pins 90890 06772 S60C8140 Pulser coil output peak voltage White red W R Black B White black W B Black B r min Unloaded L...

Page 310: ...e oil pressure switch 1 Connect the special service tool to the oil pressure switch 2 Slowly operate the special service tool 3 Check the switch for continuity at the specified pressure Replace if there is no continuity Throttle position sensor input voltage Red R Orange O 5 V Throttle position sensor output voltage Pink P Orange O 0 48 5 25 V Thermo sensor resistance at 20 C 68 F 2 45 kΩ at 40 C ...

Page 311: ...uity Checking the engine shut off switch 1 Check the engine shut off switch for con tinuity Replace if there is no continuity Lead color Switch position White W Black B Red R Yellow Y Brown Br OFF ON START Lead color White W Black B Remove the lock plate a Install the lock plate b Push the button c Ignition system and ignition control system ...

Page 312: ...13 60C5D11 Starting system 8 1 Fuse 30 A 2 Fuse 20 A 3 Starter motor 4 Starter relay 5 Battery 6 10 pin coupler 7 Neutral switch 8 Engine start switch È Tiller handle model B Black Br Brown R Red W White Y Yellow B W Black white ...

Page 313: ... Connect the brown Br lead to the posi tive battery terminal 3 Connect the black B lead to the nega tive battery terminal 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 the brown or black lead Replace if there is continuity Checking the neutral switch 1 Check t...

Page 314: ...ELEC Electrical systems 8 15 60C5D11 Starter motor 8 16 17 18 19 21 23 24 25 15 13 14 12 11 10 9 8 4 3 2 1 5 27 26 28 6 7 29 22 20 S60C8250 A A A A ...

Page 315: ... Clutch assembly 1 10 E clip 1 Not reusable 11 Thrust washer 1 12 Center bracket 1 13 Pinion shaft 1 14 Planetary gear 3 15 Outer gear 1 16 Plate 1 17 Armature 1 18 Stator 1 19 Brush assembly 1 20 Brush holder assembly 1 21 Plate 1 22 Thrust washer 1 23 Lower bracket 1 24 Screw 2 M4 14 mm 25 Bolt 2 M6 120 mm 26 Shift lever 1 27 Spring 1 28 Relay assembly 1 29 Nut 1 Starter motor ...

Page 316: ...wear Replace if necessary 2 Check for smooth operation Replace if necessary NOTE Turn the pinion clockwise to check that it operates smoothly and turn it counterclock wise to check that it locks in place Checking the armature 1 Check the commutator for dirt Clean with 600 grid sandpaper and com pressed air if necessary 2 Measure the commutator diameter Replace the armature if out of specifica tion...

Page 317: ...sh length Replace the brush assembly if out of specification 2 Check the brush holder assembly for continuity Replace if out of specifica tions Commutator undercut limit a 0 2 mm 0 01 in Armature continuity Commutator segments b Continuity Segment Armature core c No continuity Segment Armature shaft d No continuity Brush length limit a 9 5 mm 0 37 in Brush continuity Brush 1 Brush 2 No continuity ...

Page 318: ...second otherwise the relay may be damaged Do not connect the positive battery ter minal the position a shown 4 Check that there is continuity between the relay terminals Replace if there is no continuity 5 Check that there is no continuity after the negative battery terminal is removed Replace if there is continuity NOTE The starter motor pinion should be pushed out while the relay is on Checking ...

Page 319: ... 1 Lighting coil 2 Rectifier Regulator 3 Fuse 30 A 4 Battery 5 Starter motor 6 Starter relay B Black G Green R Red W White G W Green white B R R G G G W G W G G G R B R R G G G W G W G W G W W W W W S60C8360 B B B B W R Starter motor Charging system ...

Page 320: ...ove specification NOTE Disconnect the output lead red lead of the Rectifier Regulator when measuring the out put peak voltage Digital circuit tester 90890 03174 Peak voltage adaptor 90890 03172 Test harness 3 pins 90890 06770 Lighting coil output peak voltage White W White W r min Unloaded Loaded Cranking 1 500 3 500 DC V 7 5 8 0 15 5 15 5 Lighting coil resistance use as reference White W White W ...

Page 321: ...62Y5A11 TRBL SHTG 1 2 3 4 5 6 7 8 9 Troubleshooting Power unit 9 1 Bracket unit 9 11 Electrical systems 9 15 ...

Page 322: ... free from corrosion and that the battery is fully charged to 12 V Power unit 9 Symptom Engine does not crank Check the starting system Check the power unit Check that the gearshift is in the neutral position Check the neutral switch for continuity Check the engine start switch for continuity Check the engine shut off switch for continuity Is the gearshift in neutral Is there conti nuity Is there ...

Page 323: ... the power unit Can the oper ation sound be heard Yes Yes No Is there conti nuity Replace the fuse Yes No Replace the engine shut off switch Is there conti nuity No Yes Check the fuse for continuity Replace the starter motor No Check the starter motor opera tion Replace the wiring harnesses Is there conti nuity Yes No Good operat ing condition Power unit ...

Page 324: ... the connections of the spark gap tester leads Do not let sparks leak out of the removed spark plug caps Keep flammable gas or liquids away since this test can produce sparks Start the engine using dried or new spark plugs No Yes Yes No Check that the spark plugs pro duce sparks No Yes Below the spark gap specification Are there sparks Check the ignition coil Check the ignition system output peak ...

Page 325: ...starting operation Failure in starting operation Check the fuel system Check the condition of the spark plugs again Check the compression pres sure of the combustion chamber Check the valve clearance Adjust the valve clearance No No Yes Yes Yes No No Yes Check the cylinder head cylin der body and piston assembly Power unit ...

Page 326: ...er or resi due Good operat ing condition Kinks or fuel leakage Replace the fuel pump Check for water or residue in the fuel filter Open the fuel vent screw Replace the respective parts Clean the fuel system from the fuel tank to the fuel filter Check the fuel hose for kinks or fuel leakage Check the carbure tors No Yes Yes Yes Yes No No No Check the fuel pump operation Check that the fuel vent scr...

Page 327: ...t of specifi cation Replace the spark plug Check the ignition system out put peak voltage Yes No Is there air intake Replace the respective seals Check the compression pres sure of the combustion chamber No Yes Check that there is no secondary air intake on the contact surfaces of the intake manifold and crankcase Power unit ...

Page 328: ...lean them if necessary Out of specifi cation Do the valves close simul taneously Check the second ary air intake on the O ring and manifold plate and the gas kets of the vacuum check bolts Check the ignition timing Yes Yes No No Check the operation of the car buretor throttle valves by removing the throttle cable and link rods Check the operation of the throttle cable and link rods Yes No Adjust t...

Page 329: ...ors Check the ignition system Check the compression pressure of the power unit Adjust the throttle cable Clogs debris or wear Yes No Yes No Check the throttle cable opera tion Clean the carburetor or replace the respective parts Do the carbu retor throttle valves close simulta neously Check the ignition system and the compression pressure of the engine Disassemble the carburetor and check the inte...

Page 330: ...stem Cooling system Check the water inlet for clogs or debris Check the thermo sensor Check that cooling water is dis charged from the pilot water outlet Replace the thermostat Replace the CDI unit Replace the thermo sensor Check the water pump impeller Check the water passage Clogs or debris Is water dis charged Good condition Clean the water inlet Yes No No Yes Yes Yes No No Check the thermostat...

Page 331: ...vel Check the oil pressure Check the oil pressure switch Clean or replace the respective parts At specified level Out of specifi cation Debris or leaks Check the oil pas sage Yes No Yes No Yes Yes No No Add engine oil to the correct level Replace the oil pressure switch Replace the CDI unit Good condition Power unit ...

Page 332: ... tilt motor Replace the power trim and tilt relay Close the valve Can 12 V be obtained Can 12 V be obtained Can the oper ation sound be heard Can the oper ation sound be heard Replace the power trim and tilt relay Check for continuity between the battery relays and switch Check the voltage between the blue L lead and green G lead Check the voltage between each terminal Between the sky blue Sb lead...

Page 333: ... Clean or replace the filters Debris or dirt No Yes No Yes Add fluid to the correct level At specified level Yes No Disassemble the power trim and tilt unit and then check the filter for debris or dirt Clogs or debris Measure the hydraulic pressure for F100B Check the power trim and tilt unit for leaks Out of specifi cation Yes No Bracket unit ...

Page 334: ...luid level Close the valve Add fluid to the correct level At specified level Is it closed Yes Yes No No Check the fluid passages for clogs or debris Clean the passages Check the internal parts valves pistons gear etc Clean or replace the filters Debris or dirt No Yes No Yes Disassemble the power trim and tilt unit and then check the fil ters for debris or dirt Clogs or debris ...

Page 335: ...case Replace the shift rod Check the shift cables and links of the remote control box Check the detent of the bottom cowling Good operat ing condition Good operat ing condition Connected properly Yes Yes Yes No No No Check the shift cable operation Disassemble the lower case and then check the operation of the dog clutch Check the forward gear and reverse gear Yes No Replace the respective parts G...

Page 336: ...g system Measure the Rectifier Regulator output peak voltage Replace the lighting coil Out of specifi cation Out of specifi cation Replace the Rectifier Regulator No No Yes Yes Measure the output peak voltage of the lighting coil Replace the battery and then check the voltage of all electri cal equipment on your boat ...

Page 337: ...Checking the carburetor 4 15 Checking the CDI unit 8 9 Checking the check valve 4 15 Checking the compression pressure 5 9 Checking the cooling water passage 3 8 Checking the crankshaft 5 42 Checking the crankshaft main journal oil clearance 5 45 Checking the crankshaft pin oil clearance 5 43 Checking the cylinder bore 5 40 Checking the cylinder head 5 32 Checking the diaphragm and valves 4 8 Chec...

Page 338: ...belt and sprockets 5 18 Checking the top cowling 3 4 Checking the trim sensor 7 91 Checking the valve clearance 3 7 5 6 Checking the valve guides 5 27 Checking the valve seat 5 28 Checking the valve springs 5 26 Checking the valves 5 26 7 39 7 83 Checking the water pump and shift rod 6 8 6 36 Checking the wiring harness 10 pins 8 14 Clamp brackets F100B 7 25 Clamp brackets F100C 7 65 Control syste...

Page 339: ...bricants and sealants 1 3 Power trim and tilt electrical system 7 90 Power trim and tilt motor F100B 7 42 Power trim and tilt motor F100C 7 86 Power trim and tilt unit 3 12 Power trim and tilt unit F100B 7 29 Power trim and tilt unit F100C 7 69 Power unit 1 6 2 3 3 5 5 3 9 1 Predelivery checks 1 25 Propeller selection 1 25 Propeller shaft housing F100B 6 9 Propeller shaft housing F100C 6 37 Propel...

Page 340: ... and steering arm F100B 7 21 Symbols 1 2 Synchronizing the carburetors 4 20 T Technical tips 1 16 Test run 1 28 Throttle control 4 9 Tightening torques 2 14 Tiller handle 7 3 Tiller handle model 8 5 Tilt cylinder and trim cylinder F100B 7 31 Tilt cylinder and trim cylinder F100C 7 71 Timing belt and sprockets 5 12 Top cowling 3 4 U Upper case F100B 7 11 Upper case F100C 7 53 V Ventilation 1 3 W Wi...

Page 341: ......

Page 342: ...il pressure switch E Prime Start F Hour meter G Fuse 30A H Fuse 20A I Neutral switch J Trailer switch K Power trim and tilt switch L Trim sensor M Engine stop switch N Engine start switch È Tiller handle model Color code B Black Br Brown G Green Gr Gray L Blue Lg Light green O Orange P Pink R Red Sb Sky blue W White Y Yellow B O Black orange B W Black white B Y Black yellow G R Green red G W Green...

Page 343: ......

Page 344: ...YAMAHA MOTOR CO LTD Printed in the Netherlands Jun 2001 0 5 1 CR F100BET F100CET E ...

Page 345: ... G P R B W O P B B B Br G W G R R L B B O W B W R B P W O P Y P P W B Y P B B W Br Lg B O W P B W R Y Y R Br 1 4 2 3 B W B W B O R W O Gy P B Lg B Br G Gy L Lg O P R Sb W Y B O B W B Y G R G W P B P W W B W R Sb R Lg UP FREE DOWN Sb R Lg UP FREE DOWN Sb Lg R Sb R R R R Sb Sb Sb Sb Lg Lg Lg Lg Lg Lg Sb R Sb Sb Lg Lg R Sb B B B Gy G W Sb W P R B Sb Lg G W Br B P R G Br Lg Y P B W Y P W G R P B G W S...

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