1993-1998 Yamaha 50 60 70 80 90hp 2stroke Outboard Repair – PDF DOWNLOAD

1993 - 1998 OUTBOARD / MOTEUR HORS-BORD

SERVICE MANUAL / MANUEL D’ATELIER

Model : C75TLRW, P60TLHT, P60TLHU

6H228197Z311 *6H228197Z311*

1993 Outboard Model: P60S/70S Part: 6H228197Z311

A20000-O

NOTICE This manual has been prepared by the Yamaha Motor Company 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 _

P60S/70S/90S 50G/60F/70B/80A/90A SERVICEMANUAL Š1993 Yamaha Motor Co., Ltd. 1st. Edition, November 1993 All rights reserved.

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.

Printed in Japan P/N 6H2-28197-Z3-11

AS0000-0

HOW TO USE THIS MANUAL MANUAL

FORMAT

This manual provides the mechanic with descriptions of the operations of disassembly, repair, assembly, adjustment and inspection, each of which is presented in a sequential, step-by-step procedure, To assist you to find your way about this manual, the Section Title and Major Heading is given at the head of every page.

An Index to contents is provided on the first page of each Section.

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: O, (_),Q. 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.

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 a following table.

For U.S.A. and CANADA) Model Item _-_,

P60TH

70TR

90TR

Control system

Manual control

Remote control

Remote control

Tilt system

Power trim and tilt

Power trim and tilt

Power trim and tilt

(Except for U.S.A. and CANADA) Model 50GEO Item Tilt system

50GETO

6OFEO

6OFETO

70BEO

Manual tilt

Power trim and tilt

Manual tilt

Power trim and tilt

Manual tilt

70BETO

80AEO

80AETO

90AEO

90AETO

Powertrim andtilt

Manual tilt

Powertrim andtilt

Manual tilt

Powertrim andtilt

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 ATr'ENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! IF!_TAT!_'I ;t k_ IIL_ lei 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.

A CAUTION indicates board motor.

special precautions

that must be taken to avoid damage

NOTE: A NOTE provides key information to make procedures easier or clearer.

IMPORTANT: This part has been subjected to change of specification during production.

to the out-

_)

(_)

-

GEN INFO 'T (_

SYMBOLS

SPEC

_

Symbols O to O designed as thumbtabs to indicate the are content of a chapter.

(_)

INSP ADJ

(_) General Information (D Specifications

FUEL

O

LOWR

BRKT _' ®

I

Symbols (_)to _) indicate specific data:

·

i_

=-'-----

<_

® Specified liquid (_) Special service tool

',-,"','---

(_) Specified engine speed (_) Specified torque

-...-. (_)

_

ii_ _

iimmmmlmw_lm

=,

(_)

_) Specified

grease

_) Specified electrical value (_) Specified measurement [Resistance (4), Voltage (V), Electric current (A)]

--

'_--_ _............._._ , 0

i

ELEC, _"_ _

TRBL SHTG

:(_

(_) Trouble-shooting (_) Electrical System

® I

-

QPeriodiclnspectionandAdjustment O Power Unit _ Lower Unit O Bracket Unit

_ p

I

®

@

®Fuel System

J_

(_

POWR _

_

-

AS0001-1-4

·,

q_ _

-

Symbol

_

-_7)

(_

271

242

and location

indi-

of lubrica-

_) _) (_ (_

Apply gear oil Apply molybdenum disulfide oil Apply engine oil Apply water resistant grease (Yamaha marine grease A, Yamaha marine grease)

indicate grade of sealing or locking agent, Symbols (_) to (_ in an exploded diagram and location of application point:

_

_

diagram

tion point:

_

_

in an exploded

cate grade of lubricant

_)

:(_

(_) to _

Apply LOCTITE ® No. 271 (Red LOCTITE) (_ Apply LOCTITE Gasket maker _ Apply ® No.®242 (Blue LOCTITE) _) Apply LOCTITE ® No. 572

.L

NOTE:

_1_

In this manual, the above symbols may not be used in every case.

u572

oooo.o

INDEX

GENERAL INFORMATION

SPECIFICATIONS PERIODIC INSPECTION AND ADJUSTMENT FUEL SYSTEM POWER UNIT

BRACKET UNIT

ELECTRICAL SYSTEM TROU BLE-SHOOTING

3..

GEN

INFO

_g" p

SPEC

i_-_ ADJ FUEL

E

POWR

G

BRKT

_

ELEC

T_L SHTG

[_

I GEN CHAPTER 1 GENERAL INFORMATION IOENTIFICATJON

...........................................................................................

SERIAL

NUMBER

ENGINE

SERIAL

S'_ART_NG

SAFETY

SERIAL

WHILE F_RE VE S

LA'_

LF'PR

NUMBERS

WORKING

PREVF_ NT_

E

....................................................................................

NUMBER

N'_ O O"FE_CT_

N

..................................................................... ..............................................................

..........................................................................

O

N

..................................................................................

.........................................................................................

O

N

................................................................................

1 - 1 1-1 '1-'1 1-1

1-2 '1-2 1-2 1-2

OILS, GREASESAND SEALING FLUIDS ..............................................1-2 GOOD WORKING PRACTICES...............................................................1-3 DISASSEMBLY AND ASSEMBLY..........................................................1-4

SPECIAL

TOOLS

FOR FOR FOR FOR

...........................................................................................

TUNE-UP .........................................................................................

POWER UNIT SERVICE ..................................................................

LOWER UNIT SERVICE ..................................................................

P.T.T. SERVICE .............................................................................

1 '5

1-5 1-6 1-7 1-12

I GEN iNFOI

I IDENTIFICATION A60000-1'

·

:

,.,,

SERIAL NUMBER The serial number of the outboard

motor is

stamped on a plate attached to the port side of the clamp bracket.

O Serial number NOTE: ForU.S.A. model: /(_)

r

I

Y

)

_MAHAli_!!:.?:?!i;!!i.?!iifili?;?:??i!i'i;i:;: ? ,,

/YAMAHA M(_TOR CO., LTD, /MADE IN J_PAN t' D'ORI_INE [iiiiiiiiiiiiiiiiii!ii:iiiPAYS '''''_*'_(_'-_ _!i};i!iiiii:JAPONiii!iiiil}i ii:i!;ii;!!i!il J --

which the outboard motor a serial is As an anti-theft measure, specialnumber label on stamped is bonded to the port side of the clamp bracket. The label is specially treated the serial number. (_) Model name (_) model SOApproved that peeling it No. off causes cracks across O Transom height ® Serial number

The engine serial number is stamped the port side of the cylinder body.

-_O,_

_mib_ iff

on

STARTING SERIAL NUMBERS ENGINE SERIAL NUMBER lows: The starting serial number blocks are as folModel

Approved model No.

50GEe 50GETO

62F

60FEe 60FETe

6H2

P60THS 70BEe 70BETO (70TRS} 80AEO 80AETO 90AEO 90AETO (90TRS)

6H3

6H0

6H1

1-1 *: For U.S.A. and CANADA

Serial Number S: 100153 ~ L: 400424 ~ S: 200129 ~ L: 500871 ~ S: 100793 ~ L: 406295 ~ S: 150657 ~ L: 465483 ~ UL: 730666 ~ L: 550832 ~* S: 100216~ L: 401718 ~ S: 150329 ~ L: 483416 ~* UL: 730798 ~ L: 401100 ~ L: 456637 ~ UL: 850765 ~ L: 401067 ~ L: 486330 ~* UL: 854694~

I INFO{ GEN

'_

{ SAFETYWHILEWORKING SAFETY WHILE WORKING The procedures given in this manual are those recommended by Yamaha to be followed by Yamaha dealers and their mechanics.

FIREPREVENTION _.

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 life. Engine exhaust gases are harmful to breathe. test-running an support engine inhaled in When large quantities will not indoors, maintain good ventilation.

__ _.....,_

SELF-PROTECTION Protect your eyes with suitable safety glasses or safety goggles when using comt_,.. ¡

any operation which may cause particles to pressed air, when grinding or when doing flyoff.

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, greases and sealing fluids or those recommended by Yamaha.

i

1-2

_

I INFOI GEN 'TI

sAFETY WHILE WORKING Under normal conditions of use, there should be no hazards from the use of the lubricants mentioned in this manual, but safety is all-important, and by adopting good safety practises, 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 right tool in the right manner -- don't t

parts from damage. Use the 2. protect Tightening torque improvise.

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 INFOI

J SAFETY WHILE WORKING 3. Non-reusable items _

._

rings, oil seals, split-pins and circlips etc. on reassembly.

+__,._,.,_

Always use new gaskets, packing, 0-

1. Clean parts with compressed-air on disassembling them.

DISASSEMBLY AND ASSEMBLY

(__"TF_

on assembly.

'---__E_=_ _

-

2. Oil the contact surfaces of moving parts 3. After assembly, check that parts operate normally.

moving

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

-

I INFO GEN

J _

I SPECIAL TOOLS A80701-0'

SPECIALTOOLS 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 U.S.A. and Canada, use part number starting with "YB-", "YU-" or "YW-". · For others, use part number starting with "90890-".

FOR TUNE-UP YU-3097

90890-01252

1. Dial gauge and stand 90890-01252

YU-34899-A

2. Digital multi meter P/N. YU-34899-A 90890-06752

90890-06752

YU-91022-B

3. C.D.I. tester P/N. YU-91022-B

1-5

INFO GEN I _ YU-33223

I SPEClALTOOLS 4. Compression gauge P/N. YU-33223

90890-06751

90890-06751

YM-33277-A

90890-03141

YU-8036-A

90890-06760

YB-35956

90890-06762

_:=

YB-6117

5. Timing light P/N. YU-33277-A 90890-03141

6. Tachometer P/N. YU-8036-A 90890-06760

7. Leakage tester P/N. YB-35956 90890-06762

p

FOR POWER

90890-06521

UNIT SERVICE

1. Flywheel puller P/N. YB-6117

(__

90890-06521

1-6

,. olI

I GEN

YB-6139

YB-6287 YB-6107

2. Flywheel holder P/N. YB-6139 90890-06522

90890-06522

3. Connecting

90890-06527

rod

small

end

installer 50 hp/60 bp/70 hp: 90890-06527 80 hp/90 hp: P/N. YB-6107 90890-06527

YU-33294

4. Piston slider P/N. YU-33294 9O89O-0653O

90890-06530

FOR LOWER UNIT SERVICE 1. Stopper guide plate P/N. 90890-06501

9o89o-o6501

0 YB-6207

2. Bearing housing puller 50 hp/60 hp/70 hp: P/N. YB-6207

90890-06503

80 hp/90 hp: P/N. YB-6207 90890-06502 90890-06503

_

1-7

bearing

I E",.Fo ? Is,Ec.A, Too,s

3. Center bolt P/N. 90890-06504

90890-06504

4. Pinion nut holder P/N. 90890-06505

90890-06505

YB-34447

YB-6049 YB-6151

_

90890-06511

5. Ring nut wrench P/N. YB-34447 90890-06511

9089O-O6513

6. Extension (ring nut wrench) P/N. 90890-06513

90890-06518 90890-06519

7. Drive shaft holder 50 hp/60 hp/70 hp: P/N. YB-6049 90890-06518 P/N. YB-6151 90890-06519 80 hp/90 hp:

_

1-8

,.toI IsPEc'A'T°°'s YB-6096

8. Slide hammer set P/N. YB-6096

YB-6117

9. Universal puller P/N. YB-6117

YB-6153

10. Bearing housing needle bearing remover P/N. YB-6153 90890-06612

90890-06612

11. Bearing outer race puller P/N. 90890-06523

90890-06523

YB-6219

12. Bearing separator P/N. YB-6219 90890-06534

90890-06534

1-9

I INFOI GEN _l

sPEcIALT°°Ls 13. Bearing puller P/N. 90890-06535

90890-06535

14. Stopper guide stand P/N. 90890-06538

90890-06538

YB-6071

90890-06602 90890-06604 90890-06605 90890-06606

.....

15. Drive rod P/N. YB-6071 90890-06602 90890-06604 90890-06606

_

90890-06605

YB-6152

16. Bearing housing installer P/N. YB-6152

needle

17. Bearing housing oil seal installer P/N. YB-6269

YB-6269

1-10

bearing

I INFOI GEN

_

I SPECIALTOOLS 18. Bearing depth plate P/N. 90890-06603

90890-06603

YB-6155

YB-6156 YB-6276-B

19. Needle bearing a_achment

90890-06611 90890-06614

P/N. YB-6155 90890-06611 90890-06614

20. Bearing outerrace a_achment

90890-06621 90890-06626 90890-06627

P/N. YB-6156, YB-6276-B 90890-06621 90890-06627

(__

_--_

YU-34481

90890-06705

YB-6265

90890-06706

90890-06626

21. Magnet base P/N. YU-34481 90890-06705

22. Backlash indicator P/N. YB-6265 90890-06706

1-11

I INFOI GEN

I sPECIALT°°Ls

YB-34473

23. Drive shaft needle bearing depth stop P/N. YB-34473

YB-6052

24. Shift rod wrench P/N. YB-6052

YB-6175-1A

90890-06542

YB-6175-2A

90890-06541

FOR P.T.T. SERVICE 1. Cylinder end screw wrench P/N. YB-6175-1A 90890-06542

2. Cylinder end screw wrench P/N. YB-6175-2A 90890-06541

3. Pressure gauge P/N. YB-6181

YB-6181

1-12

CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATION...........................................................................2-1 MAINTENANCE SPECIFICATIONS...............................................................2-4 ENGINE ...................................................................................................2-4 ELECTRICAL ............................................................................................

2-6 DIMENSIONS ..........................................................................................

2-9 TIGHTENING TORQUE................................................................................2-14 GENERAL TORQUE SPECIFICATIONS.......................................................2-15

r_

V

Is.EclI E.E.A.S.EC,F,CAT, C20000-0'

GENERAL SPECIFICATION __

Unit __

Model 70hp *_: 70BEO .2: 70TR/ 70BETO

50hp 60hp .l: 50CEO .1: 60FEO .2: 50GETO .2: 60FETO .3: P60TH/ 60FEMTO

Model

Approved model No. Overall Length

mm (in)

Overall Width

mm (in)

62F 698 (27.5)

80hp .l: 80AEO .2: 80AETO

6H2 6H3 713 (28.1)

1337(52.6).3 J 364 (14.3) -393 (15.5)*3 I 1230 (48.4) 1252 (49.3) 1351 (53.2) 1374 (54.1)

90hp .l: 90AEO .2: 90TR/ 90AETO

6H0 6H1 726 (28.6)

--

I

374 (14.7)

B

Overall Height

S L

mm (in) mm (in)

Boat transom height

UL S L

mm (in) mm (in) mm (in)

m 381 (15.0)

UL S L

mm (in) mm (in) mm (in)

--

O/M transom height

UL S

Weight (Al.)

Weight (SUS.)

520 (20.5)

mm (in) kg (lb)

-93 (205)*_ 101 (223)*2

648 (25.5)*_ 95.5 (211)*_ 103.5 (228)*2

L

kg (lb)

94 (207)*_ 102 (225)*2

97.5 (215)*_ 105.5 (233)*2

UL S

kg (lb) kg (lb)

-----

111 (245)*3 I 108.5 (239)*l 97.5 (215)*_ 105.5 (233)*2

L

kg (lb)

--

99.5(219) *l 107.5 (237)*2

UL

kg (lb) rpm kW (hp)/ rpm

_

Maximum fuel consumption

Compression ratio Compression pressure Carburetor number

1501 (59.1) 381 (15.0) 508 (20.0) 635 (25.0) 400 (15.7) 521 (20.5)

Full throttle speed range Output (ISO)

Type Cylinders Total Displacement Bore x Stroke

1413 (55.6)

L (US gal, Imp gal)/h at rpm

cm 3 (cu in) mm (in)

} m

1540 (60.6)*21

--

I --520 (20.5) 647 (25.5)*2 I _ 112.5 (248)*_ 120.5 (266)*2 123.5(272)*21

--

114.5(252) *l 122.5 (270)*2

110.5 (244)*_ 125.5(277).21 -4500~ 5500 5000~ 6000 4500 ~ 5500 37.3 (50)/ 44.7 (60)/ 52.2 (70)/ 59.7 (80)/ 67,1 (90)/ 5000 5000 5500 5000 5000 22 (5.81, 4.84) at 5500

26 32 34.5 (6.87, 5.72) (8.45, 7.04) (9.11, 7.59) at 5500 at 5500 at 5500 2stroke -L 3 848 (51.8) 1140 (69.6) 72.0 x 69.5 (2.83 Ã&#x2014; 2.74) 82.0 x 72.0 (3.23 x 2.83)

6.30 kPa(kg/cm2)

23 (6.08, 5.06) at 5500

J

6.20 I 853 (8.53)

6.20

5.90 922 (9.22)

3

Intake system Scavenging system

Reed valve Loop charge

Starting system Ignition system

Electric C.D.I.

Alternator output Carburetor starting system

6A

I Prime start

2-1

10A

SPECI

I GENERAL

SPECIFICATION

Unit

Model

50hp I 60hp I 70hp I 80hp I 90hp

Advance type

Micro computer

Spark plug (NGK) Sparkplug(CHAMPION) Spark plug with noise suppressor (NGK) Spark plug with noise suppressor (CHAMPION) Exhaust system Cooling system Lubrication system Fueltype Fuel rating Engine oil type/grade Gear oil type

Tilt angle

Steering angle

Through prop boss Water Oil injection

cm 3(US oz, Imp oz) L (US qt, Imp qt) degree

Engine oil tank capacity

Trim angle (P.T.T. model)

RL82C/Register plug-cap

Reguler gasoline Min. 86 TC-W2 or TC-W3.2 Hypoid gear oiI-SAE#90 .3

P.O.N.1

Gear oil quantity

Tilt-up angle

BR8HS-10 I B8HS-10 RL78C I L78C BR8HS-10/Register plug-cap (standard)

S: L:

500 (16.91, I 17.60) I 2.8 (2.96, 2.46)

3.3 (3.49, 2.90)

8/12/16/20/24

degree

63

I 67

at 12 transom

-4 ~ 15

degree (left + right)

Gear shift position Gear ratio

I

I

35 + 35

30 + 30

F-N-R.4 12: 28 (2.333)

14: 24 (1.714)

Gear type Clutch type Propeller direction Propeller drive system

13: 26 (2.000)

Spiral bevel gear Dog clutch Clockwise Spline

Propeller series mark Battery capacity Cold crankin_l

610 (20.62, 21.47)

G

I

Ah (kC) Amps

K 70 (252) 380

Pump Octane Number; (Research octane + Motor octane)/2 .2 YAMALUBE two-cycle outboard motor oil is recommended in U.S.A. YAMALUBE 1 is recommended in Canada -x-3 GEAR CASE LUBE is recommended in U.S.A. .4 Forward-Neutral-Reverse 91

2-2

SPEC

{ GENERAL SPECIFICATION Item

Unit

Propeller No. of blades x diameter x pitch

in

Item

Model 50hp G type (aluminum) 3 x 11-3/8 x 12 3 x 11-1/8 x 13 Model 60, 70 hp

Unit

Propeller No. of blades x diameter x pitch

in

K type (aluminum) 3 x 13-1/4x 17 3 x 13 x 23 3 x 12-5/8x 21 3x 13x 19 3 Ă&#x2014; 13-1/2 x 15 3 x 13-5/8x 13

P' High performance propeller

K type (stainless) 3 x 13 x 17 3 x 13 x 19 3 x 13 x 21 3x 13x23 3 x 13 x 25 3 x 13-1/2 x 14 3 x 13-1/2 x 16

P type (stainless) in

3 x 14 x 20 3x 14x24 3x 14x28 Model

Item

Unit

Propeller No. of blades x diameter

in

x pitch

80, 90 hp K type (aluminum) 3 x 12-5/8x 21

K type (stainless) 3 x 13 x 17

3 x 13x 19 3x 13x23 3x 13-1/4 x 17 3x 13-1/2 x 15 3 x 13-5/8 x 13 3x 14x 11

3 x 13 x 19 3x 13x21 3x 13 x 23 3x 13 x 25 3 x 13-1/2x 14 3x 13-1/2x 16

P:High performance propeller

P type (stainless) in

3x 3x 3x 3x 3x

i

2-3

14Ă&#x2014;20 14x22 14x24 14x26 14x28

JSPECJ

J MAINTENANCE SPECIFICATIONS

C31000-0 _

MAINTENANCE ENGINE

SPECIFICATIONS

Item

Unit

Model

50hp J 60hp J 70hp I 80hp I 90hp Cylinder head: Warpage limit

mm (in)

(Lines indicate straight measurement) Cylinder: Bore size Taper limit Out of round limit Piston: Piston to cylinder clearance <Limit> Piston size "D" Measuring point "H"

0,1 (0,004)

mm (in) mm (in) mm (in)

72.00 ~ 72.02 (2.834 ~ 2.835) 0.08 (0.003) 0.05 (0.002)

mm (in) mm (in) mm (in) mm (in)

0.050 ~ 0.055 (0.0020 ~ 0.0022) 0.1 (0.004) 71.945 ~ 71.970 (2.8325 ~ 2.8335) 10 (0.4)

82.00 ~ 82.02 (3.228 ~ 3.229)

0.060 ~ 0.065 (0.0024 ~ 0.0026) 81.935 ~ 8'1.960 (3.2258 ~ 3,2268)

0 L r.

D

Oversize:

at -i

1st 2nd

mm (in) mm (in) mm (in)

Offset [direction] Piston ring: Sectional sketch Top ring & 2nd ring

72.25 (2.844)* 72.50 (2.854) 0,5 (0,0197) [Exhaust side]

Type

82.25 (3.238)* 82.50 (3.248) 1,0 (0.039) [Exhaust side]

Keystone

.T.

,-_a

B T

mm (in) mm (in)

2.0 (0.079) 3.0 (0.118)

*: Except for U.S.A.

2-4

2.0 (0.079) 3.2 (0.126)

SPECI

I MAINTENANCE SPECIFICATIONS Item

Unit

End gap [Installed] Top ring & 2nd ring

Model

50hp I 60hp I 70hp

80hp I 90hp

mm (in)

0.30 ~ 0.50 (0.012 ~ 0.020)

0.40 ~ 0.60 (0.016 ~ 0.024)

mm (in)

0.03 ~ 0.07 (0.0012 ~ 0.0028)

0.03 ~ 0.06 (0.0012 ~ 0.0024)

57.90 ~ 57.95 (2.280 ~ 2.281) 151.7 ~ 152.0 (5.972 ~ 5.984) 245.5 ~ 246.1 (9.67 ~ 9.69) 0.03 (0.0012)

0.05 (0.0020)

Side clearance Top ring & 2nd ring Crankshaft: Crank width -ACrank width "BCrank width "CMaximum deflection "D" Connecting rod side clearance "E" Connecting rod maximum axial play "F"

mm mm mm mm

(in) (in) (in) (in)

mm (in) mm (in)

0.20 ~ 0.70 (0.008 ~ 0.028) 2.0 (0.08)

0.12 ~ 0.26 (0.005 ~ 0.010)

Carburetor: Stamp mark Main jet Mainair jet Pilotjet Pilotairjet Pilot screw Float height

62F00 6H20A 6H30A 6H007 6H107 (M.J.) # 125 140 145(L) 150 160 (M.A.J.) # 170 175 160 180 I 175 (P.J.) # 65 65 75 78 (P.A.J.) # 70 75 70 80 70 (P.S.) Turns out 1-3/8_+1/4 1-1/2+ 1/4 1-1/4+ 1/4 1-3/8+__ 1/4 1-1/4+ 1/4 (F.H.) mm 15.0 _+1.0 14.0 + 1.0 (in) (0.591 +_ (0.551 + 0.039)

L_ _-::_:_-'_'__ Valve seat size Idling speed Lubrication system: Oil injection pump Stamped mark Discharge

0.039) _ r/min

cm 3 (US oz, Imp oz)

1.2 (0.047)

1.4 (0.055) I 800 + 50

62F00 6H302 1.90_+0.20 2.20 _ 0.20 (o.064_+o.070,(0.074_+0.007, 0.067_+0.070) 0.077 _+0.007)

*: Lower cylinder 2-5

1.6 (0.063)

6H102 3.10 + 0.30 (0.105_+0.010, 0.109 +_0.011)

Is,EclIMA..TE.A"C S,EC.F.CAT'O Item Reed valve: Stopper height Warpage limit Thermostat: Valve opening temperature Full-opening temperature Valvelift

Unit

mm (in) mm(in)

50hp ,I 60hp 3.0 + 0.2 (0.118+ 0.008)

Model

70hp I 80hp I 90hp 9.9 + 0.2 (0.390+ 0.008) 0.2(0.008)

°C(°F)

48- 52(118~ 126)

°C(°F) mm(in)

60(140) 3(0.12)

C32000-0'

ELECTRICAL Item

Unit

Model

50hp I 60hp I 70hp Ignition system: Ignition timing at full reversed at full advanced cam roller pick-up Piston position at full advanced

ATDC degrees BTDC degrees ATDC degrees BTDC mm (in)

80hp I 90hp

7 __I

8 ___ 1

22 + 1

20 _+1

22 ___ 1

7 _+1 3.23 __0.28 (0.127 __+ 0.11)

8 _+I 2.68 _+ 0.26 (0.106_+ 0.010)

2.83 _+ 3.41 _ 0.27 0.29 (0.111 _+ (0.134_+ 0.011) 0.011)

Charging coil resistance [20°C (68°F)]

_

136 ~ 204 (Brown -- Blue)

191 ~ 288 (Brown -- Red) 64 ~ 96 (Blue -- Red)

Pulser coil resistance [20°C (68°F)]

Q

240 ~ 360 (White/Red -- White/Black)

241 ~ 362 (White/Red -White/Black)

Ignition coil: Primary coil resistance [20°C (68°F)] Secondary coil resistance [20°C(68°F)] Crank position sensor resistance [20°C (68°F)] Spark plug: Sparkplug gap

D

0.18 ~ 0.24 (Black/White -- Black)

kD

3.3 ~ 4.9 (Black -- High tension cord)

k_

158 ~ 236 (Blue/White -- Blue/Red)

mm (in)

0.9 ~ 1.0(0.035~ 0.039) 2-6

!SPECI

I MAINTENANCE SPECIFICATIONS Item

Unit

Model

50hp I 60hp I 70hp I 80hp J 90hp C.D.I. unit: __

50, 60, 70 hp /

_o

/_ 7 /_

For char_le coil

Y;.

_

p

'

/-_ c:_ _::_. ._ _'_-_._-_--_ "_

Sr _

' _ __

_ _c_

Unit: k_

_.:_

_.,

L

15~40

B

2.5 ~ 6.7

B

12 - 29

8 - 18

__

9.5~22

2.7 ~ 70

_._

For pulser coil

Unit: k_ W/R

-_::_.

L

,_

W/R W/B B

W/B

B

_..._.

35 ~ 500 37.5 ~ 1,000 _.._.

2.7 ~7.0 2.7 ~ 7.0

37.5 28 ~~ 1,000' 175 __

For ignition coil B/W -- B 2.7 ~ 7.0k_ For crank position

sensor

Unit: k_

L/W L/W

__........

L/R B /--

__--_'

7

a

_..

_c:_ kX _(_:_

'

_[:_

.,w _

m ___ .,w

,

_

O_,_ _

13-37

Black Brown Blue Red

W/R: White/Black White/Red W/B: W/G: White/Green B/VV: L/W: Black/White Blue/White L/R : Blue/Red

15-40

L

I

13-37

B 8~17

i_

9.5--22

For pulser coil

Unit: k_

_

: : · :

0 8.9 - 20

R

15-40

W/R W/R W/B B

B Br L R

_

Unit: k_ Br

L

:___w::_

oo

__.J

Br

,,w

oo

For charge coil _ _T_

_,

., /![ !\,?_

B

80, 90 hp

iv

I '_c:_ .....

8.9 ~ 20 2.7 ~ 7.0

L/R

W/B

B

__...

35 ~ 400 37.5 ~ 1,000 _ 3~7 3-7

23 ~ 90 28 ~ 140

For ignition coil B/W -- B 2.5 ~ 6.7kQ For..crank position _ r_ O '"'_ L/W L/R B 2-7

sensor

L/W ___.

10 ~ 24 10 ~ 24

Unit: k_ L/R oo i_

B oo 0

--_ 0

__

, I

ISPECI t;;P_I MAINTENANCE SPECIFICATIONS Item Lighting system: Lighting coil resistance STD (12V 80W) [20째C (68째F)] Starter motor:

Unit

_

Rating

Sec

Output Clutch type Brushlength <Wearlimit> Commutator undercut <Repair limit> Commutatoroutside diameter

kW

<Repair limit> Pinion/ring gear gap Others: Electrothermal valve resistance [20째C (68째F)] Trim sensor resistance Fuse

Model

50hp J 60bp I 70bp 0.57 ~ 0.85 (Green/White -- Green)

80bp I 90bp 0.4 ~ 0.6 (Green/White -Green)

30 0.6

mm(in) mm(in) mm (in) mm (in) mm(in)

I Overrunning 12.5(0.49) 9 (0.35) 0.8 (0.03) 0.2 (0.01) 30 (1.18)

mm (in) mm (in)

29 (1.14) 3 ~ 5 (0.12 ~ 0.20)

1.0 16.0(0.63) 12.0(0.47) 1.0 (0.04) 0.5 (0.02) 33(1.30) 31 (1.22)

Q

2.3 _ 3.5 (Blue -- Black)

_

360 ~ 540 (Pink- Black) 800 ~ 1200 (Pink -- Orange) 20

A

2-8

ISPECI _

I MAINTENANCE SPECIFICATIONS

C34000-0'

DIMENSIONS

g !

/ !

,/ J 2

gl/ !

/

L3

I'"

L1

L7 L2

i' -,

Wl

L10

¢ )

i

[

tO

L4 L9

2-9

L6

!sPEcl MA,..E.A.CES.EC, 50, 60, 70, 90 hp

L7

L1

_

o /

- __..._,

/

_ 'C

lo In I

o

o

_.

-r

t,

f_x /' [ '

--

"

-_-

F"

12° 'L4 LO T1

2-10

_ .

LO

1

SpECI

LENGTH L1 L2

{ MAINTENANCE

S: L,UL: S: L,UL:

L3 L4

SPECIFICATIONS

Unit

50hp

mm (in)

547 (21.5)

mm (in)

151 (5.9) 166 (6.5) m

mm(in)

P60TH/ 60, 70 hp 60FEMTO Model

80, 90 hp

w 547 (21.5) 532 (20.9) 545 (21.5) -151 (5.9) 270 (10.6) 166 (6.5) 180 (7.1) 651(25.6) --

S: L,UL: S: L: UL:

mm (in) mm(in)

531 (20.9) _ 562 (22.1) { 516 (20.3) 547 (21.5) 113 (4.4) m 113(4.4) 124 (4.9) 91 (3.6) 88 (3.5) -80 (3.1)

S: L: UL:

mm (in)

818 (32.2) 918 (36.1)

L7

S: L,UL:

mm (in)

L9

S: L:

L5

L6

H1

403 (15.9) I 0 (0.0)

--

mm(in)

758(29.8) 879(34.6)

S: L:

400 (15.7) {

mm (in) mm (in)

-623 (24.5) 675 (26.6)

H7

S. L,UL:

mm(in)

262(10.3)I

H9

S: L,UL:

mm (in)

S: L: UL:

H10 Hll

--

-31 (1.2)

780(30.7) 901(35.5) { 1028 (40.5) 472 (18.6) 190.5 (7.5)

--

I' 400 (15.7) { 520 (20.5)

--

--

648 (25.5) { 647 (25.5) 473 (18.6) -645 (25.4) 696 (27.4) 698 (27.5) -764 (30.1)

719 (28.3) }

mm(in) S: L:

-457 (18.0)

I 0 (0.0) 14 (0.6) m

_

mm (in)

403 (15.9)

I 67(2.6)

mm(in) mm(in)

UL: H5 H6

--

mm (in)

UL: H2 H3 H4

I

-411 (16.2)

mm(in) S: L:

868 (34.2) I 968 (38.1) 1081 (42.6)

--

UL: L10 HEIGHT

--

mm (in)

0 (0.0)

UL:

} --

2-11

_ 249(9.8)

262(10.3) 226(8.9)

-I 719 (28.3) 706(27.8) 47(1.9) -28 (1.1)

I }

0 (0.0)

-730(28.7)

27 (1.1) 27 (1.1)

s,Ecl

I MA..,E A.CES"EC.,.CAT.O S Unit

WIDTH Wl W2 W3 W5

mm(in) mm(in) mm(in) mm(in)

W6 ANGLE A1

mm (in)

50hp

m

182(7.2) ----

P60TH/ 60FEMTO

60, 70 hp

80, 90 hp

-159 (6.3) 182 (7.2) 321(12.6)

182{7.2)

187(7.4)

I 550 (21.7) I p

q

-331(13.0) --

35

30

A2

S: L,UL:

63

{ q

--

{ 67

63

A3

S: L, UL:

0

I

--

I 4

0

CLAM P C3 T1

_

mm(in) mm (in)

l

-I

--

68.5 (2.7) --

2-12

II 600 (23.6)

SPECJ

J MAINTENANCE SPECIFICATIONS B5

B5

--i

D1

B8

B1

Unit mm (in)

B2 B3 B4 B5

mm mm mm mm

B6 B7 B8 B9 D1 D2 D4

S: L,UL:

_

P60TH/ 60, 70 hp 60FEMTO 125.4 (4.9)

50hp

(in) (in) (in) (in)

mm (in) mm mm mm mm mm mm

B

80, 90 hp

254 (10.0) 163.5 (6.4) 50.8 (2.0) 180 (7.1) 329 (13.0)

(in) (in) (in) (in) (in) (in)

2-13

I

--

I 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)

I

JSPECJg"J JTtGHTEN,NG TORQUE C33000-0

TIGHTENING TORQUE Part Parts to be tightened name ENGINE: Crank case 1st Bolt 2nd 1st 2nd B°lt 1st Bolt 2nd Connecting rod 1st 2nd B°lt Cylinder head

Intakemanifold

size M6

Q'ty

50'60'180'0070hp hp Nm Im.kgft,i --

12

M8

6

M10

8

M8

Tightening torque

-8

--

6

1st Bolt

Exhaust cover

Thread

2nd 1st Bolt 2nd 1st Bolt 2nd 1st

M8

14

M6

16

M8

--

14

18

b

Remarks

4 0.4 12 1.2 10 1.0 20 2.0 20 2.0 40 4.0 12 1.2 35 3.5

2.9 8.7 7.2 14 14 29 8.7 25

15 32 30 3 8 9 18 4

1.5 3.2 3.0 0.3 0.8 0.9 1.8 0.4

11 23 50,60,70 hp 22 90hp 2.2 5.8 6.5 13 2.9

8 12

0.8 1.2

5.8 50,60,70hp 8.7 90hp

Bolt

M6

8

12

Bolt Nut Bolt

M14 M20 M8

3 1 8

3 1 11

Starter motor mounting Bolt Straight screw plug Screw UPPERCASE AND GEAR CASE:

M8 M12

2 I

2 1

20 23

2.0 2.3

1.7

Upper mount rubber Bracket bolt

Nut Nut

M10 M22

2 1

2 1

24 13

2.4 1.3

9.4

Uppercasemounting Exhaust guide

Bolt Bolt

M8 M8

11 4

11 4

21 21

2.1 2.1

15 15

Exhaust manifold Muffler

Bolt Bolt

M8 M8

4 4

4 4

21 21

2.1 2.1

15 15

Ringnut

Nut

--

1

1

75 7.5 145 14.5

Pinionnut

Nut

M16

I

1

Lower case mounting Propeller Tiller handle mounting Throttle cable

Bolt Nut Nut Nut

M10 M16 M10 M10

5 1 1 1

5 1 ---

130 95 40 35 38 38

13 9.5 4.0 3.5 3.8 3.8

94 50bp 69 29 25 27 P60TH 27 P60TH

Handlebracket mounting

Nut

M10

2

--

38

3.8

27 P60TH

2nd Sparkplug Flywheel Powerunit mounting

2-14

25 2.5 18 160 16.0 115 21 2.1 15 14

17

_

242

:-._ 242

-_

572

-_

572

54 50hp 105

iSPECi

I

GENERAL TORQUE SPECIFICATIONS TIGHTENING TORQUE/ Part

Thread

Partstobetightened POWER TRIM AND TILT:

name

size

Tilt cylinder

Screw

--

I

1

Screw

--

2

2

Fluid-level plug

Bolt

--

1

Lock nut

Nut

--

Valve spring mounting

Screw

Valve lock screw

end screw

Trim cylinder end screw

Gear pump mounting Manualvalve Main valve

Nut (A)

Bolt (B)

8 mm 10mm 12 mm l4 mm 17 mm

M5 M6 M8 M10 M12

Q'ty

Tightening

torque

50'60'180'9070hp hp Nm Im.kglft.lb

Remarks

80 90 70 160

8.0 9.0 7.0 16.0

I

3 7 10

0.3 0.7 1.0

2.2 6H307 5.1 6H1-13,62F-00 7.2 6H307

6

6

15

1.5

11 6H1-13,62F-00

--

2

2

4

0.4

2.9 6H1-13, 62F-00

Screw

--

1

1

13 4

1.3 0.4

9.4 6H307 2.9 6H1-13,62F-00

Bolt

M6

3

3

Screw

--

I

1

Screw

--

2

2

5 4 3 10 11

0.5 0.4 0.3 1.0 1.1

3.6 6H307 2.9 2.2 7.2 6H307 8.0 6H1-13,62F-00

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

GENERAL

58 6H307 65 6H1-13,62F-00 50 6H307 115 6H1-13,62F-00

TORQUE

SPECIFICATIONS This chart specifies the torques for tightenlng standard fastners with standard clean dry ISO threads at room temperature.

Torque specifications for special compenents or assemblies are given in applicable sections of this manual. To avoid causing warpage, tighten multifastener assemblies in crisscross fashion, in progressive stages until the specified torque is reached.

2-15

I INSP CHAPTER 3 PERIODIC INSPECTION AND ADJUSTMENT PREDELIVERYSERVICE................................................................................3-1 CONTENTS .............................................................................................3-1 PACKING LIST ........................................................................................3-1 ELECTRICALWIRING .............................................................................3-2 FUEL LINE ...............................................................................................3~6 GEAR OIL LEVEL.....................................................................................3-7 OPERATION OF CONTROLS AND MOVING PARTS............................3-7 AIR-BLEEDING OF THE OIL INJECTION PUMP (80, 90 hp) .................3-8 FUEL LEAKAGE ......................................................................................3-8 WATER LEAKAGE ..................................................................................3-8 EXHAUST LEAKAGE..............................................................................3-8 ENGINE AND LOWER UNIT NOISE ......................................................3-8 IDLE-SPEED.............................................................................................3-9 IGNITION TIMING ...................................................................................3-9 MOTOR EXTERIOR.................................................................................3-9 INSTRUCTING THE NEW OWNER ........................................................3-9 PERIODICSERVICE.....................................................................................3-10 MAINTENANCE SCHEDULE ................................................................3-10 ANODE ..................................................................................................3-10 BATTERY...............................................................................................3-11 CARBURETOR.......................................................................................3-13 CARBURETORLINK ADJUSTMENT ...................................................3-13 CYLINDER HEAD BOLTS, ENGINE MOUNTING BOLTS, AND FLYWHEEL NUT .........................................................................3-14 FUEL FILTER.........................................................................................3-14 FUEL TANK AND FUEL LINE ...............................................................3-14 GEAR OIL ..............................................................................................3-15 IDLE-SPEED...........................................................................................3-15 IGNITION TIMING ADJUSTMENT ......................................................3-16 TIMING PLATE POSITION ADJUSTMENT ....................................3-16 THROTTLE SENSOR CONTROL LINK ADJUSTMENT ..................3-17 IGNITION TIMING ADJUSTMENT .................................................3-18 PICK-UPTIMING ADJUSTMENT ....................................................3-19 OIL INJECTION PUMP ..........................................................................3-20 OPERATIONAL TEST.......................................................................3-20 CHECKINGTHE OIL LEVELWARNING SYSTEM ...............................3-21 OIL PUMP LINK ADJUSTMENT ..........................................................3-22 POWER TRIM AND TILT FLUID (P.T.T. model) ...................................3-22 PROPELLER...........................................................................................3-23 SPARK PLUG ........................................................................................3-23

r_

I INSP D20000-0*

.., ..

PREDEMVERY SERVICE CONTENTS Model Item

_

50, 60,70hp

80,90 hp

Referpage

1.Packing list

O

O

3-1

2. Electric wiring

©

©

3-2

3. Fuel line (gasoline and oil)

©

©

3-6

4. Gear oil level

O

O

3-7

5.Operation of controls and moving parts

O

O

3-7

6. Air bleeding of the oil injection pump

--

O

3-8

7. Fuel leakage

O

O

3-8

8. Water leakage

O

O

3-8

9.Exhaust leakage

O

O

3-8

10.Engineandlowerunit noise

O

O

3-8

11. Idle-speed

0

0

3-9

12. Ignition timing

0

0

3-9

13.Motor exterior

0

0

3-9

14.Instructingthenewowner

0

0

3-9

D21000-0'

PACKINGLIST On unpacking, check that all accessories to the model are included. _-_ Packing

Model 50,60, 70 hp

80, 90 hp

O

O

Fuel tank

0 *_

0 *_

Remote control box

0 *7

O *_

Service tools

O*_

O*_

Outboard motor

Emergency starter rope

O

O

Meter

O

O

Motor mounting parts Remote control cables

O --

©

Spare spark plugs

O *_

O *_

Owner's manual

O

O

*_: Except for U.S.A.

3-1

I INSP D22000-0

ELECTRICAL WIRING Check that all leads and connectors are properly connected.

i

50, 60, 70 hp

"_-

O Clamp (_) Power trim and tilt motor lead* (_)Trimsensor lead* ® Power trim and tilt switch coupler* O Power trim and tilt switch* [] To wire harness [] To power trim and tilt motor* [] To trim sensor* [] To lighting coil * For P.T.T. model

_)-_ _

_

....

?

'_

_;' '_ \ ,, / O ; _ '1

_,

.r_

_

B · Black j'

L : Blue Lg: Light green R : Red Sb: Sky blue

0

'f

b-------

P60TH/60FEMTO O Main switch O Engine stop switch (_) Neutral switch (_) Starter relay

_ \ /

v

Y

[] [] [] [] [] []

To To To To To To

trim sensor oil level sensor starter motor battery wire harness earth bracket

,.w

B : Br : G : G/R : G/W:

Black Brown Green Green/Red Green/White

Lg O P P/B R 3-2

: Light green : Orange : Pink : Pink/Black : Red

Sb W Y

: Sky blue :White : Yellow

I INSP A--_ I _

I PREDELIVERY SERVICE

O Pulser coil coupler (_) Trim sensor coupler (:_ Oil level sensor coupler (_ Wire harness coupler (_) Ground lead from rectifier regulator (_) Ground lead from starter relay (:_ Ground lead from wire harness ® Power trim and tilt relay coupler* Charge coil coupler _) Crank position sensor coupler [] ToC.D.I. unit [] To power trim and tilt motor* [] To trim sensor [] To oil level sensor [] To meter [] To electrothermal valve [] To power trim and tilt switch* * For P.T.T. model

B Br G Gy L Lg O P R Sb W Y

i

: Black : Brown : Green : Gray : Blue : Light green : Orange : Pink : Red : Sky blue :White : Yellow

JL

"

-

B

[]

®

3-3

O_

I INSP 80,90hp 0 Power trim and tilt switch coupler* [] To electrothermal valve [] To battery [] To starter relay [] To lighting coil [] To wire harness [] To meter [] To trim sensor [] To power trim and tilt motor* * For P.T.T. model

B : Black Lg : Light green R : Red Sb : Sky blue

.

B

) I

-,_[_ R

R

3-4

-

I INSP A Dj I

I PREDEL,VERY SERV,CE

O Crank position sensor coupler O Clamp (_) Clamp (_) Wire harness coupler O Trim sensor coupler (_) Oil level sensor coupler 0 Clamp 0 Ground lead from power trim and tilt relay* (_) Ground lead from wire harness (_) Ground lead from rectifier regulator @ Charge coil coupler (_) Power trim and tilt relay coupler Q Pulser coil coupler (_ Ground lead from starter relay _) Ground lead from C.DI unit [] To electrothermal valve [] To trim sensor [] To power trim and tilt motor* [] To oil level sensor [] To meter [] To starter motor [] To power trim and tilt switch* * For P.T.T. model

B Br G Gy L Lg 0 P R Sb W Y

: Black : Brown : Green : Gray : Blue : Light green : Orange : Pink : Red : Sky blue : White : Yellow

B

O

t

[]

ÂŽ

L

e

s

3-5

B,

IINSP ADJI

O_JPREDELIVERYSERVlCE

D22500-0

FUEL

LINE

Check that the fuel line is correctly

installed.

50, 60, 70 hp

/' O Oil tank (_) Oil injection pump Carburetor (_) Fuel filter Fuel pump

J (_) Oil tank (_) Oil injection pump Carburetor (_) Fuel filter (_) Fuel pump 3-6

INSP D23000-0

/

.

.

GEAR OIL LEVEL Remove the oil-drain plug O and oil-level plug Q and add the specified gear oil through the oil-drain hole until it overflows from the oil-level hole. Re-fit the plugs. (The oil level plug first.)

NOTE: Be sure the motor is positioned straight up when checking the oil level.

D23600-0

OPERATION OF CONTROLS AND MOVING PARTS 1. Check for correct operation of the shift control.

2. Check for correct operation of the tiltlock mechanism.

3. Check for smooth steering control.

operation

of the

4. Check for smooth throttle control.

operation

of the

5. Check for correct operation of the spark advancer.

6. Check for correct operation of the power trim and tilt unit. (P.T.T. model) 7. Check for correct operation of the choke system.

8. Noting the following WARNING and CAUTION, check for correct operation of the starting system.

Before attempting to check the starter systern, replace the propeller with the specifled test propeller, and make the tests with the motor placed in a test tank.

YB-1620/90890-01620

3-7

I INSP _-_ J_

J PREDELIVERY SERVICE

Use a 50: 1 gasoline-oil engine.

mixture

9. Check for correct engine stop system.

'

to start the

operation

of

the

D24Q00-1

INJECTION PUMP (80, 90 hp) 1. Pour the specified

oil into the oil tank screw attached to the oil injection pump.

__ L

AIR-BLEEDINGOF OIL and loosen the THE air-bleeding %,_] _'_

2. After confirming that oil starts overflowing through the screw-hole, tighten the screw completely.

·

3. Noting

the

following

CAUTION,

start

speed. /'--

the engine and keep it running at idleUse a 50: 1 gasoline-oil mixture to start the engine.

4. Check that oil flows through pipes.

the oil feed

D24500-0

FUEL LEAKAGE Check for fuel leakage.

D25000-0

WATER LEAKAGE Check for water leakage.

D25500-0

EXHAUST LEAKAGE Check for exhaust leakage.

D26000-0

ENGINEAND LOWER UNIT NOISE Check the engine mainoise.

3-8

and lower

unit for abnor-

JlNSP D26500-0

IDLE-SPEED Check that the engine speed at fully-closed throttle is correct.

D27000-0

IGNITION TIMING Check that the ignition timing at fullyclosed and fully-open throttle positions are correct.

D27500-0

MOTOR EXTERIOR Check the motor exterior for any flaking of the paint and if necessary, touch-up with paint of the original color.

D28000-1

INSTRUCTING THE NEW OWNER Instruct the new owner on the operation of all controls and the break-in procedure.

Also advise him on propeller-to-boat matching,

3-9

PERIODICSERVICE 030000-1 _

PERIODICSERVICE MAINTENANCE SCHEDULE The following procedures.

chart may be taken as a helpful guide to the intervals

'___ntervals Item

10 hours Intial 50 hours (Break-in) (3 months)

_

Anode Battery

Carburetor Carburetor

O 0 (everymonth) link

between

100 hoursEvery 200 hours (6 months) (1 year)

O

O O O

maintenance

Refer page

O

3-10 3-11

O O

3-13

Cylinder head bolts, engine mounting bolts, and flywheel nut

O

O

Fuel filter Fuel tank and fuel line

O

Gear oil Idle-speed

O

O O

3-15

Ignition timing

O

O

3-16

Oil injection pump Oil level warning system

O O

O O

3-20 3-21

Oil pump link Power trim and tilt fluid

O

O

Propeller Spark plug

O

3-14 O

O O

O O

O O

O

3-14 3-14

3-22 3-23

D31000-0

ANODE Inspect the anode. If it is worn out, replace it with a new one. If scaling of the surface is a wire brush and remove all trace of oil or grease. After cleaning, polish the contact surfaces of the anode mount and re-install. evident, remove the anode and clean it with Never paint the anode. To ensure good electrical contact, keep the anode contact surface clean of oil or grease.

3-10

INSP ,

I

I. PERIODIC SERVICE D31305-0'

ffl_dl-q _'__/_ _-._/_.

;t [_IWJell

Battery electrolyte contains sulphuric acid which is poisonous and corrosive, i.e., it Avoid all contact withandthedamage skin, eyes, or can cause skin burns to eyes. clothing.

First Aid: Eyes: Flush with water for fifteen minutes (if necessary, holding the eye open with clean fingers) and get prompt medical attention.

Internal: Do not make the casualty vomit.

Give plenty of water to dilute the acid. Add if possible, 2 tablespoons of chalk, milk of magnesia, plaster or whitewash to a pint of water.

Skin burns: Thoroughly flood the part with water.

Remove contaminated clothing.

Bathe the part in an alkaline solution such as two teaspoons of baking soda (bicarbonate of soda) or washing soda (carbonate of soda) to one pint of warm water.

Batteries produce explosive gases. Keep sparks and flames away.

Do not smoke where batteries are charged or stored. Ventilate the area when charging or using batteries in any enclosed space.

KEEP BATTERIES AND ELECTROYTE OUT OF THE REACH OF CHILDREN.

._.._--__)/

il"ec째mmen"e c...c,t Rating ........ 12V 70AH (252 kC) Minimum cold crank performance ......... 380 Amps at -17.8째C (0째F) Minimum reserve capacity .... 124 minutes at 26.7째C (80F')

1. The electrolyte level should be between the upper and lower level marks. Use only distilled water if refilling is necesI__

sary.

-

! _-IPP_-R

.

LEVEL

Normal tap water contains minerals which are harmful to the battery, therefore, refill only with distilled water.

(_

Low_,L_v_L _--_

3-11

0 Upper level (_ Lower level

INSP I

I PERIODICSERVICE 2. Before

first

use,

the

battery

must

....... :_

_

ensure maximum performance. receive its initial electrical charge.

Failure to must chargebe the battery The battery charged beforeproperly use to before first use or a Iow electrolyte level will cause premature failure of the battery.

/_

Charge at 7.0 amperes for 10 hours or until the specific gravity reaches 1.280 at 20°C (68°F) Charging:

_

3. Thoroughly clean the battery terminals, and tightly connect the leads to the terminals.

Lightly grease the terminals nectors with petroleum jelly.

· · ·

and con-

Don't forget to turn off the main switch when checking or replacing the battery.

When installing the battery connect the positive terminal (red lead) first.

When removing the battery disconnect the negative terminal (black lead) first.

NOTE: Replace the battery if: 1. The voltage does not rise to an opencircuit value of at least 2.2 volts per cell, or bubbles fail to rise even after many hours of charging.

2. The plates show a whitish color, or there is an accumulation of material in the bottom of the cell, indicating that sulphation of one or more cells has occurred.

3. Specific gravity readings after a long slow charge indicate one or more cells to be lower than the rest.

4. There is visible warping or buckling plates or insulators in any cell.

3-12

of

I INSP

s .v,c D31600-1

CARBURETOR sages for fouling or clogging. Clean fouled parts with suitable cleaning solvent and blow out clogged passages with compressed.

1. Checkthe fuel passages and air pas-

___

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 and middle carburetors by turning counterclockwise.

O Idle adjust screw O Throttle lever Q Throttle lever securingscrew

3-13

INSP (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.

O Idle adjust screw Q Throttle lever O Throttle lever securing screw

D32000-0

.... 4-

CYLINDER HEAD BOLTS, ENGINE MOUNTING BOLTS, AND FLYWHEEL NUT 1. Retighten to specifications.

'=-=='_-.

sary.

2. Check other fixings and tighten if necesD32300-0

_ [_ 0

O

Clean strainer of dust and impurities.

FUEL the FILTER

(_

O Strainer O Strainer body (_)O-ring ® Strainer cup

(_)

D32600-0

1. Check the fuel tank and fuel line for leaks.

i_

I

FUEL TANK AND FUEL LINE

._

2. Clean the fuel tank thoroughly.

3-14

INSP D32900-0 /

_-

/

u._

_

_

GEAR OIL in new oil.

2. Check for water or metallic sediment in

__ __'_--

----'_

1. Drain the gear oil thoroughly and pour

__

NOTE: thegear drained oil.

If the oil becomes "milky", check the gear case oil seals and shift boot for water entry.

D33000-0°

-_J_

IDLE-SPEED seated.

2. Turn the pilot screw outward to the specified setting.

1.Turn the pilot screw until it is lightly

_

I_

60 hp: 1-112_+1/4 turns out Pilot screw: 70, 90 hp: 1-1/4 _+1/4 turns out 50, 80 hp: 1-3/8 + 1/4 turns out

__

a few minutes.

3. for Start the motor, and allow it to warm up

50, 60, 70 hp_

4. Set the idle-speed to the specified level by setting the throttle stop-screw. Use a

80, 90 hpk /_l

,._

/

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.

er

YU-8036-A/90890-06760

800 + 50 rpm

3-15

I I

s .v,c

I INSP

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

_,___ --I-T--

'-

['

O\,, 1__1 //_

50,60,70hp ._

a dial-gauge

in the spark-plug

of timing-plate No. 1 cylinder. adjustment, it is For hole easy NOTE: 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.

_.

Cl

4. If the end of the timing 80,90 hp _

I

TDC1

/J ,,,}_{ '"-

plate

is not

1

aligned with the TDC mark on the CDI

]

set screw, align the timing plate end magneto rotor, loosen the timing plate screw.

5. Remove the dial gauge from the No. 1 cylinder install thethen spark plugs the for with theand TDCmark, tighten each cylinder.

!_

NOTE: After tightening the screw, paint over the screw-head to discourage tampering with the adjustment.

3-16

INSP ,

I

I PERIODICSERVICE

50, 60, 70 hp_ J[

ADJUSTMENT 1. Adjust the SENSOR lengths of the throttle sensor THROTTLE CONTROL LINK

vI _ O//___ -

to specifications.

)_

_

__/)_.__

I

80, 90 hp

50, 60, 70 hp __

2. Adjust the length of the full-retard adjusting screw so that when the full-

I y

length 速: Throttle control link60,and throttle link 50, 70 sensor hp: 129 cam _ control 0.5 control mm link (5.08 +_0.02 in) 80, 90 hp: 93.5 __0.5 mm {3.68 +_0.02 in) Throttle cam link length 速: 50, 60, 70 hp: 58 mm (2.28 in) 80, 90 hp: 120.5 mm {4.74 in)

速

retard adjusting screw contacts stopper, the full-retard indication on the the C.D.I. unit aligns with the timing indicator.

O Timing indicator (_) Full-retard indication (50, 60, 70 hp) (_) Full-retard indication (80, 90 hp) 速 Full-retard adjusting screw NOTE:

_ 2 mm (0.08in)

_

The the magneto controlthe lever be 2nut mmin (0.08 in) off from end should of the

l

magneto

50, 60, 70 hp

control lever.

adjusting screw so that when the fulladvance adjusting screw contacts the stopper, the full-advance indication on

_3(_ _)_

_

Adjust indicator the length of the full-advance O3.Timing (_) Full-advance indication (50, 60 bp) indicator. the C.D.I. unit aligns with the timing (_) Full-advance indication (70 hp) O Full-advance adjusting screw

_cc ,_ 3-17

I INSP 80, 90 hp

: 3_

50, 60, 70 hp

_

Q Full-advance indication (80 hp) O Full-advance indication (90 hp) O Full-advance adjusting screw

[

80, 90 hp ____

IGNITION TIMING ADJUSTMENT

.......... .............................. .....

_

· ' _.

..i..._:

ing light, be sure to replace the propeller with the specified test propeller, and make tests __'-_._ ::)),)i(

_--__._ 50, 60, 70 hp _--_-_-_

---'1"_

'_l

80, 90 hp

1

ignition

engine.Bef°re adjusting,

placed timing

in a test

using a tim-

be sure to warm

up the

80, 90 hp

1. Attach the timing light and tachometer to the No. 1 cylinder high tension code.

ITDC8

2.

While

keeping

the stopper

in contact

measure the full-retard ignition timing with the timing light.

If the timing is out of specification, with screw, adjust theit full-retard by turning adjusting the full-retard adjusting screw.

G_-_

50, 60, 70hp ! _'_ 80, 90hp _L'-"lr__ /'k_...

machine

NOTE:

_-_

' /b_

the

tank.

When checking

_f_,_'_-_4_)_ _

50, 60, 70 hp ITDC7

/ _;__,.

with

NOTE:

,I

When

measuring

the

full-retard

ignition

Full-retard800 +__ 50 rpmSide engine speed: __- '___ '_-_/-_'i

timing, 3-18

keep the specified engine speed.

50, 60, 70 hp: 7 _+1" ATDC Full-retard side ignition timing: 80, 90 hp: 8 _+1° ATDC

0]

INSP I

I PERIODICSERVICE

70, 80 hp I

_

3. While keeping the stopper in contact with the full-advance adiusting screw,

50, 60, 90 hp

_

[ I._..22I_,_ 1

_

measure the full-retard with the timing light. adjust it by turning adjusting screw.

.

I

the

timing

full-advance

NOTE: When measuring the full-advance ignition timing, keep the specified engine speed.

T

50, 60, 70 hpy

ignition

/ 80, 90 hp

50, 60 hp: 5,000 _+500 rpm ,_

'

70 hp: 5,500 _+500 rpm 80, 90 hp: 5,000 + 500 rpm _/

_'N_

_)_

-

[

_

_

Z _Z;

I Full'advance side engine speed: 50, 60, 90 hp: 22 +_1° BTDC Full-advance 70, 80 hp: 20side +_1°ignition BTDC timing:

Engine idle speed should be adjusted

__

prop-

erly before adjusting the pick-up timing.

1. Turn the magneto control lever to the full-retard position.

3 50, 60, 70 hp 4..,,,,

2. Bring the throttle cam to lightly contact the throttle lever roller. (The throttle valve should not open.)

Adjust the accelerator link length and

80, 90 hp 4_,

acceleratormagneto cam. connect

__

3-19

control

lever to the

I INSP ]

I PERIODICSERVICE D34000-0'

OIL INJECTIONPUMP '=

OPERATIONAL TEST 1. Start

i

i_-'j_iiii

_ ·

the

engine,

and

'_

throttle-stop lever. speed at 1,500 rpm -_:_ ·

set the

by adjusting

idling

the

· .

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.

(3 mini1 cylinder) Specified 50 hp: discharge: 1.90 _+0.20 cm 3 [62F00] (0.064 _ 0.007 US oz, 0.067 +_0.007 Imp oz) 60, 70 hp: 2.20 +_0.20 cm = [6H302] (0.074_+ 0.007 US oz, 0.077 _+0.007 Imp oz) 80, 90 hp: 3.10 _+0.30 cm 3 [6H102] (0.105_+ 0.010 US oz, 0.109 _ 0.011 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 Iow, 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 3-20

rate of discharge

per minute.

P,oo,c SE.V,C

I INSP

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.

Do not allow the engine to operate without oil even briefly for this will cause malfunction or engine seizure.

50, 60, 70 :_*i_::_;_ hp _!i?_-_i_,:*.:

.__ J/

-_ /

'

_

/

Case

Oil level

I

770 ¢m 3

Oil level

Warning

Speed drop

warninglamp GREEN buzzer OFF

function OFF

(0.81 US qt) 770 cm 3

2 _--_- --_

i

__

U

(0.81 US qt) ~ 280 cm 3

YELLO W

OFF

OFF

More than (0.3 US qt) 280 cm 3

i

or.ss,0sqt,

80, 90 hp /_. ,r___n ,oo _._'_ Case

Oil level

I

More than 1,130cms

_-_ _

Oil level warning lamp

Warning buzzer

Speed drop function

GREEN

OFF

OFF

W YELLO

OFF

OFF

RED

ON

ON

(1.19 US qt) \

1,130 cm 3

:::.'-. m

i

2 3

3-21

310 cm3 (1.19 (0.33 US USqt) qt) ~ or less 310cm (0.33 US a qt)

IINSP A--_ I _ [ 50,60,70hp

I PERIODIC SERVICE t_, / I/ [ 80,90hplli!

,,_

, '

D34300-1

OIL PUMP LINK ADJUSTMENT 1. Fully-open

_l

_

throttle

valve.

open side stopper. With the lever in this position, adjust the length of the rod connecting the oil-pump to the carburetor and tighten the Iocknut.

2. Set the oil-pump lever I mm off full-

!_

_____

the carburetor

4. By operating the carburetor, 3. Install the connecting-rod. throttle-valve opens fully.

._, __

check the

D34600-0

(P.T.T. model) 1. Tilt-up the motor and lock it with POWERTRIM tilt-lock lever.AND TILT FLUID

I

the

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 Iow, top up with the recommended fluid.

Yamaha '_'_. _-

power

trim and tilt fluid

_._._r_,_g_

_;__

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

q_(

3-22

plug and tighten

[6H307] Fluid-level plug: 3 Nm (0.3 m 路 kg, 2.2 ft 路 lb) [6H1-13, 62F-00] 7 Nm (0.7 m 路 kg, 5.1 ft 路 lb)

it.

s .v,c

INSP

D349O0-0

1. Check the blades for wear, damage or cavitation erosion.

. ... _ ff,

_ _:__,a_

2. Check thesplineforwearanddamage.

D35000-0'

SPARK PLUG :.,___]2 :.... .: ,.:..

1. Check the electrode O condition and state of wear, note the insulator Q 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

0.9 ~ 1.0 mm (0.035 ~ 0.039 in) Spark plug gap: tion.t° adjust the plug gap_to specifica i 3. If the electrode becomes too worn, replace the spark plug.

I_

.__._ __ _ ®

Standard spark plugs:

50 hp 60, 70, 80, 90 hp'

3-23

Except for CANADA and Europe

For CANADA and Europe

BR8HS-10

BR8HS-10

B8HS-10

BR8HS-10

IINSP ADJ I _1_ I

PERIODIC SERVICE 4. When installing the spark plug, clean the gasket surface, wipe off any grime that may be on the surface of the plug and screw in the spark plug to the cor-

,,/_

25 Nm (2.5 m · kg, 18 ft · lb) rest torque.

)_®

,.-_-.----_

NOTE: Screw spark plug in finger-tight ®, then torque spark plug to specification ®.

3-24

[

CHAPTER 4 FUEL SYSTEM FUEL SYSTEM ...............................................................................................4-1 EXPLODEDDIAG RAM ............................................................................4-1 REMOVAL ...............................................................................................4-2 CLEANING AND INSPECTION...............................................................4-2 FUELTANK ........................................................................................4-2 FUEL METER COMPLETE .................................................................4-3 PRIMING PUMP .................................................................................4-3 FUEL FILTER......................................................................................4-3 FUELJOINTS .....................................................................................4-4 FUEL PUMP........................................................................................4-4 INSTALLATION .......................................................................................4-4 CARBURETOR................................................................................................4-5 EXPLODEDDIAGRAM ............................................................................4-5 REMOVAL AND DISASSEMBLY ............................................................4-6 INSPECTION ...........................................................................................4-7 CARBURETORBODY ........................................................................4-7 NEEDLEVALVE..................................................................................4-7 PILOT SCREW....................................................................................4-7 COLLAR..............................................................................................4-7 FLOAT.................................................................................................4-7 ENRICHING FUEL PUMP ...................................................................4-8 ELECTROTHERMALVALVE ..............................................................4-8 ASSEMBLY .............................................................................................4-9 INSTALLATION .....................................................................................4-11 OIL-INJECTION SYSTEM ............................................................................4-12 EXPLODED DIAGRAM ..........................................................................4-12 REMOVAL .............................................................................................4-14 CLEANING AND INSPECTION.............................................................4-14 OIL-TANK .........................................................................................4-14 OIL-LEVEL SENSOR ........................................................................4-14 OIL-HOSES.......................................................................................4-14 INSTALLATION .....................................................................................4-14

IFUE'IIF.'SYST M E20000-1

FUEL SYSTEM EXPLODEDDIAGRAM O (_) O (_)

Carburetor Electrothermal valve Fuel pump assembly Fuel filter assembly Fuel joint (_) Priming pump O Fuel meter assembly

(_) Fuel tank cap (_) Fuel tank

____ _ ,_1,._?:._,

._

0_

Q

_o,_o,_

.W_

4-1

®

I uE,I,uE, sYsTEM REMOVAL

1.

2.

3.

4.

Fire prevention Gasoline (petrol) is highly flammable.

Petroleum vapour is explosive if ignited. Do not smoke while handling and keep it away from heat, sparks and open flames.

Ventilation Petroleum vapour is heavier than air and if inhaled in large quantities will not support life. Engine exhaust gases are harmful to breathe. When test-running an engine indoors, maintain good ventilation.

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 on to the bottom cowling.

Leaks Failure to check for and correct fuel leaks may result in fire or explosion.

1. Referring to the exploded remove the fuel line.

diagram,

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 pletely.

4-2

solvent com-

FUE'IFU.SVS, EM 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 the rubber gasket to the fuel ensuring that there are no between the fuel meter and the tank.

with tank, leaks fuel

O Fuel meter assembly O Suction pipe O Fuel strainer

_4

_u

PRIMING PUMP 1. Visually inspect for cracks or breaks in the priming-pump and fuel-hoses and E21030-0 replace them if required.

i_

2. Check the by blowing

operation of the check-valve into the pump.

O Priming valve (_) Arrow mark '_

O Check valve (outlet)

j

va,ve,,n,e I E21040-0

1. After removing the nut and filter-cap, FUEL FILTER disassemble the fuel filter.

2. Visually inspect the filter body for cracks or damage to the thread and

O (_

replace if required. i

4-3

rUELIFUELSYSTEM

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.

FUEL JOINTS 1. Inspect the fuel joints for leaks and E21050-0

/ ¡ /

cracks and replace as required.

E21060-0

FUEL PUMP 1. Using a screwdriver, fuel pump.

._.

disassemble the

cracks and replace if required.

2. Visually inspect the pump body for

_o__

tion and replace if required.

4. Inspect the diaphragm for sign of dam3. Inspect the valves for cracks or distorreplace if required.

"__--___

5. Assemble the fuel pump with new gaskets. _,________..__

age,

perforation

or

stretching

and

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.

4-4

CARBURETOR E31001-1

CARBURETOR EXPLODEDDIAGRAM O (_) (_) (_) (_) (_) (_)

Pilot screw Needle valve Pilot jet Main nozzle Main jet Float Drain screw

® _ (_) (_ _ _)

Float chamber Throttle stop screw Collar Electrothermal valve Valve Diaphragm

_5

4-5

IFUE'ICA..U.ETO. 50, 60, 70 hp

REMOVAL

AND DISASSEMBLY

r!I_AVI_'I ;t L_ II _Jell At this step, ensure there is no spillage _,*l

_ _.._

/_..

gasoline on removing

the connections.

1. tor.

Remove the silencer

(_"_° )__._

of

cover, disconnect

the fuel hose, then remove the carbure-

2. Referring to the diagram, use a screwdriver to disassemble the carburetor.

80, 90 hp

3. Using solvent, clean the components thoroughly and blow-dry them with

_'_ _/1F_X,?_,. ._

_

?..--_ _ ?] c,' _,,_--_,_ _) /J'_'j/_(_._ _ _'_-_' _ '

W!lvAV!:l;t_lll_[ ell Protect your eyes with suitable safety compressed air. pressed air. Protect your eyes and the eyes glasses or safety goggles when using com-

'__

i___,_/_-_

pressed-air downward, noting that solvent and small parts may be blown off. _

of others _._ -__*_:i"*:

by directing

the

flow

of com-

':_"

Do not use steel wire for cleaning the jets as this may enlarge the jet diameters and seriously affect performance.

4-6

I u,l IcA..u.ETo. E32000-1'

INSPECTION CARBURETOR BODY 1. Inspect the carburetor body for cracks or clogging of the passages.

NEEDLE VALVE

i_ _

ment and wear and replace if required. i_x_

1. Inspect the needle valve for free move-

i

PILOT SCREW 1. Inspect the pilot screw for wear and

^ /l

replace if required.

J i

COLLAR ::;_.-_.__0_

1. Inspect the collar at the end of the required.

O___-

_

accelerator-arm for wear and replace if

FLOAT 1. Visually inspect the float for damage or

® _,

[

_,_,_=_, ...... _::_:_:: ] _] _:'_'_ _:.:.:._.__ .:.:.,._:_ ,._

2. Measure the float height. If it is more than 2 mm (0.08 in) greater or less than the specified float height, recheck the vaIve seat and need le-va lye. cracks and replace if required.

4-7

IFUE'I ICA..,.E,O. 50 hp: Float height 15.0 + 1.0 ®: mm (0.591_+0.039 in) 60,70,80,90bp: 14.0 _+1.0 mm (0.551 _+0.039 in)

_

E21060-0

ENRICHING FUEL PUMP 1. Using a screwdriver,

disassemble the

2. Visually inspect the pump body for cracks and replace if required.

3. Inspect the valves for cracks or distortion and replace if required. fuel pump.

'_

age, perforation or replace if required. __

%_c¢'_'__'"'_.._

stretching

and

4. Inspect the diaphragm for sign of dam-

ELECTROTHERMAL VALVE

Inspect the body for cracks and the wire lead for defects.

O 1.Needlevalve Inspect the needle valve for bend and (_) Piston valve O Body wear, and the piston valve for flow. (_) Wire lead

'_T_

i

i

2. Measure the resistance of the electro-

=_

Blue -- Black Electrothermal valve resistance: 2.3 ~ 3.5 D at 20°C (68°F)

i

__L

_

_

thermal valve.

4-8

IFUE'ICA..U.ETO. NOTE: When measuring the resistance of 10 .Q or less using the digital tester, the correct measurement cannot be obtained. Refer to "Lower resistance measurement" (page 89).

-

3. Check the piston valve height.

If the piston valve height is not difference ÂŽ to (_, replace the electrothermal I

([

,_1_'_

-

valve. a) Measure the piston valve height ÂŽ.

_) ;._. aO____ _

c) Measure the pistonvalveheightÂŽ after several minutes. d) Compare the valve height _ with (_. b) Connect the wire leads to a l2V bat-tory.

___

ASSEMBLY the body and secure with the screws.

A__

1. Install a new O-ring and the valves on

'

_ _

2. Install the diaphragm on the carburetor with new gaskets, install the pump cover on the carburetor and secure with the screws.

,_ t_

3. Install a new O-ring to the electrotherwith the plate and secure with the screws. mai valve, install it to the carburetor

_,__

4. Insert the main nozzle fully and screw in 5. Screw in the pilot jet fully and install the cap.

the main jet until tight.

4-9

IruE, I cA..u. To. 6. Install the needle-valve on the float, -_° _(_,

with the float-pin and tighten the screw.

_

attach the float to the carburetor body

_

7. Install a new O-ring to the float-chamsecure with the screws.

___

'

_

bet, install it to the carburetor body and

'

-

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

Do not cause damage to the tip of the pilot _(__

the specified number of turns. screw by over-tightening it. _

4-10

60 hp: 1-1/2 _+1/4 Pilot screw (turns out): 50, 80 hp: 1-3/8 _+1/4 70, 90 hp: 1-1/4 +_1/4

_

FUE'I I CA..U.ETO.

E34004-1

50, 60, 70 hp

INSTALLATION q. lnstall the carburetors new gaskets.

O Idle adjust screw (_) Throttle lever O Throttle lever securing

and plate with

screw

2. Connect the fuel hoses to the carburetors and fit the hose-clips over the recesses to ensure leak-proof connec-

..... .

80,90hp

tions.

3. Connect the electrothermal

valve leads.

4. Connect the oil-pump link-rod to the carburetor and oil-injection pump.

5. Install the silencer cover and tighten the bolt to the specified torque.

cove I,

2 Nm (0.2 m ¡ kg, 1.4 ft ¡ lb)

4-11

IFUELI ._ I OIL-INJECTION SYSTEM OIL-INJECTION SYSTEM EXPLODED DIAGRAM O Oil level sensor (_) Oil strainer O Strainer cover gasket O Oil injection pump assembly _) Check valve (_) Oil tank 0 Special washer

(_) Oil tank cap assembly (_) Hook (_ Filler tube

50, 60, 70 hp

n r_,-_, __:>_

4-12

IruE.IIo,.-,.JEcT,o, svsT.0 Check valve (_) Oil injection pump assembly 0 Drain screw (_) Oil tank (_) Strainer cover gasket (_) Oil strainer 0 Oil level sensor

ÂŽ Special washer (_) Oil tank cap assembly (_) Hook 0 Filler tube

80, 90 hp

4-13

IFUE'I I REMOVAL 1. Drain the oil from the oil-tank and remove the carburetor.

2. Disconnect the hoses and remove oil-injection system.

the

E42001-0'

CLEANING AND INSPECTION OIL-TANK 1. Using solvent, clean the oil-tank. '_

2. Drainthe solventand dry the tank.

_j

3. Inspect the oil-tank

for

cracks, and

OIL-LEVEL SENSOR _,

it ifpages required. ¡replace Refer to 8-24 ~ 8-25.

OIL-HOSES

f

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.

O Driven gear (_) Washer O O-ring (_) Distancecollar z/

ÂŽ (_

__

3. Install the oil-pump to the power-head.

( _-_ _

4. Assembletheoil-tankandinstallit.

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 (refer to pages 3-2 ~ 3-6).

\

7. Bleed the air from the lines (refer to -_

page 3-8). ,_'_'__ _,_,l[;_jll_tlt_._._EN_ffi_'__. .'"__. _,..-._ __

After reinstalling the oil injection pump, be sure to bleed the pump. For details, refer to page 3-8.

4-14

I.ow.I

CHAPTER 5 POWERUNIT

EXPLODEDDIAGRAM ...................................................................................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 REEDVALVE .........................................................................................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

I

_

I.ow.I ASSEMBLY

AND

ADJUSTMENT

...............................................................

5-1

4

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 (80, 90 bp) ...... 5-16 OIL SEAL HOUSING .............................................................................

5-17 CRANK CYLINDER ASSEMBLY (50, 60, 70 bp) ..................................

5-17 CRANK CYLINDER ASSEMBLY (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

EXPLODED DIAGRAM G20000-0

EXPLODED DIAGRAM O (_ (_ (_ O ® O

Cylinder head cover Head cover gasket Cylinder head Cylinder head gasket Thermostat Thermostat cover Exhaust cover gasket

(_) Exhaust inner cover (_) Exhaust outer cover (_ Piston pin clip O Piston pin _ Drive gear Q Bearing (_) Oil seal

..

_) _) (_ _ _) _

O-ring Oil seal housing Intake manifold Valve seat packing Reed valve plate Reed valve assembly

160 Nm (16 m · kg, 115ft · lb)

I

I

12nd 32 Nm (3.2 m · kg, 23ft · Ib)j Ilst15 Nm(1.5m° kg, 11ft · lb)

I_,_i__J____

3 Nm (2.3 m · kg, 17 ft · lb) [

O

IM10

_

®

1st 20 Nm (2.0 m ° kg, 14 ft · lb) 2nd 40 Nm (4.0 m · kg, 29 ft ° lb)

l

_ _il

2nd_01st 4 Nm (0.4 m. kg, 2.9 ft. lb) I

'_'_'

! .8 m · kg, 5.8ft · lb) I

_5_ !

I 1st 10 Nm (1.0 m ° kg, 7.2 ft °

jl_

Ilst3Nm(0.3m'kg, 2.2*t'lbl

o

C'_I

t'_l

12nd 20 Nm (2.0 m · kg, 14ft · lb)

5-1

_

12nd 8 Nm (0'8 m ' kg' 5'8 ft' lb)

i,ow,i O Q O (_ O (_ O ®

Ex,,oDE°D.A ,AM

Thermostat cover Thermostat Thermo sensor Cylinder head cover Head cover gasket Cylinderhead Cylinder head gasket Exhaust cover gasket

_ _) ® _) Q Q (_ _)

Exhaust inner cover Exhaust outer cover Piston pin clip Piston pin Bearing Drivegear Circlip Oil seal

80, 90 hp 1160 Nm (16 m ' kg, 115 t_ ft' lb) _-__

(_ _) (_ (_ (_ _

O-ring Oil seal housing Intakemanifold Valve seat packing Reed valve plate Reedvalve assembly

11st 2nd 15 30Nm Nm (1.5 (3.0mm..kg, kg, 11ft..lb) 22ft lb),I

® _,_'_

_

(_)

1st 20 Nm (2.0 m · kg, 14 ft. lb) 2nd 40 Nm (4.0 m · kg, 29 ft · lb)

(2.5 m ° kg, 18 ft · lb)

1st 4 Nm (0.4 m · kg, 2.9 ft · lb) 2nd 12 Nm (1.2 m · kg, 8.7 ft · lb)

® 23 Nm (2.3 m · kg, 17ft.

· 1st 4 Nm (0.4 m. kg, 2.9 ft° lb) //,l_ _----_J D6

2nd 35 Nm (3.5 m

Jlst9 Nm (0.9 m.kg, _

I,,_%

kg, 25ft

6.5 fl °lb)

.tA j_12ndl8Nm(1.am

Ibl

5-2

kg, 13ft

ID)

i.ow.i..E.A.AT,O..O. OVE..AU.,.EM 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.

NOTF' 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 referring to pages 8-1 ~ 8-2.

parts

O Grand lead from the cylinder head cover Battery cable Power trim and tilt motor leads (P.T.T. model) Power trim and tilt relay (P.T.T. model) Oil level sensor lead 2. Remove the fuel system parts and hose referring to page 4-1.

Fuel hose on the strainer I

O Cooling water pilot hose

5-3

POW[_--_

REMOVAL mechanism.

I

)

O Throttle cablejoint by removing the hair pin (_ Shift rod bracketbolt 3. Remove the throttle cable and the shift the hair pin

_

'__

Q Shift cable joint and bushing by removing 4. Remove the front and rear aprons.

50, 60, __ 70 hp/, f

80, 90hpp_ _

-

5. bolts, Remove installation and the thenpower removehead the power head from the upper casing.

j

_L_:

t

_0, _0_

. .. .. .. .. .. .. .

The power head may be difficult to separate from the bottom cowling because of a NOTE: stuck gasket holding them together. If this is the case, lever it off the bottom cowling with a piece wood. Use care not to damage the bottom cowling or power head with the wood.

'l

o

,__o,t

6. Remove the dowel pins from the bottom cowling or power head. To protect the dowel pins against damage, cover them with rags.

o _

5-4

.ow.II°,sAss. M.LY

G50003-0

.

Referring to the exploded diagram, remove 1. Cylinder head

DISASSEMBLY ¢

the following parts.

2. Intake manifold

3. Exhaust cover and thermostat cover /_

_3%_

O

,__._. ___

4. Oil seal housing

{_)

oil seal one by one from housing.

_

Using the oil seal remover, remove the 5. Crankcase

o,,_

/o__

Remove the two dowel pins. and crankshaft. (80, 90 hp) 7. Crankshaft and connecting rod.

6. Connecting rod caps, needle bearings

j_ =,/o ,_

£_/____q_)o,.__

(50, 60, 70 hp) 8. Piston and piston pin 9. Piston rings Note the following points: 1. When disassembling the piston and pising rod to catch the needle bearings.

2. Only carry outa exchange crankton pin, place tray under ofthethe connectshaft bearing if the bearing is malfunctioning.

__ o 5-5

I,ow,I..s,EcT.o.

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.

/___

-

_

Do not scratch the surfaces of the cylinder

3. Using a soft brush, clean the water and jacket. combustion chamber.

_

INSPECTION feeler-gauge, measure the surface contacting the cylinder block for warping. i_ ,_ _

1. Using a precision straight-edge 0.1 mm (0.004 in) [] Lines indicate straight-line [¢_ Warpagelimit:

_

and

measurement

i

specification, re-surface the cylinderhead as follows: If the degree of warping exceeds this i i iiiiiiii!iiii?::::'_ __.._

_

.... _-_'_;_.:!iZ::i:: !;::II:_II:

5-6

thePlace Oninder_headSurface_plate,using 400-600 gritaandfigure-eightresurface wet-or-d ry paper sandingthe cylpattern.

_

INSPECTION 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 If cracks are found, replace the cylinder cracks block. and scratches.

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, _.'

-''_'"'---''"1-____,_'I '_-._ -._-_ '

cylinder bore at three positions in the thrust and axial directions.

'_'"",:: ................ 'ÂĽ _' [/"'_._ _-_J_

O Axial direction (_ Thrust direction

A: 10 mm (0.4in) below the cylinder top

-

-

measure the

C: 5 mm (0.2in) below the scavenging port m__k_A _-Ct _

t

I

[]

_

t t

B: 5 mm (0.2in) abovethe exhaust port NOTE: Do not place the cylinder-gauge on the port hole.

B

lY

Cylinder boresize: 50, 60, 70 hp: 72.00 (2.834~~72.02 2.835mm in) 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

I,ow,II 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.

The top ring is a keystone-type ring, fore, do not use a broken top ring for ing the other ring grooves, nor broken ring from a lower groove for ing the top groove.

therecleanuse a clean-

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.

-

i

2. Using the measured cylinder bore diameter in thrust directions, subtract the piston diameter measurement from the cylinder bore diameter measurement.

50, 60, 70 hp: 0.050 ~ 0.055 mm Piston clearance:(0.0020 ~ 0.0022 in) 80, 90 hp:

5-8

0.060 ~ 0.065 mm (0.0024~ 0.0026 in)

-

-

I,ow,I ..s,Ec..o.

If this clearance is not within the specifications, replace the piston to standard or oversize and/or rebore the cylinder.

50, 60, 70 hp: Oversize piston: *1st 72.25 mm 2nd 72.50 mm 80, 90 hp: *1st 82.25 mm 2nd 82.50 mm

_

(2.844 in) (2.854 in) (3.238 in) (3.248 in)

i

* Except for U.S.A. PISTON RING INSPECTION 1. Using a feeler gauge, measure the clearance between the piston ring and the groove land.

G62501'0°

__

BI

Side 50, clearance: 60, 70 hp: 0.03 ~ 0.07 mm (0.0012 ~ 0.0028 in) 80, 90hp: Top/2nd ring:

50, 60 70hp/ W

/

/

/80, 90hp

x_

Top/2nd ring:

_,'_X_'_

I

(0.0012~0.0024 in) the specifiIf the clearance notmm within 0.03 ~ is 0.06 cations, replace the piston.

__

[] Top/2nd: Keystonetype [] Piston markedwith "W" (50,60,70 hp) __.

_

j

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.

Take care not to scratch the piston. Using a thickness gauge, measure the end-gap.

¢_

5-9

50, 60, 70 hp: Ring end gapmm (installed): 0.3 ~ 0.5 (0.012 ~ 0.020 in) 80, 90 hp: 0.4 ~ 0.6 mm (0.016 ~ 0.024 in)

I,ow,II..s,Ec..o.

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 cyl~ inder and use an over-size piston and piston-ring.

G63000_0

PISTON PIN AND SMALL END

_\i_ _'--_

CLEANING 1. Use a soft brush and solvent to clean the parts.

BEARING INSPECTION 1.Visually inspect for surface defects, breakage, scratches and pitting. If it is decided to replace the small end bear-

/_

_.-!__

ings, replace them all.

G63500-0'

CRANKSHAFT

aligneror on V-blocks.

2.

Using the a dial gauge, measure the conINSPECTION 1. Place crankshaft on a crankshaftnecting-rod 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) 50, 60, 70 hp

_

Connecting-rod side clearance: 50, 60, 70 hp: 0.2 ~ 0.7 mm (0.008 ~ 0.028 in) 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

,.s.

EcT,o.

4. Using

dial gauges,

ii__L_

_

tio_. Maximum

deflection:

If the deflection is greater than the specified maximum, correct the alignment by use of a copper hammer and a

80, 90 hp

,___,

50, 60 hp

the deflec-

50, 60, 70 hp: 0.03 mm (0.0012 in) 80, 90 hp: 0.05 mm (0.0020 in)

¡ 50,

measure

wedge.

(_

REED G64000-0' VALVE INSPECTION

(_

1. Visually inspect for warping of the reed valve. If warped, measure the distortion with feeler gauges.

0.2 mm (0.008 in) If the amount 70, 80, 90 hp (_)

(_

of warping

the specification, valve.

replace

2. Using a vernier caliper, valve stopper height.

_

is greater the

measure

than reed the

50, 60 hp: Valve 3.0 stopper _ 0.2 mmheight (0.118ÂŽ:_+0.008 in) 70, 80, 90 hp: 9.9 _ 0.2 mm (0.390 _ 0.008 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

Ieow.

I ,.SPECT,O. 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.

Below temperature 48°C(118'F) Water

0 mmlift Valve

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' f

ir,

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

P

INSPECTION G65500-0

._

_o

_

DRIVE GEAR

_

(OIL INJECTION PUMP DRIVE) 1. Visually inspect drive gear teeth for cracks, pitting or wear and replace the gear if any are found.

INSPECTION DRIVEN GEAR (OIL INJECTION

PUMP DRIVE)

1.Visually inspect driven gear teeth for cracks, pitting or wear and replace the gear if any are found.

INSPECTION

5-13

Pow. I IAssEM..Y A.D ADJUSTME.T G71000-1

50, 60, 70 hp

ASSEMBLY

AND

ADJUSTMENT

BEARING, OIL SEAL AND O-RING 1. Press in the new bearing.

J

i_,_;,i_'"_ '-"_'"-_'"' ':"'__i ¡ 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

80, 90 hp

towards the illustration.

crank

side as shown

in the

Install the circlip O Circlip Q Oil injection pump drive gear O 80,Crank 90 hp:lower bearing

[_ jr ,.

2. Install

the new oil seal in the needle

The direction bearing.

__

of the

oil seal must

be as

age will be caused. __

shown

in the illustration,

otherwise

dam-

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

1. Install the top and 2nd piston rings into their respective ring grooves with the

c_ ,___

_J:'_

PISTON AND PISTON RING 2. Align each ring end-gap locating pins.

5-14

with

their

IPOWRI _[

ASSEMBLY AND ADJUSTMENT G73000-0'

SMALL END BEARINGSAND PISTON ASSEMBLY 1. Count the small-end

bearing needles.

per I Number of needles

small end: 28-pcs. I

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 sides.

_1 _

installer: C°nnecting r°d small end bearing 50, 60, 70 hp: YB-6287/90890-06527 80, 90 hp: YB-6107/90890-06527

The washer convex sides

YAMAHA

on both

should be placed facing the piston.

with

their

A

3. Insert the piston-pin

I I

4. Align the "UP" mark on the piston crown towards the crankshaft's tapered

_

_

UP

into the piston.

rod small end, insert the piston-pin, then install new piston-pin clips.

5. end.

Lubricate bearing 2-stroke Install each the piston in thewith connectingoutboard-motor oil.

..__

5-15

I.ow.IIAssEM.,Y ADJVSTME.T G78000-0'

BEARING ASSEMBLY (80, 90 hp) 1. Install the piston.

CONNECTING ROD BIG pins END Align the ring ends with locating in

_

push the piston into the cylinder. _'_

the grooves and using the piston slider, YU-33294/90890-06530

I

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.

-II1_ I-

_ _

---,l{_

"

2. Place the the crankshaft on the cylinder, and align upper, upper middle and pins on the cylinder, and fit the crankshaft correctly to the cylinder. lower middle bearing pin holes with the

._

3. Install the bearing in the big end and install the cap. o

o

_

following manner. a. Lightly screw in the bolts by hand while making sure the cap and rod Theends cap bolts should be tightened Then, in the are aligned completely. tighten the bolts to the 1st specified torque.

Next, tighten to the 2nd specified torque. Check to see that the cap and do the above procedure all over again. b. Loosen the bolts 1/2 turn and tighten rod ends If not aligned, them to are the aligned.

1st specified torque.

j __ __

Then, tighten to the 2nd specified torque.

5-16

POWRI _

] ASSEMBLY AND ADJUSTMENT NOTE:

f _

necting disassembled.

Replace rod the iscap bolts each time the con-

%1

COnnecting hp)lst rodmbig end:8.7 (80' 12step: Nm (1.2 · kg, ft 90 · lb) 2ndstep: 35 Nm {3.5 m · kg, 25 ft · lb)

OIL SEAL HOUSING

o00

1. Press-fit the oil seals one by one.

When press-fitting the oil seal, be sure that it faces in the correct direction.

2. Fit new O-ring in the grooves in the oil seal housing outer surfaces. pack oil seal lip and outer surface of Oring with water resistant grease.

3. After installing the oil seal and O-ring,

(

/

_?_,] oi_,

° //x-_._

(_

_

oL/

# _ _

.oTE:

@

Avoid cutting or stretching housing O-ring.

the oil seal

4. Install the oil seal housing onto the cylinder and align the bolt holes.

G74000-0'

ICI

CRANK CYLINDER ASSEMBLY (50, 60, 70 hp) with 2-stroke outboard-motor oil and install the crank assembly into the cylini_.

der block.

5-17

i.ow.iIAssEM..v A.o ADJUSTME.T 5

2. Lift the crank assembly a little so in order to install a washer on the lower crankcase and align each locating-pin of the bearings and labyrinth-seals with each cut on the cylinder-block, then fit the crank assembly in place.

6

_3

3. Film-coat the cylinder-block mating surface with Gasket Maker or equivalent.

4. Install the dowel-pins.

O4

30 11

i_12

5. Match the cylinder-block and tighten the bolts to the specified torque in t)

sequence and in two steps.

r

O8

70

1st step: ----------_Crankcase bolt{1.0m (50, 60, 707.2 hp)ft · lb) MS: 10Nm · kg, M10:20 Nm (2.0m · kg, 14ft · lb) 2nd step: M8:20 Nm (2.0m · kg, 14 ft · lb) M10:40 Nm (4.0m · kg, 29ft · lb) 6.Check that G74002-0'

the

crankshaft turns

'

CRANK CYLINDERASSEMBLY (80, 90 hp) 1 Align each locating-pin of the bearings and labyrinthseals 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.

O_7 O 5

_._

Il 72

608_

_4 40_

4. Match the cylinder-block

sequenceandin two steps. the bolts to the specified torque in _1 Crankcase bolt (80, 90 hp):

2eo_o _J

V,%l O_11! _ 4

io I

20

.8

and tighten

30

197 7._

M6:4 Nm (0.4 m · kg, 2.9 ft · lb) M10:20 Nm (2.0m · kg, 14ft · lb) 2nd step: 1st step: M6:12 Nm (1.2m · kg, 8.7 ft · lb)

M10: 40 Nm (4.0m - kg, 29ft.lb) 5 Check that the crankshaft turns smoothly

5-18

I.ow.IIASSEM.LY A.D AOJUSTME.T Al

G75000-0°

50, 60, 70 hp

CYLINDER ,

_

_<

Al

k[ ,_,_'d_,,

-

o_ ?2 o

Cylinder head (80, 90 hp): 1st step: 15 Nm (1.5 m · kg, 11 ft.

._.g_

[] Tightening sequence 2,

,,

16

22

2\ /o

20<

50, 60, 70 hp

_/

) _9 (.. o _)78

gl

[] Tightening sequence

6c ,o

3 Nm (0.3 m · kg, 2.2 ft · lb) 2nd step: 8 Nm (0.8 m · kg, 5.8 ft · lb) Exhaust cover (80, 90 hp):

_30

.o ,,o_

80, 90 hp

lb)

2nd 30 step: Nm (3.0 m · kg, 22 ft. lb} 32 Nm (3.2 m. kg, 23 ft. lb)

BI 80, 90 hp

1st step: Cylinder 60, 70 hp): 15 Nmhead (1.5 (50, m · kg, 11 ft · lb) 2nd step:

8_,_% _._ _), 9¥ _,0

/i/_.'_:

cover

in sequence and in two steps. [] Tightening sequence

_

,Io ,_ _o

EXHAUST

2. Tighten the bolts to the specified torque

_)

__

AND

COVER 1. Install the gaskets cylinder-head and exhaust cover.

'<

80, 90 hp

HEAD

9 Nm (0.9 m · kg, 6.5 ft · lb) 1ststep: 2nd step: 18 Nm (1.8 m · kg, 13 ft · lb)

Cl

___!_

3. Install the thermostat, 5-19

gasket and cover.

POW

ASSEMBLY AND ADJUSTMENT G75500-0

5

DRAINAGEHOSE 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.

80, 90 hp

_

,i

I._

,C

G76000-0*

50, 60,70 hp

..¢,_ _

INTAKE MANIFOLD

manifold. ___,_ .__ ._

___._,' _'_

2.

1. Install Install the the reed-valve manifold assembly assembly and to the the crankcase and tighten the bolts to the specified torque in sequence and in two gasket steps. reed-valve plate to the intake

_

80,90 hp

q_l

e"

1st step: Intake manifold 4 Nm (0.4 m ·(50, kg, 60, 2.9 70 ft ·hP): lb) 2nd step: 8 Nm {0.8 m · kg, 5.8 ft · lb) Intake manifold (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 AND ELECTRICAL SYSTEM 1. Install the fuel system referring to page 4-1.

2. Install the electrical system referring to page 8-1.

5-20

INSTALLATION G80000-0'

o

_, ,

1. Install exhaustlocating guide. pins in position on the ket with dowel pins and place the gas_

"_

2.

Align the locating-pin holes gas3. ket Install power head onto on the the bottom on the the bottom cowling. cowling, tighten the mounting-bolts to the specified torque.

21 Nm (2.1 m ¡ kg, 15 ff ¡ lb)

[ ?

:_

4. referring Connect to thepages hoses,3-2 cables ~ 3-6. and wires 5. Bolt-on the apron.

0

6. Check the fittings installation, cable connections and functions before starting the engine to check operation and to check for leaks, referring to page 3-7.

5-21

I

ILOW"I

CHAPTER 6 LOWER UNIT

EXPLODED DIAGRAM ...................................................................................6-1 PREPARATION FORREMOVAL ....................................................................6-2 DISASSEMBLY ..............................................................................................6-2 INSPECTION ..................................................................................................6-8 GEAR CASE.............................................................................................6-8 BEARING HOUSING ...............................................................................6-8 CLAW-WASHER ......................................................................................6-8 RING-NUT ...............................................................................................6-8 WATER PUMP HOUSING ......................................................................6-9 IMPELLER................................................................................................6-9 OIL-SEAL HOUSING (Water pump housing) ........................................6-9 GEAR .......................................................................................................6-9 BEARING .................................................................................................6-9 CLUTCH DOG AND COMPONENTS....................................................6-10 DRIVE AND PROPELLERSHAFT .........................................................6-10 DRIVE SHAFT SLEEVE .........................................................................6-10 PROPELLER/TRIMTAB/ANODE ...........................................................6-10 ASSEMBLY AND ADJUSTMENT ...............................................................6-11 ASSEMBLY ...........................................................................................6-11 PINION SHIM SELECTION..............................................................6-11 FORWARD GEAR SHIM SELECTION.............................................6-11 REVERSEGEAR SHIM SELECTION................................................6-11 PROPELLER-SHAFTHOUSING.......................................................6-11 GEAR CASE......................................................................................6-12 SHIM SELECTION.................................................................................6-16 FOR U.S.A. AND CANADA (60, 70, 90 hp) .....................................6-16 EXCEPTFOR U.S.A. AND CANADA ...............................................6-21 MEASURING THE BACKLASH ............................................................6-24 WATER PUMP INSTALLATION ...........................................................6-27 INSTALLATION ............................................................................................6-28 LOWER UNIT LEAKAGE CHECK..........................................................6-30

_r_

[e

ILOWRI 1_ I EXPLODED DIAGRAM EXPLODED DIAGRAM O (_) O (_ (_) (_) O ® (_) (_

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

O _) (_) (_) (_) _) (_ _) (_) (_

Shifter Shift slide Forward gear Clutch dog Cross pin Propeller shaft Reverse gear O-ring Bearing Bearing housing

2 t_

(_) _ (_ (_ (_ _ _) _

Needle bearing Claw washer Ring nut Spacer Propeller Castle nut Trim tab Pinion gear

'_

I

o

50 hp: 130 Nm 145 Nm (14.5 m · kg, (13 m · kg,105 94 ft ft ·· lb) lb)

242

p

50hp

%

]

Nm <"'° m'

_

95 Nm (9.5 m · kg, 69 ft · lb)

E3

6-1

.ow.JI

FO". MOVA',D 120001-0°

!

PREPARATION FOR REMOVAL 1Remove the nut and washer and remove the 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. Referring to page 3-15.

up

i_ _,,,_,, j/_ \

/h /

4. Tilt the lower unit and lock it with the 3. tilt Setlock the shift lever.lever into neutral position.

5.Removethe trim tab. Beforeremoving

_

/ _--_F '-_,_

__

the anticavitation plate.

6. Remove the bolts. it, put a mark indicating its position on

_

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)

_

_

(_

___

_i ,

,

em°ve necessaryS,ideYB.6096hammerO the °il seals' set: if 90890-06501 O Bearing puller: Stopper guide plate: 90890-06535 O Stopper guide stand: 90890-06538 ®

[] Except for U.S.A. and CANADA

_tJ_

[] ForU.S.A. andCANADA

6-2

·ow.II.,sAss -.LY _ -,_

' '

_

Al

4) Shift-rod

J/

5) Ring-nut O and claw-washer

O

YB-34447 ...............................

90890-06511 ..........................

Extension (ring nut wrench): _

90890-06513

..........................

Q ® O

[] Except for U.S.A. and CANADA [] For U.S.A. and CANADA NOTE:

BI

..._

_

y%

the claw-washer by using a screwdriver.

To remove a ring-nut: straighten the lobe of

(&)_

3_

then attach and turn it in the direction of the

_

(_

I%

I_

_1

l_ ._i_

_,_.%%_

BI

___..

off mark using the special service tool.

'Al

6) Bearing-housing

l,-__

_1

_' (_

Using special service tool.

YB'6207 .................................

90890-06503 {50, 60, 70 hp) ..

90890-06502 (80, 90 hp) .......

Universal puller: YB-6117 .................................

Stopper guide plate: Bearing housing.......................... puller: 90890-06501 Center bolt: 90890-06504

..........................

[] For U.S.A. and CANADA (_

[] Except for U.S.A. and CANADA

®

6-3

O Q (_) Q (_) O

.ow.

I I.,sAssEM..Y

7) Propeller shaft

50hp

_

O Clutch dog Q Crosspin (_)Cross pin ring

60,70, 80,90 hp

60, 70,80, 90 hp

8) Shift slide (60, 70, 80, 90 hp) Using a slotted screwdriver, remove tral position and pull out the shift the shift slide balls O from the neuslide 0 and shifter Q.

_)

Al

___

9) Reverse gear and bearing

4_1

i

YB-6096 ................................. O Slide hammer Stopper guide set: plate: Bearing puller: 90890-06535 .......................... O Stopper guide stand: 90890-06538 .......................... ÂŽ 90890-06501 .......................... Q

i []

BI

For U.S.A. and CANADA

[] Exceptfor U.S.A.and CANADA

6-4

ILOW"I I.,SASSEM. Y Al

10) Oil seals and needle bearing

_

__

"

6__,_.11

,/_1

YB-6096 ................................. 0 Stopper guide plate: 90890-06501 .......................... Q Bearing puller 90890-06535 ..........................

O Stopper guide stand: __%___...I Slide hammer .......................... set: 90890-06538 _) Drive rod: YB-6071/90890-06602 .......... O Bearing housing needle bearing remover:

'

[] For U.S.A.and CANADA [] Exceptfor U.S.A. and CANADA YB-6153/90890-06612 .......... ®

Al

._

(_

11)Pinion nut, pinion and drive shaft _

bearing innerrace <_1

_

BI

(,.,3

50/60_70 hp: YB-6049/90890-06518 ........ 0 80/90 hp: YB-6151/90890-06519 ........ 0 Pinion nut holder: Drive 90890-06505 shaft holder: .......................... (_)

[] For U.S.A. and CANADA [] Exceptfor U.S.A.and CANADA

(_ _

NOTE:

(_

For ease of reassembly and adjustment, removed. keep shim

__

6-5

packs

in their

groups

as

IL ow.

I ID'SASS M"LV Al

_

12) Forward gear bearing outer race

_1

Slide hammer set: 90890-06523 ..........................

O

[] For U.S.A.and CANADA [] Exceptfor U.S.A.and Bearing outer CANADA race puller: NOTE: For ease of reassembly and adjustment, keep shim packs in their groups as

I(:_)

l

_._

removed.

13) Drive shaft bearing outer race

(_:_1

_.. ¢__

(_

YB-6096 ................................. O Slide hammer Stopper guide set: plate: 90890-06501 .......................... (_) Bearing puller: 90890-06535 .......................... (_ Stopper guide stand: 90890-06538 .......................... 0

[] For U.S.A.and CANADA

____

2(_ '

[] Exceptf°r U'S'A' and CANADA

O

_'

14) Drive shaft sleeve

_D

'

Needle bearing attachment: YB-6155/90890-06611 .......... (_)

O

16)Reverse gear bearing and forward Separate the bearing from the gear

_'_i

_{_

gear bearing. hydraulic press. using special service Bearing separator:

(_

-

I_

_

,.

tool

and

90890-06534 .......................... O YB-6219 .................................

O 6-6

ILOWRI I DISASSEMBLY

617

,ow, I !..s,EcT.oN 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 passage for clogging.

and water

151500-0

J

BEARING HOUSING the housing 1[

_I

thoroughly.

2.

1. Using Visually a inspect soft brush housing solvent, for cracks clean and corrosion.

If the any and damage is found,

Pr

replace the bearing housing.

152000-0

CLAW-WASHER 1.Visually inspect the washer for cracks. If washer.

152500-0

/'___,

a crack is found, replace the clawRING-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.

6-8

ILow, i. I..s,EcT.o.

153000-0

WATER

PUMP

HOUSING

signs of twisting or scratches of the inner cartridge. If twisted or scratched excessively, replace the housing.

2. inspect the 1. During Inspect the theabove water operation, pump housing for impeller plate and replace this if damaged.

153500-0

1. Visually

inspect the impeller

for cracks,

found, replace the impeller.

IMPELLER distortion or burning. If any damage is

_

154000-0

OIL-SEAL (Water

HOUSING

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.

GEAR

O

1. Visually inspect the teeth and dogs on the gears for cracks, peeling or distor154500-0 tion due to gear-crashing.

If damage is

_

a new one. _O

found on any of the gears, replace with 155000-0

BEARING 1. Inspect the bearings for pitting, scratch__ __:_

by turning the bearing by hand), and replace them if they are not in good condition. lng or rumbling (which may be detected

_

i

ii

6-9

Low,II..s,EcT.o.

155600-0

..

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 r __

!]

,::{ { {[ _

I

Il

I lII

_

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.

m_}_'"-"['_

166300-0

DRIVE SHAFT SLEEVE cracks. If any damage the sleeve.

is found,

replace

1. Visually inspect the sleeve for wear and

157000-0'

PROPELLER/TRIM TAB/ANODE 1. Refer to pages 3-10, 3-23 for periodic inspection instructions.

6-10

I,ow,IIAssEM.,v ADJUSTMENT 161009-0'

ASSEMBLY AND ADJUSTMENT ASSEMBLY PINION SHIM SELECTION 1. Refer to page 6-16, 6-21.

FORWARD GEAR SHIM SELECTION 1. Refer to page 6-18, 6-22.

REVERSEGEAR SHIM SELECTION 1. Refer to page 6-19, 6-23.

PROPELLER-SHAFTHOUSING

..rrT'Tc_

_._/'_'_--_

Al

· V

1. ball-bearing Install theth to rust thewasher reverseand gear. press-fit a

_)

2. Install a needle-bearing and oil seals, and then press-fit the reverse gear complete into the bearing housing.

.'_ ¢._.. #/_

NOTE:

_/_

ture's marks or numbers facing outward. ,nsta,, the need,e bearing with its manufac-

(__j

'4

_ (_)

_i'

_

®

Depth (_): 50 hp: 27.0 mm (1.06 in) 25.5 mm (1.00 in)

Needle attachment: 50 hp:bearing /90890-06614 ........... Q YB-6152/90890-06612 .......... O Bearingdepthplate

.......

(_ _._

/90890-06603 ........... Q

4[

___

I_

Depth(_: 5 mm (0.20 in)

_1

................................. O OilYB-6071 seal attachment: YB-6269 Drive rod: (60, 70, 80, 90 hp) .. (_)

[] For U.S.A.and CANADA [] Except for U.S.A. and CANADA 6-11

LOWR I

_L_I ASSEMBLY ANDADJUSTMENT GEAR CASE

Al 60, 70, 80, 90 hp

(_)_

1. Install a new needle-bearing NOTE:

i(_)

The needle bearing should be installed with ment. the mark facing

(_

_._

(_)_

the flange side of attach-

YB-6071 .................................

Drive rod: Needle bearing installer: YB-34473 ...............................

Needle bearing attachment: YB-6155 .................................

Driver rod: 90890-06602 ..........................

Bearing depth plate: 90890-06603 ..........................

Needle bearing attachment: 50 hp: 90890-06614 ..............

90890-06611 ..............

<_1

B_]

in position.

O Q (_) ÂŽ O (_) (_

[] For U.S.A. and CANADA

I'_/_/

,

[] Except for U.S.A. and CANADA

I (_)

'_ _'__-_

Depth 50 hp:(_):(7.81 198.3 ~~ 7.83 198.8in)mm (7.39 ~ 7.43 in)

._L

187.6 ~ 188.6 mm

2. Align the drive-shaft

sleeve locating-rib

with in the sleeve gear case place the the recess drive-shaft into and the

L

_

_

gear case.

_ (_[__--_

_

3. Place pinion-gear positionthe and install

0

shim-pack O in the taper-roller

bearing outer race Q on the shim-pack.

....... ÂŽ

Bearing outer race attachment: 50 hp: 100800-08827 ........... (_) YB-6156190890-06626 .......... 0

or, v ro.: 6-12

I ASSEMBLY ANDADJUSTMENT

LOWR I

(_)

4. Place the forward-gear

shim-pack

O in

outer race Q on the shim-pack. ,,j

_-__._

j

position _l

and

install

the forward-gear

......

Driver r°d: Bearing outer race attachment: 50 hp: /90890-06622 ........... Q YB-6276-B/90890-06621 ....... O

v

ta

IIQ

_

_

_

ward-gear, then place the forward-gear the outer 5. complete Install the onto bearing inner race. race to the for-

'

_

90890-06662 .............. O

(_

Bearing inner race attachment:

0

6. Place the drive-shaft

in the gear case

and insert it into the pinion.

Tighten the pinion nut to the specified _

torque.

_'_

q_l

4_1

50 hp

Pini°n nut:50 hp: 75 Nm (7.5 m · kg, 54 ft · lb) 95 Nm (9.5 m · kg, 69 ft · lb)

50, 60, 70 hp: Drive shaft holder: YB-6049/90890-06518 ........ O 80, 90 hp: YB-6151/90890-06519 ........ · Pinion nut holder: 90890-06505 .......................... O

7. Referring to the illustration, the propeller shaft.

_.

_.__i_.

(_) "F" mark side

6-13

assemble

J ASSEMBLY ANDADJUSTMENT

LOWR I

1) Insert the free shaft O into the shift slide (_). on the shift slide.

l_l/_

j

Grease the balls so that they will not come NOTE: 2) Install thethe twoshift balls (]) and ÂŽ off easily from slide, thusshifter making your work easier.

J]:Jo__!__j

3) Align the hole in the shift slide cross pin with the slot in the propeller shaft cross pin and insert the shift

when the balls move into the neutral groove in the propeller shaft making slide a slick. into the propeller shaft.

4) Push the shifterandstoppushingit 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

a _______

splined of the shaft. pin holeportion is aligned withpropeller the slot in the

_,._,_,,u)-'-_'cg_ jl NOTE: (_/_._r_e=_

on the the clutch dogdog is so on that the forward gear Install clutch the "F" mark 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

_"___':'_- j

_I

L

holes, then install the cross pin ring.

7) Place the shift cam on the shifter with the "F" mark on the shift cam ler shaft

into the forward

gear.

iL__

facing forward and insert the propel-

6-14

I ASSEMBLY ANDADJUSTMENT

:LOWR I

8) Grease the lips of the oil-seals and _ -_-

insert the propeller shaft complete into the bearing housing, then place

'

gear case.

_-_'_

the bearing housing complete to the 9) Look into the gear case through the hole and align the shift rod hole in

_

the shift cam O and install the shift rod gear O. case with the splined hole in the

?_

I

10) Place the reverse-gear shim O in place, then install the bearing houslng O aligning the key-way in the gear-case with that in the bearing housing and insert the key O.

O

O%.hv,_

ll)Place a claw-washer in place, install facingoutwardawayfromthe bearing housing), tighten the ring-nut to a ring-nut (with its embossed marks

_

claw-washer over the ring-nut to lock it. _oh_L_

"_

the specified torque and bend the 145 Nm (14.5 m ¡ kg, 105 ft ¡ lb)

JJ __

_

_

_

(_i_

_l

Ring nut wrench: 90890-06511 .......................... O 90890-06513 ..........................

O YB-34447 ...............................

O Extension (ring nut wrench):

(_

6-15

JLOWR I

_

I ASSEMBLY ANDADJUSTMENT SHIM SELECTION NOTF' 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 gearcase.

3. If the bearing(s) and/or gear(s) are replaced, carry out the shim selection.

FOR U.S.A. AND CANADA (60, 70, 90 hp)

NOTE: EL--''''/_

_

Pinion Gear Shim selecting shims until the specified measurement pinion (M) withgear the special tool is obtained.

Find shim thickness (T3) by

'

t

_

1. Findthespecifiedmeasurement(M).

0.20 mm + P/lO0 mm i

6-16

I

I ASSEMBLY ANDADJUSTMENT

LLOWRI

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.

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 YS-34432-10 YB-34432-11 YU-26900.8 YU-26900-9 _¡

o_

_

shown in the illustration. drive shaft, bearing and shim(s) as

_

YB-34432-17-A

NOTE:

YB-34432-17-A

/_

2. Assemble the shimming gauge with the

,_,

J

YB'3441_10 _ /, ,,-n, f_ _ _

J_'-;--? l

Jr_

i YB-34432-9xl

'-'

Bearing

,/,"

1.Attach the adapter plate (YB-34432-10) 4 bolts with appropriate sizes. tO the gauge base (YB-34432-11)using 2. If the original shim(s) is unavailable,

_

_

start with a 0.50 mm shim.

YB-34432-11-AShim

tighten the nut to the specified torque.

'IL

4. Using feeler gauge(s) at the specified check the fit between the shimming gauge and lower surface of the pinion as shown. measurement (M) established above,

_, _ TT_Ili_M f

5. If the feeler gauge(s) at the M specification will not fit, then remove or add the shim(s) until feeler gauge(s) just fit between the tool surfaces.

I._

6-17

0.05, 0.08, 0.12, 0.30 and 0.50 mm Available shim thickness: I

LOWR

ASSEMBLYAND ADJUSTMENT Forward

Gear Shim

NOTE: Find forward gear shim thickness (T1) by selecting shims until the specified measurement (M) with the special tool is obtained. i

1. Find the specified measurement (M).

S.e "ie 'ea I 1.50 mm + F/lO0 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.

Example: If F mark is "+5", then M=1.50+(+5)/100 mm =1.50+0.05 mm =1.55 mm If F mark is "-3", then M=1.50+(-3)/100 mm =1.50-0.03 mm =1.47 mm

yB__._A.S.1 yB__..?S_ 7 YB.3A.A.A. 5.5 YB_3A.A. AS.3

YU-26900-8

forwardbearingand original shim(s)as shown in the illustration.

Tighten the nut four turns after contacting the

YU.26900-9

spring.

YB-3

{_ YB-5 _=_"'_A__ _

YB-7 YB-1

with a 0.50 mm shim.

If the original shim(s) is unavailable, start

''_'_

t_SHIM

3. Using

n-n

_, ,'

feeler

gauge(s)

at the specified

check the fit between the shimming measurement (M) established above, gauge and the upper disc of the tool.

M J

6-18

ILOWR I

I ASSEMBLY AND ADJUSTMENT 4. If the feeler gauge(s) at the M specification will not fit, then remove or add the shim(s) until feeler gauge(s) between the tool surfaces.

I ¢_

C_

C_j

__

fit

0.05, 0.08, 0.12, 0.30 and 0.50 mm Available shim thicknesses:

NOTE: Reverse Gear Shim Find reverse gear shim thickness

'_____.

just

I

(T2) by

ment (M) with the special tool is obtained. selecting shims until the specified measure1. Find the specified measurement (M).

-

T2__

Specified Measurement

(M)=

60 hp/70 hp: 1.00 mm - R/100 mm 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.

Example: (60 hp/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: (90 hp) If R mark is "+5", then M=1.50-(+5)/100 mm =1.50-0.05 mm =1.45 mm If R mark is "-3", then M=1.50-(-3)/100 mm =1.50+0.03 mm =1.53 mm

6-19

ILOWRI

I ASSEMBLY ANDADJUSTMENT M

....... _' 'i_}2:_q_E ..:.=.,_;?.:_.¢*_ _-.._}7'_.;;_,;:,,_**:_,:::...:..-:..:,. '_::×-_'.':';:.-' :_:_ ^_......_.o::: -...... ..... _-****..,::,..>?.,_,_;_.,.:<: .......... .............. ,_ I

2. Place the original shim(s) on the thrust washer mounted on the bearing hous-

90hp: YB-34468.3

_ai,-"---__,__,____;___,-_, ........

-----,.-_-.,,., -

'i_/_i_'.i

'"

lng and place the shimming gauge on

60_hp/70 hp:

Y_

t°Ptration.°f the shimls) as shown in the illus1. If the original shim(s) is unavailable, start with a 0.50 mm shim.

NOTE: 2. Be sure to remove the O-ring from under the thrust washer.

3. Using feeler gauge(s) 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.

4. If the feeler gauge(s) at the M specification will not fit, then remove or add the shim(s) until feeler gauge(s) just fit between the tool surfaces.

0.05, 0.08, 0.12, 0.30 and 0.50 mm

6-20

I ASSEMBLY ANDADJUSTMENT

.OWRJ

EXCEPTFOR U.S.A. AND CANADA Pinion Gear Shim

[_ T3 J

_

<

1. Find pinion gear shim thickness {T3) by surement (M) with the special tool is obtained.

_'_- _

selecting the drive specified 2. Install theshims pinionuntil on the shaftmeaand tighten the nut to the specified torque.

,

50 hp:

._=_-,J I

_

90890.06704 90890-06702

Pinion 95 Nmnut: (9.5 m · kg, 69 ft · lb) 3. Assemble the pinion· kg, height 75 Nm (7.5m 54 ft gauge · lb) with

__________ _

the drive shaft and bearing as shown in the illustration. Bolt the bearing housbolts. lng to the special tool with at least two 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.

i_M

-

50 hp: M - 40.2 mm - P/lO0 mm Shim thickness M - 31.5(T3)= mm - P/lO0 mm

I_

I

5. P is the deviation of the lower case

1_)\

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 dimension from standard. It is stamped

·

Example: when unit mm" is assembled.

If M isthe "32.10 P is "+2", then T3 = 32.10 - 31.5 - 2/100 = 0.58

'____

_

6-21

50 hp: 0.10, 0.12, 0.15, 0.18, 0.30, Available 0.40 shimand thickness: 0.50 mm 0.05, 0.08, 0.12, 0.30 and 0.50 mm

I ASSEMBLY ANDADJUSTMENT

ILOWRI

NOTE: ¡ Use a minimum

¡

to

_

obtain the thickness equal or nearly equal to the calculation.

Install the shims with the thicker one on the outer side.

_

Forward

number

of shims

Gear Shim

by selecting shims until the specified measurement (M) with the special tool is obtained. _1__

1. Find forward

gear shim thickness

measurement (M) established measure the bearing height.

i [_

-_-__ 90890-06701 _ "08"0'06704

(Il)

above,

50 hp: 22.70 mm + F/100 mm - M 2. Using a digital caliper the mm specified 24.50 mm + at F/100 - M _

Shim thickness

(Il)=

_M,

"' 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

_

6-22

50 hp: 0.10, 0.12, 0.15, 0.18, 0.30, Available 0.40and shim thickness: 0.50mm 0.05, 0.08, 0.12, 0.30 and 0.50 mm

J

ILOWR I

I ASSEMBLY ANDADJUSTMENT 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.

90890-06704 90890-067o1"

measure the (M) distance betweenabove, the measurement established washer top and special tool top as 2. Using a digital caliper at the specified Shim thickness (T2)=

·_ _

__

z/)

iM

50Mhp: - 25.40 mm - R/lO0 mm shown.60, 70 hp: M - 28.00 mm - R/lO0 mm 80, 90 hp: M - 26.00 mm - R/lO0 mm

i_

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.

i

6-23

JLOWRJ

JASSEMBLY ANDADJUSTMENT Example: If M is "28.60 mm" R is "-1", then T2 = 28.60 - 28.00 + 1/100 = 0.61 Available shim thickness: 50 hp: 0.10, 0.12, 0.15, 0.18, 0.30, 0.40 and 0.50 mm 0.05, 0.08, 0.12, 0.30 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

When measuring the backlash, do not install the water pump.

1. Place the shift rod in neutral.

NOTE:

j_ (_

2. Install a dial 3. backlash gaugeindicator on the gear gauge case. (special service tool) on the drive shaft and make the dial gauge stem contact the mark on the indicator gauge.

_::_1

YU-3097/90890-01252 ..........

Dial gauge: Magnet base: YU-34481/90890-06705 ........

Backlash indicator: YB-6265/90890-06706 ..........

Backlash adjusting plate: YB-7003 .................................

O (_ O ®

NOTE: Measure both the forward gear backlash and the reverse gear backlash before making any shim changes. If both backlash measurements are less than specified, the pinion shim may be too large. If both backlash measurements are greater than specified, the pinion shim may be too small.

Recheck the pinion shim selection.

6-24

I,°w.IASSEM.'YA.DADJU _. _

i'

-

Forward Gear service tool) in the bearing housing so 1.1nstallabearinghousingpuller(special that it gets engages with the center bolt

_0

of the propeller shaft.

YB-6207190890-06503 --_ Bearing housing puller: _-

90890-06502 (50, 60, 70 hp)(80, 90 hp) Universal puller: YB-6117 Stopper guide plate: 90890-O6501 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.

_

60, Forward 70 hpgear backlash

Decrease or increase

Less than 0.09 mm (0.004 in)

decreased (mm) = (0.19 - measurement) x 1.86

0,09 - 0.28 mm (0.004- 0.011 in)

Decrease or increase Thickness ofshimtobe will be unnecessary

More than 0.28 mm (0.011in)

Thickness of shim to be increased (mm) = (measurement- 0.19) x 1.86

50, 80, 90 hp Forward

6-25

gear backlash

Decrease or increase

Less than 0.08 mm (0.003 in)

Thickness of shim to be decreased (mm} = (0.16- measurement) x 1.67

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 - 0.16) x 1.67

:LOWR

I

_ÂĽ

I

ASSEMBLY

AND

ADJUSTMENT

Reverse Gear 1. Install a propeller on the propeller shaft, with the front facing backward, fit the 2. Slowly turn the drive shaft in and out, and readtighten. the dial gauge when the drive nut and shaft stops in each direction. the chart.

3. Determine the shim size according to

tO_

Reverse gear backlash

50 hp

Decrease or increase

Less than 0.84 mm (0.033 in)

Thickness of shim to be increased (mm) = (1.01 - measurement) x 1.67

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) x 1.67

60, 70 hp Reverse gear backlash

Decrease or increase

Less than 0.75 mm (0.033 in)

Thickness of shim to be increased (mm) = (0.94 - measurement) x 1.86

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 imm) = (measurement - 0.94) x 1.86

80, 90 hp Reverse gear backlash

6-26

Decrease or increase

Less than 0.67 mm (0.026 in)

Thickness of shim to be increased (mm) = (0.83 - measurement) x 1.67

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 - 0.83) x 1.67

ILOW"I IASSEM.LY A.D A.JUSTM .T 164000-0

I

i

1. InstallPUMP a newINSTALLATION oil seal in the oil-seal WATER

_)_

ring groove.

CC___I Drive rod: YB-6071 housing, and fit................................. anew O-ring in theO OBearing housing oil seal installer: YB-6269 ................................. (_

I i"_ _

_

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 3. Aligning with the dowel-pins, install a new gasket, a plate and a new gasket dowel-pins. housing. ontheoil-seal

!_

4. Install a key in the keyway on the driveshaft and insert a impeller.

J14:_l=_'_"

water-pump housing, turning the drive 5. shaft Grease the and the install clockwise, impeller then tighten bolts.the

6-27

,ow,II..s,A,LA..o.

INSTALLATION

'

1. Check that the clutch dog shifts to "Forward", "Neutral" and "Reverse" correctly by turning the shift rod, and shift into "Neutral".

_

RN_FF_

''_

F

I_::_l

] --N--

Shi" YB-6052 rod wre"ch:

I

--R--

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 specified torque.

the bolts to the

40 Nm (4.0 m · kg, 29 ft · lb) I'r'-

,_)_

-_

_

Iq_l

i

i

6-28

L°werunitm°untingb°lts:

I

LOWR

I _L_'

I INSTALLATION sure to align the marks put on both of they removed.

Place 4. them Install when the trim tabwere on the gear case.

Be the cap over the bolt hole.

/_

5. Install the spacers, propeller, washer, and propeller nut over the propeller shaft.

35 Nm (3.5 m ¡ kg, 25 ft ¡ lb) 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.

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.

plug-hole until oil flows out through the level-plug hole, then secure the plugs in these two holes.(Securethe check plug / --

_'_-_z-r_____

7. Fill with fresh gear oil through the oil

._ __;_

fi rst.)

6-29

.ow.

I I'"STAL'AT'O" 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 Then, place the gear case in the water tank. of 100 kPa (1.0 kg/cm2, 14.2 psi).

3. Check that the pressure is held at 100

_._______

pB

.----_

_,_

kPa (1.0 kg/cm2, 14.2 psi) for 10 seconds.

.e.._=_=_

.t

If the pressure falls, leakage from the lower unit is unacceptable, requiring re-inspection of its component parts.

YB-35956/90890-06762 [] For U.S.A.an(JCANADA [] Exceptfor U.S.A.and CANADA

6-30

I

IB"KTI I

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 ..............................................................................

INSPECTION .........................................................................................

7-11 7-11

POWER TRIM AND TILT UNIT ....................................................................

REMOVAL .............................................................................................

7-11 7-11

EXPLODED DIAGRAM (Short transom [6H307]) ................................

DISASSEMBLY .....................................................................................

INSPECTION .........................................................................................

TILT-ROD AND TRIM-ROD ..............................................................

ASSEMBLY ...........................................................................................

EXPLODED DIAGRAM (Long transom [6H1-13], [62F-00]) ................

DISASSEMBLY .....................................................................................

INSPECTION .........................................................................................

TILT-ROD AND TRIM-ROD ..............................................................

ASSEMBLY ...........................................................................................

FILLING WITH HYDRAULIC FLUID AND AIR-BLEEDING ...................

HYDRAULIC FLUID PRESSURE TEST .................................................

INSTALLATION .....................................................................................

P.T.T. MOTOR ..............................................................................................

DISASSEMBLY .....................................................................................

INSPECTION .........................................................................................

ARMATURE COIL ............................................................................

BRUSH ..............................................................................................

BASE ASSEMBLY ............................................................................

CIRCUIT BREAKER ..........................................................................

ASSEMBLY ...........................................................................................

7-12 7-14 7-16 7-16 7-16 7-20 7-22 7-24 7-24 7-24 7-28 7-28 7-30 7-31 7-31 7-31 7-31 7-32 7-32 7-32 7-33

_

JBRKTJ_"_ ] BRACKET UNIT BRACKET UNIT EXPLODEDDIAGRAM MANUAL HANDLE P60TH/60FETMO O Tiller handle (_) Washer {Nylon) O Bracket O Shift handle O Main switch (_) Engine stop switch

O Grip _) Throttle cable

38 Nm (3.8 m · kg, 27 ft · lb) I / / ,/

/

/ O

/'

/( I

Nm (3.8 m. kg, 27 ft.

lb)I

I I { I I

I

.--

I

I I

?

I

Q'

¢¢.

I

&

t

////

y"'

.... ..,'

'

-

38 Nm (3.8 m · kg, 27 ft · lb) J _

I_

14 Nm (0.4 m. kg, 2.9 ft.

lb)I

t 15Nm (0.5 m. kg, 3.6 ft.

7-1

lb)I

I...TI I..Ac. ET u.,T K15000-0

UPPER CASING 50, 60,7O hp O Exhaust guide O Exhaust manifold O Muffler (_) Upper case (_ Apron (_) Seal O Bottom cowling

I_

c_

42'

_

121 Nm (2.1...m- kg, 15ft. lb)

E

/-

-__

_'_

121Nm (2.1m - kg, 15ft.lb)

i

I

0

21 Nm (2.1 m · kg, 15ft · lb)

7-2

I""KTI I ..ACK TU.,T 80, 90 hp O Exhaust guide Q Exhaust manifold ® Muffler O Upper case O Apron ® Seal O Bottom cowling

21 Nm (2.1 m. kg, 15ft · lb) I

.

242

_

?' -

._/1_" ,_ 7-3

I""KTII..ACKETU.,.

K- 15300-0

BOTTOM COWLING O Power trim and tilt motor lead (P.T.T. model) (_) Trim sender lead (P.T.T. model) O Grommet O Clamp (P.T,T. model) 0 Bottom cowling fitting plate (_) Shift handle assembly

%

ÂŽ_'_...

k:_-3",

l

U

7-4

I...TI

I ..Ac.ET..,T

K15600-0

BRACKET UNIT O Upper mount rubber cover (_ Cap (_) Upper mount rubber nut (_)Screw (_ Lower mount rubber cover ® Ground lead O Bolt

® Mount rubber housings (_) Lower mount rubber nut _) Anode @ Read wire

I

I_m,_,m-_,_"_, I _

_£

J18 Nm (1.8 m, kg, 13ff' lb) I

_-..

®'x2/ 7~5

I

I...TI I..Ac. ET u.,T BRACKET O (_ (_ O O

UNIT (Manual

tilt model)

Tilt unit Tilt lever Clamp bracket spacer Lower shock mount pin Bushing

-'

L/-

7-6

I""KTII ..ACKET..,T K15900-0

BRACKET (Short transom) O Circlip Q Lower mount housing O Steering pivot shaft 速 Bushing O O-ring 速 Bushing O Greasenipple 速 Ground lead (_ Tilt rod

(_ Clamp bracket nut O Bolt (6 bolts) @ Clamp bracket bolt (_ Washer _) Bushing (_ Clampbracket _ Trim sensor (P.T.T.model) _ Circlip _ Pin

(_ Bushing (_ Power trim and tilt unit (P.T.T. model) (_ Cotter pin _ Tilt lock lever _ Bushing (_ Washer _ Spring (_ Collar

mm

Ill,

'1

_

_).......__2,)

@

_.

-_速

@ 1 572

.

'Y

_%

_

P.T.T. model

7-7

,i

_

is.

I""KTI "ZI..ACKET..,T K15900-0

BRACKET (Long transom) O Circlip (_ Lower mount housing O Steering pivot shaft O Bushing O O-ring (_)Bushing O Grease nipple _) Groundlead (_ Tilt rod

(_ Clampbracketnut ÂŽ Bolt (6 bolts) @ Clamp bracket bolt (_ Washer (_ Bushing _) Clampbracket _) Trim sensor (P.T.T. model) (_ Circlip _) Pin

13 Nm (1.3 m. kg, 9.4ft .Ib)l

(_ Bushing _ Power trim and tilt unit (P.T.T.model) (_ Tilt lock lever _ Bushing _ Spring _ Collar

_ ''_

<x

_

_'_.

I x'.,l &

572

7-8

--

B"KTIIB.ACK U.,TT

K20002-0

REMOVAL 1. Remove the power-head.

==_e--__\ .,,,__.__,_ _

-__

___ ,2. ,_,_,_i,_. upperRem°Vecasing.the _ swivel-bracket

from the

_:_._._..:'..:..._._.._

Lay the outboard motor carw out this removal.

on the floor to

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.

1. Inspect the bracket and replace them, if cracked.

TRIM SENSOR 1. Check resistance of the new trim sensor.

BRACKET

_/_

B

360 ~ 540 Pink -- Orange 800 ~ 1200

o

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

""KTII Trim sensor adjustment Fully tilt up the outboard motor.

Loosen the two bolts securing the trim sensor until it moves slightly.

r?lw_,Id

II_Jell 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.

F.o_.s_^._

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 installation bolts.

motor and tighten

both

r?lvAVlzl:t lei 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 assemble the bracket unit.

7-10

diagram,

""KTII.YD.AU.,C T,.T U.,T,.OWE. T.,M A.D T,.T U.,T HYDRAULIC

TILT UNIT

,!1_VA_lzl ;] kN IIkN [ell This cylinder is highly pressurized. There

INSPECTION

for never overhaul or damage it.

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 ,,_

o

1. Disconnect the leads from the relay in

_/_

REMOVAL 2. Remove the tilt-rod, the clamp-bracket.

_

bolts and nut, and

3. Remove the circlip and the power trim the and bottom tilt unit cowling. complete.

_,

7-11

I...TI I.owT.,M . A..T,.T..,T K51000-0

EXPLODED DIAGRAM (Short transom [6H307]) O Reservoir body (_) Pipe (_) Reservoir plug O Relief valve seat (_) Motor assembly (_ Down relief spring (_ Trim cylinder end screw (_) Gear pump assembly O Trim piston assembly (_) Shaft connector (_) Valve seat screw (_ Filter 2 O Down relief spring 2 _) Up relief valve lock screw (_ Main valve assembly _) Up relief spring _) Shuttle piston _) Relief valve seat

2.2m' ft. kg, lb)II 3 Nm (0.3

__

_ (_ _) _ _ (_ _ (_

Filter 1 Manual valve seat Manual release spring Adapter Manual valve Free piston Back-up ring 2 Tilt cylinder assembly

4 Nm (0.4 m · kg, 2.9 ft. Ib)l

6 Nm (0.6 m · kg, I 4.3 ft. lb) I

]10 Nm (1.0 m- kg, 7.2 ft. lb)

{_ u

©

®D

Nm (7.0 m° kg, 50 ft'

,b)I

15Nm(0'*'n'kQ, _

(__

__

2.2 ft · lb) 3 Nm (0.3 m° kg, I

_

10 Nm(1.0 m. kg, [ 7.2 ft ° lb) I

13 Nm (0'3 m - kg' I 2.2 ft · lb) 112Nm (1.2m. kg, I 8.7 ft · lb)

Nm (1.0 m · kg, 7.2 ft ·

Nm I1.0 m · kg, 7.2 ft · lb) 7-12

1...TII.owE. T.,M A.oT, LT U,T (_ Power trim and tilt motor (_)Gearpump _) Down-relief valve (48 kg/cra2) (_) Main valve 2-way check valve (_ Reservoir

...._

O Up-relief valve (40 kg/cm2) _ Manualvalve _) Tilt cylinder (_) Absorber valve (80 kg/crn2) ÂŽ Freepiston _) Trim cylinder

Up Down

%

@

7-13

IBRKT

I POWER TRIMANDTILTUNIT K52002-0

DISASSEMBLY :::::;:::::::::...._:::+,............:...:.., .y. _¡t.:: t._...;._.;::.

2 :::::::::.,:.... _ .. .. ¡ .,._:_::.: <..:_.... ... : _...,...:

1. Do not wipe components of the hydraulic system with rags or paper tissues, etc., as fibers from such 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 hydraulic-fluid and drain the hydraulic-fluid.

level-plug

3. Remove the delivery pipes and drain the hydraulic-fluid. w_,V_

v

4. Remove the hydraulic-fluid

,,_)/_w ,,,,

and the tilt-motor.

_

.._

:___

reservoir

_

5. Remove Remove the the filter shaft and connector.

6. the gear-pump.

_o

down relief-valve.

7. Remove the O-rings and the complete

_

Do not disassemble the gear-pump unit which is factory-adjusted, but replace the complete gear-pump unit if necessary.

W o

8. Loosen the bolt and remove the completeup-reliefvalve.

o

L_

7-14

...Ti.TI.OW..T.,MA..T,'T..,T 9. Using the special service tool, loosen the trim-cylinder end-screw and pull out YB-6175-1A/90890-06542

____._

the trim-piston and components.

10. Using ',_

the special

service

tool,

I

loosen

the tile-piston and the free-piston. r!lvAv!_,l ;t_i i_[til tilt-cylinder andeasily pull out Thethe free*piston canend-screw be removed by blowing compressed air into the drain-hole of the cylinder, but when doing so, cover the open end of the cylinder with a rag to prevent the free-piston from being ejected and damaged of from harming persons.

i

i

I

YB-6175-2A/90890-06541

11. Remove the main valves and the shut/_J

, "'

/

tie-piston.

12. Remove the circlip, and remove manual-valve and components.

G0 _0_

NOTE: _

'_u

The manual-valve screw is left handed.

7-15

the

BRKTJ

I

POWER

TRIM

AND TILT UNIT 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.

I_

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.

_--._

K54O00-0

ASSEMBLY NOTE: The components in this assembly are to be lightly coated with hydraulic fluid before assembly.

1. Install pipes.

the tilt-cylinder

and the delivery

O Bushing (3:)Lower mount loin c_

NOTE: Q Tilt-cylinder

_____ _ . _,_

Feed oil into each pipe.

ocnu,.

10 Nm (1.0 m ¡ kg, 7.2 ft ° lb)

)

7-16

I

BRKTI_"_ I

POWER TRIM AND TILT UNIT 2. Install

_t_/O_

_) _

r

the

manual-valve

in the

body

with new O O-ring (fittedO-rings. into the body)

_

O Manual release spring (L = 6.0 mm, D = 11.5 mm) ® Adapter 1 O O-ring ® (_) Manual Manual valve valve (left seat handed thread) O Circlip

__/___

_

_

_

_

_

_

_

3 Nm 10.3 m. kg, 2.2 ft.

lb)

v// 'y-_

3. Install a new O-ring on the shuttle-piston, and insert the piston into the body, then install the main valves with new O-

(_) Shuttle-piston rings.

O O-ring ® O-ring O Q Main O-ringvalve

,/_%_ _)

(__ _)%(_

l0 Nm (1.0 m · kg, 7.2 ft · lb)

¥ (_

4. Install the up-relief valve with a new Oring and tighten the locking-bolt to the specified torque.

ii

O Filter

®Orin

. °

O Up relief valve seat O Ball

® Up relief spring (L = 19.7 mm, D = 5 mm) O Valvesupportpin O Valve locking-bolt

J_ 7-17

""KTII.OWE. T.,.

A..T,.T..,T

Lock.,,, I

®

_

13 Nm (1.3 m · kg, 9.4 ft · lb)

5. Fit a new O-ring and the back-up ring to the trim-piston, fit new O-rings and a _.(_ _O

new oil-seal to the end-screw and install the complete trim-piston in the fluid and install and tighten screw to the specified torque.

i. 1

__

cylinder.

Fill the cylinder

the

end-

.n,t t,,I

with hydraulic

0 O-ring O Back-upring

_.

70 Nm (7.0 m · kg, 50 ft · lb)

' ._

I<_1 cy''"der ends_re_wre"_h: YB-6175-1A/90890-6542

_J____/_ _

h_ '_

complete gear-pump with new O-rings, tighten the screws and fit the shaft con6. Install the down relief-valve and the

o!___ _Ji____

I

--_

fluid.nect°r and filter, then fill with hydraulic

2-_-_

O Down relief spring (L = 13 mm, D = 6.1 mm) O O Gear pump Q Washer O-rings Q Washer ® Screw (Use hexagon wrench) O Shaft connector (_) Filter

____

Iq_l

7-18

5 Nm (0.5 m · kg, 3.6 ft · lb) Gear pump mounting screw: i

I

BRKTI

I

POWER TRIM AND TILT UNIT 7. Fit a new O-ring and the back-up ring on the free-piston and install it into the

ciner

(9 O-ring

Q Back-up ring

8. Fit a new O-ring and the back-up ring to . ?j_

_

the tilt-piston and install it into the cylinder.

Fill the cylinder with hydraulic fluid and torque.

Q Back-up tighten ring the end-screw O O-ring

i_.

to the specified

YB-6175-2A/90890-6541

I%

80 Nm (8.0 m 路 kg, 58 ft 路 lb) I Tilt cylinder end screw:

9. Align vvJJ_' o

_P_r'_'_vv II i/ _lj o

the connector-shaft

keyway

the motor-shaft projection the motor with new O-ring.

-_

10. Install the hydraulic-fluid new O-ring.

7-19

with

and install

reservoir

6 Nm (0.6 m 路 kg, 4.3 ft 路 lb) O O-ring

J

with

IBRKT q_

I POWER TRIMANDTILTUNIT

K51000-0

EXPLODED

DIAGRAM

(Long

(_ Brush holder assembly (_ Yoke assembly O O-ring O Armature assembly .Q Bracket assembly (_) Filter O Gear pump assembly ® Taper screw plug (_) Down relief spring

transom

[6H1-13],

(_ Valye support pin @ Main valve seal (_) Trim dust seal Q Trim cylinder end screw (_ Reservoir plug _) Back up ring d_)Shuttle piston _ Lower shock mount pin (_ Pipe

17 Nm,0.7 m.

1(9.0 m. kg, I I 6sft'lb)l

_I

2 1'

!

2.9 ft. Ib) l r ]

_._'

[62F-00])

j

l_

'"-.

_

(_) Valve lock screw (_ Manual valve seat (_ Manual release spring _ Adapter 1 (_ Manual release screw (_ Snap ring _ Free piston _ Back up ring

Nm ,O.4

'_/ i

4 Nm (0'4 m* kg' I

_,._

29ft.,b) I

® "/

O

3 Nm (0.3 m · kg, 2.2ft*lb)

_

/.J

160 Nm (16 m · kg, I 115 ft. lb) I

1 Nm (1.1 m *kg, 8.0 ft · lb) /

115 Nm (1.5 m. kg, 11ff. lb) 7-20

_

I...TI IPow T.,.

A.. . T, LT..,T O Trim down valve (0,2 kg/cm2) (_) Trim down valve (1 kg/cm 2) (_ Reservoir Up-relief valve (100 kg/cra2) O Manual valve (_) Tilt cylinder

_ .... Up Down

O Absorber valve (180 kg/cm 2) _ Trim cylinder (_) Main valve (0.5 kg/cm2) (_) Down-relief valve (30 kg/cra2) @ Gear pump (_ Power trim and tilt motor

(_)

@

ÂŽ 7-21

I...TI I

A..T,.T u.,T K52002-0

_::_i_ ____i 1. Do not wipe DISASSEMBLY

!_

2.

components of the hydraulic system with rags or paper tissues, etc., as fibers from such entering the system will cause malfunction.

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 v_l t_ _-_l/=-_lt ,,,, _,_!t

manual position.

2. Remove the delivery

3. Remove

the

pipes

hydraulic-fluid

and

the

reservoir

and the tilt-motor.

4. Remove tho shaft connector. hydraulic-fluid level-plug.

_

5. Remove the filter and the gear-pump.

W _' L,_ _1 r-J_/'__ -----_

7" _

6. down Remove the O-rings relief-valve.

_J

and the complete

_'_'_' _,____--_'_'_'_:._ÂĽ,_._,_...... ;"" _"_' ' :,..` _"_tJ[ '__ _' ,; :__._,_.__:_.:_,_._: ''

,,_

Do not

disassemble

the

gear-pump

)_

complete gear-pump unit if necessary. which is factory-adjusted, but replace the 7. Loosen the screw and remove

_-_

O---_ _2 _i (_ _ _(_)_ (_) _L,_

_ I_'-. ! .

relief valve complete.

___(_ I_ i _ -'.:

(_) Up relief spring (_) Valve support pin Q Relief valve seal Q Relief valve seat (7) Filter (6_O-ring ÂŽ Trim spring

___ 7-22

unit

the up-

_

I....I.TI.owE. T.,M A.DT,.T u.,T

8. Remove the one-way valve seal.

O Q @ @ (_

valve

and main

Valve lock screw O-ring Ball Washer Main valve seal

9. Loosen

the trim-cylinder

end-screw

pull out the trim-piston

and

and compo-

Cylinder end screw wrench: YB-6175-1A/90890-6542

I ts' 10. Loosen _.,_,

the

tilt-cylinder

pull out the tilt-piston

_

end-screw

and

and the free-pis-

The ton. free-piston can be removed easily by blowing compressed air into the drain-hole of the cylinder, but when doing so, cover the open end of the cylinder with a rag to prevent the free-piston from being ejected and damaged of from harming persons.

Cylinder end screw wrench: YB-6175-2A/90890-06541

11. Remove tie-piston.

7-23

the main

valves

and the shut-

I

I...TI I.owE. T.,M A.o T,.T U.,T 12. Remove the circlip and the manualvalve and components.

O Snap ring (_) O-ring (_) Manual release screw (_) O-ring O Manualvalve seat ÂŽ Manual release spring 1 O Adapter 1 ÂŽ Manual release spring 2 K53000-0

TILT-ROD AND TRIM-ROD 1. Clean these components using a soft brush and solvent and inspect them INSPECTION carefully.

If there are light scratches on the surfaces, these may be polished off using fine wet-or-dry sandpaper (440 ~ scratching, replace the components.

2. Clean all the parts thoroughly using a soft and solvent dry them 600 brush grit), but if there and is excessive with compressed air.

3. Inspect the tilt-cylinder and pump-unit and replace them if they are badly cor-

O

roded.

?

K54001-0'

ASSEMBLY NOTE: The components in this assembly are to be lightly coated with hydraulic fluid before assembly.

7-24

BRKTI

I

POWERTRIM AND TILT UNIT 1. Install the tilt-cylinder

and the delivery

pipes.

0 Bushing 0 Lower mount pin (_)Tilt-cylinder NOTE: Feed oil into each pipe.

15 Nm (1.5 m · kg, 11 ft · lb) 6 2. Install the manual-valve with new O-rings.

in the

body

O Snap ring 0 O-ring O Manual release screw "_%

_._,_

O O-ring (_ Manual valve seat ® Manual release spring 1 (_0,6 mm)

_

(_'1__/_-_-_

_

J_,_T_

_'_-.L'_'_-'_

Manualvalve: 3 Nm (0.3 m · kg, 2.2 ft · lb)

V//_

i Adq__iter 1

® ® _

I

ton and insert the piston into the body, then install the main valves with new Orings,

f'_.

O O-ring (_) Shuttle-piston 3. Install a new O-ring on the shuttle-pis® O-ring ® Main valve O O-ring

(_) Q

__

''n"ve

11 Nm (1.1 m · kg, 8.0 ft · lb)

®®® 7-25

I

I""KTI 'TI.OWE. T.,.

A..T, LT U.,T 4. Install the up-relief o-___

the screw to the specified torque.

__ _¢"_ __

way valve valve seal with new O-rings and tighten O Main (:_ Washer

i

O Valve lock screw ® Filter O O-ring ® Relief valve seat O Relief valve seal Q Valve support pin ® Up relief spring @ Trim spring @ Screw pan head W/W

---r'--

4 Nm (0.4 m · kg, 2.9 ft · lb) Valve lock screw: Screw: 4 Nm (0.4 m · kg, 2.9 ft · lb)

q_l

'.__"'(_)',,

valve and the one-

on the trim-piston, fit new O-rings and a new oil-seal on the end-screw and 5. Fit a new O-ring and the back-up ring

%3

cylinder.

Fill the cylinder with fluid and install and tighten screw to the specified torque, [L__i__j_,_

hydraulic the end-

I. )1m h .owI

___

install

the complete

trim-piston

in the

0 O-ring _._--"_

Q Back-up ring End-screw (trim cylinder): 160 Nm (16 m · kg, 115ft · lb)

¢ y _a 5,,,

I_1

7-26

YB-6175-1A/90890-6542 Cylinder end screw wrench:

I I

"""TI

I .owE.T.,MA.. T,.T..,. _

6. Install the down relief-valve and the gear-pump complete with new O-rings,

® _L_)

_-__

shaft and filter, then fill with hydraulic tighten the bolts, and fit the connector-

,._ .._

O Down relief-valve

)_ t_,¢

O O-ring (_) Q Bolt Shaft-connector

"°'

I

4 Nm (0.4 m · kg, 2.0 ft · Ibl

install it into the cylinder. _ G_

O7.O-ring Fit a new O-ring on the free-piston and

8. Fit a new O-ring ('=O') ' '1 _ _ i I

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.

_ _ _

I

0 O-ring Q Back-up ring

I

I _=_

End-screw Iq_l

90 Nm (9.0 m. kg, 65 ft.

I<_1

YB-6175-2A/90890-6541 Cylinder end screw wrench:

9. Align

O

II _,-J vvd v_'_Tr_ _ o -O

{tilt cylinder):

the connector-shaft

lb)I

keyway

I

with

the motor with a new O-ring. the motor-shaft projection and install 10. Install the hydraulic-fluid reservoir with a new O-ring.

IxJ

7 Nm (0.7 m · kg, 5.1 ft · lb)

O O-ring

7-27

I

IBRKTI

I

POWERTRIM AND TILT UNIT

'

_, _

I

FILLING

_

WITH

HYDRAULIC

1. Pour in the fluid until it overflows

!_

AND

FLUID from

AIR-BLEEDING

$_1

Yamaha power trim and tilt fluid thereservoirflUid-leVelplug, plug-hole and install th i 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, open the manual valve and repeat these operations two or three times. Then turn the manual-

-__

valve

fully

towards

power-tilt.

3. Check the level of the hydraulic fluid at full tilt up, top up with fluid if necessary.

Insert and tighten the fluid-level plug.

4. Connect the leads to a battery to check the function. i

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:

7-28

¡

Feed hydraulic

fluid into each pipe while

¡

Two set of hoses are required so that taking care not to allow air to enter. both of the trim and tilt pressures can be measured at the same time.

IB"KTI' IPOWE. T.,MA. DT,.TU.,T

3. Connect the leads to a battery to check the fluid discharge pressure during down-operation.

I

Trim and tilt down ............... Green (+) Blue (-)

A

;_.¢< . .___'__,__,._,_ z_. ,.;._.. _ _

¡

_::_:._: :_ _'_.,, _,_;

The motor should not be operated for more than three seconds after trim and tilt down is completed.

B: Trim operating pressure A: Tilt operating pressure _ At the end of down operation: [Stamped mark] [6H307] A: 4,100 ~ 5,800 kPa (41 ~ 58 kg/cm 2,583 ~ 825 psi) B: 600 -- 1,100 kPa (6 ~ 11 kg/cm 2,85 ~ 157 psi) [6H1-13], [62F-00] A: 2,200 ~ 3,800 kPa (22 ~ 38 kg/cm 2, 313 ~ 540 psi) B: 600 ~ 1,100 kPa (6 ~ 11 kg/cm 2, 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 be operated within teen seconds for tilt up-operation.

7-29

four-

BRKTI

_

} POWER

TRIM

AND

TILT

UNIT

A: Tilt operating pressure B: Trim operating pressure I

A

A: 0 ~up 500operation kPa During pressure: (0 ~ 5 kg/cra 2, 0 ~ 71 psi) B: 0 ~ 500 kPa (0 ~ 5 kg/cra 2, 0 _ 71 psi)

_

B

At pressure:the end of up-operation A: 0 kPa (0 kg/cm 2, 0 psi) [6H307] B: 3,500 ~ 4,500 kPa (35 ~ 45 kg/cra 2,500 ~ 640 psi) B: 9,000 ~ 11,000 kPa [6H1-13] (90~ 110kg/cm 2,1;280~ 1_565psi) [62F-00] B: 2,140 ~ 3,770 kPa (21.4 ~ 37.7cm 2, 304 ~ 536 psi)

'

.

5. Removethe 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

_'t

'

power trim and tilt unit to the bracket.

'_'l'_._

1. Referring

7-30

to the illustration,

install

the

BRKT!

I P.T.T.MOTOR '

P.T.T. MOTOR 1. Loosen the screws and remove the stator, O-ring and the armature.

2. Disconnect

_ x _-__

the connector.

3. brush, Loosen cover the plate, screw circuit and remove the breaker and __._.

thespring.

K82001-0'

INSPECTION ARMATURE COIL face and if it shows signs of roughness, polish it with 600-grit wet-or-dry sand1. Visually inspect the commutator surpaper.

(____

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.

¢_

7-31

diameter: Armature outside Standard:minimum 22 mm (0.87 in) Minimum: 21 mm (0.83 in)

""KT I'TI.TT MoTe" 3. Scrape between the segments with a hack-saw blade and then carefully remove all particles of metal and mica

withcompressed air.

4. Check for continuity _------"]

or discontinuity

of

the armature coil. If it is out of specification, replace the armature.

discontinuity _ Armature coil continuity/ Commutator segments_) Continuity ,----

Segment-Laminations(_)

Discontinuity

Segment-Shaft(_)

Discontinuity

BRUSH

__} .........

,I

,I

I I

I I

Standard: 9.7 mm (0.38 in) 1' Measure thesize brushes for wear.

Brush, (_): Minimum: 4.7 mm (0.19 in)

I(_

BASE ASSEMBLY 1. Inspect the base assembly for crackes or burns and replace the base assembly if such are found.

2. Check for continuity nector and lead wire.

between the conIf there is disconti-

nuity, replace the base assembly.

CIRCUIT BREAKER and the terminal.

(_

If there

1. Check for continuity

7-32

is discontinu-

between

the brush

_

B"KTIIPTT.OTO. K63000-0'

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.

?

o_

^ssEM.[v 4 Nm (0.4 m · kg, 2.0 ft ° lb) 3. Place the O-ring on the motor assembly

gg_l_,

jgc_-_vg I _1

and align and the gear grooves the motor assembly pump,of then install the bolts.

J_ r-j

___

_1

[Stamped mark] [6H307] 6 Nm (0.6 m · kg, 4.3 ft ° lb) P'T'T' m°t°r [62F-00] mounting b°lt= [6H3-13], 7 Nm (0.7 m · kg, 5.1 ft · lb)

7-33

I

IE'EcI[

CHAPTER8 ELECTRICAL SYSTEM

ELECTRICALCOMPONENTS........................................................................8-1 WIRING DIAGRAM ........................................................................................8-3 REMOTE CONTROL BOX .......................................................................8-6 DIGITAL METER ................................................................................8-6 REMOVAL ......................................................................................................8-7 MAGNETO BASE....................................................................................8-7 CLEANING, INSPECTION AND REPAIR.......................................................8-9 LOW RESISTANCE MEASUREMENT...............................................8-9 TESTING THE C.D.I. SYSTEM (For U.S.A. and CANADA) ...................8-9 USING THE 1-Y IGNITION-TESTER..................................................8-9 PULSER COIL........................................................................................8-14 CHARGECOIL .......................................................................................8-14 LIGHTING COIL.....................................................................................8-15 IGNITION COIL......................................................................................8-15 REPLACEMENTOF SPARK-PLUG CAP...............................................8-16 C.D.I. UNIT ............................................................................................8-17 CRANK POSITION SENSOR ................................................................8-19 STARTER RELAY..................................................................................8-19 POWERTRIM AND TILT RELAY..........................................................8-19 POWERTRIM AND TILT SWITCH .......................................................8-20 RECTIFIERREGULATOR......................................................................8-21 FUSE......................................................................................................8-21 THERMOS-SWITCH..............................................................................8-22 OIL INJECTION SYSTEM .....................................................................8-23 OIL-LEVEL SENSOR .............................................................................8-24 OIL-LEVELWARNING LAMP (L.E.D.) ..................................................8-26 WIRING HARNESS...............................................................................8-26 BRACKET...............................................................................................8-27 BA'I-I'ERY...............................................................................................8-27 ENGINE STOP SWITCH (P60TH/60FEMTO)........................................8-27 MAIN SWITCH (P60TH/60FEMTO)......................................................8-28 INSTALLATION ............................................................................................8-28 FLYWHEEL MAGNETO ........................................................................8-28

[:

STARTER MOTOR .......................................................................................8-29 REMOVAL .............................................................................................8-29 DISASSEMBLY .....................................................................................8-29 INSPECTION .........................................................................................8-30 PINION..............................................................................................8-30 STARTER CLUTCH ..........................................................................8-30 BRUSH..............................................................................................8-30 BRUSH-HOLDER..............................................................................8-30 ARMATURE ......................................................................................8-31 ASSEMBLY (50, 60, 70 hp) ...................................................................8-32 INSTALLATION (50, 60, 70 hp) ............................................................8-33 ASSEMBLY (80, 90 hp).........................................................................8-33 INSTALLATION (80, 90 hp) ..................................................................8-34

I LECIE.ECT.,CA. I COMPO.E.TS M20000-O

ELECTRICAL COMPONENTS 50, 60, 70 hp (_) Ignition coil (_) Spark-plug O Thermo-switch (_ Power trim and tilt replay (P.T.T. model) (_) Power trim and tilt switch (P.T.T. model)

(_) Starter relay Q Oil warning lamp (_) Charge coil ® Crank position sensor _) Lighting coil ® Pulser coil @ Wire harness

Q Fuse (_) C.D.I. unit Q Starter motor (_ Trim sensor (P.T.T. model) O Rectifier regulator

f

8-1

I .Ecl l M20001-0

ELECT.,CAL CO..O. .TS

80, 90 hp O Ignition coil Q Spark-plug O Thermo-switch ® Power trim and tilt switch (P.T.T.model) O Fuse (_)Wire harness

O ® ® (_ @ @

Pulser coil Statorassembly C.D.I.unit Rectifier regulator Crank position sensor Powertrim and tilt replay (P.T.T.model)

8-2

(_ Starter relay (_ Startermotor (_ Trim sensor (P.T.T.model)

--

_

--

-

M30000-0

WIRING DIAGRAM

i _

m

__oS _

m.-

i

_

[] ·

_

_8

I'

'

'ii!

_i

ii i, L, i i ',1 iJJ

:

:

:

®1 ,_

:ii® .............

I

®

:

·

-_, E

_°

EE -- m _''-= "=-

:

¢.'1 ''' .......'

>.

_-,

_

,E_

_m :

· · ->. -' ' i '_

._ --'_, : : : : : _,_:o,._.. ...........

====

E

-=_--

_=o_ _ _ _=o_.__ i___ _

50, 60, 70 hp

S

c: _

_:_:

c-__r_

_',_

8-3

M30000-O

o_.mSu)

_,

_

[;11

g

____.

-,-.o=_-----

'E

[]

[]

iI

,_ ®

', i :

l/l/ ....

IIII

:

:

:

iii

5'J,i

:

:

:

e'.,_

1............ q-_ ._:

:

,- ,--= _,-.E :

t

:

· :

"0

E

°

_.

I

===================

:

- :· ': : : : : : : : .D: : ' >- .....

t:_ ._-0 _-,:

o_

I_.__--

m_-_.-_o__-_--m-=_-_

......

E

-;_i ..................... i..... _....

Till

L____-.,_, _,"_., P."_

I,=L cl l 80, 90 hp

g

_-_-o

8-4

IE'EC} I P60TH/60FEMTO O Buzzer O Fuse (10A) O Main switch (_) Engine stop switch [] To tachometer [] To P.T.T.switch (option)

_

[] To trim sensor [] To oil level sensor [] To lamp switch (option)

_ _ ,_

i1"

[] _

tr

. _I ,

o

BG

®{

}®

® ®

Y

['_,1

I I I,

G /_W

W

Lg ____1

[_:3.c_-W R y B i_B

R Y Br

IR

Sb P

L

W

G

Br

_]-_--

_

®--

_w'

t...._/G _m.m.

'1 b_--ir_Y

w_7=::=:_

P

iff

TM

B ............Black Br...........Brown G ............ Green Gy .......... Gre¥ 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 8-5

_

P

IE'ECII M31000-0

REMOTE CONTROL BOX

r---®---_

Q

I I_Isbi"IL.I

_ I_-----Jw

t II

ii

.I.l,le,

ON I STARTI

ouwN I ]_t_ll

I

I0tOl I IOK_

'u:!!,L_J_"'°"'°°"" '-_ I_-J ;L_ _:_O®

,

i

............ "

L---_f

'_

(_)

_

_

DIGITAL METER

o

/

/ ®..zzer

_*

/

i___,__j Ix1/_, Ell.-n

O

i

·

O Main switch

(_) Neutral switch

1

_iJ_-_---

!

--"r7 '__--J,

Q Power O Engine trim stop and switch tilt switch

[ALT° meter harness

(_)

o

L

L

m--[. %-_ ®

¢%

Ii

!:,'!

'... [, --_--n

® [_]

O Digital tachometer (_) Digital speedometer (o/p) O To fuel management meter (o/p) O Lamp switch (o/p) O Fuse (10A) (_ Fuel sensor (o/p)

[] To remote control box [] To trim sensor [] To oil level gauge

8-6

_........... ,,_c_ Br .......... Brown G ........... Green

Gy ......... Grey L ............ Blue Lg .......... Light-green O ........... Orange P............ Pink R ........... Red Sb ......... Sky-blue W .......... White Y ........... Yellow

IE'EC)I .EMOVA. M40003-0

50, 60, 70 hp [

REMOVAL

80, 90 hp

1. Remove the flywheel

,__

cover.

2. Remove the starter-pulley.

___

MAGNETO BASE

Â¥

3. Loosen the flywheel with the crankshaft.

nut until it is flush

YB-6139190890-06522

The major load must be carried in the direction of the arrows. If not, the holder may easily slip off.

/

F.

Keep the nut side flush with the crankshaft end until the flywheel comes off the ?;_"_..-.'_.. .___ _ _ ._i'_!_ tapered portion of the crankshaft.

///i._i_

8-7

I

L cjr j. MovAL ¥B-6117

4. Remove the flywheel magneto.

'''w'ee'"u''e IYB-6117/90890-06521 i

.._'i:11_ '°7_¢''_. · -,_..· ,_.'..,__:.,._.;...=_

_._.____ _

_._.-_

_..

bolts evenly and completely so that the puller plate is parallel to the flywheel.

TO prevent damage to the engine or tools, screw in the flywheel magneto-puller set-

r_, ..._

5. Remove the woodruff key from the crankshaft keyway using a screwdriver.

,_i...,_.o_;_._ ._-_-_._

Take specialcare not to damagethe surflywheel magneto, lift it up while tilting it slightly, Do not allow the magneto to contact the timing plate. face of the crankshaft. When removing the

8-8

IE'ECI I ,.SPECT,O. A.D.EPA,.

M51000-0 _

CLEANING, INSPECTION AND REPAIR _<_Z_ _<x_..' _ _:_:_f,:.'.._:;_ _::.:.:.:-:.:.:_.:-_::::::::: _:

All measuring instruments should be handled with special care or correct measurement will be impossible.

On an instrument powered by dry batteries, they should be checked for voltage periodically and replaced, if necessary.

LOW RESISTANCE MEASUREMENT When measuring the resistance of 10 _ 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.

Displayed measurementCorrect Internal value= resistance

NOTE: The internal obtained nals.

resistance

by connecting

of the tester can be both of its termi-

M54002-1

TESTING THE C.D.I. SYSTEM (For U.S.A. and CANADA) USING THE 1-Y IGNITION-TESTER 1. High scale test: 1) Place switch in HIGH position. Plug the simulator into an electric outlet.

117VAC for ten seconds.

2) Remove the simulator from the outlet and connect the "P" and "N" leads from the tester to the simulator simulator.

3) Set the tester dial to 50 or less.

Depress the button on the simulator.

The indicator lamp on the tester as indicated should light. on the bottom of the

_yy

8-9

IELECI

I

CLEANING, INSPECTION AND REPAIR 2. Low scale test: 1) Place switch in LOW position.

2) Set tester dial to 50 or less.

3) Connect yellow lead to negative terminal of 12V battery. Connect red lead to positive terminal of 12V battery. Indicator lamp should light.

If lamp does not light, check tester batterles. If they are installed correctly and are good, check the clip leads for faulty connec-

,'f'

warranty statement for instructions for sending the tester back to Electro-Specialitions.Inc. ties, If no fault canbe found, refer to the

¡_'_,-__'_'__

_'__'_'_-_-_ ____.L--j

DO not touch the plug pins on the simulator while depressing the button. A mild shock will result.

I

8-10

IELEClfrlC_EA...C...S,_C_.O. ^.0RE,A., 3. Pre-test procedure: 1) If there is no spark, or the spark is weak, continue with the C.D.I. test.

2) If a good spark is obtained, the problem is not with the C.D.I. system, but possibly the spark-plug or other component is defective.

4. Connection of 1-Y ignition tester Test #1 1) Disconnect the Black/White leads from the ignition coils.

2) Connect the tester's 'P" and 'N" clip leads as shown.

NOTE:, In this test, connect the load coil, provided along with the tester, between the C.D.I. unit output and the ground.

TEST # 1

I

90 hp only

CDI UNIT I OUTPUT REPEATTEST TWo T MES 0], F51)

l

.....

.......

1

Pulser

I W/B

__

W/B

CDI unit

_LJ

?

i

rw ii/R

90hponly

L

'l!i'I --

A--',N/

90 hp only

8-11

i

iiI III I

i

I

5. Tests #2 and #3 1) Disconnect the Brown, Blue, White/ Red and White/Black leads from the C.D.I. unit.

2) Connect the tester's leads as shown.

"P" and "N" clip

90 hp only

!..,u r Jiirill tl

r_

'""'I

COl LS OUTPUT N

MAGNETO

W/R CDI unit

LCd\_'' ,

_l

'

'iw,.

'--__.--R--/_ _

....

I_ MAGNETO _'

I

;

COIL

Br CHARGE

R

I

OUTPUT

90

8-12

hp only

hp only

,

PULSER

ELE I,[i

CLEANING, INSPECTION AND REPAIR 6. Testing the C.D.I. system 1) Place the tester range switch

40 _, .60 3oTYa_/x'_7o_ 2o-_ (_ _;_ _-8o _o_x,_r9o o _0o (_

LOW

RESET

to the

position indicated on the chart.

2) Set the dial to the setting shown on the chart.

3) Crank the engine; if the light comes on, the component is good, so pro-

HIGH

ceed to the next test. If the light does not come on, replace the component.

4) When the indicator lamp lights in each test, reset the indicator circuit by depressing the RESET button for the next test.

INDICATOR

O TEST LEAD CONNECTIONS

TEST SEQUENCE Test #1 C.D.I. output #1 #3

"P" Black/White

"N"

60 hp 70 hp

90 hp

Ground

50

60

(B/W)

Test #2a Charge coil Test #2b Charge coil Test #3 Pulser coil

DIAL SETTING

RANGE SWITCH

H Use load coil

Brown (Br)

Blue (L)

60

70

H

Red (R)

Blue (L)

--

65

H

40

45

L

White/Red (W/R)

White/Black (W/B)

NOTE: Normally, #2 cylinder will not fire when cranking with starting motor. It powers all ignition coils, except #2, when the engine speed is 500 r/min or less from the cranking speed.

The coil output varies greatly with cranking speed.

Testing with the spark plugs out and good battery.

Cranking the cold engine with the plugs in and a weak battery cannot be found proper readings.

r.tw,

T!_,l:;m,;[_

While taking spark volt checker".

check

be carefull

not to touch

8-13

any connection

of lead wires

of the "spark

ELE L,lli

j

CLEANING, INSPECTION AND REPAIR M51500-0'

PULSERCOIL 1. Check the resistance of the pulser coils. at 20°C (68°F) White/Black -- White/Red: 50, 60, 70 hp: 240 ~ 360 80, 90 hp: 241 ~ 362

M51800-0'

CHARGECOIL Check the resistance of the charge coil.

50, 6O,70 hp

50, 60, 70 hp

_=_

Brown w Blue: Charge 136 ~coil 204resistance: _2at 20°C (68°F)

B

80, 90 hp

80, g0

Il[iii III

Charge coil resistance: Brown--Red: 191 ~ 288 _2at 200C(68°F} Blue -- Red: 64_°F)

G/W

G

L

8-14

I.Ecll c. ,.S.ECT,O.A.D.E M52000-0'

50, 60, 70 ho

LIGHTING

COIL

1. Check the resistance of the lighting 50, 60, 70 hp

L

G

_._iI

coil.

Green/White -- Green: Lighting resistance: Standardcoil(12V, 80W): 0.57 ~ 0.85 f_ at 20°C (68°F)

80, 90 hp

80, 90

Green/White -- Green: Standard (12V, 120W): 0.4 ~ 0.6 Q at 20°C (68°F) Lighting coil resistance:

_ NOTE: G_w G L

B_

When measuring the resistance of 10 Q or less using the digital tester, the correct measurement cannot be obtained. Refer to "Lower resistance measurement".

M52502-0'

IGNITION COIL 1. Inspect the high-tension cables and spark-plug caps for damage or cracks.

2. Measure coil.

___iI

the resistance

of the primary

Black -- Black/White: Ignition Primary coil coil:resistance: 0.18 ~ 0.24 Q at 20°C (68"F)

NOTE: When measuring the resistance of 10 _ or less using the digital tester, the correct measurement cannot be obtained. Refer to "Lower resistance measurement".

8-15

IELECll II

,.SPECT, O.A.DREP^,R 3. Measure

the resistance

of the second-

ary coil, Black -- Secondary

lead.

Black -- Secondary lead: Secondary coil: 3.3 ~ 4.9 _ at 20°C (68°F) Ignition coil resistance:

_

M53005-0

REPLACEMENT [Standard _

.....

OF SPARK-PLUG

type]

the cap, and remove the plug-cap spring from the high-tension cable.

.__"'%...,., :---

1. Remove the spark-plug

2. Cut an amount

___

_

®

___

cable.

5 mm (0.2 in)

l --

3. Fit onto the plug cap-spring. _I_ _,

tJ

.....

4. Push the cap-spring

into the plug-cap.

[With resister type] 1. Remove the spark-plug the cap.

'____ '_'_':" '_--" "'"_'_""

cap by pulling

of about ® off the end

of the high-tension

Jr

_]

CAP

_=:::::: :::==_=____

2. high-tension Install the cable. spark-plug

8-16

cap by turning

cap onto the

IEL C{CLEA...

I ,NS.ECT,ONAND M53500-0'

50, 60, 70 hp ,,j

_:_'

,/4

_.'_::_. _--_-_w '.-<o_

I Y/R

P

C.D.I. 1. Measure UNIT

/

the

resistances

of the

C.D.I.

unit.

1

--f

,,_

o_,_J

/ I /

{_

I_

_

'1_.,_____ 1

_ ,____.

j__ _

"__.-_

Y

'_:B._L:/R_ :r '

_

can not

for

this

Digital

路

meter resistance to meter, values especially elecC.D.I. will with vary from inspection. Use analogue tester. tronic digital meters. For some testers, polarity of leads is reversed.

' /._._.

tester

be used

路

Br : Brown 50, 70 hp L 60, 路 Blue

Y

W/B: White/Black L/R 路 Blue/Red W'R L/W: :Wh,te,aed Blue/White

_

For charge coil

Unit: k_ Br

Br

L

_

12~29

L

15~40

B

2.5~6.7

_

8~18 9.5~22

2.7~7.0

For pulser coil

Unit: kD

W/R W/R

_

W/B

37.5~1_}00 _

B

B

2.7~7.0

W/B

B

35 ~ 500

37.5~ 1_00 28 ~ 175

2.7~7.0

For ignition coil B/W -- B 2.7 ~ 7.0 k_ For crank

)osition sensor

L/W L/W L/R B 8-17

_ 8.9 ~ 20 2.7~7.0

o_: No continuity

Unit: kQ

L/R

B

oo

o_

_

0 8.9~20

IELECI CLEA..

I ,.S.ECT,O. A.D.E.A..

80, 90 hp r

_._'

_7

/___y ,'._O_ Y

_"--[_-_

_0

o_'o _ k'_

!

80, 90 hp Br · Brown L · Blue

"1

7 Y/R

B/W

R

'--_[_-'_B/w_ _:3_T- _._c___ _[_ B/w

t o@_1_..__

'_.

,_

W/R:White/Red. W/B White/Black L/R 'Blue/Red

__-_)

"-[---_]

:Red

L/W: B,ue/White

W

L/w ir_

'_

_'_'h

Br For

L/R

R

charge_ coil Br R

B

13~37

oo

2.4

L

B Unit: 8~17 k_

13~37

_

oo

6,3 2.8~7.4

2.5

For pulser coil

o_

6.7 Unit: k_

W/R

W/B

B

35 ~ 400

23 ~ 90

'_1 W/R W/B

37.5~ 1J_00

B

28 ~ 140

3~7

3~7

For ignition coil B/W -- B 2.5 ~ 6.7k_ For crank

)osition sensor

L/W L/W L/R

B

_ 10 ~ 24 10~24

_o:No continuity 8-18

Unit: k_

LIR

B

_

o_

_

0 0

IE.cl lc. ,.S.ECT, O. A...E.A,.

CRANK POSITION SENSOR Measure the resistance of the crank position sensor.

_=_

Blue/Red -- Blue/White: Crank 158position ~ 236 _ sensor at 20°Cresistance: (68°F)

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

r

_,_xlo

battery.leads of the starter-relay to a 12-V Brown lead .....................................(+)

B : Black Br: 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

G

POWER TRIM AND TILT RELAY 1. Check the relay for terminal looseness

®o-_

·

and for wiring rust and corrosion.

Replace the relay if any of the three

Sb _

Lg

defects is found.

LO

B 8-19

2. Connect the (+) terminal and O terminal and the (+) terminal and (_) terminal to the tester and check that the resistance becomes ooin each case.

IELECI

I

CLEANING, INSPECTION AND REPAIR

ÂŽ

3. Connect the (-) terminal

*

the tester and check the continuity each case.

Sb: Sky blue LO: Light green B : and Blackthe (-) terminal and Q terminal

-_

01.__

and O terminal

4. Connect the black terminal

_ _/)__OiL0_,

in

to

to the (-) ter-

terminal to the (+) terminal of the battery. Then connect the (+) terminal and O terminal to the tester and check the continuity. minal of the battery and the light green

_

%

5. Connect the black terminal

to the (-) ter-

terminal to the (+) terminal of the battery. Then connect the (+) terminal and (_) terminal to the tester and check the iZ_i__

(

'_,,

¡

'_

minal

"__/' --__+

of the battery

and the sky-blue

continuity.

M56100-0

POWER u'_p TSblR Lg O O FREE DOW_ C)-O

TRIM

AND TILT SWITCH

1. TO see that there is continuity, switch.

push the Unit:

--_Lg._ Sb_J

_

Sky blue Checkingleads Light green

I

Red UP

2. Check

rubber

Replace u_a.

8-20

Continuity

I

Red Discontinuity

seal.

the seal if it has any damage.

DOWN

Discontinuity

Continuity

ELEC I

CLEANING, INSPECTION AND REPAIR M56501-0

_

RECTIFIER 1. Check theREGULATOR continuity of the

B

_ G___ V'

rectifier.

Tester

___ Rectifier regulator check OT_est er_ Green Green/whiteRed Green

oo

Black

nuity Conti-

Green/

Conti- '_

Conti-

Conti-

White

nuity

nuity

nuity

Red

oo

oo

Black

Conti' nuity

Continuity

_ _

oo Continuity

oo:No continuity If continuity the rectifier.

is not as specified,

replace

NOTE: 路 Digital tester can not be used for this inspection. 路 Never connect the rectifier directly to the battery to check continuity. 路 When testing, disconnect the battery terminals. 路 When resistance is measured at less than 100 Q, 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

8-21

I

ELE

CLEANING, INSPECTION AND REPAIR M57300-0

THERMOS-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.

6 __ 8 _

84 ~ 90'C (183 ~ 194°F) ON OFFtemperature temperature (_: (_:

[]

_'ih_/

//' []

O Q O [] []

8-22

Discontinuity Continuity Discontinuity Temperature Time

IELECI I M57500-0

O. A...E.A,.

OIL INJECTION SYSTEM O Oil level sensor (_) Digital meter (Oil level warning lamps/control unit) O Lead wire ® Lead wire O Lead wire assembly

50, 60, 70 hp

80, 90 hp

8-23

I 50, 60, 70 hp

A...E.A,.

M58004-0

80, 90 hp

OIL-LEVEL

SENSOR

1. Remove the circlip and disassemble the

¢_

___

O Oil-levelsensor

(_(_

oil-level sensor.

.(_

2_

--

(_ Strainer cover O Gasket

2. Referring to the illustrations and tables, check the continuity and resistance.

_-----,-_ _--,.

[_ ___.____,_ -- -_-___-_U_ $W._2 $W_1

ON

50, 60, 70 hp _-----m_'_

I

Marking:

- ---ll_

6H3-16

Unit:

Oil level sensor Float SW. 1 ON

ON

_ 79,5 ~ 82,5 mm (3.15 ~ 3,25 in)

Black

O _'2'_

_ester Tester_ (_) Green

=_

resistance Float SW. 2 ON

_ 114,5 ~ 117,3 mm (4.51 ~ 4,62 in)

Green

0

Black

O

Black

_

Red

.oo

Black Tester_ _ester Green/ Red

0

(_ 640

Oil level sensor resistance Float SW. 1, SW. 2, both OFF

_Tester T_eest O · ''''_ r "_ _ (_) Black (_) Green (_) Green/Red

(_) Black (_ _ -% oo *oo

Green (_)

Red Green/

°°

*_

_

*oo *_

· -oo- indicates that the pointer once and returns to %0" oo:No continuity

8-24

deflects

IELECJ

I

CLEANING, INSPECTION AND REPAIR 80, 90 hp

_-

____

Marking: 6H3-15

_--' -----I-"-I-_ U_ SW. 2

_!-

ON

....

'-_

/' ....

___i IIIIIIIII I

L._.J

Oil level sens°r resistance

Float SW. I ON

sw. Jl_

_!-

Unit:

Float SW. 2 ON

® 5.8 ~ 8.8 mm ~ 0.35 in)

_) 42.3 ~ 45.3 mm ~ 1.78 in)(_)

(0.23 _Tester

ON

Tester_ 0(_--)_(_)

(1.67 _Tester

Black Green (_) 0 (O')st_, Te er_ _

Black -

(_) Green

Black Red (_ Green/

Black 0

_

640 Red

== Oil level sensor resistance Float SW. 1, SW. 2, both OFF _Tester

0 Black 0

st Te e--.....

0 r '_ _ (_) Black

_

_) Green

o_

_) Green/Red

*_

Green 0

Red Green/

o_

*o_

_

*oo .oo

*"_" indicates that the pointer once and returns to "o_" o_:No continuity 3. Assemble O (_ O O

®

deflects

as shown in the diagram.

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.

®

8-25

E'ECI)

,.SPECT,O. A.D.E.A,.

M57602-0

(50 hp) Test the Light Emitting If no light lamp. f

___

_a_

is enitted,

Diode (L.E.D.) using replace the warning

a 1'5-V dW-cell bakery' r--]_oltage: _

1

1.5V

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

I Br

Ln--_

_--e \

WIRING HARNESS 1. Check the continuity

L

__W___

P __Sb G _ _"_R

between

the cou-

pier 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

8-26

: Light green : Pink : Brown ¡ Black : Blue : Sky blue ¡ White : Yellow : Red : Green

LEclm IC.E..,.O.,.S,ECT,O...D NI58800-0

50,6o, 7o hp

8O,9Ohp

BRACKET 1. Inspect the bracket and replace it if its cracked.

(

M58900-0'

BATI'ERY ¡ Refer to page 3-11.

M59000-0

(P60TH/60FEMTO) 1. When removing and installing the lockplate, check for continuity according to

Ir_-_l

_.c,.__o.$w,_c. the chart below. _-Jl

Lockplate

Removed Installed

8-27

W color B Wire 0

0

ELECJ_'I I CLEANING, W

e

OFF 0--0 ON START

W

B

R

Y

Replace if continuity

-0

O-

_-C) Y

1. Check the continuity of the main switch.

Sr

0

R

INSPECTION AND REPAIR/INSTALLATION MAIN SWITCH (P60TH/60FEMTO)

DJ_

Checkingleads

fall

Br

[

is not as specified.

White I Black

Red I Yellow

Red I Yellow I Brown Discontinui_ Discontinuity

DiscontiContinuity nuity c ..o Disconti'_ ._ ON nuity Continuity t_a.

DiscontiDiscontiSTART nuity nuity Continuity OFF

M61002-0'

INSTALLATION FLYWHEEL MAGNETO 1. Install the magneto retainer-plate. i

base

onto

the

2. Install so that the woodruff key in the keyways fits in the crankshaft.

3. Lock the flywheel rotor with the washer and nut. Tighten the nut to the specified torque.

Flywheel nut: 160 Nm (16 m · kg, 115ft · lb)

o.r

YB-6139/90890-06522 4. Install the flywheel

8-28

cover.

I I

I LcII sTA.T ..oTo. M71001-0'

STARTER MOTOR REMOVAL 1. Disconnect the cables and remove the starter-motor.

DISASSEMBLY 1. Remove the starter-clutch. screw-driver, pry off the clip.

Using

a

O Clip Q Pinion (starter clutch) ///_ III

50, 60, 70

'NOTE: (_) Pinion stopper Push the pinion stopper by hand toward the pinion and remove the clip.

/

'-ho_._O

2. Remove the two through-bolts and pull out the front cover lightly tapping it

80,90 hp O-----_

_

_) ___._

_,________?!'_ÂŽ (-_.)-_

(_)-r-_ _

_:_ _L...(_

_

with a plastic hammer,

if necessary.

brush springs and remove the brushes from the brush-holders.

3. Using a piece of steel wire, separate the

-

4. tapping Remove itthewithyoke assembly by lightly a plastic hammer and remove the armature.

O Clip O Spring O Front cover (_) O-ring (_) Pinion stopper O Washer O Pinion (starter clutch)

(_) ,_

(_ 0_1(_)

_ (_)

(_ r__

ÂŽ Washer O Washer (50, 60, 70 hp:t = 2.0 mm, 80, 90 hp:t = 1.0 mm) (50,60, 70 hp:t = 0.15 mm, 80, 90 hp:t = 0.3 mm) (_) O Armature Yoke assembly

_ _

_) r-_

(_ Brush holder (_) O-ring (50, 60, 70 hp) (_) Rear cover (_ Through-bolt

(_

!T 8-29

ELECI

I

STARTER MOTOR INSPECTION PINION 1. Inspect the pinion and inner teeth for ion sliding motion and replace, if damaged. wear or damage and check ease of pin2. Inspect the flywheel gear and replace, if worn or damaged.

,

STARTER CLUTCH 1. Check the clutch movement. Rotate the freely. Also, try to rotate the pinion counter-clockwise and confirm that it locks.

Ii_

pinion clockwise and check that it turns

BRUSH 1. Measure the brushes for wear.

_ ;_ :,-'

(_

Brush (_):hp: 12.5 mm (0.49 in) 50, size 60, 70 80, 90 hp: 16.0 mm (0.63 in) Minimum: 50, 60, 70 hp: 9.0 mm (0.35 in) 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 continuity, assembly. o_ =

replace

the

between

the

brush-holder

brush-holder and earth. If there is any

8-30

I ,EcI IsTA.TE. MOTO.

ARMATURE

s.t e tors ace an

_

these are dirty or burnt, clean with 400grit wet-or-dry sandpaper.

2. Inspect the commutator deflection with a dialgauge and block and replace the armature if the deflection is out of specification.

0.05 mm (0.0020 in) Maximum deflection:

I_

I

If the deflection is greater than the specified deflection, replace the armature.

3.Measurethediameterof thecommutatot.

_

50, 60, 70 hp: 30 mm Standard diameter: 80, 90 hp: 33 mm Minimum diameter: 50, 60, 70 hp: 29 mm 80, 90 hp: 31 mm

(1.18 in) (1.30 in) (1.14 in) (1.22 in)

If the commutator diameter is out of specification, replace the armature.

4. Measure

_/'"/"_

_

I

the commutator

mica under-

50, 60, 70 hp: 0.8 mm (0.03 in} Standard mica undercut depth: 80, 90 hp: 1.0 mm (0.04 in) cut depth.

Minimum undercut depth: 50, 60, 70 hp: 0.2 mm (0.01 in) 80, 90 hp: 0.5 mm (0.02 inJ If the undercut depth is less than the segments with a hacksaw blade, then remove all particles of mica and metal

_

with compressed air. specifiedminimum,scrapebetweenthe

8-31

ELEJ"--

STARTER MOTOR 5. Check the insulation between the shaft or laminations and earth. 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 taklng care not to scratch the brush or contaminate it with grease.

'_

2. Install the yoke assembly,

IIIII

aligning

the

tion on the stator and ensuring that the O-ring fits correctly in the rear cover groove. recess on the rear cover with the projec-

I_ _:__t_ I1_('_")1

3. Mount

the two washers

on the arma-

tant grease to the front cover bushing, ensure that the O-ring fits into the armature shaft and insert the shaft into ture shaft.cover.

Sparingly apply water resisthe front

,' ,

8-32

I,Ecl l sTA.TE. MOTO, 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

i

and fit

Use athesocket-wrench thatReform fits properly over armature shaft. the circlip by using pliers. Lift up the pinionstopper until its bottom contacts the circlip. the circlip into the groove in the shaft.

_t

I INSTALLATION r (_'--_J _'-_ ..._.

_-'__'_ __ _

,,

(50, 60, 70 hp)

1. Place the starter-motor on the starter-

_-___/_

motor stay and tighten the bolts to the

s,..er mo,or 20 Nm (2.0 m ¡ kg, 14 ft ¡ lb) mounting

_____l

_

_

bolt:

2. Secure the starter-motor to the engine specified with the torque. four starter-motor mounting- I bolts.

/

3. Connect the positive and negative wires to the starter-motor.

_:j

_ (_

ASSEMBLY (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.

(_

O Brush holder

8-33

,Ecl ISTA.TE..OTO. 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 installing.

I t_ _)

O Positive brush (_)Spring o

0

3. Mount the two steel washers and resin shaft and install the front cover onto the yoke assembly.

O Front cover washer, in that order, on the armature

f

'

_

when

the brush holder with the gap in the brush holder so that the through-bolt can be inserted.

)_o_ _

_

4. Align the cut (for the through-bolt)

in

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: grease) to the front and rear cover bearings. ¡¡ Apply To seala out mating surfaces thin water, coat ofthegrease (anti-freeze are coated with sealing compound.

_)_

INSTALLATION (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.

8-34

s. q?l

ITRBL I

CHAPTER 9 TROUBLESHOOTING

TROUBLE-SHOOTING DIAGRAM ...............................................................9-1 HOW TO TROUBLE-SHOOT ..................................................................9-1 ENGINE WILL NOT START ..........................................................................9-2 ROUGH IDLING .............................................................................................9-9 ENGINE STALLS ..........................................................................................9-10 ENGINE WILL NOT STOP ..........................................................................9-11 PRIME START ..............................................................................................9-12 POWER TRIM AND TILT SYSTEM ..............................................................9-14 GEAR SHIFTING IS IMPOSSIBLE OR HARD..............................................9-16 OIL INJECTION SYSTEM ............................................................................9-17

ITRBL I SHTGI ?

I TROUBLE-SHOOTING DIAGRAM

02OOOO-O

TROUBLE-SHOOTING

DIAGRAM

I Trouble? I

1 Check the equipment visually or by operating it according to pre-delivery check or periodic check procedures.

I Basic checking

Symptoms of trouble

Repair or adjust

'lsoo roueis oca neo..

I

I

O,scover,he conditions under which the equipment

ev ent cause I.e.air ora_jus, I

went out of order and reproduce the same conditions.

!

Confirmatory test I I

End

HOW TO TROUBLE-SHOOT 1. In case of trouble,

first check the equipment

according

to the pre-delivery

check

and peri-

odic check procedures.

2. Conduct 3. Repair

a test under the defect

simulated

and conduct

conditions

and investigate

a confirmatory

the symptom

of the trouble.

test to make sure that the trouble

has been

repaired.

4. When the symptom of the trouble those in which the trouble occurred

cannot be reproduced, set up conditions and conduct a test again.

9-1

similar

to

?

ITRBLI SHTG1 --

I

ENGINE WILL NOT START

O45001-1'

ENGINE WILL NOT START starter-switch on?

I Does the starter-motor run with the

GO TO [] (P. 9-3)

_1,1_ YES Can the flywheel be turned by hand?

j

_vl_

I

GO TO [] (P. 9-4)

_o

YES

Are the battery cables connected?

Connect. (P. 3-2 ~ 3-5)

YES

loose?

I Are the battery terminal-c°nnecti°ns

,,_

I YES

_

NO

I

Recharge.

Check using a battery tester.

Replace if necessary. (P. 3-11 ~ 3-12)

YES

Is thefuse blown?

1YES

Replace.(P.8-21)

,,_ NO

Does the starter sound?

I

NO

Is the battery in good condition? _vl_

Tighten. (P. 3-2 ~ 3-5)

I

I

YES

relay make operating

NO

I

Are the terminals connected correctly?

_o

Correct them. (P. 3-2 ~ 3-5)

YES erly?

Doesthewiring harnessconductprop-

NO

Replace.

(P.3-2~3-5)

I]

YES

I I

Does the key-switch have good contact?

Replace.

YES

Does the starter relay function normally?

Replace. (P. 8-19)

YESJ__

9-2

I I

TRBLI SHTG! ?

I ENGINEWILLNOTSTART

* If the relay chatters, turn off the power immediately to prevent damage to the relay.

Charge the battery completely and re-check the relay. If it still chatters, either the battery or the starter motor may be faulty - Check.

YES Does the terminal on the secondary side (connected to starter-motor) conduct?

NO

Replace the starter-relay. (P. 8-19)

I

Repair. (P. 8-29 ~ 8-35)

I

I

'_YES

Iche_ the star_er-m°t°r''_' _-_' I_S_ ,_o Is any trouble found?

RE-CHECK

m

Isetherthesta IYES erpn°n°rthef'w I I I gear broken?

Replace. (P. 8-29)

_.

NO

Is there enough fuel in the tank? _v_

YES

Ican the crankshaft be turned by hand?

YES

IIs pres-sure? the c°mpressi°n

Add fuel.

at the specified

_IGOTOr_(P.9-4) N

NIGO

TO [] (P. 9-5)

'_YES 'lisa strong blue spark produced?

I _,,_

GO TO [] (P. 9-6)

YES

IDoes fuel reach the carburetor?

YES operate ldo both normally? the carburetor linkage and valve ,_

""Ni_

Ni

NO

GOTOITl(P.9-7)

Connect this. (P. 3-13, 3-14)

II

YES

I Is the carburetor overflowing?

YES

9-3

V_ I(P. 4-7)the float and needle-valve.

I_Check

II

ITRBL I SHTGI ?

I

ENGINE WILL NOT START

N° Does water collect in the float-bowl?

,,_

Clean the float-bowl. (P. 4-7)

NO

Is any jet clogged-up?

Clean. (P. 4-7)

,41,-NO i Does the prime start function correctly?

N_

GO TO PRIME START (P. 9-12)

YES I

Is the ignition timing correct? '_

damage. (P. 8-8) Check the flywheel woodruff key for II

NO

(P. 5-11) the reed-valve assembly.

Replace

YES

not the damaged7 I is Does reed-valve form a good seal and ,_

NO

YES Check the following

Check the compression leakage from the

parts and

replace as necessary: (P. 5-6 ~ 5-12) 1) Oil-seal

crankcase.

Is the compression of the crankcase normai? _1_

II

2) O-ring 3) Crankcase - cracks, distortions and scratches on mating surfaces.

YES

Is there any damage to the cylinder7

bly. (P. 5-17, 5-18) YES

_ Replace the crank cylinder assem-

i, N° RE-CHECK

Remove the lower unit and check if the flywheel can be turned by hand?

YES I

l N° 9-4

1)Impeller blades are caught; 2) Gear/bearing damaged; 3) Shimtheadjustment Check lower unit:wrong (P. 6-8 ~ 6-15)

]

m

_ j

ITRBL

SHTG ?

]

ENGINE WILL NOTSTART

(P. 5-6 ~ 5-10) Is any piston seizure found?

der.

NO condition? lis the connecting-rod bearing in good YES

Replace. (P. 5-10)

NO

I

Is crankshaft bearing in good condition7

Replace. (P. 5-12)

II

I

,J_ YES RE-CHECK

NO Is the spark-plug installed correctly?

Install it correctly. (P. 3-23 ~ 3-24)

'_YES Does the piston face the correct direction? _1_

Correct. (P. 5-14)

YES

the piston holed?

IRemovethecylinder-headandcheckit'lsl

YES

_

Replace. (P. 5-6)

I

NO Is the head gasket in good condition?

Replace. (P. 5-6)

YES scratchedor deformed?

I Isthepist°n°rcylindercracked'

I YES

_

Replace.(P.5-7 ~ 5-8)

NO Is the piston ring damaged or worn?

Replace. (P. 5-9)

RE-CHECK

9-5

I

ITRBLI SHTG_ ?

--

I ENGINEWILLNOTSTART

® Is the key-switch in good condition?

I

_o

Replace.

1_ YES I Iseachc°nnecti°nl°°se?

I YES

_){ Tighten'

I

NO YES Is the spark-plug cracked?

Replace. (P. 3-23)

NO

I I I I

Is the spark-plug type correct?

Replace it with correct type. (P. 3-23)

17. YES

Is the spark-plug in good condition?

Replace. (P. 3-23)

YES

Is the spark-plug gap correct?

Adjust it. (P. 3-23)

YES

Does the spark-plug cap have no leaks?

-_

YES

,o

Replace. (P. 8-16)

leaking?

I I I I

Replace.

(P.8-16)

-_- NO correctly?

I Are the C.D.l.-unit terminals connected _17

Connectcorrectly.(P.3-2~ 3-5)

I

YES

pulser coil all in good condition? and I Arethe ignition-coil,source-coil _,_

NO

NO

Replace. (P. 8-14 ~ 8-16)

I

Replace. (P. 8-17 ~ 8-18)

I

YES

I

Is the C.D.l.-unit in good condition?

,J_ YES RE-CHECK

9-6

?

ITRBLI SHTGI --

] ENGINE WILL NOT START

F_ NO Is there sufficient fuel in the tank?

Add fuel. (P. 4-1)

YES Is the fuel dirty?

Clean. (P. 4-2)

NO Is the fuel-tank filter clogged-up?

Clean it. (P. 4-3)

.41- NO

I

Is the fuel meter suction pipe clogged-up?

_.

Replace. (P. 4-3)

I

Replace and fit correctly. (P. 4-1)

II

NO

and is in it fitted correctly?in good conlisdition the O-ring the connector

NO

YES

I I

Is the fuel joint of the tank clogged-up?

Clean or replace. (P. 3-6, 4-4)

.41- NO

Is the fuel-hose cracked or damaged?

.._

NO

face towards the engine?

I pump Does the embossed arrow on the priming _'

I NO

Replace. (P. 4-1)

Correct the pump position. (P. 4-3)

I I II

YES

rectly?

I Does the priming-pump function cor-

NO

Replace. (P. 4-3)

I

,_vl_ YES function normally?

I Doesthe fuel joint on the engine side

NO

Replace. (P. 4-4)

II

Replace. (P. 4-3)

I

,_1,17 YES

I

Is the fuel filter clogged-up?

'41' NO

Disassemble the fuel-pump and check it (P. 4-4). Is the diaphragm in good condition?

NO Replace. (P. 4-4)

,_YES 9-7

SHTGI ?

ENGINE WILL NOT START ,J_

YES

Is the check valve cracked or leaking?

_

Replace. (P. 4-3)

NO

I

Are the fuel hoses connected correctly?

Correct them. (P. 4-1)

L YES RE-CHECK

9-8

I

ITRBLI SHTGI ?

I ROUGH IDLING

0-50005- I ·

ROUGH IDLING Is the fuel fresh?

Replace the fuel. _

I I

YES

Are all wiring connections tight? _

YES

Are the spark-plugs tightly screwed in? _

YES

J Does sparking take place in allcylinders? ·_

hten. (P. 3-2 ~ 3-5)

,o iN

hten. (P. 3-23)

GOTO[](P.

I I

9-6)

YES

load?

Disconnect the load.

_

NO

rect?

Are the ignition sequence and timing cor_ YES

NO

Are the settings of the carburetor _

II

Correct the setting. (P. 4-9 ~ 4-10)

YES

Is the magneto base loose?

,_

Correct this. (P. 3-16)

Replace the magneto base.

NO

Does the reed-valve seal effectively?

Replace the reed-valve. (P. 5-11)

YES out7 I Does the flywheel have excessive run-

YES

I

lng.

Check the crankshaft and its bear-

,,_ NO Does the fuel-pump operate normally?

I

Replace. (P. 4-4)

YES

Does the compression meet the specified pressure?

Jv LYES RE-CHECK

NO

9-9

Inspect the cylinder piston head gas- I ket and piston rings for wear and damage. (P. 5-6 ~ 5-9)

ITRBL I SHTGI

?

J ENGINESTALLS

O60005-0'

ENGINE STALLS (A) The engine stalls in any gear.

I I I I

Is the fuel-hose connected correctly? '_

Correct. (P. 3-6)

YES

Is the engine warmed-up? _

Warm it up.

YES

,o

Does the choke function normally? _"

Repair. (P. 4-5)

YES

Is the choke placed in the set position? ',_

YES

rect?

I Are idling speed and ignition-timing '_

I,s ,t?

,,_

cor-

NO

Does the prime start function correctly?

GOTO[] (P.9-7)

NO

_o NO

GO TO PRIME START (P. 9-12)

unit.(P.8-15~8-18) Check the ignition coil and C.D.I.

II

YES

Has the engine ever overheated?

I

~..

YES

stalls? is a blue spark produced when the engine '_

I

YES

I

·_

Connect this.(P.3-15~3-18)

NO

YES

condition?

I Are the fuel-pump and fuel-line in good _

Place in set position.

I I I I

I YES

9-10

signs of seizure. (P. 5-6 ~ 5-9) _)iCheckthepist°nandcylinderf°r

I

ITRBL_ SHTq ?

J ENGINE

STALLS/ENGINE

WILL NOT STOP

(B) Engine stalls when gear is changed.

In addition to the above check points, go through the following: Is something coiled around the propeller?

_

I

Is the propeller

NO

stiff to turn in neutral?

,_

I

Remove it. (P. 3-23)

NO

i

IYES '°tho'°worun I check it. (P. 6-1)

Is the spark-plug tight?

Tighten. (P. 3-2:3) YES

Is the spark-plug gap correct?

.o

YES

I I

Is the spark-plug in good condition? ·_

Replace. (P. 3-23)

YES

Is the head-gasket in good condition?

(P. 6-1) I Disassemble

_

Adjust. (P. 3-23)

Replace. (P. 5-6)

YES

I !

I I

I

the lower unit and check it. I

O70000-0'

ENGINE WILL NOT STOP I Does earthing the white lead of the C.D.I. unit stopthe engine?

NO

I

Replace the C.D.I. unit.

(P.8-17~ 8-18)

I

I

'_YES lead?

ID°esthewiringharnesshaveabr°ken

_

I YES

NO !

Check the stop-switch

and key-switch.

II

9-11

_{

Replacethe wiring harness.(P.8-26) I

ITRBL I SHTGJ ?

PRIME START

I PRIMEsTART

{A) Engine does not start when engine is cold. connected correctly?

I Are the electrothermal valve terminals _ YES

NO

tioned correctly? lis the manual enrichment lever posiYES

NO

I

Is the fuel hose cracked or damaged?

NO

I

correctly? (P. 4-8) I Does the electrothermal valve function YES

NO

Ilsthecarburetorslowcircuitclogged-up?l

YES

Connect correctly. (P. 8-1 ~ 8-2)

[

Correct it.

Replace.

Replace.

_ Cleanit'

I

,,_ NO Is the (P. enriching fuel pump in good condition?

4-8)

NO

_ YES RE-CHECK

9-12

Replace,

I

I

TRBL I SHTG1 ?

I PRIMESTART

(B) Engine does not start when engine is hot.

(C) Engine turns over but stalls. connected correctly?

I Are the electrothermal valve terminals

NO

Connect correctly. (P.8-1 ~ 8-2)

J

YES tioned correctly?

I is the manual enrichment lever posi_ _v_

NO

Correct it.

I

YES YES

Is the fuel hose cracked or damaged?

Replace.

NO 10) lis the light coil in good condition? (P. 8YES

NO

Is the (P. rectifier tion?

8-21) regulator in good condi-

NO

Replace.

Replace.

II

I I

YES correctly? (P. 4-8) ideas the electrothermal valve function YES

I

NO

Is the carburetor slow circuit clogged-up?

Replace.

Clean it.

41' NO

tion? (P. 4-8) J lsthe enriching fuel pump in good condi-

NO

.J_ YES RE-CHECK

9-13

Replace.

]

I II

?

ITRBLI SHTGI --

I POWER TRIM AND TILT SYSTEM

085005-0*

POWER TRIM AND TILT SYSTEM (A) The motor will not turn over.

I I

.o .o

Is the battery in good condition? '_

Recharge or replace. (P. 3-11)

YES

Are the battery cables connected? '_

Connect them. (P. 3-11)

YES

tight?

I Are the battery terminal-connections '_' YES

NO

I

.o

Is the control-switch cable connected?

I

,_,1,1_YES

Does the relay make an operating sound?

Tighten. (P. 3-11)

NO

yes

I

nection. (P. 8-19) Check for a broken lead or discon-

I

relay. (P. 8-19)

YES

Does the motor turn over when connected directly to the battery?

I

Connect it. (P. 3-2 ~ 3-5)

coo__

i

I I

41'No_ Goo_

II °rc° nect.

NO fromtheengine?

I Does the motor turn over when removed _Vl_

NO

YES

pump be moved lightly by hand?

I Remove the gear-pump. Can the gear_' (P. 7-12) I Disassemble

I

(P.7-21) Disassemble the motor and check it. I

NO

YES

I

the relief valve and check it. I

9-14

Replace the gear-pump. (P. 7-12)

II

SHTG1 TRBLI ?

I POWERTRIM AND TILT SYSTEM

(n) The motor turns out.

I

Is there leakage of fluid?

I YES

,,_ NO

replace the O-ring. _Tighten°rreplacetheuni°nseat°rl

NO

Is the hydraulic-fluid level correct?

Top-up. (P. 3-22, 7-18)

YES Is air present in the hydraulic-fluid?

Bleed. (P. 7-18) YES

I

,,_ NO

friction excessive? inder. (P. 7-17 ~ 7-18) ITumthema va,vetomanua,.,st ua, YES e Overha ,the ,, t ,mp,stonand I

_

I

NO

Is the hydraulic pressure correct?

NO

YES RE-CHECK

9-15

(P. 7-18 ~ 7-19) Check the hydraulic system.

I

ITRBLI SHTGI

q --

J GEAR

SHIFTING IS IMPOSSIBLE OR HARD

O90005-0'

GEAR SHIFTING IS IMPOSSIBLE

OR HARD

STOP THE ENGINE. Do not start the engine during the following inspections. Remove the battery terminals.

Turn the propeller and check that the gears are in "Neutral" and "Forward".

Gears are not in "Neutral" and "Forward"...Gears are faulty.

Gears are in "Neutral" and "Forward"...Remote control is faulty. trol box?

I Are there irregularities in the remote con'_'I YES

_

Check the shift rod.

I

_,- NO tor correct?

I lsthe connection of the cable and connec_1_

NO

Adjust.

I

Replace it, if necessary.

Clean rust or salt from the cable.

J

I

YES

cable smooth? is the movement of the remote control

NO

I

YES box operate normally?

I Does the link inside the remote control YES

NO

correctly? lis the shift handle or shift lever connected ,_VIr YES

NO

Correct this or replace it.

Connect.

damaged?

IArethed째gs째ftheclutchd째g째rgear I YES _ Replace. (P. 6-7)

NO damaged? lis the shift-cam, shift-slider or shifter

II YES

Replace. (P. 6-3 ~ 6-4)

_I' NO Is the cross pin or cross pin ring broken?

Replace. (P. 6-4)

RE-CHECK

9-16

II I

ITRBLI SHTGI ?

[ OILINJECTION SYSTEM

P10005-0°

OIL INJECTION SYSTEM (A) Red oil level warning

I I I I I

lamp lights up.

Is the key-switch turned off at that time?

Switch off.

YES

Is a sufficient amount ofoil in the tank? '_

Is the hose connection

Add oil. (P. 3-7, 4-10, 4-11)

YES correct?

Connect. (P. 3-6, 4-12, 4-14)

YES

Are the lead wires connected correctly7 ,_

Connect. (P. 3-2 ~ 3-5)

YES

Is the oil level sensor operating normally7

Replace. (P. 3-21, 8-24)

I I I I I

YES RE-CHECK (B) There is too much exhaust smoke.

There is too much oil consumption.

I

Does the oil pump link operate normally? '_

Adjust the oil pump link. (P. 3-22)

YES

Measure the oil discharge. Is the discharge of oil from the pump in the specifled discharge range? _

NO Replace the oil pump. (P. 3-20)

YES !

Oil deterioration is considered.

I

I

9-17

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ITRBL I SHTGI ?

I OILINJECTION SYSTEM

lC) Engine overheats.

There is not enough

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oil discharge.

Is there sufficient oil in the oil tank? ',_

Add oil. (P. 3-7, 4-12 ~ 4-13)

YES

Has the oil deteriorated or is it dirty?

,,_

Replace. (P. 3-7, 4-12 ~ 4-13)

NO

Are the oil hoses flattened, bent, disconnected, cracked or damaged?

YES Replace. (P. 3-6, 4-12 ~ 4-14)

NO Is air contained

in the hoses? [80, 90 hp]

_

Bleed. (P. 3-8, 4-14) [80, 90 hp]

NO

Does the oil pump link operate normally?

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Adjust the link. (P. 3-22)

YES

Is air contained in the pump?

,,_

Bleed. (P. 3-8)

NO

Measure the oil discharge. Is the discharge of oil from the pump is in the specified discharge range?

NO

YES RE-CHECK

9-18 .

Check the pump drive gear and driven gear. Replace the pump, if necessary.

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YAMAHA YAMAHA MOTORCO.,LTD.

Printed in Japan Nov. 1993- 1.01 x 1 CR

6H2-28197-Z3-11 (50GEO,

_)

50GETO,

60FEO, 60FETO,

60FEMTO,

70BEO,

70BETO,

80AEO,

80AETO,

90AEO,

90AETO)

Printed on recycled pa

Yamaha Motor Canada Ltd. 480 Gordon Baker Road Toronto, ON M2H 3B4