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HOW TO USE THIS MANUAL

1. Tightening sequence Exhaust cover 50 60 70 hp 1st step 3 Nm 0 3 m kg 2 2 ft Ib 2nd step 8 Nm 0 8 m kg 5 8 ft Ib Exhaust cover 75 80 90 hp 1st step 9 Nm 0 9 m kg 6 5 ft Ib 2nd step 18 Nm 1 8 m kg 13 ft Ib 3 Install the thermostat gasket and cover ASSEMBLY AND ADJUSTMENT CE G75500 0 DRAINAGE HOSE 1 Fit two clips around the drainage hose 2 Connect one end of the hose to the delivery side of the check valve and the other end to the joint on the intake side and lock with the clips G76000 0 INTAKE MANIFOLD 1 Install the reed valve assembly and the gasket reed valve plate to the intake manifold 2 Install the manifold assembly to the crankcase and tighten the bolts to the specified torque in sequence and in two Intake manifold 50 60 70 hp 1st step 4 Nm 0 4 m kg 2 9 ft Ib 2nd step 8 Nm 0 8 m kg 5 8 ft Ib Intake manifold 75 80 90 hp 1st step 4 Nm 0 4 m kg 2 9 ft Ib 2nd step 12 Nm 1 2 m kg 8 7 ft Ib G77000 0 FUEL SYSTEM AND ELECTRICAL SYSTEM 1 Install the fuel system Refer to
2. 21 21 21 N gt O1 O1 Ring nut Pinion nut Lower case mounting Propeller Tiller handle mounting Handle bracket mounting No A TIGHTENING TORQUE SPEC GENERAL TORQUE SPECIFICATIONS CES Tightening torque Parts to be tightened Remarks Nm Im kgl fte 16 POWER TRIM AND TILT 80 8 0 58 90 9 0 65 70 7 0 50 Tilt cylinder end screw Trim cylinder end screw 0 3 2 2 0 7 5 1 1 0 7 2 1 5 11 Valve spring mounting 0 4 2 9 1 3 9 4 0 4 2 9 0 5 3 6 0 4 2 9 Manual valve 0 3 2 2 1 0 7 2 1 1 8 0 Fluid level plug Lock nut Valve lock screw Gear pump mounting Main valve GENERAL TORQUE G It SPECIFICATIONS This chart specifies the torque for tighten ing standard fastners with standard fast ners with standard clean dry ISO threads at room temperature Torque specifications for special components or assemblies are given in applicable sections of this manual To avoid causing warpage tighten multifas tener assemblies in crisscross fashion and in progressive stages a until the specified torque is reached INSP ADJ Q _____ gt CHAPTER 3 PERIODIC INSPECTION AND ADJUSTMENT PERIODIC SERVICE cine
3. Cylinder head bolts engine mounting bolts and flywheel nut Fuel filter Fuel tank and fuel line Gear oil Idle speed Ignition timing Oil injection pump Oil level warning system Oil pump link Power trim and tilt system Propeller Spark plug 3 1 D31000 0 ANODE Inspect the anode If it is worn out replace it with a new one If scaling of the surface is evident remove the anode clean it with a wire brush and remove all trace of oil or grease After cleaning polish the contact surfaces of the anode mount and re install CAUTION Never paint the anode To ensure good electrical contact keep the anode contact surface clean of oil or grease INSP ADJ PERIODIC SERVICE 3 2 D31305 0 BATTERY WARNING Battery electrolyte is dangerous it contains sulfuric acid which is poisonous and highly caustic Always follow these preventive measures e Avoid bodily contact with electrolyte as it can cause severe burns or permanent eye injury e Wear protective eye gear when handling or working near batteries Antidote EXTERNAL e SKIN Wash with water eEYES Flush with water for 15 minutes and get immediate medical attention Antidote INTERNAL e Drink large quantities of water or milk fol lowed with milk of magnesia beaten egg or vegetable oil Get immediate medical attention Batteries gen
4. ee 7 6 BRACKET Short transom 7 7 BRACKET Long iiie nni ennt acus acne assa Re end 7 8 REMOV EE 7 9 DISASSEMBEY Eeer 7 9 INSPEGTION E 7 9 2646 1021 00 02 sm ER 7 9 7 9 TRIM SENSOR an na a a See Seege NEE 7 9 ASSEMBLY EE 7 10 HYDRAULIC TILT 2 2 2 7 11 INSPECTION oec etre estt eet ee eee hec ee ev 7 11 POWER TRIM AND TILT 7 11 7 11 EXPLODED DIAGRAM Short transom 6 308 7 12 DISASSEMBLY EE 7 14 INSPECTION 5 45 ten ne extr E ee a E E ne redd 7 16 TILT ROD AND 2 7 16 ASSEMBLY roten tt ve eder tee e NAE E A a 7 16 EXPLODED DIAGRAM Long transom 6H1 15 62F 02 7 20 EE eege eege ege eege 7 22 INSPECTION tt a ang Coco peo ete 7 24 TILT ROD AND 2 44 7 24 55 7 24 FILLING WITH HYDRAULIC FLUID AND AIR BLEEDING 7 28 HYDRAULIC FLUID PRESSURE T
5. 70 75 80 hp 50 60 90 hp NOTE 72 When measuring the full advance ignition timing keep the specified engine speed Full advance side engine speed 50 60 75 80 90 ph 5 000 500 rpm 70 hp 5 500 500 rpm 50 60 70 GZ 5 1 Q Full advance side ignition timing 50 60 90 hp 22 1 BTDC 70 75 80 hp 20 1 BTDC PICK UP TIMING ADJUSTMENT 50 60 70 75 80 90 hp 3 Engine idle speed should be adjusted erly before adjusting the pick up timing 1 Turn the magneto control lever to the full retard position 2 Bring the throttle cam to lightly contact the throttle lever roller The throttle valve should not open Adjust the accelerator link length and connect magneto control lever to the accelerator cam 3 9 INSP ADJ PERIODIC SERVICE D34000 0 OIL INJECTION PUMP OPERATIONAL TEST 1 Start the engine and set the idling speed at 1 500 rpm by adjusting the throttle stop lever CAUTION Use only oil mixed fuel 50 1 as malfunc tion or engine seizure may otherwise result 2 Remove the oil pump link rod and fix the oil pump lever in the full throttle position 3 Measure the oil discharge from each port for three minutes using a measur ing cylinder graduated in steps of at least 0 1 cc to confirm that the specified amount is discharged Specified discharge 3 min 1 cylinder 50 hp 1 90 0 50 cm 0 064 0 017
6. The needle bearing should be installed with the mark facing the flange side of attach ment Driver rod f YB 6071 Needle bearing depth stop Needle bearing attachment Driver rod 90890 06602 Bearing depth plate 90890 06603 Needle bearing attachment 50 hp 90890 06614 60 90 hp 90890 06611 Depth 50 hp 198 3 198 8 mm 7 81 7 83 in 60 90 hp 187 6 188 6 mm 7 39 7 43 in For USA and Canada Except for USA and Canada gt 2 Align the drive shaft sleeve locating rib with the recess in the gear case and place the drive shaft sleeve into the gear case 3 Place the pinion gear shim pack 1 in position and install the taper roller bearing outer race on the shim pack YS Drive rod f YB 6071 90890 06606 Bearing outer race attachment 50 hp 90890 06627 60 90 hp YB 6156 90890 06626 Loun e ASSEMBLY AND ADJUSTMENT 4 Place the forward gear shim pack 1 position and install the forward gear outer race on the shim pack 2 Driver rod j YB 6071 90890 06605 Bearing outer race attachment 50 hp 90890 06622 60 90 hp 6276 90890 06621 7 5 Install the bearing inner race to the for ward gear then place the forward gear complete onto the outer race 222 Bearing inner race attachment 50 90890 06640 60 90 hp 90890 06662 6 Place the drive shaft in the gear case and insert i
7. co indicates that the pointer deflects once and returns to oo Discontinuity 8 26 ELEC ELECTRICAL ANALYSIS CE 75 80 90 hp Marking 6H1 15 Unit Bi Oil level sensor resistance Float SW 1 ON Float SW 2 ON 5 8 8 8 mm 42 3 45 3 mm 0 23 0 35 in 1 67 1 78 in Tester Tester Black Green Black Green Tester Tester Red Eo dis Black Black 9 MUN 0 Green 640 Red Oil level sensor resistance Float SW 1 SW 2 both OFF Tester Green Green 20 Tester Black Green Green Red oo indicates that the pointer deflects once and returns to co Discontinuity 3 Assemble as shown in the diagram Strainer cover Float Magnet 3 Plate 4 Gasket NOTE ePlace the float with the magnet side upward Assemble the plate which has a hole at the bottom 8 27 ELEC ELECTRICAL ANALYSIS C60ER 60FED 8 28 M57602 0 OIL LEVEL WARNING LAMP L E D 50GETO Test the Light Emitting Diode L E D using a 1 5 V dry cell battery If no light is emitted replace the warning lamp Battery voltage ei 1 5V CAUTION Do not use a 12 V battery or a larger capac ity type as this may damage the L E D We recommend using a pen light battery M58300 0 WIRING HARNESS 1 Check the continuity between the cou
8. SPEC oo GENERAL SPECIFICATION Model 75hp 80hp 90hp C75TR 75CET 1 75TR 75CETO 75 75 3 80AETO 90AEHD 90AED C90TR 90AET 90TR 90AETO 4 B90TR 90AETO 4 Approved model No 6HO 6H1 Overall Length Overall Width Overall Height Boat transom height O M transom height Weight Al OO Sr Weight SUS kg Ib kg Ib kg Ib 726 28 6 12 1 343 52 9 3 374 14 7 12 398 15 7 3 726 28 6 374 14 7 726 28 6 234 1 343 52 9 374 14 7 234 398 15 7 1 540 60 6 5 635 25 0 5 647 25 5 5 119 5 263 120 5 266 2 124 5 275 3 120 5 266 123 5 272 115 5 255 111 5 246 2 119 5 263 3 120 5 266 123 5 272 5 122 5 270 125 5 277 113 5 250 2 121 5 268 3 122 5 270 5 125 5 277 Full throttle speed range Output ISO Maximum fuel consumption r min kW hp r min L US gal Imp gal h r min 4 500 5 500 55 2 75 5 000 58 8 80 5 000 32 8 45 7 04 5 500 66 2 90 5 000 34 5 9 11 7 59 5 500 Total Displacement Bore x Stroke Compression ratio Compression pressure Carburetor number Intake system cm cu in mm in kPa kg cm 2 stroke L 3 1 141 69 6 82 0 x 72 0 3 23 x 2 83 5 90 2 2 922 9 22 3 Reed valve SPEC oo
9. dence necs EE 5 16 OIL SEAL HOUSING ass erue EE 5 17 CRANK CYLINDER ASSEMBLY 50 60 70 5 17 CRANK CYLINDER ASSEMBLY 75 80 90 5 18 CYLINDER HEAD AND EXHAUST COVER ses 5 19 DRAINAGE e 5 20 INTAKE MANIFOLD 22 aan aan eta Eege 5 20 FUEL SYSTEM AND ELECTRICAL SYSTEM serres 5 20 INSTALLATION rtr ann ad ada aana a una i sex 5 21 EXPLODED DIAGRAM G20000 0 EXPLODED DIAGRAM Cylinder head cover Head cover gasket Cylinder head Cylinder head gasket 5 Thermostat 6 Thermostat cover Exhaust cover gasket 50 60 70 hp M10 1st 20 Nm 2 0 m kg 14 ft Ib 2nd 40 Nm 4 0 kg 29 ft Ib 1st 4 Nm 0 4 m kg 2 9 ft Ib 2nd 8 Nm 0 8 m kg 5 8 ft Ib M8 1st 10 Nm 1 0 m kg 7 2 ft 2nd 20 Nm 2 0 m kg 14 ft Exhaust inner cover 9 Exhaust outer cover Piston pin clip Piston pin 42 Drive gear 43 Bearing Oil seal 5 1 5 O ring Oil seal housing Intake manifold Valve seat packing Reed valve plate Reed valve assembly 160 Nm 16 kg 115 ft Ib 1st 15 Nm 1 5 m kg 11 ft Ib 2nd 32 Nm 3 2 m kg 23 ft Ib 1st 3 Nm 0 3 m kg 2 2 ft Ib 2nd 8 Nm 0 8 m kg 5 8 ft Ib EXPLODED DIAGRAM CES D Thermostat cover Exhaust outer cover Intake manifold Thermostat p Pist
10. 2 O LH3309 H LO9d YOUMS pue 02 114 yams 1811211 6 013909 due 8 114 pue J9Mog 2 O LH3309 H LO9d UOJIMS 6 1911815 6 qo voz esn4 114 JOJOUW pue J9Mog 6 114 10sues 09 0 10130 1911815 uonoefut 110 Josues 349 IO 8 1090 H3092 104 14 BAIA EUJ1941040129 3 1109 5 Jasingd 0 Josues uonisod 15 101 YyoUMs D 8 7 H1099 104 1 x H3092 104 H1092 104 Mola SARA 6777 qs pe ess jug ee 2 EID O ENG 1 DIER D umoig S 81092 104 pue Gp 81092 104 Aejas pue uoniu 19148616 0 Hun 0 voz esn4 0 Moneg JOJOW 1914615 9 4 D Dunufr ioo 109 7 Josues uonisod xueJ 1 YyoUMs ouuoeu D Sl m d 6 jap ELEC WIRING DIAGRAM C60ER C60TR 8 8 ELEC
11. 3 1 MAINTENANCE SCHEDULE ecuaciones cune 3 1 ANODE gaen 3 1 BATTERY EE 3 2 3 3 CARBURETOR LINK ADJUSTMENT es 3 3 CYLINDER HEAD BOLTS ENGINE MOUNTING BOLTS AND FLYWHEEL NU E 3 4 POE PIETER EE 3 4 FUEL TANK AND FUEL Neger eege 3 4 GEAR Olsen esa 3 5 IBD SSP ED Ee EE E 3 5 IGNITION TIMING ADJUSTMENT eene enne 3 6 TIMING PLATE POSITION ADJUSTMENT 3 6 THROTTLE SENSOR CONTROL LINK ADJUSTMENT 3 7 IGNITION TIMING ADJUSTMENT eene 3 8 PICK UP TIMING ADJUSTMENT een 3 9 OIL INJECTION PUMP roce ird be nean aga gg anaa 3 10 OPERATIONAL TEST rada aa eege tin fe culto es 3 10 CHECKING THE OIL LEVEL WARNING SYSTEM 3 11 OIL PUMP LINK ADIUS deret toon nter tierra eet 3 12 POWER TRIM AND TILT FLUID PTT model 3 12 3 13 Set BEE 3 13 GREASIING RENE 3 14 SE PERIODIC SERVICE D30000 1 PERIODIC SERVICE MAINTENANCE SCHEDULE The following chart may be taken as a helpful guide to the intervals between maintenance procedures Intervals Item Initial Every 10 hours Break in 50 hours 3 months 100 hours 6 months 200 hours 1 year Anode Battery every month Carburetor Carburetor link
12. tilt switch Throttle cable B Black K Shift cable Br Brown G Green Tels Except for G Y Green Yellow 8 3 ELEC ELECTRICAL WIRING 50 60 70 hp B Black Pulser coil coupler Br Brown Trim sensor coupler Green 9 Oil level sensor coupler 2 Gy Gray Wire harness coupler 7P 3 10P L Blue 5 Ground lead from rectifier regulator Lg Light green Ground lead from starter relay Orange Ground lead from wire harness Power trim and tilt relay coupler R Bed Charge coil coupler Sb Sky blue Crank position sensor coupler W White Y Yellow A To CDI unit B To power trim and tilt motor 1 For PTT model C To trim sensor 2 For oil injection model D To oil level sensor 1 For C60ER 60FED E To meter 4 Except for C60ER 60FED 2 Except for C60ER C60TR 6 For C60ER C60TR E To electrothermal valve To fuel enrichment valve 6 D H To trailer switch coupler 8 4 ELEC ELECTRICAL WIRING 75 80 90 hp B Black D Trailer switch coupler L Blue Lg Light green To electrothermal 2 R Bed B To battery Sb Sky blue C To starter relay D To lighting coil E To wire harness F To meter To trim sensor H To power trim and tilt motor 1 For PTT model 2 Except for 75 8 5 ELEC ELECTRICAL WIRING 75 80 90 hp
13. 5 6 CY LINDERSHEAD 2 ri ittis 5 6 CEEANING inre tree xe Bek a ee Sec eee 5 6 INSPECTION Eeer eg 5 6 CYLEINDER BLEQOGCIK inedita eege ege 5 7 5 7 5 he d ease dE Zeen Ne 5 7 PISTON ce eo onere a ers 5 8 5 8 INSPECTION ea eoe baeo Me ede nus 5 8 PISTON RING aaa ee RETE es 5 9 INSPECTION T 5 9 PISTON PIN AND SMALL END BEARING nenne 5 10 CLEANING e ie te eee 5 10 INSPECTION m 5 10 CRANIKSEALET EE 5 10 INSPECTION cS 5 10 REED VALVES 5 11 INSPECTION 5 11 THERMOSTAT yerba az eredi 5 12 CLEANING sinere aaa 5 12 INSPECTION nnnm nnnm nnn nnn nnn naar narrar E nnn 5 12 CRANK MAIN BEARING kk 5 12 CUEANING eti ei ete SR 5 12 INSPEGCTIQD 3 5 it neci oco be rei totos estre estia does 5 12 DRIVE GEAR OIL INJECTION PUMP DRIVE eese 5 13 lejanos 5 13 DRIVEN GEAR OIL INJECTION PUMP DRIVE 5 13 INSPECTION enee Se Seed eher 5 13 8 0 0 0 00 0c ASSEMBLY AND ADJUSTMENT nn 5 14 BEARING OIL SEAL AND O RING 5 14 PISTON AND PISTON RING 5 14 SMALL END BEARINGS AND PISTON 5 15 CONNECTING ROD BIG END BEARING ASSEMBLY 75 80 90 HD cs
14. BRKT L d BRACKET UNIT 75 80 90 Exhaust guide Exhaust manifold Muffler Upper case 5 Apron Seal Bottom cowling A 21 Nm 2 1 m kg 15 ft Ib DES 5 4 BRKT BRACKET UNIT K 15300 0 BOTTOM COWLING Power trim and tilt motor lead PTT model Trim sender lead PTT model Grommet Flushing kit BOOTR 90AETO 5 Clamp model Bottom cowling fitting plate Shift actuator 3 Nm 0 3 m kg 2 2 ft Ib 7 4 BRKT L d BRACKET UNIT 15600 0 BRACKET UNIT Upper mount rubber cover Lower mount rubber nut Cap Anode PTT model Upper mount rubber nut Read wire PTT model 4 Screw 5 Low mount rubber cover Ground lead 7 Bolt Mount rubber housing 7 5 BRKT L d BRACKET UNIT BRACKET UNIT Manual tilt model Tilt unit Tilt lever Clamp bracket spacer Lower shock m tp 5 Bushi BRKT L d BRACKET UNIT K15900 0 BRACKET Short transom Circlip Lower mounting housing 3 Steering pivot shaft Bushing 5 O ring 8 Bushing Grease nipple Ground lead 9 Tilt rod manual tilt model Clamp bracket nut Bolt 6 bolts 42 Clamp bracket bolt 3 Washer Bushing 49 Clamp bracket Trim sensor PTT model Circlip Pin 7 7 Bushing Power trim and tilt unit PTT model Cotter pi
15. N 7 gt oo gt 2 Lines indicate straight measurement 0 1 0 004 Cylinder Bore size Taper limit Out of round limit Piston Piston to cylinder clearance lt Limit gt Piston size D Measuring point H Oversize Offset direction 72 00 72 02 2 834 2 835 82 00 82 02 3 228 3 229 0 08 0 003 0 05 0 002 0 050 0 055 0 0020 0 0022 0 105 0 0041 71 945 71 970 2 8325 2 8335 0 060 0 065 0 0024 0 0026 0 115 0 0045 81 935 81 960 3 2258 3 2268 10 0 4 72 25 2 844 72 50 2 854 0 5 0 0197 Exhaust side 82 25 3 238 82 50 3 248 1 0 0 039 Exhaust side Piston ring Sectional sketch Top ring amp 2nd ring T Type T End gap installed Top ring amp 2nd ring Side clearance Top ring amp 2nd ring Except for USA Keystone 2 0 0 08 3 0 0 12 0 3 0 5 0 012 0 020 0 03 0 07 0 0012 0 0028 2 5 3 2 0 13 0 4 0 6 0 016 0 024 0 03 0 06 0 0012 0 0024 SPEC MAINTENANCE SPECIFICATIONS Item Model 50 hp 60hp 70 hp 75 hp Crankshaft Crank width A Crank width B Crank width C Maximum deflection Connecting rod side clearance E Connecting rod maxi mum axial play F 57 90 57 95 2 280 2 281 151 7 152 0 5 972 5 984 245 5 246 1 9 67 9 69 284
16. 1 F is the deviation of the lower case dimension from standard It is stamped on the trim tab mounting surface of the lower case in 0 01 mm units If the F mark is missing or unreadable assume an F mark of 0 and check the backlash when the unit is assembled 2 If the F value is negative then sub tract the F value from the measurement Example If F mark is 5 then M 1 69 5 100 mm 1 69 0 05 mm 1 74mm If F mark is 3 then M 1 69 3 100 mm 1 69 0 03 mm 1 66 mm 2 Assemble the shimming gauge with the forward bearing and original shim s as shown in the illustration Tighten the nut four turns after contacting the spring NOTE 2 If the original shim s is unavailable start with a 0 50 mm shim Base plate YB 34446 1 Compression spring YB 34446 3 Press plate YB 34446 5 Gauge pin YB 34446 7 lt Loun e SHIM SELECTION FOR USA AND CANADA CED 3 Using a thickness gauge at the specified measurement M established above check the fit between the shimming gauge and upper disc of the tool Thickness gauge YU 26900 8 YU 26900 9 4 If the thickness gauge at the M specifi cation will not fit then remove or add the shim s until the thickness gauge just fits between the tool surfaces Available shim thicknesses 0 10 0 12 0 15 0 18 0 30 0 40 and 0 50 mm Reverse gear shim NOTE Find the reverse g
17. 28 00 1 100 0 61 Available shim thickness 0 10 0 12 0 15 0 18 0 30 0 40 and 0 50 mm NOTE eUse a minimum number of shims to obtain the thickness equal or nearly equal to the calculation e install the shims with the thicker one the outer side 163015 0 MEASURING THE BACKLASH NOTE 000124 eDo not install the water pump compo nents when measuring the backlash e Both forward and reverse gear backlashes should be measured elf both the forward and reverse gear back lashes are larger than specified the pinion may be too high elf both forward and reverse gear back lashes are smaller than specified the pin ion may be too low elf either of these conditions exists then check the pinion shim selection 1 Place the shift rod in neutral 2 Install a dial gauge on the gear case 3 Install a backlash indicator gauge spe cial service tool on the drive shaft 50 60 70 hp 18 mm in diameter 75 80 90 hp 20 mm in diameter and make the dial gauge stem contact the mark on the indicator gauge 2 Dial gauge YU 3097 90890 01252 Magnet base YU 34481 90890 06705 Backlash indicator YB 6265 90890 06706 Backlash adjusting plate YB 7003 Loun e SHIM SELECTION T RN En Forward gear 1 Install a bearing housing puller special service tool in the bearing housing so that it engages with the center bolt of the propeller shaft NOT
18. 40 2 mm 100 mm 60 90 hp M 31 5 mm P 100 mm 5 P is the deviation of the lower case dimension from standard It is stamped on the trim tab mounting surface of the lower case in 0 01 mm units If the P mark is missing or unreadable assume a P mark of 0 and check the backlash when the unit is assembled Example If M is 32 10 mm P is 2 then 32 10 31 5 2 100 0 58 Available shim thickness 0 10 0 12 0 15 0 18 0 30 0 40 and 0 50 mm 6 22 SHIM SELECTION Loun e EXCEPT FOR USA AND CANADA CE eUse a minimum number of shims to obtain the thickness equal or nearly equal to the calculation Install the shims with the thicker one the outer side Forward gear shim 1 Find forward gear shim thickness T1 by selecting shims until the specified measurement M with the special tool is obtained 90890 06701 2 Using a digital caliper at the specified measurement M established above measure the bearing height 90890 06704 Shim thickness T1 50 hp 22 70 mm F 100 mm M 60 90 hp 24 50 mm F 100 mm M Shimming plate 90890 06701 Digital caliper 90890 06704 3 F is the deviation of the lower case dimension from standard It is stamped on the trim tab mounting surface of the lower case in 0 01 mm units If the F mark is missing or unreadable assume an F mark of 0 and check the backlash when th
19. 75 80 90 hp 3 pins tester harness YB 06443 90890 06757 2 Connect the tester to the measure ment terminal 3 Setthe tester dial to specification 4 Crank or start the engine 5 Measure the charge coil output 6 If the output is below specification replace the charge coil 7 Ifthe output is beyond specification measure pulser coil output ELEC ELECTRICAL ANALYSIS CE 50 60 70 hp Charge coil Output peak voltage minimum Charge coil Output peak voltage minimum R Br r min Open Connect V 55 60 170 150 Charge coil Output peak voltage minimum R L Connect 100 3 Pulser coil output 1 Disconnect the pulse coil couple Connect the 2 pins test harness 2 pins test harness YB 38831 90890 06767 2 Connect the tester to the measure ment terminal 3 Setthe tester dial to specification 4 Crank or start the engine 5 Measure the pulser coil output 6 Ifthe output is beyond specification replace CDI unit 7 If the output is below specification replace pulser coil ELEC ELECTRICAL ANALYSIS CE 50 60 70 hp Pulser coil Output peak voltage minimum W R W B Pulser coil Output peak voltage minimum W R W B Cranking r min Open Connect 4 Lighting coil output 1 Connect the tester to the lighting coil as shown 2 Setthe tester dial to specification 3 Start the engine 4 Measure the lighting coil out
20. Back up ring End screw tilt cylinder 90 Nm 9 0 m 65 ft Ib Cylinder end screw wrench 22 y YB 6175 2B 90890 06544 9 Align the connector shaft keyway with the motor shaft projection and install the motor with a new O ring IN Bolt tilt motor 22 04 m kg 2 9 ft Ib 10 Install the hydraulic fluid reservoir with a new O ring Bolt reservoir body 7 Nm 0 7 m kg 5 1 ft Ib D O ring BRKT L d POWER TRIM AND TILT UNIT CE FILLING WITH HYDRAULIC FLUID AND AIR BLEEDING 1 Pour in the fluid until it overflows from the fluid level plug hole and install the reservoir plug ATF automatic transmission fluid 2 Turn the manual valve fully towards manual tilt Depress the tilt rod fully then close the manual valve Use the motor to go fully up check hydraulic and top if necessary Open the manual valve and repeat these operations two or three times Then turn the manual valve fully towards power tilt 3 Check the level of the hydraulic fluid at full tilt up top up with fluid if necessary Insert and tighten the fluid level plug 4 Connect the leads to a battery to check the function Trim and tilt up Blue Green Trim and tilt down Green Blue K55506 0 HYDRAULIC FLUID PRESSURE TEST Drive the motor to check trim and tilt up and down operation and fluid leakage 1 Close the manual valve 2 Connect the pressure gauge
21. Full advance indication 70 hp 4 Full advance adjusting screw 3 7 Timing indicator Full advance indication 75 80 hp 3 Full advance indication 90 hp Full advance adjusting screw 75 80 90 hp IGNITION TIMING ADJUSTMENT I CAUTION When checking ignition timing using a tim ing light be sure to replace the propeller with the specified test propeller and make tests with the machine placed in a test tank NOTE 0 0 0 0 0 10 17 0 40401 04 Before adjusting be sure to warm up the engine 1 Attach the timing light and tachometer to the No 1 cylinder high tension code 50 60 70 h Oh 2 While keeping the stopper in contact with the full retard adjusting screw measure the full retard ignition timing with the timing light If the timing is out of specification adjust it by turning the full retard adjusting screw Ki H NOTE When measuring the full retard ignition timing keep the specified engine speed Full retard side engine speed 22 800 50 rpm Full retard side ignition timing 50 60 70 hp 7 1 ATDC n 7 pm c 75 80 90 hp 8 1 ATDC 3 8 SE PERIODIC SERVICE CE 3 While keeping the stopper in contact with the full advance adjusting screw measure the full retard ignition timing with the timing light If the timing is out of specification adjust it by turning the full advance adjusting screw
22. NOTE eFeed hydraulic fluid into each pipe while taking care not to allow air to enter e Two set of hoses are required so that both of the trim and tilt pressures can be mea sured at the same time 7 28 BRKT L d POWER TRIM AND TILT UNIT CE 7 29 3 Connect the leads to a battery to check the fluid discharge pressure during down operation Trim and tilt down Green Blue CAUTION The motor should not be operated for more than three seconds after trim and tilt down is completed A Tilt operating pressure B Trim operating pressure At the end of down operation Stamped mark 6H308 A 4 100 5 500 kPa 41 55 kg cm 583 782 psi B 600 1 100 kPa 6 11 85 157 psi 6H1 15 A 2 200 3 800 kPa 22 38 kg cnv 313 540 psi B 600 1 100 kPa 6 11 85 157 psi 62F 02 A 2 100 3 700 kPa 21 37 kg cnv 299 526 psi B 600 1 100 kPa 6 11 85 157 psi 4 Connect the leads to a battery to check the fluid discharge pressure during up operation Trim and tilt up Blue Green NOTE The motor should not be operated for more than fourteen seconds after full tilt up oper ation BRKT L d POWER TRIM AND TILT UNIT CE A Tilt operating pressure B Trim operating pressure During up operation pressure A 0 500 kPa 0 5 kg cm 0 71 psi B 0 500 kPa
23. US oz 0 067 0 018 Imp oz 60 70 hp 2 20 0 50 cm 0 074 0 017 US oz 0 077 0 018 Imp oz 75 80 90 hp 3 10 0 70 cm 0 105 0 024 US oz 0 0109 0 025 Imp oz NOTE Oil temperature 10 30 C 50 86 F 1 Before measuring bleed the pump com pletely and ensure no air bubbles are present in the oil flowing out of the oil feed pipe 2 When measuring with the measuring cyl inder ensure that no oil clings to the cyl inder wall otherwise the measurement will be inaccurate 3 Use only genuine Yamaha oil If the vis cosity is too high or too low the mea surement of the discharge will be inaccurate 4 The longer the time over which measure ment is made the more accurate will be the measurement Calculate the rate of discharge per minute PERIODIC SERVICE CE D33900 0 CHECKING THE OIL LEVEL WARNING SYSTEM 1 Fill the oil tank with oil 2 Start the engine 3 By letting the oil little by little out of the drain hose check that the oil level warning system operates correctly CAUTION Do not allow the engine to operate without oil even briefly for this will cause malfunc tion or engine seizure 50 60 70 hp Cil level Cil level warning lamp Warning buzzer More than 770 cm GREEN 0 81 US qt 770 cm 0 31 Us qt 280 cm 0 3 US qt YELLOW 280 cm or less 0 3 US qt 75 80 90 hp Cil level Cil level warni
24. inder head using a figure eight sanding pattern 5 7 G61501 0 CYLINDER BLOCK CLEANING 1 Using gasket scraper remove all traces of gasket material from the cylin der block surface 2 Using a soft brush and solvent clean the cylinder block INSPECTION 1 Visually inspect the cylinder sleeves for cracks and scratches If cracks are found replace the cylinder block If scratches are found check the degree of out of round and then hone the cyl inder or re bore it if necessary 2 Using a cylinder gauge measure the cylinder bore at three positions in the thrust and axial directions Axial direction Thrust direction A 10 mm 0 4 in below the cylinder top B 5 mm 0 2 in above the exhaust port C 5 mm 0 2 in below the scavenging port NOTE Do not place the cylinder gauge on the port hole Cylinder bore size 50 60 70 hp 72 00 72 02 mm 2 834 2 835 in 75 80 90 hp 82 00 82 02 mm 3 228 3 229 in Taper limit 0 08 mm 0 003 in Out of round limit 0 05 mm 0 002 in If diameter is greater than the limit hone or rebore the cylinder or if neces sary replace the cylinder block INSPECTION G62001 0 PISTON CLEANING 1 Using a gasket scraper remove the car bon from the piston top 2 Using a broken ring clean the ring grooves 3 Using a soft brush and solvent thor oughly clean the piston If necessary use 600 800 grit wet or dry sandpaper
25. pler side and each connector Cores and pins of identical colors must be con nected or a continuity test can not be made 2 1 any of the cores is open circuit replace the wiring harness Lg Light green P Br Brown Black Blue Sky blue White Yellow Red Green ODLEW ELEC ELECTRICAL ANALYSIS CE 50 60 70 hp 75 80 90 hp 8 29 M58800 0 BRACKET 1 Inspect the bracket and replace it if it s cracked M58900 0 BATTERY Refer to PERIODIC SERVICE section in chapter 3 ENGINE STOP SWITCH P60TH 60FEHTO P75TH 75CEHTO 90AEHD 1 When removing and installing the lock plate check for continuity according to the chart below Wire color W B Removed O Installed Lock plate ELEC ELECTRICAL ANALYSIS INSTALLATION CES 8 30 MAIN SWITCH P60TH 60FEHTO P75TH 75CEHTO 90AEHD 1 Check the continuity of the main switch Replace if continuity is not as specified Checking leads Red White Red Yellow Black Yellow Brown Disconti Disconti nuity nuity Disconti ee Disconti Continuity nuity nuity Continuity Disconti Disconti nuity nuity Continuity Switch Position NEUTRAL SWITCH P60TH 60FEHTO P75TH 75CEHTO 90AEHD 90TR 90 B90TR 90AETO 1 Check the continuity of the neutral switch Replace if continuity is not as specified
26. switch Unit Q Checking leads Sky blue Red Light green Red Position 8 22 Continuity Discontinuity Discontinuity Discontinuity 2 Check rubber seal Replace the seal if it has any damage Discontinuity Continuity ELEC ELECTRICAL ANALYSIS 8 23 RECTIFIER REGULATOR 1 Check the continuity of the rectifier reg ulator Green White Fed Green Conti nuity Conti nuity Discontinuity If continuity is not as specified replace the rectifier regulator NOTE LLL e The digital tester cannot be used for this inspection eNever connect the rectifier regulator directly to the battery to check continuity e When testing disconnect the battery ter minals e When resistance is measured at less than 100 Q it can be said that there is continu ity M57001 0 FUSE 1 Referring to the diagram check the con tinuity of the fuse If the fuse is blown replace with a fuse of correct rating Fuse rating RU 20a ELEC ELECTRICAL ANALYSIS 57300 0 THERMO SWITCH 1 Immerse the thermo switch in water While heating the water check the con tinuity at the specified temperature 2 While cooling the water check the con tinuity at the specified temperature If continuity is not as specified replace the thermo switch ON temperature 3 84 90 C 183 194 F OFF temperature
27. 0 5 kg cm 0 71 psi At the end of up operation pres sure A 0 kPa 0 kg cn 0 psi 6H308 B 3 500 4 500 kPa 35 45 500 640 psi 6H1 15 B 9 000 11 000 kPa 90 110 kg cm2 1 280 1 565 psi 62F 02 B 5 690 6 570 kPa 57 66 kg cm 299 526 psi 5 Remove the fluid pressure gauge and install the delivery pipes NOTE When the fluid pressure gauge has been removed be sure to bleed the air from the system K56000 0 INSTALLATION 1 Referring to the illustration install the power trim and tilt unit to the bracket 7 30 BRKT L d POWER TRIM AND TILT MOTOR CE POWER TRIM AND TILT MOTOR DISASSEMBLY 1 Loosen the screws and remove the sta tor O ring and the armature 2 Disconnect the connector 3 Loosen the screw and remove the brush cover plate circuit breaker and the spring K62001 0 INSPECTION ARMATURE COIL 1 Visually inspect the commutator sur face and if it shows signs of roughness polish it with 600 grit wet or dry sand paper 2 Measure the outside diameter of the commutator by use of a vernier caliper If the diameter is less than the specified minimum outside diameter replace the whole armature Armature minimum outside diameter Standard 22 mm 0 87 in Minimum 21 mm 0 83 in 7 31 BRKT L d POWER TRIM AND TILT MOTOR CE 3 Scrape between the segments with a hack saw blade and then carefully remove all particles of me
28. 9 YB 34432 10 YB 34432 11 YU 26900 8 2 Assemble the shimming gauge with the drive shaft bearing and shim s as 2 IL shown in the illustration YB 34432 17 A NOTE 1 Attach the adapter plate to the gauge base using 4 bolts with appropriate sizes 2 If the original shim s is unavailable start with a 0 50 mm shim 7 Gauge block j YB 34432 9 Adapter plate YB 34432 10 Gauge base YB 34432 11 A Clamp YB 34432 17 A 3 Install the pinion on the drive shaft and tighten the nut to the specified torque 4 Using a thickness gauge at the specified measurement M established above check the fit between the shimming gauge and lower surface of the pinion as shown Thickness gauge YU 26900 8 YU 26900 9 5 If the thickness gauge at the M specifi cation will not fit then remove or add the shim s until the thickness gauge just fits between the tool surfaces Available shim thickness 0 10 0 12 0 15 0 18 0 30 0 40 and 0 50 mm Loun e SHIM SELECTION FOR USA AND CANADA CED YB 34446 1 YB 34446 7 YB 34446 5 YB 34446 3 YU 26900 8 YU 26900 9 SSSM Forward gear shim NOTE LL Find forward gear shim thickness T1 by selecting shims until the specified measure ment M with the special tool is obtained 1 Find the specified measurement M Specified Measurement M 1 69 mm F 100 mm NOTE _______________________
29. 90AEHD 8 30 NEUTRAL SWITCH P60TH 60FEHTO P75TH 75CEHTO 90AEHD 90TR 90AETO 9 90 8 30 INSTALLATION LES 8 30 FLYWHEEL REESEN 8 30 STARTER MOTOR rentia c oin eb ved vane 2 EE 8 31 REMOVA EE 8 31 DISASSEMBLY EE 8 31 INSPECTION E 8 32 PINION EE 8 32 STARTER Cli Ci EE 8 32 ln EE 8 32 BH USHSHOBBER E 8 32 ARMATURE EE 8 33 ASSEMBLY 50 60 70 hp tentaret reise 8 34 INSTALLATION 150 60 70 s rie erret tuer rns 8 35 ASSEMBLY 75 80 90 sasana gita gas aga 8 35 INSTALLATION 752 80 90 PD 8 36 ELEC ELECTRICAL COMPONENTS CED M20000 0 ELECTRICAL COMPONENTS 50 60 70 hp Ignition coil Neutral switch P60TH 60FEHTO Fuse Spark plug 7 Starter relay 5 CDI unit 8 Thermo switch Oil warning lamp 50GETO Starter motor Power trim and tilt replay 9 Charge coil Trim sensor PTT model PTT model Crank position sensor Rectifier regulator 5 Trailer switch PTT model Lighting coil Power trim and tilt connec except for USA Canada 2 Pulser coil tor assy P60TH 60FEHTO and Oceania model 3 Wire harness 8 1 ELEC ELECTRICAL COMPONENTS M20001 0 75 80 90 hp Ignition coil Neutral switch P75TH 0 Spark plug 75CEHTO 90AEHD 90TR Thermo switch 90AETO B90TR 90AETO Trailer swit
30. CLEANING AND INSPECTION OIL TANK 1 Using solvent clean the oil tank 2 Drain the solvent and dry the tank 3 Inspect the oil tank for cracks and replace it if required OIL LEVER SENSOR Refer to OIL LEVEL SENSOR sec tion in chapter 8 OIL HOSES 1 Inspect the oil hoses for damage or cracks and replace them if required E43001 0 INSTALLATION 1 Connect the oil hoses to the oil pump and tighten the clips on the hoses 2 Install the driven gear D Driven gear Washer 3 O ring Distance collar 3 Install the oil pump to the power head NOTE Tighten the bolts to the specified torque in sequence Cil injection pump mounting bolt 7 Nm 0 7 kg 5 1 ft Ib FUEL D OIL INJECTION SYSTEM CE gt 4 Assemble the oil tank and install it 5 Connect the oil delivery hoses to the intake manifolds and tighten the clips on the hoses 6 Lead the wire of the oil level sensor to the port side of the engine and connect the cores 7 Bleed the air from the lines CAUTION After reinstalling the oil injection pump be sure to bleed the pump CHAPTER 5 POWER UNIT EXPLODED DIAGRAM ii 5 1 PREPARATION FOR OVERHAUL 2 2 2 5 3 ia Exe ree ERR CERT Soins bide OUR eh 5 3 DISASSEMBEY get atu un pagenan wa ut ba ngen tatan naban nata kun e a e E naga nan 5 5 INSPECTION nei niche ieee
31. Color Distance GC 19 6 20 3 2 Discontinuity 18 5 19 5 mm BE 0 73 0 77 in Continuity M61002 0 INSTALLATION FLYWHEEL MAGNETO 1 Install the magneto base onto the retainer plate 2 Install so that the woodruff key in the keyways fits in the crankshaft 3 Lock the flywheel rotor with the washer and nut Tighten the nut to the specified torque Flywheel holder YB 6139 90890 06522 4 Install the flywheel cover ELEC STARTER MOTOR 50 60 70 hp 2 e a 8 31 M71001 0 STARTER MOTOR REMOVAL 1 Disconnect the cables and remove the starter motor DISASSEMBLY 1 Remove the starter clutch Using a screw driver pry off the clip Clip Pinion Stopper 9 Pinion starter clutch NOTE Push the pinion stopper by hand toward the pinion and remove the clip 2 Remove the two through bolts and pull out the front cover lightly tapping it with a plastic hammer if necessary 3 Using a piece of steel wire separate the brush springs and remove the brushes from the brush holders 4 Remove the yoke assembly by lightly tapping it with a plastic hammer and remove the armature Clip Pinion stopper 3 Spring 4 Pinion starter clutch 5 Front cover 6 O ring Washer 50 60 70 hp t 1 0 mm 75 80 90 hp t 2 0 mm Washer 50 60 70 hp t 0 15 mm 75 80 90 hp t 0 3 mm Washer 50 60 70 hp t 2 0 mm 75 80 90 hp t
32. Crank position sensor coupler Fuel enrichment valve 3 Clamp Clamp 5 Wire harness coupler 8 Trim sensor coupler 2 7 Oil level sensor coupler Clamp Ground lead from power trim and tilt relay Ground lead from wire harness 4 Ground lead from rectifier regulator 2 Charge coil coupler 3 Power trim and tilt relay coupler 2 Pulser coil coupler 49 Ground lead from starter relay Ground lead from CDI unit 2 To electrothermal valve 4 To trim sensor 2 To power trim and tilt motor 2 To oil level sensor To meter To starter motor To trailer switch 2 To neutral switch 9 1 m 5 8 6 B Black Br Brown G Green Gy Gray Lg Light green R Red Sb Sky blue W White Yellow 1 For C75TR 2 For PTT model 3 For oil injection model 4 Except for C75TR 5 For 75 75 90AEHD 90TR 90AETO B90TR 90AETO ELEC WIRING DIAGRAM M30000 0 WIRING DIAGRAM 50 60 70 hp 61 pe y MOJJ9A 77 A M 7 224122 BICI GR J RERS Seu PO 1q AS 95 Aes menm Jopouu pm 8 00 11 6 usan 9 777 OL
33. EE 6 10 BEARING nrt Q 6 10 CLUTCH DOG AND COMPONENTS 6 11 DRIVE AND PROPELLER SAP WEE 6 11 DRIVESHAFT S VEE GE 6 11 PROPELLER TRIM TAB ANODE 6 11 ASSEMBLY AND ADJUSTMENT 6 12 PROPELEER SHAPT HOUSING seiicseuleenelhwtiereestetcutenneasietahccigencereniand 6 12 GEAR e 6 13 ood CH ust ac net ant NENGENA NGNE TAR 6 17 FOR USA AND Se ZE 6 17 EXCEPT FOR USA AND 6 22 MEASURING THE BACKLASH eaaa n deeg Ee 6 25 WATER PUMP 1 5 icant wai 6 28 INSTALLATION ag ta citi met Eege eegen initie 6 29 LOWER UNIT LEAKAGE 6 31 LowR exrtoeooucram ce EXPLODED DIAGRAM FOR 50GETO C60ER C60TR 60FET OCEANIA C75TR 90AEHD 90AED C90TR 90AET Water pump housing 4 Shifter Needle bearing Q Impeller 2 Shift slide 62 Claw washer Cartridge outer plate 3 Forward gear Ring nut Cartridge outer plate gasket Clutch dog 03 Spacer 5 Oil seal housing 5 Cross pin 09 Propeller 6 Water pump gasket Propeller shaft Castle nut Drive shaft Reverse gear Trim tab Woodruff key O ring Pinion gear 9 Drive shaft sleeve Beari
34. WIRING DIAGRAM M30000 0 114 75 80 90 hp e se ed DEE EE 7 pay y 77777 M yung 7 d njq MS T qs oBue1Qo u9916 14611 ee 67 ang 5 T 5 UMOJg 7 19 7 g uoniub 69 1911815 6 114 9 pue 6 OLH39GL H1G d YOUMS pue Q 114 yams 1811811 09 110 69 013V06 41069 1 06 106 GH3V06 O1H3298 H1844d YOUMs 09 voz esn4 6 114 JOJOUW pue WI 19MO4 6 10sues D D JOJOW 1914815 1 uonoefur 10 10805 IO 8 18 9 10 14 BAIA 211910119913 1109 Jasjngd ioo Josues uonisod xue42 1 1 uoiMs ouueu D 8 9 C75TR M As 77 qs n y yung 77 d oBueio TT O u9916 67 eng 7 5 Ap Ugen 5 UMOJg 7 19 xoelg 7 g 19146165 6 6 pue 49Mog 09 asn JOJOW 111 pue Jo
35. b 60 74 C 140 165 F D Discontinuity Continuity 3 Discontinuity A Temperature B Time FUEL ENRICHMENT VALVE 1 Measure the resistance of the fuel enrichment valve Fuel enrichment valve resistance at 20 C 68 F L B 3 4 4 00 _________________________ Refer to Low resistance measurement for this inspection 8 24 ELEC ELECTRICAL ANALYSIS M57500 0 OIL INJECTION SYSTEM Oil injection model Oil level sensor Digital Meter Oil level warning lamps control unit Lead wire Lead wire Lead wire assembly 50 60 70 hp 75 80 90 hp 8 25 ELEC ELECTRICAL ANALYSIS 58004 0 50 60 70 h 75 80 90 h S OIL LEVEL SENSOR 1 Remove the circlip and disassemble the BO oil level sensor D Oil level sensor f D Strainer cover Y Gasket 2 Referring to the illustrations and tables check the continuity and resistance 50 60 70 hp Marking 6H3 16 Unit Bi Oil level sensor resistance Float SW 1 ON Float SW 2 ON 79 5 82 5 mm B 114 5 117 3 mm 3 13 3 25 in 4 51 4 62 in Tester Tester 9 Black Green Black Green Tester Tester Red 42 28 Black Black KH 0 Green 640 Red Oil level sensor resistance Float SW 1 SW 2 both OFF Tester Green Green RM Tester CD Black Green 3 Green Red
36. identified thus D 3 REFERENCES These have been kept to a minimum however when you are referred to another section of the manual you are told the page number to go to www motorka org SPECIFICATIONS These are given in bold type at each procedure It is not necessary to leave the section deal ing with the procedure in order to look up the specifications It is important to note the differences in specifications of models Where a procedure relates to more than one model the main differences in specifications will be shown in the following table Model name 50GETO 60FEHTO 60FEDO 60FET 60FETO 70BEDO 70 USA and Canada name PooTH C60TR 70TR Manual control Remote Remote control control Control system Power trim Manual tilt and tilt Tilt system Power trim and tilt Manual tilt Power trim and tilt Lubrication system Model name Oil injection 75CET 75CETO Pre mixed 75CEHTO Oil injection 80AETO Pre mixed 90AEHD Oil injection 90AET 90AETO USA and Canada name C75TR 75TR P75H C90TR 90TR B90TR Control system Remote control Manual control Remote control Manual control Remote control Tilt system Power trim and tilt Manual tilt Power trim and tilt Lubrication Pre mixed system Pre mixed Oil injection Oil injection WARNINGS CAUTIONS AND NOTES Atten
37. outboard motor Loosen the two bolts securing the trim sen sor until it moves slightly WARNING Be sure to support the engine with the tilt support lever while loosening the bolts to prevent the engine from tilting down due to lack of oil pressure Fully tilt down the outboard motor Connect battery cables of the outboard motor to a battery and set the main switch to ON Adjust the trim sensor position by pushing a screw driver so that one segment on the trim indicator on the digital meter goes on Tilt up the outboard motor and tighten both installation bolts WARNING Be sure to support the engine with the tilt support lever while tightening the bolts to prevent the engine from tilting down due to lack of oil pressure ASSEMBLY 1 Referring to the exploded diagram assemble the bracket unit HYDRAULIC TILT UNIT BRKT L d POWER TRIM AND TILT UNIT CE HYDRAULIC TILT UNIT WARNING This cylinder is highly pressurized There fore never overhaul or damage it INSPECTION 1 Inspect the tilt cylinder assembly for scratches or corrosion If any scratches are found replace the tilt cylinder assembly POWER TRIM AND TILT UNIT REMOVAL 1 Disconnect the leads from the relay in the bottom cowling 2 Remove the tilt rod bolts and nut and the clamp bracket 3 Remove the circlip and the complete power trim and tilt unit 7 11 BRKT L d POWER TRIM AND TILT UNIT CE K51000 0 EX
38. output peak voltage minimum color cranking open cranking connect 1 500 r min 3 500 r min B W B B W 1 3 105 111 3 130 2 2 145 155 105 130 Lighting system Lighting coil resistance STD 12V 80W 20 C 68 F Lighting coil output peak voltage minimum color cranking open cranking connect 1 500 r min 3 500 r min Starter motor Rating Output Clutch type Brush length lt Wear limit gt Commutator undercut lt Repair limit gt 0 57 0 85 G W G 0 4 0 6 G W G Overrunning 12 5 0 49 16 0 0 63 9 0 0 35 12 0 0 47 0 8 0 03 0 2 0 01 2 8 SPEC MAINTENANCE SPECIFICATIONS Item 60hp 80hp Commutator outside diameter lt Repair limit gt Pinion ring gear gap 30 1 18 33 1 30 29 1 14 31 1 22 3 0 5 0 0 12 0 20 Others Electrothermal valve resistance 20 68 F Fuel enrichment valve resistance 20 C 68 F Trim sensor resistance Fuse 2 9 2 3 3 5 L B 3 4 4 0 L B 360 540 P B 800 1 200 B O 20 SPEC oo MAINTENANCE SPECIFICATIONS DIMENSION mm in degree degree degree mm in Model 60 70 hp 868 34 2 75 80 90 hp 968 1 081 38 1 42 6 403 15 9 411 16 2 457 18 0
39. removed gt 13 Drive shaft bearing outer Stopper guide plate 90890 06501 Bearing puller 90890 06535 Stopper guide stand 90890 06538 For USA and Canada Except for USA and Canada 5 gt lt lt 2 14 Drive shaft sleeve 15 Drive shaft needle bearing 2 Driver rod 2 6071 90890 06602 Needle bearing attachment YB 6155 90890 06611 6 7 om lt gt 16 Reverse gear bearing and forward gear bearing Bearing separator 90890 06534 NOTE 4 4 0 0 0 1 14034 Separate the bearing from the gear using special service tool and hydraulic press 6 8 ES oan e INSPECTION CED 151001 0 INSPECTION GEAR CASE 1 Using a soft brush and solvent clean the case and water passage 2 Visually inspect the gear case for cracks corrosion or distortion If any crack or excessive corrosion is found replace the gear case 3 Check the water inlet cover and water passage for clogging 151500 0 BEARING HOUSING 1 Using a soft brush and solvent clean the housing thoroughly 2 Visually inspect the housing for cracks and corrosion If any damage is found replace the bearing housing 152000 0 CLAW WASHER 1 Visually inspect the washer for cracks If a crack is found replace the claw washer 152500 0 RING NUT 1 Using a soft brush and solvent clean t
40. that the F mark on the clutch dog is on the forward gear side 6 7 Bring the cross pin hole in the clutch dog with the hole in the shift slide and insert the cross pin into these holes Then install the cross pin ring Place the shift cam on the shifter with the F mark on the shift cam facing forward and insert the pro peller shaft into the forward gear Loun e ASSEMBLY AND ADJUSTMENT y 8 10 11 Grease the lips of the oil seals and insert the propeller shaft complete into the bearing housing Then place the bearing housing complete to the gear case Look into the gear case through the hole and align the shift rod hole in the gear case with the splined hole in the shift cam and install the shift rod 2 Except for 5OGETO C60ER C60TR 60FET Oceania C75TR 90AEHD 90AED 90 90 Place the reverse gear shim D in place then install the bearing housing aligning the key way in the gear case with that in the bearing housing and insert the key 3 Place a claw washer in place install a ring nut with its embossed marks fac ing outward away from the bearing housing tighten the ring nut to the specified torque and bend the claw washer over the ring nut to lock it Ring nut 50 hp 130 Nm 13 0 m kg 0 94 ft Ib 60 70 75 80 90 hp 145 Nm 14 5 m kg 105 ft Ib Ring nut wrench 50 hp YB 06048 90890 065
41. the circlip the manual valve and components NOTE 00 00 0 008 0 0 2 The manual valve screw is threaded left handed BRKT L d POWER TRIM AND TILT UNIT CE K53000 0 INSPECTION TILT ROD AND TRIM ROD 1 Clean these components using a soft brush and solvent and inspect them carefully If there are light scratches on the surfaces these may be polished off using fine wet or dry sandpaper 440 600 grit but if there is excessive scratching replace the components 2 Clean all the parts thoroughly using a soft brush and solvent and dry them with compressed air 3 Inspect the tilt cylinder and pump unit and replace them if they are badly cor roded K54000 0 ASSEMBLY NOTE _________________________ The components in this assembly are to be lightly coated with hydraulic fluid before assembly 1 Install the tilt cylinder and the delivery pipes Bushing Q Tilt cylinder Lower mount pin 4 Delivery pipe NOTE Feed oil into each pipe Lock nut delivery pipe 10 Nm 1 0 m kg 7 2 ft Ib BRKT L d POWER TRIM AND TILT UNIT CE 2 Install the manual valve in the body with new O rings D O ring fitted into the body Manual valve seat Manual release spring L 2 6 0 mm D 11 5 mm Adapter 1 5 O ring Manual valve left handed thread 7 Circlip E 3 Nm 0 3 m kg 2 2 ft Ib NX 3 Install new O ring
42. through normal wear Mated sets should be re used on reassembly or replaced com pletely G40003 0 REMOVAL 1 Remove the electrical system parts Refer to ELECTRICAL COMPONENTS section in chapter 8 D Ground lead from the cylinder head cover Battery cable Power trim and tilt motor leads PTT model Power trim and tilt relay PTT model Oil level sensor lead oil injection model 2 Remove the fuel system parts and hose Refer to FUEL SYSTEM section in chapter 4 D Cooling water pilot hose Fuel hose on the strainer 5 3 GP woen gt 3 Remove the throttle cable and the shift mechanism Throttle cable joint by removing the hair pin Shift rod bracket bolt Shift cable joint and bushing by removing the hair pin 4 Remove the front and rear aprons 5 Remove the power head installation bolts and then remove the power head from the upper casing 50 60 70 8 bolts 75 80 90 hp ie 11 bolts NOTE The power head may be difficult to separate from the bottom cowling because of a stuck gasket holding them together If this is the case lever it off the bottom cowling with a piece of wood Use care not to damage the bottom cowling or power head with the wood 6 Remove the dowel pins from the bot tom cowling or power head To protect the dowel pins against damage cover them with rags 5 4 G50003 0 DISASSEMBLY Referring to the expl
43. 0 hp 3 Using a thickness gauge at the specified measurement M established above check the fit between the shimming gauge and the reverse gear Force the shimming gauge against the shims and thrust washer when checking the fit Thickness gauge YU 26900 8 YU 26900 9 4 If the thickness gauge at the M specifi cation will not fit then remove or add the shim s until the thickness gauge just fits between the tool surfaces Available shim thickness 0 10 0 12 0 15 0 18 0 30 0 40 and 0 50 mm SHIM SELECTION LOWR t EXCEPT FOR USA AND CANADA CES EXCEPT FOR USA AND CANADA Pinion gear shim 1 Find pinion gear shim thickness T3 by selecting shims until the specified mea surement M with the special tool is obtained 2 Install the pinion on the drive shaft and tighten the nut to the specified torque Pinion nut 50 hp 75 Nm 7 5 m kg 54 ft Ib 60 90 hp 95 Nm 9 5 m kg 69 ft Ib 3 Assemble the pinion height gauge with the drive shaft and bearing as shown in the illustration Bolt the bearing hous ing to the special tool with at least two bolts 90890 06702 Pinion height gauge 90890 06702 Digital caliper 90890 06704 90890 06704 T 4 Using a digital caliper at the specified measurement M established above measure the distance between the pin ion height gauge and lower surface of the pinion as shown Shim thickness T3 50 hp M
44. 07 1 1 4 1 4 turns out FUEL D CARBURETOR 50 60 70 hp 75 80 90 hp E34004 1 INSTALLATION 1 Install the carburetors and plate with new gaskets Idle adjust screw Throttle lever 3 Throttle lever securing screw 2 Connect the fuel hoses to the carbure tors and fit the hose clips over the recesses to ensure leak proof connec tions 3 Connect the electrothermal valve leads 4 Connect the oil pump link rod to the carburetor and oil injection pump 5 Install the silencer cover and tighten the bolt to the specified torque Bolt silencer cover 2 Nm 0 2 m kg 1 4 ft Ib FUEL D OIL INJECTION SYSTEM OIL INJECTION SYSTEM Oil injection model EXPLODED DIAGRAM Oil level sensor Oil tank cap assembly Oil strainer Hook 3 Strainer cover gasket Filler tube Oil injection pump assembly 5 Check valve amp Oil tank Special washer 50 60 70 hp 4 14 FUEL D OIL INJECTION SYSTEM Check valve Special washer Oil injection pump assembly Oil tank cap assembly Drain screw Hook Oil tank 0 Filler tube 5 Strainer cover gasket Oil strainer Oil lever sensor 75 80 90 hp 4 15 FUEL D OIL INJECTION SYSTEM CE gt REMOVAL 1 Drain the oil from the oil tank and remove the carburetor 2 Disconnect the hoses and remove the oil injection system E42001 0
45. 0FEDO 4 C60TR 60FET 5 73 70BEDO 5 70TR 70BETO Approved model No 62F 6H2 Overall Length Overall width Overall height Boat transom height O M transom height D OU OO Weight Al Weight SUS kg Ib kg Ib kg Ib kg Ib 698 27 5 713 1 330 52 4 364 14 3 1 351 53 2 1 252 49 3 234 1 374 1 501 5 381 15 0 23 45 54 1 9 1 145 508 20 0 520 20 5 102 225 635 25 0 145 400 15 7 2345 521 20 5 648 25 5 145 94 207 2 95 5 211 3 104 229 4 103 5 228 gt 97 5 215 3 105 5 233 gt 112 247 96 212 2 106 234 4 115 254 109 240 4 108 5 239 gt 97 5 215 3 105 5 233 gt 99 5 219 3 107 5 237 gt 110 5 244 5 Full throttle speed range Output ISO Maximum fuel consumption r min kW hp r min L US gal Imp gal h r min 4 500 5 500 36 8 50 5 000 22 5 81 4 84 5 500 44 1 60 5 000 23 6 08 5 06 5 500 5 000 6 000 51 5 70 5 500 26 6 87 5 72 5 500 Type Cylinders Total displacement Bore x Stroke Compression ratio Compression pressure Carburetor number Intake system cm cu in mm in kPa kg cm 2 stroke L 3 849 51 8 72 0 x 69 5 2 83 x 2 74 6 10 2 1 853 8 53 3 Reed valve
46. 0GETO C60ER C60TR 60FET Oceania C75TR 90AEHD 90AED C90TR 90AET Using a slotted screwdriver remove the shift slide balls D from the neu tral position and pull out the shift slide 2 and shifter 3 9 Reverse gear and bearing Stopper guide plate 90890 06501 Bearing puller 90890 06535 Stopper guide stand 90890 06538 For USA and Canada Except for USA and Canada gt r 0 ANG SS A E as gt 6 5 oan e DISASSEMBLY gt 10 seals and needle bearing Stopper guide plate 90890 06501 Bearing puller 90890 06535 Stopper guide stand 90890 06538 Driver rod YB 607 1 90890 06602 Needle bearing attachment YB 6153 90890 06612 For USA and Canada Except for USA and Canada gt 11 Pinion nut pinion and drive shaft bearing inner race 2 Drive shaft holder 2 50 60 70 hp 2 YB 6049 90890 06518 75 80 90 hp YB 6151 90890 06519 Pinion nut holder 90890 06505 A For USA and Canada B Except for USA and Canada NOTE 14 4 1 0 1 2 For ease of reassembly and adjustment keep shim packs in their groups as removed 6 6 om lt gt 12 Forward gear bearing outer Bearing outer race puller 90890 06523 For USA and Canada Except for USA and Canada NOTE For ease of reassembly and adjustment keep shim packs in their groups as
47. 1 0 mm Armature Yoke assembly 2 Brush Brush holder O ring 50 60 70 hp 49 Rear cover Through bolt 8 32 INSPECTION PINION 1 Inspect the pinion and inner teeth for wear or damage and check ease of pin ion sliding motion and replace if dam aged 2 Inspect the flywheel gear and replace if worn or damaged STARTER CLUTCH 1 Check the clutch movement Rotate the pinion clockwise and check that it turns freely Also try to rotate the pinion counterclockwise and confirm that it locks BRUSH 1 Measure the brushes for wear Brush size 3 Standard 50 60 70 hp 12 5 mm 0 49 in 75 80 90 hp 16 0 mm 0 63 in Minimum 50 60 70 hp 9 0 mm 0 35 in 75 80 90 hp 12 0 mm 0 47 in If the size is less than the minimum specification replace the complete brush holder assemblies BRUSH HOLDER 1 Check the insulation between the brush holder and ground If there is any conti nuity replace the brush holder assem bly ELEC STARTER MOTOR 8 33 ARMATURE 1 Inspect the commutator surfaces and if these are dirty or burnt clean with 400 grit wet or dry sandpaper 2 Inspect the commutator deflection with a dial gauge and block and replace the armature if the deflection is out of spec ification Maximum deflection 0 05 mm 0 0020 in If the deflection is greater than the spec ified deflection replace the armature 3 Measure the diameter of the
48. 10 60 90 hp 90890 06511 Extension ring nut wrench 90890 06513 Loun e SHIM SELECTION FOR USA AND CANADA CED SHIM SELECTION NOTE 1 When reassembling the lower unit with the original gear case and inner parts shim selection is not required 2 When replacing the gear case only read the numeral preceded by F R P and adjust the shims according to the differ ence between numerals of the original gear case and the new gear case 3 If the bearing s and or gear s are replaced carry out the shim selection FOR USA AND CANADA Pinion gear shim NOTE Find pinion gear shim thickness T3 by selecting shims until the specified measure ment M with the special tool is obtained 1 Find the specified measurement M Specified Measurement M 0 20 mm P 100 mm NOTE ______________________ 1 is the deviation of the lower case dimension from standard It is stamped on the trim tab mounting surface of the lower case in 0 01 mm units If the P mark is missing or unreadable assume a P mark of 0 and check the backlash when the unit is assembled 2 If the P value is negative then sub tract the P value from the measurement LS Loun e SHIM SELECTION FOR USA AND CANADA CED Example If P mark is 5 then M 0 20 5 100 mm 0 20 0 05 mm 0 25 mm If P mark is 3 then M 0 20 3 100 mm 0 20 0 03 mm 0 17 mm YB 34432
49. 2 284 8 11 19 11 21 0 03 0 0012 0 20 0 70 0 008 0 05 0 0020 0 028 0 12 0 26 0 005 0 010 2 0 0 08 Carburetor Stamp mark Main jet M J M A J P J P A J P S Main air jet Pilot jet Pilot air jet Pilot screw Float height F H Um Ac Valve seat size Idling speed Turns out mm in 62F00 6H20A 6H210 140 145 03 175 180 65 70 75 80 125 170 65 70 1 3 8 1 4 1 1 2 14 1 1 3 8 1 4 6H007 6 015 180 78 80 2 78 80 75 80 1 3 8 1 4 75 70 1 4 1 4 15 0 1 0 0 59 0 04 14 0 1 0 0 55 0 04 14 0 2 0 0 55 0 08 19 5 3 0 0 77 0 12 1 2 0 047 1 6 0 063 1 1 4 0 055 4 0 055 1 6 0 063 800 Oil injection pump Stamped mark Discharge 62F00 1 90 0 50 0 064 0 017 0 067 0 018 68302 2 20 0 50 0 074 0 017 0 077 0 018 6H102 3 10 0 70 0 105 0 024 0 109 0 025 Reed valve Stopper height Warpage limit 1 For C60ER C60TR 2 For C75TR 3 Lower cylinder 3 0 0 2 0 12 0 01 9 9 0 2 0 39 0 01 2 6 0 2 0 01 SPEC MAINTENANCE SPECIFICATIONS CE TM Model 50 hp 60hp 70hp 75hp Thermostat Valve opening temper 48 52 118 126 ature Full opening tempera 60 140 ture Valve lift 3 0 12 C
50. 2 Check the spline for wear and damage D35000 0 SPARK PLUG 1 Check the electrode condition and state of wear note the insulator 2 color and the electrode gap Normal condition is a medium to light tan color Distinctly different color Check the engine condition White color Lean fuel mixture Plugged filter jet Air leak Wrong settings Blackish color Electrical malfunction Defective spark plug 2 Clean the spark plug with spark plug cleaner or wire brush Use a wire gauge to adjust the plug gap to specifica tion Spark plug gap 0 9 1 0 mm 0 035 0 039 in 3 If the electrode becomes too worn replace the spark plug Standard spark plugs Except for Canada For Canada Europe China and Europe China South Africa and South Africa 50 hp BR8HS 10 BR8HS 10 60 70 75 80 90 hp B8HS 10 BR8HS 10 PERIODIC SERVICE 4 When installing the spark plug clean the gasket surface wipe off any grime that may be on the surface of the plug and screw in the spark plug to the cor rect torque INN Tightening torque A 25 Nm 2 5 m kg 18 ft Ib NOTE If a torque wrench is not available a good estimate of the correct torque is a further 1 4 to 1 2 turns on finger tightened spark plug GREASING POINTS 1 Apply e Water resistant grease FUEL D CES CHAPTER 4 FUEL SYSTEM FUEL SYSTEM 5555 Aan a eege 4 1 EXPLODED DIAGRA
51. 2 0 m kg 14 ft Ib 2nd step 8 20 Nm 2 0 m kg 14 ft Ib M10 40 Nm 4 0 m kg 29 ft Ib 6 Check that the crankshaft turns smoothly G74002 0 CRANK CYLINDER ASSEMBLY 75 80 90 hp 1 Align each locating pin of the bearings and labyrinth seals with each cut on the cylinder block Then fit the crank assembly in place 2 Film coat the cylinder block mating sur face with Gasket Maker or equivalent 3 Install the dowel pins 4 Match the cylinder block and tighten the bolts to the specified torque in sequence and in two steps Crankcase bolt 75 80 90 hp 1st step M6 4 Nm 0 4 m kg 2 9 ft Ib M10 20 Nm 2 0 m kg 14 ft Ib 2nd step M6 12 Nm 1 2 m kg 8 7 ft Ib M10 40 Nm 4 0 m kg 29 ft Ib 5 Check that the crankshaft turns smoothly ASSEMBLY AND ADJUSTMENT CE CYLINDER HEAD AND EXHAUST COVER 1 Install the gaskets cylinder head cover and exhaust cover 50 60 70 hp 2 Tighten the bolts to the specified torque in sequence and in two steps Tightening sequence Cylinder head 50 60 70 hp 1st step 3e 15 Nm 1 5 kg 11 ft Ib 516 2nd step 32 Nm 3 2 m kg 23 ft Ib jo 0 fells Cylinder head 75 80 90 hp 116 1st step 184 o o 15 Nm 1 5 m kg 11 ft Ib 816 2nd step ih SE 30 Nm 3 0 m kg 22 ft Ib Tightening sequence
52. 32000 0 ELECTRICAL Item Ignition system Ignition timing at full reversed at full advanced cam roller pick up Piston position at full advanced 3 23 0 28 2 68 2 83 0 27 3 41 0 127 0 11 0 26 0 111 0 011 0 29 0 106 0 134 0 010 0 011 Charging coil resistance 136 204 Brown Blue 64 96 Br R 20 C 68 F 191 288 B R Charge coil output peak voltage minimum color Br L R L 9 cranking open 120 55 90 cranking connect 150 60 100 1 500 r min 160 170 135 3 500 r min 120 150 135 Pulser coil resistance 240 360 W R W B 241 362 W R W B 20 C 68 F Pulser coil output peak voltage minimum color W R W B W R W B cranking open 4 5 7 0 cranking connect 2 5 5 0 1 500 r min 6 5 14 3 500 r min 10 20 2 7 SPEC MAINTENANCE SPECIFICATIONS Item Model 60hp 70hp 75hp 80hp Ignition coil Primary coil resistance 20 C 68 F Secondary coil resis tance 20 C 68 F Crank position sensor resistance 20 C 68 F 0 18 0 24 Black White Black 3 26 4 88 Black White High tension cord 158 236 Blue White Blue Red Crank position sensor peak voltage minimum color cranking open cranking connect 1 500 r min 3 500 r min Spark plug Spark plug gap 0 9 1 0 0 035 0 039 CDI unit
53. 400 15 7 520 20 5 648 25 5 719 28 3 647 25 5 706 27 8 730 28 7 204 8 0 135 5 3 205 8 1 203 8 0 321 12 6 331 13 0 600 23 6 2 1 For P60TH 60FEHTO 7 75 2 Except for P75TH 75CEHTO 90AEHD SPEC oo MAINTENANCE SPECIFICATIONS CED B9B9B9 B4 Unit Model 50 hp 60 hp 70 hp 75 80 90 hp B1 mm in 125 4 4 9 B2 mm in 254 10 0 B3 mm in 163 5 6 4 B4 mm in 50 8 2 0 B5 mm in 180 7 1 B6 S mm in 329 13 0 L X 351 13 8 B7 mm in 138 1 5 4 B8 mm in 203 2 8 0 B9 mm in 18 5 0 7 D1 mm in 13 0 5 D2 mm in 55 5 2 2 D4 mm in 12 0 5 SPEC oo TIGHTENING TORQUE ED C33000 0 TIGHTENING TORQUE Tightening torque Parts to be tightened Remarks Nm Im kgl 16 Crank case Connecting rod Cylinder head Exhaust cover 0 4 2 9 Intake manifold 0 8 5 8 1 2 8 7 2 1 Spark plug 3 2 1 5 5 8 Flywheel Nut M20 160 16 0 115 iG Power unit mounting Bolt M8 1 21 2 1 15 M8 20 2 0 14 1 Starter motor mounting Bolt 2 Straight screw plug Screw M12 1 23 2 3 1 7 UPPER CASE AND GEAR CASE Upper mount rubber Nut M10 2 2 24 2 4 17 E Bracket bolt Nut M22 1 5 Upper case mounting Bolt M8 Exhaust guide Bolt M8 Exhaust manifold Bolt M8 Muffler
54. 5 Nm 0 5 m kg 3 6 ft Ib BRKT L d POWER TRIM AND TILT UNIT CE 7 Fit a new O ring and the back up ring on the free piston and install it into the cyl inder D O ring Back up ring 8 Fit a new O ring and the back up ring to the tilt piston and install it into the cylin der Fill the cylinder with hydraulic fluid and tighten the end screw to the specified torque O ring Back up ring CZ Cylinder end screw wrench 6175 2 90890 06544 EN Tilt cylinder end screw A 80 Nm 8 0 m kg 58 ft Ib 9 Align the connector shaft keyway with the motor shaft projection and install the motor with new O ring NG Bolt tilt motor 22 4Nm 04 m kg 2 9 ft Ib 10 Install the hydraulic fluid reservoir with new O ring Bolt reservoir body 6 Nm 0 6 m kg 4 3 ft Ib D O ring 11 Air bleeding Refer to page 7 28 BRKT L d POWER TRIM AND TILT UNIT CE EXPLODED DIAGRAM Long transom 6H1 15 62F 02 D Reservoir body Down relief spring Manual release spring Reservoir plug 2 Gear pump assembly 0 Adapter Motor assembly 43 Shaft connector Manual release screw Trim cylinder end screw Filter 1 Free piston Trim piston assembly 5 Valve lock screw Back up ring Main valve assembly Trim spring Shuttle piston Up relief spring Pipe Up relief valve seat 9 Main valve seal Filter 2 Valve support pin 09 Manual valve seat 7 Nm 0 7
55. 80 90 hp 5 Remove the dial gauge from the No 1 cylinder and install the spark plugs for each cylinder After tightening the screw paint over the screw head to discourage tampering with the adjustment 3 6 SE PERIODIC SERVICE CE THROTTLE SENSOR CONTROL LINK ADJUSTMENT 1 Adjust the lengths of the throttle sensor control link and throttle cam control link to specifications Throttle sensor control link length 2 50 60 70 hp 120 0 5 mm 4 72 0 02 in 75 80 90 hp 93 5 0 5 mm 3 68 0 02 in Throttle cam link length 50 60 70 hp 95 mm 3 74 in 75 80 90 hp 120 5 mm 4 74 in 2 Adjust the length of the full retard adjusting screw so that when the full retard adjusting screw contacts the stopper the full retard indication on the CDI unit aligns with the timing indica tor 50 60 70 hp D Timing indicator 2 Full retard indication 50 60 70 hp 3 Full retard indication 75 80 90 hp Full retard adjusting screw NOTE _________________________ The nut in the magneto control lever should be 2 mm 0 08 in off from the end of the magneto control lever 3 Adjust the length of the full advance adjusting screw so that when the full advance adjusting screw contacts the stopper the full advance indication on the CDI unit aligns with the timing indi cator Timing indicator Full advance indication 50 60 hp 3
56. AL WIRING ise eege Seegen E 8 3 WIRING DIAGRAM T tracer tee UHR eR oid seriis eect 8 7 REMOTE CONTROL BOUE esc diuisa befand aita qa 8 12 DIGITAL Et EE 8 12 REMOVAL nn ren 8 13 MAGNETO BASE gite 8 13 ELECTRICAL ANALYSIS tee 8 15 INS PEG WE 8 15 IGNITION 88221584 542258 652 8 16 CDI SYSTEM PEAK ind Runtime 8 16 REPLACEMENT OF SPARK PLUG 8 20 CRANK POSITION SGENGOR EE 8 20 STARTER RELAY ip e Sareea doo ae eee ad et ef 8 21 POWER TRIM RELAY E 8 21 TRAILER iini acca anaa aa nee ae aaa KE ma NG Ee 8 22 RECTIFIER BEGU LATONR 222 ih cendre nex eee ce deeg gedoe 8 23 Bil GET 8 23 THERMO SVVI EG D 8 24 FUEL ENRICHMENT VALVE RE ea em eua E 8 24 OIL INJECTION SYSTEM Oil injection model 8 25 OIELEVEL SENS OR sida tudo deo Portu tees Ihesu stu 8 26 OIL LEVEL WARNING LAMP LE D 8 28 WIRINGHARNESS sn EEN pa SEN 8 28 BRACKET sasinan mt 8 29 8 29 ENGINE STOP SWITCH P60TH 60FEHTO P75TH 75CEHTO 90AEHD 8 29 MAIN SWITCH P60TH 60FEHTO P75TH 75CEHTO
57. E Tighten the center bolt while turning the propeller shaft a few times clockwise EN Center bolt 22 5 Nm 0 5 m kg 3 6 ft Ib 50 60 70 hp 90890 06502 Universal puller YB 6117 Stopper guide plate 90890 06501 Center bolt 90890 06504 2 Slowly turn the drive shaft in and out and read the dial gauge when the drive shaft stops in each direction 3 Determine the shim size according to the chart 50 75 80 90 hp Forward gear Decrease or increase backlash Thickness of shim to be decreased mm 0 17 measurement x 0 60 Less than 0 08 mm 0 003 in 0 08 0 25 mm 0 003 0 009 in Decrease or increase will be unnecessary Thickness of shim to be increased mm mea surement 0 17 x 0 60 More than 0 25 mm 0 009 in SHIM SELECTION 60 70 hp Forward gear backlash Decrease or increase Less than 0 09 mm 0 004 in Thickness of shim to be decreased mm 0 19 measurement x 0 53 0 09 0 28 mm 0 004 0 011 in Decrease or increase will be unnecessary More than 0 28 mm 0 011 in Reverse gear Thickness of shim to be increased mm mea surement 0 19 x 0 53 1 Install a propeller on the propeller shaft with the front facing backward fit the nut and tighten ES Nut propeller 22 5 Nm 0 5 m kg 3 6 ft Ib 2 Slowly turn the drive shaft in and out and read the dial gauge when the drive sha
58. EST 7 28 INSTALLATION ee etes EL p EE 7 30 POWER TRIM AND TILT 2 2 2 4 2 7 31 DISASSEMBEY ee Tene 7 31 dex teret Eten EE 7 31 ARMATURE COIL eese eene nennen nennen nnne 7 31 tace pair d Nera p at a ai 7 32 ASSEMBLY aede ree ecce tees et terii teret an ai genea 7 32 CIRCUIT BREAKER anan aana aan anan 7 32 ASSEMBLY asana genap adana dadana gaga anga aana nada dina Tan ag na saa an d 7 33 BRKT L d BRACKET UNIT BRACKET UNIT EXPLODED DIAGRAM MANUAL HANDLE P60TH 60FEHTO 1 P75TH 75CEHTO 90AEHD Steering handle Link assembly Main switch lead 2 Bracket Shift cable 2 Extension wire lead Main switch Cover 3 PTT switch PTT model Engine stop switch Grip Steering friction 5 Throttle cable Battery cable PTT model 38 Nm 3 8 m kg 27 ft lb wa 7 1 BRACKET UNIT UPPER CASING 50 60 70 hp BRKT K15000 0 Exhaust guide Exhaust manifold Muffler Upper case 5 Apron Seal Bottom cowling 21Nm 21 kg 15 ft 10 re x D E er E 2 7 2
59. FUEL SYSTEM section in chapter 4 2 Install the electrical system Refer to ELECTRICAL COMPONENTS section in chapter 8 5 20 INSTALLATION CED G8000 0 INSTALLATION 1 Install locating pins in position on the exhaust guide 2 Align the locating pin holes on the gas ket with dowel pins and place the gas ket on the bottom cowling 3 Install the power head onto the bottom cowling tighten the mounting bolts to 75 80 90 hp the specified torque ES Mounting bolts 22 21 Nm 2 1 m kg 15 ft Ib 4 Connect the hoses cables and wires 5 Install the apron 6 Check the fittings installation cable connections and functions before start ing the engine to check operation and to check for leaks 5 21 Loun e ES CHAPTER 6 LOWER UNIT EXPLODED DIAGRAM FOR 50GETO C60ER C60TR 60FET OCEANIA C75TR 90AEHD 90AED 90 90 6 1 EXPLODED DIAGRAM EXCEPT FOR 50GETO C60ER C60TR 60FET OCEANIA C75TR 90AEHD 90AED 90 90 6 2 PREPARATION FOR REMOVAL AE 6 3 DISASSEMBLY Se M 6 3 INSPECTION ees 6 9 EISE E 6 9 BEARING HOUSING EE 6 9 Eeer 6 9 ly LETS EE 6 9 WATER PUMP HOUSING Ta biede Kn e Pete sure aa waned 6 10 IMPELLER pcr 6 10 OIL SEAL HOUSING Water pump housing 6 10 GEA
60. GENERAL SPECIFICATION Model 70 75 hp Scavenging system Starting system Ignition system Loop charge Electric CDI Alternator output Carburetor starting system 6A 10A Choke valve Prime start Advance type Spark plug NGK Spark plug with noise suppressor NGK Micro computer BR8HS 10 B8HS 10 BR8HS 10 Register plug cap standard Exhaust system Cooling system Lubrication system Through prop boss Water Pre mixed gasoline amp oil Oil injection Fuel type Fuel rating Engine oil type grease Gear oil type Gear oil quantity Engine oil tank capacity Tilt angle Manual tilt model Tilt up angle S L X Trim angle PTT model Steering angle Gear shift position Gear ratio Gear type Clutch type Propeller direction Propeller drive system Propeller series mark cm US oz Imp oz L US qt Imp qt degree degree at 12 transom degree left right Regular gasoline Min 86 TC w3 4 Hypoid gear oil SAE 90 500 16 91 17 60 610 20 62 21 47 2 8 2 96 2 46 3 3 3 49 2 90 8 12 16 20 24 R 6 13 26 2 000 12 28 2 333 Spiral bevel gear Dog clutch Clockwise Spline K Battery capacity Cold cranking 1 2 3 4 For C60ER C60TR C75TR YAMALUBE 1 is recommended in Canada 5 6 Forward Neutral Reverse GEAR CASE L
61. M he ne gegen ease qe 4 1 FUEL EE aaa 4 2 REMOVAL iis iuit ecc onde das sean acces ere e eee 4 3 CLEANING AND INSPEC TION 2 24558056 hes 4 3 ER 4 3 FUEL METER COMPLETE de 4 4 PRIMING PUM Eege a 4 4 EUELFIETER 4 4 RE 4 5 FUEL RTE 4 5 INS s 4 5 CARBURETOR Re Eos Dude Sec Meet ede eee 4 6 EXPLODED DIAGRAM Except for C60ER C60TR C75TR 4 6 EXPLODED DIAGRAM For C60ER C60TR 75 4 7 REMOVAL AND DISASSEMBLY EE 4 8 INSPECTION ER 4 9 ees 4 9 NEEDLE VALVE Ee Seed 4 9 EIERE Neue Ee 4 9 COLLAR MR 4 9 597 3 WE 4 9 ENRICHING FUEL PUMP Edge access 4 10 ELECTROTHERMAL MEA 4 10 EE 4 11 INSTALLATIONS Re EE Eeer 4 13 OIL INJECTION SYSTEM Oil injection model 4 14 EXPLODED DIAGRAM uite 05919 ng aaa disant agen TU 4 14 EE 4 16 CLEANING AND INSPECTION 4 16 TIAN dec ES 4 16 OIL LEVER SENSOR eee 4 16 OIESHOSES deed 4 16 FUEL D F
62. PLODED DIAGRAM Short transom 6H308 D Reservoir body 9 Pipe Up relief valve seat Reservoir plug Down relief valve seat Filter 1 Motor assembly Down relief spring Manual valve seat Trim cylinder end screw Gear pump assembly Manual release spring Trim piston assembly 43 Shaft connector Adapter Valve seat screw Filter 2 62 Free piston C Main valve assembly 5 Up relief valve lock screw 3 Back up ring 2 Shuttle piston Up relief spring Tilt cylinder assembly 3 Nm 0 3 m kg 2 2 ft Ib 6 0 6m kg 4 3 ft Ib l i i 1 i 1 i 1 1 1 1 1 1 3 0 3 m kg 2 2 ft Ib 10 Nm 1 0 m kg 7 2 ft Ib 12 Nm 1 2 m kg 8 7 ft Ib 20 IP C 2 eg 3 BRKT L d POWER TRIM AND TILT UNIT CE D Power trim and tilt motor Absorber valve 80 kg cm Gear pump Free piston 3 Down relief valve 48 kg cm 42 Trim cylinder Main valve 5 2 way check valve Reservoir Up relief valve 40 kg cm Manual valve 9 Tilt cylinder BRKT L d POWER TRIM AND TILT UNIT CE K52002 0 DISASSEMBLY CAUTION 1 Do not wipe components of the hydrau lic system with rags or paper tissues etc as fibers entering the system will cause malfunction 2 After removing the tilt motor or oil res ervoir do not de
63. UBE is recommended in USA 2 3 70 252 380 For C60ER 60FED C60TR 60FET C75TR 90AEHD 90AED C90TR 90AET Pump Octane Number Research octane Motor octane 2 YAMALUBE two cycle outboard motor oil is recommended in USA SPEC GENERAL SPECIFICATION Item Model 50 hp Propeller No of blades x diameter x pitch Item G type aluminum 3x 11 3 8 x 12 3 x 11 1 8 x 13 Model 60 70 hp Propeller No of blades x diameter x pitch P High performance propeller Item K type aluminum K type stainless 3 x 13 1 4 x 17 3 x 13x 17 3 x 13 x 23 3 x 13 x 19 3 x 12 5 8 x 21 3 x 13 x 21 3 x 13 x 19 3 x 13 x 23 3 x 13 1 2 x 15 3 x 13 x 25 3 x 13 5 8 x 13 3 x 13 1 2 x 14 3 x 13 1 2 x 16 P type stainless 3 x 14 x 20 3 x 14 x 24 3 x 14 x 28 Model 75 80 90 hp Propeller No of blades x diameter x pitch P High performance propeller K type aluminum K type stainless 3 x 12 5 8 x 21 13 17 3 x 13 x 19 3 x 13 x 19 3 x 13 x 23 3x 13 x 21 3 x 13 1 4 x 17 3 x 13 x 23 3 x 13 1 2 x 15 3 x 13 x 25 3 x 13 1 2 x 17 3 x 13 1 2 x 14 3 x 13 5 8 x 13 3 x 13 1 2 x 16 14x11 P type stainless 3 x 14 x 20 3 x 14 x 22 3 x 14 x 24 3 x 14 x 26 3 x 14 x 28 2 4 SPEC MAINTENANCE SPECIFICATIONS C31000 0 MAINTENANCE SPECIFICATIONS ENGINE Item Model 50 hp 60hp 70 hp 75 hp Cylinder head Warpage limit
64. UEL SYSTEM 20000 1 FUEL SYSTEM EXPLODED DIAGRAM Carburetor Fuel tank cap Electrothermal valve Fuel tank Fuel pump assembly 4 Fuel filter assembly 5 Fuel joint 6 Priming pump Fuel meter assembly Except for C60ER C60TR C75TR 2 Nm 0 2 m kg 1 4 ft Ib 4 1 FUEL D FUEL SYSTEM CE D22500 0 FUEL LINE Check that the fuel line is correctly installed 50 60 70 hp D Oil tank Oil injection pump Carburetor Fuel filter 5 Fuel pump 75 80 90 hp D Oil tank Q Oil injection pump 3 Carburetor Fuel filter Fuel pump Oil injection model 4 2 FUEL D FUEL SYSTEM 4 3 REMOVAL A WARNING 1 Fire prevention Gasoline petrol is highly flammable Petroleum vapour is explosive if ignited Do not smoke while handling and keep it away from heat sparks and open flames Ventilation Petroleum vapour is heavier than air and if inhaled in large quantities will not sup port life Engine exhaust gases are harm ful to breathe When test running an engine indoors maintain good ventila tion Spillage Remember that fuel remains in the fuel hose between the fuel joint and the car buretor Drain all remaining fuel out into a container or soak it up with a cloth so that the fuel does not spill onto the bot tom cowling Leaks Failure to check for and correct fuel leaks may result in fire or explosion 1 Referri
65. XPLODED DIAGRAM For C60ER C60TR C75TR Pilot screw Needle valve Pilot jet Main nozzle 5 Main jet Float Drain screw Float chamber Throttle stop screw Collar 4 7 FUEL D CARBURETOR 50 60 70 hp 75 80 90 hp 4 8 GE REMOVAL AND DISASSEMBLY A WARNING At this step ensure there is no spillage of gasoline on removing the connections 1 Remove the silencer cover disconnect the fuel hose then remove the carbure tor Except for C60ER C60TR C75TR 2 Referring to the diagram use a screw driver to disassemble the carburetor 3 Using solvent clean the components thoroughly and blow dry them with compressed air A WARNING Protect your eyes with suitable safety glasses or safety goggles when using com pressed air Protect your eyes and the eyes of others by directing the flow of com pressed air downward noting that solvent and small parts may be blown off CAUTION Do not use steel wire for cleaning the jets as this may enlarge the jet diameters and seriously affect performance FUEL D CARBURETOR CED E32000 1 INSPECTION CARBURETOR BODY 1 Inspect the carburetor body for cracks or clogging of the passages NEEDLE VALVE 1 Inspect the needle valve for free move ment and wear and replace if required PILOT SCREW 1 Inspect the pilot screw for wear and replace if required COLLAR 1 Inspect the collar at the end of the accel erator arm for wear
66. and replace if required FLOAT 1 Visually inspect the float for damage or cracks and replace if required 2 Measure the float height 3 If it is more than 2 mm 0 08 in greater or less than the specified float height recheck the valve seat and needle valve 4 9 FUEL D CARBURETOR Float height Stamped mark 62F00 15 0 1 0 mm 0 59 0 04 in 6H20A 6H30A 6H007 6H107 14 0 1 0 mm 0 55 0 04 in 6H210 14 0 2 0 mm 0 55 0 08 in 6H015 19 5 3 0 mm 0 77 0 12 in E21060 0 ENRICHING FUEL PUMP 1 Using a screwdriver disassemble the fuel pump 2 Visually inspect the pump body for cracks and replace if required 3 Inspect the valves for cracks or distor tion and replace if required 4 Inspect the diaphragm for any sign of damage perforation or stretching and replace if required ELECTROTHERMAL VALVE 1 Inspect the needle valve for any bend ing and wear and the piston valve for flow Inspect the body for cracks and the wire lead for defects D Needle valve 2 Piston valve Body Wire lead 2 Measure the resistance of the electro thermal valve Electrothermal valve resistance Blue Black 2 3 3 5 Q at 20 C 68 FUEL D CARBURETOR CED NOTE When measuring the resistance of 10 or less using the digital tester the correct measurement cannot be obtained Refer to Lower resistance measurement page 8 15 3 C
67. ce exceeds the speci fication replace the crankshaft assem bly INSPECTION CE 4 Using dial gauges measure the deflec tion Maximum deflection 50 60 70 hp 0 03 mm 0 0012 in 75 80 90 hp 0 05 mm 0 0020 in If the deflection is greater than the spec ified maximum correct the alignment by use of a copper hammer and a wedge If the deflection is greater than the spec ified maximum replace the crankshaft assembly zs G64000 0 50 60 hp 5 REED VALVE INSPECTION 1 Visually inspect for warping of the reed valve If warped measure the distortion with feeler gauges Warpage limit 0 2 mm 0 01 in If the amount of warping is greater than the specification replace the reed valve 2 Using a vernier caliper measure the valve stopper height Valve stopper height 50 60 hp 3 0 0 2 mm 0 12 0 01 in 70 75 80 90 hp 9 9 0 2 mm 0 39 0 01 in If the valve stopper height is outside the specification adjust it by bending it 3 Visually inspect for cracks on the reed valve If cracks are found replace the reed valve INSPECTION G64500 0 THERMOSTAT CLEANING 1 Using a soft brush and water remove all traces of salt dirt or corrosion INSPECTION 1 Visually inspect the thermostat for dam age If the thermostat is damaged or if it opens when cold replace it 2 Immerse the thermostat in water heat the water gradually Check the valve
68. ch Pulser coil PTT model except for C75TR 9 Stator assembly 75CET 90 90 CDI unit 5 Fuse 4 Rectifier regulator Wire harness Crank position sensor 3 Power trim and tilt relay PTT model Starter relay 8 Starter motor Trim sensor PTT model 8 2 ELECTRICAL WIRING D22000 0 ELECTRICAL WIRING Check that all leads and connectors are properly connected up 50 60 70 gt 24 Electrothermal valve 2 f win Power trim and tilt motor lead Ah 2 d Trim sensor lead are een Trailer switch coupler 2 Trailer switch 3 Fuel enrichment valve 4 7 A wire harness N 8 To power trim and tilt motor 2 C To trim sensor D To lighting coil 1 Except for C60ER C60TR 2 For PTT model 3 For PTT model except for USA Canada and Oceania model 4 For C60ER C60TR B Black L Blue Lg Light green R Sb Sky blue P60TH 60FEHTO 1 P75TH 75CEHTO 90AEHD Main switch Engine stop switch Sg 3 Neutral switch Starter relay A To battery B To oil level sensor C To trim sensor 2 27 D To power trim and tilt motor m NS E To power trim and tilt relay 9 ait ei 2 d 1 M 7 d Si F To thermo switch 6 To 10P coupler H To Main switch To power trim
69. commuta tor Standard diameter 50 60 70 hp 30 mm 1 18 in 75 80 90 hp 33 mm 1 30 in Minimum diameter 50 60 70 hp 29 mm 1 14 in 75 80 90 hp 31 mm 1 12 in If the commutator diameter is out of specification replace the armature 4 Measure the commutator mica under cut depth Standard mica undercut depth 0 8 mm 0 03 in Minimum undercut depth 0 2 mm 0 01 in If the undercut depth is less than the specified minimum scrape between the segments with a hacksaw blade then remove all particles of mica and metal with compressed air ELEC STARTER MOTOR 8 34 CES 5 Check the insulation between the shaft or laminations and ground If there is any continuity replace the armature 6 Inspect that the commutator is an open circuit by checking for continuity between segments If any segment is not continuous replace the armature ASSEMBLY 50 60 70 hp 1 Apply a thin coat of water resistant grease to the rear cover bushing and install the armature in the rear cover assembly NOTE Install by lifting the brushes and inserting the armature straight into the bushing tak ing care not to scratch the brush or contam inate it with grease 2 Install the yoke assembly aligning the recess on the rear cover with the projec tion on the stator and ensuring that the O ring fits correctly in the rear cover groove 3 Mount the two washers on the arma ture s
70. diagram indicate grade of sealing or locking agent and location of application point Apply Gasket Maker Apply LOCTITE No 271 Red LOCTITE 63 Apply LOCTITE No 242 Blue LOCTITE Apply LOCTITE No 572 NOTE In this manual the above symbols may not be used in every case www motorka org sel 1 CHAPTER 1 GENERAL INFORMATION TEIN TIFICATION ar E 1 1 SERIAL NUMBER us ag eege 1 1 STARTING SERIAL NUMBERS 1 1 SAFETY WHILE WORKING 5 rne 1 2 FIRE PREVENTION eet eost eset tay eter Ee 1 2 VENTILATION E 1 2 SELF PROTECTION dana ian ngawangi naga agan Ded gge 1 2 OILS GREASES AND SEALING FEUIDS etie oii onn ttes 1 2 GOOD WORKING PRACTICES 52 2 artc orae Eed 1 3 DISASSEMBLY AND ASSEMBLY anter 1 4 SPECIAL TOOLS 1 5 MEASURING EE 1 6 REMOVAL AND INSTALLATION arra nn nemini 1 8 3 D SE YAMAHA MOTOR CO LTD MADE IN JAPAN PAYS D ORIGINE JAPON A60000 1 IDENTIFICATION SERIAL NUMBER The serial number of the outboard motor is stamped on a plate attached to the port side of the clamp bracket Serial number NOTE For USA model As an anti theft meas
71. dpaper 440 600 grit but if there is excessive scratching replace the components 2 Clean all the parts thoroughly using a soft brush and solvent and dry them with compressed air 3 Inspect the tilt cylinder and pump unit and replace them if they are badly cor roded K54001 0 ASSEMBLY NOTE The components in this assembly are to be lightly coated with hydraulic fluid before assembly BRKT L d POWER TRIM AND TILT UNIT CE Ee 8 6 ects 7 25 1 Install the tilt cylinder and the delivery pipes Bushing Q Tilt cylinder Lower mount pin 4 Delivery pipe NOTE Feed oil into each pipe IN Lock nut delivery pipe A 15 Nm 1 5 m kg 11 ft Ib 2 Install the manual valve in the body with new O rings Snap ring Q O ring Manual release screw O ring 5 Manual valve seat 6 Manual release spring 00 6 mm Adapter 1 Manual release spring 01 2 mm 3 Nm 0 3 m kg 2 2 ft Ib 3 Install a new O ring on the shuttle pis ton and insert the piston into the body then install the main valves with new O rings D O ring Shuttle piston 3 O ring O ring 5 Main valve Main valve 22 1 1 8 0 ft Ib BRKT L d POWER TRIM AND TILT UNIT CE 4 Install the up relief valve and the valve lock screw with new O rings and tighten the screw to the specified t
72. e unit is assembled Example If M is 23 90 mm is 5 then T1 24 50 5 100 23 90 0 65 Available shim thickness 0 10 0 12 0 15 0 18 0 30 0 40 and 0 50 mm 6 23 SHIM SELECTION Loun e EXCEPT FOR USA AND CANADA CED 2 eUse a minimum number of shims to obtain the thickness equal or nearly equal to the calculation Install the shims with the thicker one the outer side Reverse gear shim 1 Find reverse gear shim thickness T2 by selecting shims until the specified measurement M with the special tool 1 is obtained NOTE _ Be sure to remove the O ring from under the thrust washer 90850 06101 2 Using a digital caliper at the specified measurement established above measure the distance between the washer top and special tool top as 90890 06704 shown Shim thickness T2 50 hp M 25 40 mm R 100 mm 60 70 hp M 28 00 mm R 100 mm 75 90 hp M 26 00 mm R 100 mm Shimming plate 90890 06701 Digital caliper 90890 06704 3 R is the deviation of the lower case dimension from standard It is stamped on the trim tab mounting surface of the lower case in 0 01 mm units If the R mark is missing or unreadable assume an R mark of 0 and check the back lash when the unit is assembled 6 24 Loun e SHIM SELECTION 6 25 Example If Mis 28 60 mm R is 1 then T2 28 60
73. ear shim thickness T2 by ED selecting shims until the specified measure P ment M with the special tool is obtained 1 Find the specified measurement M Specified Measurement M 60 70 hp 1 00 mm R 100 mm 75 90 hp 1 50 mm R 100 mm NOTE ________________________ 1 is the deviation of the lower case dimension from standard It is stamped on the trim tab mounting surface of the lower case in 0 01 mm units If the R mark is missing or unreadable assume an R mark of 0 and check the backlash when the unit is assembled 2 If the R value is negative then add the R value to the measurement 6 20 Loun e SHIM SELECTION FOR USA AND CANADA 6 21 CE Example 60 70 hp If R mark is 5 then M 1 00 5 100 mm 1 00 0 05 mm 0 95 mm If R mark is 3 then M 1 00 3 100 mm 1 00 0 03 mm 1 03 mm Example 75 90 hp If R mark is 5 then M 21 50 5 100 mm 21 50 0 05 mm 0 45 mm If R mark is 3 then M 21 50 3 100 mm 21 50 0 03 mm 21 53 mm 2 Place the original shim s on the thrust washer mounted on the bearing hous ing and place the shimming gauge on top of the shim s as shown in the illus tration NOTE 1 If the original shim s is unavailable start with a 0 50 mm shim 2 Be sure to remove the O ring from under the thrust washer Shimming gauge YB 34468 5 60 70 hp YB 34468 3 75 9
74. ect the mating gear and replace both if necessary 156000 0 DRIVE AND PROPELLER SHAFT 1 Visually inspect the shafts looking for grooved wear on the surface in contact with the bearings and oil seals and checking for wear on the splines Replace if worn or damaged 156300 0 DRIVE SHAFT SLEEVE 1 Visually inspect the sleeve for wear and cracks If any damage is found replace the sleeve 157000 0 PROPELLER TRIM TAB ANODE 1 Refer to PERIODIC SERVICE section in chapter 3 Loun e ASSEMBLY AND ADJUSTMENT 161009 0 ASSEMBLY AND ADJUSTMENT PROPELLER SHAFT HOUSING 1 Install the thrust washer and press fit a ball bearing to the reverse gear 50GETO 2 Install a needle bearing and oil seals and then press fit the reverse gear com plete into the bearing housing NOTE _ ____ _ Install the needle bearing with its manufac ture s marks or numbers facing outward Depth 2 50 hp 20 7 mm 1 06 in 60 90 hp 25 5 mm 1 00 in 2 Drive rod YB 6071 90890 06604 Needle bearing attachment 50 hp 90890 06614 60 90 hp YB 6152 90890 06611 Bearing depth plate 90890 06603 For USA and Canada Except for USA and Canada Depth b 5 mm 0 20 in 2 Driver rod 6071 Oil seal attachment gt 60 90 hp YB 6259 253 ASSEMBLY AND ADJUSTMENT CE GEAR CASE 1 Install a new needle bearing in position NOTE
75. er element thoroughly Inspect the filter element for breakage or distor tion and replace if required 4 Using a soft brush and solvent clean the filter cup thoroughly Inspect the fil ter cup for cracks or thread damage and replace if required 5 Place the O ring on the filter body install the element and screw in the fil ter cup E21050 0 FUEL JOINTS 1 Inspect the fuel joints for leaks and cracks and replace as required E21060 0 FUEL PUMP 1 Using a screwdriver disassemble the fuel pump 2 Visually inspect the pump body for cracks and replace if required 3 Inspect the valves for cracks or distor tion and replace if required 4 Inspect the diaphragm for sign of dam age perforation or stretching and replace if required 5 Assemble the fuel pump with new gas kets E22000 0 INSTALLATION Referring to the diagram install the fuel system Note the following points When connecting the fuel hoses to the fuel pump and fuel filter follow the direction of flow indicated by the embossed arrows Place the clips in position connect the hoses and tighten the clips Check for leaks FUEL D CARBURETOR ED E31001 1 CARBURETOR EXPLODED DIAGRAM Except for C60ER C60TR C75TR Pilot screw Float chamber Needle valve Throttle stop screw 3 Pilot jet Collar Main nozzle Electrothermal valve 5 Main jet 2 Valve Float 4 Diaphragm Drain screw 4 6 FUEL D CARBURETOR E
76. erate explosive hydrogen gas Always follow these preventive mea sures e Charge batteries in a well ventilated area e Keep batteries away from fire sparks or open flames e g welding equipment lighted cigarettes eDO NOT SMOKE when charging or han dling batteries KEEP BATTERIES AND ELECTROLYTE OUT OF REACH OF CHILDREN Recommended battery capacity Rating 12V 70AH 252 kC Minimum cold crank performance 380 Amps at 17 8 C 0 F Minimum reserve capacity 124 minutes at 26 7 C 80 F INSP ADJ PERIODIC SERVICE 3 3 D31600 1 CARBURETOR 1 Check the fuel passages and air pas sages for fouling or clogging Clean fouled parts with suitable cleaning sol vent and blow out clogged passages with compressed air WARNING Protect your eyes with suitable safety glasses or safety goggles when using com pressed air 2 Check the needle valve for wear and replace it if worn D31902 1 CARBURETOR LINK ADJUSTMENT 50 60 70 hp 1 Loosen the idle adjust screw and fully close the throttle valve 2 Loosen the throttle lever securing screws of upper and middle carburetors by turning clockwise 3 While lightly pushing the throttle lever of the lower carburetor in the direction of the arrow full closed tighten the throttle lever securing screw of the upper middle carburetors by turning counterclockwise Idle adjust screw 2 Throttle lever 3 Throttle lever sec
77. ered end Install the piston in the connecting rod small end insert the piston pin then install new piston pin clips 5 Lubricate each bearing with 2 stroke outboard motor oil ASSEMBLY AND ADJUSTMENT CE CONNECTING ROD BIG END BEARING ASSEMBLY 75 80 90 hp 1 Install the piston Align the ring ends with locating pins in the grooves and using the piston slider push the piston into the cylinder Piston slider YU 33294 90890 06530 NOTE The UP mark on the piston crown should be on the flywheel side Be sure to apply oil to the piston and cylinder wall 2 Place the crankshaft on the cylinder and align the upper upper middle and lower middle bearing pin holes with the pins on the cylinder and fit the crank shaft correctly to the cylinder 3 Install the bearing in the big end and install the cap The cap bolts should be tightened in the following manner a Lightly screw in the bolts by hand while making sure the cap and rod ends are aligned completely Then tighten the bolts to the 1st specified torque Next tighten to the 2nd specified torque Check to see that the cap and rod ends are aligned If not aligned do the above procedure all over again b Loosen the bolts 1 2 turn and tighten them to the 1st specified torque Then tighten to the 2nd specified torque ASSEMBLY AND ADJUSTMENT CE NOTE Replace the cap bolts each time the con nect
78. ers and resin washer in that order on the armature shaft and install the front cover onto the yoke assembly Front cover 4 Align the cut for the through bolt in the brush holder with the gap in the brush holder so that the through bolt can be inserted 5 Install the rear cover onto the yoke assembly insert the through bolt into the rear cover and screw it into the front cover eApply a thin coat of grease anti freeze grease to the front and rear cover bear ings e To seal out water the mating surfaces are coated with sealing compound INSTALLATION 75 80 90 hp 1 Place the starter motor on the starter motor stay and tighten the bolts 2 Secure the starter motor to the engine with the four starter motor mounting bolts 3 Connect the positive and negative wires to the starter motor 8 36 TRBL ANS D CHAPTER 9 TROUBLE ANALYSIS TROUBLE ANALYSIS te anana nn e te eer nee 9 1 TROUBLE ANALYSIS CHART rete ratto ten tnt nan ntn nione seas 9 1 TRBL ANLS 2 TROUBEANALYSIS CE TROUBLE ANALYSIS NOTE The following items should be obtained before trouble analysis 1 Battery is charged and its specified gravity is in specification 2 There is no incorrect wiring connection 3 Wiring connections are surely engaged and without any rust 4 Lanyard is installed to the engine stop switch 5 Shift position is in neutral 6 Fuel is coming
79. everse gear bearing Propeller shaft housing oil seal Drive shaft outer bearing Ring nut wrench YB 06048 YB 34447 90890 06510 90890 06511 Ring nut Extension 90890 06513 Ring nut Claw YB 06207 90890 06502 90890 06503 Propeller shaft housing Universal puller YB 06117 N A Propeller shaft housing Center bolt 90890 06504 Propeller shaft housing Drive rod YB 06071 90890 06602 Propeller shaft housing oil seal Drive shaft needle bearing Needle bearing attachment YB 06153 90890 06612 Propeller shaft housing bearing Drive shaft holder YB 06049 YB 06151 90890 06518 90890 06519 Pinion nut Pinion nut holder N A 90890 06505 Pinion nut Bearing outer race puller N A 90890 06523 Forward gear outer bearing Needle bearing attachment YB 06155 90890 06611 Drive shaft needle bearing Bearing separator YB 06219 90890 06534 Crank shaft bearing Reverse gear bearing Forward gear bearing Drive rod YB 06071 90890 06604 Propeller shaft needle bearing Needle bearing attachment YB 06153 1 8 90890 06612 90890 06614 Propeller shaft needle bearing Gs SEN A m Tool name SPECIAL TOOLS Tool No USA and Canada Except for USA and Canada Use for Bearing depth plate N A 90890 06603 Propeller shaft needle bearin
80. f inhaled in large quantities will not support life Engine exhaust gases are harmful to breathe When test running an engine indoors maintain good ventilation SELF PROTECTION Protect your eyes with suitable safety glasses or safety goggles when using com pressed air when grinding or when doing any operation which may cause particles to fly off Protect hands and feet by wearing safety gloves or protective shoes if appropriate to the work you are doing OILS GREASES AND SEALING FLUIDS Use only genuine Yamaha oils grease and sealing fluids or those recommended by Yamaha Kee d SAFETY WHILE WORKING CE 1 3 Under normal conditions of use there should be no hazards from the use of the lubricants mentioned in this manual How ever safety is all important and by adopt ing good safety practices any risk is minimized A summary of the most important precau tions is as follows 1 While working maintain good stan dards of personal and industrial hygiene 2 Clothing which has become contami nated with lubricants should be changed as soon as practicable and laundered before further use 3 Avoid skin contact with lubricants do not for example place a soiled wiping rag in one s pocket 4 Hands and any other part of the body which have been in contact with lubri cants or lubricant contaminated cloth ing should be thoroughly washed with hot water and soap as soon as practica ble 5 To p
81. ft stops in each direction 3 Determine the shim size according to 6 27 the chart 50 hp Reverse gear backlash Decrease or increase Less than 0 84 mm 0 033 in Thickness of shim to be increased mm 1 01 measurement x 0 60 0 84 1 17 mm 0 033 0 046 in Decrease or increase will be unnecessary More than 1 17 mm 0 046 in 60 70 hp Reverse gear backlash Thickness of shim to be decreased mm mea surement 1 01 x 0 60 Decrease or increase Less than 0 75 mm 0 033 in Thickness of shim to be increased mm 0 94 measurement x 0 53 0 75 1 13 mm 0 033 0 044 in Decrease or increase will be unnecessary More than 1 13 mm 0 044 in Thickness of shim to be decreased mm mea surement 0 94 x 0 53 ou smmseecnon ce 75 80 90 Reverse gear Decrease or increase backlash Thickness of shim to be increased mm 0 84 measurement x 0 60 Less than 0 67 mm 0 026 in 0 67 1 00 mm Decrease or increase will 0 026 0 039 in be unnecessary Thickness of shim to be decreased mm mea surement 0 84 x 0 60 More than 1 00 mm 0 039 in 164000 0 WATER PUMP INSTALLATION 1 Install a new oil seal in the oil seal housing and fit a new O ring in the O ring groove 22 Driver rod 6071 Oil seal attachment YB 6269 2 Grease the O ring and
82. g YB 34446 3 Forward shimming Press plate YB 34446 5 N A Forward shimming Gauge pin YB 34446 7 N A Forward shimming Digital multimeter YU 34899 A 90890 06752 Electrical N Pocket tester YU 03112 90890 03112 Electrical Pressure gauge YB 06181 N A PTT unit Shimming gauge YB 34468 3 YB 34468 5 Reverse shimming N 3 pins test harness YB 06443 1 6 90890 06757 Peak voltage measurement 58 SPECIAL TOOLS CE Tool name SPECIAL TOOLS REMOVAL AND INSTALLATION Tool No USA and Canada Except for USA and Canada Use for Small end bearing installer YB 06107 YB 06287 90890 06527 Connecting rod Piston slider YU 33294 90890 06530 Cylinder piston Slide hammer set YB 06096 Water pump housing oil seal Reverse gear bearing Propeller shaft housing oil seal Drive shaft outer bearing Forward gear outer bearing Stopper guide plate 90890 06501 Water pump housing oil seal Bearing housing Reverse gear bearing Propeller shaft housing oil seal Drive shaft outer bearing Bearing puller 90890 06535 Water pump housing oil seal Reverse gear bearing Propeller shaft housing oil seal Drive shaft outer bearing Stopper guide stand N A 90890 06538 Water pump housing oil seal R
83. g Drive shaft needle bearing Oil seal attachment YB 06269 N A Propeller shaft oil seal Needle bearing depth stop YB 34473 N A Drive shaft needle bearing Driver rod YB 06071 90890 06606 Drive shaft outer bearing Bearing outer race attach ment YB 06156 90890 06626 90890 06627 Drive shaft outer bearing Driver rod YB 06071 90890 06605 Forward gear outer bearing Bearing outer race attach ment YB 06276 B 90890 06621 90890 06622 Forward gear outer bearing Bearing inner race attach ment N A 90890 06640 90890 06662 Forward gear inner bearing Shift rod wrench YB 06052 N A Shift rod Cylinder end screw wrench YB 06175 1A N A PTT Cylinder end screw wrench YB 06175 2B 90890 06544 90890 06548 PTT Flywheel holder YB 06139 90890 06522 Flywheel Flywheel puller YB 06117 90890 06521 Flywheel SPEC CE CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATION eene 2 1 MAINTENANCE SPECIEIGATIONS enn 2 5 ENGINE tipos idu ee 2 5 SE EE 2 7 DIMENSION E acce EE 2 10 TIGHTENING TOROUE EE 2 12 GENERAL TORQUE SPECIFICATIONS 2 13 SPEC GENERAL SPECIFICATION C20000 0 GENERAL SPECIFICATION Model 50 hp 60 hp 70 hp 50GETO 71 6 60FEHTO 2 C60ER 60FED 3 6
84. haft Sparingly apply water resis tant grease to the front cover bushing ensure that the O ring fits into the arma ture shaft and insert the shaft into the front cover ELEC STARTER MOTOR 8 35 4 Insert the through bolts into the rear cover and screw them into the front cover 5 Mount the pinion spring and pinion stopper on the armature shaft 6 Hold down the pinion stopper and fit the circlip into the groove in the shaft Use a socket wrench that fits properly over the armature shaft Reform the cir clip by using pliers Lift up the pinion stopper until its bottom contacts the cir clip INSTALLATION 50 60 70 hp 1 Place the starter motor on the starter motor stay and tighten the bolts to the specified torque EN Starter motor mounting bolt A 20 Nm 2 0 m kg 14 ft Ib 2 Secure the starter motor to the engine with the four starter motor mounting bolts 3 Connect the positive and negative wires to the starter motor ASSEMBLY 75 80 90 hp 1 Insert the armature into the yoke assembly Fit the brush attached to the negative side of the brush holder into the armature Brush holder ELEC STARTER MOTOR 2 Install the positive brush on the stator coil side in the brush holder and hold it with the spring LL EM me H H Use care not to scratch the brushes when E EL installing brush Spring 3 Mount the two steel wash
85. he thread of the ring nut 2 Visually inspect the ring nut for cracks or damage to the thread If cracked or damaged replace the ring nut 6 9 Loun e INSPECTION 153000 0 WATER PUMP HOUSING 1 Inspect the water pump housing for signs of twisting or scratches of the inner cartridge If twisted or scratched excessively replace the housing 2 During the above operation inspect the impeller plate and replace this if dam aged 153500 0 IMPELLER 1 Visually inspect the impeller for cracks distortion or burning If any damage is found replace the impeller 154000 0 OIL SEAL HOUSING Water pump housing 1 Using a soft brush and solvent clean the oil seal housing 2 Visually inspect the housing for cracks or corrosion If a crack and or excessive corrosion is found replace the oil seal housing 154500 0 GEAR 1 Visually inspect the teeth and dogs on the gears for cracks peeling or distor tion due to gear crashing If damage is found on any of the gears replace with a new one 155000 0 BEARING 1 Inspect the bearings for pitting scratch ing or rumbling which may be detected by turning the bearing by hand and replace them if they are not in good condition Loun e INSPECTION 15500 0 CLUTCH DOG AND COMPONENTS 1 Visually inspect the clutch dog looking particularly for rounding of the dog edge cracks and other signs of damage or wear If the dog is excessively rounded insp
86. heck the piston valve height If the piston valve height is not different from to D replace the electrothermal valve a Measure the piston valve height 2 b Connect the wire leads to a 12V bat tery c Measure the piston valve height b after several minutes d Compare the valve height with ASSEMBLY 1 Install a new O ring the valves on the body and secure with the screws 2 Install the diaphragm on the carburetor with new gaskets install the pump cover on the carburetor and secure with the screws 3 Install a new O ring to the electrother mal valve install it to the carburetor with the plate and secure with the screws 4 Insert the main nozzle fully and screw in the main jet until tight 5 Screw in the pilot jet fully and install the cap FUEL D CARBURETOR CE 6 Install the needle valve on the float attach the float to the carburetor body with the float pin and tighten the screw 7 Install a new O ring to the float cham ber install it to the carburetor body and secure with the screws 8 Install the plate with new packing and secure with the screws 9 Install the pilot screw with its spring screw it in until seated then screw it out the specified number of turns CAUTION Do not cause damage to the tip of the pilot screw by over tightening it Pilot screw stamped mark 62F00 6H210 6H007 6H015 1 3 8 1 4 turns out 6H20A 1 1 2 1 4 turns out 6H30A 6H1
87. ing rod is disassembled Connecting rod big end 75 80 90 hp 1st step 12 Nm 1 2 8 7 ft Ib 2nd step 35 Nm 3 5 m kg 25 ft Ib G79000 1 OIL SEAL HOUSING 1 Press fit the oil seals one by one CAUTION When press fitting the oil seal be sure that if faces in the correct direction 2 Fit the new O ring in the grooves in the oil seal housing outer surfaces 3 After installing the oil seal and O ring pack the oil seal lip and outer surface of the O ring with water resistant grease NOTE 272 2 Avoid cutting or stretching the oil seal housing O ring 4 Install the oil seal housing onto the cyl inder and align the bolt holes G74000 0 CRANK CYLINDER ASSEMBLY 50 60 70 hp 1 Lubricate the piston rings and pistons with 2 stroke outboard motor oil and install the crank assembly into the cylin der block ASSEMBLY AND ADJUSTMENT CE 2 Lift the crank assembly a little in order to install a washer on the lower crank case and align each location pin of the bearings and labyrinth seals with each cut on the cylinder block Then fit the crank assembly in place 3 Film coat the cylinder block mating sur face with Gasket Maker or equivalent 4 Install the dowel pins 5 Match the cylinder block and tighten the bolts to the specified torque in sequence and in two steps Crankcase bolt 50 60 70 hp 1st step M8 10 Nm 1 0 m kg 7 2 ft Ib M10 20 Nm
88. l cap side of the bearing should be installed towards the crank side as shown in the illustration 75 80 90 hp Install the circlip Circlip Q Oil injection pump drive gear 3 Crank lower bearing 2 Install the new oil seal in the needle bearing CAUTION The direction of the oil seal must be as shown in the illustration otherwise dam age will be caused 3 Install the new O ring 4 Lubricate the bearing with 2 stroke out board motor oil Apply water resistant grease or equivalent to the inside lip of the oil seal and to the O ring G72001 0 PISTON AND PISTON RING 1 Install the top and 2nd piston rings into their respective ring grooves with the markings facing upward 2 Align each ring end gap with their loca tion pins ASSEMBLY AND ADJUSTMENT CE SMALL END BEARINGS AND PISTON ASSEMBLY 1 Count the small end bearing needles Number of needles per small end 28 pcs CAUTION Do not use a mixture of new and used bear ing needles in the same small end 2 Using the special service tool install the bearings in the connecting rod small end and place washers on both sides Small end bearing installer i 50 60 70 hp YB 6287 90890 06527 75 80 90 hp YB 6107 90890 06527 CAUTION The washer should be placed with their convex sides facing the piston 3 Insert the piston pin into the piston 4 Align the UP mark on the piston crown towards the crankshaft s tap
89. lowing parts 1 Water pump housing and insert car tridge 2 Impeller and woodruff key 3 Oil seal housing Water pump housing Remove the oil seals if necessary Slide hammer set YB 6096 1 Stopper guide plate 90890 06501 2 Bearing puller 90890 06535 3 Stopper guide stand 90890 06538 4 A For USA and Canada Except for USA and Canada 00 6 3 om lt gt 4 Shift rod 5 Ring nut D and claw washer 2 222 Ring nut wrench 90890 06511 Extension ring nut wrench 90890 06513 A For USA and Canada Except for USA and Canada 00 NOTE To remove the ring nut straighten the lobe of the claw washer by using a screwdriver then attach and turn it in the direction of the off mark using the special service tool 6 Bearing housing Using special service tool 50 60 70 hp 90890 06503 75 80 90 hp 90890 06502 Flywheel puller Stopper guide plate 90890 06501 Center bolt 90890 06504 For USA and Canada B Except for USA and Canada 6 4 losen 7 Propeller shaft For 50GETO C60ER C60TR 60FET Oceania C75TR 90AEHD 90AED C90TR 90AET Clutch dog Cross pin Cross pin ring 7 Propeller shaft Except for 50GETO C60ER C60TR 60FET Oceania C75TR 90AEHD 90AED C90TR 90AET D Clutch dog 0 Cross pin Cross pin ring 8 Shift slide Except for 5
90. ls 3 Check the relay operation 1 Connect a tester between the termi nals of the starter relay Connect the leads of the starter relay to a 12 V battery Brown lead Black lead Battery voltage oi vv Black Br Brown 4 Check that there is continuity between the starter relay terminals If the opera tion is not as specified replace the starter relay M51410 0 POWER TRIM AND TILT RELAY 1 Check the relay for terminal looseness and for wiring rust and corrosion Replace the relay if any of the three defects is found 2 Connect the terminal and terminal and the terminal and terminal to the tester and check that the resistance becomes in each case 8 21 ELEC ELECTRICAL ANALYSIS ow CE Connect the terminal and terminal and the terminal and 2 terminal to the tester and check the continuity in each case Sky blue Light green Black Connect the black terminal to the ter minal of the battery and the light green terminal to the terminal of the bat tery Then connect the terminal and terminal to the tester and check the continuity Connect the black terminal to the ter minal of the battery and the sky blue terminal to the terminal of the bat tery Then connect the terminal and terminal to the tester and check the continuity M56100 0 TRAILER SWITCH 1 To see that there is continuity push the
91. m kg 5 1 ft Ib 90 Nm 9 0 kg 4 Nm 0 4 m kg 2 9 ft Ib 160 16 m kg 115 ft Ib Fees 2 2 ft Ib 277 p 15 Nm 1 5 m kg 11 ft ib 7 20 POWER TRIM AND TILT UNIT Trim down valve 0 2 kg cm Trim down valve 1 kg cm BRKT Reservoir Down relief valve 30 kg cm 4 Gear pump Power trim and tilt motor Up relief valve 100 kg cm 5 Manual valve Tilt cylinder 180 kg cm Absorber valve Trim cylinder 2 0 5 kg cm Main valve 7 21 BRKT L d POWER TRIM AND TILT UNIT CE 7 22 K52002 0 DISASSEMBLY CAUTION 1 Do not wipe components of the hydrau lic system with rags or paper tissues etc as fibers entering the system will cause malfunction 2 After removing the tilt motor or oil res ervoir do not depress the tilt rod or trim rod which may cause hydraulic fluid to be ejected from the port Turn the manual valve fully towards the manual position 2 Remove the delivery pipes and the hydraulic fluid level plug 3 Remove the hydraulic fluid reservoir and the tilt motor 4 Remove the shaft connector 5 Remove the filter and the gear pump 6 Remove the O rings and the complete down relief valve CAUTION Do not disassemble the gear pump unit which is factory adjusted but replace the complete gear pump unit if necessary 7 Loosen the screw and re
92. minals between which there is a continuity of electricity i e a closed circuit at the respective switch position Peak voltage measurement NOTE L eThe coil output varies greatly at cranking speed e Cranking a cold engine with the plugs in and a weak battery does not enable proper readings 22 Digital multimeter J 39299 90890 06752 Peak volt adapter YU 39991 90890 03169 Low resistance measurement When measuring a resistance of 10 Q or less using the digital tester the correct measurement cannot be obtained because of the tester s internal resistance To obtain the correct value subtract this internal resistance from the displayed measurement Correct value Displayed measurement Internal resistance internal resistance of the tester be obtained by connecting both of its termi nals ELEC ELECTRICAL ANALYSIS IGNITION SPARK GAP WARNING e While checking the spark be careful not to touch any connection of lead wires of the Ignition spark gap tester e When doing the spark test take special care not to allow leakage from the plug cap which has been removed This check is likely to produce sparks so be sure that no flammable gas or fluid is present 1 Ignition spark gap 1 Adjustthe spark gap to specification by turning the adjusting knob 22 Spark gap tester YM 34487 90890 06754 2 Connect the spark plug cap to the spark ga
93. move the com plete up relief valve D Screw Up relief spring Valve support pin Relief valve seal 5 Relief valve seat 6 O ring Filter Trim spring BRKT L d POWER TRIM AND TILT UNIT CE 8 Remove the one way valve and main valve seal 9 Valve lock screw O ring Ball 2 Washer Main valve seal 9 Loosen the trim cylinder end screw and pull out the trim piston components 2222 Cylinder end screw wrench 2 YB 6175 1A 90890 6548 10 Loosen the tilt cylinder end screw and pull out the tilt piston and the free pis ton A WARNING The free piston can be removed easily by blowing compressed air into the drain hole of the cylinder Be sure to cover the open end of the cylinder with a rag to prevent the free piston from being ejected which could cause injury or piston damage 22 Cylinder end screw wrench 24 YB 6175 2B 90890 06544 11 Remove the main valves and the shut tle piston 7 23 BRKT L d POWER TRIM AND TILT UNIT CE 7 24 12 Remove the circlip and the manual valve and components Snap ring Q O ring Manual release screw O ring 5 Manual valve seat Manual release spring 1 Adapter 1 Manual release spring 2 K53000 0 INSPECTION TILT ROD AND TRIM ROD 1 Clean these components using a soft brush and solvent and inspect them carefully If there are light scratches on the surfaces these may be polished off using fine wet or dry san
94. n 62 Tilt lock lever Bushing 03 Washer 0 Spring Collar BRKT L d BRACKET UNIT K15900 0 BRACKET Long transom Circlip Lower mounting housing 9 Steering pivot shaft Bushing 5 O ring 8 Bushing Grease nipple Ground lead 9 Tilt rod manual tilt model Clamp bracket nut Bolt 6 bolts 42 Clamp bracket bolt 43 Washer Bushing 49 Clamp bracket Trim sensor PTT model Circlip Pin 7 8 Bushing Power trim and tilt unit PTT model 6 Tilt lock lever 03 Bushing Spring Collar BRKT L d BRACKET UNIT K20002 0 REMOVAL 1 Remove the power head 2 Remove the swivel bracket from the upper casing CAUTION Lay the outboard motor on the floor to carry out this removal DISASSEMBLY 1 Referring to the exploded diagram dis assemble the bracket unit INSPECTION ANODE 1 Check anode and replace with new one when the size is less than 1 3 of original length BRACKET 1 Inspect the bracket and replace them if cracked TRIM SENSOR 1 Check resistance of the new trim sensor Trim sensor resistance Pink Black 360 540 Q Black Orange 800 1200 Q 2 Measure resistance between black and pink leads to check that the value changes gradually in the whole trim and tilt range If not replace trim sensor with new one 7 9 BRKT L d BRACKET UNIT Trim sensor adjustment Fully tilt up the
95. nd Canada use part numbers starting with YB YM YU or YW e For others use part numbers starting with 90890 MEASURING Tool name SPECIAL TOOLS Tool No USA and Canada Except for USA and Canada Use for Tachometer YU 08036 A 90890 06760 Idle speed Dynamic spark tester YM 34487 90890 06754 Ignition system CDI tester YU 91022 B N A Ignition system Mity Vac YB 35956 90890 06756 Fuel joint Pressure tester YB 35956 90890 06762 Lower case Dial gauge YU 03097 90890 01252 Backlash Backlash indicator YB 06265 90890 06706 Backlash Magnet base YU 34481 90890 06705 Backlash CO CO NI OD 01 BI IN Backlash adjusting plate YB 07003 Backlash Thickness gauge YU 26900 8 Shimming o Pinion height gauge N A 90890 06702 Pinion shimming Digital caliper N A 90890 06704 Pinion Forward shimming shimming Gauge block YB 34432 9 N A Pinion shimming Adapter plate YB 34432 10 N A Pinion shimming Gauge base YB 34432 11 N A Pinion shimming Clamp YB 34432 17 N A Pinion shimming Shimming plate N A 90890 06701 Forward shimming Base plate YB 34446 1 N A Forward shimming Compression sprin
96. ng lamp Warning buzzer More than 1 130 cm GREEN 1 19 US qt 1 130 cm 1 19 Us qt 310 cm 0 33 US qt YELLOW 310 cm or less 0 33 US qt SE PERIODIC SERVICE 50 60 70 hp iz 75 80 90 hp D34300 1 OIL PUMP LINK ADJUSTMENT 1 Fully open the carburetor throttle valve 2 Set the oil pump lever 1 mm off full open side stopper With the lever in this position adjust the length of the rod connecting the oil pump to the carbure tor and tighten the locknut 3 Install the connecting rod 4 By operating the carburetor check that the throttle valve opens fully POWER TRIM AND TILT FLUID PTT model 1 Tilt up the motor and lock it with the tilt lock lever 2 Remove the fluid level plug to check the fluid level With the motor tilted up the fluid level should be immediately below the fluid hole If the fluid level is low top up with the recommended fluid ATF automatic transmission fluid CAUTION When checking the fluid level with the unit removed from the engine hold the unit in the vertical position and set the tilt rod in the tilt up position 3 Re fit the fluid level plug and tighten it Fluid level plug Short transom 6H308 3 Nm 0 3 m kg 2 2 ft Ib Long transom 6H1 15 62F 02 7 Nm 0 7 kg 5 1 ft Ib SE PERIODIC SERVICE CE D34900 0 PROPELLER 1 Check the blades for wear damage or cavitation erosion
97. ng 09 Spacer 50GETO Needle bearing Bearing housing 50 hp 130 Nm 13 kg 94 ft Ib 60 90 hp 145 Nm 14 5 m kg 105 ft Ib 6 1 LOWR cD EXPLODED DIAGRAM EXCEPT FOR 50GETO C60ER C60TR 60FET OCEANIA C75TR 90AEHD 90AED C90TR 90AET Water pump housing 4 Shifter Needle bearing Q Impeller 42 Shift slide 62 Claw washer Cartridge outer plate 3 Forward gear 3 Ring nut Cartridge outer plate gasket Clutch dog 03 Spacer 5 Oil seal housing 5 Cross pin 09 Propeller 6 Water pump gasket Propeller shaft Castle nut Drive shaft Reverse gear Trim tab Woodruff key O ring Pinion gear 9 Drive shaft sleeve Bearing Needle bearing Bearing housing 95 Nm 9 5 m kg 69 ft Ib 6 2 Loun e PREPARATION FOR REMOVAL DISASSEMBLY lt gt 120001 0 PREPARATION FOR REMOVAL 1 Remove the nut washer propeller and spacer from the propeller shaft 2 Drain the gear oil by removing the plugs from the oil filling hole and the oil level hole Be sure to remove the oil filling plug first 3 Set the shift lever into neutral position 4 Tilt up the lower unit and lock it with the tilt lock lever 5 Remove the trim tab Before removing it put a mark indicating its position on the anticavitation plate 6 Remove the bolts 140007 0 DISASSEMBLY 1 Referring to the exploded diagram remove the fol
98. ng a piston push the piston ring a little beyond the bottom of the ring travel to a depth of 20 mm 0 8 in from the top of the cylinder block CAUTION Take care not to scratch the piston Using a thickness gauge measure the end gap Ring end gap installed 50 60 70 hp 0 3 0 5 mm 0 012 0 020 in 75 80 90 hp 0 4 0 6 mm 0 016 0 024 in If the clearance is not within the specifi cations replace the piston ring NOTE mmmn If the clearance is greater than maximum even with a new piston ring rebore the cyl inder and use an over size piston and pis ton ring 5 9 INSPECTION 50 60 70 hp PISTON PIN AND SMALL END BEARING CLEANING 1 Use a soft brush and solvent to clean the parts INSPECTION 1 Visually inspect for surface defects breakage scratches and pitting If it is decided to replace the small end bear ings replace them all G63500 0 CRANKSHAFT INSPECTION 1 Place the crankshaft on a crankshaft aligner or on V blocks 2 Using a dial gauge measure the con necting rod axial play Maximum axial play 2 0 mm 0 08 in If this axial play is greater than the max imum axial play replace the crankshaft assembly 3 Using feeler gauges measure the con necting rod side clearance 50 60 70 hp Connecting rod side clearance 50 60 70 hp 0 2 0 7 mm 0 008 0 028 in 75 80 90 hp 0 12 0 26 mm 0 005 0 010 in If this side clearan
99. ng to the exploded diagram remove the fuel line E21010 0 CLEANING AND INSPECTION FUEL TANK 1 Add a small quantity of a suitable clean ing solvent into the fuel tank and thor oughly clean the tank interior by shaking the tank 2 Drain off the cleaning solvent com pletely FUEL D FUEL SYSTEM 21020 0 FUEL METER COMPLETE 1 Using a soft brush and solvent clean the strainer on the end of the suction pipe and blow dry it with compressed air 2 Visually inspect the strainer for damage and replace the fuel meter complete if required 3 Inspect the fuel meter components for cracks and replace the fuel meter com plete if required 4 Re install the fuel meter complete with the rubber gasket to the fuel tank ensuring that there are no leaks between the fuel meter and the fuel tank Fuel meter assembly Suction pipe Fuel strainer E21030 0 PRIMING PUMP 1 Visually inspect for cracks or breaks in the priming pump and fuel hoses and replace them if required 2 Check the operation of the check valve by blowing into the pump Priming valve Arrow mark 3 Check valve inlet Check valve outlet E21040 0 FUEL FILTER 1 After removing the nut and filter cap disassemble the fuel filter 2 Visually inspect the filter body for cracks or damage to the thread and replace if required 4 4 FUEL D FUEL SYSTEM 4 5 3 Using a soft brush and solvent clean the filt
100. o the hole Be sure to bend the cotter pin ends NOTE _ __ If the propeller nut does not align with the propeller shaft hole when the nut is tight ened to specification turn it in further so that they align 7 Fill with fresh gear oil through the oil plug hole until oil flows out through the level plug hole then secure the plugs in these two holes Secure the check plug first oan e INSTALLATION 6 31 GE LOWER UNIT LEAKAGE CHECK 1 Tighten the gear oil drain screw and connect the tester to the oil level hole 2 Pump the tester and apply a pressure of 100 kPa 1 0 kg cm 14 2 psi Then place the gear case in the water tank 3 Check that the pressure is held 100 kPa 1 0 kg cm 14 2 psi for 10 sec onds CAUTION Do not overpressurize NOTE 10 4 41 1 0 02000201 2023242 If the pressure falls leakage from the lower unit is unacceptable requiring re inspection of its component parts Pressure tester YB 35956 90890 06762 A For USA and Canada B Except for USA and Canada BRKT L d CES CHAPTER 7 BRACKET UNIT BRACKET mE 7 1 EXPLODED DIAGRAM A 7 1 MANUAL HAN DBLE c rh en t 7 1 UPPER CASING casia Ee Steck EE Sue 7 2 BOTTOM COWLING fotum pedet pde doa Cod du dedii 7 4 LhredWippee 7 5 BRACKET UNIT Manual tilt model
101. oded diagram remove the following parts 1 Cylinder head 2 Intake manifold 3 Exhaust cover and thermostat cover 4 Oil seal housing Using the oil seal remover remove the oil seal one by one from the housing 5 Crankcase Remove the two dowel pins 6 Crankshaft and connecting rod 50 60 70 hp 7 Connecting rod caps needle bearings and crankshaft 75 80 90 hp 8 Piston and piston pin 9 Piston rings Note the following points 1 When disassembling the piston and pis ton pin place a tray under the connect ing rod to catch the needle bearings 2 Only carry out exchange of the crank shaft bearing if the bearing is malfunc tioning 5 5 INSPECTION 5 6 G61000 0 INSPECTION CYLINDER HEAD CLEANING 1 Using a gasket scraper remove all traces of gasket material from the cylin der head 2 Using a round scraper remove carbon deposits from the combustion chamber CAUTION Do not scratch the surfaces of the cylinder and combustion chamber 3 Using a soft brush clean the water jacket INSPECTION 1 Using a precision straight edge and thickness gauge measure the surface contacting the cylinder block warping Warpage limit 0 1 mm 0 004 in Lines indicate straight line measurement If the degree of warping exceeds this specification re surface the cylinder head as follows Place 400 600 grit wet or dry paper on the surface plate and resurface the cyl
102. on pin clip 9 Valve seat packing 3 Thermo sensor 2 Piston pin Reed valve plate Cylinder head cover 3 Bearing Reed valve assembly 5 Head cover gasket Drive gear Cylinder head 5 Circlip Cylinder head gasket Oil seal Exhaust cover gasket O ring Exhaust inner cover Oil seal housing B9OTR 90AETO M10 1st 20 Nm 2 0 m kg 14 ft Ib 2nd 40 Nm 4 0 m kg 29 ft tb ist 4 Nm 0 4 m kg 2 9 ft 15 2nd 12 Nm 1 2 kg 8 7 ft 1b Ist 9 Nm 0 9 m kg 6 5 ft Ib 2nd 18 Nm 1 8 m kg 13 ft Ib 1st 4 Nm 0 4 m kg 2 9 ft Ib 2nd 12 Nm 1 2 m kg 8 7 ft Ib 1st 12 Nm 1 2 m kg 8 7 ft 10 2nd 35 Nm 3 5 m kg 25 ft Ib PREPARATION FOR OVERHAUL REMOVAL CE G30000 0 PREPARATION FOR OVERHAUL 1 Clean all dirt mud dust and foreign material from the engine before the engine is removed and disassembled 2 To ensure that you can perform the work cleanly and efficiently check that you have the proper tools and cleaning equipment before commencing engine removal and disassembly 3 During engine disassembly as parts are disassembled clean them and place them in trays in their order of disassem bly This will speed up assembly and help ensure that all parts are correctly reinstalled NOTE M When disassembling the engine keep mated parts together e g cylinder and pis ton and other parts that have been mated
103. opening temperature and the valve lift Water temperature Valve lift Below 48 52 C 118 126 F Above 60 C Minimum 140 F 3 mm 0 12 in 0 mm If the valve opening and or temperature and valve lift are not within the specifi cations replace the thermostat G65000 0 CRANK MAIN BEARING CLEANING 1 Using a soft brush and solvent thor oughly clean the bearing Dry it with air and sparingly lubricate it with 2 stroke outboard motor oil NOTE Do not spin bearing with air blower This can damage the bearing Also take care not to scratch the bearing balls when cleaning INSPECTION 1 Hold the bearing inner race and slowly turn the bearing outer race with your fingers If any rough spots are felt replace the bearing INSPECTION 5 13 G65500 0 DRIVE GEAR OIL INJECTION PUMP DRIVE INSPECTION 1 Visually inspect drive gear teeth for cracks pitting or wear and replace the gear if any are found DRIVEN GEAR OIL INJECTION PUMP DRIVE INSPECTION 1 Visually inspect driven gear teeth for cracks pitting or wear and replace the gear if any are found ASSEMBLY AND ADJUSTMENT CE 50 60 70 hp 75 80 90 hp G71000 1 ASSEMBLY AND ADJUSTMENT BEARING OIL SEAL AND O RING 1 Press in the new bearing CAUTION When reassembling the lower crank bear ing and or the oil pump drive gear the tapered side of the drive gear and the sea
104. orque m 4 0 oo Main valve seal 4 Washer B Ball O ring e e 5 Valve lock screw Filter O ring Up relief valve seat Up relief valve seal Valve support pin Up relief spring 42 Trim spring 43 Screw Valve lock screw 4 Nm 0 4 m kg 2 9 ft Ib Screw 4 Nm 0 4 m kg 2 9 ft Ib 5 Fit a new O ring and the back up ring on the trim piston fit new O rings and a new Oil seal on the end screw and install the complete trim piston in the cylinder Fill the cylinder with hydraulic fluid and install and tighten the end screw to the specified torque ATF automatic transmission fluid D O ring Back up ring End screw trim cylinder 160 Nm 16 m kg 115 ft Ib 222 Cylinder end screw wrench 2 YB 6175 1A 90890 6548 7 26 BRKT L d POWER TRIM AND TILT UNIT CE 7 27 6 Install the down relief valve and the gear pump complete with new O rings tighten the bolts and fit the connector shaft and filter then fill with hydraulic fluid Down relief valve assembly Shaft connector 3 O ring Bolt Bolt 22 0 4m kg 2 9 ft Ib 7 Fit a new O ring on the free piston and install it into the cylinder O ring 8 Fit a new O ring and the back up ring to the tilt piston and install the piston in the cylinder Fill the cylinder with hydraulic fluid and tighten the end screw to the specified torque O ring
105. p tester 3 Remove the spark plugs from the engine 4 Crank the engine and check the sparks from the ignition system through the discharge window 5 Measure the ignition spark gap 6 If the output is out of specification measure the CDI SYSTEM PEAK VOLTAGE Spark gap 9 mm 0 35 in CDI SYSTEM PEAK VOLTAGE A WARNING While taking CDI unit check be careful not to touch any connection of lead wires of the Digital tester 9 NOTE ________________________ elf there is no spark or the spark is weak continue with the CDI test elf a good spark is obtained the problem is not with the CDI system but possibly the spark plug or other component is defec tive ELEC ELECTRICAL ANALYSIS 1 CDI unit output 1 Connect the tester to the CDI unit as shown 2 Set the tester dial to specification 3 Crank or start the engine 4 Measure all the CDI unit output 5 Ifthe output is beyond specification replace the ignition coil 6 If the output is below specification measure the charge coil output 50 60 70 hp CDI unit Output peak voltage minimum B W B Connect 1 3 105 12 CDI unit Output peak voltage minimum B W B Cranking Open Connect 31 3 130 2 1 500 3 500 2 Charge coil output 1 Disconnect the charge coil coupler Connect the 2 3 pins test harness 50 60 70 hp 2 pins test harness YB 38831 90890 06767
106. ped mark 62F00 6H210 6H007 6H015 1 3 8 1 4 turns out 6H20A 1 1 2 1 4 turns out 6H30A 6H107 1 1 4 1 4 turns out 3 Start the motor and allow it to warm up for a few minutes 4 Set the idle speed to the specified level by setting the throttle stop screw Use a tachometer for checking the speed when adjusting the motor speed NOTE Turning the throttle stop screw clockwise increases the motor speed turning it coun terclockwise decreases the motor speed Tachometer YU 8036 A 90890 06760 22 Idle speed 800 50 rpm SE PERIODIC SERVICE CE D33304 0 IGNITION TIMING ADJUSTMENT TIMING PLATE POSITION ADJUSTMENT If the timing plate is moved even a little dur ing inspection or repair operation it should be set in the following way This adjustment must be made before adjusting the ignition timing 1 Remove the spark plugs from the cylin ders 2 Install a dial gauge in the spark plug hole of No 1 cylinder NOTE _________________________ For easy timing plate adjustment it is advisable to remove the spark plugs from all the cylinders 3 Slowly turn the flywheel CLOCKWISE 50 60 70 h and stop it when the piston is at TDC AH the end of the timing plate is not TDC1 aligned with the TDC mark on the CDI magneto rotor loosen the timing plate set screw align the timing plate end with the TDC mark then tighten the screw 75
107. press the tilt rod or trim rod since this may cause hydraulic fluid to be ejected from the port 1 Turn the manual valve fully towards the manual position 2 Remove the hydraulic fluid level plug and drain the hydraulic fluid 3 Remove the delivery pipes and drain the hydraulic fluid 4 Remove the hydraulic fluid reservoir and the tilt motor 5 Remove the shaft connector 6 Remove the filter and the gear pump 7 Remove the O rings and the complete down relief valve CAUTION Do not disassemble the gear pump unit which is factory adjusted but replace the complete gear pump unit if necessary 8 Loosen the bolt and remove the com plete up relief valve 90 BRKT L d POWER TRIM AND TILT UNIT CE CE 9 Using the special service tool loosen the trim cylinder end screw and pull out the trim piston and components 222 Cylinder end screw wrench YB 6175 1A 90890 06542 10 Using the special service tool loosen the tilt cylinder end screw and pull out the tile piston and the free piston WARNING The free piston can be removed easily by blowing compressed air into the drain hole of the cylinder Be sure to cover the open end of the cylinder with a rag to prevent the free piston from being ejected which could cause injury or piston damage 22 Cylinder end screw wrench YB 6175 2B 90890 06544 11 Remove the main valves and the shut tle piston 12 Remove
108. put 5 Ifthe output is beyond specification replace rectifier regulator 6 If the output is below specification replace lighting coil 50 60 70 hp Lighting coil Output peak voltage minimum G G W Cranking Open Connect 8 5 8 0 Lighting coil Output peak voltage minimum G G W Cranking Open Connect 10 11 ELEC ELECTRICAL ANALYSIS 8 20 53005 0 REPLACEMENT SPARK PLUG Standard type 1 Remove the spark plug cap by pulling the cap and remove the plug cap spring from the high tension cable 2 Cut an amount of about off the end of the high tension cable Distance 3 5 mm 0 2 in 3 Fit onto the plug cap spring 4 Push the cap spring into the plug cap Resistance specification type 1 Remove the spark plug cap by turning the cap 2 Install the spark plug cap onto the high tension cable CRANK POSITION SENSOR Measure the peak voltage of the crank posi tion sensor as shown 50 60 70 hp Crank position sensor Output peak voltage minimum L R L W Cranking Open Connect 5 0 5 0 Crank position sensor Output peak voltage minimum L R L W Cranking Open Connect 5 5 5 5 ELEC ELECTRICAL ANALYSIS 55000 0 STARTER RELAY 1 Check for continuity between the termi nals and the ends of the black and brown leads 2 Test to ensure there is no continuity between termina
109. rotect the skin the application of a suitable barrier cream to the hands before working is recommended 6 A supply of clean lint free cloths should be available for wiping purposes GOOD WORKING PRACTICES 1 The right tools Use the special tools that are advised to protect parts from damage Use the right tool in the right manner dont improvise 2 Tightening torque Follow the torque tightening instruc tions When tightening bolts nuts and screws tighten the larger sizes first and tighten inner positioned fixings before outer positioned ones d SAFETY WHILE WORKING CE 1 4 3 Non reusable items When reassembling always use new gaskets packing O rings oil seals split pins and circlips etc DISASSEMBLY AND ASSEMBLY 1 2 3 5 Clean parts with compressed air when disassembling them Oil the contact surfaces of moving parts before assembly After assembly check that moving parts operate normally Install bearings with the manufacturer s markings on the side exposed to view and liberally oil the bearings When installing oil seals apply a light coating of water resistant grease to the outside circumference GEN e A80000 0 SPECIAL TOOLS The use of correct special tools recommended by Yamaha will aid the work and enable accu rate assembly and tune up Improvisations and use of improper tools can cause damage to the equipment NOTE eFor USA a
110. sues 0 0 J0jouu 191416 6 Hun 149 109 1109 1109 BunuBr Josues uonisod yugi 1 1 youms D 8 10 ELEC WIRING DIAGRAM gt P60TH 60FEHTO Buzzer Fuse 10A Main switch Engine stop switch A To tachometer 2 power trim and tilt switch option C To trim sensor D To oil level sensor F E To lamp switch option E P Black Y G Green E lt 1 7 Gray G R Green Red vx Ii Blue o Orange D pos Pink Red Sb Sky blue W White Yellow I5 Light green G W Green White 4 P B Pink Black 2 ELEC WIRING DIAGRAM M31000 0 REMOTE CONTROL BOX DIGITAL METER Main switch Buzzer Neutral switch Engine stop switch 5 Power trim and tilt switch To meter harness A To remote control box Digital speedometer option B To trim sensor IC Digital tachometer To fuel management meter option To oil level gauge Lamp switch option 5 Fuse 10A Fuel sensor option uu Orange Pate Pink Russ Red Sb Sky blue W White Vire Yello
111. t into the pinion Tighten the pinion nut to the specified torque Pinion nut 50 hp 75 Nm 7 5 m kg 54 ft Ib 60 90 hp 95 Nm 9 5 m kg 69 ft Ib Drive shaft holder 4 50 60 70 6049 90890 06518 75 80 90 6151 90890 06519 Pinion nut holder 90890 06505 7 Assemble the propeller shaft For 50GETO C60ER C60TR 60FET Oceania C75TR 90AEHD 9OAED 9 90 1 Referring to the illustration F mark side Loun e ASSEMBLY AND ADJUSTMENT 7 Assemble the propeller shaft Except for 50GETO C60ER C60TR 60FET Oceania C75TR 90AEHD 90AED C90TR 90AET 1 2 NOTE Insert the free shaft O into the shift slide 2 Insert the two balls 3 and shifter on the shift slide Grease the balls so that they will not come off easily from the shift slide thus making your work easier 3 4 5 NOTE Align the hole in the shift slide cross pin with the slot in the propeller shaft cross pin and insert the shift slide into the propeller shaft Push the shifter and stop pushing it when the balls move into the neu tral groove in the propeller shaft making a slick If the balls move into the reverse groove passing the neutral be sure to bring them back to neutral Install the clutch dog so that its cross pin hole is aligned with the slot in the splined portion of the propeller shaft Install the clutch dog so
112. tal and mica with compressed air 4 Check for continuity or discontinuity of the armature coil If it is out of specifica tion replace the armature Armature coil continuity discontinuity Commutator segments 8 Segment Laminations b Continuity Discontinuity Segment Shaft C Discontinuity BRUSH 1 Measure the brushes for wear Brush size 3 Standard 9 8 mm 0 39 in Minimum 4 8 mm 0 19 in BASE ASSEMBLY 1 Inspect the base assembly for cracks or burns and replace the base assembly if such are found 2 Check for continuity between the con nector and lead wire If there is disconti nuity replace the base assembly CIRCUIT BREAKER 1 Check for continuity between the brush and the terminal If there is discontinu ity replace the circuit breaker 7 32 BRKT L d POWER TRIM AND TILT MOTOR CE 7 33 K63000 0 ASSEMBLY 1 Install the armature into the frame end 2 Place the O ring on the frame end and install the yoke assembly then install the screws N Screw 22 4Nm 0 4 m kg 2 9 ft Ib 3 Place the O ring on the motor assembly and align the grooves of the motor assembly and gear pump then install the bolts Power trim and tilt motor mounting bolt Stamped mark 6H308 6 Nm 0 6 m kg 4 3 ft Ib 6H 1 15 162 021 7 Nm 0 7 m kg 5 1 ft Ib CHAPTER 8 ELECTRICAL SYSTEMS ELECTRICAL COMPONENTS unn 8 1 ELECTRIC
113. the lip of the oil seal then install the oil seal housing complete to the gear case and fit the dowel pins 3 Aligning with the dowel pins install a new gasket a plate and a new gasket on the oil seal housing 4 Install a key in the keyway on the drive shaft and insert a impeller 5 Grease the impeller and install the water pump housing turning the drive shaft clockwise then tighten the bolts 6 28 Loun e INSTALLATION CED 170003 0 INSTALLATION 1 Check that the clutch dog shifts to For ward Neutral and Reverse cor rectly by turning the shift rod and shift into Neutral Shift rod wrench YB 6052 2 Align the mark on the shift lever with the arrow mark on the bottom cowling 3 Grease the spline of the drive shaft and the water tube outer face align the water tube and drive shaft install the lower unit and tighten the bolts to the specified torque EN Lower unit mounting bolts A 40 Nm 4 0 m kg 29 ft Ib 6 29 Loun e INSTALLATION 6 30 CE 4 Install the trim tab on the gear case Be sure to align the marks put on both of them when they were removed Place the cap over the bolt hole 5 Install the spacers propeller washer and propeller nut over the propeller shaft AS Propeller nut A 35 Nm 3 5 kg 25 ft Ib 6 Align the recess in the propeller nut with the hole in the propeller shaft and insert the cotter pin int
114. the shuttle pis ton insert the piston into the body then install the main valves with new O rings O ring Shuttle piston 3 O ring O ring 5 Main valve 55 Main valve 2 10 Nm 1 0 kg 7 2 ft Ib 4 Install the up relief valve with a new O ring and tighten the locking bolt to the specified torque Filter 0 O ring Up relief valve seat Ball 5 Valve support pin 6 Up relief spring L 19 7 mm D 5 mm 7 Up relief valve lock screw BRKT L d POWER TRIM AND TILT UNIT CE Locking bolt 13 Nm 1 3 m kg 9 4 ft Ib 5 Fit a new O ring and the back up ring to the trim piston fit new O rings and a new oil seal to the end screw and install the complete trim piston in the cylinder Fill the cylinder with hydraulic fluid and install and tighten the end screw to the specified torque ATF automatic transmission fluid O ring Back up ring 53 Trim cylinder end screw A 70 Nm 7 0 m kg 50 ft Ib CZ Cylinder end screw wrench YB 6175 1A 90890 6548 6 Install the down relief valve and the complete gear pump with new O rings tighten the screws and fit the shaft con nector and filter then fill with hydraulic fluid D Down relief spring L 13 mm D 6 1 mm Down relief valve seat 3 O rings Gear pump 5 Washer 6 Washer Screw Use hexagon wrench Shaft connector 9 Filter 553 Gear pump mounting screw 22
115. tion is drawn to the various Warnings Cautions and Notes which distinguish important information in this manual in the following ways N The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED WARNING Failure to follow WARNING instructions could result in severe injury or death to the machine operator a bystander or a person inspecting or repairing the outboard motor CAUTION A CAUTION indicates special precautions that must be taken to avoid damage to the out board motor NOTE A NOTE provides key information to make procedures easier or clearer www motorka org A50001 1 4 SYMBOLS Symbols D to are designed as thumb tabs to indicate the content of a chapter General Information Specifications 3 Periodic Inspection and Adjustment Fuel System 5 Power Unit 6 Lower Unit Bracket Unit Electrical Systems Trouble Analysis Symbols 9 to 49 indicates specific data Special service tool Specified liquid 2 Specified grease 3 Specified engine speed Specified torque 49 Specified measurement Specified electrical value Resistance Q Voltage V Electric current A Symbol to 09 in an exploded diagram indicate grade of lubricant and location of lubrication point Apply engine oil Apply gear oil Apply molybdenum disulfide oil 9 Apply water resistant grease Yamaha marine grease A Yamaha marine grease Symbols to in an exploded
116. to remove score marks or varnish INSPECTION 1 Using a micrometer measure the pis ton diameter at right angles to the pis ton pin center line 10 mm 0 4 in above the bottom edge Piston diameter Standard 50 60 70 hp 71 945 71 970 mm 2 8325 2 8335 in 75 80 90 hp 81 935 81 960 mm 3 2258 3 2268 in 2 Using the measured cylinder bore diameter in thrust directions subtract the piston diameter measurement from the cylinder bore diameter measure ment Piston clearance 50 60 70 hp 0 050 0 055 mm 0 0020 0 0022 in 75 80 90 hp 0 060 0 065 mm 0 0024 0 0026 in If this clearance is not within the specifi cations replace the piston with stan dard or oversize and or rebore the cylinder Oversize piston 50 60 70 hp 1st 72 25 mm 2 844 in 2nd 72 50 mm 2 854 in 75 80 90 hp 5151 82 25 mm 3 238 in 2nd 82 50 mm 3 248 in Except for USA 5 8 INSPECTION CED G62501 0 PISTON RING INSPECTION 1 Using a thickness gauge measure the clearance between the piston ring and the groove land Side clearance 50 60 70 hp Top 2nd ring 0 03 0 07 mm 0 0012 0 0028 in 75 80 90 hp Top 2nd ring 0 03 0 06 mm 0 0012 0 0024 in If the clearance is not within the specifi cations replace the piston Top 2nd Keystone type Piston marked with W 50 60 70 hp 2 Insert the piston ring into the cylinder Usi
117. to the carburetor 7 Correct rigging and engine setting are obtained 8 Engine is free from any Hull problem TROUBLE ANALYSIS CHART Trouble mode Check elements Reference Chapter Relative part ENGINE WILL NOT START ROUGH IDLING ENGINE STALLS ENGINE WILL NOT STOP POOR PERFORMANCE OVERHEATING LOOSE STEERING LOOSE TILT HOLDING TILT MOTOR WILL NOT RUN HARD SHIFTING IRREGULAR WARNING INDICATION POOR BATTERY CHARGING FUEL SYSTEM Idle speed Fuel hose Fuel joint Fuel filter Fuel pump Carburetor Pilot screw setting POWER UNIT Link adjustment Compression Read valve Cylinder head gasket Cylinder block Piston Piston ring Crank case Bearing Thermostat Water passage 0 O1 O1 OI OI O1 1 OI GO 9 1 TRBL ANLS TROUBLE ANALYSIS Trouble mode Check elements ENGINE WILL NOT START ROUGH IDLING ENGINE STALLS ENGINE WILL NOT STOP POOR PERFORMANCE OVERHEATING LOOSE STEERING LOOSE TILT HOLDING TILT MOTOR WILL NOT RUN HARD SHIFTING IRREGULAR WARNING INDICATION POOR BATTERY CHARGING Relative part LOWER UNIT Reference Chapter Neutral position Clutch Gear Water inlet Water pump Propeller shaft Shift rod Shift slider Shift cam Lower case Shim adj
118. ure a special label on which the outboard motor serial number is stamped is bonded to the port side of the clamp bracket The label is specially treated so that peeling it off causes cracks across the serial number Model name Approved model No Transom height Serial number STARTING SERIAL NUMBERS The starting serial number blocks are as fol lows Serial number Approved Canada model No 50GETO 70BEDO Serial number Approved Canada model No 402029 L 400805 L 551924 X 750186 60FEHTO 70BETO 491824 731262 S 001118 60FED 75CET 001251 L 305624 75CETO 951540 S 100850 L 407212 S 050474 60FEDO 75CEHTO 80AETO 900371 457543 851331 L 357665 90AEHD 320132 X 710231 90AED 401108 S 150756 90AET 354053 60FETO L 472180 X 732000 1 1 90AETO 498690 856313 Kee d SAFETY WHILE WORKING CE 1 2 SAFETY WHILE WORKING The procedures given in this manual are those recommended by Yamaha to be fol lowed by Yamaha dealers and their mechanics FIRE PREVENTION Gasoline petrol is highly flammable Petroleum vapor is explosive if ignited Do not smoke while handling and keep it away from heat sparks and open flames VENTILATION Petroleum vapor is heavier than air and i
119. uring screw SE PERIODIC SERVICE CE 75 80 90 hp 1 Loosen the idle adjust screw and fully close the throttle valve 2 Loosen the throttle lever securing screws of upper and lower carburetors by turning clockwise 3 While lightly pushing the throttle lever of the middle carburetor in the direction of the arrow full closed tighten the throttle lever securing screw of the upper and lower carburetors by turning counterclockwise Idle adjust screw 0 Throttle lever 3 Throttle lever securing screw D32000 0 CYLINDER HEAD BOLTS ENGINE MOUNTING BOLTS AND FLYWHEEL NUT 1 Retighten to specifications 2 Check other fixings and tighten if neces sary D32300 0 FUEL FILTER Clean the strainer of dust and impurities D Strainer body Strainer 3 O ring 4 Strainer cup D32600 0 FUEL TANK AND FUEL LINE 1 Check the fuel tank and fuel line for leaks 2 Clean the fuel tank thoroughly 3 4 INSP ADJ PERIODIC SERVICE T TS TT 3 5 CEJ D32900 0 GEAR OIL 1 Drain the gear oil thoroughly and pour in new oil 2 Check for water or metallic sediment in the drained oil NOTE If the gear oil becomes milky check the gear case oil seals and shift boot for water entry D33000 0 IDLE SPEED 1 Turn the pilot screw until it is lightly seated 2 Turn the pilot screw outward to the specified setting Pilot screw stam
120. ustment BRACKET UNIT OO OO OO 9 OO Bracket Mount rubber Shift actuator PTT UNIT Fluid level Relief valve Fluid passage PTT motor PTT control system ELECTRICAL Pulser coil Charge coil Lighting coil Ignition coil Spark plug cap CDI unit Crank position sensor Starter relay Power trim and tilt relay Trailer switch 9 2 Rectifier regulator 00 00 00 00 00 CO OO CO www motorka org TRBL ANLS 2 TROUBLEANALYSIS gt Trouble mode Check elements Reference Relative part Chapter TILT MOTOR WILL NOT RUN IRREGULAR WARNING INDICATION oc lt o 2 Er LU e ENGINE STALLS ENGINE WILL NOT STOP POOR PERFORMANCE OVERHEATING LOOSE STEERING HARD SHIFTING ROUGH IDLING POOR BATTERY CHARGING LOOSE TILT HOLDING Fuse Thermo switch Oil level sensor Oil level warning lamp Wire harness Battery Engine stop switch Main switch Neutral switch Starter motor 00 00 CO CO GO 00 00 OO 9 3 YAMAHA YAMAHA MOTOR CO LTD Printed in USA Feb 1999 x1CR BOGETO 60FEHTO 60FED 60FEDO 60FET 60FETO 70BEDO 70BETO 75CET 75CETO 75CEHTO 80AETO 90AEHD 90AED 90AET 90AETO GE Printed on recycled paper
121. w ELEC REMOVAL 50 60 70 75 80 90 hp M40003 0 REMOVAL MAGNETO BASE 1 Remove the flywheel cover 2 Remove the starter pulley 3 Loosen the flywheel nut until it is flush with the crankshaft Flywheel holder YB 6139 90890 06522 CAUTION The major load must be carried in the direc tion of the arrows If not the holder may easily slip off CAUTION Keep the nut side flush with the crankshaft end until the flywheel comes off the tapered portion of the crankshaft ELEC REMOVAL YB 6117 GE 4 Remove the flywheel magneto Flywheel puller YB 6117 90890 06521 CAUTION To prevent damage to the engine or tools screw in the flywheel magneto puller set bolts evenly and completely so that the puller plate is parallel to the flywheel 5 Remove the woodruff key from the crankshaft keyway using a screwdriver CAUTION Take special care not to damage the sur face of the crankshaft When removing the flywheel magneto lift it up while tilting it slightly Do not allow the magneto to con tact the timing plate ELEC ELECTRICAL ANALYSIS ELECTRICAL ANALYSIS INSPECTION CAUTION All measuring instruments should be han dled with special care or the correct mea surement is impossible On an instrument powered by dry batter ies the latter should be checked for voltage periodically and replaced if necessary NOTE 0 0 indicates the ter
122. www motorka org A50000 0 HOW TO USE THIS MANUAL MANUAL FORMAT This manual provides the mechanic with descriptions of the operations of disassembly repair assembly adjustment and inspection each of which is presented in a sequential step by step procedure To assist you to find your way about this manual the Section Title and Major Heading is given at the head of every page An Index to contents is provided on the first page of each section MODEL INDICATION Multiple models are shown in this manual These indications are noted as follows Model name USA and Canada name 50GETO 60FEHTO P60TH 60FEDO 60FETO 70BEDO 70 70TR Indication Model name 50GETO 60FEHTO 75CETO 75CEHTO 60FEDO 80AETO 90AEHD 60FETO 70BEDO 70 90 USA and Canada name 75TR P75TH 90TR B90TR Indication 75CETO 75CEHTO 80AETO 90AEHD 90AETO THE ILLUSTRATIONS Some illustrations in this manual may differ from the model you have This is because the procedure described may relate to several models though only one may be illustrated The name of the model described will be mentioned in the description To help you identify components and understand the correct procedures of disassembly and assembly exploded diagrams are provided Steps in the procedures are numbered thus 1 2 3 Parts shown in the illustrations are

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