Yamaha F50D Servise Manual Download | Manualshive

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5-22

0

1

2

3

4

5

6

7

8

9

10

A

5.

Connect the tester leads to the starter
relay terminals

c

and

d

.

6.

Connect the starter relay lead Brown (Br)
to the positive battery terminal, and then
connect the ground lead (B) to the nega-
tive battery terminal. Check that there is
continuity between the starter relay ter-
minals. Replace if there is no continuity.

7.

Disconnect the starter relay lead Brown
(Br) from the battery terminal. Check that
there is no continuity between the starter
relay terminals. Replace if there is conti-
nuity.

8.

Install the starter relay

3

, and then con-

nect the positive battery lead

2

, starter

motor lead

1

, starter relay lead connec-

tor

a

, and ground lead

b

. To route and

connect the wirings, see “Electrical com-
ponent and wiring harness routing” (5-1).

Checking the neutral switch

1.

Disconnect the neutral switch lead con-
nectors

a

and

b

.

2.

Turn the engine start switch to “START”,
and then measure the input voltage at
the neutral switch connectors

a

and

b

.

Check the engine start switch and wiring
harness if below specification.

Starter relay continuity:

Battery lead

Terminal

c

d

Connected

Disconnected

1

2

b

3

Br

B

c

3

d

Starter relay terminal nut:

3.4 N·m (0.3 kgf·m, 2.5 ft·lb)

Br

Br

Br

B

Br

a

b

b

a

å

Ignition unit and components / Starting unit and components

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Summary of Contents for F50D

Page 1: ...SERVICE MANUAL F50D FT50C 60A 28197 5L 11 YAMAHA MOTOR CO LTD Printed in Japan Aug 2008 0 5 1 n E Printed on recycled paper F50D FT50C ...

Page 2: ...tions and significant changes in specifications and procedures and these are incorporated in successive editions of this manual Also up to date parts information is available in YPEC web Additional information and up to date information on Yamaha product and services are available on Service Portal Important information Particularly important information is distinguished in this manual by the foll...

Page 3: ... Technical features and description TECH FEA 2 Rigging information RIG GING 3 Troubleshooting TRBL SHTG 4 Electrical system ELEC 5 Fuel system FUEL 6 Power unit POWR 7 Lower unit LOWR 8 Bracket unit BRKT 9 Maintenance MNT 10 Index A Appendix A Contents ...

Page 4: ......

Page 5: ...0 1 Ventilation 0 1 Self protection 0 2 Working with crane 0 2 Handling of burner 0 2 Part lubricant and sealant 0 2 Handling of sealant 0 2 Special service tool 0 3 Tightening torque 0 3 Non reusable part 0 3 Disassembly and assembly 0 3 How to use this manual 0 4 Manual format 0 4 Abbreviation 0 5 Sealant and locking agent 0 6 Symbol 0 6 Special service tool 0 7 ...

Page 6: ...ne has cooled Electric shock Do not touch any electrical parts while start ing or operating the engine They can cause shock or electrocution Propeller Do not hold the propeller with your hands when loosening or tightening it Handling of gasoline 9 Gasoline is highly flammable Keep gaso line and all flammable products away from heat sparks and open flames 9 Gasoline is poisonous and can cause injur...

Page 7: ...l ropes or the like so that the outboard motor can be lifted and carried in a stable manner Handling of burner 9 Incorrect handling of burner may result in burns Refer to the operation manual issued by the manufacturer to assure the correct handling 9 When using a burner keep it away from the gasoline and oil to prevent a fire 9 Components become very hot enough to cause burns Do not touch directl...

Page 8: ...e new gaskets seals O rings cot ter pins circlips and so on when installing or assembling parts Disassembly and assembly 9 Use compressed air to remove dust and dirt during disassembly 9 Apply engine oil to the contact surfaces of moving parts before assembly 9 Install bearings with the manufacture identi fication mark in the direction indicated in the installation procedure In addition make sure ...

Page 9: ...ive shaft and shift rod assembly 1 Loosen the pinion nut 1 as shown 2 Remove the pinion nut 1 drive shaft 4 oil seal housing assembly 5 pinion 6 and forward gear assembly 7 3 Remove the shift rod assembly 8 and shift cam 9 Disassembling the drive shaft assembly 1 Install the pinion nut 1 tighten it finger tight and then remove the drive shaft bearing 2 using a press NOTICE Do not press the drive s...

Page 10: ...ere CDI Capacitor Discharge Ignition C L Centerline D model Hydro tilt model DN Downside or downward EN European Norm European standard EX Exhaust F Forward H model Tiller handle model IEC International Electrotechnical Commission IN Intake LED Light Emitting Diode N Neutral PORT Port side PTT Power Trim and Tilt R Reverse R model Remote control model RON Research Octane Number SAE Society of Auto...

Page 11: ...lication Yamaha 4 stroke motor oil Lubricant Gear oil Lubricant Water resistant grease Yamaha grease A Lubricant Molybdenum disulfide grease Lubricant Corrosion resistant grease Yamaha grease D Lubricant Low temperature resistant grease Yamaha grease C Lubricant Symbol Name Application Gasket Maker Sealant LOCTITE 271 red Sealant LOCTITE 242 blue Sealant LOCTITE 572 white Sealant Silicon sealant S...

Page 12: ...tributed by Parts Division Drilling plate 90890 06783 Digital circuit tester 90890 03174 Peak voltage adapter B 90890 03172 Ignition tester 90890 06754 Test harness 2 pins 90890 06867 Vacuum pressure pump gauge set 90890 06756 Throttle sensor adjusting lead 3 pins 90890 06857 Digital caliper 90890 06704 ThreeBond 1401 Sealant Symbol Name Application ...

Page 13: ...meter 90890 06760 Compression gauge 90890 03160 Flywheel 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 90890 06801 Sealant and locking agent Special service tool ...

Page 14: ...0890 04101 Valve seat cutter holder 90890 06316 Valve seat cutter 30 90890 06326 Valve seat cutter 30 90890 06328 Valve seat cutter 45 90890 06555 Valve seat cutter 60 90890 06323 Valve seat cutter 60 90890 06315 Bearing outer race attachment 90890 06626 Driver rod LS 90890 06606 ...

Page 15: ... 06529 Shift rod push arm 90890 06052 Stopper guide plate 90890 06501 Bearing housing puller claw S 90890 06564 Center bolt 90890 06504 Bearing separator 90890 06534 Stopper guide stand 90890 06538 Bearing puller assembly 90890 06535 Driver rod L3 90890 06652 Special service tool ...

Page 16: ...06604 Bearing depth plate 90890 06603 Bearing inner race attachment 90890 06653 Bearing inner race attachment 90890 06639 Needle bearing attachment 90890 06607 Drive shaft holder 4 90890 06518 Pinion nut holder 90890 06715 Bearing inner race attachment 90890 06641 Magnet base plate 90890 07003 ...

Page 17: ...ter race attachment 90890 06622 Driver rod LL 90890 06605 Driver rod SL 90890 06602 Bearing outer race attachment 90890 06627 Leakage tester 90890 06840 Backlash indicator 90890 06706 Handle stopper EU0 23814 30 Dial gauge set 90890 01252 Magnet base 90890 06844 Special service tool ...

Page 18: ... wrench extension 90890 06513 Bearing housing puller claw L 90890 06502 Needle bearing attachment 90890 06612 Ball bearing attachment 90890 06655 Bearing inner race attachment 90890 06661 Needle bearing attachment 90890 06611 Bearing inner race attachment 90890 06662 Bearing inner race attachment 90890 06643 ...

Page 19: ...ng outer race attachment 90890 06621 Pinion height gauge set 90890 06669 Bearing outer race attachment 90890 06628 Needle bearing attachment 90890 06615 Cylinder end screw wrench 90890 06568 Timing light 90890 03141 Special service tool ...

Page 20: ...General information 0 15 GEN INFO MEMO ...

Page 21: ... 6 Ignition timing control system 1 6 Engine speed control system 1 7 Charging system 1 7 Starting system 1 7 Fuel system technical data 1 8 Fuel system 1 8 Power unit technical data 1 9 Power unit 1 9 Cylinder head assembly 1 9 Crankcase assembly 1 10 Lower unit technical data 1 13 Lower unit assembly 1 13 Bracket unit technical data 1 13 PTT system 1 13 Special tightening torque 1 14 Fuel system...

Page 22: ...take 9 Blowby gas reburning system 9 Anti abrasion piston rings 9 IN and EX valves with Stellite cobalt based alloy treatment b Electrical 9 Prime Start 9 Maintenance free CDI 9 Hour meter 9 Over revolution limiter 9 Overheat alert 9 Low oil pressure alert 9 Start in gear protection c Bracket unit 9 Single cylinder unit wide range PTT 9 Hydro tilt with shallow water drive d Upper case 9 Stainless ...

Page 23: ...e regular rotation FT 4 stroke regular rotation high thrust 2 Model name 50 50 3 Product generation A A and up 4 Functions E Electric starter H Tiller handle T Power trim and tilt D Hydro trim and tilt 5 6 7 Transom height L L 20 in X UL 25 in YAMAHA MOTOR CO LTD MADE IN JAPAN PAYS D ORIGINE JAPON 2 3 1 4 Model name Approved model code Starting serial No F50DET 60A 1000984 FT50CET 61S 1008356 FT50...

Page 24: ... 0 X mm in 635 0 25 0 635 0 25 0 Weight With AL propeller L kg lb 108 0 238 0 112 0 247 0 108 0 238 0 115 0 254 0 X kg lb 115 5 255 0 119 1 263 0 Item Unit Model F50DET FT50CET FT50CED FT50CEHD Maximum output kW HP 36 8 50 0 at 5500 r min Full throttle operating range r min 5000 6000 Maximum fuel consumption L US gal Imp gal hr 17 3 4 6 3 8 at 6000 r min Engine idle speed r min 800 900 900 1000 It...

Page 25: ... qt Imp qt 2 0 2 1 1 8 with oil filter replacement L US qt Imp qt 2 2 2 3 1 9 Gear oil type Hypoid gear oil Gear oil grade 2 API GL 4 SAE 90 Gear oil quantity L US qt Imp qt 0 43 0 45 0 38 0 67 0 71 0 59 Item Unit Model F50DET FT50CET FT50CED FT50CEHD Type 4 stroke L Cylinder quantity 4 Total displacement cm3 cu in 935 0 56 1 Bore stroke mm in 63 0 75 0 2 48 2 95 Compression ratio 9 3 Control syst...

Page 26: ...Clutch type Dog clutch Propeller shaft type Spline Propeller direction rear view Clockwise Propeller mark G K Item Unit Model F50DET FT50CET FT50CED FT50CEHD Trim angle at 12 boat transom Degree 4 to 20 Tilt up angle Degree 65 63 Steering angle Degree 40 40 Trim and tilt system PTT Hydro Item Unit Model F50DET FT50CET FT50CED FT50CEHD Fluid type ATF Dexron 2 Fluid type quantity L US qt Imp qt 0 31...

Page 27: ...p mm in 0 5 1 0 0 02 0 04 Resistance 1 at 20 C 68 F Ω 396 0 594 0 Output peak voltage 1 at cranking unloaded V 6 3 at cranking loaded V 3 5 at 1500 r min loaded V 7 4 at 3500 r min loaded V 11 2 Thermoswitch Temperature Switch ON C F 76 84 169 183 Switch OFF C F 63 77 145 171 Charge coil Resistance 1 at 20 C 68 F Ω 272 0 408 0 Output peak voltage 1 at cranking unloaded V 140 at cranking loaded V 1...

Page 28: ...0 C 68 F Ω 1 2 1 8 Output peak voltage 1 at cranking unloaded V 11 9 at 1500 r min unloaded V 42 0 at 3500 r min unloaded V 90 0 Fuse A 20 0 Rectifier Regulator Output peak voltage 1 at 1500 r min unloaded V 13 0 at 3500 r min unloaded V 13 0 Item Unit Model F50DET FT50CET FT50CED FT50CEHD Starter motor Type Bendix Output kW 1 1 Cranking time limit Second 30 0 Brushes Standard length mm in 17 0 0 ...

Page 29: ... pump Holding pressure Inlet positive pressure kPa kgf cm2 psi 50 0 0 50 7 3 Inlet negative pressure kPa kgf cm2 psi 30 0 0 30 4 4 Outlet positive pressure kPa kgf cm2 psi 50 0 0 50 7 3 Carburetor Float height mm in 9 5 10 5 0 37 0 41 Valve seat size mm in 1 2 0 05 Main jet MJ 1 124 2 126 3 116 4 114 Main air jet MAJ 150 Main nozzle MN mm in 2 5 0 10 Pilot jet PJ 39 Pilot air jet PAJ 70 Pilot scre...

Page 30: ...490 0 2156 0 2161 Exhaust mm in 5 460 5 475 0 2150 0 2156 Runout Intake mm in 0 030 0 0012 Exhaust mm in 0 030 0 0012 Valve stem guide Inside diameter Intake mm in 5 500 5 512 0 2165 0 2170 Exhaust mm in 5 500 5 512 0 2165 0 2170 Stem to guide clearance Intake mm in 0 010 0 037 0 0004 0 0015 Exhaust mm in 0 025 0 052 0 0010 0 0020 Valve spring Free length mm in 39 85 1 569 Tilt mm in 1 7 0 07 1 Me...

Page 31: ... Intake mm in 0 900 1 100 0 0354 0 0433 Exhaust mm in 0 900 1 100 0 0354 0 0433 Margin thickness Intake mm in 0 600 1 000 0 0236 0 0394 Exhaust mm in 0 700 1 100 0 0276 0 0433 Item Unit Model F50DET FT50CET FT50CED FT50CEHD Cylinder Bore mm in 63 000 63 015 2 4803 2 4809 Piston Diameter mm in 62 950 62 965 2 4783 2 4789 Measuring point mm in 5 0 0 20 Piston clearance mm in 0 035 0 065 0 0014 0 002...

Page 32: ...n 0 200 0 700 0 0079 0 0276 Side clearance mm in 0 050 0 190 0 0020 0 0075 Connecting rod Small end inside diameter mm in 15 985 15 998 0 6293 0 6298 Big end inside diameter mm in 36 000 36 024 1 4173 1 4183 Big end side clearance 1 mm in 0 050 0 220 0 0020 0 0087 Big end bearing thickness 1 Green mm in 1 488 1 492 0 0586 0 0587 Pink mm in 1 492 1 496 0 0587 0 0589 Red mm in 1 496 1 500 0 0589 0 0...

Page 33: ...98 1 502 0 0590 0 0591 Yellow mm in 1 502 1 506 0 0591 0 0593 Lower Green mm in 1 490 1 494 0 0587 0 0588 Pink mm in 1 494 1 498 0 0588 0 0590 Red mm in 1 498 1 502 0 0590 0 0591 Yellow mm in 1 502 1 506 0 0591 0 0593 Thermostat Valve opening temperature C F 58 0 62 0 136 4 143 6 Valve opening stroke at 60 C 140 F mm in 0 05 0 002 Fully open temperature C F 70 0 158 0 Fully open stroke mm in 3 0 0...

Page 34: ... reverse gear Backlash mm in 0 71 1 06 0 028 0 04 Pinion shim T3 mm 0 10 0 12 0 15 0 18 0 30 0 40 0 50 Forward gear shim T1 mm 0 10 0 12 0 15 0 18 0 30 0 40 0 50 Reverse gear shim T2 mm 0 10 0 12 0 15 0 18 0 30 0 40 0 50 Propeller shaft Runout mm in 0 02 0 0008 Drive shaft Runout mm in 0 2 0 008 Item Unit Model F50DET FT50CET FT50CED FT50CEHD Trim and tilt sensor Setting resistance at 20 C 68 F Ω ...

Page 35: ... 3 22 1 Starter motor positive terminal nut 7 0 7 5 2 Engine oil drain bolt 18 1 8 13 3 Oil filter UNF 18 1 8 13 3 Union bolt 40 4 0 29 5 Pulser coil screw M5 4 0 4 3 0 Flywheel magnet nut 157 15 7 115 8 Base assembly bolt M6 4 0 4 3 0 Cover screw 3 0 3 2 2 Starter relay terminal nut 3 4 0 3 2 5 Oil pressure switch 8 0 8 5 9 Oil pressure switch terminal screw M4 2 0 2 1 5 Mounting bolt M8 21 2 1 1...

Page 36: ...5 1 5 11 1 Pinion nut 74 7 4 54 6 Part to be tightened Thread size Tightening torques N m kgf m ft lb Gear oil drain screw 9 0 9 6 6 Gear oil check screw 9 0 9 6 6 Lower unit mounting bolt nut M10 40 4 29 5 Propeller nut 35 3 5 25 8 Ring nut 103 10 3 76 0 Pinion nut 94 9 4 69 3 Part to be tightened Thread size Tightening torques N m kgf m ft lb Tiller handle nut 38 3 8 28 0 Steering friction piece...

Page 37: ...fications require clean dry threads Components should be at room temperature Part to be tightened Thread size Tightening torques N m kgf m ft lb Gear pump bracket bolt M5 5 3 0 5 3 9 Relief valve bracket bolt M5 5 3 0 5 3 9 Gear pump bolt M6 7 0 7 5 2 PTT motor bolt M6 4 0 4 3 0 Tilt piston bolt M10 61 6 1 45 0 Trim cylinder end screw 80 8 59 0 Tilt cylinder end screw 90 9 66 4 Reservoir cap 7 0 7...

Page 38: ...Specification 1 17 SPEC MEMO ...

Page 39: ...tronic control system 2 1 CDI unit with microcomputer 2 1 Ignition system 2 2 Ignition timing control 2 4 Fuel system 2 7 Four carburetors 2 7 Starting system Prime Start 2 8 Carburetor operation 2 9 Acceleration pump 2 10 Lubrication system 2 11 Oil flow 2 11 PTT unit 2 12 ...

Page 40: ...oil pressure switch CDI 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 sig nals received from the pulser coil thermoswitch and oil pressure switch 1 CDI unit 2 Flywheel magnet 3 Stator assembly 4 Pulser coil 5 Thermoswitch 6 Ignition coil 7 Oil pressure switch 2 3 4 5 1 7 6 ...

Page 41: ...st overheating over revolution and oil pressure drops as well as to control alert devices 1 Pulser coil 2 Flywheel magnet 3 Charge coil 4 CDI unit 5 Microcomputer 6 Ignition coil 1 and 4 7 Ignition coil 2 and 3 8 Oil pressure switch 9 Thermoswitch Flywheel magnet Three protrusions for the pulser coil are provided along the ambience of the flywheel magnet The purpose of these protrusions is for det...

Page 42: ... thus enabling the pulser 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 identification signals generated by the protrusion for identifying cylinders and on the pulser signals generated by the protrusions for generating ignition signals 1 Flywheel magnet ...

Page 43: ... 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 identification protrusion 2 Pulser coil 3 Protrusion for cylinders 1 and 4 4 Protrusion for cylinders 2 and 3 5 Pulser coil signal 6 Cylinder identification signal 7 Identification signal for cylinders 1 and 4...

Page 44: ...l 6 Cylinder identification signal 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 to the ignition timing based on the warm up map for 3 minutes From the time the 3 minute warm up control has been completed the control transfers to the normal map a Igniti...

Page 45: ...n of cylinders 1 and 4 if the engine speed is over 2000 r min At the same time the microcom puter issues a warning by operating the alert indicator and the alert buzzer When the overheating control is activated it will not be deactivated until the engine is stopped or the engine temperature decreases to under 70 C 158 F The determination of overheating stops when the engine is stopped However unti...

Page 46: ...em to further increase starting performance and serviceability Furthermore the acceleration pump and the dashpot have been integrated to simplify construction and to ease serviceability The four carburetors can be accurately and easily adjusted due to the simple construction of the links 1 Prime Start 2 Acceleration pump 1 1 2 ...

Page 47: ...plunger then gradually closes the fuel enrichment valve A few minutes after the engine has started the Prime Start plunger completely closes the fuel enrichment valve thus ending the fuel enrichment by the Prime Start system The Prime Start unit attached to carburetor 1 8 operates for cylinders 1 and 2 while the Prime Start unit attached to carburetor 3 9 operates for cylinders 3 and 4 1 Prime Sta...

Page 48: ...ation Medium speed operation ç High speed operation 1 Pilot screw 2 Pilot outlet 3 Bypass holes 4 Venturi 5 Main nozzle 6 Pilot jet 7 Main jet 8 Pilot air jet 9 Main air jet 0 Throttle valve a Air b Air fuel mixture c Fuel 3 2 2 1 0 9 8 7 6 5 4 3 1 0 9 8 5 7 6 4 3 2 3 2 5 6 7 9 0 1 2 3 å ç a b c ...

Page 49: ...buretors by passing through the pipes that are connected to the carburetors The pressurized 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 and thus achieves the fuel enrichment å Throttle valve closing Throttle valve opening 1 Main air jet 2 Main noz...

Page 50: ...ow Block diagram for lubrication Sleeve Crankcase Cylinder head Piston Connecting rod Crankshaft Crank journal IN and EX valve Rocker arm Camshaft Spray lubrication Cam journal Rocker shaft Main gallery Oil pressure switch Oil filter Oil pump Oil strainer Oil pan Relief valve ...

Page 51: ...rvoir tank and the PTT motor in order to achieve a smaller and more compact unit PTT unit components å Hydraulic system diagram 1 Cylinder 2 PTT ram 3 Check valve 4 Down main valve 5 Down relief valve 6 PTT motor 7 Gear pump 8 Up main valve 9 Reservoir 0 Manual valve q Up relief valve w Up shuttle piston e Down shuttle piston r Trim cylinder base t Free piston y Tilt piston 2 3 5 4 6 7 8 9 0 q w 9...

Page 52: ...urn to the gear pump 6 and also sucks fluid in through the reservoir 8 The pressurized fluid forces up the trim cylinder 3 along with the tilt piston e free piston q and trim cylinder base w As the trim cylinder 3 moves up the PTT ram 2 extends and the outboard motor is trimmed up The end of the trim range is when the trim cylinder 3 tops out in the PTT cyl inder 1 1 PTT cylinder 2 PTT ram 3 Trim ...

Page 53: ...d back to the gear pump 8 And the pressur ized fluid continues to flow into the lower part of the trim cylinder 5 pushing up the tilt piston r and free piston e and further extending the PTT ram 2 1 PTT cylinder 2 PTT ram 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 q Down shuttle piston w Trim cylinder base e Free piston r...

Page 54: ...on q which causes fluid to flow into the upper part of the trim cylinder 3 and forces the tilt piston t down 1 PTT cylinder 2 PTT 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 q Down shuttle piston w Ball e Trim cylinder base r Free piston t Tilt piston a Return b Send c Moving direction 1 2 3 4 5 6 7 8 9 0 q...

Page 55: ...or hits something during operation When the outboard motor hits something highly pressurized fluid in the upper part of the PTT cylin der 1 pushes down the check valve 7 of the trim cylinder 2 At the same time fluid pressure in the upper part of the trim cylinder 2 increases and the tilt piston absorber 4 is pushed down As a result the tilt piston 5 and the PTT ram 3 are pushed up without the free...

Page 56: ...Technical features and description 2 17 TECH FEA MEMO ...

Page 57: ...lling the tiller handle 3 11 Installing the steering friction assembly 3 12 Wiring harness connection 3 12 Connecting the wiring harness 3 12 Control cable installation 3 13 Installing the shift cable rod and throttle cable 3 13 Remote control box installation 3 15 Installing the battery 3 15 Battery wiring without house accessory battery 3 16 Battery wiring with house accessory battery 3 16 Syste...

Page 58: ...ge the boat s center of gravity buoyancy operat ing balance or performance which could cause loss of control or swamping Consult the boat manufacturer for the maximum engine weight allowable on the transom which is differ ent from the overall boat capacity Overloading the transom with a motor that is too heavy could also damage the hull the transom the deck or the helm area as well as the motor an...

Page 59: ...ET 345 13 6 mm in 933 36 7 407 16 0 576 22 7 148 5 8 142 5 6 63 2 5 181 7 1 733 28 9 519 20 4 876 34 5 24 0 9 175 6 9 533 21 0 44 1 7 3 5 0 1 327 12 9 3 5 5 1 4 0 69 2 7 97 3 8 0 6 0 02 532 20 9 711 28 0 4 0 4 12 65 Outboard motor installation Dimensions ...

Page 60: ... 0 X 406 16 0 L 63 2 5 X 62 2 4 L 560 22 1 X 561 22 1 L 733 28 9 X 738 29 1 L 917 36 1 X 1026 40 4 L 28 1 1 X 27 1 1 L 519 20 4 X 524 20 6 L 327 12 9 X 332 13 1 L 44 1 7 X 49 1 9 191 7 5 L 3 5 0 1 X 1 4 0 06 L 0 8 0 03 X 16 0 6 L 98 3 9 X 85 3 4 L 3 5 5 1 4 0 X 3 5 0 1 3 8 L 536 21 1 X 645 25 4 L 749 29 5 X 813 32 0 4 12 65 4 0 L 989 38 9 X 1095 43 1 ...

Page 61: ...ior FT50CED 345 13 6 mm in 989 38 9 397 15 6 576 22 7 149 5 9 142 5 6 63 2 5 181 7 1 738 29 1 519 20 4 917 36 1 28 1 1 191 7 5 536 21 1 44 1 7 0 5 0 02 330 13 0 3 5 5 1 4 0 69 2 7 98 3 9 0 8 0 03 560 22 0 723 28 5 4 0 4 12 63 Dimensions ...

Page 62: ...22 7 L 63 2 5 X 62 2 4 L 272 10 7 X 271 10 7 L 189 7 4 X 188 7 4 L 560 22 1 X 561 22 1 L 738 29 1 X 743 29 3 L 917 36 1 X 1026 40 4 L 28 1 1 X 27 1 1 L 680 26 8 X 685 27 0 L 519 20 4 X 524 20 6 L 330 13 0 X 335 13 2 L 44 1 7 X 49 1 9 191 7 5 L 110 4 3 X 105 4 1 L 0 8 0 03 X 16 0 6 L 98 3 9 X 85 3 4 L 3 5 5 1 4 0 X 3 5 0 1 3 8 L 536 21 1 X 645 25 4 L 723 28 5 X 783 30 8 4 12 63 4 0 ...

Page 63: ...0 1 2 3 4 5 6 7 8 9 10 A Clamp bracket L transom model 69 2 7 163 5 6 4 163 5 6 4 180 7 1 180 7 1 254 10 0 50 8 2 0 18 5 0 7 60 5 2 4 13 0 5 355 14 0 13 0 5 126 5 0 126 5 0 139 5 5 139 5 5 mm in Dimensions ...

Page 64: ...Rigging information 3 7 RIG GING Clamp bracket X transom model 69 2 7 163 5 6 4 163 5 6 4 180 7 1 mm in 180 7 1 249 9 8 50 8 2 0 18 5 0 7 60 5 2 4 13 0 5 350 13 8 13 0 5 126 5 0 126 5 0 139 5 5 139 5 5 ...

Page 65: ...d the notice and understand what pictographs mean to avoid a damage to the product when handling transporting and or keeping the crate Lifting fork insert position Care handling indication Water avoidance indication Product barycentric position Upward indication Care handling indication Dimensions Crate top cover pictograph description ...

Page 66: ... flywheel magnet cover 1 6 Attach a lifting harness 2 securely to the engine hangers 3 TIP Put a rag a between the flywheel magnet and the lifting harness 7 Remove the skeg holder 4 8 Carefully lift up the outboard motor together with the bottom frame 5 NOTICE Do not allow the lifting harness to damage any parts of the outboard motor 9 Remove the clamp bracket bolts 6 10 Remove the steering retain...

Page 67: ... that the vertical centerline is straight The distance a and b are equal length Also c and d are too 2 Adjust the outboard motor so the height of the anti cavitation plate e is equal to or slightly above the bottom of the boat transom TIP This mounting height information is for refer ence only It is impossible to provide com plete instructions for every possible boat and outboard motor combination...

Page 68: ...m the clamp bracket top is recommended for the upper mounting bolt 6 Secure the bolts and firmly tighten the nut to the extent that the clamp bracket does not bite into the boat transom 7 Firmly tighten the locknuts Tiller handle installation Installing the tiller handle 1 Remove the nut 1 cap 2 nuts 3 and plate 4 Drilling plate 2 90890 06783 1 2 H g f C L 1 3 4 4 5 6 D 6 3 4 4 5 3 4 4 5 6 Boat tr...

Page 69: ...ghten the wing nut 6 to the specified torque TIP The steering friction assembly 2 can be installed on the both PORT or STBD Wiring harness connection Connecting the wiring harness 1 Remove the retaining plate 2 Connect the 10 pin main wiring harness coupler a positive battery cable 1 and negative battery cable 2 and then fas ten the plastic tie 3 3 Fasten the 10 pin main wiring harness coupler a w...

Page 70: ...en the battery cable with the plastic tie 0 H model å H model R model Control cable installation Installing the shift cable rod and throttle cable 1 Install the grommet 1 onto the shift cable rod 2 and throttle cable 3 and install the cable guide 4 to the groove of the shift cable 2 R model and throttle cable 3 Then install them to the bottom cowling 4 1 3 5 2 a 6 b 7 6 8 9 7 8 9 å 8 9 7 0 å 1 2 3...

Page 71: ...hing a is aligned with the alignment mark b on the bracket 5 Adjust the shift cable joint 5 to the pin c of shift lever NOTICE The shift cable joint must be screwed in a minimum of 8 0 mm 0 31 in d 6 Install the shift cable joint 5 to the pin c and then tighten the locknut 7 Then install the clip 8 TIP Pull the inner cable to avoid the free play backlash of the cable and install it to the pin R mo...

Page 72: ...nd install it to the pin 11 Install the retaining plate t and then tighten the bolts y Remote control box installation See Remote control box operation manual or Rigging guide Installing the battery 9 Improper battery connections or cable size selection may result in a fire 9 When installing an isolator lead to the positive battery terminal or battery switch over current protection in com pliance ...

Page 73: ...ttery a negative battery cable must be installed between the house battery and the engine battery This cable must be sized equivalent to the engine battery cables or larger AWG cable size in accordance with ABYC specifications 9 Battery switches must be capable of meeting intermittent and continuous current ratings for engines and accessories Battery cable Red Black Outboard motor ON OFF Battery s...

Page 74: ...ication 1 Remote control box 2 Tachometer unit 3 Trim meter unit PTT model 4 Gauge harness 5 Main wiring harness Color code B Black G Green Gy Gray L Blue P Pink R Red Y Yellow Br B Brown Black G R Green Red P B Pink Black P W Pink White Y B Yellow Black Y R Yellow Red ...

Page 75: ...3 18 0 1 2 3 4 5 6 7 8 9 10 A Gy P B P W G R R B G Y P P 1 Y R 2 G P B 1 Y B 2 Br B Gy G R X R G P P P L L L Y Y Y Y B B G G B B B B 1 2 3 4 5 1 PTT model 2 D model System diagram ...

Page 76: ...e and negative cables Select an extension battery cable and terminal which meets ABYC requirements or equivalent Select a stud of battery which is best suited to the terminal size Solder the connection of terminals and cables to prevent them from corroding CCA Cold Cranking Amperage EN European Norm European standard IEC International Electro technical Commission Atmospheric temperature above 0 C ...

Page 77: ... the propeller is indicated on the propeller blade on the propeller boss end and on the side 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 5000 6000 r min the ideal propeller for the boat is one that provides maximum performance in relation to boat speed and fu...

Page 78: ...3 21 RIG GING FT50C Propeller size in Material 12 5 8 21 K Aluminum 13 19 K 13 23 K 13 25 K 13 1 4 17 K 13 1 2 15 K 13 5 8 13 K 13 5 8 14 K 14 11 K 13 1 2 14 K Stainless 13 1 2 16 K 13 17 K 13 19 K 13 21 K 13 23 K 13 25 K ...

Page 79: ...BL SHTG Troubleshooting Troubleshooting the outboard motor 4 1 Troubleshooting procedure 4 1 Troubleshooting table format 4 1 Troubleshooting the power unit 4 2 Troubleshooting the PTT unit 4 7 Troubleshooting the lower unit 4 8 ...

Page 80: ...connectors and battery terminals are securely connected 9 When checking the input voltage of a part the coupler or connector must be disconnected How ever be careful not to short circuit the wiring harness Troubleshooting table format Troubleshooting consists of the following 4 items Symptom 1 Specific trouble conditions Symptom 2 Trouble conditions of an area or individual part Cause 1 The conten...

Page 81: ... 5 22 Starter relay malfunction Check the starter relay input voltage and continuity 5 21 Short open or loose connection in starter motor circuit Check the wiring harness continuity WD Starter motor malfunction Disassemble and check the starter motor 5 24 Starter motor oper ates but the engine does not crank Piston lock due to water in the combustion chamber Disassemble and check the power unit 7 ...

Page 82: ... pulser coil output peak voltage and resistance 5 13 Engine shut off switch malfunction Check the engine shut off switch continu ity 5 19 Fuel not supplied Pinched or kinked fuel hose Check the fuel hoses and fuel hose joint 6 1 Clogged fuel filter Clean or replace the fuel filter 10 15 Fuel pump malfunction Disassemble and check the fuel pump 6 7 Carburetor malfunction Malfunction of the carbu re...

Page 83: ... or replace the fuel filter 10 15 Fuel pump malfunction Disassemble and check the fuel pump 6 7 Carburetor malfunction Throttle stop screw not adjusted correctly Adjust the throttle stop screw 10 12 Pilot screw not adjusted correctly Adjust the pilot screw except for tamper proof type 1 8 Malfunction of the carbu retor internal parts Disassemble and check the carburetor 6 13 Prime Start system mal...

Page 84: ... malfunction Throttle stop screw not adjusted correctly Adjust the throttle stop screw 10 12 Pilot screw not adjusted correctly Adjust the pilot screw except for tamper proof type 1 8 Malfunction of the carbu retor internal parts Disassemble and check the carburetor 6 13 Throttle control lever does not return to fully closed position Throttle control system malfunction Throttle cable not adjusted ...

Page 85: ...mpeller 8 6 F50D 8 46 FT50C Check the Woodruff key Water leakage from water pump housing Check the water pump housing Check the insert cartridge Check the outer plate cartridge Thermostat malfunction Check the thermostat 10 20 Thermoswitch malfunction Check the thermoswitch input voltage and continuity 5 15 Buzzer comes on R model Oil pressure alert indi cator comes on Engine oil quantity Check th...

Page 86: ... circuit Check the wiring harness continuity WD PTT motor malfunction Disassemble and check the PTT motor 9 32 PTT motor operates but the trim and PTT ram does not extend Manual valve left open Check the manual valve 9 38 PTT fluid quantity Check the fluid level 10 18 PTT fluid leakage Check the PTT unit for leakage Clogged filter Disassemble and check the PTT unit 9 41 Clogged fluid passages 9 36...

Page 87: ...ly closed position Shift cable and shift cable joint malfunction Check and adjust the shift cable and shift cable joint 10 19 Remote control box malfunction R model Check the remote control box R model Shift rod malfunction Check the shift rod 8 13 F50D 8 46 FT50C Detent malfunction Check the shift rod cam 8 13 F50D Shift mechanism malfunction in lower unit Disassemble and check the lower unit 8 4...

Page 88: ...Troubleshooting 4 9 TRBL SHTG MEMO ...

Page 89: ...the oil pressure switch 5 16 Checking the alert indicator 5 17 Checking the Prime Start 5 18 Checking the engine start switch 5 18 Checking the engine shut off switch 5 19 Checking the hour meter 5 20 Starting unit and components 5 21 Checking the fuse 5 21 Checking the starter relay 5 21 Checking the neutral switch 5 22 Starter motor 5 24 Removing the starter motor 5 25 Checking the starter motor...

Page 90: ...ectifier Regulator coupler 3 Charge coil coupler 4 Pulser coil coupler 5 Thermoswitch connector Black 6 Thermoswitch connector Gray Black 7 Hour meter connector Green 8 Hour meter connector Yellow 9 Oil pressure switch 0 Ignition coil 2 3 lead Black q Thermoswitch w Ignition coil 2 3 e Spark plug wire 2 r Ignition coil 2 3 connector t Spark plug wire 1 y Ignition coil 1 4 ...

Page 91: ...a Ground lead Black s Hour meter coupler d CDI coupler f Wiring harness g Ground lead h Alert indicator coupler j Hour meter k Rectifier Regulator å Fasten the spark plug wire 1 and spark plug wire 3 with the clamp Fasten the ignition coil connector Orange with the clamp ç Install the ignition coil ground leads and wiring harness ground lead Electrical component and wiring harness routing ...

Page 92: ...Electrical system 5 3 ELEC å ç o p a s d g f h e r t y u i 4 6 5 7 8 q w 0 9 1 2 3 k j Install the ground lead to the bracket Fasten the leads with the plastic tie ...

Page 93: ...oard view å 4 5 2 3 1 1 Prime Start 3 2 Prime Start 1 3 Prime Start connectors 4 CDI unit 5 Prime Start coupler å Fasten the Prime Start connectors and intake silencer with the plastic tie Electrical component and wiring harness routing ...

Page 94: ...nnector Brown 6 Fuse 20A 7 Positive battery cable 8 10 pin main wiring harness 9 Prime Start coupler 0 Oil pressure switch connector Pink q Prime Start lead w Negative battery cable å Fasten the leads except for the fuse holder lead Red with the plastic tie Clamp the fuse holder to the positive bat tery cable ç Install the wiring harness ground leads to the bracket ...

Page 95: ... 2 3 4 5 6 w q 0 9 7 8 Insert the 10 pin main wiring harness cou pler to the holder and then fasten with the plastic tie Install the Prime Start lead onto the holder on the intake silencer Electrical component and wiring harness routing ...

Page 96: ...lay connector Brown 6 PTT switch connector Sky blue 7 PTT switch connector Light green 8 Fuse 20A 9 Positive battery cable 0 Trim meter lead q Alert indicator lead w PTT relay ground lead Black e PTT motor lead Blue r PTT relay lead Black t PTT relay y PTT motor lead Green u 10 pin main wiring harness i Starter relay lead Red o Prime Start coupler p Oil pressure switch connector Pink ...

Page 97: ...or lead trim meter lead and alert indicator lead with the plas tic tie Install the wiring harness ground leads and PTT relay ground lead to the bracket Fasten the PTT switch lead and starter relay lead Red with the plastic tie Do not fasten at the connector ƒ Insert the 10 pin main wiring harness cou pler to the holder and then fasten with the plastic tie Install the Prime Start lead onto the hold...

Page 98: ...2 3 4 5 1 a 1 Stator assembly 2 Pulser coil lead 3 Pulser coil 4 Charge coil lead 5 Lighting coil lead å Fasten the pulser coil lead to the boss on the magnet base with the plastic tie Cut off the surplus of the plastic tie leaving 10 mm a ...

Page 99: ...ead connector Light green 5 PTT motor lead connector Sky blue 6 Trim meter coupler å Fasten the center of the turned up PTT motor lead with the plastic tie Fasten the leads except for the fuse holder lead Red wiring harness ground lead Black and starter relay lead Brown with the plastic tie Electrical component and wiring harness routing ...

Page 100: ...rt indicator 6 Engine shut off switch connector White 7 Engine shut off switch connector Black 8 Engine start switch 9 Engine shut off switch 0 Battery cable å Pass the engine start switch lead and engine shut off switch lead through the grommet Fasten the battery cable and shift arm bracket with the plastic tie ç Align the white tape of the battery cable through the grommet end ...

Page 101: ...Use the peak voltage adapter B with the recommended digital circuit tester 9 Connect the positive pin of peak voltage adapter B to the positive terminal of the dig ital tester and the negative pin to the nega tive terminal 9 When measuring the peak voltage set the selector on the digital circuit tester to the DC voltage mode Ignition unit and components Checking the ignition spark 9 Make sure to i...

Page 102: ...the ignition coil resistance Replace if out of specification 4 Install the spark plug caps to the spark plug wires by turning the caps clockwise and then connect the ignition coil con nector and terminal Checking the pulser coil 1 Disconnect the pulser coil coupler a and then connect the test harness 1 2 Measure the pulser coil output peak volt age Check the pulser coil air gap if below specificat...

Page 103: ...assembly if below specification TIP 9 To prevent the engine from starting when cranking it make sure to disconnect all spark plug caps 9 Do not remove the clip from the engine shut off switch 9 If measuring the output peak voltage under the unloaded conditions disconnect the coupler b 3 Disconnect the test harness 1 Pulser coil output peak voltage reference data White Red W R Black B r min Unloade...

Page 104: ... Checking the thermoswitch 1 Disconnect the thermoswitch connectors a 2 Turn the engine start switch to START and then measure the input voltage CDI unit end Replace the CDI unit if below specification TIP 9 To prevent the engine from starting when cranking it make sure to disconnect all spark plug caps 9 Measure the input voltage while the engine is cranking Charge coil resistance reference data ...

Page 105: ... measure the input voltage CDI unit end Replace the CDI unit if below specification TIP 9 To prevent the engine from starting when cranking it make sure to disconnect all spark plug caps 9 Measure the input voltage while the engine is cranking 3 Turn the engine off 4 Check the oil pressure switch 1 for con tinuity when the engine is stopped and when it is running Check the oil pressure switch usin...

Page 106: ...tery 1 5 V when checking the LEDs Other batteries example alkaline batteries or high volt age batteries will damage the diodes 9 Do not apply more than 1 7 V to the leads when checking the LEDs 1 Disconnect the alert indicator coupler 2 Connect the Yellow Black Y B lead to the positive penlight battery terminal 1 5 V and connect the Pink Black P B lead to the negative terminal and then check that ...

Page 107: ...t the Prime Start connectors a wiring harness end Check the wiring harness and Rectifier Regulator if below specifi cation TIP To prevent the engine from starting when cranking it make sure to disconnect all spark plug caps 3 Turn the engine off Checking the engine start switch 1 Disconnect the 10 pin main wiring har ness coupler 2 Measure the input voltage at the 10 pin main wiring harness couple...

Page 108: ...switch 4 Connect the 10 pin main wiring harness coupler Checking the engine shut off switch 1 Disconnect the 10 pin main wiring har ness coupler 2 Turn the engine start switch to ON and then check the engine shut off switch for continuity Check the engine start switch or replace the engine shut off switch if out of specification Engine start switch input voltage Terminal a Terminal b 12 0 V batter...

Page 109: ... 3 Turn the engine start switch to START and then measure the input voltage at the hour meter coupler a Check the wir ing harness and Rectifier Regulator if below specification Engine shut off switch continuity Switch position Terminal a b Clip installed Clip removed ON OFF START a b å OFF ON START a b Throttle sensor adjusting lead 3 pins 1 90890 06857 Hour meter input voltage Yellow Y Black B 12...

Page 110: ... special service tool 1 and then connect the hour meter coupler a Starting unit and components Checking the fuse 1 Check the fuse 1 and fuse holder 2 for continuity Replace if there is no continu ity Checking the starter relay 1 Disconnect the starter relay lead connec tor a 2 Set the gear shift to the N position 3 Turn the engine start switch to START and then measure the input voltage at the sta...

Page 111: ...he starter relay 3 and then con nect the positive battery lead 2 starter motor lead 1 starter relay lead connec tor a and ground lead b To route and connect the wirings see Electrical com ponent and wiring harness routing 5 1 Checking the neutral switch 1 Disconnect the neutral switch lead con nectors a and b 2 Turn the engine start switch to START and then measure the input voltage at the neutral...

Page 112: ...l switch connectors c and d Replace if out of specification å H model R model 5 Connect the neutral switch lead connec tors Br Neutral switch input voltage Brown Br a Brown Br b 12 0 V battery voltage 6BC80890 a Br Br b a b Br Br f e Br Br å 1 d c f e Br Br 1 c d Neutral switch continuity Switch position Terminal c d Free e F or R Pushed f N ...

Page 113: ... name Q ty Remarks 1 Pinion stopper 1 2 Starter motor pinion 1 3 Cover 1 4 Washer kit 5 Armature 1 6 Washer 2 t 0 3 mm 7 Stator 1 8 Brush holder assembly 1 9 Brush set 1 10 Brush spring 4 11 Washer 1 12 Spring washer 1 13 Nut 1 14 Bracket 1 15 Screw 2 M4 12 mm 16 Bolt 2 M8 115 mm Starting unit and components Starter motor ...

Page 114: ...ds 9 If the starter motor is disassembled for maintenance make sure to check the oper ation again after assembling it 3 Disconnect the negative battery cable 2 and positive battery cable 1 from the battery terminals Removing the starter motor pinion 1 Slide the pinion stopper 1 down and then remove the clips 2 pinion stopper 1 spring and pinion 3 Checking the starter motor pinion Make sure to disc...

Page 115: ...rmature 1 Check the commutator Clean with 600 grit sandpaper and compressed air if dirty 2 Measure the commutator diameter a Replace if below specification 3 Measure the commutator undercut b Replace if below specification 2 4 5 6 3 1 1 8 9 7 Digital caliper 1 90890 06704 Standard diameter a 33 0 mm 1 30 in Wear limit 32 0 mm 1 26 in Standard undercut b 0 5 0 8 mm 0 02 0 03 in Wear limit 0 2 mm 0 ...

Page 116: ...h holder assembly if below specification Assembling the starter motor Do not allow grease or oil to contact the commutator of the armature 1 Install the brush holder 1 to the bracket 2 and then tighten the screws 3 2 Install the washers 4 armature 5 washer set 6 stator 7 cover 8 and then tighten the bolts 9 Armature continuity c d e f Brush holder assembly continuity a b c d e d e f c a b c d e c ...

Page 117: ...tall clips w Installing the starter motor 1 Install the starter motor to the power unit See Starter motor 7 15 Charging unit and components Checking the lighting coil 1 Disconnect the lighting coil coupler a and then connect the test harness 1 to the lighting coil coupler 2 Measure the lighting coil output peak voltage Replace the stator assembly if below specification 8 6 5 4 7 9 9 a A A 8 7 2 8 ...

Page 118: ...d coupler a Rectifier Regulator end Check the Rectifier Regulator for continu ity if below specification TIP 9 Do not use peak voltage adapter B when measuring the Rectifier Regulator output peak voltage 9 Make sure to check the lighting coil before measuring the Rectifier Regulator output peak voltage 3 Disconnect the test harness 1 and then disconnect the lighting coil coupler b 4 Check the Rect...

Page 119: ...er a and charge coil coupler b Rectifier Regulator continuity testing diode mode Tester lead Display value reference data c d OL e OL f 0 445 V g OL k 0 444 V d c OL e OL f 0 454 V g OL h OL k 0 453 V e c OL d OL f 0 447 V g OL h OL k 0 455 V PTC c d e f g h k n p m f c OL d OL e OL g OL h OL k OL g c 0 453 V d 0 451 V e 0 784 V f 0 447 V h 0 453 V k 0 800 V h d OL e OL f 0 445 V g OL k 0 444 V k ...

Page 120: ...Electrical system 5 31 ELEC MEMO ...

Page 121: ...ump 6 8 Disassembling the fuel pump 6 8 Checking the diaphragm and valve 6 9 Assembling the fuel pump 6 9 Intake silencer 6 11 Carburetor unit 6 13 Removing the carburetor 6 15 Disassembling the carburetor 6 15 Checking the carburetor 6 15 Checking the Prime Start 6 15 Assembling the carburetor 6 16 Installing the carburetor 6 16 Synchronizing the carburetor 6 17 Adjusting the throttle link rod 6 ...

Page 122: ...arburetor 5 Fuel hose joint to 4 carburetor 6 Fuel hose joint to 3 carburetor 7 Fuel hose 3 carburetor to joint 8 Fuel hose joint to 2 carburetor 9 Fuel hose 2 carburetor to 1 carburetor 0 Hose 1 carburetor to 2 carburetor from Prime Start plunger q Hose 2 carburetor to 3 carburetor from Prime Start plunger w Hose acceleration pump to 1 carbure tor e Hose acceleration pump to 2 carbure tor r Hose ...

Page 123: ... h d k m u Blowby hose cylinder head cover to joint hose i Blowby joint hose o Blowby hose joint hose to intake silencer a Fuel joint b Fuel filter c Fuel pump d Fuel hose joint 2 carburetor to 3 carburetor e Fuel hose joint 3 carburetor to 4 carburetor f Acceleration pump g Carburetor 1 h Carburetor 2 k Carburetor 3 m Carburetor 4 Hose routing ...

Page 124: ...l system 6 3 FUEL Cooling water hose 2 3 1 a b c 1 Cooling water hose exhaust cover to joint 2 Cooling water hose 3 Cooling water hose joint to exhaust guide a Joint b Cooling water pilot hole c Hose clamp ...

Page 125: ...taining plate 1 2 Bolt 3 M6 20 mm 3 Fuel joint 1 4 Fuel filter assembly 1 5 Fuel filter cup 1 6 O ring 1 7 Fuel filter element 1 8 Fuel pump assembly 1 9 Bolt 1 M6 25 mm 10 Seal 1 11 Fuel hose 1 Fuel joint to fuel filter 12 Clip 3 13 Bolt 1 M8 14 mm 14 Nut 1 15 Bracket 1 16 Fuel hose 1 Fuel filter to fuel pump 17 Fuel hose 2 Fuel pump to carburetor Hose routing Fuel filter ...

Page 126: ...em 6 5 FUEL 1 2 3 4 2 5 N m 0 3 kgf m 1 8 ft lb 9 10 18 11 22 22 14 15 13 5 6 7 17 12 12 18 12 16 18 8 19 19 21 20 No Part name Q ty Remarks 18 Clip 3 19 Bolt 2 M6 30 mm 20 Bracket 1 21 O ring 1 22 Plastic tie 2 ...

Page 127: ...a rubber plug 2 and then apply the specified positive pressure Replace the O ring fuel filter cup or fuel filter assembly if the specified pressure cannot be maintained for at least 15 seconds TIP 9 To check the fuel filter element see Checking the fuel filter 10 15 9 Use a commercially available vacuum pres sure pump gauge and meter that can be pressurized up to 200 0 kPa 2 0 kgf cm2 29 0 psi Vac...

Page 128: ...m 0 2 kgf m 1 5 ft lb 0 5 N m 0 1 kgf m 0 4 ft lb 0 5 N m 0 1 kgf m 0 4 ft lb 3 7 6 No Part name Q ty Remarks 1 Screw 4 M5 44 mm 2 Cover 1 3 Fuel pump body 2 1 4 Fuel pump body 1 1 5 Nut 4 6 Plunger 1 7 Spring 1 8 Spring 1 9 Pin 1 10 Diaphragm 1 11 Gasket 1 ...

Page 129: ...other fuel pump outlet with a rubber plug 2 and then apply the speci fied positive pressure and check that there is no air leakage Disassembling the fuel pump 1 Remove the screws 1 and then disas semble the fuel pump assembly 2 Push down on the plunger 2 and turn fuel pump body 1 3 approximately 90 And then remove the pin 4 Vacuum pressure pump gauge set 1 90890 06756 Specified positive pressure 5...

Page 130: ...oak the diaphragm in gasoline before assembly Assembling the fuel pump 1 Install the diaphragm 1 spring 2 3 and plunger 4 into fuel pump body 1 5 2 Push down on the plunger 4 install the pin 6 and then turn fuel pump body 1 5 approximately 90 TIP Install so that both the diaphragm tab a and slot b face toward the same direction 3 Install fuel pump body 1 5 fuel pump body 2 7 and a new gasket 8 and...

Page 131: ...ure a good seal 9 Assemble the fuel pump so that tab a on the diaphragm is positioned on the opposite side of the fuel inlet and outlets c 9 After assembling the fuel pump check it for air leaks See Checking the fuel pump 6 8 Fuel pump screw 9 2 N m 0 2 kgf m 1 5 ft lb a c 9 5 7 8 9 Fuel pump ...

Page 132: ... 30 29 25 24 13 14 14 22 23 3 N m 0 3 kgf m 2 2 ft lb 26 27 28 17 16 15 15 15 No Part name Q ty Remarks 1 Carburetor 4 2 Intake silencer 1 3 Plastic tie 1 4 Blowby hose 1 5 Bolt 8 M6 90 mm 6 Collar 8 7 O ring 4 8 Plate 1 9 O ring 12 10 O ring 4 11 Joint 1 12 Insulator 1 13 Dowel 2 14 Rivet 2 15 Bolt 8 M6 25mm 16 Fuel hose 2 17 Clip 2 ...

Page 133: ... 29 25 24 13 14 14 22 23 3 N m 0 3 kgf m 2 2 ft lb 26 27 28 17 16 15 15 15 No Part name Q ty Remarks 18 Holder 1 19 Prime Start lead 1 20 Bolt 2 M6 30mm 21 Collar 2 22 Acceleration pump 1 23 Screw 2 M5 10mm 24 Link rod 1 25 Hose 1 26 Hose 2 27 Hose 1 28 Hose 1 29 Throttle link rod 1 30 Link rod 1 31 Plastic tie 1 Intake silencer ...

Page 134: ... ft lb 2 2 2 N m 0 2 kgf m 1 5 ft lb 12 13 2 N m 0 2 kgf m 1 5 ft lb 21 No Part name Q ty Remarks 1 Carburetor body assembly 4 1 2 3 4 2 Screw 32 M4 13 mm 3 Cover 4 4 Seal 4 5 Pilot jet 4 6 Main jet 4 1 2 3 4 7 Needle valve 4 8 Main nozzle 4 9 O ring 4 10 Plug 4 11 Float 4 12 Screw 4 M4 6 mm 13 Float pin 4 14 Gasket 4 15 Float chamber 4 1 2 3 4 16 Drain screw 4 17 O ring 4 ...

Page 135: ...f m 1 5 ft lb 2 2 2 N m 0 2 kgf m 1 5 ft lb 12 13 2 N m 0 2 kgf m 1 5 ft lb 21 No Part name Q ty Remarks 18 Fuel hose 2 Float chamber to body 1 3 19 Prime Start 2 1 3 20 Screw 2 M4 7 mm 1 3 21 Bracket 2 1 3 22 Screw 4 Carburetor 1 M4 17 mm Carburetor 3 M4 22 mm 23 Gasket 2 1 3 24 Spring 4 25 O ring 4 26 Pilot screw 4 27 Plug 4 Tamperproof type Carburetor unit ...

Page 136: ...ters may be enlarged which may seriously affect performance 4 Check the pilot screw and needle valve Replace if there is bend or wear 5 Check the float Replace if there is crack or deform 6 Measure the float height a Replace the float or needle valve 1 if out of specifi cation TIP 9 Measure the float height when it is resting on the needle valve 1 Do not push down on the float 9 Take measurements ...

Page 137: ... valve seat b 9 Install the float pin 8 into the slit c on the carburetor body and lock it with the screw 9 3 Install the spring 0 a new O ring q and pilot screw w turn it in until it is lightly seated then out the specified number of turns Installing the carburetor 1 Install the carburetors to the power unit See Intake silencer 6 11 Prime Start plunger length a after supply ing power reference da...

Page 138: ...ed to 1000 r min by turning the throttle stop screw 4 in direction b or c TIP 9 To increase the idle speed turn the throttle stop screw in direction b 9 To decrease the idle speed turn the throttle stop screw in direction c 5 Measure the vacuum pressure of carbu retor 4 6 Turn the throttle valve adjusting screws 5 to adjust the vacuum pressure of car buretors 1 2 and 3 to the same vac uum variatio...

Page 139: ...ting the dashpot 1 Attach the special service tool 1 to spark plug wire 1 a 2 Start the engine and warm up for 5 10 minutes 3 Open the throttle cam 2 slowly and check the engine speed when the accel eration pump stopper b comes into con tact with point c 4 Adjust the engine speed at the operation point of dashpot if out of specification 5 Open the throttle cam 2 slowly and check that the accelerat...

Page 140: ...lead 7 9 Install the wire lead hose and cable 7 10 Power unit assembly 7 13 Removing the power unit 7 14 Installing the power unit 7 14 Starter motor 7 15 Throttle link and throttle cam 7 17 Timing belt 7 18 Removing the timing belt and sprocket 7 19 Checking the timing belt and sprocket 7 20 Installing the sprocket and timing belt 7 20 Exhaust cover 7 23 Removing the exhaust cover 7 24 Checking t...

Page 141: ...embling the cylinder block 7 44 Checking the piston diameter 7 45 Checking the cylinder bore 7 45 Checking the piston ring 7 45 Checking the piston ring end gap 7 46 Checking the piston ring groove 7 46 Checking the piston ring side clearance 7 46 Checking the piston pin boss inside diameter 7 47 Checking the piston pin 7 47 Checking the connecting rod small end and big end inside diameter 7 47 Ch...

Page 142: ...sure again TIP 9 If the compression pressure increases check the pistons and piston rings for wear 9 If the compression pressure does not increase check the valve clearance valve valve seat cylinder head gasket and cylin der head 8 Remove the special service tool 1 9 Repeat the step 4 step 8 for each cylin der Checking the oil pressure 1 Disconnect the oil pressure switch lead at the oil pressure ...

Page 143: ... pulser coil screws adjust the pulser coil 1 position and then tighten the screws temporarily 3 Set the flywheel magnet and then check the pulser coil air gap again 4 Tighten the pulser coil screws and fly wheel magnet nut to the specified torques Checking the valve clearance Measure the valve clearances when the engine is cold Do not turn the flywheel magnet counter clockwise otherwise the water ...

Page 144: ... 2 and 4 Adjust if out of specification 7 Loosen the valve adjusting locknut 4 and then turn the adjusting screw 5 until the specified valve clearance is obtained TIP 9 To decrease the valve clearance turn the adjusting screw 5 in direction f 9 To increase the valve clearance turn the adjusting screw 5 in direction g 8 Tighten the valve adjusting locknut 4 and then check the valve clearances 9 Ins...

Page 145: ... 3 N m 0 3 kgf m 2 2 ft lb 13 12 5 5 2 1 No Part name Q ty Remarks 1 Flywheel magnet 1 2 Stator assembly 1 3 Cover 1 4 Grommet 2 5 Grommet 2 6 Nut 1 7 Washer 1 8 Bolt 3 M6 25 mm 9 Base assembly 1 10 Screw 4 M6 24 mm 11 Dowel 2 12 Woodruff key 1 13 Cover 1 14 Screw 3 M6 35 mm Power unit check and adjustment Flywheel magnet ...

Page 146: ... and Woo druff key NOTICE To prevent damage to the engine or tools screw in the flywheel puller set bolts evenly and completely so that the flywheel puller is parallel to the flywheel magnet TIP Apply force to the crankshaft end until the fly wheel magnet comes off the tapered portion of the crankshaft 5 Disconnect the charge coil coupler a lighting coil coupler b and then remove the stator assemb...

Page 147: ...and flywheel magnet 5 TIP 9 Make sure to remove any grease from the tapered portion d of the crankshaft and the inner surface e of the flywheel magnet 9 Apply engine oil to the thread f of the fly wheel magnet nut and upper and lower sur faces g of the washer before installation 4 Tighten the flywheel magnet nut to the specified torque b a 3 c 4 5 c b 3 a 2 1 Flywheel holder 6 90890 06522 Flywheel...

Page 148: ...7 å å å H model No Part name Q ty Remarks 1 PTT relay 1 PTT model 2 Battery cable 1 3 Bolt 1 M8 16 mm 4 Grommet 1 5 Nut 1 6 Spring washer 1 7 Positive battery lead 1 8 PTT relay positive lead 1 PTT model 9 Fuse holder lead 1 10 Clip 1 11 Plastic tie 1 12 Hose 1 13 Bolt 2 M6 20 mm 14 Neutral switch 1 H model 15 Plate 1 R model 16 Ground lead 1 PTT model 17 Bolt 1 M6 12 mm ...

Page 149: ...å å å H model No Part name Q ty Remarks 18 Nut 2 PTT model 19 Spring washer 2 PTT model 20 Bolt 2 M6 20 mm PTT model 21 Retaining plate 1 22 Bolt 3 M6 20 mm 23 Shift cable 1 R model 24 Shift rod 1 H model 25 Cable guide 1 R model 26 Cable guide 1 H model 27 Clip 2 28 Throttle cable 1 29 Grommet 1 30 Grommet 1 H model 31 Corrugate tube 1 32 Plastic tie 1 Wiring harness ...

Page 150: ...el 3 Disconnect the fuel hose 5 4 Remove the plastic tie 6 corrugate tube 7 fuse holder 8 and then disconnect the battery cables 9 PTT relay lead PTT model and 10 pin main wiring har ness coupler a 5 Disconnect PTT motor leads b and c PTT model and ground leads d 6 Disconnect the gauge coupler e R model or alert indicator coupler H model 2 1 4 3 å 4 3 5 9 9 a 6 7 8 c d b ...

Page 151: ...TT model 10 Remove the shift rod bolts r and plate t R model or neutral switch y H model and then remove the clip u å R model H model Install the wire lead hose and cable 1 Install the plate 1 R model or neutral switch 2 H model and then tighten the bolts 3 Then install the shift rod lever 4 to the shift rod 5 and then install the clip 6 e f g 0 q e w w t å r u y u r 1 5 å 3 6 4 Wiring harness ...

Page 152: ...ch coupler a and trim sensor coupler b 5 Connect the gauge coupler c R model or alert indicator coupler H model 6 Connect the ground lead d and PTT motor leads e and f PTT model 7 Connect the 10 pin main wiring harness coupler g PTT relay lead PTT model and battery cables q and then install the fuse holder w corrugate tube e and plastic tie r 5 4 6 2 3 7 8 8 0 9 a b c e d f ...

Page 153: ...9 10 A 8 Connect the fuel hose q 9 Install the throttle cable and shift cable rod See Installing the shift cable rod and throttle cable 3 13 Starter relay terminal nut 3 4 N m 0 3 kgf m 2 5 ft lb q q g e r w q Wiring harness ...

Page 154: ... Power unit assembly 2 3 4 4 6 7 8 9 21 N m 2 1 kgf m 15 5 ft lb 1 6 5 4 4 No Part name Q ty Remarks 1 Power unit 1 2 Dipstick 1 3 Gasket 1 4 Dowel 2 5 Bolt 2 M6 16 mm 6 Bolt 8 M8 80 mm 7 Apron 1 8 Screw 2 M6 24 mm 9 Nut 2 ...

Page 155: ...1 Clean the power unit mating surface and install the dowels 1 and a new gasket 2 TIP Make sure to check the shift rod is properly installed onto the bottom cowling before installing the power unit 2 Install the lifiting harnesses to the engine hangers 3 and then install the power unit by installing the bolts 4 then tight ening them to the specified torque 3 Install the apron 1 2 2 3 3 Mounting bo...

Page 156: ... N m 3 0 kgf m 22 1 ft lb 30 N m 3 0 kgf m 22 1 ft lb 31 24 23 3 28 29 No Part name Q ty Remarks 1 Bracket 1 2 Starter motor 1 3 Spark plug cap 4 4 Ignition coil 2 5 Wiring harness 1 6 Thermoswitch 1 7 Holder 1 8 Bolt 1 M6 12 mm 9 Bolt 1 M6 12 mm 10 Oil pressure switch 1 11 Screw 1 12 Bolt 4 M6 30 mm 13 Bolt 2 M8 25 mm 14 Bolt 3 M8 35 mm 15 Nut 1 16 Spring washer 1 17 Starter motor lead 1 ...

Page 157: ...m 1 5 ft lb 26 27 30 N m 3 0 kgf m 22 1 ft lb 30 N m 3 0 kgf m 22 1 ft lb 31 24 23 3 28 29 No Part name Q ty Remarks 18 Spring washer 1 19 Nut 1 20 Bolt 1 M8 45 mm 21 Hour meter 1 22 Bolt 1 M6 12 mm 23 Bolt 2 M6 20 mm 24 Engine hanger 1 25 Screw 2 M5 16 mm 26 Bolt 2 M6 40 mm 27 Washer 2 28 Bracket 1 29 Rectifier Regulator 1 30 Plastic tie 1 31 Clamp 1 Starter motor ...

Page 158: ... 17 No Part name Q ty Remarks 1 Throttle link rod 1 2 Throttle cam 1 3 Throttle control lever 1 4 Bushing 1 5 Cotter pin 1 6 Clip 1 7 Bushing 1 8 Bolt 1 M6 20 mm 9 Spring 1 10 Collar 1 11 Bracket 1 12 Bolt 1 M6 25 mm 13 Shift rod lever 1 14 Bolt 1 M6 30 mm 15 Bracket 1 16 Spring 1 17 Bolt 1 ...

Page 159: ...110 6 ft lb 15 11 8 N m 0 8 kgf m 5 9 ft lb No Part name Q ty Remarks 1 Timing belt 1 2 Drive sprocket 1 3 Driven sprocket 1 4 Bolt 1 5 Bolt 1 M8 20 mm 6 Tensioner 1 7 Spring 1 8 Nut 1 9 Retaining plate 2 10 Woodruff key 1 11 Bolt 1 M10 40 mm 12 Washer 1 13 Bolt 2 M6 20 mm 14 Blowby hose 1 15 Pipe 1 16 Dowel 1 Throttle link and throttle cam Timing belt ...

Page 160: ...m for this pro cedure 9 Do not turn the crankshaft when loosening the drive sprocket nut 3 Remove the bolts 4 blowby hose 5 tensioner 6 and timing belt 7 from the driven sprocket side 4 Loosen the driven sprocket bolt and remove the driven sprocket 8 TIP Do not turn the camshaft when loosening the driven sprocket bolt 5 Remove the nut 0 retaining plates q drive sprocket w and Woodruff key e Cranks...

Page 161: ...age or wear Installing the sprocket and timing belt 1 Check that the 1 mark a on the driven sprocket 1 is aligned with the mark b on the cylinder head and then tighten the bolt 2 temporarily 2 Install the retaining plate 3 Woodruff key 4 drive sprocket 5 retaining plate 3 and nut 6 3 Align the mark c on the retaining plate with the mark d on the cylinder block 0 q q w e 1 2 1 2 a b 6 6 5 3 3 3 3 5...

Page 162: ...temporarily tighten the bolt 0 7 Install a new timing belt q onto the drive sprocket 5 and then install it onto the driven sprocket 1 Then loosen the bolt 0 1 2 turn 8 Tighten the driven sprocket bolt 2 to the specified torque 9 Tighten the drive sprocket nut 6 to the specified torque d c 8 7 9 e f 8 0 Flywheel holder w 90890 06522 Driven sprocket bolt 2 38 N m 3 8 kgf m 28 0 ft lb q 5 1 w ...

Page 163: ... the cylinder head and that the mark c on the drive sprocket is aligned with the mark d on the crankcase 11 Tighten the tensioner bolts to the speci fied torque 12 Install the blowby hose e Crankshaft holder 18 r 90890 06562 Drive sprocket nut 6 150 N m 15 0 kgf m 110 6 ft lb t r 6 e Tensioner bolt 9 8 N m 0 8 kgf m 5 9 ft lb Tensioner bolt adjusting bolt 0 25 N m 2 5 kgf m 18 4 ft lb a b d c 9 0 ...

Page 164: ...13 6 6 6 N m 0 6 kgf m 4 4 ft lb 12 N m 1 2 kgf m 8 9 ft lb No Part name Q ty Remarks 1 Exhaust cover 1 2 Gasket 1 3 Thermostat 1 4 Gasket 1 5 Cover 1 6 Bolt 12 M6 35 mm 7 Clamp 2 8 Grommet 1 9 Anode 1 10 Cover 1 11 Plate 1 12 Bolt 1 M6 20 mm 13 Bolt 1 M5 12 mm 14 Joint 1 ...

Page 165: ...ace if cracked or corroded Checking the exhaust cover anode 1 Check the anode Clean if there are scales grease or oil appeared or replace if excessively eroded Installing the exhaust cover 1 Install a new gasket 1 2 and the exhaust cover 3 and then tighten the exhaust cover bolts 4 to the specified torques in 2 stages and in the sequence numbers UP 1 2 1 1 1 1 1 1 1 4 3 4 4 4 4 4 4 4 1 2 Exhaust c...

Page 166: ...Power unit 7 25 POWR Exhaust cover bolt 4 1st 6 N m 0 6 kgf m 4 4 ft lb 2nd 12 N m 1 2 kgf m 8 9 ft lb UP ...

Page 167: ... ft lb 6 N m 0 6 kgf m 4 4 ft lb 12 N m 1 2 kgf m 8 9 ft lb No Part name Q ty Remarks 1 Cylinder head 1 2 Oil pump assembly 1 3 Cylinder head cover 1 4 Bolt 7 M6 20 mm 5 Cylinder head cover gasket 1 6 Plate 1 7 Screw 4 8 Bolt 10 M9 95 mm 9 Spark plug 4 10 Bolt 5 M6 25 mm 11 Dowel 2 12 Cylinder head gasket 1 13 Grommet 4 14 Anode 4 15 Cover 4 16 Bolt 4 M5 12 mm 17 Cover 4 Exhaust cover Cylinder hea...

Page 168: ... N m 1 8 kgf m 13 3 ft lb 23 N m 2 3 kgf m 17 0 ft lb 47 N m 4 7 kgf m 34 7 ft lb 6 N m 0 6 kgf m 4 4 ft lb 12 N m 1 2 kgf m 8 9 ft lb No Part name Q ty Remarks 18 Bolt 4 M6 20 mm 19 O ring 1 20 O ring 1 21 O ring 1 22 Bolt 4 M6 45 mm 23 Bolt 2 M6 20 mm 24 Engine hanger 1 25 O ring 1 26 Oil filler cap 1 ...

Page 169: ...ts 3 4 in the sequence numbers Remove the cylinder head 5 and gasket 6 NOTICE Do not scratch or damage the mating surfaces of the cylinder head and cylinder block 3 Remove the oil pump assembly 7 Installing the cylinder head 1 Install new O rings 1 2 3 and the oil pump assembly 4 by aligning the oil pump drive shaft a with the camshaft pin b 1 2 3 3 4 4 4 4 5 6 4 3 7 Cylinder head ...

Page 170: ...4 Adjust the valve clearances See Check ing the valve clearance 7 2 5 Install a new gasket 0 and cylinder head cover q and then tighten the cylinder head cover bolts w a b 1 2 4 3 9 9 8 8 8 8 7 6 8 5 5 9 Cylinder head bolt M9 8 1st 23 N m 2 3 kgf m 17 0 ft lb 2nd 47 N m 4 7 kgf m 34 7 ft lb Cylinder head bolt M6 9 1st 6 N m 0 6 kgf m 4 4 ft lb 2nd 12 N m 1 2 kgf m 8 9 ft lb 0 q w w ...

Page 171: ... 17 17 19 20 20 18 23 22 23 22 No Part name Q ty Remarks 1 Rocker arm 8 2 Rocker arm shaft 1 3 Cylinder head 1 4 Exhaust 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 Valve seal 8 12 Circlip 8 13 Valve guide 8 14 Retaining bolt 1 15 Gasket 1 16 Oil seal 1 17 Bolt 5 M8 22 mm Cylinder head Camshaft and valve ...

Page 172: ...11 12 13 14 15 16 17 18 19 20 21 13 5 N m 1 4 kgf m 10 0 ft lb a b c d e f 19 21 1 17 17 17 19 20 20 18 23 22 23 22 No Part name Q ty Remarks 18 Rocker arm retainer 2 19 Tensioner 2 e f 20 Stopper 2 a b 21 Rocker arm retainer 1 c d 22 Adjusting screw 8 23 Nut 8 ...

Page 173: ...to keep the parts in the order as they were removed 3 Remove the retaining bolt 0 and cam shaft q in the direction arrowed 4 Remove the intake valve and exhaust valves TIP 9 When replacing the valve also replace the valve guide and stem seal 9 Make sure to keep the valves springs and other parts in order as they were removed 2 1 3 3 6 6 3 4 7 5 7 4 8 9 9 1 2 1 2 Valve spring compressor w 90890 040...

Page 174: ... a Replace if out of specification 3 Measure the valve stem diameter b Replace if out of specification 4 Measure the valve stem runout Replace if above specification Degital caliper 1 90890 06704 Valve spring free length a 39 85 mm 1 569 in Valve spring tilt b 1 7 mm 0 07 in a 1 b Valve margin thickness a Intake 0 600 1 000 mm 0 0236 0 0394 in Exhaust 0 700 1 100 mm 0 0276 0 0433 in Valve stem dia...

Page 175: ...side 2 Install a new valve guide 3 using the special service tool 2 from the camshaft side until the valve guide clip 4 contacts the cylinder head TIP Apply engine oil to the surface of new valve guides 3 Insert the special service tool 5 into the valve guide 3 and then ream the valve guide Valve stem runout Intake 0 030 mm 0 0012 in Exhaust 0 030 mm 0 0012 in Valve guide inside diameter a 5 500 5...

Page 176: ...e tool 1 4 Measure the valve seat contact width a where the blueing dye is adhered to the valve face Reface the valve seat if the valve is not seated properly or if the valve seat contact width is out of specification Replace the valve guide if the valve seat contact width is uneven Refacing the valve seat After every lapping procedure make sure to clean off any remaining lapping com pound from th...

Page 177: ...th of the top edge of the valve seat b Previous contact width 4 Use a 60 cutter to adjust the contact width of the bottom edge of the valve seat b Previous contact width 5 Use a 45 cutter to adjust the contact width of the valve seat to specification b Previous contact width c Specified contact width 6 Check the valve seat contact area of the valve See Checking the valve seat 7 35 Valve seat cutte...

Page 178: ...lve face use a 60 cutter to cut the bottom edge of the valve seat and then use a 45 cutter to center the area and set its width b Previous contact width 10 After refacing the valve seat to the speci fied contact width apply a thin even layer of lapping compound onto the valve seat and then lap the valve using the special service tool 1 NOTICE Do not get the lapping compound on the valve stem and v...

Page 179: ...warpage using a straightedge 1 and thickness gauge 2 in 5 directions Replace if above spec ification Rocker arm inside diameter b 16 000 16 018 mm 0 6299 0 6306 in Rocker arm shaft outside diameter c 15 971 15 991 mm 0 6288 0 6296 in Cam lobe a Intake 30 888 30 988 mm 1 2161 1 2200 in Exhaust 30 824 30 924 mm 1 2135 1 2175 in Cam lobe b Intake 25 950 26 050 mm 1 0217 1 0256 in Exhaust 25 950 26 05...

Page 180: ...vice tool 6 and 7 TIP Face the fine pitch side a of the valve spring toward the spring seat 3 Compress the valve spring and then install the valve cotter 8 4 Lightly tap the spring retainer with a plas tic hammer to set the valve cotters securely Cylinder head warpage limit 0 10 mm 0 0039 in 1 2 1 Valve spring compressor 6 90890 04019 Valve spring compressor attachment 7 90890 06320 a 2 3 4 5 7 6 ...

Page 181: ...ng the rocker arm assembly 1 Install the valve adjusting screw 1 and locknut 2 onto the rocker arm 3 tempo rarily 2 Assemble the rocker arm assemblies and rocker arm shaft 4 tensioners 5 rocker arm retainers 6 7 and stoppers 8 by installing the bolts 9 Bearing outer race attachment 2 90890 06626 Driver rod LS 3 90890 06606 1 2 3 1 2 3 4 6 5 4 5 6 a 5 9 7 8 8 9 3 3 1 2 6 9 9 1 2 9 Camshaft and valv...

Page 182: ...sioners 5 are facing up 9 Make sure that the rocker arm retainer 7 and stoppers 8 are assembled facing in the direction shown 3 Install the rocker arm shaft assembly to the cylinder head and then tighten the bolts 9 to the specified torque and in the sequence numbers 9 9 ...

Page 183: ...0 6 kgf m 4 4 ft lb 17 N m 1 7 kgf m 12 5 ft lb 6 N m 0 6 kgf m 4 4 ft lb 12 N m 1 2 kgf m 8 9 ft lb No Part name Q ty Remarks 1 Oil filter 1 2 Union bolt 1 3 Crankshaft 1 4 Bolt 10 M8 82 mm 5 Bolt 10 M6 35 mm 6 Crankcase 1 7 Oil seal 1 8 Crankshaft bearing 10 9 Oil seal 1 10 Crankpin bearing 8 11 Bolt 8 12 Dowel 4 13 Cylinder block 1 14 Connecting rod 4 15 Piston pin clip 8 16 Piston pin 4 17 Pis...

Page 184: ...lb 7 3 6 4 4 10 11 9 8 8 4 4 8 8 8 8 12 12 15 16 14 13 10 1 15 17 18 21 20 19 5 5 5 5 2 40 N m 4 0kgf m 29 5 ft lb 6 N m 0 6 kgf m 4 4 ft lb 17 N m 1 7 kgf m 12 5 ft lb 6 N m 0 6 kgf m 4 4 ft lb 12 N m 1 2 kgf m 8 9 ft lb No Part name Q ty Remarks 18 Piston 4 19 Top ring 4 20 Second ring 4 21 Oil ring 4 ...

Page 185: ...h 2 Remove the crankcase bolts 1 and 2 in the sequence numbers and then remove the crankcase 3 3 Remove the connecting rod cap bolts 4 and connecting rod caps a and then remove the connecting rod and piston assemblies 5 4 Remove the crankshaft 6 crankshaft bearings 7 and oil seal 8 and 9 Oil filter wrench 90890 01426 1 2 2 1 2 2 2 1 1 1 3 4 5 4 a Cylinder block ...

Page 186: ... and c and in direction d which is parallel to the crankshaft and direction e which is at a right angle to the crankshaft a 20 mm 0 8 in b 60 mm 2 4 in c 100 mm 3 9 in Checking the piston ring 1 Measure the piston ring dimensions B and T Replace the piston ring set if out of specification 6 7 8 9 7 7 7 0 0 q w Piston diameter a 62 950 62 965 mm 2 4783 2 4789 in Measuring point b 5 0 mm 0 20 in up ...

Page 187: ... Piston ring dimensions Top ring a B 1 170 1 190 mm 0 0461 0 0469 in T 2 250 2 450 mm 0 0886 0 0965 in Second ring b B 1 470 1 490 mm 0 0579 0 0587 in T 2 400 2 600 mm 0 0945 0 1024 in Oil ring c B 2 340 2 460 mm 0 0921 0 0969 in T reference data 2 750 mm 0 1083 in B B B T T T a b c a b 1 Piston ring end gap reference data a Top ring 0 150 0 300 mm 0 0059 0 0118 in Second ring 0 300 0 500 mm 0 011...

Page 188: ...of specification Checking the connecting rod big end side clearance 1 Measure the connecting rod big end side clearance a Replace the connecting rod or crankshaft or both if out of specifi cation Piston ring side clearance Top ring a 0 040 0 080 mm 0 0016 0 0032 in Second ring b 0 030 0 070 mm 0 0012 0 0028 in Oil ring c 0 050 0 190 mm 0 0020 0 0075 in Piston pin boss inside diameter 15 974 15 985...

Page 189: ...2 Install half of the bearings 1 and the crankshaft 2 into the cylinder block 3 TIP 9 Install the bearings in their original posi tions 9 Install the protrusion of the bearing into the groove a in the cylinder block 3 Put a piece of Plastigauge PG 1 on each journal parallel to the crankshaft Connecting rod big end side clearance a 0 050 0 220 mm 0 0020 0 0087 in Crankshaft journal diameter a 42 98...

Page 190: ...ankcase bolts 5 and 6 to the specified torques in 2 stages and in the sequence numbers TIP Do not turn the crankshaft until the journal oil clearance measurement has been com pleted 7 Remove the crankcase 4 and measure the width of the compressed Plastigauge PG 1 on each journal Replace the bearing if out of specification 6 5 6 6 6 5 5 5 4 Crankcase bolt M8 5 1st 15 N m 1 5 kgf m 11 1 ft lb 2nd 30...

Page 191: ...tall the connecting rod to the crankpin TIP 9 Align the alignment marks b on the con necting rod 9 Face the alignment marks b toward the fly wheel magnet side of the crankshaft 5 Tighten the connecting rod bolts 3 to the specified torques in 2 stages TIP Do not turn the connecting rod until the crankpin oil clearance measurement has been completed 6 Remove the connecting rod cap and measure the wi...

Page 192: ...y small metal particles and oil from the contact surfaces of the cylinder block and the crankshaft journal bearing 5 Measure the crankshaft journal oil clear ance again See Checking the crank shaft journal oil clearance 7 48 Selecting the crankpin bearing 1 When replacing the crankpin bearing select the suitable crankpin bearing as follows 2 Check the crankpin mark a on the crankshaft 1 and the co...

Page 193: ...in clips 4 TIP 9 Face the alignment mark a on the con necting rod 2 in the same direction as the UP mark b on the piston 1 9 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 second ring 6 and top ring 7 to the piston with the T mark d on the piston rings facing upward 3 Offset the piston ring end gaps as shown NOT...

Page 194: ...e groove on the connecting rod 5 Apply engine oil to side of the piston assembly and then install the piston with the UP mark on the piston crown facing towards the flywheel magnet side 6 Install the crankshaft journal bearings q so that the holes f in the crankshaft journal bearings q and the holes g are aligned TIP Install the crankshaft journal bearings q in the original positions Piston slider...

Page 195: ...P Align the alignment marks s on the connect ing rod 9 Apply sealant to the mating surface of the crankcase y TIP Do not get any sealant on the crankshaft journal bearings Crankshaft journal bearing installation position reference data h 1 14 200 14 800 mm 0 5591 0 5827 in k 2 95 400 96 000 mm 3 7559 3 7795 in m 3 167 400 168 000 mm 6 5905 6 6142 in n 4 239 400 240 000 mm 9 4252 9 4488 in p 5 16 6...

Page 196: ...he bolts u and i to the specified torques in 2 stages and in the sequence numbers Crankcase bolt M8 u 1st 15 N m 1 5 kgf m 11 1 ft lb 2nd 30 N m 3 0 kgf m 22 1 ft lb Crankcase bolt M6 i 1st 6 N m 0 6 kgf m 4 4 ft lb 2nd 12 N m 1 2 kgf m 8 9 ft lb u i i i u u u y i i u ...

Page 197: ...sembly 8 8 Assembling the propeller shaft assembly 8 9 Drive shaft and lower case F50D 8 10 Removing the drive shaft and shift rod assembly 8 12 Disassembling the drive shaft assembly 8 12 Disassembling the forward gear 8 12 Disassembling the lower case 8 13 Checking the pinion and forward gear 8 13 Checking the shift rod 8 13 Checking the drive shaft 8 13 Checking the lower case 8 14 Assembling t...

Page 198: ...everse gear shim thickness T2 8 36 Reverse gear shim T2 selection chart 8 38 Lower unit FT50C 8 40 Removing the lower unit 8 42 Water pump and shift rod FT50C 8 44 Removing the water pump and shift rod 8 46 Checking the water pump and shift rod 8 46 Propeller shaft housing FT50C 8 47 Removing the propeller shaft housing assembly 8 49 Disassembling the propeller shaft assembly 8 49 Disassembling th...

Page 199: ... 59 Installing the propeller shaft housing assembly 8 59 Installing the shift rod 8 60 Assembling the oil seal housing 8 60 Installing the water pump 8 61 Checking the lower unit for air leakage 8 62 Installing the lower unit 8 62 Shimming FT50C 8 64 Shimming workflow 8 64 Shimming check sheet 8 65 Removing the water pump 8 67 Measuring the forward gear backlash before disassembly 8 67 Shimming 8 ...

Page 200: ...gf m 29 5 ft lb 8 4 4 5 6 4 1 4 11 18 10 19 12 13 14 15 16 17 7 6 No Part name Q ty Remarks 1 Lower unit 1 2 Plastic tie 1 3 Hose 1 4 Bolt 4 M10 40 mm 5 Check screw 1 6 Gasket 2 7 Drain screw 1 8 Dowel 2 9 Bolt 1 M8 35 mm 10 Anode 1 11 Bolt 1 M8 60 mm 12 Spacer 1 13 Propeller 1 14 Washer 1 15 Washer 1 16 Propeller nut 1 17 Cotter pin 1 ...

Page 201: ... 9 9 N m 0 9 kgf m 6 6 ft lb 9 N m 0 9 kgf m 6 6 ft lb 35 N m 3 5 kgf m 25 8 ft lb 40 N m 4 0 kgf m 29 5 ft lb 8 4 4 5 6 4 1 4 11 18 10 19 12 13 14 15 16 17 7 6 No Part name Q ty Remarks 18 Trim tab 1 19 Bolt 1 M8 25 mm Lower unit F50D ...

Page 202: ...ening or tightening it 1 Drain the gear oil 2 Remove the cotter pin 3 Set the gear shift to the N position place a block of wood between the anti cavitation plate and propeller to keep the propeller from turning and then remove the propeller nut and propeller 4 Remove the trim tab bolt 1 and trim tab 2 TIP Mark the trim tab at the area shown 5 Remove the bolts 3 and 4 speedome ter hose 5 and then ...

Page 203: ... m 11 1 ft lb 20 3 No Part name Q ty Remarks 1 Spacer 1 2 Grommet 1 3 Bolt 4 M8 30 mm 4 Water pump housing 1 5 Insert cartridge 1 6 Impeller 1 7 O ring 1 8 Outer plate cartridge 1 9 Gasket 1 10 Dowel 2 11 Woodruff key 1 12 Slider 1 13 Spring 1 14 Cross pin 1 15 Dog clutch 1 16 Spring 1 17 Propeller shaft 1 Lower unit F50D Propeller shaft housing F50D ...

Page 204: ...21 22 23 24 25 26 27 28 15 N m 1 5 kgf m 11 1 ft lb 20 3 No Part name Q ty Remarks 18 Shift plunger 1 19 Washer 1 20 Bolt 2 M8 25 mm 21 Reverse gear 1 22 Reverse gear shim 23 Ball bearing 1 24 O ring 1 25 O ring 2 26 Propeller shaft housing 1 27 Needle bearing 1 28 Oil seal 2 ...

Page 205: ...move the insert car tridge when checking the housing 2 Check the impeller insert cartridge and outer plate cartridge Replace if cracked or worn 3 Check the Woodruff key and keyway on the drive shaft Replace if deformed or worn Removing the propeller shaft housing assembly 1 Remove the bolts 1 from the lower case 2 Remove the propeller shaft housing 2 and then remove the propeller shaft assembly fr...

Page 206: ...ing Replace if corroded cracked or dam aged Checking the reverse gear 1 Check the teeth and dogs of the reverse gear Replace if cracked or worn Checking the propeller shaft 1 Check the propeller shaft spline Replace if damaged or worn 2 Measure the propeller shaft runout Replace if above specification Bearing separator 1 90890 06534 Stopper guide plate 2 90890 06501 Stopper guide stand 3 90890 065...

Page 207: ...propeller side 9 When using the driver rod do not strike the special service tool in a manner that will force the stopper c out of place 2 Install new oil seals into the propeller shaft housing to the specified depth 3 Install the original shim s 6 and a new ball bearing 7 onto the reverse gear 8 Propeller shaft runout 0 02 mm 0 0008 in Driver rod SS 1 90890 06604 Needle bearing attachment 2 90890...

Page 208: ...ller shaft assembly 1 Install the dog clutch 1 with the F mark a facing toward the forward gear onto the propeller shaft 2 TIP Align the hole b in the dog clutch 1 with the hole c in the propeller shaft 2 2 Install the spring 3 and slider 4 into the propeller shaft 2 3 Install the cross pin 5 and spring 6 TIP Align the hole in the dog clutch with the hole d in the slider when installing the cross ...

Page 209: ... 32 25 26 No Part name Q ty Remarks 1 Drive shaft 1 2 Oil seal housing assembly 1 3 Taper roller bearing 1 4 Pinion shim 5 Sleeve 1 6 Needle bearing 1 7 Pinion 1 8 Nut 1 9 Forward gear shim 10 Taper roller bearing 1 11 Forward gear 1 12 Cover 1 13 Oil seal housing 1 14 O ring 1 15 Oil seal 2 16 Washer 1 17 O ring 1 Propeller shaft housing F50D Drive shaft and lower case F50D ...

Page 210: ... 23 24 27 28 29 30 31 74 N m 7 4 kgf m 54 6 ft lb 25 32 25 26 No Part name Q ty Remarks 18 Oil seal 1 19 Plate 1 20 O ring 1 21 Circlip 1 22 Shift rod 1 23 Shift cam 1 24 Screw 1 25 Water inlet cover 2 26 Nut 1 27 Hose 1 28 Plastic tie 1 29 Joint 1 30 Seal 1 31 Plate 1 32 Lower case 1 ...

Page 211: ...e pinion nut 1 tighten it tempo rarily and then remove the taper roller bearing 2 NOTICE Do not press the drive shaft threads a directly Disassembling the forward gear 1 Remove the taper roller bearing from the forward gear Drive shaft holder 4 2 90890 06518 Pinion nut holder 3 90890 06715 3 2 1 4 5 6 1 7 9 8 Bearing inner race attachment 3 90890 06641 Bearing separator 1 90890 06534 Solid cylinde...

Page 212: ...rned 3 Heat the installation area of the taper roller bearing outer race in the lower case with a gas torch and then remove the taper roller bearing outer race 5 shim s 6 and drive shaft sleeve 7 NOTICE When heating the lower case heat the entire installation area evenly Otherwise the paint on the lower case could be burned Checking the pinion and forward gear 1 Check the teeth of pinion Check the...

Page 213: ...he bearing always replace it with a new one Installing the shift rod 1 Install new O rings 1 2 plate 3 a new oil seal 4 circlip 5 shift rod 6 and shift cam 7 Assembling the lower case 9 Use heat resistant gloves otherwise burns could result 9 Remove any flammable substances such as gasoline and oil around the working area to avoid the risk of fire 9 Heat the lower case in a well ventilated area Dr...

Page 214: ...that the taper roller bearing outer race is installed prop erly If a high pitched metallic sound is produced when the special service tool is struck the outer race is installed prop erly 3 Install a new needle bearing into the lower case to the specified depth TIP 9 Install a new needle bearing with the manu facture identification mark b facing upward 9 When using the driver rod do not strike the ...

Page 215: ...olding the special service tool 3 strike the tool to check that the taper roller bearing outer race is installed prop erly If a high pitched metallic sound is produced when the special service tool is struck the outer race is installed prop erly Installing the drive shaft 1 Install the forward gear assembly 1 drive shaft 2 pinion 3 and pinion nut 4 into the lower case TIP When installing the pinio...

Page 216: ...aft housing 3 2 Install the shift plunger 4 and propeller shaft housing assembly into the lower case 3 Tighten the bolts 5 to the specified torque Installing the water pump 1 Install the dowels 1 a new gasket 2 and outer plate cartridge 3 Drive shaft holder 4 0 90890 06518 Pinion nut holder q 90890 06715 Pinion nut 4 74 N m 7 4 kgf m 54 6 ft lb 2 5 6 7 8 3 4 1 9 F q 0 4 Propeller shaft housing bol...

Page 217: ...n install the grommet q and spacer w NOTICE Do not turn the drive shaft counterclockwise otherwise the water pump impeller may be damaged TIP 9 When installing the water pump housing apply grease to the inside of the insert car tridge and then turn the drive shaft clock wise while pushing down on the water pump housing 9 Align the spacer protrusion d with the hole e in the water pump housing Check...

Page 218: ...power unit installed make sure to sus pend the outboard motor If the out board motor is not suspended it can fall suddenly and result in severe injury 1 Set the gear shift to the N position at the lower unit 2 Align the pin a on the bushing with the alignment mark b on the bracket 3 Install the dowels 2 into the lower unit 4 Install the anode 3 to the lower case 5 Install the speedometer hose 4 6 ...

Page 219: ...to keep the propeller from turning and then tighten the propeller nut to the specified torque TIP If the grooves in the propeller nut 0 do not align with the cotter pin hole tighten the pro peller nut until they are aligned Recommended gear oil Hypoid gear oil API GL 4 SAE 90 Gear oil quantity 0 43 L 0 45 US qt 0 38 Imp qt Propeller nut 0 35 N m 3 5 kgf m 25 8 ft lb F 9 0 Drive shaft and lower cas...

Page 220: ...not required YES NO NO YES Disassemble the lower unit Select the pinion shims T3 Assemble the lower unit Measure the backlash Install the water pump assembly and oil seal housing Within specification TIP 9 Shimming is not required if the backlash is within specification 9 Shimming is required when assembling the original inner parts and a new lower case 9 Shimming is required when replacing the pi...

Page 221: ...ht Measuring the forward gear backlash Serial number P F R Remarks mm Measurements Measurement point 1 Measurement point 2 Measurement point 3 Measurement point 4 Average Truncated average M mm Measurements Before disassembly After disassembly Measurement point 1 Measurement point 2 Measurement point 3 Measurement point 4 Average Truncated average BL1 Shimming F50D ...

Page 222: ...gear shim thickness T2 Measure the thickness of each reverse gear shim T2 in 2 places mm Measurements Before disassembly After disassembly Measurement point 1 Measurement point 2 Measurement point 3 Measurement point 4 Average Truncated average BL2 mm Number of shim s Subtotal 0 10 0 12 0 15 0 18 0 30 0 40 0 50 Total mm Number of shim s Subtotal 0 10 0 12 0 15 0 18 0 30 0 40 0 50 Total ...

Page 223: ...to seat the taper roller bearing 5 Tighten the center bolt 4 to the specified torque while holding the drive shaft not to turn 6 Turn the lower unit upright 7 Install the special service tool 5 onto the drive shaft at the lowest possible position where the shaft diameter is 18 mm 0 71 in 8 Install the special service tool 6 so that it sits on the step at the position a on the drive shaft and then ...

Page 224: ...h measurement Note the measurement data in the shimming check sheet 9 When turning the drive shaft hold it with a little force A knocking sound may be heard when the drive shaft is rotated but this is the sound of the pinion contacting the reverse gear and does not affect the back lash measurement 12 Determine the backlash average and then truncate it by dropping the numbers after the 1 100 place ...

Page 225: ...ear backlash is out of specification 19 Remove the special service tools and then install the oil seal housing and water pump assembly See Installing the drive shaft 8 16 step 2 and Installing the water pump 8 17 Shimming 9 Make sure to select the pinion shim s T3 before selecting the forward gear shim s T1 and reverse gear shim T2 9 When assembling the lower unit to mea sure the backlash after se...

Page 226: ...Lower unit 8 27 LOWR Shim location T2 T1 T3 ...

Page 227: ...4 and pinion nut 5 and then tighten the pinion nut 5 tempo rarily 3 Check the gap a between the pinion 4 and the special service tool 1 NOTICE When tightening the pinion nut 5 check that the drive shaft rotates smoothly Also make sure that there is a gap a between the pinion 4 and the special service tool 1 If there is no gap and the drive shaft does not rotate the special service tool could be da...

Page 228: ...oint Do not insert the thickness gauge at an angle TIP 9 Measure the gap at 4 points c d e and f 9 Note the measurement data in the shim ming check sheat 11 Determine the gap average and then truncate it by dropping the numbers after the 1 100 place without rounding 12 Determine the pinion shim thickness T3 in the Pinion shim T3 selection tables according to the truncated average M and the deviati...

Page 229: ...surface of the lower case in 0 01 mm units If the P mark is unreadable replace the lower case 13 Remove the special service tools and then install the shim s T3 determined Available shim thicknesses 0 10 0 12 0 15 0 18 0 30 0 40 and 0 50 mm Pinion height measurement M Stamped value on the lower case P 0 18 0 19 0 20 2 d 3 a 0 60 4 2 4 3 g Shimming F50D ...

Page 230: ...0 60 0 60 0 62 0 62 0 65 0 65 0 65 12 0 55 0 58 0 58 0 58 0 60 0 60 0 62 0 62 0 65 0 65 0 65 0 68 13 0 58 0 58 0 58 0 60 0 60 0 62 0 62 0 65 0 65 0 65 0 68 0 68 P M å 0 17 0 18 0 19 0 20 0 21 0 22 0 23 0 24 0 25 0 26 0 27 0 28 13 0 42 0 45 0 45 0 45 0 48 0 48 0 48 0 50 0 50 0 52 0 52 0 55 12 0 45 0 45 0 45 0 48 0 48 0 48 0 50 0 50 0 52 0 52 0 55 0 55 11 0 45 0 45 0 48 0 48 0 48 0 50 0 50 0 52 0 52...

Page 231: ...8 0 78 0 78 0 80 0 80 0 82 0 82 0 85 0 85 0 85 8 0 75 0 78 0 78 0 78 0 80 0 80 0 82 0 82 0 85 0 85 0 85 0 88 9 0 78 0 78 0 78 0 80 0 80 0 82 0 82 0 85 0 85 0 85 0 88 0 88 10 0 78 0 78 0 80 0 80 0 82 0 82 0 85 0 85 0 85 0 88 0 88 0 88 11 0 78 0 80 0 80 0 82 0 82 0 85 0 85 0 85 0 88 0 88 0 88 0 90 12 0 80 0 80 0 82 0 82 0 85 0 85 0 85 0 88 0 88 0 88 0 90 0 90 13 0 80 0 82 0 82 0 85 0 85 0 85 0 88 0 ...

Page 232: ...nut See Install ing the drive shaft 8 16 3 Check that drive shaft rotates smoothly 4 Install the propeller shaft housing assem bly See Installing the propeller shaft housing assembly 8 17 5 Check that the drive shaft rotates smoothly 6 Measure the forward gear backlash See Measuring the forward gear and reverse gear backlash before disassembly 8 24 step 1 step 12 Adjusting the forward gear shim th...

Page 233: ...ked points on the chart 4 Calculate the new forward gear shim thickness T1 as same way in the exam ples Calculation formula New forward gear shim thickness T1 Cur rent forward gear shim thickness Shim thickness adjustment Example If the current forward gear shim thickness is 0 50 mm and the shim thickness adjustment is 0 20 mm then T1 0 50 mm 0 20 mm 0 70 mm If the current forward gear shim thickn...

Page 234: ...m thickness 0 30 0 20 0 10 0 00 0 10 0 20 0 30 0 40 0 50 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110 115 120 0 20 0 17 0 14 0 12 0 17 0 12 0 14 0 20 0 23 0 25 0 28 0 32 0 34 0 37 0 39 0 43 0 45 0 48 å 60 65 70 75 80 85 90 95 100 105 110 115 120 55 50 45 40 35 30 25 20 15 10 5 0 å 1 100mm mm ...

Page 235: ...ly 8 17 3 Check that the drive shaft rotates smoothly 4 Measure the reverse gear backlash See Measuring the forward gear and reverse gear backlash before disassembly 8 24 step 15 step 17 Adjusting the reverse gear shim thickness T2 1 Remove the reverse gear See Disas sembling the propeller shaft housing assembly 8 7 step 1 2 Measure the thickness of each original reverse gear shim T2 in 2 places T...

Page 236: ...arked points on the chart 4 Calculate the new reverse gear shim thickness T2 as same way in the exam ples Calculation formula New reverse gear shim thickness T2 Cur rent reverse gear shim thickness Shim thickness adjustment Example If the current reverse gear shim thickness is 0 62 mm and the shim thickness adjustment is 0 24 mm then T2 0 62 mm 0 24 mm 0 86 mm If the current reverse gear shim thic...

Page 237: ...5 95 90 85 80 75 70 65 60 55 50 45 40 35 10 15 20 25 30 120 115 110 105 100 0 60 0 70 0 50 0 40 0 30 0 20 0 10 0 00 0 10 0 20 0 30 0 40 0 50 0 60 0 70 0 80 0 90 1 00 0 0 18 0 15 0 12 0 1 0 0 1 4 0 1 6 0 1 8 0 22 0 24 0 27 0 30 0 33 0 36 0 39 0 42 0 44 0 47 0 50 95 90 85 80 75 70 65 60 55 50 45 40 35 30 25 20 15 10 5 120 115 110 105 100 å Shimming F50D ...

Page 238: ...0 175 170 165 160 155 150 145 140 135 130 125 120 0 60 0 70 0 50 0 40 0 30 0 20 0 10 0 00 0 10 0 20 0 30 0 40 0 50 0 60 0 70 0 80 0 90 1 00 å 0 80 0 77 0 74 0 72 0 68 0 65 0 63 0 60 0 58 0 54 0 52 0 48 0 46 0 43 0 40 0 37 0 35 0 32 0 29 0 26 0 24 0 20 0 18 230 225 220 215 210 205 200 195 190 185 180 175 170 165 160 155 150 145 140 135 130 125 120 ...

Page 239: ... 7 7 20 21 22 23 21 22 23 24 X 35 N m 3 5 kgf m 25 8 ft lb No Part name Q ty Remarks 1 Lower unit 1 2 Plastic tie 1 3 Hose 1 4 Check screw 1 5 Gasket 2 6 Dowel 2 7 Bolt 4 M10 40 mm L transom 8 Drain screw 1 9 Grommet 1 10 Bolt 1 M10 45 mm 11 Bolt 1 M8 60 mm L transom 12 Spacer 1 13 Propeller 1 14 Washer 1 15 Washer 1 16 Propeller nut 1 17 Cotter pin 1 Shimming F50D Lower unit FT50C ...

Page 240: ... m 29 5 ft lb 5 4 7 11 18 12 13 14 15 16 19 19 17 6 6 2 3 9 10 7 7 20 21 22 23 21 22 23 24 X 35 N m 3 5 kgf m 25 8 ft lb No Part name Q ty Remarks 18 Trim tab 1 19 Dowel 2 20 Extension 1 X transom 21 Washer 4 X transom 22 Spring washer 4 X transom 23 Nut 4 X transom 24 Bolt 1 M8 185 mm X transom ...

Page 241: ...ld the propeller with your hands when loosening or tightening it 1 Drain the gear oil 2 Remove the cotter pin 3 Set the gear shift to the N position place a block of wood between the anti cavitation plate and propeller to keep the propeller from turning and then remove the propeller nut and propeller 4 Remove the grommet 1 trim tab bolt 2 and trim tab 3 TIP Mark the trim tab at the area shown 5 Re...

Page 242: ...wer unit 8 43 LOWR å L transom X transom TIP When disassembling the lower unit measure the backlash before disassembly See Mea suring the forward gear backlash before dis assembling 8 67 7 6 4 4 1 4 5 3 2 ...

Page 243: ...y Remarks 1 Oil seal 1 2 Oil seal housing 1 3 O ring 1 4 Circlip 1 5 Shift rod 1 6 O ring 1 7 Bolt 2 M6 16 mm 8 Woodruff key 1 9 Bolt 2 M8 55 mm 10 Bolt 2 M8 45 mm 11 Water pump housing 1 12 Grommet 1 13 Gasket 1 14 Insert plate cartridge 1 15 Impeller 1 16 Outer plate cartridge 1 17 Gasket 1 Lower unit FT50C Water pump and shift rod FT50C ...

Page 244: ...Lower unit 8 45 LOWR 1 2 3 4 5 7 10 11 12 13 14 15 16 19 7 6 8 22 21 20 18 18 17 9 No Part name Q ty Remarks 18 Dowel 2 19 Gasket 1 20 Oil seal housing 1 21 O ring 1 22 Oil seal 2 ...

Page 245: ... clockwise 4 Remove the oil seal housing 0 Checking the water pump and shift rod 1 Check the water pump housing Replace if deformed TIP If the engine is overheated the inside of the water pump housing may be deformed therefore make sure to remove the insert car tridge when checking the housing 2 Check the impeller insert cartridge and outer plate cartridge Replace if cracked or worn 3 Check the Wo...

Page 246: ... 3 4 5 6 7 8 18 No Part name Q ty Remarks 1 Ball 2 2 Slider 1 3 Shift plunger 1 4 Cross pin 1 5 Dog clutch 1 6 Spring 1 7 Propeller shaft 1 8 Washer 1 9 Straight key 1 10 Claw washer 1 11 Ring nut 1 12 Reverse gear 1 13 Thrust washer 1 14 Ball bearing 1 15 O ring 1 16 Propeller shaft housing 1 17 Needle bearing 1 ...

Page 247: ...8 48 0 1 2 3 4 5 6 7 8 9 10 A 9 11 12 13 14 15 16 17 10 103 N m 10 3 kgf m 76 0 ft lb 1 1 2 3 4 5 6 7 8 18 No Part name Q ty Remarks 18 Oil seal 2 Propeller shaft housing FT50C ...

Page 248: ...y from the lower case Disassembling the propeller shaft assembly 1 Remove the spring 1 and then remove the cross pin 2 and dog clutch 3 2 Remove the slider 4 balls 5 and shift plunger 6 TIP Take care not to lose the balls 5 when removing the slider 4 from the propeller shaft Disassembling the propeller shaft housing assembly 1 Remove the reverse gear and thrust washer Ring nut wrench 3 4 90890 065...

Page 249: ...out Replace if above specification Checking the dog clutch 1 Check the dog clutch slider cross pin balls and spring Replace if cracked or worn Assembling the propeller shaft housing assembly Do not reuse the bearing always replace it with a new one 1 Install a new needle bearing into the pro peller shaft housing to the specified depth Bearing separator 1 90890 06534 Stopper guide plate 2 90890 065...

Page 250: ...to the reverse gear 8 TIP Install a new ball bearing with the manufac ture identification mark e facing toward the propeller shaft housing propeller side 4 Install the reverse gear assembly into the propeller shaft housing Driver rod SS 1 90890 06604 Needle bearing attachment 2 90890 06612 Bearing depth plate 3 90890 06603 Installation depth a 25 0 25 5 mm 0 98 1 00 in a 2 1 3 c b 5 4 d Driver rod...

Page 251: ...e propeller shaft 2 TIP Align the hole b in the dog clutch 1 with the hole c in the propeller shaft 2 2 Install the shift plunger 3 and balls 4 into the slider 5 and then install the slider 5 into the propeller shaft 3 Install the cross pin 6 and spring 7 TIP Align the hole b in the dog clutch with the hole d in the slider when installing the cross pin 4 Check that the dog clutch operates smoothly...

Page 252: ... kgf m 69 3 ft lb 9 20 No Part name Q ty Remarks 1 Drive shaft 1 2 Taper roller bearing 1 3 Pinion shim 4 Sleeve 1 5 Hose 1 6 Plastic tie 1 7 Joint 1 8 Nut 1 9 Water inlet cover 2 10 Screw 1 11 Seal 1 12 Plate 1 13 Forward gear shim 14 Taper roller bearing 1 15 Needle bearing 1 16 Forward gear 1 17 Needle bearing 1 ...

Page 253: ...4 0 1 2 3 4 5 6 7 8 9 10 A F 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 19 18 17 94 N m 9 4 kgf m 69 3 ft lb 9 20 No Part name Q ty Remarks 18 Pinion 1 19 Nut 1 20 Lower case 1 Drive shaft and lower case FT50C ...

Page 254: ...rward gear 1 Remove the taper roller bearing from the forward gear Disassembling the lower case 9 Use heat resistant gloves otherwise burns could result 9 Remove any flammable substances such as gasoline and oil around the working area to avoid the risk of fire 9 Heat the lower case in a well ventilated area Drive shaft holder 4 2 90890 06518 Pinion nut holder 3 90890 06715 3 2 1 1 5 4 6 Bearing i...

Page 255: ...rive shaft sleeve 7 NOTICE When heating the lower case heat the entire installation area evenly Otherwise the paint on the lower case could be burned Checking the pinion and forward gear 1 Check the teeth of pinion Check the teeth and dogs of forward gear Replace the pinion and forward gear if cracked or worn Checking the drive shaft 1 Check the drive shaft spline Replace if damaged or worn 2 Meas...

Page 256: ... around the working area to avoid the risk of fire 9 Heat the lower case in a well ventilated area Do not reuse the original bearing replace it with a new one 1 Heat the installation area of the taper roller bearing outer race in the lower case with a gas torch and then install the original shim s 1 and a new taper roller bearing outer race 2 NOTICE When heating the lower case heat the entire inst...

Page 257: ...per roller bear ing outer race 0 NOTICE When heat ing the lower case heat the entire installation area evenly Otherwise the paint on the lower case could be burned TIP 9 Install the drive shaft sleeve with the protru sion c facing forward 9 Do not reuse a shim if it is any deformed or scratched 5 While holding the special service tool 3 strike the tool to check that the taper roller bearing outer ...

Page 258: ...tes smoothly Installing the propeller shaft housing assembly 1 Set the dog clutch 1 to the N position 2 Install the washer 2 and propeller shaft assembly 3 into the propeller shaft housing 4 3 Install the propeller shaft housing assem bly 5 into the lower case and then install the straight key 6 claw washer 7 and ring nut 8 Driver rod LL 3 90890 06605 Bearing outer race attachment q 90890 06626 q ...

Page 259: ... installing the shift rod fit the pin a into the groove b 9 After assembling the lower unit check that the shift rod operates smoothly Check also that the drive shaft and propeller shaft rotate smoothly Assembling the oil seal housing 1 Install new oil seals 1 into the oil seal housing 2 to the specified depth and then install a new O ring 3 Ring nut wrench 3 9 90890 06511 Ring nut wrench extensio...

Page 260: ...ge 8 and grom met 9 into the water pump housing 0 TIP Align the insert cartridge protrusion b with the holes c in the water pump housing 5 Install a new gasket q and water pump housing assembly w into the lower unit and then tighten the bolts e and r NOTICE Do not turn the drive shaft counterclockwise otherwise the water pump impeller may be damaged Needle bearing attachment 4 90890 06641 Driver r...

Page 261: ...nit 9 Do not hold the propeller with your hands when loosening or tightening it 9 Make sure to disconnect the battery cables from the battery and the clip from the engine shut off switch 9 When installing the lower unit with the power unit installed make sure to sus pend the outboard motor If the out board motor is not suspended it can fall suddenly and result in severe injury 1 Set the gear shift...

Page 262: ...ler nut w Place a block of wood between the anti cavitation plate and propeller to keep the propeller from turning and then tighten the propeller nut to the specified torque TIP If the grooves in the propeller nut w do not align with the cotter pin hole tighten the pro peller nut until they are aligned Lower unit mounting bolt 6 and 7 40 N m 4 0 kgf m 29 5 ft lb 2 2 3 4 6 7 5 6 6 å 2 2 8 5 9 9 4 9...

Page 263: ... pinion forward gear bearings shaft and housing Remove the water pump assembly and oil seal housing Measure the backlash before disassembly Adjust the forward gear shim thickness T1 Within specification Shimming is not required YES NO NO YES Disassemble the lower unit Select the pinion shims T3 Assemble the lower unit Measure the backlash Install the water pump assembly and oil seal housing Within...

Page 264: ...ight Measuring the forward gear backlash Serial number P F R Remarks mm Measurements Measurement point 1 Measurement point 2 Measurement point 3 Measurement point 4 Average Truncated average M mm Measurements Before disassembly After disassembly Measurement point 1 Measurement point 2 Measurement point 3 Measurement point 4 Average Truncated average BL1 ...

Page 265: ... 3 4 5 6 7 8 9 10 A Adjusting the forward gear shim thickness T1 Measure the thickness of each forward gear shim T1 in 2 places mm Number of shim s Subtotal 0 10 0 12 0 15 0 18 0 30 0 40 0 50 Total Shimming FT50C ...

Page 266: ...ile holding the drive shaft not to turn 6 Turn the lower unit upright 7 Install the special service tool 5 onto the drive shaft at the lowest possible position where the shaft diameter is 18 mm 0 71 in 8 Install the special service tool 6 so that it sits on the step at the position a on the drive shaft and then tighten the nuts b temporarily 9 Install the special service tools 7 8 9 and put anothe...

Page 267: ...heet 9 When turning the drive shaft hold it with a little force A knocking sound may be heard when the drive shaft is rotated but this is the sound of the pinion contacting the reverse gear and does not affect the back lash measurement 12 Determine the backlash average and then truncate it by dropping the numbers after the 1 100 place without rounding Magnet base plate 7 90890 07003 Dial gauge set...

Page 268: ...and water pump assembly See Installing the water pump 8 61 Shimming 9 Make sure to select the pinion shim s T3 before selecting the forward gear shim s T1 9 When assembling the lower unit to mea sure the backlash after selecting the pinion shim s do not apply gear oil grease or sealant to the parts 9 When assembling the lower unit after shim ming is completed make sure to apply gear oil grease and...

Page 269: ...8 70 0 1 2 3 4 5 6 7 8 9 10 A Shim location T1 T3 Shimming FT50C ...

Page 270: ...on 4 and pinion nut 5 and then tighten the pinion nut 5 tempo rarily 3 Check the gap a between the pinion 4 and the special service tool 1 NOTICE When tightening the pinion nut 5 check that the drive shaft rotates smoothly Also make sure that there is a gap a between the pinion 4 and the special service tool 1 If there is no gap and the drive shaft does not rotate the special service tool could be...

Page 271: ...insert the end of the thickness gauge straight into the gap at the measurement point Do not insert the thickness gauge at an angle TIP 9 Measure the gap at 4 points c d e and f 9 Note the measurement data in the shim ming check sheet 11 Determine the gap average and then truncate it by dropping the numbers after the 1 100 place without rounding Pinion height gauge bolt 3 1st 1 N m 0 1 kgf m 0 7 ft...

Page 272: ...e Pinion shim T3 selection table TIP The P mark g is stamped on the trim tab mounting surface of the lower case in 0 01 mm units If the P mark is unreadable replace the lower case 13 Remove the special service tools and then install the shim s T3 determined Available shim thicknesses 0 10 0 12 0 15 0 18 0 30 0 40 and 0 50 mm Pinion height measurement M Stamped value on the lower case P 0 18 0 19 0...

Page 273: ...0 0 60 0 62 0 62 0 65 0 65 0 65 12 0 55 0 58 0 58 0 58 0 60 0 60 0 62 0 62 0 65 0 65 0 65 0 68 13 0 58 0 58 0 58 0 60 0 60 0 62 0 62 0 65 0 65 0 65 0 68 0 68 P M å 0 17 0 18 0 19 0 20 0 21 0 22 0 23 0 24 0 25 0 26 0 27 0 28 13 0 42 0 45 0 45 0 45 0 48 0 48 0 48 0 50 0 50 0 52 0 52 0 55 12 0 45 0 45 0 45 0 48 0 48 0 48 0 50 0 50 0 52 0 52 0 55 0 55 11 0 45 0 45 0 48 0 48 0 48 0 50 0 50 0 52 0 52 0 ...

Page 274: ... 78 0 78 0 78 0 80 0 80 0 82 0 82 0 85 0 85 0 85 8 0 75 0 78 0 78 0 78 0 80 0 80 0 82 0 82 0 85 0 85 0 85 0 88 9 0 78 0 78 0 78 0 80 0 80 0 82 0 82 0 85 0 85 0 85 0 88 0 88 10 0 78 0 78 0 80 0 80 0 82 0 82 0 85 0 85 0 85 0 88 0 88 0 88 11 0 78 0 80 0 80 0 82 0 82 0 85 0 85 0 85 0 88 0 88 0 88 0 90 12 0 80 0 80 0 82 0 82 0 85 0 85 0 85 0 88 0 88 0 88 0 90 0 90 13 0 80 0 82 0 82 0 85 0 85 0 85 0 88 ...

Page 275: ... See Install ing the drive shaft 8 59 3 Check that drive shaft rotates smoothly 4 Install the propeller shaft housing assem bly See Installing the propeller shaft housing assembly 8 59 5 Check that the drive shaft rotates smoothly 6 Measure the forward gear backlash See Measuring the forward gear backlash before disassembly 8 67 step 1 step 12 Adjusting the forward gear shim thickness T1 1 Remove ...

Page 276: ...arked points on the chart 4 Calculate the new forward gear shim thickness T1 as same way in the exam ples Calculation formula New forward gear shim thickness T1 Cur rent forward gear shim thickness Shim thickness adjustment Example If the current forward gear shim thickness is 0 52 mm and the shim thickness adjustment is 0 20 mm then T1 0 52 mm 0 20 mm 0 72 mm If the current forward gear shim thic...

Page 277: ... 11 0 20 0 11 0 14 0 17 0 22 0 25 0 28 0 31 0 34 0 37 0 39 0 42 0 45 0 48 0 51 0 54 0 56 0 59 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110 115 120 125 130 135 å 0 30 0 20 0 10 0 00 0 10 0 20 0 30 0 40 0 50 0 60 0 70 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100105110115 120 125 130135 å 1 100mm mm Shimming FT50C ...

Page 278: ... 16 Assembling the upper case 9 16 Oil pan and exhaust manifold 9 18 Disassembling the oil pan 9 20 Checking the oil strainer 9 20 Assembling the oil pan 9 20 Steering arm swivel bracket and clamp brackets 9 22 Removing the steering arm 9 25 Installing the steering arm 9 25 Removing the clamp bracket 9 26 Installing the clamp bracket 9 27 Adjusting the trim sensor 9 28 PTT unit 9 29 Removing the P...

Page 279: ...e tilt cylinder 9 46 Disassembling the trim cylinder 9 46 Checking the tilt cylinder and trim cylinder 9 46 Assembling the trim cylinder 9 47 Assembling the tilt cylinder 9 48 Bleeding the PTT unit 9 49 PTT electrical system 9 50 Checking the fuse 9 50 Checking the PTT relay 9 50 Checking the PTT switch 9 51 Checking the trim sensor 9 51 Hydro tilt unit 9 52 Removing the hydro tilt unit 9 53 Insta...

Page 280: ... 32 31 30 28 29 27 26 25 33 1 34 18 19 21 22 20 23 24 21 22 No Part name Q ty Remarks 1 Tiller handle assembly 1 2 Bolt 1 M8 35 mm 3 Friction piece 1 4 Wing nut 1 5 Friction rod 1 6 Washer 2 7 Nut 1 8 Link rod 1 9 Bolt 1 M6 30 mm 10 Washer 1 11 Nut 1 12 Grommet 1 13 Nut 2 14 Retaining plate 1 15 Bolt 3 M6 20 mm 16 Grommet 1 17 Cable guide 1 ...

Page 281: ...18 19 21 22 20 23 24 21 22 No Part name Q ty Remarks 18 Steering friction assembly 1 19 Shift rod 1 1 20 Shift rod 2 1 21 Washer 2 22 Clip 2 23 Nut 1 24 Cable joint 2 25 Bolt 1 26 Housing 1 27 Collar 1 28 Engine start switch 1 29 Screw 1 M6 30 mm 30 Housing 1 31 Screw 1 M6 25 mm 32 Screw 1 M6 30 mm 33 Engine shut off switch 1 34 Nut 1 Tiller handle removing ...

Page 282: ...32 33 34 39 1 12 13 14 13 15 16 6 5 30 29 28 22 19 18 18 17 27 22 23 21 20 24 26 25 No Part name Q ty Remarks 1 Tiller handle 1 2 Throttle cable 1 3 Gear 1 4 Pin 1 5 Throttle shaft 1 6 Case 1 7 Bolt 1 M6 25 mm 8 Friction piece 1 9 Washer 1 10 Wing nut 1 11 Bolt 1 M6 25 mm 12 Bushing 1 13 Washer 2 14 Spring 1 15 Throttle grip 1 16 Screw 1 M5 25 mm 17 Bracket 1 ...

Page 283: ...1 12 13 14 13 15 16 6 5 30 29 28 22 19 18 18 17 27 22 23 21 20 24 26 25 No Part name Q ty Remarks 18 Bolt 4 M6 16 mm 19 Shift arm guide 1 20 Shift arm 1 21 Shift knob 1 22 Bushing 2 23 Spring 1 24 Ball 1 25 Washer 1 26 Clip 1 27 Collar 1 28 Washer 1 29 Washer 1 30 Nut 1 31 Nut 1 32 Bolt 1 M12 70 mm 33 Washer 1 34 Bushing 1 Tiller handle disassembling ...

Page 284: ... 3 7 8 9 11 10 42 43 44 42 41 40 31 32 33 34 39 1 12 13 14 13 15 16 6 5 30 29 28 22 19 18 18 17 27 22 23 21 20 24 26 25 No Part name Q ty Remarks 35 Washer 2 36 Plastic washer 2 37 Wave washer 1 38 Nut 1 39 Bracket 1 40 Gasket 1 41 Cover 1 42 Screw 4 M5 12 mm 43 Grease nipple 1 44 Screw 1 M6 8 mm ...

Page 285: ...tiller handle 2 so that the pin 3 of the throttle shaft 1 is aligned with the mating sur face a of the tiller handle 2 in horizontal position 2 Insert the throttle cable 4 into the gear 5 until the inner cable b is winded with the gear Then fully pull the outer cable c toward the cable end of the outboard motor side 3 Turn the throttle shaft 1 clockwise to wind the inner cable until the outer cabl...

Page 286: ...tle grip 9 and cover 0 into the tiller handle 2 6 Push the throttle grip 9 so that the hole g on the throttle glip 9 is aligned with the hole h on the throttle shaft 1 and then tighten the screw q Lubricating the throttle gear 1 Apply grease into the grease nipple until grease comes out from the screw hole a Locknut d 11 N m 1 1 kgf m 8 1 ft lb e f 6 7 8 8 9 0 2 q 9 1 h g a ...

Page 287: ... 8 5 4 3 2 9 8 12 24 N m 2 4 kgf m 17 7 ft lb No Part name Q ty Remarks 1 Bottom cowling 1 2 Detent bolt 1 3 Spring 1 4 Ball 1 5 Bracket 1 6 Cotter pin 1 7 Washer 1 8 Bushing 2 9 Shift rod 1 10 Grommet 1 11 Grommet 1 12 Rubber seal 4 13 Bolt 4 M6 30 mm 14 Gasket 4 15 Screw 1 M6 14 mm H model 16 Alert indicator 1 H model 17 Grommet 1 H model Tiller handle disassembling Shift rod and bottom cowling ...

Page 288: ...5 4 3 2 9 8 12 24 N m 2 4 kgf m 17 7 ft lb No Part name Q ty Remarks 18 Collar 4 19 Pilot water outlet 1 20 Plastic tie 2 21 Collar 2 22 Grommet 2 23 Bushing 2 24 Joint 1 25 Cowling lock lever 1 26 Pin 1 27 Cotter pin 2 28 Pin 1 29 Cotter pin 1 30 Bolt 2 M6 12 mm PTT model 31 Bracket 1 PTT model 32 PTT switch 1 PTT model 33 Grommet 1 PTT model 34 Clamp 1 PTT model ...

Page 289: ...7 28 29 23 21 22 12 13 14 18 30 31 32 13 14 18 39 38 36 35 34 33 10 20 37 6 7 8 5 4 3 2 9 8 12 24 N m 2 4 kgf m 17 7 ft lb No Part name Q ty Remarks 35 Screw 1 M6 24 mm PTT model 36 Rubber seal 1 37 Hose 1 38 Grommet 1 D model 39 Plug 1 D model 40 Grommet 1 R model Shift rod and bottom cowling ...

Page 290: ...4 11 15 16 16 17 18 19 20 17 18 19 20 13 10 12 9 8 14 15 21 3 2 1 23 No Part name Q ty Remarks 1 Nut 2 2 Nut 2 3 Washer 2 4 Bolt 3 M8 30 mm 5 Upper mount 1 6 Plate 1 L transom 7 Bolt 2 M8 175 mm 8 Cap 2 9 Bolt 2 M12 160 mm 10 Grommet 2 11 Ground lead 1 12 Screw 2 M6 16 mm 13 Cover 2 14 Bolt 4 M8 25 mm 15 Housing 2 16 Spring 4 17 Washer 2 ...

Page 291: ...4 2 kgf m 31 0 ft lb 4 6 22 5 16 16 8 9 10 12 13 14 14 11 15 16 16 17 18 19 20 17 18 19 20 13 10 12 9 8 14 15 21 3 2 1 23 No Part name Q ty Remarks 18 Rubber washer 2 19 Lower mount 2 20 Washer 2 21 Grease nipple 1 22 Plate 1 X transom 23 Oil seal 1 Upper case and mounts ...

Page 292: ...eal 8 5 Remove the bolts 9 housings 0 ground lead q and springs w 6 Remove the bolts e washers r rubber washers t lower mounts y and wash ers u Installing the upper case 1 Install the upper mount 1 and bolts 2 into the upper case and then tighten the bolts 3 2 Install the oil seal 4 3 Install the washers 7 lower mounts 8 rubber washers 9 washers 0 and bolts q to the upper case 4 2 3 1 7 6 6 5 8 X ...

Page 293: ...he upper case y into the bracket assembly 6 Install the upper mounting nuts u and lower mounting nuts i and then tighten them to the specified torques 7 Install the covers o by installing the screws p 9 q w 7 8 0 e r t t e w y u i p o o p Upper mounting nut u 24 N m 2 4 kgf m 17 7 ft lb Lower mounting nut i 42 N m 4 2 kgf m 31 0 ft lb Upper case and mounts ...

Page 294: ...2 21 N m 2 1 kgf m 15 5 ft lb X 4 10 11 1 No Part name Q ty Remarks 1 Upper case 1 2 Rubber seal 1 3 Rubber seal 1 4 Dowel 2 5 Rubber seal 1 6 Guide 1 7 Screw 2 M5 16 mm 8 Baffle plate 1 9 Bolt 4 M8 30 mm 10 Bushing 1 11 Circlip 1 12 Stud bolt 4 X transom ...

Page 295: ...drive shaft bushing 6 from the upper case Checking the drive shaft bushing 1 Check the drive shaft bushing Replace if cracked or worn Assembling the upper case 1 Install the drive shaft bushing 1 into the upper case and then install the circlip 2 2 1 1 3 4 Shaft 7 reference Diameter a 20 mm 0 8 in Length 370 mm 14 6 in Driver rod L3 3 90890 06652 Needle bearing attachment 4 90890 06615 6 7 5 7 6 a...

Page 296: ... 9 17 BRKT 2 Install the baffle plate 5 and guide 6 3 Install a new rubber seal 7 into the upper case 4 Install the muffler assembly 8 by insert ing the tip of the water pipe 9 into the rubber seal 7 6 5 9 8 7 9 7 ...

Page 297: ... 25 26 19 30 22 18 N m 1 8 kgf m 13 3 ft lb No Part name Q ty Remarks 1 Exhaust guide 1 2 Grommet 1 3 Anode 1 4 Cover 1 5 Bolt 1 M5 12 mm 6 Cover 1 7 Bolt 1 M6 20 mm 8 Gasket 1 9 Dowel 2 10 Bolt 10 M6 25 mm 11 Oil pan 1 12 Gasket 1 13 Exhaust manifold 1 14 Protector 1 15 Bolt 3 M6 50 mm 16 Gasket 1 17 Gasket 1 Upper case Oil pan and exhaust manifold ...

Page 298: ...26 27 10 10 28 29 10 9 25 25 26 19 30 22 18 N m 1 8 kgf m 13 3 ft lb No Part name Q ty Remarks 18 Bolt 6 M6 25 mm 19 Muffler 1 20 Washer 1 21 Pipe 1 22 Rubber seal 1 23 Gasket 1 24 Relief valve 1 25 Bolt 3 26 Bolt 2 M6 25 mm 27 Oil strainer 1 M6 16 mm 28 Gasket 1 29 Drain bolt 1 30 Damper 1 ...

Page 299: ... from the exhaust guide 4 4 Remove the oil strainer 5 5 Remove the gasket 6 and relief valve 7 Checking the oil strainer 1 Check the oil strainer Clean if there is dirt or residue Assembling the oil pan 1 Install the gaskets 1 and 2 onto the exhaust guide 3 2 Install the relief valve 4 and then tighten the bolts 5 temporarily 1 3 2 4 5 7 6 Oil pan and exhaust manifold ...

Page 300: ...e bolts q temporarily 6 Install a new gasket w e and the exhaust manifold r protector t and then tighten the bolts y temporarily 7 Tighten the exhaust manifold bolts y to the specified torque and then tighten the oil pan bolts q 8 Install a new gasket u and the muffler i onto the oil pan 3 4 5 1 2 6 7 5 Manifold bolt y 11 N m 1 1 kgf m 8 1 ft lb 9 0 r q 8 q e w y t i u ...

Page 301: ... 10 32 35 30 19 20 31 13 33 34 33 38 2 3 4 5 20 N m 2 0 kgf m 14 8 ft lb 33 34 2 N m 0 2 kgf m 1 5 ft lb No Part name Q ty Remarks 1 Steering arm 1 2 Washer 1 3 Bushing 1 4 O ring 2 5 Bushing 2 6 Swivel bracket 1 7 Bushing 1 8 Steering yoke 1 9 Circlip 1 10 Clamp bracket 1 L transom 11 Clamp bracket 1 L transom 12 Screw 1 M6 8 mm 13 Self locking nut 2 14 Washer 2 15 Bushing 2 16 Through tube 1 17 ...

Page 302: ...5 30 31 14 10 32 35 30 19 20 31 13 33 34 33 38 2 3 4 5 20 N m 2 0 kgf m 14 8 ft lb 33 34 2 N m 0 2 kgf m 1 5 ft lb No Part name Q ty Remarks 18 Grease nipple 3 19 Tilt stop lever 1 20 Bushing 2 21 Bushing 1 22 Distance collar 1 23 Pin 2 24 Bushing 1 25 Hook 1 26 Spring 1 27 Tilt stop lever 1 28 Bolt 1 M6 10 mm 29 Clamp 1 30 Trim sensor 1 PTT model 31 Screw 2 M6 15 mm PTT model 32 Plastic tie 1 33 ...

Page 303: ... 14 15 18 17 36 18 29 24 22 26 25 21 28 23 9 8 7 5 4 18 39 16 15 30 31 14 10 32 35 30 19 20 31 13 33 34 33 38 2 3 4 5 20 N m 2 0 kgf m 14 8 ft lb 33 34 2 N m 0 2 kgf m 1 5 ft lb No Part name Q ty Remarks 35 Clamp bracket 1 X transom 36 Clamp bracket 1 X transom 37 Steering hook 1 R model 38 Nut 2 R model 39 Ground lead 1 Steering arm swivel bracket and clamp brackets ...

Page 304: ...r 2 Remove the steering arm 3 from the swivel bracket 4 3 Remove the bushing 5 O ring 6 bush ing 7 8 and washer 9 from the swivel bracket 4 Installing the steering arm 1 Install the washer 1 bushing 2 3 and a new O ring 4 onto the steering arm 5 2 Install the steering arm onto the swivel bracket 6 3 Install the bushing 7 a new O ring 8 and bushing 9 into the swivel bracket 6 1 1 2 9 3 7 4 6 5 8 6 ...

Page 305: ...to the thick part of the steering yoke 0 and then install it by striking with a hammer 6 Install the circlip q 7 Apply grease into the grease nipple w until it comes out from both the upper and lower bushings d Removing the clamp bracket 1 Remove the ground lead 1 2 Remove the self locking nuts 2 and through tube 3 and then remove the clamp brackets 4 and 5 from the swivel bracket 3 Remove the tri...

Page 306: ...he same direction aligning b with c 3 Install the pins 6 hook 7 and spring 8 TIP Hook the longer end of spring 8 to the dis tance collar 4 4 Install the trim sensor 9 5 Install the bushings 0 washers q clamp brackets w e and through tube r to the swivel bracket and then install the self locking nuts t Then tighten the self locking nuts t to the specified torque 6 Install the ground lead y and then...

Page 307: ...ten the screws 2 to the specified torque TIP 9 To increase the resistance turn the trim sensor in direction a 9 To decrease the resistance turn the trim sensor in direction b 6 Fully tilt the swivel bracket down and then measure the trim sensor resistance again Self locking nut t 23 N m 2 3 kgf m 17 0 ft lb Grease nipple u 3 N m 0 3 kgf m 2 2 ft lb Trim sensor setting resistance Pink P Black B 9 0...

Page 308: ...KT PTT unit 1 2 3 4 5 6 7 8 9 10 11 12 7 3 4 No Part name Q ty Remarks 1 PTT unit 1 2 Plastic tie 1 3 Bolt 2 M8 17 mm 4 Washer 2 5 Circlip 1 6 Shaft 1 7 Bushing 2 8 Collar 1 9 Tilt pin 1 10 Collar 1 11 Collar 1 12 Shaft 1 ...

Page 309: ... up and then support it with the tilt stop lever 1 2 Remove the lower mount shaft bolts 2 washers 3 and then remove the lower mount shaft 4 3 Remove the circlip 5 and upper mount shaft 6 and then remove the PTT unit 7 from the bracket assembly Installing the PTT unit 9 After tilting the swivel bracket up make sure to support it with the tilt stop lever 9 When installing the PTT unit with the power...

Page 310: ... the PTT unit into the swivel bracket and then install the upper mount shaft 4 and circlip 5 4 Install the collars 6 7 lower mount shaft 8 and washers 9 and then tighten the lower mount shaft bolts 0 5 Apply grease to all grease nipples until grease comes out from the bushings See Lubrication 10 16 0 9 8 5 4 0 9 6 7 2 2 3 ...

Page 311: ...9 10 13 16 14 14 15 16 No Part name Q ty Remarks 1 PTT motor assembly 1 2 Screw 3 M5 20 mm 3 Yoke 1 4 O ring 1 5 Armature 1 6 Washer 1 7 Bushing 1 8 Screw 2 M4 12 mm 9 Wire lead 1 10 Brush 1 1 11 Brush 2 1 12 Brush holder 1 13 Circuit breaker 1 14 Brush spring 2 15 PTT motor base 1 16 Bolt 3 M6 20 17 Oil seal 1 PTT unit PTT motor ...

Page 312: ...Bracket unit 9 33 BRKT 1 2 3 4 5 6 7 18 19 4 N m 0 4 kgf m 3 0 ft lb 4 N m 0 4 kgf m 3 0 ft lb 17 17 2 11 8 12 8 9 10 13 16 14 14 15 16 No Part name Q ty Remarks 18 O ring 1 19 Joint 1 ...

Page 313: ...rom the PTT motor base Checking the PTT motor 1 Check the commutator Clean with 600 grit sandpaper and compressed air if dirty 2 Measure the commutator diameter a Replace if below specification 3 Check the armature for continuity Replace if out of specification 4 3 2 1 1 6 5 5 Digital caliper 1 90890 06704 Commutator diameter wear limit a 21 0 mm 0 83 in Armature continuity b c d e a 1 b c d e PTT...

Page 314: ...9 Do not reuse the oil seal and O rings always replace them with new ones 9 Do not allow grease or oil to contact the commutator of the armature 1 Install a new oil seal 1 and bushing 2 into the motor base 3 2 Install the circuit breaker 4 onto brush 1 5 together with the brush holder 6 and connect the wire lead 7 3 Install the springs 8 brush holder 9 and brush 2 0 into the motor base 4 Install t...

Page 315: ...Gear pump assembly 1 2 Bolt 2 M5 8 mm 3 Relief valve bracket 1 L transom 4 Screw 1 L transom 5 Nut 1 L transom 6 Adapter 1 L transom 7 Up relief spring 1 17 5 mm 0 69 in L transom 8 Valve support pin 1 L transom 9 Up relief valve 1 L transom 10 Filter 1 11 Backup ring 1 12 Down relief spring 1 14 5 mm 0 57 in 13 Valve support pin 1 14 Down relief valve 1 15 Bolt 3 M6 40 mm 16 O ring 2 17 Stopper p...

Page 316: ... 0 7 kgf m 5 2 ft lb 15 12 13 14 17 18 16 19 20 21 1 10 11 3 4 5 6 7 8 9 No Part name Q ty Remarks 18 Filter 2 19 O ring 1 20 Manual valve 1 21 Circlip 1 22 Relief valve bracket 1 X transom 23 Valve lock screw 1 X transom 24 Up relief spring 1 X transom 25 Valve support pin 1 X transom 26 O ring 1 X transom ...

Page 317: ...X 8 8 8 8 16 No Part name Q ty Remarks 1 Bolt 2 M5 20 mm 2 Washer 2 3 Gear pump bracket 1 4 O ring 2 5 Spacer 2 6 Spring 2 7 Absorber valve pin 2 8 Ball 6 9 Manual release spring 1 10 Spring 2 11 Down main valve 1 12 O ring 1 13 Main valve seal 2 14 Circlip 2 15 Up main valve 1 16 Pin 2 17 O ring 1 X transom Gear pump removing Gear pump disassembling ...

Page 318: ...ket unit 9 39 BRKT 1 2 2 3 4 5 6 7 8 4 5 6 7 8 9 10 11 12 13 14 10 15 13 14 16 17 18 19 5 3 N m 0 5 kgf m 3 9 ft lb X 8 8 8 8 16 No Part name Q ty Remarks 18 Up relief valve 1 X transom 19 Ball 1 X transom ...

Page 319: ... O rings always replace them with new ones 1 Remove the manual valve 1 and gear pump assembly 2 2 Remove the relief valve bracket 3 down relief valve 4 and up relief valve 5 L transom NOTICE Do not remove the screw 6 and nut 7 L transom å L transom X transom TIP When removing the valve lock screw 8 make sure to note the number of times it is turned out from its set position X transom 3 Remove the ...

Page 320: ...gear pump assembly if damaged or worn Assembling the gear pump 9 Do not use a rag when assembling the PTT unit because dust and particles on the PTT unit components can lead to poor performance 9 Do not reuse the O rings always replace them with new ones 1 Install the drive gear a driven gear b shaft c and pins 1 into the gear pump housing d 2 Install the balls 2 into the gear pump housing d 3 Ins...

Page 321: ...in s spring d a new O ring j valve support pin k spring l valve lock screw backup ring g and filter h X transom 10 Install the relief valve bracket z and then tighten the bolts x to the specified torque å L transom X transom 11 Install the filters c stopper plates v new O rings b and gear pump assem bly n and then tighten the bolts m to the specified torque 12 Install a new O ring manual valve cir...

Page 322: ...o the correct level f 15 Install the PTT motor and then tighten the bolts to the specified torque Gear pump bolt m 7 N m 0 7 kgf m 5 2 ft lb Manual valve 2 N m 0 2 kgf m 1 5 ft lb Reservoir cap 7 N m 0 7 kgf m 5 2 ft lb n m b v c b v c Recommended PTT fluid ATF Dexron 2 PTT motor bolt 4 N m 0 4 kgf m 3 0 ft lb f ...

Page 323: ... 45 0 ft lb 80 N m 8 0 kgf m 59 0 ft lb 13 14 15 16 17 19 20 UP No Part name Q ty Remarks 1 PTT ram assembly 1 2 Ball 6 3 Snap ring 1 4 Trim cylinder base 1 5 Spring 2 6 Plate 1 7 Circlip 1 8 Tilt cylinder assembly 1 9 O ring 1 10 Reservoir cap 1 11 Anode 1 12 Bolt 2 M6 25 mm 13 O ring 1 14 O ring 1 15 O ring 1 16 Trim piston 1 17 O ring 1 Gear pump disassembling PTT cylinder ...

Page 324: ... m 5 2 ft lb 90 N m 9 0 kgf m 66 4 ft lb 11 2 5 5 13 14 15 16 17 18 19 20 21 22 61 N m 6 1 kgf m 45 0 ft lb 80 N m 8 0 kgf m 59 0 ft lb 13 14 15 16 17 19 20 UP No Part name Q ty Remarks 18 Trim cylinder 1 19 O ring 1 20 Backup ring 1 21 O ring 1 22 Free piston 1 ...

Page 325: ...w 2 and then remove it NOTICE Do not damage the check valve b when loosening the end screw Checking the tilt cylinder and trim cylinder 1 Check the inner walls of the trim cylinder and tilt cylinder Replace if there are scratches 2 Check the outer surface of the tilt piston and free piston Replace the PTT ram assembly or free piston if there are scratches 3 Check the PTT ram Polish with 400 600 gr...

Page 326: ... end screw b 3 Install a new O ring 3 and backup ring 4 onto the tilt piston c 4 Install new O rings 5 and 6 onto the trim piston 7 and then install the trim piston 7 to the trim cylinder 8 5 Install the PTT ram assembly into the trim cylinder 8 6 Hold the trim cylinder in a vise using alu minum plates on both sides 7 Install the trim cylinder end screw b and then tighten it to the specified torqu...

Page 327: ...o the trim cylinder 3 and then install the trim cylinder 3 into the tilt cylinder q TIP Apply grease to the balls to prevent them from falling out of the cylinder 6 Install the tilt cylinder end screw w and then tighten it to the specified torque 7 Fully extend the PTT ram and then add sufficient recommended fluid to the cor rect level 8 Install a new O ring r and the reservoir cap t Trim cylinder...

Page 328: ...in the reservoir 4 If the fluid level is below the correct level add sufficient recommended fluid to the correct level 5 Install the reservoir cap 6 Connect the PTT motor leads a to the battery terminals to fully retract the PTT ram 7 Reverse the PTT motor leads a between the battery terminals to fully extend the PTT ram Reservoir cap t 7 N m 0 7 kgf m 5 2 ft lb Manual valve 1 2 N m 0 2 kgf m 1 5 ...

Page 329: ...ce if there is no continu ity Checking the PTT relay 1 Check the PTT relay for continuity Replace if out of specification 2 Connect the digital circuit tester between PTT relay terminals a and c 3 Connect the positive battery lead to the Light green Lg lead and the negative battery lead to the Black B lead 4 Check for continuity between terminals a and c Replace if there is no continu ity Ram PTT ...

Page 330: ...nals b and c Replace if there is no continu ity Checking the PTT switch 1 Check the PTT switch for continuity Replace if out of specification Checking the trim sensor 1 Fully tilt the outboard motor up and then measure the trim sensor resistance Replace if out of specification B Sb b c R Sb Lg R a b c Terminal color Switch position a b c UP Free DN Trim sensor resistance Pink P Black B 168 3 288 3...

Page 331: ...lt unit 1 2 3 6 7 5 8 4 9 10 11 6 5 2 3 No Part name Q ty Remarks 1 Hydro tilt 1 2 Bolt 2 M8 17 mm 3 Washer 2 4 Tilt pin 1 5 Bushing 2 6 Circlip 2 7 Shaft 1 8 Collar 1 9 Collar 1 10 Collar 1 11 Shaft 1 PTT electrical system Hydro tilt unit ...

Page 332: ...2 washers 3 and then remove the lower mount shaft 4 3 Remove the circlip 5 and upper mount shaft 6 and then remove the hydro tilt unit 7 from the bracket assembly WARNING Do not disassemble or puncture the hydro tilt unit as high pressure gas is contained Do not apply heat or fire to the hydro tilt unit as high pressure gas is contained Installing the hydro tilt unit 9 After tilting the swivel bra...

Page 333: ...hydro tilt unit into the swivel bracket and then install the upper mount shaft 4 and circlips 5 4 Install the collar 6 7 lower mount shaft 8 and washers 9 and then tighten the lower mount shaft bolts 0 5 Apply grease to all grease nipples until grease comes out from the bushings See Lubrication 10 16 2 2 3 5 4 5 0 9 9 0 8 6 7 Hydro tilt unit ...

Page 334: ...Bracket unit 9 55 BRKT MEMO ...

Page 335: ...est run 10 9 General periodic maintenance 10 9 Checking the anode 10 9 Checking the battery 10 10 Checking the cooling water passage 10 10 Checking the top cowling 10 11 Checking the engine idle speed 10 12 Checking the engine oil 10 12 Changing the engine oil 10 13 Replacing the oil filter 10 14 Checking the engine start switch and engine shut off switch 10 14 Checking the fuel filter 10 15 Check...

Page 336: ...rvicing will be required especially the engine oil and gear oil changes Examples of the intensive operation will be wide open throttle trolling or idling operations for extended period of time carrying heavy loads or frequent starting and stop ping or shifting In most cases the frequent maintenance pays off in increased engine life and greater owner satisfaction Consult Yamaha dealer for additiona...

Page 337: ...Engine oil Change 10 13 Engine oil filter Replace 10 14 Fuel filter Check replace 10 15 Fuel line Check replace 10 15 Fuel pump Check replace 6 8 Fuel oil leakage Check 10 15 Gear oil Change 10 15 Impeller water pump housing Check replace 8 6 F50D 8 46 FT50C Impeller water pump housing Replace 8 6 F50D 8 46 FT50C Lubrication points Lubricate 10 16 Propeller propeller nut cotter pin Check replace 1...

Page 338: ... Wiring harness connec tions lead coupler con nections Check replace Water inlet Check 10 10 Yamaha meter gauge Check Yamaha fuel tank Check replace Item Actions Initial Every Refer to page 20 hours 3 months 100 hours 1 year 300 hours 3 years 500 hours 5 years Item Actions Every Refer to page 1000 hours Exhaust guide exhaust manifold Check replace 9 18 Timing belt Replace 10 21 ...

Page 339: ...ies away from fire sparks or open flames example welding equip ment lighted cigarettes 9 DO NOT SMOKE when charging or han dling batteries KEEP BATTERIES AND ELECTROLYTE OUT OF REACH OF CHILDREN 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...

Page 340: ...evel mark a add sufficient oil until the level is between a and b Checking the fuel system This is a 4 stroke engine Never use premixed fuel or 2 stroke outboard motor oil 1 Check that the fuel hoses are securely connected and that the fuel tank is filled with fuel OFF ON START å Recommended engine oil 4 stroke motor oil with combination of the following SAE and API oil classifi cation API SE SF S...

Page 341: ...em 1 Check that the outboard motor tilts up and down smoothly when operating the PTT unit 2 Check that there is no abnormal noise produced when the outboard motor is tilted up or down 3 Check that there is no interference with wires or hoses when the tilted up out board motor is steered 4 Check that the trim meter points down when the outboard motor is tilted all the way down Checking the tilt sys...

Page 342: ...d from the N to F or R position H model Check that the gear shift operates smoothly when the remote control lever is shifted from the N to F or R posi tion R model 2 Check that the throttle operates smoothly when the throttle grip is turned from the fully closed position to the fully opened position a H model Check that the throttle operates smoothly when the remote control lever is shifted from t...

Page 343: ...r is discharged from the cooling water pilot hole Checking the outboard motor mounting height 1 Check that the anti cavitation plate is aligned with the bottom of the boat If the mounting height is too high cavitation will occur and propulsion will be reduced Also the engine speed will increase abnormally and cause the engine to overheat If the mounting height is too low water resistance will incr...

Page 344: ...ease engine speed as much as nec essary to put the boat on plane but avoid full throttle operation then back off on the throttle while keeping the boat at a planing speed 3 Remaining 8 hours c Run the engine at any speed However avoid operating at full throttle for more than 5 minutes at a time 4 After the 1st 10 hours Operate the engine normally å Hour After test run 1 Check for water in the gear...

Page 345: ...ssembly procedure in this manual Checking the battery 1 Check the battery See Checking the battery 10 4 Checking the cooling water passage 1 Remove the cooling water inlet covers 1 and trim tab 2 2 Check the cooling water inlet covers and cooling water inlets Clean if clogged 3 Install the cooling water inlet covers 1 and trim tab 2 and then tighten the screw 3 and bolt 4 to the specified torque å...

Page 346: ...ater flow check the cooling water passages inside the outboard motor Checking the top cowling 1 Check the fitting by pushing the cowling with both hands Adjust if there is free play 2 Loosen the bolts 1 3 Move the hook 2 up or down slightly to adjust its position TIP 9 To tighten the fitting move the hook 2 in direction a 9 To loosen the fitting move the hook 2 in direction b 4 Tighten the bolts 1...

Page 347: ...direc tion c or d until the specified engine idle speed is obtained TIP 9 To increase the idle speed turn the throttle stop screw in direction c 9 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 then check the stability of the engine Checking the engine oil 1 Place the outboard motor in an upright position NOTIC...

Page 348: ...iller cap 1 Pull out the dipstick 2 and use the oil changer 3 to extract the oil completely 6 Add the correct amount of oil through the filler hole Put back the filler cap 1 and the dipstick 2 NOTICE Overfilling the oil could cause leakage or damage If the oil level is above the upper level mark extract until the level meets the specified capacity 7 Leave the outboard motor for 5 10 min utes 8 Rem...

Page 349: ...oil filter and then tighten it to the specified torque using a 64 mm 2 5 in oil filter wrench 1 5 Pour the specified amount of the recom mended engine oil into the oil filler hole 6 Install the oil filler cap and oil dipstick and then start the engine and warm it up 7 Turn the engine off and then check the oil level and that there is no oil leakage If the oil level is low add engine oil to the cor...

Page 350: ...joint to carburetor 1 Check the fuel hose connections for leaks Also check the fuel joint 1 fuel hoses fuel filter 2 fuel pump 3 and carburetor 4 Replace if there is leakage or deterioration Changing the gear oil Never get under the lower unit while it is tilted Otherwise the outboard motor could suddenly lower if the PTT unit should lose fluid pressure or Hydro tilt unit should lose gas pressure ...

Page 351: ...nd then change the oil 6 Insert a gear oil tube or gear oil pump into the drain hole b and slowly fill with gear oil until oil flows out of the check hole and no air bubbles are visible 7 Install new gaskets and gear oil check screw 4 and quickly install the gear oil drain screw 3 and then tighten them to the specified torque Lubrication 1 Apply water resistant grease to the areas shown a 2 4 3 b ...

Page 352: ...le until it flows from the bushings a 2 Apply low temperature resistant grease to the areas shown 3 Apply anti corrosion grease to the areas shown Checking the propeller 1 Check the propeller blades and spline Replace the propeller if cracked dam aged or worn a a a å a ...

Page 353: ...ue to internal pressure TIP If the fluid is at the correct level a small amount of fluid should overflow out of the filler hole when the reservoir cap is removed 4 If the fluid is below the correct level add the recommended fluid 5 Install a new O ring and the reservoir cap 3 and then tighten the reservoir cap to the specified torque 6 Install the tilt pin to its original position and then fully t...

Page 354: ...e throttle cable for smooth oper ation Adjusting the shift cable 1 Set the gear shift to the neutral position 2 Loosen the locknut 1 remove the clip 2 and then disconnect the shift cable joint 3 3 Align the pin a in the center of the shift bracket with the alignment mark b on the bracket 4 Adjust the position of the shift cable joint 3 until its hole is aligned with the pin a NOTICE The shift cabl...

Page 355: ...y and then tighten them to the specified torque using a spark plug wrench 6 Connect the spark plug caps Checking the thermostat 1 Remove the cover 1 thermostat cover 2 and thermostat 3 NOTICE Do not reuse the gasket 4 always replace it with a new one 2 Suspend the thermostat in a container of water 3 Place a thermometer in the water and slowly heat the water 4 Measure the thermostat valve opening ...

Page 356: ...ets when the timing belt is not installed Otherwise the pistons and valves will collide with each other and be damaged 9 Do not twist turn inside out or bend the timing belt beyond the maximum limit of 25 0 mm 1 0 in otherwise it can be damaged 9 Do not get oil or grease on the timing belt 1 Remove the flywheel magnet stator assembly and base assembly See Removing the flywheel magnet 7 5 2 Remove ...

Page 357: ...stall a new timing belt 3 onto the drive sprocket 7 and then install it onto the driven sprocket 8 Then loosen the bolt 6 1 2 turn 8 Turn the crankshaft clockwise fully twice and then check that the 1 mark a on the driven sprocket is aligned with the mark b on the cylinder head and that the mark c on the drive sprocket is aligned with the mark d on the crankcase 1 a b c d 2 4 5 e e f 2 6 3 7 8 a b...

Page 358: ...the spark plug wire 1 a 2 Start the engine and warm it up for 10 minutes 3 Check the engine idle speed 4 Check that the T mark b on the fly wheel magnet is aligned with the base pointer c on the base assembly Tensioner bolt 5 8 N m 0 8 kgf m 5 9 ft lb Tensioner bolt adjusting bolt 6 25 N m 2 5 kgf m 18 4 ft lb Digital tachometer 1 90890 06760 Timing light 2 90890 03141 Engine idle speed F50D 800 9...

Page 359: ...g the gear oil 10 15 Charging system 1 7 Charging unit and components 5 28 Checking the alert indicator 5 17 Checking the anode 10 9 Checking the armature 5 26 Checking the battery 10 4 10 10 Checking the brush 9 35 Checking the brush holder and brush 5 27 Checking the camshaft 7 38 Checking the carburetor 6 15 Checking the CDI unit 5 15 Checking the charge coil 5 14 Checking the compression press...

Page 360: ...ng the starter relay 5 21 Checking the steering system 10 8 Checking the thermostat 10 20 Checking the thermoswitch 5 15 Checking the throttle cable and shift rod 9 6 Checking the tilt cylinder and trim cylinder 9 46 Checking the tilt system D model 10 6 Checking the timing belt 10 21 Checking the timing belt and sprocket 7 20 Checking the top cowling 10 11 Checking the trim sensor 9 51 Checking t...

Page 361: ... 16 Installing the clamp bracket 9 27 Installing the cylinder head 7 28 Installing the drive shaft 8 16 8 59 Installing the exhaust cover 7 24 Installing the flywheel magnet 7 6 Installing the hydro tilt unit 9 53 Installing the lower unit 8 19 8 62 Installing the power unit 7 14 Installing the propeller shaft housing assembly 8 17 8 59 Installing the PTT unit 9 30 Installing the rocker arm assemb...

Page 362: ...8 3 8 42 Removing the power unit 7 14 Removing the propeller shaft housing assembly 8 6 8 49 Removing the PTT unit 9 30 Removing the starter motor 5 25 Removing the starter motor pinion 5 25 Removing the steering arm 9 25 Removing the timing belt and sprocket 7 19 Removing the upper case 9 13 Removing the water pump 8 6 8 24 8 67 Removing the water pump and shift rod 8 46 Replacing the oil filter ...

Page 363: ...roubleshooting procedure 4 1 Troubleshooting table format 4 1 Troubleshooting the lower unit 4 8 Troubleshooting the outboard motor 4 1 Troubleshooting the power unit 4 2 Troubleshooting the PTT unit 4 7 U Uncrate procedure 3 9 Upper case 9 15 Upper case and mounts 9 11 V Ventilation 0 1 W Water pump and shift rod FT50C 8 44 Wiring harness 7 7 Wiring harness connection 3 12 Working with crane 0 2 ...

Page 364: ......

Page 365: ...0 1 2 3 4 5 6 7 8 9 10 A Appendix Wiring diagram A 1 How to use the wiring diagram A 1 F50DET FT50CET A 2 FT50CEHD FT50CED A 4 ...

Page 366: ... FT50CEHD and FT50CED Legend symbols in the wiring diagrams 1 Double colors wire 2 No wire connector Color Code B Black Br Brown G Green L Blue Lg Light green O Orange P Pink R Red Sb Sky blue W White Y Yellow P B Pink Black P W Pink White B O Black Orange B W Black White G W Green White Gy B Gray Black Y B Yellow Black Y R Yellow Red W B White Black W R White Red 1 2 ...

Page 367: ...tions and significant changes in specifications and procedures and these are incorporated in successive editions of this manual Also up to date parts information is available in YPEC web Additional information and up to date information on Yamaha product and services are available on Service Portal Important information Particularly important information is distinguished in this manual by the foll...

Page 368: ...SERVICE MANUAL F50D FT50C 60A 28197 5L 11 YAMAHA MOTOR CO LTD Printed in Japan Aug 2008 0 5 1 n E Printed on recycled paper F50D FT50C ...

Page 369: ... G Y B P W B P W B W Gy B Gy B B O P B W R W B G W W O B P L Br Y R P B B O Gy B W B W R B W P W Y B G G R B L G W G W 2 3 1 4 B W B O P W P B P P B P P B B G G W B Y Y W R B Battery PTT relay PTT motor Fuse 20A Starter relay Starter motor Prime Start CDI unit Charge coil Lighting coil Rectifier Regulator Pulser coil Oil pressure switch Thermoswitch PTT switch Trim sensor Hour meter Ignition coil ...

Page 370: ...wn G Green L Blue O Orange P Pink R Red W White Y Yellow P B Pink Black P W Pink White B O Black Orange B W Black White G W Green White Gy B Gray Black Y B Yellow Black Y R Yellow Red W B White Black W R White Red å H model A 3 ...

Page 371: ... W Y B B O Gy B W B W R B W L Br P W O B Gy B Gy B P W B W B O P B P W B W R W B G W G G W B Y Y G Y G W R G G G G W G W G G L R B B P B W B O P W P B Battery Starter motor Starter relay Neutral switch Fuse 20A Prime Start CDI unit Charge coil Lighting coil Rectifier Regulator Pulser coil Oil pressure switch Thermoswitch Engine start switch Engine shut off switch Alert indicator Hour meter Spark p...

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