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Yamaha F60A, Supplementary Service Manual

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Yamaha F60A Supplementary Service Manual Download Page 47

69W3D1X

40

Hose routing

4

Fuel and blowby hoses

1

Blowby hose

2

Hose (acceleration pump-to-carburetor)

3

Fuel hose (fuel joint-to-fuel filter)

4

Fuel hose (fuel filter-to-fuel pump)

5

Fuel hose (fuel pump-to-carburetor)

6

Hose (carburetor-to-carburetor)

7

Hose 
(acceleration pump-to-acceleration pump)

General / Hose routing

1
2
3
4
5
6
7
8
9

Summary of Contents for F60A

Page 1: ...SERVICE MANUAL 292098 69W 28197 3D 1X SUPPLEMENTARY F60A ...

Page 2: ...FETY IS INVOLVED WARNING Failure to follow WARNING instructions could result in severe injury or death to the machine operator a bystander or a person inspecting or repairing the outboard motor CAUTION A CAUTION indicates special precautions that must be taken to avoid damage to the out board motor NOTE A NOTE provides key information to make procedures easier or clearer F50A FT50B FT50C SERVICE M...

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

Page 4: ...3 Propeller size 13 Selection 13 Predelivery checks 14 Checking the fuel system 14 Checking the gear oil 14 Checking the engine oil 14 Checking the battery 14 Checking the outboard motor mounting height 14 Checking the shift throttle cables 15 Checking the steering system 15 Checking the gearshift and throttle operation 16 Checking the tilt system 16 Checking the engine start switch and engine sto...

Page 5: ... and adjustments Special service tools 34 Maintenance interval chart 36 Top cowling 37 Checking the top cowling 37 Fuel system 37 Checking the fuel filter 37 Power unit 37 Checking the thermostat 37 General 38 Checking the anodes 38 Lubrication 39 Fuel system Hose routing 40 Fuel and blowby hoses 40 Cooling water hose 41 Fuel line and fuel filter 42 Carburetor unit 43 Adjusting the dashpot acceler...

Page 6: ...ng the forward gear 59 Installing the drive shaft 59 Shimming 60 Shimming 61 Selecting the forward gear shims 61 Bracket unit Tiller handle 63 Bottom cowling 65 Upper case 67 Disassembling the oil pan 71 Assembling the oil pan 71 Installing the upper case 72 Clamp brackets 74 Adjusting the trim sensor 75 Swivel bracket and steering arm 76 Power trim and tilt unit 77 Disassembling the gear pump 82 ...

Page 7: ...5 Ignition and ignition control system 86 Checking the spark plug caps 88 Checking the pulser coil air gap 88 Checking the engine start switch 88 Starting system 89 Starter motor 90 Checking the armature 91 Checking the brushes 91 Wiring diagram ...

Page 8: ...ghtening torque specifications are provided in the exploded diagrams and after a numbered step with tightening instructions 3 Symbols are used to indicate important aspects of a procedure such as the grade of lubricant and lubrication point 4 The components list consist of parts and part quantities as well as bolt screw O ring and hose dimensions 5 Service points regarding removal checking and ins...

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

Page 10: ...wing models Serial number The outboard motor serial number is stamped on a label attached to the port clamp bracket 1 Model name 2 Approved model code 3 Transom height 4 Serial number Applicable models F60AEHT F60AET Model name Approved model code Starting serial No F60AEHT 69W L 500101 F60AET L 400101 ...

Page 11: ...head pistons and the intake silencer Cylinder head The shape of the combustion chamber has been changed to increase its capacity The diameter of the intake and exhaust valves have been enlarged to increase output 1 Combustion chamber 2 Intake valve 3 Exhaust valve S69W1200 F50 F60 F60 F50 83 5 mm 3 29 in 84 1 mm 3 31 in 84 0 mm 3 31 in 84 8 mm 3 34 in 30 0 mm 1 18 in 26 0 mm 1 02 in 32 0 mm 1 26 i...

Page 12: ... Embossed letters for identification Carburetors To achieve the high power output of the F60 the carburetor bores have been enlarged Oil discharge volume F50 21 5 L 5 68 US gal 0 22 Imp gal min F60 23 5 L 6 21 US gal 5 17 Imp gal min Comparison chart of carburetor bores Throttle valve Venturi F50 ø27 ø22 F60 ø30 ø25 S69W1210 22 mm 0 87 in 24 mm 0 94 in F50 F60 S69W1220 F50 F60 Ø27 Ø22 Ø30 Ø25 ...

Page 13: ...shape of the intake silencer È Air Power nozzle The F60 uses a power nozzle in its carburetors This nozzle provides a rich air fuel mixture to ensure the proper output when operating at high engine speeds 1 Power nozzle 2 Fuel inlet È Air fuel mixture S69W1230 F50 F60 Comparison chart of main jet diameters Cylinder 1 2 3 4 F50 124 126 116 114 F60 124 124 124 124 S69W1240 Features and benefits ...

Page 14: ...n machined with involute splines to increase durability A section of the midspan of the drive shaft has been reduced to 14 4 mm 0 57 in to prevent the drive shaft from breaking under impact loads In addition two grooves are provided on the drive shaft for iden tification purposes 1 Grooves for identification 2 Involute splines 3 Angled splines S69W1250 95 5 mm 3 76 in Ø14 4 F50 F60 ...

Page 15: ...aring 2 Grooves for identification 3 Forward gear Propeller The propeller of the F60 has been newly designed 69W series The strength of the propeller blades and the slipping resistance of the damper have been increased The 11 13 and 15 inch propellers of the currently used 663 series will be gradually replaced by the 69W series Bearing comparison chart Forward gear bearing Forward gear F50 22 2 mm...

Page 16: ...increased in size with the increase in its power output and secures it in place 1 PTT motor 2 Identification mark 3 Tilt piston absorber 4 Tilt and trim cylinder 5 Manual valve 6 Up relief valve 7 Down relief valve 8 Gear pump È Shut off pressure of the F60 valves É Shut off pressure of the F50 valves Specified PTT motor output F50A 12 V 0 15 kW F60A 12 V 0 20 kW 69W 00 S69W1270 31 MPa 316 kgf cm2...

Page 17: ...it Starter motor The starter motor uses six magnets and four brushes to enhance its operating torque 1 Bearing 2 Starter relay 3 Neutral switch 4 Engine start switch 5 Magnet 6 Brush 7 Starter motor 8 Battery S69W1280 S69W1290 F50 F60 Operating torque F50 2 74 N m 0 27 kgf m 2 0 ft lb F60 3 50 N m 0 35 kgf m 2 5 ft lb Features and benefits ...

Page 18: ...tion rate and the pollution of the exhaust gases the carburetors of the F60 are set lean There fore the air fuel mixture becomes lean at high engine speeds when greater output is needed The power nozzle supplies a richer fuel mixture at high engine speed to realize the optimal air fuel ratio to produce output 1 Throttle valve 2 Power nozzle È Air É Air fuel mixture Ê Fuel S69W1300 ...

Page 19: ...ilt unit Shuttle piston A ball type shut off construction is used for both the up shuttle and down shuttle pistons The ball type realizes a reliable shut off operation and high shut off pressure 1 Ball F50 F60 S69W1310 Technical tips ...

Page 20: ... of the boat and the outboard motor Propeller size The size of the propeller is indicated on the propeller blade or outside of the propeller boss a Propeller diameter in inches b Propeller pitch in inches c Propeller type propeller mark Selection When the engine speed is at the full throttle operating range 5 000 6 000 r min the ideal propeller for the boat is one that pro vides maximum performanc...

Page 21: ...ufficient oil until the level is between a and b Checking the battery 1 Check the capacity electrolyte level and specified gravity of the battery 2 Check that the red and black battery cables are securely connected 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 pr...

Page 22: ... position and fully close the throttle lever or throttle grip 2 Check that the set pin a is aligned with the alignment mark b Adjust if neces sary 3 Check that the alignment mark c is aligned with the mark d Adjust if neces sary CAUTION The shift throttle cable joint must be screwed in a minimum of 8 0 mm 0 31 in e Checking the steering system 1 Check the steering friction for proper adjustment 2 ...

Page 23: ...re is no abnormal noise produced when the outboard motor is tilted up or down 3 Check that there is no interference with wires and 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 engine start switch and engine stop switch engine shut off switch 1 Check that the engine starts when the engine ...

Page 24: ...oes not tilt up when shifting into reverse and that water does not flow in over the transom NOTE The test run is part of the break in operation Break in During the test run perform the break in operation in the following three stages 1 One hour a at 2 000 r min or at approxi mately half throttle 2 One hour b at 3 000 r min or 3 4 throttle and one minute out of every ten at full throttle 3 Eight ho...

Page 25: ...on L US gal lmp gal hr at 6 000 r min 19 5 5 15 4 29 Power unit Type In line 4 stroke OHC 8 valves Cylinder quantity 4 Displacement cm3 cu in 996 60 8 Bore stroke mm in 65 0 75 0 2 56 2 95 Compression ratio 9 5 Carburetor quantity 4 Control system Tiller handle Remote control Starting system Electric Ignition control system Microcomputer CDI Ignition timing Degree TDC 0 BTDC 25 Alternator output V...

Page 26: ...9 without oil filter replacement L US qt lmp qt 2 0 2 1 1 8 Gear oil type Hypoid gear oil Gear oil grade API SAE GL 4 90 Gear oil quantity L US qt lmp qt 0 43 0 45 0 38 Bracket Trim angle at 12 degree boat transom Degree 4 to 16 Tilt up angle Degree 69 Steering angle Degree 40 40 Drive unit Gearshift positions F N R Gear ratio 1 85 24 13 Reduction gear type Spiral bevel gear Clutch type Dog clutch...

Page 27: ... of round limit mm in 0 01 0 0004 Pistons Piston diameter D mm in 64 95 64 96 2 5571 2 5574 Measuring point H mm in 5 0 2 Piston to cylinder clearance mm in 0 035 0 065 0 0014 0 0025 Piston pin boss bore size mm in 15 974 15 985 0 6289 0 6293 Oversize piston 1st mm in 0 25 0 0098 2nd mm in 0 50 0 0196 Oversize piston diameter 1st mm in 65 20 65 21 2 5669 2 5673 2nd mm in 65 45 65 46 2 5768 2 5771 ...

Page 28: ... 0 0016 0 0070 Camshafts Intake A mm in 30 89 30 99 1 2161 1 2200 Exhaust A mm in 30 82 30 92 1 2135 1 2175 Intake and exhaust B mm in 25 95 26 05 1 0217 1 0256 Camshaft journal diameter 1 mm in 36 93 36 94 1 4539 1 4543 2 3 4 mm in 36 94 36 95 1 4543 1 4547 Camshaft journal oil clearance 1 mm in 0 06 0 10 0 0023 0 0039 2 3 4 mm in 0 05 0 09 0 0020 0 0035 Maximum camshaft runout mm in 0 04 0 0016 ...

Page 29: ...ee length mm in 39 85 1 5689 Minimum free length mm in 37 85 1 4901 Tilt limit mm in 1 7 0 067 Connecting rods 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 Crankpin oil clearance mm in 0 016 0 040 0 0006 0 0015 Big end bearing thickness Yellow mm in 1 500 1 504 0 0591 0 0592 Red mm in 1 496 1 500 0 0589 0 0591 Pink mm in 1 49...

Page 30: ... clearance limit mm in below 0 12 0 0047 Rotor to cover clearance mm in 0 03 0 08 0 0012 0 0031 Thermostat Opening temperature C F 60 140 Fully open temperature C F 70 158 Valve open lower limit mm in 3 0 0 12 Fuel pump Discharge L US gal Imp gal hr at 6 000 r min 70 18 5 15 4 Pressure kPa kgf cm2 psi 49 0 49 7 0 Plunger stroke mm in 5 85 9 65 0 2303 0 3799 Carburetor ID mark 69W00 Main jet 124 Pi...

Page 31: ...egree TDC 0 Charge coil output peak voltage L Br at cranking unloaded V 159 at cranking loaded V 164 at 1 500 r min loaded V 168 at 3 500 r min loaded V 126 Charge coil resistance 1 L Br Ω 272 408 Pulser coil output peak voltage W R W B at cranking unloaded V 9 5 at cranking loaded V 5 5 at 1 500 r min loaded V 11 0 at 3 500 r min loaded V 15 5 Pulser coil resistance 1 W R W B Ω 396 594 CDI unit o...

Page 32: ...ameter mm in 33 0 1 30 Wear limit mm in 32 0 1 26 Mica Standard undercut mm in 0 5 0 8 0 02 0 03 Wear limit mm in 0 2 0 01 Charging system Fuse A 20 Lighting coil output peak voltage G G at cranking unloaded V 14 0 at 1 500 r min unloaded V 38 at 3 500 r min unloaded V 86 Lighting coil resistance 1 G G Ω 1 2 1 8 Rectifier Regulator output peak voltage R B at 1 500 r min unloaded V 22 at 3 500 r mi...

Page 33: ...sistance P B Ω 9 288 3 Fluid type ATF Dexron II Brushes Standard length mm in 10 0 39 Wear limit mm in 3 5 0 14 Commutator Standard diameter mm in 22 0 0 87 Wear limit mm in 21 0 0 83 Mica Standard undercut mm in 1 5 0 06 Item Unit Model F60AEHT F60AET Maintenance specifications ...

Page 34: ...SPEC Specifications 27 69W3D1X Dimensions Exterior L3 L6 L7 H9 H5 H2 H7 H1 H11 H4 H3 C1 B6 L5 L8 L9 L4 A3 A2 H6 H10 H8 L2 L1 L10 W2 W6 A1 W5 W1 S69W2150 ...

Page 35: ...m in L10 mm in 62 2 4 H1 L mm in 870 34 3 X mm in H2 mm in 545 21 5 H3 mm in 175 6 9 H4 L mm in 527 20 7 X mm in H5 mm in 758 29 8 H6 L mm in 708 27 9 X mm in H7 mm in 354 13 9 H8 mm in 37 1 5 H9 mm in 759 29 9 H10 mm in 49 1 9 H11 L mm in 24 0 9 X mm in W1 mm in 192 7 6 W2 mm in 124 4 9 W3 mm in W4 mm in W5 mm in 360 14 2 W6 mm in 645 25 4 A1 Degree 40 A2 Degree 69 A3 Degree 4 T1 mm in Maintenanc...

Page 36: ...SPEC Specifications 29 69W3D1X Exterior L6 L7 W5 W1 A1 H9 H2 H7 H1 H11 H4 H3 C1 B6 L5 L9 L4 A3 A2 H6 H10 H8 L8 L2 L1 L10 S69W2160 ...

Page 37: ...0 0 X mm in L10 mm in 62 2 4 H1 L mm in 870 34 3 X mm in H2 mm in 545 21 5 H3 mm in 175 6 9 H4 L mm in 527 20 7 X mm in H5 mm in H6 L mm in 708 27 9 X mm in H7 mm in 354 13 9 H8 mm in 22 5 0 9 H9 mm in 759 29 9 H10 mm in 49 1 9 H11 L mm in 24 0 9 X mm in W1 mm in 192 7 6 W2 mm in W3 mm in W4 mm in W5 mm in 360 14 2 W6 mm in A1 Degree 40 A2 Degree 69 A3 Degree 4 T1 mm in Maintenance specifications ...

Page 38: ...60AEHT F60AET B1 mm in 126 5 0 B2 mm in 249 10 0 B3 mm in 163 5 6 4 B4 mm in 50 8 2 0 B5 mm in 180 7 1 B6 mm in 350 13 8 B7 mm in B8 mm in B9 mm in 18 5 0 7 C1 mm in 69 2 7 C2 mm in D1 mm in 13 0 5 D2 mm in 60 5 2 4 B5 B3 B4 B9 B9 B9 D1 D1 B1 B6 C1 B8 B2 D2 S69W2170 ...

Page 39: ...ng bolt M8 25 2 5 18 Drive sprocket nut 140 14 101 Driven sprocket bolt M10 38 3 8 28 Spark plug 18 1 8 13 Cylinder head bolt 1st M6 6 0 6 4 3 2nd 12 1 2 8 7 1st M9 23 2 3 17 2nd 47 4 7 34 Oil pump screw M6 4 0 4 2 9 Rocker shaft bolt M8 18 1 8 13 Oil filter 18 1 8 13 Oil drain bolt M14 17 1 7 12 Exhaust cover bolt 1st M6 6 0 6 4 3 2nd 12 1 2 8 7 Crankcase bolt 1st M6 6 0 6 4 3 2nd 12 1 2 8 7 1st ...

Page 40: ...t 38 3 8 27 Engine start switch nut 5 0 5 3 7 Tiller handle bracket bolt M5 7 0 7 5 1 Friction plate bolt M6 8 0 8 5 8 Friction plate self locking nut 4 0 4 2 9 Upper mount nut 24 2 4 17 Lower mount nut 42 4 2 30 Clamp bracket self locking nut 23 2 3 17 Power trim and tilt Tilt cylinder end screw 90 9 0 65 PTT motor bolt M5 4 0 4 2 9 Reservoir cap 7 0 7 5 1 Trim cylinder end screw 80 8 0 58 Tilt p...

Page 41: ...haft holder 4 90890 06518 Pinion nut holder 90890 06505 Socket adapter 1 90890 06506 Bearing separator 90890 06534 Bearing inner race attachment 90890 06643 Shimming plate 90890 06701 Digital caliper 90890 06704 Digital circuit tester 90890 03174 Tightening torques Special service tools 1 2 3 4 5 6 7 8 9 ...

Page 42: ...CHK ADJ Periodic checks and adjustments 35 69W3D1X Dial gauge set 90890 01252 Magnet base 90890 06705 ...

Page 43: ...wling fit Check Fuel system Fuel joint and fuel hoses Check Fuel filter Check replace Fuel tank Cleaning Power unit Engine oil Change Oil filter Change Timing belt Check Valve clearance Check adjust Spark plugs Clean adjust replace Thermostat Check Water leakage Check Motor exterior Check Exhaust leakage Check Cooling water passage Clean Control system Throttle cable Check adjust Shift cable Check...

Page 44: ...eck the fitting again and if necessary repeat steps 2 4 Fuel system 3 Checking the fuel filter 1 Check the fuel filter element 1 for dirt and residue and check the fuel filter cup 2 for foreign substances and cracks Clean with straight gasoline and replace the cup if necessary NOTE Be sure not to spill any fuel when removing the fuel filter cup Power unit 3 Checking the thermostat 1 Remove the cov...

Page 45: ...cking the anodes 1 Check the anodes and trim tab for scales grease or oil Clean if necessary CAUTION Do not oil grease or paint the anodes otherwise they will be ineffective 2 Replace the anodes and trim tab if excessively eroded Water temperature Valve lift a 60 C 140 F Valve begins to lift above 70 C 158 F more than 3 0 mm 0 12 in S69W3050 S69W3110 Top cowling Fuel system Power unit General ...

Page 46: ...stments 39 69W3D1X Lubrication 1 Apply water resistant grease to the areas shown NOTE Apply grease to the grease nipple until it flows from the bushings a 2 Apply corrosion resistant grease to the areas shown S69W3120 A A S69W3150 A A ...

Page 47: ... Hose acceleration pump to carburetor 3 Fuel hose fuel joint to fuel filter 4 Fuel hose fuel filter to fuel pump 5 Fuel hose fuel pump to carburetor 6 Hose carburetor to carburetor 7 Hose acceleration pump to acceleration pump General Hose routing 1 2 3 4 5 6 7 8 9 ...

Page 48: ...FUEL Fuel system 41 69W3D1X Cooling water hose 1 Pilot water hose 2 Flushing hose È Flushing device model É View in direction of arrow S69W4020 ...

Page 49: ... joint to fuel filter 5 Bolt 1 M8 14 mm 6 Nut 1 7 Bracket 1 8 Body 1 9 Fuel filter element 1 10 Float 1 11 O ring 1 Not reusable 12 Cup 1 13 Fuel hose 2 Fuel pump to carburetor 14 Fuel hose 1 Fuel filter to fuel pump 15 Fuel pump 1 16 O ring 1 Not reusable 17 Bracket 1 18 Bolt 2 M6 30 mm Hose routing Fuel line and fuel filter ...

Page 50: ...FUEL Fuel system 43 69W3D1X Carburetor unit 4 No Part name Q ty Remarks 1 Acceleration pump 1 2 Screw 3 ø5 9 mm 3 Link rod 1 4 Hose 1 5 Hose 4 6 Link rod 1 7 Clip 1 Not reusable ...

Page 51: ...con tact with point a 5 If out of specification adjust the dashpot until the specified engine speed is obtained 6 Open the throttle cam 2 slowly and check that the acceleration pump stopper 3 comes in contact with point a 7 Turn the adjusting screw 4 in or out until the specified engine speed is obtained 8 Open and close the throttle cam a few times and then check that the engine speed at the oper...

Page 52: ...POWR Power unit 45 69W3D1X Power unit 5 ...

Page 53: ...Clip 1 12 Warning indicator coupler 1 Tiller handle model 13 PTT switch coupler 1 14 Plastic tie 1 Not reusable 15 Pilot water hose 1 16 Bolt 2 M6 20 mm 17 Neutral switch 1 Tiller handle model 18 Plate 1 Remote control model 19 Neutral switch lead 2 Tiller handle model 20 Ground lead 3 21 Bolt 1 M6 12 mm 22 PTT relay lead 2 23 Nut 2 24 Spring washer 2 25 PTT motor lead 2 Green blue 26 Bolt 2 M6 20...

Page 54: ...POWR Power unit 47 69W3D1X ...

Page 55: ...M6 12 mm 11 Oil pressure switch 1 12 Oil pressure switch lead 1 13 Screw 1 14 Ignition coil lead 2 15 Bolt 4 M6 30 mm 16 Thermoswitch lead 2 17 Rectifier Regulator coupler 1 18 CDI unit coupler 1 19 Bolt 2 M8 25 mm 20 Bolt 3 M8 35 mm 21 Nut 1 22 Spring washer 1 23 Starter motor lead 1 24 Spring washer 1 25 Nut 1 26 Bolt 1 M8 45 mm 27 Oil pressure switch lead 1 28 Starter relay lead 1 Power unit ...

Page 56: ...POWR Power unit 49 69W3D1X ...

Page 57: ...asket 1 Not reusable 11 Grommet 4 12 Anode 4 13 Cover 4 14 Bolt 4 15 Cover 4 16 Bolt 4 17 O ring 1 Not reusable 1 9 36 8 mm 18 O ring 1 Not reusable 1 8 17 1 mm 19 O ring 1 Not reusable 1 2 13 9 mm 20 Bolt 4 M6 40 mm 21 Housing 1 22 Drive shaft 1 23 Pin 1 24 Inner rotor 1 25 Outer rotor 1 26 Gasket 1 Not reusable 27 Cover 1 28 Screw 2 ø6 20 mm 29 Engine hanger 1 30 Bolt 2 M6 20 mm 31 Screw 4 ø4 10...

Page 58: ...POWR Power unit 51 69W3D1X ...

Page 59: ...e 4 6 Camshaft 1 7 Valve cotter 16 8 Spring retainer 8 9 Valve spring 8 10 Spring seat 8 11 Stem seal 8 Not reusable 12 Valve guide 8 Not reusable 13 Retaining bolt 1 14 Gasket 1 Not reusable 15 Oil seal 1 Not reusable 16 Bolt 5 M8 22 mm 17 Rocker arm retainer 2 18 Tensioner 2 19 Rocker arm retainer 1 20 Stopper guide 2 Power unit ...

Page 60: ...POWR Power unit 53 69W3D1X ...

Page 61: ... bearing 8 10 Connecting rod cap 4 11 Bolt 8 12 Dowel pin 2 13 Cylinder block 1 14 Connecting rod 4 15 Piston pin clip 8 Not reusable 16 Piston pin 4 17 Piston 4 18 Oil ring 4 19 Second ring 4 20 Top ring 4 21 Gasket 1 Not reusable 22 Exhaust cover 1 23 Thermostat 1 24 Gasket 1 Not reusable 25 Cover 1 26 Clamp 2 27 Grommet 1 28 Anode 1 29 Cover 1 30 Cover 1 31 Bolt 1 M6 20 mm 32 Bolt 1 M5 12 mm 33...

Page 62: ...l to the cylin der and then check the pressure again NOTE If the compression pressure increases check the piston and piston rings for wear Replace if necessary If the compression pressure does not increase check the valve clearance valve valve seat cylinder sleeve cylinder head gasket and cylinder head Adjust or replace if necessary Checking the oil pressure 1 Remove the cover 2 Remove the oil pre...

Page 63: ...e the out of round limit Replace or rebore the cylinder block if out of spec ification Checking the piston ring grooves 1 Measure the piston ring grooves Replace the piston if out of specification Cylinder bore D1 D6 65 00 65 01 mm 2 5591 2 5594 in Taper limit D1 D5 direction d D2 D6 direction e 0 08 mm 0 0031 in Out of round limit D2 D1 measuring point a D6 D5 measuring point c 0 01 mm 0 0004 in ...

Page 64: ...LOWR Lower unit 57 69W3D1X Drive shaft and lower case 6 ...

Page 65: ...ousing 1 14 O ring 1 Not reusable 15 Oil seal 2 Not reusable 16 Seal 1 17 Plate 1 18 Hose 1 19 Plastic tie 1 Not reusable 20 Joint 1 21 Nut 1 22 Water inlet cover 2 23 Screw 1 24 Shift cam 1 25 Needle bearing 1 26 Pinion 1 27 Nut 1 28 Forward gear shim As required 29 Bearing outer race 1 Not reusable 30 Taper roller bearing 1 Not reusable 31 Forward gear 1 32 Lower case 1 33 Cover 1 34 Gasket 1 No...

Page 66: ...he forward gear using a press Installing the drive shaft 1 Install the forward gear then the drive shaft assembly pinion and pinion nut and then tighten the nut to the specified torque Drive shaft holder 4 1 90890 06518 Pinion nut holder 2 90890 06505 Socket adapter 1 3 90890 06506 Bearing splitter plate 1 commercially obtainable Bearing separator 1 90890 06534 S69W6020 S69W6030 Bearing inner race...

Page 67: ...69W3D1X 60 Shimming 6 Drive shaft and lower case Shimming ...

Page 68: ... find the height average 2 Calculate the forward gear shim thickness T1 as shown in the examples below NOTE F is the deviation of the lower case dimen sion from standard The F mark a is stamped on the trim tab mounting surface of the lower case in 0 01 mm units If the F mark is unreadable assume that F is zero and check the backlash when the unit is assembled Example If M is 26 06 mm and F is 1 th...

Page 69: ...69W3D1X 62 Example If T1 is 0 45 mm then the forward gear shim is 0 42 mm If T1 is 0 60 mm then the forward gear shim is 0 58 mm Shimming ...

Page 70: ...BRKT Bracket unit 63 69W3D1X Tiller handle 7 ...

Page 71: ...35 mm 13 Washer 1 14 Red battery cable 1 15 Connector 1 16 Clip 1 17 Shift cable 1 18 Cover 1 19 Screw 3 ø6 35 mm 20 PTT switch coupler 1 21 PTT switch coupler 1 Tiller handle model 22 Plastic tie 1 23 Nut 2 24 Bolt 1 M5 20 mm 25 Bracket 1 26 Friction lock shaft 1 27 Collar 2 28 Washer 2 29 Friction lock lever 1 30 Friction piece 2 31 Friction plate 1 32 Washer 2 33 Bolt 2 34 Nut 1 35 Washer 1 36 ...

Page 72: ...BRKT Bracket unit 65 69W3D1X Bottom cowling 7 ...

Page 73: ... model 14 Flushing hose 1 Flushing device model 15 Bolt 4 M6 30 mm 16 Grommet 4 17 Collar 4 18 Grommet 1 19 PTT motor lead 1 20 Trim sensor coupler 1 21 Screw 1 ø6 25 mm 22 Bolt 2 M6 20 mm 23 Bracket 1 24 Power trim and tilt switch 1 25 Warning indicator 1 Tiller handle model 26 Screw 1 ø6 14 mm Tiller handle model 27 Pilot water hose 1 28 Collar 2 29 Grommet 2 30 Cowling lock lever 1 31 Washer 1 ...

Page 74: ...BRKT Bracket unit 67 69W3D1X Upper case 7 ...

Page 75: ...Bolt 4 M8 30 mm 11 Drive shaft bushing 1 12 Circlip 1 13 Ground lead 1 14 Screw 1 ø6 8 mm 15 Cap 2 16 Bolt 2 M12 170 mm 17 Washer 2 18 Rubber washer 2 19 Washer 2 20 Lower mount 2 21 Washer 2 22 Mount cover 2 23 Bolt 4 M8 30 mm 24 Bolt 2 M8 175 mm 25 Plate 1 26 Bolt 3 M8 30 mm 27 Upper mount 1 28 Nut 2 29 Grease nipple 1 30 Washer 2 31 Nut 2 32 Cover 1 33 Bolt 2 M8 20 mm Upper case ...

Page 76: ...BRKT Bracket unit 69 69W3D1X ...

Page 77: ...Spring 1 14 Cotter pin 1 Not reusable 15 Bolt 2 M6 25 mm 16 Bolt 2 M6 16 mm 17 Oil strainer 1 18 Bolt 1 M6 25 mm 19 Gasket 1 Not reusable 20 Pipe 1 21 Rubber seal 1 22 Dowel pin 2 23 Bolt 10 M6 25 mm 24 Drain bolt 1 25 O ring 1 Not reusable 26 Oil pan 1 27 Gasket 1 Not reusable 28 Exhaust manifold 1 29 Bracket 1 30 Washer 3 31 Bolt 3 M6 50 mm 32 Gasket 1 Not reusable 33 Gasket 2 Not reusable 34 Pl...

Page 78: ... valve housing 7 Assembling the oil pan 1 Install the gaskets onto the exhaust guide 1 2 Install the relief valve assembly 2 by installing the bolts then tightening them finger tight 3 Install the oil strainer 3 by installing the bolts 4 Install the water pipe 4 5 Install the oil pan 5 and bolts and then tighten the bolts finger tight 6 Install the exhaust manifold 6 and bolts and then tighten the...

Page 79: ... pipe 4 into the joint hole a of the upper case 10 Tighten the upper case bolts B and then tighten them to the specified torque Installing the upper case 1 Install the upper mount 1 and bolts 2 into the upper case 2 Install the lower mounts 3 and bolts 4 into the upper case 3 Install the mount covers 5 T R Exhaust manifold bolt 8 10 N m 1 0 kgf m 7 2 ft lb S69W7100 LT 572 LT 572 T R Upper case bol...

Page 80: ...lts into the swivel bracket 6 simulta neously 5 Install the upper mounting nut 7 and lower mounting nut 8 and then tighten them to the specified torque 6 Install the cover 9 T R Upper mounting nut 7 24 N m 2 4 kgf m 17 ft lb Lower mounting nut 8 42 N m 4 2 kgf m 30 ft lb ...

Page 81: ... sensor 1 4 Trim sensor coupler 1 5 Plastic tie 1 Not reusable 6 Self locking nut 2 7 Cap 2 8 Bolt 4 M6 25 mm 9 Anode 2 10 Port clamp bracket 1 11 Washer 2 12 Bushing 2 13 Through tube 1 14 Ground lead 1 15 Grease nipple 1 16 Screw 1 ø6 8 mm 17 Starboard clamp bracket 1 18 Bracket 1 Upper case Clamp brackets ...

Page 82: ...finger tight 4 Fully tilt the outboard motor down 5 Measure the trim sensor resistance Repeat steps 1 5 if out of specification 6 Tighten the screws 2 7 Fully tilt the outboard motor up and then support it with the tilt stop lever WARNING After tilting up the outboard motor be sure to support it with the tilt stop lever Otherwise the outboard motor could sud denly lower if the power trim and tilt ...

Page 83: ...ng 2 Not reusable 5 Bushing 2 6 Swivel bracket 1 7 Bushing 2 8 Port tilt stop lever 1 9 Circlip 1 10 Steering yoke 1 11 Bushing 1 12 Bushing 2 13 Tilt stop lever joint 1 14 Spring holder 1 15 Bolt 1 M6 10 mm 16 Spring 1 17 Pin 2 Not reusable 18 Starboard tilt stop lever 1 Clamp brackets Swivel bracket and steering arm ...

Page 84: ...and tilt unit 7 No Part name Q ty Remarks 1 Power trim and tilt unit 1 2 Plastic tie 3 Not reusable 3 PTT motor lead 2 4 Washer 2 5 Bolt 2 M8 16 mm 6 Circlip 1 7 Shaft 1 8 Bushing 2 9 Collar 1 10 Tilt pin 1 11 Collar 1 12 Collar 1 13 Shaft 1 ...

Page 85: ...lve lock screw 1 5 Up relief spring 1 6 Valve support pin 1 7 O ring 1 Not reusable 8 Ball 1 9 Down relief spring 1 10 Valve support pin 1 11 Relief valve seal 1 12 Filter 1 13 O ring 2 Not reusable 14 Spacer 2 15 Filter 2 16 O ring 1 Not reusable 17 Manual valve 1 18 Circlip 1 Power trim and tilt unit ...

Page 86: ...5 20 mm 2 Washer 2 3 Bracket 1 4 O ring 2 Not reusable 5 Spacer 2 6 Spring 2 7 Valve pin 2 8 Ball 2 9 Manual release spring 1 10 Ball 2 11 Gear pump cover 1 12 Spring 2 13 Shuttle piston 1 14 O ring 1 Not reusable 15 Valve seal 2 16 Circlip 2 17 Pin 2 18 Drive gear 1 ...

Page 87: ...69W3D1X 80 No Part name Q ty Remarks 19 Shaft 1 20 Driven gear 1 21 Ball 2 22 Shuttle piston 1 23 Valve plate 1 24 Plate 1 25 Gear pump housing 1 Power trim and tilt unit ...

Page 88: ...marks 1 Screw 3 ø5 20 mm 2 Yoke 1 3 O ring 1 Not reusable 4 Armature 1 5 Washer 1 6 Bushing 1 7 Screw 2 ø4 12 mm 8 Lead 1 9 Brush 2 1 10 Brush 1 1 11 Brush holder 1 12 Circuit breaker 1 13 Brush spring 2 14 PTT motor base 1 15 Oil seal 1 Not reusable ...

Page 89: ...ttle pistons 9 and balls 0 5 Remove the drive gear A and driven gear B Checking the valves 1 Check the operation of the check valve a of the trim cylinder end screw and check the valve for dirt or residue Clean if necessary 2 Check the operation of the tilt piston absorber valve and check for dirt or resi due Clean if necessary 3 Check the up relief valve and down relief valve for dirt or residue ...

Page 90: ...Install the balls 6 and shuttle pistons 7 into the gear pump housing 5 3 Install the gear pump cover 8 4 Install the balls 9 manual release spring 0 and bracket A by installing the bolts B then tightening them to the specified torque 5 Install the relief valve seal C ball D and filter E 6 Install the relief valve bracket F by installing the bolts G then tightening them to the specified torque S69W...

Page 91: ...O then tightening them to the specified torque Checking the trim sensor 1 Measure the trim sensor resistance Replace if out of specification NOTE Turn the lever 1 and measure the resistance as it gradually changes T R Relief valve bracket bolt G 5 N m 0 5 kgf m 3 6 ft lb T R Gear pump bolt J 7 N m 0 7 kgf m 5 1 ft lb Recommended power trim and tilt fluid ATF Dexron II T R PTT motor bolt O 4 N m 0 ...

Page 92: ... Oil pressure switch B Black Br Brown G Green L Blue Lg Light green P Pink R Red Sb Sky blue W White Y Yellow B O Black orange B W Black white P B Pink black P W Pink white Y B Yellow black Y R Yellow red Lg Lg SbSb R R B B B Br R Y Y G B B B B Y P L P G Lg Sb Y R P B P W Lg Lg Lg Sb Sb Sb Br Br R P B B B R R L Y P L B P R R G B B B B B P LgSb Y Y G G W B Y W G P W P W B O B O B W Y R Y R B W P B ...

Page 93: ...coil 4 Pulser coil 5 Engine start switch 6 Engine shut off switch 7 10 pin coupler 8 CDI unit È Tiller handle model B Black Br Brown L Blue O Orange W White B O Black orange B W Black white W B White black W R White red Wiring harness Ignition and ignition control system 1 2 3 4 5 6 7 8 9 ...

Page 94: ...ermoswitch 2 Oil pressure switch 3 CDI unit 4 Oil pressure warning indicator 5 Overheat warning indicator 6 Warning indicator È Tiller handle model B Black P Pink Gy B Gray black P B Pink black P W Pink white Y B Yellow black Y R Yellow red ...

Page 95: ...en the pulser coil screws adjust the pulser coil 1 position and then tighten the screws finger tight 5 Install the flywheel magnet and then check the gap and if necessary repeat steps 3 5 6 Tighten the pulser coil screws and fly wheel magnet nut to the specified torques Checking the engine start switch 1 Check the engine start switch for continu ity Replace if there is no continuity Spark plug cap...

Page 96: ... system 8 1 Fuse 2 10 pin coupler 3 Engine start switch 4 Starter motor 5 Battery 6 Neutral switch 7 Starter relay È Tiller handle model B Black Br Brown R Red OFF W B R P Br ON START N S M R Br Br Br R R R R B B B B B B B R R Br Br Br S69W8090E ...

Page 97: ... 1 6 Washer 1 1 7 Shim As required 8 Washer 2 1 9 Armature 1 10 Washer 2 11 Stator 1 12 Brush holder assembly 1 13 Brush set 1 14 O ring 1 Not reusable 15 Nut 1 16 Lower bracket 1 17 Screw 2 ø4 12 mm 18 Bolt 2 M6 120 mm S69W8100 1 2 3 4 5 9 10 6 7 8 11 12 13 16 18 14 15 17 T R 7 N m 0 7 kgf m 5 1 ft Ib Starting system Starter motor ...

Page 98: ...sure the commutator undercut a Replace the armature if out of specifica tion 5 Check the armature for continuity Replace if out of specifications Checking the brushes 1 Measure the brush length Replace the brush assembly if out of specification Dial gauge set 1 90890 01252 Magnet base 2 90890 06705 Free play limit 0 6 mm 0 024 in Diameter limit 32 0 mm 1 26 in Commutator undercut limit 0 2 mm 0 01...

Page 99: ... specifications Brush length limit a 10 0 mm 0 39 in Brush assembly continuity Brush 1 Brush assembly holder 4 Continuity Brush 2 Brush assembly holder 3 Brush 1 Brush 2 No continuity Brush 1 Brush assembly holder 3 Brush 2 Brush assembly holder 4 S69W8170 Starter motor ...

Page 100: ...R W W W B B B P R W P G Y B R R O B B G G Y Y L L L B B B B B B Y P P L L Y L Y L R R R R G L Br Br Br Br W Y B P W B O W B Y R L W P B Y R B W B W Y B P W Y R P B Y B P W Y R P B B O P B Y B P W B O P B B W Gy B Gy B W R W R W R W B W B G W G W G W Sb Sb Lg Lg Sb Sb Sb Lg Lg Br Br L G G G G G G B G L R R B G Br Br Br 2 3 1 4 Sb R Lg Sb Sb Sb Sb P B Gy Lg Lg Lg Lg R Sb Lg S69WWD01E Y Y L L B O P W...

Page 101: ...h B Prime Start C Oil pressure switch D CDI unit E Thermoswitch F Charge coil G Pulser coil H Lighting coil I Rectifier Regulator J Ignition coil K Spark plug L Trim sensor Color code B Black Br Brown G Green Gy Gray L Blue Lg Light green O Orange P Pink R Red Sb Sky blue W White Y Yellow B O Black orange B W Black white G W Green white Gy B Gray black P B Pink black P W Pink white W B White black...

Page 102: ...R W P G Y B R O B B G G Y Y L L L B B B B B B Y P P L L Y L Y L R R R R G L Br Br W Y B P W B O W B Y R L W P B Y R B W B W Y B P W Y R P B B O P B Y B P W B O P B B W Gy B Gy B W R W R W R W B W B G W G W G W Sb Sb Lg Lg Sb Sb Sb Lg Lg Br Br L G G G G G G B G L R R B G Br Br 2 3 1 4 Sb P B Gy Lg S69WWD03E B Br G Gy L Lg O P R Sb W Y B O B W G W Gy B P B P W W B W R Y B Y R Y Y L L B O P W B W L S...

Page 103: ...coil D Lighting coil E Rectifier Regulator F Power trim and tilt switch G Ignition coil H Spark plug È To remote control É To warning indicator Ê To trim meter Color code B Black Br Brown G Green Gy Gray L Blue Lg Light green O Orange P Pink R Red Sb Sky blue W White Y Yellow B O Black orange B W Black white G W Green white Gy B Gray black P B Pink black P W Pink white W B White black W R White re...

Page 104: ......

Page 105: ...YAMAHA MOTOR CO LTD Printed in the Netherlands Jul 2001 1 3 1 CR F60AEHT F60AET E ...

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