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Yamaha F50F Service Manual

Summary of F50F

  • Page 1

    F50f ft50g f60c ft60d service manual 6c1-28197-3g-11 290551.

  • Page 2: Notice

    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: Contents

    Contents general information 1 gen info specifications 2 spec periodic checks and adjustments 3 chk adj fuel system 4 fuel power unit 5 powr lower unit 6 lowr bracket unit 7 brkt electrical systems 8 elec troubleshooting 9 trbl shtg index – +.

  • Page 5: Gen

    6c13g11 gen info 1 2 3 4 5 6 7 8 9 general information how to use this manual ................................................................................. 1-1 manual format............................................................................................ 1-1 symbols......................

  • Page 6: Gen

    Gen info general information 1-1 6c13g11 how to use this manual 1 manual format the format of this manual has been designed to make service procedures clear and easy to under- stand. Use the information below as a guide for effective and quality service. 1 parts are shown and detailed in an exploded...

  • Page 7: Gen

    6c13g11 1-2 1 2 3 4 5 6 7 8 9 symbols the symbols below are designed to indicate the content of a chapter. General information specifications periodic checks and adjustments fuel system power unit lower unit bracket unit electrical systems troubleshooting gen info spec chk adj fuel powr lowr brkt el...

  • Page 8: Gen

    Gen info general information 1-3 6c13g11 safety while working 1 to prevent an accident or injury and to ensure quality service, follow the safety pro- cedures provided below. Fire prevention gasoline is highly flammable. Keep gasoline and all flammable products away from heat, sparks, and open flame...

  • Page 9: Identification

    6c13g11 1-4 1 2 3 4 5 6 7 8 9 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

    Gen info general information 1-5 6c13g11 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 (*) hydro tilt model (for europe) (*) tiller handle model (for oceania) model name app...

  • Page 11: Outline of Features

    6c13g11 1-6 1 2 3 4 5 6 7 8 9 outline of features 1 new electronic fuel injected f50 and f60 outboard motors have a mainly redesigned fuel and intake system based on the carbureted f60 outboard motor. S6c11120 power unit • single throttle body, single throttle valve • multi-point injection system, g...

  • Page 12: Gen

    Gen info general information 1-7 6c13g11 features and benefits 1 fuel system a pressure regulator is built into the vapor separator to obtain compact and simple fuel delivery structure. A plastic fuel rail is used to prevent it from corrosion and for light weight. Fuel discharged from the pressure r...

  • Page 13

    6c13g11 1-8 1 2 3 4 5 6 7 8 9 solenoid valve just after the engine is stopped, the cooling water supply is also stopped and the heat is conducted to the vapor separator from the engine, causing birth of many fuel vapor gases. The vapor gases are fed into the intake silencer to reburn them. However, ...

  • Page 14: Gen

    Gen info general information 1-9 6c13g11 electronic control system the electronic control system is built up by the sensors and the ecm (electric control module). The ecm receives signals from the sensors and determines the air and fuel mixture (a/f), and igni- tion timing. Under various condition, ...

  • Page 15

    6c13g11 1-10 1 2 3 4 5 6 7 8 9 ecm (electric control module) this engine is controlled by the ecm to obtain precision combustion under various operations, and can realize high power output, low fuel consumption, and low emission. The ecm controls the ignition timing, fuel injection timing, and the f...

  • Page 16: Gen

    Gen info general information 1-11 6c13g11 variable trolling rpm switch (optional) this device is an optional equipment for tiller handle model. The idling and/or trolling rpm can be controlled in the range of 620 through 900 r/min with 50 r/min interval. Especially for 620 through 700 r/min, the eng...

  • Page 17: Propeller Selection

    6c13g11 1-12 1 2 3 4 5 6 7 8 9 propeller selection 1 the performance of a boat and outboard motor will be critically affected by the size and type of propeller you choose. Propellers greatly affect boat speed, acceleration, engine life, fuel economy, and even boating and steering capabilities. An in...

  • Page 18: Gen

    Gen info general information 1-13 6c13g11 predelivery checks 1 to make the delivery process smooth and efficient, the predelivery checks should be completed as explained below. Checking the fuel system 1. Check that the fuel hoses are securely connected and that the fuel tank is full with fuel. Caut...

  • Page 19

    6c13g11 1-14 1 2 3 4 5 6 7 8 9 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 abnormally and cau...

  • Page 20: Gen

    Gen info general information 1-15 6c13g11 2. Check that the steering operates smoothly. È tiller handle model É remote control model 3. Check that there is no interference with wires or hoses when the outboard motor is steered. Checking the gear shift and throttle operation 1. Check that the gear sh...

  • Page 21

    6c13g11 1-16 1 2 3 4 5 6 7 8 9 checking the engine start switch and engine stop lanyard switch 1. Check that the engine starts when the engine start switch is turned to start. 2. Check that the engine turns off when the engine start switch is turned to off. È tiller handle model É remote control mod...

  • Page 22: Gen

    Gen info general information 1-17 6c13g11 test run 1. Start the engine, and then check that the gear shift operates smoothly. 2. Check the engine idle speed after the engine has been warmed up. 3. Operate at trolling speed. 4. Run the outboard motor for 1 hour at 2,000 r/min or at half throttle, the...

  • Page 23: Spec

    6c13g11 spec 1 2 3 4 5 6 7 8 9 specifications general specifications................................................................................... 2-1 maintenance specification ............................................................................ 2-5 power unit..............................

  • Page 24: Spec

    Spec specifications 2-1 6c13g11 general specifications 2 item unit model f50fed f50feht f50fet ft50get dimension overall length mm (in) 706 (27.8) 1,339 (52.7) 706 (27.8) overall width mm (in) 384 (15.1) overall height (l) mm (in) 1,415 (55.7) 1,455 (57.3) (x) (*1) mm (in) — 1,569 (61.8) boat transo...

  • Page 25

    6c13g11 2-2 1 2 3 4 5 6 7 8 9 (*1) ron: research octane number pon: pump octane number = (ron + motor octane number)/2 (*2) meeting both api and sae requirements (*3) cca: cold cranking ampere en: european norm (european standard) iec: international electrotechnical commission fuel and oil fuel type...

  • Page 26: Spec

    Spec specifications 2-3 6c13g11 item unit model f60ceht f60cet ft60det dimension overall length mm (in) 1,339 (52.7) 706 (27.8) overall width mm (in) 384 (15.1) overall height (l) mm (in) 1,415 (55.7) 1,455 (57.3) (x) (*1) mm (in) — 1,569 (61.8) boat transom height (l) mm (in) 508 (20.0) (x) (*1) mm...

  • Page 27

    6c13g11 2-4 1 2 3 4 5 6 7 8 9 (*1) ron: research octane number pon: pump octane number = (ron + motor octane number)/2 (*2) meeting both api and sae requirements (*3) cca: cold cranking ampere en: european norm (european standard) iec: international electrotechnical commission fuel and oil fuel type...

  • Page 28: Spec

    Spec specifications 2-5 6c13g11 maintenance specification 2 power unit item unit model f50fed f50feht f50fet ft50get power unit minimum compression pressure (*1) kpa (kgf/cm 2 , psi) 960 (9.6, 139.2) oil pressure (*2) kpa (kgf/cm 2 , psi) 125 (1.25, 18.1) at engine idle speed cylinder head warpage l...

  • Page 29

    6c13g11 2-6 1 2 3 4 5 6 7 8 9 2nd piston ring dimension b mm (in) 1.47–1.49 (0.0579–0.0587) dimension t mm (in) 2.60–2.80 (0.1024–0.1102) end gap mm (in) 0.30–0.50 (0.0118–0.0197) side clearance mm (in) 0.02–0.06 (0.0008–0.0024) oil ring dimension b mm (in) 2.36–2.48 (0.0929–0.0976) dimension t (*1)...

  • Page 30: Spec

    Spec specifications 2-7 6c13g11 stem diameter intake mm (in) 5.475–5.490 (0.2156–0.2161) exhaust mm (in) 5.460–5.475 (0.2150–0.2156) guide inside diameter intake and exhaust mm (in) 5.500–5.512 (0.2165–0.2170) stem-to-guide clearance intake and exhaust mm (in) 0.025–0.052 (0.0010–0.0020) stem runout...

  • Page 31

    6c13g11 2-8 1 2 3 4 5 6 7 8 9 lower unit oil pump type trochoid outer rotor-to-housing clearance mm (in) 0.09–0.15 (0.0035–0.0059) outer rotor-to-inner rotor clearance limit mm (in) 0.12 (0.0047) rotor-to-cover clearance mm (in) 0.03–0.08 (0.0012–0.0031) relief valve operating pressure kpa (kgf/cm 2...

  • Page 32: Spec

    Spec specifications 2-9 6c13g11 electrical item unit model f50fed f50feht f50fet ft50get ignition and ignition control system ignition timing range (*1) degree atdc 10-btdc 25 spark plug gap mm (in) 0.8–0.9 (0.031–0.035) ignition coil resistance primary coil (r – b/w) at 20 °c (68 °f) Ω 1.53–2.07 se...

  • Page 33

    6c13g11 2-10 1 2 3 4 5 6 7 8 9 starter motor type sliding gear output kw 1.4 cranking time limit second 30 brushes standard length mm (in) 15.5 (0.61) wear limit mm (in) 9.5 (0.37) commutator standard diameter mm (in) 29.0 (1.14) wear limit mm (in) 28.0 (1.10) mica standard undercut mm (in) 0.8 (0.0...

  • Page 34: Spec

    Spec specifications 2-11 6c13g11 power unit item unit model f60ceht f60cet ft60det power unit minimum compression pressure (*1) kpa (kgf/cm 2 , psi) 960 (9.6, 139.2) oil pressure (*2) kpa (kgf/cm 2 , psi) 125 (1.25, 18.1) at engine idle speed cylinder head warpage limit mm (in) 0.10 (0.0039) (lines ...

  • Page 35

    6c13g11 2-12 1 2 3 4 5 6 7 8 9 2nd piston ring dimension b mm (in) 1.47–1.49 (0.0579–0.0587) dimension t mm (in) 2.60–2.80 (0.1024–0.1102) end gap mm (in) 0.30–0.50 (0.0118–0.0197) side clearance mm (in) 0.02–0.06 (0.0008–0.0024) oil ring dimension b mm (in) 2.36–2.48 (0.0929–0.0976) dimension t (*1...

  • Page 36: Spec

    Spec specifications 2-13 6c13g11 stem diameter intake mm (in) 5.475–5.490 (0.2156–0.2161) exhaust mm (in) 5.460–5.475 (0.2150–0.2156) guide inside diameter intake and exhaust mm (in) 5.500–5.512 (0.2165–0.2170) stem-to-guide clearance intake and exhaust mm (in) 0.025–0.052 (0.0010–0.0020) stem runou...

  • Page 37

    6c13g11 2-14 1 2 3 4 5 6 7 8 9 lower unit oil pump type trochoid outer rotor-to-housing clearance mm (in) 0.09–0.15 (0.0035–0.0059) outer rotor-to-inner rotor clearance limit mm (in) 0.12 (0.0047) rotor-to-cover clearance mm (in) 0.03–0.08 (0.0012–0.0031) relief valve operating pressure kpa (kgf/cm ...

  • Page 38: Spec

    Spec specifications 2-15 6c13g11 electrical item unit model f60ceht f60cet ft60det ignition and ignition control system ignition timing range (*1) degree atdc 10-btdc 24 spark plug gap mm (in) 0.8–0.9 (0.031–0.035) ignition coil resistance primary coil (r – b/w) at 20 °c (68 °f) Ω 1.53–2.07 secondar...

  • Page 39

    6c13g11 2-16 1 2 3 4 5 6 7 8 9 starter motor type sliding gear output kw 1.4 cranking time limit second 30 brushes standard length mm (in) 15.5 (0.61) wear limit mm (in) 9.5 (0.37) commutator standard diameter mm (in) 29.0 (1.14) wear limit mm (in) 28.0 (1.10) mica standard undercut mm (in) 0.8 (0.0...

  • Page 40: Spec

    Spec specifications 2-17 6c13g11 dimensions exterior f50, f60 (remote control model) a: hydro tilt model (for europe) b: power trim and tilt model s6c12030 mm (in) a: 63˚ b: 65˚ 4 0 ˚ 192 (7.6) 188 (7.4) 360 (14.2) 192 (7.6) 870 (34.3) 527 (20.7) a: 762 (30.0) b: 759 (29.9) 354 (13.9) 49 (1.9) a: 25...

  • Page 41

    6c13g11 2-18 1 2 3 4 5 6 7 8 9 f50, f60 (tiller handle model) (*1) power trim and tilt model (*1) for oceania s6c12020e mm (in) 4 0 ˚ 192 (7.6) 188 (7.4) 360 (14.2) 192 (7.6) 759 (29.9) 645 (25.4) 354 (14.0) 49 (1.9) 37 (1.5) 175 (6.9) 4˚ 708 (27.9) 533 (21.0) 24 (0.9) 755 (29.7) 417 (16.4) 226 (8.9...

  • Page 42: Spec

    Spec specifications 2-19 6c13g11 ft50, ft60 x: for oceania s6c12010 mm (in) 4 0 ˚ 192 (7.6) 188 (7.4) 360 (14.2) 192 (7.6) 759 (29.9) 354 (13.9) 62 (2.4) 22 (0.9) 191 (7.5) 4˚ 561 (22.1) 24 (0.9) 417 (16.4) 147 (5.8) 122 (4.8) 62 (2.4) 584 (23.0) 545 (21.5) l : 996 (39.2) x: 1,099 (43.3) l : 530 (20...

  • Page 43

    6c13g11 2-20 1 2 3 4 5 6 7 8 9 clamp bracket s6c12070 mm (in) 13 (0.5) 180 (7.1) 163.5 (6.4) 254.0 (10.0) 55.5 (2.2) 350 (13.8) 163.5 (6.4) 126 (5.0) 126 (5.0) 180 (7.1) 13 (0.5) 50.8 (2.0) 18.5 (0.7) 70.5 (2.78) maintenance specification.

  • Page 44: Spec

    Spec specifications 2-21 6c13g11 tightening torques 2 specified torques part to be tightened thread size tightening torques n·m kgf·m ft·lb fuel system fuel filter cup — 3 0.3 2.2 fuel pump screw m5 3 0.3 2.2 fuel pump valve screw m3 0.5 0.05 0.36 idle speed control screw m5 4 0.4 3.0 sensor assembl...

  • Page 45

    6c13g11 2-22 1 2 3 4 5 6 7 8 9 cylinder head bolt 1st m6 6 0.6 4.4 2nd 12 1.2 8.9 1st m9 12 1.2 8.9 2nd 23 2.3 17.0 3rd 90° spark plug — 17 1.7 12.5 cooling water temperature sensor — 23 2.3 17.0 oil pressure switch — 8 0.8 5.9 oil pressure switch lead bolt m4 2 0.2 1.5 exhaust cover bolt 1st m6 6 0...

  • Page 46: Spec

    Spec specifications 2-23 6c13g11 bracket unit retaining plate bolt m6 10 1.0 7.4 tiller handle nut — 37 3.7 27.3 self-locking nut — 4 0.4 3.0 engine stop lanyard switch nut — 2 0.2 1.5 tiller handle bracket nut — 37 3.7 27.3 tiller handle bracket bolt m12 37 3.7 27.3 engine start switch nut — 4 0.4 ...

  • Page 47

    6c13g11 2-24 1 2 3 4 5 6 7 8 9 general torques this chart specifies tightening torques for standard fasteners with a standard iso thread pitch. Tightening torque specifications for special components or assemblies are provided in applicable sections of this man- ual. To avoid warpage, tighten multi-...

  • Page 48: Spec

    Spec specifications 2-25 6c13g11 — memo —.

  • Page 49: Chk

    6c13g11 chk adj 1 2 3 4 5 6 7 8 9 periodic checks and adjustments special service tools ..................................................................................... 3-1 maintenance interval chart............................................................................ 3-2 top cowling ......

  • Page 50: Chk

    Chk adj periodic checks and adjustments 3-1 6c13g11 special service tools 3 digital tachometer 90890-06760 leakage tester 90890-06840 oil filter wrench 90890-01426 flywheel holder 90890-06522 flywheel puller 90890-06521.

  • Page 51: Maintenance Interval Chart

    6c13g11 3-2 1 2 3 4 5 6 7 8 9 maintenance interval chart 3 use the following chart as a guideline for general maintenance. Adjust the maintenance intervals according to the operating conditions of the outboard motor. Note: when operating in salt water, turbid or muddy water, the engine should be flu...

  • Page 52: Chk

    Chk adj periodic checks and adjustments 3-3 6c13g11 top cowling 3 checking the top cowling 1. Check the fitting by pushing the cowling with both hands. Adjust if necessary. 2. Loosen the nuts 1. 3. Move the hook 2 up or down slightly to adjust its position. Note: • to loosen the fitting, move the ho...

  • Page 53

    6c13g11 3-4 1 2 3 4 5 6 7 8 9 2. Remove the oil dipstick, wipe it clean, and then insert it back into the dipstick hole. 3. Remove the oil dipstick again to check the oil level and to check the oil for dis- coloration and its viscosity. Note: • change the oil if it appears milky or dirty. • if the e...

  • Page 54: Chk

    Chk adj periodic checks and adjustments 3-5 6c13g11 2. Remove the oil dipstick and oil filler cap 1. 3. Place a drain pan under the drain hole, and then remove the drain bolt 2 and gasket and let the oil drain completely. Note: be sure to clean up any oil spills. 4. Install the gasket and drain bolt...

  • Page 55

    6c13g11 3-6 1 2 3 4 5 6 7 8 9 5. Pour the specified amount of the recom- mended engine oil into the oil filler hole. 6. Install the oil filler cap and oil dipstick, and then start the engine and warm it up for 5 minutes. 7. Turn the engine off, and then check the oil level and correct it if necessar...

  • Page 56: Chk

    Chk adj periodic checks and adjustments 3-7 6c13g11 3. Loosen the flywheel magnet nut. Caution: apply force in the direction of the arrows shown to prevent the flywheel holder from slipping off easily. 4. Remove the flywheel magnet, then the woodruff key. Caution: to prevent damage to the engine or ...

  • Page 57

    6c13g11 3-8 1 2 3 4 5 6 7 8 9 8. Install a new timing belt 3 onto the drive sprocket, then onto the driven sprocket with its part number in the upright posi- tion. Caution: • do not damage the timing belt during installation. • do not twist, turn inside out, or bend the timing belt beyond the maximu...

  • Page 58: Chk

    Chk adj periodic checks and adjustments 3-9 6c13g11 2. Clean the electrodes 1 with a spark plug cleaner or wire brush. Replace the spark plug if necessary. 3. Check the electrodes for erosion and excessive carbon or other deposits, and the gasket for damage. Replace the spark plug if necessary. 4. C...

  • Page 59: Control System

    6c13g11 3-10 1 2 3 4 5 6 7 8 9 5. Install the thermostat, gasket, and cover. Checking the cooling water passage 1. Check the cooling water inlet cover 1 and cooling water inlet for clogs. Clean if necessary. È f50, f60 2. Place the lower unit in water, and then start the engine. 3. Check for water f...

  • Page 60: Chk

    Chk adj periodic checks and adjustments 3-11 6c13g11 3. Loosen the locknut 1, and then adjust the throttle link rod length a. 4. Align the alignment mark b on the throt- tle control lever with the alignment mark c on the bracket. 5. Connect the throttle link rod to the throttle body. Note: connect t...

  • Page 61

    6c13g11 3-12 1 2 3 4 5 6 7 8 9 10. Adjust the position of the throttle cable joint until its hole is aligned with the set pin. Note: pull the throttle cable towards the set pin to remove any free play in the cable before adjusting the position of the throttle cable joint. 11. Connect the throttle ca...

  • Page 62: Chk

    Chk adj periodic checks and adjustments 3-13 6c13g11 5. Adjust the position of the shift cable joint until its hole is aligned with the set pin. Warning the shift cable joint must be screwed in a minimum of 8.0 mm (0.31 in) c. 6. Connect the cable joint, install the clip, and then tighten the locknu...

  • Page 63: Lower Unit

    6c13g11 3-14 1 2 3 4 5 6 7 8 9 checking the power trim and tilt fluid level 1. Fully tilt the outboard motor up, and then support it with the tilt stop lever 1. Warning after tilting up the outboard motor, be sure to support it with the tilt stop lever. Otherwise, the outboard motor could sud- denly...

  • Page 64: Chk

    Chk adj periodic checks and adjustments 3-15 6c13g11 3. If necessary, add sufficient gear oil of the recommended type until it overflows out of the check hole. 4. Install the check screw, and then tighten it to the specified torque. Changing the gear oil 1. Tilt the outboard motor up slightly. 2. Pl...

  • Page 65: General

    6c13g11 3-16 1 2 3 4 5 6 7 8 9 2. Apply the specified pressure to check that the pressure is maintained in the lower unit for at least 10 seconds. Caution: do not over pressurize the lower unit, oth- erwise the oil seals can be damaged. Note: cover the check hole with a rag when remov- ing the teste...

  • Page 66: Chk

    Chk adj periodic checks and adjustments 3-17 6c13g11 È power trim and tilt model É hydro tilt model Ê f50, f60 Ë ft50, ft60 caution: do not oil, grease, or paint the anodes or the trim tab, otherwise they will be ineffec- tive. Note: if it is necessary to disassemble the outboard motor to check an a...

  • Page 67

    6c13g11 3-18 1 2 3 4 5 6 7 8 9 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. S6c13270 a a s6c13290 a a a a a s6c17360 É s6c17540 a a a general.

  • Page 68: Chk

    Chk adj periodic checks and adjustments 3-19 6c13g11 2. Apply low temperature resistant grease to the area shown. 3. Apply corrosion resistant grease to the area shown. S6c13280 c.

  • Page 69: Fuel

    6c13g11 fuel 1 2 3 4 5 6 7 8 9 fuel system special service tools ..................................................................................... 4-1 hose routing ................................................................................................... 4-2 fuel and blowby hoses..........

  • Page 70: Fuel

    Fuel fuel system 4-1 6c13g11 special service tools 4 vacuum/pressure pump gauge set 90890-06756 fuel pressure gauge 90890-06786 fuel pressure gauge adapter b 90890-06942.

  • Page 71: Hose Routing

    6c13g11 4-2 1 2 3 4 5 6 7 8 9 hose routing 4 fuel and blowby hoses 1 blowby hose 2 fuel hose (fuel joint-to-fuel filter) 3 fuel hose (fuel filter-to-fuel pump) 4 fuel hose (fuel pump-to-strainer) 5 fuel hose (strainer-to-vapor separator) 6 high-pressure fuel hose (vapor separator-to-fuel rail) 7 fue...

  • Page 72: Fuel

    Fuel fuel system 4-3 6c13g11 cooling water pilot hoses 1 cooling water pilot hose (fuel cooler to fuel cooler) 2 cooling water pilot hose (fuel cooler to fuel joint) 3 cooling water pilot hose (fuel joint to upper case) 4 flushing hose (hose joint to fuel joint) 5 cooling water pilot hose (fuel join...

  • Page 73: Fuel Filter and Fuel Pump

    6c13g11 4-4 1 2 3 4 5 6 7 8 9 fuel filter and fuel pump 4 no. Part name q’ty remarks 1 fuel pump assembly 1 2 bolt 2 m6 × 30 mm 3 fuel hose 1 4 holder 1 5 strainer 1 6 o-ring 1 not reusable 7 screw 1 ø6 × 14 mm 8 bolt 1 m8 × 16 mm 9 nut 1 10 bracket 1 11 fuel filter assembly 1 12 o-ring 1 not reusab...

  • Page 74: Fuel

    Fuel fuel system 4-5 6c13g11 4 no. Part name q’ty remarks 1 screw 4 ø5 × 43 mm 2 cover 1 3 seal 1 not reusable 4 fuel pump body 2 assembly 1 5 diaphragm 1 6 pin 1 7 spring 1 8 fuel pump body 1 1 9 nut 4 10 spring 1 11 plunger 1 12 spring washer 4.

  • Page 75

    6c13g11 4-6 1 2 3 4 5 6 7 8 9 checking the fuel pump 1. 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 positive pressure. Check that there is no air leak- age. 4. Appl...

  • Page 76: Fuel

    Fuel fuel system 4-7 6c13g11 checking the diaphragm and valves 1. Check the diaphragm for tears and the valves for cracks. Replace if necessary. Assembling the fuel pump note: clean the parts and soak the valves and the diaphragm in gasoline before assembly to obtain prompt operation of the fuel pum...

  • Page 77: Intake Manifold

    6c13g11 4-8 1 2 3 4 5 6 7 8 9 intake manifold 4 no. Part name q’ty remarks 1 blowby hose 1 2 holder 1 3 hose 1 4 bolt 2 m6 × 35 mm 5 bolt 3 m6 × 45 mm 6 bolt 5 m8 × 40 mm 7 intake manifold assembly 1 8 cooling water pilot hose 1 9 pressure regulator hose 1 10 dowel 2 11 plastic tie 1 not reusable s6...

  • Page 78: Fuel

    Fuel fuel system 4-9 6c13g11 4 no. Part name q’ty remarks 1 fuel rail 1 2 gasket 1 not reusable 3 idle speed control 1 4 screw 2 ø5 × 13 mm 5 wiring harness 1 6 o-ring 1 not reusable 7 screw 2 ø5 × 13 mm 8 sensor assembly 1 9 o-ring 1 not reusable 10 collar 2 11 grommet 2 12 intake silencer 1 13 scr...

  • Page 79

    6c13g11 4-10 1 2 3 4 5 6 7 8 9 4 no. Part name q’ty remarks 18 link rod 1 19 gasket 1 not reusable 20 intake manifold 1 21 fuel injector 4 22 o-ring set 4 not reusable 23 clip 2 24 bolt 2 m6 × 38 mm s6c14110 t r . . 9 n · m (0.9 kgf · m, 6.6 ft · ib) t r . . 4 n · m (0.4 kgf · m, 3.0 ft · ib) t r . ...

  • Page 80: Fuel

    Fuel fuel system 4-11 6c13g11 checking the throttle position sensor 1. Check the throttle position sensor output voltage using the yamaha diagnostic system. If the output voltage is out of specification, replace the throttle posi- tion sensor. Installing the throttle position sensor 1. Install the t...

  • Page 81: Vapor Separator

    6c13g11 4-12 1 2 3 4 5 6 7 8 9 vapor separator 4 no. Part name q’ty remarks 1 vapor separator 1 2 collar 3 3 grommet 3 4 bolt 3 m6 × 30 mm 5 cooling water pilot hose 1 6 bolt 1 m6 × 15 mm 7 corrugated tube 1 s6c14130 6 3 2 4 1 5 4 4 3 3 7 2 2 intake manifold / vapor separator.

  • Page 82: Fuel

    Fuel fuel system 4-13 6c13g11 4 no. Part name q’ty remarks 1 hose 1 2 joint 1 3 hose 1 4 fuel hose 1 5 holder 1 6 fuel hose 1 7 hose 1 8 screw 6 ø5 × 14 mm 9 cover assembly 1 10 gasket 1 not reusable 11 hose 1 12 hose 1 13 screw 2 ø6 × 14 mm 14 fuel cooler 1 15 hose 1 16 fuel hose 1 17 joint screw 1...

  • Page 83

    6c13g11 4-14 1 2 3 4 5 6 7 8 9 4 no. Part name q’ty remarks 18 o-ring 1 not reusable 19 drain hose 1 20 drain screw 1 21 o-ring 1 not reusable 22 float chamber 1 23 fuel pump damper 1 24 high-pressure fuel hose 1 25 clamp 1 26 hose 1 27 solenoid valve 1 28 clamp 2 s6c14140 water fuel water t r . . 1...

  • Page 84: Fuel

    Fuel fuel system 4-15 6c13g11 4 no. Part name q’ty remarks 1 cover 1 2 pressure regulator 1 3 bolt 2 m6 × 12 mm 4 o-ring 1 not reusable 5 joint screw 1 6 o-ring 1 not reusable 7 electric fuel pump 1 8 grommet 1 9 collar 1 10 filter 1 11 screw 2 ø4 × 6 mm 12 wiring harness 1 13 float 1 14 needle valv...

  • Page 85

    6c13g11 4-16 1 2 3 4 5 6 7 8 9 disconnecting the quick connector 1. Wrap the quick connector with a rag, and then rotate the quick connector tab 1 to the stopper position a. Warning if the quick connector is removed sud- denly, pressurized fuel could spray out. To gradually release the fuel pressure...

  • Page 86: Fuel

    Fuel fuel system 4-17 6c13g11 3. Turn the engine start switch to on, and then measure the fuel pressure within 3 seconds. Warning before measuring the fuel pressure, make sure that the drain screw is tightened securely. Note: the fuel pressure decreases 3 seconds after the engine start switch is tur...

  • Page 87

    6c13g11 4-18 1 2 3 4 5 6 7 8 9 warning • before measuring the fuel pressure, make sure that the drain screw is tight- ened securely. • do not loosen the drain screw while measuring the fuel pressure. Loosening the drain screw can cause fuel to spray out creating a fire hazard. • after measuring the ...

  • Page 88: Fuel

    Fuel fuel system 4-19 6c13g11 5. Remove the needle valve and other com- ponents. Checking the vapor separator 1. Check the needle valve for bends or wear. Replace if necessary. 2. Check the float for deterioration. Replace if necessary. 3. Check the filter for dirt or residue. Clean if necessary. 4....

  • Page 89

    6c13g11 4-20 1 2 3 4 5 6 7 8 9 2. Adjust the lever c of the float by bending it until the float height d is within specifi- cation. Note: when adjusting the float height, do not bend the lever e. Assembling the vapor separator 1. Install the float chamber. 2. Install all parts removed during dissas-...

  • Page 90: Powr

    Powr 6c13g11 power unit special service tools ..................................................................................... 5-1 power unit....................................................................................................... 5-3 checking the compression pressure ...............

  • Page 91

    6c13g11 1 2 3 4 5 6 7 8 9 cylinder block .............................................................................................. 5-37 disassembling the cylinder block ............................................................ 5-38 checking the piston diameter ..................................

  • Page 92: Powr

    Powr power unit 5-1 6c13g11 special service tools 5 compression gauge 90890-03160 flywheel holder 90890-06522 flywheel puller 90890-06521 crankshaft holder 18 90890-06562 valve spring compressor 90890-04019 valve spring compressor attachment 90890-06320 valve guide remover/installer 90890-06801 valv...

  • Page 93

    6c13g11 5-2 1 2 3 4 5 6 7 8 9 valve seat cutter 90890-06312, 90890-06315, 90890-06323, 90890-06327, 90890-06328, 90890-06555 bearing outer race attachment 90890-06626 oil filter wrench 90890-01426 piston slider 90890-06529 special service tools.

  • Page 94: Powr

    Powr power unit 5-3 6c13g11 power unit 5 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...

  • Page 95

    6c13g11 5-4 1 2 3 4 5 6 7 8 9 checking the valve clearance caution: do not turn the flywheel magnet counter- clockwise, otherwise the valve system may be damaged. 1. Remove the flywheel magnet cover, and then remove the blowby hose 1. 2. Remove the fuel pump 2 and fuel filter 3. 3. Disconnect the sp...

  • Page 96: Powr

    Powr power unit 5-5 6c13g11 7. Check the intake valve clearance for cyl- inders #3 and #4, and the exhaust valve clearance for cylinders #2 and #4. Adjust if out of specification. Note: check the valve clearance when the engine is cold. 8. Loosen the rocker arm locknut 5, and then turn the adjusting...

  • Page 97

    6c13g11 5-6 1 2 3 4 5 6 7 8 9 5 no. Part name q’ty remarks 1 power unit 1 2 oil dipstick 1 3 gasket 1 not reusable 4 dowel 2 5 bolt 2 m6 × 16 mm 6 bolt 8 m8 × 80 mm 7 apron 1 8 screw 2 ø6 × 24 mm 9 nut 2 10 flywheel magnet cover 1 11 grommet 2 12 neutral switch 1 tiller handle model 13 shift positio...

  • Page 98: Powr

    Powr power unit 5-7 6c13g11 5 no. Part name q’ty remarks 1 nut 1 2 washer 1 3 flywheel magnet 1 4 bolt 3 m6 × 30 mm 5 stator coil 1 6 stator coil bracket 1 7 bolt 4 m6 × 30 mm 8 collar 2 9 pulser coil 1 10 bolt 2 m5 × 12 mm 11 woodruff key 1 12 bolt 1 m6 × 20 mm.

  • Page 99

    6c13g11 5-8 1 2 3 4 5 6 7 8 9 5 no. Part name q’ty remarks 1 timing belt 1 2 nut 1 width across flats: 41 mm (1.6 in) 3 retaining plate 1 4 drive sprocket 1 5 bolt 1 m10 × 35 mm 6 washer 1 7 driven sprocket 1 8 dowel 1 9 woodruff key 1 power unit.

  • Page 100: Powr

    Powr power unit 5-9 6c13g11 5 no. Part name q’ty remarks 1 rectifier regulator 1 2 bolt 2 m6 × 25 mm 3 spark plug 4 4 spark plug wire 4 5 holder 1 6 ignition coil 2 7 bolt 4 m6 × 30 mm 8 holder 2 9 bracket 1 10 bracket 1 11 cover 1 12 holder 1 s6c15050 t r . . 17 n · m (1.7 kgf · m, 12.5 ft · ib) t ...

  • Page 101

    6c13g11 5-10 1 2 3 4 5 6 7 8 9 5 no. Part name q’ty remarks 1 starter motor 1 2 bolt 3 m8 × 45 mm 3 screw 1 ø4 × 5 mm 4 cap 1 5 starter relay 1 6 bolt 2 m6 × 10 mm 7 cap 2 8 holder 1 9 screw 1 ø6 × 19 mm 10 fuse 1 30 a 11 cap 1 12 terminal 1 13 nut 1 14 cap 1 s6c15040 t r . . 29 n · m (2.9 kgf · m, ...

  • Page 102: Powr

    Powr power unit 5-11 6c13g11 5 no. Part name q’ty remarks 1 bracket 1 2 junction box 1 3 ecm 1 4 main and fuel pump relay 1 5 power trim and tilt relay 1 6 cover 1 7 wiring harness 1 8 bolt 8 m6 × 28 mm 9 grommet 8 10 collar 8 11 screw 1 ø6 × 19 mm 12 bolt 2 m6 × 20 mm 13 screw 4 ø6 × 55 mm 14 bolt ...

  • Page 103

    6c13g11 5-12 1 2 3 4 5 6 7 8 9 5 no. Part name q’ty remarks 18 bolt 2 m6 × 20 mm 19 holder 1 20 bolt 1 m6 × 14 mm 21 bolt 2 m8 × 25 mm 22 bolt 1 m6 × 20 mm 23 grommet 1 24 holder 1 25 bolt 1 m6 × 20 mm 26 fuse 3 20 a 27 cap 3 28 bolt 2 m6 × 14 mm 29 bolt 1 m6 × 14 mm 30 screw 1 ø6 × 19 mm 31 cap 2 3...

  • Page 104: Powr

    Powr power unit 5-13 6c13g11 5 no. Part name q’ty remarks 1 throttle cam 1 2 throttle control lever 1 3 bracket 1 4 lever 1 5 washer 1 6 bushing 1 7 clip 1 8 bolt 2 m6 × 25 mm 9 bolt 1 m6 × 35 mm 10 collar 1 11 wave washer 1 12 cotter pin 1 not reusable 13 throttle cam roller 1 14 bolt 1 m6 × 35 mm ...

  • Page 105

    6c13g11 5-14 1 2 3 4 5 6 7 8 9 removing the power unit note: it is recommended to loosen the flywheel magnet nut before removing the power unit to improve working efficiency. 1. Remove the flywheel magnet cover. 2. Disconnect the battery leads, ptt motor leads 1, and main switch coupler 2. 3. Discon...

  • Page 106: Powr

    Powr power unit 5-15 6c13g11 10. Remove the power unit by removing the bolts b. 11. Remove the flywheel magnet, then the woodruff key. Caution: to prevent damage to the engine or tools, screw in the puller set bolts evenly and completely so that the puller plate is par- allel to the flywheel magnet....

  • Page 107

    6c13g11 5-16 1 2 3 4 5 6 7 8 9 note: • use a deep socket 2 for this procedure. • make sure that the camshaft does not turn when loosening the drive sprocket nut. 3. Remove the timing belt 4 from the driven sprocket, then from the drive sprocket. Caution: do not turn the drive sprocket or the driven ...

  • Page 108: Powr

    Powr power unit 5-17 6c13g11 installing the timing belt and sprockets caution: do not turn the drive sprocket or the driven sprocket when the timing belt is not installed. Otherwise the piston and valves will interfere with each other and be damaged. 1. Install the driven sprocket, and then check th...

  • Page 109

    6c13g11 5-18 1 2 3 4 5 6 7 8 9 caution: • do not damage the timing belt during installation. • do not twist, turn inside out, or bend the timing belt beyond the maximum limit of 25 mm (1.0 in), otherwise it can be dam- aged. • do not get oil or grease on the timing belt. 5. Turn the drive sprocket c...

  • Page 110: Powr

    Powr power unit 5-19 6c13g11 cylinder head 5 no. Part name q’ty remarks 1 cylinder head 1 2 screw 6 ø4 × 20 mm 3 plate 1 4 engine hanger 1 5 bolt 2 m6 × 20 mm 6 gasket 1 not reusable 7 cylinder head cover 1 8 bolt 7 m6 × 20 mm 9 o-ring 1 10 oil filler cap 1 11 bolt 10 m9 × 93 mm 12 grommet 4 13 anod...

  • Page 111

    6c13g11 5-20 1 2 3 4 5 6 7 8 9 5 no. Part name q’ty remarks 18 dowel 2 19 gasket 1 not reusable 20 grommet 2 21 bolt 5 m6 × 25 mm 22 oil pump assembly 1 23 bolt 4 m6 × 45 mm cylinder head.

  • Page 112: Powr

    Powr power unit 5-21 6c13g11 5 no. Part name q’ty remarks 1 camshaft 1 2 oil seal 1 not reusable 3 gasket 1 not reusable 4 retaining bolt 1 5 washer 7 6 rocker arm assembly 7 7 rocker arm assembly 1 8 valve cotter 16 9 valve spring retainer 8 10 valve spring 8 11 valve spring seat 8 12 valve seal 8 ...

  • Page 113

    6c13g11 5-22 1 2 3 4 5 6 7 8 9 5 no. Part name q’ty remarks 18 stopper guide 1 19 tensioner 1 20 stopper guide 1 21 tensioner 1 cylinder head.

  • Page 114: Powr

    Powr power unit 5-23 6c13g11 removing the cylinder head 1. Remove the cylinder head cover. 2. Remove the cylinder head bolts in the sequence shown. Caution: do not scratch or damage the mating sur- faces of the cylinder head and cylinder block. 3. Remove the oil pump assembly 1. 4. Remove the rocker...

  • Page 115

    6c13g11 5-24 1 2 3 4 5 6 7 8 9 6. Remove the intake and exhaust valves. Note: be sure to keep the valves, springs, and other parts in the order as they were removed. Checking the valve springs 1. Measure the valve spring free length a. Replace if below specification. 2. Measure the valve spring tilt...

  • Page 116: Powr

    Powr power unit 5-25 6c13g11 3. Measure the valve stem diameter b. Replace if out of specification. 4. Measure the valve stem runout. Replace if above specification. Checking the valve guides note: before checking the valve guide make sure that the valve stem diameter is within specifi- cation. 1. M...

  • Page 117

    6c13g11 5-26 1 2 3 4 5 6 7 8 9 note: apply engine oil to the surface of the new valve guide. 3. Insert the special service tool into the valve guide 2, and then ream the valve guide. Note: • turn the valve guide reamer clockwise to ream the valve guide. • do not turn the reamer counterclockwise when...

  • Page 118: Powr

    Powr power unit 5-27 6c13g11 4. Measure the valve seat contact width a where the blueing dye is adhered to the valve face. Reface the valve seat if the valve is not seated properly or if the valve seat contact width is out of specification. Replace the valve guide if the valve seat contact is uneven...

  • Page 119

    6c13g11 5-28 1 2 3 4 5 6 7 8 9 b previous contact width 4. Use a 60° cutter to adjust the contact width of the bottom edge of the valve seat. B previous contact width 5. Use a 45° cutter to adjust the contact width of the valve seat to specification. B previous contact width c specified contact widt...

  • Page 120: Powr

    Powr power unit 5-29 6c13g11 9. Apply a thin, even layer of lapping com- pound onto the valve seat, and then lap the valve using a valve lapper (commer- cially available). Caution: do not get the lapping compound on the valve stem and valve guide. 10. After every lapping procedure, be sure to clean ...

  • Page 121

    6c13g11 5-30 1 2 3 4 5 6 7 8 9 3. Measure the camshaft journal diameters c and d, and cylinder head journal inside diameter e. Replace the camshaft and cylinder head if out of specification. Checking the cylinder head 1. Eliminate carbon deposits from the com- bustion chambers and check for deterio-...

  • Page 122: Powr

    Powr power unit 5-31 6c13g11 checking the oil pump 1. Measure the oil pump rotor clearances as shown. Replace if out of specification. Installing the valves 1. Install a new valve seal 1 onto the valve guide. 2. Install the valve 2, valve spring seat 3, valve spring 4, and valve spring retainer 5 in...

  • Page 123

    6c13g11 5-32 1 2 3 4 5 6 7 8 9 4. Lightly tap the valve spring retainer with a plastic hammer to set the valve cotter securely. Installing the camshaft 1. Install a new oil seal 1. 2. Install the camshaft 2 in the direction shown, then the retaining bolt 3. Installing the rocker arm shaft assembly 1...

  • Page 124: Powr

    Powr power unit 5-33 6c13g11 2. Assemble the rocker arm assemblies 1 and rocker arm shaft 2, and then install the tensioners 3 and stopper guides 4 to the rocker arm shaft by installing the bolts 5. Note: make sure that the arrow marks b on the tensioners are facing up. 3. Install the rocker arm sha...

  • Page 125

    6c13g11 5-34 1 2 3 4 5 6 7 8 9 installing the cylinder head 1. Install the driven sprocket, and then check that the “ 1” mark a on the driven sprocket 1 is aligned with the “ ” mark b on the cylinder head, and then tighten the bolt 2. 2. Check that the “ ” mark c on the retain- ing plate is aligned ...

  • Page 126: Powr

    Powr power unit 5-35 6c13g11 exhaust cover 5 no. Part name q’ty remarks 1 cooling water temperature sensor 1 2 gasket 1 not reusable 3 bolt 1 m6 × 14 mm 4 holder 1 5 bolt 1 m6 × 14 mm 6 plug 1 m14 × 12 mm 7 gasket 1 not reusable 8 plug 1 m8 × 17 mm 9 gasket 1 not reusable 10 thermostat 1 11 gasket 1...

  • Page 127

    6c13g11 5-36 1 2 3 4 5 6 7 8 9 5 no. Part name q’ty remarks 18 cover 1 19 bolt 1 m5 × 12 mm 20 plate 1 21 bolt 1 m6 × 20 mm 22 joint 1 23 hose 1 24 hose 1 25 joint 1 26 hose 1 27 holder 1 28 bolt 1 m4 × 8 mm 29 oil pressure switch lead 1 30 oil pressure switch 1 31 oil filter 1 32 joint 1 33 gasket ...

  • Page 128: Powr

    Powr power unit 5-37 6c13g11 cylinder block 5 no. Part name q’ty remarks 1 bolt 10 m8 × 82 mm 2 bolt 10 m6 × 35 mm 3 crankcase 1 4 main bearing 10 5 bolt 8 m6 × 30 mm 6 connecting rod assembly 4 7 connecting rod bearing 8 8 crankshaft 1 9 oil seal 1 not reusable 10 oil seal 1 not reusable 11 cylinde...

  • Page 129

    6c13g11 5-38 1 2 3 4 5 6 7 8 9 disassembling the cylinder block 1. Remove the thermostat cover and exhaust cover by removing the bolts in the sequence shown. 2. Remove the oil filter. Note: be sure to clean up any oil spills. 3. Remove the crankcase bolts in the sequence shown. 4. Remove the connect...

  • Page 130: Powr

    Powr power unit 5-39 6c13g11 checking the piston diameter 1. Measure the piston outside diameter at the specified measuring point. Replace if out of specification. Checking the cylinder bore 1. Measure the cylinder bore (d 1 –d 6 ) at measuring points a, b, and c, and in direction d (d 1 , d 3 , d 5...

  • Page 131

    6c13g11 5-40 1 2 3 4 5 6 7 8 9 2. Level the piston ring 1 in the cylinder with a piston crown. 3. Check the piston ring end gap d at the specified measuring point. Replace if out of specification. Checking the piston ring grooves 1. Measure the piston ring grooves. Replace the piston if out of speci...

  • Page 132: Powr

    Powr power unit 5-41 6c13g11 checking the piston ring side clearance 1. Measure the piston ring side clearance. Replace the piston and piston rings as a set if out of specification. Checking the piston pin boss bore 1. Measure the piston pin boss bore. Replace the piston if out of specification. Che...

  • Page 133

    6c13g11 5-42 1 2 3 4 5 6 7 8 9 checking the crankshaft 1. Measure the crankshaft journal diameter a, crankpin diameter b, and crankpin width c. Replace the crankshaft if out of specification. 2. Measure the crankshaft runout. Replace the crankshaft if above specification. Checking the crankpin oil c...

  • Page 134: Powr

    Powr power unit 5-43 6c13g11 3. Put a piece of plastigauge (pg-1) onto the crankpin, parallel to the crankshaft. Note: be sure not to put the plastigauge (pg-1) over the oil hole in the crankpin of the crank- shaft. 4. Install the connecting rod onto the crank- pin 3. Note: make sure that the marks ...

  • Page 135

    6c13g11 5-44 1 2 3 4 5 6 7 8 9 3. Select the suitable color b for the con- necting rod bearing from the table. Checking the crankshaft journal oil clearance 1. Clean the bearings, crankshaft journals, and bearing portions of the crankcase and cylinder block. 2. Place the cylinder block upside down o...

  • Page 136: Powr

    Powr power unit 5-45 6c13g11 6. Install the crankcase onto the cylinder block. 7. Apply engine oil to the threads of the crankcase bolts, and then tighten them to the specified torques in two stages and in the sequence shown. 8. Remove the crankcase, and then mea- sure the width of the compressed pl...

  • Page 137

    6c13g11 5-46 1 2 3 4 5 6 7 8 9 assembling the power unit 1. Assemble the piston 1, connecting rod 2, piston pin 3, and piston pin clips 4. Note: • face the embossed “y” mark a on the connecting rod in the same direction as the “up” mark b on the piston. • always use new piston pin clips, and do not ...

  • Page 138: Powr

    Powr power unit 5-47 6c13g11 5. Install the piston with the “up” mark on the piston crown facing towards the fly- wheel magnet. Note: apply engine oil to the side of the pistons and piston rings before installation. 6. Install half of the main bearings 9 into the cylinder block 0. Note: • install th...

  • Page 139

    6c13g11 5-48 1 2 3 4 5 6 7 8 9 note: • align the alignment marks g on the con- necting rod cap and connecting rod. • apply engine oil to the connecting rod bolts before installation. 9. Install half of the bearings into the crank- case. Note: • install the main bearings in their original positions. ...

  • Page 140: Powr

    Powr power unit 5-49 6c13g11 14. Install the oil filter, and then tighten it to the specified torque using the oil filter wrench. Note: apply a thin coat of engine oil to the o-ring of the new oil filter before installation. 15. Install a new gasket and the exhaust cover. 16. Install the thermostat ...

  • Page 141

    6c13g11 5-50 1 2 3 4 5 6 7 8 9 7. Install the ptt switch coupler, ptt motor leads, and battery leads. 8. Connect the throttle cable 6, shift cable 7, and throttle link rod 8, and then adjust their lengths. For adjustment pro- cedures, see chapter 3, “adjusting the throttle link and throttle cable” a...

  • Page 142: Lowr

    Lowr 6c13g11 lower unit special service tools ..................................................................................... 6-1 lower unit (f50, f60) ..................................................................................... 6-5 removing the lower unit ...............................

  • Page 143

    6c13g11 1 2 3 4 5 6 7 8 9 lower unit (ft50, ft60)............................................................................... 6-28 removing the lower unit .......................................................................... 6-31 removing the water pump and shift rod............................

  • Page 144: Lowr

    Lowr lower unit 6-1 6c13g11 special service tools 6 bearing housing puller claw l 90890-06502 bearing housing puller claw s 90890-06564 stopper guide plate 90890-06501 bearing separator 90890-06534 stopper guide stand 90890-06538 bearing puller assembly 90890-06535 needle bearing attachment 90890-06...

  • Page 145

    6c13g11 6-2 1 2 3 4 5 6 7 8 9 ball bearing attachment 90890-06655 driver rod ls 90890-06606 bearing inner race attachment 90890-06639, 90890-06641, 90890-06643, 90890-06644, 90890-06661 drive shaft holder 4 90890-06518 pinion nut holder new: 90890-06715 current: 90890-06505 bearing outer race puller...

  • Page 146: Lowr

    Lowr lower unit 6-3 6c13g11 shift rod push arm 90890-06052 pinion height gauge 90890-06710 pinion height gauge plate b 90890-06712 digital caliper 90890-06704 shimming plate 90890-06701 backlash indicator 90890-06706 magnet base plate 90890-07003 dial gauge set 90890-01252 magnet base b 90890-06844 ...

  • Page 147

    6c13g11 6-4 1 2 3 4 5 6 7 8 9 ring nut wrench 3 90890-06511 ring nut wrench extension 90890-06513 special service tools.

  • Page 148: Lowr

    Lowr lower unit 6-5 6c13g11 lower unit (f50, f60) 6 no. Part name q’ty remarks 1 lower unit 1 2 check screw 1 3 gasket 2 not reusable 4 drain screw 1 5 bolt 4 m10 × 40 mm 6 dowel 2 7 bolt 1 m8 × 35 mm 8 anode 1 9 spacer 1 10 propeller 1 11 washer 1 12 washer 1 13 propeller nut 1 14 cotter pin 1 not ...

  • Page 149

    6c13g11 6-6 1 2 3 4 5 6 7 8 9 6 no. Part name q’ty remarks 1 cover 1 2 seal 1 3 bolt 4 m8 × 30 mm 4 water pump housing 1 5 insert cartridge 1 6 impeller 1 7 o-ring 1 not reusable 8 dowel 2 9 outer plate cartridge 1 10 gasket 1 not reusable 11 seal 1 12 plate 1 13 woodruff key 1 lower unit (f50, f60).

  • Page 150: Lowr

    Lowr lower unit 6-7 6c13g11 removing the lower unit 1. Drain the gear oil. 2. Set the gear shift to the neutral position, and place a block of wood between the anti-cavitation plate and propeller to keep the propeller from turning, and then remove the propeller nut and propeller. Warning • do not ho...

  • Page 151

    6c13g11 6-8 1 2 3 4 5 6 7 8 9 propeller shaft housing (f50, f60) 6 no. Part name q’ty remarks 1 shift plunger 1 2 dog clutch 1 3 cross pin 1 4 spring 1 5 shift slider 1 6 spring 1 7 propeller shaft 1 8 reverse gear 1 9 reverse gear shim — 10 o-ring 1 not reusable 11 ball bearing 1 not reusable 12 o-...

  • Page 152: Lowr

    Lowr lower unit 6-9 6c13g11 removing the propeller shaft housing assembly 1. Remove the bolts, and then pull out the propeller shaft housing assembly. 2. Remove the propeller shaft assembly. Disassembling the propeller shaft assembly 1. Remove the spring 1, then the cross pin 2, dog clutch 3, shift ...

  • Page 153

    6c13g11 6-10 1 2 3 4 5 6 7 8 9 checking the propeller shaft housing 1. Clean the propeller shaft housing using a soft brush and cleaning solvent, and then check it for cracks. Replace if necessary. 2. Check the teeth and dogs of the reverse gear for cracks or wear. Replace the gear if necessary. 3. ...

  • Page 154: Lowr

    Lowr lower unit 6-11 6c13g11 2. Apply grease to new oil seals, and then install them into the propeller shaft hous- ing to the specified depth. Note: install an oil seal halfway into the propeller shaft housing, then the other oil seal. 3. Install the original shim(s) 5 and new ball bearing 6 onto t...

  • Page 155

    6c13g11 6-12 1 2 3 4 5 6 7 8 9 drive shaft and lower case (f50, f60) 6 no. Part name q’ty remarks 1 seal 1 2 oil seal housing 1 3 o-ring 1 not reusable 4 oil seal 2 not reusable 5 washer 1 6 drive shaft 1 7 forward gear 1 8 taper roller bearing assembly 1 not reusable 9 forward gear shim — 10 needle...

  • Page 156: Lowr

    Lowr lower unit 6-13 6c13g11 6 no. Part name q’ty remarks 18 screw 1 ø5 × 28 mm 19 cooling water inlet cover 2 20 nut 1 21 joint 1 22 plastic tie 1 not reusable 23 hose 1 24 shift rod 1 25 circlip 1 26 o-ring 1 not reusable 27 shift rod housing 1 28 oil seal 1 not reusable.

  • Page 157

    6c13g11 6-14 1 2 3 4 5 6 7 8 9 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 finger tight, and then remove the drive shaft bearing 2 using a press. Caution: • do not pr...

  • Page 158: Lowr

    Lowr lower unit 6-15 6c13g11 disassembling the lower case 1. Remove the taper roller bearing outer race and shim(s). Note: install the claws as shown. 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. Checki...

  • Page 159

    6c13g11 6-16 1 2 3 4 5 6 7 8 9 checking the lower case 1. Check the skeg and torpedo for cracks or damage. Replace the lower case if nec- essary. Assembling the oil seal housing 1. Apply grease to new oil seals, and then install them into the oil seal housing. Assembling the lower case 1. Install th...

  • Page 160: Lowr

    Lowr lower unit 6-17 6c13g11 3. Install the sleeve, original shim(s), and taper roller bearing outer race. Caution: add or remove shim(s), if necessary, if replacing the taper roller bearing or lower case. Note: • apply gear oil to the inside and outside of the sleeve before installation. • install ...

  • Page 161

    6c13g11 6-18 1 2 3 4 5 6 7 8 9 installing the oil seal housing 1. Install a new o-ring 1, the oil seal hous- ing 2, and the seal 3. Installing the propeller shaft housing 1. Install the washer 1 and propeller shaft assembly 2 into the propeller shaft housing assembly 3. 2. Apply grease to a new o-ri...

  • Page 162: Lowr

    Lowr lower unit 6-19 6c13g11 installing the water pump 1. Install a new gasket 1, the outer plate cartridge 2, and dowels 3. 2. Install the woodruff key into the drive shaft. 3. Align the groove in the impeller 4 with the woodruff key 5, and then install the impeller onto the drive shaft. 4. Install...

  • Page 163

    6c13g11 6-20 1 2 3 4 5 6 7 8 9 2. Align the center of the set pin a with the alignment mark b on the bracket. 3. Install the two dowels 1 into the lower unit. 4. Install the lower unit into the upper case, and then tighten the lower case mounting bolts 2 to the specified torque. 5. Install the trim ...

  • Page 164: Lowr

    Lowr lower unit 6-21 6c13g11 6. Install the propeller and propeller nut, and then tighten the nut finger 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. Warning • do not hold the prope...

  • Page 165: Shimming (F50, F60)

    6c13g11 6-22 1 2 3 4 5 6 7 8 9 shimming (f50, f60) 6 drive shaft and lower case (f50, f60) / shimming (f50, f60).

  • Page 166: Lowr

    Lowr lower unit 6-23 6c13g11 shimming note: • shimming is not required when assembling the original lower case and inner parts. • shimming is required when assembling the original inner parts and a new lower case. • shimming is required when replacing the inner part(s). Selecting the pinion shims 1....

  • Page 167

    6c13g11 6-24 1 2 3 4 5 6 7 8 9 example: if “m3” is 11.70 mm and “p” is (+5), then t3 = 11.70 – 11.30 – (+5)/100 mm = 0.40 – 0.05 mm = 0.35 mm 5. Select the pinion shim(s) (t3) as follows. Example: if “t3” is 0.35 mm, then the pinion shim is 0.35 mm. If “t3” is 0.46 mm, then the pinion shim is 0.48 m...

  • Page 168: Lowr

    Lowr lower unit 6-25 6c13g11 2. Calculate the forward gear shim thick- ness (t1) as shown in the examples below. Note: “f” is the deviation of the lower case dimen- sion from standard. The “f” mark a is stamped on the trim tab mounting surface of the lower case in 0.01 mm units. If the “f” mark is u...

  • Page 169

    6c13g11 6-26 1 2 3 4 5 6 7 8 9 3. Install the special service tools so that it pushes against the propeller shaft. Note: tighten the center bolt while turning the drive shaft until the drive shaft can no longer be turned. 4. Install the backlash indicator onto the drive shaft (18.0 mm [0.71 in] in d...

  • Page 170: Lowr

    Lowr lower unit 6-27 6c13g11 8. Apply a load to the reverse gear by installing the propeller 8 (without the washer 9 and 0), then the spacer a as shown. Note: tighten the propeller nut b while turning the drive shaft until the drive shaft can no longer be turned. 9. Slowly turn the drive shaft clock...

  • Page 171: Lower Unit (Ft50, Ft60)

    6c13g11 6-28 1 2 3 4 5 6 7 8 9 lower unit (ft50, ft60) 6 no. Part name q’ty remarks 1 lower unit 1 2 hose 1 3 check screw 1 4 gasket 2 not reusable 5 dowel 2 6 bolt 4 m10 × 40 mm/l-transom model 7 drain screw 1 8 grommet 1 9 bolt 1 m10 × 45 mm 10 bolt 1 m8 × 60 mm/l-transom model 11 spacer 1 12 prop...

  • Page 172: Lowr

    Lowr lower unit 6-29 6c13g11 6 no. Part name q’ty remarks 18 stud bolt 4 x-transom model 19 bolt 1 m8 × 185 mm/x-transom model 20 dowel 2 x-transom model 21 extension 1 x-transom model 22 washer 4 x-transom model 23 spring washer 4 x-transom model 24 nut 4 x-transom model.

  • Page 173

    6c13g11 6-30 1 2 3 4 5 6 7 8 9 6 no. Part name q’ty remarks 1 o-ring 1 not reusable 2 bolt 2 m6 × 16 mm 3 oil seal 1 not reusable 4 oil seal housing 1 5 o-ring 1 not reusable 6 shift rod 1 7 woodruff key 1 8 bolt 2 m8 × 55 mm 9 bolt 2 m8 × 45 mm 10 water pump housing 1 11 seal 1 12 gasket 1 not reus...

  • Page 174: Lowr

    Lowr lower unit 6-31 6c13g11 removing the lower unit 1. Drain the gear oil. 2. Set the gear shift to the neutral position, and place a block of wood between the anti-cavitation plate and propeller to keep the propeller from turning, and then remove the propeller nut and propeller. Warning • do not h...

  • Page 175

    6c13g11 6-32 1 2 3 4 5 6 7 8 9 note: pull up the shift rod assembly a little a to dis- connect it from the shift slider 2, turn it coun- terclockwise 90° b, and then remove it. 2. Remove the woodruff key, and then remove the outer plate cartridge. Checking the water pump and shift rod 1. Check the w...

  • Page 176: Lowr

    Lowr lower unit 6-33 6c13g11 propeller shaft housing (ft50, ft60) 6 no. Part name q’ty remarks 1 slider 1 2 shift plunger 1 3 cross pin 1 4 dog clutch 1 5 spring 1 6 propeller shaft 1 7 washer 1 8 reverse gear 1 9 thrust washer 1 10 ball bearing 1 not reusable 11 o-ring 1 not reusable 12 propeller s...

  • Page 177

    6c13g11 6-34 1 2 3 4 5 6 7 8 9 removing the propeller shaft housing assembly 1. Straighten the claw washer tabs a, and then remove the ring nut and claw washer. 2. Pull out the propeller shaft housing assembly. 3. Remove the propeller shaft assembly. Disassembling the propeller shaft assembly 1. Rem...

  • Page 178: Lowr

    Lowr lower unit 6-35 6c13g11 2. Remove the ball bearing. Caution: do not reuse the bearing, always replace it with a new one. 3. Remove the oil seals and needle bear- ing. Checking the propeller shaft housing 1. Clean the propeller shaft housing using a soft brush and cleaning solvent, and then chec...

  • Page 179

    6c13g11 6-36 1 2 3 4 5 6 7 8 9 note: • install the needle bearing with the manufac- ture identification mark a facing toward the oil seal (propeller side). • when using the driver rod, do not strike the special tool in a manner that will force the stopper c out of place. 2. Apply grease to the new o...

  • Page 180: Lowr

    Lowr lower unit 6-37 6c13g11 drive shaft and lower case (ft50, ft60) 6 no. Part name q’ty remarks 1 drive shaft 1 2 taper roller bearing 1 not reusable 3 pinion shim — 4 sleeve 1 5 hose 1 6 plastic tie 1 not reusable 7 joint 1 8 nut 1 9 cooling water inlet cover 2 10 screw 1 ø5 × 41 mm 11 seal 1 12 ...

  • Page 181

    6c13g11 6-38 1 2 3 4 5 6 7 8 9 6 no. Part name q’ty remarks 18 pinion 1 19 nut 1 20 lower case 1 21 oil seal housing 1 22 o-ring 1 not reusable 23 oil seal 1 not reusable drive shaft and lower case (ft50, ft60).

  • Page 182: Lowr

    Lowr lower unit 6-39 6c13g11 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 finger tight, and then remove the drive shaft bearing 2 using a press. Caution: • do not pres...

  • Page 183

    6c13g11 6-40 1 2 3 4 5 6 7 8 9 disassembling the lower case 1. Remove the taper roller bearing outer race and shim(s). Note: install the claws as shown. 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. Chec...

  • Page 184: Lowr

    Lowr lower unit 6-41 6c13g11 assembling the lower case 1. Install the needle bearing into the lower case to the specified depth. Note: • install the needle bearing with the manufac- ture identification mark a facing toward. • when using the driver rod, do not strike the special tool in a manner that...

  • Page 185

    6c13g11 6-42 1 2 3 4 5 6 7 8 9 2. Install the new needle bearing into the forward gear to the specified depth. Assembling the drive shaft 1. Install a new drive shaft bearing into the drive shaft using a press. Installing the pinion 1. Install the forward gear, then the drive shaft assembly, pinion,...

  • Page 186: Lowr

    Lowr lower unit 6-43 6c13g11 3. Install the propeller shaft housing assem- bly 4 into the lower case, and then install the straight key 5, claw washer 6, and ring nut 7. 4. Tighten the ring nut to the specified torque. Note: • to secure the ring nut, bend one tab a of the claw washer into a slot in ...

  • Page 187

    6c13g11 6-44 1 2 3 4 5 6 7 8 9 3. Install a new o-ring 5, onto the oil seal housing 7. 4. Install a new gasket 6, the oil seal hous- ing 7, a new gasket 8, and the outer plate cartridge 9. 5. Install the woodruff key into the drive shaft. 6. Align the groove on the impeller 0 with the woodruff key a...

  • Page 188: Lowr

    Lowr lower unit 6-45 6c13g11 2. Align the alignment mark a on the bush- ing with the alignment mark b on the bracket. 3. Install the dowels 1 into the lower unit. 4. Install the lower unit into the upper case, and then tighten the lower case mounting bolts (nuts) to the specified torque. È x-transom...

  • Page 189

    6c13g11 6-46 1 2 3 4 5 6 7 8 9 6. Install the propeller and propeller nut, and then tighten the nut finger 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. Warning • do not hold the pro...

  • Page 190: Lowr

    Lowr lower unit 6-47 6c13g11 shimming (ft50, ft60) 6.

  • Page 191

    6c13g11 6-48 1 2 3 4 5 6 7 8 9 shimming note: • shimming is not required when assembling the original lower case and inner parts. • shimming is required when assembling the original inner parts and a new lower case. • shimming is required when replacing the inner part(s). Selecting the pinion shims ...

  • Page 192: Lowr

    Lowr lower unit 6-49 6c13g11 4. Calculate the pinion shim thickness (t3) as shown in the examples below. Note: “p” is the deviation of the lower case dimen- sion from standard. The “p” mark a is stamped on the trim tab mounting surface of the lower case in 0.01 mm units. If the “p” mark unreadable, ...

  • Page 193: Backlash (Ft50, Ft60)

    6c13g11 6-50 1 2 3 4 5 6 7 8 9 note: “f” is the deviation of the lower case dimen- sion from standard. The “f” mark a is stamped on the trim tab mounting surface of the lower case in 0.01 mm units. If the “f” mark unreadable, assume that “f” is zero and check the backlash when the unit is assembled....

  • Page 194: Lowr

    Lowr lower unit 6-51 6c13g11 4. Install the backlash indicator onto the drive shaft (18 mm [0.71 in] in diameter), then the dial gauge onto the lower unit. Note: install the dial gauge so that the plunger a contacts the mark b on the backlash indica- tor. 5. Slowly turn the drive shaft clockwise and...

  • Page 195: — Memo —

    6c13g11 6-52 1 2 3 4 5 6 7 8 9 — memo — backlash (ft50, ft60).

  • Page 196: Brkt

    Brkt 6c13g11 bracket unit special service tools ..................................................................................... 7-1 tiller handle .................................................................................................... 7-2 checking the throttle cable and shift cable...

  • Page 197

    6c13g11 1 2 3 4 5 6 7 8 9 tilt cylinder and trim cylinder ..................................................................... 7-40 disassembling the trim cylinder............................................................... 7-42 disassembling the tilt cylinder ......................................

  • Page 198: Brkt

    Brkt bracket unit 7-1 6c13g11 special service tools 7 bearing puller assembly 90890-06535 bearing puller claw 1 90890-06536 stopper guide stand 90890-06538 stopper guide plate 90890-06501 driver rod ls 90890-06605 ball bearing attachment 90890-06637 cylinder-end screw wrench 90890-06588 cylinder-end...

  • Page 199: Tiller Handle

    6c13g11 7-2 1 2 3 4 5 6 7 8 9 tiller handle 7 no. Part name q’ty remarks 1 tiller handle assembly 1 2 grommet 1 3 nut 2 4 clip 1 5 throttle cable 1 6 retaining plate 1 7 bolt 3 m6 × 15 mm 8 clip 1 9 shift cable 1 10 cable guide 1 11 grommet 1 12 friction plate 1 13 bolt 1 m5 × 20 mm 14 bracket 1 15 ...

  • Page 200: Brkt

    Brkt bracket unit 7-3 6c13g11 7 no. Part name q’ty remarks 18 collar 1 short 19 washer 1 20 friction piece 1 21 collar 1 long 22 friction piece 1 23 steering lock washer 1 24 nut 1 25 self-locking nut 1 26 washer 2 27 bolt 2 s6c17010 4 5 7 6 8 9 10 11 1 3 2 27 26 25 24 23 22 12 21 20 19 18 17 16 15 ...

  • Page 201

    6c13g11 7-4 1 2 3 4 5 6 7 8 9 7 no. Part name q’ty remarks 1 tiller handle sub assembly 1 2 screw 2 ø6 × 10 mm 3 shift lever cover 1 4 bolt 1 m8 × 40 mm 5 shift lever 1 6 bushing 1 7 washer 1 8 bushing 2 9 nut 1 10 engine stop lanyard switch 1 11 nut 1 12 washer 1 13 bracket 1 14 collar 1 15 wave wa...

  • Page 202: Brkt

    Brkt bracket unit 7-5 6c13g11 7 no. Part name q’ty remarks 18 grease nipple 1 19 engine start switch housing 1 20 engine start switch 1 21 nut 1 22 bolt 1 m6 × 25 mm 23 screw 1 ø6 × 24 mm 24 bolt 1 m6 × 20 mm 25 cover 1 26 power trim and tilt switch 1 27 screw 5 ø6 × 15 mm 28 screw 2 ø6 × 15 mm 29 s...

  • Page 203

    6c13g11 7-6 1 2 3 4 5 6 7 8 9 7 no. Part name q’ty remarks 1 tiller handle 1 2 cotter pin 1 not reusable 3 friction adjusting knob 1 4 grommet 1 5 plastic tie 1 not reusable 6 cable clamp 1 7 stay 1 8 bolt 1 m6 × 14 mm 9 throttle cable 1 short 10 clip 1 11 throttle arm 1 12 throttle arm shaft 1 13 s...

  • Page 204: Brkt

    Brkt bracket unit 7-7 6c13g11 7 no. Part name q’ty remarks 18 screw 2 ø5 × 10 mm 19 bolt 1 m6 × 14 mm 20 spring housing 1 21 spring 1 22 actuator 1 23 roller 1 24 bushing 1 25 shift arm 1 26 pin 1 27 gear 1 28 holder 1 29 bolt 2 m6 × 30 mm 30 throttle shaft 1 31 friction piece 1 32 nut 1 1 2 4 5 3 1...

  • Page 205

    6c13g11 7-8 1 2 3 4 5 6 7 8 9 checking the throttle cable and shift cable 1. Check the operation of the throttle cable and shift cable. 2. Check the inner wire and outer wire of both cables for bends or damage, and the rubber seals for damage. Replace if necessary. Assembling the tiller handle 1. In...

  • Page 206: Brkt

    Brkt bracket unit 7-9 6c13g11 bottom cowling 7 no. Part name q’ty remarks 1 washer 1 2 bushing 1 3 bracket 1 4 bushing 1 5 bolt 1 m5 × 14 mm 6 shift rod 1 7 bushing 1 8 cotter pin 1 not reusable 9 bolt 1 10 spring 1 11 ball 1 12 flushing hose 1 13 hose joint 1 14 adapter 1 15 screw 2 ø6 × 19 mm 16 s...

  • Page 207

    6c13g11 7-10 1 2 3 4 5 6 7 8 9 7 no. Part name q’ty remarks 18 bolt 1 m6 × 25 mm 19 fuel joint 1 20 seal 1 21 bottom cowling assembly 1 22 bolt 1 m6 × 20 mm 23 holder 1 24 washer 1 25 washer 1 26 holder 1 27 nut 1 28 fuel hose 1 29 joint 1 30 fuel hose 1 31 corrugated tube 1 32 holder 1 33 bracket 1...

  • Page 208: Brkt

    Brkt bracket unit 7-11 6c13g11 7 no. Part name q’ty remarks 1 seal 1 tiller handle model 2 warning indicator 1 tiller handle model 3 collar 1 tiller handle model 4 bolt 1 m6 × 35 mm, tiller handle model 5 bolt 1 m6 × 20 mm, tiller handle model 6 grommet 1 7 bottom cowling 1 8 grommet 1 9 collar 2 10...

  • Page 209

    6c13g11 7-12 1 2 3 4 5 6 7 8 9 7 no. Part name q’ty remarks 18 cowling lock lever 1 19 washer 1 20 wave washer 1 21 bushing 1 22 bolt 4 m6 × 30 mm 23 grommet 4 24 collar 4 25 grommet 4 26 grommet 1 remote control model 27 ptt motor lead 1 power trim and tilt model 28 bolt 2 m6 × 20 mm 29 stay 1 30 p...

  • Page 210: Brkt

    Brkt bracket unit 7-13 6c13g11 upper case 7 no. Part name q’ty remarks 1 upper case assembly 1 2 nut 2 3 bolt 2 m12 × 170 mm 4 washer 2 5 bolt 3 m8 × 30 mm 6 upper mount 1 7 plate 1 8 bolt 2 m8 × 175 mm 9 cap 2 10 nut 2 11 mount cover 2 12 washer 2 13 rubber washer 2 14 washer 2 15 lower mount 2 16 ...

  • Page 211

    6c13g11 7-14 1 2 3 4 5 6 7 8 9 7 no. Part name q’ty remarks 18 bolt 4 m8 × 30 mm 19 screw 1 ø6 × 7 mm 20 cover 1 high thrust model 21 bolt 2 m8 × 20 mm, high thrust model s6c17080 21 20 19 2 3 4 17 16 15 14 13 12 10 9 1 11 18 5 6 7 8 8 t r . . 24 n · m (2.4 kgf · m, 17.7 ft · ib) lt 271 a a lt 572 l...

  • Page 212: Brkt

    Brkt bracket unit 7-15 6c13g11 7 no. Part name q’ty remarks 1 muffler assembly 1 2 rubber seal 1 3 grommet 1 4 dowel 2 5 upper case 1 6 drive shaft bushing 1 7 circlip 1 8 bolt 6 m10 × 45 mm 9 gasket 1 not reusable 10 drain bolt 1 m14 × 12 mm s6c17090 1 3 2 8 4 4 5 6 7 9 10 t r . . 17 n · m (1.7 kgf...

  • Page 213

    6c13g11 7-16 1 2 3 4 5 6 7 8 9 7 no. Part name q’ty remarks 1 exhaust guide 1 2 oil seal 1 not reusable 3 hose 1 4 joint 1 5 housing 1 6 gasket 1 not reusable 7 oil strainer 1 8 bolt 6 m6 × 30 mm 9 gasket 1 not reusable 10 oil pan 1 11 pipe 1 1 12 pipe 2 1 13 dowel 2 14 gasket 1 not reusable 15 exha...

  • Page 214: Brkt

    Brkt bracket unit 7-17 6c13g11 7 no. Part name q’ty remarks 18 rubber seal 1 19 gasket 1 not reusable 20 plate 1 21 dowel 2 22 grommet 1 23 pipe 1 24 gasket 1 not reusable 25 muffler 1 26 bolt 6 m6 × 24 mm 27 bolt 4 m8 × 30 mm s6c17100 4 9 5 13 6 10 7 16 17 22 20 21 23 8 15 18 14 26 3 1 2 21 24 25 1...

  • Page 215

    6c13g11 7-18 1 2 3 4 5 6 7 8 9 removing the upper case 1. Place a drain pan under the drain hole, and then remove the drain bolt and let the oil drain completely. 2. Remove the bolts, and then remove the covers. 3. Remove the upper mounting nuts and lower mounting bolts, and then remove the upper ca...

  • Page 216: Brkt

    Brkt bracket unit 7-19 6c13g11 assembling the oil pan 1. Install a new gasket 1 onto the exhaust guide 2. 2. Install the oil strainer 3, a new gasket, and the housing onto the exhaust guide, and then tighten the bolts to the specified torque. Note: align the projection a of the oil strainer with the...

  • Page 217

    6c13g11 7-20 1 2 3 4 5 6 7 8 9 8. Install the muffler assembly a by insert- ing the tip of the cooling water pipe b into the joint hole b of the upper case. 9. Install the muffler assembly bolts c, and then tighten them. 10. Install the upper mount d and bolts into the upper case, and then tighten t...

  • Page 218: Brkt

    Brkt bracket unit 7-21 6c13g11 installing the upper case 1. Install the upper and lower mounting bolts into the swivel bracket 1 simulta- neously. 2. Install the upper mounting nuts 2, and then tighten the nuts to the specified torque. 3. Install and tighten the lower mounting nuts 3. 4. Install the...

  • Page 219: Steering Arm

    6c13g11 7-22 1 2 3 4 5 6 7 8 9 steering arm 7 no. Part name q’ty remarks 1 steering arm 1 2 washer 1 3 bushing 1 4 o-ring 2 not reusable 5 bushing 2 6 swivel bracket assembly 1 7 bushing 1 8 circlip 1 9 steering yoke 1 10 steering yoke 1 high thrust model 2 1 3 4 5 6 5 4 7 8 9 10 a a a a upper case ...

  • Page 220: Brkt

    Brkt bracket unit 7-23 6c13g11 removing the steering arm 1. Remove the circlip 1. 2. Remove the steering yoke 2 by striking it with a plastic hammer. 3. Remove the steering arm from the swivel bracket assembly by pulling the arm off the bracket. Installing the steering arm 1. Install the washer 1, b...

  • Page 221

    6c13g11 7-24 1 2 3 4 5 6 7 8 9 steering arm.

  • Page 222: Brkt

    Brkt bracket unit 7-25 6c13g11 clamp brackets and swivel bracket 7 no. Part name q’ty remarks 1 swivel bracket assembly 1 2 screw 2 ø6 × 16 mm/power trim and tilt model 3 trim sensor 1 power trim and tilt model 4 plastic tie 1 not reusable power trim and tilt model 5 self-locking nut 2 6 bolt 4 m6 ×...

  • Page 223

    6c13g11 7-26 1 2 3 4 5 6 7 8 9 7 no. Part name q’ty remarks 1 swivel bracket 1 2 bushing 1 3 tilt stop lever 1 4 bushing 1 5 collar 2 distance a: 30.3–30.4 mm (1.19–1.20 in) 6 pin 1 7 bushing 1 8 pin 2 9 spring 1 10 spring holder 1 11 bolt 1 m6 × 10 mm 12 bushing 1 13 tilt stop lever 1 s6c17390 5 a ...

  • Page 224: Brkt

    Brkt bracket unit 7-27 6c13g11 removing the clamp brackets 1. Remove the power trim and tilt or hydro tilt. For removal procedure, see “remov- ing the power trim and tilt unit/hydro tilt unit.” 2. Loosen the self-locking nuts 1, and then remove clamp brackets 2 and 3. 3. Remove the trim sensor 4. In...

  • Page 225

    6c13g11 7-28 1 2 3 4 5 6 7 8 9 warning after tilting up the outboard motor, be sure to support it with the tilt stop lever. Otherwise, the outboard motor could sud- denly lower if the power trim and tilt unit should lose fluid pressure. 2. Loosen the cam screws 2. 3. Adjust the position of the trim ...

  • Page 226: Brkt

    Brkt bracket unit 7-29 6c13g11 power trim and tilt unit 7 no. Part name q’ty remarks 1 power trim and tilt unit 1 power trim and tilt model 2 hydro tilt unit 1 hydro tilt model 3 plastic tie 1 not reusable power trim and tilt model 4 washer 2 5 bolt 2 m8 × 19 mm 6 circlip 1 power trim and tilt model...

  • Page 227

    6c13g11 7-30 1 2 3 4 5 6 7 8 9 removing the power trim and tilt unit/hydro tilt unit 1. Fully tilt the outboard motor up, and then support it with the tilt stop lever 1. Warning after tilting up the outboard motor, be sure to support it with the tilt stop lever. Otherwise, the outboard motor could s...

  • Page 228: Brkt

    Brkt bracket unit 7-31 6c13g11 power trim and tilt motor 7 no. Part name q’ty remarks 1 stator 1 2 screw 3 ø5 × 20 mm 3 o-ring 1 not reusable 4 bearing 2 not reusable 5 armature 1 6 screw 2 ø4 × 10 mm 7 spring 2 8 brush 2 9 circuit breaker 1 10 brush holder 1 11 bolt 3 m5 × 20 mm 12 ptt motor base 1...

  • Page 229

    6c13g11 7-32 1 2 3 4 5 6 7 8 9 disassembling the power trim and tilt motor 1. Remove the power trim and tilt motor, o- ring, and joint from the power trim and tilt unit. Caution: • make sure that the tilt ram is fully extended when removing the power trim and tilt motor, otherwise fluid can spurt ou...

  • Page 230: Brkt

    Brkt bracket unit 7-33 6c13g11 3. Measure the commutator diameter. Replace if below specification. 4. Check the armature for continuity. Replace if out of specifications. 5. Check the base for cracks or damage. Replace if necessary. 6. Check the bearings and oil seal for dam- age or wear. Replace if...

  • Page 231

    6c13g11 7-34 1 2 3 4 5 6 7 8 9 6. Install the stator onto the motor base. Note: place a clean cloth over the end of the arma- ture shaft, hold it with a pair of pliers, and then carefully slide the stator over the arma- ture. S6c17520 6 7 6 power trim and tilt motor.

  • Page 232: Brkt

    Brkt bracket unit 7-35 6c13g11 gear pump 7 no. Part name q’ty remarks 1 gear pump assembly 1 2 spacer 2 3 pin 1 4 lever 1 5 bolt 1 m3 × 16 mm 6 bolt 1 m3 × 35 mm 7 spring 2 8 shuttle piston 1 9 backup ring 1 10 down-relief valve seat 1 11 washer 1 12 spring 1 13 washer 1 14 cap 1 15 bolt 2 m5 × 30 m...

  • Page 233

    6c13g11 7-36 1 2 3 4 5 6 7 8 9 7 no. Part name q’ty remarks 18 washer 1 19 spring 1 20 washer 1 21 up-relief valve seat 1 22 bolt 2 m5 × 25 mm 23 o-ring 1 not reusable 24 shuttle piston 1 25 bolt 2 m5 × 45 mm 26 bolt 2 m5 × 50 mm 27 filter 1 28 plate 1 29 o-ring 2 not reusable 30 filter 2 31 o-ring ...

  • Page 234: Brkt

    Brkt bracket unit 7-37 6c13g11 7 no. Part name q’ty remarks 1 manual release spring 1 2 ball 2 3 bracket 1 4 bolt 1 m3 × 5 mm 5 bolt 2 m5 × 6 mm 6 washer 2 7 o-ring 2 not reusable 8 adapter 2 9 spring 2 10 ball 2 11 gear 2 12 drive shaft 1 13 pin 2 14 driven shaft 1 15 ball 2 16 pin 2 s6c17450 t r ....

  • Page 235

    6c13g11 7-38 1 2 3 4 5 6 7 8 9 disassembling the gear pump 1. Remove the manual valve, then the gear pump and filters. 2. Remove the relief valve seat caps, then the up-relief valve seat 1 and down- relief valve seat 2. 3. Remove the lever 3, then the shuttle pistons 4. 4. Remove the gear pump brack...

  • Page 236: Brkt

    Brkt bracket unit 7-39 6c13g11 3. Install the gear pump cover 4, then the pins 5. 4. Install the adapters 6 into the gear pump cover. 5. Install the balls 7 into the gear pump cover with the manual release spring 8. 6. Install the gear pump bracket 9 by installing the bolts, and then tighten them to...

  • Page 237

    6c13g11 7-40 1 2 3 4 5 6 7 8 9 tilt cylinder and trim cylinder 7 no. Part name q’ty remarks 1 tilt piston assembly 1 2 oil seal 1 not reusable 3 dust seal 1 not reusable 4 o-ring 1 not reusable 5 trim cylinder end screw 1 6 o-ring 1 not reusable 7 o-ring 1 not reusable 8 o-ring 1 not reusable 9 back...

  • Page 238: Brkt

    Brkt bracket unit 7-41 6c13g11 7 no. Part name q’ty remarks 18 free piston 1 19 o-ring 1 not reusable 20 ball 6 21 tilt cylinder 1.

  • Page 239

    6c13g11 7-42 1 2 3 4 5 6 7 8 9 disassembling the trim cylinder 1. Hold the power trim and tilt unit 1 in a vise using aluminum plates a on both sides. 2. Loosen the trim cylinder end screw 2, and then remove it. Warning make sure that the ram is fully extended before removing the end screw. 3. Drain...

  • Page 240: Brkt

    Brkt bracket unit 7-43 6c13g11 checking the tilt cylinder and trim cylinder 1. Check the inner walls of the trim cylinder and tilt cylinder for scratches. Replace if necessary. 2. Check the outer surface of the tilt piston and free piston for scratches. Replace if necessary. 3. Check the tilt ram fo...

  • Page 241

    6c13g11 7-44 1 2 3 4 5 6 7 8 9 6. Install the backup ring and new o-ring into the tilt piston 7. 7. Install balls 8 and 9, absorber valve pin, spring, pins, plate, and washer into the tilt piston. 8. Hold the tilt ram end in a vise using alu- minum plates on both sides. 9. Install the tilt piston to...

  • Page 242: Brkt

    Brkt bracket unit 7-45 6c13g11 assembling the power trim and tilt unit 1. Hold the trim cylinder in a vise using alu- minum plates on both sides. 2. Install the filters and gear pump assem- bly 1 by installing the bolts 2, then tight- ening them to the specified torque. 3. Install the manual valve 3...

  • Page 243

    6c13g11 7-46 1 2 3 4 5 6 7 8 9 7. Install the balls 6 into the tilt cylinder, and then insert the tilt cylinder into the trim cylinder 7. Note: apply grease to the balls to prevent them from falling off. 8. Install the trim cylinder end screw 8, and then tighten it to the specified torque. 9. Fully ...

  • Page 244: Brkt

    Brkt bracket unit 7-47 6c13g11 5. Install the reservoir cap, and then tighten it to the specified torque. 6. Connect the ptt motor leads to the bat- tery terminals to fully retract the tilt ram. 7. Reverse the ptt motor leads between the battery terminals to fully extend the tilt ram. Note: • repeat...

  • Page 245

    6c13g11 7-48 1 2 3 4 5 6 7 8 9 6. Route the ptt motor leads through the hole, and then install the plastic tie. 7. Connect the ground lead to the bottom of the power trim and tilt unit, and then tighten the bolt. 8. Install the tilt pin (hydro tilt model). Bleeding the power trim and tilt unit (buil...

  • Page 246: Brkt

    Brkt bracket unit 7-49 6c13g11 7. Remove the reservoir cap 2, and then check the fluid level in the reservoir. Note: if the fluid is at the correct level, the fluid should overflow out of the filler hole when the reservoir cap is removed. 8. If necessary, add sufficient fluid of the recommended type...

  • Page 247

    6c13g11 7-50 1 2 3 4 5 6 7 8 9 2. Connect the digital circuit tester between power trim and tilt relay terminals 2 and 3. 3. Connect the light green (lg) lead to the positive battery terminal and the black (b) lead to the negative battery terminal as shown. 4. Check for continuity between terminals ...

  • Page 248: Brkt

    Brkt bracket unit 7-51 6c13g11 checking the trim sensor 1. Measure the trim sensor resistance. Replace if out of specification. Note: turn the lever 1 and measure the resistance as it gradually changes. Trim sensor resistance: pink (p) – black (b) 168.3–288.3 Ω at 20 °c (68 °f) a 9–11 Ω at 20 °c (68...

  • Page 249: — Memo —

    6c13g11 7-52 1 2 3 4 5 6 7 8 9 — memo — power trim and tilt electrical system.

  • Page 250: Elec

    Elec – + 6c13g11 electrical systems special service tools ..................................................................................... 8-1 checking the electrical components............................................................ 8-2 measuring the peak voltage .............................

  • Page 251

    6c13g11 1 2 3 4 5 6 7 8 9 starting system ............................................................................................ 8-15 checking the fuses .................................................................................. 8-15 checking the starter relay..............................

  • Page 252: Elec

    Elec electrical systems – + 8-1 6c13g11 special service tools 8 ignition tester 90890-06754 digital circuit tester 90890-03174 peak voltage adapter b 90890-03172 test harness (2 pins) 90890-06792 test harness (2 pins) new: 90890-06867 current: 90890-06767 vacuum/pressure pump gauge set 90890-06756 t...

  • Page 253: Checking The Electrical

    6c13g11 8-2 1 2 3 4 5 6 7 8 9 checking the electrical components 8 measuring the peak voltage note: before troubleshooting the peak voltage, check that all electrical connections are tight and free from corrosion, and that the battery is fully charged to 12 v. The condition of the ignition system ca...

  • Page 254: Elec

    Elec electrical systems – + 8-3 6c13g11 electrical components 8 port view 1 power trim and tilt relay 2 starter motor 3 oil pressure switch 4 cooling water temperature sensor 5 rectifier regulator 6 ignition coil 7 starter relay 8 fuse (30 a) (starter relay) s6c18160 1 2 3 4 5 6 7 8.

  • Page 255

    6c13g11 8-4 1 2 3 4 5 6 7 8 9 bow view 1 sensor assembly (intake air temperature and intake air pressure) 2 ecm 3 fuse (20 a) (ecm, ignition coil, electric fuel pump, fuel injector, idle speed control, and vapor separator) 4 fuse (20 a) (main switch and power trim and tilt switch) 5 fuse (20 a) (rec...

  • Page 256: Elec

    Elec electrical systems – + 8-5 6c13g11 starboard view 1 fuel injector 2 ecm 3 throttle position sensor 4 idle speed control 5 sensor assembly (intake air temperature and intake air pressure) s6c18180 1 1 2 3 5 4.

  • Page 257

    6c13g11 8-6 1 2 3 4 5 6 7 8 9 top view 1 solenoid valve 2 rectifier regulator 3 spark plug 4 ignition coil 5 power trim and tilt switch (remote control model) 6 oil pressure switch 7 pulser coil 8 starter motor 9 fuse (30 a) (starter relay) 0 fuse (20 a) (rectifier regulator) a fuse (20 a) (main swi...

  • Page 258: Elec

    Elec electrical systems – + 8-7 6c13g11 tiller handle model 1 shift position switch 2 neutral switch (tiller handle model) 3 warning indicator (tiller handle model) 4 power trim and tilt switch 5 engine stop lanyard switch 6 variable trolling rpm switch (optional) s6c18200 1 2 3 6 4 5.

  • Page 259: System

    6c13g11 8-8 1 2 3 4 5 6 7 8 9 ignition and ignition control system 8 checking the ignition spark 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 spe- cial se...

  • Page 260: Elec

    Elec electrical systems – + 8-9 6c13g11 3. Measure the ignition coil resistance. Replace if out of specification. Checking the ecm 1. Disconnect an ignition coil coupler. 2. Connect the test harness (2 pins) to the ignition coil. 3. Measure the ecm output peak voltage. If below specification, measur...

  • Page 261

    6c13g11 8-10 1 2 3 4 5 6 7 8 9 checking the pulser coil air gap 1. Remove the flywheel magnet cover. 2. Turn the flywheel magnet clockwise to align the projection of the flywheel mag- net with the pulser coil projection. 3. Measure the pulser coil air gap a. Adjust if out of specification. 4. Loosen...

  • Page 262: Elec

    Elec electrical systems – + 8-11 6c13g11 4. Check the switch for no continuity at the specified pressure. Replace if there is continuity. Checking the cooling water temperature sensor 1. Place the cooling water temperature sen- sor in a container of water and slowly heat the water. 2. Measure the co...

  • Page 263

    6c13g11 8-12 1 2 3 4 5 6 7 8 9 2. Connect the digital circuit tester leads to the relay terminals 2 and 3. 3. Connect the positive battery terminal to the main and fuel pump relay terminal 4. 4. Connect the negative battery terminal to the main and fuel pump relay terminal 5. 5. Check for continuity...

  • Page 264: Elec

    Elec electrical systems – + 8-13 6c13g11 checking the warning indicators (tiller handle model) 1. Connect a positive penlight battery termi- nal (1.5 v) to the yellow (y) lead. 2. Connect a negative penlight battery ter- minal (1.5 v) to the pink and white (p/w) lead. 3. Check that the low oil press...

  • Page 265

    6c13g11 8-14 1 2 3 4 5 6 7 8 9 note: after the engine start switch is turned to on, the electric fuel pump will operate for 3 sec- onds. Checking the main and fuel pump relay (fuel control) 1. Remove the main and fuel pump relay 1. 2. Connect the digital circuit tester leads to the relay terminals 2...

  • Page 266: Elec

    Elec electrical systems – + 8-15 6c13g11 starting system 8 checking the fuses 1. Check the fuses for continuity. Replace if there is no continuity. Checking the starter relay 1. Connect the digital circuit tester leads to the starter relay terminals. 2. Connect the positive battery terminal to the b...

  • Page 267: Starter Motor

    6c13g11 8-16 1 2 3 4 5 6 7 8 9 starter motor 8 no. Part name q’ty remarks 1 clip 1 2 pinion stopper 1 3 starter motor pinion 1 4 spring 1 5 bolt 2 m6 × 35 mm 6 housing 1 7 bearing 1 8 clutch assembly 1 9 e-clip 1 not reusable 10 washer 1 11 bracket 1 12 pinion shaft 1 13 planetary gear 3 14 outer ge...

  • Page 268: Elec

    Elec electrical systems – + 8-17 6c13g11 8 no. Part name q’ty remarks 18 brush assembly 1 19 brush spring 4 20 brush holder 1 21 plate 1 22 washer 1 23 bracket 1 24 screw 2 ø4 × 15 mm 25 bolt 2 m6 × 120 mm 26 rubber seal 1 27 shift lever 1 28 spring 1 29 magnet switch assembly 1 30 washer 1 31 nut 1...

  • Page 269

    6c13g11 8-18 1 2 3 4 5 6 7 8 9 disassembling the starter motor 1. Slide the pinion stopper 1 down as shown, and then remove the clip 2. Note: remove the clip with a thin screwdriver. 2. Remove the bolt, and then disassemble the starter motor. Checking the starter motor pinion 1. Check the teeth of t...

  • Page 270: Elec

    Elec electrical systems – + 8-19 6c13g11 4. Check the armature for continuity. Replace if out of specifications. Checking the brushes 1. Measure the brush length. Replace the brush assembly if below specification. 2. Check the brush holder assembly for continuity. Replace if out of specification. Ch...

  • Page 271: Charging System

    6c13g11 8-20 1 2 3 4 5 6 7 8 9 charging system 8 checking the stator coil 1. Disconnect the stator coil coupler. 2. Connect the test harness (6 pins) to the stator coil coupler. 3. Measure the stator coil output peak volt- age. Replace the stator coil if below specification. Checking the rectifier r...

  • Page 272: Elec

    Elec electrical systems – + 8-21 6c13g11 — memo —.

  • Page 273: Trbl

    6c13g11 trbl shtg 1 2 3 4 5 6 7 8 9 troubleshooting special service tools ..................................................................................... 9-1 yamaha diagnostic system .......................................................................... 9-2 introduction.......................

  • Page 274: Trbl

    Trbl shtg troubleshooting 9-1 6c13g11 special service tools 9 yamaha diagnostic system 60v-85300-02 yamaha diagnostic system 60v-ws853-02 diagnostic flash indicator b 90890-06865 yamaha diagnostic system installation manual.

  • Page 275: Yamaha Diagnostic System

    6c13g11 9-2 1 2 3 4 5 6 7 8 9 yamaha diagnostic system 9 introduction features the newly developed yamaha diagnostic system provides quicker detection and analysis of engine malfunctions for quicker troubleshooting procedures than traditional methods. By connecting your computer to the ecm (electron...

  • Page 276: Trbl

    Trbl shtg troubleshooting 9-3 6c13g11 hardware requirements make sure that your computer meets the following requirements before using this software. Computer: ibm-compatible computer operating system: microsoft windows 95, windows 98, windows me, windows 2000, or win- dows xp (english version) cpu:...

  • Page 277

    6c13g11 9-4 1 2 3 4 5 6 7 8 9 connecting the communication cable to the outboard motor bow view s6c19010 3-pin communication coupler yamaha diagnostic system.

  • Page 278: Trbl

    Trbl shtg troubleshooting 9-5 6c13g11 self-diagnosis 9 diagnosing the electronic control system 1. Connect the special service tool to the outboard motor as shown. Note: when performing this diagnosis, all of the electrical wires must be properly connected. 2. Start the engine and let it idle. 3. Ch...

  • Page 279

    6c13g11 9-6 1 2 3 4 5 6 7 8 9 code symptom 1 normal 15 incorrect cooling water temperature sensor signal 18 incorrect throttle position sensor signal 19 incorrect battery voltage 23 incorrect sensor assembly (intake air temperature sensor) signal 28 incorrect neutral switch signal 29 incorrect senso...

  • Page 280: Trbl

    Trbl shtg troubleshooting 9-7 6c13g11 note: • before troubleshooting the outboard motor, check the mounting and rigging of the outboard motor. Also, make sure that the specified fuel has been used and that the battery is fully charged. • to diagnose a mechanical malfunction, use the troubleshooting ...

  • Page 281

    6c13g11 9-8 1 2 3 4 5 6 7 8 9 yes no check the wiring harness for continuity. Yes repair or replace the wiring har- ness. No disassemble and check the starter motor. Replace the starter relay. Is there continuity? Is there continuity? Yes no check the engine start switch for continuity. Yes no repla...

  • Page 282: Trbl

    Trbl shtg troubleshooting 9-9 6c13g11 ignition system check the condition of the spark plugs. Clean, adjust, or replace the spark plugs. No check the ignition spark using the ignition tester. Warning • do not touch any of the connections of the ignition tester leads. • do not let sparks leak out of ...

  • Page 283

    6c13g11 9-10 1 2 3 4 5 6 7 8 9 yes repair or replace the spark plug wire. No good condition? Check the ecm output peak voltage. Check the main and fuel pump relay (main control) for continu- ity. No is there continuity? Yes replace the main and fuel pump relay. Check the resistance of each spark plu...

  • Page 284: Trbl

    Trbl shtg troubleshooting 9-11 6c13g11 fuel system check the electric fuel pump operation. Yes no yes no replace the electrical fuel pump. Repair or replace the defective parts. Check the fuse and wiring har- ness for continuity. Is there continuity? Can the opera- tion sound be heard? Continued on ...

  • Page 285

    6c13g11 9-12 1 2 3 4 5 6 7 8 9 check the ignition system and compression pressure. No yes replace the needle valve. Is the needle valve bent or worn? Check the fuel filters for clogs, dirt, or water and the hoses for leaks. No yes replace the diaphragm. Check the vapor separator needle valve. Cracks...

  • Page 286: Trbl

    Trbl shtg troubleshooting 9-13 6c13g11 symptom 2: engine speed at wide open throttle is low, engine speed decreases, or engine stalls (poor acceleration or poor deceleration). Yes repair or replace the defective parts. No yes repair or replace the defective parts. No check the throttle valve for ben...

  • Page 287

    6c13g11 9-14 1 2 3 4 5 6 7 8 9 ignition system yes out of specification? No check the ignition system, fuel system, lubrication system, or cooling system. Check the valve clearances or disassemble and check the engine. Check the condition of the spark plugs. Clean, adjust, or replace the spark plugs...

  • Page 288: Trbl

    Trbl shtg troubleshooting 9-15 6c13g11 replace the engine stop lan- yard switch. Yes no is there continuity? Check the resistance of each ignition coil. Yes repair or replace the spark plug wire. No good condition? Check the ecm output peak voltage. Yes replace the ignition coils. No check the resis...

  • Page 289

    6c13g11 9-16 1 2 3 4 5 6 7 8 9 fuel system continued on next page. Check the fuel filters for clogs, dirt, or water and the hoses for leaks. Yes no repair or replace the defective parts. Good condition? Check the fuel pressure. Check the fuel pump dia- phragm. No yes no replace the injec- tors. Good...

  • Page 290: Trbl

    Trbl shtg troubleshooting 9-17 6c13g11 lubrication system no yes replace the needle valve. Is the needle valve bent or worn? Check the ignition system, lubri- cation system, or cooling sys- tem. No yes check the vapor separator nee- dle valve. Replace the diaphragm. Cracks or damage? Add engine oil ...

  • Page 291

    6c13g11 9-18 1 2 3 4 5 6 7 8 9 cooling system check the oil pump for debris or oil leaks. Yes no check the oil passage. Debris or leaks? Yes no clean or replace the defective parts. Check the ignition system, fuel system, or cooling system. Out of specification? Clean or replace the cooling water pa...

  • Page 292: Trbl

    Trbl shtg troubleshooting 9-19 6c13g11 symptom 3: engine speed not stable at low speeds or hunting occurs. Check the water pump. Replace the cooling water tem- perature sensor. No yes out of specification? Replace the water pump. Good condition? Check the ignition system, fuel system, or lubrication...

  • Page 293

    6c13g11 9-20 1 2 3 4 5 6 7 8 9 ignition system check the condition of the spark plugs. Clean, adjust, or replace the spark plugs. No check the ignition spark using the ignition tester. Yes warning • do not touch any of the connections of the ignition tester leads. • do not let sparks leak out of the...

  • Page 294: Trbl

    Trbl shtg troubleshooting 9-21 6c13g11 fuel system check the fuel pump dia- phragm. Check the vapor separator nee- dle valve. Yes no replace the diaphragm. Replace the needle valve. Replace the injectors. Check the resistance of each injector and check the injectors for clogs. Check the ignition sys...

  • Page 295: Power Trim and Tilt Unit

    6c13g11 9-22 1 2 3 4 5 6 7 8 9 power trim and tilt unit 9 symptom 1: power trim and tilt unit does not operate. Check the power trim and tilt motor operation. Can the opera- tion sound be heard? No yes check the battery and fuse. Yes no good condition? Repair or replace the defective parts. Check th...

  • Page 296: Trbl

    Trbl shtg troubleshooting 9-23 6c13g11 symptom 2: power trim and tilt unit does not hold the outboard motor up. Yes no check the power trim and tilt fluid level. Yes no close the manual valve. Add fluid to the correct level. Is it closed? Disassemble and check the power trim and tilt unit. At specif...

  • Page 297

    6c13g11 i-1 1 2 3 4 5 6 7 8 9 index a. Adjusting the float .....................................4-19 adjusting the friction plate...........................7-8 adjusting the throttle link and throttle cable ....................................3-10 adjusting the trim sensor .............................

  • Page 298

    Index i-2 6c13g11 checking the main and fuel pump relay (main control) ..........................................8-11 checking the neutral switch (tiller handle model) ................................8-11 checking the oil pressure ...........................5-3 checking the oil pressure switch ........

  • Page 299

    6c13g11 i-3 1 2 3 4 5 6 7 8 9 index e. Ecm (electric control module) .................1-10 electrical ........................................... 2-9 , 2-15 electrical components.................................8-3 electronic control system ............................1-9 exhaust cover ................

  • Page 300

    Index i-4 6c13g11 removing the water pump and shift rod ............................................6-31 replacing the oil filter..................................3-5 replacing the timing belt.............................3-6 replacing the valve guides .......................5-25 s. Safety while work...

  • Page 301: — Memo —

    6c13g11 i-5 1 2 3 4 5 6 7 8 9 index — memo —.

  • Page 302: Wiring Diagram

    Wiring diagram f50fed, f50feht, f50fet, ft50get, f60ceht, f60cet, ft60det 1 ignition coil 2 spark plug 3 power trim and tilt switch (tiller handle) 4 power trim and tilt switch (bottom cowling) 5 battery 6 cooling water temperature sensor 7 starter motor 8 fuse (30 a) 9 fuse (20 a) 0 neutral switch ...

  • Page 304

    Yamaha motor co., ltd. Printed in the netherlands jul. 2004 – 1.2 × 1 cr (e_2).

  • Page 305

    F50fed, f50feht, f50fet, ft50get, f60ceht f60cet, ft60det sb r lg up free down 4 3 2 1 1 2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 6 7 5 1 2 3 8 4 1 2 ...