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Yamaha e60hmhd Service Manual

Other manuals for e60hmhd: Service Manual

Summary of e60hmhd

  • Page 1

    Service manual 69d-28197-5g-11 e60h a4cover 06.8.25 10:08 page 1.

  • Page 2

    Notice this manual has been prepared by yamaha primarily for use by yamaha dealers and their trained mechanics when performing maintenance procedures and repairs to yamaha equipment. It has been written to suit the needs of persons who have a basic understanding of the mechanical and electrical conc...

  • Page 3: Specifications

    Specifications general information periodic checks and adjustments fuel system power unit bracket unit electrical systems troubleshooting index contents lower unit 9 8 7 6 2 1 gen info spec chk adj fuel powr lowr brkt elec trbl shtg 3 4 5 69d5g11_01 06.10.16 13:22 page 1.

  • Page 4

    69d5g11_01 06.10.16 13:22 page 2.

  • Page 5: General Information

    69d5g11 1- 9 8 7 6 5 4 3 2 1 general information how to use this manual ............................................................................... 1-1 manual format .......................................................................................... 1-1 symbols ..............................

  • Page 6

    Gen info 1- 69d5g11 general information 1-1 how to use this manual manual format the format of this manual has been designed to make service procedures clear and easy to under- stand. Use the information below as a guide for effective and quality service. 1 parts are shown and detailed in an explode...

  • Page 7

    69d5g11 9 8 7 6 5 4 3 2 1 1-2 gen info symbols the symbols below indicate the content of a chapter. General information fuel system bracket unit specifications power unit electrical systems periodic checks and adjustments lower unit troubleshooting symbols 1 to 6 indicate specific data. 1 special to...

  • Page 8

    Gen info 1- 69d5g11 general information 1-3 safety while working to prevent an accident or injury and to ensure quality service, follow the safety procedures provided below. Fire prevention gasoline is highly flammable. Keep gasoline and all flammable products away from heat, sparks, and open flames...

  • Page 9

    1-4 69d5g11 9 8 7 6 5 4 3 2 1 6. Keep a supply of clean, lint-free cloths for wiping up spills, etc. Good working practices special service tools use the recommended special service tools to protect parts from damage. Use the right tool in the right manner–do not improvise. Tightening torques follow...

  • Page 10

    Gen info 1- 69d5g11 general information 1-5 identification applicable model this manual covers the following models. Serial number the outboard motor serial number is stamped on a label attached to the port clamp bracket. 1 model name 2 approved model code 3 transom height 4 serial number propeller ...

  • Page 11

    1-6 69d5g11 9 8 7 6 5 4 3 2 1 selection when the engine speed is at the full throttle operating range (4,500–5,500 r/min), the ideal propeller for the boat is one that pro- vides maximum performance in relation to boat speed and fuel consumption. Predelivery checks to make the delivery process smoot...

  • Page 12

    Gen info 1- 69d5g11 general information 1-7 checking the outboard motor mounting height 1. Check that the anti-cavitation plate is aligned with the bottom of the boat. If the mounting height is too high, cavitation will occur and propulsion will be reduced. Also, the engine speed will increase abnor...

  • Page 13

    69d5g11 1-8 9 8 7 6 5 4 3 2 1 predelivery checks w the shift/throttle cable joint must be screwed in a minimum of 8.0 mm (0.31 in) b. Note: check the throttle valve fully open, after set- ting the remote control cables. Checking the steering system 1. Check the steering friction for proper adjustmen...

  • Page 14

    Gen info 1-9 69d5g11 general information checking the engine start switch, engine stop lanyard switch and engine stop button 1. Check that the engine starts when the engine start switch is turned to start. (whd, wd) 2. Check that the engine turns off when the engine start switch is turned to off. (w...

  • Page 15

    69d5g11 1-10 9 8 7 6 5 4 3 2 1 break-in during the test run, perform the break-in operation in the following 5 stages. 1. 10 minutes a at the lowest possible speed. A fast idle in neutral is best. 2. 50 minutes b at 1/2 throttle (approxi- mately 3,000 r/min) or less. Vary engine speed occasionally. ...

  • Page 16: — Memo —

    Gen info 1-11 69d5g11 — memo — 69d5g11_01 06.10.16 13:22 page 14.

  • Page 17: Specifications

    69d5g11 9 8 7 6 5 4 3 2 1 spec specifications general specification ................................................................................... 2-1 maintenance specification .......................................................................... 2-3 power unit ...............................

  • Page 18

    Spec 2-1 69d5g11 specifications general specification item unit model e60hmhd e60hwhd e60hwd dimensions overall length mm (in) 1,197 (47.1) 713 (28.1) overall width mm (in) 364 (14.3) overall height (s) mm (in) 1,358 (53.5) – – (l) mm (in) 1,479 (58.2) (x) mm (in) 1,556 (61.3) – – boat transom heigh...

  • Page 19

    69d5g11 2-2 9 8 7 6 5 4 3 2 1 general specification item unit model e60hmhd e60hwhd e60hwd fuel and oil fuel type regular gasoline engine oil 2-stroke outboard motor oil engine oil grade nmma-certified tc-w3 gear oil type hypoid gear oil gear oil grade (*1) api gl-4 sae 90 gear oil quantity cm 3 (us...

  • Page 20

    Spec 2-3 69d5g11 specifications maintenance specification power unit item unit model e60hmhd e60hwhd e60hwd power unit minimum compression kpa 540 (5.4, 76) pressure (*1) (kgf/cm 2 , psi) cylinder head warpage limit mm (in) 0.1 (0.0039) (lines indicate straightedge position) cylinders bore size mm (...

  • Page 21

    Item unit model e60hmhd e60hwhd e60hwd piston rings top ring dimension b mm (in) 1.970–1.990 (0.0776–0.0783) dimension t mm (in) 2.900–3.100 (0.1142–0.1220) end gap mm (in) 0.30–0.50 (0.0118–0.0197) side clearance mm (in) 0.03–0.07 (0.0012–0.0028) oversize diameter 1st mm (in) 72.25 (2.845) 2nd mm (...

  • Page 22

    Electrical item unit model e60hmhd e60hwhd e60hwd ignition and ignition control system ignition timing (full retarded) degree atdc 1.0–3.0 pston position (full retarded) mm (in) atdc 0.01–0.05 (0.0004–0.0020) ignition timing (full advanced) degree btdc 18.0–20.0 pston position (full advanced) mm (in...

  • Page 23

    69d5g11 2-6 9 8 7 6 5 4 3 2 1 maintenance specification item unit model e60hmhd e60hwhd e60hwd pulser coil output peak voltage (w/r–b, w/b–b, w/g–b) at cranking (unloaded) v 2.0 at cranking (loaded) v 2.0 at 1,500 r/min (loaded) v 6.0 at 3,500 r/min (loaded) v 10.0 pulser coil resistance (w/r–b) Ω 1...

  • Page 24

    Spec 2-7 69d5g11 specifications 525 (20.7) 527 (20.8)** 457 (18.0)* 451 (17.8) ** 1,021 (10.2) 913 (35.9) ** 260 (10.2) 254 (10.0) ** 542 (21.3) 547 (21.6) ** 67 (2.6) 640 (25.2)* 635 (25.0)** 556 (21.9) 561 (22.1)** 4.0 (0.16) -6.0 (-0.24)** 264 (10.4)* 248 (9.8)** 208 (8.2) 229 (9.0)** 40 (1.6) 85...

  • Page 25

    69d5g11 2-8 9 8 7 6 5 4 3 2 1 maintenance specification 180 (7.1) 180 (7.1) 163.5 (6.4) 163.5 (6.4) 126 (5.0) 126 (5.0) 13 (0.5) 69 (2.7) 18.5 (0.7) 355 (14.0) 327.5 (12.9)* 50.8 (2.0) 13 (0.5) 55.5 (2.2) 254 (10.0) clamp bracket (s, l-transom model) mm (in) *s-transom 69d5g11_02 04.9.21 15:21 page ...

  • Page 26

    Spec 2-9 69d5g11 specifications 180 (7.1) 180 (7.1) 163.5 (6.4) 163.5 (6.4) 126 (5.0) 126 (5.0) 13 (0.5) 69 (2.7) 18.5 (0.7) 355 (14.0) 50.8 (2.0) 13 (0.5) 55.5 (2.2) 254 (10.0) clamp bracket (x-transom model) mm (in) 69d5g11_02 04.9.21 15:21 page 10

  • Page 27

    69d5g11 2-10 9 8 7 6 5 4 3 2 1 maintenance specification/tightening torques tightening torques specified torques part to be tightened thread size tightening torques n·m kgf·m ft·lb fuel system intake silencer — 2 0.2 1.5 power unit power unit mounting bolt m8 21 2.1 15.5 flywheel nut m20 160 16 115 ...

  • Page 28

    Spec 2-11 69d5g11 specifications general torques this chart specifies tightening torques for standard fasteners with a standard iso thread pitch. Tightening torque specifications for special components or assemblies are provided in applicable sections of this manu- al. To avoid warpage, tighten mult...

  • Page 29

    69d5g11 9 8 7 6 5 4 3 2 1 3 1 periodic checks and adjustments special service tools ................................................................................... 3-1 maintenance interval chart .......................................................................... 3-2 top cowling .............

  • Page 30

    Chk adj 69d5g11 3-1 special service tools periodic checks and adjustments chk adj digital tachometer 90890-06760 leakage tester 90890-06840 timing light 90890-03141 dial gauge set 90890-01252 69d5g11_03_1 06.10.16 13:36 page 2.

  • Page 31

    69d5g11 9 8 7 6 5 4 3 2 1 3-2 3 1 maintenance interval chart use the following chart as a guideline for general maintenance. Adjust the maintenance intervals according to the operating conditions of the outboard motor. Special service tools/maintenance interval chart initial every refer item actions...

  • Page 32

    Chk adj 3-3 69d5g11 periodic checks and adjustments top cowling checking the top cowling 1. Check the fitting by pushing the cowling with both hands. Adjust if necessary. 2. Loosen the bolts 1, and then move the hook 2 up or down slightly to adjust its position. Note: 9 to loosen the fitting, move t...

  • Page 33

    Checking the thermostat 1. Remove the thermostat cover 1, gasket 2, and thermostat 3. 2. Suspend the thermostat in a container of water. 3. Place a thermometer in the water and slowly heat the water. 4. Check the thermostat valve opening at the specified water temperatures. Replace if out of specifi...

  • Page 34

    Control system adjusting the start-in-gear protec- tion 1. Set the gear shift to the neutral position. 2. Loosen the bolt 1, and then adjust the start-in-gear protection cable 2 until the mark a on the guide, aligns with the mark b on the stopper. 3. Tighten the bolt 1. Synchronizing the carburetors...

  • Page 35

    69d5g11 3-6 9 8 7 6 5 4 3 2 1 power unit/control system 3. While lightly pushing the throttle lever 4 of the carburetor #3 in the direction of the arrow (full-closed), and then tighten the screws 3 of the carburetor #1 and #2. Note: after synchronizing the carburetor, adjust the engine idling speed ...

  • Page 36

    1. Loosen the locknut 1, remove the clip 2 and then remove the throttle cable joint 3. 2. Set the throttle grip or remote control lever to the fully closed position. 3. Check that the control lever 4 contacts the crankcase 5. 4. Adjust the position of the throttle cable joint 3 until its hole aligne...

  • Page 37

    Checking the gear shift operation 1. Check that the gear shift operates smoothly when shifting it from neutral to forward or reverse. Adjust the shift cable if necessary. 2. Set the gear shift to the neutral position. 3. Loosen the locknut 1, remove the clip 2, and then remove the shift cable joint ...

  • Page 38

    Chk adj 3-9 69d5g11 periodic checks and adjustments 8. Check that the neutral switch 6 is push- ing by the shift lever 7. (whd) checking the ignition timing 1. Start the engine and warm it up for 5 min- utes. 2. Attach the special service tool to spark plug wire #1 1, and then check the engine idle ...

  • Page 39

    69d5g11 3-10 9 8 7 6 5 4 3 2 1 control system adjusting the ignition timing note: 9 remove the all spark plugs and the engine stop lanyard switch clip before adjusting the ignition timing. 9 make sure that the engine is stopped before adjusting the ignition timing. 1. Remove the throttle cable or th...

  • Page 40

    Chk adj 3-11 69d5g11 periodic checks and adjustments 8. Slowly turn the flywheel magnet to clock- wise to the dial gauge indicates to the specified position. 9. Check that the scale a on the flywheel magnet with the timing plate b are spec- ified position. 10. When the piston at atdc position, set t...

  • Page 41

    69d5g11 3-12 9 8 7 6 5 4 3 2 1 lower unit checking the gear oil level 1 fully tilt the outboard motor down. 2. Remove the check screw 1, and then check the gear oil level in the lower case. Changing the gear oil 1. Fully tilt the outboard motor up. 2. Place a drain pan under the drain screw 1, remov...

  • Page 42

    2. Apply the specified pressure to check that the pressure is maintained in the lower unit for at least 10 seconds. Note: cover the check hole with a rag when remov- ing the special service tool from the lower unit. 3. If pressure drops below specification, check the drive shaft, propeller shaft oil...

  • Page 43

    Lubricating the outboard motor 1. Apply water resistant grease to the areas shown. Note: apply grease to the grease nipple until it flows from the bushings a. 69d5g11 3-14 9 8 7 6 5 4 3 2 1 w battery electrolyte is dangerous; it con- tains sulfuric acid which is poisonous and highly caustic. 9 avoid...

  • Page 44

    Chk adj 3-15 69d5g11 periodic checks and adjustments å tiller handle model 2. Apply corrosion resistant grease to the area shown. 69d30220 a a 69d30225 a 6b430300 å 69d5g11_03_1 06.10.16 13:36 page 16.

  • Page 45: Fuel System

    69d5g11 9 8 7 6 5 4 3 2 1 fuel system special service tools ................................................................................... 4-1 hose routing ................................................................................................. 4-2 fuel line ..............................

  • Page 46

    Fuel 4-1 69d5g11 fuel system special service tools vacuum/pressure pump gauge set 90890-06756 digital caliper 90890-06704 69d5g11_04 06.10.16 13:41 page 2.

  • Page 47

    69d5g11 4-2 9 8 7 6 5 4 3 2 1 special service tools/hose routing hose routing 1 fuel hose (fuel joint-to-fuel filter) 2 fuel hose (fuel filter-to-fuel pump) 3 fuel hose (fuel pump-to-carburetors) 4 pilot water hose 69d4010e 1 2 3 4 3 1 2 3 69d5g11_04 06.10.16 13:41 page 3.

  • Page 48

    Fuel 4-3 69d5g11 fuel system fuel line wd 2 n·m (0.2 kgf·m, 1.5 ft·lb) 69d4020e no. Part name q’ty remarks 1 lock tie 4 2 fuel hose 1 3 bolt 1 m6 × 25 mm 4 fuel joint 1 5 clamp 10 6 fuel hose 1 7 fuel hose 1 8 bolt 2 m6 × 40 mm 9 fuel pump 1 10 gasket 1 11 bolt 3 m6 × 16 mm 12 bolt 1 m6 × 14 mm 13 b...

  • Page 49

    69d5g11 4-4 9 8 7 6 5 4 3 2 1 fuel line wd 2 n·m (0.2 kgf·m, 1.5 ft·lb) 69d4020e no. Part name q’ty remarks 18 o-ring 1 19 fuel filter element 1 20 spring 1 21 float 1 22 fuel hose 1 23 fuel hose 1 24 fuel hose 1 25 fuel hose 1 26 pipe 2 27 screw 4 ø6 × 45 mm 28 washer 4 29 intake silencer 1 30 bolt...

  • Page 50

    Fuel 4-5 69d5g11 fuel system wd 2 n·m (0.2 kgf·m, 1.5 ft·lb) 69d4020e no. Part name q’ty remarks 35 carburetor assembly #1 1 36 carburetor assembly #2 1 37 carburetor assembly #3 1 38 gasket 1 39 joint 1 40 choke rod 1 41 grommet 1 42 choke solenoid 1 wd model not reusable 69d5g11_04 06.10.16 13:41 ...

  • Page 51

    69d5g11 4-6 9 8 7 6 5 4 3 2 1 fuel line/carburetor carburetor 69d4030e no. Part name q’ty remarks 1 screw 6 ø4 × 30 mm 2 plate 3 3 gasket 3 4 plate 3 5 main air jet 3 6 gasket 3 7 plate 3 8 pilot air jet 3 9 o-ring 3 10 plate 3 11 pilot air screw 3 12 spring 3 13 screw 3 #1 and #2 carburetor 14 wash...

  • Page 52

    Fuel 4-7 69d5g11 fuel system 69d4030e no. Part name q’ty remarks 18 float 3 19 float pin 3 20 needle valve 3 21 clip 3 22 pin 3 23 cap 3 24 pilot jet 3 25 main jet 3 26 main nozzle 3 27 drain screw 3 28 gasket 3 29 throttle stop screw 1 #2 carburetor 30 spring 1 #2 carburetor 31 cap 1 #3 carburetor ...

  • Page 53

    4. Check the pilot screw and needle valve for bends or wear. Replace if necessary. 5. Check the float for deterioration. Replace if necessary. 6. Measure the float height a. Replace the float and needle valve as a set, if out of specification. Note: the float should be resting on the needle valve 1,...

  • Page 54

    6. Install the pilot screw, turn it in until it is lightly seated, then out the specified number of turns. Note: 9 adjust the throttle cable whenever the car- buretor has been disassembled or the engine idle speed has been adjusted. 9 for adjustment procedures, see chapter3. 7. Install the carbureto...

  • Page 55

    69d5g11 4-10 9 8 7 6 5 4 3 2 1 carburetor/fuel pump fuel pump 69d4040e no. Part name q’ty remarks 1 screw 3 ø6 × 30 mm 2 cover 1 3 diaphragm 1 4 gasket 1 5 fuel pump body 1 6 gasket 1 7 diaphragm 1 8 check valve 2 9 gasket 1 10 cover 1 11 screw 2 10 nut 2 not reusable not reusable not reusable 69d5g...

  • Page 56

    Fuel 4-11 69d5g11 fuel system checking the fuel pump 1. Place a drain pan under the fuel hose connections, and then disconnect the fuel hoses from the fuel pump. 2. Connect the special service tool to the fuel pump inlet. 3. Cover the fuel pump outlet with a finger, and then apply the specified posi...

  • Page 57

    69d5g11 4-12 9 8 7 6 5 4 3 2 1 checking the fuel joint 1. Visually check the fuel joint for cracks or damage. 2. Connect the special service tool at the outlet of fuel joint. 3. Apply the specified pressure to check that the pressure is maintained for 10 seconds. Replace the fuel joint if neces- sar...

  • Page 58: — Memo —

    Fuel 4-13 69d5g11 — memo — 69d5g11_04 06.10.16 13:41 page 14.

  • Page 59: Power Unit

    69d5g11 9 8 7 6 5 4 3 2 1 power unit special service tools ................................................................................... 5-1 power unit ..................................................................................................... 5-5 checking the compression pressure .....

  • Page 60

    Powr 5-1 69d5g11 power unit special service tools compression gauge 90890-03160 flywheel holder 90890-06522 flywheel puller 90890-06521 crankshaft aligner 90890-03107 driver rod l3 90890-06652 driver rod ls 90890-06606 bearing separator 90890-06534 crank jig set 90890-02422 needle bearing attachment...

  • Page 61

    69d5g11 9 8 7 6 5 4 3 2 1 5-2 special service tools flange 90890-02351 body 90890-02352 bolt 90890-02353 washer 90890-02354 bushing-9 (d30) 90890-02363 b-9 press body 90890-02385 bearing pressure c 90890-02393 c height ring (h-11) 90890-02377 h-11 plate c 90890-02402 crank separater kit (set 02416 +...

  • Page 62

    Powr 5-3 69d5g11 power unit disassembling kit 90890-02416 nut 90890-02407 pressure plate 90890-02408 pole 90890-02409 plate a 90890-02410 plate b 90890-02411 assembling kit 90890-02417 guide 90890-02412 guide plate 90890-02413 guide pole 90890-02414 69d5g11_05_1 06.10.16 13:51 page 4.

  • Page 63

    69d5g11 5-4 9 8 7 6 5 4 3 2 1 special service tools base 90890-02415 small end bearing installer 90890-06527 cylinder gauge 90890-06759 bearing inner race attachment 90890-06641 69d5g11_05_1 06.10.16 13:51 page 5.

  • Page 64

    Powr 5-5 69d5g11 power unit power unit checking the compression pressure 1. Start the engine, warm it up for 5 min- utes, and then turn it off. 2. Remove the clip from the engine stop lanyard switch. 3. Remove the spark plug caps and all spark plugs, and then install the special service tools into a...

  • Page 65

    69d5g11 5-6 9 8 7 6 5 4 3 2 1 power unit 21 n·m (2.1 kgf·m, 15.5 ft·lb) 4 n·m (0.4 kgf·m,3.0 ft·lb) 8 n·m (0.8 kgf·m, 5.8 ft·lb) 69d5010e no. Part name q’ty remarks 1 power unit 1 2 manual starter assembly 1 3 collar 3 4 grommet 6 5 bolt 2 m8 × 30 mm 6 bolt 1 m8 × 26 mm 7 bolt 2 m8 × 30 mm 8 grommet...

  • Page 66

    Powr 5-7 69d5g11 power unit 21 n·m (2.1 kgf·m, 15.5 ft·lb) 4 n·m (0.4 kgf·m,3.0 ft·lb) 8 n·m (0.8 kgf·m, 5.8 ft·lb) 69d5010e no. Part name q’ty remarks 18 bolt 1 m6 × 25 mm 19 neutral switch assembly 1 20 bolt 1 m6 × 12 mm 21 bracket 1 22 starter relay 1 23 wireharness 1 24 bolt 1 m6 × 16 mm 69d5g11...

  • Page 67

    69d5g11 5-8 9 8 7 6 5 4 3 2 1 power unit 160 n·m (16 kgf·m, 115 ft·lb) whd, wd wd 69d5020e no. Part name q’ty remarks 1 flywheel magnet 1 2 bolt 3 m8 × 12 mm 3 starter pulley 1 4 nut 1 5 washer 1 6 bolt 1 m6 × 10 mm 7 timing plate 1 8 woodruff key 1 69d5g11_05_1 06.10.16 13:51 page 9.

  • Page 68

    Powr 5-9 69d5g11 power unit 20 n·m (2.0 kgf·m, 15 ft·lb) mhd 69d5030e no. Part name q’ty remarks 1 screw 2 2 cover 1 3 bolt 6 m6 × 25 mm 4 ignition coil 3 5 bolt 3 m6 × 16 mm 6 screw 2 7 bracket 1 8 grommet 3 9 collar 3 10 cdi unit 1 11 screw 1 ø6 × 25 mm : whd and wd models 12 rectifier 1 whd and w...

  • Page 69

    69d5g11 5-10 9 8 7 6 5 4 3 2 1 power unit 20 n·m (2.0 kgf·m, 15 ft·lb) mhd 69d5030e no. Part name q’ty remarks 18 lighting coil 1 19 screw 2 ø5 × 25 mm 20 charge coil 1 21 screw 3 ø6 × 12 mm 22 retainer 3 23 base assembly 1 24 retainer 1 25 washer 1 26 starter motor 1 whd and wd models 69d5g11_05_1 ...

  • Page 70

    Powr 5-11 69d5g11 power unit 69d5040e no. Part name q’ty remarks 1 joint 1 2 bolt 1 m6 × 16 mm 3 collar 1 4 bolt 1 m6 × 25 mm 5 collar 1 6 wave washer 1 7 cam 1 8 link rod 1 9 joint 2 10 nut 2 11 bolt 1 m6 × 45 mm 12 washer 1 13 collar 1 14 control lever 1 15 spring 1 16 control lever 1 17 washer 1 ...

  • Page 71

    69d5g11 5-12 9 8 7 6 5 4 3 2 1 power unit 69d5040e no. Part name q’ty remarks 18 control lever 1 19 screw 2 20 nut 2 21 cap 2 69d5g11_05_1 06.10.16 13:51 page 13.

  • Page 72

    Powr 5-13 69d5g11 power unit 69d5050e no. Part name q’ty remarks 1 manual starter case 1 2 stay 5 3 washer 2 4 spiral spring 1 5 collar 1 6 sheave drum 1 7 cover 1 8 clip 1 9 collar 1 10 drive pawl 1 11 spring 1 12 spring 1 13 drive plate 1 14 washer 1 15 bolt 1 m6 × 16 mm 16 bolt 1 m6 × 25 mm 17 wa...

  • Page 73

    69d5g11 5-14 9 8 7 6 5 4 3 2 1 power unit 69d5050e no. Part name q’ty remarks 18 bushing 1 19 roller 1 20 bolt 2 m6 × 30 mm 21 grommet 2 22 collar 2 23 cover 1 24 manual starter handle 1 25 damper 1 26 starter rope guide 1 27 starter rope 1 28 bolt 1 m6 × 12 mm 29 clip 1 30 washer 1 31 start-in-gear...

  • Page 74

    Powr 5-15 69d5g11 power unit 69d5050e no. Part name q’ty remarks 35 stopper 1 36 spring 1 69d5g11_05_1 06.10.16 13:51 page 16.

  • Page 75

    69d5g11 5-16 9 8 7 6 5 4 3 2 1 power unit disassembling the manual starter 1. Turn the sheave drum 1 clockwise until the spiral spring is free. Note: 9 turn the sheave drum so that the notch on the outer surface of the sheave drum faces toward the manual starter handle. 9 pass the starter rope 2 thr...

  • Page 76

    Powr 5-17 69d5g11 power unit checking the spiral spring 1. Check the spiral spring for cracks, bends, or damage. Replace if necessary. Checking the drive pawl 1. Check the drive pawl for cracks or dam- age. Replace if necessary. Measuring the starter rope 1. Measure the starter rope length. Replace ...

  • Page 77

    69d5g11 5-18 9 8 7 6 5 4 3 2 1 power unit 7. Install the collar 6, cover 7, clip 8, drive pawl 9, spring 0, spring q, and drive plate w. 8. Turn the sheave drum 6 times in the direction of the arrow shown, and then remove the starter rope from the notch e. 9. Pull the manual starter handle several t...

  • Page 78

    Powr 5-19 69d5g11 power unit 3. Disconnect the neutral switch connector 2. (whd) 4. Remove the neutral switch bracket 3 (whd) and bracket 4. Note: set the shift position to the reverse, when remove the neutral switch bracket and brack- et. 5. Disconnect the remote control cables (remote control mode...

  • Page 79

    Note: apply force to the crankshaft end until the fly- wheel magnet comes off the tapered portion of the crankshaft. 3. Remove the woodruff key. Removing the electrical components 1. Remove the bracket 1, the starter motor 2 (whd, wd models). 2. Remove the base assembly 3, the light- ing coil 4, and...

  • Page 80

    Powr 5-21 69d5g11 power unit assembling the control lever 1. Install the spring into the control lever 1, and then install the control lever 2. Note: align the projection a on the control lever 2 with projection b on the control lever 1 to turn the direction. 69d50240 2 1 69d50245 a b 69d5g11_05_1 0...

  • Page 81

    69d5g11 5-22 9 8 7 6 5 4 3 2 1 power unit/reed valves 0.8 n·m (0.08 kgf·m, 0.6 ft·lb) 4 n·m (0.4 kgf·m,3.0 ft·lb) 8 n·m (0.8 kgf·m, 5.8 ft·lb) 69d5060e no. Part name q’ty remarks 1 screw 1 2 timing plate 1 3 bolt 7 m6 × 25 mm 4 intake manifold assembly 1 5 screw 6 ø5 × 16 mm 6 reed valve assembly 3 ...

  • Page 82

    Powr 5-23 69d5g11 power unit 2. Measure the valve stopper height b. Replace if out of specification. Removing the reed valve assembly 1. Remove the intake manifold bolts 1, and then remove the intake manifold cover 2, gasket and reed valve assembly. Checking the reed valves 1. Check the reed valves ...

  • Page 83

    69d5g11 5-24 9 8 7 6 5 4 3 2 1 reed valves/cylinder head 15 n·m (1.5 kgf·m,11.1 ft·lb) 32 n·m (3.2 kgf·m, 23 ft·lb) 3 n·m (0.3 kgf·m,2.2 ft·lb) 8 n·m (0.8 kgf·m, 5.8 ft·lb) 23 n·m (2.3 kgf·m, 17 ft·lb) 25 n·m (2.5 kgf·m, 18 ft·lb) 10 n·m (1.0 kgf·m, 7.2 ft·lb) 69d5070e no. Part name q’ty remarks 1 g...

  • Page 84

    Powr 5-25 69d5g11 power unit 15 n·m (1.5 kgf·m,11.1 ft·lb) 32 n·m (3.2 kgf·m, 23 ft·lb) 3 n·m (0.3 kgf·m,2.2 ft·lb) 8 n·m (0.8 kgf·m, 5.8 ft·lb) 23 n·m (2.3 kgf·m, 17 ft·lb) 25 n·m (2.5 kgf·m, 18 ft·lb) 10 n·m (1.0 kgf·m, 7.2 ft·lb) 69d5070e no. Part name q’ty remarks 18 exhaust outer cover 1 19 gas...

  • Page 85

    69d5g11 5-26 9 8 7 6 5 4 3 2 1 cylinder head removing the cylinder head 1. Remove the spark plugs, thermostat cover, thermostat and thermoswitch. 2. Remove the cylinder head bolts (nut) in the sequence shown. C c do not scratch or damage the mating sur- faces of the cylinder head and cylinder block....

  • Page 86

    Powr 5-27 69d5g11 power unit 2. Install the two nuts 2, and then locking the nut as shown. 3. Tighten the nuts to specified torque. 4. Remove the two nuts from the stud bolt. Installing the thermoswitch 1. Install the thermoswitch 1, push into the bottom of the flange on the cylinder head cover 2. 6...

  • Page 87

    69d5g11 5-28 9 8 7 6 5 4 3 2 1 cylinder head/crankcase 10 n·m (1.0 kgf·m,7.2 ft·lb) 20 n·m (2.0 kgf·m, 15 ft·lb) 20 n·m (2.0 kgf·m,15 ft·lb) 40 n·m (4.0 kgf·m, 29.5 ft·lb) 69d5080e no. Part name q’ty remarks 1 crankshaft assembly 1 2 cylinder block 1 3 dowel 2 4 oil seal 1 5 oil seal 1 6 o-ring 1 7 ...

  • Page 88

    Powr 5-29 69d5g11 power unit 10 n·m (1.0 kgf·m,7.2 ft·lb) 20 n·m (2.0 kgf·m, 15 ft·lb) 20 n·m (2.0 kgf·m,15 ft·lb) 40 n·m (4.0 kgf·m, 29.5 ft·lb) 69d5080e no. Part name q’ty remarks 18 bolt 2 m8 × 20 mm 19 plate 1 20 bracket 1 69d5g11_05_1 06.10.16 13:51 page 30

  • Page 89

    69d5g11 5-30 9 8 7 6 5 4 3 2 1 crankcase 69d5090e no. Part name q’ty remarks 1 upper bearing 1 2 o-ring 1 3 clip 1 4 oil seal 1 5 circlip 6 6 washer 6 7 needle bearing 84 8 piston ring set 3 9 piston pin 3 10 piston 3 11 crank assembly #1 1 12 roller bearing assembly 2 13 labyrinth ring 2 14 crank a...

  • Page 90

    Powr 5-31 69d5g11 power unit 69d5090e no. Part name q’ty remarks 18 washer 6 19 roller bearing 3 20 connecting rod 3 21 crank pin 3 22 crank 2 2 23 crank 3 2 24 crank 4 1 69d5g11_05_1 06.10.16 13:51 page 32.

  • Page 91

    69d5g11 5-32 9 8 7 6 5 4 3 2 1 crankcase removing the oil seal housing 1. Remove the oil seal housing 1. Removing the crankcase 1. Remove the crankcase bolts in the sequence shown. Note: insert a flat-head screw driver between the pry tabs to pry off the crankcase. Removing the crankshaft assembly 1...

  • Page 92

    Powr 5-33 69d5g11 power unit 2. Apply grease to new oil seal, then install them into the oil seal housing. 3. Apply grease to new o-ring 5, and then install. Disassembling the upper bearing 1. Remove the o-ring and oil seal. Assembling the upper bearing 1. Apply grease to the new oil seal 1, o- ring...

  • Page 93

    69d5g11 5-34 9 8 7 6 5 4 3 2 1 crankcase checking the piston diameter 1. Measure the piston outside diameter at the specified measuring point. Replace if out of specification. Checking the piston clearance 1. Calculate the piston clearance using the piston outside diameter and the cylinder bore spec...

  • Page 94

    Powr 5-35 69d5g11 power unit checking the piston ring side clear- ance 1. Measure the piston ring side clearance. Replace the piston and piston rings as a set if out of specification. Checking the piston pin boss bore 1. Measure the piston pin boss bore. Replace the piston if out of specification. C...

  • Page 95

    69d5g11 5-36 9 8 7 6 5 4 3 2 1 crankcase disassembling the crankshaft 1. Insert the special service tools between #1 crank assembly 1 and #2 crank assembly 2, and then separate them using a press. Note: when forcing out the crank assembly, use care so that they do not fall. 2. Remove the roller bear...

  • Page 96

    Powr 5-37 69d5g11 power unit 6. Using the bearing separator to slightly move the inner race w off the shaft, and then remove the inner race. Assembling the crankshaft c c 9 when reassembling the crankshaft, wash all component parts in clean kerosene (do not use gasoline). 9 do not reuse bearings, al...

  • Page 97

    69d5g11 5-38 9 8 7 6 5 4 3 2 1 crankcase 4. Install the labyrinth ring u onto #2 crank assembly 8 and install the roller bearing i onto #1 crank assembly t, before assembling the #2 and #1. Note: make sure the pin side of the bearing faces #1 crank assembly. 5. Align the crank angle of #1 t for #2 c...

  • Page 98

    Powr 5-39 69d5g11 power unit note: 9 install the guide o, and then align the crank angle. 9 place the press body p on the assembling kit. C c do not apply force in excess of 7 tons. 10. Remove the guide plate as same #1 and #2 procedure. 11. Install the lower bearing to #3 crank assembly using a pre...

  • Page 99

    2. Install the needle bearings 3, washers 4, piston pin 5, and new clips 6. Note: 9 make sure that the piston and piston pin bearings are installed in their original com- bination. 9 use the small end bearing installer 7 to install the needle bearings. 9 make sure that the up mark on the piston crow...

  • Page 100

    Note: 9 apply engine oil to the pistons, piston rings and bearings before installation. 9 align the dowels of the bearings with the slot 1 on the cylinder block. 9 align the rings 2 with the grooves in the cylinder block. 2. Apply sealant to the mating surface of the crankcase. Note: do not get any ...

  • Page 101

    5. Install a new gasket and the exhaust cover, and then tighten the bolts to the specified torques in two stages and in the sequence shown. Note: apply loctite 572 to the exhaust cover bolts before installation. 6. Install a new cylinder head gasket, the cylinder head, thermoswitch, a new cylin- der...

  • Page 102

    11. Install the control levers, and the electri- cal components to the power unit. Installing the power unit 1. Clean the power unit mating surface, and install the dowels 1 and a new gasket 2. 2. Install the power unit 3, and then tighten the power unit mounting bolts 4 to the specified torque. 3. ...

  • Page 103

    69d5g11 5-44 9 8 7 6 5 4 3 2 1 crankcase 13. Install the starter pulley. 14. Install the manual starter and start-in- gear protection cable 8, and then adjust it length. For adjustment procedures, see chapter 3. 15. Install all removed parts. 16. Set the shift lever to the neutral position and check...

  • Page 104: — Memo —

    Powr 5-45 69d5g11 — memo — 69d5g11_05_1 06.10.16 13:51 page 46.

  • Page 105: Lower Unit

    69d5g11 9 8 7 6 5 4 3 2 1 lowr lowr lower unit special service tools ................................................................................... 6-1 lower unit .................................................................................................... 6-5 removing the lower unit ......

  • Page 106

    Lowr 6-1 69d5g11 lower unit special service tools dial gauge set 90890-01252 stopper guide plate 90890-06501 bearing puller assembly 90890-06535 drive shaft holder 3 90890-06517 bearing outer race puller assembly 90890-06523 bearing separator 90890-06534 ring nut wrench extension 90890-06513 bearing...

  • Page 107

    69d5g11 6-2 9 8 7 6 5 4 3 2 1 special service tools driver rod ls 90890-06606 needle bearing attachment 90890-06608 needle bearing attachment 90890-06611, 90890-06612 bearing outer race attachment 90890-06621, 90890-06626 shift rod push arm 90890-06052 stopper guide stand 90890-06538 driver rod sl 9...

  • Page 108

    Lowr 6-3 69d5g11 lower unit pinion height gauge 90890-06710 pinion height gauge plate b 90890-06712 pinion nut holder new: 90890-06715 current: 90890-06505 magnet base b 90890-06844 backlash indicator 90890-06706 bearing inner race attachment 90890-06639, 90890-06643 90890-06662 ball bearing attachm...

  • Page 109

    69d5g11 6-4 9 8 7 6 5 4 3 2 1 special service tools magnet base plate 90890-07003 69d5g11_06 06.10.16 18:09 page 5.

  • Page 110

    Lowr 6-5 69d5g11 lower unit lower unit 40 n·m (4.0 kgf·m, 29.5 ft·lb) 35 n·m (3.5 kgf·m, 25.3 ft·lb) 4.5 n·m (0.45 kgf·m, 3.3 ft·lb) x 40 n·m (4.0 kgf·m, 29.5 ft·lb) 69d6010e no. Part name q’ty remarks 1 lower unit 1 2 check screw 1 3 gasket 3 4 drain screw 1 5 screw 1 6 dowel 2 7 cover 1 8 bolt 1 m...

  • Page 111

    69d5g11 6-6 9 8 7 6 5 4 3 2 1 lower unit 40 n·m (4.0 kgf·m, 29.5 ft·lb) 35 n·m (3.5 kgf·m, 25.3 ft·lb) 4.5 n·m (0.45 kgf·m, 3.3 ft·lb) x 40 n·m (4.0 kgf·m, 29.5 ft·lb) 69d6010e no. Part name q’ty remarks 18 spring washer 4 19 washer 4 20 water inlet cover 2 21 screw 1 ø5 × 42 mm 22 nut 1 23 seal 1 2...

  • Page 112

    Lowr 6-7 69d5g11 lower unit 69d6020e no. Part name q’ty remarks 1 circlip 1 2 shift rod 1 3 circlip 1 4 o-ring 1 5 plate 1 6 oil seal 1 7 o-ring 1 8 bolt 2 m6 × 45 mm 9 cap 1 10 screw 2 11 grommet 1 12 seal 1 13 bolt 2 m8 × 70 mm 14 bolt 2 m8 × 50 mm 15 water pump housing 1 16 insert cartridge 1 17 ...

  • Page 113

    69d5g11 6-8 9 8 7 6 5 4 3 2 1 lower unit 69d6020e no. Part name q’ty remarks 18 dowel 2 19 gasket 1 20 outer plate cartridge 1 21 gasket 1 22 oil seal housing 1 23 gasket 1 24 o-ring 1 25 oil seal 2 26 woodruff key 1 not reusable not reusable not reusable not reusable not reusable 69d5g11_06 06.10.1...

  • Page 114

    Lowr 6-9 69d5g11 lower unit removing the lower unit 1. Drain the gear oil. 2. Shift the shift lever or remote control lever to neutral, place a block of wood between the anti-cavitation plate and pro- peller to keep the propeller from turning, and then remove the propeller nut and propeller. W 9 do ...

  • Page 115

    69d5g11 6-10 9 8 7 6 5 4 3 2 1 lower unit note: set the shift to the neutral position using the special service tool,before remove the shift rod assembly. Checking the water pump and shift rod 1. Check the water pump housing for defor- mation. Replace if necessary. 2. Check the impeller and insert c...

  • Page 116

    Lowr 6-11 69d5g11 lower unit propeller shaft housing 69d6030e 105 n·m (10.5 kgf·m, 76 ft·lb) no. Part name q’ty remarks 1 slider 1 2 shifter 1 3 shift slider 1 4 shaft assembly 1 5 ball 2 6 pin 1 7 cross pin 1 8 spring 1 9 spring 1 10 dog clutch 1 11 spring nut 2 12 plunger 2 13 spring 1 14 washer 1...

  • Page 117

    69d5g11 6-12 9 8 7 6 5 4 3 2 1 propeller shaft housing 69d6030e 105 n·m (10.5 kgf·m, 76 ft·lb) no. Part name q’ty remarks 18 reverse gear shim — 19 washer 1 20 o-ring 1 21 bearing 1 22 propeller shaft housing 1 23 straight key 1 24 needle bearing 1 25 oil seal 2 26 lock washer 1 27 ring nut 1 not re...

  • Page 118

    Lowr 6-13 69d5g11 lower unit removing the propeller shaft hous- ing assembly 1. Remove the ring nut from the propeller shaft housing, use the special service tools. Note: 9 straighten the one tab 1 of the lock wash- er, then turn the ring nut. 9 when the ring nut toward to “off”. 2. Remove the prope...

  • Page 119

    69d5g11 6-14 9 8 7 6 5 4 3 2 1 propeller shaft housing 2. Remove the ball bearing. C c do not reuse the bearing, always replace it with a new one. 3. Remove the oil seals and needle bearing. Checking the propeller shaft hous- ing 1. Clean the propeller shaft housing using a soft brush and cleaning s...

  • Page 120

    Lowr 6-15 69d5g11 lower unit assembling the propeller shaft housing 1. Install the needle bearing into the pro- peller shaft housing to the specified depth. Note: install the needle bearing with the manufac- ture identification mark a facing toward the oil seal (propeller side). 2. Apply grease to n...

  • Page 121

    69d5g11 6-16 9 8 7 6 5 4 3 2 1 propeller shaft housing/drive shaft and lower case drive shaft and lower case 95 n·m (9.5 kgf·m, 68 ft·lb) 69d6040e no. Part name q’ty remarks 1 drive shaft 1 2 forward gear 1 3 taper roller bearing assembly 1 4 forward gear shim — 5 nut 1 6 pinion gear 1 7 lower case ...

  • Page 122

    Lowr 6-17 69d5g11 lower unit removing the drive shaft 1. Remove the drive shaft assembly and pinion, and then pull out the forward gear. Disassembling the drive shaft 1. Install the pinion nut 1, tighten it tempo- rary tight, and then remove the drive shaft bearing 2 using a press. C c 9 do not pres...

  • Page 123

    69d5g11 6-18 9 8 7 6 5 4 3 2 1 drive shaft and lower case 2. Remove the drive shaft bearing outer race, shim(s), and drive shaft sleeve. Note: install the claws as shown. 3. Remove the needle bearing. Checking the pinion and forward gear 1. Check the teeth of the pinion, and the teeth and dogs of th...

  • Page 124

    Lowr 6-19 69d5g11 lower unit 2. Install the sleeve, original shim(s), and drive shaft bearing outer race. C c add or remove shim(s), if necessary, if replacing the pinion or lower case. Note: 9 apply gear oil to the inside and outside of the sleeve before installation. 9 install the sleeve with the ...

  • Page 125

    69d5g11 6-20 9 8 7 6 5 4 3 2 1 drive shaft and lower case installing the shift rod and oil seal housing 1. Install the shift rod 1, new o-ring 2 and plate assembly 3. Note: using a special service tool 4, check the for- ward, neutral and reverse position of the shift rod to set the neutral position....

  • Page 126

    Lowr 6-21 69d5g11 lower unit note: to secure the ring nut, and lock washer 6 bend one lobe into the ring nut slot, and the other towards the gear side. Installing the water pump 1. Install a new gasket 1, and outer plate cartridge 2. 2. Install the woodruff key into the drive shaft. 3. Align the gro...

  • Page 127

    69d5g11 6-22 9 8 7 6 5 4 3 2 1 drive shaft and lower case 5. Install the seal 7, grommet 8, a new gasket 9 and pump housing assembly 0 into the lower case, tighten the bolts q. Note: when installing the pump housing, apply grease to the inside of the housing, and then turn the drive shaft clockwise ...

  • Page 128

    Lowr 6-23 69d5g11 lower unit 6. Install the propeller and propeller nut, and then tighten the nut temporary tight. Place a block of wood between the anti- cavitation plate and propeller to keep the propeller from turning, and then tighten the nut to the specified torque. W 9 do not hold the propelle...

  • Page 129

    69d5g11 6-24 9 8 7 6 5 4 3 2 1 drive shaft and lower case/shimming shimming t3 m3 m2 69d6050e t2 t1 m1 69d5g11_06 06.10.16 18:10 page 25.

  • Page 130

    Lowr 6-25 69d5g11 lower unit shimming note: 9 shimming is not required when assembling the original lower case and inner parts. 9 shimming is required when assembling the original inner parts and a new lower case. 9 shimming is required when replacing the inner part(s). Selecting the pinion shims 1....

  • Page 131

    69d5g11 6-26 9 8 7 6 5 4 3 2 1 shimming example: if “m3” is 32.10 mm and “p” is (–5), then t3 = 32.10 – 31.50 – (–5)/100 mm = 0.60 + 0.05 mm = 0.65 mm 5. Select the pinion shim(s) (t3) as follows. Example: if “t3” is 0.43 mm, then the pinion shim is 0.45 mm. If “t3” is 0.38 mm, then the pinion shim ...

  • Page 132

    Lowr 6-27 69d5g11 lower unit example: if “m1” is 24.00 mm and “f” is (+5), then t1 = 24.50 + (+5)/100 – 24.00 mm = 24.50 + 0.05 – 24.00 mm = 0.55 mm 3. Select the forward gear shim(s) (t1) as follows. Example: if “t1” is 0.44 mm, then the forward gear shim is 0.42 mm. If “t1” is 0.50 mm, then the fo...

  • Page 133

    69d5g11 6-28 9 8 7 6 5 4 3 2 1 shimming/backlash example: if “m2” is 28.60 mm and “r” is (–1), then t2 = 28.60 mm – 28.00 mm – (–1)/100 = 28.60 – 28.00 + 0.01 = 0.61 mm 4. Select the reverse gear shim(s) (t2) as follows. Example: if “t2” is 0.47 mm, then the reverse gear shim is 0.48 mm. If “t2” is ...

  • Page 134

    Lowr 6-29 69d5g11 lower unit 5. Slowly turn the drive shaft clockwise and counterclockwise and measure the back- lash when the drive shaft stops in each direction. 6. Add or remove shim(s) if out of specifica- tion. M: measurement 7. Remove the special service tools from the propeller shaft. 8. Appl...

  • Page 135: Bracket Unit

    69d5g11 9 8 7 6 5 4 3 2 1 brkt bracket unit tiller handle (mhd, whd) ............................................................................ 7-1 checking the throttle cable and shift rod ................................................. 7-5 assembling the tiller handle ............................

  • Page 136

    Brkt 7-1 69d5g11 bracket unit 40 n·m (4.0 kgf·m, 29.5 ft·lb) 4 n·m (0.4 kgf·m, 3.0 ft·lb) 40 n·m (4.0 kgf·m, 29.5 ft·lb) 69d7010e whd no. Part name q’ty remarks 1 clip 2 2 joint 2 3 nut 2 4 throttle cable 1 5 bolt 2 m6 × 16 mm 6 cable clamp 1 7 grommet 1 8 nut 1 9 tiller handle bracket 1 10 plastic ...

  • Page 137

    69d5g11 7-2 9 8 7 6 5 4 3 2 1 tiller handle (mhd, whd) 40 n·m (4.0 kgf·m, 29.5 ft·lb) 4 n·m (0.4 kgf·m, 3.0 ft·lb) 40 n·m (4.0 kgf·m, 29.5 ft·lb) 69d7010e whd no. Part name q’ty remarks 18 cotter pin 2 19 washer 2 20 collar 1 21 shift rod 1 22 shift rod 1 23 nut 1 24 washer 1 25 collar 2 m5 × 10 mm ...

  • Page 138

    Brkt 7-3 69d5g11 bracket unit 40 n·m (4.0 kgf·m, 29.5 ft·lb) 4 n·m (0.4 kgf·m, 3.0 ft·lb) 40 n·m (4.0 kgf·m, 29.5 ft·lb) 69d7010e whd no. Part name q’ty remarks 35 start switch 1 36 nut 1 37 screw 1 38 throttle grip 1 39 washer 1 40 spring 1 41 collar 1 42 screw 4 ø5 × 12 mm 43 screw 1 ø6 × 8 mm 44 ...

  • Page 139

    69d5g11 7-4 9 8 7 6 5 4 3 2 1 tiller handle (mhd, whd) 40 n·m (4.0 kgf·m, 29.5 ft·lb) 4 n·m (0.4 kgf·m, 3.0 ft·lb) 40 n·m (4.0 kgf·m, 29.5 ft·lb) 69d7010e whd no. Part name q’ty remarks 52 nut 2 53 bracket 1 54 bolt 1 m6 × 25 mm 69d5g11_07_1 06.10.16 14:11 page 5.

  • Page 140

    Brkt 7-5 69d5g11 bracket unit checking the throttle cable and shift rod 1. Check that the operation of the throttle cable and shift rod. 2. Check the inner wire, outer wire of the cable and rod for bends or damage, and the rubber seals for damage. Replace if necessary. Assembling the tiller handle 1...

  • Page 141

    69d5g11 7-6 9 8 7 6 5 4 3 2 1 tiller handle (mhd, whd)/bottom cowling 69d7020e no. Part name q’ty remarks 1 clip 2 2 bushing 1 3 cotter pin 1 4 washer 1 5 ball 1 6 spring 1 7 plug 1 8 collar 1 9 washer 1 10 shift rod lever 1 11 shift rod lever assembly 1 12 bolt 2 m6 × 12 mm 13 bracket 1 14 wave was...

  • Page 142

    Brkt 7-7 69d5g11 bracket unit 69d7020e no. Part name q’ty remarks 18 bracket 1 19 washer 1 20 cowling lock lever 1 21 bolt 4 m6 × 30 mm 22 grommet 4 23 collar 4 24 boot 1 25 seal 1 26 grommet 1 27 damper 1 28 warning indicator 1 29 grommet 1 30 clamp 1 whd and wd models 31 shift bracket 1 32 bolt 2 ...

  • Page 143

    69d5g11 7-8 9 8 7 6 5 4 3 2 1 bottom cowling/upper case, pivot shaft x 69d7030e no. Part name q’ty remarks 1 bolt 3 m8 × 35 mm 2 upper mount housing 1 3 cap 2 4 bolt 2 m10 × 174 mm 5 washer 2 6 washer 2 7 washer 2 8 upper mount 2 9 nut 2 10 screw 2 11 cover 2 12 collar 2 13 bolt 4 m8 × 25 mm 14 grou...

  • Page 144

    Brkt 7-9 69d5g11 bracket unit x 69d7030e no. Part name q’ty remarks 18 lower mount 2 19 washer 2 20 washer 2 21 bolt 2 m8 × 155 mm 22 cap 2 23 lower mount housing 2 24 spring 4 25 upper case 1 69d5g11_07_1 06.10.16 14:11 page 10

  • Page 145

    69d5g11 7-10 9 8 7 6 5 4 3 2 1 upper case, pivot shaft 69d7050e no. Part name q’ty remarks 1 pivot shaft 1 2 washer 1 3 bushing 1 4 o-ring 2 5 bushing 2 6 bushing 1 7 mount housing 1 8 circlip 1 not reusable 69d5g11_07_1 06.10.16 14:11 page 11.

  • Page 146

    Brkt 7-11 69d5g11 bracket unit 21 n·m (2.1 kgf·m, 15.5 ft·lb) 21 n·m (2.1 kgf·m, 15.5 ft·lb) 21 n·m (2.1 kgf·m, 15.5 ft·lb) f 69d7040e no. Part name q’ty remarks 1 bolt 2 m8 × 30 mm 2 exhaust guide 1 3 gasket 1 4 bolt 3 m8 × 30 mm 5 exhaust manifold 1 6 bolt 4 m8 × 30 mm 7 rubber washer 1 8 collar 1...

  • Page 147

    69d5g11 7-12 9 8 7 6 5 4 3 2 1 upper case, pivot shaft removing the pivot shaft 1 remove the circlip 1. 2. Remove the mount housing 2 by striking it with a plastic hammer. 3. Remove the pivot shaft from the swivel bracket by pulling the arm off the bracket. Installing the pivot shaft 1. Installing t...

  • Page 148

    2. Remove the muffler 3, exhaust manifold 4, water pipe 5 and gasket 6. Checking the upper case 1. Check the water pipe for deformation or corrosion. Replace if necessary. 2. Check the exhaust guide and exhaust manifold for damage or corrosion. Replace if necessary. Assembling the upper case 1. Inst...

  • Page 149

    69d5g11 7-14 9 8 7 6 5 4 3 2 1 upper case, pivot shaft 2. Install the muffler assembly 5 into the uppercase 6. Installing the upper case 1. Install the upper mount 1, upper mount housing 2 and bolts 3 into the upper case. Note: first tighten the center located, when tighten the bolts 3. 2. Set the l...

  • Page 150

    Brkt 7-15 69d5g11 bracket unit 6. Install the ground lead w into the mount housing 7 as shown, and then install the cover e. å s, l-transom models (port side) ∫ x-transom model (starboard side) w 69d70110 7 e w 69d70100 7 e å ∫ 69d5g11_07_1 06.10.16 14:11 page 16.

  • Page 151

    69d5g11 7-16 9 8 7 6 5 4 3 2 1 upper case, pivot shaft/clamp brackets, swivel bracket 22 n·m (2.2 kgf·m, 16.2 ft·lb) 69d7060e no. Part name q’ty remarks 1 tilt pin 1 2 nut 2 3 washer 2 4 bolt 1 5 spacer 1 6 bolt 2 m6 × 25 mm 7 anode 1 8 bolt 1 m6 × 10 mm 9 ground lead 2 10 screw 1 ø6 × 8 mm 11 circl...

  • Page 152

    Brkt 7-17 69d5g11 bracket unit 22 n·m (2.2 kgf·m, 16.2 ft·lb) 69d7060e no. Part name q’ty remarks 18 anode 1 19 bushing 2 20 bolt 1 m6 × 10 mm 21 tilt lever 1 22 cap 1 23 grease nipple 3 24 ground lead 1 25 cap 2 26 self-locking nut 2 27 through tube 1 28 swivel bracket 1 29 washer 2 30 bushing 2 31...

  • Page 153

    69d5g11 7-18 9 8 7 6 5 4 3 2 1 clamp brackets, swivel bracket 22 n·m (2.2 kgf·m, 16.2 ft·lb) 69d7060e no. Part name q’ty remarks 35 collar 1 36 bushing 4 37 tilt stop lever 1 38 tilt stop lever 1 39 clamp bracket 1 40 clamp bracket 1 41 pin 2 42 clamp handle 2 43 pad pin 2 44 clamp pad 2 69d5g11_07_...

  • Page 154

    Brkt 7-19 69d5g11 bracket unit 15 n·m (1.5 kgf·m, 11.1 ft·lb) 8 n·m (0.8 kgf·m, 5.8 ft·lb) 69d7070e no. Part name q’ty remarks 1 tilt pin 1 2 bolt 2 m6 × 16 mm 3 bolt 2 m6 × 29 mm 4 washer 2 5 anode 1 6 plate 1 7 bolt 6 m10 × 45 mm 8 pin 1 9 bushing 6 10 hydro tilt assembly 1 11 spacer 1 12 bushing ...

  • Page 155

    69d5g11 7-20 9 8 7 6 5 4 3 2 1 clamp brackets, swivel bracket 15 n·m (1.5 kgf·m, 11.1 ft·lb) 8 n·m (0.8 kgf·m, 5.8 ft·lb) 69d7070e no. Part name q’ty remarks 18 rod 1 19 joint 1 20 grease nipple 3 21 cap 2 22 self-locking nut 1 23 through tube 1 24 washer 2 25 bushing 2 26 bolt 1 m6 × 10 mm 27 plate...

  • Page 156

    Brkt 7-21 69d5g11 bracket unit 15 n·m (1.5 kgf·m, 11.1 ft·lb) 8 n·m (0.8 kgf·m, 5.8 ft·lb) 69d7070e no. Part name q’ty remarks 35 cap 2 36 tilt stop lever 1 37 clamp bracket 1 38 clamp bracket 1 39 pin 2 40 clamp handle 2 41 pad pin 2 42 clamp pad 2 43 screw 1 44 ground lead 1 45 swivel bracket 1 69...

  • Page 157

    69d5g11 7-22 9 8 7 6 5 4 3 2 1 clamp brackets, swivel bracket removing the hydro tilt assembly 1. Fully tilt the outboard motor up, and then support it with the tilt stop lever 1. å s, l-transom models ∫ x-transom model w after tilting up the outboard motor, be sure to support it with the tilt stop ...

  • Page 158

    Brkt 7-23 69d5g11 bracket unit installing the hydro tilt assembly 1. Fully tilt the outboard motor up, and then support it with the tilt stop lever 1. Note: after tilting up the outboard motor, be sure to support it with the tilt stop lever 1. 2. Install the hydro tilt assembly on to the clamp brack...

  • Page 159: Electrical Systems

    69d5g11 9 8 7 6 5 4 3 2 1 elec electrical systems special service tools ................................................................................... 8-1 checking the electrical components ........................................................ 8-2 measuring the peak voltage ....................

  • Page 160

    Elec 8-1 69d5g11 electrical systems special service tools ignition tester 90890-06754 digital circuit tester 90890-03174 peak voltage adaptor b 90890-03172 test harness (4 pins) new: 90890-06875 current: 90890-06775 69d5g11_08 04.9.24 9:21 page 2.

  • Page 161

    69d5g11 8-2 9 8 7 6 5 4 3 2 1 special service tools/checking the electrical components checking the electrical components measuring the peak voltage note: before troubleshooting the peak voltage, check that all electrical connections are tight and free from corrosion. The condition of the ignition s...

  • Page 162

    Elec 8-3 69d5g11 electrical systems electrical components top view 1 2 3 6 7 8 9 0 q 4 5 69d80010 1 starter motor (whd, wd) 2 starter relay (whd, wd) 3 ignition coil 4 spark plug 5 lighting coil 6 charge coil 7 pulser coil 8 engine start switch (whd) 9 engine stop lanyard switch (mhd, whd) 0 warning...

  • Page 163

    69d5g11 8-4 9 8 7 6 5 4 3 2 1 port view (wd) 69d80040 1 1 choke solenoid electrical components 69d5g11_08 04.9.24 9:21 page 5.

  • Page 164

    Elec 8-5 69d5g11 electrical systems starboard view (mhd) 69d80020 1 2 3 4 5 1 spark plug 2 ignition coil 3 cdi unit 4 warning indicator 5 thermoswitch 69d5g11_08 04.9.24 9:21 page 6.

  • Page 165

    69d5g11 8-6 9 8 7 6 5 4 3 2 1 electrical components starboard view (whd, wd) 69d80030 1 2 3 4 5 6 7 8 9 1 spark plug 2 ignition coil 3 cdi unit 4 starter motor 5 warning indicator 6 starter relay 7 fuse 8 rectifier 9 thermoswitch 69d5g11_08 04.9.24 9:21 page 7.

  • Page 166

    Elec 8-7 69d5g11 electrical systems 69d80110 ignition and ignition control system 1 spark plug 2 ignition coil 3 charge coil 4 pulser coil 5 cdi unit b : black br : brown b/w : black/white w/b : white/black w/r : white/red w/g : white/green 69d5g11_08 04.9.24 9:21 page 8.

  • Page 167

    69d5g11 8-8 9 8 7 6 5 4 3 2 1 ignition and ignition control system 69d80115 1 thermoswitch 2 cdi unit 3 warning indicator 4 engine stop lanyard switch (mhd, whd) 5 engine start switch (whd) å mhd, whd ∫ whd b : black p : pink w : white y/r : yellow/red 69d5g11_08 04.9.24 9:22 page 9.

  • Page 168

    Elec 8-9 69d5g11 electrical systems checking the ignition spark gap 1. Disconnect the spark plug caps from the spark plugs. 2. Connect a spark plug cap to the special service tool. 3. Crank the engine and observe the spark through the discharge window of the spark gap tester. Check the ignition sys-...

  • Page 169

    69d5g11 8-10 9 8 7 6 5 4 3 2 1 ignition and ignition control system checking the cdi unit 1. Measure the cdi unit output peak volt- age. If below specification, measure the pulser coil output peak voltage. Replace the cdi unit if the output peak voltage of the pulser coil is above specification. Not...

  • Page 170

    Elec 8-11 69d5g11 electrical systems cdi unit resistance chart (reference) 1. Check the cdi unit terminal resistance. If out of specification, replace the cdi unit. Pulser ground ignition charge stop overheat thermo- over-rev. Switch 1 2 3 4 5 6 7 8 9 0 q w e w/r w/b w/g b b/w #1 b/w #2 b/w #3 br w ...

  • Page 171

    69d5g11 8-12 9 8 7 6 5 4 3 2 1 ignition and ignition control system checking the pulser coils 1. Disconnect the cdi unit coupler. 2. Connect the test harness (4 pins) to the pulser coil. 3. Measure the pulser coil output peak volt- age. Replace the pulser coil if below specification. Checking the ch...

  • Page 172

    Elec 8-13 69d5g11 electrical systems c c make sure use the 1.5 v dry sell battery, other than higher voltage batteries will be burnt the diode. Note: led has an direction for electrical current. Therefore try reverse connection if there is no lighting. Checking the engine stop lanyard switch (mhd, w...

  • Page 173

    69d5g11 8-14 9 8 7 6 5 4 3 2 1 ignition and ignition control system/starting system 69d80140 starting system (whd, wd) 1 fuse 2 engine start switch (whd) 3 neutral switch (whd) (wd: if equipped) 4 starter motor 5 battery 6 starter relay 7 choke solenoid (wd) å whd ∫ wd b : black br : brown b/w : bla...

  • Page 174

    Elec 8-15 69d5g11 electrical systems checking the neutral switch (whd) (wd: if equipped) 1. Check the neutral switch for continuity. Replace if there is no continuity. Checking the choke solenoid (wd) 1. Measure the resistance of the choke solenoid. Checking the fuse (whd,wd) 1. Check the fuse for c...

  • Page 175

    69d5g11 8-16 9 8 7 6 5 4 3 2 1 starting system/starter motor 69d8000e no. Part name q’ty remarks 1 clip 1 2 pinion stopper 1 3 spring 1 4 pinion assembly 1 5 bolt 2 6 washer 2 7 washer 2 8 o-ring 2 9 front cover 1 10 o-ring 1 11 washer set — 12 armature assembly 1 13 yoke assembly 1 14 bracket 1 15 ...

  • Page 176

    Elec 8-17 69d5g11 electrical systems 69d8000e no. Part name q’ty remarks 18 plate washer 1 19 bushing 1 20 o-ring 1 21 bushing 1 22 brush 2 23 spring 2 24 screw 2 25 brush holder 1 26 bolt 1 27 washer 1 not reusable 69d5g11_08 04.9.24 9:22 page 18.

  • Page 177

    69d5g11 8-18 9 8 7 6 5 4 3 2 1 starter motor removing the starter motor pinion 1. Slide the pinion stopper 1 down as shown, and then remove the clip 2. Note: remove the clip with a thin screwdriver. Checking the starter motor pinion 1. Check the teeth of the pinion for cracks or wear. Replace if nec...

  • Page 178

    Elec 8-19 69d5g11 electrical systems 4. Check the armature for continuity. Replace if out of specifications. Checking the brushes 1. Measure the brush length a. Replace the brush assembly if below specifica- tion. 2. Check the brush holder assembly for continuity. Replace if out of specifica- tions....

  • Page 179

    69d5g11 8-20 9 8 7 6 5 4 3 2 1 starter motor/charging system 69d80170 charging system 1 rectifier (whd, wd) 2 lighting coil 3 battery (whd, wd) 4 fuse (whd, wd) å 1-lighting coil model ∫ 2-lighting coil model b : black g : green r : red 69d5g11_08 04.9.24 9:22 page 21.

  • Page 180

    Elec 8-21 69d5g11 electrical systems checking the rectifier (whd, wd) 1. Measure the rectifier output peak volt- age. If below specification, measure the lighting coil output peak voltage. Replace the rectifier if the output peak voltage of the lighting coil is above specification. Note: after start...

  • Page 181: Troubleshooting

    69d5g11 9 8 7 6 5 4 3 2 1 trbl shtg trbl shtg troubleshooting power unit ..................................................................................................... 9-1 ignition system ......................................................................................... 9-1 fuel system...

  • Page 182

    Trbl shtg 9-1 69d5g11 trbl shtg troubleshooting note: 9 to diagnose a mechanical malfunction, use the troubleshooting charts pertaining to the trouble located in this chapter. Also, when checking and maintaining the outboard motor, see chapters 4–8 for safe maintenance procedures. 9 check that all e...

  • Page 183

    69d5g11 9-2 9 8 7 6 5 4 3 2 1 power unit ignition system (continued from previous page) replace the cdi unit. Check the fuel system and compression pressure. Check the charge coil output peak voltage. Yes yes check the connection of the leads from cdi unit. Yes replace the charge coil. No replace th...

  • Page 184

    Trbl shtg 9-3 69d5g11 troubleshooting fuel system 9 consult this chart after the ignition system has been checked. Check the fuel hoses for fuel leakage by kinks or craks. Check for water accumulation or clogging of the fuel filter and inside the carburetor. No yes 9 clean the fuel system from the f...

  • Page 185

    69d5g11 9-4 9 8 7 6 5 4 3 2 1 power unit compression pressure 9 consult this chart after the ignition and fuel systems have been checked. Measure the compression pressure. No add a small amount of engine oil into the cylinder through the spark plug hole. Check the piston, piston rings, and cylinder ...

  • Page 186

    Trbl shtg 9-5 69d5g11 troubleshooting symptom: the engine idle speed does not remain steady. Check the operation of the carburetors. Check the throttle cable, link operation and pick up timing. Yes no adjust the throttle cable, throttle link and pick up timing. Yes no adjust the pilot screw accordin...

  • Page 187

    69d5g11 9-6 9 8 7 6 5 4 3 2 1 power unit symptom: the engine speed does not exceed 2,000 r/min. 9 be sure use the correct octane gasoline. No clean the thremostat. Replace the thermostat as necessary. Is it operating correctly? Yes check the carburetors synchro- nization. Yes no adjust the carbureto...

  • Page 188

    Trbl shtg 9-7 69d5g11 troubleshooting lower unit symptom: the forward and reverse gear shift mechanism does not operate properly. Check the shift cable connection. Check the gear shift operation. Yes no no adjust the gear shift. Connect correctly or replace the shift rod as necessary. No replace the...

  • Page 189

    69d5g11 9-8 9 8 7 6 5 4 3 2 1 lower unit/electrical electrical system symptom: the starter motor does not operate. (whd, wd) 9 engine stop lanyard switch is operating normally. Starting system check the battery for fully charged. Check the fuse for blown. No yes replace the fuse. No fully charge or ...

  • Page 190

    Trbl shtg 9-9 69d5g11 troubleshooting starting system (continued from previous page) disassemble and check the starter motor. Yes check the starter relay for continuity. No replace the starter relay. Is there continuity? Symptom: the battery loses power quickly. (whd, wd) 9 be sure the electrolyte l...

  • Page 191

    69d5g11 i-1 9 8 7 6 5 4 3 2 1 a. Adjusting the ignition timing .................... 3-10 adjusting the pick up timing ...................... 3-7 adjusting the start-in-gear protection ........ 3-5 adjusting the throttle cable ....................... 3-7 adjusting the throttle link position ............

  • Page 192

    I-2 69d5g11 index checking the spark plugs ......................... 3-3 checking the spiral spring ...................... 5-17 checking the starter motor operation ..... 8-19 checking the starter motor pinion ........... 8-18 checking the starter relay (whd, wd) .......................................

  • Page 193

    69d5g11 i-3 9 8 7 6 5 4 3 2 1 propeller selection .................................... 1-5 propeller shaft housing ........................... 6-11 propeller size ............................................ 1-5 r. Reed valves ............................................ 5-22 removing the clamp brac...

  • Page 194

    69d5g11 wiring diagram e60hmhd 1 ignition coil 2 spark plug 3 thermoswitch 4 charge coil 5 pulser coil 6 lighting coil 7 cdi unit 8 engine stop lanyard switch 9 warning indicator å 1-lighting coil model ∫ 2-lighting coil model color code b : black br : brown p : pink w : white b/w : black/white w/g ...

  • Page 195

    A4cover 04.9.20 17:53 page 3.

  • Page 196

    Yamaha motor co., ltd. Printed in japan oct. 2004 – 0.9 × 1 ! (e_ 2 ) printed on recycled paper a4cover 06.8.25 10:08 page 4.

  • Page 197

    E60hmhd 1 2 3 b p b b b p p p b b p br br br g b g g g g p w b /w b /w b /w p y /r p y /r w b/w w/r w/b w/g w/g w/b w/r b/w b/w b b b w/b ( f ) ( m ) w/g w/r w/g w/r.

  • Page 198

    Wiring diagram e60hwhd, e60hwd 1 ignition coil 2 spark plug 3 thermoswitch 4 charge coil 5 pulser coil 6 lighting coil 7 cdi unit 8 rectifier 9 fuse 0 starter motor q starter relay w neutral switch (wd: if equipped) e battery r warning indicator t engine start switch (whd) y engine stop lanyard swit...

  • Page 199

    E60hwd,e60hwhd 1 2 3 w br b y r off 10a b p b p p br br br b br br br g b g g g g b /w b /w p p w r r r y /r b /w r w/r w/b w/g w/g w/b w/r b/w b/w b b p p b p p b b/w b 15b b g r r r p r g w b b y/r br br w r b br y r w w w b b b 15b 15b 15b 15b b w/b ( f ) ( m ) w/g w/r w/g w/r br w b r w r b.