50G, 60F, 70B,
75C, 90A
SERVICE
MANUAL
6H2-28197-Z9-11
E
NOTICE
This manual has been prepared by the Yamaha Motor Company Ltd. 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 the Yamaha Motor Company Ltd. 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.
A10001-0*
50G, 60F, 70B, 75C, 90A
SERVICE MANUAL
1999 Yamaha Motor Co., Ltd.
1st Edition, February 1999
No part of this publication may be
reproduced or transmitted in any form or by
any means including photocopying and
recording without the written permission of
the copyright holder. Such written
permission must also be obtained before
any part of this publication is stored in a
retrieval system of any nature.
E
A50000-0
HOW TO USE THIS MANUAL
MANUAL FORMAT
This manual provides the mechanic with descriptions of the operations of disassembly,
repair, assembly, adjustment and inspection, each of which is presented in a sequential, stepby-step procedure.
To assist you to find your way about this manual, the Section Title and Major Heading is
given at the head of every page.
An Index to contents is provided on the first page of each section.
MODEL INDICATION
Multiple models are shown in this manual. These indications are noted as follows.
Model name
50GETO
60FEHTO
60FED
60FEDO
60FET
60FETO
70BEDO
70BETO
USA and
Canada name
—
P60TH
C60ER
—
C60TR
—
—
70TR
Indication
50GETO
60FEHTO
60FED
60FEDO
60FET
60FETO
70BEDO
70BETO
Model name
75CET
75CETO
75CEHTO
80AETO
90AEHD
90AED
90AET
90AETO
USA and
Canada name
C75TR
75TR
P75TH
—
—
—
C90TR
90TR
B90TR
Indication
75CET
75CETO
75CEHTO
80AETO
90AEHD
90AED
90AET
90AETO
THE ILLUSTRATIONS
Some illustrations in this manual may differ from the model you have. This is because the
procedure described may relate to several models, though only one may be illustrated. (The
name of the model described will be mentioned in the description.)
To help you identify components and understand the correct procedures of disassembly and
assembly, exploded diagrams are provided. Steps in the procedures are numbered thus: 1),
2), 3). Parts shown in the illustrations are identified thus: 1, 2, 3.
REFERENCES
These have been kept to a minimum, however, when you are referred to another section of
the manual, you are told the page number to go to.
E
SPECIFICATIONS
These are given in bold type at each procedure. It is not necessary to leave the section dealing with the procedure in order to look up the specifications.
It is important to note the differences in specifications of models. Where a procedure relates
to more than one model, the main differences in specifications will be shown in the following
table.
Model name
50GETO
60FEHTO
60FED
60FEDO
60FET
60FETO
70BEDO
70BETO
USA and
Canada name
—
P60TH
C60ER
—
C60TR
—
—
70TR
Control system
Remote
control
Manual
control
Manual tilt
Power trim
and tilt
Tilt system
Power trim and tilt
Lubrication
system
Oil injection
Remote control
Manual tilt
Power trim and tilt
Pre-mixed
Oil injection
Pre-mixed
Oil injection
Model name
75CET
75CETO
75CEHTO
80AETO
90AEHD
90AED
90AET
90AETO
USA and
Canada name
C75TR
75TR
P75H
—
—
—
C90TR
90TR
B90TR
Manual
control
Remote
control
Manual
control
Control system
Remote control
Tilt system
Lubrication
system
Power trim and tilt
Pre-mixed
Oil injection
Remote control
Manual tilt
Pre-mixed
Power trim and tilt
Oil injection
WARNINGS, CAUTIONS AND NOTES
Attention is drawn to the various Warnings, Cautions and Notes which distinguish important
information in this manual in the following ways.
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 outboard motor.
NOTE:
A NOTE provides key information to make procedures easier or clearer.
E
1
A50001-1-4
2
GEN
INFO
SYMBOLS
Symbols 1 to 9 are designed as thumbtabs to indicate the content of a chapter.
SPEC
3
1
2
3
4
5
6
7
8
9
4
INSP
ADJ
FUEL
5
6
LOWR
POWR
7
General Information
Specifications
Periodic Inspection and Adjustment
Fuel System
Power Unit
Lower Unit
Bracket Unit
Electrical Systems
Trouble Analysis
8
BRKT
–
ELEC
9
Symbols 0 to F indicates specific data:
0
0
A
B
C
D
E
F
TRBL
ANLS
B
C
D
E
F
Special service tool
Specified liquid
Specified grease
Specified engine speed
Specified torque
Specified measurement
Specified electrical value
[Resistance (Ω), Voltage (V),
Electric current (A)]
T.
A
+
R.
Symbol G to J in an exploded diagram
indicate grade of lubricant and location of
lubrication point:
G
H
G
E
I
G
H
I
J
J
A
M
K
L
GM
LT
271
M
N
LT
LT
242
572
Apply engine oil
Apply gear oil
Apply molybdenum disulfide oil
Apply water resistant grease (Yamaha
marine grease A, Yamaha marine grease)
Symbols K to N in an exploded diagram
indicate grade of sealing or locking agent,
and location of application point:
K
L
M
N
Apply Gasket Maker
Apply LOCTITE No. 271 (Red LOCTITE)
Apply LOCTITE No. 242 (Blue LOCTITE)
Apply LOCTITE No. 572
NOTE:
In this manual, the above symbols may not
be used in every case.
E
A30000-0
INDEX
GENERAL INFORMATION
SPECIFICATIONS
PERIODIC INSPECTION AND
ADJUSTMENT
FUEL SYSTEM
POWER UNIT
LOWER UNIT
BRACKET UNIT
GEN
INFO
SPEC
INSP
ADJ
FUEL
POWR
LOWR
BRKT
–
ELECTRICAL SYSTEMS
TROUBLE ANALYSIS
+
ELEC
TRBL
ANLS
1
2
3
4
5
6
7
8
9
GEN
INFO
E
CHAPTER 1
GENERAL INFORMATION
IDENTIFICATION ............................................................................................ 1-1
SERIAL NUMBER ..................................................................................... 1-1
STARTING SERIAL NUMBERS ............................................................... 1-1
SAFETY WHILE WORKING ............................................................................ 1-2
FIRE PREVENTION ................................................................................... 1-2
VENTILATION........................................................................................... 1-2
SELF-PROTECTION.................................................................................. 1-2
OILS, GREASES AND SEALING FLUIDS................................................ 1-2
GOOD WORKING PRACTICES ................................................................ 1-3
DISASSEMBLY AND ASSEMBLY ........................................................... 1-4
SPECIAL TOOLS ............................................................................................. 1-5
MEASURING ............................................................................................ 1-6
REMOVAL AND INSTALLATION ............................................................ 1-8
1
2
3
4
5
6
7
8
9
GEN
INFO
IDENTIFICATION
E
A60000-1*
IDENTIFICATION
SERIAL NUMBER
The serial number of the outboard motor is
stamped on a plate attached to the port side
of the clamp bracket.
1 Serial number
NOTE:
For USA model:
As an anti-theft measure, a special label on
which the outboard motor serial number is
stamped is bonded to the port side of the
clamp bracket. The label is specially treated
so that peeling it off causes cracks across
the serial number.
1
2
3
4
Model name
Approved model No.
Transom height
Serial number
STARTING SERIAL NUMBERS
The starting serial number blocks are as follows:
Model
Worldwide
USA
Canada
Approved
model No.
50GETO
—
—
62F
60FEHTO
P60TH
P60TH
60FED
—
C60ER
60FEDO
—
—
C60TR
C60TR
L: 400805 ~
Model
Worldwide
USA
Canada
70BEDO
—
—
L: 551924 ~
—
—
Serial
number
6H3
L: 491824 ~
L: 402029 ~
70TR
70TR
S: 001118 ~
75CET
C75TR
C75TR
L: 001251 ~
L: 305624 ~
75CETO
—
75TR
L: 951540 ~
S: 100850 ~
75CEHTO
P75TH
—
80AETO
—
—
L: 407212 ~
S: 050474 ~
L: 357665 ~
90AEHD
—
—
X: 710231 ~
90AED
—
—
S: 150756 ~
60FETO
Approved
model No.
70BETO
X: 750186 ~
6H2
60FET
Serial
number
L: 472180 ~
X: 732000 ~
90AET
C90TR
C90TR
90AETO
90TR
B90TR
90TR
1-1
X: 731262 ~
6H0
L: 900371 ~
L: 457543 ~
X: 851331 ~
L: 320132 ~
L: 401108 ~
6H1
L: 354053 ~
L: 498690 ~
X: 856313 ~
GEN
INFO
SAFETY WHILE WORKING
E
SAFETY WHILE WORKING
The procedures given in this manual are
those recommended by Yamaha to be followed by Yamaha dealers and their
mechanics.
FIRE PREVENTION
Gasoline (petrol) is highly flammable.
Petroleum vapor is explosive if ignited.
Do not smoke while handling and keep it
away from heat, sparks, and open flames.
VENTILATION
Petroleum vapor is heavier than air and if
inhaled in large quantities will not support
life. Engine exhaust gases are harmful to
breathe. When test-running an engine
indoors, maintain good ventilation.
SELF-PROTECTION
Protect your eyes with suitable safety
glasses or safety goggles when using compressed air, when grinding or when doing
any operation which may cause particles to
fly off.
Protect hands and feet by wearing safety
gloves or protective shoes if appropriate to
the work you are doing.
OILS, GREASES AND SEALING
FLUIDS
Use only genuine Yamaha oils, grease and
sealing fluids or those recommended by
Yamaha.
1-2
GEN
INFO
SAFETY WHILE WORKING
E
Under normal conditions of use, there
should be no hazards from the use of the
lubricants mentioned in this manual. However, safety is all-important and by adopting good safety practices, any risk is
minimized.
A summary of the most important precautions is as follows:
1. While working, maintain good standards of personal and industrial
hygiene.
2. Clothing which has become contaminated with lubricants should be
changed as soon as practicable, and
laundered before further use.
3. Avoid skin contact with lubricants; do
not, for example, place a soiled wipingrag in one’s pocket.
4. Hands, and any other part of the body
which have been in contact with lubricants or lubricant-contaminated clothing, should be thoroughly washed with
hot water and soap as soon as practicable.
5. To protect the skin, the application of a
suitable barrier cream to the hands
before working is recommended.
6. A supply of clean, lint-free cloths should
be available for wiping purposes.
GOOD WORKING PRACTICES
1. The right tools
Use the special tools that are advised to
protect parts from damage. Use the
right tool in the right manner - don’t
improvise.
2. Tightening torque
Follow the torque tightening instructions. When tightening bolts, nuts and
screws, tighten the larger sizes first, and
tighten inner-positioned fixings before
outer-positioned ones.
1-3
GEN
INFO
SAFETY WHILE WORKING
E
3. Non-reusable items
When reassembling, always use new
gaskets, packing, O-rings, oil seals,
split-pins and circlips, etc.
DISASSEMBLY AND ASSEMBLY
1. Clean parts with compressed-air when
disassembling them.
2. Oil the contact surfaces of moving parts
before assembly.
3. After assembly, check that moving parts
operate normally.
4. Install bearings with the manufacturer’s
markings on the side exposed to view
and liberally oil the bearings.
5. When installing oil seals, apply a light
coating of water-resistant grease to the
outside circumference.
1-4
GEN
INFO
SPECIAL TOOLS
E
A80000-0*
SPECIAL TOOLS
The use of correct special tools recommended by Yamaha will aid the work and enable accurate assembly and tune-up. Improvisations and use of improper tools can cause damage to
the equipment.
NOTE:
● For USA and Canada, use part numbers starting with “YB-”, “YM-”, “YU-” or “YW-”.
● For others, use part numbers starting with “90890-”.
1-5
GEN
INFO
SPECIAL TOOLS
E
MEASURING
Tool name
1
2
3
4
5
6
7
8
9
10
11
Tachometer
Dynamic spark tester
CDI tester
Mity Vac
Pressure tester
Dial gauge
Backlash indicator
Magnet base
Backlash adjusting plate
Thickness gauge
Pinion height gauge
12
Digital caliper
13
14
15
16
17
18
19
20
21
22
23
24
Gauge block
Adapter plate
Gauge base
Clamp
Shimming plate
Base plate
Compression spring
Press plate
Gauge pin
Digital multimeter
Pocket tester
Pressure gauge
25
Shimming gauge
26
3 pins test harness
Tool No.
Except for
USA and
USA and
Canada a
Canada b
YU-08036-A
90890-06760
YM-34487
90890-06754
YU-91022-B
N.A.
YB-35956
90890-06756
YB-35956
90890-06762
YU-03097
90890-01252
YB-06265
90890-06706
YU-34481
90890-06705
YB-07003
N.A.
YU-26900-8
N.A.
N.A.
90890-06702
Use for:
N.A.
90890-06704
YB-34432-9
YB-34432-10
YB-34432-11
YB-34432-17
N.A.
YB-34446-1
YB-34446-3
YB-34446-5
YB-34446-7
YU-34899-A
YU-03112
YB-06181
YB-34468-3
YB-34468-5
YB-06443
N.A.
N.A.
N.A.
N.A.
90890-06701
N.A.
N.A.
N.A.
N.A.
90890-06752
90890-03112
N.A.
Idle speed
Ignition system
Ignition system
Fuel joint
Lower case
Backlash
Backlash
Backlash
Backlash
Shimming
Pinion shimming
Pinion
Forward
shimming
shimming
Pinion shimming
Pinion shimming
Pinion shimming
Pinion shimming
Forward shimming
Forward shimming
Forward shimming
Forward shimming
Forward shimming
Electrical
Electrical
PTT unit
N.A.
Reverse shimming
90890-06757
Peak voltage measurement
1-6
GEN
INFO
SPECIAL TOOLS
E
1-7
GEN
INFO
SPECIAL TOOLS
E
REMOVAL AND INSTALLATION
1
Small end bearing installer
2
Piston slider
Tool No.
Except for
USA and
USA and
Canada a
Canada b
YB-06107
90890-06527
YB-06287
YU-33294
90890-06530
3
Slide hammer set
YB-06096
N.A.
4
Stopper guide plate
N.A.
90890-06501
5
Bearing puller
N.A.
90890-06535
6
Stopper guide stand
N.A.
90890-06538
7
Ring nut wrench
8
Extension
YB-06048
YB-34447
N.A.
9
Claw
YB-06207
10
11
Universal puller
Center bolt
YB-06117
N.A.
90890-06510
90890-06511
90890-06513
90890-06502
90890-06503
N.A.
90890-06504
12
Drive rod
YB-06071
90890-06602
13
Needle bearing attachment
14
Drive shaft holder
15
16
17
Pinion nut holder
Bearing outer race puller
Needle bearing attachment
YB-06153
YB-06049
YB-06151
N.A.
N.A.
YB-06155
90890-06612
90890-06518
90890-06519
90890-06505
90890-06523
90890-06611
18
Bearing separator
YB-06219
90890-06534
19
Drive rod
YB-06071
20
Needle bearing attachment
YB-06153
90890-06604
90890-06612
90890-06614
Tool name
1-8
Use for:
Connecting rod
Cylinder piston
Water pump housing oil seal
Reverse gear bearing
Propeller shaft housing oil seal
Drive shaft outer bearing
Forward gear outer bearing
Water pump housing oil seal
Bearing housing
Reverse gear bearing
Propeller shaft housing oil seal
Drive shaft outer bearing
Water pump housing oil seal
Reverse gear bearing
Propeller shaft housing oil seal
Drive shaft outer bearing
Water pump housing oil seal
Reverse gear bearing
Propeller shaft housing oil seal
Drive shaft outer bearing
Ring nut
Ring nut
Propeller shaft housing
Propeller shaft housing
Propeller shaft housing
Propeller shaft housing oil seal
Drive shaft needle bearing
Propeller shaft housing bearing
Pinion nut
Pinion nut
Forward gear outer bearing
Drive shaft needle bearing
Crank shaft bearing
Reverse gear bearing
Forward gear bearing
Propeller shaft needle bearing
Propeller shaft needle bearing
GEN
INFO
SPECIAL TOOLS
E
1-9
GEN
INFO
SPECIAL TOOLS
Tool name
E
Tool No.
Except for
USA and
USA and
Canada a
Canada b
21
Bearing depth plate
22
23
24
29
30
Oil seal attachment
Needle bearing depth stop
Driver rod
Bearing outer race attachment
Driver rod
Bearing outer race attachment
Bearing inner race attachment
Shift rod wrench
Cylinder end screw wrench
YB-06052
YB-06175-1A
31
Cylinder end screw wrench
YB-06175-2B
32
33
Flywheel holder
Flywheel puller
25
26
27
28
N.A.
90890-06603
YB-06269
YB-34473
YB-06071
N.A.
N.A.
90890-06606
90890-06626
90890-06627
90890-06605
90890-06621
90890-06622
90890-06640
90890-06662
N.A.
N.A.
90890-06544
90890-06548
90890-06522
90890-06521
YB-06156
YB-06071
YB-06276-B
N.A.
YB-06139
YB-06117
1-10
Use for:
Propeller shaft needle bearing
Drive shaft needle bearing
Propeller shaft oil seal
Drive shaft needle bearing
Drive shaft outer bearing
Drive shaft outer bearing
Forward gear outer bearing
Forward gear outer bearing
Forward gear inner bearing
Shift rod
PTT
PTT
Flywheel
Flywheel
SPEC
E
CHAPTER 2
SPECIFICATIONS
GENERAL SPECIFICATION ............................................................................ 2-1
MAINTENANCE SPECIFICATIONS................................................................ 2-5
ENGINE..................................................................................................... 2-5
ELECTRICAL ............................................................................................. 2-7
DIMENSION............................................................................................ 2-10
TIGHTENING TORQUE ................................................................................ 2-12
GENERAL TORQUE SPECIFICATIONS ....................................................... 2-13
1
2
3
4
5
6
7
8
9
SPEC
GENERAL SPECIFICATION
E
C20000-0*
GENERAL SPECIFICATION
Unit
Model
Approved model No.
Overall Length
Overall width
Overall height
Boat transom height
O/M transom height
Weight (Al.)
Weight (SUS.)
mm (in)
S
L
X
S
L
X
S
L
X
S
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
kg (lb)
L
kg (lb)
X
kg (lb)
S
kg (lb)
L
kg (lb)
X
kg (lb)
r/min
Full throttle speed range
Output (ISO)
Maximum fuel consumption
Type
Cylinders
Total displacement
Bore × Stroke
Compression ratio
Compression pressure
Carburetor number
Intake system
kW (hp) @ r/min
L (US gal, lmp
gal)/h @ r/min
cm3 (cu in)
mm (in)
kPa (kg/cm2)
Model
60 hp
70 hp
*1: P60TH/
*3: 70BEDO
*5: 70TR/70BETO
60FEHTO
*2: C60ER/60FED
*3: 60FEDO
*4: C60TR/60FET
*5: 60FETO
62F
6H2
6H3
698 (27.5)
713 (28.1)
—
1,330 (52.4)*1
—
364 (14.3)
—
1,252 (49.3)*2,3,4
—
1,351 (53.2)
1,374 (54.1)
—
1,501 (59.1)*1,4,5
—
381 (15.0) *2,3,4,5
—
508 (20.0)
—
635 (25.0)*1,4,5
—
400 (15.7) *2,3,4,5
—
520 (20.5)
521 (20.5)
—
648 (25.5)*1,4,5
—
94 (207)*2
—
95.5 (211)*3
104 (229)*4
103.5 (228)*5
102 (225)
97.5 (215)*3
105.5 (233)*5
112 (247)*1
—
96 (212)*2
106 (234)*4
—
115 (254)*1
108.5 (239)*5
*4
109 (240)
—
97.5 (215)*3
—
*5
—
105.5 (233)
—
—
99.5 (219)*3
—
107.5 (237)*5
—
110.5 (244)*5
4,500 ~ 5,500
5,000 ~ 6,000
36.8 (50) @ 5,000 44.1 (60) @ 5,000 51.5 (70) @ 5,500
22 (5.81, 4.84)
23 (6.08, 5.06)
26 (6.87, 5.72)
@ 5,500
@ 5,500
@ 5,500
2 stroke - L
3
849 (51.8)
72.0 × 69.5 (2.83 × 2.74)
6.33
6.10
853 (8.53)
3
Reed valve
50 hp
50GETO
2-1
SPEC
GENERAL SPECIFICATION
Unit
Model
Approved model No.
Overall Length
mm (in)
Overall Width
mm (in)
Overall Height
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
kg (lb)
kg (lb)
X
S
L
kg (lb)
kg (lb)
kg (lb)
X
Full throttle speed range
Output (ISO)
Maximum fuel consumption
kg (lb)
r/min
O/M transom height
Weight (Al.)
Weight (SUS.)
Type
Cylinders
Total Displacement
Bore × Stroke
Compression ratio
Compression pressure
Carburetor number
Intake system
75hp
C75TR/75CET*1
75TR/75CETO*2
P75TH/75CEHTO*3
Model
80hp
80AETO
6H0
S
L
X
S
L
X
S
L
X
S
L
Boat transom height
E
kW (hp) @ r/min
L (US gal, lmp
gal)/h @ r/min
cm3 (cu in)
mm (in)
kPa (kg/cm2)
(28.6)*1,2
726
1,343 (52.9)*3
374 (14.7)*1,2
398 (15.7)*3
—
—
—
119.5 (263)*1
120.5 (266)*2
124.5 (275)*3
—
121.5 (268)*1
122.5 (270)*2
—
726 (28.6)
—
374 (14.7)
—
—
1,413 (55.6)
1,540 (60.6)
—
508 (20.0)
635 (25.0)
—
520 (20.5)
647 (25.5)
—
120.5 (266)
123.5 (272)
—
122.5 (270)
90hp
90AEHD*1
90AED*2
C90TR/90AET*3
90TR/90AETO*4
B90TR/90AETO*4
6H1
726 (28.6)*2,3,4
1,343 (52.9)*1
374 (14.7)*2,3,4
398 (15.7)*1
1,540 (60.6)*4
635 (25.0)*4
647 (25.5)*4
115.5 (255)*1
111.5 (246)*2
119.5 (263)*3
120.5 (266)*4
123.5 (272)*4
113.5 (250)*2
121.5 (268)*3
122.5 (270)*4
125.5 (277)*4
125.5 (277)
4,500 ~ 5,500
55.2 (75) @ 5,000 58.8 (80) @ 5,000 66.2 (90) @ 5,000
32 (8.45, 7.04)
34.5 (9.11, 7.59)
@ 5,500
@ 5,500
2 stroke-L
3
1,141 (69.6)
82.0 × 72.0 (3.23 × 2.83)
5.90
5.86
922 (9.22)
3
Reed valve
2-2
SPEC
GENERAL SPECIFICATION
Unit
Scavenging system
Starting system
Ignition system
Alternator output
Carburetor starting system
Advance type
Spark plug (NGK)
Spark plug with noise
suppressor (NGK)
Exhaust system
Cooling system
Lubrication system
Fuel type
Fuel rating
Engine oil type/grease
Gear oil type
Gear oil quantity
Engine oil tank capacity
Tilt angle (Manual tilt model)
Tilt-up angle
S
L, X
Trim angle (PTT model)
Steering angle
*1:
*2:
*3:
*4
:
*5:
*6:
60 hp
Model
70 hp
75 hp
Loop charge
Electric
CDI
80 hp
90 hp
6A
10A
*1
Choke valve /Prime start
Micro computer
BR8HS-10
B8HS-10
BR8HS-10/Register plug-cap (standard)
P.O.N.*3
cm3 (US oz,
lmp oz)
L (US qt,
lmp qt)
degree
degree
Through prop boss
Water
Pre-mixed gasoline & oil *2/Oil injection
Regular gasoline
Min.86
TC-W3*4
Hypoid gear oil-SAE#90*5
500
610 (20.62, 21.47)
(16.91,
17.60)
2.8 (2.96, 2.46)
3.3 (3.49, 2.90)
8/12/16/20/24
63
—
67
at 12 transom
degree
(left + right)
–4 ~ 15
35 + 35
–4 ~ 16
30 + 30
F-N-R*6
Gear shift position
Gear ratio
Gear type
Clutch type
Propeller direction
Propeller drive system
Propeller series mark
Battery capacity
Cold cranking
50 hp
E
14:24
(1.714)
Ah (kC)
Amps
12:28
(2.333)
Spiral bevel gear
Dog clutch
Clockwise
Spline
K
70 (252)
380
For C60ER, C60TR, C75TR
For C60ER/60FED, C60TR/60FET, C75TR, 90AEHD, 90AED, C90TR/90AET
Pump Octane Number; (Research octane + Motor octane)/2
YAMALUBE two-cycle outboard motor oil is recommended in USA
YAMALUBE 1 is recommended in Canada
GEAR CASE LUBE is recommended in USA
Forward-Neutral-Reverse
2-3
13:26
(2.000)
SPEC
GENERAL SPECIFICATION
Item
Unit
Propeller
No. of blades × diameter
× pitch
in
Item
Unit
Propeller
No. of blades × diameter
× pitch
in
P: High performance
propeller
Model
50 hp
G type (aluminum)
3 × 11-3/8 × 12
3 × 11-1/8 × 13
Model
60, 70 hp
K type (aluminum)
K type (stainless)
3 × 13 × 17
3 × 13-1/4 × 17
3 × 13 × 19
3 × 13 × 23
3 × 13 × 21
3 × 12-5/8 × 21
3 × 13 × 23
3 × 13 × 19
3 × 13 × 25
3 × 13-1/2 × 15
3 × 13-1/2 × 14
3 × 13-5/8 × 13
3 × 13-1/2 × 16
P type (stainless)
3 × 14 × 20
3 × 14 × 24
3 × 14 × 28
in
Item
Unit
Propeller
No. of blades × diameter
× pitch
in
P: High performance
propeller
E
Model
75, 80, 90 hp
K type (aluminum)
K type (stainless)
3 × 13 × 17
3 × 12-5/8 × 21
3 × 13 × 19
3 × 13 × 19
3 × 13 × 21
3 × 13 × 23
3 × 13 × 23
3 × 13-1/4 × 17
3 × 13 × 25
3 × 13-1/2 × 15
3 × 13-1/2 × 14
3 × 13-1/2 × 17
3 × 13-1/2 × 16
3 × 13-5/8 × 13
3 × 14 × 11
P type (stainless)
3 × 14 × 20
3 × 14 × 22
3 × 14 × 24
3 × 14 × 26
3 × 14 × 28
in
2-4
SPEC
MAINTENANCE SPECIFICATIONS
E
C31000-0*
MAINTENANCE SPECIFICATIONS
ENGINE
Item
Unit
Cylinder head:
Warpage limit
mm (in)
(Lines indicate straight
measurement)
Cylinder:
Bore size
mm (in)
Taper limit
Out of round limit
Piston:
Piston to cylinder
clearance
<Limit>
Piston size “D”
50 hp
60 hp
Model
70 hp
75 hp
mm (in)
mm (in)
Measuring point “H”
mm (in)
Oversize
mm (in)
mm (in)
mm (in)
1st
2nd
Offset
[direction]
Piston ring:
Sectional sketch
Top ring & 2nd ring
Type
B
T
End gap [installed]
Top ring & 2nd ring
Side clearance
Top ring & 2nd ring
90 hp
0.1 (0.004)
72.00 ~ 72.02
(2.834 ~ 2.835)
mm (in)
mm (in)
mm (in)
80 hp
82.00 ~ 82.02
(3.228 ~ 3.229)
0.08 (0.003)
0.05 (0.002)
0.050 ~ 0.055
(0.0020 ~ 0.0022)
0.105 (0.0041)
71.945 ~ 71.970
(2.8325 ~ 2.8335)
0.060 ~ 0.065
(0.0024 ~ 0.0026)
0.115 (0.0045)
81.935 ~ 81.960
(3.2258 ~ 3.2268)
10 (0.4)
72.25 (2.844)*
72.50 (2.854)
0.5 (0.0197)
[Exhaust side]
82.25 (3.238)*
82.50 (3.248)
1.0 (0.039)
[Exhaust side]
Keystone
mm (in)
mm (in)
3.0 (0.12)
2.0 (0.08)
3.2 (0.13)
mm (in)
0.3 ~ 0.5 (0.012 ~ 0.020)
0.4 ~ 0.6 (0.016 ~ 0.024)
mm (in)
0.03 ~ 0.07
(0.0012 ~ 0.0028)
0.03 ~ 0.06
(0.0012 ~ 0.0024)
*: Except for USA
2-5
SPEC
MAINTENANCE SPECIFICATIONS
Item
Unit
Crankshaft:
Crank width “A”
Crank width “B”
Crank width “C”
Maximum deflection
“D”
Connecting rod side
clearance “E”
Connecting rod maximum axial play “F”
Carburetor:
Stamp mark
60 hp
Model
70 hp
75 hp
80 hp
90 hp
mm (in) 57.90 ~ 57.95 (2.280 ~ 2.281)
—
mm (in) 151.7 ~ 152.0 (5.972 ~ 5.984)
—
mm (in) 245.5 ~ 246.1 (9.67 ~ 9.69) 284.2 ~ 284.8 (11.19 ~ 11.21)
mm (in)
0.03 (0.0012)
0.05 (0.0020)
mm (in)
0.20 ~ 0.70 (0.008 ~ 0.028)
mm (in)
0.12 ~ 0.26 (0.005 ~ 0.010)
2.0 (0.08)
62F00
Main jet
Main air jet
Pilot jet
Pilot air jet
Pilot screw
50 hp
E
(M.J.)
(M.A.J.)
(P.J.)
(P.A.J.)
(P.S.)
6H20A, 6H30A 6H007, 6H007 6H107
6H210*1
6H015*2
150
160
#
125
140,
*3
145 (L)
160
180
175
#
170
175, 180*1
*1
*2
#
65
65, 70
75
78, 80
78
78
*1
*2
#
70
75, 80
70
80, 75
80
70
1-1/2
±
1/4,
Turns out 1-3/8 ± 1/4
1-1/4 ± 1/4
1-3/8 ± 1/4
1-1/4 ± 1/4
1-3/8 ± 1/4*1
Float height
(F.H.)
mm (in)
Valve seat size
ø
Idling speed
Oil injection pump:
Stamped mark
Discharge
r/min
1.90 ± 0.50
(US oz, (0.064 ± 0.017,
lmp oz) 0.067 ± 0.018)
mm (in)
Warpage limit
mm (in)
14.0 ± 1.0 (0.55 ± 0.04)
14.0 ± 2.0 (0.55 ± 0.08)*1
19.5 ± 3.0 (0.77 ± 0.12)*2
1.2 (0.047) 1.6 (0.063), 1.4 (0.055)
1.4 (0.055)*1
800 ± 50
62F00
cm3
Reed valve:
Stopper height
*1:
*2:
*3:
15.0 ± 1.0
(0.59 ±
0.04)
6H302
2.20 ± 0.50
(0.074 ± 0.017,
0.077 ± 0.018)
3.0 ± 0.2
(0.12 ± 0.01)
6H102
3.10 ± 0.70
(0.105 ± 0.024,
0.109 ± 0.025)
9.9 ± 0.2 (0.39 ± 0.01)
0.2 (0.01)
For C60ER, C60TR
For C75TR
Lower cylinder
2-6
1.6 (0.063)
SPEC
MAINTENANCE SPECIFICATIONS
Item
Thermostat:
Valve opening temperature
Full-opening temperature
Valve lift
Unit
50 hp
E
Model
70 hp
75 hp
60 hp
°C (°F)
48 ~ 52 (118 ~ 126)
°C (°F)
60 (140)
mm (in)
3 (0.12)
80 hp
90 hp
80hp
90hp
C32000-0*
ELECTRICAL
Item
Ignition system:
Ignition timing
at full reversed
at full advanced
cam roller pick-up
Piston position
at full advanced
Charging coil resistance
[20°C (68°F)]
Charge coil output peak
voltage
(minimum)
color
@ cranking (open)
@ cranking (connect)
@ 1,500 r/min
@ 3,500 r/min
Pulser coil resistance
[20°C (68°F)]
Pulser coil output peak
voltage
(minimum)
color
@ cranking (open)
@ cranking (connect)
@ 1,500 r/min
@ 3,500 r/min
Unit
ATDC
degree
BTDC
degree
ATDC
degree
50hp
60hp
Model
70hp
75hp
7±1
22 ± 1
8±1
20 ± 1
22 ± 1
7±1
8±1
3.23 ± 0.28
(0.127 ± 0.11)
2.83 ± 0.27
(0.111 ± 0.011)
3.41 ±
0.29
(0.134 ±
0.011)
64 ~ 96 (Br – R)
191 ~ 288 (B – R)
Ω
2.68 ±
0.26
(0.106 ±
0.010)
136 ~ 204 (Brown – Blue)
V
V
V
V
Ω
Br – L
120
150
160
120
240 ~ 360 (W/R – W/B)
R – Br
R–L
55
90
60
100
170
135
150
135
241 ~ 362 (W/R – W/B)
V
V
V
V
W/R – W/B
4.5
2.5
6.5
10
W/R – W/B
7.0
5.0
14
20
BTDC
mm (in)
2-7
SPEC
MAINTENANCE SPECIFICATIONS
Item
Ignition coil:
Primary coil resistance
[20°C (68°F)]
Secondary coil resistance
[20°C (68°F)]
Crank position sensor
resistance [20°C (68°F)]
Crank position sensor
peak voltage: (minimum)
color
@ cranking (open)
@ cranking (connect)
@ 1,500 r/min
@ 3,500 r/min
Spark plug:
Spark plug gap
CDI unit output peak
voltage:
(minimum)
color
@ cranking (open)
@ cranking (connect)
@ 1,500 r/min
@ 3,500 r/min
Lighting system:
Lighting coil resistance
STD (12V 80W)
[20°C (68°F)]
Lighting coil output
peak voltage (minimum)
color
@ cranking (open)
@ cranking (connect)
@ 1,500 r/min
@ 3,500 r/min
Starter motor:
Rating
Output
Clutch type
Brush length
<Wear limit>
Commutator undercut
<Repair limit>
Unit
50hp
60hp
E
Model
70hp
75hp
80hp
90hp
Ω
0.18 ~ 0.24 (Black/White – Black)
kΩ
3.26 ~ 4.88 (Black/White – High tension cord)
Ω
158 ~ 236 (Blue/White – Blue/Red)
V
V
V
V
L/R – L/W
5.0
5.0
20
16
mm (in)
L/R – L/W
5.5
5.5
25
20
0.9 ~ 1.0 (0.035 ~ 0.039)
V
V
B/W – B
—
#1, 3: 105
#2: —
145
105
B/W – B
—
#1,3: 130
#2: —
155
130
Ω
0.57 ~ 0.85 (G/W – G)
0.4 ~ 0.6 (G/W – G)
V
V
V
V
G – G/W
8.5
8.0
25
25
G – G/W
10
11
25
25
Sec
kW
0.6
V
V
30
1.0
Overrunning
mm (in)
mm (in)
mm (in)
mm (in)
12.5 (0.49)
9.0 (0.35)
16.0 (0.63)
12.0 (0.47)
0.8 (0.03)
0.2 (0.01)
2-8
SPEC
MAINTENANCE SPECIFICATIONS
Model
70hp
75hp
E
Item
Unit
Commutator outside
diameter
<Repair limit>
Pinion/ring gear gap
Others:
Electrothermal valve
resistance [20°C (68°F)]
Fuel enrichment valve
resistance [20°C (68°F)]
Trim sensor resistance
mm (in)
60hp
30 (1.18)
mm (in)
mm (in)
29 (1.14)
31 (1.22)
3.0 ~ 5.0 (0.12 ~ 0.20)
Ω
2.3 ~ 3.5 (L – B)
Ω
3.4 ~ 4.0 (L – B)
Ω
360 ~ 540 (P – B)
800 ~ 1,200 (B – O)
20
Fuse
50hp
A
2-9
80hp
33 (1.30)
90hp
SPEC
MAINTENANCE SPECIFICATIONS
E
DIMENSION
Item
L6
L7
H4
H9
H12
W5
A1
A2
A3
T1
*1: For
*2:
Unit
S
L
X
S
L, X
S
L
X
S
L, X
S
L
X
S
L, X
S
L, X
mm (in)
mm (in)
Model
60, 70 hp
868 (34.2)
50 hp
—
918 (36.1)
—
—
75, 80, 90 hp
—
968 (38.1)
1,081 (42.6)
403 (15.9)
—
457 (18.0)
—
411 (16.2)
mm (in)
—
mm (in)
—
—
400 (15.7)
520 (20.5)
648 (25.5)
719 (28.3)
647 (25.5)
—
730 (28.7)
—
203 (8.0)
706 (27.8)
mm (in)
—
204 (8.0)
—
mm (in)
degree
degree
—
degree
—
135 (5.3)
205 (8.1)
264 (10.4)
321 (12.6)
35
mm (in)
63
67, 62*1
0
4
—
P60TH/60FEHTO, P75TH/75CEHTO
Except for P75TH/75CEHTO, 90AEHD
2-10
331 (13.0)
30
—
—
600 (23.6)*2
SPEC
MAINTENANCE SPECIFICATIONS
Unit
B1
B2
B3
B4
B5
B6
B7
B8
B9
D1
D2
D4
S
L, X
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
E
Model
50 hp
60 hp
125.4 (4.9)
254 (10.0)
163.5 (6.4)
50.8 (2.0)
180 (7.1)
329 (13.0)
351 (13.8)
138.1 (5.4)
203.2 (8.0)
18.5 (0.7)
13 (0.5)
55.5 (2.2)
12 (0.5)
—
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
2-11
70 hp
75, 80, 90 hp
—
SPEC
TIGHTENING TORQUE
E
C33000-0
TIGHTENING TORQUE
Parts to be tightened
Q’ty
Part Thread
name
size 50, 60, 75, 80,
70 hp 90 hp
Tightening torque
Nm
m • kg ft • lb
Remarks
Pinion nut
Lower case mounting
Propeller
Tiller handle mounting
Handle bracket mounting
—
6
Bolt
M8
—
14
—
14
14
Bolt
M6
16
—
Bolt
M8
—
18
Bolt
M6
M14
M20
M8
M8
M12
M10
M22
M8
M8
M8
M8
8
Nut
—
Nut
M12
1
—
75
7.5
54
Nut
Bolt
Nut
Nut
Nut
M16
M10
M16
M10
M10
1
5
1
1
2
1
5
1
1
2
95
40
35
38
38
9.5
4.0
3.5
3.8
3.8
69
29
25
27
27
2-12
E
M8
E
Bolt
E
8
E
17
11
15
15
15
15
94
105
8
LT
2.4
1.5
2.1
2.1
2.1
2.1
13
14.5
M10
242
24
15
21
21
21
21
130
145
Bolt
LT
2
1
11
4
4
4
—
1
—
271
2
1
11
4
4
4
1
1
6
Spark plug
Bolt
Flywheel
Nut
Power unit mounting
Bolt
Starter motor mounting
Bolt
Straight screw plug
Screw
UPPER CASE AND GEAR CASE:
Upper mount rubber
Nut
Bracket bolt
Nut
Upper case mounting
Bolt
Exhaust guide
Bolt
Exhaust manifold
Bolt
Muffler
Bolt
Ring nut
—
3
1
8
2
1
M8
LT
2nd
12
—
12
3
1
11
2
1
Bolt
572
Intake manifold
1st
2nd
1st
2nd
1st
12
LT
Exhaust cover
2nd
2.9
8.7
7.2
14
14
29
8.7
25
11
23
22
2.2
5.8
6.5
13
2.9
5.8
8.7
18
115
15
14
1.7
—
572
Cylinder head
0.4
1.2
1.0
2.0
2.0
4.0
1.2
3.5
1.5
3.2
3.0
0.3
0.8
0.9
1.8
0.4
0.8
1.2
2.5
16.0
2.1
2.0
2.3
M6
50 hp
E
Connecting rod
4
12
10
20
20
40
12
35
15
32
30
3
8
9
18
4
8
12
25
160
21
20
23
Bolt
50 hp
E
Crank case
1st
2nd
1st
2nd
1st
2nd
1st
2nd
1st
E
ENGINE:
TIGHTENING TORQUE/
GENERAL TORQUE SPECIFICATIONS
SPEC
Parts to be tightened
Q’ty
Part Thread
name
size 50, 60, 75, 80,
70 hp 90 hp
E
Tightening torque
Nm
m • kg ft • lb
Remarks
POWER TRIM AND TILT:
Tilt cylinder end screw
Screw
—
1
Trim cylinder end screw
Screw
—
2
Fluid-level plug
Bolt
—
1
Lock nut
Nut
—
6
Valve spring mounting
Screw
—
2
Valve lock screw
Screw
—
1
Bolt
M6
3
Manual valve
Screw
—
1
Main valve
Screw
—
2
Gear pump mounting
Nut (A)
8 mm
10 mm
12 mm
14 mm
17 mm
Bolt (B)
M5
M6
M8
M10
M12
—
1
—
2
—
1
—
6
2
—
1
—
3
1
—
2
80
90
70
160
3
7
10
15
4
13
4
5
4
3
10
11
8.0
9.0
7.0
16.0
0.3
0.7
1.0
1.5
0.4
1.3
0.4
0.5
0.4
0.3
1.0
1.1
58
65
50
115
2.2
5.1
7.2
11
2.9
9.4
2.9
3.6
2.9
2.2
7.2
8.0
6H308
6H1-15, 62F-02
6H308
6H1-15, 62F-02
6H308
6H1-15, 62F-02
6H308
6H1-15, 62F-02
6H1-15, 62F-02
6H308
6H1-15, 62F-02
6H308
6H1-15, 62F-02
6H308
6H1-15, 62F-02
GENERAL TORQUE
SPECIFICATIONS
General torque
specifications
Nm m•kg ft•lb
5.0
0.5
3.6
8.0
0.8
5.8
18
1.8
13
36
3.6
25
43
4.3
31
This chart specifies the torque for tightening standard fastners with standard fastners with standard clean dry ISO threads at
room temperature. Torque specifications
for special components or assemblies are
given in applicable sections of this manual.
To avoid causing warpage, tighten multifastener assemblies in crisscross fashion and
in progressive stages a until the specified
torque is reached.
2-13
INSP
ADJ
E
CHAPTER 3
PERIODIC INSPECTION AND ADJUSTMENT
PERIODIC SERVICE ........................................................................................ 3-1
MAINTENANCE SCHEDULE ................................................................... 3-1
ANODE...................................................................................................... 3-1
BATTERY .................................................................................................. 3-2
CARBURETOR .......................................................................................... 3-3
CARBURETOR LINK ADJUSTMENT....................................................... 3-3
CYLINDER HEAD BOLTS, ENGINE MOUNTING BOLTS,
AND FLYWHEEL NUT............................................................................. 3-4
FUEL FILTER............................................................................................. 3-4
FUEL TANK AND FUEL LINE................................................................... 3-4
GEAR OIL.................................................................................................. 3-5
IDLE-SPEED .............................................................................................. 3-5
IGNITION TIMING ADJUSTMENT.......................................................... 3-6
TIMING PLATE POSITION ADJUSTMENT ...................................... 3-6
THROTTLE SENSOR CONTROL LINK ADJUSTMENT.................... 3-7
IGNITION TIMING ADJUSTMENT ................................................... 3-8
PICK-UP TIMING ADJUSTMENT ..................................................... 3-9
OIL INJECTION PUMP ........................................................................... 3-10
OPERATIONAL TEST ...................................................................... 3-10
CHECKING THE OIL LEVEL WARNING SYSTEM ................................ 3-11
OIL PUMP LINK ADJUSTMENT............................................................ 3-12
POWER TRIM AND TILT FLUID (PTT model)....................................... 3-12
PROPELLER ............................................................................................ 3-13
SPARK PLUG.......................................................................................... 3-13
GREASING POINTS ............................................................................... 3-14
1
2
3
4
5
6
7
8
9
INSP
ADJ
PERIODIC SERVICE
E
D30000-1*
PERIODIC SERVICE
MAINTENANCE SCHEDULE
The following chart may be taken as a helpful guide to the intervals between maintenance
procedures.
Intervals
Item
Initial
10 hours
50 hours
(Break-in)
(3 months)
Every
100 hours
200 hours
(6 months)
(1 year)
Anode
Battery
Refer
page
3-1
3-2
(every month)
Carburetor
Carburetor link
Cylinder head bolts,
engine mounting bolts,
and flywheel nut
Fuel filter
Fuel tank and fuel line
Gear oil
Idle-speed
Ignition timing
Oil injection pump
Oil level warning system
Oil pump link
Power trim and tilt system
Propeller
Spark plug
3-3
3-4
3-4
3-5
3-6
3-10
3-11
3-12
3-13
D31000-0
ANODE
Inspect the anode. If it is worn out, replace
it with a new one. If scaling of the surface is
evident, remove the anode, clean it with a
wire brush and remove all trace of oil or
grease. After cleaning, polish the contact
surfaces of the anode mount and re-install.
CAUTION:
Never paint the anode. To ensure good
electrical contact, keep the anode contact
surface clean of oil or grease.
3-1
INSP
ADJ
PERIODIC SERVICE
E
D31305-0*
BATTERY
WARNING
Battery electrolyte is dangerous; it contains
sulfuric acid which is poisonous and highly
caustic.
Always follow these preventive measures:
● Avoid bodily contact with electrolyte as it
can cause severe burns or permanent eye
injury.
● Wear protective eye gear when handling
or working near batteries.
Antidote (EXTERNAL):
● SKIN - Wash with water.
● EYES - Flush with water for 15 minutes
and get immediate medical attention.
Antidote (INTERNAL):
● Drink large quantities of water or milk followed with milk of magnesia, beaten egg
or vegetable oil. Get immediate medical
attention.
Batteries generate explosive, hydrogen
gas. Always follow these preventive measures:
● Charge batteries in a well-ventilated area.
● Keep batteries away from fire, sparks or
open flames (e.g., welding equipment,
lighted cigarettes).
● DO NOT SMOKE when charging or handling batteries.
KEEP BATTERIES AND ELECTROLYTE OUT
OF REACH OF CHILDREN.
Recommended battery capacity:
Rating..........12V 70AH (252 kC)
Minimum cold crank performance
......... 380 Amps at –17.8˚C (0˚F)
Minimum reserve capacity
..... 124 minutes at 26.7˚C (80˚F)
3-2
INSP
ADJ
PERIODIC SERVICE
E
D31600-1
CARBURETOR
1. Check the fuel passages and air passages for fouling or clogging. Clean
fouled parts with suitable cleaning solvent and blow out clogged passages
with compressed air.
WARNING
Protect your eyes with suitable safety
glasses or safety goggles when using compressed air.
2. Check the needle-valve for wear and
replace it if worn.
D31902-1*
CARBURETOR LINK ADJUSTMENT
(50, 60, 70 hp)
1. Loosen the idle adjust screw and fully
close the throttle valve.
2. Loosen the throttle lever securing
screws of upper and middle carburetors
by turning clockwise.
3. While lightly pushing the throttle lever
of the lower carburetor in the direction
of the arrow (full-closed), tighten the
throttle lever securing screw of the
upper middle carburetors by turning
counterclockwise.
1 Idle adjust screw
2 Throttle lever
3 Throttle lever securing screw
3-3
INSP
ADJ
PERIODIC SERVICE
E
(75, 80, 90 hp)
1. Loosen the idle adjust screw and fully
close the throttle valve.
2. Loosen the throttle lever securing
screws of upper and lower carburetors
by turning clockwise.
3. While lightly pushing the throttle lever
of the middle carburetor in the direction
of the arrow (full-closed), tighten the
throttle lever securing screw of the
upper and lower carburetors by turning
counterclockwise.
1 Idle adjust screw
2 Throttle lever
3 Throttle lever securing screw
D32000-0
CYLINDER HEAD BOLTS, ENGINE
MOUNTING BOLTS, AND FLYWHEEL
NUT
1. Retighten to specifications.
2. Check other fixings and tighten if necessary.
D32300-0
FUEL FILTER
Clean the strainer of dust and impurities.
1
2
3
4
Strainer body
Strainer
O-ring
Strainer cup
D32600-0
FUEL TANK AND FUEL LINE
1. Check the fuel tank and fuel line for
leaks.
2. Clean the fuel tank thoroughly.
3-4
INSP
ADJ
PERIODIC SERVICE
E
D32900-0
GEAR OIL
1. Drain the gear oil thoroughly and pour
in new oil.
2. Check for water or metallic sediment in
the drained oil.
NOTE:
If the gear oil becomes “milky”, check the
gear case oil seals and shift boot for water
entry.
D33000-0*
IDLE-SPEED
1. Turn the pilot screw until it is lightly
seated.
2. Turn the pilot screw outward to the
specified setting.
Pilot screw [stamped mark]:
62F00, 6H210, 6H007, 6H015:
1-3/8 ± 1/4 turns out
6H20A: 1-1/2 ± 1/4 turns out
6H30A, 6H107:
1-1/4 ± 1/4 turns out
3. Start the motor and allow it to warm up
for a few minutes.
4. Set the idle-speed to the specified level
by setting the throttle stop-screw. Use a
tachometer for checking the speed
when adjusting the motor speed.
NOTE:
Turning the throttle stop-screw clockwise
increases the motor speed; turning it counterclockwise decreases the motor speed.
Tachometer:
YU-8036-A/90890-06760
Idle speed:
800 ± 50 rpm
3-5
INSP
ADJ
PERIODIC SERVICE
E
D33304-0*
IGNITION TIMING ADJUSTMENT
TIMING PLATE POSITION ADJUSTMENT
If the timing plate is moved even a little during inspection or repair operation, it should
be set in the following way:
This adjustment must be made before
adjusting the ignition timing.
1. Remove the spark plugs from the cylinders.
2. Install a dial-gauge in the spark-plug
hole of No. 1 cylinder.
NOTE:
For easy timing-plate adjustment, it is
advisable to remove the spark plugs from
all the cylinders.
3. Slowly turn the flywheel CLOCKWISE,
and stop it when the piston is at TDC.
4. If the end of the timing plate is not
aligned with the TDC mark on the CDI
magneto rotor, loosen the timing plate
set screw, align the timing plate end
with the TDC mark, then tighten the
screw.
5. Remove the dial gauge from the No. 1
cylinder and install the spark plugs for
each cylinder.
NOTE:
After tightening the screw, paint over the
screw-head to discourage tampering with
the adjustment.
3-6
INSP
ADJ
PERIODIC SERVICE
THROTTLE SENSOR CONTROL LINK
ADJUSTMENT
1. Adjust the lengths of the throttle sensor
control link and throttle cam control link
to specifications.
50, 60, 70 hp
a
E
b
Throttle sensor control link
length a:
50, 60, 70 hp: 120 ± 0.5 mm
(4.72 ± 0.02 in)
75, 80, 90 hp: 93.5 ± 0.5 mm
(3.68 ± 0.02 in)
Throttle cam link length b:
50, 60, 70 hp: 95 mm (3.74 in)
75, 80, 90 hp: 120.5 mm (4.74 in)
50, 60, 70 hp
2. Adjust the length of the full-retard
adjusting screw so that when the fullretard adjusting screw contacts the
stopper, the full-retard indication on the
CDI unit aligns with the timing indicator.
4
1
1
2
3
4
2
Timing indicator
Full-retard indication (50, 60, 70 hp)
Full-retard indication (75, 80, 90 hp)
Full-retard adjusting screw
NOTE:
The nut in the magneto control lever should
be 2 mm (0.08 in) off from the end of the
magneto control lever.
3. Adjust the length of the full-advance
adjusting screw so that when the fulladvance adjusting screw contacts the
stopper, the full-advance indication on
the CDI unit aligns with the timing indicator.
50, 60, 70 hp
4
1
1
2
3
4
2 3
3-7
Timing indicator
Full-advance indication (50, 60 hp)
Full-advance indication (70 hp)
Full-advance adjusting screw
INSP
ADJ
PERIODIC SERVICE
E
1
2
3
4
Timing indicator
Full-advance indication (75, 80 hp)
Full-advance indication (90 hp)
Full-advance adjusting screw
IGNITION TIMING ADJUSTMENT
CAUTION:
When checking ignition timing using a timing light, be sure to replace the propeller
with the specified test propeller, and make
tests with the machine placed in a test
tank.
NOTE:
Before adjusting, be sure to warm up the
engine.
1. Attach the timing light and tachometer
to the No. 1 cylinder high tension code.
2. While keeping the stopper in contact
with the full-retard adjusting screw,
measure the full-retard ignition timing
with the timing light.
If the timing is out of specification,
adjust it by turning the full-retard
adjusting screw.
NOTE:
When measuring the full-retard ignition
timing, keep the specified engine speed.
Full-retard side engine speed:
800 ± 50 rpm
Full-retard side ignition timing:
50, 60, 70 hp: 7 ± 1˚ ATDC
75, 80, 90 hp: 8 ± 1˚ ATDC
3-8
INSP
ADJ
PERIODIC SERVICE
E
3. While keeping the stopper in contact
with the full-advance adjusting screw,
measure the full-retard ignition timing
with the timing light.
If the timing is out of specification,
adjust it by turning the full-advance
adjusting screw.
NOTE:
When measuring the full-advance ignition
timing, keep the specified engine speed.
Full-advance side engine speed:
50, 60, 75, 80, 90 ph:
5,000 ± 500 rpm
70 hp:
5,500 ± 500 rpm
Full-advance side ignition timing:
50, 60, 90 hp: 22 ± 1˚ BTDC
70, 75, 80 hp: 20 ± 1˚ BTDC
PICK-UP TIMING ADJUSTMENT
NOTE:
Engine idle speed should be adjusted properly before adjusting the pick-up timing.
1. Turn the magneto control lever to the
full-retard position.
2. Bring the throttle cam to lightly contact
the throttle lever roller. (The throttle
valve should not open.)
Adjust the accelerator link length and
connect magneto control lever to the
accelerator cam.
3-9
INSP
ADJ
PERIODIC SERVICE
E
D34000-0*
OIL INJECTION PUMP
OPERATIONAL TEST
1. Start the engine and set the idling
speed at 1,500 rpm by adjusting the
throttle-stop lever.
CAUTION:
Use only oil-mixed fuel (50:1) as malfunction or engine seizure may otherwise
result.
2. Remove the oil-pump link-rod and fix
the oil-pump lever in the full-throttle
position.
3. Measure the oil discharge from each
port for three minutes using a measuring cylinder graduated in steps of at
least 0.1 cc to confirm that the specified
amount is discharged.
Specified discharge:
(3 min/1 cylinder)
50 hp:
1.90 ± 0.50 cm3 (0.064 ± 0.017
US oz, 0.067 ± 0.018 Imp oz)
60, 70 hp:
2.20 ± 0.50 cm3 (0.074 ± 0.017
US oz, 0.077 ± 0.018 Imp oz)
75, 80, 90 hp:
3.10 ± 0.70 cm3 (0.105 ± 0.024
US oz, 0.0109 ± 0.025 Imp oz)
NOTE:
Oil temperature: 10 ~ 30˚C (50 ~ 86˚F)
1. Before measuring, bleed the pump completely and ensure no air-bubbles are
present in the oil flowing out of the oil
feed pipe.
2. When measuring with the measuring cylinder, ensure that no oil clings to the cylinder wall, otherwise the measurement
will be inaccurate.
3. Use only genuine Yamaha oil. If the viscosity is too high or too low, the measurement of the discharge will be
inaccurate.
4. The longer the time over which measurement is made, the more accurate will be
the measurement. Calculate the rate of
discharge per minute.
3-10
INSP
ADJ
PERIODIC SERVICE
E
D33900-0*
CHECKING THE OIL LEVEL WARNING
SYSTEM
1. Fill the oil-tank with oil.
2. Start the engine.
3. By letting the oil little by little out of the
drain-hose, check that the oil-level
warning system operates correctly.
CAUTION:
Do not allow the engine to operate without
oil even briefly for this will cause malfunction or engine seizure.
50, 60, 70 hp
Oil level
Speed
Warning
warning
drop
buzzer
lamp
function
Case
Oil level
1
More than
770 cm3
(0.81 US qt)
GREEN
OFF
OFF
2
770 cm3
(0.31 Us qt) ~
280 cm3
(0.3 US qt)
YELLOW
OFF
OFF
3
280 cm3 or less
(0.3 US qt)
RED
ON
ON
75, 80, 90 hp
3-11
Oil level
Speed
Warning
warning
drop
buzzer
lamp
function
Case
Oil level
1
More than
1,130 cm3
(1.19 US qt)
GREEN
OFF
OFF
2
1,130 cm3
(1.19 Us qt) ~
310 cm3
(0.33 US qt)
YELLOW
OFF
OFF
3
310 cm3 or less
(0.33 US qt)
RED
ON
ON
INSP
ADJ
PERIODIC SERVICE
E
D34300-1
OIL PUMP LINK ADJUSTMENT
1. Fully-open the carburetor throttle valve.
2. Set the oil-pump lever 1 mm off fullopen side stopper. With the lever in this
position, adjust the length of the rod
connecting the oil-pump to the carburetor and tighten the locknut.
3. Install the connecting-rod.
4. By operating the carburetor, check that
the throttle-valve opens fully.
D34600-0
POWER TRIM AND TILT FLUID
(PTT model)
1. Tilt-up the motor and lock it with the tiltlock lever.
2. Remove the fluid-level plug to check the
fluid level. With the motor tilted-up, the
fluid level should be immediately below
the fluid-hole. If the fluid level is low,
top up with the recommended fluid.
ATF
(automatic transmission fluid)
CAUTION:
When checking the fluid level (with the unit
removed from the engine), hold the unit in
the vertical position and set the tilt-rod in
the tilt-up position.
3. Re-fit the fluid-level plug and tighten it.
T.
R.
3-12
Fluid-level plug:
Short transom [6H308]:
3 Nm (0.3 m • kg, 2.2 ft • lb)
Long transom [6H1-15, 62F-02]:
7 Nm (0.7 m • kg, 5.1 ft • lb)
INSP
ADJ
PERIODIC SERVICE
E
D34900-0
PROPELLER
1. Check the blades for wear, damage or
cavitation erosion.
2. Check the spline for wear and damage.
D35000-0*
SPARK PLUG
1. Check the electrode 1 condition and
state of wear, note the insulator 2 color
and the electrode gap.
Normal condition is a medium to light
tan color.
Distinctly different color → Check the
engine condition.
White color
: Lean fuel mixture
• Plugged filter, jet
• Air leak
• Wrong settings
Blackish color : Electrical malfunction
• Defective spark plug
2. Clean the spark plug with spark-plug
cleaner or wire brush. Use a wire gauge
to adjust the plug gap a to specification.
Spark plug gap:
0.9 ~ 1.0 mm (0.035 ~ 0.039 in)
3. If the electrode becomes too worn,
replace the spark plug.
Standard spark plugs:
50 hp
60, 70, 75,
80, 90 hp
3-13
Except for Canada,
Europe, China and
South Africa
For Canada,
Europe, China
and South Africa
BR8HS-10
BR8HS-10
B8HS-10
BR8HS-10
INSP
ADJ
PERIODIC SERVICE
E
4. When installing the spark plug, clean
the gasket surface, wipe off any grime
that may be on the surface of the plug
and screw in the spark plug to the correct torque.
T.
Tightening torque:
25 Nm (2.5 m • kg, 18 ft • lb)
R.
NOTE:
If a torque wrench is not available, a good
estimate of the correct torque is a further 1/4
to 1/2 turns b on finger-tightened a spark
plug.
GREASING POINTS
1. Apply:
● Water resistant grease
3-14
FUEL
E
CHAPTER 4
FUEL SYSTEM
FUEL SYSTEM ................................................................................................ 4-1
EXPLODED DIAGRAM ............................................................................. 4-1
FUEL LINE................................................................................................. 4-2
REMOVAL................................................................................................. 4-3
CLEANING AND INSPECTION ................................................................ 4-3
FUEL TANK ........................................................................................ 4-3
FUEL METER COMPLETE ................................................................. 4-4
PRIMING PUMP................................................................................. 4-4
FUEL FILTER ...................................................................................... 4-4
FUEL JOINTS..................................................................................... 4-5
FUEL PUMP ....................................................................................... 4-5
INSTALLATION ........................................................................................ 4-5
CARBURETOR ................................................................................................ 4-6
EXPLODED DIAGRAM (Except for C60ER, C60TR, C75TR) .................. 4-6
EXPLODED DIAGRAM (For C60ER, C60TR, C75TR) .............................. 4-7
REMOVAL AND DISASSEMBLY ............................................................. 4-8
INSPECTION............................................................................................. 4-9
CARBURETOR BODY ........................................................................ 4-9
NEEDLE VALVE ................................................................................. 4-9
PILOT SCREW.................................................................................... 4-9
COLLAR.............................................................................................. 4-9
FLOAT ................................................................................................ 4-9
ENRICHING FUEL PUMP ................................................................ 4-10
ELECTROTHERMAL VALVE............................................................ 4-10
ASSEMBLY............................................................................................. 4-11
INSTALLATION ...................................................................................... 4-13
OIL-INJECTION SYSTEM (Oil injection model)......................................... 4-14
EXPLODED DIAGRAM ........................................................................... 4-14
REMOVAL............................................................................................... 4-16
CLEANING AND INSPECTION .............................................................. 4-16
OIL-TANK ......................................................................................... 4-16
OIL-LEVER SENSOR........................................................................ 4-16
OIL-HOSES....................................................................................... 4-16
INSTALLATION ...................................................................................... 4-16
1
2
3
4
5
6
7
8
9
FUEL
FUEL SYSTEM
E
E20000-1
FUEL SYSTEM
EXPLODED DIAGRAM
1
2
3
4
5
6
7
Carburetor
Electrothermal valve*
Fuel pump assembly
Fuel filter assembly
Fuel joint
Priming pump
Fuel meter assembly
8 Fuel tank cap
9 Fuel tank
* Except for C60ER, C60TR, C75TR
4-1
FUEL
FUEL SYSTEM
E
D22500-0
FUEL LINE
Check that the fuel line is correctly installed.
50, 60, 70 hp
1
2
3
4
5
Oil tank*
Oil injection pump*
Carburetor
Fuel filter
Fuel pump
75, 80, 90 hp
1
2
3
4
5
Oil tank*
Oil injection pump*
Carburetor
Fuel filter
Fuel pump
* Oil injection model
4-2
FUEL
FUEL SYSTEM
E
REMOVAL
WARNING
1. Fire prevention
Gasoline (petrol) is highly flammable.
Petroleum vapour is explosive if ignited.
Do not smoke while handling and keep it
away from heat, sparks and open
flames.
2. Ventilation
Petroleum vapour is heavier than air and
if inhaled in large quantities will not support life. Engine exhaust gases are harmful to breathe. When test-running an
engine indoors, maintain good ventilation.
3. Spillage
Remember that fuel remains in the fuel
hose between the fuel joint and the carburetor. Drain all remaining fuel out into
a container, or soak it up with a cloth so
that the fuel does not spill onto the bottom cowling.
4. Leaks
Failure to check for and correct fuel leaks
may result in fire or explosion.
1. Referring to the exploded diagram,
remove the fuel line.
E21010-0
CLEANING AND INSPECTION
FUEL TANK
1. Add a small quantity of a suitable cleaning solvent into the fuel tank and thoroughly clean the tank interior by
shaking the tank.
2. Drain off the cleaning solvent completely.
4-3
FUEL
FUEL SYSTEM
E
E21020-0
FUEL METER COMPLETE
1. Using a soft brush and solvent, clean
the strainer on the end of the suction
pipe and blow-dry it with compressed
air.
2. Visually inspect the strainer for damage
and replace the fuel meter complete if
required.
3. Inspect the fuel meter components for
cracks and replace the fuel meter complete if required.
4. Re-install the fuel meter complete with
the rubber gasket to the fuel tank,
ensuring that there are no leaks
between the fuel meter and the fuel
tank.
1 Fuel meter assembly
2 Suction pipe
3 Fuel strainer
E21030-0
PRIMING PUMP
1. Visually inspect for cracks or breaks in
the priming-pump and fuel-hoses and
replace them if required.
2. Check the operation of the check-valve
by blowing into the pump.
1
2
3
4
Priming valve
Arrow mark
Check valve (inlet)
Check valve (outlet)
E21040-0
FUEL FILTER
1. After removing the nut and filter-cap,
disassemble the fuel filter.
2. Visually inspect the filter body for
cracks or damage to the thread and
replace if required.
4-4
FUEL
FUEL SYSTEM
E
3. Using a soft brush and solvent, clean
the filter element thoroughly. Inspect
the filter element for breakage or distortion and replace if required.
4. Using a soft brush and solvent, clean
the filter-cup thoroughly. Inspect the filter-cup for cracks or thread damage and
replace if required.
5. Place the O-ring on the filter body,
install the element and screw in the filter cup.
E21050-0
FUEL JOINTS
1. Inspect the fuel joints for leaks and
cracks and replace as required.
E21060-0
FUEL PUMP
1. Using a screwdriver, disassemble the
fuel pump.
2. Visually inspect the pump body for
cracks and replace if required.
3. Inspect the valves for cracks or distortion and replace if required.
4. Inspect the diaphragm for sign of damage, perforation or stretching and
replace if required.
5. Assemble the fuel pump with new gaskets.
E22000-0
INSTALLATION
Referring to the diagram, install the fuel
system.
Note the following points:
When connecting the fuel hoses to the fuel
pump and fuel filter, follow the direction of
flow indicated by the embossed arrows.
Place the clips in position, connect the
hoses, and tighten the clips. Check for
leaks.
4-5
FUEL
CARBURETOR
E
E31001-1
CARBURETOR
EXPLODED DIAGRAM (Except for C60ER, C60TR, C75TR)
1
2
3
4
5
6
7
Pilot screw
Needle valve
Pilot jet
Main nozzle
Main jet
Float
Drain screw
8
9
0
A
B
C
Float chamber
Throttle stop screw
Collar
Electrothermal valve
Valve
Diaphragm
4-6
FUEL
CARBURETOR
E
EXPLODED DIAGRAM (For C60ER, C60TR, C75TR)
1
2
3
4
5
6
7
8
9
0
Pilot screw
Needle valve
Pilot jet
Main nozzle
Main jet
Float
Drain screw
Float chamber
Throttle stop screw
Collar
4-7
FUEL
CARBURETOR
E
REMOVAL AND DISASSEMBLY
WARNING
At this step, ensure there is no spillage of
gasoline on removing the connections.
1. Remove the silencer cover, disconnect
the fuel hose, then remove the carburetor.
* Except for C60ER, C60TR, C75TR
2. Referring to the diagram, use a screwdriver to disassemble the carburetor.
3. Using solvent, clean the components
thoroughly and blow-dry them with
compressed air.
WARNING
Protect your eyes with suitable safety
glasses or safety goggles when using compressed air. Protect your eyes and the eyes
of others by directing the flow of compressed-air downward, noting that solvent
and small parts may be blown off.
CAUTION:
Do not use steel wire for cleaning the jets
as this may enlarge the jet diameters and
seriously affect performance.
4-8
FUEL
CARBURETOR
E
E32000-1*
INSPECTION
CARBURETOR BODY
1. Inspect the carburetor body for cracks
or clogging of the passages.
NEEDLE VALVE
1. Inspect the needle valve for free movement and wear and replace if required.
PILOT SCREW
1. Inspect the pilot screw for wear and
replace if required.
COLLAR
1. Inspect the collar at the end of the accelerator-arm for wear and replace if
required.
FLOAT
1. Visually inspect the float for damage or
cracks and replace if required.
2. Measure the float height a. If it is more
than 2 mm (0.08 in) greater or less than
the specified float height, recheck the
valve seat and needle-valve.
4-9
FUEL
CARBURETOR
E
Float height a [Stamped mark]:
62F00:
15.0 ± 1.0 mm (0.59 ± 0.04 in)
6H20A, 6H30A, 6H007, 6H107:
14.0 ± 1.0 mm (0.55 ± 0.04 in)
6H210:
14.0 ± 2.0 mm (0.55 ± 0.08 in)
6H015:
19.5 ± 3.0 mm (0.77 ± 0.12 in)
E21060-0
ENRICHING FUEL PUMP
1. Using a screwdriver, disassemble the
fuel pump.
2. Visually inspect the pump body for
cracks and replace if required.
3. Inspect the valves for cracks or distortion and replace if required.
4. Inspect the diaphragm for any sign of
damage, perforation or stretching and
replace if required.
ELECTROTHERMAL VALVE
1. Inspect the needle valve for any bending and wear, and the piston valve for
flow.
Inspect the body for cracks and the wire
lead for defects.
1
2
3
4
Needle valve
Piston valve
Body
Wire lead
2. Measure the resistance of the electrothermal valve.
Electrothermal valve resistance:
Blue – Black
2.3 ~ 3.5 Ω at 20˚C (68˚F)
4-10
FUEL
CARBURETOR
E
NOTE:
When measuring the resistance of 10 Ω or
less using the digital tester, the correct
measurement cannot be obtained. Refer to
“Lower resistance measurement” (page 815).
3. Check the piston valve height.
If the piston valve height is not different
from a to b, replace the electrothermal
valve.
a) Measure the piston valve height a.
b) Connect the wire leads to a 12V battery.
c) Measure the piston valve height b
after several minutes.
d) Compare the valve height a with b.
ASSEMBLY
1. Install a new O-ring, the valves on the
body and secure with the screws.
2. Install the diaphragm on the carburetor
with new gaskets, install the pump
cover on the carburetor and secure with
the screws.
3. Install a new O-ring to the electrothermal valve, install it to the carburetor
with the plate and secure with the
screws.
4. Insert the main nozzle fully and screw in
the main jet until tight.
5. Screw in the pilot jet fully and install the
cap.
4-11
FUEL
CARBURETOR
E
6. Install the needle-valve on the float,
attach the float to the carburetor body
with the float-pin and tighten the screw.
7. Install a new O-ring to the float-chamber, install it to the carburetor body and
secure with the screws.
8. Install the plate with new packing and
secure with the screws.
9. Install the pilot-screw with its spring,
screw it in until seated then screw it out
the specified number of turns.
CAUTION:
Do not cause damage to the tip of the pilot
screw by over-tightening it.
Pilot screw [stamped mark]:
62F00, 6H210, 6H007, 6H015:
1-3/8 ± 1/4 turns out
6H20A: 1-1/2 ± 1/4 turns out
6H30A, 6H107:
1-1/4 ± 1/4 turns out
4-12
FUEL
CARBURETOR
E
E34004-1
INSTALLATION
1. Install the carburetors and plate with
new gaskets.
1 Idle adjust screw
2 Throttle lever
3 Throttle lever securing screw
2. Connect the fuel hoses to the carburetors and fit the hose-clips over the
recesses to ensure leak-proof connections.
3. Connect the electrothermal valve leads.
4. Connect the oil-pump link-rod to the
carburetor and oil-injection pump.
5. Install the silencer cover and tighten the
bolt to the specified torque.
T.
R.
4-13
Bolt (silencer cover):
2 Nm (0.2 m • kg, 1.4 ft • lb)
FUEL
OIL-INJECTION SYSTEM
OIL-INJECTION SYSTEM (Oil injection model)
EXPLODED DIAGRAM
1
2
3
4
5
6
7
Oil level sensor
Oil strainer
Strainer cover gasket
Oil injection pump assembly
Check valve
Oil tank
Special washer
8 Oil tank cap assembly
9 Hook
0 Filler tube
4-14
E
FUEL
1
2
3
4
5
6
7
OIL-INJECTION SYSTEM
Check valve
Oil injection pump assembly
Drain screw
Oil tank
Strainer cover gasket
Oil strainer
Oil lever sensor
8
9
0
A
Special washer
Oil tank cap assembly
Hook
Filler tube
4-15
E
FUEL
OIL-INJECTION SYSTEM
E
REMOVAL
1. Drain the oil from the oil-tank and
remove the carburetor.
2. Disconnect the hoses and remove the
oil-injection system.
E42001-0*
CLEANING AND INSPECTION
OIL-TANK
1. Using solvent, clean the oil-tank.
2. Drain the solvent and dry the tank.
3. Inspect the oil-tank for cracks and
replace it if required.
OIL-LEVER SENSOR
Refer to “OIL-LEVEL SENSOR” section in chapter 8.
OIL-HOSES
1. Inspect the oil-hoses for damage or
cracks and replace them if required.
E43001-0*
INSTALLATION
1. Connect the oil-hoses to the oil-pump
and tighten the clips on the hoses.
2. Install the driven gear.
1
2
3
4
Driven gear
Washer
O-ring
Distance collar
3. Install the oil-pump to the power-head.
NOTE:
Tighten the bolts to the specified torque in
sequence.
T.
R.
4-16
Oil injection pump mounting bolt:
7 Nm (0.7 m • kg, 5.1 ft • lb)
FUEL
OIL-INJECTION SYSTEM
E
4. Assemble the oil-tank and install it.
5. Connect the oil delivery-hoses to the
intake manifolds and tighten the clips
on the hoses.
6. Lead the wire of the oil-level sensor to
the port side of the engine and connect
the cores.
7. Bleed the air from the lines.
CAUTION:
After reinstalling the oil injection pump, be
sure to bleed the pump.
4-17
POWR
E
CHAPTER 5
POWER UNIT
EXPLODED DIAGRAM ................................................................................... 5-1
PREPARATION FOR OVERHAUL .................................................................. 5-3
REMOVAL ....................................................................................................... 5-3
DISASSEMBLY ............................................................................................... 5-5
INSPECTION ................................................................................................... 5-6
CYLINDER HEAD...................................................................................... 5-6
CLEANING ......................................................................................... 5-6
INSPECTION ...................................................................................... 5-6
CYLINDER BLOCK.................................................................................... 5-7
CLEANING ......................................................................................... 5-7
INSPECTION ...................................................................................... 5-7
PISTON ..................................................................................................... 5-8
CLEANING ......................................................................................... 5-8
INSPECTION ...................................................................................... 5-8
PISTON RING ........................................................................................... 5-9
INSPECTION ...................................................................................... 5-9
PISTON PIN AND SMALL END BEARING ............................................ 5-10
CLEANING ....................................................................................... 5-10
INSPECTION .................................................................................... 5-10
CRANKSHAFT ........................................................................................ 5-10
INSPECTION .................................................................................... 5-10
REED VALVE........................................................................................... 5-11
INSPECTION .................................................................................... 5-11
THERMOSTAT........................................................................................ 5-12
CLEANING ....................................................................................... 5-12
INSPECTION .................................................................................... 5-12
CRANK MAIN BEARING ........................................................................ 5-12
CLEANING ....................................................................................... 5-12
INSPECTION .................................................................................... 5-12
DRIVE GEAR (OIL INJECTION PUMP DRIVE) ...................................... 5-13
INSPECTION .................................................................................... 5-13
DRIVEN GEAR (OIL INJECTION PUMP DRIVE).................................... 5-13
INSPECTION .................................................................................... 5-13
POWR
ASSEMBLY AND ADJUSTMENT ................................................................ 5-14
BEARING, OIL SEAL AND O-RING ....................................................... 5-14
PISTON AND PISTON RING.................................................................. 5-14
SMALL END BEARINGS AND PISTON ASSEMBLY............................ 5-15
CONNECTING ROD BIG END BEARING ASSEMBLY
(75, 80, 90 hp)........................................................................................ 5-16
OIL SEAL HOUSING .............................................................................. 5-17
CRANK CYLINDER ASSEMBLY (50, 60, 70 hp).................................... 5-17
CRANK CYLINDER ASSEMBLY (75, 80, 90 hp).................................... 5-18
CYLINDER HEAD AND EXHAUST COVER ........................................... 5-19
DRAINAGE HOSE................................................................................... 5-20
INTAKE MANIFOLD ............................................................................... 5-20
FUEL SYSTEM AND ELECTRICAL SYSTEM ........................................ 5-20
INSTALLATION............................................................................................. 5-21
E
1
2
3
4
5
6
7
8
9
POWR
EXPLODED DIAGRAM
E
G20000-0
EXPLODED DIAGRAM
1
2
3
4
5
6
7
Cylinder head cover
Head cover gasket
Cylinder head
Cylinder head gasket
Thermostat
Thermostat cover
Exhaust cover gasket
8
9
0
A
B
C
D
Exhaust inner cover
Exhaust outer cover
Piston pin clip
Piston pin
Drive gear
Bearing
Oil seal
5-1
E
F
G
H
I
J
O-ring
Oil seal housing
Intake manifold
Valve seat packing
Reed valve plate
Reed valve assembly
POWR
1
2
3
4
5
6
7
8
9
EXPLODED DIAGRAM
Thermostat cover
Thermostat
Thermo sensor
Cylinder head cover
Head cover gasket
Cylinder head
Cylinder head gasket
Exhaust cover gasket
Exhaust inner cover
0
A
B
C
D
E
F
G
H
Exhaust outer cover
Piston pin clip
Piston pin
Bearing
Drive gear
Circlip
Oil seal
O-ring
Oil seal housing
E
I
J
K
L
Intake manifold
Valve seat packing
Reed valve plate
Reed valve assembly
*B90TR/90AETO
5-2
POWR
PREPARATION FOR OVERHAUL/REMOVAL
E
G30000-0
PREPARATION FOR OVERHAUL
1. Clean all dirt, mud, dust and foreign
material from the engine before the
engine is removed and disassembled.
2. To ensure that you can perform the
work cleanly and efficiently, check that
you have the proper tools and cleaning
equipment before commencing engine
removal and disassembly.
3. During engine disassembly, as parts are
disassembled, clean them and place
them in trays in their order of disassembly. This will speed up assembly and
help ensure that all parts are correctly
reinstalled.
NOTE:
When disassembling the engine, keep
mated parts together, e.g., cylinder and piston and other parts that have been ‘mated’
through normal wear. Mated sets should be
re-used on reassembly or replaced completely.
G40003-0*
REMOVAL
1. Remove the electrical system parts.
Refer to “ELECTRICAL COMPONENTS”
section in chapter 8.
1 Ground lead from the cylinder head cover
Battery cable
Power trim and tilt motor leads
(PTT model)
Power trim and tilt relay (PTT model)
Oil level sensor lead (oil injection model)
2. Remove the fuel system parts and hose.
Refer to “FUEL SYSTEM” section in
chapter 4.
1 Cooling water pilot hose
Fuel hose on the strainer
5-3
POWR
REMOVAL
E
3. Remove the throttle cable and the shift
mechanism.
1 Throttle cable joint by removing the hair pin
2 Shift rod bracket bolt
3 Shift cable joint and bushing by removing
the hair pin
4. Remove the front and rear aprons.
5. Remove the power head installation
bolts, and then remove the power head
from the upper casing.
50, 60, 70 hp ..................................8 bolts
75, 80, 90 hp ................................11 bolts
NOTE:
The power head may be difficult to separate
from the bottom cowling because of a stuck
gasket holding them together. If this is the
case, lever it off the bottom cowling with a
piece of wood. Use care not to damage the
bottom cowling or power head with the
wood.
6. Remove the dowel pins from the bottom cowling or power head. To protect
the dowel pins against damage, cover
them with rags.
5-4
POWR
DISASSEMBLY
E
G50003-0
DISASSEMBLY
Referring to the exploded diagram, remove
the following parts.
1. Cylinder head
2. Intake manifold
3. Exhaust cover and thermostat cover.
4. Oil seal housing
Using the oil seal remover, remove the
oil seal one by one from the housing.
5. Crankcase
Remove the two dowel pins.
6. Crankshaft and connecting rod.
(50, 60, 70 hp)
7. Connecting rod caps, needle bearings
and crankshaft. (75, 80, 90 hp)
8. Piston and piston pin
9. Piston rings
Note the following points:
1. When disassembling the piston and piston pin, place a tray under the connecting rod to catch the needle bearings.
2. Only carry out exchange of the crankshaft bearing if the bearing is malfunctioning.
5-5
POWR
INSPECTION
E
G61000-0*
INSPECTION
CYLINDER HEAD
CLEANING
1. Using a gasket scraper, remove all
traces of gasket material from the cylinder head.
2. Using a round scraper, remove carbon
deposits from the combustion chamber.
CAUTION:
Do not scratch the surfaces of the cylinder
and combustion chamber.
3. Using a soft brush, clean the water
jacket.
INSPECTION
1. Using a precision straight-edge and
thickness gauge, measure the surface
contacting the cylinder block for
warping.
Å
Warpage limit:
0.1 mm (0.004 in)
Å Lines indicate straight-line measurement
If the degree of warping exceeds this
specification, re-surface the cylinderhead as follows:
Place 400-600 grit wet-or-dry paper on
the surface-plate, and resurface the cylinder-head using a figure-eight sanding
pattern.
5-6
POWR
INSPECTION
E
G61501-0*
CYLINDER BLOCK
CLEANING
1. Using a gasket-scraper, remove all
traces of gasket material from the cylinder-block surface.
2. Using a soft brush and solvent, clean
the cylinder-block.
INSPECTION
1. Visually inspect the cylinder sleeves for
cracks and scratches.
If cracks are found, replace the cylinder
block.
If scratches are found, check the degree
of out-of-round, and then hone the cylinder or re-bore it if necessary.
2. Using a cylinder-gauge, measure the
cylinder bore at three positions in the
thrust and axial directions.
1 Axial direction
2 Thrust direction
A: 10 mm (0.4 in) below the cylinder top
B: 5 mm (0.2 in) above the exhaust port
C: 5 mm (0.2 in) below the scavenging port
NOTE:
Do not place the cylinder-gauge on the port
hole.
Cylinder bore size;
50, 60, 70 hp: 72.00 ~ 72.02 mm
(2.834 ~ 2.835 in)
75, 80, 90 hp: 82.00 ~ 82.02 mm
(3.228 ~ 3.229 in)
Taper limit:
0.08 mm (0.003 in)
Out of round limit:
0.05 mm (0.002 in)
If diameter is greater than the limit,
hone or rebore the cylinder or, if necessary, replace the cylinder-block.
5-7
POWR
INSPECTION
E
G62001-0*
PISTON
CLEANING
1. Using a gasket-scraper, remove the carbon from the piston top.
2. Using a broken ring, clean the ring
grooves.
3. Using a soft brush and solvent, thoroughly clean the piston. If necessary,
use 600 ~ 800 grit wet-or-dry sandpaper
to remove score marks or varnish.
INSPECTION
1. Using a micrometer, measure the piston diameter at right angles to the piston-pin center line, 10 mm (0.4 in)
above the bottom edge.
Piston diameter:
Standard:
50, 60, 70 hp:71.945 ~ 71.970 mm
(2.8325 ~ 2.8335 in)
75, 80, 90 hp:81.935 ~ 81.960 mm
(3.2258 ~ 3.2268 in)
2. Using the measured cylinder bore
diameter in thrust directions, subtract
the piston diameter measurement from
the cylinder bore diameter measurement.
Piston clearance:
50, 60, 70 hp: 0.050 ~ 0.055 mm
(0.0020 ~ 0.0022 in)
75, 80, 90 hp: 0.060 ~ 0.065 mm
(0.0024 ~ 0.0026 in)
If this clearance is not within the specifications, replace the piston with standard or oversize and/or rebore the
cylinder.
Oversize piston:
50, 60, 70 hp:
*1st 72.25 mm (2.844 in)
2nd 72.50 mm (2.854 in)
75, 80, 90 hp:
*1st 82.25 mm (3.238 in)
2nd 82.50 mm (3.248 in)
* Except for USA
5-8
POWR
INSPECTION
E
G62501-0*
PISTON RING
INSPECTION
1. Using a thickness gauge, measure the
clearance between the piston ring and
the groove land.
Side clearance:
50, 60, 70 hp:
Top/2nd ring:
0.03 ~ 0.07 mm
(0.0012 ~ 0.0028 in)
75, 80, 90 hp:
Top/2nd ring:
0.03 ~ 0.06 mm
(0.0012 ~ 0.0024 in)
If the clearance is not within the specifications, replace the piston.
Å Top/2nd: Keystone type
ı Piston marked with “W” (50, 60, 70 hp)
Å
ı
2. Insert the piston ring into the cylinder.
Using a piston, push the piston ring a
little beyond the bottom of the ring
travel to a depth of 20 mm (0.8 in) from
the top of the cylinder block.
CAUTION:
Take care not to scratch the piston. Using a
thickness gauge, measure the end-gap.
Ring end gap (installed):
50, 60, 70 hp:
0.3 ~ 0.5 mm (0.012 ~ 0.020 in)
75, 80, 90 hp:
0.4 ~ 0.6 mm (0.016 ~ 0.024 in)
If the clearance is not within the specifications, replace the piston-ring.
NOTE:
If the clearance is greater than maximum,
even with a new piston ring, rebore the cylinder and use an over-size piston and piston-ring.
5-9
POWR
INSPECTION
E
G63000-0
PISTON PIN AND SMALL END
BEARING
CLEANING
1. Use a soft brush and solvent to clean
the parts.
INSPECTION
1. Visually inspect for surface defects,
breakage, scratches and pitting. If it is
decided to replace the small end bearings, replace them all.
G63500-0*
CRANKSHAFT
INSPECTION
1. Place the crankshaft on a crankshaftaligner or on V-blocks.
2. Using a dial gauge, measure the connecting-rod axial play.
Maximum axial play:
2.0 mm (0.08 in)
If this axial play is greater than the maximum axial play, replace the crankshaft
assembly.
3. Using feeler gauges, measure the connecting-rod side clearance.
(50, 60, 70 hp)
Connecting-rod side clearance:
50, 60, 70 hp:
0.2 ~ 0.7 mm (0.008 ~ 0.028 in)
75, 80, 90 hp:
0.12 ~ 0.26 mm (0.005 ~ 0.010 in)
If this side clearance exceeds the specification, replace the crankshaft assembly.
5-10
POWR
INSPECTION
E
4. Using dial gauges, measure the deflection.
Maximum deflection:
50, 60, 70 hp:
0.03 mm (0.0012 in)
75, 80, 90 hp:
0.05 mm (0.0020 in)
If the deflection is greater than the specified maximum, correct the alignment
by use of a copper hammer and a
wedge.
If the deflection is greater than the specified maximum, replace the crankshaft
assembly.
G64000-0*
REED VALVE
INSPECTION
1. Visually inspect for warping of the reed
valve. If warped, measure the distortion
with feeler gauges.
Warpage limit a:
0.2 mm (0.01 in)
If the amount of warping is greater than
the specification, replace the reed valve.
2. Using a vernier caliper, measure the
valve stopper height.
Valve stopper height b:
50, 60 hp:
3.0 ± 0.2 mm (0.12 ± 0.01 in)
70, 75, 80, 90 hp:
9.9 ± 0.2 mm (0.39 ± 0.01 in)
If the valve stopper height is outside the
specification, adjust it by bending it.
3. Visually inspect for cracks on the reed
valve. If cracks are found, replace the
reed valve.
5-11
POWR
INSPECTION
E
G64500-0*
THERMOSTAT
CLEANING
1. Using a soft brush and water, remove
all traces of salt, dirt or corrosion.
INSPECTION
1. Visually inspect the thermostat for damage. If the thermostat is damaged or if it
opens when cold, replace it.
2. Immerse the thermostat in water and
heat the water gradually. Check the
valve opening temperature and the
valve lift.
Water
temperature
Valve lift
Below 48 ~ 52˚C
(118 ~ 126˚F)
0 mm
Above 60˚C
(140˚F)
Minimum
3 mm (0.12 in)
If the valve opening and/or temperature
and valve-lift are not within the specifications, replace the thermostat.
G65000-0*
CRANK MAIN BEARING
CLEANING
1. Using a soft brush and solvent, thoroughly clean the bearing. Dry it with air,
and sparingly lubricate it with 2-stroke
outboard motor oil.
NOTE:
Do not spin bearing with air blower. This
can damage the bearing. Also, take care not
to scratch the bearing balls when cleaning.
INSPECTION
1. Hold the bearing inner race and slowly
turn the bearing outer race with your
fingers. If any rough spots are felt,
replace the bearing.
5-12
POWR
INSPECTION
E
G65500-0
DRIVE GEAR
(OIL INJECTION PUMP DRIVE)
INSPECTION
1. Visually inspect drive gear teeth for
cracks, pitting or wear and replace the
gear if any are found.
DRIVEN GEAR
(OIL INJECTION PUMP DRIVE)
INSPECTION
1. Visually inspect driven gear teeth for
cracks, pitting or wear and replace the
gear if any are found.
5-13
POWR
ASSEMBLY AND ADJUSTMENT
E
G71000-1
ASSEMBLY AND ADJUSTMENT
BEARING, OIL SEAL AND O-RING
1. Press in the new bearing.
CAUTION:
When reassembling the lower crank bearing and/or the oil-pump drive gear, the
tapered side of the drive gear and the sealcap side of the bearing should be installed
towards the crank side as shown in the
illustration.
75, 80, 90 hp:
Install the circlip
1 Circlip
2 Oil injection pump drive gear
3 Crank lower bearing
2. Install the new oil seal in the needle
bearing.
CAUTION:
The direction of the oil seal must be as
shown in the illustration, otherwise damage will be caused.
3. Install the new O-ring.
4. Lubricate the bearing with 2-stroke outboard motor oil. Apply water resistant
grease or equivalent to the inside lip of
the oil seal and to the O-ring.
G72001-0
PISTON AND PISTON RING
1. Install the top and 2nd piston rings into
their respective ring grooves with the
markings facing upward.
2. Align each ring end-gap with their location pins.
5-14
POWR
ASSEMBLY AND ADJUSTMENT
E
G73000-0*
SMALL END BEARINGS AND PISTON
ASSEMBLY
1. Count the small-end bearing needles.
Number of needles per small end: 28-pcs.
CAUTION:
Do not use a mixture of new and used bearing needles in the same small end.
2. Using the special service tool, install the
bearings in the connecting-rod small
end and place washers on both sides.
Small end bearing installer:
50, 60, 70 hp:
YB-6287/90890-06527
75, 80, 90 hp:
YB-6107/90890-06527
CAUTION:
The washer should be placed with their
convex sides facing the piston.
3. Insert the piston-pin into the piston.
4. Align the “UP” mark on the piston
crown towards the crankshaft's tapered
end. Install the piston in the connectingrod small end, insert the piston-pin,
then install new piston-pin clips.
5. Lubricate each bearing with 2-stroke
outboard-motor oil.
5-15
POWR
ASSEMBLY AND ADJUSTMENT
E
G78000-0*
CONNECTING ROD BIG END
BEARING ASSEMBLY (75, 80, 90 hp)
1. Install the piston.
Align the ring ends with locating pins in
the grooves and using the piston slider,
push the piston into the cylinder.
Piston slider:
YU-33294/90890-06530
NOTE:
The “UP” mark on the piston crown should
be on the flywheel side. Be sure to apply oil
to the piston and cylinder wall.
2. Place the crankshaft on the cylinder,
and align the upper, upper middle and
lower middle bearing pin holes with the
pins on the cylinder, and fit the crankshaft correctly to the cylinder.
3. Install the bearing in the big end and
install the cap.
The cap bolts should be tightened in the
following manner.
a. Lightly screw in the bolts by hand
while making sure the cap and rod
ends are aligned completely. Then,
tighten the bolts to the 1st specified
torque.
Next, tighten to the 2nd specified
torque. Check to see that the cap and
rod ends are aligned. If not aligned,
do the above procedure all over
again.
b. Loosen the bolts 1/2 turn and tighten
them to the 1st specified torque.
Then, tighten to the 2nd specified
torque.
5-16
POWR
ASSEMBLY AND ADJUSTMENT
E
NOTE:
Replace the cap bolts each time the connecting rod is disassembled.
T.
R.
Connecting rod big end:
(75, 80, 90 hp)
1st step:
12 Nm (1.2 m • kg, 8.7 ft • lb)
2nd step:
35 Nm (3.5 m • kg, 25 ft • lb)
G79000-1*
OIL SEAL HOUSING
1. Press-fit the oil seals one by one.
CAUTION:
When press-fitting the oil seal, be sure that
if faces in the correct direction.
2. Fit the new O-ring in the grooves in the
oil seal housing outer surfaces.
3. After installing the oil seal and O-ring,
pack the oil seal lip and outer surface of
the O-ring with water resistant grease.
NOTE:
Avoid cutting or stretching the oil seal
housing O-ring.
4. Install the oil seal housing onto the cylinder and align the bolt holes.
G74000-0*
CRANK CYLINDER ASSEMBLY
(50, 60, 70 hp)
1. Lubricate the piston-rings and pistons
with 2-stroke outboard-motor oil and
install the crank assembly into the cylinder block.
5-17
POWR
ASSEMBLY AND ADJUSTMENT
E
2. Lift the crank assembly a little in order
to install a washer on the lower crankcase and align each location-pin of the
bearings and labyrinth-seals with each
cut on the cylinder-block. Then, fit the
crank assembly in place.
3. Film-coat the cylinder-block mating surface with Gasket Maker or equivalent.
4. Install the dowel-pins.
5. Match the cylinder-block and tighten
the bolts to the specified torque in
sequence and in two steps.
T.
R.
Crankcase bolt (50, 60, 70 hp)
1st step:
M8: 10 Nm (1.0 m • kg, 7.2 ft • lb)
M10: 20 Nm (2.0 m • kg, 14 ft • lb)
2nd step:
M8: 20 Nm (2.0 m • kg, 14 ft • lb)
M10: 40 Nm (4.0 m • kg, 29 ft • lb)
6. Check that
smoothly.
the
crankshaft
turns
G74002-0*
CRANK CYLINDER ASSEMBLY
(75, 80, 90 hp)
1. Align each locating-pin of the bearings
and labyrinth-seals with each cut on the
cylinder-block. Then, fit the crank
assembly in place.
2. Film-coat the cylinder-block mating surface with Gasket Maker or equivalent.
3. Install the dowel-pins.
4. Match the cylinder-block and tighten
the bolts to the specified torque in
sequence and in two steps.
T.
R.
Crankcase bolt (75, 80, 90 hp)
1st step:
M6: 4 Nm (0.4 m • kg, 2.9 ft • lb)
M10: 20 Nm (2.0 m • kg, 14 ft • lb)
2nd step:
M6: 12 Nm (1.2 m • kg, 8.7 ft • lb)
M10: 40 Nm (4.0 m • kg, 29 ft • lb)
5. Check that
smoothly.
5-18
the
crankshaft
turns
POWR
ASSEMBLY AND ADJUSTMENT
E
G75000-0*
Å
CYLINDER HEAD AND EXHAUST
COVER
1. Install the gaskets cylinder-head cover
and exhaust cover.
2. Tighten the bolts to the specified torque
in sequence and in two steps.
Å Tightening sequence
T.
Å
R.
Cylinder head (50, 60, 70 hp):
1st step:
15 Nm (1.5 m • kg, 11 ft • lb)
2nd step:
32 Nm (3.2 m • kg, 23 ft • lb)
Cylinder-head (75, 80, 90 hp):
1st step:
15 Nm (1.5 m • kg, 11 ft • lb)
2nd step:
30 Nm (3.0 m • kg, 22 ft • lb)
ı
ı Tightening sequence
Ç
Ç Tightening sequence
T.
R.
Exhaust cover (50, 60, 70 hp):
1st step:
3 Nm (0.3 m • kg, 2.2 ft • lb)
2nd step:
8 Nm (0.8 m • kg, 5.8 ft • lb)
Exhaust cover (75, 80, 90 hp):
1st step:
9 Nm (0.9 m • kg, 6.5 ft • lb)
2nd step:
18 Nm (1.8 m • kg, 13 ft • lb)
Ç
3. Install the thermostat, gasket and cover.
5-19
POWR
ASSEMBLY AND ADJUSTMENT
E
G75500-0
DRAINAGE HOSE
1. Fit two clips around the drainage hose.
2. Connect one end of the hose to the
delivery side of the check valve and the
other end to the joint on the intake side
and lock with the clips.
G76000-0*
INTAKE MANIFOLD
1. Install the reed-valve assembly and the
gasket reed-valve plate to the intake
manifold.
2. Install the manifold assembly to the
crankcase and tighten the bolts to the
specified torque in sequence and in two
steps.
T.
R.
Intake manifold (50, 60, 70 hp):
1st step:
4 Nm (0.4 m • kg, 2.9 ft • lb)
2nd step:
8 Nm (0.8 m • kg, 5.8 ft • lb)
Intake manifold (75, 80, 90 hp):
1st step:
4 Nm (0.4 m • kg, 2.9 ft • lb)
2nd step:
12 Nm (1.2 m • kg, 8.7 ft • lb)
G77000-0*
FUEL SYSTEM
SYSTEM
AND
ELECTRICAL
1. Install the fuel system.
Refer to “FUEL SYSTEM” section in
chapter 4.
2. Install the electrical system.
Refer to “ELECTRICAL COMPONENTS”
section in chapter 8.
5-20
POWR
INSTALLATION
E
G8000-0*
INSTALLATION
1. Install locating pins in position on the
exhaust guide.
2. Align the locating-pin holes on the gasket with dowel pins and place the gasket on the bottom cowling.
3. Install the power head onto the bottom
cowling, tighten the mounting-bolts to
the specified torque.
T.
Mounting bolts:
21 Nm (2.1 m • kg, 15 ft • lb)
R.
4. Connect the hoses, cables and wires.
5. Install the apron.
6. Check the fittings installation, cable
connections and functions before starting the engine to check operation and to
check for leaks.
5-21
LOWR
E
CHAPTER 6
LOWER UNIT
EXPLODED DIAGRAM
(FOR 50GETO, C60ER, C60TR/60FET (OCEANIA), C75TR,
90AEHD, 90AED, C90TR/90AET).................................................................. 6-1
EXPLODED DIAGRAM
(EXCEPT FOR 50GETO, C60ER, C60TR/60FET (OCEANIA), C75TR,
90AEHD, 90AED, C90TR/90AET).................................................................. 6-2
PREPARATION FOR REMOVAL .................................................................... 6-3
DISASSEMBLY ............................................................................................... 6-3
INSPECTION ................................................................................................... 6-9
GEAR CASE .............................................................................................. 6-9
BEARING HOUSING ................................................................................ 6-9
CLAW-WASHER ....................................................................................... 6-9
RING-NUT................................................................................................. 6-9
WATER PUMP HOUSING...................................................................... 6-10
IMPELLER ............................................................................................... 6-10
OIL-SEAL HOUSING
(Water pump housing) ......................................................................... 6-10
GEAR....................................................................................................... 6-10
BEARING ................................................................................................ 6-10
CLUTCH DOG AND COMPONENTS ..................................................... 6-11
DRIVE AND PROPELLER SHAFT........................................................... 6-11
DRIVE SHAFT SLEEVE........................................................................... 6-11
PROPELLER/TRIM TAB/ANODE ............................................................ 6-11
ASSEMBLY AND ADJUSTMENT ................................................................ 6-12
PROPELLER-SHAFT HOUSING ............................................................. 6-12
GEAR CASE ............................................................................................ 6-13
SHIM SELECTION......................................................................................... 6-17
FOR USA AND CANADA ................................................................ 6-17
EXCEPT FOR USA AND CANADA.................................................. 6-22
MEASURING THE BACKLASH.............................................................. 6-25
WATER PUMP INSTALLATION............................................................. 6-28
INSTALLATION............................................................................................. 6-29
LOWER UNIT LEAKAGE CHECK ........................................................... 6-31
1
2
3
4
5
6
7
8
9
LOWR
EXPLODED DIAGRAM
E
EXPLODED DIAGRAM (FOR 50GETO, C60ER, C60TR/60FET (OCEANIA),
C75TR, 90AEHD, 90AED, C90TR/90AET)
1
2
3
4
5
6
7
8
9
0
Water pump housing
Impeller
Cartridge outer plate
Cartridge outer plate gasket
Oil-seal housing
Water pump gasket
Drive shaft
Woodruff key
Drive shaft sleeve
Needle bearing
A
B
C
D
E
F
G
H
I
J
Shifter
Shift slide
Forward gear
Clutch dog
Cross pin
Propeller shaft
Reverse gear
O-ring
Bearing
Bearing housing
6-1
K
L
M
N
O
P
Q
R
S
Needle bearing
Claw washer
Ring nut
Spacer
Propeller
Castle nut
Trim tab
Pinion gear
Spacer (50GETO)
LOWR
EXPLODED DIAGRAM
E
EXPLODED DIAGRAM (EXCEPT FOR 50GETO, C60ER, C60TR/60FET
(OCEANIA), C75TR, 90AEHD, 90AED, C90TR/90AET)
1
2
3
4
5
6
7
8
9
0
Water pump housing
Impeller
Cartridge outer plate
Cartridge outer plate gasket
Oil-seal housing
Water pump gasket
Drive shaft
Woodruff key
Drive shaft sleeve
Needle bearing
A
B
C
D
E
F
G
H
I
J
Shifter
Shift slide
Forward gear
Clutch dog
Cross pin
Propeller shaft
Reverse gear
O-ring
Bearing
Bearing housing
6-2
K
L
M
N
O
P
Q
R
Needle bearing
Claw washer
Ring nut
Spacer
Propeller
Castle nut
Trim tab
Pinion gear
LOWR
PREPARATION FOR REMOVAL/DISASSEMBLY
E
120001-0*
PREPARATION FOR REMOVAL
1. Remove the nut, washer, propeller and
spacer from the propeller shaft.
2. Drain the gear oil by removing the
plugs from the oil-filling hole and the
oil-level hole. Be sure to remove the oil
filling plug first.
3. Set the shift lever into neutral position.
4. Tilt up the lower unit and lock it with the
tilt lock lever.
5. Remove the trim tab. Before removing
it, put a mark indicating its position on
the anticavitation plate.
6. Remove the bolts.
140007-0
DISASSEMBLY
1. Referring to the exploded diagram,
remove the following parts.
1) Water pump housing and insert cartridge
2) Impeller and woodruff key
3) Oil-seal housing
(Water pump housing)
Remove the oil seals, if necessary
Å
Slide hammer set:
YB-6096 1
Stopper guide plate:
90890-06501 2
Bearing puller:
90890-06535 3
Stopper guide stand:
90890-06538 4
ı
Å For USA and Canada
ı Except for USA and Canada
6-3
LOWR
DISASSEMBLY
E
4) Shift-rod
5) Ring-nut 1 and claw-washer 2
Å
Ring nut wrench:
YB-34447................................ 3
90890-06511........................... 4
Extension (ring nut wrench):
90890-06513........................... 5
Å For USA and Canada
ı Except for USA and Canada
ı
NOTE:
To remove the ring-nut: straighten the lobe
of the claw-washer by using a screwdriver,
then attach and turn it in the direction of the
off mark using the special service tool.
4
5
6) Bearing-housing
Using special service tool.
Å
ı
Claw:
YB-6207.................................. 1
50, 60, 70 hp:
90890-06503........................ 2
75, 80, 90 hp:
90890-06502........................ 2
Flywheel puller:
YB-6117.................................. 3
Stopper guide plate:
90890-06501........................... 4
Center bolt:
90890-06504........................... 5
2
4
Å For USA and Canada
ı Except for USA and Canada
5
6-4
LOWR
DISASSEMBLY
E
7) Propeller shaft
(For 50GETO, C60ER, C60TR/60FET
(Oceania), C75TR, 90AEHD, 90AED,
C90TR/90AET)
1 Clutch dog
2 Cross pin
3 Cross pin ring
7) Propeller shaft
(Except for 50GETO, C60ER, C60TR/
60FET (Oceania), C75TR, 90AEHD,
90AED, C90TR/90AET)
1 Clutch dog
2 Cross pin
3 Cross pin ring
8) Shift slide
(Except for 50GETO, C60ER, C60TR/
60FET (Oceania), C75TR, 90AEHD,
90AED, C90TR/90AET)
Using a slotted screwdriver, remove
the shift slide balls 1 from the neutral position and pull out the shift
slide 2 and shifter 3.
9) Reverse gear and bearing
Å
Slide hammer set:
YB-6096.................................. 1
Stopper guide plate:
90890-06501........................... 2
Bearing puller:
90890-06535........................... 3
Stopper guide stand:
90890-06538........................... 4
Å For USA and Canada
ı Except for USA and Canada
ı
6-5
LOWR
DISASSEMBLY
E
10) Oil seals and needle bearing
Å
Slide hammer set:
YB-6096.................................. 1
Stopper guide plate:
90890-06501........................... 2
Bearing puller:
90890-06535........................... 3
Stopper guide stand:
90890-06538........................... 4
Driver rod:
YB-6071/90890-06602 ........... 5
Needle bearing attachment:
YB-6153/90890-06612 ........... 6
ı
Å For USA and Canada
ı Except for USA and Canada
Å
11) Pinion nut, pinion and drive shaft
bearing inner race
1
Drive shaft holder:
50, 60, 70 hp:
YB-6049/90890-06518 ........ 1
75, 80, 90 hp:
YB-6151/90890-06519 ........ 2
Pinion nut holder:
90890-06505........................... 3
ı
Å For USA and Canada
ı Except for USA and Canada
2
NOTE:
For ease of reassembly and adjustment,
keep shim packs in their groups as
removed.
3
6-6
LOWR
Å
DISASSEMBLY
E
12) Forward gear bearing outer race
1
Slide hammer set:
YB-6096.................................. 1
Bearing outer race puller:
90890-06523........................... 2
Å For USA and Canada
ı Except for USA and Canada
ı
Å
NOTE:
For ease of reassembly and adjustment,
keep shim packs in their groups as
removed.
2
13) Drive shaft bearing outer race
1
Slide hammer set:
YB-6096.................................. 1
Stopper guide plate:
90890-06501........................... 2
Bearing puller:
90890-06535........................... 3
Stopper guide stand:
90890-06538........................... 4
ı
Å For USA and Canada
ı Except for USA and Canada
2
3
4
14) Drive shaft sleeve
15) Drive shaft needle bearing
1
Driver rod:
YB-6071/90890-06602 ........... 1
Needle bearing attachment:
YB-6155/90890-06611 ........... 2
2
6-7
LOWR
DISASSEMBLY
E
16) Reverse gear bearing and forward
gear bearing
1
Bearing separator:
YB-6219.................................. 1
90890-06534........................... 2
2
NOTE:
Separate the bearing from the gear using
special service tool and hydraulic press.
6-8
LOWR
INSPECTION
E
151001-0
INSPECTION
GEAR CASE
1. Using a soft brush and solvent, clean
the case and water passage.
2. Visually inspect the gear case for
cracks, corrosion or distortion. If any
crack or excessive corrosion is found,
replace the gear case.
3. Check the water inlet cover and water
passage for clogging.
151500-0
BEARING HOUSING
1. Using a soft brush and solvent, clean
the housing thoroughly.
2. Visually inspect the housing for cracks
and corrosion. If any damage is found,
replace the bearing housing.
152000-0
CLAW-WASHER
1. Visually inspect the washer for cracks. If
a crack is found, replace the clawwasher.
152500-0
RING-NUT
1. Using a soft brush and solvent, clean
the thread of the ring-nut.
2. Visually inspect the ring-nut for cracks
or damage to the thread. If cracked or
damaged, replace the ring-nut.
6-9
LOWR
INSPECTION
E
153000-0
WATER PUMP HOUSING
1. Inspect the water pump housing for
signs of twisting or scratches of the
inner cartridge. If twisted or scratched
excessively, replace the housing.
2. During the above operation, inspect the
impeller plate and replace this if damaged.
153500-0
IMPELLER
1. Visually inspect the impeller for cracks,
distortion or burning. If any damage is
found, replace the impeller.
154000-0
OIL-SEAL HOUSING
(Water pump housing)
1. Using a soft brush and solvent, clean
the oil-seal housing.
2. Visually inspect the housing for cracks
or corrosion. If a crack and/or excessive
corrosion is found, replace the oil-seal
housing.
154500-0
GEAR
1. Visually inspect the teeth and dogs on
the gears for cracks, peeling or distortion due to gear-crashing. If damage is
found on any of the gears, replace with
a new one.
155000-0
BEARING
1. Inspect the bearings for pitting, scratching or rumbling (which may be detected
by turning the bearing by hand), and
replace them if they are not in good
condition.
6-10
LOWR
INSPECTION
E
15500-0
CLUTCH DOG AND COMPONENTS
1. Visually inspect the clutch dog, looking
particularly for rounding of the dog
edge, cracks and other signs of damage
or wear. If the dog is excessively
rounded, inspect the mating gear, and
replace both if necessary.
156000-0
DRIVE AND PROPELLER SHAFT
1. Visually inspect the shafts, looking for
grooved wear on the surface in contact
with the bearings and oil-seals and
checking for wear on the splines.
Replace if worn or damaged.
156300-0
DRIVE SHAFT SLEEVE
1. Visually inspect the sleeve for wear and
cracks. If any damage is found, replace
the sleeve.
157000-0*
PROPELLER/TRIM TAB/ANODE
1. Refer to “PERIODIC SERVICE” section in
chapter 3.
6-11
LOWR
ASSEMBLY AND ADJUSTMENT
E
161009-0*
ASSEMBLY AND ADJUSTMENT
PROPELLER-SHAFT HOUSING
1. Install the thrust washer and press-fit a
ball-bearing to the reverse gear.
Å 50GETO
Å
2. Install a needle-bearing and oil seals,
and then press-fit the reverse gear complete into the bearing housing.
1
NOTE:
Install the needle bearing with its manufacture's marks or numbers facing outward.
2
ı
Depth a:
50 hp
: 20.7 mm (1.06 in)
60 ~ 90 hp: 25.5 mm (1.00 in)
1
Drive rod:
YB-6071/90890-06604 ........... 1
Needle bearing attachment:
50 hp: 90890-06614 ............... 2
60 ~ 90 hp:
YB-6152/90890-06611 ........ 3
Bearing depth plate:
90890-06603........................... 4
23
4
Å For USA and Canada
ı Except for USA and Canada
Depth b:
5 mm (0.20 in)
Driver rod:
YB-6071.................................. 5
Oil seal attachment:
60 ~ 90 hp:
YB-6259 .............................. 6
6-12
LOWR
ASSEMBLY AND ADJUSTMENT
E
GEAR CASE
Å
1. Install a new needle-bearing in position.
NOTE:
The needle bearing should be installed with
the mark facing the flange side of attachment.
Driver rod:
YB-6071.................................. 1
Needle bearing depth stop:
YB-34473................................ 2
Needle bearing attachment:
YB-6155.................................. 3
Driver rod:
90890-06602........................... 4
Bearing depth plate:
90890-06603........................... 5
Needle bearing attachment:
50 hp:
90890-06614 ...... 6
60 ~ 90 hp: 90890-06611 ...... 6
ı
Depth a:
50 hp
: 198.3 ~ 198.8 mm
(7.81 ~ 7.83 in)
60 ~ 90 hp : 187.6 ~ 188.6 mm
(7.39 ~ 7.43 in)
Å For USA and Canada
ı Except for USA and Canada
2. Align the drive-shaft sleeve locating-rib
with the recess in the gear case and
place the drive-shaft sleeve into the
gear case.
3. Place the pinion-gear shim-pack 1 in
position and install the taper-roller
bearing outer race 2 on the shim-pack.
3
4
Drive rod:
YB-6071/90890-06606 ........... 3
Bearing outer race attachment:
50 hp: 90890-06627 ............... 4
60 ~ 90 hp:
YB-6156/90890-06626 ........ 4
6-13
LOWR
ASSEMBLY AND ADJUSTMENT
E
4. Place the forward-gear shim-pack 1 in
position and install the forward-gear
outer race 2 on the shim-pack.
3
Driver rod:
YB-6071/90890-06605 ........... 3
Bearing outer race attachment:
50 hp: 90890-06622 ............... 4
60 ~ 90 hp:
YB-6276B/90890-06621...... 4
4
5. Install the bearing inner race to the forward-gear, then place the forward-gear
complete onto the outer race.
1
Bearing inner race attachment:
50 hp: 90890-06640 ............... 1
60 ~ 90 hp: 90890-06662 ....... 1
6. Place the drive-shaft in the gear case
and insert it into the pinion.
Tighten the pinion nut to the specified
torque.
1
2
T.
R.
Pinion nut:
50 hp:
75 Nm (7.5 m • kg, 54 ft • lb)
60 ~ 90 hp:
95 Nm (9.5 m • kg, 69 ft • lb)
Drive shaft holder:
50, 60, 70 hp:
YB-6049/90890-06518 ........ 1
75, 80, 90 hp:
YB-6151/90890-06519 ........ 1
Pinion nut holder:
90890-06505........................... 2
7. Assemble the propeller shaft.
(For 50GETO, C60ER, C60TR/60FET
(Oceania), C75TR, 90AEHD, 90AED,
C90TR/90AET)
1) Referring to the illustration.
a “F” mark side
6-14
LOWR
ASSEMBLY AND ADJUSTMENT
E
7. Assemble the propeller shaft.
(Except for 50GETO, C60ER, C60TR/
60FET (Oceania), C75TR, 90AEHD,
90AED, C90TR/90AET)
1) Insert the free shaft 1 into the shift
slide 2.
2) Insert the two balls 3 and shifter 4
on the shift slide.
NOTE:
Grease the balls so that they will not come
off easily from the shift slide, thus making
your work easier.
3) Align the hole in the shift slide cross
pin with the slot in the propeller
shaft cross pin and insert the shift
slide into the propeller shaft.
4) Push the shifter and stop pushing it
when the balls move into the neutral groove in the propeller shaft
making a slick.
If the balls move into the reverse
groove passing the neutral, be sure
to bring them back to neutral.
5) Install the clutch dog so that its
cross pin hole is aligned with the
slot in the splined portion of the
propeller shaft.
NOTE:
Install the clutch dog so that the “F” mark on
the clutch dog is on the forward gear side.
6) Bring the cross pin hole in the
clutch dog with the hole in the shift
slide and insert the cross pin into
these holes. Then, install the cross
pin ring.
7) Place the shift cam on the shifter
(with the “F” mark on the shift cam
facing forward) and insert the propeller shaft into the forward gear.
6-15
LOWR
ASSEMBLY AND ADJUSTMENT
E
8. Grease the lips of the oil-seals and
insert the propeller shaft complete into
the bearing housing. Then, place the
bearing housing complete to the gear
case.
9. Look into the gear case through the
hole and align the shift rod hole in the
gear case with the splined hole in the
shift cam 1 and install the shift rod 2.
(Except for 50GETO, C60ER, C60TR/
60FET (Oceania), C75TR, 90AEHD,
90AED, C90TR/90AET)
10. Place the reverse-gear shim 1 in place,
then install the bearing housing 2
(aligning the key-way in the gear-case
with that in the bearing housing) and
insert the key 3.
11. Place a claw-washer in place, install a
ring-nut (with its embossed marks facing outward away from the bearing
housing), tighten the ring-nut to the
specified torque and bend the clawwasher over the ring-nut to lock it.
1
T.
R.
Ring-nut:
50 hp:
130 Nm (13.0 m • kg, 0.94 ft • lb)
60, 70, 75, 80, 90 hp:
145 Nm (14.5 m • kg, 105 ft • lb)
Ring nut wrench:
50 hp:
YB-06048/90890-06510
60 ~ 90 hp:
YB-34447 ............................. 1
90890-06511........................ 2
Extension (ring nut wrench):
90890-06513........................... 3
2
3
6-16
LOWR
SHIM SELECTION (FOR USA AND CANADA)
E
SHIM SELECTION
NOTE:
1. When reassembling the lower unit with
the original gear case and inner parts,
shim selection is not required.
2. When replacing the gear case only, read
the numeral preceded by “F, R, P” and
adjust the shims according to the difference between numerals of the original
gear-case and the new gear-case.
3. If the bearing(s) and/or gear(s) are
replaced, carry out the shim selection.
FOR USA AND CANADA
Pinion gear shim
NOTE:
Find pinion gear shim thickness (T3) by
selecting shims until the specified measurement (M) with the special tool is obtained.
1. Find the specified measurement (M).
Specified Measurement (M) =
0.20 mm + P/100 mm
NOTE:
1. P is the deviation of the lower case
dimension from standard. It is stamped
on the trim tab mounting surface of the
lower case in 0.01 mm units. If the P
mark is missing or unreadable, assume a
P mark of “0” and check the backlash
when the unit is assembled.
2. If the P value is negative (–), then subtract the P value from the measurement.
6-17
LOWR
SHIM SELECTION (FOR USA AND CANADA)
E
Example:
If P mark is “+5”, then
M = 0.20 + (+5)/100 mm
= 0.20 + 0.05 mm
= 0.25 mm
If P mark is “–3”, then
M = 0.20 + (–3)/100 mm
= 0.20 – 0.03 mm
= 0.17 mm
YB-34432-9
YB-34432-10
YB-34432-11
2. Assemble the shimming gauge with the
drive shaft, bearing and shim(s) as
shown in the illustration.
YU-26900-8
YU-26900-9
NOTE:
1. Attach the adapter plate to the gauge
base using 4 bolts with appropriate sizes.
2. If the original shim(s) is unavailable, start
with a 0.50 mm shim.
YB-34432-17-A
Gauge block:
YB-34432-9
Adapter plate:
YB-34432-10
Gauge base:
YB-34432-11-A
Clamp:
YB-34432-17-A
3. Install the pinion on the drive shaft and
tighten the nut to the specified torque.
4. Using a thickness gauge at the specified
measurement (M) established above,
check the fit between the shimming
gauge and lower surface of the pinion
as shown.
Thickness gauge:
YU-26900-8
YU-26900-9
5. If the thickness gauge at the M specification will not fit, then remove or add
the shim(s) until the thickness gauge
just fits between the tool surfaces.
Available shim thickness:
0.10, 0.12, 0.15, 0.18, 0.30, 0.40
and 0.50 mm
6-18
LOWR
SHIM SELECTION (FOR USA AND CANADA)
E
Forward gear shim
NOTE:
Find forward gear shim thickness (T1) by
selecting shims until the specified measurement (M) with the special tool is obtained.
1. Find the specified measurement (M).
Specified Measurement (M) =
1.69 mm + F/100 mm
NOTE:
1. F is the deviation of the lower case
dimension from standard. It is stamped
on the trim tab mounting surface of the
lower case in 0.01 mm units. If the F
mark is missing or unreadable, assume
an F mark of “0” and check the backlash
when the unit is assembled.
2. If the F value is negative (–), then subtract the F value from the measurement.
YB-34446-1
YB-34446-7
YB-34446-5
Example:
If F mark is “+5”, then
M = 1.69 + (+5)/100 mm
= 1.69 + 0.05 mm
= 1.74mm
If F mark is “–3”, then
M = 1.69 + (–3)/100 mm
= 1.69 – 0.03 mm
= 1.66 mm
YB-34446-3
2. Assemble the shimming gauge with the
forward bearing and original shim(s) as
shown in the illustration. Tighten the
nut four turns after contacting the
spring.
YU-26900-8
YU-26900-9
NOTE:
If the original shim(s) is unavailable, start
with a 0.50 mm shim.
Base plate:
YB-34446-1
Compression spring:
YB-34446-3
Press plate:
YB-34446-5
Gauge pin:
YB-34446-7
6-19
LOWR
SHIM SELECTION (FOR USA AND CANADA)
E
3. Using a thickness gauge at the specified
measurement (M) established above,
check the fit between the shimming
gauge and upper disc of the tool.
Thickness gauge:
YU-26900-8
YU-26900-9
4. If the thickness gauge at the M specification will not fit, then remove or add
the shim(s) until the thickness gauge
just fits between the tool surfaces.
Available shim thicknesses:
0.10, 0.12, 0.15, 0.18, 0.30, 0.40
and 0.50 mm
Reverse gear shim
NOTE:
Find the reverse gear shim thickness (T2) by
selecting shims until the specified measurement (M) with the special tool is obtained.
1. Find the specified measurement (M).
Specified Measurement (M) =
60, 70 hp:
1.00 mm – R/100 mm
75, 90 hp:
1.50 mm – R/100 mm
NOTE:
1. R is the deviation of the lower case
dimension from standard. It is stamped
on the trim tab mounting surface of the
lower case in 0.01 mm units. If the R
mark is missing or unreadable, assume
an R mark of “0” and check the backlash
when the unit is assembled.
2. If the R value is negative(–), then add the
R value to the measurement.
6-20
LOWR
SHIM SELECTION (FOR USA AND CANADA)
E
Example: (60, 70 hp)
If R mark is “+5”, then
M = 1.00 – (+5)/100 mm
= 1.00 – 0.05 mm
= 0.95 mm
If R mark is “–3”, then
M = 1.00 – (–3)/100 mm
= 1.00 + 0.03 mm
= 1.03 mm
Example: (75, 90 hp)
If R mark is “+5”, then
M =1.50 – (+5)/100 mm
=1.50 – 0.05 mm
=0.45 mm
If R mark is “–3”, then
M =1.50 – (–3)/100 mm
=1.50 + 0.03 mm
=1.53 mm
2. Place the original shim(s) on the thrust
washer mounted on the bearing housing and place the shimming gauge on
top of the shim(s) as shown in the illustration.
NOTE:
1. If the original shim(s) is unavailable, start
with a 0.50 mm shim.
2. Be sure to remove the O-ring from under
the thrust washer.
Shimming gauge:
YB-34468-5 (60, 70 hp)
YB-34468-3 (75, 90 hp)
3. Using a thickness gauge at the specified
measurement (M) established above,
check the fit between the shimming
gauge and the reverse gear. Force the
shimming gauge against the shims and
thrust washer when checking the fit.
Thickness gauge:
YU-26900-8
YU-26900-9
4. If the thickness gauge at the M specification will not fit, then remove or add
the shim(s) until the thickness gauge
just fits between the tool surfaces.
Available shim thickness:
0.10, 0.12, 0.15, 0.18, 0.30, 0.40
and 0.50 mm
6-21
LOWR
SHIM SELECTION
(EXCEPT FOR USA AND CANADA)
E
EXCEPT FOR USA AND CANADA
Pinion gear shim
1. Find pinion gear shim thickness (T3) by
selecting shims until the specified measurement (M) with the special tool is
obtained.
2. Install the pinion on the drive shaft and
tighten the nut to the specified torque.
T.
R.
Pinion nut:
50 hp:
75 Nm (7.5 m • kg, 54 ft • lb)
60 ~ 90 hp:
95 Nm (9.5 m • kg, 69 ft • lb)
3. Assemble the pinion height gauge with
the drive shaft and bearing as shown in
the illustration. Bolt the bearing housing to the special tool with at least two
bolts.
90890-06702
Pinion height gauge:
90890-06702
Digital caliper:
90890-06704
90890-06704
4. Using a digital caliper at the specified
measurement (M) established above,
measure the distance between the pinion height gauge and lower surface of
the pinion as shown.
Shim thickness (T3)=
50 hp:
M – 40.2 mm – P/100 mm
60 ~ 90 hp:
M – 31.5 mm – P/100 mm
5. P is the deviation of the lower case
dimension from standard. It is stamped
on the trim tab mounting surface of the
lower case in 0.01 mm units. If the P
mark is missing or unreadable, assume
a P mark of “0” and check the backlash
when the unit is assembled.
Example:
If M is “32.10 mm” P is “+2”, then
T3 = 32.10 – 31.5 – 2/100 = 0.58
Available shim thickness:
0.10, 0.12, 0.15, 0.18, 0.30, 0.40
and 0.50 mm
6-22
LOWR
SHIM SELECTION
(EXCEPT FOR USA AND CANADA)
E
NOTE:
● Use a minimum number of shims to
obtain the thickness equal or nearly equal
to the calculation.
● Install the shims with the thicker one on
the outer side.
Forward gear shim
1. Find forward gear shim thickness (T1)
by selecting shims until the specified
measurement (M) with the special tool
is obtained.
2. Using a digital caliper at the specified
measurement (M) established above,
measure the bearing height.
90890-06701
90890-06704
Shim thickness (T1)=
50 hp:
22.70 mm + F/100 mm – M
60 ~ 90 hp:
24.50 mm + F/100 mm – M
Shimming plate:
90890-06701
Digital caliper:
90890-06704
3. F is the deviation of the lower case
dimension from standard. It is stamped
on the trim tab mounting surface of the
lower case in 0.01 mm units. If the F
mark is missing or unreadable, assume
an F mark of “0” and check the backlash
when the unit is assembled.
Example:
If M is “23.90 mm” F is “+5”, then
T1 = 24.50 + 5/100 – 23.90 = 0.65
Available shim thickness:
0.10, 0.12, 0.15, 0.18, 0.30, 0.40
and 0.50 mm
6-23
LOWR
SHIM SELECTION
(EXCEPT FOR USA AND CANADA)
E
NOTE:
● Use a minimum number of shims to
obtain the thickness equal or nearly equal
to the calculation.
● Install the shims with the thicker one on
the outer side.
Reverse gear shim
1. Find reverse gear shim thickness (T2)
by selecting shims until the specified
measurement (M) with the special tool
is obtained.
NOTE:
Be sure to remove the O-ring from under
the thrust washer.
2. Using a digital caliper at the specified
measurement (M) established above,
measure the distance between the
washer top and special tool top as
shown.
90890-06701
90890-06704
Shim thickness (T2)=
50 hp:
M – 25.40 mm – R/100 mm
60, 70 hp
M – 28.00 mm – R/100 mm
75 ~ 90 hp:
M – 26.00 mm – R/100 mm
Shimming plate:
90890-06701
Digital caliper:
90890-06704
3. R is the deviation of the lower case
dimension from standard. It is stamped
on the trim tab mounting surface of the
lower case in 0.01 mm units. If the R
mark is missing or unreadable, assume
an R mark of “0” and check the backlash when the unit is assembled.
6-24
LOWR
SHIM SELECTION
E
Example:
If M is “28.60 mm” R is “–1”, then
T2 = 28.60 – 28.00 + 1/100 = 0.61
Available shim thickness:
0.10, 0.12, 0.15, 0.18, 0.30, 0.40
and 0.50 mm
NOTE:
● Use a minimum number of shims to
obtain the thickness equal or nearly equal
to the calculation.
● Install the shims with the thicker one on
the outer side.
163015-0*
MEASURING THE BACKLASH
NOTE:
● Do not install the water pump components when measuring the backlash.
● Both forward and reverse gear backlashes
should be measured.
● If both the forward and reverse gear backlashes are larger than specified, the pinion
may be too high.
● If both forward and reverse gear backlashes are smaller than specified, the pinion may be too low.
● If either of these conditions exists, then
check the pinion shim selection.
1. Place the shift rod in neutral.
2. Install a dial gauge on the gear case.
3. Install a backlash indicator gauge (special service tool) on the drive shaft (50,
60, 70 hp: 18 mm in diameter, 75, 80, 90
hp: 20 mm in diameter) and make the
dial gauge stem contact the mark on the
indicator gauge.
Dial gauge:
YU-3097/90890-01252........... 1
Magnet base:
YU-34481/90890-06705......... 2
Backlash indicator:
YB-6265/90890-06706 ........... 3
Backlash adjusting plate:
YB-7003.................................. 4
6-25
LOWR
SHIM SELECTION
E
Forward gear
1. Install a bearing housing puller (special
service tool) in the bearing housing so
that it engages with the center bolt of
the propeller shaft.
NOTE:
Tighten the center bolt while turning the
propeller shaft a few times clockwise.
T.
Center bolt:
5 Nm (0.5 m • kg, 3.6 ft • lb)
R.
Claw:
YB-6207/90890-06503
50, 60, 70 hp:
90890-06502
Universal puller:
YB-6117
Stopper guide plate:
90890-06501
Center bolt:
90890-06504
2. Slowly turn the drive shaft in and out
and read the dial gauge when the drive
shaft stops in each direction.
3. Determine the shim size according to
the chart.
50, 75, 80, 90 hp:
Forward gear
backlash
6-26
Decrease or increase
Less than
0.08 mm (0.003 in)
Thickness of shim to be
decreased (mm) = (0.17 –
measurement) × 0.60
0.08 – 0.25 mm
(0.003 – 0.009 in)
Decrease or increase will
be unnecessary
More than
0.25 mm (0.009 in)
Thickness of shim to be
increased (mm) = (measurement – 0.17) × 0.60
LOWR
SHIM SELECTION
E
60, 70 hp:
Forward gear
backlash
Decrease or increase
Less than
0.09 mm (0.004 in)
Thickness of shim to be
decreased (mm) = (0.19
– measurement) × 0.53
0.09 – 0.28 mm
(0.004 – 0.011 in)
Decrease or increase
will be unnecessary
More than
0.28 mm (0.011 in)
Thickness of shim to be
increased (mm) = (measurement – 0.19) × 0.53
Reverse gear
1. Install a propeller on the propeller shaft,
with the front facing backward, fit the
nut and tighten.
T.
Nut (propeller):
5 Nm (0.5 m • kg, 3.6 ft • lb)
R.
2. Slowly turn the drive shaft in and out
and read the dial gauge when the drive
shaft stops in each direction.
3. Determine the shim size according to
the chart.
50 hp:
Reverse gear
backlash
Decrease or increase
Less than
0.84 mm (0.033 in)
Thickness of shim to be
increased (mm) = (1.01 –
measurement) × 0.60
0.84 – 1.17 mm
(0.033 – 0.046 in)
Decrease or increase will
be unnecessary
More than
1.17 mm (0.046 in)
Thickness of shim to be
decreased (mm) = (measurement – 1.01) × 0.60
60, 70 hp:
Reverse gear
backlash
6-27
Decrease or increase
Less than
0.75 mm (0.033 in)
Thickness of shim to be
increased (mm) = (0.94 –
measurement) × 0.53
0.75 – 1.13 mm
(0.033 – 0.044 in)
Decrease or increase will
be unnecessary
More than
1.13 mm (0.044 in)
Thickness of shim to be
decreased (mm) = (measurement – 0.94) × 0.53
LOWR
SHIM SELECTION
E
75, 80, 90 hp:
Reverse gear
backlash
Decrease or increase
Less than
0.67 mm (0.026 in)
Thickness of shim to be
increased (mm) = (0.84 –
measurement) × 0.60
0.67 – 1.00 mm
(0.026 – 0.039 in)
Decrease or increase will
be unnecessary
More than
1.00 mm (0.039 in)
Thickness of shim to be
decreased (mm) = (measurement – 0.84) × 0.60
1
164000-0
WATER PUMP INSTALLATION
1. Install a new oil seal in the oil-seal
housing, and fit a new O-ring in the Oring groove.
2
Driver rod:
YB-6071.................................. 1
Oil seal attachment:
YB-6269.................................. 2
2. Grease the O-ring and the lip of the oilseal, then install the oil-seal housing
complete to the gear-case and fit the
dowel-pins.
3. Aligning with the dowel-pins, install a
new gasket, a plate and a new gasket on
the oil-seal housing.
4. Install a key in the keyway on the driveshaft and insert a impeller.
5. Grease the impeller and install the
water-pump housing, turning the drive
shaft clockwise, then tighten the bolts.
6-28
LOWR
INSTALLATION
E
170003-0*
INSTALLATION
1. Check that the clutch dog shifts to “Forward”, “Neutral” and “Reverse” correctly by turning the shift rod, and shift
into “Neutral”.
Shift rod wrench:
YB-6052
2. Align the mark on the shift lever with
the arrow mark on the bottom cowling.
3. Grease the spline of the drive-shaft and
the water-tube outer face, align the
water-tube and drive-shaft, install the
lower unit and tighten the bolts to the
specified torque.
T.
R.
6-29
Lower unit mounting bolts:
40 Nm (4.0 m • kg, 29 ft • lb)
LOWR
INSTALLATION
E
4. Install the trim tab on the gear case. Be
sure to align the marks put on both of
them when they were removed. Place
the cap over the bolt hole.
5. Install the spacers, propeller, washer,
and propeller nut over the propeller
shaft.
T.
Propeller nut:
35 Nm (3.5 m • kg, 25 ft • lb)
R.
6. Align the recess in the propeller nut
with the hole in the propeller shaft and
insert the cotter pin into the hole. Be
sure to bend the cotter pin ends.
NOTE:
If the propeller nut does not align with the
propeller shaft hole when the nut is tightened to specification, turn it in further so
that they align.
7. Fill with fresh gear oil through the oil
plug-hole until oil flows out through the
level-plug hole, then secure the plugs in
these two holes. (Secure the check plug
first.)
6-30
LOWR
INSTALLATION
E
165000-0
Å
LOWER UNIT LEAKAGE CHECK
1. Tighten the gear oil-drain screw and
connect the tester to the oil-level hole.
2. Pump the tester, and apply a pressure
of 100 kPa (1.0 kg/cm2, 14.2 psi).
Then, place the gear case in the water
tank.
3. Check that the pressure is held at
100 kPa (1.0 kg/cm2, 14.2 psi) for 10 seconds.
ı
CAUTION:
Do not overpressurize.
NOTE:
If the pressure falls, leakage from the lower
unit is unacceptable, requiring re-inspection
of its component parts.
Pressure tester:
YB-35956/90890-06762
Å For USA and Canada
ı Except for USA and Canada
6-31
BRKT
E
CHAPTER 7
BRACKET UNIT
BRACKET UNIT............................................................................................... 7-1
EXPLODED DIAGRAM ............................................................................. 7-1
MANUAL HANDLE ............................................................................ 7-1
UPPER CASING ................................................................................. 7-2
BOTTOM COWLING.......................................................................... 7-4
BRACKET UNIT.................................................................................. 7-5
BRACKET UNIT (Manual tilt model) ................................................ 7-6
BRACKET (Short transom) ............................................................... 7-7
BRACKET (Long transom) ................................................................ 7-8
REMOVAL................................................................................................. 7-9
DISASSEMBLY......................................................................................... 7-9
INSPECTION............................................................................................. 7-9
ANODE ............................................................................................... 7-9
BRACKET ........................................................................................... 7-9
TRIM SENSOR ................................................................................... 7-9
ASSEMBLY............................................................................................. 7-10
HYDRAULIC TILT UNIT ................................................................................ 7-11
INSPECTION........................................................................................... 7-11
POWER TRIM AND TILT UNIT..................................................................... 7-11
REMOVAL............................................................................................... 7-11
EXPLODED DIAGRAM (Short transom [6H308]) ................................. 7-12
DISASSEMBLY....................................................................................... 7-14
INSPECTION........................................................................................... 7-16
TILT-ROD AND TRIM-ROD.............................................................. 7-16
ASSEMBLY............................................................................................. 7-16
EXPLODED DIAGRAM (Long transom [6H1-15], [62F-02]) ................. 7-20
DISASSEMBLY....................................................................................... 7-22
INSPECTION........................................................................................... 7-24
TILT-ROD AND TRIM-ROD.............................................................. 7-24
ASSEMBLY............................................................................................. 7-24
FILLING WITH HYDRAULIC FLUID AND AIR-BLEEDING .................... 7-28
HYDRAULIC FLUID PRESSURE TEST .................................................. 7-28
INSTALLATION ...................................................................................... 7-30
POWER TRIM AND TILT MOTOR................................................................ 7-31
DISASSEMBLY....................................................................................... 7-31
INSPECTION........................................................................................... 7-31
ARMATURE COIL ............................................................................ 7-31
BRUSH ............................................................................................. 7-32
BASE ASSEMBLY............................................................................ 7-32
CIRCUIT BREAKER .......................................................................... 7-32
ASSEMBLY............................................................................................. 7-33
1
2
3
4
5
6
7
8
9
BRKT
BRACKET UNIT
E
BRACKET UNIT
EXPLODED DIAGRAM
MANUAL HANDLE
P60TH/60FEHTO*1, P75TH/75CEHTO, 90AEHD*2
1
2
3
4
5
Steering handle
Bracket
Main switch
Engine stop switch
Throttle cable
6
7
8
9
0
Link assembly
Shift cable
Cover
Grip
Battery cable
7-1
A
B
C
D
Main switch lead
Extension wire lead
PTT switch (PTT model)
Steering friction
(PTT model)
BRKT
BRACKET UNIT
E
K15000-0
UPPER CASING
50, 60, 70 hp
1
2
3
4
5
6
7
Exhaust guide
Exhaust manifold
Muffler
Upper case
Apron
Seal
Bottom cowling
7-2
BRKT
BRACKET UNIT
E
75, 80, 90 hp
1
2
3
4
5
6
7
Exhaust guide
Exhaust manifold
Muffler
Upper case
Apron
Seal
Bottom cowling
7-3
BRKT
BRACKET UNIT
E
K-15300-0
BOTTOM COWLING
1
2
3
4
5
6
7
Power trim and tilt motor lead (PTT model)
Trim sender lead (PTT model)
Grommet
Flushing kit (B90TR/90AETO)
Clamp (PTT model)
Bottom cowling fitting plate
Shift actuator
7-4
BRKT
BRACKET UNIT
E
K-15600-0
BRACKET UNIT
1
2
3
4
5
6
7
8
Upper mount rubber cover
Cap
Upper mount rubber nut
Screw
Low mount rubber cover
Ground lead
Bolt
Mount rubber housing
9 Lower mount rubber nut
0 Anode (PTT model)
A Read wire (PTT model)
7-5
BRKT
BRACKET UNIT
E
BRACKET UNIT (Manual tilt model)
1
2
3
4
5
Tilt unit
Tilt lever
Clamp bracket spacer
Lower shock mount pin
Bushing
7-6
BRKT
BRACKET UNIT
E
K15900-0
BRACKET (Short transom)
1
2
3
4
5
6
7
8
9
Circlip
Lower mounting housing
Steering pivot shaft
Bushing
O-ring
Bushing
Grease nipple
Ground lead
Tilt rod (manual tilt model)
0
A
B
C
D
E
F
G
H
Clamp bracket nut
Bolt (6 bolts)
Clamp bracket bolt
Washer
Bushing
Clamp bracket
Trim sensor (PTT model)
Circlip
Pin
7-7
I Bushing
J Power trim and tilt unit
(PTT model)
K Cotter pin
L Tilt lock lever
M Bushing
N Washer
O Spring
P Collar
BRKT
BRACKET UNIT
E
K15900-0
BRACKET (Long transom)
1
2
3
4
5
6
7
8
9
Circlip
Lower mounting housing
Steering pivot shaft
Bushing
O-ring
Bushing
Grease nipple
Ground lead
Tilt rod (manual tilt model)
0
A
B
C
D
E
F
G
H
Clamp bracket nut
Bolt (6 bolts)
Clamp bracket bolt
Washer
Bushing
Clamp bracket
Trim sensor (PTT model)
Circlip
Pin
7-8
I Bushing
J Power trim and tilt unit
(PTT model)
K Tilt lock lever
L Bushing
M Spring
N Collar
BRKT
BRACKET UNIT
E
K20002-0
REMOVAL
1. Remove the power-head.
2. Remove the swivel-bracket from the
upper casing.
CAUTION:
Lay the outboard motor on the floor to
carry out this removal.
DISASSEMBLY
1. Referring to the exploded diagram, disassemble the bracket unit.
INSPECTION
ANODE
1. Check anode and replace with new one
when the size is less than 1/3 of original
length.
BRACKET
1. Inspect the bracket and replace them, if
cracked.
TRIM SENSOR
1. Check resistance of the new trim
sensor.
Trim sensor resistance:
Pink – Black
360 ~ 540 Ω
Black – Orange
800 ~ 1200 Ω
2. Measure resistance between black and
pink leads to check that the value
changes gradually in the whole trim
and tilt range. If not, replace trim sensor
with new one.
7-9
BRKT
BRACKET UNIT
E
Trim sensor adjustment
Fully tilt up the outboard motor.
Loosen the two bolts securing the trim sensor until it moves slightly.
WARNING
Be sure to support the engine with the tilt
support lever while loosening the bolts to
prevent the engine from tilting down due
to lack of oil pressure.
Fully tilt down the outboard motor.
Connect battery cables of the outboard
motor to a battery and set the main switch
to “ON”.
Adjust the trim sensor position by pushing
a screw driver so that one segment on the
trim indicator on the digital meter goes on.
Tilt up the outboard motor and tighten both
installation bolts.
WARNING
Be sure to support the engine with the tilt
support lever while tightening the bolts to
prevent the engine from tilting down due
to lack of oil pressure.
ASSEMBLY
1. Referring to the exploded diagram,
assemble the bracket unit.
7-10
BRKT
HYDRAULIC TILT UNIT/
POWER TRIM AND TILT UNIT
E
HYDRAULIC TILT UNIT
WARNING
This cylinder is highly pressurized. Therefore, never overhaul or damage it.
INSPECTION
1. Inspect the tilt cylinder assembly for
scratches or corrosion.
If any scratches are found, replace the
tilt cylinder assembly.
POWER TRIM AND TILT UNIT
REMOVAL
1. Disconnect the leads from the relay in
the bottom cowling.
2. Remove the tilt-rod, bolts and nut, and
the clamp-bracket.
3. Remove the circlip and the complete
power trim and tilt unit.
7-11
BRKT
POWER TRIM AND TILT UNIT
E
K51000-0
EXPLODED DIAGRAM (Short transom [6H308])
1
2
3
4
5
6
7
8
Reservoir body
Reservoir plug
Motor assembly
Trim cylinder end screw
Trim piston assembly
Valve seat screw
Main valve assembly
Shuttle piston
9
0
A
B
C
D
E
F
Pipe
Down relief valve seat
Down relief spring
Gear pump assembly
Shaft connector
Filter 2
Up relief valve lock screw
Up relief spring
7-12
G
H
I
J
K
L
M
N
Up relief valve seat
Filter 1
Manual valve seat
Manual release spring
Adapter
Free piston
Back-up ring 2
Tilt cylinder assembly
BRKT
1
2
3
4
5
6
7
8
9
POWER TRIM AND TILT UNIT
Power trim and tilt motor
Gear pump
Down-relief valve (48 kg/cm2)
Main valve
2-way check valve
Reservoir
Up-relief valve (40 kg/cm2)
Manual valve
Tilt cylinder
0 Absorber valve (80 kg/cm2)
A Free piston
B Trim cylinder
7-13
E
BRKT
POWER TRIM AND TILT UNIT
E
K52002-0
DISASSEMBLY
CAUTION:
1. Do not wipe components of the hydraulic system with rags or paper tissues,
etc., as fibers entering the system will
cause malfunction.
2. After removing the tilt-motor or oil-reservoir, do not depress the tilt-rod or
trim-rod, since this may cause hydraulic
fluid to be ejected from the port.
1. Turn the manual valve fully towards the
manual position.
2. Remove the hydraulic-fluid level-plug
and drain the hydraulic-fluid.
3. Remove the delivery pipes and drain
the hydraulic-fluid.
4. Remove the hydraulic-fluid reservoir
and the tilt-motor.
5. Remove the shaft connector.
6. Remove the filter and the gear-pump.
7. Remove the O-rings and the complete
down relief-valve.
CAUTION:
Do not disassemble the gear-pump unit
which is factory-adjusted, but replace the
complete gear-pump unit if necessary.
8. Loosen the bolt and remove the complete up-relief valve.
7-14
BRKT
POWER TRIM AND TILT UNIT
E
9. Using the special service tool, loosen
the trim-cylinder end-screw and pull out
the trim-piston and components.
Cylinder end screw wrench:
YB-6175-1A/90890-06542
10. Using the special service tool, loosen
the tilt-cylinder end-screw and pull out
the tile-piston and the free-piston.
WARNING
The free-piston can be removed easily by
blowing compressed air into the drain-hole
of the cylinder. Be sure to cover the open
end of the cylinder with a rag to prevent
the free-piston from being ejected, which
could cause injury or piston damage.
Cylinder end screw wrench:
YB-6175-2B/90890-06544
11. Remove the main valves and the shuttle-piston.
12. Remove the circlip, the manual-valve
and components.
NOTE:
The manual-valve screw is threaded left
handed.
7-15
BRKT
POWER TRIM AND TILT UNIT
E
K53000-0
INSPECTION
TILT-ROD AND TRIM-ROD
1. Clean these components using a soft
brush and solvent and inspect them
carefully. If there are light scratches on
the surfaces, these may be polished off
using fine wet-or-dry sandpaper (440 ~
600 grit), but if there is excessive
scratching, replace the components.
2. Clean all the parts thoroughly using a
soft brush and solvent and dry them
with compressed air.
3. Inspect the tilt-cylinder and pump-unit
and replace them if they are badly corroded.
K54000-0
ASSEMBLY
NOTE:
The components in this assembly are to be
lightly coated with hydraulic fluid before
assembly.
1. Install the tilt-cylinder and the delivery
pipes.
1
2
3
4
Bushing
Tilt-cylinder
Lower mount pin
Delivery pipe
NOTE:
Feed oil into each pipe.
T.
R.
7-16
Lock nut (delivery pipe):
10 Nm (1.0 m • kg, 7.2 ft • lb)
BRKT
POWER TRIM AND TILT UNIT
E
2. Install the manual-valve in the body
with new O-rings.
1 O-ring (fitted into the body)
2 Manual valve seat
3 Manual release spring
(L = 6.0 mm, D = 11.5 mm)
4 Adapter 1
5 O-ring
6 Manual valve (left-handed thread)
7 Circlip
T.
Manual valve:
3 Nm (0.3 m • kg, 2.2 ft • lb)
R.
3. Install a new O-ring on the shuttle-piston, insert the piston into the body, then
install the main valves with new Orings.
1
2
3
4
5
O-ring
Shuttle-piston
O-ring
O-ring
Main valve
T.
Main valve:
10 Nm (1.0 m • kg, 7.2 ft • lb)
R.
4. Install the up-relief valve with a new Oring and tighten the locking-bolt to the
specified torque.
1
2
3
4
5
6
7
7-17
Filter
O-ring
Up relief valve seat
Ball
Valve support pin
Up relief spring (L = 19.7 mm, D = 5 mm)
Up relief valve lock screw
BRKT
POWER TRIM AND TILT UNIT
E
T.
Locking bolt:
13 Nm (1.3 m • kg, 9.4 ft • lb)
R.
5. Fit a new O-ring and the back-up ring to
the trim-piston, fit new O-rings and a
new oil-seal to the end-screw and install
the complete trim-piston in the cylinder.
Fill the cylinder with hydraulic fluid and
install and tighten the end-screw to the
specified torque.
ATF
(automatic transmission fluid)
1 O-ring
2 Back-up ring
T.
Trim cylinder end screw:
70 Nm (7.0 m • kg, 50 ft • lb)
R.
Cylinder end screw wrench:
YB-6175-1A/90890-6548
6. Install the down relief-valve and the
complete gear-pump with new O-rings,
tighten the screws and fit the shaft connector and filter, then fill with hydraulic
fluid.
1
2
3
4
5
6
7
8
9
Down relief spring (L = 13 mm, D = 6.1 mm)
Down relief valve seat
O-rings
Gear pump
Washer
Washer
Screw (Use hexagon wrench)
Shaft connector
Filter
T.
R.
7-18
Gear pump mounting screw:
5 Nm (0.5 m • kg, 3.6 ft • lb)
BRKT
POWER TRIM AND TILT UNIT
E
7. Fit a new O-ring and the back-up ring on
the free-piston and install it into the cylinder.
1 O-ring
2 Back-up ring
8. Fit a new O-ring and the back-up ring to
the tilt-piston and install it into the cylinder.
Fill the cylinder with hydraulic fluid and
tighten the end-screw to the specified
torque.
1 O-ring
2 Back-up ring
Cylinder end screw wrench:
YB-6175-2B/90890-06544
T.
Tilt cylinder end screw:
80 Nm (8.0 m • kg, 58 ft • lb)
R.
9. Align the connector-shaft keyway with
the motor-shaft projection and install
the motor with new O-ring.
T.
Bolt (tilt motor):
4 Nm (0.4 m • kg, 2.9 ft • lb)
R.
10. Install the hydraulic-fluid reservoir with
new O-ring.
T.
Bolt (reservoir body):
6 Nm (0.6 m • kg, 4.3 ft • lb)
R.
1 O-ring
11. Air bleeding. Refer to page 7-28.
7-19
BRKT
POWER TRIM AND TILT UNIT
E
EXPLODED DIAGRAM (Long transom [6H1-15], [62F-02])
1
2
3
4
5
6
7
8
9
0
Reservoir body
Reservoir plug
Motor assembly
Trim cylinder end screw
Trim piston assembly
Main valve assembly
Shuttle piston
Pipe
Main valve seal
Valve support pin
A
B
C
D
E
F
G
H
I
J
Down relief spring
Gear pump assembly
Shaft connector
Filter 1
Valve lock screw
Trim spring
Up relief spring
Up relief valve seat
Filter 2
Manual valve seat
7-20
K
L
M
N
O
Manual release spring
Adapter
Manual release screw
Free piston
Back up ring
BRKT
1
2
3
4
5
6
7
8
9
POWER TRIM AND TILT UNIT
Trim down valve (0.2 kg/cm2)
Trim down valve (1 kg/cm2)
Reservoir
Up-relief valve (100 kg/cm2)
Manual valve
Tilt cylinder
Absorber valve (180 kg/cm2)
Trim cylinder
Main valve (0.5 kg/cm2)
0 Down-relief valve (30 kg/cm2)
A Gear pump
B Power trim and tilt motor
7-21
E
BRKT
POWER TRIM AND TILT UNIT
E
K52002-0
DISASSEMBLY
CAUTION:
1. Do not wipe components of the hydraulic system with rags or paper tissues,
etc., as fibers entering the system will
cause malfunction.
2. After removing the tilt-motor or oil-reservoir, do not depress the tilt-rod or
trim-rod which may cause hydraulic fluid
to be ejected from the port.
1. Turn the manual valve fully towards the
manual position.
2. Remove the delivery pipes and the
hydraulic-fluid level-plug.
3. Remove the hydraulic-fluid reservoir
and the tilt-motor.
4. Remove the shaft connector.
5. Remove the filter and the gear-pump.
6. Remove the O-rings and the complete
down relief-valve.
CAUTION:
Do not disassemble the gear-pump unit
which is factory-adjusted, but replace the
complete gear-pump unit if necessary.
7. Loosen the screw and remove the complete up-relief valve.
1
2
3
4
5
6
7
8
7-22
Screw
Up relief spring
Valve support pin
Relief valve seal
Relief valve seat
O-ring
Filter
Trim spring
BRKT
POWER TRIM AND TILT UNIT
E
8. Remove the one-way valve and main
valve seal.
9
0
A
B
C
Valve lock screw
O-ring
Ball
Washer
Main valve seal
9. Loosen the trim-cylinder end-screw and
pull
out
the
trim-piston
and
components.
Cylinder end screw wrench:
YB-6175-1A/90890-6548
10. Loosen the tilt-cylinder end-screw and
pull out the tilt-piston and the free-piston.
WARNING
The free-piston can be removed easily by
blowing compressed air into the drain-hole
of the cylinder. Be sure to cover the open
end of the cylinder with a rag to prevent
the free-piston from being ejected, which
could cause injury or piston damage.
Cylinder end screw wrench:
YB-6175-2B/90890-06544
11. Remove the main valves and the shuttle-piston.
7-23
BRKT
POWER TRIM AND TILT UNIT
E
12. Remove the circlip and the manual
valve and components.
1
2
3
4
5
6
7
8
Snap ring
O-ring
Manual release screw
O-ring
Manual valve seat
Manual release spring 1
Adapter 1
Manual release spring 2
K53000-0
INSPECTION
TILT-ROD AND TRIM-ROD
1. Clean these components using a soft
brush and solvent and inspect them
carefully. If there are light scratches on
the surfaces, these may be polished off
using fine wet-or-dry sandpaper (440 ~
600 grit), but if there is excessive
scratching, replace the components.
2. Clean all the parts thoroughly using a
soft brush and solvent and dry them
with compressed air.
3. Inspect the tilt-cylinder and pump-unit
and replace them if they are badly corroded.
K54001-0*
ASSEMBLY
NOTE:
The components in this assembly are to be
lightly coated with hydraulic fluid before
assembly.
7-24
BRKT
POWER TRIM AND TILT UNIT
E
1. Install the tilt-cylinder and the delivery
pipes.
1
2
3
4
Bushing
Tilt-cylinder
Lower mount pin
Delivery pipe
NOTE:
Feed oil into each pipe.
T.
Lock nut (delivery pipe):
15 Nm (1.5 m • kg, 11 ft • lb)
R.
2. Install the manual-valve in the body
with new O-rings.
1
2
3
4
5
6
7
8
Snap ring
O-ring
Manual release screw
O-ring
Manual valve seat
Manual release spring (ø0.6 mm)
Adapter 1
Manual release spring (ø1.2 mm)
T.
Manual valve:
3 Nm (0.3 m • kg, 2.2 ft • lb)
R.
3. Install a new O-ring on the shuttle-piston and insert the piston into the body,
then install the main valves with new Orings.
1
2
3
4
5
O-ring
Shuttle-piston
O-ring
O-ring
Main valve
T.
R.
7-25
Main valve:
11 Nm (1.1 m • kg, 8.0 ft • lb)
BRKT
POWER TRIM AND TILT UNIT
E
4. Install the up-relief valve and the valve
lock screw with new O-rings and tighten
the screw to the specified torque.
1
2
3
4
5
6
7
8
9
0
A
B
C
Main valve seal
Washer
Ball
O-ring
Valve lock screw
Filter
O-ring
Up relief valve seat
Up relief valve seal
Valve support pin
Up relief spring
Trim spring
Screw
T.
R.
Valve lock screw:
4 Nm (0.4 m • kg, 2.9 ft • lb)
Screw:
4 Nm (0.4 m • kg, 2.9 ft • lb)
5. Fit a new O-ring and the back-up ring on
the trim-piston, fit new O-rings and a
new oil-seal on the end-screw and
install the complete trim-piston in the
cylinder. Fill the cylinder with hydraulic
fluid and install and tighten the endscrew to the specified torque.
ATF
(automatic transmission fluid)
1 O-ring
2 Back-up ring
T.
End-screw (trim cylinder):
160 Nm (16 m • kg, 115 ft • lb)
R.
Cylinder end screw wrench:
YB-6175-1A/90890-6548
7-26
BRKT
POWER TRIM AND TILT UNIT
E
6. Install the down relief-valve and the
gear-pump complete with new O-rings,
tighten the bolts, and fit the connectorshaft and filter, then fill with hydraulic
fluid.
1
2
3
4
Down relief-valve assembly
Shaft-connector
O-ring
Bolt
T.
Bolt:
4 Nm (0.4 m • kg, 2.9 ft • lb)
R.
7. Fit a new O-ring on the free-piston and
install it into the cylinder.
1 O-ring
8. Fit a new O-ring and the back-up ring to
the tilt-piston and install the piston in
the cylinder. Fill the cylinder with
hydraulic fluid and tighten the endscrew to the specified torque.
1 O-ring
2 Back-up ring
T.
End-screw (tilt cylinder):
90 Nm (9.0 m • kg, 65 ft • lb)
R.
Cylinder end screw wrench:
YB-6175-2B/90890-06544
9. Align the connector-shaft keyway with
the motor-shaft projection and install
the motor with a new O-ring.
T.
Bolt (tilt motor):
4 Nm (0.4 m • kg, 2.9 ft • lb)
R.
10. Install the hydraulic-fluid reservoir with
a new O-ring.
T.
R.
1 O-ring
7-27
Bolt (reservoir body):
7 Nm (0.7 m • kg, 5.1 ft • lb)
BRKT
POWER TRIM AND TILT UNIT
E
FILLING WITH HYDRAULIC FLUID
AND AIR-BLEEDING
1. Pour in the fluid until it overflows from
the fluid-level plug-hole and install the
reservoir plug.
ATF
(automatic transmission fluid)
2. Turn the manual-valve fully towards
manual-tilt. Depress the tilt-rod fully,
then close the manual valve. Use the
motor to go fully up, check hydraulic
and top if necessary. Open the manual
valve and repeat these operations two
or three times. Then, turn the manualvalve fully towards power-tilt.
3. Check the level of the hydraulic fluid at
full tilt up, top up with fluid if necessary.
Insert and tighten the fluid-level plug.
4. Connect the leads to a battery to check
the function.
Trim and tilt up.............. Blue (+)
Green (–)
Trim and tilt down ........ Green (+)
Blue (–)
K55506-0*
HYDRAULIC FLUID PRESSURE TEST
Drive the motor to check trim and tilt up
and down operation and fluid leakage.
1. Close the manual valve.
2. Connect the pressure gauge.
NOTE:
● Feed hydraulic fluid into each pipe while
taking care not to allow air to enter.
● Two set of hoses are required so that both
of the trim and tilt pressures can be measured at the same time.
Pressure gauge:
YB-6181
7-28
BRKT
POWER TRIM AND TILT UNIT
E
3. Connect the leads to a battery to check
the fluid discharge pressure during
down-operation.
Trim and tilt down ........ Green (+)
Blue (–)
CAUTION:
The motor should not be operated for more
than three seconds after trim and tilt down
is completed.
A: Tilt operating pressure
B: Trim operating pressure
At the end of down operation:
[Stamped mark]
[6H308]
A: 4,100 ~ 5,500 kPa
(41 ~ 55 kg/cm2, 583 ~ 782 psi)
B: 600 ~ 1,100 kPa
(6 ~ 11 kg/cm2, 85 ~ 157 psi)
[6H1-15]
A: 2,200 ~ 3,800 kPa
(22 ~ 38 kg/cm2, 313 ~ 540 psi)
B: 600 ~ 1,100 kPa
(6 ~ 11 kg/cm2, 85 ~ 157 psi)
[62F-02]
A: 2,100 ~ 3,700 kPa
(21 ~ 37 kg/cm2, 299 ~ 526 psi)
B: 600 ~ 1,100 kPa
(6 ~ 11 kg/cm2, 85 ~ 157 psi)
4. Connect the leads to a battery to check
the fluid discharge pressure during upoperation.
Trim and tilt up.............. Blue (+)
Green (–)
NOTE:
The motor should not be operated for more
than fourteen seconds after full tilt up-operation.
7-29
BRKT
POWER TRIM AND TILT UNIT
E
A: Tilt operating pressure
B: Trim operating pressure
During up operation pressure:
A: 0 ~ 500 kPa
(0 ~ 5 kg/cm2, 0 ~ 71 psi)
B: 0 ~ 500 kPa
(0 ~ 5 kg/cm2, 0 ~ 71 psi)
At the end of up-operation pressure:
A: 0 kPa (0 kg/cm2, 0 psi)
[6H308]
B: 3,500 ~ 4,500 kPa
(35 ~ 45 kg/cm2, 500 ~ 640 psi)
[6H1-15]
B: 9,000 ~ 11,000 kPa
(90 ~ 110 kg/cm2,
1,280 ~ 1,565 psi)
[62F-02]
B: 5,690 ~ 6,570 kPa
(57 ~ 66 kg/cm2, 299 ~ 526 psi)
5. Remove the fluid pressure gauge and
install the delivery pipes.
NOTE:
When the fluid pressure gauge has been
removed, be sure to bleed the air from the
system.
K56000-0
INSTALLATION
1. Referring to the illustration, install the
power trim and tilt unit to the bracket.
7-30
BRKT
POWER TRIM AND TILT MOTOR
E
POWER TRIM AND TILT MOTOR
DISASSEMBLY
1. Loosen the screws and remove the stator, O-ring and the armature.
2. Disconnect the connector.
3. Loosen the screw and remove the
brush, cover plate, circuit breaker and
the spring.
K62001-0*
INSPECTION
ARMATURE COIL
1. Visually inspect the commutator surface and if it shows signs of roughness,
polish it with 600-grit wet-or-dry sandpaper.
2. Measure the outside diameter of the
commutator by use of a vernier caliper.
If the diameter is less than the specified
minimum outside diameter, replace the
whole armature.
Armature minimum outside
diameter:
Standard: 22 mm (0.87 in)
Minimum: 21 mm (0.83 in)
7-31
BRKT
POWER TRIM AND TILT MOTOR
E
3. Scrape between the segments with a
hack-saw blade and then carefully
remove all particles of metal and mica
with compressed air.
4. Check for continuity or discontinuity of
the armature coil. If it is out of specification, replace the armature.
Armature coil continuity/
discontinuity
Commutator
segments a
Continuity
SegmentLaminations b
Discontinuity
Segment-Shaft c
Discontinuity
BRUSH
1. Measure the brushes for wear.
Brush, size a:
Standard: 9.8 mm (0.39 in)
Minimum: 4.8 mm (0.19 in)
BASE ASSEMBLY
1. Inspect the base assembly for cracks or
burns and replace the base assembly if
such are found.
2. Check for continuity between the connector and lead wire. If there is discontinuity, replace the base assembly.
CIRCUIT BREAKER
1. Check for continuity between the brush
and the terminal. If there is discontinuity, replace the circuit breaker.
7-32
BRKT
POWER TRIM AND TILT MOTOR
E
K63000-0*
ASSEMBLY
1. Install the armature into the frame-end.
2. Place the O-ring on the frame-end and
install the yoke assembly, then install
the screws.
T.
Screw:
4 Nm (0.4 m • kg, 2.9 ft • lb)
R.
3. Place the O-ring on the motor assembly
and align the grooves of the motor
assembly and gear pump, then install
the bolts.
T.
R.
7-33
Power trim and tilt motor
mounting bolt:
[Stamped mark]
[6H308]
6 Nm (0.6 m • kg, 4.3 ft • lb)
[6H1-15], [62F-02]
7 Nm (0.7 m • kg, 5.1 ft • lb)
ELEC
–
+
E
CHAPTER 8
ELECTRICAL SYSTEMS
ELECTRICAL COMPONENTS......................................................................... 8-1
ELECTRICAL WIRING ..................................................................................... 8-3
WIRING DIAGRAM ......................................................................................... 8-7
REMOTE CONTROL BOX ...................................................................... 8-12
DIGITAL METER .............................................................................. 8-12
REMOVAL ..................................................................................................... 8-13
MAGNETO BASE ................................................................................... 8-13
ELECTRICAL ANALYSIS .............................................................................. 8-15
INSPECTION........................................................................................... 8-15
IGNITION SPARK GAP........................................................................... 8-16
CDI SYSTEM PEAK VOLTAGE .............................................................. 8-16
REPLACEMENT OF SPARK-PLUG CAP ................................................ 8-20
CRANK POSITION SENSOR.................................................................. 8-20
STARTER RELAY.................................................................................... 8-21
POWER TRIM AND TILT RELAY ........................................................... 8-21
TRAILER SWITCH................................................................................... 8-22
RECTIFIER/REGULATOR........................................................................ 8-23
FUSE ....................................................................................................... 8-23
THERMO SWITCH.................................................................................. 8-24
FUEL ENRICHMENT VALVE .................................................................. 8-24
OIL INJECTION SYSTEM (Oil injection model) ................................... 8-25
OIL-LEVEL SENSOR............................................................................... 8-26
OIL-LEVEL WARNING LAMP (L.E.D.) ................................................... 8-28
WIRING HARNESS................................................................................. 8-28
BRACKET ................................................................................................ 8-29
BATTERY ................................................................................................ 8-29
ENGINE STOP SWITCH
(P60TH/60FEHTO, P75TH/75CEHTO, 90AEHD) ................................... 8-29
MAIN SWITCH (P60TH/60FEHTO, P75TH/75CEHTO, 90AEHD) .......... 8-30
NEUTRAL SWITCH (P60TH/60FEHTO, P75TH/75CEHTO,
90AEHD, 90TR/90AETO, B90TR/90AETO) ........................................... 8-30
ELEC
–
+
E
INSTALLATION............................................................................................. 8-30
FLYWHEEL MAGNETO.......................................................................... 8-30
STARTER MOTOR ........................................................................................ 8-31
REMOVAL............................................................................................... 8-31
DISASSEMBLY....................................................................................... 8-31
INSPECTION........................................................................................... 8-32
PINION ............................................................................................. 8-32
STARTER CLUTCH .......................................................................... 8-32
BRUSH ............................................................................................. 8-32
BRUSH-HOLDER.............................................................................. 8-32
ARMATURE ..................................................................................... 8-33
ASSEMBLY (50, 60, 70 hp) .................................................................... 8-34
INSTALLATION (50, 60, 70 hp) ............................................................. 8-35
ASSEMBLY (75, 80, 90 hp) .................................................................... 8-35
INSTALLATION (75, 80, 90 hp) ............................................................. 8-36
1
2
3
4
5
6
7
8
9
ELEC
–
+
ELECTRICAL COMPONENTS
E
M20000-0
ELECTRICAL COMPONENTS
50, 60, 70 hp
Ignition coil
Spark-plug
Thermo switch
Power trim and tilt replay
(PTT model)
5 Trailer switch (PTT model
except for USA, Canada
and Oceania model)
1
2
3
4
6
7
8
9
0
A
B
C
Neutral switch (P60TH/60FEHTO)
Starter relay
Oil warning lamp (50GETO)
Charge coil
Crank position sensor
Lighting coil
Pulser coil
Wire harness
8-1
D
E
F
G
H
I
Fuse
CDI unit
Starter motor
Trim sensor (PTT model)
Rectifier/regulator
Power trim and tilt connector assy (P60TH/60FEHTO)
ELEC
–
+
ELECTRICAL COMPONENTS
E
M20001-0
75, 80, 90 hp
Ignition coil
Spark-plug
Thermo switch
Trailer switch
(PTT model except for C75TR/
75CET, C90TR/90AET)
5 Fuse
6 Wire harness
1
2
3
4
7 Neutral switch (P75TH/
75CEHTO, 90AEHD, 90TR/
90AETO, B90TR/90AETO)
8 Pulser coil
9 Stator assembly
0 CDI unit
A Rectifier/regulator
B Crank position sensor
8-2
C Power trim and tilt relay
(PTT model)
D Starter relay
E Starter motor
F Trim sensor (PTT model)
ELEC
–
+
ELECTRICAL WIRING
E
D22000-0
ELECTRICAL WIRING
Check that all leads and connectors
are properly connected.
50, 60, 70 hp
1 Electrothermal valve*1
2 Clamp
3 Power trim and tilt motor lead*2
4 Trim sensor lead*2
5 Trailer switch coupler*2
6 Trailer switch*3
7 Fuel enrichment valve*4
Å To wire harness
ı To power trim and tilt motor*2
Ç To trim sensor*2
Î To lighting coil
*1: Except for C60ER, C60TR
*2: For PTT model
*3: For PTT model except
for USA, Canada and
Oceania model
*4: For C60ER, C60TR
B
L
Lg
R
Sb
: Black
: Blue
: Light green
: Red
: Sky blue
P60TH/60FEHTO*1, P75TH/75CEHTO, 90AEHD*2
1
2
3
4
Main switch
Engine stop switch
Neutral switch
Starter relay
Å
ı
Ç
Î
‰
To battery
To oil level sensor*1
To trim sensor*1
To power trim and tilt motor*1
To power trim and tilt relay*1
Ï
Ì
Ó
È
Ô

To thermo switch
To 10P coupler
To Main switch
To power trim and tilt switch*1
Throttle cable
Shift cable
*1:
Except for 90AEHD
B
Br
G
G/Y
: Black
: Brown
: Green
: Green/Yellow
8-3
P
R
W
Y
: Pink
: Red
: White
: Yellow
ELEC
–
+
ELECTRICAL WIRING
50, 60, 70 hp
E
1
2
3
4
5
6
7
8
9
0
Pulser coil coupler
Trim sensor coupler*1
Oil level sensor coupler*2
Wire harness coupler (7P*3/10P*4)
Ground lead from rectifier/regulator
Ground lead from starter relay
Ground lead from wire harness
Power trim and tilt relay coupler*1
Charge coil coupler
Crank position sensor coupler
B
Br
G
Gy
L
Lg
O
P
R
Sb
W
Y
Å
ı
Ç
Î
‰
Ï
Ì
Ó
To CDI unit
To power trim and tilt motor*1
To trim sensor*1
To oil level sensor*2
To meter
To electrothermal valve*5
To fuel enrichment valve*6
To trailer switch coupler*1
*1:
*2:
*3:
*4:
*5:
*6:
8-4
: Black
: Brown
: Green
: Gray
: Blue
: Light green
: Orange
: Pink
: Red
: Sky blue
: White
: Yellow
For PTT model
For oil injection model
For C60ER/60FED
Except for C60ER/60FED
Except for C60ER, C60TR
For C60ER, C60TR
ELEC
–
+
ELECTRICAL WIRING
75, 80, 90 hp
1 Trailer switch
E
B
L
Lg
R
Sb
coupler*1
Å To electrothermal valve*2
ı To battery
Ç To starter relay
Î To lighting coil
‰ To wire harness
Ï To meter
Ì To trim sensor*1
Ó To power trim and tilt motor*1
*1: For PTT model
*2: Except for C75TR
8-5
: Black
: Blue
: Light green
: Red
: Sky blue
ELEC
–
+
ELECTRICAL WIRING
75, 80, 90 hp
1
2
3
4
5
6
7
8
9
0
A
B
C
D
E
F
E
B
Br
G
Gy
L
Lg
O
P
R
Sb
W
Y
Crank position sensor coupler
Fuel enrichment valve*1
Clamp
Clamp
Wire harness coupler
Trim sensor coupler*2
Oil level sensor coupler*3
Clamp
Ground lead from power trim and tilt relay *2
Ground lead from wire harness
Ground lead from rectifier/regulator
Charge coil coupler
Power trim and tilt relay coupler*2
Pulser coil coupler
Ground lead from starter relay
Ground lead from CDI unit
*1:
*2:
*3:
*4:
*5:
Å To electrothermal valve*4
ı To trim sensor*2
Ç To power trim and
tilt motor*2
Î To oil level sensor*3
‰ To meter
Ï To starter motor
Ì To trailer switch*2
Ó To neutral switch*5
8-6
: Black
: Brown
: Green
: Gray
: Blue
: Light green
: Orange
: Pink
: Red
: Sky blue
: White
: Yellow
For C75TR
For PTT model
For oil injection model
Except for C75TR
For P75TH/75CEHTO, 90AEHD,
90TR/90AETO, B90TR/90AETO
8-7
Sb .......Sky blue
W ........White
Y .........Yellow
Lg .......Light green
WIRING DIAGRAM
B .........Black
Br ........Brown
G .........Green
Gy .......Gray
L..........Blue
O .........Orange
P..........Pink
R .........Red
Å To oil level gauge
ı To trim gauge
K
I
J
H
G
C
D
E
F
9
0
A
B
Thermo switch
Rectifier/regulator
Crank position sensor
Pulser coil
Charge coil
Lighting coil
Electrothermal valve
(except for C60ER, C60TR)
Oil level sensor
(oil injection model)
Starter motor
Battery
Trim sensor (PTT model)
Power trim and tilt motor
(PTT model)
Fuse (20A)
CDI unit
Starter relay
Neutral switch
(P60TH/60FEHTO)
Power trim and tilt relay
(PTT model)
Oil warning lamp
(50GETO)
Trailer switch (PTT model)
Power trim and tilt switch
(P60TH/60FEHTO)
Ignition coil
–
8
1
2
3
4
5
6
7
ELEC
+
E
M30000-0
WIRING DIAGRAM
50, 60, 70 hp
Thermo switch
Rectifier/regulator
Crank position sensor
Pulser coil
Charge coil
Lighting coil
Fuel enrichment valve
Starter motor
Battery
Fuse (20A)
CDI unit
Starter relay
Ignition coil
Power trim and tilt relay (For C60TR)
Power trim and tilt motor (For C60TR)
–
B......... Black
Br ....... Brown
G ........ Green
Gy ...... Gray
L ......... Blue
O ........ Orange
P......... Pink
R......... Red
Sb ...... Sky blue
W ....... White
Y......... Yellow
Lg....... Light green
1
2
3
4
5
6
7
8
9
0
A
B
C
D
E
ELEC
+
WIRING DIAGRAM
E
C60ER, C60TR
8-8
8-9
Sb ...... Sky blue
W ....... White
Y ........ Yellow
WIRING DIAGRAM
B......... Black
Gr ....... Brown
G ........ Green
Gy ...... Gray
L ......... Blue
Lg ....... Light green
O ........ Orange
P ......... Pink
R......... Red
Å To oil level gauge
ı To trim gauge
I
J
H
E
F
G
C
D
9
0
A
B
Thermo switch
Rectifier/regulator
Crank position sensor
Lighting coil
Charge coil
Pulser coil
Electrothermal valve
(except for C75TR)
Oil level sensor
(oil injection model)
Starter motor
Battery
Trim sensor (PTT model)
Power trim and tilt motor
(PTT model)
Fuse (20A)
Neutral switch
(P75TH/75CEHTO, 90AEHD,
90TR/90AETO, B90TR/90AETO)
CDI unit
Trailer switch (PTT model)
Power trim and tilt switch
(P75TH/75CEHTO)
Power trim and tilt relay
(PTT model)
Starter relay
Ignition coil
–
8
1
2
3
4
5
6
7
ELEC
+
E
M30000-0
75, 80, 90 hp
Thermo switch
Rectifier/regulator
Crank position sensor
Lighting coil
Charge coil
Pulser coil
CDI unit
Fuel enrichment valve
Starter motor
Battery
Trim sensor
Power trim and tilt motor
Fuse
Power trim and tilt relay
Ignition coil
Starter relay
–
B......... Black
Gr....... Brown
G ........ Green
Gy ...... Gray
L ......... Blue
Lg....... Light green
O ........ Orange
P......... Pink
R......... Red
Sb ...... Sky blue
W ....... White
Y......... Yellow
1
2
3
4
5
6
7
8
9
0
A
B
C
D
E
F
ELEC
+
WIRING DIAGRAM
C75TR
8-10
E
ELEC
–
+
WIRING DIAGRAM
P60TH/60FEHTO
1
2
3
4
Buzzer
Fuse (10A)
Main switch
Engine stop switch
Å To tachometer
ı To power trim and tilt switch
(option)
Ç To trim sensor
Î To oil level sensor
‰ To lamp switch (option)
B .........Black
Br........Brown
G.........Green
Gy.......Gray
G/R .....Green/Red
L .........Blue
O.........Orange
P .........Pink
R .........Red
Sb .......Sky blue
W ........White
Y .........Yellow
Lg .......Light green
G/W ....Green/White
P/B ......Pink/Black
8-11
E
ELEC
–
+
WIRING DIAGRAM
E
M31000-0
REMOTE CONTROL BOX
1
2
3
4
5
Å
Main switch
Buzzer
Neutral switch
Engine stop switch
Power trim and tilt switch
To meter harness
DIGITAL METER
1
2
3
4
5
6
Digital tachometer
Digital speedometer (option)
To fuel management meter (option)
Lamp switch (option)
Fuse (10A)
Fuel sensor (option)
Å To remote control box
ı To trim sensor
Ç To oil level gauge
8-12
B ........ Black
Br ....... Brown
G ........ Green
Gy ...... Gray
L......... Blue
Lg....... Light green
O ........ Orange
P......... Pink
R ........ Red
Sb ...... Sky blue
W ....... White
Y ........ Yellow
ELEC
–
+
REMOVAL
E
M40003-0
REMOVAL
MAGNETO BASE
1. Remove the flywheel cover.
2. Remove the starter-pulley.
3. Loosen the flywheel nut until it is flush
with the crankshaft.
Flywheel holder:
YB-6139/90890-06522
CAUTION:
The major load must be carried in the direction of the arrows. If not, the holder may
easily slip off.
CAUTION:
Keep the nut side flush with the crankshaft
end until the flywheel comes off the
tapered portion of the crankshaft.
8-13
ELEC
–
+
REMOVAL
E
4. Remove the flywheel magneto.
YB-6117
Flywheel puller:
YB-6117/90890-06521
CAUTION:
To prevent damage to the engine or tools,
screw in the flywheel magneto-puller setbolts evenly and completely so that the
puller plate is parallel to the flywheel.
5. Remove the woodruff key from the
crankshaft keyway using a screwdriver.
CAUTION:
Take special care not to damage the surface of the crankshaft. When removing the
flywheel magneto, lift it up while tilting it
slightly. Do not allow the magneto to contact the timing plate.
8-14
ELEC
–
+
ELECTRICAL ANALYSIS
E
ELECTRICAL ANALYSIS
INSPECTION
CAUTION:
All measuring instruments should be handled with special care or the correct measurement is impossible.
On an instrument powered by dry batteries, the latter should be checked for voltage
periodically and replaced, if necessary.
NOTE:
“
” indicates the terminals between
which there is a continuity of electricity; i.e.,
a closed circuit at the respective switch
position.
Peak voltage measurement
NOTE:
● The coil output varies greatly at cranking
speed.
● Cranking a cold engine with the plugs in
and a weak battery does not enable
proper readings.
Digital multimeter:
J-39299/90890-06752
Peak volt adapter:
YU-39991/90890-03169
Low resistance measurement
When measuring a resistance of 10 Ω or
less using the digital tester, the correct
measurement cannot be obtained because
of the tester's internal resistance.
To obtain the correct value, subtract this
internal resistance from the displayed
measurement.
Correct value =
Displayed measurement –
Internal resistance
NOTE:
The internal resistance of the tester can be
obtained by connecting both of its terminals.
8-15
ELEC
–
+
ELECTRICAL ANALYSIS
E
IGNITION SPARK GAP
WARNING
● While
checking the spark be careful not to
touch any connection of lead wires of the
“Ignition spark gap tester”.
● When doing the spark test, take special
care not to allow leakage from the plug
cap which has been removed.
This check is likely to produce sparks, so be
sure that no flammable gas or fluid is
present.
1. Ignition spark gap:
1) Adjust the spark gap to specification
by turning the adjusting knob.
Spark gap tester:
YM-34487/90890-06754
2) Connect the spark plug cap to the
spark gap tester.
3) Remove the spark plugs from the
engine.
4) Crank the engine and check the
sparks from the ignition system
through the discharge window.
5) Measure the ignition spark gap.
6) If the output is out of specification,
measure the CDI SYSTEM PEAK
VOLTAGE.
Spark gap:
9 mm (0.35 in)
CDI SYSTEM PEAK VOLTAGE
WARNING
While taking CDI unit check be careful not
to touch any connection of lead wires of
the “Digital tester”.
NOTE:
● If there is no spark or the spark is weak,
continue with the CDI test.
● If a good spark is obtained, the problem is
not with the CDI system, but possibly the
spark plug or other component is defective.
8-16
ELEC
–
+
ELECTRICAL ANALYSIS
E
1. CDI unit output:
1) Connect the tester to the CDI unit as
shown.
2) Set the tester dial to specification.
3) Crank or start the engine.
4) Measure all the CDI unit output.
5) If the output is beyond specification,
replace the ignition coil.
6) If the output is below specification,
measure the charge coil output.
50, 60, 70 hp
CDI unit
Output peak voltage (minimum)
B/W – B
r/min
V
Cranking
1,500
Open
Connect
#1, 3: 105
145
—
#2: —
3,500
105
75, 80, 90 hp
CDI unit
Output peak voltage (minimum)
B/W – B
r/min
V
Cranking
1,500
Open
Connect
#1, 3: 130
—
155
#2: —
3,500
130
2. Charge coil output:
1) Disconnect the charge coil coupler.
Connect the 2/3 pins test harness.
50, 60, 70 hp
2 pins test harness:
YB-38831/90890-06767
75, 80, 90 hp
3 pins tester harness:
YB-06443/90890-06757
2) Connect the tester to the measurement terminal.
3) Set the tester dial to specification.
4) Crank or start the engine.
5) Measure the charge coil output.
6) If the output is below specification,
replace the charge coil.
7) If the output is beyond specification,
measure pulser coil output.
8-17
ELEC
–
+
ELECTRICAL ANALYSIS
E
50, 60, 70 hp
Charge coil
Output peak voltage (minimum)
Br – L
r/min
V
Cranking
Open Connect
120
150
1,500
3,500
160
120
75, 80, 90 hp
Charge coil
Output peak voltage (minimum)
R – Br
r/min
V
Cranking
Open Connect
55
60
1,500
3,500
170
150
Charge coil
Output peak voltage (minimum)
R–L
r/min
V
Cranking
Open Connect
90
100
1,500
3,500
135
135
3. Pulser coil output:
1) Disconnect the pulse coil couple.
Connect the 2 pins test harness.
2 pins test harness:
YB-38831/90890-06767
2) Connect the tester to the measurement terminal.
3) Set the tester dial to specification.
4) Crank or start the engine.
5) Measure the pulser coil output.
6) If the output is beyond specification,
replace CDI unit.
7) If the output is below specification,
replace pulser coil.
8-18
ELEC
–
+
ELECTRICAL ANALYSIS
E
50, 60, 70 hp
Pulser coil
Output peak voltage (minimum)
W/R – W/B
r/min
V
Cranking
Open Connect
4.5
2.5
1,500
3,500
6.5
10
75, 80, 90 hp
Pulser coil
Output peak voltage (minimum)
W/R – W/B
r/min
V
Cranking
Open Connect
7.0
5.0
1,500
3,500
14
20
4. Lighting coil output:
1) Connect the tester to the lighting
coil as shown.
2) Set the tester dial to specification.
3) Start the engine.
4) Measure the lighting coil output.
5) If the output is beyond specification,
replace rectifier/regulator.
6) If the output is below specification,
replace lighting coil.
50, 60, 70 hp
Lighting coil
Output peak voltage (minimum)
G – G/W
r/min
V
Cranking
Open Connect
8.5
8.0
1,500
3,500
25
25
75, 80, 90 hp
Lighting coil
Output peak voltage (minimum)
G – G/W
r/min
V
8-19
Cranking
Open Connect
10
11
1,500
3,500
25
25
ELEC
–
+
ELECTRICAL ANALYSIS
E
M53005-0
REPLACEMENT OF SPARK-PLUG CAP
[Standard type]
1. Remove the spark-plug cap by pulling
the cap and remove the plug-cap spring
from the high-tension cable.
2. Cut an amount of about a off the end of
the high-tension cable.
Distance a:
5 mm (0.2 in)
3. Fit onto the plug cap-spring.
4. Push the cap-spring into the plug-cap.
[Resistance specification type]
1. Remove the spark-plug cap by turning
the cap.
2. Install the spark-plug cap onto the hightension cable.
CRANK POSITION SENSOR
Measure the peak voltage of the crank position sensor as shown.
50, 60, 70 hp
Crank position sensor
Output peak voltage (minimum)
L/R – L/W
r/min
V
Cranking
Open Connect
5.0
5.0
1,500
3,500
20
16
75, 80, 90 hp
Crank position sensor
Output peak voltage (minimum)
L/R – L/W
r/min
V
8-20
Cranking
Open Connect
5.5
5.5
1,500
3,500
25
20
ELEC
–
+
ELECTRICAL ANALYSIS
E
M55000-0
STARTER RELAY
1. Check for continuity between the terminals and the ends of the black and
brown leads.
2. Test to ensure there is no continuity
between terminals.
3. Check the relay operation.
1) Connect a tester between the terminals of the starter relay. Connect the
leads of the starter-relay to a 12-V
battery.
Brown lead........................................ (+)
Black lead .......................................... (–)
Battery voltage:
12V
B
Br
: Black
: Brown
4. Check that there is continuity between
the starter relay terminals. If the operation is not as specified, replace the
starter relay.
M51410-0
POWER TRIM AND TILT RELAY
1. Check the relay for terminal looseness
and for wiring rust and corrosion.
Replace the relay if any of the three
defects is found.
2. Connect the (+) terminal and 1 terminal
and the (+) terminal and 2 terminal to
the tester and check that the resistance
becomes ∞ in each case.
8-21
–
+
ELECTRICAL ANALYSIS
E
3. Connect the (–) terminal and 1 terminal
and the (–) terminal and 2 terminal to
the tester and check the continuity in
each case.
Sb : Sky blue
Lg : Light green
B
: Black
4. Connect the black terminal to the (–) terminal of the battery and the light green
terminal to the (+) terminal of the battery. Then, connect the (+) terminal and
1 terminal to the tester and check the
continuity.
5. Connect the black terminal to the (–) terminal of the battery and the sky-blue
terminal to the (+) terminal of the battery. Then, connect the (+) terminal and
2 terminal to the tester and check the
continuity.
M56100-0
TRAILER SWITCH
1. To see that there is continuity, push the
switch.
Unit: Ω
Checking leads
Switch
Position
ELEC
Sky blue
|
Red
Light green
|
Red
Continuity
Discontinuity
FREE
Discontinuity
Discontinuity
DOWN
Discontinuity
Continuity
UP
2. Check rubber seal.
Replace the seal if it has any damage.
8-22
ELEC
–
+
ELECTRICAL ANALYSIS
E
M56501-0
RECTIFIER/REGULATOR
1. Check the continuity of the rectifier/regulator.
Rectifier/regulator check
Tester +
Green
Tester Green
Green/
White
Red
Black
∞
Continuity
∞
Continuity
Continuity
Green/
White
Continuity
Red
∞
∞
Black
Continuity
Continuity
∞
Continuity
∞ : Discontinuity
If continuity is not as specified, replace
the rectifier/regulator.
NOTE:
● The digital tester cannot be used for this
inspection.
● Never
connect the rectifier/regulator
directly to the battery to check continuity.
● When testing, disconnect the battery terminals.
● When resistance is measured at less than
100 Ω, it can be said that there is continuity.
M57001-0*
FUSE
1. Referring to the diagram, check the continuity of the fuse. If the fuse is blown,
replace with a fuse of correct rating.
Fuse rating:
20A
8-23
ELEC
–
+
ELECTRICAL ANALYSIS
E
M57300-0
THERMO SWITCH
1. Immerse the thermo switch in water.
While heating the water, check the continuity at the specified temperature.
2. While cooling the water, check the continuity at the specified temperature.
If continuity is not as specified, replace
the thermo switch.
ON temperature a:
84 ~ 90˚C (183 ~ 194˚F)
OFF temperature b:
60 ~ 74˚C (140 ~ 165˚F)
1
2
3
Å
ı
Discontinuity
Continuity
Discontinuity
Temperature
Time
FUEL ENRICHMENT VALVE
1. Measure the resistance of the fuel
enrichment valve.
Fuel enrichment valve resistance:
at 20˚C (68˚F)
L – B: 3.4 ~ 4.0 Ω
NOTE:
Refer to “Low resistance measurement” for
this inspection.
8-24
ELEC
–
+
ELECTRICAL ANALYSIS
M57500-0
OIL INJECTION SYSTEM (Oil injection model)
1 Oil level sensor
2 Digital Meter
(Oil level warning lamps/control unit)
3 Lead wire
4 Lead wire
5 Lead wire assembly
50, 60, 70 hp
75, 80, 90 hp
8-25
E
ELEC
–
50, 60, 70 hp
+
ELECTRICAL ANALYSIS
E
M58004-0
75, 80, 90 hp
OIL-LEVEL SENSOR
1. Remove the circlip and disassemble the
oil-level sensor.
1 Oil-level sensor
2 Strainer cover
3 Gasket
2. Referring to the illustrations and tables,
check the continuity and resistance.
50, 60, 70 hp
Marking: 6H3-16
Unit: Ω
Oil level sensor resistance
Float SW.1 ON
A 79.5 ~ 82. 5 mm
(3.13 ~ 3.25 in)
Tester
+
Tester
Tester
+
1
Black
2
Green -
Tester
1
Black
2
Green
Float SW. 2 ON
B 114.5 ~ 117.3 mm
(4.51 ~ 4.62 in)
0
1
Black
3
Green/
Red
0
1
Black
3
Green/
Red
*∞
640
Oil level sensor resistance
Float SW. 1, SW. 2, both OFF
Tester +
2 Green
2 Green
3 Green/
Red
∞
*∞
Tester 1 Black
2 Green
∞
3 Green/Red
*∞
∞
∞
* “∞” indicates that the pointer deflects
once and returns to “∞”.
∞ : Discontinuity
8-26
ELEC
–
+
ELECTRICAL ANALYSIS
E
75, 80, 90 hp
Marking: 6H1-15
Unit: Ω
Oil level sensor resistance
Float SW.1 ON
A 5.8 ~ 8.8 mm
(0.23 ~ 0.35 in)
Tester
+
Tester
Tester
+
1
Black
2
Green -
Tester
1
Black
2
Green
Float SW. 2 ON
B 42.3 ~ 45.3 mm
(1.67 ~ 1.78 in)
0
1
Black
3
Green/
Red
0
1
Black
3
Green/
Red
*∞
640
Oil level sensor resistance
Float SW. 1, SW. 2, both OFF
Tester +
2 Green
2 Green
3 Green/
Red
∞
*∞
Tester 1 Black
2 Green
∞
3 Green/Red
*∞
∞
∞
* “∞” indicates that the pointer deflects
once and returns to “∞”.
∞ : Discontinuity
3. Assemble as shown in the diagram.
1
2
3
4
Strainer cover
Float (Magnet)
Plate
Gasket
NOTE:
● Place
the float with the magnet side
upward.
● Assemble the plate which has a hole at
the bottom.
8-27
ELEC
–
+
ELECTRICAL ANALYSIS
E
M57602-0
OIL-LEVEL WARNING LAMP (L.E.D.)
(50GETO)
Test the Light Emitting Diode (L.E.D.) using
a 1.5-V dry-cell battery.
If no light is emitted, replace the warning
lamp.
Battery voltage:
1.5V
CAUTION:
Do not use a 12-V battery or a larger capacity type, as this may damage the L.E.D. We
recommend using a pen light battery.
M58300-0
WIRING HARNESS
1. Check the continuity between the coupler side and each connector. Cores and
pins of identical colors must be connected or a continuity test can not be
made.
2. If any of the cores is open-circuit,
replace the wiring harness.
Lg
P
Br
B
L
Sb
W
Y
R
G
8-28
: Light green
: Pink
: Brown
: Black
: Blue
: Sky blue
: White
: Yellow
: Red
: Green
ELEC
–
50, 60, 70 hp
+
ELECTRICAL ANALYSIS
E
M58800-0
75, 80, 90 hp
BRACKET
1. Inspect the bracket and replace it if it’s
cracked.
M58900-0*
BATTERY
Refer to “PERIODIC SERVICE” section
in chapter 3.
M59000-0
ENGINE STOP SWITCH
(P60TH/60FEHTO, P75TH/75CEHTO,
90AEHD)
1. When removing and installing the lockplate, check for continuity according to
the chart below.
Lock plate
Removed
Installed
8-29
Wire color
W
B
–
+
ELECTRICAL ANALYSIS/INSTALLATION
E
MAIN SWITCH (P60TH/60FEHTO,
P75TH/75CEHTO, 90AEHD)
1. Check the continuity of the main switch.
Replace if continuity is not as specified.
Checking leads
Red
|
Yellow
|
Brown
Disconti- DiscontiContinuity
nuity
nuity
DiscontiDiscontiContinuity
nuity
nuity
White
|
Black
Switch Position
ELEC
OFF
ON
START
Discontinuity
Red
|
Yellow
DiscontiContinuity
nuity
NEUTRAL SWITCH (P60TH/60FEHTO,
P75TH/75CEHTO, 90AEHD, 90TR/
90AETO, B90TR/90AETO)
1. Check the continuity of the neutral
switch.
Replace if continuity is not as specified.
Distance
Color:
Brown – Brown
Free
a
19.6 ~ 20.5 mm
(0.77 ~ 0.81 in)
Discontinuity
Push
b
18.5 ~ 19.5 mm
(0.73 ~ 0.77 in)
Continuity
M61002-0*
INSTALLATION
FLYWHEEL MAGNETO
1. Install the magneto base onto the
retainer-plate.
2. Install so that the woodruff key in the
keyways fits in the crankshaft.
3. Lock the flywheel rotor with the washer
and nut. Tighten the nut to the specified
torque.
T.
Flywheel nut:
160 Nm (16 m • kg, 115 ft • lb)
R.
Flywheel holder:
YB-6139/90890-06522
4. Install the flywheel cover.
8-30
ELEC
–
+
STARTER MOTOR
E
M71001-0*
STARTER MOTOR
REMOVAL
1. Disconnect the cables and remove the
starter-motor.
DISASSEMBLY
1. Remove the starter-clutch. Using a
screw-driver, pry off the clip.
1 Clip
2 Pinion Stopper
3 Pinion (starter clutch)
NOTE:
Push the pinion stopper by hand toward the
pinion and remove the clip.
50, 60, 70 hp
2. Remove the two through-bolts and pull
out the front cover lightly tapping it
with a plastic hammer, if necessary.
75, 80, 90 hp
3. Using a piece of steel wire, separate the
brush springs and remove the brushes
from the brush-holders.
4. Remove the yoke assembly by lightly
tapping it with a plastic hammer and
remove the armature.
1
2
3
4
5
6
7
8
9
0
A
B
C
D
E
F
8-31
Clip
Pinion stopper
Spring
Pinion (starter clutch)
Front cover
O-ring
Washer
(50, 60, 70 hp: t = 1.0 mm,
75, 80, 90 hp: t = 2.0 mm)
Washer
(50, 60, 70 hp: t = 0.15 mm,
75, 80, 90 hp: t = 0.3 mm)
Washer
(50, 60, 70 hp: t = 2.0 mm,
75, 80, 90 hp: t = 1.0 mm)
Armature
Yoke assembly
Brush
Brush holder
O-ring (50, 60, 70 hp)
Rear cover
Through-bolt
ELEC
–
+
STARTER MOTOR
E
INSPECTION
PINION
1. Inspect the pinion and inner teeth for
wear or damage and check ease of pinion sliding motion and replace, if damaged.
2. Inspect the flywheel gear and replace, if
worn or damaged.
STARTER CLUTCH
1. Check the clutch movement. Rotate the
pinion clockwise and check that it turns
freely. Also, try to rotate the pinion
counterclockwise and confirm that it
locks.
BRUSH
1. Measure the brushes for wear.
Brush size a:
Standard:
50, 60, 70 hp: 12.5 mm (0.49 in)
75, 80, 90 hp: 16.0 mm (0.63 in)
Minimum:
50, 60, 70 hp: 9.0 mm (0.35 in)
75, 80, 90 hp: 12.0 mm (0.47 in)
If the size is less than the minimum
specification, replace the complete
brush-holder assemblies.
BRUSH-HOLDER
1. Check the insulation between the brushholder and ground. If there is any continuity, replace the brush-holder assembly.
8-32
ELEC
–
+
STARTER MOTOR
E
ARMATURE
1. Inspect the commutator surfaces and if
these are dirty or burnt, clean with 400grit wet-or-dry sandpaper.
2. Inspect the commutator deflection with
a dial gauge and block and replace the
armature if the deflection is out of specification.
Maximum deflection:
0.05 mm (0.0020 in)
If the deflection is greater than the specified deflection, replace the armature.
3. Measure the diameter of the commutator.
Standard diameter:
50, 60, 70 hp: 30 mm (1.18 in)
75, 80, 90 hp: 33 mm (1.30 in)
Minimum diameter:
50, 60, 70 hp: 29 mm (1.14 in)
75, 80, 90 hp: 31 mm (1.12 in)
If the commutator diameter is out of
specification, replace the armature.
4. Measure the commutator mica undercut depth.
Standard mica undercut depth:
0.8 mm (0.03 in)
Minimum undercut depth:
0.2 mm (0.01 in)
If the undercut depth is less than the
specified minimum, scrape between the
segments with a hacksaw blade, then
remove all particles of mica and metal
with compressed air.
8-33
ELEC
–
+
STARTER MOTOR
E
5. Check the insulation between the shaft
or laminations and ground. If there is
any continuity, replace the armature.
6. Inspect that the commutator is an open
circuit by checking for continuity
between segments. If any segment is
not continuous, replace the armature.
ASSEMBLY (50, 60, 70 hp)
1. Apply a thin coat of water resistant
grease to the rear cover bushing and
install the armature in the rear cover
assembly.
NOTE:
Install by lifting the brushes, and inserting
the armature straight into the bushing taking care not to scratch the brush or contaminate it with grease.
2. Install the yoke assembly, aligning the
recess on the rear cover with the projection on the stator and ensuring that the
O-ring fits correctly in the rear cover
groove.
3. Mount the two washers on the armature shaft. Sparingly apply water resistant grease to the front cover bushing,
ensure that the O-ring fits into the armature shaft and insert the shaft into the
front cover.
8-34
ELEC
–
+
STARTER MOTOR
E
4. Insert the through-bolts into the rear
cover and screw them into the front
cover.
5. Mount the pinion, spring and pinionstopper on the armature shaft.
6. Hold down the pinion-stopper and fit
the circlip into the groove in the shaft.
Use a socket-wrench that fits properly
over the armature shaft. Reform the circlip by using pliers. Lift up the pinionstopper until its bottom contacts the circlip.
INSTALLATION (50, 60, 70 hp)
1. Place the starter-motor on the starter
motor stay and tighten the bolts to the
specified torque.
T.
Starter motor mounting bolt:
20 Nm (2.0 m • kg, 14 ft • lb)
R.
2. Secure the starter-motor to the engine
with the four starter-motor mounting
bolts.
3. Connect the positive and negative wires
to the starter-motor.
ASSEMBLY (75, 80, 90 hp)
1. Insert the armature into the yoke
assembly. Fit the brush attached to the
negative side of the brush holder into
the armature.
1 Brush holder
8-35
ELEC
–
+
STARTER MOTOR
E
2. Install the positive brush (on the stator
coil side) in the brush holder and hold it
with the spring.
NOTE:
Use care not to scratch the brushes when
installing.
1 Positive brush
2 Spring
3. Mount the two steel washers and resin
washer, in that order, on the armature
shaft and install the front cover onto the
yoke assembly.
1 Front cover
4. Align the cut (for the through-bolt) in
the brush holder with the gap in the
brush holder so that the through-bolt
can be inserted.
5. Install the rear cover onto the yoke
assembly, insert the through-bolt into
the rear cover and screw it into the front
cover.
NOTE:
● Apply a thin coat of grease (anti-freeze
grease) to the front and rear cover bearings.
● To seal out water, the mating surfaces are
coated with sealing compound.
INSTALLATION (75, 80, 90 hp)
1. Place the starter-motor on the startermotor stay and tighten the bolts.
2. Secure the starter-motor to the engine
with the four starter-motor mountingbolts.
3. Connect the positive and negative wires
to the starter-motor.
8-36
TRBL
ANLS
E
CHAPTER 9
TROUBLE ANALYSIS
TROUBLE ANALYSIS ..................................................................................... 9-1
TROUBLE ANALYSIS CHART ................................................................. 9-1
1
2
3
4
5
6
7
8
9
TRBL
ANLS
TROUBLE ANALYSIS
E
TROUBLE ANALYSIS
NOTE:
The following items should be obtained before “trouble analysis”.
1. Battery is charged and its specified gravity is in specification.
2. There is no incorrect wiring connection.
3. Wiring connections are surely engaged and without any rust.
4. Lanyard is installed to the engine stop switch.
5. Shift position is in neutral.
6. Fuel is coming to the carburetor.
7. Correct rigging and engine setting are obtained.
8. Engine is free from any “Hull problem”.
TROUBLE ANALYSIS CHART
POOR BATTERY CHARGING
IRREGULAR WARNING INDICATION
HARD SHIFTING
Check elements
TILT MOTOR WILL NOT RUN
LOOSE TILT HOLDING
LOOSE STEERING
OVERHEATING
POOR PERFORMANCE
ENGINE WILL NOT STOP
ENGINE STALLS
ROUGH IDLING
ENGINE WILL NOT START
Trouble mode
Relative part
FUEL SYSTEM
Idle speed
Fuel hose
Fuel joint
Fuel filter
Fuel pump
Carburetor
Pilot screw setting
POWER UNIT
Link adjustment
Compression
Read valve
Cylinder head gasket
Cylinder block
Piston
Piston ring
Crank case
Bearing
Thermostat
Water passage
9-1
Reference
Chapter
3
3
4
4
4
4
4
3
5
5
5
5
5
5
5
5
5
5
TRBL
ANLS
TROUBLE ANALYSIS
POOR BATTERY CHARGING
IRREGULAR WARNING INDICATION
HARD SHIFTING
Check elements
TILT MOTOR WILL NOT RUN
LOOSE TILT HOLDING
LOOSE STEERING
OVERHEATING
POOR PERFORMANCE
ENGINE WILL NOT STOP
ENGINE STALLS
ROUGH IDLING
ENGINE WILL NOT START
Trouble mode
E
Relative part
LOWER UNIT
Neutral position
Clutch
Gear
Water inlet
Water pump
Propeller shaft
Shift rod
Shift slider
Shift cam
Lower case
Shim adjustment
BRACKET UNIT
Bracket
Mount rubber
Shift actuator
PTT UNIT
Fluid level
Relief valve
Fluid passage
PTT motor
PTT control system
ELECTRICAL
Pulser coil
Charge coil
Lighting coil
Ignition coil
Spark plug cap
CDI unit
Crank position sensor
Starter relay
Power trim and tilt relay
Trailer switch
Rectifier/regulator
9-2
Reference
Chapter
6
6
6
6
6
6
6
6
6
6
6
7
7
7
7
7
3
7
7
8
8
8
8
8
8
8
8
8
8
8
TRBL
ANLS
TROUBLE ANALYSIS
POOR BATTERY CHARGING
IRREGULAR WARNING INDICATION
HARD SHIFTING
Check elements
TILT MOTOR WILL NOT RUN
LOOSE TILT HOLDING
LOOSE STEERING
OVERHEATING
POOR PERFORMANCE
ENGINE WILL NOT STOP
ENGINE STALLS
ROUGH IDLING
ENGINE WILL NOT START
Trouble mode
E
Relative part
Fuse
Thermo switch
Oil level sensor
Oil level warning lamp
Wire harness
Battery
Engine stop switch
Main switch
Neutral switch
Starter motor
9-3
Reference
Chapter
8
8
8
8
8
3
8
8
8
8
YAMAHA MOTOR CO., LTD.
Printed in USA
Feb. 1999 – ?.? × 1 CR
(50GETO, 60FEHTO, 60FED, 60FEDO, 60FET, 60FETO, 70BEDO, 70BETO,
75CET, 75CETO, 75CEHTO, 80AETO, 90AEHD, 90AED, 90AET, 90AETO)
Printed on recycled paper