Yamaha F50A Service Manual Download Page 45

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62Y3A11

2-2

1
2
3
4
5
6
7
8

* PON: Pump Octane Number (Research Octane Motor Octane Number)/2

RON: Research Octane Number

Fuel and oil

Fuel type

Regular unleaded gasoline

Fuel rating

*PON

RON

86
91

Engine oil type

4-stroke motor oil

Engine oil grade

API

SAE

SE, SF, SG, SH

10W-30, 10W-40, or 20W-40

Engine oil quantity

(with oil filter replacement)

(US qt, lmp qt)

2.2 (2.3, 1.9)

(without oil filter replacement)

(US qt, lmp qt)

2.0 (2.1, 1.8)

Gear oil type

Hypoid gear oil

Gear oil grade

API

SAE

GL-4

Gear oil quantity

(US qt, lmp qt)

0.43 (0.45, 0.38)

Bracket

Trim angle
(at 12 degree boat transom)

Degree

–4–20

Tilt-up angle

Degree

Steering angle

Degree

40 + 40

Drive unit

Gear shift positions

F-N-R

Gear ratio

1.85 (24/13)

Reduction gear type

Spiral bevel gear

Clutch type

Dog clutch

Propeller shaft type

Spline

Propeller direction

(rear view)

Clockwise

Propeller identification mark

Electrical

Battery capacity

Ah (kC)

70–100 (252–360)

Minimum cold cranking
performance

380

Item

Unit

Model

USA

—

F50TR

Canada

—

F50TH

—

F50TR

Worldwide

F50AEHD

F50AEHT

F50AED

F50AET

General specifications

Summary of Contents for F50A

Page 1: ...SERVICE MANUAL 62Y 28197 3A 11 290408 F50A FT50B FT50C...

Page 2: ...ns 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...

Page 3: ...nts General information 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...

Page 4: ......

Page 5: ...10 Acceleration pump 1 15 Ignition system 1 17 Ignition timing control 1 19 Power trim and tilt 1 22 Propeller selection 1 32 Propeller size 1 32 Selection 1 32 Predelivery checks 1 33 Checking the fu...

Page 6: ...3 Cylinder head cover 1 4 Bolt 7 M6 20 mm 5 Cylinder head cover gasket 1 Not reusable 6 Bolt 10 M9 95 mm 1st 2nd 23 47 2 3 4 7 17 34 7 Spark plug 4 18 1 8 13 8 Bolt 5 M6 25 mm 1st 2nd 6 12 0 6 1 2 4...

Page 7: ...ant grease Yamaha grease A Yamaha marine grease 3 Apply molybdenum disulfide grease 4 Apply anti corrosion grease Yamaha grease D 5 Apply low temperature resistant grease Yamaha grease C Symbols 6 to...

Page 8: ...ing an air compressor Protect your hands and feet by wearing pro tective gloves and safety shoes when neces sary Parts lubricants and sealants Use only genuine Yamaha parts lubricants and sealants or...

Page 9: ...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 an...

Page 10: ...del code 3 Transom height 4 Serial number Applicable models USA Canada Worldwide F50AEHD F50TH F50AEHT F50AED F50TR F50AET T50TR FT50BET FT50CEHD FT50CED FT50CET Model name Approved model code Startin...

Page 11: ...for the starting system to further increase starting performance and serviceability Further more the acceleration pump and the dashpot have been integrated to simplify construction and to ease servic...

Page 12: ...I unit and ignition coil The CDI unit contains a built in microcomputer that determines the ignition timing separately for acceleration and for normal operation based on signals received from the puls...

Page 13: ...hat are used in a higher class model provides ample dura bility making it possible to accommodate a wider range of applications throughout the market Pinion Forward gear Reverse gear Gear ratio Model...

Page 14: ...opted the shift slider type shift mechanism This shift mechanism enables a prompt engagement of the dog clutch regardless of the operating speed of the shift lever Thus smooth and positive shift opera...

Page 15: ...med up Once the engine starts current flows from the lighting coil of the to the thermo heater allowing the wax in the Prime Start unit to expand The expanded wax moves the thermo heater plunger in th...

Page 16: ...Prime Start The enriched air fuel mixture is delivered to cylinders 1 and 2 by the Prime Start system attached to carburetor 1 The enriched air fuel mixture is delivered to cylinders 3 and 4 by the P...

Page 17: ...es through the pilot air jet mix enabling the air fuel mixture that has been regulated by the pilot screw to be fed through the pilot outlet Because the throttle valve opens slightly when the engine i...

Page 18: ...and all the bypass holes In addition air fuel mixture is also supplied from the main nozzle in accordance with the opening angle of the throttle valve 1 Pilot screw 2 Pilot outlet 3 Bypass holes 4 Ve...

Page 19: ...lated by the main air jet are mixed in the main nozzle The resultant mixture is then sprayed by the main nozzle into the venturi The air fuel mixture that is sprayed through the venturi is then fed in...

Page 20: ...not possible to supply the volume of fuel that is necessary for the large volume of air that has been introduced Thus because it is not possible to achieve the air fuel mixture that is required by th...

Page 21: ...d and distributed air then utilizes the passage of the main air jet to flow into the main nozzle The pressure of the air helps suck fuel from the main jet which increases the fuel in the main nozzle a...

Page 22: ...otect the engine against overheating over revolution and oil pressure drops as well as to control warning devices 1 Pulser coil 2 Flywheel 3 Charge coil 4 CDI unit 5 Microcomputer 6 Ignition coils 1 a...

Page 23: ...ser coil to simultaneously ignite two cylinders To provide ignition signals to the cylinders the microcomputer determines the ignition cylinder and ignition timing These are based on the cylinder iden...

Page 24: ...linders 2 and 3 pass by the pulser coil are used to calculate the engine speed In addition the pulser sig nals are used to determine the forecast starting position of the ignition timing 1 Cylinder id...

Page 25: ...ignal 7 Starting signal 5 BTDC for cylinders 1 and 4 8 Starting signal 5 BTDC for cylinders 2 and 3 9 Rotating direction Warm up control After the starting control is completed the control transfers t...

Page 26: ...stop the igni tion of cylinders 1 and 4 if the engine speed is over 2 000 r min At the same time the microcom puter issues a warning by operating the warning lamp and the warning buzzer When the over...

Page 27: ...lt functions The power trim and tilt cylinder has been integrated with the gear pump housing the reservoir tank and the power trim and tilt motor in order to achieve a smaller and more compact unit Hy...

Page 28: ...inder 2 Ram 3 Check valve 4 Down main valve 5 Down relief valve 6 Motor 7 Gear pump 8 Up main valve 9 Reservoir 0 Manual valve A Up relief valve B Up shuttle piston C Down shuffle piston D Trim cylind...

Page 29: ...gear pump and also sucks fluid in through the reservoir The pressurized fluid forces up the trim cylinder along with the tilt piston free piston and trim cylin der base As the trim cylinder moves up...

Page 30: ...ressurized fluid continues to flow into the lower part of the trim cylinder pushing up the tilt piston and free piston and further extending the ram As the tilt piston moves up and off of the trim cyl...

Page 31: ...3 End screw 4 Check valve 5 Trim cylinder 6 Reservoir 7 Down main valve 8 Gear pump 9 Up main valve 0 Up shuttle piston A Down shuttle piston B Trim cylinder base C Free piston D Tilt piston E Balls R...

Page 32: ...al information 1 27 62Y3A11 Circular flow 1 Power trim and tilt cylinder 2 Ram 3 Trim cylinder 4 Motor 5 Reservoir 6 Up relief valve 7 Gear pump 8 Free piston 9 Tilt piston Return Send 1 2 3 4 5 6 5 7...

Page 33: ...to move inward Once the balls move in the trim cylinder is then able to move down and power trim and tilt fluid continues to flow into the cylinder and pushes the trim cylinder down along with the til...

Page 34: ...Ram 3 Trim cylinder 4 Down relief valve 5 Down main valve 6 Gear pump 7 Reservoir 8 Up relief valve 9 Up shuttle piston 0 Up main valve A Down shuttle piston B Ball C Trim cylinder base D Free piston...

Page 35: ...event inter nal damage to the power trim and tilt unit and help to protect the bracket and lower unit from dam age in case the outboard motor hits something during operation When the outboard motor hi...

Page 36: ...31 62Y3A11 Damper function 1 Power trim and tilt cylinder 2 Trim cylinder 3 Ram 4 Tilt piston absorber 5 Tilt piston 6 Free piston 7 Check valve 8 Tilt piston absorber 9 Tilt piston Send Moving direct...

Page 37: ...When the engine speed is at the full throttle operating range 5 000 6 000 r min an ideal propeller for the boat is one that provides maximum performance in relation to boat speed and fuel consumption...

Page 38: ...he 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 betwee...

Page 39: ...b Adjust if neces sary 3 Check that the alignment mark c is aligned with the mark d Adjust if neces sary CAUTION The shift throttle cable joint must be screwed in a minimum of 8 0 mm 0 31 in e Checki...

Page 40: ...ngine 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 en...

Page 41: ...n 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 Hour After test run 1 Check for water in...

Page 42: ...GEN INFO General information 1 37 62Y3A11 MEMO...

Page 43: ...tions General specifications 2 1 Maintenance specifications 2 5 Power unit 2 5 Lower unit 2 9 Electrical 2 9 Power unit 2 12 Lower unit 2 16 Electrical 2 16 Dimensions 2 19 Tightening torques 2 29 Spe...

Page 44: ...ut kW hp 5 500 r min 36 8 50 Full throttle operating range r min 5 000 6 000 Maximum fuel consumption L US gal lmp gal hr 6 000 r min 17 3 4 57 3 81 Power unit Type In line 4 stroke OHC 8 valves Cylin...

Page 45: ...r oil type Hypoid gear oil Gear oil grade API SAE GL 4 90 Gear oil quantity L US qt lmp qt 0 43 0 45 0 38 Bracket Trim angle at 12 degree boat transom Degree 4 20 Tilt up angle Degree 69 Steering angl...

Page 46: ...el consumption L US gal lmp gal hr 6 000 r min 17 3 4 57 3 81 Power unit Type In line 4 stroke OHC 8 valves Cylinder quantity 4 Displacement cm3 cu in 935 57 1 Bore stroke mm in 63 0 75 0 2 48 2 95 Co...

Page 47: ...l type Hypoid gear oil Gear oil grade API SAE GL 4 90 Gear oil quantity L US qt lmp qt 0 61 0 64 0 54 Bracket Trim angle at 12 degree boat transom Degree 4 20 Tilt up angle Degree 69 Steering angle De...

Page 48: ...m in 63 00 63 01 2 480 2 481 Taper limit mm in 0 08 0 003 Out of round limit mm in 0 05 0 002 Pistons Piston diameter D mm in 62 95 62 96 2 478 2 479 Measuring point H mm in 5 0 2 Piston to cylinder c...

Page 49: ...in 36 94 36 95 1 4543 1 4547 Camshaft journal oil clearance 1 mm in 0 055 0 100 0 0022 0 0039 2 3 4 mm in 0 045 0 090 0 0018 0 0035 Maximum camshaft runout mm in 0 04 0 0016 Rocker arm shafts Outside...

Page 50: ...024 1 4173 1 4183 Crank pin oil clearance mm in 0 016 0 040 0 0006 0 0015 Big end bearing thickness Yellow mm in 1 500 1 504 0 0591 0 0592 Red mm in 1 496 1 500 0 0589 0 0591 Pink mm in 1 492 1 496 0...

Page 51: ...open lower limit mm in 3 0 0 12 Fuel pump Discharge L US gal Imp gal hr 6 000 r min 70 18 5 15 4 Pressure kPa kgf cm2 psi 49 0 49 7 0 Plunger stroke mm in 5 85 9 05 0 23 0 35 Carburetor ID mark USA a...

Page 52: ...ada F50TH F50TR Worldwide F50AEHD F50AEHT F50AED F50AET Ignition system Ignition timing engine idle speed Degree TDC 1 5 Charge coil output peak voltage L Br cranking 1 1 V 144 cranking 2 1 V 137 1 50...

Page 53: ...ard undercut mm in 0 8 0 03 Wear limit mm in 0 2 0 01 Charging system Fuse A 20 Lighting coil output peak voltage G G cranking 1 V 11 9 1 500 r min 1 V 42 3 500 r min 1 V 127 Lighting coil resistance...

Page 54: ...ance P B 10 288 3 Fluid type ATF Dexron II Brushes Standard length mm in 10 0 39 Wear limit mm in 3 5 0 14 Commutator Standard diameter mm in 22 0 0 87 Wear limit mm in 21 0 0 83 Mica Standard undercu...

Page 55: ...aper limit mm in 0 08 0 003 Out of round limit mm in 0 05 0 002 Pistons Piston diameter D mm in 62 95 62 96 2 478 2 479 Measuring point H mm in 5 0 2 Piston to cylinder clearance mm in 0 04 0 06 0 001...

Page 56: ...1 4543 2 3 4 mm in 36 94 36 95 1 4543 1 4547 Camshaft journal oil clearance 1 mm in 0 055 0 100 0 0022 0 0039 2 3 4 mm in 0 045 0 090 0 0018 0 0035 Maximum camshaft runout mm in 0 04 0 0016 Rocker arm...

Page 57: ...183 Crank pin oil clearance mm in 0 016 0 040 0 0006 0 0015 Big end bearing thickness Yellow mm in 1 500 1 504 0 0591 0 0592 Red mm in 1 496 1 500 0 0589 0 0591 Pink mm in 1 492 1 496 0 0587 0 0589 Gr...

Page 58: ...alve open lower limit mm in 3 0 0 12 Fuel pump Discharge L US gal Imp gal hr 6 000 r min 70 18 5 15 4 Pressure kPa kgf cm2 psi 49 0 49 7 0 Plunger stroke mm in 5 85 9 05 0 23 0 35 Carburetor ID mark U...

Page 59: ...ED FT50CET Ignition system Ignition timing engine idle speed Degree TDC 1 5 Charge coil output peak voltage L Br cranking 1 1 V 144 cranking 2 1 V 137 1 500 r min V 169 3 500 r min V 129 Charge coil r...

Page 60: ...1 22 Mica Standard undercut mm in 0 8 0 03 Wear limit mm in 0 2 0 01 Charging system Fuse A 20 Lighting coil output peak voltage G G cranking 1 V 11 9 1 500 r min 1 V 42 3 500 r min 1 V 127 Lighting...

Page 61: ...88 3 Fluid type ATF Dexron II Brushes Standard length mm in 10 0 39 Wear limit mm in 3 5 0 14 Commutator Standard diameter mm in 22 0 0 87 Wear limit mm in 21 0 0 83 Mica Standard undercut mm in 1 5 0...

Page 62: ...SPEC Specifications 2 19 62Y3A11 Dimensions Exterior...

Page 63: ...6 0 02 X mm in 16 8 0 7 L10 mm in 63 2 5 H1 L mm in 876 34 5 X mm in 990 39 0 H2 mm in 519 20 4 H3 mm in 175 6 9 H4 L mm in 536 21 1 X mm in 647 25 5 H5 mm in 732 28 8 H6 L mm in 685 27 0 711 28 0 X...

Page 64: ...SPEC Specifications 2 21 62Y3A11 Exterior...

Page 65: ...n 0 6 0 02 0 8 0 03 X mm in 16 8 0 7 L10 mm in 63 2 5 H1 L mm in 876 34 5 917 36 1 X mm in 990 39 0 H2 mm in 519 20 4 H3 mm in 175 6 9 191 7 5 H4 L mm in 536 21 1 X mm in 647 25 5 H5 mm in H6 L mm in...

Page 66: ...SPEC Specifications 2 23 62Y3A11 Exterior W2 W5 W1 W3 W6 L3 L7 L2 L10 H9 H5 H7 H10 H8 H4 H3 H11 H1 L8 C1 L5 L9 L4 A3 A2 H6 H2 L6 L1 A1 S62Y2230...

Page 67: ...mm in 0 8 0 03 X mm in L10 mm in 63 2 5 H1 L mm in 917 36 1 X mm in H2 mm in 519 20 4 H3 mm in 191 7 5 H4 L mm in 536 21 1 X mm in H5 mm in 680 26 8 H6 L mm in 723 28 5 X mm in H7 mm in 330 13 0 H8 m...

Page 68: ...SPEC Specifications 2 25 62Y3A11 Exterior...

Page 69: ...9 L9 L mm in 0 8 0 03 X mm in L10 mm in 63 2 5 H1 L mm in 917 36 1 X mm in H2 mm in 519 20 4 H3 mm in 191 7 5 H4 L mm in 536 21 1 X mm in H5 mm in H6 L mm in 723 28 5 X mm in H7 mm in 330 13 0 H8 mm i...

Page 70: ...TR Canada F50TH F50TR Worldwide F50AEHD F50AEHT F50AED F50AET B1 mm in 126 5 0 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 355 14 0 B7 mm in B8 mm in 139 5 5 B9 mm...

Page 71: ...TR Worldwide FT50BET FT50CEHD FT50CED FT50CET B1 mm in 126 5 0 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 355 14 0 B7 mm in B8 mm in 139 5 5 B9 mm in 18 5 0 7 C2...

Page 72: ...r unit bolt M8 21 2 1 15 Tensioner bolt 8 0 8 5 8 Tensioner adjusting bolt M8 25 2 5 18 Drive sprocket nut 140 14 101 Driven sprocket bolt M10 38 3 8 28 Spark plug 18 1 8 13 Cylinder head bolt 1st M6...

Page 73: ...r handle assembly nut FT50C 37 3 7 27 Throttle cable short locknut FT50C 37 3 7 27 Upper mount nut 24 2 4 17 Lower mount nut 42 4 2 30 Trim sensor screw M6 2 0 2 1 4 Clamp bracket self locking nut 23...

Page 74: ...able sections of this man ual To avoid warpage tighten multi fastener assemblies in a crisscross fashion and pro gressive stages until the specified torque is reached Unless otherwise specified torque...

Page 75: ...nce 3 10 Checking the spark plugs 3 11 Checking the thermostat 3 12 Checking the cooling water passage 3 13 Control system 3 13 Checking the throttle cable operation 3 13 Checking the gearshift operat...

Page 76: ...et holder YB 06139 Universal puller YB 06117 Inductive self powered tachometer YU 08036 B Battery powered timing light YM 33277 A Pressurfge vacuum tester YB 35956 A Oil filter wrench 90890 01426 Flyw...

Page 77: ...62Y3A11 3 2 1 2 3 4 5 6 7 8 I Timing light 90890 03141 Leakage tester 90890 06762 Special service tools...

Page 78: ...Top cowling fit Check 3 4 Fuel system Fuel joint and fuel hoses Check 3 4 Fuel filter Check replace 3 5 Fuel tank Cleaning Power unit Engine oil Change 3 5 Oil filter Change 3 5 Timing belt Check 3 7...

Page 79: ...move the hook away from the seal 4 Tighten the nuts and bolts 5 Check the fitting again and if necessary repeat steps 2 4 Fuel system 3 Checking the fuel joint and fuel hoses fuel joint to carburetor...

Page 80: ...Place the outboard in an upright position 2 Remove the engine oil dipstick wipe it clean and then insert it back into the oil filler hole 3 Remove the dipstick again to check the oil level and the oi...

Page 81: ...l 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 7 Fill the specified engine oil into the oil filler h...

Page 82: ...r b of the timing belt for cracks damage or wear Replace if necessary CAUTION Do not turn the flywheel magnet counter clockwise otherwise the valve system may be damaged Replacing the timing belt 1 Tu...

Page 83: ...the fly wheel magnet NOTE Apply force to the crankshaft end until the fly wheel magnet comes off the tapered portion of the crankshaft 3 Disconnect the stator couplers 3 and then remove the stator 4 4...

Page 84: ...out 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 8 Install the tensioner and bolts and then tighten the b...

Page 85: ...en disconnect the high tension cords and blowby hose 1 2 Remove the spark plugs fuel pump 2 and cylinder head cover 3 3 Turn the flywheel clockwise and align the 1 mark a on the driven sprocket with t...

Page 86: ...sen the locknut 4 and then turn the adjusting screw 5 until the specified valve clearance is obtained NOTE To decrease the valve clearance turn the adjusting screw clockwise To increase the valve clea...

Page 87: ...ark plug gap a Adjust if out of specification 5 Install the spark plug tighten it finger tight b then to the specified torque with a spark plug wrench c Checking the thermostat 1 Remove the cover 1 th...

Page 88: ...gine 3 Check for water flow at the cooling water outlet If there is no water flow check the cooling water passage inside the out board Control system 3 Checking the throttle cable operation 1 Check th...

Page 89: ...at the gearshift operates smoothly when shifting from neutral into forward and reverse Adjust the shift cable length if necessary 2 Set the gearshift to the neutral position 3 Loosen the locknut 1 rem...

Page 90: ...n b 4 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 the engine Checking the ignition timing 1 Start the engine and warm it...

Page 91: ...isten to the winding sound of the PTT motor for smooth operation 2 Fully tilt the outboard up and then sup port it with the tilt stop lever 1 to check the lock mechanism of the lever Checking the powe...

Page 92: ...oil level in the lower case NOTE The gear oil level should be at the brim of the check hole 3 If necessary add sufficient gear oil of the recommended type to the correct level 4 Install the check scr...

Page 93: ...r oil pump into the drain hole and slowly fill the gear oil until oil flows out of the check hole and no air bubbles are visible 7 Install the check screw quickly install the drain screw and then tigh...

Page 94: ...ls may be damaged NOTE Cover the check hole with a rag when remov ing the pressure vacuum tester from the lower unit 3 If pressure drops below specification check the drive shaft and propeller shaft o...

Page 95: ...Always follow these preventive measures Avoid bodily contact with electrolyte as it can cause severe burns or permanent eye injury Wear protective eye gear when handling or working near batteries Ant...

Page 96: ...mentioned in this manual may not always apply therefore consult the instruc tion manual of the battery Disconnect the negative lead first then the positive lead Lubrication 1 Apply water resistant gre...

Page 97: ...62Y3A11 3 22 1 2 3 4 5 6 7 8 I NOTE Apply grease to the grease nipple until it flows from the bushings a 2 Apply anti corrosion grease to the areas shown General...

Page 98: ...CHK ADJ Periodic checks and adjustments 3 23 62Y3A11 MEMO...

Page 99: ...fuel pump 4 9 Disassembling the fuel pump 4 9 Checking the diaphragm and valves 4 10 Assembling the fuel pump 4 10 Carburetor unit 4 11 Carburetor 4 17 Checking the carburetor 4 19 Checking the Prime...

Page 100: ...ls 4 Pressure vacuum tester YB 35956 A Inductive self powered tachometer YU 08036 B Carburetor synchronizer YU 08030 Vacuum pressure pump gauge set 90890 06756 Digital tachometer 90890 06760 Vacuum ga...

Page 101: ...and blowby hoses 1 Blowby hose 2 Hose acceleration pump to carburetor 3 Fuel hose fuel joint to fuel filter 4 Fuel hose fuel filter to fuel pump 5 Fuel hose fuel pump to carburetor 6 Hose carburetor...

Page 102: ...FUEL Fuel system 4 3 62Y3A11 Cooling water hose Models with flushing device...

Page 103: ...62Y3A11 4 4 1 2 3 4 5 6 7 8 I MEMO Hose routing...

Page 104: ...FUEL Fuel system 4 5 62Y3A11 Fuel line 4...

Page 105: ...lter 1 F50 F50A 3 Fuel filter 1 T50 FT50B FT50C 4 Fuel pump 1 5 Bolt 1 M6 25 mm 6 Seal 1 7 Fuel hose 1 Fuel joint to fuel filter 8 Clip 3 9 Bolt 1 M8 14 mm 10 Nut 1 11 Bracket 1 12 Fuel hose 1 Fuel fi...

Page 106: ...FUEL Fuel system 4 7 62Y3A11 Fuel filter and fuel pump 4...

Page 107: ...lter cup 1 2 O ring 1 Not reusable 3 Fuel filter element 1 4 Body 1 5 Float 1 6 Screw 4 M5 35 mm 7 Cover 1 8 Fuel pump body 2 1 9 Fuel pump body 1 1 10 Nut 4 11 Plunger 1 12 Spring 1 13 Spring 1 14 Pi...

Page 108: ...sive 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 e...

Page 109: ...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 an...

Page 110: ...FUEL Fuel system 4 11 62Y3A11 Carburetor unit 4...

Page 111: ...lb 1 Carburetor assembly 1 Joint to silencer 2 Clip 1 3 Blowby hose 1 4 Prime Start coupler 1 5 Bolt 2 M6 30 mm 6 Collar 2 7 Throttle link rod 1 8 O ring 8 Not reusable 9 Insulator 1 10 Dowel pin 2 1...

Page 112: ...FUEL Fuel system 4 13 62Y3A11...

Page 113: ...Part name Q ty Remarks Tightening torques Stage N m kgf m ft lb 1 Acceleration pump 1 2 Screw 3 M5 9 mm 3 Link rod 1 4 Hose 1 Acceleration pump to acceleration pump 5 Hose 4 Acceleration pump to carbu...

Page 114: ...FUEL Fuel system 4 15 62Y3A11...

Page 115: ...encer 1 3 Plastic tie 1 Not reusable 4 Blowby hose 1 Silencer to joint 5 Bolt 8 M6 90 mm 6 Collar 8 7 O ring 4 Not reusable 8 Plate 1 9 O ring 4 Not reusable 10 O ring 4 Not reusable 11 Joint 1 12 Pla...

Page 116: ...FUEL Fuel system 4 17 62Y3A11 Carburetor 4...

Page 117: ...8 Main nozzle 1 9 O ring 1 Not reusable 10 Plug 1 11 Float 1 12 Screw 1 M4 6 mm 13 Float pin 1 14 Gasket 1 Not reusable 15 Float chamber 1 16 Drain screw 1 17 O ring 1 Not reusable 18 Screw 4 M4 13 m...

Page 118: ...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 je...

Page 119: ...ed 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 Measur...

Page 120: ...ghtly seated then out the specified number of turns Adjusting the throttle link rod 1 Push the throttle control lever 1 to the fully open position as shown and then measure the gap between the carbure...

Page 121: ...ion a until the engine idle speed has decreased to approximately 50 r min then in direction b 5 8 turn 4 Turn the throttle stop screw 3 in direc tion c or d until the specified engine idle speed is ob...

Page 122: ...NOTE For best results use a vacuum gauge 3 commercially obtainable with four adapters like the one shown in the illustration 4 Adjust the idle speed to 1 000 r min by turning the throttle stop screw 4...

Page 123: ...in Hg and to check the stability of the engine Adjusting the dash pot acceleration pump 1 Start the engine and warm it up for 5 min utes and then check the engine speed at the operation point of the...

Page 124: ...he acceleration pump stopper 3 comes in contact with point a 6 Turn the adjusting screw 4 in or out until the specified engine speed is obtained 7 Open and close the throttle cam a few times and check...

Page 125: ...62Y3A11 4 26 1 2 3 4 5 6 7 8 I MEMO...

Page 126: ...ing belt and sprockets 5 32 Cylinder head 5 35 Removing the cylinder head 5 39 Checking the valve springs 5 40 Checking the valves 5 40 Checking the valve guides 5 41 Replacing the valve guides 5 41 C...

Page 127: ...rance 5 58 Checking the piston pin boss bore 5 58 Checking the piston pin 5 58 Checking the connecting rod small end inside diameter 5 59 Checking the connecting rod big end side clearance 5 59 Checki...

Page 128: ...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 Replace the engine shut off switch Is t...

Page 129: ...gasoline Check the starter motor Check operation of the starter motor pinion Remove all spark plugs and then the engine Listen for the operation sound of the starter relay Check the power unit Is ther...

Page 130: ...n of the spark plugs again Check the compression pres sure of the combustion chamber Check the ignition system out put peak voltage Check the valve clearance WARNING Do not touch any of the connection...

Page 131: ...ing condition Kinks or fuel leakage Replace the pri mary 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 fu...

Page 132: ...es 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 Check the ignition spark gap using the spark gap teste...

Page 133: ...e throttle cable opera tion and lubricate it if necessary Out of specifi cation Do the valves close simul taneously Do the valves close simul taneously Check the second ary air intake on the O ring an...

Page 134: ...the compression pressure of power unit Check the needle valve of the carburetor for debris or wear Adjust the throttle cable Check each jet of the carburetor for clogs or debris Clean or replace the r...

Page 135: ...heck the water inlet for clogs or debris Check the thermoswitch Check that cooling water is dis charged from the pilot water outlet Replace the thermostat Replace the CDI unit Replace the thermoswitch...

Page 136: ...the oil pressure Check the oil pressure switch Clean or replace the respective parts At specified level Out of specifi cation Good condi tion Debris or wear Check the oil pas sage Yes No Yes No Yes Y...

Page 137: ...der YB 06139 Universal puller YB 06117 Crankshaft holder YB 06562 Valve spring compressor YM 01253 Valve guide remover YM 01122 Valve guide reamer YM 01196 Valve seat cutter set YM 91043 C Drive shaft...

Page 138: ...ywheel holder 90890 06522 Flywheel puller 90890 06521 Crankshaft holder 18 90890 06562 Valve spring compressor 90890 04019 Valve spring compressor attachment 90890 06320 Valve guide remover installer...

Page 139: ...2 3 4 5 6 7 8 I Valve seat cutter 90890 06315 90890 06323 90890 06326 90890 06328 90890 06555 Bearing outer race attachment 90890 06626 Oil filter wrench 90890 01426 Piston slider 90890 06529 Special...

Page 140: ...POWR Power unit 5 13 62Y3A11 Power unit 5...

Page 141: ...eel magnet 1 2 Stator coil 1 3 Cover 1 4 Grommet 2 5 Nut 1 160 16 116 6 Washer 1 7 Bolt 3 M6 25 mm 8 Lighting coil coupler 1 9 Charge coil coupler 1 10 Stator base 1 11 Pulser coil coupler 1 12 Screw...

Page 142: ...POWR Power unit 5 15 62Y3A11...

Page 143: ...0B FT50C 7 Carburetor assembly 1 8 Bolt 3 M6 20 mm 9 Plate 1 10 Clip 1 11 Clip 1 12 Grommet 1 13 Holder 1 F50 F50A T50 FT50B 14 Holder 1 FT50C 15 Bolt 2 16 O ring 1 Not reusable 17 Clip 2 18 Fuel hose...

Page 144: ...POWR Power unit 5 17 62Y3A11...

Page 145: ...models 10 Fuse holder lead 1 11 Clip 1 12 Warning indicator coupler 1 EHD EHT models 13 Trailer switch coupler 1 EHT ET models 14 Plastic tie 1 Not reusable 15 Pilot water hose 1 16 Bolt 2 M6 20 mm 1...

Page 146: ...POWR Power unit 5 19 62Y3A11...

Page 147: ...9 Ground lead 3 10 Bolt 1 M6 12 mm 11 Oil pressure switch 1 9 0 9 6 5 12 Oil pressure switch lead 1 13 Screw 1 2 0 2 1 4 14 Ignition coil lead 2 15 Bolt 4 M6 30 mm 7 0 7 5 1 16 Thermoswitch lead 2 17...

Page 148: ...POWR Power unit 5 21 62Y3A11...

Page 149: ...Part name Q ty Remarks Tightening torques Stage N m kgf m ft lb 1 Power unit 1 2 Engine oil dipstick 1 3 Gasket 1 Not reusable 4 Dowel pin 2 5 Bolt 2 M6 16 mm 6 Bolt 8 M8 80 mm 21 2 1 15 7 Apron 1 8 S...

Page 150: ...POWR Power unit 5 23 62Y3A11...

Page 151: ...torques Stage N m kgf m ft lb 1 Throttle link rod 1 2 Throttle cam 1 3 Throttle control lever 1 4 Clip 1 5 Bushing 1 6 Bolt 1 M6 20 mm 7 Spring 1 8 Collar 1 9 Bracket 1 10 Bolt 1 M6 30 mm 11 Shift rod...

Page 152: ...add a small amount of 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 c...

Page 153: ...lipping off easily To prevent damage 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 Appl...

Page 154: ...isconnect the battery leads 5 10 pin coupler 6 PTT relay leads 7 EHT ET PTT motor leads 8 EHT ET ground lead 9 EHT ET warning indi cator coupler 0 EHD EHT trailer switch coupler A EHT ET pilot water h...

Page 155: ...62Y3A11 5 28 1 2 3 4 5 6 7 8 I 7 Remove the power unit by removing the bolts G Power unit...

Page 156: ...POWR Power unit 5 29 62Y3A11 Timing belt and sprockets 5...

Page 157: ...g belt 1 2 Drive sprocket 1 3 Driven sprocket 1 4 Bolt 1 8 0 8 5 8 5 Bolt 1 M8 20 mm 25 2 5 18 6 Tensioner 1 7 Spring 1 8 Nut 1 140 14 101 9 Retaining plate 2 10 Woodruff key 1 11 Bolt 1 M10 40 mm 38...

Page 158: ...he breather hose and loosen the drive sprocket nut 1 NOTE Use a deep socket 2 M42 for this proce dure Do not turn the camshaft when loosening the drive sprocket nut 3 Remove the tensioner 4 and timing...

Page 159: ...f necessary 2 Check the drive sprocket 1 and driven sprocket 2 for cracks damage or wear Replace if necessary Installing the timing belt and sprockets 1 Check that the 1 mark a on the driven sprocket...

Page 160: ...not get oil or grease on the timing belt 5 Install the tensioner 8 and bolts and then tighten the bolts finger tight 6 Take up the timing belt slack by turning the drive sprocket clockwise at least t...

Page 161: ...For worldwide 10 Tighten the drive sprocket nut 6 to the specified torque and then install the breather hose NOTE Use a deep socket A M42 for this proce dure Flywheel magnet holder YB 06139 Flywheel h...

Page 162: ...POWR Power unit 5 35 62Y3A11 Cylinder head 5...

Page 163: ...st 2nd 23 47 2 3 4 7 17 34 7 Spark plug 4 18 1 8 13 8 Bolt 5 M6 25 mm 1st 2nd 6 12 0 6 1 2 4 3 8 7 9 Dowel pin 2 10 Cylinder head gasket 1 Not reusable 11 Grommet 4 12 Anode 4 13 Cover 4 14 Bolt 4 15...

Page 164: ...POWR Power unit 5 37 62Y3A11...

Page 165: ...t valve 4 5 Intake valve 4 6 Camshaft 1 7 Valve cotter 16 8 Spring retainer 8 9 Valve spring 8 10 Spring seat 8 11 Stem seal 8 Not reusable 12 Valve guide 8 Not reusable 13 Retaining bolt 1 14 Gasket...

Page 166: ...l pin hole a is in the position shown in the illustra tion Adjust if necessary 2 Remove the cylinder head cover bolts in the sequence shown 3 Remove the cylinder head bolts in the sequence shown 4 Rem...

Page 167: ...lve 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 pi...

Page 168: ...cation Replacing the valve guides 1 Remove the valve guide 1 by striking the special service tool from the combus tion chamber side Valve margin thickness a Intake 0 6 1 0 mm 0 024 0 039 in Exhaust 0...

Page 169: ...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 sl...

Page 170: ...e cutter evenly downward at a pressure of 40 50 N 4 5 kgf 8 8 11 lbf to prevent chatter marks 3 Use a 30 cutter to adjust the contact width of the top edge of the valve seat b Previous contact width V...

Page 171: ...Previous contact width 7 If the valve seat contact area is too nar row and situated near the top edge of the valve face use a 30 cutter to cut the top edge of the valve seat If necessary use a 45 cut...

Page 172: ...if necessary 2 Measure the rocker arms inside diameter b and rocker arm shaft outside diameter c Replace if out of specification Checking the camshaft 1 Measure the cam lobe Replace if out of specifi...

Page 173: ...d 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 Repl...

Page 174: ...guide 2 Install the valve 2 spring seat 3 valve spring 4 and spring retainer 5 in the sequence shown and then attach the special service tool NOTE Face the fine pitch side a of the valve spring toward...

Page 175: ...4 Lightly tap the spring retainer with a plas tic hammer to set the valve cotter securely Installing the camshaft 1 Install the new oil seal 1 For USA and Canada For worldwide 2 Install the camshaft 2...

Page 176: ...r arm retainer 4 stopper guide 5 by installing the bolts NOTE Make sure that the arrow marks b on the two tensioners and stopper guides are facing up 3 Install the rocker arm shaft assembly to the cyl...

Page 177: ...ce shown NOTE Apply engine oil to the cylinder head bolts M9 before installation 3 Tighten the cylinder head cover bolts in the sequence shown Cylinder head bolt M9 1st 23 N m 2 3 kgf m 17 ft lb 2nd 4...

Page 178: ...POWR Power unit 5 51 62Y3A11 Cylinder body 5...

Page 179: ...ain bearing 10 8 Oil seal 1 Not reusable 9 Connecting rod bearing 8 10 Connecting rod cap 4 11 Bolt 8 1st 2nd 6 17 0 6 1 7 4 3 12 12 Dowel pin 2 13 Cylinder body 1 14 Connecting rod 1 15 Piston pin cl...

Page 180: ...POWR Power unit 5 53 62Y3A11...

Page 181: ...8 I Tightening sequence No Part name Q ty Remarks Tightening torques Stage N m kgf m ft lb 31 Anode 1 32 Cover 1 33 Cover 1 34 Bolt 1 M6 20 mm 35 Bolt 1 M5 12 mm 36 Bolt 10 M6 35 mm 1st 2nd 6 12 0 6...

Page 182: ...ply a thin coat of the new 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 cove...

Page 183: ...at the specified measuring point Replace if out of specification Checking the cylinder bore 1 Measure the cylinder bore D1 D6 a at measuring points b c and d and in direction e which is parallel to th...

Page 184: ...crown of an inverted pis ton 3 Check the piston ring end gap d at the specified measuring point Replace if out of specification Taper limit maximum of D1 or D2 minimum of D5 or D6 0 08 mm 0 003 in Out...

Page 185: ...oss bore Replace the piston if out of specification Checking the piston pin 1 Measure the piston pin diameter Replace if out of specification Piston ring groove Top ring a 1 23 1 25 mm 0 048 0 049 in...

Page 186: ...2 Calculate the difference between a and b Replace if out of specification Checking the crankshaft 1 Measure the crankshaft journal diameter a crank pin diameter b and crank pin width c Replace the cr...

Page 187: ...ert the projection a of the bearing into the notch in the cylinder body 4 Put a piece of Plastigauge PG 1 on each main journal parallel to the crank shaft NOTE Do not put the Plastigauge PG 1 over the...

Page 188: ...ower half into the connecting rod cap 2 CAUTION Install the bearings in their original posi tions NOTE Insert the projection a of the bearing into the slot on the cap and connecting rod 3 Put a piece...

Page 189: ...ssed Plastigauge PG 1 on each crank pin Replace the connecting rod bearing if out of specification Selecting the crankshaft main journal bearing 1 When replacing the main bearing select the suitable b...

Page 190: ...ng 1 When replacing the connecting rod bear ing select the suitable connecting rod bearing as follows 2 Check the crank pin mark on the crank shaft 1 and the connecting rod cap mark or painted color o...

Page 191: ...ecting rod in the same direction as the UP mark b on the piston Always use new piston pin clips and do not allow the piston pin clip end to align with the piston pin slot c 2 Install the oil ring 5 se...

Page 192: ...aring into the notch in the cylinder body 7 Set the crankshaft A and oil seals B and C into the cylinder body as shown Apply engine oil to the inner oil seal jour nal bearings and connecting rod bear...

Page 193: ...journal bearings 11 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 cr...

Page 194: ...es and in the sequence shown Installing the power unit 1 Install the dowel pins 1 and gasket 2 2 Install the power unit 3 by installing the bolts 4 then tightening them to the specified torque 3 Insta...

Page 195: ...warn ing indicator coupler A EHD EHT ground lead B EHT ET PTT motor leads C EHT ET PTT relay leads D EHT ET 10 pin coupler E and battery leads F 6 Connect the throttle link rod G and fuel hose H 7 Co...

Page 196: ...SA and Canada For worldwide 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 ins...

Page 197: ...62Y3A11 5 70 1 2 3 4 5 6 7 8 I MEMO...

Page 198: ...case F50 F50A 6 21 Removing the drive shaft 6 23 Disassembling the drive shaft assembly 6 23 Disassembling the forward gear 6 23 Disassembling the lower case 6 24 Checking the pinion and forward gear...

Page 199: ...opeller shaft housing 6 55 Installing the propeller shaft housing 6 57 Drive shaft and lower case T50 FT50B FT50C 6 59 Removing the drive shaft 6 61 Disassembling the drive shaft 6 61 Disassembling th...

Page 200: ...lide hammer and adapters YB 06096 Bearing housing needle bearing remover YB 06112 YB 06153 Driver handle YB 06071 Bearing housing needle bearing installer YB 06111 Oil seal installer YB 06168 Forward...

Page 201: ...taper roller bearing cup installer YB 06110 Forward gear bearing cup installer YB 06109 YB 06276 B Pinion shim selecting tools YB 34432 8 YB 34432 9 YB 34432 10A YB 34432 11A YB 34432 17 Forward gear...

Page 202: ...installer YB 06269 Gland nut wrench YB 34447 Crank upper and lower seal installer YB 06244 Forward gear needle bearing and tapered roller bearing installer YB 06200 Bearing housing puller claw 90890...

Page 203: ...nt 90890 06607 90890 06610 90890 06611 90890 06612 90890 06614 90890 06653 Driver rod L3 90890 06652 Driver rod SS 90890 06604 Bearing depth plate 90890 06603 Bearing inner race attachment 90890 06639...

Page 204: ...0 06523 Outer race puller claw A 90890 06532 Driver rod SL 90890 06602 Bearing outer race attachment 90890 06621 90890 06622 90890 06626 90890 06627 Driver rod LS 90890 06606 Driver rod LL 90890 06605...

Page 205: ...0 06706 Magnet base plate 90890 07003 Dial gauge set 90890 01252 Magnet base 90890 06705 Ring nut wrench 3 90890 06511 Ring nut wrench extension 90890 06513 Bearing housing puller claw L 90890 06502 B...

Page 206: ...LOWR Lower unit 6 7 62Y3A11 Lower unit F50 F50A 6...

Page 207: ...Hose 1 4 Check screw 1 7 0 7 5 1 5 Gasket 2 Not reusable 6 Bolt 4 M10 40 mm 40 4 0 29 7 Drain screw 1 7 0 7 5 1 8 Dowel pin 2 9 Bolt 1 M8 35 mm 10 Anode 1 11 Bolt 1 M8 60 mm 12 Thrust washer 1 13 Prop...

Page 208: ...ing and then remove the propeller nut and propeller 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 en...

Page 209: ...62Y3A11 6 10 1 2 3 4 5 6 7 8 I MEMO Lower unit F50 F50A...

Page 210: ...LOWR Lower unit 6 11 62Y3A11 Water pump and propeller shaft housing F50 F50A 6...

Page 211: ...Not reusable 10 Outer plate cartridge 1 11 Gasket 1 Not reusable 12 Dowel pin 2 13 Woodruff key 1 14 Slider 1 15 Spring 1 16 Cross pin 1 17 Dog clutch 1 18 Spring 1 19 Propeller shaft 1 20 Shift plung...

Page 212: ...nada For worldwide NOTE Install the bearing separator 2 between the reverse gear and propeller shaft housing completely then the other special service tools 2 Remove the ball bearing Bearing housing p...

Page 213: ...lace if necessary 2 Check the impeller 1 and insert plate cartridge 2 for cracks or wear Replace if necessary Slide hammer and adapters 7 YB 06096 Stopper guide plate 8 90890 06501 Stopper guide stand...

Page 214: ...ent 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 Repl...

Page 215: ...oil seal propeller side Do not strike the driver rod 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 t...

Page 216: ...ith the manufacture identification mark f facing outward propel ler side 4 Install the reverse gear assembly to the propeller shaft housing using a press Oil seal installer 6 YB 06168 Driver handle 7...

Page 217: ...alling the propeller shaft assembly be sure not to drop the shift plunger 3 Installing the water pump 1 Install the new gasket and outer plate cartridge 2 Install the Woodruff key into the drive shaft...

Page 218: ...ighten the bolts 7 and then install the grommet 8 and spacer 9 NOTE When installing the pump housing apply grease to the inside of the housing and then turn the drive shaft clockwise while pushing dow...

Page 219: ...62Y3A11 6 20 1 2 3 4 5 6 7 8 I MEMO Water pump and propeller shaft housing F50 F50A...

Page 220: ...LOWR Lower unit 6 21 62Y3A11 Drive shaft and lower case F50 F50A 6...

Page 221: ...11 Pinion shim As required 12 Sleeve 1 13 Oil seal housing assembly 1 14 Washer 1 15 Oil seal housing 1 16 O ring 1 Not reusable 17 Oil seal 2 Not reusable 18 Seal 1 19 Plate 1 20 Hose 1 21 Plastic t...

Page 222: ...ess the drive shaft threads a directly Do not reuse the bearing always replace it with a new one Disassembling the forward gear 1 Remove the taper roller bearing from the forward gear using a press CA...

Page 223: ...shift rod assembly and shift cam Slide hammer and adapters 1 YB 06096 Bearing outer race puller 2 90890 06523 Outer race puller claw A 3 90890 06532 Stopper guide stand 4 90890 06538 Slide hammer and...

Page 224: ...e if necessary Checking the drive shaft 1 Check the drive shaft for bends or wear Replace if necessary Checking the shift rod and shift cam 1 Check the shift rod and shift cam for cracks or wear Repla...

Page 225: ...lacing the pinion or lower case NOTE Apply gear oil to the inside and outside of the sleeve Install the sleeve with the projection f fac ing forward Driver handle 3 YB 06071 Drive shaft needle bearing...

Page 226: ...the drive shaft 1 Install the new drive shaft bearing into the drive shaft using a press For USA and Canada For worldwide NOTE Use a special service tool or a general pipe with the specified measurem...

Page 227: ...or USA and Canada For worldwide Installing the lower unit 1 Set the gearshift to the neutral position at power unit and lower unit Oil seal installer 3 YB 06168 Driver handle 4 YB 06071 Needle bearing...

Page 228: ...torque 4 Install the trim tab 2 to its original posi tion and then connect the speedometer hose 3 5 Install the propeller and propeller nut tighten the nut finger tight Place a block of wood between...

Page 229: ...from the bat teries and the engine shut off switch Put a block of wood between the cavitation plate and propeller to keep the propeller from turning NOTE If the grooves in the propeller nut 4 do not...

Page 230: ...LOWR Lower unit 6 31 62Y3A11 Shimming F50 for USA and Canada 6...

Page 231: ...unreadable assume that P is zero and check the backlash when the unit is assembled Example If P is 5 then M0 0 30 5 100 mm 0 30 0 05 mm 0 35 mm If P is 5 then M0 0 30 5 100 mm 0 30 0 05 mm 0 25 mm 2 I...

Page 232: ...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...

Page 233: ...he neces sary shim thickness T2 Add or remove shims if out of specification For measur ing procedures see Measuring the for ward and reverse backlash in this chapter NOTE Measure the backlash with the...

Page 234: ...LOWR Lower unit 6 35 62Y3A11 Shimming F50A for worldwide 6...

Page 235: ...er 1 4 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...

Page 236: ...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 thick ness T...

Page 237: ...reverse gear shims 1 Measure the backlash to find the shim thickness T2 Add or remove shims if out of specification For measuring pro cedures see Measuring the forward and reverse backlash in this cha...

Page 238: ...acklash indicator onto the drive shaft 18 mm 0 71 in in diameter then the dial gauge onto the lower unit NOTE Install the dial gauge so that the plunger a contacts the mark b on the backlash indica to...

Page 239: ...lockwise and measuring the backlash when the drive shaft stops in each direction 10 Add or remove shims if out of specifica tion M Measurement 11 Remove the special service tools and then install the...

Page 240: ...LOWR Lower unit 6 41 62Y3A11 Lower unit T50 FT50B FT50C 6...

Page 241: ...3 Hose 1 4 Check screw 1 7 0 7 5 1 5 Gasket 2 Not reusable 6 Dowel pin 2 7 Bolt 4 M10 40 mm 40 4 0 29 8 Drain screw 1 7 0 7 5 1 9 Grommet 1 10 Bolt 1 M10 45 mm 12 mm 11 Bolt 1 M8 60 mm 12 Thrust washe...

Page 242: ...ning and then remove the propeller nut and propeller 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 e...

Page 243: ...62Y3A11 6 44 1 2 3 4 5 6 7 8 I MEMO Lower unit T50 FT50B FT50C...

Page 244: ...LOWR Lower unit 6 45 62Y3A11 Water pump and shift rod T50 FT50B FT50C 6...

Page 245: ...Not reusable 8 Bolt 2 M6 16 mm 9 Woodruff key 1 10 Bolt 2 M8 55 mm 11 Bolt 2 M8 45 mm 12 Water pump housing 1 13 Grommet 1 14 Gasket 1 Not reusable 15 Insert plate cartridge 1 16 Impeller 1 17 Outer...

Page 246: ...coun terclockwise 90 b and then 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 and insert plate cartridge 2 for c...

Page 247: ...2 2 Install the new oil seals into the oil seal housing as shown For USA and Canada For worldwide 3 Install the new O ring 7 4 Install the new gasket 8 oil seal housing 9 new gasket 0 and outer plate...

Page 248: ...F NOTE Align the insert plate cartridge projection c with the hole d in the pump housing 8 Install the new gasket G pump housing assembly F and dowel pins H to the lower case 9 Install and tighten th...

Page 249: ...62Y3A11 6 50 1 2 3 4 5 6 7 8 I MEMO Water pump and shift rod T50 FT50B FT50C...

Page 250: ...LOWR Lower unit 6 51 62Y3A11 Propeller shaft housing T50 FT50B FT50C 6...

Page 251: ...Ball 2 4 Slider 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 1 105 10 5 76 14 Reverse gear 1 15 Thrust wa...

Page 252: ...ust washer For USA and Canada For worldwide Gland nut wrench 1 YB 34447 Ring nut wrench 3 1 90890 06511 Ring nut wrench extension 2 90890 06513 Bearing housing puller 3 YB 06207 Universal puller 4 YB...

Page 253: ...2 dog clutch 3 slider and shift plunger Checking the propeller shaft housing 1 Clean the propeller shaft housing using a soft brush and cleaning solvent and then check it for cracks Replace if necessa...

Page 254: ...propeller shaft for bends or wear Replace if necessary 2 Check the dog clutch and shift slider for cracks or wear Replace if necessary Assembling the propeller shaft assembly 1 Install the dog clutch...

Page 255: ...dwide NOTE Install an oil seal halfway into the propeller shaft housing then the other oil seal 3 Install the thrust washer 0 and ball bear ing A to the reverse gear B using a press For USA and Canada...

Page 256: ...mbly 3 2 Apply grease to the new O rings 3 Install the propeller shaft housing assem bly 4 into the lower case and then install the straight key 5 claw washer 6 and ring nut 7 4 Tighten the nut to the...

Page 257: ...11 6 58 1 2 3 4 5 6 7 8 I Gland nut wrench 8 YB 34447 Ring nut wrench 3 8 90890 06511 Ring nut wrench extension 9 90890 06513 Ring nut 7 105 N m 10 5 kgf m 76 ft lb Propeller shaft housing T50 FT50B F...

Page 258: ...LOWR Lower unit 6 59 62Y3A11 Drive shaft and lower case T50 FT50B FT50C 6...

Page 259: ...required 5 Sleeve 1 6 Hose 1 7 Plastic tie 1 Not reusable 8 Joint 1 9 Nut 1 10 Water inlet cover 2 11 Screw 1 5 0 5 3 6 12 Seal 1 13 Plate 1 14 Forward gear shim As required 15 Bearing outer race 1 N...

Page 260: ...euse the bearing always replace it with a new one Disassembling the forward gear 1 Remove the taper roller bearing from the forward gear using a press CAUTION Do not reuse the bearing always replace i...

Page 261: ...SA and Canada For worldwide NOTE Install the claws as shown Slide hammer and adapters 2 YB 06096 Stopper guide plate 3 90890 06501 Stopper guide stand 4 90890 06538 Bearing puller 5 90890 06535 Bearin...

Page 262: ...bling Replace if necessary Checking the drive shaft 1 Check the drive shaft for bends or wear Replace if necessary Checking the lower case 1 Check the skeg and torpedo for cracks or damage Replace if...

Page 263: ...n 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 Driver handle 1 YB 06071 Drive shaft needle b...

Page 264: ...Canada For worldwide 2 Install the new needle bearing into the forward gear to the specified depth Forward gear bearing cup installer 9 YB 06276 B Driver handle 0 YB 06071 Bearing outer race attachmen...

Page 265: ...the drive shaft assembly pinion and pinion nut and then tighten the nut to the specified torque Installing the lower unit 1 Set the gearshift to the neutral position at power unit and lower unit Gene...

Page 266: ...torque 4 Install the trim tab 2 to its original posi tion and then connect the speedometer hose 3 5 Install the propeller and propeller nut tighten the nut finger tight Place a block of wood between...

Page 267: ...om the bat teries and the engine shut off switch Put a block of wood between the cavitation plate and propeller to keep the propeller from turning NOTE If the grooves in the propeller nut 4 do not ali...

Page 268: ...LOWR Lower unit 6 69 62Y3A11 Shimming T50 for USA and Canada 6...

Page 269: ...nreadable assume that P is zero and check the backlash when the unit is assembled Example If P is 5 then M0 0 20 5 100 mm 0 20 0 05 mm 0 25 mm If P is 5 then M0 0 20 5 100 mm 0 20 0 05 mm 0 15 mm 2 In...

Page 270: ...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...

Page 271: ...the clearance M between the gauge pin and the press plate 4 Select the forward gear shims T1 NOTE The sum of T1 and M should not be more than M0 Forward gear shim selecting tools YB 34446 1 2 YB 34446...

Page 272: ...LOWR Lower unit 6 73 62Y3A11 Shimming FT50B FT50C for worldwide 6...

Page 273: ...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...

Page 274: ...ness T1 by using 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...

Page 275: ...mm 0 50 0 05 mm 0 45 mm 3 Select the forward gear shim s T1 as follows Example If T1 is 0 45 mm then the forward gear shim is 0 42 mm If T1 is 0 50 mm then the forward gear shim is 0 48 mm Calculated...

Page 276: ...iversal puller or 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 18 mm 0 71 in in diameter then the dial...

Page 277: ...measure the back lash when the drive shaft stops in each direction 10 Check the pinion shim if out of specifica tion 11 Remove the special service tools and then install the water pump assembly Backl...

Page 278: ...cking the shift rod assembly operation 7 29 Upper case 7 31 Disassembling the oil pan 7 39 Checking the oil strainer and the relief valve 7 39 Assembling the oil pan 7 39 Installing the upper case 7 4...

Page 279: ...he trim cylinder 7 67 Assembling the tilt cylinder 7 69 Bleeding the power trim and tilt not installed 7 70 Bleeding the power trim and tilt built in 7 71 Power trim and tilt motor 7 73 Checking the p...

Page 280: ...fluid level Disassemble the power trim and tilt unit and then check it Check the power trim and tilt motor Replace the power trim and tilt relay Close the plug Add fluid to the correct level At speci...

Page 281: ...the outboard motor up Check that the manual release plug is closed Check the power trim and tilt fluid level Disassemble the power trim and tilt unit and then check it Close the plug Add fluid to the...

Page 282: ...d connection between the lower case and upper case Disassemble the lower case and then check the shifting gear mechanism and the respective parts Replace the shift rod Check the shift cables and links...

Page 283: ...Y3A11 7 4 1 2 3 4 5 6 7 8 I Special service tools 7 Trim and tilt cylinder wrench YB 06175 2B Cylinder end screw wrench 90890 06544 For USA and Canada For worldwide Troubleshooting Special service too...

Page 284: ...BRKT Bracket unit 7 5 62Y3A11 Tiller handle F50 F50A T50 FT50B 7...

Page 285: ...7 Throttle cable 1 8 Plate 1 9 Bolt 3 M6 20 mm 10 Bolt 1 M8 16 mm 9 0 9 6 5 11 Negative battery lead 1 12 Cable guide 1 13 Grommet 1 14 Nut 1 7 0 7 5 1 15 Washer 1 16 Positive battery lead 1 17 Connec...

Page 286: ...BRKT Bracket unit 7 7 62Y3A11...

Page 287: ...Remarks Tightening torques Stage N m kgf m ft lb 31 Nut 2 32 Collar 2 33 Bolt 2 M8 50 mm 34 Self locking nut 1 35 Bracket 1 36 Steering lock shaft 1 37 Steering lock knob 1 38 Friction plate 1 39 Fri...

Page 288: ...BRKT Bracket unit 7 9 62Y3A11...

Page 289: ...Bushing 2 9 Nut 1 4 0 4 2 9 10 Engine shut off switch 1 11 Nut 1 38 3 8 27 12 Washer 1 13 Bracket 1 14 Collar 1 15 Wave washer 1 16 Washer 1 17 Bolt 1 18 Clamp 1 19 Screw 1 20 Connector 2 21 Engine st...

Page 290: ...BRKT Bracket unit 7 11 62Y3A11...

Page 291: ...1 2 3 4 5 6 7 8 I No Part name Q ty Remarks Tightening torques Stage N m kgf m ft lb 31 Screw 2 M6 40 mm 32 Throttle grip 1 33 Screw 1 M5 25 mm 34 Washer 1 35 Spring 1 36 Bushing 1 Tiller handle F50 F...

Page 292: ...BRKT Bracket unit 7 13 62Y3A11...

Page 293: ...7 Stay 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 14 mm 16 Clip 1 17 Frame 1 18 Screw...

Page 294: ...e rubber seals for damage Replace if necessary Assembling the tiller handle 1 Install the throttle shaft 1 and throttle arm 2 into the frame 3 Align the mark a of the fully closed position of the thro...

Page 295: ...62Y3A11 7 16 1 2 3 4 5 6 7 8 I MEMO Tiller handle F50 F50A T50 FT50B...

Page 296: ...BRKT Bracket unit 7 17 62Y3A11 Tiller handle FT50C 7...

Page 297: ...ft lb 1 Bolt 1 M8 30 mm 2 Nut 1 3 Wing nut 1 13 1 3 9 4 4 Friction piece 1 5 Bolt 1 M6 35 mm 6 Friction rod 1 7 Washer 1 8 Nut 1 9 Washer 2 10 Link rod 1 11 Nut 1 12 Plate 1 13 Bolt 3 M6 20 mm 14 Gro...

Page 298: ...BRKT Bracket unit 7 19 62Y3A11...

Page 299: ...1 M12 70 mm 8 Clip 1 9 Throttle cable 1 37 3 7 27 10 Nut 1 11 Plastic washer 2 12 Metal washer 2 13 Wave washer 1 14 Pin 1 15 Gear 1 16 Throttle shaft 1 17 Bolt 1 M6 25 mm 18 Friction piece 1 19 Wing...

Page 300: ...BRKT Bracket unit 7 21 62Y3A11...

Page 301: ...her 1 8 Bushing 1 9 Tiller handle bracket 1 10 Nut 1 11 Bushing 1 12 Engine stop switch 1 13 Bolt 1 M6 20 mm 14 Engine start switch housing 1 15 Screw 1 M6 12 mm 16 Connector 1 Black 17 Connector 1 Wh...

Page 302: ...rottle shaft 1 into the tiller handle 2 by aligning the mark a of the tiller handle with the screw hole b of the throttle shaft 2 Install the throttle cable 3 into the gear 4 until the inner cable is...

Page 303: ...62Y3A11 7 24 1 2 3 4 5 6 7 8 I MEMO Tiller handle FT50C...

Page 304: ...BRKT Bracket unit 7 25 62Y3A11 Bottom cowling 7...

Page 305: ...Bushing 1 10 Bushing 1 11 Shift rod 1 12 Grommet 1 13 Rubber seal 4 14 Bolt 4 M6 30 mm 15 Grommet 4 16 Screw 1 M6 14 mm EHD EHT models 17 Warning indicator 1 EHD EHT models 18 Grommet 1 EHD EHT model...

Page 306: ...BRKT Bracket unit 7 27 62Y3A11...

Page 307: ...trailer switch 33 Trailer switch 1 Models with trailer switch 34 PTT motor lead 1 EHT ET models 35 Trim sensor coupler 1 EHT ET models 36 Screw 1 M6 24 mm EHT ET models 37 Grommet 1 38 Flushing hose...

Page 308: ...BRKT Bracket unit 7 29 62Y3A11 Checking the shift rod assembly operation 1 Check the shift rod assembly and detent for smooth operation F50 F50A T50 FT50B FT50C...

Page 309: ...62Y3A11 7 30 1 2 3 4 5 6 7 8 I MEMO Bottom cowling...

Page 310: ...BRKT Bracket unit 7 31 62Y3A11 Upper case 7...

Page 311: ...24 2 4 17 3 Nut 2 42 4 2 30 4 Washer 2 5 Bolt 3 M8 30 mm 6 Upper mount 1 7 Plate 1 8 Bolt 2 M8 175 mm 9 Cap 2 10 Bolt 2 M12 160 mm 11 Grommet 2 12 Ground lead 1 13 Screw 2 14 Mount cover 2 15 Bolt 4...

Page 312: ...BRKT Bracket unit 7 33 62Y3A11...

Page 313: ...ening torques Stage N m kgf m ft lb 1 Muffler assembly 1 2 Upper case 1 3 Muffler seal 1 4 Rubber seal 1 5 Dowel pin 2 6 Grommet 1 7 Guide 1 FT50C 8 Damper 1 9 Screw 2 M5 16 mm 10 Baffle plate 1 11 Bo...

Page 314: ...BRKT Bracket unit 7 35 62Y3A11 F50 F50A T50 FT50B...

Page 315: ...lt 10 M6 25 mm 7 Oil pan 1 8 Gasket 1 9 Exhaust manifold 1 10 Bolt 3 M6 50 mm 11 Gasket 1 Not reusable 12 Bolt 6 M6 25 mm 13 Muffler 1 14 Gasket 1 Not reusable 15 Pipe 1 16 Rubber seal 1 Not reusable...

Page 316: ...BRKT Bracket unit 7 37 62Y3A11 FT50C...

Page 317: ...pin 2 12 Bolt 10 M6 25 mm 13 Oil pan 1 14 Gasket 1 Not reusable 15 Exhaust manifold 1 16 Bolt 1 M6 45 mm 17 Gasket 1 Not reusable 18 Gasket 1 Not reusable 19 Bolt 6 M6 25 mm 20 Muffler 1 21 Gasket 1 N...

Page 318: ...e the oil strainer 5 and the relief valve housing 6 FT50C Checking the oil strainer and the relief valve 1 Check the oil strainer and relief valve for dirt and residue Clean if necessary Assembling th...

Page 319: ...pan 5 and bolts and then tighten the bolts finger tight 6 Install the exhaust manifold 6 and bolts and then tighten the bolts finger tight FT50C 7 Tighten the exhaust manifold bolts 7 then the oil pa...

Page 320: ...case Installing the upper case 1 Install the upper mount 1 and bolts 2 into the upper case and then tighten the bolts 3 2 Set the lower mounts 4 and bolts to the upper case 3 Install the end of the sp...

Page 321: ...vel bracket 9 simulta neously 5 Install the upper mounting nut 0 and lower mounting nut A and then tighten them to the specified torques 6 Install the cover B by installing the screw Upper mounting nu...

Page 322: ...BRKT Bracket unit 7 43 62Y3A11 Clamp brackets 7...

Page 323: ...1 4 3 Trim sensor 1 EHT ET models 4 Trim sensor coupler 1 EHT ET models 5 Plastic tie 1 Not reusable 6 Self locking nut 2 23 2 3 17 7 Cap 2 8 Bolt 1 M6 25 mm 9 Anode 1 10 Port clamp bracket 1 11 Wash...

Page 324: ...rim sensor 4 Installing the clamp brackets 1 Install the trim sensor 1 onto the port clamp brackets NOTE Adjust the trim sensor after installing the power trim and tilt 2 Assemble the clamp brackets a...

Page 325: ...on of the trim sensor 3 and then tighten the screws 2 finger tight 4 Fully tilt the outboard down 5 Measure the trim sensor resistance Repeat steps 1 5 if out of specification 6 Fully tilt the outboar...

Page 326: ...BRKT Bracket unit 7 47 62Y3A11 Swivel bracket and steering arm 7...

Page 327: ...hing 1 4 O ring 2 Not reusable 5 Bushing 2 6 Swivel bracket 1 7 Bushing 1 8 Port tilt stop lever 1 9 Circlip 1 10 Steering yoke 1 11 Bushing 1 12 Bushing 1 13 Tilt stop lever joint 1 14 Spring holder...

Page 328: ...ling the steering arm 1 Install the washer 1 bushing 2 O ring 3 and bushing 4 onto the steering arm 5 2 Place the swivel bracket 6 in an upright position and then install the steering arm onto the swi...

Page 329: ...62Y3A11 7 50 1 2 3 4 5 6 7 8 I 6 Inject grease into the grease nipple until grease comes out from both the upper and lower bushings c Swivel bracket and steering arm...

Page 330: ...BRKT Bracket unit 7 51 62Y3A11 Power trim and tilt unit 7...

Page 331: ...els 3 Plastic tie 3 Not reusable 4 PTT motor lead 2 5 Washer 2 6 Bolt 2 M8 16 mm 7 Circlip 1 EHT ET models 8 Shaft 1 EHT ET models 9 Bushing 2 EHT ET models 10 Collar 1 EHT ET models 11 Tilt pin 1 12...

Page 332: ...stop lever Otherwise the outboard could suddenly lower if the power trim and tilt unit should lose fluid pressure 2 Loosen the plastic locking tie 2 and then pull out the PTT motor lead 3 3 Remove th...

Page 333: ...62Y3A11 7 54 1 2 3 4 5 6 7 8 I MEMO Power trim and tilt unit...

Page 334: ...BRKT Bracket unit 7 55 62Y3A11 Tilt cylinder and trim cylinder 7...

Page 335: ...0 65 3 Bolt 3 M5 20 mm 4 0 4 2 9 4 O ring 1 Not reusable 5 Joint 1 6 O ring 1 Not reusable 7 Ball 6 8 O ring 1 Not reusable 9 Free piston 1 10 Circlip 1 11 Trim cylinder base 1 12 Spring 2 13 Plate 1...

Page 336: ...BRKT Bracket unit 7 57 62Y3A11 Trim cylinder 7...

Page 337: ...1 6 O ring 1 Not reusable 7 Backup ring 1 8 O ring 1 Not reusable 9 Trim cylinder end screw 1 80 8 0 58 10 O ring 1 Not reusable 11 O ring 1 Not reusable 12 Trim piston 1 13 O ring 1 Not reusable 14 T...

Page 338: ...BRKT Bracket unit 7 59 62Y3A11 Gear pump 7...

Page 339: ...bracket 1 3 Bolt 3 M6 40 mm 7 0 7 5 1 4 Valve lock screw 1 5 Up relief spring 1 6 Valve support pin 1 7 O ring 1 Not reusable 8 Ball 1 9 Down relief spring 1 10 Valve support pin 1 11 Relief valve se...

Page 340: ...BRKT Bracket unit 7 61 62Y3A11...

Page 341: ...1 4 O ring 2 Not reusable 5 Spacer 2 6 Spring 2 7 Valve pin 2 8 Ball 2 9 Manual release spring 1 10 Ball 2 11 Gear pump cover 1 12 Spring 2 13 Shuttle piston 1 14 O ring 1 Not reusable 15 Valve seal 2...

Page 342: ...screw 3 Drain the fluid Disassembling the trim cylinder 1 Hold the trim cylinder 1 in a vise using aluminum plates a on both sides NOTE Place the trim cylinder in the vise horizon tally 2 Loosen the...

Page 343: ...ket 6 then the down shuttle piston 7 and up shuttle piston 8 4 Remove the gear pump cover 9 then the down main valve 0 and up main valve A 5 Remove the drive gear B and driven gear C Checking the tilt...

Page 344: ...a of the trim cylinder end screw and check the valve for dirt or residue Clean if necessary 2 Check the operation of the tilt piston absorber valve and check for dirt or resi due Clean if necessary 3...

Page 345: ...4 Install the gear pump cover 9 5 Install the shuttle pistons 0 into the gear pump cover 9 6 Install the balls A into the gear pump cover 9 with the manual release spring B 7 Install the gear pump bra...

Page 346: ...ect level as shown 13 Install the joint O and power trim and tilt motor P by installing the bolts Q then tightening them to the specified torque Assembling the trim cylinder 1 Install the dust seal 1...

Page 347: ...lt piston E 8 Install balls F and G absorber valve pin H spring I pins J and K and washer L into the tilt piston 9 Hold the tilt ram end in a vise using alu minum plates on both sides 10 Install the t...

Page 348: ...base 6 springs 7 and plate 8 into the trim cylinder with the circlip 9 4 Hold the power trim 0 and in a vise using aluminum plates a on both sides 5 Add fluid of the recommended type to the first leve...

Page 349: ...turning it clockwise 2 Place the power trim and tilt in an upright position 3 Check the fluid level in the reservoir NOTE The fluid level should be at the brim of the filler hole 4 If necessary add su...

Page 350: ...el Bleeding the power trim and tilt built in 1 Loosen the manual release plug by turn ing it counterclockwise until it cannot be turned further 2 Fully tilt the outboard up and then release it and let...

Page 351: ...r 8 If necessary add sufficient fluid of the recommended type to the correct level NOTE The fluid level should be at the brim of the filler hole 9 Install the reservoir cap NOTE Repeat this procedure...

Page 352: ...BRKT Bracket unit 7 73 62Y3A11 Power trim and tilt motor 7...

Page 353: ...N m kgf m ft lb 1 Screw 3 M5 20 mm 2 Yoke 1 3 O ring 1 Not reusable 4 Armature 1 5 Bushing 1 6 Screw 2 M4 12 mm 7 Wire lead 1 8 Brush 2 1 9 Brush 1 1 10 Brush holder 1 11 Circuit breaker 1 12 Brush s...

Page 354: ...a Replace if out of specification 4 Check the armature coil for continuity Replace if out of specifications 5 Check the circuit breaker for continuity Replace if there is no continuity 6 Measure the b...

Page 355: ...ead 7 3 Install the springs 8 into the motor base then the brush holder into the motor base together with the brushes and circuit breaker 4 Install the armature 9 O ring 0 and yoke A Installing the po...

Page 356: ...11 2 Install the shaft 2 and bolts 3 onto both clamp brackets together with the power trim and tilt hydro tilt 4 3 Install the tilt ram upper end into the swivel bracket with the shaft 5 and cir clip...

Page 357: ...and tilt motor 2 Power trim and tilt relay 3 Trailer switch 4 Power trim and tilt switch 5 Fuse 6 Battery 7 Trim sensor Models with trailer switch B Black G Green Gy Gray L Blue Lg Light green P Pink...

Page 358: ...d to the negative battery terminal as shown 4 Check for continuity between terminals 1 and 3 Replace if there is no continu ity 5 Connect the digital circuit tester between power trim and tilt relay t...

Page 359: ...e if out of specification Checking the trim sensor 1 Measure the trim sensor resistance Replace if out of specification NOTE Turn the lever 1 and measure the resistance as it gradually changes Lead co...

Page 360: ...BRKT Bracket unit 7 81 62Y3A11 MEMO...

Page 361: ...n coil 8 14 Checking the CDI unit 8 15 Checking the charge coil 8 15 Checking the pulser coil 8 16 Checking the pulser coil air gap 8 16 Checking the engine start switch 8 17 Checking the engine shut...

Page 362: ...charged to 12 V Symptom Battery becomes weaker quickly Check the charging system Measure the Rectifier Regulator output peak voltage Replace the lighting coil Out of specifi cation Out of specifi cat...

Page 363: ...899 A Peak voltage adaptor YU 39991 Test harness 2 pins YB 06767 Pressure vacuum tester YB 35956 A Dial gauge YU 03097 Magnetic flexible stand YU 34481 Test harness 3 pins YB 06770 Test harness 4 pins...

Page 364: ...cuit tester 90890 03174 Peak voltage adaptor 90890 03172 Test harness 2 pins 90890 06767 Vacuum pressure pump gauge set 90890 06756 Dial gauge set 90890 01252 Magnet base 90890 06705 Test harness 3 pi...

Page 365: ...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 Meas...

Page 366: ...ents 8 Starboard and port views 1 Stator 2 Pulser coil 3 CDI unit 4 Ignition coil 5 Oil pressure switch 6 Thermoswitch 7 Prime Start 8 Rectifier Regulator 9 Starter relay 0 Starter motor A PTT switch...

Page 367: ...7 8 I Front view 1 Stator 2 Pulser coil 3 CDI unit 4 Fuse 5 Neutral switch tiller handle model 6 Starter relay 7 Starter motor 8 Power trim and tilt relay power trim and tilt model Tiller handle mode...

Page 368: ...ELEC Electrical systems 8 7 62Y3A11 Top view 1 Stator 2 Pulser coil 3 CDI unit 4 Ignition coil 5 Starter motor 6 Trailer switch...

Page 369: ...witch 2 Engine start switch harness 3 Engine shut off switch 4 Engine shut off switch connector 5 Neutral switch 6 Battery lead 7 Wiring harness extension 8 PTT switch lead 9 Power trim and tilt switc...

Page 370: ...C Electrical systems 8 9 62Y3A11 Tiller handle model FT50C 1 Engine start switch 2 Engine start switch harness 3 Engine shut off switch 4 Engine shut off switch connector 5 Neutral switch 6 Battery le...

Page 371: ...e Start 7 Warning indicator or digital tachometer 8 CDI unit 9 Power trim and tilt switch or trailer switch 0 Rectifier Regulator A Thermoswitch B Ignition coil C Oil pressure switch Power trim and ti...

Page 372: ...d Ignition control system 8 1 Spark plug 2 Ignition coil 3 Charge coil 4 Pulser coil 5 Engine start switch 6 Engine shut off switch 7 10 pin coupler 8 CDI unit B Black Br Brown L Blue W White B O Blac...

Page 373: ...r 5 Oil pressure warning indicator 6 Overheat warning indicator 7 Remote control box 8 Warning indicator Remote control model Tiller handle model B Black G Green R Red Y Yellow Gy B Green black P B Pi...

Page 374: ...or worldwide 4 Crank the engine and observe the spark through the discharge window of the spark gap tester Check the ignition coil if out of specification For USA and Canada For worldwide WARNING Do n...

Page 375: ...Checking the ignition coil 1 Remove the spark plug caps from the high tension cords by turning the caps counterclockwise 2 Measure the ignition coil resistance Replace if out of specification Spark pl...

Page 376: ...e selector on the digital circuit tester to the DC voltage mode Checking the charge coil 1 Measure the charge coil output peak volt age Replace the stator coil if below specification WARNING When chec...

Page 377: ...Adjust if out of specification Digital multimeter YU 34899 A Digital circuit tester 90890 03174 Peak voltage adaptor YU 39991 90890 03172 Test harness 2 pins YB 06767 90890 06767 Charge coil output p...

Page 378: ...magnet nut to the specified torques Checking the engine start switch 1 Check the engine start switch for continu ity Replace if there is no continuity Checking the engine shut off switch 1 Check the e...

Page 379: ...the 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...

Page 380: ...LEC Electrical systems 8 19 62Y3A11 Starting system 8 1 Fuse 2 10 pin coupler 3 Engine start switch 4 Starter motor 5 Battery 6 Neutral switch 7 Starter relay Tiller handle model B Black Br Brown R Re...

Page 381: ...no continuity Checking the starter relay 1 Connect the digital circuit tester leads to the starter relay terminals 2 Connect the brown Br lead to the posi tive battery terminal 3 Connect the black B l...

Page 382: ...ELEC Electrical systems 8 21 62Y3A11 Starter motor 8...

Page 383: ...r motor pinion 1 5 Upper bracket 1 6 O ring 1 Not reusable 7 Washer 1 1 8 Shim As required 9 Washer 2 1 10 Armature 1 11 Stator 1 12 O ring 1 Not reusable 13 Brush holder assembly 1 14 Brush set 1 15...

Page 384: ...operates smoothly and turn it counterclock wise to check that it locks Checking the armature 1 Check the armature axial free play Replace the washers and shim s 3 if out of specification 2 Check the...

Page 385: ...uity Replace if out of specifications Checking the starter motor operation 1 Check the operation of the starter motor after installing it to the power unit Commutator undercut limit 0 2 mm 0 01 in Arm...

Page 386: ...ELEC Electrical systems 8 25 62Y3A11 Charging system 8 1 Lighting coil 2 Rectifier Regulator 3 Fuse 4 Battery B Black G Green R Red G W Green white...

Page 387: ...ut peak voltage of the lighting coil is above specification WARNING When checking the peak voltage do not touch any of the connections of the digital tester leads NOTE Use the peak voltage adaptor wit...

Page 388: ...A11 NOTE After starting the engine disconnect the out put lead red lead of the Rectifier Regulator when measuring the output peak voltage Rectifier Regulator output peak voltage Red R Black B r min Un...

Page 389: ...62Y3A11 8 28 1 2 3 4 5 6 7 8 I MEMO...

Page 390: ...connecting rod bolt 5 59 Checking the connecting rod small end inside diameter 5 59 Checking the cooling water passage 3 13 Checking the crankshaft 5 59 Checking the crankshaft main journal oil cleara...

Page 391: ...hrottle cable operation 3 13 Checking the tilt cylinder and trim cylinder 7 64 Checking the tilt system 1 35 Checking the timing belt 3 7 Checking the timing belt and sprockets 5 32 Checking the top c...

Page 392: ...l system 7 78 Power trim and tilt motor 7 73 Power trim and tilt unit 3 16 7 51 Power unit 2 5 2 12 3 5 5 13 Predelivery checks 1 33 Propeller selection 1 32 Propeller shaft housing T50 FT50B FT50C 6...

Page 393: ...Test run 1 35 Tightening torques 2 29 Tiller handle F50 F50A T50 FT50B 7 5 Tiller handle FT50C 7 17 Tiller handle model F50 F50A T50 FT50B 8 8 Tiller handle model FT50C 8 9 Tilt cylinder and trim cyli...

Page 394: ...Thermoswitch B Oil pressure switch C Charge coil D Pulser coil E Lighting coil F Rectifier Regulator G Ignition coil H Spark plug I Hour meter EHD Option Color code B Black Br Brown G Green L Blue O...

Page 395: ...CDI unit D Thermoswitch E Charge coil F Lighting coil G Pulser coil H Rectifier Regulator I Oil pressure switch J Trailer switch K Ignition coil L Spark plug With trailer switch model Color code B Bla...

Page 396: ...ifier Regulator D Thermoswitch E Oil pressure switch F Engine start switch G Engine shut off switch H Power trim and tilt switch I Trailer switch J Trim sensor K Ignition coil L Spark plug Color code...

Page 397: ...Pulser coil C Rectifier Regulator D Thermoswitch E Oil pressure switch F Trailer switch G Ignition coil H Spark plug I Hour meter Option Color code B Black Br Brown G Green Gr Gray L Blue Lg Light gr...

Page 398: ......

Page 399: ...YAMAHA MOTOR CO LTD Printed in the Netherlands Nov 2000 1 4 1 CR F50AEHD F50AEHT F50AED F50AET FT50BET FT50CEHD FT50CED FT50CET...

Page 400: ...P B Y R P W P B Y B Y B P B P W Y R Y R P W B Br L B B W B B P W Y R B O B W Y B P B B O P W Y R B W P B W Y B L L B B B L B B B B R R R R Br Br Br Br R W Y G P Br P R W B Br Y B P B Y R P W B G G Y G...

Page 401: ...O B W Y B P B B O P W Y R B W P B W Y B L L B B B L B B B L G R B B R R R R Br Br Br Br Sb Lg R W Sb G Lg P Br P R W B Br Y B P B Y R P W Lg Sb Lg R Sb Lg Sb Lg Sb Sb Sb Lg R R R R Lg Sb R Sb R Lg Sb...

Page 402: ...P B W Y B L L B B B L B B B L G R B B R R R R Br Br Br Br Sb Lg R W Sb G P Br Lg Sb Lg R Sb Lg Sb Lg Sb Sb Sb Lg R R R R Lg Sb R Sb R Lg Sb R Lg B B I H Lg R Sb W W B B R Br Y W W W B B B O W P B B O...

Page 403: ...B W B B P W Y R B O B W Y B P B B O P W Y R B W P B W Y B L L B B B L B B B L G R B B R R R R Br Br Sb Lg R W Sb G Lg P Br Sb R Lg B B B R Br Lg Sb P W G B Sb Sb Lg Lg O P D E B G L R B A G 2 3 1 4 H...

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Yamaha F50A, Service Manual

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