Yamaha FT50C Page 1 Service Manual Download

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SERVICE MANUAL

62Y-28197-3A-11

290408

F50A

FT50B

FT50C

Summary of Contents for FT50C

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

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

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

Page 4: ......

Page 5: ... 10 Acceleration pump 1 15 Ignition system 1 17 Ignition timing control 1 19 Power trim and tilt 1 22 Propeller selection 1 32 Propeller size 1 32 Selection 1 32 Predelivery checks 1 33 Checking the fuel system 1 33 Checking the gear oil 1 33 Checking the engine oil 1 33 Checking the battery 1 33 Checking the outboard motor mounting position 1 34 Checking the remote control cables 1 34 Checking th...

Page 6: ... 3 Cylinder head cover 1 4 Bolt 7 M6 20 mm 5 Cylinder head cover gasket 1 Not reusable 6 Bolt 10 M9 95 mm 1st 2nd 23 47 2 3 4 7 17 34 7 Spark plug 4 18 1 8 13 8 Bolt 5 M6 25 mm 1st 2nd 6 12 0 6 1 2 4 3 8 7 9 Dowel pin 2 10 Cylinder head gasket 1 Not reusable 11 Grommet 4 12 Anode 4 13 Cover 4 14 Bolt 4 15 Cover 4 16 Bolt 4 17 O ring 1 Not reusable 18 O ring 1 Not reusable 19 O ring 1 Not reusable ...

Page 7: ...tant grease Yamaha grease A Yamaha marine grease 3 Apply molybdenum disulfide grease 4 Apply anti corrosion grease Yamaha grease D 5 Apply low temperature resistant grease Yamaha grease C Symbols 6 to A in an exploded diagram indicate the type of sealant or locking agent and the appli cation point 6 Apply Gasket Maker 7 Apply Yamabond No 4 8 Apply LOCTITE No 271 Red LOCTITE 9 Apply LOCTITE No 242 ...

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

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

Page 10: ...odel code 3 Transom height 4 Serial number Applicable models USA Canada Worldwide F50AEHD F50TH F50AEHT F50AED F50TR F50AET T50TR FT50BET FT50CEHD FT50CED FT50CET Model name Approved model code Starting serial No USA Canada F50TH 62Y L 451812 F50TR L 421732 T50TR 64J L 406850 Worldwide F50AEHD 62Y L 350505 F50AEHT L 451812 X 750469 F50AED L 301090 F50AET L 421626 X 700700 FT50BET 64J L 406850 FT50...

Page 11: ...d for the starting system to further increase starting performance and serviceability Further more the acceleration pump and the dashpot have been integrated to simplify construction and to ease serviceability The four carburetors can be accurately and easily adjusted due to the simple construction of the links 1 Prime Start 2 Acceleration pump Identification Features and benefits ...

Page 12: ...DI unit and ignition coil The CDI unit contains a built in microcomputer that determines the ignition timing separately for acceleration and for normal operation based on signals received from the pulser coil thermoswitch and oil pressure switch 1 CDI unit 2 Flywheel 3 Stator 4 Pulser coil 5 Thermoswitch 6 Ignition coil 7 Oil pressure switch 2 3 4 5 6 7 1 S62Y1210 ...

Page 13: ...that are used in a higher class model provides ample dura bility making it possible to accommodate a wider range of applications throughout the market Pinion Forward gear Reverse gear Gear ratio Model Number of teeth Diameter mm Number of teeth Diameter mm Number of teeth Diameter mm F50 F50A 13 45 24 74 24 75 1 8 T50 FT50B FT50C 13 46 30 95 30 95 2 3 F50 F50A T50 FT50B FT50C S62Y1220 Features and...

Page 14: ...pted the shift slider type shift mechanism This shift mechanism enables a prompt engagement of the dog clutch regardless of the operating speed of the shift lever Thus smooth and positive shift operation has been made possible 1 Shift rod 2 Propeller shaft 3 Dog clutch 4 Shift slider È Forward É Reverse ...

Page 15: ...d up Once the engine starts current flows from the lighting coil of the to the thermo heater allowing the wax in the Prime Start unit to expand The expanded wax moves the thermo heater plunger in the direction to close the enrich ment valve As a result the volume of fuel that passes through the fuel enrichment valve decreases A few minutes after the engine has started the thermo heater plunger com...

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

Page 17: ... through the pilot air jet mix enabling the air fuel mixture that has been regulated by the pilot screw to be fed through the pilot outlet Because the throttle valve opens slightly when the engine is operating at low speeds air fuel mix ture also starts to be fed from the bypass holes 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 ...

Page 18: ...nd all the bypass holes In addition air fuel mixture is also supplied from the main nozzle in accordance with the opening angle of the throttle valve 1 Pilot screw 2 Pilot outlet 3 Bypass holes 4 Venturi 5 Pilot jet 6 Main jet 7 Main nozzle 8 Pilot air jet 9 Main air jet 0 Throttle valve È Air É Air fuel mixture Ê Fuel 3 2 1 0 9 8 7 6 5 4 3 2 S62Y1270 ...

Page 19: ...ted by the main air jet are mixed in the main nozzle The resultant mixture is then sprayed by the main nozzle into the venturi The air fuel mixture that is sprayed through the venturi is then fed into the engine 1 Pilot screw 2 Pilot outlet 3 Bypass holes 4 Main nozzle 5 Pilot jet 6 Main jet 7 Main air jet 8 Throttle valve È Air É Air fuel mixture Ê Fuel S62Y1280 4 5 6 7 8 1 2 3 Technical tips ...

Page 20: ...not possible to supply the volume of fuel that is necessary for the large volume of air that has been introduced Thus because it is not possible to achieve the air fuel mixture that is required by the engine bucking or hesitation results For this reason the acceler ation pump temporarily increases the fuel volume in order to adjust the air fuel mixture to a ratio that is necessary for the engine i...

Page 21: ... 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 1 Main air jet 2 Main nozzle 3 Main jet 4 Throttle valve 5 Pilot screw 6 Pilot outlet 7 Pilot jet 8 From acceleration pump 9 Throttle valve closing 0 Throttle valve...

Page 22: ...rotect the engine against overheating over revolution and oil pressure drops as well as to control warning devices 1 Pulser coil 2 Flywheel 3 Charge coil 4 CDI unit 5 Microcomputer 6 Ignition coils 1 and 4 7 Ignition coils 2 and 3 8 Oil pressure switch 9 Thermoswitch Flywheel Three protrusions for the pulser coil are provided along the periphery of the flywheel The purpose of these protrusions is ...

Page 23: ...lser 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 2 Rotating direction 3 Protr...

Page 24: ...ylinders 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...

Page 25: ...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 three minutes From the time the three minute warm up control has been completed the control transfers to the normal map 1 Ignition timing BTDC 2 Eng...

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

Page 27: ...ilt functions The power trim and tilt cylinder has been integrated with the gear pump housing the reservoir tank and the power trim and tilt motor in order to achieve a smaller and more compact unit Hydraulic system diagram 1 Power trim and tilt cylinder 2 Ram 3 Reservoir 4 Manual valve 5 Down main valve 6 Down relief valve 7 Hydraulic pump 8 Up relief valve 9 Up main valve 1 2 4 5 6 3 7 3 8 9 3 S...

Page 28: ...linder 2 Ram 3 Check valve 4 Down main valve 5 Down relief valve 6 Motor 7 Gear pump 8 Up main valve 9 Reservoir 0 Manual valve A Up relief valve B Up shuttle piston C Down shuffle piston D Trim cylinder base E Free piston F Tilt piston 2 3 5 4 6 7 8 9 0 A B 9 C D E F 1 S62Y1380 ...

Page 29: ...gear pump and also sucks fluid in through the reservoir The pressurized fluid forces up the trim cylinder along with the tilt piston free piston and trim cylin der base As the trim cylinder moves up the ram extends and the outboard motor is trimmed up The end of the trim range is when the trim cylinder tops out in the power trim and tilt cylinder Trim up function 1 Power trim and tilt cylinder 2 R...

Page 30: ...pressurized fluid continues to flow into the lower part of the trim cylinder pushing up the tilt piston and free piston and further extending the ram As the tilt piston moves up and off of the trim cylinder base the base moves up and pushes the balls outward to fit into holes of the power trim and tilt cylinder Once the balls have been fitted into the holes the trim cylinder base cannot move The e...

Page 31: ...End screw 4 Check valve 5 Trim cylinder 6 Reservoir 7 Down main valve 8 Gear pump 9 Up main valve 0 Up shuttle piston A Down shuttle piston B Trim cylinder base C Free piston D Tilt piston E Balls È Return É Send Ê Moving direction 1 2 3 4 5 6 7 8 9 6 0 6 A B C D E S62Y1400 Technical tips ...

Page 32: ...l information 1 27 62Y3A11 Circular flow 1 Power trim and tilt cylinder 2 Ram 3 Trim cylinder 4 Motor 5 Reservoir 6 Up relief valve 7 Gear pump 8 Free piston 9 Tilt piston È Return É Send 1 2 3 4 5 6 5 7 8 9 S62Y1410 ...

Page 33: ... to move inward Once the balls move in the trim cylinder is then able to move down and power trim and tilt fluid continues to flow into the cylinder and pushes the trim cylinder down along with the tilt piston and ram The end of the tilt down range is when the tilt piston and the free piston bottom out in the trim cylin der base When the power trim and tilt fluid pushes the trim cylinder down furt...

Page 34: ...m 3 Trim cylinder 4 Down relief valve 5 Down main valve 6 Gear pump 7 Reservoir 8 Up relief valve 9 Up shuttle piston 0 Up main valve A Down shuttle piston B Ball C Trim cylinder base D Free piston E Tilt piston F Balls È Return É Send Ê Moving direction 1 2 3 4 5 6 7 8 9 0 A B F C B D E S62Y1420 ...

Page 35: ...revent inter nal damage to the power trim and tilt unit and help to protect the bracket and lower unit from dam age in case the outboard motor hits something during operation When the outboard motor hits something highly pressurized fluid in the upper part of the power trim and tilt cylinder pushes down the check valve of the trim cylinder At the same time fluid pressure in the upper part of the t...

Page 36: ...1 62Y3A11 Damper function 1 Power trim and tilt cylinder 2 Trim cylinder 3 Ram 4 Tilt piston absorber 5 Tilt piston 6 Free piston 7 Check valve 8 Tilt piston absorber 9 Tilt piston È Send É Moving direction S62Y1430 1 2 3 4 5 6 7 8 9 ...

Page 37: ...n When the engine speed is at the full throttle operating range 5 000 6 000 r min an ideal propeller for the boat is one that provides maximum performance in relation to boat speed and fuel consumption S62Y1440 10 3 4 17 G 10 3 4 17 G 13 19 K S62Y1450 13 19 K 10 3 4 17 G F50 F50A Propeller size in Material 10 15 G Aluminum 10 1 4 14 G Aluminum 10 3 8 13 G Aluminum 10 5 8 12 G Aluminum 10 3 4 16 G ...

Page 38: ...the engine oil is above the maximum level mark a drain sufficient oil until the level is between a and b If the engine oil is below the minimum level mark b add sufficient oil until the level is between a and b Checking the battery 1 Check the capacity electrolyte level and specified gravity of the battery 2 Check that the positive and negative bat tery leads are securely connected S62Y1470 Recomm...

Page 39: ...k 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 wheel tiller handle 1 Check the steering friction for proper adjustment 2 Check the steering for smooth operation 3 Check that there is no interference with wires or hoses when the ou...

Page 40: ...engine shut off switch 1 Check that the engine starts when the engine start switch is turned to START 2 Check that the engine turns off when the engine start switch is turned to OFF 3 Check that the engine turns off when the engine stop switch is pushed engine shut off cord is pulled Checking the pilot water outlet 1 Check that cooling water is discharged from the pilot water outlet Test run 1 Sta...

Page 41: ...n or 3 4 throttle and one minute out of every ten at full throttle 3 Eight hours c at any speed however avoid running at full speed for more than five minutes È Hour After test run 1 Check for water in the gear oil 2 Check for fuel leakage in the cowling 3 After a test run and while the engine is at idle flush the cooling water passage with fresh water using the flushing kit S62Y1580 0 1 2 10 Pred...

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

Page 43: ...ations General specifications 2 1 Maintenance specifications 2 5 Power unit 2 5 Lower unit 2 9 Electrical 2 9 Power unit 2 12 Lower unit 2 16 Electrical 2 16 Dimensions 2 19 Tightening torques 2 29 Specified torques 2 29 General torques 2 31 ...

Page 44: ...put kW hp 5 500 r min 36 8 50 Full throttle operating range r min 5 000 6 000 Maximum fuel consumption L US gal lmp gal hr 6 000 r min 17 3 4 57 3 81 Power unit Type In line 4 stroke OHC 8 valves Cylinder quantity 4 Displacement cm3 cu in 935 57 1 Bore stroke mm in 63 0 75 0 2 48 2 95 Compression ratio 9 3 Carburetor quantity 4 Control system Tiller handle Remote control Starting system Electric I...

Page 45: ...ar oil type Hypoid gear oil Gear oil grade API SAE GL 4 90 Gear oil quantity L US qt lmp qt 0 43 0 45 0 38 Bracket Trim angle at 12 degree boat transom Degree 4 20 Tilt up angle Degree 69 Steering angle Degree 40 40 Drive unit Gear shift positions F N R Gear ratio 1 85 24 13 Reduction gear type Spiral bevel gear Clutch type Dog clutch Propeller shaft type Spline Propeller direction rear view Clock...

Page 46: ...uel consumption L US gal lmp gal hr 6 000 r min 17 3 4 57 3 81 Power unit Type In line 4 stroke OHC 8 valves Cylinder quantity 4 Displacement cm3 cu in 935 57 1 Bore stroke mm in 63 0 75 0 2 48 2 95 Compression ratio 9 3 Carburetor quantity 4 Control system Remote control Tiller handle Remote control Starting system Electric Ignition control system Microcomputer CDI Ignition timing Degree BTDC 5 3...

Page 47: ...il type Hypoid gear oil Gear oil grade API SAE GL 4 90 Gear oil quantity L US qt lmp qt 0 61 0 64 0 54 Bracket Trim angle at 12 degree boat transom Degree 4 20 Tilt up angle Degree 69 Steering angle Degree 40 40 Drive unit Gear shift positions F N R Gear ratio 2 33 28 12 2 31 30 13 Reduction gear type Spiral bevel gear Clutch type Dog clutch Propeller shaft type Spline Propeller direction rear vie...

Page 48: ...mm in 63 00 63 01 2 480 2 481 Taper limit mm in 0 08 0 003 Out of round limit mm in 0 05 0 002 Pistons Piston diameter D mm in 62 95 62 96 2 478 2 479 Measuring point H mm in 5 0 2 Piston to cylinder clearance mm in 0 04 0 06 0 0016 0 0024 Oversize piston diameter 1st mm in 0 25 0 01 2nd mm in 0 50 0 02 Piston pins Outside diameter mm in 15 965 15 970 0 6285 0 6287 Piston rings Top ring Dimension ...

Page 49: ... in 36 94 36 95 1 4543 1 4547 Camshaft journal oil clearance 1 mm in 0 055 0 100 0 0022 0 0039 2 3 4 mm in 0 045 0 090 0 0018 0 0035 Maximum camshaft runout mm in 0 04 0 0016 Rocker arm shafts Outside diameter mm in 15 98 15 99 0 6291 0 6295 Rocker arms Inside diameter mm in 16 00 16 01 0 6299 0 6303 Valves Valve clearance cold Intake mm in 0 20 0 05 0 008 0 002 Exhaust mm in 0 30 0 05 0 012 0 002...

Page 50: ...6 024 1 4173 1 4183 Crank pin oil clearance mm in 0 016 0 040 0 0006 0 0015 Big end bearing thickness Yellow mm in 1 500 1 504 0 0591 0 0592 Red mm in 1 496 1 500 0 0589 0 0591 Pink mm in 1 492 1 496 0 0587 0 0589 Green mm in 1 488 1 492 0 0586 0 0587 Crankshaft Crankshaft journal Diameter mm in 42 984 43 000 1 6923 1 6929 Crank pin Diameter mm in 32 984 33 000 1 2986 1 2992 Runout limit mm in 0 0...

Page 51: ...e open lower limit mm in 3 0 0 12 Fuel pump Discharge L US gal Imp gal hr 6 000 r min 70 18 5 15 4 Pressure kPa kgf cm2 psi 49 0 49 7 0 Plunger stroke mm in 5 85 9 05 0 23 0 35 Carburetor ID mark USA and Canada 62Y40 ID mark worldwide 62Y30 Main jet 1 124 2 126 3 116 4 114 Pilot jet 39 Pilot screw turns out 1 3 2 1 4 1 2 4 2 1 2 1 2 Float height mm in 10 0 0 5 0 39 0 02 Engine idle speed r min 750...

Page 52: ...da F50TH F50TR Worldwide F50AEHD F50AEHT F50AED F50AET Ignition system Ignition timing engine idle speed Degree TDC 1 5 Charge coil output peak voltage L Br cranking 1 1 V 144 cranking 2 1 V 137 1 500 r min V 169 3 500 r min V 129 Charge coil resistance 2 L Br Ω 272 408 Pulser coil output peak voltage W R W B cranking 1 1 V 6 3 cranking 2 1 V 3 5 1 500 r min V 7 4 3 500 r min V 11 2 Pulser coil re...

Page 53: ...ard undercut mm in 0 8 0 03 Wear limit mm in 0 2 0 01 Charging system Fuse A 20 Lighting coil output peak voltage G G cranking 1 V 11 9 1 500 r min 1 V 42 3 500 r min 1 V 127 Lighting coil resistance 2 G G Ω 1 2 1 8 Rectifier Regulator output peak voltage R B 1 500 r min 1 V 18 9 3 500 r min 1 V 19 5 Charging current A 5 000 r min 10 Enrichment control system Prime Start Plunger projection extende...

Page 54: ...tance P B Ω 10 288 3 Fluid type ATF Dexron II Brushes Standard length mm in 10 0 39 Wear limit mm in 3 5 0 14 Commutator Standard diameter mm in 22 0 0 87 Wear limit mm in 21 0 0 83 Mica Standard undercut mm in 1 5 0 06 Item Unit Model USA F50TR Canada F50TH F50TR Worldwide F50AEHD F50AEHT F50AED F50AET ...

Page 55: ...Taper limit mm in 0 08 0 003 Out of round limit mm in 0 05 0 002 Pistons Piston diameter D mm in 62 95 62 96 2 478 2 479 Measuring point H mm in 5 0 2 Piston to cylinder clearance mm in 0 04 0 06 0 0016 0 0024 Oversize piston diameter 1st mm in 0 25 0 01 2nd mm in 0 50 0 02 Piston pins Outside diameter mm in 15 965 15 970 0 6285 0 6287 Piston rings Top ring Dimension B mm in 1 17 1 19 0 046 0 047 ...

Page 56: ... 1 4543 2 3 4 mm in 36 94 36 95 1 4543 1 4547 Camshaft journal oil clearance 1 mm in 0 055 0 100 0 0022 0 0039 2 3 4 mm in 0 045 0 090 0 0018 0 0035 Maximum camshaft runout mm in 0 04 0 0016 Rocker arm shafts Outside diameter mm in 15 98 15 99 0 6291 0 6295 Rocker arms Inside diameter mm in 16 00 16 01 0 6299 0 6303 Valves Valve clearance cold Intake mm in 0 20 0 05 0 008 0 002 Exhaust mm in 0 30 ...

Page 57: ...4183 Crank pin oil clearance mm in 0 016 0 040 0 0006 0 0015 Big end bearing thickness Yellow mm in 1 500 1 504 0 0591 0 0592 Red mm in 1 496 1 500 0 0589 0 0591 Pink mm in 1 492 1 496 0 0587 0 0589 Green mm in 1 488 1 492 0 0586 0 0587 Crankshaft Crankshaft journal Diameter mm in 42 984 43 000 1 6923 1 6929 Crankshaft pin Diameter mm in 32 984 33 000 1 2986 1 2992 Runout limit mm in 0 04 0 0016 C...

Page 58: ...Valve open lower limit mm in 3 0 0 12 Fuel pump Discharge L US gal Imp gal hr 6 000 r min 70 18 5 15 4 Pressure kPa kgf cm2 psi 49 0 49 7 0 Plunger stroke mm in 5 85 9 05 0 23 0 35 Carburetor ID mark USA and Canada 62Y40 ID mark worldwide 62Y30 62Y30 62Y50 for Brazil Main jet 1 124 2 126 3 116 4 114 Pilot jet 35 39 Pilot screw turns out 1 3 2 1 4 1 2 4 2 1 2 1 2 Float height mm in 10 0 0 5 0 39 0 ...

Page 59: ...D FT50CET Ignition system Ignition timing engine idle speed Degree TDC 1 5 Charge coil output peak voltage L Br cranking 1 1 V 144 cranking 2 1 V 137 1 500 r min V 169 3 500 r min V 129 Charge coil resistance 2 L Br Ω 272 408 Pulser coil output peak voltage W R W B cranking 1 1 V 6 3 cranking 2 1 V 3 5 1 500 r min V 7 4 3 500 r min V 11 2 Pulser coil resistance 2 W R W B Ω 396 594 CDI unit output ...

Page 60: ... 1 22 Mica Standard undercut mm in 0 8 0 03 Wear limit mm in 0 2 0 01 Charging system Fuse A 20 Lighting coil output peak voltage G G cranking 1 V 11 9 1 500 r min 1 V 42 3 500 r min 1 V 127 Lighting coil resistance 2 G G Ω 1 2 1 8 Rectifier Regulator output peak voltage R B 1 500 r min 1 V 18 9 3 500 r min 1 V 19 5 Charging current A 5 000 r min 10 Enrichment control system Prime Start Plunger pr...

Page 61: ...0 288 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 USA T50TR Canada T50TR Worldwide FT50BET FT50CEHD FT50CED FT50CET Maintenance specifications ...

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

Page 63: ...0 6 0 02 X mm in 16 8 0 7 L10 mm in 63 2 5 H1 L mm in 876 34 5 X mm in 990 39 0 H2 mm in 519 20 4 H3 mm in 175 6 9 H4 L mm in 536 21 1 X mm in 647 25 5 H5 mm in 732 28 8 H6 L mm in 685 27 0 711 28 0 X mm in 776 30 6 H7 mm in 330 13 0 327 12 9 H8 mm in 39 1 5 45 1 8 H9 mm in 738 29 0 733 28 9 H10 mm in 44 1 7 H11 L mm in 24 0 9 X mm in 24 0 9 W1 mm in 181 7 1 W2 mm in 124 4 9 W3 mm in W4 mm in W5 m...

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

Page 65: ...in 0 6 0 02 0 8 0 03 X mm in 16 8 0 7 L10 mm in 63 2 5 H1 L mm in 876 34 5 917 36 1 X mm in 990 39 0 H2 mm in 519 20 4 H3 mm in 175 6 9 191 7 5 H4 L mm in 536 21 1 X mm in 647 25 5 H5 mm in H6 L mm in 685 27 0 711 28 0 749 29 5 X mm in 776 30 6 H7 mm in 330 13 0 327 12 9 H8 mm in 0 5 0 02 3 5 0 1 H9 mm in 738 29 1 733 28 9 H10 mm in 44 1 7 H11 L mm in 24 0 9 28 1 1 X mm in 24 0 9 W1 mm in 181 7 1 ...

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

Page 67: ...L mm in 0 8 0 03 X mm in L10 mm in 63 2 5 H1 L mm in 917 36 1 X mm in H2 mm in 519 20 4 H3 mm in 191 7 5 H4 L mm in 536 21 1 X mm in H5 mm in 680 26 8 H6 L mm in 723 28 5 X mm in H7 mm in 330 13 0 H8 mm in 110 4 3 H9 mm in 738 29 1 H10 mm in 44 1 7 H11 L mm in 28 1 1 X mm in W1 mm in 181 7 1 W2 mm in 213 8 4 W3 mm in 181 7 1 W4 mm in W5 mm in 345 13 6 W6 mm in 738 29 1 A1 Degree 40 A2 Degree 63 A3...

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

Page 69: ... 9 L9 L mm in 0 8 0 03 X mm in L10 mm in 63 2 5 H1 L mm in 917 36 1 X mm in H2 mm in 519 20 4 H3 mm in 191 7 5 H4 L mm in 536 21 1 X mm in H5 mm in H6 L mm in 723 28 5 X mm in H7 mm in 330 13 0 H8 mm in 0 5 0 02 H9 mm in 738 29 1 H10 mm in 44 1 7 H11 L mm in 28 1 1 X mm in W1 mm in 181 7 1 W2 mm in W3 mm in 181 7 1 W4 mm in W5 mm in 345 13 6 W6 mm in A1 Degree 40 A2 Degree 63 A3 Degree 4 T1 mm in ...

Page 70: ...0TR Canada F50TH F50TR Worldwide F50AEHD F50AEHT F50AED F50AET B1 mm in 126 5 0 B2 mm in 254 10 0 B3 mm in 163 5 6 4 B4 mm in 50 8 2 0 B5 mm in 180 7 1 B6 mm in 355 14 0 B7 mm in B8 mm in 139 5 5 B9 mm in 18 5 0 7 C2 mm in C3 mm in 69 2 7 D1 mm in 13 0 5 D2 mm in 55 5 2 2 ...

Page 71: ...0TR Worldwide FT50BET FT50CEHD FT50CED FT50CET B1 mm in 126 5 0 B2 mm in 254 10 0 B3 mm in 163 5 6 4 B4 mm in 50 8 2 0 B5 mm in 180 7 1 B6 mm in 355 14 0 B7 mm in B8 mm in 139 5 5 B9 mm in 18 5 0 7 C2 mm in C3 mm in 69 2 7 D1 mm in 13 0 5 D2 mm in 55 5 2 2 Maintenance specifications ...

Page 72: ...er unit bolt M8 21 2 1 15 Tensioner bolt 8 0 8 5 8 Tensioner adjusting bolt M8 25 2 5 18 Drive sprocket nut 140 14 101 Driven sprocket bolt M10 38 3 8 28 Spark plug 18 1 8 13 Cylinder head bolt 1st M6 6 0 6 4 3 2nd 12 1 2 8 7 1st M9 23 2 3 17 2nd 47 4 7 34 Adjusting screw locknut 14 1 4 10 Oil filter 18 1 8 13 Drain bolt 18 1 8 13 Exhaust cover bolt 1st M6 6 0 6 4 3 2nd 12 1 2 8 7 Crankcase bolt 1...

Page 73: ...er handle assembly nut FT50C 37 3 7 27 Throttle cable short locknut FT50C 37 3 7 27 Upper mount nut 24 2 4 17 Lower mount nut 42 4 2 30 Trim sensor screw M6 2 0 2 1 4 Clamp bracket self locking nut 23 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 6 5 0 65 4 7 Trim cylinder end screw 80 8 0 58 Tilt piston bolt M12 61 6 1 44 Relief valve brack...

Page 74: ...cable sections of this man ual To avoid warpage tighten multi fastener assemblies in a crisscross fashion and pro gressive stages until the specified torque is reached Unless otherwise specified torque specifications require clean dry threads Components should be at room temperature Nut A Bolt B General torque specifications N m kgf m ft lb 8 mm M5 5 0 5 3 6 10 mm M6 8 0 8 5 8 12 mm M8 18 1 8 13 1...

Page 75: ...ance 3 10 Checking the spark plugs 3 11 Checking the thermostat 3 12 Checking the cooling water passage 3 13 Control system 3 13 Checking the throttle cable operation 3 13 Checking the gearshift operation 3 14 Checking the engine idle speed 3 15 Checking the ignition timing 3 15 Power trim and tilt unit 3 16 Checking the power trim and tilt operation 3 16 Checking the power trim and tilt fluid lev...

Page 76: ...net holder YB 06139 Universal puller YB 06117 Inductive self powered tachometer YU 08036 B Battery powered timing light YM 33277 A Pressurfge vacuum tester YB 35956 A Oil filter wrench 90890 01426 Flywheel holder 90890 06522 Flywheel puller 90890 06521 Digital tachometer 90890 06760 For USA and Canada For worldwide ...

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

Page 78: ... Top cowling fit Check 3 4 Fuel system Fuel joint and fuel hoses Check 3 4 Fuel filter Check replace 3 5 Fuel tank Cleaning Power unit Engine oil Change 3 5 Oil filter Change 3 5 Timing belt Check 3 7 Valve clearance Check adjust 3 10 Spark plugs Clean adjust replace 3 11 Thermostat Check 3 12 Water leakage Check Motor exterior Check Exhaust leakage Check Cooling water passage Clean 3 13 Control s...

Page 79: ...g move the hook away from the seal 4 Tighten the nuts and bolts 5 Check the fitting again and if necessary repeat steps 2 4 Fuel system 3 Checking the fuel joint and fuel hoses fuel joint to carburetor 1 Remove the plate 1 and then check the fuel hose connections and fuel joint 2 for leaks Replace if necessary Also check the fuel filter 3 fuel pump 4 and carbu retor 5 for leaks and the fuel hoses ...

Page 80: ...l 1 Place the outboard in an upright position 2 Remove the engine oil dipstick wipe it clean and then insert it back into the oil filler hole 3 Remove the dipstick again to check the oil level and the oil for discoloration and its viscosity NOTE Replace the oil if it appears milky or black If the engine oil is above the maximum level mark a drain sufficient oil until the level is between a and b I...

Page 81: ...il filter 5 Install the oil filter and then tighten it to the specified torque 6 Install the drain bolt and then tighten it to the specified torque 7 Fill the specified engine oil into the oil filler hole Oil filter wrench YU 38411 90890 01426 S62Y3080 2 S62Y3100 Oil filter wrench YU 38411 90890 01426 Oil filter 18 N m 1 8 kgf m 13 ft lb Drain bolt 18 N m 1 8 kgf m 13 ft lb Recommended engine oil ...

Page 82: ...or b of the timing belt for cracks damage or wear Replace if necessary CAUTION Do not turn the flywheel magnet counter clockwise otherwise the valve system may be damaged Replacing the timing belt 1 Turn the flywheel magnet clockwise and align the 1 mark a on the driven sprocket with the mark b on the cyl inder head CAUTION Do not turn the flywheel magnet counter clockwise otherwise the valve syst...

Page 83: ...to the fly wheel magnet NOTE Apply force to the crankshaft end until the fly wheel magnet comes off the tapered portion of the crankshaft 3 Disconnect the stator couplers 3 and then remove the stator 4 4 Disconnect the pulser coil coupler 5 and then remove the stator base 6 with both collars 7 5 Remove the blowby hose bolts 8 and tensioner 9 then the timing belt 0 from the driven sprocket side Fly...

Page 84: ...e out or bend the timing belt beyond the maximum limit of 25 mm 1 0 in e otherwise it may be damaged Do not get oil or grease on the timing belt 8 Install the tensioner and bolts and then tighten the bolts finger tight 9 Turn the drive sprocket clockwise two turns and then check that the alignment marks are aligned CAUTION Do not turn the sprockets counterclock wise otherwise the valve system may ...

Page 85: ... then disconnect the high tension cords and blowby hose 1 2 Remove the spark plugs fuel pump 2 and cylinder head cover 3 3 Turn the flywheel clockwise and align the 1 mark a on the driven sprocket with the mark b on the cylinder head CAUTION Do not turn the flywheel counterclock wise otherwise the valve system may be damaged 4 Check the intake valve clearance for cyl inders 1 and 2 and the exhaust...

Page 86: ...osen the locknut 4 and then turn the adjusting screw 5 until the specified valve clearance is obtained NOTE To decrease the valve clearance turn the adjusting screw clockwise To increase the valve clearance turn the adjusting screw counterclockwise 8 Tighten the locknut and then check the valve clearances Adjust if necessary 9 Install the cylinder head cover fuel pump and spark plugs 10 Connect th...

Page 87: ...park plug gap a Adjust if out of specification 5 Install the spark plug tighten it finger tight b then to the specified torque with a spark plug wrench c Checking the thermostat 1 Remove the cover 1 thermostat cover 2 and thermostat 3 2 Suspend the thermostat in a container of water 3 Place a thermometer in the water and slowly heat the water Specified spark plug DPR6EA 9 NGK Spark plug gap a 0 9 ...

Page 88: ...ngine 3 Check for water flow at the cooling water outlet If there is no water flow check the cooling water passage inside the out board Control system 3 Checking the throttle cable operation 1 Check that the throttle cam 1 is at the fully closed position a when the remote control lever is in neutral or the throttle grip is fully closed Adjust the throttle cable length if necessary as follows 2 Loo...

Page 89: ...hat the gearshift operates smoothly when shifting from neutral into forward and reverse Adjust the shift cable length if necessary 2 Set the gearshift to the neutral position 3 Loosen the locknut 1 remove the clip 2 and then disconnect the shift cable joint 3 4 Align the set pin a in the center of the shift bracket with the alignment mark b on the bracket 5 Adjust the position of the shift cable j...

Page 90: ...on b 4 After adjusting the idle speed rev the engine a few times and let it idle for at least 15 seconds to check the stability of the engine Checking the ignition timing 1 Start the engine and warm it up for 5 min utes 2 Attach the special service tool to high tension cord 1 1 and then check the engine idle speed 3 Attach the special service tool to high tension cord 1 1 Inductive self powered ta...

Page 91: ...listen to the winding sound of the PTT motor for smooth operation 2 Fully tilt the outboard up and then sup port it with the tilt stop lever 1 to check the lock mechanism of the lever Checking the power trim and tilt fluid level 1 Fully tilt the outboard up and then sup port it with the tilt stop lever 1 WARNING After tilting up the outboard be sure to support it with the tilt stop lever Otherwise...

Page 92: ...r oil level in the lower case NOTE The gear oil level should be at the brim of the check hole 3 If necessary add sufficient gear oil of the recommended type to the correct level 4 Install the check screw and then tighten it to the specified torque Replacing the gear oil 1 Fully tilt the outboard up and then sup port it with the tilt stop lever 1 2 Remove the tilt pin 2 and then install it in the u...

Page 93: ...ar oil pump into the drain hole and slowly fill the gear oil until oil flows out of the check hole and no air bubbles are visible 7 Install the check screw quickly install the drain screw and then tighten them to the specified torque Recommended gear oil GEAR CASE LUBE USA or Hypoid gear oil SAE 90 Oil quantity F50 F50A 0 43 L 0 45 US qt 0 38 Imp qt T50 FT50B FT50C 0 61 L 0 64 US qt 0 54 Imp qt Ch...

Page 94: ...seals may be damaged NOTE Cover the check hole with a rag when remov ing the pressure vacuum tester from the lower unit 3 If pressure drops below specification check the drive shaft and propeller shaft oil seals for damage Checking the propeller 1 Check the propeller blades and splines for cracks damage or wear Replace if necessary General 3 Checking the anodes 1 Check the anodes and trim tab for ...

Page 95: ...ustic Always follow these preventive measures Avoid bodily contact with electrolyte as it can cause severe burns or permanent eye injury Wear protective eye gear when handling or working near batteries Antidote EXTERNAL SKIN Wash with water EYES Flush with water for 15 minutes and get immediate medical attention Antidote INTERNAL Drink large quantities of water or milk followed with milk of magnes...

Page 96: ...entioned in this manual may not always apply therefore consult the instruc tion manual of the battery Disconnect the negative lead first then the positive lead Lubrication 1 Apply water resistant grease to the areas shown È F50 F50A T50 FT50B É FT50C Electrolyte specific gravity 1 280 at 20 C 68 F S62Y3720 A ...

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

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

Page 99: ...e fuel pump 4 9 Disassembling the fuel pump 4 9 Checking the diaphragm and valves 4 10 Assembling the fuel pump 4 10 Carburetor unit 4 11 Carburetor 4 17 Checking the carburetor 4 19 Checking the Prime Start 4 20 Assembling the carburetor 4 20 Adjusting the throttle link rod 4 21 Adjusting the pilot screw 4 22 Synchronizing the carburetors 4 23 Adjusting the dash pot acceleration pump 4 24 ...

Page 100: ...ols 4 Pressure vacuum tester YB 35956 A Inductive self powered tachometer YU 08036 B Carburetor synchronizer YU 08030 Vacuum pressure pump gauge set 90890 06756 Digital tachometer 90890 06760 Vacuum gauge 90890 03159 For USA and Canada For worldwide ...

Page 101: ...l 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 Special service tools Hose routing ...

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

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

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

Page 105: ...ilter 1 F50 F50A 3 Fuel filter 1 T50 FT50B FT50C 4 Fuel pump 1 5 Bolt 1 M6 25 mm 6 Seal 1 7 Fuel hose 1 Fuel joint to fuel filter 8 Clip 3 9 Bolt 1 M8 14 mm 10 Nut 1 11 Bracket 1 12 Fuel hose 1 Fuel filter to fuel pump 13 Fuel hose 2 Fuel pump to carburetor 14 Clip 3 15 Bolt 2 M6 30 mm 16 O ring 1 Not reusable Fuel line ...

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

Page 107: ... filter cup 1 2 O ring 1 Not reusable 3 Fuel filter element 1 4 Body 1 5 Float 1 6 Screw 4 M5 35 mm 7 Cover 1 8 Fuel pump body 2 1 9 Fuel pump body 1 1 10 Nut 4 11 Plunger 1 12 Spring 1 13 Spring 1 14 Pin 1 15 Diaphragm 1 16 Screw 2 M3 6 mm 17 Valve 2 18 Nut 2 19 Seal 1 Not reusable 20 Gasket 1 Not reusable Fuel filter and fuel pump ...

Page 108: ...ssive pressure may cause air leakage NOTE Make sure that air does not escape from the opposite side of the fuel pump To eliminate any gaps between the fuel pump valves and the fuel pump body 2 and to ensure a better seal make sure that the inside of the fuel pump is moist with gaso line Disassembling the fuel pump 1 Disassemble the fuel pump as shown Pressure vacuum tester YB 35956 A Vacuum pressu...

Page 109: ... valves 2 for cracks Replace if neces sary Assembling the fuel pump 1 Align the plunger and diaphragm installa tion holes a and then install the plunger into the diaphragm 2 Push down on the plunger and the dia phragm and then install the pin 1 3 Turn the fuel pump body 1 2 approxi mately 90 and then push down on the plunger several times to make sure that the pin does not come out 4 Assemble the ...

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

Page 111: ...t lb 1 Carburetor assembly 1 Joint to silencer 2 Clip 1 3 Blowby hose 1 4 Prime Start coupler 1 5 Bolt 2 M6 30 mm 6 Collar 2 7 Throttle link rod 1 8 O ring 8 Not reusable 9 Insulator 1 10 Dowel pin 2 11 Bolt 8 M6 25 mm 12 Fuel hose 2 Fuel pump to carburetor 13 Clip 2 14 Rivet 2 Carburetor unit ...

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

Page 113: ... Part name Q ty Remarks Tightening torques Stage N m kgf m ft lb 1 Acceleration pump 1 2 Screw 3 M5 9 mm 3 Link rod 1 4 Hose 1 Acceleration pump to acceleration pump 5 Hose 4 Acceleration pump to carburetor 6 Link rod 1 Carburetor unit ...

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

Page 115: ...lencer 1 3 Plastic tie 1 Not reusable 4 Blowby hose 1 Silencer to joint 5 Bolt 8 M6 90 mm 6 Collar 8 7 O ring 4 Not reusable 8 Plate 1 9 O ring 4 Not reusable 10 O ring 4 Not reusable 11 Joint 1 12 Plastic tie 7 Not reusable 13 Fuel hose 4 Carburetor to carburetor 14 Fuel hose 2 Carburetor to fuel pump Carburetor unit ...

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

Page 117: ...ve 1 8 Main nozzle 1 9 O ring 1 Not reusable 10 Plug 1 11 Float 1 12 Screw 1 M4 6 mm 13 Float pin 1 14 Gasket 1 Not reusable 15 Float chamber 1 16 Drain screw 1 17 O ring 1 Not reusable 18 Screw 4 M4 13 mm 19 Fuel hose 1 Float chamber to body 20 Prime Start 1 21 Screw 1 M4 7 mm 22 O ring 1 Not reusable 23 Bracket 1 24 Body 1 25 Screw 2 Carburetor 1 M4 17 mm Carburetor 3 M4 22 mm 26 Gasket 1 Not re...

Page 118: ... Direct the compressed air downward otherwise cleaning solvent may be blown into your eyes or small parts of the carburetor may be blown off Do not use steel wire for cleaning the jets otherwise the jet diameters may be enlarged which may seriously affect performance 3 Check the main jet 1 pilot jet 2 and main nozzle 3 for dirt or residue Clean if necessary 4 Check the pilot screw and needle valve...

Page 119: ...ted side Checking the Prime Start 1 Measure the length of the Prime Start plunger 2 Connect the positive Prime Start blue L lead and the negative Prime Start black B lead to a battery as shown 3 Measure the plunger length a after applying power for 5 minutes Replace if out of specification Assembling the carburetor 1 Install the main nozzle 1 plug 2 pilot jet 3 and main jet 4 to the carburetor bod...

Page 120: ...ightly seated then out the specified number of turns Adjusting the throttle link rod 1 Push the throttle control lever 1 to the fully open position as shown and then measure the gap between the carburetor throttle lever 2 and carburetor stopper 3 2 If out of specification adjust the throttle link rod length 3 Remove the throttle link rod 4 adjust it to the specified length b and then install it Pi...

Page 121: ...tion a until the engine idle speed has decreased to approximately 50 r min then in direction b 5 8 turn 4 Turn the throttle stop screw 3 in direc tion c or d until the specified engine idle speed is obtained NOTE To increase the idle speed turn the throttle stop screw in direction c To decrease the idle speed turn the throttle stop screw in direction d 5 After adjusting the idle speed rev the engi...

Page 122: ... NOTE For best results use a vacuum gauge 3 commercially obtainable with four adapters like the one shown in the illustration 4 Adjust the idle speed to 1 000 r min by turning the throttle stop screw 4 on car buretor 4 in direction a or b NOTE To increase idle speed turn the throttle stop screw in direction a To decrease idle speed turn the throttle stop screw in direction b Inductive self powered...

Page 123: ...7 in Hg and to check the stability of the engine Adjusting the dash pot acceleration pump 1 Start the engine and warm it up for 5 min utes and then check the engine speed at the operation point of the dash pot 2 Attach the special service tool to high tension cord 1 1 3 Open the throttle cam 2 slowly and check the engine speed when the accel eration pump stopper 3 comes into con tact with point a ...

Page 124: ...the acceleration pump stopper 3 comes in contact with point a 6 Turn the adjusting screw 4 in or out until the specified engine speed is obtained 7 Open and close the throttle cam a few times and check the engine speed at the operation point of dash pot again Adjust if necessary ...

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

Page 126: ...ming belt and sprockets 5 32 Cylinder head 5 35 Removing the cylinder head 5 39 Checking the valve springs 5 40 Checking the valves 5 40 Checking the valve guides 5 41 Replacing the valve guides 5 41 Checking the valve seat 5 42 Refacing the valve seat 5 43 Checking the rocker arms and rocker arm shaft 5 45 Checking the camshaft 5 45 Checking the cylinder head 5 46 Checking the oil pump 5 47 Insta...

Page 127: ...arance 5 58 Checking the piston pin boss bore 5 58 Checking the piston pin 5 58 Checking the connecting rod small end inside diameter 5 59 Checking the connecting rod big end side clearance 5 59 Checking the connecting rod bolt 5 59 Checking the crankshaft 5 59 Checking the crankshaft main journal oil clearance 5 60 Checking the crankshaft pin oil clearance 5 61 Selecting the crankshaft main journ...

Page 128: ...t is in the neutral position Check the neutral switch for continuity Check the engine start switch for continuity Check the engine shut off switch for continuity Replace the engine shut off switch Is the gearshift in neutral Is there conti nuity Is there conti nuity Is there conti nuity Is there conti nuity Set it to the neutral position Replace the neutral switch Replace the engine start switch R...

Page 129: ... gasoline Check the starter motor Check operation of the starter motor pinion Remove all spark plugs and then the engine Listen for the operation sound of the starter relay Check the power unit Is there conti nuity Can the oper ation sound be heard Does the pin ion rotate Replace the starter relay Does the engine crank Yes Yes Yes Yes No No No No Troubleshooting ...

Page 130: ...on of the spark plugs again Check the compression pres sure of the combustion chamber Check the ignition system out put peak voltage Check the valve clearance WARNING Do not touch any of the connections of the spark gap tester leads Do not let sparks leak out of the removed spark plug caps Keep flammable gas or liquids away since this test can produce sparks Start the engine using dried or new spa...

Page 131: ... ing condition Kinks or fuel leakage Replace the pri mary fuel pump Check for water or residue in the fuel filter Open the fuel vent screw Replace the respective parts Clean the fuel system from the fuel tank to the fuel filter Check the fuel hose for kinks or fuel leakage Check the carbure tors No Yes Yes Yes Yes No No No Check the primary pump operation Check that the fuel vent screw of the fuel...

Page 132: ...res sure of the combustion chamber No Yes Check that there is no secondary air intake on the contact surfaces of the intake manifold and crankcase Check the ignition spark gap using the spark gap tester Out of specifi cation Replace the spark plug Check the ignition system out put peak voltage Yes No ...

Page 133: ...he throttle cable opera tion and lubricate it if necessary Out of specifi cation Do the valves close simul taneously Do the valves close simul taneously Check the second ary air intake on the O ring and manifold plate and the gas kets of the vacuum check bolts Check the ignition timing Yes No No Yes No Yes Check the operation of the car buretor throttle valves by removing the throttle cables and l...

Page 134: ... the compression pressure of power unit Check the needle valve of the carburetor for debris or wear Adjust the throttle cable Check each jet of the carburetor for clogs or debris Clean or replace the respective parts Debris or wear Check the ignition system and the compression pres sure of the engine Clogs or debris Yes No Yes Yes No No Check the throttle cable opera tion Clean the carburetor or r...

Page 135: ...Check the water inlet for clogs or debris Check the thermoswitch Check that cooling water is dis charged from the pilot water outlet Replace the thermostat Replace the CDI unit Replace the thermoswitch Check the water pump impeller Check the water passage Clogs or debris Is water dis charged Good condi tion Good condi tion Good condi tion Clean the water inlet Yes No No Yes Yes Yes No No Check the...

Page 136: ...k the oil pressure Check the oil pressure switch Clean or replace the respective parts At specified level Out of specifi cation Good condi tion Debris or wear Check the oil pas sage Yes No Yes No Yes Yes No No Add engine oil to the correct level Replace the oil pressure switch Replace the CDI unit ...

Page 137: ...lder YB 06139 Universal puller YB 06117 Crankshaft holder YB 06562 Valve spring compressor YM 01253 Valve guide remover YM 01122 Valve guide reamer YM 01196 Valve seat cutter set YM 91043 C Drive shaft needle bearing depth stop YB 34473 Oil filter wrench YU 38411 For USA and Canada Special service tools ...

Page 138: ...lywheel 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 Valve guide reamer 90890 06804 Valve seat cutter holder 90890 06316 For worldwide ...

Page 139: ...1 2 3 4 5 6 7 8 I Valve seat cutter 90890 06315 90890 06323 90890 06326 90890 06328 90890 06555 Bearing outer race attachment 90890 06626 Oil filter wrench 90890 01426 Piston slider 90890 06529 Special service tools ...

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

Page 141: ...heel magnet 1 2 Stator coil 1 3 Cover 1 4 Grommet 2 5 Nut 1 160 16 116 6 Washer 1 7 Bolt 3 M6 25 mm 8 Lighting coil coupler 1 9 Charge coil coupler 1 10 Stator base 1 11 Pulser coil coupler 1 12 Screw 4 M6 24 mm 4 0 4 2 9 13 Dowel pin 2 14 Woodruff key 1 15 Cover 1 16 Screw 3 M6 35 mm 3 0 3 2 2 Power unit ...

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

Page 143: ...50B FT50C 7 Carburetor assembly 1 8 Bolt 3 M6 20 mm 9 Plate 1 10 Clip 1 11 Clip 1 12 Grommet 1 13 Holder 1 F50 F50A T50 FT50B 14 Holder 1 FT50C 15 Bolt 2 16 O ring 1 Not reusable 17 Clip 2 18 Fuel hose 2 Fuel pump to carburetor 19 Bolt 1 20 Clip 1 21 Fuel hose 1 Fuel filter to fuel joint 22 Bolt 8 23 O ring 4 Not reusable 24 Dowel pin 2 25 Clip 1 26 Blowby hose 1 27 Prime Start coupler 1 28 Bolt 2...

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

Page 145: ...T models 10 Fuse holder lead 1 11 Clip 1 12 Warning indicator coupler 1 EHD EHT models 13 Trailer switch coupler 1 EHT ET models 14 Plastic tie 1 Not reusable 15 Pilot water hose 1 16 Bolt 2 M6 20 mm 17 Neutral switch 1 Tiller handle models 18 Plate 1 Remote control models 19 Neutral switch lead 2 Tiller handle models 20 Ground lead 3 21 Bolt 1 M6 12 mm 22 PTT relay lead 2 EHT ET models 23 Nut 2 E...

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

Page 147: ... 9 Ground lead 3 10 Bolt 1 M6 12 mm 11 Oil pressure switch 1 9 0 9 6 5 12 Oil pressure switch lead 1 13 Screw 1 2 0 2 1 4 14 Ignition coil lead 2 15 Bolt 4 M6 30 mm 7 0 7 5 1 16 Thermoswitch lead 2 17 Rectifier Regulator coupler 1 18 CDI unit coupler 1 19 Bolt 2 M8 25 mm 30 3 0 22 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 7 0 7 5 1 26 Bolt 1...

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

Page 149: ... Part name Q ty Remarks Tightening torques Stage N m kgf m ft lb 1 Power unit 1 2 Engine oil dipstick 1 3 Gasket 1 Not reusable 4 Dowel pin 2 5 Bolt 2 M6 16 mm 6 Bolt 8 M8 80 mm 21 2 1 15 7 Apron 1 8 Screw 2 M6 24 mm 9 Nut 2 Power unit ...

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

Page 151: ... torques Stage N m kgf m ft lb 1 Throttle link rod 1 2 Throttle cam 1 3 Throttle control lever 1 4 Clip 1 5 Bushing 1 6 Bolt 1 M6 20 mm 7 Spring 1 8 Collar 1 9 Bracket 1 10 Bolt 1 M6 30 mm 11 Shift rod 1 12 Bolt 1 M6 30 mm 13 Bracket 1 14 Spring 1 15 Bolt 1 Power unit ...

Page 152: ...d add a small amount of engine oil to the cylin der and then check the pressure again NOTE If the compression pressure increases check the piston and piston rings for wear Replace if necessary If the 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 Star...

Page 153: ...m slipping off easily To prevent damage to the engine or tools screw in the flywheel puller set bolts evenly and completely so that the flywheel puller plate is parallel to the fly wheel magnet NOTE Apply force to the crankshaft end until the fly wheel magnet comes off the tapered portion of the crankshaft Flywheel magnet holder 1 YB 06139 Flywheel holder 1 90890 06522 Universal puller 2 YB 06117 ...

Page 154: ...Disconnect the battery leads 5 10 pin coupler 6 PTT relay leads 7 EHT ET PTT motor leads 8 EHT ET ground lead 9 EHT ET warning indi cator coupler 0 EHD EHT trailer switch coupler A EHT ET pilot water hose B and flushing hose models with flushing device 5 Remove the power trim and tilt relay C shift rod D and shift rod bolts E 6 Remove the apron F ...

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

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

Page 157: ...ng belt 1 2 Drive sprocket 1 3 Driven sprocket 1 4 Bolt 1 8 0 8 5 8 5 Bolt 1 M8 20 mm 25 2 5 18 6 Tensioner 1 7 Spring 1 8 Nut 1 140 14 101 9 Retaining plate 2 10 Woodruff key 1 11 Bolt 1 M10 40 mm 38 3 8 28 12 Washer 1 13 Bolt 2 M6 20 mm 14 Blowby hose 1 15 Clip 1 16 Dowel pin 1 Timing belt and sprockets ...

Page 158: ...e breather hose and loosen the drive sprocket nut 1 NOTE Use a deep socket 2 M42 for this proce dure Do not turn the camshaft when loosening the drive sprocket nut 3 Remove the tensioner 4 and timing belt 5 from the driven sprocket side 4 Loosen the driven sprocket bolt 6 and remove the driven sprocket 7 È For USA and Canada É For worldwide NOTE Do not turn the camshaft when loosening the driven s...

Page 159: ...if necessary 2 Check the drive sprocket 1 and driven sprocket 2 for cracks damage or wear Replace if necessary Installing the timing belt and sprockets 1 Check that the 1 mark a on the driven sprocket 1 is aligned with the mark b on the cylinder head and then tighten the bolt 2 2 Install the retaining plate 3 Woodruff key 4 drive sprocket 5 retaining plate 3 and nut 6 and then tighten the nut S62Y...

Page 160: ...o not get oil or grease on the timing belt 5 Install the tensioner 8 and bolts and then tighten the bolts finger tight 6 Take up the timing belt slack by turning the drive sprocket clockwise at least two full turns CAUTION Do not turn the sprockets counterclock wise otherwise the valve system may be damaged 7 Tighten the tensioner bolts to the speci fied torque 8 Turn the drive sprocket two turns ...

Page 161: ... É For worldwide 10 Tighten the drive sprocket nut 6 to the specified torque and then install the breather hose NOTE Use a deep socket A M42 for this proce dure Flywheel magnet holder YB 06139 Flywheel holder 90890 06522 Driven sprocket bolt 2 38 N m 3 8 kgf m 27 ft lb Crankshaft holder B YB 06562 Crankshaft holder 18 B 90890 06562 Drive sprocket nut 6 140 N m 14 kgf m 100 ft lb Timing belt and sp...

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

Page 163: ... 1st 2nd 23 47 2 3 4 7 17 34 7 Spark plug 4 18 1 8 13 8 Bolt 5 M6 25 mm 1st 2nd 6 12 0 6 1 2 4 3 8 7 9 Dowel pin 2 10 Cylinder head gasket 1 Not reusable 11 Grommet 4 12 Anode 4 13 Cover 4 14 Bolt 4 15 Cover 4 16 Bolt 4 17 O ring 1 Not reusable 18 O ring 1 Not reusable 19 O ring 1 Not reusable 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 N...

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

Page 165: ...st valve 4 5 Intake valve 4 6 Camshaft 1 7 Valve cotter 16 8 Spring retainer 8 9 Valve spring 8 10 Spring seat 8 11 Stem seal 8 Not reusable 12 Valve guide 8 Not reusable 13 Retaining bolt 1 14 Gasket 1 Not reusable 15 Oil seal 1 Not reusable 16 Bolt 5 M8 22 mm 18 1 8 13 17 Rocker arm retainer 2 18 Tensioner 2 19 Rocker arm retainer 1 20 Stopper guide 2 Cylinder head ...

Page 166: ...el pin hole a is in the position shown in the illustra tion Adjust if necessary 2 Remove the cylinder head cover bolts in the sequence shown 3 Remove the cylinder head bolts in the sequence shown 4 Remove the oil pump 1 rocker arm assembly 2 and rocker arm shaft 3 S62Y5260 S62Y5276 2 3 ...

Page 167: ...alve springs 1 Measure the valve spring free length a Replace if out of specification 2 Measure the valve spring tilt b Replace if out of specification Checking the valves 1 Check the valve face for pitting or wear Replace if necessary Valve spring compressor 6 YM 01253 90890 04019 Valve spring compressor attachment 7 90890 06320 Valve spring free length limit a 37 85 mm 1 490 in Valve spring tilt...

Page 168: ...ication Replacing the valve guides 1 Remove the valve guide 1 by striking the special service tool from the combus tion chamber side Valve margin thickness a Intake 0 6 1 0 mm 0 024 0 039 in Exhaust 0 7 1 1 mm 0 028 0 043 in Valve stem diameter b Intake 5 48 5 49 mm 0 2157 0 2161 in Exhaust 5 46 5 47 mm 0 2150 0 2153 in Valve stem runout Intake 0 03 mm 0 0012 in Exhaust 0 03 mm 0 0012 in Valve gui...

Page 169: ... out of specifi cation Checking the valve seat 1 Eliminate carbon deposits from the valve with a scraper 2 Apply a thin even layer of Mechanic s blueing dye Dykem onto the valve seat 3 Lap the valve slowly on the valve seat with a valve lapper commercially obtain able as shown 4 Measure the valve seat contact width a where the blueing dye is adhered to the valve face Reface the valve seat if the v...

Page 170: ...he cutter evenly downward at a pressure of 40 50 N 4 5 kgf 8 8 11 lbf to prevent chatter marks 3 Use a 30 cutter to adjust the contact width of the top edge of the valve seat b Previous contact width Valve seat contact width a Intake 0 9 1 1 mm 0 035 0 043 in Exhaust 0 9 1 1 mm 0 035 0 043 in Valve seat cutter set YM 91043 C Valve seat cutter holder 90890 06316 Valve seat cutter 30 intake 90890 06...

Page 171: ...b Previous contact width 7 If the valve seat contact area is too nar row and situated near the top edge of the valve face use a 30 cutter to cut the top edge of the valve seat If necessary use a 45 cutter to center the area and set its width b Previous contact width 8 If the valve seat contact area is too nar row and situated near the bottom edge of the valve face use a 60 cutter to cut the bottom...

Page 172: ...e if necessary 2 Measure the rocker arms inside diameter b and rocker arm shaft outside diameter c Replace if out of specification Checking the camshaft 1 Measure the cam lobe Replace if out of specification 2 Measure the camshaft runout Replace if out of specification Rocker arm inside diameter b 16 00 16 01 mm 0 6299 0 6303 in Rocker arm shaft outside diameter c 15 98 15 99 mm 0 6291 0 6295 in C...

Page 173: ...ad 1 Eliminate carbon deposits from the com bustion chambers and check for deterio ration 2 Check the cylinder head warpage using a straightedge 1 and thickness gauge 2 in five directions as shown Replace if out of specification Camshaft journal diameter c 1 36 93 36 94 mm 1 4539 1 4543 in 2 3 4 36 94 36 95 mm 1 4543 1 4547 in Cylinder head journal inside diameter d 37 00 37 02 mm 1 4567 1 4575 in...

Page 174: ... guide 2 Install the valve 2 spring seat 3 valve spring 4 and spring retainer 5 in the sequence shown and then attach the special service tool NOTE Face the fine pitch side a of the valve spring toward the spring seat Clearance a 0 09 0 15 mm 0 004 0 006 in Clearance b 0 01 0 10 mm 0 0004 0 0039 in Clearance c 0 03 0 08 mm 0 001 0 003 in Valve spring compressor 6 YM 01253 90890 04019 Valve spring ...

Page 175: ... Lightly tap the spring retainer with a plas tic hammer to set the valve cotter securely Installing the camshaft 1 Install the new oil seal 1 È For USA and Canada É For worldwide 2 Install the camshaft 2 in the direction shown then the retaining bolt 3 Drive shaft needle bearing depth stop YB 34473 Bearing outer race attachment 90890 06626 S62Y5630 1 Cylinder head ...

Page 176: ...er arm retainer 4 stopper guide 5 by installing the bolts NOTE Make sure that the arrow marks b on the two tensioners and stopper guides are facing up 3 Install the rocker arm shaft assembly to the cylinder head by installing the bolts and then tighten them to the specified torque Installing the cylinder head 1 Install the oil pump 1 by aligning the oil pump drive shaft a with the camshaft pin b S...

Page 177: ...nce shown NOTE Apply engine oil to the cylinder head bolts M9 before installation 3 Tighten the cylinder head cover bolts in the sequence shown Cylinder head bolt M9 1st 23 N m 2 3 kgf m 17 ft lb 2nd 47 N m 4 7 kgf m 34 ft lb Cylinder head bolt M6 1st 6 N m 0 6 kgf m 4 3 ft lb 2nd 12 N m 1 2 kgf m 8 7 ft lb Cylinder head ...

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

Page 179: ...Main bearing 10 8 Oil seal 1 Not reusable 9 Connecting rod bearing 8 10 Connecting rod cap 4 11 Bolt 8 1st 2nd 6 17 0 6 1 7 4 3 12 12 Dowel pin 2 13 Cylinder body 1 14 Connecting rod 1 15 Piston pin clip 2 Not reusable 16 Piston pin 1 17 Piston 1 18 Oil ring 1 19 Second ring 1 20 Top ring 1 21 Piston assembly 1 22 Gasket 1 Not reusable 23 Exhaust cover 1 24 Thermostat 1 25 Gasket 1 Not reusable 26...

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

Page 181: ... 8 I È Tightening sequence No Part name Q ty Remarks Tightening torques Stage N m kgf m ft lb 31 Anode 1 32 Cover 1 33 Cover 1 34 Bolt 1 M6 20 mm 35 Bolt 1 M5 12 mm 36 Bolt 10 M6 35 mm 1st 2nd 6 12 0 6 1 2 4 3 8 7 Cylinder body ...

Page 182: ...pply a thin coat of the new engine oil to the O ring of the new oil filter 3 Install the oil filter and then tighten it to the specified torque Disassembling the cylinder body 1 Remove the exhaust cover bolts in the sequence shown Oil filter wrench YU 38411 90890 01426 S62Y5690 S62Y5700 E Oil filter wrench YU 38411 90890 01426 Oil filter 18 N m 1 8 kgf m 13 ft lb S62Y5710 ...

Page 183: ... at the specified measuring point Replace if out of specification Checking the cylinder bore 1 Measure the cylinder bore D1 D6 a at measuring points b c and d and in direction e which is parallel to the crankshaft and direction f which is at a right angle to the crankshaft Piston diameter a 62 95 62 96 mm 2 478 2 479 in Measuring point b 5 mm 0 2 in up from the bottom of the piston skirt Oversize ...

Page 184: ... crown of an inverted pis ton 3 Check the piston ring end gap d at the specified measuring point Replace if out of specification Taper limit maximum of D1 or D2 minimum of D5 or D6 0 08 mm 0 003 in Out of round limit maximum of D1 D3 or D5 minimum of D2 D4 or D6 0 05 mm 0 002 in Piston clearance 0 04 0 06 mm 0 0016 0 0024 in Piston ring dimensions Top ring a B 1 17 1 19 mm 0 046 0 047 in T 2 39 2 ...

Page 185: ...boss bore Replace the piston if out of specification Checking the piston pin 1 Measure the piston pin diameter Replace if out of specification Piston ring groove Top ring a 1 23 1 25 mm 0 048 0 049 in Second ring b 1 52 1 54 mm 0 060 0 061 in Oil ring c 2 51 2 53 mm 0 099 0 100 in Piston ring side clearance Top ring a 0 04 0 08 mm 0 002 0 003 in Second ring b 0 03 0 07 mm 0 001 0 003 in Oil ring c...

Page 186: ... 2 Calculate the difference between a and b Replace if out of specification Checking the crankshaft 1 Measure the crankshaft journal diameter a crank pin diameter b and crank pin width c Replace the crankshaft if out of specification Connecting rod small end inside diameter a 15 985 15 998 mm 0 6293 0 6298 in Connecting rod big end side clearance a 0 05 0 22 mm 0 002 0 009 in S62Y5840 Connecting r...

Page 187: ...sert the projection a of the bearing into the notch in the cylinder body 4 Put a piece of Plastigauge PG 1 on each main journal parallel to the crank shaft NOTE Do not put the Plastigauge PG 1 over the oil hole in the main journals of the crankshaft 5 Install the remaining half of the bearings into the crankcase NOTE Insert the projection of the bearing into the notch in the crankcase 6 Install th...

Page 188: ...lower half into the connecting rod cap 2 CAUTION Install the bearings in their original posi tions NOTE Insert the projection a of the bearing into the slot on the cap and connecting rod 3 Put a piece of Plastigauge PG 1 onto the crank pin parallel to the crankshaft NOTE Be sure not to put the Plastigauge PG 1 over the oil hole in the crank pin of the crank shaft 4 Install the connecting rod to th...

Page 189: ...essed Plastigauge PG 1 on each crank pin Replace the connecting rod bearing if out of specification Selecting the crankshaft main journal bearing 1 When replacing the main bearing select the suitable bearing as follows 2 Check the crankshaft journal mark on the crankshaft 1 and the cylinder body mark on the cylinder body 2 3 Select the suitable color a for the main bearing from the table Connectin...

Page 190: ...ing 1 When replacing the connecting rod bear ing select the suitable connecting rod bearing as follows 2 Check the crank pin mark on the crank shaft 1 and the connecting rod cap mark or painted color on the connecting rod 2 3 Select the suitable color a for the con necting rod bearing from the table 4 When installing the connecting rod bear ing insert the projection of the connect ing rod bearing ...

Page 191: ...necting rod in the same direction as the UP mark b on the piston Always use new piston pin clips and do not allow the piston pin clip end to align with the piston pin slot c 2 Install the oil ring 5 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 CAUTION Do not scratch the piston or break the pis ton rings NO...

Page 192: ... bearing into the notch in the cylinder body 7 Set the crankshaft A and oil seals B and C into the cylinder body as shown Apply engine oil to the inner oil seal jour nal bearings and connecting rod bear ing 8 Install the connecting rod cap 8 to the connecting rod and then tighten the con necting rod bolts D to the specified torques in two stages Apply engine oil to the connecting rod cap and conne...

Page 193: ...e journal bearings 11 Install the crankcase bolts and then tighten them to the specified torques in two stages and in the sequence shown CAUTION The oil seals must be installed before tightening the crankcase bolts NOTE Apply engine oil to the crankcase bolt M8 before installation Connecting rod bolt 1st 6 N m 0 6 kgf m 4 3 ft lb 2nd 17 N m 1 7 kgf m 12 ft lb S62Y5A90 GM E E 9 E Crankcase bolt M8 ...

Page 194: ...ges and in the sequence shown Installing the power unit 1 Install the dowel pins 1 and gasket 2 2 Install the power unit 3 by installing the bolts 4 then tightening them to the specified torque 3 Install the apron 5 Exhaust cover bolt 1st 6 N m 0 6 kgf m 4 3 ft lb 2nd 12 N m 1 2 kgf m 8 7 ft lb Mounting bolt 4 21 N m 2 1 kgf m 15 ft lb ...

Page 195: ...T warn ing indicator coupler A EHD EHT ground lead B EHT ET PTT motor leads C EHT ET PTT relay leads D EHT ET 10 pin coupler E and battery leads F 6 Connect the throttle link rod G and fuel hose H 7 Connect the shift cable shift rod I and throttle cable J and then adjust their lengths For adjustment procedures see Chapter 3 Checking the throttle cable operation and Checking the gearshift operation...

Page 196: ...USA and Canada É For worldwide CAUTION Apply force in the direction of the arrows shown to prevent the flywheel holder from slipping off easily NOTE Apply engine oil to the flywheel magnet nut before installation Flywheel magnet holder YB 06139 Flywheel holder 90890 06522 Flywheel magnet nut 160 N m 16 kgf m 116 ft lb ...

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

Page 198: ...r case F50 F50A 6 21 Removing the drive shaft 6 23 Disassembling the drive shaft assembly 6 23 Disassembling the forward gear 6 23 Disassembling the lower case 6 24 Checking the pinion and forward gear 6 25 Checking the bearings 6 25 Checking the drive shaft 6 25 Checking the shift rod and shift cam 6 25 Checking the lower case 6 25 Assembling the lower case 6 25 Assembling the forward gear 6 27 A...

Page 199: ...ropeller shaft housing 6 55 Installing the propeller shaft housing 6 57 Drive shaft and lower case T50 FT50B FT50C 6 59 Removing the drive shaft 6 61 Disassembling the drive shaft 6 61 Disassembling the forward gear 6 61 Disassembling the lower case 6 62 Checking the pinion and forward gear 6 63 Checking the bearings 6 63 Checking the drive shaft 6 63 Checking the lower case 6 63 Assembling the lo...

Page 200: ...Slide hammer and adapters YB 06096 Bearing housing needle bearing remover YB 06112 YB 06153 Driver handle YB 06071 Bearing housing needle bearing installer YB 06111 Oil seal installer YB 06168 Forward reverse gear bearing installer YB 06270 A Bearing cup installer YB 06167 Drive shaft holder YB 06049 For USA and Canada ...

Page 201: ...t taper roller bearing cup installer YB 06110 Forward gear bearing cup installer YB 06109 YB 06276 B Pinion shim selecting tools YB 34432 8 YB 34432 9 YB 34432 10A YB 34432 11A YB 34432 17 Forward gear shim selecting tools YB 34446 1 YB 34446 3 YB 34446 4 YB 34446 5 YB 34446 7 YB 34446 15 Shift rod push arm YB 06052 Backlash indicator gauge YB 06265 Magnetic plate YB 07003 Special service tools ...

Page 202: ...l installer YB 06269 Gland nut wrench YB 34447 Crank upper and lower seal installer YB 06244 Forward gear needle bearing and tapered roller bearing installer YB 06200 Bearing housing puller claw 90890 06564 Stopper guide plate 90890 06501 Center bolt 90890 06504 Bearing separator 90890 06534 For worldwide ...

Page 203: ...ent 90890 06607 90890 06610 90890 06611 90890 06612 90890 06614 90890 06653 Driver rod L3 90890 06652 Driver rod SS 90890 06604 Bearing depth plate 90890 06603 Bearing inner race attachment 90890 06639 90890 06641 90890 06643 90890 06644 90890 06661 90890 06662 Drive shaft holder 4 90890 06518 Pinion nut holder 90890 06505 Special service tools ...

Page 204: ...90 06523 Outer race puller claw A 90890 06532 Driver rod SL 90890 06602 Bearing outer race attachment 90890 06621 90890 06622 90890 06626 90890 06627 Driver rod LS 90890 06606 Driver rod LL 90890 06605 Pinion height gauge 90890 06702 Digital caliper 90890 06704 Shimming plate 90890 06701 ...

Page 205: ...90 06706 Magnet base plate 90890 07003 Dial gauge set 90890 01252 Magnet base 90890 06705 Ring nut wrench 3 90890 06511 Ring nut wrench extension 90890 06513 Bearing housing puller claw L 90890 06502 Ball bearing attachment 90890 06655 Socket adapter 90890 06507 Special service tools ...

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

Page 207: ... Hose 1 4 Check screw 1 7 0 7 5 1 5 Gasket 2 Not reusable 6 Bolt 4 M10 40 mm 40 4 0 29 7 Drain screw 1 7 0 7 5 1 8 Dowel pin 2 9 Bolt 1 M8 35 mm 10 Anode 1 11 Bolt 1 M8 60 mm 12 Thrust washer 1 13 Propeller 1 14 Washer 1 15 Washer 1 16 Cotter pin 1 Not reusable 17 Propeller nut 1 35 3 5 25 18 Trim tab 1 19 Bolt 1 M8 20 mm Lower unit F50 F50A ...

Page 208: ...ning and then remove the propeller nut and propeller WARNING Do not hold the propeller with your hands when loosening or tightening it Be sure to remove the battery leads from the bat teries and the engine shut off switch Put a block of wood between the cavitation plate and propeller to keep the propeller from turning 3 Disconnect the speedometer hose 1 4 Mark the trim tab 2 at the area shown and ...

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

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

Page 211: ... Not reusable 10 Outer plate cartridge 1 11 Gasket 1 Not reusable 12 Dowel pin 2 13 Woodruff key 1 14 Slider 1 15 Spring 1 16 Cross pin 1 17 Dog clutch 1 18 Spring 1 19 Propeller shaft 1 20 Shift plunger 1 21 Washer 1 22 Bolt 2 M8 25 mm 23 Reverse gear 1 24 Reverse gear shim As required 25 Ball bearing 1 26 O ring 1 Not reusable 27 O ring 2 Not reusable 28 Propeller shaft housing 1 29 Needle beari...

Page 212: ... Canada É For worldwide NOTE Install the bearing separator 2 between the reverse gear and propeller shaft housing completely then the other special service tools 2 Remove the ball bearing Bearing housing puller 2 YB 06234 Universal puller 3 YB 06117 Bearing housing puller claw 4 90890 06564 Stopper guide plate 5 90890 06501 Center bolt 6 90890 06504 Slide hammer and adapters 1 YB 06096 Bearing sep...

Page 213: ...Replace if necessary 2 Check the impeller 1 and insert plate cartridge 2 for cracks or wear Replace if necessary Slide hammer and adapters 7 YB 06096 Stopper guide plate 8 90890 06501 Stopper guide stand 9 90890 06538 Bearing puller 0 90890 06535 Bearing puller claw 1 A 90890 06536 Bearing housing needle bearing remover B YB 06112 Needle bearing attachment B 90890 06614 Driver handle C YB 06071 Dr...

Page 214: ...vent and then check it for cracks Replace if necessary 2 Check the teeth and dogs of the reverse gear for cracks or wear Replace the gear if necessary 3 Check the bearings for pitting or rum bling Replace if necessary Checking the propeller shaft 1 Check the propeller shaft for bends or wear Replace if necessary 2 Check the dog clutch and shift plunger for cracks or wear Replace if necessary S62Y6...

Page 215: ... oil seal propeller side Do not strike the driver rod in a manner that will force the stopper b out of place 2 Apply grease to the new oil seals and then install them into the propeller shaft housing to the specified depth È For USA and Canada É For worldwide NOTE Install an oil seal halfway into the propeller shaft housing then the other oil seal Driver handle 1 YB 06071 Bearing housing needle be...

Page 216: ...g with the manufacture identification mark f facing outward propel ler side 4 Install the reverse gear assembly to the propeller shaft housing using a press Oil seal installer 6 YB 06168 Driver handle 7 YB 06071 Needle bearing attachment 8 90890 06653 Driver rod L3 9 90890 06652 Depth e 4 0 4 5 mm 0 16 0 18 in Forward reverse gear bearing installer A YB 06270 A Bearing inner race attachment B 9089...

Page 217: ...talling the propeller shaft assembly be sure not to drop the shift plunger 3 Installing the water pump 1 Install the new gasket and outer plate cartridge 2 Install the Woodruff key into the drive shaft 3 Align the groove on the impeller 1 with the Woodruff key 2 and then install it to the drive shaft 4 Install the insert plate cartridge 3 into the water pump housing 4 NOTE Align the projection a o...

Page 218: ...tighten the bolts 7 and then install the grommet 8 and spacer 9 NOTE When installing the pump housing apply grease to the inside of the housing and then turn the drive shaft clockwise while pushing down the pump housing Align the spacer projection a with the hole b in the pump housing S62Y6200J A a b 9 8 7 4 6 5 6 ...

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

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

Page 221: ...e 11 Pinion shim As required 12 Sleeve 1 13 Oil seal housing assembly 1 14 Washer 1 15 Oil seal housing 1 16 O ring 1 Not reusable 17 Oil seal 2 Not reusable 18 Seal 1 19 Plate 1 20 Hose 1 21 Plastic tie 1 Not reusable 22 Joint 1 23 Nut 1 24 Water inlet cover 2 25 Screw 1 5 0 5 3 6 26 Shift cam 1 27 Needle bearing 1 28 Pinion 1 29 Nut 1 17 mm 75 7 5 54 30 Forward gear shim As required 31 Bearing o...

Page 222: ...t press the drive shaft threads a directly Do not reuse the bearing always replace it with a new one Disassembling the forward gear 1 Remove the taper roller bearing from the forward gear using a press CAUTION Do not reuse the bearing always replace it with a new one Drive shaft holder 1 YB 06049 Drive shaft holder 4 2 90890 06518 Pinion nut holder 3 90890 06505 Socket adapter 1 4 90890 06506 S62Y...

Page 223: ... the shift rod assembly and shift cam Slide hammer and adapters 1 YB 06096 Bearing outer race puller 2 90890 06523 Outer race puller claw A 3 90890 06532 Stopper guide stand 4 90890 06538 Slide hammer and adapters 5 YB 06096 Stopper guide plate 6 90890 06501 Stopper guide stand 7 90890 06538 Bearing puller 8 90890 06535 Bearing puller claw 1 9 90890 06536 Drive shaft needle bearing remover and ins...

Page 224: ...ce if necessary Checking the drive shaft 1 Check the drive shaft for bends or wear Replace if necessary Checking the shift rod and shift cam 1 Check the shift rod and shift cam for cracks or wear Replace if necessary Checking the lower case 1 Check the skeg and torpedo for cracks or damage Replace if necessary Assembling the lower case 1 Install the shift rod assembly 1 and shift cam 2 as shown NO...

Page 225: ...eplacing the pinion or lower case NOTE Apply gear oil to the inside and outside of the sleeve Install the sleeve with the projection f fac ing forward Driver handle 3 YB 06071 Drive shaft needle bearing remover and installer 4 YB 06063 Drive shaft needle bearing depth stop 5 YB 34474 Driver rod SL 6 90890 06602 Needle bearing attachment 7 90890 06614 Bearing depth plate 8 90890 06603 Depth d 132 5...

Page 226: ...g the drive shaft 1 Install the new drive shaft bearing into the drive shaft using a press È For USA and Canada É For worldwide NOTE Use a special service tool or a general pipe with the specified measurements Forward gear bearing cup installer A YB 06109 Bearing outer race attachment A 90890 06622 Driver handle B YB 06071 Driver rod LL B 90890 06605 Drive shaft taper roller bearing cup installer ...

Page 227: ... For USA and Canada É For worldwide Installing the lower unit 1 Set the gearshift to the neutral position at power unit and lower unit Oil seal installer 3 YB 06168 Driver handle 4 YB 06071 Needle bearing attachment 5 90890 06653 Driver rod L3 6 90890 06652 Drive shaft holder 1 YB 06049 Drive shaft holder 4 2 90890 06518 Pinion nut holder 3 90890 06505 Socket adapter 1 4 90890 06506 Pinion nut 75 ...

Page 228: ...d torque 4 Install the trim tab 2 to its original posi tion and then connect the speedometer hose 3 5 Install the propeller and propeller nut tighten the nut finger tight Place a block of wood between the anti cavitation plate and propeller to keep the propeller from turning and then tighten the nut to the specified torque Mounting bolt 40 N m 4 0 kgf m 29 ft lb ...

Page 229: ...s from the bat teries and the engine shut off switch Put a block of wood between the cavitation plate and propeller to keep the propeller from turning NOTE If the grooves in the propeller nut 4 do not align with the cotter pin hole tighten the nut until they are aligned Propeller nut 4 35 N m 3 5 kgf m 25 ft lb Drive shaft and lower case F50 F50A ...

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

Page 231: ... unreadable assume that P is zero and check the backlash when the unit is assembled Example If P is 5 then M0 0 30 5 100 mm 0 30 0 05 mm 0 35 mm If P is 5 then M0 0 30 5 100 mm 0 30 0 05 mm 0 25 mm 2 Install the drive shaft and drive shaft bearing 1 to the shim selecting tools 3 Attach the clamp 2 to the gauge base using four bolts of appropriate sizes NOTE Install the shim selecting tools to the ...

Page 232: ... shown in the examples below NOTE F is the deviation of the lower case dimen sion from standard The F mark a is stamped on the trim tab mounting surface of the lower case in 0 01 mm units If the F mark is unreadable assume that F is zero and check the backlash when the unit is assembled Example If F is 5 then M0 0 95 5 100 mm 0 95 0 05 mm 1 00 mm If F is 5 then M0 0 95 5 100 mm 0 95 0 05 mm 0 90 m...

Page 233: ...the neces sary shim thickness T2 Add or remove shims if out of specification For measur ing procedures see Measuring the for ward and reverse backlash in this chapter NOTE Measure the backlash with the original shim s If the original shim s is unavailable start with a 0 50 mm shim Forward gear shim selecting tools YB 34446 1 2 YB 34446 3 3 YB 34446 4 4 YB 34446 15 5 Forward gear shim thickness T1 ...

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

Page 235: ...her 1 4 turn after they contact the fixing plate 2 2 Install the pinion and pinion nut and then tighten the nut to the specified torque 3 Measure the distance M between the shimming tool and the pinion as shown NOTE Measure the pinion at three points to find the clearance average 4 Calculate the pinion shim thickness T3 as shown in the examples below NOTE P is the deviation of the lower case dimen...

Page 236: ...m thickness T1 by using the specified measurement s and the calcula tion formula Measure the bearing outer race at three points to find the height average 2 Calculate the forward gear shim thick ness T1 as follows 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...

Page 237: ... reverse gear shims 1 Measure the backlash to find the shim thickness T2 Add or remove shims if out of specification For measuring pro cedures see Measuring the forward and reverse backlash in this chapter NOTE Measure the backlash with the original shim s If the original shim s is unavailable start with a 0 50 mm shim Calculated numeral at 1 100 place Rounded numeral 1 2 0 3 4 5 2 6 7 8 5 9 10 8 ...

Page 238: ...the backlash indicator onto the drive shaft 18 mm 0 71 in in diameter then the dial gauge onto the lower unit NOTE Install the dial gauge so that the plunger a contacts the mark b on the backlash indica tor Shift rod push arm YB 06052 Shift rod push arm 90890 06052 Bearing housing puller 1 YB 06234 Universal puller 2 YB 06117 Bearing housing puller claw 3 90890 06564 Stopper guide plate 4 90890 06...

Page 239: ...clockwise and measuring the backlash when the drive shaft stops in each direction 10 Add or remove shims if out of specifica tion M Measurement 11 Remove the special service tools and then install the water pump assembly Forward gear backlash 0 18 0 54 mm 0 007 0 021 in Forward gear backlash Shim thickness Less than 0 18 mm 0 007 in To be decreased by 0 36 M 0 56 More than 0 54 mm 0 021 in To be i...

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

Page 241: ... 3 Hose 1 4 Check screw 1 7 0 7 5 1 5 Gasket 2 Not reusable 6 Dowel pin 2 7 Bolt 4 M10 40 mm 40 4 0 29 8 Drain screw 1 7 0 7 5 1 9 Grommet 1 10 Bolt 1 M10 45 mm 12 mm 11 Bolt 1 M8 60 mm 12 Thrust washer 1 13 Propeller 1 14 Washer 1 15 Washer 1 16 Cotter pin 1 Not reusable 17 Propeller nut 1 35 3 5 25 18 Trim tab 1 Lower unit T50 FT50B FT50C ...

Page 242: ...rning and then remove the propeller nut and propeller WARNING Do not hold the propeller with your hands when loosening or tightening it Be sure to remove the battery leads from the bat teries and the engine shut off switch Put a block of wood between the cavitation plate and propeller to keep the propeller from turning 3 Disconnect the speedometer hose 1 4 Mark the trim tab 2 at the area shown and...

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

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

Page 245: ...1 Not reusable 8 Bolt 2 M6 16 mm 9 Woodruff key 1 10 Bolt 2 M8 55 mm 11 Bolt 2 M8 45 mm 12 Water pump housing 1 13 Grommet 1 14 Gasket 1 Not reusable 15 Insert plate cartridge 1 16 Impeller 1 17 Outer plate cartridge 1 18 Gasket 1 Not reusable 19 Dowel pin 2 20 Oil seal housing assembly 1 21 Gasket 1 Not reusable 22 Oil seal housing 1 23 O ring 1 Not reusable 24 Oil seal 2 Not reusable Water pump ...

Page 246: ... coun terclockwise 90 b and then remove it Checking the water pump and shift rod 1 Check the pump housing for deforma tion Replace if necessary 2 Check the impeller 1 and insert plate cartridge 2 for cracks or wear Replace if necessary 3 Check the Woodruff key 3 and the groove a on the drive shaft for wear Replace if necessary 4 Check the shift rod for cracks or wear Replace if necessary S62Y6535 ...

Page 247: ...2 2 Install the new oil seals into the oil seal housing as shown È For USA and Canada É For worldwide 3 Install the new O ring 7 4 Install the new gasket 8 oil seal housing 9 new gasket 0 and outer plate car tridge A 5 Install the Woodruff key into the drive shaft Bearing housing oil seal installer 3 YB 06269 Driver handle 4 YB 06071 Needle bearing attachment 5 90890 06610 Driver rod L3 6 90890 06...

Page 248: ...g F NOTE Align the insert plate cartridge projection c with the hole d in the pump housing 8 Install the new gasket G pump housing assembly F and dowel pins H to the lower case 9 Install and tighten the bolts I NOTE When installing the pump housing apply grease to the inside of the housing and then turn the drive shaft clockwise while pushing down the pump housing S62Y6580 F E D A d c S62Y6585 F I...

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

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

Page 251: ...3 Ball 2 4 Slider 1 5 Shift plunger 1 6 Cross pin 1 7 Dog clutch 1 8 Spring 1 9 Propeller shaft 1 10 Washer 1 11 Straight key 1 12 Claw washer 1 13 Ring nut 1 105 10 5 76 14 Reverse gear 1 15 Thrust washer 1 16 Ball bearing 1 17 O ring 1 Not reusable 18 Propeller shaft housing 1 19 Needle bearing 1 20 Oil seal 2 Not reusable Propeller shaft housing T50 FT50B FT50C ...

Page 252: ...rust washer È For USA and Canada É For worldwide Gland nut wrench 1 YB 34447 Ring nut wrench 3 1 90890 06511 Ring nut wrench extension 2 90890 06513 Bearing housing puller 3 YB 06207 Universal puller 4 YB 06117 Bearing housing puller claw L 5 90890 06502 Stopper guide plate 6 90890 06501 Center bolt 7 90890 06504 Slide hammer and adapters 1 YB 06096 Bearing separator 2 90890 06534 Stopper guide pl...

Page 253: ...in 2 dog clutch 3 slider and shift plunger Checking the propeller shaft housing 1 Clean the propeller shaft housing using a soft brush and cleaning solvent and then check it for cracks Replace if necessary Slide hammer and adapters 7 YB 06096 Stopper guide plate 8 90890 06501 Stopper guide stand 9 90890 06538 Bearing puller 0 90890 06535 Bearing puller claw 1 A 90890 06536 Bearing housing needle b...

Page 254: ...e propeller shaft for bends or wear Replace if necessary 2 Check the dog clutch and shift slider for cracks or wear Replace if necessary Assembling the propeller shaft assembly 1 Install the dog clutch as shown NOTE Install the dog clutch 1 with the F mark a facing toward the shift slider Assembling the propeller shaft housing 1 Install the needle bearing into the propel ler shaft housing to the s...

Page 255: ...orldwide NOTE Install an oil seal halfway into the propeller shaft housing then the other oil seal 3 Install the thrust washer 0 and ball bear ing A to the reverse gear B using a press È For USA and Canada É For worldwide Driver handle 1 YB 06071 Bearing housing needle bearing remover 2 YB 06153 Driver rod SS 3 90890 06604 Needle bearing attachment 4 90890 06612 Bearing depth plate 5 90890 06603 D...

Page 256: ...embly 3 2 Apply grease to the new O rings 3 Install the propeller shaft housing assem bly 4 into the lower case and then install the straight key 5 claw washer 6 and ring nut 7 4 Tighten the nut to the specified torque NOTE Secure the ring nut by bending one tab a into the slot in the ring nut and the other tabs toward the propeller shaft housing assembly Drive shaft needle bearing depth stop C YB...

Page 257: ...A11 6 58 1 2 3 4 5 6 7 8 I Gland nut wrench 8 YB 34447 Ring nut wrench 3 8 90890 06511 Ring nut wrench extension 9 90890 06513 Ring nut 7 105 N m 10 5 kgf m 76 ft lb Propeller shaft housing T50 FT50B FT50C ...

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

Page 259: ...s required 5 Sleeve 1 6 Hose 1 7 Plastic tie 1 Not reusable 8 Joint 1 9 Nut 1 10 Water inlet cover 2 11 Screw 1 5 0 5 3 6 12 Seal 1 13 Plate 1 14 Forward gear shim As required 15 Bearing outer race 1 Not reusable 16 Taper roller bearing 1 Not reusable 17 Needle bearing 1 18 Forward gear 1 19 Needle bearing 1 20 Pinion 1 21 Nut 1 22 mm 95 9 5 69 22 Lower case 1 Drive shaft and lower case T50 FT50B ...

Page 260: ...t reuse the bearing always replace it with a new one Disassembling the forward gear 1 Remove the taper roller bearing from the forward gear using a press CAUTION Do not reuse the bearing always replace it with a new one 2 Remove the needle bearing from the for ward gear Drive shaft holder 1 YB 06049 Drive shaft holder 4 1 90890 06518 Pinion nut holder 2 90890 06505 Socket adapter 2 3 90890 06507 S...

Page 261: ...For USA and Canada É For worldwide NOTE Install the claws as shown Slide hammer and adapters 2 YB 06096 Stopper guide plate 3 90890 06501 Stopper guide stand 4 90890 06538 Bearing puller 5 90890 06535 Bearing puller claw 1 6 90890 06536 Slide hammer and adapters 1 YB 06096 Bearing outer race puller 2 90890 06523 Outer race puller claw A 3 90890 06532 Slide hammer and adapters 4 YB 06096 Stopper gu...

Page 262: ...m bling Replace if necessary Checking the drive shaft 1 Check the drive shaft for bends or wear Replace if necessary Checking the lower case 1 Check the skeg and torpedo for cracks or damage Replace if necessary Assembling the lower case 1 Install the needle bearing into the lower case to the specified depth Bearing housing needle bearing remover 9 YB 06153 Needle bearing attachment 9 90890 06611 ...

Page 263: ...y when replacing the pinion or lower case NOTE Apply the gear oil to the inside and outside of the sleeve Install the sleeve by facing the projection d forward Driver handle 1 YB 06071 Drive shaft needle bearing remover and installer 2 YB 06155 Drive shaft needle bearing depth stop 3 YB 34473 Driver rod SL 4 90890 06602 Needle bearing attachment 5 90890 06611 Bearing depth plate 6 90890 06603 Dept...

Page 264: ...nd Canada É For worldwide 2 Install the new needle bearing into the forward gear to the specified depth Forward gear bearing cup installer 9 YB 06276 B Driver handle 0 YB 06071 Bearing outer race attachment A 90890 06621 Driver rod LL B 90890 06605 Forward gear needle bearing and tapered roller bearing installer 1 YB 06200 Bearing inner race attachment 2 90890 06662 Bearing housing needle bearing ...

Page 265: ...hen the drive shaft assembly pinion and pinion nut and then tighten the nut to the specified torque Installing the lower unit 1 Set the gearshift to the neutral position at power unit and lower unit General pipe 1 D 38 mm 1 49 in d 32 mm 1 26 in Bearing inner race attachment 2 90890 06643 Drive shaft holder 1 YB 06049 Drive shaft holder 4 1 490890 06518 Pinion nut holder 2 90890 06505 Socket adapt...

Page 266: ...d torque 4 Install the trim tab 2 to its original posi tion and then connect the speedometer hose 3 5 Install the propeller and propeller nut tighten the nut finger tight Place a block of wood between the anti cavitation plate and propeller to keep the propeller from turning and then tighten the nut to the specified torque Mounting bolt 40 N m 4 0 kgf m 29 ft lb ...

Page 267: ...rom the bat teries and the engine shut off switch Put a block of wood between the cavitation plate and propeller to keep the propeller from turning NOTE If the grooves in the propeller nut 4 do not align with the cotter pin hole tighten the nut until they are aligned Propeller nut 4 35 N m 3 5 kgf m 25 ft lb Drive shaft and lower case T50 FT50B FT50C ...

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

Page 269: ...unreadable assume that P is zero and check the backlash when the unit is assembled Example If P is 5 then M0 0 20 5 100 mm 0 20 0 05 mm 0 25 mm If P is 5 then M0 0 20 5 100 mm 0 20 0 05 mm 0 15 mm 2 Install the drive shaft and drive shaft bearing 1 to the shim selecting tools 3 Attach the clamp 2 to the gauge base using four bolts of appropriate sizes NOTE Install the shim selecting tools to the d...

Page 270: ... shown in the examples below NOTE F is the deviation of the lower case dimen sion from standard The F mark a is stamped on the trim tab mounting surface of the lower case in 0 01 mm units If the F mark is unreadable assume that F is zero and check the backlash when the unit is assembled Example If F is 5 then M0 1 70 5 100 mm 1 70 0 05 mm 1 75 mm If F is 5 then M0 1 70 5 100 mm 1 70 0 05 mm 1 65 m...

Page 271: ... the clearance M between the gauge pin and the press plate 4 Select the forward gear shims T1 NOTE The sum of T1 and M should not be more than M0 Forward gear shim selecting tools YB 34446 1 2 YB 34446 3 3 YB 34446 5 4 YB 34446 7 5 Forward gear shim thickness T1 M0 M Available shim thicknesses 0 10 0 12 0 15 0 18 0 30 0 40 and 0 50 mm Shimming T50 for USA and Canada ...

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

Page 273: ...4 of a turn after they contact the fixing plate 2 2 Install the pinion and pinion nut and then tighten the nut to the specified torque 3 Measure the distance M between the shimming tool and the pinion as shown NOTE Measure the pinion at three points to find the clearance average 4 Calculate the pinion shim thickness T3 as shown in the examples below NOTE P is the deviation of the lower case dimen ...

Page 274: ...kness T1 by using the specified measurement s and the calcula tion formula Measure the bearing outer race at three points to find height average 2 Calculate the forward gear shim thickness T1 as shown 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 unre...

Page 275: ... mm 0 50 0 05 mm 0 45 mm 3 Select the forward gear shim s T1 as follows Example If T1 is 0 45 mm then the forward gear shim is 0 42 mm If T1 is 0 50 mm then the forward gear shim is 0 48 mm Calculated numeral at 1 100 place Rounded numeral 1 2 0 3 4 5 2 6 7 8 5 9 10 8 Available shim thicknesses 0 10 0 12 0 15 0 18 0 30 0 40 and 0 50 mm Shimming FT50B FT50C for worldwide ...

Page 276: ...he universal puller or center bolt while turning the drive shaft until the drive shaft can no longer be turned 4 Install the backlash indicator onto the drive shaft 18 mm 0 71 in in diameter then the dial gauge onto the lower unit NOTE Install the dial gauge so that the plunger a contacts the mark b on the backlash indica tor Shift rod push arm YB 06052 Shift rod push arm 90890 06052 Bearing housi...

Page 277: ...d measure the back lash when the drive shaft stops in each direction 10 Check the pinion shim if out of specifica tion 11 Remove the special service tools and then install the water pump assembly Backlash indicator gauge 6 YB 06265 Backlash indicator 6 90890 06706 Magnetic plate 7 YB 07003 Magnet base plate 7 90890 07003 Dial gauge 8 YU 03097 Dial gauge set 8 90890 01252 Magnet flexible stand 9 YU...

Page 278: ...ecking the shift rod assembly operation 7 29 Upper case 7 31 Disassembling the oil pan 7 39 Checking the oil strainer and the relief valve 7 39 Assembling the oil pan 7 39 Installing the upper case 7 41 Clamp brackets 7 43 Removing the clamp brackets 7 45 Installing the clamp brackets 7 45 Adjusting the trim sensor 7 46 Swivel bracket and steering arm 7 47 Removing the steering arm 7 49 Installing...

Page 279: ...the trim cylinder 7 67 Assembling the tilt cylinder 7 69 Bleeding the power trim and tilt not installed 7 70 Bleeding the power trim and tilt built in 7 71 Power trim and tilt motor 7 73 Checking the power trim and tilt motor 7 75 Assembling the power trim and tilt motor 7 76 Installing the power trim and tilt 7 76 Power trim and tilt electrical system 7 78 Checking the fuse 7 79 Checking the powe...

Page 280: ...t fluid level Disassemble the power trim and tilt unit and then check it Check the power trim and tilt motor Replace the power trim and tilt relay Close the plug Add fluid to the correct level At specified level Can 12 V be obtained Can 12 V be obtained Can the oper ation sound be heard Can the oper ation sound be heard Replace the power trim and tilt relay Check for continuity between the battery...

Page 281: ...d the outboard motor up Check that the manual release plug is closed Check the power trim and tilt fluid level Disassemble the power trim and tilt unit and then check it Close the plug Add fluid to the correct level At specified level Is it closed Yes Yes No No Troubleshooting ...

Page 282: ...od connection between the lower case and upper case Disassemble the lower case and then check the shifting gear mechanism and the respective parts Replace the shift rod Check the shift cables and links of the remote control box Check the detent of the bottom cowling Good operat ing condition Good operat ing condition Connected properly Yes Yes Yes No No No Check the shift cable operation ...

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

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

Page 285: ... 7 Throttle cable 1 8 Plate 1 9 Bolt 3 M6 20 mm 10 Bolt 1 M8 16 mm 9 0 9 6 5 11 Negative battery lead 1 12 Cable guide 1 13 Grommet 1 14 Nut 1 7 0 7 5 1 15 Washer 1 16 Positive battery lead 1 17 Connector 1 18 Clip 1 19 Shift cable 1 20 Plastic tie 2 21 Cover 1 22 Screw 3 M6 35 mm 23 Trailer switch coupler 1 24 PTT switch coupler 1 Models with trailer switch 25 Bolt 1 M6 35 mm 26 Screw 1 M6 25 mm ...

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

Page 287: ...y Remarks Tightening torques Stage N m kgf m ft lb 31 Nut 2 32 Collar 2 33 Bolt 2 M8 50 mm 34 Self locking nut 1 35 Bracket 1 36 Steering lock shaft 1 37 Steering lock knob 1 38 Friction plate 1 39 Friction piece 2 Tiller handle F50 F50A T50 FT50B ...

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

Page 289: ... Bushing 2 9 Nut 1 4 0 4 2 9 10 Engine shut off switch 1 11 Nut 1 38 3 8 27 12 Washer 1 13 Bracket 1 14 Collar 1 15 Wave washer 1 16 Washer 1 17 Bolt 1 18 Clamp 1 19 Screw 1 20 Connector 2 21 Engine start switch housing 1 22 Engine start switch 1 23 Nut 1 5 0 5 3 7 24 Bolt 1 M6 25 mm 25 Screw 1 26 Bolt 1 M6 20 mm 27 Cover 1 28 Power trim and tilt switch 1 29 Screw 5 M6 16 mm 30 Screw 2 M6 16 mm Ti...

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

Page 291: ... 1 2 3 4 5 6 7 8 I No Part name Q ty Remarks Tightening torques Stage N m kgf m ft lb 31 Screw 2 M6 40 mm 32 Throttle grip 1 33 Screw 1 M5 25 mm 34 Washer 1 35 Spring 1 36 Bushing 1 Tiller handle F50 F50A T50 FT50B ...

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

Page 293: ... 7 Stay 1 8 Bolt 1 M6 14 mm 9 Throttle cable 1 Short 10 Clip 1 11 Throttle arm 1 12 Throttle arm shaft 1 13 Shift cable 1 Long 14 Shift cable bracket 1 15 Bolt 1 M6 14 mm 16 Clip 1 17 Frame 1 18 Screw 2 M5 14 mm 19 Bolt 1 M6 14 mm 20 Spring housing 1 21 Spring 1 22 Actuator 1 23 Roller 1 24 Bushing 1 25 Shift arm 1 26 Bolt 2 M6 30 mm 27 Throttle shaft 1 28 Friction piece 1 29 Nut 1 Tiller handle F...

Page 294: ...he rubber seals for damage Replace if necessary Assembling the tiller handle 1 Install the throttle shaft 1 and throttle arm 2 into the frame 3 Align the mark a of the fully closed position of the throt tle shaft to the shaft holder Align the mark b of the fully closed position of the throttle arm to the indent of the frame NOTE Make sure that the throttle grip is fully closed when installing the ...

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

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

Page 297: ...m ft lb 1 Bolt 1 M8 30 mm 2 Nut 1 3 Wing nut 1 13 1 3 9 4 4 Friction piece 1 5 Bolt 1 M6 35 mm 6 Friction rod 1 7 Washer 1 8 Nut 1 9 Washer 2 10 Link rod 1 11 Nut 1 12 Plate 1 13 Bolt 3 M6 20 mm 14 Grommet 1 15 Cable guide 1 16 Grommet 1 17 Plastic tie 2 18 Battery lead 1 Tiller handle FT50C ...

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

Page 299: ... 1 M12 70 mm 8 Clip 1 9 Throttle cable 1 37 3 7 27 10 Nut 1 11 Plastic washer 2 12 Metal washer 2 13 Wave washer 1 14 Pin 1 15 Gear 1 16 Throttle shaft 1 17 Bolt 1 M6 25 mm 18 Friction piece 1 19 Wing nut 1 20 Bolt 1 M6 25 mm 21 Gasket 1 22 Cover 1 23 Bolt 4 M5 14 mm 24 Bolt 1 M6 8 mm 25 Grease nipple 1 26 Case 1 27 Bushing 1 28 Spring 1 29 Washer 1 30 Throttle grip 1 31 Screw 1 M5 25 mm Tiller ha...

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

Page 301: ...sher 1 8 Bushing 1 9 Tiller handle bracket 1 10 Nut 1 11 Bushing 1 12 Engine stop switch 1 13 Bolt 1 M6 20 mm 14 Engine start switch housing 1 15 Screw 1 M6 12 mm 16 Connector 1 Black 17 Connector 1 White 18 Engine start switch 1 19 Screw 1 M6 30 mm 20 Screw 1 M6 25 mm 21 Collar 1 22 Ball 1 23 Spring 1 24 Shift arm 1 25 Washer 1 26 Shift grip 1 27 Clip 1 28 Shift rod 1 Tiller handle FT50C ...

Page 302: ...hrottle shaft 1 into the tiller handle 2 by aligning the mark a of the tiller handle with the screw hole b of the throttle shaft 2 Install the throttle cable 3 into the gear 4 until the inner cable is engaged with the gear 3 Turn the throttle shaft 1 clockwise to wind the inner cable around the gear 4 NOTE Make sure that the throttle grip is fully closed when installing the throttle cable Lubricat...

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

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

Page 305: ...9 Bushing 1 10 Bushing 1 11 Shift rod 1 12 Grommet 1 13 Rubber seal 4 14 Bolt 4 M6 30 mm 15 Grommet 4 16 Screw 1 M6 14 mm EHD EHT models 17 Warning indicator 1 EHD EHT models 18 Grommet 1 EHD EHT models 19 Collar 4 20 Pilot water outlet 1 21 Plastic tie 2 Not reusable 22 Collar 2 23 Grommet 2 24 Bushing 2 25 Joint 1 26 Cowling lock lever 1 27 Pin 1 28 Cotter pin 2 Not reusable 29 Pin 1 30 Cotter p...

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

Page 307: ...h trailer switch 33 Trailer switch 1 Models with trailer switch 34 PTT motor lead 1 EHT ET models 35 Trim sensor coupler 1 EHT ET models 36 Screw 1 M6 24 mm EHT ET models 37 Grommet 1 38 Flushing hose 1 Models with flushing device 39 Adapter 1 Models with flushing device 40 Bolt 1 M6 20 mm Models with flushing device 41 Rubber seal 1 42 Hose 1 Bottom cowling ...

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

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

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

Page 311: ...2 24 2 4 17 3 Nut 2 42 4 2 30 4 Washer 2 5 Bolt 3 M8 30 mm 6 Upper mount 1 7 Plate 1 8 Bolt 2 M8 175 mm 9 Cap 2 10 Bolt 2 M12 160 mm 11 Grommet 2 12 Ground lead 1 13 Screw 2 14 Mount cover 2 15 Bolt 4 M8 25 mm 16 Mount housing 2 17 Spring 4 18 Washer 2 19 Rubber washer 2 20 Lower mount 2 21 Washer 2 22 Grease nipple 1 Upper case ...

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

Page 313: ...tening torques Stage N m kgf m ft lb 1 Muffler assembly 1 2 Upper case 1 3 Muffler seal 1 4 Rubber seal 1 5 Dowel pin 2 6 Grommet 1 7 Guide 1 FT50C 8 Damper 1 9 Screw 2 M5 16 mm 10 Baffle plate 1 11 Bolt 4 M8 30 mm 12 Drive shaft bushing 1 13 Circlip 1 Upper case ...

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

Page 315: ...olt 10 M6 25 mm 7 Oil pan 1 8 Gasket 1 9 Exhaust manifold 1 10 Bolt 3 M6 50 mm 11 Gasket 1 Not reusable 12 Bolt 6 M6 25 mm 13 Muffler 1 14 Gasket 1 Not reusable 15 Pipe 1 16 Rubber seal 1 Not reusable 17 Gasket 1 Not reusable 18 Relief valve housing 1 19 Bolt 2 M6 25 mm 20 Bolt 2 M6 16 mm 21 Bolt 1 M6 25 mm 22 Oil strainer 1 23 Relief valve 1 24 Spring 1 25 Cotter pin 1 Not reusable Upper case ...

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

Page 317: ... pin 2 12 Bolt 10 M6 25 mm 13 Oil pan 1 14 Gasket 1 Not reusable 15 Exhaust manifold 1 16 Bolt 1 M6 45 mm 17 Gasket 1 Not reusable 18 Gasket 1 Not reusable 19 Bolt 6 M6 25 mm 20 Muffler 1 21 Gasket 1 Not reusable 22 Pipe 1 23 Rubber seal 1 Not reusable 24 Gasket 1 Not reusable 25 Relief valve housing 1 26 Bolt 2 M6 25 mm 27 Bolt 2 M6 16 mm 28 Bolt 1 M6 25 mm 29 Oil strainer 1 30 Relief valve 1 31 ...

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

Page 319: ... pan 5 and bolts and then tighten the bolts finger tight 6 Install the exhaust manifold 6 and bolts and then tighten the bolts finger tight È FT50C 7 Tighten the exhaust manifold bolts 7 then the oil pan bolts 8 8 Install the muffler 9 into the oil pan S62Y7245 7 8 Upper case ...

Page 320: ... case Installing the upper case 1 Install the upper mount 1 and bolts 2 into the upper case and then tighten the bolts 3 2 Set the lower mounts 4 and bolts to the upper case 3 Install the end of the spring 5 into the groove of the mount housing 6 and then tighten the bolts 7 NOTE Be sure to install the ground lead 8 into the mount housing 6 ...

Page 321: ...ivel bracket 9 simulta neously 5 Install the upper mounting nut 0 and lower mounting nut A and then tighten them to the specified torques 6 Install the cover B by installing the screw Upper mounting nut 0 24 N m 2 4 kgf m 17 ft lb Lower mounting nut A 42 N m 4 2 kgf m 30 ft lb Upper case ...

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

Page 323: ...2 1 4 3 Trim sensor 1 EHT ET models 4 Trim sensor coupler 1 EHT ET models 5 Plastic tie 1 Not reusable 6 Self locking nut 2 23 2 3 17 7 Cap 2 8 Bolt 1 M6 25 mm 9 Anode 1 10 Port clamp bracket 1 11 Washer 2 12 Bushing 2 13 Through tube 1 14 Bolt 2 M6 25 mm 15 Anode 1 16 Ground lead 1 17 Grease nipple 1 18 Screw 1 M6 8 mm 19 Starboard clamp bracket 1 Clamp brackets ...

Page 324: ...trim sensor 4 Installing the clamp brackets 1 Install the trim sensor 1 onto the port clamp brackets NOTE Adjust the trim sensor after installing the power trim and tilt 2 Assemble the clamp brackets and the swivel bracket by installing the self lock ing nuts 2 then tightening them to the specified torque 3 Install the power trim and tilt or hydro tilt For installing procedures see Installing the ...

Page 325: ...on of the trim sensor 3 and then tighten the screws 2 finger tight 4 Fully tilt the outboard down 5 Measure the trim sensor resistance Repeat steps 1 5 if out of specification 6 Fully tilt the outboard up and then sup port it with the tilt stop lever WARNING After tilting up the outboard be sure to support it with the tilt stop lever Otherwise the outboard could suddenly lower if the power trim an...

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

Page 327: ...shing 1 4 O ring 2 Not reusable 5 Bushing 2 6 Swivel bracket 1 7 Bushing 1 8 Port tilt stop lever 1 9 Circlip 1 10 Steering yoke 1 11 Bushing 1 12 Bushing 1 13 Tilt stop lever joint 1 14 Spring holder 1 15 Bolt 1 M6 10 mm 16 Spring 1 17 Bushing 1 18 Pin 2 19 Bushing 1 20 Starboard tilt stop lever 1 Swivel bracket and steering arm ...

Page 328: ...lling the steering arm 1 Install the washer 1 bushing 2 O ring 3 and bushing 4 onto the steering arm 5 2 Place the swivel bracket 6 in an upright position and then install the steering arm onto the swivel bracket 3 Install the bushing 7 O ring 8 and bushing 9 onto the swivel bracket 4 Install the steering arm 5 into the steer ing yoke 0 by aligning the center a of the yoke with the center b of the...

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

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

Page 331: ...dels 3 Plastic tie 3 Not reusable 4 PTT motor lead 2 5 Washer 2 6 Bolt 2 M8 16 mm 7 Circlip 1 EHT ET models 8 Shaft 1 EHT ET models 9 Bushing 2 EHT ET models 10 Collar 1 EHT ET models 11 Tilt pin 1 12 Collar 1 13 Collar 1 14 Shaft 1 15 Bushing 2 EHD ED models 16 Circlip 2 EHD ED models 17 Shaft 1 EHD ED models 18 Collar 1 EHD ED models Power trim and tilt unit ...

Page 332: ...t stop lever Otherwise the outboard could suddenly lower if the power trim and tilt unit should lose fluid pressure 2 Loosen the plastic locking tie 2 and then pull out the PTT motor lead 3 3 Remove the tilt pin 4 4 Remove the circlip s 5 and the shaft 6 5 Loosen the bolt 7 and then remove the shaft 8 6 Remove the power trim and tilt hydro tilt 9 NOTE To remove the power trim and tilt hydro tilt l...

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

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

Page 335: ...9 0 65 3 Bolt 3 M5 20 mm 4 0 4 2 9 4 O ring 1 Not reusable 5 Joint 1 6 O ring 1 Not reusable 7 Ball 6 8 O ring 1 Not reusable 9 Free piston 1 10 Circlip 1 11 Trim cylinder base 1 12 Spring 2 13 Plate 1 14 Circlip 1 15 Tilt cylinder assembly 1 16 O ring 1 Not reusable 17 Reservoir cap 1 6 5 0 65 4 7 18 Anode 1 19 Bolt 2 M6 25 mm Tilt cylinder and trim cylinder ...

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

Page 337: ... 1 6 O ring 1 Not reusable 7 Backup ring 1 8 O ring 1 Not reusable 9 Trim cylinder end screw 1 80 8 0 58 10 O ring 1 Not reusable 11 O ring 1 Not reusable 12 Trim piston 1 13 O ring 1 Not reusable 14 Trim cylinder 1 15 O ring 1 Not reusable 16 Backup ring 1 17 Ball 1 18 Tilt piston 1 19 Ball 4 20 Absorber valve pin 4 21 Spring 4 22 Pin 4 23 Pin 2 24 Washer 1 25 Bolt 1 M12 45 mm 61 6 1 44 Trim cyli...

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

Page 339: ...e bracket 1 3 Bolt 3 M6 40 mm 7 0 7 5 1 4 Valve lock screw 1 5 Up relief spring 1 6 Valve support pin 1 7 O ring 1 Not reusable 8 Ball 1 9 Down relief spring 1 10 Valve support pin 1 11 Relief valve 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 release plug 1 18 Circlip 1 Gear pump ...

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

Page 341: ... 1 4 O ring 2 Not reusable 5 Spacer 2 6 Spring 2 7 Valve pin 2 8 Ball 2 9 Manual release spring 1 10 Ball 2 11 Gear pump cover 1 12 Spring 2 13 Shuttle piston 1 14 O ring 1 Not reusable 15 Valve seal 2 16 Circlip 2 17 Pin 2 18 Drive gear 1 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 Gear pump ...

Page 342: ...d screw 3 Drain the fluid Disassembling the trim cylinder 1 Hold the trim cylinder 1 in a vise using aluminum plates a on both sides NOTE Place the trim cylinder in the vise horizon tally 2 Loosen the trim cylinder end screw 2 and then remove it CAUTION Do not damage the check valve b when loosening the end screw Trim and tilt cylinder wrench YB 06175 2B Cylinder end screw wrench 90890 06544 Trim ...

Page 343: ...cket 6 then the down shuttle piston 7 and up shuttle piston 8 4 Remove the gear pump cover 9 then the down main valve 0 and up main valve A 5 Remove the drive gear B and driven gear C Checking the tilt cylinder and trim cylinder 1 Check the power trim and tilt hydro tilt for cracks or corrosion Replace if neces sary 2 Check the inner walls of the trim cylinder and tilt cylinder for scratches Repla...

Page 344: ... a of the trim cylinder end screw and check the valve for dirt or residue Clean if necessary 2 Check the operation of the tilt piston absorber valve and check for dirt or resi due Clean if necessary 3 Check the down main valve 1 and the up main valve 2 for dirt or residue Clean if necessary 4 Check the down relief valve 3 up relief valve 4 and shuttle pistons 5 for dirt or residue Clean if necessa...

Page 345: ... 4 Install the gear pump cover 9 5 Install the shuttle pistons 0 into the gear pump cover 9 6 Install the balls A into the gear pump cover 9 with the manual release spring B 7 Install the gear pump bracket C by installing the bolts D then tightening them to the specified torque 8 Install the down relief valve E up relief valve F and filter G 9 Install the relief valve bracket H by installing the b...

Page 346: ...rect level as shown 13 Install the joint O and power trim and tilt motor P by installing the bolts Q then tightening them to the specified torque Assembling the trim cylinder 1 Install the dust seal 1 into the tilt cylinder end screw 2 2 Install the O ring 3 to the end screw 3 Install the tilt ram 4 into the end screw Gear pump bolt L 6 5 N m 0 65 kgf m 4 7 ft lb Recommended power trim and tilt fl...

Page 347: ...ilt piston E 8 Install balls F and G absorber valve pin H spring I pins J and K and washer L into the tilt piston 9 Hold the tilt ram end in a vise using alu minum plates on both sides 10 Install the tilt piston to the tilt ram by installing the bolt then tightening it to the specified torque 11 Install the trim cylinder onto the tilt ram 12 Hold the trim cylinder M in a vise using aluminum plates...

Page 348: ... base 6 springs 7 and plate 8 into the trim cylinder with the circlip 9 4 Hold the power trim 0 and in a vise using aluminum plates a on both sides 5 Add fluid of the recommended type to the first level at the bottom of tilt cylinder 6 Install the balls A into the trim cylinder and then insert the trim cylinder into the tilt cylinder B NOTE Apply grease to the balls to prevent them from falling ou...

Page 349: ... turning it clockwise 2 Place the power trim and tilt in an upright position 3 Check the fluid level in the reservoir NOTE The fluid level should be at the brim of the filler hole 4 If necessary add sufficient fluid of the recommended type to the correct level 5 Install the reservoir cap Trim and tilt cylinder wrench YB 06175 2B Cylinder end screw wrench 90890 06544 Tilt cylinder end screw C 90 N ...

Page 350: ...vel Bleeding the power trim and tilt built in 1 Loosen the manual release plug by turn ing it counterclockwise until it cannot be turned further 2 Fully tilt the outboard up and then release it and let it lower by its own weight four to five times 3 Tighten the manual release plug by turn ing it clockwise 4 Let the fluid settle for 5 minutes 5 Push and hold the power trim and tilt switch in the up...

Page 351: ...ir 8 If necessary add sufficient fluid of the recommended type to the correct level NOTE The fluid level should be at the brim of the filler hole 9 Install the reservoir cap NOTE Repeat this procedure until the fluid remains at the correct level Recommended power trim and tilt fluid ATF Dexron II Gear pump ...

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

Page 353: ...e N m kgf m ft lb 1 Screw 3 M5 20 mm 2 Yoke 1 3 O ring 1 Not reusable 4 Armature 1 5 Bushing 1 6 Screw 2 M4 12 mm 7 Wire lead 1 8 Brush 2 1 9 Brush 1 1 10 Brush holder 1 11 Circuit breaker 1 12 Brush spring 2 13 PTT motor base 1 14 Oil seal 1 Not reusable Power trim and tilt motor ...

Page 354: ... a Replace if out of specification 4 Check the armature coil for continuity Replace if out of specifications 5 Check the circuit breaker for continuity Replace if there is no continuity 6 Measure the brush length Replace if out of specification 7 Check the base for cracks or damage Replace if necessary Commutator diameter limit a 21 mm 0 83 in Armature coil continuity Commutator segments b Continu...

Page 355: ...lead 7 3 Install the springs 8 into the motor base then the brush holder into the motor base together with the brushes and circuit breaker 4 Install the armature 9 O ring 0 and yoke A Installing the power trim and tilt 1 Fully tilt the outboard up and then sup port it with the tilt stop lever 1 WARNING After tilting up the outboard be sure to support it with the tilt stop lever Otherwise the outbo...

Page 356: ...A11 2 Install the shaft 2 and bolts 3 onto both clamp brackets together with the power trim and tilt hydro tilt 4 3 Install the tilt ram upper end into the swivel bracket with the shaft 5 and cir clip s 6 4 Install the tilt pin 7 ...

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

Page 358: ...ad to the negative battery terminal as shown 4 Check for continuity between terminals 1 and 3 Replace if there is no continu ity 5 Connect the digital circuit tester between power trim and tilt relay terminals 2 and 3 6 Connect the sky blue Sb lead to the positive battery terminal and the black B lead to the negative battery terminal as shown 7 Check for continuity between terminals 2 and 3 Replac...

Page 359: ...e if out of specification Checking the trim sensor 1 Measure the trim sensor resistance Replace if out of specification NOTE Turn the lever 1 and measure the resistance as it gradually changes Lead color Switch position Skyblue Sb Red R Lightgreen Lg Up Free Down Trim sensor resistance Pink P Black B 10 288 3 Ω at 20 C 68 F Power trim and tilt electrical system ...

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

Page 361: ...on coil 8 14 Checking the CDI unit 8 15 Checking the charge coil 8 15 Checking the pulser coil 8 16 Checking the pulser coil air gap 8 16 Checking the engine start switch 8 17 Checking the engine shut off switch 8 17 Checking the thermoswitch 8 18 Checking the oil pressure switch 8 18 Starting system 8 19 Checking the fuse 8 20 Checking the wiring harness 10 pins 8 20 Checking the neutral switch 8...

Page 362: ...y charged to 12 V Symptom Battery becomes weaker quickly Check the charging system Measure the Rectifier Regulator output peak voltage Replace the lighting coil Out of specifi cation Out of specifi cation Replace the Rectifier Regulator No No Yes Yes Measure the output peak voltage of the lighting coil Replace the battery and then check the whole voltage of all electrical equipments on your boat ...

Page 363: ...4899 A Peak voltage adaptor YU 39991 Test harness 2 pins YB 06767 Pressure vacuum tester YB 35956 A Dial gauge YU 03097 Magnetic flexible stand YU 34481 Test harness 3 pins YB 06770 Test harness 4 pins YB 06771 Ignition tester 90890 06754 For USA and Canada For worldwide Troubleshooting Special service tools ...

Page 364: ...rcuit tester 90890 03174 Peak voltage adaptor 90890 03172 Test harness 2 pins 90890 06767 Vacuum pressure pump gauge set 90890 06756 Dial gauge set 90890 01252 Magnet base 90890 06705 Test harness 3 pins 90890 06770 Test harness 4 pins 90890 06771 ...

Page 365: ...the peak voltage set the selector on the digital circuit tester to the DC voltage mode Connect the positive pin on the peak volt age adaptor to the positive terminal of the digital circuit tester Measuring the lower resistance When measuring a resistance of 10 Ω or less with the digital circuit tester the correct mea surement cannot be obtained because of the internal resistance of the tester To o...

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

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

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

Page 369: ...witch 2 Engine start switch harness 3 Engine shut off switch 4 Engine shut off switch connector 5 Neutral switch 6 Battery lead 7 Wiring harness extension 8 PTT switch lead 9 Power trim and tilt switch È Applicable for tachometer trim meter or warning buzzer model Electrical components ...

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

Page 371: ...e Start 7 Warning indicator or digital tachometer 8 CDI unit 9 Power trim and tilt switch or trailer switch 0 Rectifier Regulator A Thermoswitch B Ignition coil C Oil pressure switch È Power trim and tilt model B Black Br Brown G Green L Blue Lg Light green P Pink R Red Sb Sky blue W White B O Black orange B W Black white P B Pink black P W Pink white Y B Yellow black Y R Yellow red Electrical com...

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

Page 373: ... 5 Oil pressure warning indicator 6 Overheat warning indicator 7 Remote control box 8 Warning indicator È Remote control model É Tiller handle model B Black G Green R Red Y Yellow Gy B Green black P B Pink black P W Pink white Y B Yellow black Y R Yellow red Ignition system and Ignition control system ...

Page 374: ...É For worldwide 4 Crank the engine and observe the spark through the discharge window of the spark gap tester Check the ignition coil if out of specification È For USA and Canada É For worldwide WARNING Do not touch any of the connections of the spark gap tester leads Do not let sparks leak out of the removed spark plug caps Keep flammable gas or liquids away since this test can produce sparks Dyn...

Page 375: ...hecking the ignition coil 1 Remove the spark plug caps from the high tension cords by turning the caps counterclockwise 2 Measure the ignition coil resistance Replace if out of specification Spark plug cap resistance 3 75 6 25 kΩ Ignition coil resistance Primary coil Orange O Black B 0 08 0 11 Ω at 20 C 68 F Secondary coil High tension cord High tension cord 3 5 4 7 kΩ at 20 C 68 F Ignition system...

Page 376: ...he selector on the digital circuit tester to the DC voltage mode Checking the charge coil 1 Measure the charge coil output peak volt age Replace the stator coil if below specification WARNING When checking the peak voltage do not touch any of the connections of the digital tester leads NOTE Use the peak voltage adaptor with the digi tal circuit tester When measuring the peak voltage set the select...

Page 377: ...Adjust if out of specification Digital multimeter YU 34899 A Digital circuit tester 90890 03174 Peak voltage adaptor YU 39991 90890 03172 Test harness 2 pins YB 06767 90890 06767 Charge coil output peak voltage Brown Br Blue L r min Unloaded Loaded Cranking 1 500 3 500 DC V 144 137 169 129 Charge coil resistance use as reference Brown Br Blue L 272 408 Ω at 20 C 68 F Digital multimeter YU 34899 A ...

Page 378: ... magnet nut to the specified torques Checking the engine start switch 1 Check the engine start switch for continu ity Replace if there is no continuity Checking the engine shut off switch 1 Check the engine shut off switch for con tinuity Replace if there is no continuity Pulser coil screw 4 N m 0 4 kgf m 2 9 ft lb Flywheel magnet nut 160 N m 16 kgf m 116 ft lb Lead color Switch position White W B...

Page 379: ...g the oil pressure switch 1 Connect the special service tool to the oil pressure switch 2 Slowly operate the special service tool 3 Check the switch for continuity at the specified pressure Replace if there is no continuity Thermoswitch continuity temperature Pink P Black B e 76 84 C 164 183 F f 63 77 C 145 170 F Pressure vacuum tester YB 35956 A Vacuum pressure pump gauge set 90890 06756 Specifie...

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

Page 381: ... no continuity Checking the starter relay 1 Connect the digital circuit tester leads to the starter relay terminals 2 Connect the brown Br lead to the posi tive battery terminal 3 Connect the black B lead to the nega tive battery terminal 4 Check for continuity between the starter relay terminals Replace if there is no continuity 5 Check that there is no continuity between the starter relay termin...

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

Page 383: ...er motor pinion 1 5 Upper bracket 1 6 O ring 1 Not reusable 7 Washer 1 1 8 Shim As required 9 Washer 2 1 10 Armature 1 11 Stator 1 12 O ring 1 Not reusable 13 Brush holder assembly 1 14 Brush set 1 15 O ring 1 Not reusable 16 Washer 1 17 Spring washer 1 18 Nut 1 9 0 9 6 5 19 Lower bracket 1 20 Screw 2 M4 12 mm 21 Bolt 2 M5 125 mm Starter motor ...

Page 384: ...t operates smoothly and turn it counterclock wise to check that it locks Checking the armature 1 Check the armature axial free play Replace the washers and shim s 3 if out of specification 2 Check the commutator for dirt Clean with 600 grid sandpaper and com pressed air if necessary 3 Measure the commutator diameter Replace the armature if out of specifica tion Dial gauge 1 YU 03097 Dial gauge set...

Page 385: ...nuity Replace if out of specifications Checking the starter motor operation 1 Check the operation of the starter motor after installing it to the power unit Commutator undercut limit 0 2 mm 0 01 in Armature continuity Commutator segments b Continuity Segment Armature core c No continuity Segment Armature shaft d No continuity Brush length limit a 12 0 mm 0 47 in Brush assembly continuity Brush 1 B...

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

Page 387: ...ut peak voltage of the lighting coil is above specification WARNING When checking the peak voltage do not touch any of the connections of the digital tester leads NOTE Use the peak voltage adaptor with the digi tal circuit tester When measuring the peak voltage set the selector on the digital circuit tester to the DC voltage mode Digital multimeter YU 34899 A Digital circuit tester 90890 03174 Pea...

Page 388: ...3A11 NOTE After starting the engine disconnect the out put lead red lead of the Rectifier Regulator when measuring the output peak voltage Rectifier Regulator output peak voltage Red R Black B r min Unloaded 1 500 3 500 DC V 18 9 19 5 ...

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

Page 390: ... connecting rod bolt 5 59 Checking the connecting rod small end inside diameter 5 59 Checking the cooling water passage 3 13 Checking the crankshaft 5 59 Checking the crankshaft main journal oil clearance 5 60 Checking the crankshaft pin oil clearance 5 61 Checking the cylinder bore 5 56 Checking the cylinder head 5 46 Checking the diaphragm and valves 4 10 Checking the drive shaft 6 25 6 63 Check...

Page 391: ...throttle cable operation 3 13 Checking the tilt cylinder and trim cylinder 7 64 Checking the tilt system 1 35 Checking the timing belt 3 7 Checking the timing belt and sprockets 5 32 Checking the top cowling 3 4 Checking the trim sensor 7 80 Checking the valve clearance 3 10 Checking the valve guides 5 41 Checking the valve seat 5 42 Checking the valve springs 5 40 Checking the valves 5 40 Checkin...

Page 392: ...al system 7 78 Power trim and tilt motor 7 73 Power trim and tilt unit 3 16 7 51 Power unit 2 5 2 12 3 5 5 13 Predelivery checks 1 33 Propeller selection 1 32 Propeller shaft housing T50 FT50B FT50C 6 51 Propeller size 1 32 R Refacing the valve seat 5 43 Removing and installing the oil filter 5 55 Removing the clamp brackets 7 45 Removing the cylinder head 5 39 Removing the drive shaft 6 23 6 61 R...

Page 393: ... Test run 1 35 Tightening torques 2 29 Tiller handle F50 F50A T50 FT50B 7 5 Tiller handle FT50C 7 17 Tiller handle model F50 F50A T50 FT50B 8 8 Tiller handle model FT50C 8 9 Tilt cylinder and trim cylinder 7 55 Timing belt and sprockets 5 29 Top cowling 3 4 Top view 8 7 Trim cylinder 7 57 Troubleshooting 5 1 7 1 8 1 U Upper case 7 31 V Ventilation 1 3 W Water pump and propeller shaft housing F50 F...

Page 394: ...Thermoswitch B Oil pressure switch C Charge coil D Pulser coil E Lighting coil F Rectifier Regulator G Ignition coil H Spark plug I Hour meter È EHD É Option Color code B Black Br Brown G Green L Blue O Orange P Pink R Red W White Y Yellow B O Black orange B W Black white B Y Black yellow G W Green white Gy B Gray black P B Pink black P W Pink white W B White black W R White red Y B Yellow black Y...

Page 395: ...CDI unit D Thermoswitch E Charge coil F Lighting coil G Pulser coil H Rectifier Regulator I Oil pressure switch J Trailer switch K Ignition coil L Spark plug È With trailer switch model 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 B O Black orange B W Black white B Y Black yellow G W Green white Gy B Gray black P B Pink black P W Pink...

Page 396: ...tifier Regulator D Thermoswitch E Oil pressure switch F Engine start switch G Engine shut off switch H Power trim and tilt switch I Trailer switch J Trim sensor K Ignition coil L Spark plug Color code B Black Br Brown G Green L Blue Lg Light green O Orange P Pink R Red Sb Sky blue W White Y Yellow B O Black orange B W Black white B Y Black yellow G R Green red G W Green white Gy B Gray black P B P...

Page 397: ... Pulser coil C Rectifier Regulator D Thermoswitch E Oil pressure switch F Trailer switch G Ignition coil H Spark plug I Hour meter È Option Color code B Black Br Brown G Green Gr Gray L Blue Lg Light green O Orange P Pink R Red Sb Sky blue W White Y Yellow B O Black orange B W Black white B Y Black yellow G W Green white Gy B Gray black P B Pink black P W Pink white W B White black W R White red Y...

Page 398: ......

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

Page 400: ... Y R P W P B Y B Y B P B P W Y R Y R P W B Br L B B W B B P W Y R B O B W Y B P B B O P W Y R B W P B W Y B L L B B B L B B B B R R R R Br Br Br Br R W Y G P Br P R W B Br Y B P B Y R P W B G G Y G Y 9 W W B B R Br P 2 B R Br P W G B Y O P A B B L Br G L R B C E G 2 3 1 4 H B B B 1 6 4 5 7 8 B Br G L O P R W Y B O B W B Y G W Gy B P B P W W B W R Y B Y R F D Gy B Gy B Gy B 3 L B O B B B B B O S62Y...

Page 401: ...O B W Y B P B B O P W Y R B W P B W Y B L L B B B L B B B L G R B B R R R R Br Br Br Br Sb Lg R W Sb G Lg P Br P R W B Br Y B P B Y R P W Lg Sb Lg R Sb Lg Sb Lg Sb Sb Sb Lg R R R R Lg Sb R Sb R Lg Sb R Lg B B G G J B Lg R Sb W W B B R Br P 3 B R Br Lg Sb P W G B Sb Sb Lg Lg P O D I B G L R B E F K 2 3 1 4 L Lg R Sb B B B 2 1 4 8 6 7 9 A H G Gy B Gy B 5 C B Br G L Lg O P R Sb W Y B O B W B Y G W Gy...

Page 402: ... P B W Y B L L B B B L B B B L G R B B R R R R Br Br Br Br Sb Lg R W Sb G P Br Lg Sb Lg R Sb Lg Sb Lg Sb Sb Sb Lg R R R R Lg Sb R Sb R Lg Sb R Lg B B I H Lg R Sb W W B B R Br Y W W W B B B O W P B B O W R R R Sb Lg G P Br Br Y Y Y F B R Br Lg Sb P W G B Sb Sb Lg Lg O P D E B G L R B A K 2 3 1 4 L Lg R Sb B B B 2 1 3 6 4 7 5 8 C B Gy B Gy B Gy B G 9 B Br G L Lg O P R Sb W Y B O B W B Y G R G W Gy B...

Page 403: ... B W B B P W Y R B O B W Y B P B B O P W Y R B W P B W Y B L L B B B L B B B L G R B B R R R R Br Br Sb Lg R W Sb G Lg P Br Sb R Lg B B B R Br Lg Sb P W G B Sb Sb Lg Lg O P D E B G L R B A G 2 3 1 4 H B B B 2 1 3 4 8 5 7 B Br G Gy L Lg O P R Sb W Y B O B W B Y G W Gy B P B P W W B W R Y B Y R C B Gy B Gy B 9 O B B B B 6 P B P B Gy Sb R Lg Lg R Sb R Sb Lg Lg Sb R F B P Gy O S62YWD04R Y G Y G Y G Y ...

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