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Yamaha FT50C Service Manual

Other manuals for FT50C: Servise Manual, Service Manual

Summary of FT50C

  • Page 1

    Service manual 62y-28197-3a-11 290408 f50a ft50b ft50c.

  • Page 2

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

  • Page 3: 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 index – +.

  • Page 5: General Information

    62y3a11 gen info 1 2 3 4 5 6 7 8 i general information how to use this manual ................................................................................. 1-1 manual format............................................................................................ 1-1 symbols......................

  • Page 6

    Gen info general information 1-1 62y3a11 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

    62y3a11 1-2 1 2 3 4 5 6 7 8 i 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 symbols 1 to 5 in an exploded diagram indicate the grade of ...

  • Page 8

    Gen info general information 1-3 62y3a11 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

    62y3a11 1-4 1 2 3 4 5 6 7 8 i 6. Keep a supply of clean, lint-free cloths for wiping up spills, etc. Good working practices special tools use the recommended special tools to pro- tect parts from damage. Use the right tool in the right manner—do not improvise. Tightening torques follow the tightenin...

  • Page 10

    Gen info general information 1-5 62y3a11 identification 1 applicable models this manual covers the following models. Serial number the outboard motor serial number is stamped on a label attached to the port clamp bracket. 1 model name 2 approved model code 3 transom height 4 serial number applicable...

  • Page 11

    62y3a11 1-6 1 2 3 4 5 6 7 8 i features and benefits 1 newly designed four carburetors newly designed four carburetors have been based on the current f50a. Prime start has been adopted for the starting system to further increase starting performance and serviceability. Further- more, the acceleration...

  • Page 12

    Gen info general information 1-7 62y3a11 cdi unit with microcomputer the ignition system consists of a flywheel, stator, pulser coil, thermoswitch, oil pressure switch, cdi unit, and ignition coil. The cdi unit contains a built-in microcomputer that determines the ignition timing separately for acce...

  • Page 13

    62y3a11 1-8 1 2 3 4 5 6 7 8 i lower unit higher class pinion and gears the lower unit of the new t50/ft50b, ft50c uses the same type of large gears that are used in the f100. The use of the same type of gears that are used in a higher class model provides ample dura- bility, making it possible to ac...

  • Page 14

    Gen info general information 1-9 62y3a11 shift slider type shift mechanism the t50/ft50b, ft50c has adopted the shift slider type shift mechanism. This shift mechanism enables a prompt engagement of the dog clutch regardless of the operating speed of the shift lever. Thus, smooth and positive shift ...

  • Page 15

    62y3a11 1-10 1 2 3 4 5 6 7 8 i technical tips 1 carburetor starting system (prime start) to facilitate the starting of a cold engine, an air-fuel mixture that is richer than normal is required. For this reason, the prime start system has been adopted in the f50/f50a, t50/ft50b, ft50c. In the prime s...

  • Page 16

    Gen info general information 1-11 62y3a11 1 prime start È the enriched air-fuel mixture is delivered to cylinders #1 and #2 by the prime start system attached to carburetor #1. É the enriched air-fuel mixture is delivered to cylinders #3 and #4 by the prime start system attached to carburetor #3..

  • Page 17

    62y3a11 1-12 1 2 3 4 5 6 7 8 i carburetor operation 1. Idle and low-speed operation since the vacuum at the venturi is low when the throttle valve is opened slightly, the main nozzle does not supply any air-fuel mixture to the engine. When the engine is operating at idle, the fuel that passes throug...

  • Page 18

    Gen info general information 1-13 62y3a11 2. Medium speed operation when the throttle valve opens further, air-fuel mixture is fed from the pilot outlet and all the bypass holes. In addition, air-fuel mixture is also supplied from the main nozzle in accordance with the opening angle of the throttle ...

  • Page 19

    62y3a11 1-14 1 2 3 4 5 6 7 8 i 3. High-speed operation when the throttle valve approaches its fully open position, the fuel that has been regulated by the main jet and the air that has been regulated by the main air jet are mixed in the main nozzle. The resultant mixture is then sprayed by the main ...

  • Page 20

    Gen info general information 1-15 62y3a11 acceleration pump the function of the acceleration pump is to ensure a smooth acceleration by preventing the air-fuel mixture from becoming temporarily lean in case the throttle valve is opened suddenly. When the throttle valve is opened suddenly, a large vo...

  • Page 21

    62y3a11 1-16 1 2 3 4 5 6 7 8 i operation when the throttle is opened suddenly, diaphragm 1 (via the link that is connected to the throttle lever) operates to pressurize the air in the pump chamber. The pressurized air opens diaphragm 2, and becomes distributed to the carburetors by passing through t...

  • Page 22

    Gen info general information 1-17 62y3a11 ignition system in order to determine the optimal ignition timing that is necessary for the proper operation of the engine, the built-in microcomputer in the cdi unit detects the signals from various types of sensors and controls the ignition timing in accor...

  • Page 23

    62y3a11 1-18 1 2 3 4 5 6 7 8 i pulser coil the pulser coil transmits the pulser signals, which are generated in the pulser coil in accordance with the rotation of the flywheel, to the cdi unit. Among the two protrusions that are provided for generating signals, one is used for cylinders #1 and #4, a...

  • Page 24

    Gen info general information 1-19 62y3a11 ignition timing control control circuit diagram basic control the ignition timing is determined by using the map based on the engine speed (r/min). Then, igni- tion signals are output from the microcomputer in accordance with the ignition timing map so that ...

  • Page 25

    62y3a11 1-20 1 2 3 4 5 6 7 8 i starting control when starting the engine, the timing is set to 5° btdc until the crankshaft speed maintains 600 r/min for two seconds or longer. 1 cylinder identification protrusion 2 protrusion for cylinders #1 and #4 3 pulser coil 4 protrusion for cylinders #2 and #...

  • Page 26

    Gen info general information 1-21 62y3a11 acceleration control this control is activated when the throttle valve is opened suddenly. If the engine speed increases more than the specified figures, the control of the ignition timing transfers to the acceleration map. Thereafter, the control of the ign...

  • Page 27

    62y3a11 1-22 1 2 3 4 5 6 7 8 i power trim and tilt the newly designed power trim and tilt consists of an up-main valve, a down-main valve, an up- relief valve, a single cylinder, and a single ram, which control both trim and tilt functions. The power trim and tilt cylinder has been integrated with t...

  • Page 28

    Gen info general information 1-23 62y3a11 power trim and tilt components 1 cylinder 2 ram 3 check valve 4 down-main valve 5 down-relief valve 6 motor 7 gear pump 8 up-main valve 9 reservoir 0 manual valve a up-relief valve b up-shuttle piston c down-shuffle piston d trim cylinder base e free piston ...

  • Page 29

    62y3a11 1-24 1 2 3 4 5 6 7 8 i trim-up function the gear pump pumps power trim and tilt fluid to the up-main valve. As a result, the fluid pressure opens the up-shuttle piston causing the fluid to flow into the lower part of the power trim and tilt cyl- inder. At the same time, vacuum from the gear ...

  • Page 30

    Gen info general information 1-25 62y3a11 trim-down function when the power trim and tilt switch is pressed to “down”, the motor turns the gear pump counter- clockwise and the power trim and tilt fluid flows in the opposite direction to that of the trim-up func- tion. Tilt-up function when the trim ...

  • Page 31

    62y3a11 1-26 1 2 3 4 5 6 7 8 i tilt-up function 1 power trim and tilt cylinder 2 ram 3 end screw 4 check valve 5 trim cylinder 6 reservoir 7 down-main valve 8 gear pump 9 up-main valve 0 up-shuttle piston a down-shuttle piston b trim cylinder base c free piston d tilt piston e balls È return É send ...

  • Page 32

    Gen info general information 1-27 62y3a11 circular flow 1 power trim and tilt cylinder 2 ram 3 trim cylinder 4 motor 5 reservoir 6 up-relief valve 7 gear pump 8 free piston 9 tilt piston È return É send : : 1 2 3 4 5 6 5 7 8 9 s62y1410

  • Page 33

    62y3a11 1-28 1 2 3 4 5 6 7 8 i tilt-down function when the power trim and tilt switch is pressed to “down”, the motor turns the gear pump counter- clockwise, thus pumping the power trim and tilt fluid to the down-main valve. As a result, fluid pres- sure opens the down-main valve and the down-shuttl...

  • Page 34

    Gen info general information 1-29 62y3a11 tilt-down function 1 power trim and tilt cylinder 2 ram 3 trim cylinder 4 down-relief valve 5 down-main valve 6 gear pump 7 reservoir 8 up-relief valve 9 up-shuttle piston 0 up-main valve a down-shuttle piston b ball c trim cylinder base d free piston e tilt...

  • Page 35

    62y3a11 1-30 1 2 3 4 5 6 7 8 i stopping condition when the power trim and tilt switch is not pushed (released), the gear pump does not pump the fluid, the up-main valve and the down-main valve are closed, and the power trim and tilt fluid pres- sure in the system remains constant. This allows the ra...

  • Page 36

    Gen info general information 1-31 62y3a11 damper function 1 power trim and tilt cylinder 2 trim cylinder 3 ram 4 tilt piston absorber 5 tilt piston 6 free piston 7 check valve 8 tilt piston absorber 9 tilt piston È send É moving direction : : s62y1430 1 2 3 4 5 6 7 8 9.

  • Page 37

    62y3a11 1-32 1 2 3 4 5 6 7 8 i 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 38

    Gen info general information 1-33 62y3a11 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 39

    62y3a11 1-34 1 2 3 4 5 6 7 8 i checking the outboard motor mounting position 1. Check the position of the anti-cavitation plate. 2. Check that the clamp brackets are secured with the clamp bolts. Checking the remote control cables 1. Set the remote control lever to the neu- tral position and fully c...

  • Page 40

    Gen info general information 1-35 62y3a11 2. Check that the throttle control lever con- tacts the respective stoppers when the throttle control lever is closed or fully open. Checking the tilt system 1. Check that the outboard motor can be smoothly tilted up and down by operating the power trim and ...

  • Page 41

    62y3a11 1-36 1 2 3 4 5 6 7 8 i break-in in the test run, the break-in operation is per- formed in the following three stages. 1. One hour a at 2,000 r/min or at approxi- mately half throttle. 2. One hour b at 3,000 r/min or 3/4 throttle and one minute out of every ten at full throttle. 3. Eight hour...

  • Page 42: — Memo —

    Gen info general information 1-37 62y3a11 — memo —.

  • Page 43: Specifications

    62y3a11 spec 1 2 3 4 5 6 7 8 i specifications general specifications................................................................................... 2-1 maintenance specifications .......................................................................... 2-5 power unit...............................

  • Page 44

    Spec specifications 2-1 62y3a11 general specifications 2 item unit model usa — — — f50tr canada — f50th — f50tr worldwide f50aehd f50aeht f50aed f50aet dimension overall length mm (in) 1,329 (52.3) 718 (28.3) overall width mm (in) 361 (14.2) overall height (l) mm (in) 1,397 (55.0) (x) mm (in) — 1,51...

  • Page 45

    62y3a11 2-2 1 2 3 4 5 6 7 8 i * pon: pump octane number (research octane number + motor octane number)/2 ron: research octane number fuel and oil fuel type regular unleaded gasoline fuel rating *pon ron 86 91 engine oil type 4-stroke motor oil engine oil grade api sae se, sf, sg, sh 10w-30, 10w-40, ...

  • Page 46

    Spec specifications 2-3 62y3a11 item unit model usa t50tr — — — canada t50tr — — — worldwide ft50bet ft50cehd ft50ced ft50cet dimension overall length mm (in) 718 (28.3) 1,384 (54.5) 718 (28.3) overall width mm (in) 361 (14.2) overall height (l) mm (in) 1,436 (56.5) boat transom height (l) mm (in) 5...

  • Page 47

    62y3a11 2-4 1 2 3 4 5 6 7 8 i * pon: pump octane number (research octane number + motor octane number)/2 ron: research octane number fuel and oil fuel type regular unleaded gasoline fuel rating *pon ron 86 91 engine oil type 4-stroke motor oil engine oil grade api sae se, sf, sg, sh 10w-30, 10w-40, ...

  • Page 48

    Spec specifications 2-5 62y3a11 maintenance specifications 2 power unit item unit model usa — — — f50tr canada — f50th — f50tr worldwide f50aehd f50aeht f50aed f50aet power unit minimum compression pressure* kpa (kgf/cm 2 , psi) 840 (8.4, 119) lubrication oil pressure at 55 °c (131 °f), with 10w-30 ...

  • Page 49

    62y3a11 2-6 1 2 3 4 5 6 7 8 i 2nd ring dimension b mm (in) 1.47–1.49 (0.058–0.059) dimension t mm (in) 2.49–2.51 (0.098–0.099) end gap mm (in) 0.30–0.50 (0.012–0.020) side clearance mm (in) 0.03–0.07 (0.001–0.003) oil ring dimension b mm (in) 2.34–2.46 (0.092–0.097) dimension t mm (in) 2.75 (0.108) ...

  • Page 50

    Spec specifications 2-7 62y3a11 margin thickness (d) intake mm (in) 0.6–1.0 (0.024–0.039) exhaust mm (in) 0.7–1.1 (0.028–0.043) stem diameter intake mm (in) 5.48–5.49 (0.2157–0.2161) exhaust mm (in) 5.46–5.47 (0.2150–0.2153) guide inside diameter intake and exhaust mm (in) 5.50–5.51 (0.2165–0.2169) ...

  • Page 51

    62y3a11 2-8 1 2 3 4 5 6 7 8 i oil pump type trochoid outer rotor-to-housing clearance mm (in) 0.09–0.15 (0.004–0.006) outer rotor-to-inner rotor clearance limit mm (in) 0.01–0.10 (0.0004–0.0039) rotor-to-cover clearance mm (in) 0.03–0.08 (0.001–0.003) thermostats opening temperature °c (°f) 60 (140)...

  • Page 52

    Spec specifications 2-9 62y3a11 lower unit electrical item unit model usa — — — f50tr canada — f50th — f50tr worldwide f50aehd f50aeht f50aed f50aet gear backlash pinion-to-forward gear mm (in) 0.18–0.54 (0.007–0.021) pinion-to-reverse gear mm (in) 0.71–1.07 (0.028–0.042) pinion shims mm 0.10, 0.12,...

  • Page 53

    62y3a11 2-10 1 2 3 4 5 6 7 8 i ignition control system oil pressure switch kpa (kgf/cm 2 , psi) 50 (0.5, 7.11) thermoswitch (gy/b – b) off → on °c (°f) 76–84 (169–183) on → off °c (°f) 63–77 (145–170) starter motor type bendix output kw 1.1 cranking time limit second 30 brushes standard length mm (i...

  • Page 54

    Spec specifications 2-11 62y3a11 power trim and tilt system trim sensor setting resistance Ω 9 −11 resistance (p – b) Ω 10–288.3 fluid type atf dexron ii brushes standard length mm (in) 10 (0.39) wear limit mm (in) 3.5 (0.14) commutator standard diameter mm (in) 22.0 (0.87) wear limit mm (in) 21.0 (...

  • Page 55

    62y3a11 2-12 1 2 3 4 5 6 7 8 i power unit item unit model usa t50tr — — — canada t50tr — — — worldwide ft50bet ft50cehd ft50ced ft50cet power unit minimum compression pressure* kpa (kgf/cm 2 , psi) 840 (8.4, 119) lubrication oil pressure at 55 °c (131 °f), with 10w-30 engine oil kpa (kgf/cm 2 , psi)...

  • Page 56

    Spec specifications 2-13 62y3a11 2nd ring dimension b mm (in) 1.47–1.49 (0.058–0.059) dimension t mm (in) 2.49–2.51 (0.098–0.099) end gap mm (in) 0.30–0.50 (0.012–0.020) side clearance mm (in) 0.03–0.07 (0.001–0.003) oil ring dimension b mm (in) 2.34–2.46 (0.092–0.097) dimension t mm (in) 2.75 (0.10...

  • Page 57

    62y3a11 2-14 1 2 3 4 5 6 7 8 i margin thickness (d) intake mm (in) 0.6–1.0 (0.024–0.039) exhaust mm (in) 0.7–1.1 (0.028–0.043) stem diameter intake mm (in) 5.48–5.49 (0.2157–0.2161) exhaust mm (in) 5.46–5.47 (0.2150–0.2153) guide inside diameter intake and exhaust mm (in) 5.50–5.51 (0.2165–0.2169) s...

  • Page 58

    Spec specifications 2-15 62y3a11 oil pump type trochoid outer rotor-to-housing clearance mm (in) 0.09–0.15 (0.004–0.006) outer rotor-to-inner rotor clearance limit mm (in) 0.01–0.10 (0.0004–0.0039) rotor-to-cover clearance mm (in) 0.03–0.08 (0.001–0.003) thermostats opening temperature °c (°f) 60 (1...

  • Page 59

    62y3a11 2-16 1 2 3 4 5 6 7 8 i lower unit electrical item unit model usa t50tr — — — canada t50tr — — — worldwide ft50bet ft50cehd ft50ced ft50cet gear backlash pinion-to-forward gear mm (in) 0.12–0.45 (0.005–0.018) pinion-to-reverse gear mm (in) 0.71–1.11 (0.028–0.044) pinion shims mm 0.10, 0.12, 0...

  • Page 60

    Spec specifications 2-17 62y3a11 ignition control system oil pressure switch kpa (kgf/cm 2 , psi) 50 (0.5, 7.11) thermoswitch (gy/b – b) off → on °c (°f) 76–84 (169–183) on → off °c (°f) 63–77 (145–170) starter motor type bendix output kw 1.1 cranking time limit second 30 brushes standard length mm ...

  • Page 61

    62y3a11 2-18 1 2 3 4 5 6 7 8 i power trim and tilt system trim sensor setting resistance Ω 9 −11 resistance (p – b) Ω 10–288.3 fluid type atf dexron ii brushes standard length mm (in) 10 (0.39) wear limit mm (in) 3.5 (0.14) commutator standard diameter mm (in) 22.0 (0.87) wear limit mm (in) 21.0 (0....

  • Page 62

    Spec specifications 2-19 62y3a11 dimensions exterior.

  • Page 63

    62y3a11 2-20 1 2 3 4 5 6 7 8 i symbol unit model usa — — canada — f50th worldwide f50aehd f50aeht l1 mm (in) 576 (22.7) l2 mm (in) 223 (8.8) l3 mm (in) 753 (29.6) l4 mm (in) 532 (20.9) l5 (l) mm (in) 97 (3.8) (x) mm (in) — 85 (3.3) l6 (l) mm (in) 930 (36.6) 932 (36.7) (x) mm (in) — 1,036 (40.8) l7 m...

  • Page 64

    Spec specifications 2-21 62y3a11 exterior.

  • Page 65

    62y3a11 2-22 1 2 3 4 5 6 7 8 i symbol unit model usa — f50tr t50tr canada — f50tr t50tr worldwide f50aed f50aet ft50bet l1 mm (in) 576 (22.7) l2 mm (in) 142 (5.6) l3 mm (in) — l4 mm (in) 532 (20.9) 560 (22.0) l5 (l) mm (in) 97 (3.8) (x) mm (in) — 85 (3.3) — l6 (l) mm (in) 930 (36.6) 932 (36.7) 990 (...

  • Page 66

    Spec specifications 2-23 62y3a11 exterior w2 w5 w1 w3 w6 l3 l7 l2 l10 h9 h5 h7 h10 h8 h4 h3 h11 h1 l8 c1 l5 l9 l4 a3 a2 h6 h2 l6 l1 a1 s62y2230

  • Page 67

    62y3a11 2-24 1 2 3 4 5 6 7 8 i symbol unit model usa — canada — worldwide ft50cehd l1 mm (in) 576 (22.7) l2 mm (in) 272 (10.7) l3 mm (in) 797 (31.4) l4 mm (in) 560 (22.0) l5 (l) mm (in) 97 (3.8) (x) mm (in) — l6 (l) mm (in) 990 (39.0) (x) mm (in) — l7 mm (in) 397 (15.6) l8 mm (in) 189 (7.4) l9 (l) m...

  • Page 68

    Spec specifications 2-25 62y3a11 exterior.

  • Page 69

    62y3a11 2-26 1 2 3 4 5 6 7 8 i symbol unit model usa — — canada — — worldwide ft50ced ft50cet l1 mm (in) 576 (22.7) l2 mm (in) 142 (5.6) l3 mm (in) — l4 mm (in) 560 (22.0) l5 (l) mm (in) 97 (3.8) (x) mm (in) — l6 (l) mm (in) 990 (39.0) (x) mm (in) — l7 mm (in) 397 (15.6) l8 mm (in) 149 (5.9) l9 (l) ...

  • Page 70

    Spec specifications 2-27 62y3a11 clamp bracket symbol unit model usa — — — f50tr canada — f50th — f50tr worldwide f50aehd f50aeht f50aed f50aet b1 mm (in) 126 (5.0) b2 mm (in) 254 (10.0) b3 mm (in) 163.5 (6.4) b4 mm (in) 50.8 (2.0) b5 mm (in) 180 (7.1) b6 mm (in) 355 (14.0) b7 mm (in) — b8 mm (in) 1...

  • Page 71

    62y3a11 2-28 1 2 3 4 5 6 7 8 i clamp bracket symbol unit model usa t50tr — — — canada t50tr — — — worldwide ft50bet ft50cehd ft50ced ft50cet b1 mm (in) 126 (5.0) b2 mm (in) 254 (10.0) b3 mm (in) 163.5 (6.4) b4 mm (in) 50.8 (2.0) b5 mm (in) 180 (7.1) b6 mm (in) 355 (14.0) b7 mm (in) — b8 mm (in) 139 ...

  • Page 72

    Spec specifications 2-29 62y3a11 tightening torques 2 specified torques part to be tightened thread size tightening torques n·m kgf·m ft·lb power unit flywheel magnet nut — 160 16 116 stator base screw m6 4 0.4 2.9 cover screw m6 3 0.3 2.2 negative battery lead bolt m8 9 0.9 6.5 positive battery lea...

  • Page 73

    62y3a11 2-30 1 2 3 4 5 6 7 8 i lower unit (t50/ft50b, ft50c) check screw — 7 0.7 5.1 lower unit bolt m10 40 4.0 29 drain screw — 7 0.7 5.1 propeller nut — 35 3.5 25 ring nut — 105 10.5 76 water inlet cover screw — 5 0.5 3.6 pinion nut m22 95 9.5 69 bracket unit tiller handle assembly nut (f50/f50a) ...

  • Page 74

    Spec specifications 2-31 62y3a11 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 mult...

  • Page 75

    62y3a11 chk adj 1 2 3 4 5 6 7 8 i periodic checks and adjustments special service tools ..................................................................................... 3-1 maintenance interval chart............................................................................ 3-3 top cowling ......

  • Page 76

    Chk adj periodic checks and adjustments 3-1 62y3a11 special service tools 3 oil filter wrench yu-38411 flywheel magnet holder yb-06139 universal puller yb-06117 inductive self-powered tachometer yu-08036-b battery powered timing light ym-33277-a pressurfge/vacuum tester yb-35956-a oil filter wrench ...

  • Page 77

    62y3a11 3-2 1 2 3 4 5 6 7 8 i timing light 90890-03141 leakage tester 90890-06762 special service tools.

  • Page 78

    Chk adj periodic checks and adjustments 3-3 62y3a11 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. Note: • if operating in salt water, turbid or muddy water, flush th...

  • Page 79

    62y3a11 3-4 1 2 3 4 5 6 7 8 i 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 and bolts 1. 3. Move the hook 2 up or down slightly to adjust its position. Note: • to loosen the fitting, move the hook toward th...

  • Page 80

    Chk adj periodic checks and adjustments 3-5 62y3a11 checking the fuel filter 1. Check the fuel filter element 1 for dirt and residue and check the fuel filter cup 2 for foreign substances and cracks. Clean with straight gasoline and replace the cup if necessary. È f50/f50a É t50/ft50b, ft50c note: b...

  • Page 81

    62y3a11 3-6 1 2 3 4 5 6 7 8 i 2. Place a drain pan under the drain hole, and then remove the drain bolt 2 and let the oil drain completely. 3. Place a rag under the oil filter, and then remove the filter. Note: be sure to clean up any oil spills. 4. Apply a thin coat of the new engine oil to the o-r...

  • Page 82

    Chk adj periodic checks and adjustments 3-7 62y3a11 8. Install the oil filler cap and dipstick, and then start the engine and warm it up for 5 minutes. 9. Turn the engine off, and then check the oil level and correct it if necessary. Checking the timing belt 1. Remove the flywheel magnet cover. 2. W...

  • Page 83

    62y3a11 3-8 1 2 3 4 5 6 7 8 i È for usa and canada É for worldwide caution: • apply force in the direction of the arrows shown, to prevent the flywheel holder from slipping off easily. • to prevent damage to the engine or tools, screw in the flywheel puller set bolts evenly and completely so that th...

  • Page 84

    Chk adj periodic checks and adjustments 3-9 62y3a11 6. Check that the “1” mark a on the driven sprocket is aligned with the “ ” mark b on the cylinder head, and that the “ ” mark c on the drive sprocket is aligned with the “ ” mark d on the crankcase. Align if necessary. Caution: do not turn the spr...

  • Page 85

    62y3a11 3-10 1 2 3 4 5 6 7 8 i 13. Install the flywheel magnet and flywheel magnet cover. È for usa and canada É for worldwide caution: apply force in the direction of the arrows shown, to prevent the flywheel holder from slipping off easily. Note: apply engine oil to the flywheel magnet nut before ...

  • Page 86

    Chk adj periodic checks and adjustments 3-11 62y3a11 5. Turn the flywheel clockwise and align the “4” mark c on the driven sprocket with the “ ” mark b on the cylinder head. Caution: do not turn the flywheel counterclock- wise, otherwise the valve system may be damaged. 6. Check the intake valve cle...

  • Page 87

    62y3a11 3-12 1 2 3 4 5 6 7 8 i 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. Check the spark plug g...

  • Page 88

    Chk adj periodic checks and adjustments 3-13 62y3a11 4. Check the thermostat valve opening at the specified water temperatures. Replace if out of specification. 5. Install the thermostat, new gasket, ther- mostat cover, and cover. Checking the cooling water passage 1. Check the cooling water inlet c...

  • Page 89

    62y3a11 3-14 1 2 3 4 5 6 7 8 i 3. Align the alignment mark b on the throt- tle cam 1 with the alignment mark c on the shift bracket. 4. Adjust the position of the throttle cable joint until its hole is aligned with the set pin d on the throttle cam. Caution: the throttle cable joint must be screwed ...

  • Page 90

    Chk adj periodic checks and adjustments 3-15 62y3a11 checking the engine idle speed 1. Start the engine and warm it up for 5 min- utes. 2. Attach the special service tool to high- tension cord #1 1, and then check the engine idle speed. Adjust if out of specifi- cation. 3. Turn the throttle stop scr...

  • Page 91

    62y3a11 3-16 1 2 3 4 5 6 7 8 i 4. Check that the tdc “t” mark a on the flywheel magnet is aligned with the mag- net base pointer b. Power trim and tilt unit 3 checking the power trim and tilt operation 1. Fully tilt the outboard up and down a few times and check the entire trim and tilt range for sm...

  • Page 92

    Chk adj periodic checks and adjustments 3-17 62y3a11 3. Remove the reservoir cap 3, and then check the fluid level in the reservoir. Note: the fluid level should be at the brim of the filler hole. 4. If necessary, add sufficient fluid of the recommended type to the correct level. 5. Install the rese...

  • Page 93

    62y3a11 3-18 1 2 3 4 5 6 7 8 i 4. Place a drain pan under the drain screw 3, remove the drain screw, then the check screw 4 to drain the oil. 5. Check the oil for metal, discoloration, and viscosity. Check the internal parts of the lower case if necessary. 6. Insert the gear oil tube or gear oil pum...

  • Page 94

    Chk adj periodic checks and adjustments 3-19 62y3a11 checking the lower unit (for air leakage) 1. Remove the check screw 1, and then install the special service tool. È for usa and canada É for worldwide 2. Apply the specified pressure to check whether the lower unit can hold it for at least 10 seco...

  • Page 95

    62y3a11 3-20 1 2 3 4 5 6 7 8 i È ft50c only É ehd, ed models Ê eht, et models Ë f50/f50a only caution: do not oil, grease, or paint the anodes, otherwise they will be ineffective. 2. Replace the anodes and trim tab if excessively eroded. Checking the battery 1. Check the battery electrolyte level. I...

  • Page 96

    Chk adj periodic checks and adjustments 3-21 62y3a11 note: • batteries vary per manufacturer. The pro- cedures mentioned in this manual may not always apply, therefore, consult the instruc- tion manual of the battery. • disconnect the negative lead first, then the positive lead. Lubrication 1. Apply...

  • Page 97

    62y3a11 3-22 1 2 3 4 5 6 7 8 i note: apply grease to the grease nipple until it flows from the bushings a. 2. Apply anti-corrosion grease to the areas shown. General.

  • Page 98: — Memo —

    Chk adj periodic checks and adjustments 3-23 62y3a11 — memo —.

  • Page 99: Fuel System

    62y3a11 fuel 1 2 3 4 5 6 7 8 i fuel system special service tools ..................................................................................... 4-1 hose routing ................................................................................................... 4-2 fuel and blowby hoses..........

  • Page 100

    Fuel fuel system 4-1 62y3a11 special service tools 4 pressure/vacuum tester yb-35956-a inductive self-powered tachometer yu-08036-b carburetor synchronizer yu-08030 vacuum/pressure pump gauge set 90890-06756 digital tachometer 90890-06760 vacuum gauge 90890-03159 for usa and canada for worldwide.

  • Page 101

    62y3a11 4-2 1 2 3 4 5 6 7 8 i hose routing 4 fuel and blowby hoses 1 blowby hose 2 hose (acceleration pump-to-carburetor) 3 fuel hose (fuel joint-to-fuel filter) 4 fuel hose (fuel filter-to-fuel pump) 5 fuel hose (fuel pump-to-carburetor) 6 hose (carburetor-to-carburetor) special service tools / hos...

  • Page 102

    Fuel fuel system 4-3 62y3a11 cooling water hose È models with flushing device.

  • Page 103: — Memo —

    62y3a11 4-4 1 2 3 4 5 6 7 8 i — memo — hose routing.

  • Page 104

    Fuel fuel system 4-5 62y3a11 fuel line 4.

  • Page 105

    62y3a11 4-6 1 2 3 4 5 6 7 8 i no. Part name q’ty remarks tightening torques stage n·m kgf·m ft·lb 1 fuel joint 1 2 fuel filter 1 f50/f50a 3 fuel filter 1 t50/ft50b, ft50c 4 fuel pump 1 5 bolt 1 m6 × 25 mm 6 seal 1 7 fuel hose 1 fuel joint-to-fuel filter 8 clip 3 9 bolt 1 m8 × 14 mm 10 nut 1 11 brack...

  • Page 106

    Fuel fuel system 4-7 62y3a11 fuel filter and fuel pump 4.

  • Page 107

    62y3a11 4-8 1 2 3 4 5 6 7 8 i È f50/f50a É t50/ft50b, ft50c no. Part name q’ty remarks tightening torques stage n·m kgf·m ft·lb 1 fuel filter cup 1 2 o-ring 1 not reusable 3 fuel filter element 1 4 body 1 5 float 1 6 screw 4 m5 × 35 mm 7 cover 1 8 fuel pump body 2 1 9 fuel pump body 1 1 10 nut 4 11 ...

  • Page 108

    Fuel fuel system 4-9 62y3a11 checking the fuel pump 1. Install the special service tool onto the fuel pump as shown. 2. Apply the specified pressure to each fuel pump port. 3. If air flow is reversed, check the dia- phragm for tears and the valves for cracks. Replace if necessary. Caution: do not ov...

  • Page 109

    62y3a11 4-10 1 2 3 4 5 6 7 8 i 2. Push down on the plunger and the dia- phragm, turn the fuel pump body 1 1 approximately 90° to a position where the pin 2 can be removed easily, and then remove the pin. 3. Slowly let up on the plunger and dia- phragm, and then remove them. Checking the diaphragm an...

  • Page 110

    Fuel fuel system 4-11 62y3a11 carburetor unit 4.

  • Page 111

    62y3a11 4-12 1 2 3 4 5 6 7 8 i no. Part name q’ty remarks tightening torques stage n·m kgf·m ft·lb 1 carburetor assembly 1 joint-to-silencer 2 clip 1 3 blowby hose 1 4 prime start coupler 1 5 bolt 2 m6 × 30 mm 6 collar 2 7 throttle link rod 1 8 o-ring 8 not reusable 9 insulator 1 10 dowel pin 2 11 b...

  • Page 112

    Fuel fuel system 4-13 62y3a11.

  • Page 113

    62y3a11 4-14 1 2 3 4 5 6 7 8 i no. Part name q’ty remarks tightening torques stage n·m kgf·m ft·lb 1 acceleration pump 1 2 screw 3 m5 × 9 mm 3 link rod 1 4 hose 1 acceleration pump-to- acceleration pump 5 hose 4 acceleration pump-to- carburetor 6 link rod 1 carburetor unit.

  • Page 114

    Fuel fuel system 4-15 62y3a11.

  • Page 115

    62y3a11 4-16 1 2 3 4 5 6 7 8 i no. Part name q’ty remarks tightening torques stage n·m kgf·m ft·lb 1 carburetor 4 2 silencer 1 3 plastic tie 1 not reusable 4 blowby hose 1 silencer-to-joint 5 bolt 8 m6 × 90 mm 6 collar 8 7 o-ring 4 not reusable 8 plate 1 9 o-ring 4 not reusable 10 o-ring 4 not reusa...

  • Page 116

    Fuel fuel system 4-17 62y3a11 carburetor 4.

  • Page 117

    62y3a11 4-18 1 2 3 4 5 6 7 8 i È carburetors #1, #2, and #3 É carburetor #4 Ê carburetors #1 and #3 no. Part name q’ty remarks tightening torques stage n·m kgf·m ft·lb 1 carburetor body 1 2 screw 4 m4 × 13 mm 3 cover 1 4 seal 1 not reusable 5 pilot jet 1 6 main jet 1 7 needle valve 1 8 main nozzle 1...

  • Page 118

    Fuel fuel system 4-19 62y3a11 checking the carburetor 1. Check the air and fuel passages and jets, for dirt and foreign matter. Clean the car- buretor body with a petroleum based sol- vent if necessary. 2. Blow compressed air into all passages and jets. Caution: • direct the compressed air downward,...

  • Page 119

    62y3a11 4-20 1 2 3 4 5 6 7 8 i 5. Check the float for deterioration. Replace it necessary. 6. Measure the float height a. Replace the float and needle valve, if out of specifica- tion, as a set. Note: • the float should be resting on the needle valve 4, but not compressing it. • take measurements at...

  • Page 120

    Fuel fuel system 4-21 62y3a11 2. Install the needle valve 5, float 6, float pin 7, and screw 8 as shown, and then the check the float for smooth operation. Note: • place the needle valve in the valve seat when installing the float to the carburetor body. • fit the float pin into the slit on the carb...

  • Page 121

    62y3a11 4-22 1 2 3 4 5 6 7 8 i 4. Push the throttle control lever 1 to the fully open position as shown. 5. While pushing the carburetor throttle lever 2 against the carburetor stopper 3, loosen, and then tighten the adjusting screw 5. Adjusting the pilot screw 1. Start the engine and warm it up for...

  • Page 122

    Fuel fuel system 4-23 62y3a11 synchronizing the carburetors 1. Start the engine and warm it up for 5 min- utes to check the stability of the engine. 2. Attach the special service tool to the high-tension cord #1 1. 3. Remove all of the plugs 2 and attach the special service tool and adapters to the ...

  • Page 123

    62y3a11 4-24 1 2 3 4 5 6 7 8 i 5. Measure the vacuum pressure of carbu- retor #4. 6. Turn the throttle valve adjusting screws 5 to adjust the vacuum pressure of car- buretors #1, #2, and #3 to the same vac- uum variation as carburetor #4. 7. Adjust the engine idle speed to specifica- tion. 8. After ...

  • Page 124

    Fuel fuel system 4-25 62y3a11 5. Open the throttle cam 2 slowly, and check that the acceleration pump stopper 3 comes in contact with point a. 6. Turn the adjusting screw 4 in or out until the specified engine speed is obtained. 7. Open and close the throttle cam a few times, and check the engine sp...

  • Page 125: — Memo —

    62y3a11 4-26 1 2 3 4 5 6 7 8 i — memo —.

  • Page 126: Power Unit

    Powr 62y3a11 power unit troubleshooting............................................................................................. 5-1 special service tools ................................................................................... 5-10 power unit.............................................

  • Page 127

    62y3a11 1 2 3 4 5 6 7 8 i cylinder body ............................................................................................... 5-51 removing and installing the oil filter ........................................................ 5-55 disassembling the cylinder body .............................

  • Page 128

    Powr power unit 5-1 62y3a11 troubleshooting 5 before troubleshooting the power unit, check that all electrical connections are tight and free from corrosion, and that the battery is fully charged to 12 v. Symptom: engine does not crank. • check the starting system. • check the power unit. Check that...

  • Page 129

    62y3a11 5-2 1 2 3 4 5 6 7 8 i check the wiring harnesses for continuity. Replace the wiring harnesses. Check that the combustion camber is filled with engine oil or gasoline. Check the starter motor. Check operation of the starter motor pinion. Remove all spark plugs, and then the engine. Listen for...

  • Page 130

    Powr power unit 5-3 62y3a11 symptom: engine cracks, but will not start. • check the ignition system. • check the fuel system. • check the compression pressure of power unit. Wet spark plugs? Does the engine start? Wet spark plugs? Out of specifi- cation? Out of specifi- cation? Check the condition o...

  • Page 131

    62y3a11 5-4 1 2 3 4 5 6 7 8 i symptom: engine can be started, but does not remain on. • check the fuel system. • check the ignition system. • check the compression pressure of power unit. Is the vent screw open? Water or resi- due? Good operat- ing condition? Kinks or fuel leakage? Replace the pri- ...

  • Page 132

    Powr power unit 5-5 62y3a11 is there air intake? Replace the respective seals. Check the compression pres- sure of the combustion chamber. No yes check that there is no secondary air intake on the contact surfaces of the intake manifold and crankcase. Check the ignition spark gap using the spark gap...

  • Page 133

    62y3a11 5-6 1 2 3 4 5 6 7 8 i symptom: the engine idle speed is not steady, but increases or decreases. • check the carburetors. • check the air intake system. • check the ignition system. Replace the cdi unit. Check and disassemble the car- buretors, and then clean them if necessary. Check the thro...

  • Page 134

    Powr power unit 5-7 62y3a11 symptom: engine does not accelerate when the throttle is opened quickly. The engine turns off when the throttle is opened quickly. Acceleration is tardy and the engine is likely to stop at any moment. • check the carburetors. • check the ignition system. • check the compr...

  • Page 135

    62y3a11 5-8 1 2 3 4 5 6 7 8 i symptom: engine can run, but engine speed will not increase. Overheat warning indicator is on. Oil pressure warning indicator is on. Warning indicator is on and buzzer is sounding. • check the water cooling system. • check the lubricating system. Check the water inlet f...

  • Page 136

    Powr power unit 5-9 62y3a11 check the oil pump for debris or wear. Check the engine oil level. Check the oil pressure. Check the oil pressure switch. Clean or replace the respective parts. At specified level? Out of specifi- cation? Good condi- tion? Debris or wear? Check the oil pas- sage. Yes no y...

  • Page 137

    62y3a11 5-10 1 2 3 4 5 6 7 8 i special service tools 5 compression gauge yu-33223-1 flywheel magnet holder yb-06139 universal puller yb-06117 crankshaft holder yb-06562 valve spring compressor ym-01253 valve guide remover ym-01122 valve guide reamer ym-01196 valve seat cutter set ym-91043-c drive sh...

  • Page 138

    Powr power unit 5-11 62y3a11 piston ring compressor yu-33294 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 90890-0...

  • Page 139

    62y3a11 5-12 1 2 3 4 5 6 7 8 i valve seat cutter 90890-06315, 90890-06323, 90890-06326, 90890-06328, 90890-06555 bearing outer race attachment 90890-06626 oil filter wrench 90890-01426 piston slider 90890-06529 special service tools.

  • Page 140

    Powr power unit 5-13 62y3a11 power unit 5.

  • Page 141

    62y3a11 5-14 1 2 3 4 5 6 7 8 i no. Part name q’ty remarks tightening torques stage n·m kgf·m ft·lb 1 flywheel magnet 1 2 stator coil 1 3 cover 1 4 grommet 2 5 nut 1 160 16 116 6 washer 1 7 bolt 3 m6 × 25 mm 8 lighting coil coupler 1 9 charge coil coupler 1 10 stator base 1 11 pulser coil coupler 1 1...

  • Page 142

    Powr power unit 5-15 62y3a11.

  • Page 143

    62y3a11 5-16 1 2 3 4 5 6 7 8 i no. Part name q’ty remarks tightening torques stage n·m kgf·m ft·lb 1 throttle cable 1 2 shift cable 1 f50/f50a, t50/ft50b 3 shift cable 1 ft50c 4 fuel pump 1 5 fuel filter assembly 1 f50/f50a 6 fuel filter assembly 1 t50/ft50b, ft50c 7 carburetor assembly 1 8 bolt 3 m...

  • Page 144

    Powr power unit 5-17 62y3a11.

  • Page 145

    62y3a11 5-18 1 2 3 4 5 6 7 8 i no. Part name q’ty remarks tightening torques stage n·m kgf·m ft·lb 1 power trim and tilt relay 1 eht/et models 2 bolt 1 m8 × 16 mm 9 0.9 6.5 3 negative battery lead 1 4 wiring harness extension 1 5 grommet 1 6 nut 1 7 0.7 5.1 7 spring washer 1 8 positive battery lead ...

  • Page 146

    Powr power unit 5-19 62y3a11.

  • Page 147

    62y3a11 5-20 1 2 3 4 5 6 7 8 i no. Part name q’ty remarks tightening torques stage n·m kgf·m ft·lb 1 bracket 1 2 starter motor 1 3 spark plug cap 4 4 ignition coil 2 5 wiring harness 1 6 thermoswitch 1 7 holder 1 8 bolt 1 m6 × 12 mm 9 ground lead 3 10 bolt 1 m6 × 12 mm 11 oil pressure switch 1 9 0.9...

  • Page 148

    Powr power unit 5-21 62y3a11.

  • Page 149

    62y3a11 5-22 1 2 3 4 5 6 7 8 i no. Part name q’ty remarks tightening torques stage n·m kgf·m ft·lb 1 power unit 1 2 engine oil dipstick 1 3 gasket 1 not reusable 4 dowel pin 2 5 bolt 2 m6 × 16 mm 6 bolt 8 m8 × 80 mm 21 2.1 15 7 apron 1 8 screw 2 m6 × 24 mm 9 nut 2 power unit.

  • Page 150

    Powr power unit 5-23 62y3a11.

  • Page 151

    62y3a11 5-24 1 2 3 4 5 6 7 8 i no. Part name q’ty remarks tightening torques stage n·m kgf·m ft·lb 1 throttle link rod 1 2 throttle cam 1 3 throttle control lever 1 4 clip 1 5 bushing 1 6 bolt 1 m6 × 20 mm 7 spring 1 8 collar 1 9 bracket 1 10 bolt 1 m6 × 30 mm 11 shift rod 1 12 bolt 1 m6 × 30 mm 13 ...

  • Page 152

    Powr power unit 5-25 62y3a11 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 shut-off switch on the remote control box or tiller handle. 3. Remove the all spark plugs, and then install the special service too...

  • Page 153

    62y3a11 5-26 1 2 3 4 5 6 7 8 i removing the power unit 1. Remove the flywheel magnet cover and flywheel magnet. È for usa and canada É for worldwide caution: • apply force in the direction of the arrows shown, to prevent the flywheel holder from slipping off easily. • to prevent damage to the engine...

  • Page 154

    Powr power unit 5-27 62y3a11 2. Disconnect the throttle cable 1 and shift cable/shift rod 2. 3. Disconnect the fuel hose 3 and throttle link rod 4. 4. Disconnect the battery leads 5, 10-pin coupler 6, ptt relay leads 7 (eht, et), ptt motor leads 8 (eht, et), ground lead 9 (eht, et), warning indi- ca...

  • Page 155

    62y3a11 5-28 1 2 3 4 5 6 7 8 i 7. Remove the power unit by removing the bolts g. Power unit.

  • Page 156

    Powr power unit 5-29 62y3a11 timing belt and sprockets 5.

  • Page 157

    62y3a11 5-30 1 2 3 4 5 6 7 8 i no. Part name q’ty remarks tightening torques stage n·m kgf·m ft·lb 1 timing belt 1 2 drive sprocket 1 3 driven sprocket 1 4 bolt 1 8 0.8 5.8 5 bolt 1 m8 × 20 mm 25 2.5 18 6 tensioner 1 7 spring 1 8 nut 1 140 14 101 9 retaining plate 2 10 woodruff key 1 11 bolt 1 m10 ×...

  • Page 158

    Powr power unit 5-31 62y3a11 removing the timing belt and sprockets 1. Set the cylinder #1 piston position to tdc of the compression stroke by align- ing the “1” mark a on the driven sprocket with the “ ” mark b on the cylinder head. Caution: do not turn the drive sprocket counter- clockwise, otherw...

  • Page 159

    62y3a11 5-32 1 2 3 4 5 6 7 8 i 5. Remove the nut 1, retaining plates 8, drive sprocket 9, and woodruff key 0. Checking the timing belt and sprockets 1. Check the interior and exterior of the tim- ing belt for cracks, damage, or wear. Replace if necessary. 2. Check the drive sprocket 1 and driven spr...

  • Page 160

    Powr power unit 5-33 62y3a11 3. Check that the “ ” mark c on the retain- ing plate is aligned with the “ ” mark d on the cylinder body. 4. Install the new timing belt 7 from the drive sprocket side with its part number in the upright position. Caution: • do not twist, turn inside out, or bend the ti...

  • Page 161

    62y3a11 5-34 1 2 3 4 5 6 7 8 i caution: do not turn the sprockets counterclock- wise, otherwise the valve system may be damaged. 9. Tighten the driven sprocket bolt 2 to the specified torque. È for usa and canada É for worldwide 10. Tighten the drive sprocket nut 6 to the specified torque, and then ...

  • Page 162

    Powr power unit 5-35 62y3a11 cylinder head 5.

  • Page 163

    62y3a11 5-36 1 2 3 4 5 6 7 8 i È tightening sequence no. Part name q’ty remarks tightening torques stage n·m kgf·m ft·lb 1 cylinder head 1 2 oil pump 1 3 cylinder head cover 1 4 bolt 7 m6 × 20 mm 5 cylinder head cover gasket 1 not reusable 6 bolt 10 m9 × 95 mm 1st 2nd 23 47 2.3 4.7 17 34 7 spark plu...

  • Page 164

    Powr power unit 5-37 62y3a11.

  • Page 165

    62y3a11 5-38 1 2 3 4 5 6 7 8 i no. Part name q’ty remarks tightening torques stage n·m kgf·m ft·lb 1 rocker arm assembly 8 2 rocker arm shaft 1 3 cylinder head 1 4 exhaust valve 4 5 intake valve 4 6 camshaft 1 7 valve cotter 16 8 spring retainer 8 9 valve spring 8 10 spring seat 8 11 stem seal 8 not...

  • Page 166

    Powr power unit 5-39 62y3a11 removing the cylinder head 1. Check that the camshaft dowel pin hole a is in the position shown in the illustra- tion. Adjust if necessary. 2. Remove the cylinder head cover bolts in the sequence shown. 3. Remove the cylinder head bolts in the sequence shown. 4. Remove t...

  • Page 167

    62y3a11 5-40 1 2 3 4 5 6 7 8 i 5. Remove the retaining bolt 4, then the camshaft 5 by pulling it downward. 6. Remove the intake valve and exhaust valves. Note: when replacing the valve, also replace the valve guide and stem seal. Checking the valve springs 1. Measure the valve spring free length a. ...

  • Page 168

    Powr power unit 5-41 62y3a11 2. Measure the valve margin thickness a. Replace if out of specification. 3. Measure the valve stem diameter b. Replace if out of specification. 4. Measure the valve stem runout. Replace if out of specification. Checking the valve guides 1. Measure the valve guide inside...

  • Page 169

    62y3a11 5-42 1 2 3 4 5 6 7 8 i 2. Install the new valve guide 2 by striking the special service tool from the cam- shaft side until the valve guide clip 3 contacts the cylinder head. Note: apply engine oil to the surface of the new valve guide. 3. Insert the special service tool into the valve guide...

  • Page 170

    Powr power unit 5-43 62y3a11 refacing the valve seat 1. Reface the valve seat with the valve seat cutter. 2. Cut the surface of the valve seat with a 45° cutter by turning the cutter clockwise until the valve seat face has become smooth. A slag or rough surface caution: do not over cut the valve sea...

  • Page 171

    62y3a11 5-44 1 2 3 4 5 6 7 8 i 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 width 6. If the valve seat co...

  • Page 172

    Powr power unit 5-45 62y3a11 caution: do not get the lapping compound on the valve stem and valve guide. 10. After every lapping procedure, be sure to clean off any remaining lapping com- pound from the cylinder head and the valve. 11. Check the valve seat contact area of the valve again. Checking t...

  • Page 173

    62y3a11 5-46 1 2 3 4 5 6 7 8 i 3. Measure the camshaft journal diameter c and cylinder head journal inside diam- eter d. Replace the camshaft and cylin- der head if out of specification. 4. Calculate the camshaft oil clearance e as follows. Replace the camshaft and cylinder head as a set if out of s...

  • Page 174

    Powr power unit 5-47 62y3a11 checking the oil pump 1. Measure the oil pump rotor clearances as shown. Replace if out of specification. Installing the valves 1. Install the new valve stem seal 1 to the valve guide, and then apply engine oil to the valve guide. 2. Install the valve 2, spring seat 3, v...

  • Page 175

    62y3a11 5-48 1 2 3 4 5 6 7 8 i 3. Compress the valve spring, and then install the valve cotter 8 using a thin screwdriver with a small amount of grease applied to it. 4. Lightly tap the spring retainer with a plas- tic hammer to set the valve cotter securely. Installing the camshaft 1. Install the n...

  • Page 176

    Powr power unit 5-49 62y3a11 installing the rocker arm assembly 1. Check that the camshaft dowel pin hole a is in the position shown in the illustra- tion. Adjust if necessary. 2. Assembly the rocker arm 1 and rocker arm shaft 2, and the tensioner 3, rocker arm retainer 4, stopper guide 5 by install...

  • Page 177

    62y3a11 5-50 1 2 3 4 5 6 7 8 i 2. Tighten the cylinder head bolts to the specified torques in two stages and in the sequence shown. Note: apply engine oil to the cylinder head bolts (m9) before installation. 3. Tighten the cylinder head cover bolts in the sequence shown. Cylinder head bolt (m9): 1st...

  • Page 178

    Powr power unit 5-51 62y3a11 cylinder body 5.

  • Page 179

    62y3a11 5-52 1 2 3 4 5 6 7 8 i no. Part name q’ty remarks tightening torques stage n·m kgf·m ft·lb 1 oil filter 1 18 1.8 13 2 crankshaft 1 3 bolt 10 m8 × 82 mm 1st 2nd 15 30 1.5 3.0 11 22 4 bolt 10 m6 × 35 mm 1st 2nd 6 12 0.6 1.2 4.3 8.7 5 crankcase 1 6 oil seal 1 not reusable 7 main bearing 10 8 oi...

  • Page 180

    Powr power unit 5-53 62y3a11.

  • Page 181

    62y3a11 5-54 1 2 3 4 5 6 7 8 i È tightening sequence no. Part name q’ty remarks tightening torques stage n·m kgf·m ft·lb 31 anode 1 32 cover 1 33 cover 1 34 bolt 1 m6 × 20 mm 35 bolt 1 m5 × 12 mm 36 bolt 10 m6 × 35 mm 1st 2nd 6 12 0.6 1.2 4.3 8.7 cylinder body.

  • Page 182

    Powr power unit 5-55 62y3a11 removing and installing the oil filter 1. Place a rag under the oil filter, and then remove the filter. Note: be sure to clean up any oil spills. 2. Apply a thin coat of the new engine oil to the o-ring of the new oil filter. 3. Install the oil filter, and then tighten i...

  • Page 183

    62y3a11 5-56 1 2 3 4 5 6 7 8 i 2. Remove the crankcase bolts in the sequence shown. 3. Remove the connecting rod bolts and the piston assemblies. 4. Remove the crankshaft, oil seals, and dowel pins. 5. Remove the piston pin clip 1 with pliers, and then remove the piston. Checking the piston diameter...

  • Page 184

    Powr power unit 5-57 62y3a11 2. Calculate the taper limit. Replace or rebore the cylinder body if out of specifi- cation. 3. Calculate the out-of-round limit. Replace or rebore the cylinder body if out of spec- ification. Checking the piston clearance 1. Rebore the cylinder or replace the piston and...

  • Page 185

    62y3a11 5-58 1 2 3 4 5 6 7 8 i checking the piston ring grooves 1. Measure the piston ring grooves. Replace the piston if out of specification. 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. Che...

  • Page 186

    Powr power unit 5-59 62y3a11 checking the connecting rod small end inside diameter 1. Measure the connecting rod small end inside diameter a. Replace the connect- ing rod if out of specification. Checking the connecting rod big end side clearance 1. Measure the connecting rod big end side clearance ...

  • Page 187

    62y3a11 5-60 1 2 3 4 5 6 7 8 i 2. Measure the crankshaft runout. Replace the crankshaft if out of specification. Checking the crankshaft main journal oil clearance 1. Clean the bearings, main journals, and bearing portions of the crankcase and cylinder body. 2. Place the cylinder body upside down on...

  • Page 188

    Powr power unit 5-61 62y3a11 note: do not move the crankshaft until the main journal oil clearance measurement has been completed. 8. Remove the crankcase and measure the width of the compressed plastigauge (pg-1) on each main journal. Replace the main bearing if out of specification. Checking the c...

  • Page 189

    62y3a11 5-62 1 2 3 4 5 6 7 8 i note: • align the alignment marks b on the con- necting rod cap and connecting rod. • face the embossed “y” mark on the con- necting rod toward the flywheel side of the crankshaft. 5. Tighten the connecting rod bolts to the specified torques in two stages. Note: do not...

  • Page 190

    Powr power unit 5-63 62y3a11 4. When installing the main bearing, insert the projection of the main bearing into the slot on the cylinder body. Caution: remove any small metal particles and oil from the contact surfaces of the cylinder body and the main bearing. 5. Measure the main journal oil clear...

  • Page 191

    62y3a11 5-64 1 2 3 4 5 6 7 8 i 6. If the oil clearance is below specification, check the connecting rod bearing color and clean the contact surface of the con- necting rod and the connecting rod bear- ing, and then check the crank pin oil clearance again. 7. If the oil clearance is over specificatio...

  • Page 192

    Powr power unit 5-65 62y3a11 5. Install the piston with the “up” mark on the piston crown facing towards the fly- wheel. È for usa and canada É for worldwide note: apply engine oil to side of the piston assem- bly. 6. Install half of the bearings 9 into the cyl- inder body 0. Note: insert the projec...

  • Page 193

    62y3a11 5-66 1 2 3 4 5 6 7 8 i note: align the alignment marks g on the connect- ing rod cap and connecting rod. 9. Install half of the bearings 9 into the crankcase, then dowel pins e. 10. Apply gasket maker ® to the mating sur- face of the crankcase. Note: • insert the projection h of the bearing ...

  • Page 194

    Powr power unit 5-67 62y3a11 12. Install the new gasket and exhaust cover, and then tighten the bolts to the specified torques in two stages and in the sequence shown. Installing the power unit 1. Install the dowel pins 1 and gasket 2. 2. Install the power unit 3 by installing the bolts 4, then tigh...

  • Page 195

    62y3a11 5-68 1 2 3 4 5 6 7 8 i 4. Install the shift rod bolts 6, shift rod 7 and power trim and tilt relay 8. 5. Connect the flushing hose (models with flushing device), pilot water hose 9, trailer switch coupler 0 (eht, et), warn- ing indicator coupler a (ehd, eht), ground lead b (eht, et), ptt mot...

  • Page 196

    Powr power unit 5-69 62y3a11 8. Install the woodruff key. 9. Install the flywheel magnet and flywheel magnet cover. È for usa and canada É for worldwide caution: apply force in the direction of the arrows shown, to prevent the flywheel holder from slipping off easily. Note: apply engine oil to the f...

  • Page 197: — Memo —

    62y3a11 5-70 1 2 3 4 5 6 7 8 i — memo —.

  • Page 198: Lower Unit

    Lowr 62y3a11 lower unit special service tools ..................................................................................... 6-1 lower unit (f50/f50a).................................................................................... 6-7 removing the lower unit .................................

  • Page 199

    62y3a11 1 2 3 4 5 6 7 8 i backlash (f50/f50a) .................................................................................... 6-39 measuring the forward and reverse gear backlash ................................. 6-39 lower unit (t50/ft50b, ft50c) ..................................................

  • Page 200

    Lowr lower unit 6-1 62y3a11 special service tools 6 bearing housing puller yb-06207, yb-06234 universal puller yb-06117 slide hammer and adapters yb-06096 bearing housing needle bearing remover yb-06112, yb-06153 driver handle yb-06071 bearing housing needle bearing installer yb-06111 oil seal insta...

  • Page 201

    62y3a11 6-2 1 2 3 4 5 6 7 8 i bearing splitter plate yb-06219 drive shaft needle bearing remover and installer yb-06063, yb-06155 drive shaft needle bearing depth stop yb-34473, yb-34474 drive shaft taper roller bearing cup installer yb-06110 forward gear bearing cup installer yb-06109, yb-06276-b p...

  • Page 202

    Lowr lower unit 6-3 62y3a11 dial gauge yu-03097 magnetic flexible stand yu-34481 bearing housing oil seal installer yb-06269 gland nut wrench yb-34447 crank upper and lower seal installer yb-06244 forward gear needle bearing and tapered roller bearing installer yb-06200 bearing housing puller claw 9...

  • Page 203

    62y3a11 6-4 1 2 3 4 5 6 7 8 i stopper guide stand 90890-06538 bearing puller 90890-06535 bearing puller claw 1 90890-06536 needle bearing attachment 90890-06607, 90890-06610, 90890-06611, 90890-06612, 90890-06614, 90890-06653 driver rod l3 90890-06652 driver rod ss 90890-06604 bearing depth plate 90...

  • Page 204

    Lowr lower unit 6-5 62y3a11 socket adapter 1 90890-06506 bearing outer race puller 90890-06523 outer race puller claw a 90890-06532 driver rod sl 90890-06602 bearing outer race attachment 90890-06621, 90890-06622, 90890-06626, 90890-06627 driver rod ls 90890-06606 driver rod ll 90890-06605 pinion he...

  • Page 205

    62y3a11 6-6 1 2 3 4 5 6 7 8 i shift rod push arm 90890-06052 backlash indicator 90890-06706 magnet base plate 90890-07003 dial gauge set 90890-01252 magnet base 90890-06705 ring nut wrench 3 90890-06511 ring nut wrench extension 90890-06513 bearing housing puller claw l 90890-06502 ball bearing atta...

  • Page 206

    Lowr lower unit 6-7 62y3a11 lower unit (f50/f50a) 6.

  • Page 207

    62y3a11 6-8 1 2 3 4 5 6 7 8 i no. Part name q’ty remarks tightening torques stage n·m kgf·m ft·lb 1 lower unit 1 2 plastic tie 1 not reusable 3 hose 1 4 check screw 1 7 0.7 5.1 5 gasket 2 not reusable 6 bolt 4 m10 × 40 mm 40 4.0 29 7 drain screw 1 7 0.7 5.1 8 dowel pin 2 9 bolt 1 m8 × 35 mm 10 anode...

  • Page 208

    Lowr lower unit 6-9 62y3a11 removing the lower unit 1. Drain the gear oil. For draining proce- dures, see chapter 3, “replacing the gear oil.” 2. Set the gearshift to the neutral position, and place a block of wood between the anti-cavitation plate and propeller to keep the propeller from turning, a...

  • Page 209: — Memo —

    62y3a11 6-10 1 2 3 4 5 6 7 8 i — memo — lower unit (f50/f50a).

  • Page 210

    Lowr lower unit 6-11 62y3a11 water pump and propeller shaft housing (f50/f50a) 6.

  • Page 211

    62y3a11 6-12 1 2 3 4 5 6 7 8 i no. Part name q’ty remarks tightening torques stage n·m kgf·m ft·lb 1 propeller shaft assembly 1 2 propeller shaft housing assembly 1 3 spacer 1 4 grommet 1 5 bolt 4 m8 × 20 mm 6 water pump housing 1 7 insert plate cartridge 1 8 impeller 1 9 o-ring 1 not reusable 10 ou...

  • Page 212

    Lowr lower unit 6-13 62y3a11 removing the water pump and propeller shaft housing assembly 1. Remove the water pump assembly. 2. Remove the propeller shaft housing assembly by removing the bolts 1, then pulling the housing out. È for usa and canada É for worldwide disassembling the propeller shaft ho...

  • Page 213

    62y3a11 6-14 1 2 3 4 5 6 7 8 i È for usa and canada É for worldwide 3. Remove the oil seals and needle bear- ing. Disassembling the propeller shaft assembly 1. Remove the spring 1, then the cross pin 2, dog clutch 3, slider, and spring. Checking the water pump 1. Check the pump housing for deforma- ...

  • Page 214

    Lowr lower unit 6-15 62y3a11 3. Check the woodruff key 3 and the groove a on the drive shaft for wear. Replace if necessary. 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...

  • Page 215

    62y3a11 6-16 1 2 3 4 5 6 7 8 i assembling the propeller shaft assembly 1. Install the dog clutch as shown. Note: install the dog clutch 1 with the “f” mark a facing toward the shift plunger. Assembling the propeller shaft housing 1. Install the needle bearing into the propel- ler shaft housing to th...

  • Page 216

    Lowr lower unit 6-17 62y3a11 3. Install the original shim(s) 0 and ball bearing into the reverse gear using a press. È for usa and canada É for worldwide caution: add or remove shims, if necessary, when replacing the reverse gear or propeller shaft housing. Note: install the ball bearing with the ma...

  • Page 217

    62y3a11 6-18 1 2 3 4 5 6 7 8 i installing the propeller shaft housing 1. Install the washer 1, propeller shaft assembly 2, and shift plunger 3, into the propeller shaft housing assembly 4. 2. Apply grease to the new o-rings. 3. Install the propeller shaft housing assem- bly into the lower case 5, an...

  • Page 218

    Lowr lower unit 6-19 62y3a11 5. Install the o-ring 5, pump housing assembly 4, and dowel pins 6 into the lower case, tighten the bolts 7, and then install the grommet 8 and spacer 9. Note: • when installing the pump housing, apply grease to the inside of the housing, and then turn the drive shaft cl...

  • Page 219: — Memo —

    62y3a11 6-20 1 2 3 4 5 6 7 8 i — memo — water pump and propeller shaft housing (f50/f50a).

  • Page 220

    Lowr lower unit 6-21 62y3a11 drive shaft and lower case (f50/f50a) 6.

  • Page 221

    62y3a11 6-22 1 2 3 4 5 6 7 8 i no. Part name q’ty remarks tightening torques stage n·m kgf·m ft·lb 1 shift rod assembly 1 2 drive shaft 1 3 oil seal 1 not reusable 4 oil seal housing 1 5 o-ring 1 not reusable 6 circlip 1 7 shift rod 1 8 o-ring 1 not reusable 9 taper roller bearing 1 not reusable 10 ...

  • Page 222

    Lowr lower unit 6-23 62y3a11 removing the drive shaft 1. Remove the drive shaft assembly and pinion, and then pull out the forward gear. È for usa and canada É for worldwide disassembling the drive shaft assembly 1. Install the pinion nut 1, tighten it finger tight, and then remove the drive shaft b...

  • Page 223

    62y3a11 6-24 1 2 3 4 5 6 7 8 i disassembling the lower case 1. Remove the taper roller bearing outer race and shim(s). È for usa and canada É for worldwide note: install the claw as shown. 2. Remove the drive shaft bearing outer race, shim(s), and drive shaft sleeve. È for usa and canada É for world...

  • Page 224

    Lowr lower unit 6-25 62y3a11 checking the pinion and forward gear 1. Check the teeth of the pinion, and the teeth and dogs of the forward gear for cracks or wear. Replace the pinion or gear if necessary. Checking the bearings 1. Check the bearings for pitting or rum- bling. Replace if necessary. Che...

  • Page 225

    62y3a11 6-26 1 2 3 4 5 6 7 8 i 2. Install the needle bearing into the lower case to the specified depth. È for usa and canada É for worldwide note: • install the needle bearing with the manufac- ture identification mark b facing upward. • when using the driver rod, do not strike the special tool in ...

  • Page 226

    Lowr lower unit 6-27 62y3a11 4. Install the forward gear original shim(s) and taper roller bearing outer race. Caution: add or remove shims, if necessary, when replacing the forward gear or lower case. Assembling the forward gear 1. Install the new taper roller bearing into the forward gear using a ...

  • Page 227

    62y3a11 6-28 1 2 3 4 5 6 7 8 i 2. Install the new oil seals to the oil seal housing as shown. È for usa and canada É for worldwide installing the drive shaft 1. Install the forward gear, then the drive shaft assembly, pinion, and pinion nut, and then tighten the nut to the specified torque. È for us...

  • Page 228

    Lowr lower unit 6-29 62y3a11 2. Install the two dowel pins 1 to the lower unit. 3. Install the lower unit to the upper case, and then tighten the bolts to the specified torque. 4. Install the trim tab 2 to its original posi- tion, and then connect the speedometer hose 3. 5. Install the propeller and...

  • Page 229

    62y3a11 6-30 1 2 3 4 5 6 7 8 i warning do not hold the propeller with your hands when loosening or tightening it. Be sure to remove the battery leads from the bat- teries and the engine shut-off switch. Put a block of wood between the cavitation plate and propeller to keep the propeller from turning...

  • Page 230

    Lowr lower unit 6-31 62y3a11 shimming (f50) (for usa and canada) 6.

  • Page 231

    62y3a11 6-32 1 2 3 4 5 6 7 8 i 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 parts. Selecting the pinion shims 1....

  • Page 232

    Lowr lower unit 6-33 62y3a11 5. Measure the clearance (m) between the shim selecting tool and the pinion as shown. Note: measure the pinion at three points to find the clearance average. 6. Select the pinion shims (t3). Note: the sum of t3 and m should not be more than m0. Selecting the forward gear...

  • Page 233

    62y3a11 6-34 1 2 3 4 5 6 7 8 i 2. Install the taper roller bearing 1 to the shim selecting tools. Note: tighten the nut four turns after it contacts the spring. 3. Measure the clearance (m) between the gauge pin and press plate. 4. Select the forward gear shims (t1). Note: the sum of t1 and m should...

  • Page 234

    Lowr lower unit 6-35 62y3a11 shimming (f50a) (for worldwide) 6.

  • Page 235

    62y3a11 6-36 1 2 3 4 5 6 7 8 i 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 parts. Selecting the pinion shims 1....

  • Page 236

    Lowr lower unit 6-37 62y3a11 example: if “m” 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 if “m” is “11.70 mm” and “p” is “–5”, then t3 = 11.70 – 11.30 – (–5)/100 mm = 0.40 + 0.05 mm = 0.45 mm 5. Select the pinion shim(s) (t3) as follows. Example: i...

  • Page 237

    62y3a11 6-38 1 2 3 4 5 6 7 8 i example: if “m” is “22.45 mm” and “f” is “+5”, then t1 = 22.75 + (+5)/100 – 22.45mm = 0.30 + 0.05 mm = 0.35 mm if “m” is “22.45 mm” and “f” is “–5”, then t1 = 22.75 + (–5)/100 – 22.45mm = 0.30 – 0.05 mm = 0.25 mm 3. Select the forward gear shim(s) (t1) as follows. Exam...

  • Page 238

    Lowr lower unit 6-39 62y3a11 backlash (f50/f50a) 6 measuring the forward and reverse gear backlash 1. Remove the water pump assembly. 2. Set the gearshift to the neutral position. È for usa and canada É for worldwide 3. Install the special service tool so that it pushes against the propeller shaft. ...

  • Page 239

    62y3a11 6-40 1 2 3 4 5 6 7 8 i 5. Slowly turn the drive shaft clockwise and counterclockwise and measure the back- lash when the drive shaft stops in each direction. 6. Add or remove shims if out of specifica- tion. M: measurement 7. Remove the special service tools from the propeller shaft. 8. Appl...

  • Page 240

    Lowr lower unit 6-41 62y3a11 lower unit (t50/ft50b, ft50c) 6.

  • Page 241

    62y3a11 6-42 1 2 3 4 5 6 7 8 i no. Part name q’ty remarks tightening torques stage n·m kgf·m ft·lb 1 lower unit 1 2 plastic tie 1 not reusable 3 hose 1 4 check screw 1 7 0.7 5.1 5 gasket 2 not reusable 6 dowel pin 2 7 bolt 4 m10 × 40 mm 40 4.0 29 8 drain screw 1 7 0.7 5.1 9 grommet 1 10 bolt 1 m10 ×...

  • Page 242

    Lowr lower unit 6-43 62y3a11 removing the lower unit 1. Drain the gear oil. For draining proce- dures, see chapter 3, “replacing the gear oil.” 2. Set the gearshift to the neutral position, and place a block of wood between the anti-cavitation plate and propeller to keep the propeller from turning, ...

  • Page 243: — Memo —

    62y3a11 6-44 1 2 3 4 5 6 7 8 i — memo — lower unit (t50/ft50b, ft50c).

  • Page 244

    Lowr lower unit 6-45 62y3a11 water pump and shift rod (t50/ft50b, ft50c) 6.

  • Page 245

    62y3a11 6-46 1 2 3 4 5 6 7 8 i no. Part name q’ty remarks tightening torques stage n·m kgf·m ft·lb 1 shift rod assembly 1 2 oil seal 1 not reusable 3 oil seal housing 1 4 o-ring 1 not reusable 5 circlip 1 6 shift rod 1 7 o-ring 1 not reusable 8 bolt 2 m6 × 16 mm 9 woodruff key 1 10 bolt 2 m8 × 55 mm...

  • Page 246

    Lowr lower unit 6-47 62y3a11 removing the water pump and shift rod 1. Remove the water pump assembly and shift rod assembly 1. 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. Checking the water pump and...

  • Page 247

    62y3a11 6-48 1 2 3 4 5 6 7 8 i installing the water pump and shift rod 1. Install the shift rod assembly 1. Note: install the shift rod assembly into the lower case, turn it clockwise 90° a, and then push it down b to connect it to the shift slider 2. 2. Install the new oil seals into the oil seal h...

  • Page 248

    Lowr lower unit 6-49 62y3a11 6. Align the groove on the impeller b with the woodruff key c, and then install it to the drive shaft. 7. Install the insert plate cartridge d and grommet e into the pump housing f. Note: align the insert plate cartridge projection c with the hole d in the pump housing. ...

  • Page 249: — Memo —

    62y3a11 6-50 1 2 3 4 5 6 7 8 i — memo — water pump and shift rod (t50/ft50b, ft50c).

  • Page 250

    Lowr lower unit 6-51 62y3a11 propeller shaft housing (t50/ft50b, ft50c) 6.

  • Page 251

    62y3a11 6-52 1 2 3 4 5 6 7 8 i no. Part name q’ty remarks tightening torques stage n·m kgf·m ft·lb 1 propeller shaft assembly 1 2 propeller shaft housing assembly 1 3 ball 2 4 slider 1 5 shift plunger 1 6 cross pin 1 7 dog clutch 1 8 spring 1 9 propeller shaft 1 10 washer 1 11 straight key 1 12 claw...

  • Page 252

    Lowr lower unit 6-53 62y3a11 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. È for usa and canada É for worldwide disassembling the propeller shaft housing 1. Remove th...

  • Page 253

    62y3a11 6-54 1 2 3 4 5 6 7 8 i note: install the bearing separator 2 between the reverse gear and thrust washer completely, then the other special service tools. 2. Remove the ball bearing. È for usa and canada É for worldwide 3. Remove the oil seals and needle bear- ing. Disassembling the propeller...

  • Page 254

    Lowr lower unit 6-55 62y3a11 2. Check the teeth and dogs of the reverse gear for cracks or wear. Replace the gear if necessary. 3. Check the bearings for pitting or rum- bling. Replace if necessary. Checking the propeller shaft 1. Check the propeller shaft for bends or wear. Replace if necessary. 2....

  • Page 255

    62y3a11 6-56 1 2 3 4 5 6 7 8 i È for usa and canada É for worldwide 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 b out o...

  • Page 256

    Lowr lower unit 6-57 62y3a11 note: install the ball bearing with the manufacture identification mark e facing outward (propel- ler side). 4. Install the reverse gear assembly to the propeller shaft housing using a press. Installing the propeller shaft housing 1. Install the washer 1, propeller shaft...

  • Page 257

    62y3a11 6-58 1 2 3 4 5 6 7 8 i gland nut wrench 8: yb-34447 ring nut wrench 3 8: 90890-06511 ring nut wrench extension 9: 90890-06513 ring nut 7: 105 n·m (10.5 kgf·m, 76 ft·lb) propeller shaft housing (t50/ft50b, ft50c).

  • Page 258

    Lowr lower unit 6-59 62y3a11 drive shaft and lower case (t50/ft50b, ft50c) 6.

  • Page 259

    62y3a11 6-60 1 2 3 4 5 6 7 8 i no. Part name q’ty remarks tightening torques stage n·m kgf·m ft·lb 1 drive shaft 1 2 taper roller bearing 1 not reusable 3 bearing outer race 1 not reusable 4 pinion shim — as required 5 sleeve 1 6 hose 1 7 plastic tie 1 not reusable 8 joint 1 9 nut 1 10 water inlet c...

  • Page 260

    Lowr lower unit 6-61 62y3a11 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. È for usa and canada É...

  • Page 261

    62y3a11 6-62 1 2 3 4 5 6 7 8 i È for usa and canada É for worldwide caution: do not reuse the bearing, always replace it with a new one. Disassembling the lower case 1. Remove the taper roller bearing outer race and shim(s). È for usa and canada É for worldwide note: install the claws as shown. 2. R...

  • Page 262

    Lowr lower unit 6-63 62y3a11 3. Remove the needle bearing. Checking the pinion and forward gear 1. Check the teeth of the pinion, and the teeth and dogs of the forward gear for cracks or wear. Replace if necessary. Checking the bearings 1. Check the bearings for pitting or rum- bling. Replace if nec...

  • Page 263

    62y3a11 6-64 1 2 3 4 5 6 7 8 i È for usa and canada É for worldwide note: • install the needle bearing with the manufac- ture identification mark a facing upward. • when using the driver rod, do not strike the special tool in a manner that will force the stopper b out of place. 2. Install the sleeve...

  • Page 264

    Lowr lower unit 6-65 62y3a11 3. Install the original shim(s) and taper roller bearing outer race. È for usa and canada É for worldwide caution: add or remove shims, if necessary, when replacing the forward gear or lower case. Assembling the forward gear 1. Install the new taper roller bearing into t...

  • Page 265

    62y3a11 6-66 1 2 3 4 5 6 7 8 i assembling the drive shaft 1. Install the new drive shaft bearing into the drive shaft using a press. È for usa and canada É for worldwide note: use the special service tool or a general pipe with the specified measurements. Installing the drive shaft 1. Install the fo...

  • Page 266

    Lowr lower unit 6-67 62y3a11 2. Install the two dowel pins 1 to the lower unit. 3. Install the lower unit to the upper case, and then tighten the bolts to the specified torque. 4. Install the trim tab 2 to its original posi- tion, and then connect the speedometer hose 3. 5. Install the propeller and...

  • Page 267

    62y3a11 6-68 1 2 3 4 5 6 7 8 i warning do not hold the propeller with your hands when loosening or tightening it. Be sure to remove the battery leads from the bat- teries and the engine shut-off switch. Put a block of wood between the cavitation plate and propeller to keep the propeller from turning...

  • Page 268

    Lowr lower unit 6-69 62y3a11 shimming (t50) (for usa and canada) 6.

  • Page 269

    62y3a11 6-70 1 2 3 4 5 6 7 8 i 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 270

    Lowr lower unit 6-71 62y3a11 5. Measure the clearance (m) between the shim selecting tool and the pinion as shown. Note: measure the pinion at three points to find the clearance average. 6. Select the pinion shims (t3). Note: the sum of t3 and m should not be more than m0. Selecting the forward gear...

  • Page 271

    62y3a11 6-72 1 2 3 4 5 6 7 8 i 2. Install the taper roller bearing 1 to the shim selecting tools. Note: tighten the nut four turns after it contacts the spring. 3. Measure the clearance (m) between the gauge pin and the press plate. 4. Select the forward gear shims (t1). Note: the sum of t1 and m sh...

  • Page 272

    Lowr lower unit 6-73 62y3a11 shimming (ft50b, ft50c) (for worldwide) 6.

  • Page 273

    62y3a11 6-74 1 2 3 4 5 6 7 8 i 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 274

    Lowr lower unit 6-75 62y3a11 example: if “m” is “32.10 mm” and “p” is “+5”, then t3 = 32.10 – 31.50 – (+5)/100 mm = 0.60 – 0.05 mm = 0.55 mm if “m” is “32.10 mm” and “p” is “–5”, then t3 = 32.10 – 31.50 – (–5)/100 mm = 0.60 + 0.05 mm = 0.65 mm 5. Select the pinion shim(s) (t3) as follows. Example: i...

  • Page 275

    62y3a11 6-76 1 2 3 4 5 6 7 8 i example: if “m” is “24.00 mm” and “f” is “+5”, then t1 = 24.50 + (+5)/100 – 24.00 mm = 0.50 + 0.05 mm = 0.55 mm if “m” is “24.00 mm” and “f” is “–5”, then t1 = 24.50 + (–5)/100 – 24.00 mm = 0.50 – 0.05 mm = 0.45 mm 3. Select the forward gear shim(s) (t1) as follows. Ex...

  • Page 276

    Lowr lower unit 6-77 62y3a11 backlash (t50/ft50b, ft50c) 6 measuring the forward and reverse gear backlash 1. Remove the water pump assembly. 2. Set the gearshift to the neutral position. È for usa and canada É for worldwide 3. Install the special service tool so that it pushes against the propeller...

  • Page 277

    62y3a11 6-78 1 2 3 4 5 6 7 8 i 5. Slowly turn the drive shaft clockwise and counterclockwise and measure the back- lash when the drive shaft stops in each direction. 6. Add or remove shims if out of specifica- tion. M: measurement 7. Remove the special service tools from the propeller shaft. 8. Appl...

  • Page 278: Bracket Unit

    Brkt 62y3a11 bracket unit troubleshooting............................................................................................. 7-1 special service tools ..................................................................................... 7-4 tiller handle (f50/f50a, t50/ft50b) ................

  • Page 279

    62y3a11 1 2 3 4 5 6 7 8 i gear pump .................................................................................................... 7-59 disassembling the tilt cylinder ................................................................. 7-63 disassembling the trim cylinder...........................

  • Page 280

    Brkt bracket unit 7-1 62y3a11 troubleshooting 7 before troubleshooting the power trim and tilt unit, check that all electrical connections are tight and free from corrosion, and that the battery is fully charged to 12 v. Symptom: power trim and tilt unit does not operate. Listen for the operation so...

  • Page 281

    62y3a11 7-2 1 2 3 4 5 6 7 8 i symptom: power trim and tilt unit does not hold the outboard motor up. Check that the manual release plug is closed. Check the power trim and tilt fluid level. Disassemble the power trim and tilt unit, and then check it. Close the plug. Add fluid to the correct level. A...

  • Page 282

    Brkt bracket unit 7-3 62y3a11 symptom: shift mechanism of the forward gear and reverse gear does not operate properly. Check the operation of the shift rod. Check the condition of the shift rod connection between the lower case and upper case. Disassemble the lower case, and then check the shifting ...

  • Page 283

    62y3a11 7-4 1 2 3 4 5 6 7 8 i special service tools 7 trim and tilt cylinder wrench yb-06175-2b cylinder-end screw wrench 90890-06544 for usa and canada for worldwide troubleshooting / special service tools.

  • Page 284

    Brkt bracket unit 7-5 62y3a11 tiller handle (f50/f50a, t50/ft50b) 7.

  • Page 285

    62y3a11 7-6 1 2 3 4 5 6 7 8 i no. Part name q’ty remarks tightening torques stage n·m kgf·m ft·lb 1 tiller handle assembly 1 2 friction plate 1 3 tiller handle wiring harness 1 4 tiller handle wiring harness 1 models applicable for tachometer, trim meter or warning buzzer 5 grommet 1 6 clip 1 7 thro...

  • Page 286

    Brkt bracket unit 7-7 62y3a11.

  • Page 287

    62y3a11 7-8 1 2 3 4 5 6 7 8 i no. Part name q’ty remarks tightening torques stage n·m kgf·m ft·lb 31 nut 2 32 collar 2 33 bolt 2 m8 × 50 mm 34 self-locking nut 1 35 bracket 1 36 steering lock shaft 1 37 steering lock knob 1 38 friction plate 1 39 friction piece 2 tiller handle (f50/f50a, t50/ft50b).

  • Page 288

    Brkt bracket unit 7-9 62y3a11.

  • Page 289

    62y3a11 7-10 1 2 3 4 5 6 7 8 i no. Part name q’ty remarks tightening torques stage n·m kgf·m ft·lb 1 tiller handle sub assembly 1 2 screw 2 m6 × 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 4 0.4 2.9 10 engine shut-off switch 1 11 nut 1 3...

  • Page 290

    Brkt bracket unit 7-11 62y3a11.

  • Page 291

    62y3a11 7-12 1 2 3 4 5 6 7 8 i no. Part name q’ty remarks tightening torques stage n·m kgf·m ft·lb 31 screw 2 m6 × 40 mm 32 throttle grip 1 33 screw 1 m5 × 25 mm 34 washer 1 35 spring 1 36 bushing 1 tiller handle (f50/f50a, t50/ft50b).

  • Page 292

    Brkt bracket unit 7-13 62y3a11.

  • Page 293

    62y3a11 7-14 1 2 3 4 5 6 7 8 i no. Part name q’ty remarks tightening torques stage n·m kgf·m ft·lb 1 tiller handle 1 2 cotter pin 1 not reusable 3 friction adjusting knob 1 4 grommet 1 5 plastic tie 1 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 1...

  • Page 294

    Brkt bracket unit 7-15 62y3a11 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. I...

  • Page 295: — Memo —

    62y3a11 7-16 1 2 3 4 5 6 7 8 i — memo — tiller handle (f50/f50a, t50/ft50b).

  • Page 296

    Brkt bracket unit 7-17 62y3a11 tiller handle (ft50c) 7.

  • Page 297

    62y3a11 7-18 1 2 3 4 5 6 7 8 i no. Part name q’ty remarks tightening torques stage n·m kgf·m ft·lb 1 bolt 1 m8 × 30 mm 2 nut 1 3 wing nut 1 13 1.3 9.4 4 friction piece 1 5 bolt 1 m6 × 35 mm 6 friction rod 1 7 washer 1 8 nut 1 9 washer 2 10 link rod 1 11 nut 1 12 plate 1 13 bolt 3 m6 × 20 mm 14 gromm...

  • Page 298

    Brkt bracket unit 7-19 62y3a11.

  • Page 299

    62y3a11 7-20 1 2 3 4 5 6 7 8 i no. Part name q’ty remarks tightening torques stage n·m kgf·m ft·lb 1 tiller handle 1 2 tiller handle wiring harness 1 3 clip 1 4 shift rod 1 5 nut 2 37 3.7 27 6 bushing 1 7 bolt 1 m12 × 70 mm 8 clip 1 9 throttle cable 1 37 3.7 27 10 nut 1 11 plastic washer 2 12 metal ...

  • Page 300

    Brkt bracket unit 7-21 62y3a11.

  • Page 301

    62y3a11 7-22 1 2 3 4 5 6 7 8 i no. Part name q’ty remarks tightening torques stage n·m kgf·m ft·lb 1 bracket 1 2 bolt 2 m6 × 16 mm 3 bolt 2 m6 × 16 mm 4 shift arm guide 1 5 nut 1 6 washer 1 7 washer 1 8 bushing 1 9 tiller handle bracket 1 10 nut 1 11 bushing 1 12 engine stop switch 1 13 bolt 1 m6 × ...

  • Page 302

    Brkt bracket unit 7-23 62y3a11 checking the throttle cable and shift rod 1. Check the operation of the throttle cable and shift rod. 2. Check the inner wire, outer wire of the cable and rod for bends or damage, and the rubber seals for damage. Replace if necessary. Assembling the tiller handle 1. In...

  • Page 303: — Memo —

    62y3a11 7-24 1 2 3 4 5 6 7 8 i — memo — tiller handle (ft50c).

  • Page 304

    Brkt bracket unit 7-25 62y3a11 bottom cowling 7.

  • Page 305

    62y3a11 7-26 1 2 3 4 5 6 7 8 i no. Part name q’ty remarks tightening torques stage n·m kgf·m ft·lb 1 shift rod assembly 1 2 bottom cowling 1 3 bolt 1 4 spring 1 5 ball 1 6 shift rod bracket 1 7 cotter pin 1 not reusable 8 washer 1 9 bushing 1 10 bushing 1 11 shift rod 1 12 grommet 1 13 rubber seal 4...

  • Page 306

    Brkt bracket unit 7-27 62y3a11.

  • Page 307

    62y3a11 7-28 1 2 3 4 5 6 7 8 i no. Part name q’ty remarks tightening torques stage n·m kgf·m ft·lb 31 bolt 2 models with trailer switch 32 bracket 1 models with trailer switch 33 trailer switch 1 models with trailer switch 34 ptt motor lead 1 eht/et models 35 trim sensor coupler 1 eht/et models 36 s...

  • Page 308

    Brkt bracket unit 7-29 62y3a11 checking the shift rod assembly operation 1. Check the shift rod assembly and detent for smooth operation. È f50/f50a, t50/ft50b É ft50c.

  • Page 309: — Memo —

    62y3a11 7-30 1 2 3 4 5 6 7 8 i — memo — bottom cowling.

  • Page 310

    Brkt bracket unit 7-31 62y3a11 upper case 7.

  • Page 311

    62y3a11 7-32 1 2 3 4 5 6 7 8 i no. Part name q’ty remarks tightening torques stage n·m kgf·m ft·lb 1 upper case assembly 1 2 nut 2 24 2.4 17 3 nut 2 42 4.2 30 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 bolt 2 m12 × 160 mm 11 grommet 2 12 ground lead 1 13...

  • Page 312

    Brkt bracket unit 7-33 62y3a11.

  • Page 313

    62y3a11 7-34 1 2 3 4 5 6 7 8 i no. Part name q’ty remarks tightening torques stage n·m kgf·m ft·lb 1 muffler assembly 1 2 upper case 1 3 muffler seal 1 4 rubber seal 1 5 dowel pin 2 6 grommet 1 7 guide 1 ft50c 8 damper 1 9 screw 2 m5 × 16 mm 10 baffle plate 1 11 bolt 4 m8 × 30 mm 12 drive shaft bush...

  • Page 314

    Brkt bracket unit 7-35 62y3a11 (f50/f50a, t50/ft50b).

  • Page 315

    62y3a11 7-36 1 2 3 4 5 6 7 8 i no. Part name q’ty remarks tightening torques stage n·m kgf·m ft·lb 1 oil seal 1 not reusable 2 exhaust guide 1 3 grommet 1 4 gasket 1 not reusable 5 dowel pin 2 6 bolt 10 m6 × 25 mm 7 oil pan 1 8 gasket 1 9 exhaust manifold 1 10 bolt 3 m6 × 50 mm 11 gasket 1 not reusa...

  • Page 316

    Brkt bracket unit 7-37 62y3a11 (ft50c).

  • Page 317

    62y3a11 7-38 1 2 3 4 5 6 7 8 i no. Part name q’ty remarks tightening torques stage n·m kgf·m ft·lb 1 oil seal 1 not reusable 2 exhaust guide 1 3 grommet 1 4 grommet 1 5 anode 1 6 cover 1 7 bolt 1 8 cover 1 9 bolt 1 10 gasket 1 not reusable 11 dowel pin 2 12 bolt 10 m6 × 25 mm 13 oil pan 1 14 gasket ...

  • Page 318

    Brkt bracket unit 7-39 62y3a11 disassembling the oil pan 1. Remove the muffler 1 from the oil pan 2. 2. Remove the exhaust manifold 3 from the oil pan 2. 3. Remove the oil pan 2 from the exhaust guide 4. 4. Remove the oil strainer 5 and the relief valve housing 6. È ft50c checking the oil strainer a...

  • Page 319

    62y3a11 7-40 1 2 3 4 5 6 7 8 i 4. Install the water pipe 4. 5. Install the oil pan 5 and bolts, and then tighten the bolts finger tight. 6. Install the exhaust manifold 6 and bolts, and then tighten the bolts finger tight. È ft50c 7. Tighten the exhaust manifold bolts 7, then the oil pan bolts 8. 8....

  • Page 320

    Brkt bracket unit 7-41 62y3a11 9. Install the muffler assembly 0 by insert- ing the tip of the water pipe 4 into the joint hole a of the upper case. Installing the upper case 1. Install the upper mount 1 and bolts 2 into the upper case, and then tighten the bolts 3. 2. Set the lower mounts 4 and bol...

  • Page 321

    62y3a11 7-42 1 2 3 4 5 6 7 8 i 4. Install the upper and lower mounting bolts into the swivel bracket 9 simulta- neously. 5. Install the upper mounting nut 0 and lower mounting nut a, and then tighten them to the specified torques. 6. Install the cover b by installing the screw. Upper mounting nut 0:...

  • Page 322

    Brkt bracket unit 7-43 62y3a11 clamp brackets 7.

  • Page 323

    62y3a11 7-44 1 2 3 4 5 6 7 8 i no. Part name q’ty remarks tightening torques stage n·m kgf·m ft·lb 1 swivel bracket assembly 1 2 screw 1 eht/et models m6 × 15 mm 2 0.2 1.4 3 trim sensor 1 eht/et models 4 trim sensor coupler 1 eht/et models 5 plastic tie 1 not reusable 6 self-locking nut 2 23 2.3 17 ...

  • Page 324

    Brkt bracket unit 7-45 62y3a11 removing the clamp brackets 1. Remove the power trim and tilt or hydro tilt. For removing procedures, see “removing the power trim and tilt/hydro tilt” in this chapter. 2. Loosen the self-locking nuts 1, and then remove clamp brackets 2 and 3. 3. Remove the trim sensor...

  • Page 325

    62y3a11 7-46 1 2 3 4 5 6 7 8 i 4. Inject grease into both grease nipples until grease comes out from the bushings a. Adjusting the trim sensor 1. Fully tilt the outboard up, and then sup- port it with the tilt stop lever 1. Warning after tilting up the outboard, be sure to support it with the tilt s...

  • Page 326

    Brkt bracket unit 7-47 62y3a11 swivel bracket and steering arm 7.

  • Page 327

    62y3a11 7-48 1 2 3 4 5 6 7 8 i no. Part name q’ty remarks tightening torques stage n·m kgf·m ft·lb 1 steering arm 1 2 washer 1 3 bushing 1 4 o-ring 2 not reusable 5 bushing 2 6 swivel bracket 1 7 bushing 1 8 port tilt stop lever 1 9 circlip 1 10 steering yoke 1 11 bushing 1 12 bushing 1 13 tilt stop...

  • Page 328

    Brkt bracket unit 7-49 62y3a11 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 by pulling the arm off the bracket. Installing the steering arm 1. Install the washer 1, bushing 2,...

  • Page 329

    62y3a11 7-50 1 2 3 4 5 6 7 8 i 6. Inject grease into the grease nipple until grease comes out from both the upper and lower bushings c. Swivel bracket and steering arm.

  • Page 330

    Brkt bracket unit 7-51 62y3a11 power trim and tilt unit 7.

  • Page 331

    62y3a11 7-52 1 2 3 4 5 6 7 8 i no. Part name q’ty remarks tightening torques stage n·m kgf·m ft·lb 1 power trim and tilt 1 eht/et models 2 hydro tilt 1 ehd/ed models 3 plastic tie 3 not reusable 4 ptt motor lead 2 5 washer 2 6 bolt 2 m8 × 16 mm 7 circlip 1 eht/et models 8 shaft 1 eht/et models 9 bus...

  • Page 332

    Brkt bracket unit 7-53 62y3a11 removing the power trim and tilt/hydro tilt 1. Fully tilt the outboard up, and then sup- port it with the tilt stop lever 1. Warning after tilting up the outboard, be sure to support it with the tilt stop lever. Otherwise, the outboard could suddenly lower if the power...

  • Page 333: — Memo —

    62y3a11 7-54 1 2 3 4 5 6 7 8 i — memo — power trim and tilt unit.

  • Page 334

    Brkt bracket unit 7-55 62y3a11 tilt cylinder and trim cylinder 7.

  • Page 335

    62y3a11 7-56 1 2 3 4 5 6 7 8 i no. Part name q’ty remarks tightening torques stage n·m kgf·m ft·lb 1 power trim and tilt motor 1 2 tilt cylinder end screw 1 90 9.0 65 3 bolt 3 m5 × 20 mm 4 0.4 2.9 4 o-ring 1 not reusable 5 joint 1 6 o-ring 1 not reusable 7 ball 6 8 o-ring 1 not reusable 9 free pisto...

  • Page 336

    Brkt bracket unit 7-57 62y3a11 trim cylinder 7.

  • Page 337

    62y3a11 7-58 1 2 3 4 5 6 7 8 i no. Part name q’ty remarks tightening torques stage n·m kgf·m ft·lb 1 tilt ram 1 2 dust seal 1 not reusable 3 backup ring 1 4 o-ring 1 not reusable 5 tilt cylinder end screw 1 6 o-ring 1 not reusable 7 backup ring 1 8 o-ring 1 not reusable 9 trim cylinder end screw 1 8...

  • Page 338

    Brkt bracket unit 7-59 62y3a11 gear pump 7.

  • Page 339

    62y3a11 7-60 1 2 3 4 5 6 7 8 i no. Part name q’ty remarks tightening torques stage n·m kgf·m ft·lb 1 bolt 2 m5 × 8 mm 5 0.5 3.6 2 relief valve bracket 1 3 bolt 3 m6 × 40 mm 7 0.7 5.1 4 valve lock screw 1 5 up-relief spring 1 6 valve support pin 1 7 o-ring 1 not reusable 8 ball 1 9 down-relief spring...

  • Page 340

    Brkt bracket unit 7-61 62y3a11.

  • Page 341

    62y3a11 7-62 1 2 3 4 5 6 7 8 i no. Part name q’ty remarks tightening torques stage n·m kgf·m ft·lb 1 bolt 2 m5 × 20 mm 5 0.5 3.6 2 washer 2 3 gear pump bracket 1 4 o-ring 2 not reusable 5 spacer 2 6 spring 2 7 valve pin 2 8 ball 2 9 manual release spring 1 10 ball 2 11 gear pump cover 1 12 spring 2 ...

  • Page 342

    Brkt bracket unit 7-63 62y3a11 disassembling the tilt cylinder 1. Hold the power trim and tilt 1 in a vise using aluminum plates a on both sides. 2. Loosen the tilt cylinder end screw 2, and then remove it. Warning make sure that the ram is fully extended before removing the end screw. 3. Drain the ...

  • Page 343

    62y3a11 7-64 1 2 3 4 5 6 7 8 i disassembling the gear pump 1. Remove the manual release plug 1 and gear pump 2. 2. Remove the relief valve bracket 3, then the down-relief valve 4 and up-relief valve 5. 3. Remove the gear pump bracket 6, then the down-shuttle piston 7 and up-shuttle piston 8. 4. Remo...

  • Page 344

    Brkt bracket unit 7-65 62y3a11 3. Check the outer surface of the tilt piston and free piston for scratches. Replace if necessary. 4. Check the tilt ram for bends or excessive corrosion. Polish with #400–600 grit sandpaper if there is light rust or replace if necessary. Check the valves 1. Check the ...

  • Page 345

    62y3a11 7-66 1 2 3 4 5 6 7 8 i checking the gear pump 1. Check the drive gear 1, driven gear 2, and shaft 3 for damage or excessive wear. Replace if necessary. Assembling the gear pump 1. Install the drive gear 1, driven gear 2, shaft 3, and pins 4 into the gear pump housing 5. 2. Install the balls ...

  • Page 346

    Brkt bracket unit 7-67 62y3a11 10. Install the filters j and gear pump k by installing the bolts l, then tightening them to the specified torque. 11. Install the manual release plug m and reservoir cap n. 12. Fill the reservoir with the recommended fluid to the correct level as shown. 13. Install th...

  • Page 347

    62y3a11 7-68 1 2 3 4 5 6 7 8 i 4. Install the backup ring 5 and o-rings 6 and 7 into the trim cylinder end screw 8. 5. Install the trim cylinder end screw onto the tilt ram. 6. Install o-rings 9 and 0 onto the trim pis- ton a, and then install the trim piston to the trim cylinder b. 7. Install the b...

  • Page 348

    Brkt bracket unit 7-69 62y3a11 13. Install the trim cylinder end screw n, and then tighten it to the specified torque. Caution: do not damage the check valve b when tightening the end screw. Assembling the tilt cylinder 1. Install the valve seal 1 and the circlip 2 into the free piston 3 as shown. 2...

  • Page 349

    62y3a11 7-70 1 2 3 4 5 6 7 8 i 7. Install the tilt cylinder end screw c, and then tighten it to the specified torque. 8. Fully extend the tilt rod, and then add suf- ficient fluid of the recommended type to the correct level. 9. Install the reservoir cap d. Bleeding the power trim and tilt (not inst...

  • Page 350

    Brkt bracket unit 7-71 62y3a11 6. Connect the ptt motor leads 2 to the battery terminals. 7. Reverse the ptt motor leads between the battery terminals when the tilt ram is fully extended, and then reverse them again when it is fully compressed. Note: • repeat this procedure so that the tilt ram goes...

  • Page 351

    62y3a11 7-72 1 2 3 4 5 6 7 8 i 7. Remove the reservoir cap 1, and then check the fluid level in the reservoir. 8. If necessary, add sufficient fluid of the recommended type to the correct level. Note: the fluid level should be at the brim of the filler hole. 9. Install the reservoir cap. Note: repea...

  • Page 352

    Brkt bracket unit 7-73 62y3a11 power trim and tilt motor 7.

  • Page 353

    62y3a11 7-74 1 2 3 4 5 6 7 8 i no. Part name q’ty remarks tightening torques stage n·m kgf·m ft·lb 1 screw 3 m5 × 20 mm 2 yoke 1 3 o-ring 1 not reusable 4 armature 1 5 bushing 1 6 screw 2 m4 × 12 mm 7 wire lead 1 8 brush 2 1 9 brush 1 1 10 brush holder 1 11 circuit breaker 1 12 brush spring 2 13 ptt...

  • Page 354

    Brkt bracket unit 7-75 62y3a11 checking the power trim and tilt motor 1. Check the commutator for dirt or foreign substances. Clean with #600 grit sand- paper if necessary. 2. Check the commutator undercut for dirt or foreign substances. Clean with com- pressed air if necessary. 3. Measure the commu...

  • Page 355

    62y3a11 7-76 1 2 3 4 5 6 7 8 i 8. Check the bushing 1 for damage or wear. Replace if necessary. Assembling the power trim and tilt motor 1. Install the oil seal 1 and the bushing 2 into the motor base 3 as shown. 2. Attach the circuit breaker 4 onto brush 1 5 together with the brush holder 6 and con...

  • Page 356

    Brkt bracket unit 7-77 62y3a11 2. Install the shaft 2 and bolts 3 onto both clamp brackets together with the power trim and tilt/hydro tilt 4. 3. Install the tilt ram upper end into the swivel bracket with the shaft 5 and cir- clip(s) 6. 4. Install the tilt pin 7..

  • Page 357

    62y3a11 7-78 1 2 3 4 5 6 7 8 i power trim and tilt electrical system 7 1 power trim and tilt motor 2 power trim and tilt relay 3 trailer switch 4 power trim and tilt switch 5 fuse 6 battery 7 trim sensor È models with trailer switch b : black g : green gy : gray l : blue lg : light green p : pink r ...

  • Page 358

    Brkt bracket unit 7-79 62y3a11 checking the fuse 1. Check the fuse and fuse holder for conti- nuity. Replace if there is no continuity. Checking the power trim and tilt relay 1. Check the power trim and tilt relay for continuity. Replace if out of specification. 2. Connect the digital circuit tester...

  • Page 359

    62y3a11 7-80 1 2 3 4 5 6 7 8 i checking the power trim and tilt switch/trailer switch 1. Check the power trim and tilt switch/trailer switch for continuity. Replace if out of specification. Checking the trim sensor 1. Measure the trim sensor resistance. Replace if out of specification. Note: turn th...

  • Page 360: — Memo —

    Brkt bracket unit 7-81 62y3a11 — memo —.

  • Page 361: Electrical Systems

    62y3a11 elec – + 1 2 3 4 5 6 7 8 i electrical systems troubleshooting............................................................................................. 8-1 special service tools ..................................................................................... 8-2 checking the electric...

  • Page 362

    Elec electrical systems – + 8-1 62y3a11 troubleshooting 8 before troubleshooting the charging system, check that all electrical connections are tight and free from corrosion, and that the battery is fully charged to 12 v. Symptom: battery becomes weaker quickly. • check the charging system. Measure ...

  • Page 363

    62y3a11 8-2 1 2 3 4 5 6 7 8 i special service tools 8 dynamic spark tester ym-34487 digital multimeter yu-34899-a peak voltage adaptor yu-39991 test harness (2 pins) yb-06767 pressure/vacuum tester yb-35956-a dial gauge yu-03097 magnetic flexible stand yu-34481 test harness (3 pins) yb-06770 test ha...

  • Page 364

    Elec electrical systems – + 8-3 62y3a11 digital circuit tester 90890-03174 peak voltage adaptor 90890-03172 test harness (2 pins) 90890-06767 vacuum/pressure pump gauge set 90890-06756 dial gauge set 90890-01252 magnet base 90890-06705 test harness (3 pins) 90890-06770 test harness (4 pins) 90890-06...

  • Page 365

    62y3a11 8-4 1 2 3 4 5 6 7 8 i checking the electrical components 8 measuring the peak voltage the condition of the ignition system can be determined by measuring the peak voltage. Cranking speed is effected by many factors, such as fouled or weak spark plugs, or a weak battery. If one of these facto...

  • Page 366

    Elec electrical systems – + 8-5 62y3a11 electrical components 8 starboard and port views 1 stator 2 pulser coil 3 cdi unit 4 ignition coil 5 oil pressure switch 6 thermoswitch 7 prime start 8 rectifier regulator 9 starter relay 0 starter motor a ptt switch coupler È power trim and tilt model with ti...

  • Page 367

    62y3a11 8-6 1 2 3 4 5 6 7 8 i front view 1 stator 2 pulser coil 3 cdi unit 4 fuse 5 neutral switch (tiller handle model) 6 starter relay 7 starter motor 8 power trim and tilt relay (power trim and tilt model) È tiller handle model electrical components.

  • Page 368

    Elec electrical systems – + 8-7 62y3a11 top view 1 stator 2 pulser coil 3 cdi unit 4 ignition coil 5 starter motor 6 trailer switch.

  • Page 369

    62y3a11 8-8 1 2 3 4 5 6 7 8 i tiller handle model (f50/f50a, t50/ft50b) 1 engine start switch 2 engine start switch harness 3 engine shut-off switch 4 engine shut-off switch connector 5 neutral switch 6 battery lead 7 wiring harness extension 8 ptt switch lead 9 power trim and tilt switch È applicab...

  • Page 370

    Elec electrical systems – + 8-9 62y3a11 tiller handle model (ft50c) 1 engine start switch 2 engine start switch harness 3 engine shut-off switch 4 engine shut-off switch connector 5 neutral switch 6 battery lead.

  • Page 371

    62y3a11 8-10 1 2 3 4 5 6 7 8 i wiring harness 8 connect to: 1 tiller handle main switch or remote control box or wiring harness extension 2 power trim and tilt relay 3 ground 4 starter relay 5 positive battery lead 6 prime start 7 warning indicator or digital tachometer 8 cdi unit 9 power trim and t...

  • Page 372

    Elec electrical systems – + 8-11 62y3a11 ignition system and ignition control system 8 1 spark plug 2 ignition coil 3 charge coil 4 pulser coil 5 engine start switch 6 engine shut-off switch 7 10-pin coupler 8 cdi unit b : black br : brown l : blue w : white b/o : black/orange b/w : black/white w/b ...

  • Page 373

    62y3a11 8-12 1 2 3 4 5 6 7 8 i 8 1 thermoswitch 2 oil pressure switch 3 cdi unit 4 digital tachometer 5 oil pressure warning indicator 6 overheat warning indicator 7 remote control box 8 warning indicator È remote control model É tiller handle model b : black g : green r : red y : yellow gy/b : gree...

  • Page 374

    Elec electrical systems – + 8-13 62y3a11 checking the ignition spark gap 1. Disconnect the spark plug caps from the spark plugs. 2. Connect a spark plug cap to the special service tool. È for usa and canada É for worldwide 3. Set the spark gap length on the adjusting knob. È for usa and canada É for...

  • Page 375

    62y3a11 8-14 1 2 3 4 5 6 7 8 i checking the spark plug caps 1. Remove the spark plug caps from the high-tension cords by turning the caps counterclockwise. 2. Measure the spark plug cap resistance. Replace if out of specification. Checking the ignition coil 1. Remove the spark plug caps from the hig...

  • Page 376

    Elec electrical systems – + 8-15 62y3a11 checking the cdi unit 1. Measure the cdi unit output peak volt- age. If below specification, measure the charge coil output peak voltage and the pulser coil output peak voltage. Replace the cdi unit if the output peak voltage of both coils is above specificat...

  • Page 377

    62y3a11 8-16 1 2 3 4 5 6 7 8 i checking the pulser coil 1. Measure the pulser coil output peak volt- age. Replace the pulser coil if below specification. Warning when checking the peak voltage do not touch any of the connections of the digital tester leads. Note: • use the peak voltage adaptor with ...

  • Page 378

    Elec electrical systems – + 8-17 62y3a11 3. Remove the flywheel magnet nut and fly- wheel magnet. 4. Loosen the pulser coil screws, adjust the pulser coil 2 position, and then tighten the screws finger tight. 5. Set the flywheel magnet and then check the gap again and, if necessary, repeat steps 3–5...

  • Page 379

    62y3a11 8-18 1 2 3 4 5 6 7 8 i checking the thermoswitch 1. Place the thermoswitch in a container of water and slowly heat the water. 2. Check the switch for continuity at the specified temperatures. Replace if out of specification. A temperature b time c no continuity d continuity checking the oil ...

  • Page 380

    Elec electrical systems – + 8-19 62y3a11 starting system 8 1 fuse 2 10-pin coupler 3 engine start switch 4 starter motor 5 battery 6 neutral switch 7 starter relay È tiller handle model b : black br : brown r : red.

  • Page 381

    62y3a11 8-20 1 2 3 4 5 6 7 8 i checking the fuse 1. Check the fuse and fuse holder for conti- nuity. Replace if there is no continuity. Checking the wiring harness (10 pins) 1. Check the wiring harness for continuity. Replace if there is no continuity. Checking the neutral switch 1. Check the neutra...

  • Page 382

    Elec electrical systems – + 8-21 62y3a11 starter motor 8.

  • Page 383

    62y3a11 8-22 1 2 3 4 5 6 7 8 i no. Part name q’ty remarks tightening torques stage n·m kgf·m ft·lb 1 clip 1 2 pinion stopper 1 3 spring 1 4 starter motor pinion 1 5 upper bracket 1 6 o-ring 1 not reusable 7 washer 1 1 8 shim — as required 9 washer 2 1 10 armature 1 11 stator 1 12 o-ring 1 not reusab...

  • Page 384

    Elec electrical systems – + 8-23 62y3a11 removing the starter motor pinion 1. Slide the pinion stopper 1 down as shown, and then remove the clip 2. Checking the starter motor pinion 1. Check the pinion teeth for cracks or wear. Replace if necessary. 2. Check for smooth operation. Replace if necessar...

  • Page 385

    62y3a11 8-24 1 2 3 4 5 6 7 8 i 4. Measure the commutator undercut a. Replace the armature if out of specifica- tion. 5. Check the armature for continuity. Replace if out of specifications. Checking the brushes 1. Measure the brush length. Replace the brush assembly if out of specification. 2. Check ...

  • Page 386

    Elec electrical systems – + 8-25 62y3a11 charging system 8 1 lighting coil 2 rectifier regulator 3 fuse 4 battery b : black g : green r : red g/w : green/white.

  • Page 387

    62y3a11 8-26 1 2 3 4 5 6 7 8 i checking the lighting coil 1. Measure the lighting coil output peak voltage. Replace the stator coil if below specification. Warning when checking the peak voltage do not touch any of the connections of the digital tester leads. Note: • use the peak voltage adaptor wit...

  • Page 388

    Elec electrical systems – + 8-27 62y3a11 note: after starting the engine, disconnect the out- put lead (red lead) of the rectifier regulator when measuring the output peak voltage. Rectifier regulator output peak voltage: red (r) – black (b) r/min unloaded 1,500 3,500 dc v 18.9 19.5.

  • Page 389: — Memo —

    62y3a11 8-28 1 2 3 4 5 6 7 8 i — memo —.

  • Page 390

    Index i-1 62y3a11 a. Acceleration pump ....................................1-15 adjusting the dash-pot (acceleration pump) ................................4-24 adjusting the pilot screw ...........................4-22 adjusting the throttle link rod.....................4-21 adjusting the trim sensor...

  • Page 391

    62y3a11 i-2 1 2 3 4 5 6 7 8 checking the piston diameter ...................5-56 checking the piston pin.............................5-58 checking the piston pin boss bore............5-58 checking the piston ring grooves..............5-58 checking the piston ring side clearance ...5-58 checking the ...

  • Page 392

    Index i-3 62y3a11 h. Hose routing................................................4-2 how to use this manual...............................1-1 i. Identification................................................1-5 ignition system ..........................................1-17 ignition system and igniti...

  • Page 393

    62y3a11 i-4 1 2 3 4 5 6 7 8 special service tools ..................3-1 , 4-1 , 5-10 , 6-1 , 7-4 , 8-2 specified torques ......................................2-29 starboard and port views ............................8-5 starter motor .............................................8-21 starting system...

  • Page 394

    Wiring diagram f50aehd, f50aed, ft50cehd, ft50ced 1 battery 2 engine start switch 3 engine shut-off switch 4 starter motor 5 starter relay 6 neutral switch 7 fuse (20a) 8 prime start 9 warning indicator 0 cdi unit a thermoswitch b oil pressure switch c charge coil d pulser coil e lighting coil f rec...

  • Page 395

    Wiring diagram f50th/f50aeht 1 battery 2 power trim and tilt motor 3 engine start switch 4 power trim and tilt relay 5 engine shut-off switch 6 starter motor 7 starter relay 8 neutral switch 9 fuse (20a) 0 warning indicator a prime start b power trim and tilt switch c cdi unit d thermoswitch e charg...

  • Page 396

    Wiring diagram (applicable for tachometer, trim meter or warning buzzer) f50th/f50aeht* 1 battery 2 power trim and tilt motor 3 power trim and tilt relay 4 starter motor 5 fuse (20a) 6 neutral switch 7 starter relay 8 prime start 9 cdi unit 0 charge coil a lighting coil b pulser coil c rectifier reg...

  • Page 397

    Wiring diagram f50tr/f50aet, t50tr/ft50bet, ft50cet 1 battery 2 power trim and tilt motor 3 power trim and tilt relay 4 starter motor 5 fuse (20a) 6 trim sensor 7 prime start 8 starter relay 9 cdi unit 0 charge coil a lighting coil b pulser coil c rectifier regulator d thermoswitch e oil pressure sw...

  • Page 399

    Yamaha motor co., ltd. Printed in the netherlands nov. 2000 – 1.4 × 1 cr (f50aehd, f50aeht, f50aed, f50aet, ft50bet, ft50cehd, ft50ced, ft50cet).

  • Page 400

    R br p w off on st b f50aehd, f50aed, ft50cehd, ft50ced l br g g g w/b w/r w/b w/r w/b g/w g/w g/w w/r g/w g g g g l r b g g g r g/w b l g b r p p w/b w/r l br p/b y/r b/o w y/b b/w p/w o b p b/w b/w b/o b/o p w b y/b p/b y/r p/w y/b p/b y/r p/w p/b y/b y/b p/b p/w y/r y/r p/w b br l b b w b b p/w y...

  • Page 401

    Sb r lg up free down sb r lg up free down r br p w off on st b f50th/f50aeht l br g g g w/b w/r w/b w/r g/w g/w g/w g/w g g g g l r b g g g r g/w b l g b r p/b y/r b/o w y/b b/w p/w o b b/w b/w b/o b/o p w b y/b p/b y/r p/w y/b p/b y/r p/w p/b y/b y/b p/b p/w y/r y/r p/w b br l b w b b p/w y/r b/o b...

  • Page 402

    Sb r lg up free down sb r lg up free down r br y w off on st b f50th/f50aeht ∗ j p b p b gy gy b l br g g g w/b w/r w/b w/r g/w g/w g/w g/w g g g g l r b g g g r g/w b l g b r p/b y/r b/o w y/b b/w p/w o b b/w b/w b/o b/o p w b y/b p/b y/r p/w y/b p/b y/r g/w g/r p/b p/w g/w y/b p/b p/b g/r y/r p/w ...

  • Page 403

    Sb r lg up free down y gy/b f50tr/f50aet, t50tr/ft50bet, ft50cet l b l br g g g w/b w/r w/b w/r g/w g/w g/w g/w g g g g l r b g g g r g/w b l g b r p/b y/r b/o w y/b b/w p/w o b b/w b/o b/w b/o p w b y/b p/b y/r p/w y/b p/b y/r p/w y/b p/b y/r p/w b br l b b w b b p/w y/r b/o b/w y/b p/b b/o p/w y/r...