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SERVICE MANUAL

1. ccccsseceeeeeeseeeeneeeeseeeeeaeees 6 9 Drive shaft and lower CaSe r snnurnanurnnnuunnnnunnnnnunnnnuennnnvennnnennnnvennnnennnnvennnnennn 6 10 Removing the drive shaft esses nennen nnne 6 11 Disassembling the lower case cccccccececececeecceeceeeceeeceeeseeeseeeseeeseeess 6 11 Checking the pinion and forward QeEa cccsccccseseecseeeeeeeeeeeeeeseeeeeseeeess 6 12 Checking the drive shaft sees 6 12 Checking the lower case ooccccccncccccncoconncconocononoconnnnonanononnnnonannnenannnnanos 6 12 Assembling the lower CaSe rrrnnnrnnnnrnenennunennnnevnnrnnenennnennnnernanennunennnennnne 6 12 installing the ANE SA sassanidene 6 13 Installing the propeller shaft housing ccccseeeeseeeeceeeeeseeeeseeeeesaeeenees 6 14 Installing the water pump and shift rod rrrrrernnrrrarernnnevnnnnvarennnnennnnnnnnen 6 14 Installing the lower UNIt 00 cece eee nenne ee eee HH EFE HALE HR mn 6 15 69M3E11 Lower unit Special service tools Bushing attachment 90890 06649 90890 06650 Driver rod L3 90890 06652 Needle bearing attachment 90890 06615 90890 06617 Bearing puller 90890 06535 O Stopper guide plate 90890 06501 Stopper guide stand 90890 06538 gt Bearing puller claw 2 90890 06537 Ball bearing attachment 90890 06637 90890 06638 M Driver rod LS 90890 06606 69MSE 11 Special service tools Lower
2. SERVICE MANUAL 290470 69M 28197 3E 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 information to make procedures easie
3. 2 Install the dowels 2 new O ring and outer plate cartridge 69M3E11 Drive shaft and lower case S69M6380 NOTE ey Apply Yamabond No 4 to both sides of sec tion of the gasket 3 Install the dowel 7 into the drive shaft 4 Align the groove on the impeller 8 with the dowel and then install the impeller onto the drive shaft Ma 8 YN RE 3 a S69M6390 NOTE Check the dowel 7 for wear Replace if nec essary 6 14 Lower unit 5 Install the new O ring and insert car tridge 40 into the water pump housing A S69M6400 NOTE Align the insert cartridge projection with the hole in the water pump housing 6 Install the water pump housing assembly 3 to the lower case S69M6410 AE A A A When installing the water pump housing apply grease to the inside of the housing and then turn the drive shaft clockwise while pushing the water pump housing down Installing the lower unit 1 Set the gear shift to the neutral position at the lower unit 569M6420 569M6430 2 Install the lower unit to the upper case S69M6440 L transom model NOTE Ze Align the rubber seal projection 8 with the hole in the water pump housing 69MSE 11 Drive shaft and lower case 3 Install the shift rod to the joint and then tighten the bolt to the specified WARNING
4. Periodic checks and adjustments MEMO 69M3E11 69M3E11 Fuel system Special Service 10018 saus 4 1 o mese gen etat EaR 4 2 ueland DIOWDY NOSES nn san 4 2 gib Gee aos 4 3 Carburetor and intake silencer eere eeee eee 4 4 CAME ect MC DE RN 4 5 Draining tnertuel tr 4 7 Checking the fuel tank and fuel filler cap sees 4 7 CneckIng the Tuel fier ve 4 7 GNECKING NE fuel COCK s sken 4 7 Checking the Carburetor anne 4 7 Assembling the carburetor rr arvrnnnennannvnnnnnenennnernnnernnnennnnnnnnennunennuvennneene 4 9 Iristalling ine carbur tbr iii ai sanden ai 4 9 Installing the throttle Cable 4 10 Adjusting the DIIOESCEQW aan Sen a need e Dus 4 10 vet py Fuel system Special service tools Digital tachometer 90890 06760 Pilot screw wrench 90890 03154 4 1 69M3E11 Hose routing Fuel and blowby hoses TD Doo AAN f NLA ED EA _ p ADN PJ un a IE 0 SR TNC T SE SJ LL e rata ER ie AY D 1 ae NS R IES ai as 9 N kst KAADA l N X Fuel hose 2 Blowby hose 3 Blowby hose 69M3E11 Special service tools Hose routing Pa tal gt I e EN EF 4 TR nN JDC ATT AAA A AE OL Eid H NOR me S EAN ms ed WL SANE LZ S69M4000 4 2 roe Fuel sy
5. 0 0079 0 0276 in Measuring point 8 10 mm 0 39 in Checking the piston ring grooves 1 Measure the piston ring grooves Replace the piston if out of specification S69M5590 Piston ring groove Top ring 1 03 1 05 mm 0 040 0 041 in Second ring 1 21 1 23 mm 0 047 0 048 in Oil ring O 2 01 2 03 mm 0 079 0 080 in 69M3E11 Cylinder block Checking the piston ring side clearance 1 Measure the piston ring side clearance Replace the piston and piston rings as a set if out of specification S69M5600 Piston ring side clearance Top ring 0 04 0 08 mm 0 0016 0 0031 in Second ring b 0 02 0 06 mm 0 0008 0 0024 in Oil ring 0 06 0 16 mm 0 0024 0 0063 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 12 009 12 017 mm 0 4728 0 4731 in 5 26 Checking the piston pin 1 Measure the piston pin diameter Replace if out of specification S69J5C30 Piston pin diameter 11 996 12 000 mm 0 4723 0 4724 in Checking the connecting rod small end inside diameter 1 Measure the connecting rod small end inside diameter 8 Replace the connect ing rod if out of specification S69M5650 Connecting rod small end inside diameter 3 12 006 12 020 mm 0 4727 0 4732 in Checking the connecting rod big end side clearance 1
6. 9 5 Checking the compression pressure 5 7 Checking the TCI unit air gap 3 9 Checking the connecting rod big end Checking the thermostat 3 6 side cled aN Guana 5 27 Checking the valve clearance 3 4 Checking the connecting rod small end Checking the valve guides 5 16 inside diameter 5 27 Checking the valve lifters 5 30 Checking the cooling water passage 3 7 Checking the valve seat 5 18 Checking the cooling water pilot hole 1 17 Checking the valve springs 5 15 Checking the crankpin oil clearance 5 28 Checking the valves 5 16 Checking the crankshaft 5 27 Checking the water pump and shift rod 6 6 Checking the cylinder bore 5 25 Control System au 3 7 Checking the cylinder head 5 20 Cooling water flow chart 1 14 Checking the drive shaft 6 12 CylinderblocK uu oe eer OA 5 22 Checking the engine idle speed 3 7 Cylinder head eeeeessseeeees 5 12 Checking the engine oil 1 16 3 3 Checking the engine shut off A t 1 17 8 5 Checking the fuel cock 4 7
7. L Weight L Performance Maximum output KW hp 1 8 2 5 at 5 500 r min Full throttle operating range r min 5 250 5 50 Maximum fuel consumption L US gal 1 1 0 29 0 24 Imp gal hr at 5 500 r min Power unit Type 4 stroke single cylinder OHV Cylinder quantity 1 Displacement cm cu in 72 4 4 Bore x stroke mm in 54 0 x 31 5 2 13 x 1 24 Compression ratio 9 0 Control system Tiller control otarting system Manual starter Enrichment system Choke valve Ignition control system TCI Ignition timing BTDC 30 opark plug BR6HS NGK Cooling system Water Exhaust system Under water Lubrication system Splash Includes an aluminum propeller and excludes oil and fuel 2 1 69M3E11 General specifications Fuel and oil Fuel type Regular unleaded gasoline Fuel rating PON 86 RON 91 Fuel tank capacity L US gal 0 9 0 24 0 20 Imp gal Engine oil type 4 stroke motor oil Engine oil grade API SE SF SG SH or SJ SAE 10W 30 or 10W 40 Engine oil quantity L US gal 0 35 0 09 0 08 Imp gal Gear oil type Hypoid gear oil Gear oil grade SAE 90 Gear oil quantity cm US oz 75 2 5 2 6 Imp oz Bracket Trim angle O 4 8 12 at 12 degree boat transom Tilt up angle 80 Steering angle Drive unit Gear shift positions F N Gear ratio 2 08 27 13 Reduction gear type Straight bevel gear Clutch type Dog clutch Propeller shaft type Spline Propeller direction Clockwise rear view Propeller i
8. 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 initial Every Every Referto Item Remarks 10 ae 50 hours 100 hours 200 hours er Break in 8 months 6 months 1 year pag Fuel system Fuel line Check 3 3 Fumer Tome o o o 99 Engine oil Change Valve clearance Check adjust Spark plug Clean adjust replace Thermostat Check Outboard motor Check exterior Cooling water passage Clean O Control system Carburetor Check Engine idle speed Adjust Ignition timing Check TCI unit air gap Check adjust Lower unit Gear oil Change 3 10 Propeller Check 3 11 Anodes Check replace 3 11 Bolts and nuts Tighten Lubrication points Lubricate 3 12 NOTE e The engine should be flushed with fresh water after operating in salt turbid or muddy water e f leaded gasoline is used regularly check the engine valves and related parts every 100 hours of operation in addition to the items in the maintenance interval chart 69M3E11 3 2 IR ADJ Periodic checks and adjustments Fuel system Checking the fuel line 1 Check the fuel tank for leaks Replace if necessary Also check the fuel hose for leaks and deterioration and the car buretor Y and fuel cock for leaks Replace if necessary S69M3010 Chec
9. Checking the fuel filter 3 3 4 7 Checking the fuel line 3 3 i 1 69M3E11 D DIMENSIONS nee aa Ns 2 6 Disassembling the crankcase 5 31 Disassembling the cylinder block 5 30 Disassembling the cylinder body 5 24 Disassembling the lower case 6 11 Disassembling the manual starter 5 7 Disassembling the propeller shaft assembly EE 6 8 Disassembling the propeller shaft NON TN 6 8 Disassembly and assembly 1 4 Draining Ne Tue 4 7 Drive shaft and lower case 6 10 E BICC Al S 2 5 Electrical components 8 2 F Features and benefits 1 6 Fire prevention cccccccseecceeeceeeeceeeeeeeeaees 1 3 Fuel and blowby hoses 4 2 mU EIE 3 9 Fuel tane eit br oh os i OO e 4 3 G GN 3 11 General specifications 2 1 General torques cccoccccccnccncccoccnnconcnnnnonononos 2 9 Good working practices 1 4 H HOSE COU Oi id 4 2 How to use this manual 1 1 l Idenliiicallonss ern 1 5 Idle silencer eese 1 9 Ignition system sees 1 6 8 4 Installing the Carburetor 4 9 Installing the drive
10. Measure the connecting rod big end side clearance 8 Replace the connecting rod or crankshaft or both if out of specifi cation 5 27 S69M5660 Connecting rod big end side clearance 3 0 2 0 6 mm 0 008 0 024 in Checking the crankshaft 1 Check the teeth of the crankshaft gear for damage or wear Replace if neces sary S69M5670 2 Measure the crankpin diameter and crankpin width b Replace the crank shaft if out of specification S69M5680 69M3E11 S69M5690 Crankpin diameter 23 969 23 984 mm 0 9437 0 9443 in Crankpin width 21 0 21 1 mm 0 827 0 831 in 3 Measure the crankshaft runout Replace the crankshaft if out of specification S69M5610 Crank stand alignment 90890 03107 Crankshaft runout limit 0 01 mm 0 0004 in Checking the crankpin oil clearance 1 Clean the connecting rod 2 Put a piece of Plastigauge PG 1 onto the crankpin parallel to the crankshaft 69M3E11 Cylinder block S69M5620 NOTE Be sure not to put the Plastigauge PG 1 over the oil hole in the crankpin of the crank shaft 3 Install the connecting rod to the crankpin S69M5630 NOTE Align the marks 8 on the connecting rod cap and connecting rod 5 28 4 Tighten the connecting rod bolts 2 to the specified torques in two stages S69M5640 NOTE y e Reuse the removed connecting rod bolts when checking the oil
11. break in period With the smallest engine and lowest output the idle speed tends to rise by the reduction of the engine internal friction due to the break in 1 Warm the engine up for 5 minutes and then turn it off 2 Attach the special service tool to the spark plug wire 1 o US y eg AT TEX PS A Digital tachometer 90890 06760 3 Stan the engine and then check the engine idle speed Adjust if out of specifi cation Engine idle speed 1 800 2 000 r min des i General information 4 Turn the throttle stop screw in direc tion or until the specified idle speed is obtained NOTE HA KA AAA e To increase the idle speed turn the throttle stop screw in direction 8 e To decrease the idle speed turn the throttle stop screw in direction b 5 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 If necessary repeat steps 3 5 1 19 69M3E11 Specifications General Specification eL 2 1 Maintenance specifications rannnnnnnnnnnnnnnnnnnnnnnnnennnnnnnnnnnnnennnnnnnnennnnennnennnnen 2 3 FN lo e EUR 2 3 EEMO lemes TTE 2 5 DMEM ON NNN 2 6 TIGNENNG TOUS cwn 2 8 SPECT AES ae 2 8 Genera ITS OS O an e od 2 9 69M3E11 63 Specifications General specifications iom Unit F2 5AMH Dimension Overall length Overall width Overall height S L Boat transom height
12. cutter DUNT NT S62Y 5430 2 Valve seat cutter holder 90890 06316 Valve seat cutter 30 90890 06328 45 90890 06312 60 90890 06315 5 18 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 S69M5410 S69J5870 amp Slag or rough surface CAUTION Do not over cut the valve seat Be sure to turn the cutter evenly downward at a pres sure of 40 50 N 4 5 kof 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 gt 30 S69M5B00 D Previous contact width 4 Use a 60 cutter to adjust the contact width of the bottom edge of the valve seat 5 19 7 60 569J5890 b Previous contact width 5 Use a 45 cutter to adjust the contact width of the valve seat to specification Se 457 D Previous contact width Specified contact width 569J5900 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 and a 60 cutter to cut the bottom edge to center the area and set Its width Ne 60 S69M5B10 30 b Previous contact width 69MSE 11 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 neces
13. 0 kgf m 7 4 ft lb 7 Install the cylinder head cover fuel tank bolts spark plug bottom cowling 2 fuel cock lever and carrying handle Checking the spark plug 1 Remove the grommet 1 S69M3110 2 Disconnect the spark plug cap from the spark plug and then remove the spark plug 69M3E11 3 Clean the electrodes 2 with a spark plug cleaner or wire brush Replace the spark plug if necessary S69M3120 4 Check the electrodes for erosion and excessive carbon or other deposits and the gasket for damage Replace the spark plug if necessary 5 Check the spark plug gap Adjust if out of specification S69J3200 Specified spark plug BR6HS NGK Spark plug gap 3 0 6 0 7 mm 0 024 0 028 in 6 Install the spark plug tighten it finger tight O then to the specified torque with a spark plug wrench 569J3210 69MSE 11 Power unit Spark plug 25 N m 2 5 kgf m 18 4 ft lb Checking the thermostat 1 Remove the fuel tank D manual starter 2 flywheel magnet cover thermostat cover 4 and thermostat 5 S69M3130 ds WARNING Before removing the fuel tank fuel hose and carburetor let the fuel drain com pletely 2 Suspend the thermostat in a container of water 3 Place a thermometer in the water and slowly heat the water S69J5E40 3 6 BSR ADJ Periodic checks and adjustments 4 Check the thermostat valve opening at th
14. 1 Install the bushing into the propeller shaft housing 9M6210 NOTE xi n Insert the dog clutch into the bushing slit at a 90 angle as shown in the illustration qe Needle bearing attachment 90890 06615 Driver rod L3 3 90890 06652 2 Apply grease to the new oil seals 4 and then install them into the propeller shaft housing to the specified depth S69M6220 E Needle bearing attachment 4 90890 06617 Driver rod L3 6 90890 06652 AX Depth amp 1 0 1 5 mm 0 04 0 06 in 69M3E11 Propeller shaft housing Drive shaft and lower case Drive shaft and lower case S69M6230 Remarks Drive shaft Oil seal Bushing 2 Bushing 1 Washer Pinion Circlip Ball bearing Forward gear Circlip 1 2 3 4 5 6 7 8 9 o 69M3E1 1 6 10 Lower unit Removing the drive shaft 1 Remove the circlip D pinion washer and drive shaft and then pull out the for ward gear om lt SEAN Sun ee S69M6240 Disassembling the lower case 1 Check the ball bearing for pitting or rum bling Replace if necessary S69M6250 2 Remove the ball bearing S ys Y C A CL KCC O S69M6270 NOTE Do not remove the ball bearing if not replac ing it Bearing puller 1 90890 06535 Stopper guide plate 90890 06501 Stopper guide stand 3 90890 06538 Bearing puller claw 2 4 90890 06537 3 Remove the oil se
15. 3 times and then remove the starter rope from the notch O 69M3E11 S69M5B90 NOTE The starter rope 1 turns the sheave drum 3 with the force of the spiral spring 8 Pull the manual starter handle 4 several times to check that the sheave drum turns smoothly and to check the starter rope for slack Repeat steps 2 7 if nec essary S69M5C00 9 Install the choke knob assembly Removing the power unit 1 Remove the flywheel magnet S69M5190 69M3E11 Power unit S69M5210 S69M5220 CAUTION e Apply force in the direction of the 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 speci fied bolts evenly and completely so that the flywheel puller plate is parallel to the flywheel magnet NOTE ES e Apply force to the crankshaft end until the flywheel magnet comes off the tapered por tion of the crankshaft Use the fuel tank bolts 3 with the specified measurements Flywheel holder Q 90890 06522 Flywheel puller 2 90890 06521 Fuel tank bolt 8 M6 x 35 mm 5 10 2 Loosen the throttle cable stop screw and remove the throttle cable 6 S69M5230 3 Remove the carrying handle fuel cock D bottom cowling 1 B and bottom cowling 2 9 S69M5250 S69M5240 4 Remove the power unit by removing the bolts 4 5 11 69M3E11 Power unit Cylinder head
16. Cylinder head y O 5N m 0 5 kof m 3 7 ft lb TH T34N m 1 4 kgf m 10 3 ft Ib S Gy 11 N m 1 1 kgf m 8 1 ft lb KON 30 N m 3 0 kgf m 22 1 ft Ib Ny LO 5N m 0 5 kgf m 3 7 ft Ib VO 12 N m 1 2 kgf m 8 9 ft Ib 10N m 1 0 kgf m 7 4 ft 1b on Remarks 1 Cylinder head 1 2 Gasket 1 3 Cylinder head cover 1 4 Gasket 1 5 Intake valve 1 6 Exhaust valve 1 7 Push rod 2 8 Push rod guide 1 9 Stud bolt 2 10 Rocker arm 2 11 Rocker arm pivot 2 12 Valve guide 2 13 Stem seal 2 14 Valve spring 2 15 Valve spring retainer 2 16 Valve cotter 2 17 Bolt 4 M8 x 60 mm 69M3E11 5 12 wl 5N m 0 5 kof m 3 7 ft lb T5 I 14N m 1 4 kgf m 10 3 ft Ib NO TI Nm 1 1 kgf m 8 1 ft lb AS E 30 N m 3 0 kgf m 22 1 ft Ib Ny LO 5N m 0 5 kgf m 3 7 ft Ib O 12N lt m 1 2 kgf lt m 8 9 ft lb ION m LOkgf m 7 4ft lb oo Remarks 18 Bolt 6 M6 x 16 mm 19 Bolt 2 M6 x 45 mm 20 Dowel 2 21 Nut 2 22 Blowby hose 1 5 13 69M3E11 Removing the cylinder head 1 Remove the cylinder head cover bolts in the sequence shown S69M5260 2 Remove the crankcase bolts 1 S69M5270 3 Remove the cylinder head bolts in the sequence shown S69M5280 CAUTION Do not scratch or damage the mating sur faces of the cylinder head and cylinder block 4 Remove the cylinder head and t
17. Valve margin thickness 3 Intake 0 7 mm 0 028 in Exhaust 1 0 mm 0 040 in 3 Measure the valve stem diameter b Replace if out of specification S69J5750 69M3E11 Cylinder head Valve stem diameter b Intake 5 475 5 490 mm 0 2156 0 2161 in Exhaust 5 460 5 475 mm 0 2150 0 2156 in 4 Measure the valve stem runout Replace if out of specification 569J5760 AX Valve stem runout 0 03 mm 0 0012 in Checking the valve guides NOTE A 1 Before checking the valve guide make sure that the valve stem diameter is within specifi cation 1 Measure the valve guide inside diameter S69M5350 Valve guide inside diameter a 5 500 5 512 mm 0 2165 0 2170 in 5 16 2 Calculate the valve stem to valve guide clearance as follows Replace the valve guide if out of specification Valve stem to valve guide clearance valve guide inside diameter valve stem diameter Intake 0 010 0 037 mm 0 0004 0 0015 in Exhaust 0 025 0 052 mm 0 0010 0 0020 in Replacing the valve guides 1 Remove the valve guide by striking the special service tool from the combus tion chamber side S69M5360 Valve guide remover installer f 90890 06801 2 Install the new valve guide 2 by striking the special service tool from the rocker arm side until the valve guide reaches the specified installation position a S69M5370 NOTE ETE e Bef
18. clearance e Do not turn the connecting rod until the crankpin oil clearance measurement has been completed Connecting rod bolt 1st 5 N m 0 5 kgf m 3 7 ft lb 2nd 9 N m 0 9 kgf m 6 6 ft lb 5 Remove the connecting rod cap and measure the width of the compressed Plastigauge PG 1 on the crankpin Replace the connecting rod assembly or crankshaft if out of specification S69M5700 Crankpin oil clearance 0 016 0 046 mm 0 0006 0 0018 in Checking the camshaft 1 Check the teeth of the camshaft gear for damage or wear Replace the camshaft if necessary 5 29 S69M5710 2 Check the decompressor for damage or wear Replace the camshaft if necessary S69M5720 3 Measure the camshaft lobe Replace if out of specification Y b S69J5950 Camshaft lobe 26 139 26 239 mm 1 0290 1 0330 in Camshaft lobe 21 950 22 050 mm 0 8642 0 8681 in 69M3E11 4 Measure the camshaft runout Replace if out of specification S69M5730 AX Camshaft runout limit 0 03 mm 0 0012 in Checking the valve lifters 1 Check the valve lifters for bends or wear Replace if necessary 569M5740 Checking the oil splasher gear 1 Check the teeth of the oil splasher gear for cracks damage or wear Replace if necessary S69M5750 Disassembling the cylinder block 1 Check the ball bearing for pitting or rum bling Replace if necessary 69M3E11 Cylinder block S6
19. torque e Do not hold the propeller with your hands when loosening or tightening it e Be sure to disconnect the spark plug cap from the spark plug and the clip from the engine shut off switch e Put a block of wood between the anti cavitation plate and propeller to keep the propeller from turning S69M6450 Joint bolt 3 10 N m 1 0 kgf m 7 4 ft lb Install the propeller and propeller nut 2 Place a block of wood between the anti cavitation plate and propeller to keep the propeller from turning and then tighten the nut If the holes in the propeller nut 4 do not align with the cotter pin hole loosen the nut until the holes are aligned gt S69M6460 S69M6470 69M3E11 6 16 Lower unit MEMO 6 17 69M3E11 69M3E11 Bracket unit Piler handle ae 7 1 Assembling the tiller handle rrrrnrennnnnvnnnrnnrrnnnernnnennnnnvnnnnnenennnnennnennusenne 7 3 Installing the tiller handle vsti ie caia in 7 3 Upper case swivel bracket and clamp brackets 7 4 Assembling the swivel bracket occcoccccoccccocccconccnononncnonanccnnncnannonanonos 7 8 Assembling the clamp brackets 1 esee 7 9 Installing the upper case sese 7 9 BRKT Bracket unit Tiller handle 26 N m 2 6 kgf m 19 2 ft Ib aen Remarks Tiller handle Throttle grip Screw Throttle friction adjust
20. unit Lower unit S69M6010 Lower unit Cotter pin Propeller nut Washer Propeller Spacer Anode Lock washer Bolt Gasket Drain screw Washer Bolt Bolt Gasket Check screw Dowel CON OOF WN M6 x 20 mm Not reusable L transom model M6 x 155 mm L transom model M6 x 30 mm S transom model Not reusable NO U oo O A bd os 69M3E11 6 2 Lower unit S69M6010 18 Rubber seal Extension Dowel Bushing Circlip Joint Joint Bolt Cover L transom model L transom model L transom model L transom model M6 x 20 mm NO DD i A 6 3 69M3E11 Lower unit S69M6020 Bolt M6 x 40 mm Plate Water pump housing O ring Insert cartridge Impeller Outer plate cartridge Dowel O ring Plate Gasket Shift rod Dowel Dowel Is Not reusable CO JO 0 DB Co NN Not reusable Not reusable S and L transom models LL c N HE oc py 69M3E11 6 4 Lower unit Removing the lower unit 1 Drain the gear oil For draining proce dures see Chapter 3 Changing the gear oil 2 Set the gear shift 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 S69M6030 44 WARNING e Do not hold the propeller with your hands when loosening or tightening it e Be sure to disconn
21. 120 D TCI unit 3 Flywheel Permanent magnet 8 Air gap 0 4 0 6 mm 0 016 0 024 in S69M1130 D Flywheel 6 Spark plug 2 Permanent magnet Transistor 1 3 Core Transistor 2 4 Primary coil 9 Engine shut off switch 5 Secondary coil 69M3E11 1 6 des General information Blowby gas reburning system The splash lubrication system splashes a large quantity of oil into the blowby gases Therefore a reburning system is incorporated to separate the oil from the blowby gases in two stages first in the cylinder head and second in the intake silencer Oil is first separated from the blowby gases in the cylinder head labyrinth The oil flows into the cyl inder head and the gases are discharged into the intake silencer Blowby gases from the cylinder head flow into the intake silencer and oil is then separated from the gases in the intake silencer labyrinth The oil flows from the bottom of the intake silencer into the oil pan through the blowby hose and the gases are drawn into the carburetor and reburned in the engine D gt S69M1140 D To intake silencer Blowby gas 2 From cylinder head Engine oil 9 To oil pan Cylinder head D Intake silencer 1 7 69M3E11 Features and benefits Oil check window The F2 5 is equipped with an oil check window to make engine oil level checks easier The oil checking plate in the oil check window indicates the proper oil level when the outboard motor is in an uprigh
22. 90 9 Turn tilt stop lever 1 3 in the direction of S69M7070 the arrow shown NOTE _______ 10 Insert the pin into the swivel bracket The spring should be hooked on the stop G and lever and then install the cir per 8 clip 9 to the pin 9 3 Turn tilt stop lever 1 3 in the direction of the arrow shown 4 Insert the rod into tilt stop lever 2 6 and then install tilt stop lever 2 6 onto tilt stop lever 1 3 S69M7100 Y NOTE After installation check tilt stop lever 1 3 for proper operation 569M7080 5 Align the cut out sections of tilt stop lever 1 and tilt stop lever 2 and then insert lever 1 into lever 2 completely 6 Use a hammer to insert the pin to fix lever 1 to lever 2 7 Hook the spring to the projection of tilt stop lever 2 8 Install the rod 5 into the lever 8 69M3E11 7 8 BRKT Bracket unit Assembling the clamp brackets 1 Install the swivel bracket and mount housing between the clamp brackets and then tighten the nuts to the specified torques S69M7110 NOTE After tightening clamp bracket nut 1 2 to the specified torque hold the nut with a wrench and then tighten clamp bracket nut 2 3 to the specified torque Trim rod nut 1 5 N m 0 5 kgf m 3 7 ft lb Clamp bracket nut 1 2 5 N m 0 5 kgf m 3 7 ft lb Clamp bracket nut 2 3 16 N m 1 6 kgf m 11 8 ft lb Installing the upper case 1 Insta
23. 945 End gap 0 20 0 70 0 0079 0 0276 Side clearance 0 06 0 16 0 0024 0 0063 Camshaft Intake and 26 139 26 239 1 0290 1 0330 exhaust A Intake and 21 950 22 050 0 8642 0 8681 exhaust B B Camshaft journal diameter 14 965 14 990 0 5892 0 5902 Camshaft journal oil clearance 0 010 0 053 0 0004 0 0021 Camshaft runout limit 0 03 0 0012 Valves Valve clearance cold Intake and n 0 08 0 12 0 0031 0 0047 Head diameter A Intake 23 9 24 1 0 941 0 949 Exhaust lt M i 21 9 22 1 0 862 0 870 A Face width Intake and NR 1 84 2 26 0 0724 0 0890 X Seat contact width C Intake and N 0 6 0 8 0 024 0 031 Margin thickness D Intake 0 7 0 028 Exhaust 1 0 0 040 Stem diameter Intake 5 475 5 490 0 2156 0 2161 Exhaust 5 460 5 475 0 2150 0 2156 Guide inside diameter Intake and exhaust 5 500 5 512 0 2165 0 2170 Stem to guide clearance Intake 0 010 0 037 0 0004 0 0015 Exhaust 0 025 0 052 0 0010 0 0020 Stem runout limit 0 03 0 0012 Valve springs Free length i 35 0 1 378 Tilt limit TU i 1 2 0 05 69M3E1 1 2 4 SPEC Specifications F2 5AMH Connecting rod Small end inside diameter 12 006 12 020 0 4727 0 4732 Big end inside diameter i 24 000 24 015 0 9449 0 9455 Big end side clearance 0 2 0 6 0 008 0 024 Crankpin oil clearance i 0 016 0 046 0 0006 0 0018 Crankshaft Crankshaft journ
24. 9M5755 NOTE ey Do not remove the ball bearing if not replac ing it 2 Remove the ball bearing MG S69M5770 Stopper guide plate 1 90890 06501 Stopper guide stand 2 90890 06538 Bearing puller 90890 06535 Bearing puller claw 1 90890 06536 3 Remove the oil seal 6 S69M5780 5 30 Assembling the cylinder block Disassembling the crankcase 1 Apply grease to the new oil seal and 1 Remove the bolt and oil seal housing then install it into the cylinder block S69M5830 S69M5800 NOTE A RE Driver rod L3 90890 06652 Insert a flat head screwdriver between the Needle bearing attachment tab of the oil seal housing and the tab of the 90890 06613 crankcase to pry open the two parts 2 Install the new ball bearing into the cylin 2 Remove the O ring der block S69M5840 S69M5820 3 Remove the oil seals CAUTION Do not reuse the bearing always replace it with a new one gt Driver rod LS 8 90890 06606 Bearing outer race attachment 4 90890 06624 S69M5850 5 31 69M3E11 Checking the oil seal housing 1 Check the oil seal housing for cracks damage or corrosion Replace if neces Sary AR S69M5860 Assembling the crankcase 1 Apply grease to the new oil seals and then install them into the oil seal housing S69M5880 Driver rod L3 i 90890 06652 Bushing attachment 2 90890 06649 2 Apply greas
25. Apply corrosion resistant grease Yamaha grease D Symbols 3 to 8 in an exploded diagram indicate the type of sealant or locking agent and the appli cation point 3 Apply Gasket Maker Apply LOCTITE 242 blue Apply Yamabond No 4 7 Apply LOCTITE 572 9 Apply LOCTITE 271 red Apply silicon sealant 69M3E11 1 2 des General information Safety while working To prevent an accident or injury and to ensure guality 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 S69J1010 Ventilation Gasoline vapor and exhaust gas are heavier than air and extremely poisonous If inhaled in large guantities 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 guate ventilation can be maintained S69J1020 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 569J1030 Parts lubricants and sealants Use only genuine Yamaha parts lubricants and sealants or those recommended by Yamaha when servicing or repairing the out board motor S69J 1040 Under normal co
26. Clip insialed Engine stop button o pushed C S69M8100 TCI unit resistance Primary coil White W Black B 0 56 0 84 Q Secondary coil White W Spark plug wire 11 6 17 4 kQ Checking the engine shut off switch 1 Check the engine shut off switch for con tinuity Replace if there is no continuity 8 5 69M3E11 TRBL POWER UN VENERE 9 1 Troubleshooting 69M3E11 TRBL e SHTG e Troubleshooting NOTE a e 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 Chapters 4 8 for safe maintenance procedures e Check that all electrical connections are tight and free from corrosion Power unit Symptom Engine does not start manual starter is operating normally e Check the ignition system e Check the fuel system e Check the compression pressure of the power unit Check the engine shut off switch for continuity with clip installed Replace the engine shut off Is there continuity switch Yes Check the ignition spark gap WARNING using the spark gap tester e Do not touch any of the connections of the spark gap tester leads Keep flammable gas or liquids away since this test can produce sparks Out of specifica Yes Check the TCI unit or spark plug tion cap Check the condition of the spark plug
27. Continued on next page 9 1 69M3E11 Power unit No Clean adjust or replace the Good condition spark plug Check the compression pres sure of the combustion chamber Out of specification Check the fuel system Yes Check the valve clearance Out of Yes specification Adjust the valve clearance Check the cylinder head cylin der body and piston assembly 69M3E11 9 2 TRBL e SHTG e Troubleshooting Symptom Engine can be started but does not remain on e Check the fuel system e Check the ignition system e Check the compression pressure of the power unit Fuel system Check that the air vent screw of the fuel tank is open Is the vent screw open Open the air vent screw Yes Check for residue in the fuel filter No Check the fuel hose for kinks or Residue C fuel leakage Yes Kinks or fuel Yes Replace the Clean the fuel tank leakage respective parts Check the carburetor Ignition system Check the ignition spark gap using the spark gap tester Out of Check the TCI unit or spark plug specification Cap Yes Check the spark plug 9 3 69M3E11 Power unit Compression pressure Check that there is no secondary air intake on the contact surfaces of the carburetor Is there air Yes intake Replace the respective seals Check the compression pres sure of the combustion chamber Sym
28. al S69M6280 4 Remove bushing 1 S69M6480 NOTE ZZ Use a hammer and shaft to remove bushing 1 69MSE 11 5 Use a bolt with the specified measure ments two nuts and a plate as shown in the illustration 6 Hold the bolt and turn the nut coun terclockwise to pull bushing 2 out ERR EN EI T LI J Y Specified bolt M6 x 120 mm S69M6490 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 S69M6290 Checking the drive shaft 1 Check the drive shaft for bends or wear Replace if necessary x S69M6300 69MSE 11 Drive shaft and lower case Checking the lower case 1 Check the skeg and torpedo for cracks or damage Replace if necessary S69M6310 Assembling the lower case 1 Use a bolt Q with the specified measure ments two nuts and a plate as shown in the illustration Hold the bolt and turn the nut coun terclockwise to install bushing 1 S69M6500 6 12 Lower unit 3 Install bushing 2 into the lower case to the specified depth 2 A uL D 5 Fo OMIC TI 7 ear d o S69M6320 NOTE Apply engine oil to bushing 1 2 before instal lation Bushing attachment 90890 06649 Driver rod L3 2 90890 06652 AX Depth 0 9 1 0 mm 0 03 0 04 in 4 Apply grease to the n
29. al diameter i 21 980 21 993 0 8654 0 8659 Crankpin diameter i 23 969 23 984 0 9437 0 9443 Crankpin width 21 0 21 1 0 827 0 831 Runout limit 0 01 0 0004 Thermostat Opening temperature 48 52 118 126 Fully open temperature 60 140 Valve open lower limit 3 0 12 Carburetor ID mark Main jet 62 Pilot jet 37 Pilot screw Turns out 2 3 Float height mm in 10 5 11 5 0 413 0 453 Engine speed Engine idle speed r min 1 800 2 000 Electrical Model F2 5AMH Ignition system Ignition timing BTDC 30 Ignition spark gap 7 0 28 Spark plug cap resistance 4 0 6 0 TCI unit air gap 0 4 0 6 0 016 0 024 TCI unit resistance Primary coil W B 0 56 0 84 Secondary coil 11 6 17 4 W spark plug wire 2 5 69M3E11 Maintenance specifications Dimensions Exterior an m Y N mm in o 1o o Y 3 LO O N 366 14 4 309 12 2 93 3 7 315 12 4 57 2 2 q 7 T o e d Dr co co 00 U T Y o ee ie Gy N y RET au y P i CO Ra F dr HL y Ll YD TY mA P VAR y Y BA A e A MAU Be xt SET N 167 6 6 N O TT IG 5 F a er 7 2 2 E S 645 25 4 772 N a 103 4 1 569M2010 69M3E11 2 6 63 Specifications Clamp bracket mm in 4 ul Xo S69M2020 2 7 69M3E11 Maintenance specifications Tightening torques Tightening torques Specified torques Part to be tightened Thread size Hoen
30. alve spring and valve spring retainer in the sequence 4 Lightly tap the valve spring retainer with shown and then attach the special ser a plastic hammer to set the valve cotter vice tool securely 569M5470 S69M5450 NOTE The valve spring can be installed in any direction Valve spring compressor 5 90890 04019 Valve spring compressor attachment 6 90890 06320 5 21 69M3E11 Cylinder head Cylinder block Cylinder block 13 N m 1 3 kgf m 9 6 ft Ib 5 N em 0 5 kgf m 3 7 ft Ib 11 N m 1 1 kgf m 8 1 ft Ib 5 N m 0 5 kgf m 3 7 ft Ib 18 N m 1 8 kgf m 13 3 ft Ib Y S 9 N m 0 9 kgf m 6 6 ft Ib ETE Part name Hemarks Cylinder body Crankcase Crankshaft Camshaft Connecting rod assembly Piston Oil ring Second ring Top ring Piston pin Gasket Cil splasher gear Oil seal housing Oil seal Ball bearing Oil seal Oil seal Not reusable N a Lk LL md ek dd LL kho leke ik 69M3E11 5 22 5 23 Clamp Washer Dowel Drain bolt Bolt Bolt Bolt Bolt Bolt Piston pin clip Metal gasket Metal gasket O ring Valve lifter Hose 5 N em 0 5 kgf m 3 7 ft Ib 11 N m 1 1 kgf m 8 1 ft Ib y O_ 5 N m 0 5 kgf m 3 7 ft Ib 9 N m 0 9 kgf m 6 6 ft Ib Part name NY A a po amp PO A HA CO AH NN HA 2 M8 x 20 mm M6 x 45 mm M8 x 14 mm M8 x 20 mm M6 x 29 mm M6 x 12 mm 13 N m 1 3
31. ameter eese 5 24 Checking the cylinder bore oooccoocncconccccccncconcoconnnnonncoconcnnonncnonnrnnonncnnnnens 5 25 Checking the piston clearance cccocccccocncoconoconcnconanononannonanononannonanos 5 25 Gnecking the PISTON rInd ns aan 5 25 Checking the piston ring grooves ccoocccccocccocccccononcononononacnonanononannnnanos 5 26 Checking the piston ring side clearance eseeseeeesss 5 26 Checking the piston pin boss bore cccoccccccccccccccccccocnccncncnnnonnnncnncnonanonos 5 26 CHECKING the piston pn ans 5 27 Checking the connecting rod small end inside diameter 5 27 Checking the connecting rod big end side clearance 5 27 Checking ME Crank as 5 27 Checking the crankpin oil clearance rrrrnrnnnnnnrrnnrrnnnnnennnnrnnnnnrnnnrnnnnee 5 28 Checking the camshall ins a eR EROR 5 29 Checking the valve IM usina nre Foe eer ote prae RID PES c Obr st poca Evi Sube 5 30 Checking the oil splasher gear ccoocccccocccoconocononcnnanononnnnonanononannnnnnos 5 30 Disassembling the cylinder block sees 5 30 Assembling the cylinder block reravrrrnnernnnernnrnnenennennvnnernnnernnnnnnnernnnennnnes 5 31 Disassembling the crankKCaS6 99 99ruYH HYAY HYAY R RR nenn RR NER nennen 5 31 Checking the oil seal NOUSING cccsecceceeeeceeeeeceeeeseeeeeeaue
32. at height 8 Adjust the float height by bending the tab 4 if out of specification S69M4100 NOTE y e The float should be resting on the needle valve 5 but not compressing it e Take measurements at the end of the float opposite its pivoted side AX Float height amp 10 5 11 5 mm 0 413 0 453 in ver i Fuel system Assembling the carburetor 1 Install the main nozzle D main jet pilot jet and bushing 4 to the carbu retor body as shown S69M4110 2 Install the needle valve 5 float float pin and screw 8 as shown and then check the float for smooth operation CN SES S69M4120 NOTE e Place the needle valve in the valve seat when installing the float to the carburetor body e Fit the float pin into the slit on the carbure tor body and lock it with the screw 3 Install the pilot screw 9 turn it in until it is lightly seated then out the specified number of turns 4 9 2 Pilot screw setting 2 3 turns out Installing the carburetor 1 Install the carburetor to the power unit S69M4140 BSR O A i QD O S69M4150 NOTE Align the projections 8 of gaskets and 3 and then install the carburetor 69MSE 11 2 Install the choke wire to the choke lever 5 of carburetor e7 ZA MP fe P A Installing the throttle cable 1 Turn the throttle grip to the fully closed position S69M4170 2 Make the inner wi
33. bearing using a press S62Y6735K CAUTION S Do not press the drive shaft threads directly e Do not reuse the bearing always replace it with a new one Bearing inner race attachment 3 90890 06639 Disassembling the forward gear 1 Remove the taper roller bearing from the forward gear using a press it with a new one Bearing separator 1 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 Stopper guide plate 2 90890 06501 Stopper guide stand 3 90890 06538 Bearing puller 90890 06535 Bearing puller claw 1 90890 06536 62Y5A11 69M3E11 How to use this manual Symbols The symbols below are designed to indicate the content of a chapter General information Fuel system Bracket unit FUEL ry BRKT opecifications Power unit Electrical systems Troubleshooting 38 gt El a 1 Special tool 5 Specified measurement 2 Specified oil or fluid 6 Specified electrical value 3 Specified engine speed resistance voltage electric current 4 Specified tightening torque Symbols to 2 in an exploded diagram indicate the grade of lubricant and the lubrication point Apply Yamaha 4 stroke motor oil Apply low temperature resistant grease Apply water resistant grease Yamaha grease A Yamaha grease C 9 Apply molybdenum disulfide grease d2 Apply injector grease
34. brackets Upper case swivel bracket and clamp brackets Y 5N m 0 5 kgf m 3 7 ft Ib oo LE ONS lE OE kr be L lk ek ke Remarks S and L transom models M5 x 11 mm Not reusable Not reusable 26x 15 mm Not reusable 569M7050 7 4 BRKT Bracket unit Y 5N m 0 5 kgf m 3 7 ft Ib S69M7050 Remarks Bushing Friction piece Swivel bracket Bolt Cover Screw Spring Friction screw Shift rod washer M6 x 30 mm 86 x 15 mm lt A ND AL HM mM 7 5 69M3E11 Upper case swivel bracket and clamp brackets 5N m 0 5 kgf m 3 7 ft Ib N Part name Port clamp bracket Starboard clamp bracket Swivel bracket Mount housing Mount Trim rod Washer Nut Bolt Washer Washer Nut Nut Grease nipple Cover Pin Circlip M6 x 125 mm CON OOF WN M8 x 135 mm 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 69M3E11 7 6 BRKT Bracket unit 5 N m 0 5 kgf m 3 7 ft Ib T Par name Rod Lever Tilt stop lever 2 Pin Spring Bushing Tilt stop lever 1 Clamp pad Clamp screw Clamp handle Pin DN NON NN A S o S S Not reusable 1 1 69M3E11 Upper case swivel bracket and clamp brackets Assembling the swivel bracket 1 Install the bushing into the swivel bracket and then insert tilt stop lever 1 9 partially into the swivel bracket 2 2 Hook the spring 2 onto tilt stop lever 1 S69M70
35. cd Hs Sonal HD E ee Assembling the swivel bracket 7 8 OC DD ne pist n ls A e Assembling the tiller handle 7 3 E e Nanan ee Automatic tilt support and steering pivot Checking the piston pin UT 5 27 immobilization system 1 13 EHPOKIDO me piston pin DOSS DONE ain le Checking the piston ring grooves 5 26 B Checking the piston ring side clearance 5 26 Checking the piston rings 5 25 Blowby gas reburning system 1 7 Checking the propeller 3 11 BEAN ve 1 18 Checking the propeller shaft 6 9 Checking the propeller shaft housing 6 8 C Checking the push rod guide 5 15 Cafbulelo f oett ND NO 4 5 Checking the push rods 5 15 Carburetor and intake silencer 4 4 Checking the rocker arms 5 15 Changing the engine oil 3 4 Checking the spark plug 3 5 Changing the gear oil 3 10 Checking the spark plug cap 8 4 Checking the anodes en 3 11 Checking the spiral spring 5 8 Checking the camshaft 5 29 Checking the steering system 1 16 Checking the carburetor 4 7 Checking the TCI unit
36. cting 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 propeller blade 569J1110 8 Propeller diameter in inches b Propeller pitch in inches C Propeller type propeller mark Selection When the engine speed is at the full throttle operating range 5 250 5 750 r min the ideal propeller for the boat is one that pro vides maximum performance in relation to boat speed and fuel consumption Propeller size 1 71 4x6 BS 7 1 4 x5 1 2 BS Aluminum 7 1 4 x7 1 4 BS 7 1 4 x 8 1 4 BS 7 1 2 x 5 1 2 BS 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 hose is securely con nected and that the fuel tank is full with fuel S69M1030 CAUTION This is a 4 stroke engine Never use pre mixed fuel Checking the gear oil 1 Check the gear oil level S69M1040 69M3E11 Checking the engine oil 1 Check the oil level through the oil level window 1 JA E A m S69M3030 S69M3040 NOTE e f the engine oil is above the maximum level a drain sufficient oil until the level is between a and b e f the engine oil is below the minimum level D add sufficient oil until the level is between 3 and b Recommended engine oil 4 stroke m
37. dentification mark BS PON Pump Octane Number Research Octane Number Motor Octane Number 2 RON Research Octane Number 69M3E11 2 2 63 Specifications Maintenance specifications Power unit Power unit Minimum compression kPa 700 7 0 102 pressure kgf cm psi Cylinder head Warpage limit 0 1 0 004 lines indicate straightedge position Cylinder Bore size 54 000 54 015 2 1260 2 1266 Taper limit 0 08 0 0031 Out of round limit 0 05 0 0020 Piston Piston diameter D 53 950 53 965 2 1240 2 1246 Measuring point H i O O Piston to cylinder clearance 0 035 0 065 0 0014 0 0026 Piston pin boss bore 12 009 12 017 0 4728 0 4731 Piston pin Outside diameter mm in 11 996 12 000 0 4723 0 4724 Piston rings Top ring Dimension B Dimension T End gap Side clearance 0 97 0 99 0 0382 0 0390 1 95 2 15 0 0768 0 0846 0 15 0 30 0 0059 0 0118 0 04 0 08 0 0016 0 0031 2nd ring Dimension B Dimension T End gap Side clearance 1 17 1 19 0 0461 0 0468 2 30 2 50 0 0906 0 0984 0 30 0 45 0 0118 0 0177 0 02 0 06 0 0008 0 0024 Measuring conditions Ambient temperature 20 C 68 F wide open throttle with spark plug removed from cylinder The figures are for reference only 2 3 69M3E11 Maintenance specifications Item Unit F2 5AMH Oil ring Dimension B i 1 87 1 95 0 0736 0 0768 Dimension T WE i 2 10 2 40 0 0827 0 0
38. djust if necessary Lower unit Checking the gear oil level 1 Fully tilt the outboard motor down 2 Remove the check screw 1 and then check the gear oil level in the lower case S69M3220 NOTE If the oil is at the correct level the oil should overflow out of the check hole when the check screw Is removed 3 If necessary add sufficient gear oil of the recommended type until it overflows out of the check hole Recommended gear oil Hypoid gear oil SAE 90 4 Install the check screw 69M3E11 Changing the gear oil Fully tilt the outboard up and then sup port it with the tilt stop lever 1 AE VE e E ol ANY dS uus Slide the trim rod 2 and position it to the upper trim rod position Release the tilt stop lever and tilt the out board down until it contacts the mount housing S69M3240 Place a drain pan under the drain screw 3 remove the drain screw then the check screw 4 to drain the oil 69M3E11 Control system Lower unit Check the oil for metal discoloration and viscosity Check the internal parts of the lower case if necessary Insert the gear oil tube or gear oil pump into the drain hole and slowly fill the gear oil until oil flows out of the check hole and no air bubbles are visible S69M3260 S69M3270 Recommended gear oil Hypoid gear oil SAE 90 Oil quantity 75 cm 2 5 US oz 2 6 Imp oz Install the check screw quickly insta
39. e specified water temperatures a Replace if out of specification N is PP ET M SE P um 8 FI i C IV Cas S69M3150 Control system pe Checking the engine idle speed 1 Start the engine and warm it up for 5 min AX A Valve lift amp utes temperature 48 52 C 0 mm 0 in 2 Attach the special service tool to the 118 126 F valve begins to lift spark plug wire and then check the above more than engine idle speed Adjust if out of specifi 60 C 140 F 3 mm 0 12 in cation 5 Install the thermostat new gasket ther mostat cover flywheel magnet cover manual starter and fuel tank Checking the cooling water passage 1 Check the cooling water inlet 1 for clogs Clean if necessary L S69M3170 Digital tachometer 90890 06760 Engine idle speed 1 800 2 000 r min S69M3140 2 Place the lower unit in water and then start the engine 3 Check for water flow at the cooling water pilot hole If there is no water flow check the cooling water passage inside the out board motor 3 7 69M3E11 3 Turn the throttle stop screw in direc tion or until the specified engine idle speed is obtained NOTE e To increase the idle speed turn the throttle stop screw in direction 8 e o decrease the idle speed turn the throttle stop screw in direction b e When turning the throttle stop screw in direction check that the throttle link con tac
40. e to the new oil seal and then install it into the oil seal housing S69M5900 Driver rod L3 90890 06652 Needle bearing attachment 90890 06613 69M3E11 Cylinder block 3 Install the new O ring N Ae e S69M5910 4 Install the oil seal housing to the crankcase 8 I B S69M5920 9 32 Assembling the piston and cylinder block 1 Assemble the piston 1 connecting rod 2 piston pin S and new piston pin clips S69M5930 NOTE o e Face the embossed Y 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 5 second ring 6 and top ring to the piston with the N marks of the top and second ring fac ing upward 3 Offset the piston ring end gaps as shown S69M5940 5 33 CAUTION Do not scratch the piston or break the pis ton rings NOTE A After installing the piston rings check them for smooth operation 4 Install the crankshaft 8 into the cylinder block S69M5950 5 Install the piston with the UP mark on the piston crown facing towards the fly wheel magnet NOTE TENE Apply engine oil to the piston and piston rings before installation Piston slider 9 90890 06843 69MSE 11 6 Install the connecting rod cap to the connec
41. ect the spark plug cap from the spark plug and the clip from the engine shut off switch e Put a block of wood between the anti cavitation plate and propeller to keep the propeller from turning 3 Remove the covers 1 and then loosen the bolt 2 S69M6040 4 Loosen the bolts and then remove the lower unit from the upper case 6 5 S69M6050 L transom model NOTE M Check that there is no oil on the spline and check it for rust or wear Removing the water pump and shift rod 1 Remove the water pump assembly and shift rod D hia IX e a El m ES S69M6060 69M3E11 Lower unit Checking the water pump and shift 4 Check the shift rod for cracks or wear rod Replace if necessary 1 Check the water pump housing for defor mation Replace if necessary e S69M6100 S69M6070 2 Check the impeller and insert car tridge Q for cracks or wear Replace if necessary S69M6080 3 Check the outer plate cartridge 3 and the plate 4 for cracks or damage Replace if necessary S69M6090 69M3E11 6 6 Lower unit Propeller shaft housing S69M6110 Remarks Shift plunger Spring Propeller shaft Dog clutch Washer O ring Propeller shaft housing Bushing Oil seal Bolt Not reusable CO CON Oo ON Not reusable M6 x 16 mm 1 1 1 1 1 1 1 1 2 2 o 6 69M3E11 Propeller shaft housing R
42. emoving the propeller shaft housing assembly 1 Remove the bolts 1 and then pull out the propeller shaft housing assembly S69M6120 NOTE Insert a flat head screwdriver 3 into the slit between the sealing surfaces of the lower case to pry open the two parts Disassembling the propeller shaft assembly 1 Remove the shift plunger D then the dog clutch 2 washer 3 and spring 4 S69M6130 NOTE ED To remove the dog clutch push the spring down with a flat head screwdriver 5 Disassembling the propeller shaft housing 1 Remove the oil seals 69M3E11 S69M6140 S69M6160 Bushing attachment 3 90890 06650 Driver rod L3 4 90890 06652 Checking the propeller shaft housing 1 Clean the propeller shaft housing using a soft brush and cleaning solvent and then check it for cracks or damage Replace if necessary S69M6170 6 8 Lower unit Checking the propeller shaft 1 Check the propeller shaft for bends or wear Replace if necessary S69M6180 2 Check the dog clutch shift plunger and spring for cracks or wear Replace if nec essary se A S69M6190 Assembling the propeller shaft assembly 1 Insert the spring D and then install the dog clutch 3 into the propeller shaft 2 569M6200 NOTE To install the dog clutch push the spring down with a flat head screwdriver 4 6 9 Assembling the propeller shaft housing
43. er Engine shut off switch Nut Engine shut off cord Throttle lever Bushing Spring Washer Plate Screw Bushing Washer Wave washer Friction piece 5x21mm CON OOF WN 5x12mm 2 A NO YO ol c dv ol o 7 1 69M3E11 Tiller handle S69M7010 Remarks Bushing Screw Cover Throttle cable Washer Bushing Cover Bolt M8 x 25 mm 69M3E11 7 2 BRKT Bracket unit Assembling the tiller handle 1 Install the throttle cable 1 to the throttle lever Q 569M7020 NOTE ee Make sure that the throttle grip is fully closed when installing the throttle cable Installing the tiller handle 1 Install the bushing 1 into the upper case S69M7030 NOTE Align the mark on the bushing with the mark on the upper case 2 Route the engine shut off switch lead as shown so that it does not interfere with the throttle lever S69M7140 7 3 3 Install the tiller handle assembly to the upper case and then tighten the bolt 3 to the specified torque S69M7040 NOTE a a Route the engine shut off switch lead and throttle cable G as shown Tiller handle bolt 3 26 N m 2 6 kgf m 19 2 ft lb 69M3E11 CON OOF 2o mp Upper case Water pipe Shift rod Rubber seal Bracket Bolt Washer Cotter pin Grease nipple Gasket Cover Screw Bushing O ring Shift lever Spring Ball 69M3E11 Tiller handle Upper case swivel bracket and clamp
44. er shaft housing assembly ia 6 8 Removing the water pump and shift rod 6 5 Replacing the valve guides 5 17 S Safety while working 1 3 SelectiOl s 1 15 Self Protection vun 1 3 Serial number ocoooccccccccncococonoconnnccconnnonanonos 1 5 Special service tools 3 1 4 1 5 1 6 1 8 1 Specified torques cooocccccccococccnnccconnconanonos 2 8 Splash lubrication system 1 10 SS A 1 2 T TEASE EA 1 12 TECMMICA IPS 1 12 TE UN ese Y YE eae 1 18 Tightening torques esee 2 8 Taller handle ne doin ee 7 1 OD VICW es 8 2 i 2 Index U Upper case swivel bracket and clamp DracKelS LG e died 7 4 V Ven s 1 3 W Wiring harness eere 8 3 69MSE 11 YAMAHA YAMAHA MOTOR CO LTD Printed in the Netherlands May 2002 1 3x 1 CR E
45. esseeeesaeeensaees 5 32 Assembling the crankcase rrrrnrrvnnrrnnnennenennnnnvnnrnnenennnernnnennnnennnvnnnnennene 5 32 Assembling the piston and cylinder block ssssse 5 33 Iristallind TNE power Unit 5 36 69M3E11 Special service tools Compression gauge 90890 03160 Flywheel holder 90890 06522 A 2 Flywheel puller 90890 06521 Valve spring compressor 90890 04019 No Valve spring compressor attachment 90890 06320 y Valve guide remover installer 90890 06801 di Valve guide reamer 90890 06804 a Valve seat cutter holder 90890 06316 Valve seat cutter 90890 06312 90890 06315 90890 06328 Crank stand alignment 90890 03107 69M3E11 T Stopper guide plate 90890 06501 Stopper guide stand 90890 06538 Bearing puller 90890 06535 Je Bearing puller claw 1 90890 06536 Driver rod L3 90890 06652 69M3E11 Special service tools Needle bearing attachment 90890 06613 M Driver rod LS 90890 06606 Bearing outer race attachment 90890 06624 La Bushing attachment 90890 06649 fg Piston slider 90890 06843 Power unit S69M5010 Part name Starter case Flywheel magnet cover Spiral spring Sheave drum Drive pawl Drive plate Screw Choke knob assembly Stopper Manual starter handle Damper Starter rope Spring Plate Bolt CON OOF WN O A LL LL kh k
46. este fta oz OUD O di es 3 3 Checking the fuel filter eese eene eene nnn nnn 3 3 POWEr UN re 3 3 Checking the engine Ol arna 3 3 Changing the engine Oll usos seco RG cosas tetes acti 3 4 Checking the valve clearance eeeeeeeeeeee eene nennen 3 4 necking the spark PIG see 3 5 Checking the thermostat occccconccnccoccnnococnnconnconncnanononnrononnncononnncnnnnnncnnonos 3 6 Checking the cooling water passage esee 3 7 Control system ua 3 7 Checking the engine idle speed oocccoocccococococccnncncononncnnnncononacnnnnnonos 3 7 Checking the ignition timing cessere 3 8 Checking the TE unit alr dap ei 3 9 LOWEr UN 3 9 Checking the gear oil level cseeeeseeeeeeereee nnne 3 9 Changing NE Gear OS 3 10 Checking the lower unit for air leakage essere 3 11 Checking the propeller cooocccoonccocnocccnnccnococnocncnonncnonononanonnanonnanonos 3 11 Contrata 3 11 Checking ME anodes nn ini 3 11 Lubricating the outboard MOtOr uu044s0444n nenne nnnn nenn nenn YRR HRN nennen 3 12 BR ADJ Periodic checks and adjustments Special service tools Digital tachometer 90890 06760 Timing light 90890 03141 Leakage tester 90890 06840 3 1 69M3E11
47. ew oil seal and then install it into the lower case to the specified depth A On ee O S69M6330 Ball bearing attachment 3 90890 06638 Driver rod LS 4 90890 06606 AX Depth d 1 5 2 0 mm 0 06 0 08 in 5 Install the new ball bearing into the lower case 6 13 S69M6350 CAUTION Do not reuse the bearing always replace it with a new one NOTE e Install the ball bearing with the manufacture identification mark facing toward the for ward gear e Apply engine oil to the ball bearing before installation Ball bearing attachment 90890 06637 Driver rod LS 90890 06606 Installing the drive shaft 1 Install the forward gear into the lower case 2 Install the drive shaft into the lower case and then install the washer 1 pinion and circlip 2 onto the drive shaft S69M6360 69M3E11 NOTE 5 A A J If replacing the washer 1 be sure to replace it with a new one of the same thickness AX Available washer thicknesses 2 0 2 1 2 2 and 2 3 mm Installing the propeller shaft housing 1 Install the washer 1 and propeller shaft assembly 2 into the propeller shaft housing assembly 3 2 Apply grease to the new O rings 3 Install the propeller shaft housing assem bly into the lower case S69M6370 Installing the water pump and shift rod 1 Install the shift rod D new gasket 2 and plate 9
48. g tOr UGS l AA Chkekobnt 1 ss 04 26 90 09 66 x 18 Flywheel magnetnut 1 44 44 8324 Sparkpuig 25 28 184 Olspashergearbot mw 18 18 96 Thermostat ooverbot m 80 08 59 Throttle cable lock screw 04 004 03 Drive unit Gearoilseem J 88 09 63 Engine shut off switch nut 18 02 13 Grease mipple 30 08 22 Swivelbracketbot M 12 12 89 Clamp bracketinnernut 50 08 37 Clamp bracket outermut 16 16 ns Trim rod nut so os 37 69M3E11 2 8 63 Specifications General torques This chart specifies tightening torques for standard fasteners with a standard ISO thread pitch Tightening torque specifications 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 Nut A Bolt B specifications 8 mm M5 5 0 5 3 6 10 mm M6 9 0 8 5 8 12 mm M8 18 1 8 13 569J2150 2 9 69M3E11 CHK ADJ 69M3E11 Periodic checks and adjustments Special Service TOONS ree 3 1 Maintenance interval Chart 3 2 PUG SY SUC IN Aes 3 3 CHECKING NE TUS us seede b
49. hen remove the push rods 69M3E11 Cylinder head NEN BO Em NOTE AAA Insert a flat head screwdriver between the tab of the cylinder and the tab of the cylinder head to pry open the two parts S69M5290 5 Remove the rocker arm pivot 2 rocker arm 3 and push rod guide 4 SS SS S69M5300 6 Remove the intake valve and exhaust valve S69M5310 NOTE Be sure to keep the valves springs and other parts in the order as they were removed 12 Valve spring compressor i 90890 04019 Valve spring compressor attachment 6 90890 06320 Checking the rocker arms 1 Check the rocker arms for cracks wear or damage Replace if necessary S69M5320 5 15 Checking the push rod guide 1 Check the push rod guide for cracks or damage Replace if necessary S69M5330 Checking the push rods 1 Check the push rods for bends wear or damage Replace if necessary LA S69M5340 Checking the valve springs 1 Measure the valve spring free length 3 Replace if out of specification a S69J5720 Valve spring free length 35 0 mm 1 378 in 69M3E11 2 Measure the valve spring tilt D Replace if out of specification 569J5730 AX Valve spring tilt limit amp 1 2 mm 0 05 in Checking the valves 1 Check the valve face for pitting or wear Replace if necessary 2 Measure the valve margin thickness Replace if out of specification co 569J5740
50. i M6 x 60 mm 5 3 69M3E11 Power unit 44 N m 4 4 kof m 32 4 ft Ib 25 N m 2 5 kgf m 18 4 ft Ib Remarks TCI unit Flywheel magnet Starter pulley Spark plug Grommet Clamp Bolt Bolt Nut Washer Woodruff key Spark plug cap S69M5020 M6 x 25 mm M6 x 12 mm 1 2 3 4 5 6 8 LL py ff a oc oo 69M3E11 5 4 CONDOR O mp 5 5 Power unit Gasket Bottom cowling 1 Bottom cowling 2 Carrying handle Bracket Thermostat cover Gasket Thermostat Oil filler cap O ring Anode Screw Grommet Damper Dowel Fuel cock lever zd N a mE hk i ek I ak cR Old ek VL IL E Not reusable Not reusable 65 x 25 mm Remarks db di S69M5030 69M3E11 Power unit db di S69M5030 Remarks 18 Screw 95 x 7 mm Cooling water hose Throttle cable Bolt Bolt Bolt Bolt Bolt Screw O ring Grommet Collar Spring nut M6 x 36 mm M6 x 16 mm M6 x 20 mm M6 x 20 mm M6 x 20 mm 95 x 13 mm moO FPP NO DDR OO 69M3E11 5 6 Checking the compression pressure 1 Start the engine warm it up for 5 min utes and then turn it off 2 Remove the engine shut off cord from the engine shut off switch on the tiller handle 3 Remove the grommet and spark plug and then install the special service tool to the spark plug hole gt S69M5060 CAUTION Before removing the spark plug blow compressed air in the spark
51. kgf m 9 6 ft Ib 3 18N m 1 8 kgf m 13 3 ft Ib Remarks S69M5050 69M3E11 Disassembling the cylinder body 1 Remove the crankcase cover bolts in the sequence shown S69M5510 S69M5520 NOTE Insert a flat head screwdriver between the tab of the crankcase and the tab of the cylin der block to pry open the two parts 3 Remove the camshaft D and then remove the valve lifters Q S69M5530 69M3E11 Cylinder block 4 Remove the connecting rod bolts and the connecting rod cap and then remove the connecting rod and piston assembly 5 Remove the clips 3 with pliers and then remove the piston om y 8 6 Remove the washer 2 and crankshaft 5 and then remove the oil splasher gear S69M5550 Checking the piston diameter 1 Measure the piston outside diameter at the specified measuring point Replace if out of specification S69M5560 Piston diameter 3 53 950 53 965 mm 2 1240 2 1246 in Measuring point 0 mm O in 5 24 Checking the cylinder bore 1 Measure the cylinder bore Di Ds Ds D4 Ds Dg at measuring points A b and and in direction d Di Dz Da which is parallel to the crankshaft and direction Ds Dy De which is at a right angle to the crankshaft 569J5B70 Cylinder bore D4 Ds Da Dz Ds Dg 54 000 54 015 mm 2 1260 2 1266 in 2 Calculate the taper limit Replace or rebore the cylinde
52. king the fuel filter 1 Check the fuel filter for dirt or residue Clean with straight gasoline and replace the filter if necessary S69M3020 3 3 Power unit Checking the engine oil 1 Place the outboard motor in an upright position 2 Check the oil level through the oil level window 1 JAY E S69M3030 S69M3040 NOTE e Change the oil if it appears milky or dirty e If the engine oil is above the maximum level 8 drain sufficient oil until the level is between and e f the engine oil is below the minimum level b add sufficient oil until the level is between 2 and 69M3E11 Changing the engine oil 1 Remove the oil filler cap S69M3050 2 Place a drain pan under the drain hole and then remove the drain bolt and let the oil drain completely S69M3060 NOTE Be sure to clean up any oil spills 3 Install the drain bolt and then tighten it to the specified torque Engine oil drain bolt 2 18 N m 1 8 kgf m 13 3 ft lb 4 Pour the specified amount of the recom mended engine oil into the oil filler hole 69M3E11 Fuel system Power unit Recommended engine oil 4 stroke motor oil API SE SF SG SH or SJ SAE 10W 30 or 10W 40 Oil quantity 0 35 L 0 09 US gal 0 08 Imp gal 5 Install the oil filler cap and then start the engine and warm it up for 5 minutes 6 Turn the engine off and then check the oil level and correct i
53. ll the drain screw and then tighten them 3 10 BR ADJ Periodic checks and adjustments Checking the lower unit for air leakage 1 Remove the check screw 1 and then install the special service tool S69M3290 2 Apply the specified pressure to check that the pressure is maintained in the lower unit for at least 10 seconds CAUTION Do not over pressurize the lower unit oth erwise the oil seals may be damaged NOTE y Cover the check hole with a rag when remov ing the pressure vacuum tester from the lower unit Lower unit holding pressure 100 kPa 1 0 kgf cm 14 psi 3 If pressure drops below specification check the drive shaft and propeller shaft oil seals for damage Checking the propeller 1 Check the propeller blades and splines for cracks damage or wear Replace if necessary S69M3300 General Checking the anodes 1 Check the anodes for scales grease or oil Clean if necessary S69M3310 S69M3320 CAUTION Do not oil grease or paint the anodes otherwise they will be ineffective 2 Replace the anodes if excessively eroded 69M3E11 Lubricating the outboard motor 1 Apply water resistant grease to the areas shown S69M3330 S69M3340 S69M3360 NOTE Apply grease to the grease nipple until it flows from the bushings 2 Apply corrosion resistant grease to the area shown 69M3E11 Lower unit General S69M3370 CHK ADJ 3 13
54. ll the upper case assembly to the swivel bracket and then tighten the bolts D to the specified torque ES oC N S 2 ret 7 9 2 Swivel bracket bolt 1 12 N m 1 2 kgf m 8 9 ft lb Install the cover to the swivel bracket Inject grease into the grease nipple 3 until grease comes out from the bushings 8 Inject grease into the grease nipple 4 until grease comes out from the spring fitting hole S69M7130 69M3E11 Electrical systems SPECIAL service TOOIS qe tm 8 1 Electrical components u 8 2 TOD VICON dla 8 2 Wiring NANSEN 8 3 LONON SYSTEM GN 8 4 Checking the ignition spark gap eere 8 4 Checking the spark plug cap cccocccccocncconcnccnonccnncnonncocnnncnonncncnnnnnconcnonanenos 8 4 Cnecking ine TO Un a one E 8 5 Checking the engine Shut Off switch uu004044n Rennen YH HYAY nenne nennen 8 5 69MSE 11 ELEC 7 ELEC uli Electrical systems Special service tools Ignition tester 90890 06754 Digital circuit tester 90890 03174 8 1 69MSE 11 Special service tools Electrical components Electrical components Top view Si wu hd da TE VP RES TH Sa HR LEG D Spark plug cap 2 Spark plug wire 3 TCI unit 4 Engine shut off switch 69M3E11 8 2 ELEC 7 ELEC a Electrical systems Wiring harness D l f T W B W O S B S69M8020 CD F
55. lywheel magnet B Black Q TCI unit W White 3 Engine shut off switch 4 Ground 5 Spark plug 8 3 69M3E11 Ignition system Checking the ignition spark gap 1 Disconnect the spark plug cap from the spark plug 2 Connect the special service tool to the spark plug cap and to the ground bolt S69M8040 3 Set the spark gap length on the adjusting knob S62Y8140 AX Ignition spark gap 7 mm 0 28 in 4 Crank the engine and observe the spark through the discharge window of the spark gap tester Check the TCI unit or spark plug cap if out of specification 69M3E11 Electrical components Ignition system S69M8060 WARNING e Do not touch any of the connections of the spark gap tester leads e Keep flammable gas or liquids away since this test can produce sparks Checking the spark plug cap 1 Remove the spark plug cap from the spark plug wire by turning the cap coun terclockwise CT IE IL mm s MN S69M8070 2 Measure the spark plug cap resistance Replace if out of specification EE A TFS er S69M8080 El Spark plug cap resistance 4 0 6 0 kQ 8 4 ELEC 7 ELEC uti Electrical systems Checking the TCI unit 1 Remove the spark plug cap from the 8 spark plug wire by turning the cap coun terclockwise 2 Measure the TCI unit resistance Replace if out of specification S69M8090 S69M8110 Clip removed OO
56. m locknuts e ys O 13 Install the crankcase to the cylinder block and then tighten the crankcase bolts to the specified torques in two stage and in the sequence shown S69M5480 9 35 E S69M5A20 Crankcase bolt 1st 5 N m 0 5 kgf m 3 7 ft lb 2nd 11 N m 1 1 kgf m 8 1 ft lb 14 Install the new gasket and cylinder head cover and then tighten the bolts to the specified torques in two stages and in the sequence shown S69M5500 Cylinder head cover bolt 1st 5 N m 0 5 kgf m 3 7 ft lb 2nd 12 N m 1 2 kgf m 8 9 ft lb 15 Install the thermostat 2 new gasket 62 and thermostat cover 3 and then tighten the thermostat cover bolts 4 to the specified torque S69M5A30 69M3E11 Thermostat cover bolt 4 8 N m 0 8 kgf m 5 9 ft lb Installing the power unit 1 Clean the power unit mating surfaces and then install the dowels 1 and the new gasket 2 2 Install the power unit 3 by installing the bolts and then tighten them to the specified torque S69M5A40 CAUTION Do not reuse the power unit gasket always replace it with a new one Power unit bolt 11 N m 1 1 kgf m 8 1 ft lb 3 Install bottom cowling 1 bottom cowl ing 2 and the carrying handle 69M3E11 Cylinder block S69M5A60 5 36 5 Install the flywheel magnet 9 and starter pulley 40 and then tighten the flywheel magnet nut to the specified
57. nditions the lubricants men tioned in this manual should not harm or be hazardous to your skin However 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 69M3E11 6 Keep a supply of clean lint free cloths for wiping up spills etc Good working practices Special service tools Use the recommended special service tools to protect parts from damage Use the right tool in the right manner do not improvise 569J1050 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 569J1060 69M3E11 Safety while working Disassembly and assembly 1 Use compressed air to remove dust and dirt during disas
58. ore installing the valve guide mark its installation position b as shown e Apply engine oil to the new valve guide AX Valve guide installation position amp 5 9 mm 0 23 in Valve guide remover installer 90890 06801 3 Insert the special service tool into the valve guide 2 and then ream the valve guide S69M5380 3 e Turn the valve guide reamer clockwise to ream the valve guide e Do not turn the reamer counterclockwise when removing the reamer Valve guide reamer 90890 06804 4 Measure the valve guide inside diameter Replace the valve guide if out of specifi cation Valve guide inside diameter 5 500 5 512 mm 0 2165 0 2170 in 69MSE 11 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 S69M5390 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 E 569J5830 69M3E11 Cylinder head 569J5840 AX Valve seat contact width 0 6 0 8 mm 0 024 0 031 in Refacing the valve seat 1 Reface the valve seat with the valve seat
59. otor oll API SE SF SG SH or SJ SAE 10W 30 or 10W 40 Oil quantity 0 35 L 0 09 US gal 0 08 Imp gal 69M3E11 Propeller selection Predelivery checks Checking the outboard motor mounting height 1 Check that the anti cavitation plate is between the bottom of the boat and a maximum of 25 mm 1 in below it If the mounting height is too high cavita tion will occur and propulsion will be reduced Also the engine speed will increase abnormally and cause the engine to overheat If the mounting height is too low water resistance will increase and reduce engine efficiency S69M1050 NOTE The optimum mounting height is affected by the combination of the boat and the outboard motor To determine the optimum mounting height test run the outboard motor at differ ent heights 2 Check that the clamp brackets are secured with the clamp screws Checking the steering system 1 Check the steering friction for proper adjustment q Lady AN S69M1060 des i General information 2 Check that the steering operates smoothly S69M1070 Checking the gear shift and throttle operation 1 Check that the gear shift operates smoothly when the shift lever is shifted from neutral into forward S S69M1080 2 Check that the throttle operates smoothly when the throttle grip is turned from the fully closed position to the fully open position S69M1090 Checking the engine shu
60. plug well to clear out any dirt or dust that may fall into the cylinder Compression gauge 1 90890 03160 4 Close the fuel cock and air vent screw fully open the throttle pull the starter rope 3 times and then check the com pression pressure NOTE M Do not pull the choke knob when checking the compression pressure Minimum compression pressure reference data 700 kPa 7 0 kgf cm 102 psi 5 f the compression pressure is below specification add a small amount of engine oil to the cylinder and then check the pressure again o NOTE A e If the compression pressure increases check the piston and piston rings for wear Replace if necessary f the compression pressure does not increase check the valve clearance valves valve seat cylinder sleeve cylinder head gasket and cylinder head Adjust or replace if necessary Disassembling the manual starter 1 Remove the choke knob assembly 1 S69M5070 2 Remove the drive plate and drive pawls 3 a WARNING The sheave drum can pop out Hold the sheave drum with your hand and then pull it out S69M5080 69M3E11 Power unit 3 Remove the sheave drum 4 Checking the spiral spring 1 Check the spiral spring for cracks bends or damage Replace if necessary S69M5090 A WARNING S69M5120 The spiral spring can pop out Pull the starter rope and then pull out the sheave Assembling the manual s
61. pper linked to the tilt support lever is inserted into the swivel cutout At the same time the tilt support lever automati cally supports the outboard motor on the clamp bracket If the outboard motor is tilted up with the steering in either direction the stopper is not inserted into the swivel cutout and the tilt support lever linked to the stopper does not support the outboard motor The stopper which is fitted on the swivel prevents the outboard motor from swiveling when fully tilted up in the forward steering position S69M1220 D Spring 2 Tilt support lever 3 Stopper 4 Swivel recess 1 13 69M3E11 Technical tips Cooling water flow chart Cylinder Upper case Top starboard Upper case side Inside SEERE Ll Cooling water inlet Cylinder head Thermostat Cooling water pilot hole Atmosphere Lower case exhaust port E Atmosphere amp A Bl c S69M1230 Cold water Hot water Exhaust gas and water 69M3E11 1 14 eum i General information 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 engine Use the following information as a guide for sele
62. ptom The engine idle speed is not steady but increases or decreases e Check the intake manifold e Check the air intake system e Check the ignition system Check the operation of the throttle cable and throttle link No Adjust the throttle cable and throttle link Good operat ing condition Yes Check the ignition timing Out of Check the secondary air intake specification on the O ring and the gaskets Yes Check the TCI unit air gap 69M3E11 9 4 TRBL e 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 e Check the carburetors e Check the ignition system e Check the compression pressure of the power unit Check the throttle cable operation Do the car buretor throt tle valves close simul taneously Yes No Adjust the throttle cable Disassemble the carburetor and check the internal parts for clogs debris or wear No Check the ignition system and the compression pressure of the Clogs debris or wear power unit Yes Clean the carburetor or replace the respective parts 9 5 69M3E11 Power unit Symptom Shift mechanism of the forward gear does not operate properly Check the operation of the shift lever No Check the b
63. r 2 to the open position S69M4230 3 Place a drain pan under the drain hose and then loosen the drain screw and let the fuel drain completely S69M4240 4 7 Checking the fuel tank and fuel filler cap 1 Check the fuel tank and fuel filler cap for cracks leaks or damage Replace if nec essary S69M4040 Checking the fuel filter 1 Check the fuel filter for dirt or residue Clean if necessary S69M4055 Checking the fuel cock 1 Check the fuel cock for leaks Replace the O ring or fuel cock if necessary S69M4250 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 69M3E11 2 Blow compressed air into all passages and jets S60C4170 CAUTION e 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 OD pilot jet and main nozzle 3 for dirt or residue Clean if necessary S69M4060 4 Check the pilot screw and needle valve for bends or wear Replace if necessary S69M4070 69M3E11 Carburetor S69M4080 5 Check the float for deterioration Replace if necessary S69M4090 6 Measure the flo
64. r block if out of specifi cation Taper limit D D direction D D direction 0 08 mm 0 0031 in 3 Calculate the out of round limit Replace or rebore the cylinder block if out of spec ification Out of round limit D D measuring point D Ds measuring point 0 05 mm 0 0020 in Checking the piston clearance 1 Calculate the piston clearance using the piston outside diameter and the cylinder bore specifications Replace the piston and piston rings as a set or the cylinder block or all parts or rebore the cylinder if out of specification 5 25 Piston clearance 0 035 0 065 mm 0 0014 0 0026 in Checking the piston rings 1 Check the piston ring dimensions of B and T Replace if out of specification ok E S69M5570 Piston ring dimensions Top ring B 0 97 0 99 mm 0 0382 0 0390 in T 1 95 2 15 mm 0 0768 0 0846 in Second ring b B 1 17 1 19 mm 0 0461 0 0468 in T 2 30 2 50 mm 0 0906 0 0984 in Oil ring B 1 87 1 95 mm 0 0736 0 0768 in T 2 10 2 40 mm 0 0827 0 0945 in 2 Level the piston ring D in the cylinder with a piston crown 3 Check the piston ring end gap at the specified measuring point Replace if out of specification 69MSE 11 S69M5580 Piston ring end gap d Top ring 0 15 0 30 mm 0 0059 0 0118 in Second ring 0 30 0 45 mm 0 0118 0 0177 in Oil ring 0 20 0 70 mm
65. r or clearer F2 5A SERVICE MANUAL 2002 by Yamaha Motor Co Ltd 1st Edition May 2002 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 1 NO Specifications di Periodic checks and adjustments Go zr SIA I Fuel system TI c ITI r 8 Lovver unit O Bracket unit m Electrical systems 00 Troubleshooting CO JJ UJ E eI a ha E m Il 2 I o L 6 Wo Y 69MSE 11 General information How to use this manual an id 1 1 Ianua TOT Lae Ne 1 1 wee mort P 1 2 Safety while WOLKING sebra 1 3 PIES FEIN ar 1 3 HEGE eg E cH 1 3 JP EE DUE aci Uses 1 3 Parts lubricants and sealants rrarnrnnnnnnnnnnnnnnnnnnennnnennnnnnenennnnnnennnnenenennen 1 3 Good Working DFACliCES 0 y egen 1 4 Disassembly and assembly ccccceccseeceeeeeeeeeeeeeeeeneeseeeeeeeeseueeseeeeseeesaaes 1 4 identiicaUon ua 1 5 Applicable model une a a a a 1 5 Seral NUMDET EODEM 1 5 d grE aeNeo aippostee 1 6 MINN SY SUC IN e m 1 6 Blowby gas reburning SYSteM oocccocccnncccoccconcncnncnonanonncononcnonancnncnnnnrennnnnnnos 1 7 MENING Toit DD rris td 1 8 dle MENE us ii 1 9 Splash lubrication SYSIOEM anser I COST 1 10 Low vib
66. racket spring and ball Good operat ing condition Yes Check the condition of the shift rod connection Connected properly Replace the shift rod Yes Disassemble the lower case and then check the operation of the dog clutch Good operat No ing condition Replace the respective parts Yes Check the forward gear 69M3E11 9 6 Index A Checking the fuel system 1 15 Adjusting the engine idle speed 1 18 on ini usa 4 7 Adjusting the pilot screw 4 10 Kun A NA After test tad 1 18 CNOCAN NE JE Dl a Les Applicable mOdEl 2eeeeeeeee 1 5 DE CS ME ear Ol anus ms Assembling the carburetor 4 9 YL me gear sane Assembling the clamp brackets 7 9 t rotlle operation Sat o Idd Gunn 1 17 Assembling the crankcase 5 32 CS ne nen pels ds pet Assembling the cylinder block 5 31 pete E Ju i LL gt Assembling the lower case 6 12 o TAL Y Assembling the manual starter 5 8 FAU une wet MU Dl cis arees Ll Assembling the piston and Checking the oil seal housing 5 32 cylinder block anna 5 33 AU Mier o DC SO NO ae x Assembling the propeller shaft COMI me DUGER mote AS SEMDI usanne Rd 6 9 MOMIAS negal A aa di MD s Assembling the propeller shaft housing 6 9 S
67. ration tiller handle erernvrvvnnernnrernnrennnennnnernnnennnnnnnnnnnunennunennnen 1 11 Technical UNS eme 1 12 DIG Nune ct 1 12 Automatic tilt support and steering pivot immobilization system 1 13 Cooling water TOW CHAN vasene 1 14 Propeller Selecione 1 15 FIOpell r SIZO M LT 1 15 DS ECON RE EN mE 1 15 Predelivery ChecKS vasse c 1 15 Checking the fuel system rrrrrnnnvrnnannrrvnannenvnnnernnnnnenennnsnnnnnnsrnvnnneennnnnenen 1 15 LNECKN NE JA Olis cen a ataca 1 15 Checking the engine ol 1 16 Checking the outboard motor mounting height 1 16 Checking the steering system rrrernrnennnanernvnanernvnennvnnnenennnnnnennnunnennnunenne 1 16 Checking the gear shift and throttle operation 1 17 Checking the engine shut off switch iaia 1 17 Checking the cooling water pilot hole oocccoococcccccccoconononncnnos 1 17 i i eT 1 18 zii a eb rr E 1 18 Aller test TUM 22 00 92 nei Deine y Ya icin starred eaten eee 1 18 Adjusting the engine idle SPeed rrrrrnrrernnvrvrnvrerrnvrernnrerrnerernneensnerennnsen 1 18 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 e
68. re 1 of the throttle cable taut and then connect the throttle link S69M4180 3 Check that the throttle link contacts the fully open stopper 8 when the throt tle grip is turned from the fully closed position to the fully open position 69MSE 11 Carburetor S69M4190 Adjusting the pilot screw 1 Start the engine and warm it up for 5 min utes 2 Attach the special service tool to the spark plug wire 1 M ZW Al OS I SIE S S69M3170 Digital tachometer 90890 06760 4 10 ver ED Fuel system 3 Turn the pilot screw 2 in direction until it is lightly seated then in direction D to the specified number of turns Al O De mM AX Pilot screw setting 2 3 turns out 4 Turn the throttle stop screw 4 in direc tion or until the specified engine idle speed is obtained NOTE lt e To increase the idle speed turn the throttle stop screw in direction e To decrease the idle speed turn the throttle stop screw in direction 9 Engine idle speed 1 800 2 000 r min 5 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 4 11 69M3E11 pour ES Power unit Special Service 10018 u 5 1 POWEr UN ee O Gi tscetecti EASE EEEE E 5 3 Checking the compression pressure ccccceeeceeeeceeeeceeeeeeeeseeeesaeeseeeees 5 7 Disassembling the manual star
69. sary use a 45 cutter to center the area and set its width 30 D S69M5B20 b Previous contact width 8 If the valve seat contact area is too nar row and situated near the bottom edge of the valve face use a 60 cutter to cut the bottom edge of the valve seat If neces sary use a 45 cutter to center the area and set its width 95695930 D 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 S69M5390 69M3E11 Cylinder head CAUTION Do not get the lapping compound on the valve stem or valve guide 10 After every lapping procedure be sure to 11 clean off any remaining lapping com pound from the cylinder head and the valve Check the valve seat contact area of the valve again Checking the cylinder head 1 Eliminate carbon deposits from the com bustion chambers and check for deterio ration Check the cylinder head warpage using a straightedge 1 and thickness gauge 2 in six directions as shown Replace if out of specification S69M5420 569M5430 AX Cylinder head warpage limit 0 1 mm 0 004 in 5 20 Installing the valves 3 Compress the valve spring and then 1 Install the new stem seal to the valve install the valve cotter using a thin guide screwdriver with a small amount of S69M5440 S69M5460 2 Install the valve Q v
70. sembly 2 Apply engine oil to the contact surfaces of moving parts before assembly 569J1070 3 Install bearings with the manufacture identification mark in the direction indi cated 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 periphery of an oil seal before installation 5 Check that moving parts operate nor mally after assembly 1 4 EI General information Identification Applicable model This manual covers the following model Applicable model F2 5AMH Serial number The outboard motor serial number is stamped on a label attached to the port clamp bracket S69M1010 M B K INDUSTRIE E PRODUCT ASSEMBLED IN FRANCE PRODUIT ASSEMBLE EN FRANCE S69M1020 1 Model name 2 Approved model code 3 Transom height 4 Serial number Model name PProved Starting model code serial No o 1000101 F2 5AMH 69M L 1000101 1 5 69MSE 11 Identification Features and benefits Features and benefits Ignition system A simple and compact ignition system is adopted In this ignition system high voltage is induced in the secondary coil when the electric current produced by the primary coil and the permanent mag net on the rotating flywheel is cut off This TCI Transistor Controlled Ignition system greatly contributes to a compact and lightweight engine S69M1
71. shaft 6 13 Installing the lower unit 6 15 Installing the power unit 5 36 Installing the propeller shaft housing 6 14 Installing the throttle cable 4 10 Installing the tiller handle 7 3 Installing the upper case 7 9 Installing the valves 5 21 Installing the water pump and shift rod 6 14 69MSE 11 L Low vibration tiller handle 1 11 EOWER UNI ee 3 9 6 2 Lubricating the outboard motor 3 12 M Maintenance interval chart 3 2 Maintenance specifications 2 3 Manual to Ma tirita 1 1 O Oil check window errnrrrvvrnnnrrrerrnnvrvennnnvnn 1 8 P Parts lubricants and sealants 1 3 Power unit 2 3 3 3 5 3 9 1 Predelivery checks 1 15 Propeller selection 1 15 Propeller shaft housing 6 7 Propeller SIZE asset 1 15 R Refacing the valve seat 5 18 Removing the cylinder head 5 14 Removing the drive shaft 6 11 Removing the lower unit 6 5 Removing the power unit 5 10 Removing the propell
72. stem Fuel tank 569M4010 Fuel tank M6 x 35 mm Fuel filter Fuel filler cap 4 3 69M3E11 Stopper Chain Stopper Gasket Bolt Grommet Collar Clip Fuel hose Damper Clip CON OOF WN 1 1 1 2 1 1 1 3 3 3 1 1 1 1 Fuel tank Carburetor and intake silencer Carburetor and intake silencer 569M4020 Part name Carburetor Intake silencer Blowby hose Bolt Collar O ring Plastic tie Hose Fuel cock Gasket Gasket Gasket Throttle cable O ring Fuel cock lever Screw M6 x 75 mm ooNO o Bb On _ li LL Il HU lI ll DDD Hi 69M3E11 4 4 roe Fuel system Carburetor S69M4032 Remarks Carburetor body Screw Cover Gasket Screw O ring Fuel cock Main nozzle Main jet Pilot jet Bushing Float Float pin Screw Needle valve Gasket Float chamber 4 x 10 mm Not reusable 4 x 8 mm Not reusable CON 2 o Bb On 4 x 5 mm Not reusable I Il mb lo ll ll ll Il ll l1 ll 4 4 5 69M3E11 Carburetor S69M4032 Remarks 18 Screw 2 94 x 10 mm 19 Drain screw 1 20 Spring 1 21 O ring 1 22 Pilot screw For Europe 69M3E11 4 6 ver iD Fuel system Draining the fuel WARNING Before removing the fuel tank fuel hose and carburetor let the fuel drain com pletely 1 Loosen the air vent screw 1 attached to the fuel filler cap S69M4220 2 Set the fuel cock leve
73. t if necessary Checking the valve clearance 1 Remove the engine shut off cord from the engine shut off switch on the tiller handle 2 Remove the carrying handle 1 fuel cock lever 2 bottom cowling 2 3 spark plug 4 fuel tank bolts 5 and cylinder head cover 6 S69M3070 3 4 BSR ADJ Periodic checks and adjustments 3 Slowly pull the starter rope to set the pis ton position to TDC of the compression stroke S69M3080 NOTE e Make sure that the rocker arms are not pushing the intake valve and exhaust valve 9 e Check the position of the piston from the spark plug installation hole 9 e Do not turn the flywheel magnet counter clockwise 4 Check the valve clearance Adjust if out of specification NOTE e Check the valve clearance when the engine is cold e Note the measurement Valve clearance Intake 8 0 08 0 12 mm 0 0031 0 0047 in Exhaust b 0 08 0 12 mm 0 0031 0 0047 in 3 5 5 Loosen the rocker arm locknuts AD and then turn the rocker arm pivot 42 until the specified valve clearance is obtained S69M3100 NOTE LU e To decrease the valve clearance turn the rocker arm pivot in direction C e To increase the valve clearance turn the rocker arm pivot in direction d 6 Tighten the rocker arm locknuts to the specified torque and then check the valve clearances Adjust if necessary Rocker arm locknut AD 10 N m 1
74. t off switch 1 Check that the engine turns off when the engine stop switch is pushed or the engine shut off cord is pulled from the engine shut off switch S69M1110 Checking the cooling water pilot hole 1 Check that cooling water is discharged from the cooling water pilot hole uu Cy EF Al a ANNE IV Wee A TEE S69M3150 69MSE 11 Test run 1 Start the engine and then check that the gear shift operates smoothly 2 Check the engine idle speed after the engine has been warmed up 3 Operate at trolling speed 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 NOTE mm The test run is part of the break in operation Break in During the test run perform the break in operation in the following three stages 1 One hour at 2 000 r min or at approxi mately half throttle 2 One hour at 3 000 r min or 3 4 throttle and one minute out of every ten at full throttle 3 Eight hours O at any speed however avoid running at full speed for more than five minutes 569J1240 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 69M3E11 Predelivery checks Adjusting the engine idle speed Adjust the idle speed after completing the
75. t position The end of the oil checking plate indicates the minimum level The oil level should be between the maximum and minimum levels S69M1150 D Oil checking plate a Maximum level b Minimum level 69M3E11 1 8 Fo f General information Idle silencer The idle silencer is installed to the upper case to reduce exhaust noise and carbon deposits around the exhaust idle port Exhaust gases are discharged into the idle silencer from the two upper holes in the upper case The gases flow and eddy swirl inside the silencer and then are discharged from the exhaust idle port of the silencer into the atmosphere The cooling water in the silencer flows into lower hole in the upper case j it Els S69M1160 Exhaust gas Cooling water 1 9 69M3E11 Features and benefits Splash lubrication system A simple splash lubrication system design is adopted The splasher is driven by the oil splasher gear installed on the camshaft and splashes oil in the oil pan onto the internal parts of the crankcase S69M1170 69M3E11 eum i General information Low vibration tiller handle The tiller handle is installed near the center of the outboard motor for low vibration To help reduce vibration transferring to the tiller handle a rubber damper is used at the installation point of the handle The tiller handle is equipped with a throttle indicator to indicate the throttle angle an engine shut off switch to turn
76. tarter drum 1 Pass the starter rope 1 through the starter case and then install the starter rope to the sheave drum 3 and manual starter handle 4 4 Remove the spiral spring amp from the sheave drum S69M5100 WARNING The spiral spring can pop out To remove the spring cover it with cloths NOTE A e Tie a knot at the end of the starter rope as shown in the illustration e Be sure to leave 5 10 mm at the end of the starter rope 5 Remove the starter rope S69M5110 69M3E11 5 8 2 Wind the starter rope 1 2 times around the sheave drum 3 in the direction of the arrow shown in the illustration S69M5B40 NOTE s After winding the starter rope around the sheave drum install the starter rope in the notch 3 Wind the spiral spring 5 S69M5B50 WARNING When winding the spiral spring cover it with cloths 4 Install the spiral spring 5 into the sheave drum 3 S69M5B60 5 9 NOTE MMC Bend the outer end O of the spiral spring onto the cutout d of the sheave drum 5 Install the sheave drum 3 into the starter case Q NOTE Te IEIE S Install the sheave drum so that the inner end of the spiral spring can be bent onto the cutout of the starter case 6 Install the drive pawls and drive plate 6 S69M5B80 7 Pull the starter rope in the direction of the arrow shown in the illustration turn the sheave drum G
77. ter rrrrnrrrnnnnnnnrnnnnrnnernnnnennnrnnnnennnrennnnnnnn 5 7 Checking the spiral spring ccooccccconococcncnooconononnnnanononncnnnanononacnnnanonos 5 8 Assembling the manual starter rernnrennnernnnennnnevnnernnvrnnnernnnennnnennnnnnunenne 5 8 REMOVING the power unit 99 9u YH YAA eene nennen nennen nnn nnns 5 10 eylch RD HU FED 5 12 Removing the cylinder head rernnrnnnnennnnennnrnnanennennnnnernnnennunnnnnernnnennnen 5 14 Checking the rocker arms eese nennen 5 15 Checking the push rod Quide cccooccccocccococonocccnnnncnnonncnonanononannnnnnos 5 15 Checking the push r0dS ooccccccncccoccccononncccccnonononononcnnanononannonanononannnnnnos 5 15 Checking the valve SpriNQS occccocccocccnccocnnococonononnononononnnnonanononannonanos 5 15 CNECKING the VANES sussebass ed 5 16 Checking the valve Qguides ccoooccocccnccocnnocccncconnnonocnnnnnnnonanononnnnonanos 5 16 Replacing the valve quides rrnnnnrnnnnnnnnrnnnnrnnnnnnnnrnnnnennnnennerennnsnnnnennnen 5 17 GCAECKING NE m Mcr 5 18 Refacing the valve Seat 99 9 eiii YY YHA H YEAR YL LLY nennen LLY nnns 5 18 Checking the cylinder CAC ne ae atra 5 20 Insialllfid ihe lucc TT 5 21 C ylimnder BlOCKLuassvass M 5 22 Disassembling the cylinder body 22u0424004400 Bene HARRY nenn nenn nennen 5 24 Checking the piston di
78. the engine off in an emergency and a throttle friction adjuster to adjust the friction of the throttle lever THN MM De S69M1 190 D Rubber damper 2 Throttle grip 3 Throttle indicator 4 Engine shut off switch G Throttle friction adjuster 1 11 69M3E11 Features and benefits Technical tips Technical tips TCI system The TCI system operates as follows Before ignition As the flywheel rotates the primary coil generates a voltage and an electric current This electric current opens transistor Q1 and as a result an electric current 8 flows to the primary coil S69M1200 Ignition As the flywheel continues to rotate the voltage generated by the primary coil increases When the voltage reaches the operation voltage of transistor Q2 an electric current flows to tran sistor Q2 and opens it As a result electric current flows Ignition timing occurs in this instant At ignition timing the electric current flowing to the primary coil through transistor Q1 is cut off the secondary coil generates a high voltage by electric induction and an ignition spark is fired by the spark plug S69M1210 69M3E11 1 12 eum i General information Automatic tilt support and steering pivot immobilization system The tilt support lever is constantly pushed against the clamp bracket by the force of a spring When the outboard motor is fully tilted up in the forward steering position the sto
79. ting rod and then tighten the con necting rod bolts to the specified torgues in two stages S69M5980 NOTE e Apply engine oil to the connecting rod cap and connecting rod bolts before installation e Align the marks on the connecting rod cap and connecting rod Connecting rod bolt 1st 5 N m 0 5 kgf m 3 7 ft lb 2nd 9 N m 0 9 kgf m 6 6 ft Ib 7 Install the valve lifters 2 into the cylinder block S69M5990 69M3E11 Cylinder block 8 Set the camshaft 3 into the cylinder block as shown S69M5A00 NOTE MEE Align the crankshaft mark f and the cam shaft mark 9 Install the oil splasher gear 9 and then tighten the bolt to the specified torque 10 Install the dowel 5 new gasket d6 and the washer 7 S69M5A10 CAUTION Do not reuse the crankcase gasket always replace it with a new one Oil splasher gear bolt 13 N m 1 3 kgf m 9 6 ft lb 9 34 11 Install the new gasket and cylinder head and then tighten the cylinder head bolts to the specified torques in two stages and in the sequence shown CAUTION Do not reuse the cylinder head gasket always replace it with a new one NOTE se Apply engine oil to the cylinder head bolts before installation Cylinder head bolt 43 1st 14 N m 1 4 kgf m 10 3 ft Ib 2nd 30 N m 3 0 kgf m 22 1 ft lb 12 Install the push rods rocker arms 9 and rocker arm pivots 69 and then tighten the rocker ar
80. torque E ICT S69M5A80 CAUTION Apply force in the direction of the arrows shown to prevent the flywheel holder from slipping off easily NOTE Apply engine oil to the flywheel magnet nut before installation Flywheel holder 1 90890 06522 Flywheel magnet nut 44 N m 4 4 kgf m 32 4 ft lb 6 Install the flywheel magnet cover 42 and manual starter 3 S69M5A90 5 37 69M3E11 Lower unit Special service tools un 6 1 LOWE A E ES emedeesot st misttee et 6 2 Removing the lower unit reronnrronnrervnnernnnrennnnersnnnennunersnnrensenersnvnersnnnensene 6 5 Removing the water pump and shift rOd occccconcccconnccnonnccncnnncononanos 6 5 Checking the water pump and shift rOd oocccooocccccncconcconcncnnanoncnnccnnnnns 6 6 Propeller shaft RoUSIM dietes cv cesi ee ee 6 7 Removing the propeller shaft housing assembly 6 8 Disassembling the propeller shaft assembly sssssussss 6 8 Disassembling the propeller shaft housing ssesessssssss 6 8 Checking the propeller shaft hoUusSiNg coooccccoccccnoncnconccncnacoconacnnoncnnnns 6 8 Checking the propeller Shaft ccccccccssseecseeeceeseeceeeeseeeeeceeeesseeeeseeeeess 6 9 Assembling the propeller shaft assembly seeeseeessssssse 6 9 Assembling the propeller shaft NOUSING
81. ts the screw If the throttle link does not contact the throttle stop screw follow steps 4 6 4 Check that the throttle grip is in the fully closed position 5 Loosen the throttle cable stop screw 3 and then adjust the engine idle speed f Y der G os N q Me SS S69M3400 6 After adjusting the engine idle speed adjust the throttle cable NOTE UU For adjusting procedures see Chapter 4 Installing the throttle cable 69M3E11 Power unit Control system 7 After adjusting the idle speed rev the engine a few times and let it idle for at least 15 seconds to check the stability of the engine Checking the ignition timing 1 Start the engine 2 Attach the special service tool to the spark plug wire 1 3 Check that the flywheel magnet indent is visible through the timing mark check window If not visible adjust the TCI unit air gap S69M3390 3 8 BR ADJ Periodic checks and adjustments Checking the TCI unit air gap 1 Remove the fuel tank D manual starter 2 and flywheel magnet cover 3 Art S69M3190 2 Measure the gap between both pro jections and flywheel magnet using a thickness gauge Adjust if out of specifi cation Jey tig M a Ny A AX TCI unit air gap 0 4 0 6 mm 0 016 0 024 in 3 Loosen the bolts and adjust the TCI unit air gap position 3 9 S69M3210 4 Tighten the bolts and then check the TCI unit air gap A
82. xploded 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 3 Symbols are used to indicate important aspects of a procedure such as the grade of lubricant and lubrication point 4 The components list consist of part names and part quantities as well as bolt and screw dimen sions 5 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 Lower unit Lower unit EO Lower unit Removing the drive shaft 1 Remove the drive shaft assembly and pinion and then pull out the forward S62Y6740K CAUTION Do not reuse the bearing always replace Part name Remarks S62Y6480K Lower unit Plastic tie Hose Gasket Dowel pin Bolt Grommet Bolt Bolt Propeller Washer Washer Cotter pin Trim tab Check screw Drain screw Thrust washer Propeller nut A 2 RN ND aj Not reusable Not reusable M10 40mm M10 45 mm M8 60 mm Not reusable 62Y5A11 S62Y6850K Drive shaft holder 4 1 90890 06518 Pinion nut holder 2 90890 06505 Socket adapter 2 3 90890 06507 Disassembling the drive shaft 1 Install the pinion nut D tighten it finger tight and then remove the drive shaft

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