Yamaha E60HWD Service Manual
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Yamaha E60HWD Service Manual

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E60H
SERVICE MANUAL
69D-28197-5G-11

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  • Page 1 E60H SERVICE MANUAL 69D-28197-5G-11...

  • Page 2: Important Information

    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.

  • Page 3: Table Of Contents

    Contents General information INFO Specifications SPEC Periodic checks and adjustments Fuel system FUEL Power unit POWR Lower unit LOWR Bracket unit BRKT Electrical systems ELEC Troubleshooting TRBL SHTG Index...

  • Page 5: General Information

    INFO General information How to use this manual ................1-1 Manual format ..................1-1 Symbols ....................1-2 Safety while working ................... 1-3 Fire prevention ..................1-3 Ventilation ....................1-3 Self-protection ..................1-3 Parts, lubricants, and sealants ..............1-3 Good working practices ................1-4 Disassembly and assembly ..............

  • Page 6: How To Use This Manual

    INFO 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. 1 Parts are shown and detailed in an exploded diagram and are listed in the components list.

  • Page 7: Symbols

    7 Apply Yamaha 2-stroke motor oil q Apply corrosion resistant grease 8 Apply gear oil (Yamaha grease D) 9 Apply water resistant grease (Yamaha grease A) w Apply low temperature resistant grease 0 Apply molybdenum disulfide grease (Yamaha grease C)

  • Page 8: Safety While Working

    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. Ventilation Gasoline vapor and exhaust gas are heavier than air and extremely poisonous.

  • Page 9: Good Working Practices

    Safety while working Disassembly and assembly 6. Keep a supply of clean, lint-free cloths for 1. Use compressed air to remove dust and wiping up spills, etc. dirt during disassembly. Good working practices 2. Apply engine oil to the contact surfaces Special service tools of moving parts before assembly.

  • Page 10: Identification

    Propellers Applicable models greatly affect boat speed, acceleration, E60HMHD, E60HWHD, engine life, fuel economy, and even boating E60HWD and steering capabilities. An incorrect choice could adversely affect performance and could Serial number also seriously damage the engine.

  • Page 11: Selection

    Identification/Propeller selection/Predelivery checks Selection When the engine speed is at the full throttle Use pre-mixed fuel only. operating range (4,500–5,500 r/min), the Fuel and oil mixing ratio is 50:1. For ideal propeller for the boat is one that pro- break-in period, 25:1 mixture shall be vides maximum performance in relation to used.

  • Page 12: Checking The Outboard Motor Mounting Height

    INFO General information Checking the outboard motor Checking the remote control cables mounting height (remote control model) 1. Check that the anti-cavitation plate is 1. Set the remote control lever to the neutral aligned with the bottom of the boat. If the position and fully close the throttle lever.

  • Page 13: Checking The Steering System

    Predelivery checks 6D430227 69D10180 3. Check that there is no interference with wires or hoses when the outboard motor is steered. The shift/throttle cable joint must be screwed in a minimum of 8.0 mm (0.31 in) Checking the gear shift and throttle operation 1.

  • Page 14: Checking The Engine Start Switch, Engine Stop Lanyard Switch And Engine Stop Button

    INFO General information Checking the engine start switch, engine stop lanyard switch and engine stop button 1. Check that the engine starts when the engine start switch is turned to START. (WHD, WD) 2. Check that the engine turns off when the engine start switch is turned to OFF.

  • Page 15: Break-In

    Predelivery checks Break-in After test run During the test run, perform the break-in 1. Check for water in the gear oil. operation in the following 5 stages. 1. 10 minutes a at the lowest possible 2. Check for fuel leakage in the cowling. speed.
  • Page 16 INFO — MEMO — 1-11 69D5G11...

  • Page 17: Specifications

    SPEC Specifications General specification ................... 2-1 Maintenance specification ................2-3 Power unit ....................2-3 Lower unit ....................2-5 Electrical ....................2-5 Dimensions ....................2-7 Tightening torques ..................2-10 Specified torques ................... 2-10 General torques ..................2-11 69D5G11...

  • Page 18: General Specification

    SPEC Specifications General specification Model Item Unit E60HMHD E60HWHD E60HWD Dimensions Overall length mm (in) 1,197 (47.1) 713 (28.1) Overall width mm (in) 364 (14.3) Overall height mm (in) 1,358 (53.5) – – mm (in) 1,479 (58.2) mm (in) 1,556 (61.3) –...
  • Page 19 General specification Model Item Unit E60HMHD E60HWHD E60HWD Fuel and oil Fuel type Regular gasoline Engine oil 2-stroke outboard motor oil Engine oil grade NMMA-certified TC-W3 Gear oil type Hypoid gear oil Gear oil grade (*1) GL-4 Gear oil quantity (US oz, 610 (20.62, 21.51)

  • Page 20: Maintenance Specification

    SPEC Specifications Maintenance specification Power unit Model Item Unit E60HMHD E60HWHD E60HWD Power unit Minimum compression 540 (5.4, 76) pressure (*1) (kgf/cm , psi) Cylinder head Warpage limit mm (in) 0.1 (0.0039) (lines indicate straightedge position) Cylinders Bore size mm (in) 72.000–72.020 (2.8346–2.8354)
  • Page 21 Maintenance specification Model Item Unit E60HMHD E60HWHD E60HWD Piston rings Top ring Dimension B mm (in) 1.970–1.990 (0.0776–0.0783) Dimension T mm (in) 2.900–3.100 (0.1142–0.1220) End gap mm (in) 0.30–0.50 (0.0118–0.0197) Side clearance mm (in) 0.03–0.07 (0.0012–0.0028) Oversize diameter mm (in) 72.25 (2.845)

  • Page 22: Lower Unit

    SPEC Specifications Model Item Unit E60HMHD E60HWHD E60HWD Carburetor ID mark 6K503 Main jet (M.J.) Main air jet (M.A.J.) Main nozzle (M.N.) mm (in) 3.0 (0.12) Pilot jet (P.J.) Pilot air jet (P.A.J.) Pilot screw (P.S.) turns out 1 1/4 – 1 3/4...
  • Page 23 Maintenance specification Model Item Unit E60HMHD E60HWHD E60HWD Pulser coil output peak voltage (W/R–B, W/B–B, W/G–B) at Cranking (unloaded) at Cranking (loaded) at 1,500 r/min (loaded) at 3,500 r/min (loaded) 10.0 Ω Pulser coil resistance (W/R–B) 117–143 Ω Pulser coil resistance (W/B–B) 117–143...

  • Page 24: Dimensions

    SPEC Specifications Dimensions Exterior mm (in) 640 (25.2)* 635 (25.0)** 1,021 (10.2) 457 (18.0)* 913 (35.9) ** 451 (17.8) ** 260 (10.2) 542 (21.3) 254 (10.0) ** 547 (21.6) ** 67 (2.6) 264 (10.4)* 248 (9.8)** 4.0 (0.16) 556 (21.9) -6.0 (-0.24)** 561 (22.1)** 69D2001M...
  • Page 25 Maintenance specification Clamp bracket (S, L-transom model) mm (in) 180 (7.1) 180 (7.1) 163.5 (6.4) 163.5 (6.4) 69 (2.7) 13 (0.5) 13 (0.5) 126 (5.0) 126 (5.0) *S-transom 69D5G11...
  • Page 26 SPEC Specifications Clamp bracket (X-transom model) mm (in) 180 (7.1) 180 (7.1) 163.5 (6.4) 163.5 (6.4) 69 (2.7) 13 (0.5) 13 (0.5) 126 (5.0) 126 (5.0) 69D5G11...

  • Page 27: Tightening Torques

    Maintenance specification/Tightening torques Tightening torques Specified torques Tightening torques Part to be tightened Thread size N·m kgf·m ft·lb Fuel system Intake silencer — Power unit Power unit mounting bolt 15.5 Flywheel nut Intake manifold bolt Reed valve stopper — 0.08 Starter motor bolt Plug —...

  • Page 28: General Torques

    SPEC 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 manu- To avoid warpage, tighten multi-fastener assemblies in a crisscross fashion and pro- gressive stages until the specified torque is reached.
  • Page 29 Periodic checks and adjustments Special service tools ................... 3-1 Maintenance interval chart ................3-2 Top cowling ....................3-3 Checking the top cowling ................. 3-3 Fuel system ....................3-3 Checking the fuel joint and fuel hoses (fuel joint-to-carburetors) .... 3-3 Checking the fuel filter ................3-3 Power unit .....................

  • Page 30: Chk Adj

    Periodic checks and adjustments Special service tools Digital tachometer 90890-06760 Leakage tester 90890-06840 Timing light 90890-03141 Dial gauge set 90890-01252 69D5G11...

  • Page 31: Maintenance Interval Chart

    Check / charge 3-13 Cooling water passages Clean Cowling clamp Check Fuel filter (can be dis- Check / clean assembled) Fuel system Check Fuel tank (Yamaha por- Check / clean — table tank) Gear oil Change 3-12 Lubrication points Lubricate 3-14...

  • Page 32: Periodic Checks And Adjustments

    Periodic checks and adjustments Top cowling Fuel system Checking the top cowling Checking the fuel joint and fuel 1. Check the fitting by pushing the cowling hoses (fuel joint-to-carburetors) with both hands. Adjust if necessary. 1. Check the fuel hose connections and fuel joint 1 for leaks.

  • Page 33: Checking The Thermostat

    Top cowling/Fuel system/Power unit Checking the thermostat 2. Clean the electrodes 1 with a spark plug 1. Remove the thermostat cover 1, gasket cleaner or wire brush. Replace the spark 2, and thermostat 3. plug if necessary. 6B430025 69D30050 3. Check the electrodes for erosion and 2.

  • Page 34: Checking The Cooling Water Passages

    Periodic checks and adjustments Control system 5. Install the thermostat and thermostat cover, and then tighten the cover bolts. Adjusting the start-in-gear protec- tion Checking the cooling water pas- 1. Set the gear shift to the neutral position. sages 1. Check the cooling water inlet cover 1, 2.

  • Page 35: Checking The Engine Idle Speed

    Power unit/Control system NOTE: 3. While lightly pushing the throttle lever 4 9 To increase the idle speed, turn the throttle of the carburetor #3 in the direction of the stop screw in direction a. arrow (full-closed), and then tighten the 9 To decrease the idle speed, turn the throttle screws 3 of the carburetor #1 and #2.

  • Page 36: Adjusting The Pick Up Timing

    Periodic checks and adjustments Adjusting the pick up timing 1. Loosen the locknut 1, remove the clip 2 1. Remove the link rod 1 from the control and then remove the throttle cable joint lever 2 and cam 3. 69D30085 2.

  • Page 37: Checking The Gear Shift Operation

    Control system Checking the gear shift operation 1. Check that the gear shift operates The throttle cable end must be screwed in smoothly when shifting it from neutral to a minimum of 8.0 mm (0.31in) a. forward or reverse. Adjust the shift cable if necessary.

  • Page 38: Checking The Ignition Timing

    Periodic checks and adjustments 4. Check that the ATDC 2° scale a on the 8. Check that the neutral switch 6 is push- ing by the shift lever 7. (WHD) flywheel magnet is aligned with the point- er b on the timing plate. Adjust if neces- sary.

  • Page 39: Adjusting The Ignition Timing

    Control system Adjusting the ignition timing 5. Check that the scale a on the flywheel magnet with the timing plate b are spec- NOTE: ified position. 9 Remove the all spark plugs and the engine stop lanyard switch clip before adjusting the ignition timing.

  • Page 40: Bracket

    Periodic checks and adjustments 8. Slowly turn the flywheel magnet to clock- wise to the dial gauge indicates to the specified position. Cylinder #1 piston stroke (ATDC): 0.01—0.05 mm (0.0004—0.0020 in) 9. Check that the scale a on the flywheel 69D30265 magnet with the timing plate b are spec- ified position.

  • Page 41: Lower Unit

    Control system/Bracket/Lower unit Lower unit Checking the gear oil level Fully tilt the outboard motor down. 2. Remove the check screw 1, and then check the gear oil level in the lower case. 69D10050 Recommended gear oil: Hypoid gear oil API: GL-4 SAE: 90 Oil quantity:...

  • Page 42: Chk Adj

    Periodic checks and adjustments 2. Apply the specified pressure to check that the pressure is maintained in the lower unit for at least 10 seconds. NOTE: Cover the check hole with a rag when remov- ing the special service tool from the lower unit.

  • Page 43: Lubricating The Outboard Motor

    Lower unit/General Lubricating the outboard motor 1. Apply water resistant grease to the areas Battery electrolyte is dangerous; it con- shown. tains sulfuric acid which is poisonous and highly caustic. 9 Avoid bodily contact with electrolyte as it can cause severe burns or permanent eye injury.
  • Page 44 Periodic checks and adjustments 69D30220 å 69D30225 å Tiller handle model 2. Apply corrosion resistant grease to the area shown. 6B430300 3-15 69D5G11...

  • Page 45: Fuel

    FUEL Fuel system Special service tools ................... 4-1 Hose routing ....................4-2 Fuel line ......................4-3 Carburetor ..................... 4-6 Disassembling the carburetor ..............4-8 Checking the carburetor ................4-8 Assembling the carburetors ..............4-9 Adjusting the throttle stop screw ............. 4-9 Fuel pump ....................

  • Page 46: Fuel System

    FUEL Fuel system Special service tools Vacuum/pressure pump gauge set 90890-06756 Digital caliper 90890-06704 69D5G11...

  • Page 47: Hose Routing

    Special service tools/Hose routing Hose routing 69D4010E 1 Fuel hose (Fuel joint-to-fuel filter) 2 Fuel hose (Fuel filter-to-fuel pump) 3 Fuel hose (Fuel pump-to-carburetors) 4 Pilot water hose 69D5G11...

  • Page 48: Fuel Line

    FUEL Fuel system Fuel line 2 N·m (0.2 kgf·m, 1.5 ft·lb) 69D4020E Part name Q’ty Remarks Lock tie Not reusable Fuel hose M6 × 25 mm Bolt Fuel joint Clamp Fuel hose Fuel hose M6 × 40 mm Bolt Fuel pump Gasket Not reusable M6 ×...
  • Page 49 Fuel line 2 N·m (0.2 kgf·m, 1.5 ft·lb) 69D4020E Part name Q’ty Remarks O-ring Not reusable Fuel filter element Spring Float Fuel hose Fuel hose Fuel hose Fuel hose Pipe ø6 × 45 mm Screw Washer Intake silencer M6 × 45 mm Bolt Bracket Link rod...
  • Page 50 FUEL Fuel system 2 N·m (0.2 kgf·m, 1.5 ft·lb) 69D4020E Part name Q’ty Remarks Carburetor assembly #1 Carburetor assembly #2 Carburetor assembly #3 Gasket Not reusable Joint Choke rod Grommet Choke solenoid WD model 69D5G11...

  • Page 51: Carburetor

    Fuel line/Carburetor Carburetor 69D4030E Part name Q’ty Remarks ø4 × 30 mm Screw Plate Gasket Not reusable Plate Main air jet Gasket Not reusable Plate Pilot air jet O-ring Not reusable Plate Pilot air screw Spring Screw #1 and #2 carburetor Washer #1 and #2 carburetor ø4 ×...
  • Page 52 FUEL Fuel system 69D4030E Part name Q’ty Remarks Float Float pin Needle valve Clip Pilot jet Main jet Main nozzle Drain screw Gasket Not reusable Throttle stop screw #2 carburetor Spring #2 carburetor #3 carburetor Carburetor assembly 69D5G11...

  • Page 53: Disassembling The Carburetor

    Carburetor Disassembling the carburetors 4. Check the pilot screw and needle valve for bends or wear. Replace if necessary. NOTE: 9 Before disassembling the carburetors, make sure to note the number of times the pilot screw is turned out from the seated position to its set position.

  • Page 54: Assembling The Carburetors

    FUEL Fuel system Assembling the carburetors 6. Install the pilot screw, turn it in until it is 1. Install the main air jet 1, and then install lightly seated, then out the specified the plate 2 and a new gasket 3 into the number of turns.

  • Page 55: Fuel Pump

    Carburetor/Fuel pump Fuel pump 69D4040E Part name Q’ty Remarks ø6 × 30 mm Screw Cover Diaphragm Gasket Not reusable Fuel pump body Gasket Not reusable Diaphragm Check valve Gasket Not reusable Cover Screw 69D5G11 4-10...

  • Page 56: Checking The Fuel Pump

    FUEL Fuel system Checking the fuel pump 6. Apply the specified positive pressure and 1. Place a drain pan under the fuel hose check that there is no air leakage. connections, and then disconnect the Disassemble the fuel pump if necessary. fuel hoses from the fuel pump.

  • Page 57: Assembling The Fuel Pump

    Fuel pump Assembling the fuel pump Checking the fuel joint 1. Visually check the fuel joint for cracks or NOTE: damage. Clean the parts and soak the valves and the diaphragms in gasoline before assembly to 2. Connect the special service tool at the obtain prompt operation of the fuel pump outlet of fuel joint.
  • Page 58 FUEL — MEMO — 4-13 69D5G11...

  • Page 59: Powr

    POWR Power unit Special service tools ................... 5-1 Power unit ..................... 5-5 Checking the compression pressure ............5-5 Disassembling the manual starter ............5-17 Checking the spiral spring ..............5-17 Checking the drive pawl ................ 5-17 Measuring the starter rope ..............5-17 Assembling the manual starter ..............

  • Page 60: Power Unit

    POWR Power unit Special service tools Needle bearing attachment Compression gauge 90890-06637 90890-03160 Flywheel holder Driver rod L3 90890-06522 90890-06652 Driver rod LS Flywheel puller 90890-06606 90890-06521 Crankshaft aligner Bearing Separator 90890-03107 90890-06534 Crank jig set Needle bearing attachment 90890-02422 90890-06631 69D5G11...
  • Page 61 Special service tools Press body Flange 90890-02385 90890-02351 Bearing pressure C Body 90890-02393 90890-02352 H-11 Bolt Height ring (H-11) 90890-02353 90890-02377 Washer Plate C 90890-02354 90890-02402 Bushing-9 (D30) Crank separater kit (set 02416 + 02417) 90890-02363 90890-02418 69D5G11...
  • Page 62 POWR Power unit Plate B Disassembling kit 90890-02411 90890-02416 Assembling kit 90890-02407 90890-02417 Pressure plate Guide 90890-02408 90890-02412 Guide plate Pole 90890-02413 90890-02409 Guide pole Plate A 90890-02414 90890-02410 69D5G11...
  • Page 63 Special service tools Base 90890-02415 Small end bearing installer 90890-06527 Cylinder gauge 90890-06759 Bearing inner race attachment 90890-06641 69D5G11...

  • Page 64: Power Unit

    POWR Power unit Power unit 5. If the compression pressure is below specification and the compression pres- Checking the compression pressure sure for each cylinder is unbalanced, add 1. Start the engine, warm it up for 5 min- a small amount of engine oil to the cylin- utes, and then turn it off.
  • Page 65 Power unit 21 N·m (2.1 kgf·m, 15.5 ft·lb) 4 N·m (0.4 kgf·m,3.0 ft·lb) 8 N·m (0.8 kgf·m, 5.8 ft·lb) 69D5010E Part name Q’ty Remarks Power unit Manual starter assembly Collar Grommet M8 × 30 mm Bolt M8 × 26 mm Bolt M8 ×...
  • Page 66 POWR Power unit 21 N·m (2.1 kgf·m, 15.5 ft·lb) 4 N·m (0.4 kgf·m,3.0 ft·lb) 8 N·m (0.8 kgf·m, 5.8 ft·lb) 69D5010E Part name Q’ty Remarks M6 × 25 mm Bolt Neutral switch assembly M6 × 12 mm Bolt Bracket Starter relay Wireharness M6 ×...
  • Page 67 Power unit 160 N·m (16 kgf·m, 115 ft·lb) WHD, WD 69D5020E Part name Q’ty Remarks Flywheel magnet M8 × 12 mm Bolt Starter pulley Washer M6 × 10 mm Bolt Timing plate Woodruff key 69D5G11...
  • Page 68 POWR Power unit 20 N·m (2.0 kgf·m, 15 ft·lb) 69D5030E Part name Q’ty Remarks Screw Cover M6 × 25 mm Bolt Ignition coil M6 × 16 mm Bolt Screw Bracket Grommet Collar CDI unit ø6 × 25 mm : WHD and WD models Screw Rectifier WHD and WD models...
  • Page 69 Power unit 20 N·m (2.0 kgf·m, 15 ft·lb) 69D5030E Part name Q’ty Remarks Lighting coil ø5 × 25 mm Screw Charge coil ø6 × 12 mm Screw Retainer Base assembly Retainer Washer Starter motor WHD and WD models 69D5G11 5-10...
  • Page 70 POWR Power unit 69D5040E Part name Q’ty Remarks Joint M6 × 16 mm Bolt Collar M6 × 25 mm Bolt Collar Wave washer Link rod Joint M6 × 45 mm Bolt Washer Collar Control lever Spring Control lever Washer 5-11 69D5G11...
  • Page 71 Power unit 69D5040E Part name Q’ty Remarks Control lever Screw 69D5G11 5-12...
  • Page 72 POWR Power unit 69D5050E Part name Q’ty Remarks Manual starter case Stay Washer Spiral spring Collar Sheave drum Cover Clip Collar Drive pawl Spring Spring Drive plate Washer M6 × 16 mm Bolt M6 × 25 mm Bolt Washer 5-13 69D5G11...
  • Page 73 Power unit 69D5050E Part name Q’ty Remarks Bushing Roller M6 × 30 mm Bolt Grommet Collar Cover Manual starter handle Damper Starter rope guide Starter rope M6 × 12 mm Bolt Clip Washer Start-in-gear protection cable Spring Guide Bolt 69D5G11 5-14...
  • Page 74 POWR Power unit 69D5050E Part name Q’ty Remarks Stopper Spring 5-15 69D5G11...

  • Page 75: Disassembling The Manual Starter

    Power unit Disassembling the manual starter 3. Remove the sheave 0 drum from the 1. Turn the sheave drum 1 clockwise until manual starter case. the spiral spring is free. 69D50050 69D50020 NOTE: NOTE: Insert a flat-head screwdriver into the hole b 9 Turn the sheave drum so that the notch on in the sheave drum and push down on the the outer surface of the sheave drum faces...

  • Page 76: Checking The Spiral Spring

    POWR Power unit Checking the spiral spring 4. Wind the starter rope 2-1/2 around the 1. Check the spiral spring for cracks, bends, sheave drum in the direction of the arrow or damage. Replace if necessary. shown in the illustration. Checking the drive pawl 1.

  • Page 77: Removing The Power Unit

    Power unit NOTE: 7. Install the collar 6, cover 7, clip 8, Align the mark on the stopper with guide, and drive pawl 9, spring 0, spring q, and then turn the sheave drum. drive plate w. 10. Pull the manual starter handle complete- ly, then measure the starter rope length.
  • Page 78 POWR Power unit 6. Disconnect the battery leads 7 (WHD, 3. Disconnect the neutral switch connector 2. (WHD) WD), warning indicator leads engine stop lanyard switch lead (MHD, WHD) and ground leads 8. 7. Disconnect the starter relay leads 9 (WHD, WD) and coupler 0 from the wire- harness.

  • Page 79: Removing The Flywheel Magnet

    Power unit Removing the flywheel magnet NOTE: Apply force to the crankshaft end until the fly- 1. Remove the starter pulley, and then wheel magnet comes off the tapered portion loosen the flywheel magnet nut. of the crankshaft. Flywheel puller: 90890-06521 3.

  • Page 80: Assembling The Control Lever

    POWR Power unit Assembling the control lever 1. Install the spring into the control lever 1, and then install the control lever 2. 69D50240 69D50245 NOTE: Align the projection a on the control lever 2 with projection b on the control lever 1 to turn the direction.

  • Page 81: Reed Valves

    Power unit/Reed valves Reed valves 0.8 N·m (0.08 kgf·m, 0.6 ft·lb) 4 N·m (0.4 kgf·m,3.0 ft·lb) 8 N·m (0.8 kgf·m, 5.8 ft·lb) 69D5060E Part name Q’ty Remarks Screw Timing plate M6 × 25 mm Bolt Intake manifold assembly ø5 × 16 mm Screw Reed valve assembly Gasket...

  • Page 82: Removing The Reed Valve Assembly

    POWR Power unit Removing the reed valve assembly 2. Measure the valve stopper height b. 1. Remove the intake manifold bolts 1, and Replace if out of specification. then remove the intake manifold cover 2, gasket and reed valve assembly. 69D50270 Valve stopper height b: 2.8—3.2 mm (0.11—0.13 in)
  • Page 83 Reed valves/Cylinder head Cylinder head 25 N·m (2.5 kgf·m, 18 ft·lb) 23 N·m (2.3 kgf·m, 17 ft·lb) 15 N·m (1.5 kgf·m,11.1 ft·lb) 32 N·m (3.2 kgf·m, 23 ft·lb) 10 N·m (1.0 kgf·m, 7.2 ft·lb) 3 N·m (0.3 kgf·m,2.2 ft·lb) 8 N·m (0.8 kgf·m, 5.8 ft·lb) 69D5070E Part name Q’ty...
  • Page 84 POWR Power unit 25 N·m (2.5 kgf·m, 18 ft·lb) 23 N·m (2.3 kgf·m, 17 ft·lb) 15 N·m (1.5 kgf·m,11.1 ft·lb) 32 N·m (3.2 kgf·m, 23 ft·lb) 10 N·m (1.0 kgf·m, 7.2 ft·lb) 3 N·m (0.3 kgf·m,2.2 ft·lb) 8 N·m (0.8 kgf·m, 5.8 ft·lb) 69D5070E Part name Q’ty...

  • Page 85: Cylinder Head

    Cylinder head Removing the cylinder head 1. Remove the spark plugs, thermostat cover, thermostat and thermoswitch. 2. Remove the cylinder head bolts (nut) in the sequence shown. 69D50300 Cylinder head warpage limit: 0.1 mm (0.0039 in) Removing the exhaust cover 1.

  • Page 86: Installing The Thermoswitch

    POWR Power unit Installing the thermoswitch 2. Install the two nuts 2, and then locking 1. Install the thermoswitch 1, push into the the nut as shown. bottom of the flange on the cylinder head cover 2. 69D50282 3. Tighten the nuts to specified torque. 69D50320 69D50283 Stud bolt:...

  • Page 87: Crankcase

    Cylinder head/Crankcase Crankcase 20 N·m (2.0 kgf·m,15 ft·lb) 40 N·m (4.0 kgf·m, 29.5 ft·lb) 10 N·m (1.0 kgf·m,7.2 ft·lb) 20 N·m (2.0 kgf·m, 15 ft·lb) 69D5080E Part name Q’ty Remarks Crankshaft assembly Cylinder Block Dowel Oil seal Not reusable Oil seal Not reusable O-ring Not reusable...
  • Page 88 POWR Power unit 20 N·m (2.0 kgf·m,15 ft·lb) 40 N·m (4.0 kgf·m, 29.5 ft·lb) 10 N·m (1.0 kgf·m,7.2 ft·lb) 20 N·m (2.0 kgf·m, 15 ft·lb) 69D5080E Part name Q’ty Remarks M8 × 20 mm Bolt Plate Bracket 5-29 69D5G11...
  • Page 89 Crankcase 69D5090E Part name Q’ty Remarks Upper bearing O-ring Not reusable Clip Oil seal Not reusable Circlip Washer Needle bearing Piston ring set Piston pin Piston Crank assembly #1 Roller bearing assembly Not reusable Labyrinth ring Crank assembly #2 Crank assembly #3 Ball bearing Not reusable Crank 1...
  • Page 90 POWR Power unit 69D5090E Part name Q’ty Remarks Washer Roller bearing Connecting rod Crank pin Crank 2 Crank 3 Crank 4 5-31 69D5G11...

  • Page 91: Removing The Oil Seal Housing

    Crankcase Removing the oil seal housing Removing the crankshaft assembly 1. Remove the oil seal housing 1. 1. Remove the crankshaft assembly and oil seal housing. 69D50350 Removing the crankcase 1. Remove the crankcase bolts in the sequence shown. 69D50360 Checking the cylinder bore 1.

  • Page 92: Disassembling The Oil Seal Housing

    POWR Power unit 2. Calculate the taper limit. Replace or 2. Apply grease to new oil seal, then install rebore the cylinder block if above specifi- them into the oil seal housing. cation. Taper limit: (direction d) — D (direction e) —...

  • Page 93: Checking The Piston Diameter

    Crankcase Checking the piston diameter Checking the piston rings 1. Measure the piston outside diameter at 1. Check the piston ring dimensions of B the specified measuring point. Replace if and T. Replace if out of specification. out of specification. 69D50410 Piston ring dimensions Top ring and 2nd piston ring:...

  • Page 94: Checking The Piston Ring Side Clearance

    POWR Power unit Checking the piston ring side clear- ance 1. Measure the piston ring side clearance. Replace the piston and piston rings as a set if out of specification. 6B450530 Piston pin diameter: 19.895—19.900 mm (0.7833—0.7835 in) 69D50425 Checking the internal anodes 1.

  • Page 95: Disassembling The Crankshaft

    Crankcase Disassembling the crankshaft 3. Insert the special service tools between 1. Insert the special service tools between #3 crank assembly 0 and #2 crank #1 crank assembly 1 and #2 crank assembly 2, and then separate them assembly 2, and then separate them using a press.

  • Page 96: Assembling The Crankshaft

    POWR Power unit 6. Using the bearing separator to slightly Bushing-9 (D30) 3 : 90890-02363 move the inner race w off the shaft, and Plate C 4 : 90890-02402 then remove the inner race. Bearing pressure C 5: 90890-02393 2. Insert the pin 6 on the special service tool into the hole 7 on the #2 crank assembly 8.
  • Page 97 Crankcase 4. Install the labyrinth ring u onto #2 crank 6. Remove the guide pole s (long), and assembly 8 and install the roller bearing then remove the three guide, and pull out i onto #1 crank assembly t, before the guide plate d.

  • Page 98: Checking The Crankshaft

    POWR Power unit NOTE: 12. Install the upper bearing, and then slowly 9 Install the guide o, and then align the crank turn the crankshaft and connecting rods. angle. If it does not turn smoothly, disassemble 9 Place the press body p on the assembling the crankshaft and adjust or replace any kit.

  • Page 99: Assembling The Piston

    Crankcase 2. Install the needle bearings 3, washers 3. Measure the crankshaft runout. Repair or 4, piston pin 5, and new clips 6. disassemble the crankshaft if above specification. 69D50610 Crankshaft runout limit c: 0.05 mm (0.0020 in) Crankshaft aligner: 90890-03107 69D50520 Assembling the piston...
  • Page 100 POWR Power unit 3. Install the crankcase onto the cylinder block, and then tighten the crankcase bolts to the specified torques in two stages and in the sequence shown. 69D50540 NOTE: 9 Apply engine oil to the pistons, piston rings and bearings before installation.
  • Page 101 Crankcase NOTE: 5. Install a new gasket and the exhaust Apply engine oil to the cylinder head bolts cover, and then tighten the bolts to the (nut) before installation. specified torques in two stages and in the sequence shown. Cylinder head bolt (Nut): 1st: 15 N·m (1.5 kgf·m, 11.1 ft·lb) 2nd: 32 N·m (3.2 kgf·m, 23 ft·lb) 7.

  • Page 102: Installing The Power Unit

    POWR Power unit 9. Install the bracket 6 and neutral switch 11. Install the control levers, and the electri- bracket 7 (WHD). cal components to the power unit. Installing the power unit 1. Clean the power unit mating surface, and install the dowels 1 and a new gasket 2.
  • Page 103 Crankcase 13. Install the starter pulley. 14. Install the manual starter and start-in- gear protection cable 8, and then adjust it length. For adjustment procedures, see Chapter 3. 69D50165 15. Install all removed parts. 16. Set the shift lever to the neutral position and check that the start-in-gear protec- tion lever position.(WHD) Adjust if neces- sary.

  • Page 104: 69D5G11

    POWR — MEMO — 5-45 69D5G11...

  • Page 105: Lowr

    LOWR LOWR Lower unit Special service tools ................... 6-1 Lower unit ....................6-5 Removing the lower unit ................6-9 Removing the water pump ..............6-9 Removing the oil seal housing and shift rod ........... 6-9 Checking the water pump and shift rod ..........6-10 Disassembling the oil seal housing ............

  • Page 106: Lower Unit

    LOWR Lower unit Special service tools Dial gauge set Ring nut wrench extension 90890-01252 90890-06513 Bearing puller assembly Stopper guide plate 90890-06535 90890-06501 Bearing housing puller claw L Drive shaft holder 3 90890-06517 90890-06502 Center bolt Bearing outer race puller assembly 90890-06504 90890-06523 Ring nut wrench...
  • Page 107 Special service tools Stopper guide stand Driver rod LS 90890-06606 90890-06538 Needle bearing attachment Driver rod SL 90890-06608 90890-06602 Bearing depth plate Needle bearing attachment 90890-06603 90890-06611, 90890-06612 Driver rod SS Bearing outer race attachment 90890-06604 90890-06621, 90890-06626 Driver rod LL Shift rod push arm 90890-06605 90890-06052...
  • Page 108 LOWR Lower unit Pinion height gauge Bearing inner race attachment 90890-06710 90890-06639, 90890-06643 90890-06662 Ball bearing attachment Pinion height gauge plate B 90890-06655 90890-06712 Pinion nut holder Driver rod L3 New: 90890-06715 90890-06652 Current: 90890-06505 Magnet base B Shimming plate 90890-06844 90890-06701 Backlash indicator...
  • Page 109 Special service tools Magnet base plate 90890-07003 69D5G11...

  • Page 110: Lower Unit

    LOWR Lower unit Lower unit 40 N·m (4.0 kgf·m, 29.5 ft·lb) 35 N·m (3.5 kgf·m, 25.3 ft·lb) 40 N·m (4.0 kgf·m, 29.5 ft·lb) 4.5 N·m (0.45 kgf·m, 3.3 ft·lb) 69D6010E Part name Q’ty Remarks Lower unit Check screw Gasket Not reusable Drain screw Screw Dowel...
  • Page 111 Lower unit 40 N·m (4.0 kgf·m, 29.5 ft·lb) 35 N·m (3.5 kgf·m, 25.3 ft·lb) 40 N·m (4.0 kgf·m, 29.5 ft·lb) 4.5 N·m (0.45 kgf·m, 3.3 ft·lb) 69D6010E Part name Q’ty Remarks Spring washer Washer Water inlet cover ø5 × 42 mm Screw Seal Guide...
  • Page 112 LOWR Lower unit 69D6020E Part name Q’ty Remarks Circlip Shift rod Circlip O-ring Not reusable Plate Oil seal Not reusable O-ring Not reusable M6 × 45 mm Bolt Screw Grommet Seal M8 × 70 mm Bolt M8 × 50 mm Bolt Water pump housing Insert cartridge...
  • Page 113 Lower unit 69D6020E Part name Q’ty Remarks Dowel Gasket Not reusable Outer plate cartridge Gasket Not reusable Oil seal housing Not reusable Gasket Not reusable O-ring Not reusable Oil seal Woodruff key 69D5G11...

  • Page 114: Removing The Lower Unit

    LOWR Lower unit Removing the lower unit 5. Loosen the bolt 4 and nuts 5, and then 1. Drain the gear oil. remove the lower unit from the upper case. å 69D60015 2. Shift the shift lever or remote control lever to neutral, place a block of wood between the anti-cavitation plate and pro- peller to keep the propeller from turning,...

  • Page 115: Checking The Water Pump And Shift Rod

    Lower unit Disassembling the oil seal housing 1. Remove the oil seals using a flat head screwdriver. 69D60035 NOTE: Set the shift to the neutral position using the special service tool,before remove the shift 69D60090 rod assembly. Assembling the oil seal housing 1.

  • Page 116: Propeller Shaft Housing

    LOWR Lower unit Propeller shaft housing 105 N·m (10.5 kgf·m, 76 ft·lb) 69D6030E Part name Q’ty Remarks Slider Shifter Shift slider Shaft assembly Ball Cross pin Spring Spring Dog clutch Spring nut Plunger Spring Washer Shaft Propeller shaft Reverse gear 6-11 69D5G11...
  • Page 117 Propeller shaft housing 105 N·m (10.5 kgf·m, 76 ft·lb) 69D6030E Part name Q’ty Remarks Reverse gear shim — Washer O-ring Not reusable Bearing Propeller shaft housing Straight key Needle bearing Not reusable Oil seal Not reusable Lock washer Ring nut 69D5G11 6-12...

  • Page 118: Removing The Propeller Shaft Housing Assembly

    LOWR Lower unit Removing the propeller shaft hous- Stopper guide plate 4: ing assembly 90890-06501 1. Remove the ring nut from the propeller Bearing housing puller claw L 5: shaft housing, use the special service 90890-06502 tools. Center bolt 6: 90890-06504 Disassembling the propeller shaft assembly 1.

  • Page 119: Checking The Propeller Shaft Housing

    Propeller shaft housing 2. Remove the ball bearing. 3. Check the bearings for pitting or rum- bling. Replace if necessary. Checking the propeller shaft 1. Check the propeller shaft for bends or wear. Replace if necessary. 2. Measure the propeller shaft runout. Do not reuse the bearing, always replace it with a new one.

  • Page 120: Assembling The Propeller Shaft Housing

    LOWR Lower unit Assembling the propeller shaft Depth c: housing 4.5—5.5 mm (0.177—0.214 in) 1. Install the needle bearing into the pro- 3. Install the washer 6 and new ball bear- peller shaft housing to the specified ing 7 onto the reverse gear 8 using a depth.

  • Page 121: Drive Shaft And Lower Case

    Propeller shaft housing/Drive shaft and lower case Drive shaft and lower case 95 N·m (9.5 kgf·m, 68 ft·lb) 69D6040E Part name Q’ty Remarks Drive shaft Forward gear Taper roller bearing assembly Not reusable Forward gear shim — Pinion gear Lower case Needle bearing Not reusable Sleeve...

  • Page 122: Removing The Drive Shaft

    LOWR Lower unit Removing the drive shaft Disassembling the forward gear 1. Remove the drive shaft assembly and 1. Remove the taper roller bearing from the pinion, and then pull out the forward gear. forward gear using a press. 6F660190 6F660210 Drive shaft holder 3 1: 90890-06517...

  • Page 123: Checking The Pinion And Forward Gear

    Drive shaft and lower case Checking the drive shaft 2. Remove the drive shaft bearing outer 1. Check the drive shaft for bends or wear. race, shim(s), and drive shaft sleeve. Replace if necessary. 2. Measure the drive shaft runout. NOTE: 69D60110 Install the claws as shown.

  • Page 124: Assembling The Forward Gear

    LOWR Lower unit Assembling the forward gear 2. Install the sleeve, original shim(s), and 1. Install a new taper roller bearing into the drive shaft bearing outer race. forward gear using a press. 6B460310 Bearing inner race attachment 1: 6F660290 90890-06662 Add or remove shim(s), if necessary, if Assembling the drive shaft...

  • Page 125: Installing The Shift Rod And Oil Seal Housing

    Drive shaft and lower case 2. Install a new O-ring 5, new gasket 6, oil Drive shaft holder 3 1: seal housing 7 and the dowels 8. 90890-06517 Pinion nut holder 2: Installing the propeller shaft housing New: 90890-06715 1. Install the original shim(s) 1, and pro- Current: 90890-06505 peller shaft assembly 2 into the propeller shaft housing assembly 3.

  • Page 126: Installing The Water Pump

    LOWR Lower unit 3. Align the groove in the impeller 3 with the Woodruff key 4, and then install the impeller onto the drive shaft. 6F600065 NOTE: To secure the ring nut, and lock washer 6 bend one lobe into the ring nut slot, and the 69D60235 other towards the gear side.

  • Page 127: Installing The Lower Unit

    Drive shaft and lower case 5. Install the seal 7, grommet 8, a new 3. Install the lower unit into the upper case, gasket 9 and pump housing assembly and then tighten the lower case mounting 0 into the lower case, tighten the bolts bolt and nuts 3 to the specified torque.
  • Page 128 LOWR Lower unit 6. Install the propeller and propeller nut, 7. Insert a gear oil tube or gear oil pump into and then tighten the nut temporary tight. the drain hole and slowly fill the gear oil Place a block of wood between the anti- until oil flows out of the check hole and no cavitation plate and propeller to keep the air bubbles are visible.

  • Page 129: Shimming

    Drive shaft and lower case/Shimming Shimming 69D6050E 69D5G11 6-24...

  • Page 130: Selecting The Pinion Shims

    LOWR Lower unit Shimming 2. Install the pinion and pinion nut, and then tighten the nut to the specified torque. NOTE: 9 Shimming is not required when assembling Pinion nut: the original lower case and inner parts. 95 N·m (9.5 kgf·m, 68 ft·lb) 9 Shimming is required when assembling the original inner parts and a new lower case.

  • Page 131: Selecting The Forward Gear Shims

    Shimming Example: If “M3” is 32.10 mm and “P” is (–5), then T3 = 32.10 – 31.50 – (–5)/100 mm = 0.60 + 0.05 mm = 0.65 mm 5. Select the pinion shim(s) (T3) as follows. Calculated numeral Rounded numeral at 1/100th place 1, 2 3, 4, 5...

  • Page 132: Selecting The Reverse Gear Shims

    LOWR Lower unit Calculation formula: Forward gear shim thickness (T1) = 24.50 + F/100 – M1 Example: If “M1” is 24.00 mm and “F” is (+5), then T1 = 24.50 + (+5)/100 – 24.00 mm = 24.50 + 0.05 – 24.00 mm = 0.55 mm 3.

  • Page 133: Backlash

    Shimming/Backlash 3. Install the special service tools so that it Calculation formula: pushes against the propeller shaft. Reverse gear shim thickness (T2) = M2 – 28.00 – R/100 Example: If “M2” is 28.60 mm and “R” is (–1), then T2 = 28.60 mm – 28.00 mm – (–1)/100 = 28.60 –...
  • Page 134 LOWR Lower unit 5. Slowly turn the drive shaft clockwise and 9. Slowly turn the drive shaft clockwise and counterclockwise and measure the back- counterclockwise and measure the back- lash when the drive shaft stops in each lash when the drive shaft stops in each direction.

  • Page 135: Brkt

    BRKT Bracket unit Tiller handle (MHD, WHD) ................7-1 Checking the throttle cable and shift rod ..........7-5 Assembling the tiller handle ..............7-5 Lubricating the throttle gear ..............7-5 Bottom cowling .................... 7-6 Upper case, pivot shaft ................7-8 Removing the pivot shaft ...............

  • Page 136: Bracket Unit

    BRKT Bracket unit Tiller handle (MHD, WHD) 40 N·m (4.0 kgf·m, 29.5 ft·lb) 40 N·m (4.0 kgf·m, 29.5 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb) 69D7010E Part name Q’ty Remarks Clip Joint Throttle cable M6 × 16 mm Bolt Cable clamp Grommet Tiller handle bracket Plastic washer...
  • Page 137 Tiller handle (MHD, WHD) 40 N·m (4.0 kgf·m, 29.5 ft·lb) 40 N·m (4.0 kgf·m, 29.5 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb) 69D7010E Part name Q’ty Remarks Cotter pin Washer Collar Shift rod Shift rod Washer M5 × 10 mm Collar Holder Ball...
  • Page 138 BRKT Bracket unit 40 N·m (4.0 kgf·m, 29.5 ft·lb) 40 N·m (4.0 kgf·m, 29.5 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb) 69D7010E Part name Q’ty Remarks Start switch Screw Throttle grip Washer Spring Collar ø5 × 12 mm Screw ø6 × 8 mm Screw Nipple Gasket...
  • Page 139 Tiller handle (MHD, WHD) 40 N·m (4.0 kgf·m, 29.5 ft·lb) 40 N·m (4.0 kgf·m, 29.5 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb) 69D7010E Part name Q’ty Remarks Bracket M6 × 25 mm Bolt 69D5G11...

  • Page 140: Checking The Throttle Cable And Shift Rod

    BRKT Bracket unit Checking the throttle cable and shift 2. Install the throttle cable 3 into the gear 4 until the inner cable is engaged with 1. Check that the operation of the throttle the gear. 3. Turn the throttle shaft 1 clockwise to cable and shift rod.

  • Page 141: Bottom Cowling

    Tiller handle (MHD, WHD)/Bottom cowling Bottom cowling 69D7020E Part name Q’ty Remarks Clip Bushing Cotter pin Washer Ball Spring Plug Collar Washer Shift rod lever Shift rod lever assembly M6 × 12 mm Bolt Bracket Wave washer Collar Collar Cowling lock lever 69D5G11...
  • Page 142 BRKT Bracket unit 69D7020E Part name Q’ty Remarks Bracket Washer Cowling lock lever M6 × 30 mm Bolt Grommet Collar Boot Seal Grommet Damper Warning indicator Grommet Clamp WHD and WD models Shift bracket M6 × 20 mm Bolt 69D5G11...

  • Page 143: Upper Case, Pivot Shaft

    Bottom cowling/Upper case, pivot shaft Upper case, pivot shaft 69D7030E Part name Q’ty Remarks M8 × 35 mm Bolt Upper mount housing M10 × 174 mm Bolt Washer Washer Washer Upper mount Screw Cover Collar M8 × 25 mm Bolt Ground lead Washer Washer...
  • Page 144 BRKT Bracket unit 69D7030E Part name Q’ty Remarks Lower mount Washer Washer M8 × 155 mm Bolt Lower mount housing Spring Upper case 69D5G11...
  • Page 145 Upper case, pivot shaft 69D7050E Part name Q’ty Remarks Pivot shaft Washer Bushing O-ring Not reusable Bushing Bushing Mount housing Circlip 69D5G11 7-10...
  • Page 146 BRKT Bracket unit 21 N·m (2.1 kgf·m, 15.5 ft·lb) 21 N·m (2.1 kgf·m, 15.5 ft·lb) 21 N·m (2.1 kgf·m, 15.5 ft·lb) 69D7040E Part name Q’ty Remarks M8 × 30 mm Bolt Exhaust guide Gasket Not reusable M8 × 30 mm Bolt Exhaust manifold M8 ×...

  • Page 147: Removing The Pivot Shaft

    Upper case, pivot shaft Removing the pivot shaft Installing the pivot shaft Remove the circlip 1. 1. Installing the washer 1, bushing 2, a new O-ring 3, and bushing 4 onto the pivot shaft 5. 2. Place the swivel bracket 6 in an upright position, and then install the pivot shaft onto the swivel bracket.

  • Page 148: Disassembling The Upper Case

    BRKT Bracket unit 4. Install the pivot shaft 5 into the mount 2. Remove the muffler 3, exhaust manifold housing 0 by aligning the center a of 4, water pipe 5 and gasket 6. the mount housing with the center b of the pivot shaft.

  • Page 149: Installing The Upper Case

    Upper case, pivot shaft 2. Install the muffler assembly 5 into the 2. Set the lower mount 4 and bolts 5 to uppercase 6. the upper case. 3. Install the end of the springs 6 into the groove of the lower mount housing 7, and then tighten the bolts 8.
  • Page 150 BRKT Bracket unit 6. Install the ground lead w into the mount housing 7 as shown, and then install the cover e. å 69D70100 ∫ 69D70110 å S, L-transom models (port side) ∫ X-transom model (starboard side) 7-15 69D5G11...

  • Page 151: Clamp Brackets, Swivel Bracket (S, L-Transom)

    Upper case, pivot shaft/Clamp brackets, swivel bracket Clamp brackets, swivel bracket (S, L-transom) 22 N·m (2.2 kgf·m, 16.2 ft·lb) 69D7060E Part name Q’ty Remarks Tilt pin Washer Bolt Spacer M6 × 25 mm Bolt Anode M6 × 10 mm Bolt Ground lead ø6 ×...
  • Page 152 BRKT Bracket unit 22 N·m (2.2 kgf·m, 16.2 ft·lb) 69D7060E Part name Q’ty Remarks Anode Bushing M6 × 10 mm Bolt Tilt lever Grease nipple Ground lead Self-locking nut Through tube Swivel bracket Washer Bushing M6 × 10 mm Bolt Plate Spring 7-17...
  • Page 153 Clamp brackets, swivel bracket 22 N·m (2.2 kgf·m, 16.2 ft·lb) 69D7060E Part name Q’ty Remarks Collar Bushing Tilt stop lever Tilt stop lever Clamp bracket Clamp bracket Clamp handle Pad pin Clamp pad 69D5G11 7-18...

  • Page 154: Clamp Brackets, Swivel Bracket (X-Transom Model)

    BRKT Bracket unit Clamp brackets, swivel bracket (X-transom model) 15 N·m (1.5 kgf·m, 11.1 ft·lb) 8 N·m (0.8 kgf·m, 5.8 ft·lb) 69D7070E Part name Q’ty Remarks Tilt pin M6 × 16 mm Bolt M6 × 29 mm Bolt Washer Anode Plate M10 ×...
  • Page 155 Clamp brackets, swivel bracket 15 N·m (1.5 kgf·m, 11.1 ft·lb) 8 N·m (0.8 kgf·m, 5.8 ft·lb) 69D7070E Part name Q’ty Remarks Joint Grease nipple Self-locking nut Through tube Washer Bushing M6 × 10 mm Bolt Plate Spring Bushing Lever Collar Collar Tilt stop lever 69D5G11...
  • Page 156 BRKT Bracket unit 15 N·m (1.5 kgf·m, 11.1 ft·lb) 8 N·m (0.8 kgf·m, 5.8 ft·lb) 69D7070E Part name Q’ty Remarks Tilt stop lever Clamp bracket Clamp bracket Clamp handle Pad pin Clamp pad Screw Ground lead Swivel bracket 7-21 69D5G11...

  • Page 157: Removing The Hydro Tilt Assembly

    Clamp brackets, swivel bracket Removing the hydro tilt assembly ∫ 1. Fully tilt the outboard motor up, and then support it with the tilt stop lever 1. å 69D70050 ∫ 69D70225 å S, L-transom models ∫ X-transom model 69D70060 9 Do not tamper or attempt to open the å...

  • Page 158: Installing The Hydro Tilt Assembly

    BRKT Bracket unit å Installing the hydro tilt assembly 1. Fully tilt the outboard motor up, and then support it with the tilt stop lever 1. 69D70050 NOTE: After tilting up the outboard motor, be sure to support it with the tilt stop lever 1. 2.

  • Page 159: Elec

    ELEC Electrical systems Special service tools ................... 8-1 Checking the electrical components ............8-2 Measuring the peak voltage ..............8-2 Measuring low resistance ................ 8-2 Electrical components ................. 8-3 Top view ....................8-3 Port view (WD) ..................8-4 Starboard view (MHD) ................8-5 Starboard view (WHD, WD) ..............

  • Page 160: Electrical Systems

    ELEC Electrical systems Special service tools Ignition tester 90890-06754 Digital circuit tester 90890-03174 Peak voltage adaptor B 90890-03172 Test harness (4 pins) New: 90890-06875 Current: 90890-06775 69D5G11...

  • Page 161: Checking The Electrical Components

    Special service tools/Checking the electrical components Checking the electrical Measuring low resistance When measuring a resistance of 10 or less components with the digital circuit tester, the correct mea- Measuring the peak voltage surement cannot be obtained because of the internal resistance of the tester.

  • Page 162: Electrical Components

    ELEC Electrical systems Electrical components Top view 69D80010 1 Starter motor (WHD, WD) 0 Warning indicator 2 Starter relay (WHD, WD) q Neutral switch (WHD) (WD: If equipped) 3 Ignition coil 4 Spark plug 5 Lighting coil 6 Charge coil 7 Pulser coil 8 Engine start switch (WHD) 9 Engine stop lanyard switch (MHD, WHD)

  • Page 163: Port View (Wd)

    Electrical components Port view (WD) 69D80040 1 Choke solenoid 69D5G11...

  • Page 164: Starboard View (Mhd)

    ELEC Electrical systems Starboard view (MHD) 69D80020 1 Spark plug 2 Ignition coil 3 CDI unit 4 Warning indicator 5 Thermoswitch 69D5G11...

  • Page 165: Starboard View (Whd, Wd)

    Electrical components Starboard view (WHD, WD) 69D80030 1 Spark plug 2 Ignition coil 3 CDI unit 4 Starter motor 5 Warning indicator 6 Starter relay 7 Fuse 8 Rectifier 9 Thermoswitch 69D5G11...

  • Page 166: Ignition And Ignition Control System

    ELEC Electrical systems Ignition and ignition control system 69D80110 1 Spark plug B : Black 2 Ignition coil Br : Brown 3 Charge coil B/W : Black/White 4 Pulser coil W/B : White/Black 5 CDI unit W/R : White/Red W/G : White/Green 69D5G11...
  • Page 167 Ignition and ignition control system 69D80115 1 Thermoswitch å MHD, WHD ∫ WHD 2 CDI unit 3 Warning indicator 4 Engine stop lanyard switch B : Black (MHD, WHD) P : Pink 5 Engine start switch (WHD) W : White Y/R : Yellow/Red 69D5G11...

  • Page 168: Checking The Ignition Spark Gap

    ELEC Electrical systems Checking the ignition spark gap 1. Disconnect the spark plug caps from the spark plugs. ∫ 2. Connect a spark plug cap to the special service tool. å 69D80065 69D80050 Ignition coil resistance: å Primary coil: Ignition tester: 90890-06754 Black and White (B/W) —...

  • Page 169: Checking The Cdi Unit

    Ignition and ignition control system Checking the CDI unit 1. Measure the CDI unit output peak volt- age. If below specification, measure the pulser coil output peak voltage. Replace the CDI unit if the output peak voltage of the pulser coil is above specification. 69D80060 Digital circuit tester: 90890-3174 Peak voltage adaptor B:...

  • Page 170: Cdi Unit Resistance Chart (Reference)

    ELEC Electrical systems CDI unit resistance chart (reference) 1 W/R : White/Red 2 W/B : White/Black 1. Check the CDI unit terminal resistance. If 3 W/G : White/Green out of specification, replace the CDI unit. 4 B : Black 5, 6, 7 B/W : Black/White 8 Br : Brown 9 W : White 0 Y/R : Yellow/Red...

  • Page 171: Checking The Pulser Coils

    Ignition and ignition control system Checking the pulser coils Checking the charge coil 1. Disconnect the CDI unit coupler. 1. Disconnect the CDI unit coupler. 2. Connect the test harness (4 pins) to the 2. Connect the test harness (4 pins) to the pulser coil.

  • Page 172: Checking The Thermoswitch

    ELEC Electrical systems Checking the thermoswitch 1. Place the thermoswitch in a container of Make sure use the 1.5 V dry sell battery, water and slowly heat the water. other than higher voltage batteries will be burnt the diode. NOTE: LED has an direction for electrical current.

  • Page 173: Starting System (Whd, Wd)

    Ignition and ignition control system/Starting system Starting system (WHD, WD) 69D80140 1 Fuse å WHD ∫ WD 2 Engine start switch (WHD) 3 Neutral switch (WHD) (WD: if equipped) B : Black 4 Starter motor Br : Brown 5 Battery B/W : Black/White 6 Starter relay L : Blue...

  • Page 174: Checking The Fuse (Whd,Wd)

    ELEC Electrical systems Checking the fuse (WHD,WD) Switch Lead color 1. Check the fuse for continuity. Replace if position White (W) Black (B) Red (R) Yellow (Y) Brown (Br) there is no continuity. Checking the starter relay (WHD, START 1. Connect the digital circuit tester leads to Checking the neutral switch (WHD) the starter relay terminals.

  • Page 175: Starter Motor (Whd, Wd)

    Starting system/Starter motor Starter motor (WHD, WD) 69D8000E Part name Q’ty Remarks Clip Pinion stopper Spring Pinion assembly Bolt Washer Washer O-ring Not reusable Front cover O-ring Not reusable Washer set — Armature assembly Yoke assembly Bracket O-ring Not reusable Spring washer 69D5G11 8-16...
  • Page 176 ELEC Electrical systems 69D8000E Part name Q’ty Remarks Plate washer Bushing O-ring Not reusable Bushing Brush Spring Screw Brush holder Bolt Washer 8-17 69D5G11...

  • Page 177: Removing The Starter Motor Pinion

    Starter motor Removing the starter motor pinion Checking the armature 1. Slide the pinion stopper 1 down as 1. Check the commutator for dirt. Clean with shown, and then remove the clip 2. 600– grit sandpaper and compressed air if necessary. 2.

  • Page 178: Checking The Brushes

    ELEC Electrical systems 4. Check the armature for continuity. 2. Check the brush holder assembly for Replace if out of specifications. continuity. Replace if out of specifica- tions. 6F680190 69D80160 Armature continuity Brush continuity: Commutator segments c Continuity Brush holder 1 — Segment –...

  • Page 179: Charging System

    Starter motor/Charging system Charging system 69D80170 1 Rectifier (WHD, WD) B : Black 2 Lighting coil G : Green 3 Battery (WHD, WD) R : Red 4 Fuse (WHD, WD) å 1-Lighting coil model ∫ 2-Lighting coil model 69D5G11 8-20...

  • Page 180: Checking The Rectifier (Whd, Wd)

    ELEC Electrical systems Checking the rectifier (WHD, WD) Lighting coil output peak voltage: 1. Measure the rectifier output peak volt- Green (G) – Green (G) age. If below specification, measure the Unloaded lighting coil output peak voltage. Replace r/min Cranking 1,500 3,500 the rectifier if the output peak voltage of...
  • Page 181 TRBL TRBL SHTG SHTG Troubleshooting Power unit ..................... 9-1 Ignition system ..................9-1 Fuel system ..................... 9-3 Compression pressure ................9-4 Lower unit ..................... 9-7 Electrical system ..................9-8 Starting system ..................9-8 Charging system ..................9-9 69D5G11...

  • Page 182: Trbl Shtg

    TRBL TRBL SHTG SHTG Troubleshooting NOTE: 9 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. 9 Check that all electrical connections are tight and free from corrosion. Power unit Symptom: Manual starter turns and or starter motor operate but engine will not start.
  • Page 183 Power unit Ignition system (continued from previous page) Check the CDI unit output peak voltage. (Refer to page 8-10) Does the out- put peak voltage Check the connection exceed specifi- of the leads from CDI unit. cation values? Check the charge coil output peak voltage.

  • Page 184: Fuel System

    TRBL SHTG Troubleshooting Fuel system 9 Consult this chart after the ignition system has been checked. Check for water accumulation or clogging of the fuel filter and inside the carburetor. (Refer to page 3-3, 4-8) 9 Clean the fuel system from the Is there water fuel tank to the fuel filter and or residue?

  • Page 185: Compression Pressure

    Power unit Compression pressure 9 Consult this chart after the ignition and fuel systems have been checked. Measure the compression pressure. (Refer to page 5-5) Does the pressure exceed Check ignition timing. Adjust as the specification necessary. (Refer to page 3-9, 3-10) values? Add a small amount of engine oil into the cylinder through the...
  • Page 186 TRBL SHTG Troubleshooting Symptom: The engine idle speed does not remain steady. Check the carburetors synchro- nization. (Refer to page 3-5) Are they synchro- Adjust the carburetors nize correctly? syncronization. Check the throttle cable, link operation and pick up timing. (Refer to page 3-6, 3-7) Are they operat- Adjust the throttle cable, throttle...
  • Page 187 Power unit Symptom: The engine speed does not exceed 2,000 r/min. 9 Be sure use the correct octane gasoline. (Refer to page 3-5) Check the cooling water passage. 9 Clean the all water passsages clogg and clean or replase the water inlet screen.

  • Page 188: Lower Unit

    TRBL SHTG Troubleshooting Lower unit Symptom: The forward and reverse gear shift mechanism does not operate properly. Check the gear shift operation. (Refer to page 1-8) Is it operating Adjust the gear shift. correctly? Check the shift cable connection. (Refer to page 3-8) Is it connected Connect correctly or replace the properly and in...

  • Page 189: Electrical System

    Lower unit/Electrical Electrical system Symptom: The starter motor does not operate. (WHD, WD) 9 Engine stop lanyard switch is operating normally. Starting system Check the fuse for blown. (Refer to page 8-15) Is there blown? Replace the fuse. Check the battery for fully charged.

  • Page 190: Charging System

    TRBL SHTG Troubleshooting Starting system (continued from previous page) Check the starter relay for continuity. (Refer to page 8-15) Is there continuity? Replace the starter relay. Disassemble and check the starter motor. (Refer to page 8-18) Symptom: The battery loses power quickly. (WHD, WD) 9 Be sure the electrolyte level and gravity are specific condition.
  • Page 191 Checking the cylinder bore ......5-32 Checking the cylinder head ....5-26 Adjusting the ignition timing ....3-10 Checking the drive pawl ......5-17 Adjusting the pick up timing ...... 3-7 Checking the drive shaft ......6-18 Adjusting the start-in-gear protection ..3-5 Checking the electrical components ..
  • Page 192 Index Checking the spark plugs ......3-3 Fuel line ............ 4-3 Checking the spiral spring ...... 5-17 Fuel pump ..........4-10 Checking the starter motor operation ..8-19 Fuel system ..........3-3 Checking the starter motor pinion ... 8-18 Checking the starter relay (WHD, WD) ...........
  • Page 193 Propeller selection ........1-5 Propeller shaft housing ......6-11 Test run ............. 1-9 Propeller size ..........1-5 Tightening torques ........2-10 Tiller handle (MHD, WHD) ......7-1 Top cowling ..........3-3 Top view ............ 8-3 Reed valves ..........5-22 Removing the clamp brackets ....7-23 Removing the control levers ....
  • Page 194 WIRING DIAGRAM E60HMHD 1 Ignition coil Color code 2 Spark plug B : Black 3 Thermoswitch Br : Brown 4 Charge coil P : Pink 5 Pulser coil W : White 6 Lighting coil B/W : Black/White 7 CDI unit W/G : White/Green 8 Engine stop lanyard switch W/B : White/Black...
  • Page 196 YAMAHA MOTOR CO., LTD. Printed in Japan Oct. 2004 – 0.9 × 1 ! (E_2) Printed on recycled paper...
  • Page 197 E60HMHD ( F ) ( M )
  • Page 198 WIRING DIAGRAM E60HWHD, E60HWD 1 Ignition coil Color code 2 Spark plug B : Black 3 Thermoswitch Br : Brown 4 Charge coil G : Green 5 Pulser coil P : Pink 6 Lighting coil R : Red 7 CDI unit...
  • Page 199 E60HWD,E60HWHD ( F ) ( M )

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