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1. gt lA 5 B gt C 6 3 4 VA gt A Ni WW ax t H JR 1 pr Hi E all 8 i P 7 7 d 4 Ti 0 9 13 nM 7 S62Y1420K Power trim and tilt cylinder Down shuttle piston Ram 2 Ball Trim cylinder 3 Trim cylinder base 4 Down relief valve Free piston 6 Down main valve Tilt piston Gear pump Balls Reservoir A Return Up relief valve B Send 8 Up shuttle piston C Moving direction Up main valve 62Y5A11 1 24 dm Y General information Stopping condition When the power trim and tilt switch is not pushed released the gear pump does not pump the fluid the up main valve and the down main valve are closed and the power trim and tilt fluid pres sure in the system remains constant This allows the ram to maintain its position until the power trim and tilt fluid flows through the system again When the outboard motor hits something in the water The check valve of the trim cylinder and the tilt piston absorber of the tilt piston help to prevent inter nal damage to the power trim and tilt unit and help to protect the bracket and lower unit from dam age in case the outboard motor hits something during operation When the outboard motor hits something highly pressurized fluid in t
2. EN A H S62Y5250K Part name Remarks 1 Rocker arm assembly 8 2 Rocker arm shaft 1 3 Exhaust valve 4 4 Intake valve 4 5 Camshaft 1 6 Valve cotter 16 7 Spring retainer 8 8 Valve spring 8 9 Spring seat 8 10 Stem seal 8 11 Valve guide 8 12 Retaining bolt 1 13 Gasket 1 14 Oil seal 1 15 Bolt 5 M8 x 22 mm 16 Rocker arm retainer 2 17 Tensioner 2 18 Rocker arm retainer 1 8 62Y5A11 Removing the cylinder head 1 Check that the camshaft dowel pin hole is in the position shown in the illustra tion Adjust if necessary 2 Remove the cylinder head cover bolts in the seguence shown S62Y5265 3 Remove the cylinder head bolts in the seguence shown 62Y5A11 Cylinder head CAUTION Do not scratch or damage the mating sur faces of the cylinder head and cylinder body 4 Remove the oil pump rocker arm assembly and rocker arm shaft S62Y5275 S62Y5276 5 24 5 Remove the retaining bolt then the camshaft by pulling it downward UME S62Y5280 6 Remove the intake valve and exhaust valves S62Y5290 NOTE Be sure to keep the valves and other parts in the order that they were removed 5 25 When replacing the valve also replace the valve guide and stem seal Valve spring compre
3. ss 7 38 Assembling the tilt cylinder AAA 7 40 Bleeding the power trim and tilt not installed 7 41 Bleeding the power trim and tilt built in 244ss4 444 nennen 7 42 62Y5A11 62Y5A11 Power trim and tilt mOtOPr anxnnnnnnnnnnnnnnnnnnnnnnnnnnnunnnunnnunnnunnnunnnunnnunnnunnnnnnnnnnnne 7 43 Checking the power trim and tilt motor 7 44 Assembling the power trim and tilt motor srrrrrnnnnnnnnnnnrrrnnnnnnnnrnrrnnnnnnn 7 45 Installing the power trim and ut 7 45 Power trim and tilt electrical system 7 47 Checking the fuse reene 7 48 Checking the power trim and tilt relay ooonnnnccnnnnnnccnnnnnnccnnnnaccccnnnncncnno 7 48 Checking the trailer switch ss 7 49 Checking the trim sensor 7 49 RASI XxX Bracket unit Special service tools Cylinder end screw wrench 90890 06544 Digital circuit tester 90890 03174 7 1 62Y5A11 Special service tools Tiller handle Tiller handle S62Y7060K Z o o NO O BE O MM Part name Remarks M8 x 30 mm Bolt Nut Wing nut Friction piece Bolt Friction rod Washer Nut Washer Link rod Nut Plate Bolt Grommet Cable guide Grommet Plastic tie Battery lead M6 x 35 mm M6 x 20 mm NN a 0 A sch NM sch sch 62Y5A11 7 2 RASI X Bracket unit 4137 N m 3 7 kgf m 27 ft Ib
4. 825140 2 Remove the breather hose and loosen K the drive sprocket nut 4 Loosen the driven sprocket bolt amp and remove the driven sprocket 62Y5A11 Do not turn the camshaft when loosening the driven sprocket bolt Use a deep socket 2 M42 for this proce dure Flywheel holder 90890 06522 Do not turn the camshaft when loosening the drive sprocket nut 5 Remove the nut retaining plates drive sprocket and Woodruff key Crankshaft holder 18 90890 06562 5 21 62Y5A11 1 1 62Y5A11 How to use this manual Symbols The symbols below are designed to indicate the content of a chapter General information Fuel system Bracket unit am T FUEL BRRT Specifications Power unit Electrical systems Periodic checks and adjustments Lower unit Troubleshooting CHK Q TRBL ADJ LOWR SHTG 2 Special tool 5 Specified measurement Specified oil and fluid Specified electrical value Specified engine speed Resistance Voltage Electric current Specified tightening torque Symbols to in an exploded diagram indicate the grade of lubricant and the lubrication point G Apply Yamaha 4 stroke motor oil Apply anti corrosion grease Yamaha grease D Apply water resistant grease Yamaha grease A Apply low temperature resistant grease Apply molybdenum disulfide grease Yamaha grease C Symbols 2 to 7 in an exploded diagram indicate the type of sealant or
5. MEE ms TN ut EAS MRS 2nd 12 N m 1 2 kgf m 8 7 ft Ib S62Y5685K 2nd 30 N m 3 0 kgf m 22 ft Ib 5 35 62Y5A11 Cylinder body No Part name O ty Remarks 1 Oil filter 1 2 Crankshaft 1 3 Bolt 10 M8 x 82 mm 4 Bolt 10 M6 x 35 mm 5 Crankcase 1 6 Oil seal 1 7 Main bearing 10 8 Oil seal 1 9 Connecting rod bearing 8 10 Connecting rod cap 4 11 Bolt 8 12 Dowel pin 2 13 Cylinder body 1 14 Connecting rod 1 15 Piston pin clip 2 16 Piston pin 1 17 Piston 1 18 Oil ring 1 19 Second ring 1 20 Top ring 1 21 Piston assembly 1 22 Gasket 1 23 Exhaust cover 1 24 Thermostat 1 25 Gasket 1 26 Cover 1 27 Bolt 2 M6 x 35 mm 28 Clamp 1 29 Bolt 10 30 Grommet 1 31 Anode 1 32 Cover 1 33 Cover 1 34 Bolt 1 M6 x 20 mm 35 Bolt 1 M5 x 12 mm 36 Bolt 10 M6x 35 mm Tightening sequence 62Y5A11 5 36 Removing and installing the oil filter 1 Place a rag under the oil filter and then remove the filter S62Y5690 NOTE Be sure to clean up any oil spills 2 Apply a thin coat of the new engine oil to the O ring of the new oil filter 3 Install the oil filter and then tighten it to the specified torque S62Y5700 5 37 S62Y5710 Y Oil filter 18 N m 1 8 kgf m 13 ft Ib Disassembling the cylinder body 1 Remove the exhaust cover bolts in the sequence shown S
6. M6 x 15 mm ET model ET model ET model Not reusable M6 x 25 mm M6 x 25 mm 7 18 BAR bd Bracket unit Removing the clamp brackets 1 Remove the power trim and tilt or hydro tit For removing procedures see Removing the power trim and tilt hydro tilt in this chapter Loosen the self locking nuts i and then remove clamp brackets and Remove the trim sensor 2 S62Y7310 Installing the clamp brackets 1 Install the trim sensor D onto the port clamp brackets S62Y7320 7 19 NOTE __ Adjust the trim sensor after installing the power trim and tilt Assemble the clamp brackets and the swivel bracket by installing the self lock ing nuts Q then tightening them to the specified torque S62Y7330 Self locking nut 2 23 N m 2 3 kgf m 17 ft lb Install the power trim and tilt or hydro tilt For installing procedures see Installing the power trim and tilt in this chapter Inject grease into both grease nipples until grease comes out from the bushings 62Y5A11 S62Y7335 Adjusting the trim sensor 1 Fully tilt the outboard motor up and then support it with the tilt stop lever S62Y7340 A WARNING After tilting up the outboard motor be sure to support it with the tilt stop lever Otherwise the outboard motor could sud denly lower if the power trim and tilt unit should lose fluid pressure 2 Loosen the cam screws
7. AA A NENN 7 29 Upper case Eege are it dt 7 11 Use of leaded gasoline 1 5 Ventilation 1 3 i 3 Index W Water pump and shift rod 6 7 Wiring harness A 8 7 i 4 62Y5A11 Wiring diagram FT50CEHD FT50CED Battery Engine start switch Engine shut off switch 4 Starter motor 6 Starter relay Neutral switch Fuse 20A Prime Start Warning indicator CDI unit Thermoswitch 42 Oil pressure switch 43 Charge coil Pulser coil 5 Lighting coil Rectifier Regulator 2 Ignition coil Spark plug EHD Color code B Black Br Brown G Green L Blue O Orange P Pink R Red VV VVhite B O Black orange B W Black white B Y Black yellow G W Green white Gy B Gray black P B Pink black P W Pink white W B White black VV R White red Y B Yellow black Y R Yellow red Wiring diagram FT50CET Battery Power trim and tilt motor Power trim and tilt relay 4 Starter motor Fuse 20A Trim sensor Prime Start Starter relay CDI unit Charge coil Lighting coil 2 Pulser coil 3 Rectifier Regulator Thermoswitch 5 Oil pressure switch Trailer switch 2 Ignition coil Spark plug Color code B Black Br Brown G Green Gy Gray L Blue Lg Light green O Orange P Pink R Red Sb Sky blue W White B O Black orange B W Black white B Y B
8. 62Y5A11 5 16 Removing the timing belt and sprockets 1 Set the cylinder 1 piston position to TDC of the compression stroke by align ing the 1 mark on the driven sprocket with the A mark on the cylinder head S62Y5120 CAUTION Do not turn the drive sprocket counter clockwise otherwise the valve system may be damaged 2 Remove the breather hose and loosen the drive sprocket nut S62Y5130 NOTE Use a deep socket 2 M42 for this proce dure Do not turn the camshaft when loosening the drive sprocket nut Z Crankshaft holder 18 90890 06562 3 Remove the tensioner 4 and timing belt from the driven sprocket side S62Y5140 4 Loosen the driven sprocket bolt and remove the driven sprocket S62Y5150J NOTE er Do not turn the camshaft when loosening the driven sprocket boli Flywheel holder 90890 06522 5 Remove the nut retaining plates drive sprocket 9 and Woodruff key 49 62Y5A11 S62Y5155 Checking the timing belt and sprockets 1 Check the interior and exterior of the tim ing belt for cracks damage or wear Replace if necessary S62Y5160 2 Check the drive sprocket i and driven sprocket 2 for cracks damage or wear Replace if necessary S62Y5170 62Y5A11 Timing belt and sprockets Installing the sprockets and timing belt Check that the 1 mark on the driven sprocket 1 is
9. 62Y5A11 2 10 pee ye Specifications Exterior S62Y2240 62Y5A11 Unit Maintenance specifications Model FT50CED FT50CET 62Y5A11 mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm in Degree Degree Degree mm in 576 22 7 142 5 6 560 22 0 97 3 8 990 39 0 397 15 6 149 5 9 0 8 0 03 63 2 5 917 36 1 519 20 4 191 7 5 536 21 1 723 28 5 330 13 0 0 5 0 02 738 29 1 44 1 7 28 1 1 181 7 1 181 7 1 345 13 6 560 22 0 PERE ye Specifications Clamp bracket Model S62Y2250 FT50CEHD FT50CED FT50CET 2 13 126 5 0 254 10 0 163 5 6 4 50 8 2 0 180 7 1 355 14 0 62Y5A11 Maintenance specifications Tightening torques Tightening torques Specified torques Tightening torques N m kgf m ft Ib Part to be tightened Thread size Power unit Flywheel magnet nut Stator base screw Cover screw Negative battery lead bolt Positive battery lead nut Oil pressure switch Oil pressure switch lead screw Ignition coil bolt Starter motor bolt Starter motor terminal nut Power unit bolt Tensioner bolt Tensioner adjusting bolt Drive sprocket nut Driven sprocket bolt Spark plug UNA sea 1
10. S62Y1260 Pilot screw 9 Main air jet Pilot outlet Throttle valve Bypass holes A Air Venturi B Air fuel mixture Main nozzle C Fuel 6 Pilot jet Main jet Pilot air jet 62Y5A11 1 10 dm Y General information 2 Medium speed operation When the throttle valve opens further air fuel mixture is fed from the pilot outlet and all the bypass holes In addition air fuel mixture is also supplied from the main nozzle in accordance with the opening angle of the throttle valve QP AM D S62Y1270 i Pilot screw 9 Main air jet Pilot outlet Throttle valve Bypass holes A Air Venturi B Air fuel mixture Pilot jet C Fuel Main jet G Main nozzle Pilot air jet 1 11 62Y5A11 Technical tips 3 High speed operation When the throttle valve approaches its fully open position the fuel that has been regulated by the main jet and the air that has been regulated by the main air jet are mixed in the main nozzle The resultant mixture is then sprayed by the main nozzle into the venturi The air fuel mixture that is sprayed through the venturi is then fed into the engine A B de S B 0 RS S 9 S62Y 1280 D Pilot screw A Air Pilot outlet B Air fuel mixture Bypass holes C Fuel 4 Main nozzle Pilot jet Main jet Main air jet Throttle valve 62Y5A11 1 12 dm Y Ge
11. 3 Adjust the position of the trim sensor 3 and then tighten the screws finger tight P Le K C S62Y7350 4 Fully tilt the outboard motor down 62Y5A11 Clamp brackets 5 Measure the trim sensor resistance Repeat steps 1 5 if out of specification S62Y7360 Trim sensor setting resistance Pink P Black B 9 11 O at 20 C 68 F 6 Fully tilt the outboard motor up and then support it with the tilt stop lever AA WARNING After tilting up the outboard motor be sure to support it with the tilt stop lever Otherwise the outboard motor could sud denly lower if the power trim and tilt unit should lose fluid pressure 7 Tighten the cam screws to the speci fied torgue Trim sensor cam screw 2 N m 0 2 kgf m 1 4 ft lb 8 Fully tilt the outboard motor down 7 20 RASI XxX Bracket unit Swivel bracket and steering arm S62Y7370 7 21 62Y5A11 Swivel bracket and steering arm Part name Remarks Steering arm Washer Bushing O ring D Not reusable 28 9x 3 8 mm Bushing Swivel bracket Bushing Port tilt stop lever Circlip Steering yoke Bushing Bushing Tilt stop lever joint Spring holder Bolt Spring Bushing Pin Bushing Starboard tilt stop lever M6 x 10 mm A a N 0 d py 62Y5A11 7 22 RASI XxX Bracket unit Removing the steering arm 1 Remove t
12. S62Y8360 Checking the starter motor pinion 1 Check the pinion teeth for cracks or wear Replace if necessary PN e S62Y8370 2 Check for smooth operation Replace if necessary S62Y8380 NOTE 0 Turn the pinion clockwise to check that it operates smoothly and turn it counterclock wise to check that it locks Checking the armature 1 Check the armature axial free play Replace the washers and shim s Q if out of specification 8 19 S62Y8390 GC Dial gauge set D 90890 01252 4 Magnet base 90890 06705 AS Free play limit 0 6 mm 0 024 in 2 Check the commutator for dirt Clean with 4600 grid sandpaper and com pressed air if necessary S62Y8400 3 Measure the commutator diameter Replace the armature if out of specifica tion S62Y8410 ZX Diameter limit 31 0 mm 1 22 in 62Y5A11 4 Measure the commutator undercut 8 Replace the armature if out of specifica tion S62Y8420 ZX Commutator undercut limit 0 2 mm 0 01 in 5 Check the armature for continuity Replace if out of specifications S62Y8430 Commutator segments Continuity Segment Armature core No continuity Segment Armature shaft No continuity Checking the brushes 1 Measure the brush length Replace the brush assembly if out of specification 62Y5A11 Starter motor S62Y8440 ZX Brush length limit 12 0 mm 0 47 in 2 Check the brus
13. S62Y1160K 3 Install bearings with a manufacture iden tification mark in the direction indicated in the installation procedure In addition be sure to lubricate the bearings liberally 4 Apply a thin coat of water resistant grease to the lip and out periphery of an oil seal before installation 5 Check that moving parts operate nor mally after assembly Identification Applicable models This manual covers the following models Applicable models FT50CEHD FT50CED FT50CET Serial number The outboard motor serial number is stamped on a label attached to the port clamp bracket S62Y1180 1 4 dm Y General information D YAMAHA CITT EGR BE No YAMAHA MOTOR CO mf MADE IN JAPAN PAYS D ORIGINE JAPON S62Y1190 Model name Approved model code Transom height Serial number Model name Approved model code Starting serial No FT50CEHD FT50CED FT50CET 64J L 650101 L 550101 L 450101 Features and benefits Use of leaded gasoline New FT50C F50D is designed for pleasure light commercial use for all over the world Therefore engine components anti corrosion and reliability has been increased while regular leaded gasoline is used However always use regular unleaded gasoline for longer engine life Newly designed four carburetors Newly designed four carburetors have been based on the current F50A Prime Start has b
14. Intake 0 9 1 1 mm 0 035 0 043 in Exhaust 0 9 1 1 mm 0 035 0 043 in Refacing the valve seat 1 Reface the valve seat with the valve seat cutter HO S62Y5430 Z Valve seat cutter holder 90890 06316 Valve seat cutter 30 intake 90890 06326 30 exhaust 90890 06328 45 intake and exhaust 90890 06555 60 intake 90890 06323 60 exhaust 90890 06315 62Y5A11 Cylinder head 2 Cut the surface of the valve seat with a 45 cutter by turning the cutter clockwise until the valve seat face has become smooth S62Y5440 S62Y5450 Slag or rough surface CAUTION Do not over cut the valve seat Make sure to turn the cutter evenly downward at a pressure of 40 50 N 4 5 kgf 8 8 11 Ibf to prevent chatter marks 3 Use a 30 cutter to adjust the contact width of the top edge of the valve seat O 30 S62Y5460 Previous contact width 4 Use a 60 cutter to adjust the contact width of the bottom edge of the valve seat 5 28 A O Previous contact width S62Y5461 5 Use a 45 cutter to adjust the contact width of the valve seat to specification Se 45 S62Y5462 Previous contact width Specified contact width 6 If the valve seat contact area is too wide and situated in the center of the valve face use a 30 cutter to cut the top edge of the valve seat a 60 cutter to cut the bottom edge to center the area and
15. 0 0039 0 045 0 090 0 0018 0 0035 0 04 0 0016 Rocker arm shafts Outside diameter 15 98 15 99 0 6291 0 6295 Rocker arms Inside diameter 16 00 16 01 0 6299 0 6303 Valves Valve clearance cold Intake Exhaust Head diameter A Intake Exhaust A Face width B Intake Exhaust Seat contact width C Intake Exhaust 62Y5A11 0 20 0 05 0 008 0 002 0 30 0 05 0 012 0 002 29 9 30 1 1 177 1 185 25 9 26 1 1 020 1 027 1 84 2 97 0 072 0 117 1 98 3 11 0 078 0 122 0 9 1 1 0 035 0 043 0 9 1 1 0 035 0 043 2 4 SE ye Specifications Item Model FT50CEHD FT50CED FT50CET Margin thickness D Intake Si Exhaust p Stem diameter Intake Exhaust Guide inside diameter Intake and exhaust Stem to guide clearance Intake Exhaust Stem runout limit 0 6 1 0 0 024 0 039 0 7 1 1 0 028 0 043 5 48 5 49 0 2157 0 2161 5 46 5 47 0 2150 0 2153 5 50 5 51 0 2165 0 2169 0 01 0 03 0 0004 0 0012 0 03 0 05 0 0012 0 0020 0 03 0 0012 Valve springs Free length Minimum free length Tilt limit 39 85 1 569 37 85 1 490 1 7 0 07 Connecting rods Small end inside diameter Big end inside diameter Crank pin oil clearance 15 985 15 998 0 6293 0 6298 36 000 36 024 1 4173 1 4183 0 016 0 040 0 0006 0 0015 Crankshaft Crankshaft journal Diameter Crankshaft pin Diameter Runout limit 42 984 43
16. 4 Adjust the idle speed to 1 000 r min by turning the throttle stop screw 4 on car buretor 4 in direction or S62Y4410 NOTE ee To increase idle speed turn the throttle stop screw in direction 3 To decrease idle speed turn the throttle stop screw in direction 5 Measure the vacuum pressure of carbu retor 4 4 15 6 Turn the throttle valve adjusting screws to adjust the vacuum pressure of car buretors 1 2 and 3 to the same vac uum variation as carburetor 4 S62Y4420 7 Adjust the engine idle speed to specifica tion Engine idle speed 850 950 r min 8 After adjusting the idle speed rev the engine a few times and let it idle for at least 15 seconds to check that the vac uum pressures stay within 50 mm Hg 67 m bar 1 97 in Hg and to check the stability of the engine Adjusting the dash pot acceleration pump 1 Start the engine and warm it up for 5 min utes and then check the engine speed at the operation point of the dash pot 2 Attach the special service tool to high tension cord 1 a R BAX RY 62Y5A11 Digital tachometer 90890 06760 3 Open the throttle cam 2 slowly and check the engine speed when the accel eration pump stopper 8 comes into con tact with point S62Y4440 Engine speed 2 700 r min 4 If out of specification adjust the engine speed at the operation point of dash pot 5 Open the thr
17. arrows shown to prevent the flywheel holder from slipping off easily e To prevent damage to the engine or tools screw in the flywheel puller set bolts evenly and completely so that the flywheel puller plate is parallel to the fly wheel magnet NOTE __ gt Apply force to the crankshaft end until the fly wheel magnet comes off the tapered portion of the crankshaft qa Flywheel holder 90890 06522 Flywheel puller 90890 06521 2 Disconnect the throttle cable and shift cable shift rod 62Y5A11 S62Y5081K 3 Disconnect the fuel hose and throttle link rod S62Y5082 4 Disconnect the battery leads 10 pin coupler PTT relay leads ET PTT motor leads 8 ET ground lead ET warning indicator coupler EHD trailer switch coupler ET pilot water hose 2 5 Remove the power trim and tilt relay 9 shift rod and shift rod bolts 5 S62Y5084K S62Y5083 6 Remove the apron 9 7 Remove the power unit by removing the bolts 5 15 62Y5A11 Power unit Timing belt and sprockets Timing belt and sprockets S62Y5110K Z o o NO O BE O MM Part name Remarks Timing belt Drive sprocket Driven sprocket Bolt Bolt Tensioner Spring Nut Retaining plate Woodruff key Bolt Washer Bolt Blowby hose Clip Dowel pin M8 x 20 mm M10 x 40 mm M6 x 20 mm 1 4 4 4 4 4 4 4 2 4 4 4 2 4 4 4
18. ficient fluid of the recommended type to the correct level 9 Install the reservoir cap S62Y7830 Bleeding the power trim and tilt not installed 1 Close the manual valve by turning it clockwise 7 41 S62Y7840 2 Place the power trim and tilt in an upright position 3 Check the fluid level in the reservoir NOTE The fluid level should be at the brim of the filler hole 4 If necessary add sufficient fluid of the recommended type to the correct level 5 Install the reservoir cap 6 Connect the PTT motor leads to the battery terminals S62Y7850 62Y5A11 Battery Tilt rod PTT motor lead terminal Blue L Up 7 Reverse the PTT motor leads between the battery terminals when the tilt ram is fully extended and then reverse them again when it is fully compressed NOTE 0 Repeat this procedure so that the tilt ram goes up and down four to five times The sound of the power trim and tilt motor will change when the tilt ram is fully extended 8 Check the fluid level again when the tilt ram is fully extended Add sufficient fluid if necessary and then repeat step 7 NOTE Repeat this procedure until the fluid remains at the correct level Bleeding the power trim and tilt built in 1 Loosen the manual valve by turning it counterclockwise until it cannot be turned further S62Y 7860 2 Fully tilt the outboard motor up and then r
19. taneousiy2 Chect the operation of the car buretor throttle valves by removing the throttle cables and link rods Check the ignition timing Out of specifi cation Replace the CDI unit Dothe valves close simul taneously Yes Check and disassemble the car buretors and then clean them if necessary 62Y5A11 r Check the throttle cable opera tion and lubricate it if necessary N p Check the second ary air intake on the O ring and manifold plate and the gas kets of the vacuum check bolts y 9 6 TRBL 1 SHTG e Troubleshooting Symptom Engine does not accelerate when the throttle is opened quickly The engine turns off when the throttle is opened quickly Acceleration is tardy and the engine is likely to stop at any moment Check the carburetors Check the ignition system e Check the compression pressure of power unit Check the throttle cable opera tion Do the carbu retor throttle valves close simulta neously Adjust the throttle cable Check the needle valve of the carburetor for debris or wear Check each jet of the carburetor for clogs or debris Debris or wear Check the ignition Clean the carburetor or replace Clogs or No system and the respective parts debris compression pres sure of t
20. 1 7 2 6 3 12 6 5 Lubricating the throttle gear 7 10 Lubrieation otra lcd 3 16 M Maintenance interval chart 3 2 Maintenance specifications 2 3 Manual format 1 1 Measuring the forward gear backlash 6 27 Measuring the lower resistance 8 2 Measuring the peak voltage 8 2 N Newly designed four carburetors 1 5 P Parts lubricants and sealants 1 3 Power trim and ut 1 19 Power trim and tilt electrical system 7 47 Power trim and tilt motor 7 43 Power trim and tilt unit 3 11 7 25 Power unit 2 3 3 4 5 3 9 1 Predelivery CHECKS A 1 26 Propeller selection 1 26 Propeller shaft housing 6 11 Propeller setze AANEREN 1 26 R Refacing the valve Seat 5 28 Removing and installing the oil filter 5 37 Removing the clamp brackets 7 19 Removing the cylinder head 5 24 Removing the drive shafft 6 19 Removing the lower unit 6 6 Removing the power trim and tilt yaro UN sie ir 7 26 Removing the power unit 5 13 62Y5A11 Removing the propeller shaft housing U assembly un He en 6 13 Removing th
21. 4 Install the connecting rod to the crank pin S62Y5970 NOTES 3 Align the alignment marks on the con necting rod cap and connecting rod e Face the embossed Y 11 mark on the con necting rod toward the flywheel side of the crankshaft 5 Tighten the connecting rod bolts to the specified torques in two stages S62Y5980 62Y5A11 Cylinder body NOTE 0 Do not turn the connecting rod until the crank pin oil clearance measurement has been completed Connecting rod bolt 1st 6 N m 0 6 kgf m 4 3 ft Ib 2nd 17 N m 1 7 kgf m 12 ft lb 6 Remove the connecting rod cap and measure the width of the compressed Plastigauge PG 1 on each crank pin Replace the connecting rod bearing if out of specification S62Y5990 Crank pin oil clearance 0 016 0 040 mm 0 0006 0 0015 in 5 44 Selecting the crankshaft main 4 When installing the main bearing insert journal bearing the projection of the main bearing into 1 When replacing the main bearing select the slot on the cylinder body the suitable bearing as follows CAUTION 2 Check the crankshaft journal mark on the Remove any small metal particles and oil crankshaft and the cylinder body mark from the contact surfaces of the cylinder on the cylinder body 2 body and the main bearing 3 Select the suitable color for the main bearing from the table 5 Measure the main journal oil clearance with a piece of Pla
22. 6 17 E Electricals agak aan NA asa 2 6 Electrical components AA 8 3 Electrical systems 9 13 F Features and benefits 1 5 Fire Drevention een 1 3 Front VIGW kaa aia 8 4 Fuel and blowby hoses 4 2 Fuel filter and fuel PUMP 4 3 Fuel system u samen 3 3 G Gear DUump ana nanacnnns 7 31 Generalistas ptr 3 14 General specifications nenn 2 1 General torques 2 15 Good working practices 1 4 H Hose routing sek 4 2 How to use this manual 1 1 l Identification ooooonnocccnnnnicccnnnnnccccncnnnnanncno 1 4 Ignition system 1 15 Ignition system and Ignition control SYSTEM EE 8 8 Ignition timing control 1 17 Installing the camshaft 5 33 Installing the clamp brackets 7 19 Installing the cylinder head 5 34 62Y5A11 Installing the lower unit 6 22 Installing the pinion 4 44 6 22 Installing the power trim and tilt 7 45 Installing the power unit 5 49 Installing the propeller shaft housing 6 16 Installing the rocker arm assembly 5 33 Installing the sprockets and timing belt 5 18 Installing the steering arm 7 23 Installing the upper case 7 17 Installing the valves 5 32 Installing the water pump and shift rod 6 9 L Lower unit
23. D Measuring point H D Piston to cylinder clearance Oversize piston diameter 1st 2nd Piston pin boss bore 62 95 62 96 2 478 2 479 5 0 2 0 04 0 06 0 0016 0 0024 0 25 0 001 0 50 0 002 15 974 15 985 0 6289 0 6293 Piston pins Outside diameter 15 965 15 970 0 6285 0 6287 Piston rings Top ring Dimension B Dimension T End gap Side clearance GO Measuring conditions 1 17 1 19 0 046 0 047 2 39 2 41 0 094 0 095 0 15 0 30 0 006 0 012 0 04 0 08 0 002 0 003 Ambient temperature 20 C 68 F wide open throttle with plugs disconnected from all cylinders The figures are for reference only 2 3 62Y5A11 Item Maintenance specifications Model FT50CEHD FT50CED FT50CET 2nd ring Dimension B METE Dimension T LT End gap Side clearance Oil ring 1 Dimension B ME EI Dimension T T Side clearance 1 47 1 49 0 058 0 059 2 49 2 51 0 098 0 099 0 30 0 50 0 012 0 020 0 03 0 07 0 001 0 003 2 34 2 46 0 092 0 097 2 75 0 108 0 20 0 70 0 008 0 028 0 05 0 19 0 002 0 008 Camshafts Intake A Exhaust A Intake and exhaust B B Camshaft journal diameter 1 2 3 4 Camshaft journal oil clearance 1 2 3 4 Maximum camshaft runout 30 89 30 99 1 2161 1 2200 30 82 30 92 1 2135 1 2175 25 95 26 05 1 0217 1 0256 36 93 36 94 1 4539 1 4543 36 94 36 95 1 4543 1 4547 0 055 0 100 0 0022
24. Technical tips Starting control When starting the engine the timing is set to 5 BTDC until the crankshaft speed maintains 600 r min for two seconds or longer ao S62Y1350 Cylinder identification protrusion Starting signal 5 BTDC for cylinders 1 and Protrusion for cylinders 1 and 4 4 Pulser coil Starting signal 5 BTDC for cylinders 2 and 4 Protrusion for cylinders 2 and 3 3 6 Pulser coil signal Rotating direction Cylinder identification signal Warm up control After the starting control is completed the control transfers to the ignition timing based on the warm up map for three minutes From the time the three minute warm up control has been completed the control transfers to the normal map 1 2 3 4 5 6 S62Y1360 Ignition timing BTDC Engine speed x 1 000 r min Warm up map 4 Acceleration map 6 Normal map 62Y5A11 1 18 dm Y General information Acceleration control This control is activated when the throttle valve is opened suddenly If the engine speed increases more than the specified figures the control of the ignition timing transfers to the acceleration map Thereafter the control of the ignition timing transfers gradually to the control map before accelera tion If it was under warm up control the timing transfers to the warm up control map and if it was under normal control the timing tr
25. YAMAHA Hall DEVICE MANUAL 290418 62Y 28197 5A 11 NOTICE This manual has been prepared by Yamaha primarily for use by Yamaha dealers and their trained mechanics when performing maintenance procedures and repairs to Yamaha equipment It has been written to suit the needs of persons who have a basic understanding of the mechanical and electrical concepts and procedures inherent in the work for without such knowledge attempted repairs or service to the equipment could render it unsafe or unfit for use Because Yamaha has a policy of continuously improving its products models may differ in detail from the descriptions and illustrations given in this publication Use only the latest edition of this manual Authorized Yamaha dealers are notified periodically of modifications and significant changes in specifications and procedures and these are incorporated in successive editions of this manual Important information Particularly important information is distinguished in this manual by the following notations 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 informa
26. set the selector on the digital circuit tester to the DC voltage mode Connect the positive pin on the peak volt age adaptor to the positive terminal of the digital circuit tester Measuring the lower resistance 62Y5A11 When measuring a resistance of 10 O or less with the digital circuit tester the correct mea surement cannot be obtained because of the internal resistance of the tester To obtain the correct value subtract the internal resistance from the displayed measurement Correct value displayed measurement internal resistance NOTE __ ___ ___ Obtain the internal resistance of the digital circuit tester by connecting both of its probes and checking the display 8 2 ERES Electrical systems Electrical components Starboard and port views O SY X WS ed NN ei IE ST D Tor S62Y8030K Stator Starter relay Pulser coil Starter motor CDI unit Ignition coil 6 Oil pressure switch Thermoswitch Prime Start Rectifier Regulator 8 3 62Y5A11 Electrical components Front view a EZ Sy y 2 EH D a P AN E oN D WI S62Y8040K Stator Tiller handle model Pulser coil CDI unit Fuse Neutral switch tiller handle model Starter relay Starter motor Power trim and tilt relay power trim and tilt model 6
27. you should follow these precautions to minimize any risk when working with lubricants 1 Maintain good standards of personal and industrial hygiene 2 Change and wash clothing as soon as possible if soiled with lubricants 3 Avoid contact with skin Do not for example place a soiled rag in your pocket 4 Wash hands and any other part of the body thoroughly with soap and hot water after contact with a lubricant or lubricant soiled clothing has been made 5 To protect your skin apply a protective cream to your hands before working on the outboard motor 62Y5A11 6 Keep a supply of clean lint free cloths for wiping up spills etc Good working practices Special tools Use the recommended special tools to pro tect parts from damage Use the right tool in the right manner do not improvise S62Y1140 Tightening torques Follow the tightening torque specifications provided throughout the manual When tight ening nuts bolts and screws tighten the large sizes first and tighten fasteners starting in the center and moving outward Non reusable parts Always use new gaskets seals O rings cot ter pins circlips etc when installing or assembling parts eS S62Y1150 Disassembly and assembly 1 Use compressed air to remove dust and dirt during disassembly D Apply engine oil to the contact surfaces of moving parts before assembly 62Y5A11 Safety while working Identification
28. 000 1 6923 1 6929 32 984 33 000 1 2986 1 2992 0 04 0 0016 Crankcase Crankcase main journal inside diameter Crankshaft main journal oil clearance 46 000 46 024 1 8110 1 8120 0 012 0 036 0 0005 0 0014 Oil pump Type Outer rotor to housing clearance Outer rotor to inner rotor clearance limit Rotor to cover clearance Trochoid 0 09 0 15 0 001 0 006 0 01 0 10 0 0004 0 0039 0 03 0 08 0 001 0 003 Thermostats Opening temperature Fully open temperature Valve open lower limit 2 5 60 140 70 158 3 0 0 12 62Y5A11 Unit Maintenance specifications Model FT5OCEHD FT50CED FT50CET Fuel pump Discharge Pressure Plunger stroke L US gal Imp gal hr 6 000 r min kPa kgf cm psi mm in 70 18 5 15 4 49 0 49 7 0 5 85 9 05 0 23 0 35 Carburetor ID mark Main jet Pilot jet Pilot screw Float height Engine idle speed Lower unit Item turns out mm in r min 62Y30 62Y50 for Brazil 1 124 2 126 3 116 4 114 39 1 3 1 3 4 2 3 4 4 2 3 9 5 10 5 0 37 0 41 850 950 Model FT50CEHD FT50CED FT50CET Gear backlash Pinion to forward gear Pinion to reverse gear Pinion shims Forward gear shims 0 12 0 45 0 005 0 018 0 10 0 12 0 15 0 18 0 30 0 40 0 50 0 10 0 12 0 15 0 18 0 30 0 40 0 50 Electrical Item Unit Mouel FT50CEHD F
29. 1 7 Technical DS cia nia 1 8 Garb relor en elle 1 8 Acceleration PUMP siria ta ata 1 13 Ignition system saure ee ee dee 1 15 Ignition timing Controls see nat cie 1 17 Power inn ard tl ee 1 19 Propeller Selecionar een 1 26 Propeller Size 1 26 SEGONE eee nen 1 26 62Y5A11 Predelivery eC iii aia 1 26 Checking the fuel system AEN 1 26 Checking the gear ol see COLL O FA 1 27 Checking the engine Olli ae ee 1 27 Checking the Dathery secs schen el 1 27 Checking the outboard motor mounting position 1 27 Checking the remote control cables 1 27 Checking the steering system EEN 1 28 Checking the gearshift and throttle operation 1 28 Checking the tilt SY SUSI so ect a ee 1 28 Checking the engine start switch and engine stop switch engine shut off switch EE 1 29 Checking the pilot water outlet AAA 1 29 Tes E 1 29 ie OR lee aaa AN nganan 1 29 After test EE 1 29 62Y5A11 General information How to use this manual Manual format The format of this manual has been designed to make service procedures clear and easy to under stand Use the information below as a guide for effective and quality service Parts are shown and detailed in an exploded diagram and are listed in the components list 2 Tightening torque specifications are provided in the exploded diagrams and after a numbered step with tightening instructions Symbols are used to indicate important aspects of a procedure such as the grade of
30. 7 1 Till r EN UE 7 2 Bottom CON NO cessitats tasts 7 7 Checking the throttle cable and shift rod A 7 9 Assembling the tiller handle 7 9 Lubricating the throttle gear 7 10 Checking the shift rod assembly operaton nennen 7 10 Upper Casualidad 7 11 Disassembling the oil Pan He 7 15 Checking the oil strainer and the relief valve 7 15 Assembling the oil pan nenen eaaa aane anana nana nana eaaa 7 15 Installing the upper Case ann iron entente 7 17 Glamp brackels tas see atenta 7 18 Removing the clamp brackets oooomniononcccnnnnnnnconcncnnnnennnonanncnnnnnnnnnnnnns 7 19 Installing the clamp brackets sms rie 7 19 Adjusting the trim sensor ebe en Gees trad 7 20 Swivel bracket and Steering arm 7 21 Removing the Steering arm oooocccccccnononcononcnononnnnnnnnnncnnnnnnnnnnnn nn nnnnnennnnnnes 7 23 Installing the steering arm annee 7 23 Power trinidad 7 25 Removing the power trim and tilt hydro mt 7 26 Tilt cylinder and trim cylinder sn 7 27 Trim Ee da e EE 7 29 E 7 31 Disassembling the tilt cylinder AAA 7 35 Disassembling the trim cylinder 7 35 Disassembling the gear pump 7 35 Checking the tilt cylinder and trim cylinder errnrrrnnnnrnvrnnnnnnnnrnnnnnnnrnnnnnr 7 36 CHECK the Valves nass neigen 7 36 Checking the titers u ee ee 7 37 Checking the gear pump ne ae 7 37 Assembling the gear pump seen ne 7 37 Assembling the trim cylinder
31. Black B Terminal Terminal 4 Terminal Terminal Terminal Terminal Terminal Terminal Continuity Continuity No continuity 2 Connect the digital circuit tester between power trim and tilt relay terminals D and 62Y5A11 Power trim and tilt electrical system 3 Connect the light green Lg lead to the positive battery terminal and the black B lead to the negative battery terminal as shown Check for continuity between terminals and 3 Replace if there is no continu ity SA OW AU AT Po OD i Kone S62Y7A50 Connect the digital circuit tester between power trim and tilt relay terminals 2 and Connect the sky blue Sb lead to the positive battery terminal and the black B lead to the negative battery terminal as shown Check for continuity between terminals and Replace if there is no continu ity S62Y7A60 7 48 e hd Bracket unit Checking the trailer switch 1 Check the trailer switch for continuity Replace if out of specification S62Y7A70 Lead color Switch position Sky blue Sb Red R Light green Lg Up O Free Down Checking the trim sensor 1 Measure the trim sensor resistance O Replace if out of specification Tu Trim sensor resistance ul Pink P Black B S62Y7A90 10 288 3 Q at 20 C 68 F NOT
32. Bolt Thermoswitch lead Rectifier Regulator coupler CDI unit coupler Bolt Bolt Nut Spring washer Starter motor lead Spring washer Nut Bolt M6 x 12 mm M6 x 12 mm M6 x 30 mm M8 x 25 mm M8 x 35 mm 1 4 4 2 1 1 1 1 3 1 1 1 1 2 4 2 1 1 2 3 1 1 1 1 1 1 M8 x 45 mm 62Y5A11 5 10 a 21 N m 2 1 kgf m 15 ft Ib S62Y5050K Part name Remarks Power unit Engine oil dipstick Gasket Dowel pin Bolt Bolt Apron Screw Nut Not reusable M6 x 16 mm M8 x 80 mm M6 x 24 mm NN NN NN ch ch 1 2 3 4 5 6 7 8 9 5 11 62Y5A11 Power unit S62Y5060K Part name Remarks Throttle link rod Throttle cam Throttle control lever Clip Bushing Bolt Spring Collar Bracket Bolt Shift rod Bolt Bracket Spring Bolt M6 x 20 mm o NO O BE O Mm M6 x 30 mm M6 x 30 mm ll sch dd sch sch sch sch sch HU 62Y5A11 5 12 Checking the compression pressure 1 Start the engine warm it up for 5 min utes and then turn it off 2 Remove the clip from the engine shut off switch on the remote control box or tiller handle 3 Remove the all spark plugs and then install the special service tool to each spark plug hole CAUTION Before removing the spark plugs blow compressed air in the spark plug well to clear out any dirt or dust that may fall into the cylinder yb Compression ga
33. Ds Da or De 0 08 mm 0 003 in Checking the piston clearance 1 Rebore the cylinder or replace the piston and piston rings as a set or the cylinder body or both if out of specification ZX Piston clearance 0 04 0 06 mm 0 0016 0 0024 in Checking the piston rings 1 Check the piston ring dimensions of B and T Replace if out of specification yh De te S62Y5770K Piston ring dimensions Top ring 8 B 1 17 1 19 mm 0 046 0 047 in T 2 39 2 41 mm 0 094 0 095 in Second ring B 1 47 1 49 mm 0 058 0 059 in T 2 49 2 51 mm 0 098 0 099 in Oil ring B 2 34 2 46 mm 0 092 0 097 in T 2 75 mm 0 108 in 5 39 Level the piston ring in the cylinder with the piston crown of an inverted pis ton Check the piston ring end gap at the specified measuring point Replace if out of specification S62Y5780 Piston ring end gap 0 Top ring 0 15 0 30 mm 0 006 0 012 in Second ring 0 30 0 50 mm 0 012 0 020 in Oil ring 0 20 0 70 mm 0 008 0 028 in Measuring point 8 20 mm 0 8 in 62Y5A11 Checking the piston ring grooves 1 Measure the piston ring grooves Replace the piston if out of specification S62Y5790 Piston ring groove Top ring 8 1 23 1 25 mm 0 048 0 049 in Second ring 1 52 1 54 mm 0 060 0 061 in Oil ring C 2 51 2 53 mm 0 099 0 100 in Checking the piston ring side clearance 1 Measure the piston ring side
34. Engine speed control Over revolution Warning buzzer in remote control Low oil pressure Oil pressure unit gt Damage prevention Warning lamp low oil pressure Overheat Warning lamp to overheat S62Y1330 Basic control The ignition timing is determined by using the map based on the engine speed r min Then igni tion signals are output from the microcomputer in accordance with the ignition timing map so that ignition can take place at the optimal timing in relation to the engine speed Then the microcom puter corrects the ignition timing in accordance with the operating conditions of the engine as detected by the signals that are input from the engine temperature sensor and oil pressure sensor The pulser signals that are output when the protrusions for cylinders 1 and 4 and for cylinders 2 and 3 pass by the pulser coil are used to calculate the engine speed In addition the pulser sig nals are used to determine the forecast starting position of the ignition timing o ag P nr we S62Y1340 Cylinder identification protrusion Cylinder identification signal Pulser coil Identification signal for cylinders 1 and 4 G Protrusion for cylinders 1 and 4 Identification signal for cylinders 2 and 3 4 Protrusion for cylinders 2 and 3 9 Rotating direction Pulser coil signal 1 17 62Y5A11
35. Is it closed Close the valve Yes Check the power trim and tilt fluid level At specified level Add fluid to the correct level Disassemble the power trim and tilt unit and then check it 9 11 62Y5A11 Bracket unit Symptom Shift mechanism of the forward gear and reverse gear does not operate properly Check the shift cable operation Check the shift cables and links of the remote control box Good operat ing condition Check the operation of the shift rod Check the detent of the bottom cowling Good operat ing condition Check the condition of the shift rod connection between the lower case and upper case Connected properly Replace the shift rod Disassemble the lower case and then check the shifting gear mechanism and the respective parts 62Y5A11 9 12 TRBL H SHTG e Troubleshooting Electrical systems Symptom Battery becomes weaker quickly Check the charging system Measure the output peak voltage of the lighting coil Out of specifi cation Replace the lighting coil Measure the Rectifier Regulator output peak voltage Out of specifi cation Replace the Rectifier Regulator Replace the battery and then check the whole voltage of all electrical equipments on your boat 9 13 62Y5A11 A Accelera
36. Rd Wd sea DE Wee Y GYF GE TEN 5 33 Installing the rocker arm assembly 5 33 Installing the cylinder head ne een 5 34 62Y5A11 Cyllnder DOCV H H EA 5 35 Removing and installing the oil filter b 37 Disassembling the cylinder body 5 37 Checking the piston diameter 5 38 Checking the cylinder bore ss 5 38 Checking the piston clearance ENNEN 5 39 Checking the piston rings EEN 5 39 Checking the piston ring grooves EEN 5 40 Checking the piston ring side clearance saene easeeeeanaee nenen anae 5 40 Checking the piston pin boss bore srnrrrsrnrvnvrrnvvrnnrrnvnnnrrvanersrnersvverervennr 5 40 Checking the piston pin ss 5 40 Checking the connecting rod small end inside diameter 5 41 Checking the connecting rod big end side clearance 5 41 Checking the connecting rod bolt sssssesesssseeesnnresserrnserrrnrerennresrerrset 5 41 Checking the crankshaft 5 41 Checking the crankshaft main journal oil clearance 5 42 Checking the crankshaft pin oil clearance 0sssesese ene enea aane nenene 5 43 Selecting the crankshaft main journal bearing 5 45 Selecting the connecting rod big end bearing ocooocccccnnncccnnonanccnnnancncnnn 5 45 Assembling the cylinder body 5 46 Installing the power unit isis A tania 5 49 62Y5A11 Special service tools Ke E Compress
37. S62Y3080K S62Y3085K NOTE To extract and change the oil through the dip stick hole you can use an oil changer like the one shown in the illustration 3 Place a rag under the oil filter and then remove the filter NOTE Be sure to clean up any oil spills 3 4 CHK Q ADJ Periodic checks and adjustments 4 Apply a thin coat of the new engine oil to the O ring of the new oil filter 5 Install the oil filter and then tighten it to the specified torque S62Y3110 S62Y3115 Y Oil filter 18 N m 1 8 kgf m 13 ft lb 6 Install the drain bolt and then tighten it to the specified torque Drain bolt 18 N m 1 8 kgf m 13 ft lb 3 5 7 Fill the specified engine oil into the oil filler hole Recommended engine oil 4 stroke motor oil API SE SF SG or SH SAE 10W 30 10W 40 or 20W 40 Oil quantity With oil filter replacement 2 2 L 2 3 US at 1 9 Imp qt Without oil filter replacement 2 0 L 2 1 US qt 1 8 Imp qt 8 Install the oil filler cap and dipstick and then start the engine and warm it up for 5 minutes 9 Turn the engine off and then check the oil level and correct it if necessary Checking the timing belt 1 Remove the flywheel magnet cover 2 While turning the flywheel magnet clock wise check the interior and the exte rior of the timing belt for cracks damage or wear Replace if necessary S62Y3130 CAUTION Do not turn the flywheel
38. S62Y7070K 7 3 62Y5A11 Z o Part name Tiller handle Remarks DJ o O BE O Mm Tiller handle Tiller handle wiring harness Clip Shift rod Nut Bushing Bolt Clip Throttle cable Nut Plastic washer Metal washer Wave washer Pin Gear Throttle shaft Bolt Friction piece Wing nut Bolt Gasket Cover Bolt Bolt Grease nipple Case Bushing Spring Washer Throttle grip Screw 62Y5A11 lt 2 sch A LL sch sch ld sch sch DO A sch NM sch sch M12 x 70 mm M6 x 25 mm M6 x 25 mm M5 x 14 mm M6 x 8 mm M5 x 25 mm 7 4 BAG bd Bracket unit S62Y7080 7 5 62Y5A11 Z o Part name Tiller handle Remarks DJ O O BE O ND Bracket Bolt Bolt Shift arm guide Nut Washer Washer Bushing Tiller handle bracket Nut Bushing Engine stop switch Bolt Engine start switch housing Screw Connector Connector Engine start switch Screw Screw Collar Ball Spring Shift arm Washer Shift grip Clip Shift rod 62Y5A11 M6 x 16 mm M6 x 16 mm M6 x 20 mm M6 x 12 mm Black White M6 x 30 mm M6 x 25 mm 7 6 PASI XxX Bracket unit Bottom cowling S62Y7140K 62Y5A11 7 7 Z o Part name Bottom cowling Remarks Shift rod assembly Bottom cowling Bolt Spring Ball Shift rod bracket Cotter pin Washer Bushing Bushing Shift rod Grommet Rubber seal Bolt Gromm
39. aligned with the A mark on the cylinder head and then tighten the bolt 1 2 ei S62Y5180 Install the retaining plate Woodruff key 2 drive sprocket retaining plate and nut and then tighten the nut po 3 Check that the mark on the retain ing plate is aligned with the A mark 9 on the cylinder body S62Y5200 4 Install the timing belt from the drive sprocket side with its part number in the upright position Um XA Um SSS d NU S x dx ke x S62Y5210 CAUTION Do not twist turn inside out or bend the timing belt beyond the maximum limit of 25 mm 1 0 in otherwise it may be damaged Do not get oil or grease on the timing belt 5 19 5 Install the tensioner and bolts and then tighten the bolts finger tight Seov521 5 Si 6 Take up the timing belt slack by turning the drive sprocket clockwise at least two full turns CAUTION Do not turn the sprockets counterclock wise otherwise the valve system may be damaged 7 Tighten the tensioner bolts to the speci fied torque S62Y5216 Tensioner bolt 9 8 N m 0 8 kgf m 5 8 ft Ib Tensioner bolt adjusting bolt 0 25 N m 2 5 kgf m 18 ft Ib 8 Turn the drive sprocket two turns and then check that the alignment marks are aligned 62Y5A11 CAUTION Do
40. fit into holes of the power trim and tilt cylinder Once the balls have been fitted into the holes the trim cylinder base cannot move The end of the tilt up range is when the tilt piston tops out in the trim cylinder and the ram is fully extended The tilt up function operates when the fluid pressure is under 10 MPa 100 kgf cm 1 423 psi When the fluid pressure in the lower part of the trim cylinder increases to over 10 MPa 100 kgf cm 1 423 psi the up relief valve opens and allows the pressurized fluid to flow into the reservoir Thus the tilt piston and free piston are not pushed up and the ram cannot be extend further 2 A 2 B gt C 3 4 5 c 1 BI 9 6 6 7 dei 14 ICH 1 J 13 Al tt 11 6 10 d 2 S62Y1400K Power trim and tilt cylinder Up shuttle piston Ram 9 Down shuttle piston End screw 42 Trim cylinder base Check valve 43 Free piston Trim cylinder Tilt piston Reservoir Balls Down main valve A Return Gear pump B Send Up main valve C Moving direction 62Y5A11 4 22 an Y General information Circular flow S62Y1410 D Power trim and tilt cylinder 2 Gear pump Ram Free piston Trim cylinder O Tilt piston Motor A Return Reservoi
41. manufacture identification mark facing outward propel ler side Cz Bearing inner race attachment O 90890 06639 62Y5A11 4 Install the reverse gear assembly to the propeller shaft housing using a press S62Y6700K Bearing inner race attachment 0 90890 06661 Installing the propeller shaft housing 1 Install the washer G propeller shaft assembly into the propeller shaft housing assembly 2 Apply grease to the new O rings Propeller shaft housing 3 Install the propeller shaft housing assem bly 4 into the lower case and then install the straight key claw washer and ring nut 4 Tighten the nut to the specified torque S62Y6710 S62Y6715 NOTE y Secure the ring nut by bending one tab 8 into the slot in the ring nut and the other tabs toward the propeller shaft housing assembly Ring nut wrench 3 8 90890 06511 Ring nut wrench extension 9 90890 06513 Ring nut 7 S62Y6705 62Y5A11 105 N m 10 5 kgf m 76 ft lb 6 16 mask Lower unit Drive shaft and lower case S62Y6720K 6 17 62Y5A11 Drive shaft and lower case Z o o NO O BE O Mm Part name Remarks Drive shaft Taper roller bearing Not reusable Bearing outer race Not reusable Pinion shim As required Sleeve Hose Plastic tie Joint Nut Water inlet cover Screw Seal Plate Forward gear shim 200 0 mm 7 9 in Not reusable A gt _ NN sc
42. o YO N sch sch Bb OD A A BA PA D 2 ND o DN Joint to silencer Not reusable 34 5 x 1 9 mm M6 x 25 mm Fuel pump to carburetor M5 x 9 mm Acceleration pump to acceleration pump Acceleration pump to carburetor Not reusable Silencer to joint M6 x 90 mm Not reusable 37 7 x 3 5 mm Not reusable 34 5 x 1 9 mm Not reusable 4 8 de ry Fuel system Carburetor S62Y4205 62Y5A11 4 9 Z o Part name Carburetor Remarks Carburetor body Screw Cover Seal Pilot jet Main jet Needle valve Main nozzle O ring Plug Float Screw Float pin Gasket Float chamber Drain screw O ring Screw Fuel hose Prime Start Screw O ring Bracket Body Screw o NO O BE O Mm Gasket Spring O ring Pilot screw A Carburetors 1 2 and 3 B Carburetor 4 C Carburetors 1 and 3 62Y5A11 1 4 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 4 1 1 1 1 1 1 2 M4 x 13 mm Not reusable Not reusable M4x6 mm Not reusable Not reusable M4 x 13 mm Float chamber to body M4 x 7 mm Not reusable Carburetor 1 M4 x 17 mm Carburetor 3 M4 x 22 mm Not reusable Not reusable 4 10 dian ry Fuel system Checking the carburetor 1 Check the air and fuel passages and jets for dirt and foreign matter Clean the car buretor body with a petroleum based sol vent if necessary 2 Blow compressed air into all passa
43. piston i connecting rod 2 piston pin and piston pin clips 4 S62Y5A20 Connecting rod cap mark color Red A Yellow Red Il Blue II Blue M Yellow IIl Yellow Green Crank pin Bearing mark color Red Pink 4 When installing the connecting rod bear ing insert the projection of the connect ing rod bearing into the slot on the connecting rod CAUTION Remove any small metal particles and oil from the contact surfaces of the connect ing rod and the connecting rod bearing 5 Measure the crank pin oil clearance with a piece of Plastigauge PG 1 62Y5A11 5 46 NOTE __ e Face the embossed Y11 mark on the connecting rod in the same direction as the UP mark on the piston Always use new piston pin clips and do not allow the piston pin clip end to align with the piston pin slot 2 Install the oil ring second ring and top ring to the piston with the T mark on the piston rings facing upward 3 Offset the piston ring end gaps as shown 5 S62Y5A40 CAUTION Do not scratch the piston or break the pis ton rings NOTE After installing the piston rings check that they move smoothly 4 Install the upper half of the bearing into the connecting rod 2 and the lower half into the connecting rod cap 5 47 S62Y5A45 CAUTION Install the bearings in their original posi tion NOTE __ Inser
44. shaft for bends or wear Replace if necessary S62Y6660 2 Check the dog clutch and shift slider for cracks or wear Replace if necessary DE 6 14 EE Lower unit Assembling the propeller shaft assembly 1 Install the dog clutch as shown S62Y6665 NOTE 0 Install the dog clutch with the F mark facing toward the shift slider Assembling the propeller shaft housing 1 Install the needle bearing into the propel ler shaft housing to the specified depth S62Y6675K NOTE Install the needle bearing with the manufac ture identification mark facing toward the oil seal propeller side When using the driver rod do not strike the special tool in a manner that will force the stopper b out of place Cz Driver rod SS G 90890 06604 Needle bearing attachment 90890 06612 Bearing depth plate 3 90890 06603 A Depth A 25 0 25 5 mm 0 98 1 00 in 2 Apply grease to the new oil seals and then install them into the propeller shaft housing to the specified depth y E NOTE Install an oil seal halfway into the propeller shaft housing then the other oil seal 200 el S62Y6685K CZ Ball bearing attachment 90890 06655 Driver rod LS G 90890 06606 ZX Depth 4 5 5 5 mm 0 18 0 22 in 3 Install the thrust washer 6 and ball bear ing to the reverse gear using a press S62Y6695K NOTE Install the ball bearing with the
45. the filters ani 7 37 Checking the fuel filter 3 3 Checking the fuel joint and fuel hoses fuel joint to carburetor asana 3 3 Checking the fuel poump anae 4 5 Checking the fuel system 1 26 Checking the fUSe 7 48 8 16 Checking the gear oil 1 27 Checking the gear oil level 3 12 Checking the gear pump ne 7 37 Checking the gearshift and throttle operation 1 28 Checking the gearshift operation 3 9 Checking the ignition Coil 8 11 Checking the ignition spark gap 8 10 Checking the ignition timing 3 11 Checking the lighting Coil 8 22 Checking the lower case 6 21 Checking the lower unit for air leakage 3 14 Checking the neutral switch 8 16 Checking the oil pressure 5 13 Checking the oil pressure switch 8 14 Checking the oil pump 5 31 Checking the oil strainer and the relief Valve kk 7 15 Checking the outboard motor mounting POSON nennen a 1 27 Checking the pilot water outlet 1 29 Checking the pinion and forward gear 6 20 Checking the piston clearance 5 39 Checking the piston diameter 5 38 Checking the piston pin 5 40 Index Checkin
46. the vise horizon tally 13 Install the trim cylinder end screw 63 and then tighten it to the specified torque 62Y5A11 S62Y7780K CAUTION Do not damage the check valve b when tightening the end screw yo Cylinder end screw wrench 90890 06544 Trim cylinder end screw 63 80 N m 8 0 kgf m 58 ft lb Assembling the tilt cylinder 1 Install the valve seal and the circlip into the free piston 8 as shown 2 Install the free piston into the trim cylin der 4 by installing the circlip S62Y7790 3 Install the trim cylinder base springs 2 and plate 8 into the trim cylinder with the circlip 9 62Y5A11 Gear pump FF em RRN LL 4 Hold the power trim and in a vise using aluminum plates on both sides S62Y7805 5 Add fluid of the recommended type to the first level at the bottom of tilt cylinder 6 Install the balls into the trim cylinder and then insert the trim cylinder into the tilt cylinder 2 S62Y7810 NOTE Apply grease to the balls to prevent them from falling out of the cylinder Recommended power trim and tilt fluid ATF Dexron II 7 40 RASI E d Bracket unit 7 Install the tilt cylinder end screw 3 and then tighten it to the specified torque S62Y7820 Gi Cylinder end screw wrench 90890 06544 Tilt cylinder end screw 3 90 N m 9 0 kgf m 65 ft Ib 8 Fully extend the tilt rod and then add suf
47. using a straightedge and thickness gauge in five directions as shown Replace if out of specification S62Y5580K Clearance 0 09 0 15 mm 0 004 0 006 in Clearance 0 01 0 10 mm 0 0004 0 0039 in Clearance 0 03 0 08 mm 0 001 0 003 in 5 31 62Y5A11 Installing the valves 1 Install the new valve stem seal to the valve guide and then apply engine oil to the valve guide S62Y5590 2 Install the valve spring seat 3 valve spring 4 and spring retainer in the seguence shown and then attach the special service tool S62Y5600 NOTE Face the fine pitch side of the valve spring toward the spring seat 2 Valve spring compressor 90890 04019 Valve spring compressor attachment D 90890 06320 62Y5A11 Cylinder head 3 Compress the valve spring and then install the valve cotter using a thin screwdriver with a small amount of grease applied to it a LA S62Y5610 4 Lightly tap the spring retainer with a plas tic hammer to set the valve cotter securely S62Y5620 5 32 Installing the camshaft 1 Install the new oil seal D Assembly the rocker arm and rocker arm shaft and the tensioner G rocker arm retainer 4 by installing the bolts 90890 06626 2 Install the camshaft in the direction shown then the retaining bolt S62Y5660 NOTE S Make sure that the arrow marks on t
48. valve opening at the specified water temperatures Replace if out of specification 62Y5A11 Power unit S62Y3310 Water temperature Valve lift below 60 C 140 F above more than 70 C 158 F 3 mm 0 12 in 0 mm O in 5 Install the thermostat new gasket ther mostat cover and cover Checking the cooling water passage 1 Check the cooling water inlet cover and cooling water inlet for clogs Clean if necessary S62Y3320 2 Place the lower unit in water and then start the engine 3 8 CHK Q ADJ Periodic checks and adjustments 3 Check for water flow at the cooling water outlet If there is no water flow check the cooling water passage inside the out board motor S62Y3330 Control system Checking the throttle cable operation 1 Check that the throttle cam G is at the fully closed position when the remote control lever is in neutral or the throttle grip is fully closed Adjust the throttle cable length if necessary as follows S62Y3370 2 Loosen the locknut remove the clip 3 and then disconnect the throttle cable joint S62Y3380 3 Align the alignment mark on the throt tle cam with the alignment mark on the shift bracket 3 9 4 Adjust the position of the throttle cable joint until its hole is aligned with the set pin on the throttle cam S62Y3390 S62Y3400 CAUTION The throttle cable joint m
49. wire lead S62Y7970 Install the springs 8 into the motor base then the brush holder into the motor base together with the brushes and circuit breaker 7 45 Install the armature 9 O ring 9 and yoke S62Y7980 Installing the power trim and tilt Fully tilt the outboard motor up and then support it with the tilt stop lever S62Y7990 NOTE After tilting up the outboard motor be sure to support it with the tilt stop lever 62Y5A11 Power trim and tilt motor 2 Install the shaft 2 and bolts onto both clamp brackets together with the power trim and tilt hydro tilt 4 3 Install the tilt ram upper end into the swivel bracket with the shaft and cir clip s 6 4 Install the tilt pin EE gt S62Y7A10 62Y5A11 7 46 RANI bd Bracket unit Power trim and tilt electrical system S62Y7A20K i Power trim and tilt motor B Black Power trim and tilt relay G Green Trailer switch Gy Gray Fuse L Blue Battery Lg Light green Trim sensor P Pink R Red Sb Sky blue 7 47 62Y5A11 Checking the fuse 1 Check the fuse and fuse holder for conti nuity Replace if there is no continuity S62Y7A30 Checking the power trim and tilt relay 1 Check the power trim and tilt relay for continuity Replace if out of specification S62Y7A40 Power trim and tilt relay continuity Sky blue Sb Black B Light green Lg
50. x 25 mm Fuel joint to fuel filter M8 x 14 mm 22 a ap a a a a a a O Fuel filter to fuel pump 205 0 mm 8 1 in Fuel hose Fuel pump to carburetor Clip Bolt M6 x 30 mm O ring 24 4 x 3 1 mm Fuel filter cup O ring 32 2 x 2 0 mm Fuel filter element Body Float Screw Cover Fuel pump body 2 Fuel pump body 1 Nut Plunger Spring Spring Pin Diaphragm Screw Valve Nut Seal Gasket Not reusable Not reusable 62Y5A11 4 4 SE Wu Fuel system Checking the fuel pump 1 Install the special service tool onto the fuel pump as shown S62Y4050 Vacuum pressure pump gauge set 90890 06756 2 Apply the specified pressure to each fuel pump port 3 If air flow is reversed check the dia phragm for tears and the valves for cracks Replace if necessary CAUTION Do not over pressurize the fuel pump oth erwise excessive pressure may cause air leakage NOTE Make sure that air does not escape from the opposite side of the fuel pump 4 5 To eliminate any gaps between the fuel pump valves and the fuel pump body 2 and to ensure a better seal make sure that the inside of the fuel pump is moist with gaso line Fuel pump pressure 8 50 kPa 0 5 kgf cm 7 1 psi Fuel pump negative pressure 30 kPa 0 3 kgf cm 4 3 psi Disassembling the fuel pump 1 Disassemble the fuel pump as shown S62Y4090 2 Push down on the plunge
51. 1 Measure the charge coil output peak volt age Replace the stator coil if below specification 62Y5A11 Ignition system and Ignition control system S62Y8210 WARNING When checking the peak voltage do not touch any of the connections of the digital tester leads NOTE Use the peak voltage adaptor with the digi tal circuit tester When measuring the peak voltage set the selector on the digital circuit tester to the DC voltage mode gt Digital circuit tester 90890 03174 Peak voltage adaptor 90890 03172 Test harness 2 pins 90890 06767 Charge coil output peak voltage Brown Br Blue L Unloaded Loaded Cranking 1 500 144 137 169 Charge coil resistance use as reference Brown Br Blue L 272 408 Q at 20 C 68 F 62Y5A11 Checking the pulser coil 1 Measure the pulser coil output peak volt age Replace the pulser coil if below specification S62Y8220 AA WARNING When checking the peak voltage do not touch any of the connections of the digital tester leads NOTE 0 Use the peak voltage adaptor with the digi tal circuit tester When measuring the peak voltage set the selector on the digital circuit tester to the DC voltage mode Ko Digital circuit tester 90890 03174 Peak voltage adaptor 90890 03172 Test harness 2 pins 90890 06767 Pulser coil output peak voltage W
52. 2Y5A11 7 28 RASI X Bracket unit Trim cylinder e 3 4 6 O O 8 10 S62Y7470K 7 29 62Y5A11 Part name Trim cylinder Remarks Tilt ram Dust seal Backup ring O ring Tilt cylinder end screw O ring Backup ring O ring Trim cylinder end screw O ring O ring Trim piston O ring Trim cylinder O ring Backup ring Ball Tilt piston Ball Absorber valve pin Spring Pin Pin Washer Bolt 62Y5A11 2 ND BO BO AR BA 4 Not reusable Not reusable Not reusable Not reusable Not reusable Not reusable 43 7 X 3 5 mm Not reusable 47 7 X 3 5 mm Not reusable 28 7 x 3 5 mm 7 30 RASI bd Bracket unit Gear pump S62Y7480K 7 31 62Y5A11 Gear pump No Part name O ty Remarks 1 Bolt 2 M5 x 8 mm 2 Relief valve bracket 2 3 Bolt 3 M6 x 45 mm 4 Adapter 1 5 Up relief spring 1 17 5 mm 0 69 in 6 Valve support pin 1 7 Relief valve seal 1 8 Down relief spring 1 14 2 mm 0 56 in 9 Valve support pin 1 10 Relief valve seal 1 11 Filter 1 12 Gear pump 1 13 O ring 2 5 8 x 1 9 mm 14 Filter 2 15 O ring 1 17 8 x 2 4 mm 16 Manual valve 1 17 Circlip 1 62Y5A11 7 32 S62Y7490K 62Y5A11 2 oi E E OY x em 19 o e ra n Te se Ba BAG TL Bracket unit 7 33 Gear pump Part name Remarks Q lt Bolt M5 x 20 mm Washer Gear pump bracket O rin
53. 2Y5A11 8 4 ELEG W s Electrical systems Top view o LO o co gt N o o i Stator Pulser coil CDI unit 4 Ignition coil Starter motor Trailer switch 62Y5A11 8 5 Electrical components Tiller handle model S62Y8070 Engine start switch Engine start switch harness Engine shut off switch 4 Engine shut off switch connector Neutral switch 6 Battery lead 62Y5A11 8 6 PLES Electrical systems Wiring harness B W B go Y B fand Y R om om P le M Gs y NA eN A PO es D Pl S62Y8080 Comnect to G Warning indicator or Power trim and tilt W White O Tiller handle main digital tachometer model B O Black orange switch or remote CDI unit B W Black white control box or wiring O Trailer switch B Black P B Pink black harness extension Rectifier Regulator Br Brown DAN Pink white Power trim and tilt y Thermoswitch G Green Y B Yellow black relay 42 Ignition coil L Blue Y R Yellow red Ground 43 Oil pressure switch Lg Light green 4 Starter relay P Pink Positive battery lead R Red Prime Start Sb Sky blue ES 62Y5A11 Wiring harness Ignition system and Ignition control system Ignition system and Ignition control system D WIR WD L Br ap 0 Es mm W RW BL Br S62Y8090 Spark plug B Black Ignition coil Br Brown Charge coil L Blue 4 Pulser coil
54. 36 Checking the anodes eeeeeeeeeee 3 14 Checking the armaiure 8 19 Checking the battery 1 27 3 15 Checking the bearings 6 20 Checking the brushes nn 8 20 Checking the camshaft 5 30 Checking the Carburetor 4 11 Checking the CDI unit 8 11 Checking the charge COoil 8 11 Checking the compression pressure 5 13 Checking the connecting rod big end side clearance 5 41 62Y5A11 Checking the connecting rod bolt 5 41 Checking the connecting rod small end inside diameter 5 41 Checking the cooling water passage 3 8 Checking the crankshaft 1000441 5 41 Checking the crankshaft main journal oil Cl arance ire H gset 5 42 Checking the crankshatt pin oil COCO uti nic 5 43 Checking the cylinder bore 5 38 Checking the cylinder head 5 31 Checking the diaphragm and valves 4 6 Checking the drive shaft 10141 6 20 Checking the electrical components 8 2 Checking the engine idle speed 3 10 Checking the engine oil 1 27 3 4 Checking the engine shut off switch 8 13 Checking the engine start switch 8 13 Checking the engine start switch and engine stop switch engine shut off SWIICH eines ida 1 29 Checking
55. 4 90890 06518 N Pinion nut holder 90890 06505 Bearing outer race puller 90890 06523 Outer race puller claw A 90890 06532 62Y5A11 Special service tools Ra Driver rod SL 90890 06602 o Bearing outer race attachment 90890 06621 90890 06626 ee Driver rod LS 90890 06606 Driver rod LL 90890 06605 Pinion height gauge 90890 06702 6 2 EE Lower unit Digital caliper Dial gauge set 90890 06704 90890 01252 Shimming plate Magnet base 90890 06701 90890 06705 L Shift rod push arm Ring nut wrench 3 90890 06052 90890 06511 e Backlash indicator Ring nut wrench extension 90890 06706 90890 06513 Magnet base plate Bearing housing puller claw L 90890 07003 90890 06502 6 3 62Y5A11 Special service tools e Ball bearing attachment 90890 06655 Socket adapter 2 90890 06507 62Y5A11 6 4 EE Lower unit Lower unit Z o Part name e 7 8 1 S A MY 7 N em 0 7 kgf m 5 1 ft Ib S62Y6480K Remarks Lower unit Plastic tie Hose Check screw Gasket Dowel pin Bolt Drain screw Grommet Bolt Bolt Thrust washer Propeller Washer Washer Cotter pin Propeller nut Trim tab DJ O O BE O MM 6 5 X oo sch ld dd bb D NA tt Not reusable Not reusable M10 x 40 mm M10 x 45 mm M8 x 60 mm Not reusable 62Y5A11 Lower unit Removing the lower unit 1 Drain the gear oil For draining proce du
56. 504 Disassembling the propeller shaft housing 1 Remove the reverse gear and thrust washer 6 13 S62Y6615K g Bearing separator i 90890 06534 7 1 Stopper guide plate 90890 06501 Stopper guide stand 3 90890 06538 Bearing puller 4 90890 06535 Bearing puller claw 1 90890 06536 NOTE Install the bearing separator D between the reverse gear and thrust washer completely then the other special service tools 2 Remove the ball bearing S62Y6625K GC Stopper guide plate 90890 06501 A Stopper guide stand D 90890 06538 Bearing puller 8 90890 06535 Bearing puller claw 1 90890 06536 3 Remove the oil seals and needle bear ing 62Y5A11 S62Y6630K GC Needle bearing attachment 90890 06612 Driver rod L3 o 90890 06652 Disassembling the propeller shaft assembly 1 Remove the spring and then remove the cross pin dog clutch slider and shift plunger i c Checking the propeller shaft housing 1 Clean the propeller shaft housing using a soft brush and cleaning solvent and then check it for cracks Replace if necessary S62Y6635 S62Y6650 2 Check the teeth and dogs of the reverse gear for cracks or wear Replace the gear if necessary 62Y5A11 Propeller shaft housing S62Y6640 3 Check the bearings for pitting or rum bling Replace if necessary S62Y6645 Checking the propeller shaft 1 Check the propeller
57. 6 116 0 4 2 9 0 3 2 2 0 9 6 5 0 7 5 1 0 9 6 5 0 2 1 4 0 7 5 1 3 0 22 0 7 5 1 2 1 15 0 8 5 8 2 5 18 o o N N 00 N al Cylinder head bolt Adjusting screw locknut Oil filter Drain bolt Exhaust cover bolt Crankcase bolt Connecting rod cap bolt Lower unit Check screw Lower unit bolt Drain screw Propeller nut Ring nut Water inlet cover screw Pinion nut 62Y5A11 2 14 SE ye Specifications Part to be tightened Thread size Tightening torques N m kgf m Bracket unit Tiller handle assembly nut 37 3 7 Throttle cable short locknut 37 3 7 Upper mount nut 24 2 4 Lower mount nut 42 4 2 Trim sensor screw 2 0 2 Clamp bracket self locking nut 23 2 3 Power trim and tilt Tilt cylinder end screw 90 9 0 PTT motor bolt 4 0 4 Reservoir cap 6 5 0 65 Trim cylinder end screw 80 8 0 Tilt piston bolt 61 6 1 Relief valve bracket bolt 5 3 0 53 Gear pump assembly bolt 6 5 0 65 Gear pump bracket bolt 0 53 Electrical unit Pulser coil screw 0 4 Starter motor nut General torques This chart specifies tightening torques for standard fasteners with a standard ISO thread pitch Tightening torque spe
58. 62Y5720 2 Remove the crankcase bolts in the sequence shown 62Y5A11 S62Y5730 CAUTION Do not scratch or damage the mating sur faces of the cylinder head and cylinder body 3 Remove the connecting rod bolts and the piston assemblies A Remove the crankshaft oil seals and dowel pins 5 Remove the piston pin clip with pliers and then remove the piston S62Y5740 Checking the piston diameter 1 Measure the piston outside diameter at the specified measuring point Replace if out of specification 62Y5A11 Cylinder body S62Y5750 Piston diameter 8 62 95 62 96 mm 2 478 2 479 in Measuring point 5 mm 0 2 in up from the bottom of the piston skirt Oversize piston diameter Oversize 1 0 25 mm 0 01 in Oversize 2 0 50 mm 0 02 in Checking the cylinder bore 1 Measure the cylinder bore D D at measuring points and and in direction which is parallel to the crankshaft and direction which is at a right angle to the crankshaft 100mm 3 9in Cylinder bore 8 63 00 63 01 mm 2 480 2 481 in 5 38 2 Calculate the taper limit Replace or rebore the cylinder body if out of specifi cation Taper limit maximum of D or D minimum of D or De 0 08 mm 0 003 in 3 Calculate the out of round limit Replace or rebore the cylinder body if out of spec ification Out of round limit maximum of D Dz or De minimum of
59. 6570K 5 Install the Woodruff key into the drive shaft 6 Align the groove on the impeller 0 with the Woodruff key 4 and then install it to the drive shaft S62Y6575K 7 Install the insert plate cartridge and grommet into the pump housing NOTE SE When installing the pump housing apply grease to the inside of the housing and then turn the drive shaft clockwise while pushing down the pump housing 62Y5A11 6 10 E Lower unit Propeller shaft housing S62Y6590K 6 11 62Y5A11 Propeller shaft housing Z o DJ O O BE O Mm Part name Remarks Propeller shaft assembly Propeller shaft housing assembly Ball Slider Shift plunger Cross pin Dog clutch Spring Propeller shaft Washer Straight key Claw washer Ring nut Reverse gear Thrust washer Ball bearing O ring A gt gt sch sch sch dd MN 86 8 x mm Propeller shaft housing Needle bearing Oil seal Not reusable 62Y5A11 6 12 Ba Lower unit Removing the propeller shaft housing assembly 1 Straighten the claw washer tabs A and then remove the ring nut and claw washer S62Y6595 Cz Ring nut wrench 3 90890 06511 Ring nut wrench extension 2 90890 06513 2 Pull out the propeller shaft housing assembly S62Y6605K GC Bearing housing puller claw L 90890 06502 Stopper guide plate 90890 06501 Center bolt 6 90890 06
60. Checking the power trim and tilt fluid level nn 3 12 Lower Olga 3 12 Checking the gear oil level 3 12 Replacing the gear oli sea een ee 3 13 Checking the lower unit for air leakage nennen 3 14 Checking the Propeller nee ee 3 14 AAPP O 3 14 Checking the anodes tre nennene 3 14 Checking th batas di 3 15 A a ee EE EE AN Gaga NUW NE 3 16 CHK Q ADJ Periodic checks and adjustments Special service tools Oil filter wrench 90890 01426 Digital tachometer 90890 06760 Timing light 90890 03141 Leakage tester 90890 06762 3 1 62Y5A11 Special service tools Maintenance interval chart Maintenance interval chart Use the following chart as a guideline for general maintenance Adjust the maintenance intervals according to the operating conditions of the outboard motor Item Remarks Initial Every 10 hours Break in 50 hours 3 months 100 hours 6 months 200 hours 1 year Referto page Top cowling Top cowling fit Check O O 3 3 Fuel system Fuel joint and fuel hoses Fuel filter Fuel tank Check Check replace Cleaning Power unit Engine oil Oil filter Timing belt Valve clearance Spark plugs Thermostat Water leakage Motor exterior Exhaust leakage Cooling water passage Change Change Check Check adjust Clean adjust replace Check Check Check Check Clean
61. Control system Throttle cable Shift cable Engine idle speed Ignition timing Check adjust Check adjust Adjust Check Power trim and tilt unit Power trim and tilt Check Lower unit Gear oil Lower unit leakage Propeller Change Check Check O O General Anodes Battery Wiring and connectors Nuts and bolts Lubrication points NOTE Check replace Check Check reconnect Tighten Lubricate O O O every 1 month O O If operating in salt water turbid or muddy water flush the engine with fresh water after each use e If leaded gasoline is used regularly check the engine valves and related parts every 300 hours of operation in addition to the items in the maintenance interval chart 62Y5A11 3 2 CHK Q ADJ Periodic checks and adjustments Top cowling Checking the top cowling 1 Check the fitting by pushing the cowling with both hands Adjust if necessary S62Y3010 2 Loosen the nuts and bolts 3 Move the hook up or down slightly to adjust its position S62Y3020 NOTE AAA To loosen the fitting move the hook toward the seal To tighten the fitting move the hook away from the seal 4 Tighten the nuts and bolts 5 Check the fitting again and if necessary repeat steps 2 4 3 3 Fuel system Checking the fuel joint and fuel hoses fuel joint to carburetor 1 Remove the plate i and then chec
62. E Turn the lever and measure the resistance as it gradually changes 7 49 62Y5A11 62Y5A11 Electrical systems Special Service ii 8 1 Checking the electrical components ss 8 2 Measuring the peak voltage oooooocccoccccnnocooncccniconononnannnnnonnnnnnnnnnnnnncncnnnnnnns 8 2 Measuring the lower resistance 8 2 Electrical COMPONBNIS nenne 8 3 Starboard and port VIEWS ee ae 8 3 Fron VIGW eege 8 4 TOP VEN iia rs 8 5 Tiller handle model comic ion 8 6 Wiring E 8 7 Ignition system and Ignition control system 8 8 Checking the ignition Spark gap cooococcnncccccnnocccinonaanncnnnanncccnnanancn nana nc 8 10 Checking the spark plug Caps cooooccccccnncccccononaccnnonancncnonnn cnn nana nana nana 8 10 CHECKING the IGMILOMCOll eu ee eeschte id 8 11 Checking the CDI unit auch DL Fd EF 8 11 Checking the charge EE 8 11 Checking the pulser Col 8 12 Checking the pulser coil air gap EEN 8 13 Checking the engine start switch 8 13 Checking the engine shut off switch 8 13 Checking the thermoswitch asana eaaa anana EEN 8 14 Checking the oil pressure switch 8 14 eir ld ue system zn es o 8 15 GHECKING ME Tuse eiar ma en 8 16 Checking the wiring harness 10 pins 00ooccccnnocicnnnoccccnnnncccccnnnnacnnncnnn cnn 8 16 Checking the neutral switch sense ee 8 16 Checking the starter relay 8 16 Starter MOLO eege e
63. F50A FT50C S62Y1220K Pinion Forward gear Reverse gear Number Diameter Number Diameter Number Diameter Gear ratio of teeth mm of teeth mm of teeth mm 13 45 24 74 24 75 1 8 13 46 30 95 30 95 2 3 1 7 62Y5A11 Features and benefits Technical tips Shift slider type shift mechanism The FT50C has adopted the shift slider type shift mechanism This shift mechanism enables a prompt engagement of the dog clutch regardless of the operating speed of the shift lever Thus smooth and positive shift operation has been made possible S62Y1230 Shift rod A Forward Propeller shaft B Reverse Dog clutch Shift slider Technical tips Carburetor Starting system Prime Start To facilitate the starting of a cold engine an air fuel mixture that is richer than normal is required For this reason the Prime Start system has been adopted in the FT50C In the Prime Start system the thermo heater plunger is in a position that fully opens the fuel enrichment valve while the engine is being started Thus fuel enrichment is achieved during the starting of the engine and continues while the engine is being warmed up Once the engine starts current flows from the lighting coil of the to the thermo heater allowing the wax in the Prime Start unit to expand The expanded wax moves the thermo heater plunger in the direction to close the enrichment valve As a result the vol ume of fu
64. If the grooves in the propeller nut do not align with the cotter pin hole tighten the nut until they are aligned Propeller nut 35 N m 3 5 kgf m 25 ft lb 62Y5A11 Drive shaft and lower case Shimming Shimming A3 Y EZ ARA 7 VBA S62Y6900 62Y5A11 6 24 EE Lower unit Shimming NOTE Shimming is not required when assembling the original lower case and inner parts Shimming is required when assembling the original inner parts and a new lower case Shimming is required when replacing the inner part s Selecting the pinion shims 1 Install the drive shaft and drive shaft bearing to the shimming tools S62Y6905 S62Y6910 NOTE 0 Select the shim thickness T3 by using the specified measurement s and the calcula tion formula Install the shimming tool to the drive shaft so that the shaft is at the center of the hole Tighten the wing nuts another 1 4 of a turn after they contact the fixing plate Q Pinion height gauge 90890 06702 2 Install the pinion and pinion nut and then tighten the nut to the specified torgue 6 25 Pinion nut 95 N m 9 5 kgf m 69 ft lb 3 Measure the distance M between the shimming tool and the pinion as shown NO E D Measure the pinion at three points to find the clearance average Digital caliper 4 90890 06704 4 Calc
65. NOTE e If the engine oil is above the maximum level mark 8 drain sufficient oil until the level is between and If the engine oil is below the minimum level mark add sufficient oil until the level is between and Recommended engine oil API SE SF SG SH SAE 10W 30 10W 40 or 20W 40 Oil capacity Without oil filter replacement 2 0 L 2 1 US qt 1 8 Imp at Checking the battery 1 Check the capacity electrolyte level and specified gravity of the battery 1 27 Battery capacity 70 100 Ah Minimum cold cranking performance 380 A Electrolyte specific gravity 1 28 at 20 C 68 F 2 Check that the positive and negative bat tery leads are securely connected Checking the outboard motor mounting position 1 Check the position of the anti cavitation plate S62Y1490K 2 Check that the clamp brackets are secured with the clamp bolts Checking the remote control cables 1 Set the remote control lever to the neu tral position and fully close the throttle lever throttle grip 2 Check that the set pin is aligned with the alignment mark Adjust if neces sary 62Y5A11 3 Check that the alignment mark is aligned with the mark Adjust if neces sary S62Y1520 S62Y1530 CAUTION The shift throttle cable joint must be screwed in a minimum of 8 0 mm 0 31 in Checking the steering system 1 Check the steering friction for proper adjust
66. Not reusable 34 5 x 1 9 mm Aot A NN Dowel pin Clip Blowby hose Prime Start coupler Bolt Collar Throttle link rod M6 x 30 mm a N p 62Y5A11 5 6 S62Y5030K 5 7 62Y5A11 Z o Part name Power unit Remarks Power trim and tilt relay Bolt Negative battery lead Wiring harness extension Grommet Nut Spring washer Positive battery lead PTT relay positive lead Fuse holder lead Clip Warning indicator coupler Trailer switch coupler Plastic tie Pilot water hose Bolt Neutral switch Plate Neutral switch lead Ground lead Bolt PTT relay lead Nut Spring washer PTT motor lead Bolt o NO O BE O ND 62Y5A11 1 4 4 4 4 4 4 4 4 4 4 4 4 4 4 2 4 4 2 3 4 2 2 2 2 2 ET model M8x 16 mm ET model EHD model ET model 110 0 mm 4 3 in M6 x 20 mm Tiller handle models Remote control models Tiller handle models M6 x 12 mm ET model ET model ET model ET model Green blue M6 x 20 mm ET model 5 8 30 N m 3 0 kgf m 22 ft Ib m 0 7 kgf m 5 1 ft Ib S62Y5040K 2 N N E A E O x o 2 E zZ o co se Ei 62Y5A11 5 9 Power unit Z o o NO O BE O Mm Part name Remarks Bracket Starter motor Spark plug cap Ignition coil Wiring harness Thermoswitch Holder Bolt Ground lead Bolt Oil pressure switch Oil pressure switch lead Screw Ignition coil lead
67. Not reusable M6 x 25 mm ma a a a a a a a u o Not reusable M6 x 45 mm Not reusable Not reusable M6 x 25 mm Not reusable Not reusable Not reusable M6 x 25 mm M6 x 16 mm M6 x 25 mm o sch sch 1 N NM sch sch sch D A sch sch sch Not reusable 62Y5A11 7 14 BAE bd Bracket unit Disassembling the oil pan 1 Remove the muffler from the oil pan O 2 Remove the exhaust manifold 3 from the oil pan 3 Remove the oil pan from the exhaust guide 4 4 Remove the oil strainer and the relief valve housing 6 S62Y7210K CAUTION Do not reuse the gaskets always replace them with a new one Checking the oil strainer and the relief valve 7 15 1 Check the oil strainer and relief valve for dirt and residue Clean if necessary Assembling the oil pan 1 Install the gaskets onto the exhaust guide 2 Install the relief valve assembly by installing the bolts then tightening them finger tight bolts S62Y7230 4 Install the water pipe 5 Install the oil pan and bolts and then tighten the bolts finger tight 6 Install the exhaust manifold and bolts and then tighten the bolts finger tight 62Y5A11 Upper case S62Y7250K 9 Install the muffler assembly 0 by insert ing the tip of the water pipe into the S62Y7240K joint hole of the upper case 7 Tighten the
68. T50CED FT50CET Ignition system Ignition timing engine idle speed Degree TDC Charge coil output peak voltage L Br cranking 1 V 144 cranking 209 V 137 1 500 r min V 169 3 500 r min V 129 Charge coil resistance Q 272 408 L Br 1 Cranking 1 unloaded Cranking 2 loaded 2 The figures are for reference only 62Y5A11 2 6 SE ye Specifications Item Model FT50CEHD FT50CED FT50CET Pulser coil output peak voltage W R W B cranking 1 O cranking 2 1 500 r min 3 500 r min Pulser coil resistance W R W B CDI unit output peak voltage B O B B W B cranking 1 cranking 2 1 500 r min 3 500 r min Ignition coil resistance Primary coil High tension cord high tension cord Spark plug gap O B Q RO mm in 6 3 3 5 7 4 11 2 396 594 126 150 151 116 396 594 0 08 0 11 3 5 4 7 0 9 0 035 Ignition control system Oil pressure switch Thermoswitch Gy B B OFF ON ON OFF kPa kgf cm psi 50 0 5 7 11 76 84 169 183 63 77 145 170 Starter motor Type Output Cranking time limit Brushes Standard length Wear limit Commutator Standard diameter Wear limit Mica Standard undercut Wear limit 1 Cranking 1 unloaded Cranking 2 loaded 2 The figures are for reference only 2 7 Bendix 1 1 30 16 0 0 63 12 0 0 47 62Y5A11 Item Mai
69. W White Engine start switch B O Black orange Engine shut off switch DAN Black white 10 pin coupler W B White black CDI unit W R White red 62Y5A11 8 8 ERES Electrical systems S62Y8100 Thermoswitch A Remote control model B Black Oil pressure switch B Tiller handle model G Green CDI unit R Red Digital tachometer Y Yellow Oil pressure warning indicator Gy B Gray black Overheat warning indicator P B Pink black Remote control box PMV Pink white Warning indicator Y B Yellow black Y R Yellow red ony 62Y5A11 Ignition system and Ignition control system Checking the ignition spark gap 1 Disconnect the spark plug caps from the spark plugs 2 Connect a spark plug cap to the special service tool 3 Set the spark gap length on the adjusting knob S62Y8140J ZX Ignition spark gap 9 mm 0 35 in 4 Crank the engine and observe the spark through the discharge window of the spark gap tester Check the ignition coil if out of specification S62Y8160J 62Y5A11 AA WARNING Do not touch any of the connections of the spark gap tester leads e Do not let sparks leak out of the removed spark plug caps e Keep flammable gas or liquids away since this test can produce sparks Checking the spark plug caps 1 Remove the spark plug caps from the high tension cords by turning the caps counterclockwise VE S62Y8170K 2 Measure the s
70. aller 90890 06801 S62Y5340 62Y5A11 5 26 2 Install the new valve guide by striking the special service tool from the cam shaft side until the valve guide clip contacts the cylinder head S62Y5370 NOTE Apply engine oil to the surface of the new valve guide GC Valve guide remover installer i 90890 06801 3 Insert the special service tool into the valve guide 2 and then ream the valve guide S62Y5380 NOTE Turn the valve guide reamer clockwise to ream the valve guide Do not turn the reamer counterclockwise when removing the reamer Valve guide reamer 90890 06804 5 27 4 Measure the valve guide inside diameter Replace the valve guide if out of specifi cation Valve guide inside diameter 5 50 5 51 mm 0 2165 0 2169 in Checking the valve seat 1 Eliminate carbon deposits from the valve with a scraper 2 Apply a thin even layer of Mechanic s blueing dye Dykem onto the valve seat 3 Lap the valve slowly on the valve seat with a valve lapper commercially obtain able as shown S62Y5400 4 Measure the valve seat contact width where the blueing dye is adhered to the valve face Reface the valve seat if the valve is not seated properly or if the valve seat contact width is out of specification Replace the valve guide if the valve seat contact is uneven S62Y5410 62Y5A11 S62Y5420 Valve seat contact width 8
71. and then tighten them to the specified torgues in two stages and in the seguence shown S62Y5B10 CAUTION The oil seals must be installed before tightening the crankcase bolts 5 49 NOTE SZ 2 20 Apply engine oil to the crankcase bolt M8 before installation Crankcase bolt M8 1st 15 N m 1 5 kgf m 11 ft lb 2nd 30 N m 3 0 kgf m 22 ft lb Crankcase bolt M6 1st 6 N m 0 6 kgf m 4 3 ft lb 2nd 12 N m 1 2 kgf m 8 7 ft lb 12 Install the new gasket and exhaust cover and then tighten the bolts to the specified torques in two stages and in the sequence shown S62Y5B20 Exhaust cover bolt 1st 6 N m 0 6 kgf m 4 3 ft Ib 2nd 12 N m 1 2 kgf m 8 7 ft lb Installing the power unit 1 Install the dowel pins and gasket 2 Install the power unit 3 by installing the bolts 4 then tightening them to the specified torgue 3 Install the apron 62Y5A11 Cylinder body S62Y5086K S62Y5088 Mounting bolt 4 6 Connect the throttle link rod and fuel 21 N m 2 1 kgf m 15 ft Ib hose 4 Install the shift rod bolts shift rod and power trim and tilt relay 5 Connect the pilot water hose 9 trailer switch coupler 0 ET warning indicator coupler 4 EHD ground lead 42 ET PTT motor leads 3 ET PTT relay leads ET 10 pin coupler and bat tery leads 8 S62Y5089 7 Connect the shift cable shift rod 49 a
72. ansfers to the normal control map The control described above will be repeated if the engine is accelerated again Over revolution control This control operates by detecting the engine speed If the engine speed increases to over 6 200 r min the ignition of cylinders 1 and 4 is stopped in order to regulate the speed If the engine speed increases further to over 6 300 r min the ignition of cylinders 2 and 3 is also stopped This control will not be deactivated until the engine speed drops below 6 200 r min Overheating control This control operates in accordance with the engine temperature which is detected by the signal that is input from the thermoswitch When the microcomputer detects via the thermoswitch signal that the engine temperature has increased to over 80 C 176 F it outputs a signal to stop the igni tion of cylinders 1 and 4 if the engine speed is over 2 000 r min At the same time the microcom puter issues a warning by operating the warning lamp and the warning buzzer When the overheating control is activated it will not be deactivated until the engine is stopped or the engine temperature decreases to under 70 C 158 F The determination of overheating stops when the engine is stopped However until the engine tem perature decreases to approximately 70 C 158 F or below the overheating control will be acti vated upon restarting the engine Upon restarting if the engine speed is under 2 000 r min the ov
73. ch Replace the CDI unit 9 9 62Y5A11 Power unit Bracket unit Bracket unit Symptom Power trim and tilt unit does not operate Listen for the operation sound of the power trim and tilt relay Can the oper ation sound be heard Check the voltage between each terminal Between the sky blue Sb lead and black B lead Between the light green Lg lead and black B lead Can 12 V be obtained Check for continuity between the battery relay and switch gt Listen for the operation sound of the power trim and tilt motor NG Replace the power trim and tilt relay Can the oper ation sound be heard Nu Check the voltage between the d sky blue Sb lead and black B lead Can 12 V be obtained Replace the power trim and tilt relay de Check that the manual valve is closed Ke Check the power trim and tilt motor a Is it closed NG Close the valve Yes Check the power trim and tilt fluid level At specified level Add fluid to the correct level Disassemble the power trim and tilt unit and then check it 62Y5A11 9 10 TRBL 1 SHTG e Troubleshooting Symptom Power trim and tilt unit does not hold the outboard motor up Check that the manual valve is closed
74. cifications for special components or assemblies are provided in applicable sections of this man ual To avoid warpage tighten multi fastener assemblies in a crisscross fashion and pro gressive stages until the specified torque is reached Unless otherwise specified torque specifications require clean dry threads Components should be at room temperature General torque specifications N m kgfm ft lb 5 0 5 3 6 8 0 8 5 8 18 1 8 13 36 3 6 25 43 4 3 31 0 9 S62Y2260 62Y5A11 CHK ADJ 62Y5A11 Periodic checks and adjustments Special Service tools 2 ia 3 1 Maintenance interval chart ssnnnnne 3 2 TOP COMING FE Hn 3 3 Checking the top GOWINd career 3 3 Fuel System ans ee bredte 3 3 Checking the fuel joint and fuel hoses fuel joint to carburetor 3 3 Checking the fuel filter see ee 3 3 Power Uli 3 4 Checking the engine oil u dee 3 4 Replacing the engine oil Geseke eher 3 4 Checking the timing beit a 3 5 Checking the valve clearance 3 5 Checking the spark plugs un ee 3 7 CHECKING the thermostat aiii 3 8 Checking the cooling water D ssage nen 3 8 Control system aar 3 9 Checking the throttle cable Operation nen 3 9 Checking the gearshift operation 3 9 Checking the engine idle speed 3 10 Checking the ignition timing ss 3 11 Power trim and i EN 3 11 Checking the power trim and tilt operation ernennen 3 11
75. clearance Replace the piston and piston rings as a set if out of specification S62Y5800 62Y5A11 Cylinder body Piston ring side clearance Top ring 8 0 04 0 08 mm 0 002 0 003 in Second ring 0 03 0 07 mm 0 001 0 003 in Oil ring 0 05 0 19 mm 0 002 0 007 in Checking the piston pin boss bore 1 Measure the piston pin boss bore Replace the piston if out of specification Piston pin boss bore 15 974 15 985 mm 0 6289 0 6293 in Checking the piston pin 1 Measure the piston pin diameter Replace if out of specification S62Y5820 Piston pin diameter 15 965 15 970 mm 0 6285 0 6287 in 5 40 Checking the connecting rod small end inside diameter 1 Measure the connecting rod small end inside diameter Replace the connect ing rod if out of specification S62Y5830 Connecting rod small end inside diameter 8 15 985 15 998 mm 0 6293 0 6298 in Checking the connecting rod big end side clearance 1 Measure the connecting rod big end side clearance 8 Replace the connecting rod or crankshaft or both if out of specifi cation S62Y5840 Connecting rod big end side clearance a 0 05 0 22 mm 0 002 0 009 in Checking the connecting rod bolt 1 Measure the connecting rod bolt thread diameter at the two points and 2 Calculate the difference between and Replace if out of specification 5 41 5 mm 0 2 in mm
76. cnonccccnnnnnnnonannncnnnnnnnnnnnnnnrnnnnnnnnnnnns 4 5 Checking the diaphragm and valves oooocccconncccccccoocccccconnncnnnnnannccnnnanaccnnnns 4 6 Assembling the fuel Pump it 4 6 Carburetor UN ago 4 7 Carburetor viasat 4 9 Checking the cArburet r nenne else 4 11 Checking the Prime Start 4 12 Assembling the carburetor eher 4 12 Adjusting the throttle link rod 4 13 Adjusting the pilot StrewW nee id GC SS FR YF ies 4 13 Synchronizing hinne 4 14 Adjusting the dash pot acceleration pump 4 15 an Wu Fuel system Special service tools Vacuum pressure pump gauge set 90890 06756 Digital tachometer 90890 06760 Vacuum gauge 90890 03159 Vacuum gauge digital commercially obtainable Vacuum gauge 4 analog meters commercially obtainable Vacuum gauge adaptor commercially obtainable 62Y5A11 Special service tools Hose routing Hose routing Fuel and blowby hoses S62Y4010K Blowby hose Hose acceleration pump to carburetor G Fuel hose fuel joint to fuel filter 4 Fuel hose fuel filter to fuel pump 6 Fuel hose fuel pump to carburetor Hose carburetor to carburetor 62Y5A11 4 2 se Wu Fuel system Fuel filter and fuel pump 4 3 S62Y4030K 62Y5A11 Fuel filter and fuel pump Z o o AN O O A ON Part name Remarks Fuel joint Fuel filter Fuel pump Bolt Seal Fuel hose Clip Bolt Nut Bracket Fuel hose M6
77. crew until the specified valve clearance is obtained S62Y3250 NOTE e To decrease the valve clearance turn the adjusting screw clockwise To increase the valve clearance turn the adjusting screw counterclockwise 8 Tighten the locknut and then check the valve clearances Adjust if necessary 9 Install the cylinder head cover fuel pump and spark plugs 10 Connect the blowby hose and high ten sion cords and then install the flywheel magnet cover Checking the spark plugs 1 Disconnect the high tension cords and then remove the spark plugs 2 Clean the electrodes with a spark plug cleaner or wire brush Replace the spark plug if necessary 3 7 S62Y3260 3 Check the electrodes for erosion and excessive carbon or other deposits and the gasket for damage Replace the spark plug if necessary 4 Check the spark plug gap Adjust if out of specification S62Y3270 Specified spark plug DPR6EA 9 NGK Spark plug gap 8 0 9 mm 0 035 in 5 Install the spark plug tighten it finger tight then to the specified torque with a spark plug wrench S62Y3280 Spark plug 18 N m 1 8 kgf m 13 ft lb 62Y5A11 Checking the thermostat 1 Remove the cover G thermostat cover and thermostat S62Y3290 2 Suspend the thermostat in a container of water 3 Place a thermometer in the water and slowly heat the water S62Y3300 4 Check the thermostat
78. diameter 15 98 15 99 mm 0 6291 0 6295 in Checking the camshaft 1 Measure the cam lobe Replace if out of specification S62Y5520 62Y5A11 Cylinder head Cam lobe 8 Intake 30 89 30 99 mm 1 2161 1 2200 in Exhaust 30 82 30 92 mm 1 2135 1 2175 in Cam lobe b Intake 25 95 26 05 mm 1 0217 1 0256 in Exhaust 25 95 26 05 mm 1 0217 1 0256 in 2 Measure the camshaft runout Replace if out of specification S62Y5530 ZX Camshaft runout limit 0 04 mm 0 0016 in 3 Measure the camshaft journal diameter O and cylinder head journal inside diam eter Replace the camshaft and cylin der head if out of specification 5 30 Camshaft journal diameter 1 36 93 36 94 mm 1 4539 1 4543 in 2 3 4 36 94 36 95 mm 1 4543 1 4547 in Cylinder head journal inside diameter 37 00 37 02 mm 1 4567 1 4575 in 4 Calculate the camshaft oil clearance 8 as follows Replace the camshaft and cylinder head as a set if out of specifica tion amp 9 O 1 0 06 0 10 mm 0 0022 0 0039 in S62Y5560 2 3 4 0 05 0 09 mm AS Cylinder head warpage limit 0 0018 0 0035 in 0 1 mm 0 004 in Checking the cylinder head Checking the oil pump 1 Eliminate carbon deposits from the com 1 Measure the oil pump rotor clearances bustion chambers and check for deterio as shown Replace if out of specification ration 2 Check the cylinder head warpage
79. djustments 4 Install the check screw and then tighten 4 Insert the gear oil tube or gear oil pump it to the specified torque into the drain hole and slowly fill the gear oil until oil flows out of the check hole and Check screw no air bubbles are visible 7 N m 0 7 kgf m 5 1 ft lb Replacing the gear oil 1 Tilt the outboard motor up slightly 2 Place a drain pan under the drain screw remove the drain screw then the check screw to drain the oil S62Y3560 S62Y3550K 3 Check the oil for metal discoloration and S62Y3570K viscosity Check the internal parts of the lower case if necessary Recommended gear oil Hypoid gear oil SAE 90 Oil guantity 0 61 L 0 64 US at 0 54 Imp at 5 Install the check screw quickly install the drain screw and then tighten them to the specified torque Check and drain screw 7 N m 0 7 kgf m 5 1 ft lb 3 13 62Y5A11 Checking the lower unit for air leakage 1 Remove the check screw G and then install the special service tool S62Y3580J 2 Apply the specified pressure to check whether the lower unit can hold it for at least 10 seconds CAUTION Do not over pressurize the lower unit otherwise the oil seals may be damaged Cover the check hole with a rag when removing the pressure vacuum tester from the lower unit since oil may spray out ZX Lower unit holding pressure 100 kPa 1 0 kgf cm 14 psi 3 If pressure drops b
80. e starter motor pinion 8 19 Removing the steering arm 7 23 Removing the timing belt and sprockets 5 17 Removing the water pump and shift rod 6 9 Replacing the engine oil 3 4 Replacing the gear oil 3 13 Replacing the valve guides 5 26 Safety while working nen 1 3 Selecting the connecting rod big end bearing an rt tees 5 45 Selecting the crankshaft main journal D aring ira liinda 5 45 Selecting the forward gear shims 6 26 Selecting the pinion shims 1 111 6 25 Selecting the reverse gear shims 6 27 A een 1 26 Self protection oooocccinncccnnccccnnncccnancnnnanananno 1 3 Serial number rennnnnnnnnnrnnnnnvrnnnnrnnnenvrnnennne 1 4 Shimming 6 24 6 25 Special service FOOIS xiii 2 3 1 4 1 5 1 6 1 7 1 8 1 Specified torques ee 2 14 Starboard and port views 8 3 Starter moior nn 8 17 Starting system 8 15 Swivel bracket and steering arm 7 21 Symbols need rs vende 1 2 Synchronizing the carburetors 4 14 Technical tips 1 8 TOSTU iyen tement 1 29 Tightening torques 2 14 Tiller handle AAA 7 2 Tiller handle model 8 6 Tilt cylinder and trim cylinder 7 27 Timing belt and sprockets 5 16 Top cowling 3 3 Top view 8 5 Trim cylinder
81. ecified TOQUES rd E 2 14 ENER TE 2 15 62Y5A11 akan ye Specifications General specifications Item Model FT50CEHD FT50CED FT50CET Dimension Overall length Overall width Overall height L Boat transom height L 1 384 54 5 718 28 3 361 14 2 1 436 56 5 508 20 0 Weight with aluminum propeller L kg Ib 111 5 246 108 238 112 247 Performance Maximum output Full throttle operating range Maximum fuel consumption kW hp 5 500 r min r min L US gal Imp gal hr 6 000 r min 36 8 50 5 000 6 000 17 3 4 57 3 81 Power unit Type Cylinder quantity Displacement Bore x stroke Compression ratio Carburetor quantity Control system Starting system Ignition control system Ignition timing Alternator output Enrichment system Choke valve control Spark plugs Cooling system Exhaust system Lubrication system 2 1 cm cu in mm in Degree Vv A In line 4 stroke OHC 8 valves 4 935 57 1 63 0 x 75 0 2 48 x 2 95 9 3 4 Tiller handle Remote control Electric Microcomputer CDI TDC BTDC 30 12 10 Prime Start DPR6EA 9 NGK Water Through propeller boss Wet sump 62Y5A11 Item General specifications Model FT50CEHD FT50CED FT50CET Fuel and oil Fuel type Fuel rating Engine oil type Engine oil grade Engine oil quantity with oil filter replacement without oil filte
82. ecified depth S62Y6850K SEVEREK S Drive shaft holder 4 1 90890 06518 Pinion nut holder 2 90890 06505 Socket adapter 2 3 90890 06507 Needle bearing attachment i 90890 06614 Driver rod L3 8 90890 06652 Pinion nut 95 N m 9 5 kgf m 68 ft Ib EES Installing the lower unit 1 Setthe gearshift to the neutral position at Assembling the drive shaft the lower unit 1 Install the new drive shaft bearing into the drive shaft using a press S62Y6840K S62Y6505K 62Y5A11 6 22 SC Lower unit 2 Install the two dowel pins to the lower unit 3 Install the lower unit to the upper case and then tighten the bolts to the specified torque S62Y6510K Mounting bolt 40 N m 4 0 kgf m 29 ft Ib 4 Install the trim tab to its original posi tion and then connect the speedometer hose G S62Y6511K 6 23 5 Install the propeller and propeller nut tighten the nut finger tight Place a block of wood between the anti cavitation plate and propeller to keep the propeller from turning and then tighten the nut to the specified torque S62Y6515 S62Y6520 WARNING Do not hold the propeller with your hands when loosening or tightening it Be sure to remove the battery leads from the bat teries and the engine shut off switch Put a block of wood between the cavitation plate and propeller to keep the propeller from turning NOTE
83. ection of the bearing into the notch in the crankcase 6 Install the crankcase onto the cylinder body and apply engine oil onto the threads of the crankcase bolts 5 42 7 Tighten the crankcase bolts to the speci fied torgues in two stages and in the seguence shown S62Y5930 NOTE Do not move the crankshaft until the main journal oil clearance measurement has been completed Crankcase bolt M8 1st 15 N m 1 5 kgf m 11 ft lb 2nd 30 N m 3 0 kgf m 22 ft lb Crankcase bolt M6 1st 6 N m 0 6 kgf m 4 3 ft Ib 2nd 12 N m 1 2 kgf m 8 7 ft lb 8 Remove the crankcase and measure the width of the compressed Plastigauge PG 1 on each main journal Replace the main bearing if out of specification S62Y5940 5 43 Crankshaft main journal oil clearance 0 012 0 036 mm 0 0005 0 0014 in Checking the crankshaft pin oil clearance 1 Clean the bearings and the connecting rod 2 Install the upper half of the bearing into the connecting rod and the lower half into the connecting rod cap S62Y5950 CAUTION Install the bearings in their original posi tions NOTE 0 Insert the projection of the bearing into the slot on the cap and connecting rod 3 Puta piece of Plastigauge PG 1 onto the crank pin parallel to the crankshaft S62Y5960 62Y5A11 NOTE Be sure not to put the Plastigauge PG 1 over the oil hole in the crank pin of the crank shaft
84. een adopted for the starting system to further increase starting performance and serviceability Further more the acceleration pump and the dashpot have been integrated to simplify construction and to ease serviceability The four carburetors can be accurately and easily adjusted due to the simple construction of the links S62Y1200K Prime Start Acceleration pump 1 5 62Y5A11 Identification Features and benefits CDI unit with microcomputer The ignition system consists of a flywheel stator pulser coil thermoswitch oil pressure switch CDI unit and ignition coil The CDI unit contains a built in microcomputer that determines the ignition timing separately for acceleration and for normal operation based on signals received from the pulser coil thermoswitch and oil pressure switch o S62Y1210 CDI unit Flywheel Stator 4 Pulser coil Thermoswitch Ignition coil Oil pressure switch 62Y5A11 1 6 dm Y General information Lower unit Higher class pinion and gears The lower unit of the new FT50C uses the same type of large gears that are used in the F100 The use of the same type of gears that are used in a higher class model provides ample durability mak ing it possible to accommodate a wider range of applications throughout the market
85. el that passes through the fuel enrichment valve decreases A few minutes after the engine has started the thermo heater plunger completely closes the fuel enrichment valve thus ending the fuel enrichment by the Prime Start system 62Y5A11 1 8 dm General information A B C S62Y1240K Prime Start Carburetor Intake manifold of the engine Intake silencer Thermo heater plunger A Air 4 Fuel enrichment valve B Fuel To carburetor 2 or 4 C Plunger movement S62Y1250K Prime Start The enriched air fuel mixture is delivered to The enriched air fuel mixture is delivered to cylinders 3 and 4 by the Prime Start system cylinders 1 and 2 by the Prime Start system attached to carburetor 3 attached to carburetor 1 1 9 62Y5A11 Technical tips Carburetor operation 1 Idle and low speed operation Since the vacuum at the venturi is low when the throttle valve is opened slightly the main nozzle does not supply any air fuel mixture to the engine When the engine is operating at idle the fuel that passes through the pilot jet and the air that passes through the pilot air jet mix enabling the air fuel mixture that has been regulated by the pilot screw to be fed through the pilot outlet Because the throttle valve opens slightly when the engine is operating at low speeds air fuel mix ture also starts to be fed from the bypass holes o El gt
86. elease it and let it lower by its own weight four to five times 62Y5A11 Gear pump 3 Tighten the manual valve by turning it clockwise 4 Letthe fluid settle for 5 minutes 5 Push and hold the power trim and tilt switch in the up position until the out board motor is fully tilted up 6 Support the outboard motor with the tilt stop lever and then let the fluid settle for 5 minutes AA WARNING After tilting up the outboard motor be sure to support it with the tilt stop lever Otherwise the outboard motor could sud denly lower if the power trim and tilt unit should lose fluid pressure 7 Remove the reservoir cap and then check the fluid level in the reservoir 8 If necessary add sufficient fluid of the recommended type to the correct level NOTE mim The fluid level should be at the brim of the filler hole Recommended power trim and tilt fluid ATF Dexron II 9 Install the reservoir cap NOTE __ Repeat this procedure until the fluid remains at the correct level 7 42 PASI XxX Bracket unit Power trim and tilt motor m ES D PUTIN a H al Q PA OTZZZZZITIO gt TT NAM G x N S62Y7890K No Part name Qty Remarks Screw 3 M5 x 20 mm 2 Yoke 1 3 O ring 1 52 0x 1 9 mm 4 Armature 1 5 Bushing 1 6 Screw 2 M4 x 12 mm 7 Wire lead 1 8 Brush 2 1 9 Brush 1 1 10 Brush holder 1 11 Ci
87. elow specification check the drive shaft and propeller shaft oil seals for damage 62Y5A11 Lower unit General Checking the propeller Check the propeller blades and splines for cracks damage or wear Replace if necessary 1 S62Y3585 General Checking the anodes 1 Check the anodes and trim tab for scales grease or oil Clean if necessary S62Y3600K 3 14 CHK Q ADJ Periodic checks and adjustments S62Y3610J S62Y3620J Al EHD ED models Bl ET model S62Y3640 CAUTION Do not oil grease or paint the anodes otherwise they will be ineffective 2 Replace the anodes and trim tab if excessively eroded Checking the battery 1 Check the battery electrolyte level If the level is at or below the minimum level mark a add distilled water until the level is between the maximum and minimum level marks 3 15 S62Y3650 2 Check the specific gravity of the electro lyte Fully charge the battery if out of specification AA WARNING Battery electrolyte is dangerous it con tains sulfuric acid which is poisonous and highly caustic Always follow these preventive measures Avoid bodily contact with electrolyte as it can cause severe burns or permanent eye injury Wear protective eye gear when handling or working near batteries Antidote EXTERNAL SKIN Wash with water EYES Flush with water for 15 minutes and get immediate med
88. erheating control will not be activated for 75 seconds However if the engine is operated at over 2 000 r min for more than 25 seconds the overheating control will be activated Oil pressure control The oil pressure control operates in accordance with the signals from the oil pressure switch The oil pressure is determined to have dropped if the engine continues to operate at over 2 000 r min with an oil pressure of under 49 kPa 0 49 kgf cm 6 97 psi for more than one second When the oil pressure control is activated the warning buzzer sounds and the warning lamp illuminates If the engine speed is over 2 000 r min the control stops the ignition of cylinders 1 and 4 so that the engine speed will not increase to over 2 000 r min Once an oil pressure drop is determined this control will not be deactivated even if the oil pressure recuperates until the engine is stopped Power trim and tilt The newly designed power trim and tilt consists of an up main valve a down main valve an up relief valve a single cylinder and a single ram which control both trim and tilt functions The power trim and tilt cylinder has been integrated with the gear pump housing the reservoir tank and the power trim and tilt motor in order to achieve a smaller and more compact unit 1 19 62Y5A11 Technical tips Hydraulic system diagram Power trim and tilt cylinder O Ram emm Mn G Reservoir Down main valve Down relief valve G Hydraulic pu
89. es ee EES 8 17 Removing the starter motor PINION uuusssesssssnnnnnnnnnnennnnnnnnnnnnnnnnnn ern 8 19 Checking the starter motor pinion EE 8 19 Checking the armature ENEE 8 19 Checking the brushes net ee 8 20 Checking the starter motor operation 8 20 Gharoing ET E 8 21 Checking the lighting coil 8 22 Checking the Rectifier Regulator 8 23 ELEG Electrical systems Special service tools Ignition tester 90890 06754 Dial gauge set 90890 01252 Digital circuit tester Magnet base 90890 03174 90890 06705 Peak voltage adaptor Test harness 3 pins 90890 03172 90890 06770 Test harness 2 pins Test harness 4 pins 90890 06767 90890 06771 Vacuum pressure pump gauge set 90890 06756 8 1 62Y5A11 Special service tools Checking the electrical components Checking the electrical components Measuring the peak voltage The condition of the ignition system can be determined by measuring the peak voltage Cranking speed is effected by many factors such as fouled or weak spark plugs or a weak battery If one of these factors is present the peak voltage will be lower than specification In addition if the peak voltage is lower than specification the engine will not operate properly S62Y8010 S62Y8020 NOTE Use the peak voltage adaptor with the digi tal circuit tester When measuring the peak voltage
90. et Screw Warning indicator Grommet Collar Pilot water outlet Plastic tie Collar Grommet Bushing Joint Cowling lock lever Pin Cotter pin Pin Cotter pin Bolt Bracket Trailer switch PTT motor lead Trim sensor coupler Screw Grommet Rubber seal Hose DJ O O BE O MM 62Y5A11 Not reusable M6 x 30 mm M6 x 14 mm EHD model EHD model EHD model Not reusable Not reusable Not reusable Models with trailer switch Models with trailer switch Models with trailer switch ET model ET model M6 x 24 mm ET model 7 8 RASI XxX Bracket unit Checking the throttle cable and shift rod 1 Check the operation of the throttle cable and shift rod 2 Check the inner wire outer wire of the cable and rod for bends or damage and the rubber seals for damage Replace if necessary b x AS N y o S62Y7090 Assembling the tiller handle 1 Install the throttle shaft into the tiller handle by aligning the mark A of the tiller handle with the screw hole of the throttle shaft lt 3 i S62Y7100 S62Y7110 7 9 2 Install the throttle cable into the gear until the inner cable is engaged with the gear 3 Turn the throttle shaft clockwise to wind the inner cable around the gear 2 S62Y7120K NOTE Make sure that the throttle grip is fully closed when installing the throttle cable 62Y5A11 Bottom cowling Lubricating
91. exhaust manifold bolts then the oil pan bolts S62Y7245K S62Y7260 8 Install the muffler 9 into the oil pan 62Y5A11 7 16 RASI E d Bracket unit Installing the upper case Install the upper mount and bolts into the upper case and then tighten the bolts 1 S62Y7270 Set the lower mounts 4 and bolts to the upper case Install the end of the spring into the groove of the mount housing and then tighten the bolts S62Y7280 NOTE E Be sure to install the ground lead into the mount housing 4 Install the upper and lower mounting bolts into the swivel bracket 9 simulta neously Install the upper mounting nut and lower mounting nut and then tighten them to the specified torques Install the cover 2 by installing the screw S62Y7290 Upper mounting nut 49 24 N m 2 4 kgf m 17 ft lb Lower mounting nut AD 42 N m 4 2 kgf m 30 ft lb 62Y5A11 Clamp brackets Z o Part name Upper case Clamp brackets 2 Ne m 0 2 kgf m 1 4 ft Ib Mx 23 N m 2 3 kgf m 17 ft Ib Remarks S62Y7300K o AJ o O1 BE o N A Swivel bracket assembly Screw Trim sensor Trim sensor coupler Plastic tie Self locking nut Cap Bolt Anode Port clamp bracket Washer Bushing Through tube Bolt Anode Ground lead Grease nipple Screw Starboard clamp bracket 62Y5A11 gt 2 gt 12 MD NW MI NO
92. from corrosion and that the battery is fully charged to 12 V Power unit Symptom Engine does not crank e Check the starting system e Check the power unit Check that the gearshift is in the neutral position Is the gearshift No in neutral Set it to the neutral position Yes Check the neutral switch for continuity Is there conti nuity Replace the neutral switch Yes Check the engine start switch for continuity Is there conti nuity Replace the engine start switch Check the engine shut off switch for continuity Continued on next page 9 1 62Y5A11 Power unit Is there conti nuity Replace the engine shut off switch Check the fuse for continuity Is there conti nuity Replace the fuse Yes Check the wiring harnesses for continuity Is there conti nuity Replace the wiring harnesses Yes Check operation of the starter motor pinion Does the pin ion rotate Listen for the operation sound of the starter relay Can the oper ation sound be heard Replace the starter relay Remove all spark plugs and then the engine Check the starter motor Does the engine ee Check the power unit crank Check that the combustion camber is filled with engine oil
93. g D 4 DD Not reusable 5 8 x 1 9 mm Spring Spacer Down shuttle piston Up shuttle piston Manual release spring Ball Gear pump cover Down main valve O ring Valve seal Circlip Pin Drive gear Shaft Driven gear Ball Return spring Up main valve Valve seal Circlip Gear pump housing Not reusable 2 2 2 1 1 2 1 1 1 1 1 2 1 1 1 2 2 1 1 1 1 62Y5A11 7 34 RASI bd Bracket unit Disassembling the tilt cylinder 1 Hold the power trim and tilt in a vise using aluminum plates amp on both sides S62Y7500 2 Loosen the tilt cylinder end screw 2 and then remove it S62Y7510 AA WARNING Make sure that the ram is fully extended before removing the end screw GC Cylinder end screw wrench 90890 06544 3 Drain the fluid Disassembling the trim cylinder 1 Hold the trim cylinder in a vise using aluminum plates on both sides 7 35 NOTE Place the trim cylinder in the vise horizon tally 2 Loosen the trim cylinder end screw and then remove it S62Y7530K CAUTION Do not damage the check valve when loosening the end screw K Cylinder end screw wrench 90890 06544 Disassembling the gear pump 1 Remove the manual valve and gear pump S62Y7540K 2 Remove the relief valve bracket 9 then the down relief valve 4 and up relief valve 62Y5A11 Gear pump 1 Check the power trim and tilt hyd
94. g the piston pin boss bore 5 40 Checking the piston ring grooves 5 40 Checking the piston ring side clearance 5 40 Checking the piston rings 5 39 Checking the power trim and tilt A 3 12 Checking the power trim and tilt motor 7 44 Checking the power trim and tilt Opera Marriott 3 11 Checking the power trim and tilt relay 7 48 Checking the Prime Start asana raa 4 12 Checking the propeller 3 14 Checking the propeller shaft 6 14 Checking the propeller shaft housing 6 14 Checking the pulser coll 8 12 Checking the pulser coil air gap 8 13 Checking the Rectifier Regulator 8 23 Checking the remote control cables 1 27 Checking the rocker arms and rocker arm shaft AAA 5 30 Checking the shift rod assembly operation 7 10 Checking the spark plug caps 8 10 Checking the spark pDlugs 3 7 Checking the starter motor operation 8 20 Checking the starter motor pinion 8 19 Checking the starter relay 8 16 Checking the steering system 1 28 Checking the thermostat 3 8 Checking the thermoswitch 8 14 Checking the throttle cable and shift rod 7 9 Checking the throttle cable operation 3 9 Checking the tilt cylinder and trim cylinder 7 36 Checki
95. ges and jets S62Y4220 CAUTION Direct the compressed air downward otherwise cleaning solvent may be blown into your eyes or small parts of the carburetor may be blown off Do not use steel wire for cleaning the jets otherwise the jet diameters may be enlarged which may seriously affect performance 3 Check the main jet pilot jet and main nozzle G for dirt or residue Clean if necessary JL 4 Check the pilot screw and needle valve for bends or wear Replace if necessary S62Y4230 S62Y4240 5 Check the float for deterioration Replace it necessary UT S62Y4250 6 Measure the float height Replace the float or needle valve if out of specifica tion S62Y4290 62Y5A11 NOTE A The float should be resting on the needle valve 4 but not compressing it Take measurements at the top of the float flange opposite its pivoted side Float height 9 5 10 5 mm 0 37 0 41 in Checking the Prime Start 1 Measure the length of the Prime Start plunger 2 Connect the positive Prime Start blue L lead and the negative Prime Start black B lead to a battery as shown 3 Measure the plunger length 2 after applying power for 5 minutes Replace if out of specification S62Y4260 Prime Start plunger extended length a More than 24 6 mm 0 97 in Assembling the carburetor 1 Install the main nozzle plug pilot jet and main jet to the carburet
96. h sch As required Not reusable Not reusable Bearing outer race Taper roller bearing Needle bearing Forward gear Needle bearing Pinion Nut Lower case sch sch sch ech ech 62Y5A11 6 18 KONE Lower unit Removing the drive shaft 1 Remove the drive shaft assembly and pinion and then pull out the forward gear S62Y6850K Cz Drive shaft holder 4 D 90890 06518 Pinion nut holder 90890 06505 Socket adapter 2 3 90890 06507 Disassembling the drive shaft 1 Install the pinion nut tighten it finger tight and then remove the drive shaft bearing using a press S62Y6735K CAUTION e Do not press the drive shaft threads directly e Do not reuse the bearing always replace it with a new one CL Bearing inner race attachment 90890 06639 Disassembling the forward gear 1 Remove the taper roller bearing from the forward gear using a press 6 19 S62Y6740K CAUTION Do not reuse the bearing always replace it with a new one Bearing separator D 90890 06534 2 Remove the needle bearing from the for ward gear S62Y6750K CAUTION Do not reuse the bearing always replace it with a new one 2 Stopper guide plate 90890 06501 A Stopper guide stand 90890 06538 Bearing puller 4 90890 06535 Bearing puller claw 1 90890 06536 62Y5A11 Disassembling the lower case 1 Remove the tape
97. h holder for continuity Replace if out of specifications S62Y8450 Brush assembly continuity Brush Brush Brush Brush Brush Brush Brush holder 4 Brush assembly holder 5 Continuity No continuity Checking the starter motor operation 1 Check the operation of the starter motor after installing it to the power unit 8 20 ES Electrical systems Charging system S62Y8460 Lighting coil B Black Rectifier Regulator G Green Fuse R Red 4 Battery G W Green white ia 62Y5A11 Checking the lighting coil 1 Measure the lighting coil output peak voltage Replace the stator coil if below specification S62Y8470 4h WARNING When checking the peak voltage do not touch any of the connections of the digital tester leads NOTE _ Use the peak voltage adaptor with the digi tal circuit tester When measuring the peak voltage set the selector on the digital circuit tester to the DC voltage mode N Z Digital circuit tester 90890 03174 Peak voltage adaptor 90890 03172 Test harness 3 pins 90890 06770 Lighting coil output peak voltage Green G Green G Unloaded Cranking 1 500 DC V 11 9 42 r min 62Y5A11 Charging system Lighting coil resistance use as reference Green G Green G 1 2 1 8 O at 20 C 68 F 8 22 REE Electrical systems Checki
98. he circlip 2 Remove the steering yoke by striking it with a plastic hammer S62Y7380 3 Remove the steering arm from the swivel bracket by pulling the arm off the bracket Installing the steering arm 1 Install the washer bushing O ring 3 and bushing onto the steering arm 2 Place the swivel bracket in an upright position and then install the steering arm onto the swivel bracket S62Y7390K 3 Install the bushing G O ring and bushing 9 onto the swivel bracket 7 23 S62Y7400K Install the steering arm into the steer ing yoke by aligning the center of the yoke with the center of the steer ing arm Install the circlip 4 Pa S62Y7410 62Y5A11 6 Inject grease into the grease nipple until grease comes out from both the upper and lower bushings S62Y7420 62Y5A11 Swivel bracket and steering arm 7 24 PASI XxX Bracket unit Power trim and tilt unit S62Y7430K Z o o NO O BE O MM Part name Remarks Power trim and tilt ET model Hydro tilt EHD ED models Plastic tie PTT motor lead Washer Bolt Circlip Shaft Bushing Collar Tilt pin Collar Collar Shaft Bushing Circlip Shaft Collar M8 x 16 mm ET model ET model ET model ET model EHD ED models EHD ED models EHD ED models EHD ED models X A D N sch PN ech NO MD Mm WO 7 25 62Y5A11 Removing the power tr
99. he engine Yes Clean or replace the respective parts 9 7 62Y5A11 Power unit Symptom Engine can run but engine speed will not increase Overheat warning indicator is on Oil pressure warning indicator is on Warning indicator is on and buzzer is sounding e Check the water cooling system Check the lubricating system Cooling system Check the water inlet for clogs or debris Check that cooling water is dis charged from the pilot water outlet Clogs or debris Is water dis Clean the water inlet charged Check the water pump impeller Good condi tion Check the water Check the thermostat operation passage Replace the impel ler Good condi tion Replace the thermostat Check the thermoswitch Good condi E Replace the thermoswitch tion Replace the CDI unit 62Y5A11 9 8 TRBL 1 SHTG e Troubleshooting Lubricating system Check the engine oil level Add engine oil to the correct level At specified level Check the oil pressure Out of specifi cation Check the oil pump for debris or wear Debris or wear Check the oil pas sage Clean or replace the respective Check the oil pressure switch parts Good condi tion Replace the oil pressure swit
100. he two tensioners are facing up MG S62Y5640 Installing the rocker arm assembly 1 Check that the camshaft dowel pin hole is in the position shown in the illustra tion Adjust if necessary 5 33 62Y5A11 3 Install the rocker arm shaft assembly to the cylinder head by installing the bolts and then tighten them to the specified torque and in the sequence shown S62Y5665 N Bolt 18 N m 1 8 kgf m 13 ft lb Installing the cylinder head 1 Install the oil pump by aligning the oil pump drive shaft with the camshatt pin S62Y5666 2 Tighten the cylinder head bolts to the specified torques in two stages and in the sequence shown 62Y5A11 Cylinder head O A DON S ds Or dy Ze D or O amp i x S62Y5670K CAUTION Do not reuse the cylinder head gasket always replace it with a new one NOTE Apply engine oil to the cylinder head bolts M9 before installation Cylinder head bolt M9 1st 23 N m 2 3 kgf m 17 ft lb 2nd 47 N m 4 7 kgf m 34 ft lb Cylinder head bolt M6 1st 6 N m 0 6 kgf m 4 3 ft Ib 2nd 12 N m 1 2 kgf m 8 7 ft Ib 3 Tighten the cylinder head cover bolts in the seguence shown gt oO S62Y5680K 5 34 Cylinder body st le N m 0 6 kgf m 4 3 ft Ib 17 N m 1 7 kgf m 12 ft lb
101. he upper part of the power trim and tilt cylinder pushes down the check valve of the trim cylinder At the same time fluid pressure in the upper part of the trim cylinder increases and the tilt piston absorber is pushed down As a result the tilt piston and the ram are pushed up without the free piston The tilt piston is stopped before reaching the top of the trim cylinder by the damper function of the tilt piston absorber to protect the power trim and tilt unit from damage Damper function Samun 6 mb A B S62Y1430K Power trim and tilt cylinder Check valve Trim cylinder Tilt piston absorber Ram 9 Tilt piston 2 Tilt piston absorber A Send Tilt piston B Moving direction Free piston 1 25 62Y5A11 Technical tips Propeller selection Predelivery checks Propeller selection The performance of a boat and outboard motor will be critically affected by the size and type of propeller you choose Propellers greatly affect boat speed acceleration engine life fuel economy and even boating and steering capabilities An incorrect choice could adversely affect performance and could also seriously damage the motor Use the following information as a guide for selecting a propeller that meets the operating conditions of the boat and the outboard motor Propeller size The size of the propeller is indicated on the
102. hite red W R White black W B Unloaded Loaded Cranking 1 500 6 3 3 5 7 4 8 12 ERES Electrical systems Pulser coil resistance use as reference White red W R White black W B 396 594 O at 20 C 68 F Checking the pulser coil air gap 1 Turn the flywheel clockwise to align the projection of the flywheel with the pulser coil projection 2 Measure the gap between both projec tions with a thickness gauge Adjust if out of specification U e S62Y8230K ZX Pulser coil air gap 0 5 1 0 mm 0 020 0 039 in Remove the flywheel magnet nut and fly wheel magnet o gt Loosen the pulser coil screws adjust the pulser coil position and then tighten the screws finger tight 5 Set the flywheel magnet and then check the gap again and if necessary repeat steps 3 5 8 13 6 Tighten the pulser coil screws and fly wheel magnet nut to the specified torgues Pulser coil screw 4 N m 0 4 kgf m 2 9 ft lb Flywheel magnet nut 160 N m 16 kgf m 116 ft Ib Checking the engine start switch 1 Check the engine start switch for continu ity Replace if there is no continuity S62Y8250 Lead color Switch White Black Red Pink position W B OFF OO ON START Checking the engine shut off switch 1 Check the engine shut off switch for con tinuity Replace if there is no cont
103. ical attention Antidote INTERNAL Drink large quantities of water or milk followed with milk of magnesia beaten egg or vegetable oil Get immediate medical attention Batteries generate explosive hydrogen gas Always follow these preventive mea sures e Charge batteries in a well ventilated area Keep batteries away from fire sparks or open flames e g welding eguipment lighted cigarettes DO NOT SMOKE when charging or han dling batteries KEEP BATTERIES AND ELECTROLYTE OUT OF REACH OF CHILDREN 62Y5A11 General NOTE y Batteries vary per manufacturer The pro cedures mentioned in this manual may not always apply therefore consult the instruc tion manual of the battery Disconnect the negative lead first then the positive lead ZX Electrolyte specific gravity 1 280 at 20 C 68 F Lubrication 1 Apply water resistant grease to the areas shown S62Y3690 S62Y3660 S62Y3670 S62Y3720K NOTE Apply grease to the grease nipple until it flows from the bushings 8 S62Y3680 62Y5A11 3 16 CHK Q ADJ Periodic checks and adjustments 2 Apply anti corrosion grease to the areas shown S62Y3730 3 17 62Y5A11 62Y5A11 Fuel system Special Service tools 2 2 een 4 1 HOS6 routing EE 4 2 Fuel and blowby GS ES eis era Sed bee 4 2 Fuel filter and fuel Bump mesken an 4 3 Checking the fuel pump su 4 5 Disassembling the fuel pump ccococcconnn
104. im and tilt hydro tilt 1 Fully tilt the outboard motor up and then support it with the tilt stop lever S62Y7440 4h WARNING After tilting up the outboard motor be sure to support it with the tilt stop lever Otherwise the outboard motor could sud denly lower if the power trim and tilt unit should lose fluid pressure 2 Loosen the plastic locking tie Q and then pull out the PTT motor lead 3 Remove the tilt pin 4 4 Remove the circlip s and the shaft 5 Loosen the bolt G and then remove the shaft 8 6 Remove the power trim and tilt hydro tilt 9 62Y5A11 Power trim and tilt unit S62Y7450 NOTE __ To remove the power trim and tilt hydro tilt lower the tilt rod slightly 7 26 RASI bd Bracket unit Tilt cylinder and trim cylinder MAN m 0 4 kgf m 2 9 ft Ib 7 27 90 N m 9 0 kgf m 65 ft Ib S62Y7460K 62Y5A11 Tilt cylinder and trim cylinder Z o o NO O BE O MM Part name Remarks Power trim and tilt motor Tilt cylinder end screw Bolt O ring Joint O ring Ball O ring M5 x 20 mm Not reusable Not reusable Not reusable 28 7 x 3 5 mm O gt WO sch Free piston Valve seal Circlip Circlip Trim cylinder base Spring Plate Circlip Tilt cylinder assembly O ring A gt gt NNN sch Not reusable 8 8 x 1 9 mm Reservoir cap Anode Bolt M6 x 25 mm 6
105. ints to find height average Shimming plate 90890 06701 Digital caliper 8 90890 06704 2 Calculate the forward gear shim thickness T1 as shown in the examples below S62Y6935 NOTE 00 F is the deviation of the lower case dimen sion from standard The F mark is stamped on the trim tab mounting surface of the lower case in 0 01 mm units If the F mark unreadable assume that F is zero and check the backlash when the unit is assembled Forward gear shim thickness T1 24 50 F 100 M 6 26 EE Lower unit Example If M is 24 00 mm and F is 5 then T1 24 50 5 100 24 00 mm 0 50 0 05 mm 0 55 mm If M is 24 00 mm and F is 5 then T1 24 50 5 100 24 00 mm 0 50 0 05 mm 0 45 mm 3 Select the forward gear shim s T1 as follows Calculated numeral at 1 100 place 1 2 3 4 5 6 7 8 Rounded numeral 9 10 Available shim thicknesses 0 10 0 12 0 15 0 18 0 30 0 40 and 0 50 mm Example If T1 is 10 45 mm then the forward gear shim is 0 42 mm If T1 is 10 50 mm then the forward gear shim is 0 48 mm Selecting the reverse gear shims There is no need to select the reverse gear shims Backlash Measuring the forward gear backlash 1 Remove the water pump assembly 2 Set the gearshift to the neutral position S62Y6940K 6 27 Shif
106. inuity 62Y5A11 Ignition system and Ignition control system S62Y8260 Lead color White W Black B Remove the lock plate Install the lock plate b Push the button Checking the thermoswitch 1 Place the thermoswitch in a container of water and slowly heat the water 666664 S62Y8270 2 Check the switch for continuity at the specified temperatures Replace if out of specification 62Y5A11 O S62Y8280 2 Temperature Time No continuity Continuity Thermoswitch continuity temperature Pink P Black B 76 84 C 164 183 F D 63 77 C 145 170 F Checking the oil pressure switch 1 Connect the special service tool to the oil pressure switch 2 Slowly operate the special service tool S62Y8290 3 Check the switch for continuity at the specified pressure Replace if there is no continuity Cz Vacuum pressure pump gauge set 90890 06756 aN Specified oil pressure 15 kPa 0 15 kgf cm 2 13 psi 8 14 ELEG Electrical systems Starting system S62Y8300 Fuse B Black 10 pin coupler Dr Brown Engine start switch R Red 4 Starter motor Battery Neutral switch G Starter relay Tiller handle model 8 15 62Y5A11 Checking the fuse 1 Check the fuse and fuse holder for conti nuity Replace if there is no continuity Checking the wiring harness 10 pins 1 Check the wiring harne
107. ion gauge Valve spring compressor attachment 90890 03160 90890 06320 Flywheel holder Valve guide remover installer 90890 06522 90890 06801 o AN Ly ES E Flywheel puller Valve guide reamer 90890 06521 90890 06804 Crankshaft holder 18 Valve seat cutter holder 90890 06562 90890 06316 O Valve spring compressor Valve seat cutter 90890 04019 90890 06315 90890 06323 90890 06326 90890 06328 90890 06555 5 1 62Y5A11 Bearing outer race attachment 90890 06626 Oil filter wrench 90890 01426 Piston slider 90890 06529 62Y5A11 Special service tools 5 2 Power unit y IMI3N m 0 3 kgf m 2 2 ft Ib S62Y5010K 5 3 62Y5A11 Power unit No 1 2 3 4 5 6 7 8 Part name Remarks Flywheel magnet Stator coil Cover Grommet Nut Washer Bolt Lighting coil coupler Charge coil coupler Stator base Pulser coil coupler Screw Dowel pin Woodruff key Cover Screw M6 x 25 mm M6 x 24 mm DA sch po bb W NYO sch M6 x 35 mm 62Y5A11 5 4 Power unit Z o o NO O BE O ND Part name Remarks Throttle cable Shift cable Fuel pump Fuel filter assembly Carburetor assembly Bolt Plate Clip Clip Grommet Holder Bolt O ring M6 x 20 mm NN 4 Q A sch Not reusable 24 4 x 3 1 mm Clip Fuel hose Bolt Clip Fuel hose Bolt O ring Fuel pump to carburetor Fuel filter to fuel joint
108. k the fuel hose connections and fuel joint 2 for leaks Replace if necessary Also check the fuel filter fuel pump 2 and carbu retor 5 for leaks and the fuel hoses for leaks and deterioration Replace if nec essary S62Y3030K Checking the fuel filter 1 Check the fuel filter element G for dirt and residue and check the fuel filter cup 2 for foreign substances and cracks Clean with straight gasoline and replace the cup if necessary e Y S62Y3040K NOTE Be sure not to spill any fuel when removing the fuel filter cup 62Y5A11 Power unit Checking the engine oil 1 Place the outboard motor in an upright position 2 Remove the engine oil dipstick wipe it clean and then insert it back into the oil filler hole 3 Remove the dipstick again to check the oil level and the oil for discoloration and its viscosity NOTE Replace the oil if it appears milky or black e If the engine oil is above the maximum level mark 8 drain sufficient oil until the level is between and If the engine oil is below the minimum level mark add sufficient oil until the level is between and Replacing the engine oil 1 Remove the engine oil dipstick and oil filler cap AN pe AN S62Y3070 62Y5A11 Top cowling Fuel system Power unit 2 Place a drain pan under the drain hole and then remove the drain bolt 2 and let the oil drain completely
109. lack yellow G W Green white Gy B Gray black P B Pink black P W Pink white W B White black W R White red Y B Yellow black Y R Yellow red YAMAHA YAMAHA MOTOR CO LTD Printed in the Netherlands Jun 2001 0 4 x 1 CR FT50CEHD FT50CED FT50CET E FT50CEHD FT50CED 5 o z m 6 A Onen rc So n O 0000000080 S o e S62YWDO1K FT50CET RGBL YR PB w Bro Y B P W OOO S62YWDO4K Lg Lg R Sb Lg Sb R Sb Sb
110. lo mm 0 4 in S62Y5850 Connecting rod bolt thread diameter limit difference between and 0 0 1 mm 0 0 004 in Checking the crankshaft 1 Measure the crankshaft journal diameter crank pin diameter and crank pin width Replace the crankshaft if out of specification S62Y5860 62Y5A11 Crankshaft journal diameter 8 42 984 43 000 mm 1 6923 1 6929 in Crank pin diameter 32 984 33 000 mm 1 2986 1 2992 in Crank pin width 21 000 21 070 mm 0 8268 0 8295 in 2 Measure the crankshaft runout Replace the crankshaft if out of specification S62Y5870K ZX Crankshaft runout limit 0 04 mm 0 0016 in Checking the crankshaft main journal oil clearance 1 Clean the bearings main journals and bearing portions of the crankcase and cylinder body 2 Place the cylinder body upside down on a bench 3 Install half of the bearings and the crankshaft 2 into the cylinder body S62Y5910 62Y5A11 Cylinder body CAUTION Install the bearings in their original posi tions NOTE Insert the projection of the bearing into the notch in the cylinder body 4 Put a piece of Plastigauge PG 1 on each main journal parallel to the crank shaft S62Y5920 NOTE Do not put the Plastigauge PG 1 over the oil hole in the main journals of the crankshaft 5 Install the remaining half of the bearings into the crankcase NOTE Insert the proj
111. locking agent and the appli cation point Apply Gasket Maker 8 Apply LOCTITE No 242 Blue LOCTITE 43 Apply Yamabond No 4 Apply LOCTITE No 572 Apply LOCTITE No 271 Red LOCTITE Apply silicon sealant 62Y5A11 1 2 dm Y General information Safety while working To prevent an accident or injury and to ensure quality service follow the safety pro cedures provided below Fire prevention Gasoline is highly flammable Keep gasoline and all flammable products away from heat sparks and open flames S62Y1100 Ventilation Gasoline vapor and exhaust gas are heavier than air and extremely poisonous If inhaled in large quantities they may cause loss of consciousness and death within a short time When test running an engine indoors e g in a water tank be sure to do so where ade quate ventilation can be maintained Self protection Protect your eyes by wearing safety glasses or safety goggles during all operations involv ing drilling and grinding or when using an air compressor Protect your hands and feet by wearing pro tective gloves and safety shoes when neces sary 1 3 S62Y1120 Parts lubricants and sealants Use only genuine Yamaha parts lubricants and sealants or those recommended by Yamaha when servicing or repairing the outboard motor S62Y1130 Under normal conditions the lubricants men tioned in this manual should not harm or be hazardous to your skin However
112. lubricant and lubrication point The components list consist of parts and part quantities as well as bolt screw O ring and hose dimensions Service points regarding removal checking and installation are shown in individual illustrations to explain the relevant procedure NOTE For troubleshooting procedures see Chapter 9 Troubleshooting POWR Es Povver unit Cylinder head Cylinder head No Part name Q ty Remarks 1 Cylinder head 1 2 Oil pump 1 3 Cylinder head cover 1 N 4 Bolt 7 M6x20mm 23 N m 2 3 kgf m 170 6 3 5 Cylinder head cover gasket 1 47 N lt m 4 7 kgf m 34 ft 1b 6 Bolt 10 M9x95mm 7 Spark plug 4 8 Bolt 5 M6 x 25 mm 9 Dowel pin 2 10 Cylinder head gasket 1 Not reusabie 11 Grommet 4 12 Anode 4 Cover 4 418 N m 1 8 kgf m 13t 1b POWR amp Power unit Tst J6N m 0 6 kgt m 4 3 ft lb Removing the timing belt and 3 Remove the tensioner 2 and timing belt end 12 N m 1 2 kgf m 8 7 ft lb sprockets O from the driven sprocket side 1 Set the cylinder 1 piston position to TDC of the compression stroke by align ing the 1 mark on the driven sprocket with the a mark on the cylinder Do not turn the drive sprocket counter clockwise otherwise the valve system may be damaged
113. magnet counter clockwise otherwise the valve system may be damaged Checking the valve clearance 1 Remove the flywheel magnet cover and then disconnect the high tension cords and blowby hose 62Y5A11 2 Remove the spark plugs fuel pump and cylinder head cover 3 E Al AAA S62Y3220 3 Turn the flywheel clockwise and align the 1 mark 8 on the driven sprocket with the A mark on the cylinder head S62Y3230K CAUTION Do not turn the flywheel counterclock wise otherwise the valve system may be damaged 4 Check the intake valve clearance for cyl inders 1 and 2 and the exhaust valve clearance for cylinders 1 and 3 Adjust if necessary 5 Turn the flywheel clockwise and align the 4 mark on the driven sprocket with the A mark on the cylinder head 62Y5A11 Power unit S62Y3230K CAUTION Do not turn the flywheel counterclock wise otherwise the valve system may be damaged 6 Check the intake valve clearance for cyl inders 3 and 4 and the exhaust valve clearance for cylinders 2 and 4 Adjust if out of specification S62Y3240 NOTE _ Adjust the valve clearance when the engine is cold 3 6 CHK Q ADJ Periodic checks and adjustments Valve clearance Intake 0 20 0 05 mm 0 008 0 002 in Exhaust 8 0 30 0 05 mm 0 012 0 002 in 7 Loosen the locknut 4 and then turn the adjusting s
114. ment S62Y1535K 2 Check the steering for smooth operation 62Y5A11 Predelivery checks S62Y 1540K 3 Check that there is no interference with wires or hoses when the outboard motor is steered Checking the gearshift and throttle operation 1 Check that the gearshift operates smoothly when shifting from neutral into forward and reverse 2 Check that the throttle control lever con tacts the respective stoppers when the throttle control lever is closed or fully open S S62Y1550K Checking the tilt system 1 Check that the outboard motor can be smoothly tilted up and down by operating the power trim and tilt unit 2 Check that there is no abnormal noise produced when the outboard motor is tilted up and down 3 Check that there is no interference with wires and hoses when the tilted up motor is steered 1 28 dm Y General information 4 Check that the trim meter points down when the outboard motor is tilted all the way down Checking the engine start switch and engine stop switch engine shut off switch 1 Check that the engine starts when the engine start switch is turned to START 2 Check that the engine turns off when the engine start switch is turned to OFF 3 Check that the engine turns off when the engine stop switch is pushed engine shut off cord is pulled S62Y1560K Checking the pilot water outlet 1 Check that cooling water is discharged from the pilot wate
115. mm 0 02 in 3 Remove the throttle link rod 4 adjust it to the specified length and then install it 4 13 62Y5A11 Carburetor 5 After adjusting the idle speed rev the Digital tachometer 90890 06760 engine a few times and let it idle for at least 15 seconds to check the stability of the engine Adjust the carburetor syn 3 Turn the pilot screws 2 in direction chronization if necessary until the engine idle speed has decreased to approximately 50 r min Synchronizing the carburetors then in direction 5 8 turn 1 Start the engine and warm it up for 5 min utes to check the stability of the engine 2 Attach the special service tool to the high tension cord 1 S62Y4360 3 Remove all of the plugs and attach the Engine idl special service tool and adapters to the ngne AIS See RID carburetor assembly as shown 4 Turn the throttle stop screw 3 in direc tion or until the specified engine idle speed is obtained S62Y4370 NOTE AA To increase the idle speed turn the throttle stop screw in direction S62Y4390K To decrease the idle speed turn the throttle stop screw in direction 9 Vacuum gauge 90890 03159 62Y5A11 4 14 dla Wu Fuel system S62Y4400K KZ Vacuum gauge digital commercially obtainable Vacuum gauge 4 analog meters commercially obtainable 4 Vacuum gauge adaptor commercially obtainable
116. mp 2 gt Up relief valve 9 Up main valve Fr A S62Y1370 Power trim and tilt components 6 1 2 3 MP G 9 5 4 X XL CH a DI H Ll z Fa E O 16 i 13 9 11 JO 19 14 S62Y1380K Cylinder 9 Reservoir Ram Manual valve Check valve Up relief valve Down main valve 42 Up shuttle piston 6 Down relief valve 3 Down shuffle piston Motor Trim cylinder base G Gear pump Free piston Up main valve Tilt piston 62Y5A11 1 20 dm Y General information Trim up function The gear pump pumps power trim and tilt fluid to the up main valve As a result the fluid pressure opens the up shuttle piston causing the fluid to flow into the lower part of the power trim and tilt cyl inder At the same time vacuum from the gear pump opens the down main valve and down shuttle piston which causes fluid from the upper part of the power trim and tilt cylinder to return to the gear pump and also sucks fluid in through the reservoir The pressurized fluid forces up the trim cylinder along with the tilt
117. n S62Y7700 Recommended power trim and tilt fluid ATF Dexron II 13 Install the joint and power trim and tilt motor by installing the bolts then tightening them to the specified torgue S62Y7710 PTT motor bolt 4 N m 0 4 kgf m 2 9 ft lb Assembling the trim cylinder 1 Install the dust seal into the tilt cylinder end screw 7 38 RASI bd Bracket unit 2 Install the O ring to the end screw 3 Install the tilt ram 4 into the end screw EE 35 S62Y7720 4 Install the backup ring and O rings and into the trim cylinder end screw S62Y7730 5 Install the trim cylinder end screw onto the tilt ram 6 Install O rings and onto the trim pis ton and then install the trim piston to the trim cylinder S62Y7750 7 Install the backup ring 9 and O ring into the tilt piston 7 39 8 Install balls 9 and 2 absorber valve pin 8 spring pins and and washer 22 into the tilt piston 9 Hold the tilt ram end in a vise using alu minum plates on both sides 10 Install the tilt piston to the tilt ram by installing the bolt then tightening it to the specified torque Tilt piston 61 N m 6 1 kgf m 44 ft Ib 11 Install the trim cylinder onto the tilt ram 12 Hold the trim cylinder 63 in a vise using aluminum plates on both sides NOTE gt a ee ss Place the trim cylinder in
118. nd throttle cable 9 and then adjust their lengths For adjustment procedures see Chapter 3 Checking the throttle cable operation and Checking the gearshift operation 62Y5A11 5 50 NOTE __ Apply engine oil to the flywheel magnet nut before installation Flywheel holder 90890 06522 Flywheel magnet nut 160 N m 16 kgf m 116 ft Ib S62Y5091K 8 Install the Woodruff key S62Y5090 9 Install the flywheel magnet and flywheel magnet cover S62Y5100J CAUTION Apply force in the direction of the arrows shown to prevent the flywheel holder from slipping off easily 5 51 62Y5A11 62Y5A11 Lower unit Special Service tools 2a 6 1 COW A ias 6 5 Removing the lower unit ss 6 6 Water pump and shift rod 0aesesesena naen ann aii 6 7 Removing the water pump and shift rod 6 9 Checking the water pump and shift rod 6 9 Installing the water pump and Shift rod 6 9 Propeller sh ft housing ana 6 11 Removing the propeller shaft housing assembly 6 13 Disassembling the propeller shaft bousimg nn 6 13 Disassembling the propeller shaft assembly n 6 14 Checking the propeller shaft housing 6 14 Checking the propeller shaft 6 14 Assembling the propeller shaft assembly 6 15 Assembling the propeller shaft houseimg nenn nennen 6 15 Installing the propeller shaft housing 6 16 Drive shaft and lower CaSe sssrrrnnnnn
119. neral information Acceleration pump The function of the acceleration pump is to ensure a smooth acceleration by preventing the air fuel mixture from becoming temporarily lean in case the throttle valve is opened suddenly When the throttle valve is opened suddenly a large volume of air is introduced into the engine However because fuel is heavier than air it is not possible to supply the volume of fuel that is necessary for the large volume of air that has been introduced Thus because it is not possible to achieve the air fuel mixture that is required by the engine bucking or hesitation results For this reason the acceler ation pump temporarily increases the fuel volume in order to adjust the air fuel mixture to a ratio that is necessary for the engine in case the throttle valve is opened suddenly S62Y1290 Bypass hose Acceleration pump Pump chamber Diaphragm 1 6 Throttle lever A Air flow B Throttle valve opening direction 1 13 62Y5A11 Operation Technical tips When the throttle is opened suddenly diaphragm 1 via the link that is connected to the throttle lever operates to pressurize the air in the pump chamber The pressurized air opens diaphragm 2 and becomes distributed to the carburetors by passing through the pipes that are connected to the carburetors The pressurized and distributed air then utilizes the passage of the main air jet to flow into the main nozzle The pressure of the air hel
120. ng the Rectifier Regulator 1 Measure the Rectifier Regulator output peak voltage If below specification mea sure the lighting coil output peak voltage Replace the Rectifier Regulator if the out put peak voltage of the lighting coil is above specification S62Y8480 WARNING When checking the peak voltage do not touch any of the connections of the digital tester leads NOTE Use the peak voltage adaptor with the digi tal circuit tester When measuring the peak voltage set the selector on the digital circuit tester to the DC voltage mode N Digital circuit tester 90890 03174 Peak voltage adaptor 90890 03172 Test harness 4 pins 90890 06771 Rectifier Regulator output peak voltage Red R Black B Unloaded 1 500 3 500 DC V 18 9 19 5 r min 8 23 NOTE After starting the engine disconnect the out put lead red lead of the Rectifier Regulator when measuring the output peak voltage 62Y5A11 TRBL Troubleshooting Power UN in AT 9 1 Br cket UN eege d Eege 9 10 Electrical SMS 9 13 62Y5A11 TRBL 1 SHTG e Troubleshooting NOTE To diagnose a mechanical malfunction use the troubleshooting charts pertaining to the trouble located in this chapter Also when checking and maintaining the outboard motor see Chapter 4 8 to check the part necessary to carry out safety maintenance e Check that all electrical connections are tight and free
121. ng the tilt system 1 28 Checking the timing belt 3 5 Checking the timing belt and sprockets 5 18 Checking the top cowling eee eeee 3 3 Checking the trailer switch 7 49 Checking the trim sensor 7 49 Checking the valve clearance 3 5 Checking the valve guides 5 26 Checking the valve seat 5 27 Checking the valve Springs 5 25 Checking the valves 5 25 Checking the water pump and shift rod 6 9 Checking the wiring harness 10 pins 8 16 Clamp brackets A 7 18 Control system 3 9 Cylinder Doch 5 35 Cylinder head 5 21 D Dimensions em 2 9 Disassembling the cylinder body 5 37 Disassembling the drive shaft 6 19 Disassembling the forward gear 6 19 Disassembling the fuel pump 4 5 Disassembling the gear pump 7 35 Disassembling the lower case 6 20 Disassembling the oil pan 7 15 Disassembling the propeller shaft assembly nao 08e ti 6 14 Disassembling the propeller shaft MOUSING socio AAN 6 13 Disassembling the tilt cylinder 7 35 Disassembling the trim cylinder 7 35 Disassembly and assembly 1 4 Drive shaft and lower case
122. nnnnnnnnnnnnnnnnnnnnnnennnnnnnnnnnnnnnnnnennnnnnnnnnevennr 6 17 Removing the drive u ae la 6 19 Disassembling the drive shaft 6 19 Disassembling the forward gear 6 19 Disassembling the lower case 6 20 Checking the pinion and forward gear 6 20 Checking the Dear Scars O 6 20 Checking the drive shaft ua a 6 20 Checking the lower case ss 6 21 Assembling the lower case sus sin ee 6 21 Assembling the forward gear 6 21 Assembling the drive shaft AAA 6 22 Installing thepirniont saetas ida 6 22 Installing the lower unit 6 22 SHINMING BEE 6 24 ShIMMING cts 6 25 Selecting the pinion shims 6 25 Selecting the forward gear shims 0occccconccccccconoccconanancnnnnnncnccnonannnnnnna nc 6 26 Selecting the reverse gear shims EEN 6 27 BaCRIaS Rent HN OS 6 27 Measuring the forward gear backlash A 6 27 a Lower unit Special service tools 7 4 Stopper guide plate Bearing puller claw 1 90890 06501 90890 06536 40 Center bolt Needle bearing attachment 90890 06504 90890 06610 90890 06611 90890 06612 90890 06614 Bearing separator 90890 06534 Driver rod L3 90890 06652 Stopper guide stand 90890 06538 Driver rod SS 90890 06604 Bearing puller 90890 06535 Bearing depth plate 90890 06603 6 1 62Y5A11 Bearing inner race attachment 90890 06639 90890 06643 90890 06661 90890 06662 Drive shaft holder
123. not turn the sprockets counterclock wise otherwise the valve system may be damaged 9 Tighten the driven sprocket bolt 2 to the specified torque S62Y5220J Driven sprocket bolt 2 38 N m 3 8 kgf m 27 ft Ib 10 Tighten the drive sprocket nut 6 to the specified torgue and then install the breather hose S62Y5230 NOTE 0 Use a deep socket M42 for this proce dure 62Y5A11 CZ N 4 Timing belt and sprockets Crankshaft holder 18 42 90890 06562 Drive sprocket nut 6 140 N m 14 kgf m 100 ft Ib 5 20 Cylinder head i I A Se 18 N m 1 8 kgf m 13 ft Ib S62Y5240K 5 21 62Y5A11 Cylinder head Z o o NO O BE Mm Part name Remarks Cylinder head Oil pump Cylinder head cover Bolt Cylinder head cover gasket Bolt Spark plug Bolt Dowel pin Cylinder head gasket Grommet Anode Cover Bolt Cover Bolt O ring M6 x 20 mm Not reusable M9x 95 mm A N o M6 x 25 mm Not reusable 4 5 2 1 4 4 4 4 4 4 4 33 0 x 1 9 mm O ring 13 5 x 1 8 mm O ring 11 5 x 1 2 mm M6 x 40 mm Bolt Housing Drive shaft Pin Inner rotor Outer rotor Gasket Cover Screw Not reusable M6 x 20 mm D oo Tightening sequence 62Y5A11 5 22
124. ntenance specifications Model FT50CEHD FT50CED FT50CET Charging system Fuse Lighting coil output peak voltage G G cranking 1 500 r min 3 500 r min Lighting coil resistance G G Rectifier Regulator output peak voltage R B 1 500 r min 3 500 r min Charging current V V A 5 000 r min 20 Enrichment control system Prime Start ll Plunger extended length More than 24 6 0 97 Power trim and tilt system Trim sensor Setting resistance Resistance P B Fluid type Brushes Standard length Wear limit Commutator Standard diameter Wear limit Mica Standard undercut CD Unloaded 2 The figures are for reference only 62Y5A11 9 11 10 288 3 ATF Dexron II 10 0 39 3 5 0 14 22 0 0 87 21 0 0 83 1 5 0 06 2 8 Dimensions Exterior W6 H2 H6 S62Y2230 2 9 62Y5A11 Maintenance specifications Model FT50CEHD 576 22 7 272 10 7 797 31 4 SE 22 0 8 Unit SE 990 89 0 397 15 6 189 7 4 0 8 0 03 63 2 5 917 36 1 519 20 4 m i 191 7 5 536 21 1 680 26 8 723 28 5 330 13 0 110 4 3 738 29 1 mm in Degree Degree Degree mm in
125. of the lever S62Y3480 62Y5A11 Control system Power trim and tilt unit Lower unit Checking the power trim and tilt fluid level 1 Fully tilt the outboard motor up and then support it with the tilt stop lever S62Y3490 WARNING After tilting up the outboard motor be sure to support it with the tilt stop lever Otherwise the outboard motor could sud denly lower if the power trim and tilt unit should lose fluid pressure 2 Remove the tilt pin S62Y3500 3 Remove the reservoir cap and then check the fluid level in the reservoir zNI S62Y3510 62Y5A11 NOTE The fluid level should be at the brim of the filler hole 4 If necessary add sufficient fluid of the recommended type to the correct level Recommended power trim and tilt fluid ATF Dexron II 5 Install the reservoir cap and then tighten it to the specified torque Reservoir cap 8 N m 0 8 kgf m 5 8 ft Ib 6 Install the tilt pin to its original position Lower unit Checking the gear oil level 1 Fully tilt the outboard motor down 2 Remove the check screw D and then check the gear oil level in the lower case S62Y3520 NOTE NW The gear oil level should be at the brim of the check hole 3 If necessary add sufficient gear oil of the recommended type to the correct level Recommended gear oil Hypoid gear oil SAE 90 3 12 CHK Q ADJ Periodic checks and a
126. op screw in direc tion or until the specified engine idle speed is obtained S62Y3420 NOTE eeng To increase the idle speed turn the throttle stop screw in direction 8 To decrease the idle speed turn the throttle stop screw in direction 4 After adjusting the idle speed rev the engine a few times and let it idle for at least 15 seconds to check the stability of the engine 3 10 CHK Q ADJ Periodic checks and adjustments Checking the ignition timing 1 Startthe engine and warm it up for 5 min utes 2 Attach the special service tool to high tension cord 1 G and then check the engine idle speed OLD an ENY XI EA Engine idle speed 850 950 r min 3 Attach the special service tool to high tension cord 1 G 9 A AN a JAN 4 Check that the TDC T mark 8 on the flywheel magnet is aligned with the mag net base pointer CLC TI ZX Ignition timing TDC Power trim and tilt unit Checking the power trim and tilt operation 1 Fully tilt the outboard motor up and down a few times and check the entire trim and tilt range for smooth operation Check the power trim and tilt fluid level if necessary NOTE Be sure to listen to the winding sound of the PTT motor for smooth operation 2 Fully tilt the outboard motor up and then support it with the tilt stop lever to check the lock mechanism
127. or body as shown 62Y5A11 Carburetor S62Y4270 2 Install the needle valve float float pin and screw 8 as shown and then the check the float for smooth operation NOTE SE e Place the needle valve in the valve seat when installing the float to the carburetor body Fit the float pin into the slit on the carbure tor body and lock it with the screw 4 12 dla Wu Fuel system 3 Install the pilot screw 9 turn it in until it is lightly seated then out the specified number of turns S62Y4330 ZX Throttle link rod length 144 mm 5 67 in 4 Push the throttle control lever to the fully open position as shown S62Y4300 5 While pushing the carburetor throttle Pilot screw setting lever against the carburetor stopper Carburetors 1 2 and 3 9 loosen and then tighten the adjusting 1 3 4 2 3 4 turns out screw 5 Carburetor 4 2 3 turns out Adjusting the throttle link rod 1 Push the throttle control lever to the fully open position as shown and then measure the gap between the carburetor throttle lever 2 and carburetor stopper 2 If out of specification adjust the throttle link rod length Adjusting the pilot screw 1 Start the engine and warm it up for 5 min utes to check the stability of the engine Adjust the pilot screw if necessary 2 Attach the special service tool to high tension cord 1 ZX Gap Less than 0 5
128. or gasoline 62Y5A11 9 2 TRBL H SHTG e Troubleshooting Symptom Engine cranks but will not start Check the ignition system Check the fuel system Check the compression pressure of power unit Check the ignition spark using the spark gap tester 4 WARNING Do not touch any of the connections of the spark gap tester leads Check the ignition system Do not let sparks leak out Below the spark gap specification output peak voltage of the removed spark plug caps Keep flammable gas or Check the condition of the spark liguids away since this plugs test can produce sparks Wet spark plugs Check the fuel system Start the engine using dried or new spark plugs Does the engine start Check the compression pres sure of the combustion chamber Out of specifi cation 2 Check the condition of the spark Failure in starting operation plugs again 9 X J N Check the valve clearance Wet spark plugs Failure in starting operation L y Adjust the valve clearance Out of specifi cation Check the fuel system Check the cylinder head cylin der body and piston assembly 9 3 62Y5A11 Power unit Symptom Engine can be started but does not remain on Check the fuel system Check the ignition system Check the compre
129. ottle cam 2 slowly and check that the acceleration pump stopper comes in contact with point 6 Turn the adjusting screw 2 in or out until the specified engine speed is obtained 62Y5A11 Carburetor S62Y4450 7 Open and close the throttle cam a few times and check the engine speed at the operation point of dash pot again Adjust if necessary row E Power unit Special Service 16018 2a 5 1 Power Tt a A NG en sante ANAN ARIAN 5 3 Checking the compression pressure cooooocccccnonocincononccnnnnnncncnnnnnnnnnnnnnncnnns 5 13 Checking the oil pressure ar aaa 5 13 Removing the power Uni eek 5 13 Timing belt and SprocketS rnnvnnnnnnnnnnnnnnvnnnnnnnnnnnnnnnnnnnennnnnnnnnnnnnnnnnnnnnnnnner 5 16 Removing the timing belt and eprockets AAA 5 17 Checking the timing belt and Sprockets AAA 5 18 Installing the sprockets and timing belt 5 18 Cylinder head Lana 5 21 Removing the cylinder head 5 24 Checking the Valve Springs a na 5 25 CHECKING EE 5 25 Checking the valve guides ia hem tada 5 26 Replacing the valve guides 5 26 Checking the valve seat ss 5 27 Refacing the valve seat nenne ahi eet awe si 5 28 Checking the rocker arms and rocker arm sbaft AAA 5 30 Checking the camshafte casi es ee o ee ea 5 30 Checking the cylinder head AAA 5 31 Checking the oil pUMp asnicar bene 5 31 Installing the valves nen ee es 5 32 Inetallihgthe camsTiafl aui nt
130. park plug cap resistance Replace if out of specification S62Y8180 EN Spark plug cap resistance 3 75 6 25 kO EFE Electrical systems Checking the ignition coil 1 Remove the spark plug caps from the high tension cords by turning the caps counterclockwise 2 Measure the ignition coil resistance Replace if out of specification S62Y8185K S62Y8190K Ignition coil resistance Primary coil Orange O Black B 0 08 0 11 O at 20 C 68 F Secondary coil High tension cord High tension cord 3 5 4 7 KO at 20 C 68 F Checking the CDI unit 1 Measure the CDI unit output peak volt age If below specification measure the charge coil output peak voltage and the pulser coil output peak voltage Replace the CDI unit if the output peak voltage of both coils is above specification S62Y8200 WARNING When checking the peak voltage do not touch any of the connections of the digital tester leads NOTE __ Use the peak voltage adaptor with the digi tal circuit tester When measuring the peak voltage set the selector on the digital circuit tester to the DC voltage mode S ZA Digital circuit tester 90890 03174 Peak voltage adaptor 90890 03172 CDI unit output peak voltage Black orange B O Black B Black white B W Black B Unloaded Loaded Cranking 1 500 3 500 126 150 151 116 Checking the charge coil
131. piston free piston and trim cylin der base As the trim cylinder moves up the ram extends and the outboard motor is trimmed up The end of the trim range is when the trim cylinder tops out in the power trim and tilt cylinder gt S62Y1390 Power trim and tilt cylinder Up shuttle piston Ram Down shuttle piston Trim cylinder Free piston 4 Down main valve 2 Trim cylinder base 6 Motor 3 Tilt piston Gear pump A Return Up main valve B Send Reservoir 1 21 62Y5A11 Technical tips Trim down function When the power trim and tilt switch is pressed to Down the motor turns the gear pump counter clockwise and the power trim and tilt fluid flows in the opposite direction to that of the trim up func tion Tilt up function When the trim cylinder tops out the check valve is pushed down by the end screw wall This causes the ball in the check valve to move down opening the fluid passage and allowing the power trim and tilt fluid to flow from the upper part of the trim cylinder through the down shuttle piston and the down main valve and back to the gear pump In addition fluid is also sucked in through the reser voir and the pressurized fluid continues to flow into the lower part of the trim cylinder pushing up the tilt piston and free piston and further extending the ram As the tilt piston moves up and off of the trim cylinder base the base moves up and pushes the balls outward to
132. propeller blade or outside of the propeller boss S62Y1440K t A S62Y1450K Propeller diameter in inches Propeller pitch in inches Propeller type propeller mark Selection When the engine speed is at the full throttle operating range 5 000 6 000 r min an ideal propeller for the boat is one that provides maximum performance in relation to boat speed and fuel consumption 62Y5A11 Propeller size in Material 12 5 8 x21 K Aluminum 13x19 K Aluminum 13x23 K Aluminum 13x25 K Aluminum 13 1 4 x 17 K Aluminum 131 2x15 K Aluminum 135 8x 13 R Aluminum 14x11 K Aluminum 13x17 K Stainless 13x19 K Stainless 13x21 K Stainless 13x23 K Stainless 13x25 K Stainless 131 2x14 K 131 2x16 K Stainless Stainless Predelivery checks To make the delivery process smooth and efficient the predelivery checks should be completed as explained below Checking the fuel system 1 Check that the fuel hoses are securely connected and that the fuel tank is full with fuel S62Y1460K CAUTION This is a 4 stroke engine Do not use pre mixed fuel and 2 stroke outboard motor oil 1 26 dm Y General information Checking the gear oil 1 Check the gear oil level S62Y1470 CAUTION Do not reuse the gasket always replace it with a new one Checking the engine oil 1 Check the oil level
133. ps suck fuel from the main jet which increases the fuel in the main nozzle and thus achieves the fuel enrichment EE gt ol gt Main air jet Main nozzle Main jet 4 Throttle valve Pilot screw Pilot outlet Pilot jet From acceleration pump Throttle valve closing Throttle valve opening 62Y5A11 S62Y1300 Diaphragm 1 2 Diaphragm 2 To carburetors A Air flow B Throttle valve opening direction dm Y General information Ignition system In order to determine the optimal ignition timing that is necessary for the proper operation of the engine the built in microcomputer in the CDI unit detects the signals from various types of sensors and controls the ignition timing in accordance with a control map that is based on those signals The microcomputer also effects controls to protect the engine against overheating over revolution and oil pressure drops as well as to control warning devices O O m 4 SE SE nr 5 lt S62Y1310 TIT TT TIT TIT Pulser coil Ignition coils 1 and 4 Flywheel O Ignition coils 2 and 3 Charge coil Oil pressure switch CDI unit 9 Thermoswitch Microcomputer Flywheel Three protrusions for the pulser coil are provided along the periphery of the flywheel The purpose of these protru
134. pump and shift rod 1 Remove the water pump assembly and shift rod assembly S62Y6530K NOTE Pull up the shift rod assembly a little to dis connect it from the shift slider 2 turn it coun terclockwise 90 and then remove it Checking the water pump and shift rod 1 Check the pump housing for deforma tion Replace if necessary 2 Check the impeller and insert plate car tridge for cracks or wear Replace if nec essary 3 Check the Woodruff key and the groove on the drive shaft for wear Replace if necessary 4 Check the shift rod for cracks or wear Replace if necessary Installing the water pump and shift rod 1 Install the shift rod assembly 6 9 S62Y6555 NOTE Install the shift rod assembly into the lower case turn it clockwise 90 A and then push it down to connect it to the shift slider 2 Install the new oil seals into the oil seal housing as shown S62Y6565K Needle bearing attachment 90890 06610 Driver rod L3 4 90890 06652 3 Install the new O ring 4 Install the new gasket oil seal housing new gasket 8 and outer plate car tridge 62Y5A11 Water pump and shift rod S62Y6580K NOTE Align the insert plate cartridge projection with the hole in the pump housing 8 Install the new gasket 5 pump housing assembly 4 and dowel pins to the lower case 9 Install and tighten the bolts 2 S62Y
135. r B Send Up relief valve 1 23 62Y5A11 Technical tips Tilt down function When the power trim and tilt switch is pressed to Down the motor turns the gear pump counter clockwise thus pumping the power trim and tilt fluid to the down main valve As a result fluid pres sure opens the down main valve and the down shuttle piston which causes fluid to flow into the upper part of the trim cylinder and forces the tilt piston down When the tilt piston and the free piston reach the trim cylinder base it pushes the base down allow ing the balls to move inward Once the balls move in the trim cylinder is then able to move down and power trim and tilt fluid continues to flow into the cylinder and pushes the trim cylinder down along with the tilt piston and ram The end of the tilt down range is when the tilt piston and the free piston bottom out in the trim cylin der base When the power trim and tilt fluid pushes the trim cylinder down further trim down is started The end of the trim down range is when the trim cylinder arrives at the bottom of the power trim and tilt cylinder Before the trim cylinder arrives at the bottom of the power trim and tilt cylinder an amount of fluid equal to the volume of the ram is returned to the reservoir y
136. r and the dia phragm turn the fuel pump body 1 approximately 90 to a position where the pin can be removed easily and then remove the pin EC S62Y4100 62Y5A11 S62Y4110 3 Slowly let up on the plunger and dia phragm and then remove them Checking the diaphragm and valves 1 Check the diaphragm for tears and the valves for cracks Replace if neces sary o ak BA S62Y4120 Assembling the fuel pump 1 Align the plunger and diaphragm installa tion holes and then install the plunger into the diaphragm 2 Push down on the plunger and the dia phragm and then install the pin OF S62Y4140 3 Turn the fuel pump body 1 2 approxi mately 90 and then push down on the plunger several times to make sure that the pin does not come out 62Y5A11 Fuel filter and fuel pump S62Y4150 Assemble the cover gasket 4 and seal with the screws and then install the fuel pump S S62Y4160 4 6 dl Wu Fuel system Carburetor unit S62Y4170K 62Y5A11 Z o Part name Carburetor unit Remarks o NO O BE MM Carburetor assembly Clip Blowby hose Prime Start coupler Bolt Collar Throttle link rod O ring Insulator Dowel pin Bolt Fuel hose Clip Rivet Acceleration pump Screw Link rod Hose Hose Link rod Carburetor Silencer Plastic tie Blowby hose Bolt Collar O ring Plate O ring O ring Joint 62Y5A11
137. r outlet S62Y1570 Test run 1 Start the engine and then check for smooth gearshift operation 2 Check the engine idle speed after the engine has been warmed up 3 Operate at trolling speed 1 29 4 Run the outboard motor for one hour at 2 000 r min or at half throttle then for another hour at 3 000 r min or at 3 4 throttle 5 Check that the motor will not tilt up when shifting into reverse and that water will not flow in over the transom NOTE Se The test run is part of the break in operation Break in During the test run perform the break in operation in the following four stages 1 Ten minutes at trolling speed 2 Fifty minutes b at 3 000 r min or at approximately half throttle 3 One hour at 4 000 r min or 3 4 throttle and one minute out of every ten at full throttle 4 Eight hours at any speed however avoid running at full speed for more than five minutes ep o pen Al 0 1 2 10 S62Y1580K Hour After test run 1 Check for water in the gear oil 2 Check for fuel leakage in the cowling 3 After a test run and while the engine is at idle flush the cooling water passage with fresh water using the flushing kit 62Y5A11 Specifications General SpeCifICARIONS iii ii ee aie 2 1 Maintenance Specifications eee 2 3 Power Unicas a aH 2 3 Lower unit en A Y GG a dT 2 6 Electrical lada atr s 2 6 Dimensions iii imat eh ehe 2 9 Tightening TOrQUES TEE 2 14 Sp
138. r replacement Gear oil type Gear oil grade Gear oil quantity L US at Imp at L US at Imp at API SAE L US at Imp at Unleaded gasoline leaded gasoline 91 4 stroke motor oil SE SF SG SH 10W 30 10W 40 or 20W 40 2 2 2 3 1 9 2 0 2 1 1 8 Hypoid gear oil GL 4 90 0 61 0 64 0 54 Bracket Trim angle at 12 degree boat transom Tilt up angle Steering angle Degree Degree Degree 69 40 40 Drive unit Gear shift positions Gear ratio Reduction gear type Clutch type Propeller shaft type Propeller direction rear view Propeller identification mark F N R 2 31 30 13 Spiral bevel gear Dog clutch Spline Clockwise K Electrical Battery capacity Minimum cold cranking performance RON Research Octane Number 62Y5A11 2 2 PREG ye Specifications Maintenance specifications Power unit Item Unit Model FT50CEHD FT50CED FT50CET Power unit Minimum compression pressure Lubrication oil pressure at 55 C 131 F with 10W 30 engine oil kPa kgf cm psi kPa kgf cm psi 900 r min 840 8 4 122 100 1 0 14 Cylinder heads Warpage limit lines indicate straightedge position Cylinder head journal inside diameter mm in 37 00 37 02 1 4567 1 4575 Cylinders Bore size Taper limit Out of round limit 63 00 63 01 2 480 2 481 0 08 0 003 0 08 0 003 Pistons Piston diameter
139. r roller bearing outer race and shim s S62Y6760K NOTE Install the claws as shown Cz Bearing outer race puller i 90890 06523 Outer race puller claw A 90890 06532 2 Remove the drive shaft bearing outer race shim s and drive shaft sleeve S62Y6770K NOTE Install the claws as shown CZ Stopper guide plate 90890 06501 Stopper guide stand 2 90890 06538 Bearing puller 5 90890 06535 Bearing puller claw 1 6 90890 06536 3 Remove the needle bearing 62Y5A11 Drive shaft and lower case S62Y6775K CZ Needle bearing attachment D 90890 06611 Driver rod L3 8 90890 06652 Checking the pinion and forward gear 1 Check the teeth of the pinion and the teeth and dogs of the forward gear for cracks or wear Replace if necessary S62Y6780 Checking the bearings 1 Check the bearings for pitting or rum bling Replace if necessary S62Y6785 Checking the drive shaft 1 Check the drive shaft for bends or wear Replace if necessary 6 20 Rn Lower unit Checking the lower case 1 Check the skeg and torpedo for cracks or damage Replace if necessary Assembling the lower case 1 Install the needle bearing into the lower case to the specified depth S62Y6800K NOTE __ gt Install the needle bearing with the manufac ture identification mark facing upward When using the driver rod do not strike the special tool in a manne
140. r that will force the stopper b out of place Cz Driver rod SL 90890 06602 Needle bearing attachment 90890 06611 Bearing depth plate 8 90890 06603 ZX Depth 186 4 188 6 mm 7 34 7 43 in 2 Install the sleeve original shim s and drive shaft bearing outer race S62Y6810K 6 21 CAUTION Add or remove shims if necessary when replacing the pinion or lower case NOTE Apply the gear oil to the inside and outside of the sleeve e Install the sleeve by facing the projection forward Z Bearing outer race attachment 90890 06626 Driver rod LL 6 90890 06605 3 Install the original shim s and taper roller bearing outer race CAUTION Add or remove shims if necessary when replacing the forward gear or lower case GC Bearing outer race attachment 90890 06621 Driver rod LL 90890 06605 Assembling the forward gear 1 Install the new taper roller bearing into the forward gear using a press 62Y5A11 Drive shaft and lower case NOTE Zn Use the special service tool or a general pipe with the specified measurements qa Bearing inner race attachment 90890 06643 Installing the pinion 1 Install the forward gear then the drive amp Z Bearing inner race attachment D shaft assembly pinion and pinion nut 90890 06662 and then tighten the nut to the specified torque 2 Install the new needle bearing into the forward gear to the sp
141. rcuit breaker 1 12 Brush spring 2 13 PTT motor base 1 14 Oil seal 1 7 43 62Y5A11 Checking the power trim and tilt motor 1 Check the commutator for dirt or foreign substances Clean with 600 grit sand paper if necessary S62Y7900 2 Check the commutator undercut for dirt or foreign substances Clean with com pressed air if necessary 3 Measure the commutator diameter Replace if out of specification S62Y7910 ZX Commutator diameter limit 21 mm 0 83 in 4 Check the armature coil for continuity Replace if out of specifications S62Y7920 62Y5A11 Power trim and tilt motor S62Y7925 Armature coil continuity Commutator segments Continuity Segment laminations No continuity Segment shaft No continuity 5 Check the circuit breaker for continuity Replace if there is no continuity S62Y7930 6 Measure the brush length Replace if out of specification S62Y7940 ZX Brush length limit 3 5 mm 0 14 in 7 44 PASI E d Bracket unit 7 Check the base for cracks or damage Replace if necessary Check the bushing for damage or wear Replace if necessary S62Y7950 Assembling the power trim and tilt motor 1 Install the oil seal and the bushing into the motor base G as shown S62Y7960 Attach the circuit breaker 4 onto brush 1 together with the brush holder and connect the
142. res see Chapter 3 Replacing the gear oil 2 Set the gearshift to the neutral position and place a block of wood between the anti cavitation plate and propeller to keep the propeller from turning and then remove the propeller nut and propeller S62Y6490K S62Y6485 5 Loosen the bolts and then remove the lower unit from the upper case Do not hold the propeller with your hands when loosening or tightening it Be sure to remove the battery leads from the bat teries and the engine shut off switch Put a block of wood between the cavitation plate and propeller to keep the propeller from turning 3 Disconnect the speedometer hose 4 Mark the trim tab at the area shown and then remove it S62Y6500K 62Y5A11 6 6 EE Lower unit Water pump and shift rod S62Y6525 62Y5A11 6 7 Part name Water pump and shift rod Remarks Shift rod assembly Oil seal Oil seal housing O ring Circlip Shift rod O ring Bolt Woodruff key Bolt Bolt Water pump housing Grommet Gasket Insert plate cartridge Impeller Outer plate cartridge Gasket Dowel pin Oil seal housing assembly Gasket Oil seal housing O ring Oil seal 62Y5A11 YN sch ny MN py N Not reusable Not reusable 49 4 x 3 1 mm Not reusable Not reusable Not reusable Not reusable 46 2 x 3 1 mm Not reusable 6 8 ld Lower unit Removing the water
143. ro tilt for cracks or corrosion Replace if neces sary S 2 Check the inner walls of the trim cylinder Ca and tilt cylinder for scratches Replace if necessary es 3 Check the outer surface of the tilt piston S62Y7550 and free piston for scratches Replace if necessary 3 Remove the gear pump bracket 6 then the down shuttle piston G and up shuttle 4 Check the tilt ram for bends or excessive piston corrosion Polish with 400 600 grit sandpaper if there is light rust or replace if necessary O Check the valves 1 Check the operation of the check valve of the trim cylinder end screw and check the valve for dirt or residue Clean if necessary S62Y7560 4 Remove the gear pump cover 9 then the down main valve and up main valve 09 5 Remove the drive gear 2 and driven gear 3 S62Y7610 2 Check the operation of the tilt piston absorber valve and check for dirt or resi due Clean if necessary O ING w S62Y7570 co KOM O S62Y7620 Checking the tilt cylinder and trim cylinder 3 Check the down main valve and the up main valve 2 for dirt or residue Clean if necessary 62Y5A11 7 36 RHAI bd Bracket unit 4 Check the down relief valve 3 up relief valve 4 and shuttle pistons for dirt or residue Clean if necessary S62Y7630 Checking the filters 1 Check the gear pump filter and shuttle piston filters 2 for dirt or residue Clean if neces
144. sary S62Y7640 Checking the gear pump 1 Check the drive gear driven gear and shaft for damage or excessive wear Replace if necessary 0 S62Y7650 Assembling the gear pump 1 Install the drive gear driven gear Q shaft and pins 4 into the gear pump housing 6 7 37 2 Install the balls into the gear pump housing 6 3 Install the down main valve 7 and up main valve 8 4 Install the gear pump cover 9 S62Y7660 5 Install the shuttle pistons 0 into the gear pump cover 9 6 Install the balls into the gear pump cover 9 with the manual release spring 2 7 Install the gear pump bracket 3 by installing the bolts then tightening them to the specified torque S62Y7670 Gear pump bracket bolt 3 5 3 N m 0 53 kgf m 3 8 ft lb 8 Install the down relief valve 5 up relief valve 8 and filter 7 62Y5A11 S62Y7680 Relief valve bracket bolt 49 5 3 N m 0 53 kgf m 3 8 ft lb 10 Install the filters and gear pump by installing the bolts then tightening them to the specified torque 11 Install the manual valve and reservoir cap amp S62Y7690 62Y5A11 Gear pump 9 Install the relief valve bracket by installing the bolts 9 then tightening them to the specified torque Gear pump bolt 2 6 5 N m 0 65 kgf m 4 7 ft lb 12 Fill the reservoir with the recommended fluid to the correct level as show
145. set its width PLA by O Previous contact width 7 If the valve seat contact area is too nar row and situated near the top edge of the valve face use a 30 cutter to cut the top edge of the valve seat If necessary use a 45 cutter to center the area and set its width 5 29 AA S62Y5470 Previous contact width 8 Ifthe valve seat contact area is too nar row and situated near the bottom edge of the valve face use a 60 cutter to cut the bottom edge of the valve seat If neces sary use a 45 cutter to center the area and set its width N S62Y5480 b Previous contact width 9 Apply a thin even layer of lapping com pound onto the valve seat and then lap the valve using a valve lapper commer cially obtainable S62Y5500 CAUTION Do not get the lapping compound on the valve stem and valve guide 62Y5A11 10 After every lapping procedure be sure to clean off any remaining lapping com pound from the cylinder head and the valve 11 Check the valve seat contact area of the valve again Checking the rocker arms and rocker arm shaft 1 Check the rocker arms rocker arm shaft and rocker arm contact surface for wear Replace if necessary 2 Measure the rocker arms inside diameter and rocker arm shaft outside diameter Replace if out of specification S62Y5510 Rocker arm inside diameter 16 00 16 01 mm 0 6299 0 6303 in Rocker arm shaft outside
146. sions is for detecting the engine speed Two of them are used for ignition signals and one is used for identifying the cylinders and these signals are transmitted to the microcomputer 1 15 62Y5A11 Technical tips Pulser coil The pulser coil transmits the pulser signals which are generated in the pulser coil in accordance with the rotation of the flywheel to the CDI unit Among the two protrusions that are provided for generating signals one is used for cylinders 1 and 4 and the other for cylinders 2 and 3 thus enabling the pulser coil to simultaneously ignite two cylinders To provide ignition signals to the cylinders the microcomputer determines the ignition cylinder and ignition timing These are based on the cylinder identification signals generated by the protrusion for identifying cylinders and on the pulser signals generated by the protrusions for generating ignition signals S62Y1320 Flywheel Rotating direction G Protrusion for cylinders 1 and 4 Pulser coil 6 Cylinder identification protrusion 6 Protrusion for cylinders 2 and 3 62Y5A11 1 16 dm Y General information Ignition timing control Control circuit diagram Operation Detection Microcomputer Ignition timing control mm Positive start optimized ignition 3 timing gt Quick acceleration Engine start Engine temperature Acceleration WY Engine speed
147. ss for continuity Replace if there is no continuity Checking the neutral switch 1 Check the neutral switch for continuity Replace if there is no continuity S62Y8330 Lead color Brown Br Brown Br O o Checking the starter relay 1 Connect the digital circuit tester leads to the starter relay terminals 2 Connect the brown Br lead to the posi tive battery terminal 3 Connect the black B lead to the nega tive battery terminal 62Y5A11 Starting system Check for continuity between the starter relay terminals Replace if there is no continuity Check that there is no continuity between the starter relay terminals after discon necting the brown or black lead Replace if there is continuity S62Y8340 8 16 ERES W s Electrical systems Starter motor ESOO Y S62Y8350K 62Y5A11 8 17 Starter motor Z o DJ O O BE MM Part name Remarks Clip Pinion stopper Spring Starter motor pinion Upper bracket O ring Washer 1 Shim Washer 2 Armature Stator O ring As required Not reusable Brush holder assembly Brush set O ring Washer Spring washer Nut Lower bracket Screw Bolt Not reusable M4 x 12 mm M5 x 125 mm N po do do do 62Y5A11 8 18 Far Electrical systems Removing the starter motor pinion 1 Slide the pinion stopper down as shown and then remove the clip
148. ssion pressure of power unit Fuel system Check that the fuel vent screw of the fuel tank is open Is the vent screw open Open the fuel vent screw Yes Check for water or residue in the fuel filter Check the fuel hose for kinks or fuel leakage Water or resi due Kinks or fuel leakage Clean the fuel system from the fuel tank to the fuel filter Check the fuel Replace the respective parts pump operation Check the carbure tors Good operat ing condition No Replace the fuel pump 62Y5A11 9 4 TRBL 1 SHTG e Troubleshooting Ignition system Check the ignition spark gap using the spark gap tester Out of specifi cation Check the ignition system out put peak voltage Replace the spark plug Compression pressure e Check that there is no secondary air intake on the contact surfaces of the intake manifold and crankcase Is there air intake Replace the respective seals Check the compression pres sure of the combustion chamber 9 5 62Y5A11 Power unit Symptom The engine idle speed is not steady but increases or decreases Check the carburetors Check the air intake system Check the ignition system Check the operation of the car buretor throttle valves Do the valves close simul
149. ssor 6 90890 04019 Valve spring compressor attachment D 90890 06320 Checking the valve springs 1 Measure the valve spring free length Replace if out of specification a S62Y5300 ZX Valve spring free length limit amp 37 85 mm 1 490 in 2 Measure the valve spring tilt Replace if out of specification S62Y5310 ZX Valve spring tilt limit 1 7 mm 0 07 in Checking the valves 1 Check the valve face for pitting or wear Replace if necessary 2 Measure the valve margin thickness 8 Replace if out of specification 62Y5A11 Cylinder head a Valve stem runout Intake 0 03 mm 0 0012 in Exhaust 0 03 mm 0 0012 in CH Checking the valve guides 1 Measure the valve guide inside diameter Replace if out of specification S62Y5320 Valve margin thickness amp Intake 0 6 1 0 mm 0 024 0 039 in Exhaust 0 7 1 1 mm 0 028 0 043 in 3 Measure the valve stem diameter S62Y5350 Replace if out of specification Valve guide inside diameter limit 5 50 5 51 mm 0 2165 0 2169 in Replacing the valve guides 1 Remove the valve guide by striking the special service tool from the combus tion chamber side S62Y5330 Valve stem diameter Intake 5 48 5 49 mm 0 2157 0 2161 in Exhaust 5 46 5 47 mm 0 2150 0 2153 in S62Y5360 4 Measure the valve stem runout Replace if out of specification Valve guide remover inst
150. stigauge PG 1 Crankshaft main journal oil clearance 0 012 0 036 mm 0 0005 0 0014 in 6 Ifthe oil clearance is below specification check the main bearing color and clean the contact surface of the cylinder body and the main bearing and then check the main journal oil clearance again 7 If the oil clearance is over specification install an oversized main bearing and then check the main journal oil clearance again Selecting the connecting rod big end bearing 1 When replacing the connecting rod bear ing select the suitable connecting rod bearing as follows 2 Check the crank pin mark on the crank shaft and the connecting rod cap mark or painted color on the connecting rod S62Y5A10 Cylinder Crankshaft Bearing body mark journal mark color A Yellow Red Pink Green 5 45 62Y5A11 Cylinder body 3 Select the suitable color for the con necting rod bearing from the table Crank pin oil clearance 0 016 0 040 mm 0 0006 0 0015 in 6 If the oil clearance is below specification check the connecting rod bearing color and clean the contact surface of the con necting rod and the connecting rod bear ing and then check the crank pin oil clearance again 7 If the oil clearance is over specification install an over sized connecting rod bear ing and then check the crank pin oil clearance again Assembling the cylinder body 1 Assemble the
151. t rod push arm 90890 06052 3 Install the special service tool so that it pushes against the propeller shaft S62Y6955K NOTE Tighten the universal puller or center bolt while turning the drive shaft until the drive shaft can no longer be turned qe Bearing housing puller claw L i 90890 06502 Stopper guide plate 2 90890 06501 Center bolt 3 90890 06504 4 Install the backlash indicator onto the drive shaft 18 mm 0 71 in in diameter then the dial gauge onto the lower unit S62Y6960K 62Y5A11 Shimming Backlash NOTE Install the dial gauge so that the plunger contacts the mark on the backlash indica tor 2 Backlash indicator 90890 06706 Magnet base plate 6 90890 07003 Dial gauge set 90890 01252 Magnet base 90890 06705 5 Slowly turn the drive shaft clockwise and counterclockwise and measure the back lash when the drive shaft stops in each direction Forward gear backlash 0 12 0 45 mm 0 005 0 018 in 6 Add or remove shims if out of specifica tion Fu a Shim thickness Less than To be decreased by 0 12 mm 0 005 in 0 29 M x 0 57 More than To be increased by 0 45 mm 0 018 in M 0 29 x 0 57 M Measurement Available shim thicknesses 0 10 0 12 0 15 0 18 0 30 0 40 and 0 50 mm 7 Remove the special service tools from the propeller shaft 62Y5A11 6 28 Bracket unit Special Service tools 2 ee
152. t the projection 8 of the bearing into the slot on the cap and connecting rod 5 Install the piston with the UP mark on the piston crown facing towards the fly wheel S62Y5A70J NOTE _ gt Apply engine oil to the piston assembly before installation Piston slider 90890 06529 62Y5A11 Cylinder body 6 Install half of the bearings 9 into the cyl inder body 09 S62Y5A81K NOTE Insert the projection P of the bearing into the notch in the cylinder body 7 Set the crankshaft and oil seals gt SES and 3 into the cylinder body as shown Apply engine oil to the inner oil seal jour nal bearings and connecting rod bear ing NOTE Align the alignment marks on the connect ing rod cap and connecting rod Connecting rod bolt 1st 6 N m 0 6 kgf m 4 3 ft Ib 2nd 17 N m 1 7 kgf m 12 ft lb 9 Install half of the bearings into the crankcase then dowel pins 5 S62Y5A50 8 Install the connecting rod cap to the connecting rod and then tighten the con necting rod bolts to the specified torques in two stages Apply engine oil to the connecting rod cap and connecting rod bolt 62Y5A11 5 48 10 Apply Gasket Maker to the mating sur face of the crankcase S62Y5A90 AUTE e Insert the projection of the bearing into the notch in the crankcase Do not get any Gasket Maker on the journal bearings 11 Install the crankcase bolts
153. the throttle gear 1 Inject grease into the grease nipple until grease comes out from the screw hole S62Y7130 Checking the shift rod assembly operation 1 Check the shift rod assembly and detent for smooth operation S62Y7160K 62Y5A11 SS bd Bracket unit Upper case 42 N m 4 2 kgf m 30 ft Ib 21 S62Y7170K 7 11 62Y5A11 Upper case Z o o NO O BE O MM Part name Remarks Upper case Nut Nut Washer Bolt Upper mount Plate Bolt Cap Bolt Grommet Ground lead Screw M8 x 30 mm M8 x 175 mm M12 x 160 mm Mount cover Bolt Mount housing Spring Washer Rubber washer M8 x 25 mm Lower mount Washer Grease nipple Muffler assembly Muffler seal Rubber seal Dowel pin Grommet Guide Damper Screw Baffle plate Bolt Drive shaft bushing Circlip M5 x 16 mm M8 x 30 mm A AND ch He ch MD ch ch zk zk MM MM SM EC MM D D MD MD HA a D D ND ND 62Y5A11 7 12 RASI XxX Bracket unit dt DER ae aal S62Y7200 62Y5A11 7 13 Upper case Part name Remarks Not reusable Z o o NO O BE O Mm Oil seal Exhaust guide Grommet Grommet Anode Cover Bolt Cover Bolt Gasket Dowel pin Bolt Oil pan Gasket Exhaust manifold Bolt Gasket Gasket Bolt Muffler Gasket Pipe Rubber seal Gasket Relief valve housing Bolt Bolt Bolt Oil strainer Relief valve Spring Cotter pin
154. tion PUMP 1 13 Adjusting the dash pot acceleration pump 4 15 Adjusting the pilot SCTEW 4 13 Adjusting the throttle link rod 4 13 Adjusting the trim sensor 7 20 After test mun 1 29 Applicable models 1 4 Assembling the carburetor 4 12 Assembling the cylinder body 5 46 Assembling the drive shaft 6 22 Assembling the forward gear 6 21 Assembling the fuel pump 4 6 Assembling the gear pump 7 37 Assembling the lower case 6 21 Assembling the oil pan 7 15 Assembling the power trim and tilt motor 7 45 Assembling the propeller shaft assembly 6 15 Assembling the propeller shaft housing 6 15 Assembling the tiller handle 7 9 Assembling the tilt cylinder 7 40 Assembling the trim cylinder 7 38 Backlash AA 6 27 Bleeding the power trim and tilt built in 7 42 Bleeding the power trim and tilt C not installed 7 41 Bottom Cowltmg nennen 7 7 Bracket unit 9 10 Br cial 1 29 GCarburetol nue ti 1 8 4 9 Carburetor unt 4 7 CDI unit with microcomputer seseeeeeeeee 1 6 Charging system 8 21 Check the valves 7
155. tion to make procedures easier or clearer FT50C SERVICE MANUAL 2001 by Yamaha Motor Co Ltd 1st Edition June 2001 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in the Netherlands Contents General information z Specifications 0 y m o E Periodic checks and adjustments O I A gt I qj Fuel system i gt TI C m r Ol Lower unit O Bracket unit N Electrical systems 00 m D JIN y o d 0 Es Ze HJ O JD JJ Ww Troubleshooting co Oo T 6 ino T General information How to use this Mandala ie 1 1 Manual to Mati 1 1 A EE EEE EEE EN 1 2 Safety while working 00 ii 1 3 Fire Prevention te ne er 1 3 Ventilation 5 sasa san tea tnt nan 1 3 ue llis protectio es EEDD RR RR GN AH FU RH FFO aga dan tias 1 3 Parts lubricants and sealants oooccccconncnncnococnnonnoncncnnnononnonnnnonrononnnnconos 1 3 Good working practices EE 1 4 Disassembly and assembly 1 4 Identification aiii nido 1 4 Applicable models did 1 4 Serial DUU ege deeg me tats atacat lic alarma RY 1 4 Features and benefits ic A as 1 5 Use of leaded gasoline ss 1 5 Newly designed four carburetors 1 5 CDI unit td Ba tte eu EE 1 6 LOWER Unai
156. uge 90890 03160 4 Fully open the throttle crank the engine until the reading on the compression gauge stabilizes and then check the compression pressure ZX Minimum compression pressure 840 kPa 8 4 kgf cm 122 psi 5 If the compression pressure is below specification and the compression pres sure for each cylinder is unbalanced add a small amount of engine oil to the cylin der and then check the pressure again NOTE If the compression pressure increases check the piston and piston rings for wear Replace if necessary 5 13 e If the compression pressure does not increase check the valve clearance valve valve seat cylinder sleeve cylinder head gasket and cylinder head Adjust or replace if necessary Checking the oil pressure 1 Start the engine warm it up for 5 min utes and then turn it off 2 Remove the oil pressure switch and then install an oil pressure gauge to the oil pressure switch installation hole S62Y5066 NOTES Use a pressure gauge with an adapter with a 1 8 pitch thread 3 Check the oil pressure Check the oil pump oil suction pipe and oil strainer if out of specification Oil pressure 100 kPa 1 0 kgf cm 14 psi at idle speed 850 950 r min Removing the power unit 1 Remove the flywheel magnet cover and flywheel magnet S62Y5070J 62Y5A11 Power unit S62Y5080J S62Y5075 CAUTION Apply force in the direction of the
157. ulate the pinion shim thickness T3 as shown in the examples below S62Y6920 NOTE 0 P is the deviation of the lower case dimen sion from standard The P mark is stamped on the trim tab mounting surface of the lower case in 0 01 mm units If the P mark is unreadable assume that P is zero and check the backlash when the unit is assembled Pinion shim thickness T3 M 31 50 mm P 100 62Y5A11 Example If M is 32 10 mm and P is 5 then T3 32 10 31 50 5 100 mm 0 60 0 05 mm 0 55 mm If M is 32 10 mm and P is 5 then T3 32 10 31 50 5 100 mm 0 60 0 05 mm 0 65 mm 5 Select the pinion shim s T3 as follows Calculated numeral at 1 100 place 0 1 2 3 4 5 6 Rounded numeral 8 9 Available shim thicknesses 0 10 0 12 0 15 0 18 0 30 0 40 and 0 50 mm Example If T3 is 0 59 mm then the pinion shim is 0 60 mm If T3 is 0 64 mm then the pinion shim is 0 65 mm Selecting the forward gear shims 1 Turn the taper roller bearing outer race two or three times to seat the rollers and then measure the bearing height M as shown S62Y6925 62Y5A11 Shimming S62Y6930 NOTE 0 Select the shim thickness T1 by using the specified measurement s and the calcula tion formula Measure the bearing outer race at three po
158. ust be screwed in a minimum of 8 0 mm 0 31 in 5 Connect the cable joint install the clip and then tighten the locknut 6 Check the throttle cable for smooth oper ation and adjust the cable length if nec essary repeating steps 2 6 Checking the gearshift operation 1 Check that the gearshift operates smoothly when shifting from neutral into forward and reverse Adjust the shift cable length if necessary 2 Set the gearshift to the neutral position 3 Loosen the locknut i remove the clip 2 and then disconnect the shift cable joint 3 62Y5A11 S62Y3340 4 Align the set pin in the center of the shift bracket with the alignment mark b on the bracket S62Y3350 5 Adjust the position of the shift cable joint until its hole is aligned with the set pin S62Y3360 CAUTION The shift cable joint must be screwed in a minimum of 8 0 mm 0 31 in 6 Connect the cable joint install the clip and then tighten the locknut 7 Check the gearshift for smooth operation and adjust the shift cable length if nec essary repeating steps 3 6 Checking the engine idle speed 62Y5A11 Power unit Control system 1 Start the engine and warm it up for 5 min utes 2 Attach the special service tool to high tension cord 41 G and then check the engine idle speed Adjust if out of specifi cation El Engine idle speed 850 950 r min 3 Turn the throttle st

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