Yamaha 55D, 75A, 85A Service Manual

55D 75A 85A

SERVICE MANUAL

688-28197-5J-11

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 concepts and procedures inherent in the work, for without such knowledge attempted repairs or service to the equipment could render it unsafe or unfit for use.

Because Yamaha has a policy of continuously improving its products, models may differ in detail from the descriptions and illustrations given in this publication. Use only the latest edition of this manual. Authorized Yamaha dealers are notified periodically of modifications and significant changes in specifications and procedures, and these are incorporated in successive editions of this manual.

Important information

Particularly important information is distinguished in this manual by the following notations:

Q The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS

INVOLVED!

Failure to follow WARNING instructions could result in severe injury or death to the machine operator, a bystander, or a person inspecting or repairing the outboard motor.

A CAUTION indicates special precautions that must be taken to avoid damage to the outboard motor.

NOTE:

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

55D, 75A, 85A

SERVICE MANUAL

1st Edition, October 2006

Any reprinting or unauthorized use

without the written permission of

Yamaha Motor Co., Ltd. is expressly prohibited.

Printed in Japan

Contents

General information

Specification

Periodic check and adjustment

Fuel system

Power unit

GEN

INFO

SPEC

CHK

ADJ

FUEL

POWR

1 2 3 4 5

Lower unit

Bracket unit

Electrical system

Troubleshooting

Index

LOWR

BRKT

ELEC

TRBL SHTG

6 7 8 9

GEN

INFO

General information

How to use this manual................................................................................ 1-1

Manual format........................................................................................... 1-1

Symbol...................................................................................................... 1-2

Abbreviation.............................................................................................. 1-3

Safety while working ................................................................................... 1-4

Fire prevention ......................................................................................... 1-4

Ventilation ................................................................................................ 1-4

Self-protection ......................................................................................... 1-4

Part, lubricant, and sealant ...................................................................... 1-4

Good working practice ............................................................................. 1-5

Disassembly and assembly ..................................................................... 1-5

Identification ................................................................................................. 1-6

Model ....................................................................................................... 1-6

Serial number .......................................................................................... 1-6

1 2 3

Special service tool ..................................................................................... 1-7

Propeller selection ..................................................................................... 1-13

Propeller size ......................................................................................... 1-13

Selection ................................................................................................ 1-13

Predelivery check ....................................................................................... 1-13

Checking the fuel system ...................................................................... 1-13

Checking the gear oil ............................................................................. 1-14

Checking the battery ............................................................................. 1-14

Checking the outboard motor mounting height ..................................... 1-14

Checking the remote control cable (ED, ET) ......................................... 1-14

Checking the steering system ............................................................... 1-15

Checking the PTT system (ET) ............................................................. 1-15

Checking the gear shift and throttle operation ...................................... 1-16

Checking the engine start switch and engine stop lanyard switch ........ 1-16

Checking the cooling water pilot hole .................................................... 1-17

Test run .................................................................................................. 1-17

Break-in ................................................................................................. 1-17

After test run .......................................................................................... 1-18

4 5 6 7 8

6885J11

GEN

LOWR

Lower unit

6-5

62Y5A11

Lower unit

No. Part name Q’ty Remarks

1 Lower unit 1

2 Plastic tie 1

Not reusable

3Hose 1

4 Check screw 1

5 Gasket 2

Not reusable

6 Dowel pin 2

7 Bolt 4 M10 40 mm

8 Drain screw 1

9Grommet 1

10 Bolt 1 M10 45 mm

11 Bolt 1 M8 60 mm

12 Thrust washer 1

13 Propeller 1

14 Washer 1

15 Washer 1

16 Cotter pin 1

Not reusable

17 Propeller nut 1

18 Trim tab 1

LOWR

Lower unit

6-19

62Y5A11

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 , tighten it finger tight, and then remove the drive shaft bearing using a press.

CAUTION:

• Do not press the drive shaft threads

directly.

Do not reuse the bearing, always

replace it with a new one.

Disassembling the forward gear

1. Remove the taper roller bearing from the forward gear using a press.

CAUTION:

Do not reuse the bearing, always replace it with a new one.

2. Remove the needle bearing from the forward gear.

CAUTION:

Do not reuse the bearing, always replace it with a new one.

Drive shaft holder 4 : 90890-06518 Pinion nut holder : 90890-06505 Socket adapter 2 : 90890-06507

Bearing inner race attachment :

90890-06639

S62Y6850K

Bearing separator : 90890-06534

Stopper guide plate : 90890-06501 Stopper guide stand :

90890-06538 Bearing puller : 90890-06535 Bearing puller claw 1 :

90890-06536

S62Y6740K

1 2 3

6F660190

INFO

How to use this manual

Manual format

The format of this manual has been designed to make service procedures clear and easy to understand. Use the information below as a guide for effective and quality service.

General information

9 Parts are shown and detailed in an exploded diagram and are listed in the components list (see

in the figure below for an example page).

9 The component list consists of part names and quantities, as well as bolt and screw dimensions

(see

2 in the figure below).

9 Symbols are used to indicate important aspects of a procedure, such as the grade of lubricant and

lubrication point (see

9 Tightening torque specifications are provided in the exploded diagrams (see

3 in the figure below).

4 in the figure below

for an example), and in the related detailed instructions. Some torque specifications are listed in stages as torque figures or angles in degrees.

9 Separate procedures and illustrations are used to explain the details of removal, checking, and

installation where necessary (see

5 in the figure below for an example page).

NOTE:

For troubleshooting procedures, see Chapter 9, “Troubleshooting.”

1-1

6885J11

How to use this manual

Symbol

The symbols below are designed to indicate the content of a chapter.

General information Fuel system Bracket unit

GEN

INFO

Specification Power unit Electrical system

SPEC POWR ELEC

Periodic check and adjustment

CHK

ADJ

Symbols 1 to 6 indicate specific data.

123456

1 Special tool 2 Specified oil or fluid 3 Specified engine speed 4 Specified tightening torque

FUEL BRKT

Lower unit Troubleshooting

LOWR

5 Specified measurement 6 Specified electrical value

(resistance, voltage, electric current)

TRBL

SHTG

1 2 3 4 5

Symbols 7 to e in an exploded diagram or illustration indicate the grade of lubricant and the lubrication point.

78 0qwe

7 Apply Yamaha 2-stroke motor oil 8 Apply gear oil 9 Apply water resistant grease (Yamaha grease A) 0 Apply molybdenum disulfide grease

Symbols r to o in an exploded diagram or illustration indicate the type of sealant or locking agent and the application point.

rtyuio

r Apply Gasket Maker t Apply ThreeBond 1104J y Apply LOCTITE 271 (red)

6885J11

q Apply corrosion resistant grease

(Yamaha grease D)

w Apply low temperature resistant grease

(Yamaha grease C)

e Apply injector grease

u Apply LOCTITE 242 (blue) i Apply LOCTITE 572 o Apply silicone sealant

6 7 8 9

1-2

GEN

INFO

Abbreviation

The following abbreviations are used in this service manual.

Abbreviation Description

AFT Aft end

API American Petroleum Institute

ATDC After Top Dead Center

ATF Automatic Transmission Fluid

BOW Bow end

BTDC Before Top Dead Center

CCA Cold Cranking Ampere

CDI Capacitor Discharged Ignition system

DN Downside or downward

EN European Norm (European standard)

F Forward

IEC International Electrotechnical Commission

LED Light-Emitting Diode

N Neutral

NMMA National Marine Manufacturers Association

PCV Pressure Control Valve

PORT Port side

PTT Power Trim and Tilt

R Reverse

SAE Society of Automotive Engineers

STBD Starboard side

General information

TDC Top Dead Center

UP Upside or upward

WD Wiring Diagram

1401 ThreeBond 1401

1-3

6885J11

Safety while working

To prevent an accident or injury and to ensure quality service, follow the safety procedures provided below.

How to use this manual / Safety while working

Fire prevention

Gasoline is highly flammable. Keep gasoline and all flammable products away from heat, sparks, and open flames.

Ventilation

Gasoline vapor and exhaust gas are heavier than air and extremely poisonous. If inhaled in large quantities they may cause loss of consciousness and death within a short time. When test running an engine indoors (e.g., in a water tank) be sure to do so where adequate ventilation can be maintained.

Part, lubricant, and sealant

Use only genuine Yamaha parts, lubricants, and sealants or those recommended by Yamaha, when servicing or repairing the outboard motor.

Under normal conditions, the lubricants mentioned in this manual should not harm or be hazardous to your skin. However, you should follow these precautions to minimize any risk when working with lubricants.

1 2 3 4 5 6

Self-protection

Protect your eyes by wearing safety glasses or safety goggles during all operations involving drilling and grinding, or when using an air compressor. Protect your hands and feet by wearing protective gloves and safety shoes when necessary.

6885J11

1. Maintain good standards of personal and industrial hygiene.

2. Change and wash clothing as soon as possible if soiled with lubricants.

3. Avoid contact with skin. Do not, for example, place a soiled rag in your pocket.

4. Wash hands and any other part of the body thoroughly with soap and hot water after contact with a lubricant or lubricant soiled clothing has been made.

5. To protect your skin, apply a protective cream to your hands before working on the outboard motor.

1-4

7 8 9

GEN

INFO

General information

6. Keep a supply of clean, lint-free cloths for wiping up spills, etc.

Good working practice

Special service tool

Use the recommended special service tools to protect parts from damage. Use the right tool in the right manner–do not improvise.

Tightening torque

Follow the tightening torque specifications provided throughout the manual. When tightening nuts, bolts, and screws, tighten the large sizes first, and tighten fasteners starting in the center and moving outward.

Non-reusable part

Always use new gaskets, seals, O-rings, cotter pins, circlips, etc., when installing or assembling parts.

Disassembly and assembly

1. Use compressed air to remove dust and dirt during disassembly.

2. Apply engine oil to the contact surfaces of moving parts before assembly.

3. Install bearings with the manufacture identification mark in the direction indicated in the installation procedure. In addition, be sure to lubricate the bearings liberally.

4. Apply a thin coat of water-resistant grease to the lip and periphery of an oil seal before installation.

5. Check that moving parts operate normally after assembly.

1-5

6885J11

68810010

Safety while working / Identification

Identification

Model

This manual covers the following models.

Applicable model

55DEHD,

75AEHD, 75AED, 75AET,

85AEHD, 85AED, 85AET

Serial number

The outboard motor serial number is stamped on a label attached to the port clamp bracket.

Model name

55DEHD 63S 1001700–

75AEHD

75AED 692 1020817–

75AET

85AEHD

85AED 688 1013061–

85AET

Approved Starting

model code serial No.

1 2 3 4

1 Model name 2 Approved model code 3 Transom height 4 Serial number

5 6 7 8 9

6885J11

1-6

GEN

Digital tachometer 90890-06760

Timing light 90890-03141

Dial gauge set 90890-01252

Leakage tester 90890-06840

Vacuum/pressure pump gauge set 90890-06756

Test propeller 90890-01620

Compression gauge 90890-03160

Flywheel holder 90890-06522

Flywheel puller 90890-06521

Gear puller 90890-06540

INFO

Special service tool

General information

1-7

6885J11

Special service tool

Bearing Separator 90890-06534

Cylinder gauge 90890-06759

Support 90890-02394

Bearing pressure C 90890-02393

Driver rod SS 90890-06604

Needle bearing attachment 90890-06607, 90890-06608, 90890-06611,

90890-06612, 90890-06615, 90890-06632, 90890-06636, 90890-06655

Driver rod LS 90890-06606

Bearing inner race attachment 90890-06639, 90890-06640, 90890-06643

Small end bearing installer 90890-06527

Piston slider 90890-06530

1 2 3 4 5 6 7 8

6885J11

1-8

GEN

Ring nut wrench 3 90890-06511

Ring nut wrench extension 90890-06513

Stopper guide plate 90890-06501

Bearing housing puller claw L 90890-06502

Center bolt 90890-06504

Stopper guide stand 90890-06538

Bearing puller assembly 90890-06535

Driver rod L3 90890-06652

Bearing depth plate 90890-06603

Drive shaft holder 5 90890-06519

INFO

General information

1-9

6885J11

Special service tool

Pinion nut holder 90890-06715

Socket adapter 2 90890-06507

Bearing outer race puller assembly 90890-06523

Driver rod SL 90890-06602

Bearing outer race attachment 90890-06621, 90890-06625, 90890-06626,

90890-06628

Driver rod LL 90890-06605

Shift rod push arm 90890-06052

Pinion height gauge plate B 90890-06712

Pinion height gauge 90890-06710

Digital caliper 90890-06704

1 2 3 4 5 6 7 8

6885J11

1-10

GEN

Shimming plate 90890-06701

Backlash indicator 90890-06706

Magnet base plate 90890-07003

Magnet base B 90890-06844

Test harness 90890-06878

PTT oil pressure gauge assembly 90890-06580

Cylinder-end screw wrench 90890-06568

PTT piston vice attachment 90890-06572

Tilt rod wrench 90890-06569

Trim and tilt wrench 90890-06587

INFO

General information

1-11

6885J11

Special service tool

Throttle sensor adjusting lead 90890-06857

Test harness 90890-06871

Digital circuit tester 90890-03174

Peak voltage adapter B 90890-03172

Ignition tester 90890-06754

1 2 3 4 5 6 7 8

6885J11

1-12

GEN

abc

68810020

68810030

abc

INFO

General information

Propeller selection

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 incorrect choice could adversely affect performance and could also seriously damage the engine. Use the following information as a guide for selecting a propeller that meets the operating conditions of the boat and the outboard motor.

Propeller size

The size of the propeller is indicated as shown.

Propeller size (in) Material

12 5/8 × 21 - K

13 × 19 - K

13 1/4 × 17 - K Aluminum

13 1/2 × 15 - K

13 5/8 × 13 - K

13 × 17 - K

13 × 19 - K

13 × 21 - K

13 × 23 - K

Stainless steel

13 × 25 - K

13 1/2 × 14 - K

13 1/2 × 16 - K

14 × 11 - K

Predelivery check

To make the delivery process smooth and efficient, the predelivery check should be completed as explained below.

a Propeller diameter (in inches) b Propeller pitch (in inches) c Propeller type (propeller mark)

Selection

When the engine speed is at the full throttle operating range (4,500–5,500 r/min), the ideal propeller for the boat is one that provides maximum performance in relation to boat speed and fuel consumption.

Checking the fuel system

1. Check that the fuel hoses is securely connected and that the fuel tank is filled with fuel.

68810040

Use pre-mixed fuel only. Fuel and oil mixing ratio is 50:1. For breakin period, 25:1 mixture shall be used.

1-13

6885J11

Checking the gear oil

69D10055

69D10080

1. Check the gear oil level.

Propeller selection / Predelivery check

Recommended gear oil:

Hypoid gear oil

API: GL-4 SAE: 90

Oil quantity:

610 cm (20.62 US oz, 21.51 Imp oz)

Checking the battery

1. Check the capacity, electrolyte level, and specified gravity of the battery.

Recommended battery capacity:

CCA/EN: 430 A 20HR/IEC: 70 Ah

Electrolyte specified gravity:

1.280 at 20°C (68°F)

2. Check that the positive and negative battery cable are securely connected.

NOTE:

The optimum mounting height is affected by the combination of the boat and the outboard motor. To determine the optimum mounting height, test run the outboard motor at different heights.

2. Check that the clamp brackets are secured with the mounting bolts.

Checking the remote control cable (ED, ET)

1. Set the remote control lever to “N” posi- tion and the throttle lever to fully-closed position.

2. Check that the control lever 1 is in its fully-closed position and check that the adjusting screw 2 is contact the stopper

2 3 4 5 6

Checking the outboard motor mounting height

1. Check that the anti-cavitation plate is aligned with the bottom of the boat. If the mounting height is too high, cavitation will occur and propulsion will be reduced. Also, the engine speed will increase abnormally and cause the engine to overheat. If the mounting height is too low, water resistance will increase and reduce engine efficiency.

6885J11

68810050

3. Fully open the remote control lever, and

then check that the control lever 1 is in its fully-opened position.

1-14

GEN

68810060

68810070

6D430227

68810090

68810100

INFO

General information

4. Check that the control lever 1 comes in contact with the adjusting screw 4.

NOTE:

To adjust the throttle cable, refer to page 3-7.

5. Set the remote control lever is in “N” posi- tion, and then check that the mark a on the bracket 5 is aligned with the mark b on the shift lever 6.

Checking the steering system

1. Check that the steering operates smoothly.

2. Check that there is no interference with wires or hoses when the outboard motor is steered.

6. Check that the screwed length of the shift

/ throttle cable joint 7 .

The shift / throttle cable joint 7 must be screwed in a minimum of 8.0 mm (0.31 in) c.

Checking the PTT system (ET)

1. Check that the outboard motor tilts up and down smoothly when operating the PTT unit.

2. Check that there is no abnormal noise produced when the outboard motor is tilted up or down.

3. Check that there is no interference with wires or hoses when the tilted up outboard motor is steered.

4. Check that the trim meter points down when the outboard motor is tilted all the way down.

1-15

6885J11

69R10200

∫

68810120

6S310110

68810110

∫

6F610120

Predelivery check

Checking the gear shift and throttle operation

1. Check that the gear shift operates smoothly when the shift lever or remote control lever is shifted from “N” to “F” or “R” position.

2. Check that the throttle operates smoothly when the throttle grip (tiller handle model) is turned from the fully-closed position to the fully-opened position a. Check that the throttle operates smoothly when the remote control lever (remote control model) is shifted from “F” or “R” position to the fully-opened positions b.

Checking the engine start switch and engine stop lanyard switch

1. Check that the engine starts when the engine start switch is turned to START.

2. Check that the engine turns off when the engine start switch is turned to OFF.

1 2 3 4

å Fully-closed position ∫ Fully-opened position

å EHD ∫ ED, ET

3. Check that the choke solenoid operates when the engine start switch is pushed in. (ED, ET)

5 6 7 8 9

6885J11

1-16

GEN

68810130

69D10215

69R11220

∫

INFO

General information

4. Check that the engine turns off when the engine stop lanyard is pulled from the engine stop lanyard switch.

Test run

1. Start the engine, and then check that the gear shift operates smoothly.

2. Check that the engine idle speed after the engine has been warmed up.

3. Operate at trolling speed.

4. Run the outboard motor for 1 hour at 3,000 r/min or at half throttle, then for another hour at 4,000 r/min or at 3/4 throttle.

5. Check that the outboard motor does not tilt up when shifting into reverse and that water does not flow in over the transom.

NOTE:

The test run is part of the break-in operation.

å EHD ∫ ED, ET

Checking the cooling water pilot hole

1. Start the engine, and then check for a water flow from the cooling water pilot hole.

Break-in

During the test run, perform the break-in operation in the following 5 stages.

1. 10 minutes a at the lowest possible

speed. A fast idle in neutral is best.

2. 50 minutes b at 1/2 throttle (approxi-

mately 3,000 r/min) or less. Vary engine speed occasionally. On an easy-planing boat, accelerate at full throttle onto plane, then immediately reduce the throttle to 3,000 r/min or less.

3. 1 hour c at 3/4 throttle (approximately

4,000 r/min). Vary engine speed occasionally. Run at full throttle for 1 minute, then allow about 10 minutes of operation at 3/4 throttle or less to let the engine cool.

4. 8 hours d at any speed, but avoid oper-

ating at full throttle for more than 5 minutes at a time. Let the engine cool between full-throttle runs. Vary engine speed occasionally.

1-17

6885J11

5. After the first 10 hours. Use standard pre-

6F610180

12 10

6S310070

mix ratio of fuel and oil. Refer to page 1-13.

å Hours

Predelivery check

1 2

After test run

1. Check for water in the gear oil.

2. Check for fuel leakage in the cowling.

3. Install the flushing kit 1.

4. Set the gear shift to “N” position, and then flush the cooling water passage with engine running at idle.

3 4 5 6 7

Be sure to supply sufficient water when flushing the cooling water passage, otherwise the engine may overheat.

9 Be sure to remove the propeller before

using the flushing kit.

9 Keep hands, hair and clothes away from

the propeller shaft while the engine is running.

6885J11

8 9

1-18

GEN

INFO

General information

— MEMO —

1-19

6885J11

SPEC

Specification

General specification.....................................................................................2-1

Maintenance specification ............................................................................2-5

Power unit (55D, 75A models)...................................................................2-5

Lower unit (55D, 75A models) ...................................................................2-7

Electrical (55D, 75A models) .....................................................................2-7

Power unit (85A models) .........................................................................2-10

Lower unit (85A models)..........................................................................2-12

Electrical (85A models)............................................................................2-12

Dimension................................................................................................2-15

Tightening torque.........................................................................................2-19

Specified torque.......................................................................................2-19

General torque.........................................................................................2-21

1 2 3 4 5 6 7 8 9

6885J11

SPEC

Specification

General specification

Item Unit

Dimension

Overall length mm (in) 1,337 (52.6) 726 (28.6) Overall width mm (in) 398 (15.7) 374 (14.7) Overall height

(L) mm (in) 1,422 (56.0) (X) mm (in) — 1,548 (60.9) —

Boat transom height

(L) mm (in) 508 (20.0) (X) mm (in) — 635 (25.0) —

Weight

(with aluminum propeller) (L) kg (lb) 116 (256) 111 (245) 119 (262) (X) kg (lb) — 119 (262) 114 (251) — (with stainless propeller) (L) kg (lb) 118 (260) 113 (249) 121 (267) (X) kg (lb) — 121 (267) 116 (256) —

Performance

Maximum output kW (hp) 40.5 (55) at 55.2 (75) at

Full throttle operating range r/min 4,500–5,500 Maximum fuel consumption L 31 34

(US gal, (8.2, 6.8) (9.0, 7.5)

lmp gal)/hr 5,500 r/min 5,500 r/min

Engine idle speed r/min 750–850

Power unit

Engine type 2-stroke, L Cylinder quantity 3

Total displacement cm Bore x stroke mm (in) 82.0 Compression ratio 4.5 :1 Intake system Reed valve Scavenging system Loop charge Control system Tiller handle Remote control Starting system Electric Fuel system Carburetor Ignition control system CDI Maximum generator output V, A 12, 10 Starting enrichment Choke valve Spark plug B8HS-10 (NGK)

(cu. in) 1,140 (69.57)

55DEHD 75AEHD 75AED 75AET

5,000 r/min 5,000 r/min

Model

× 72.0 (3.23 × 2.83)

BR8HS-10 (NGK)

2-1

6885J11

General specification

Item Unit

Cooling system Water Exhaust system Propeller boss Lubrication system Pre-mixed fuel and oil

Fuel and oil

Fuel type Regular unleaded gasoline Engine oil 2-stroke outboard motor oil Engine oil grade NMMA-certified TC-W3 Gear oil type Hypoid gear oil Gear oil grade (*1) API GL-4

SAE 90

Gear oil quantity cm

Bracket unit

Trim angle Degree -4.0 to 15.0 (at 12° boat transom) Tilt-up angle Degree 67.0 Steering angle Degree 30 + 30

Drive unit

Gear shift positions F-N-R Gear ratio 2.00 (26/13) Reduction gear type Spiral bevel gear Clutch type Dog clutch Propeller shaft type Spline Propeller direction (rear view) Clockwise Propeller ID mark K

Electrical

Battery minimum capacity (*2) CCA/EN A 430 20HR/IEC Ah 70

(US oz, 610 (20.62, 21.51)

lmp oz)

55DEHD 75AEHD 75AED 75AET

Model

1 2 3 4 5 6

(*1) Meeting both API and SAE requirements (*2) CCA: Cold Cranking Ampere

EN: European Norm (European standard) IEC: International Electrotechnical Commission

6885J11

7 8 9

2-2

SPEC

Specification

Item Unit

85AEHD 85AED 85AET

Model

Dimension

Overall length mm (in) 1,337 (52.6) 726 (28.6) Overall width mm (in) 398 (15.7) 374 (14.7) Overall height

(L) mm (in) 1,422 (56.0) (Y) mm (in) 1,473 (58.0) — (X) mm (in) — 1,548 (60.9)

Boat transom height

(L) mm (in) 508 (20.0) (Y) mm (in) 559 (22.0) — (X) mm (in) — 635 (25.0)

Weight

(with aluminum propeller) (L) kg (lb) 119 (262) 111 (245) 119 (262) (Y) kg (lb) 120 (265) — (X) kg (lb) — 114 (251) 122 (269) (with stainless propeller) (L) kg (lb) 121 (267) 113 (249) 121 (267) (Y) kg (lb) 122 (269) — (X) kg (lb) — 116 (256) 124 (273)

Performance

Maximum output kW (hp) 62.5 (85) at 5,000 r/min Full throttle operating range r/min 4,500–5,500 Maximum fuel consumption L 35

(US gal, (9.2, 7.7) at 5,500 r/min

lmp gal)/hr

Engine idle speed r/min 750–850

Power unit

Engine type 2-stroke, L Cylinder quantity 3

Total displacement cm

(cu. in) 1,140 (69.57) Bore x stroke mm (in) 82.0 × 72.0 (3.23 × 2.83) Compression ratio 5.1 :1 Intake system Reed valve Scavenging system Loop charge Control system Tiller handle Remote control Starting system Electric Fuel system Carburetor Ignition control system CDI Maximum generator output V, A 12, 10 Starting enrichment Choke valve Spark plug B8HS-10 (NGK)

BR8HS-10 (NGK)

2-3

6885J11

General specification

Item Unit

Cooling system Water Exhaust system Propeller boss Lubrication system Pre-mixed fuel and oil

Fuel and oil

Fuel type Regular unleaded gasoline Engine oil 2-stroke outboard motor oil Engine oil grade NMMA-certified TC-W3 Gear oil type Hypoid gear oil Gear oil grade (*1) API GL-4

SAE 90

Gear oil quantity cm

Bracket unit

Trim angle Degree -4.0 to 15.0 (at 12° boat transom) Tilt-up angle Degree 67.0 Steering angle Degree 30 + 30

Drive unit

Electrical

Battery minimum capacity (*2) CCA/EN A 430 20HR/IEC Ah 70

(US oz, 610 (20.62, 21.51)

lmp oz)

85AEHD 85AED 85AET

Model

1 2 3 4 5 6

(*1) Meeting both API and SAE requirements (*2) CCA: Cold Cranking Ampere

EN: European Norm (European standard) IEC: International Electrotechnical Commission

6885J11

7 8 9

2-4

SPEC

Specification

Maintenance specification

Power unit (55D, 75A models)

Item Unit

Power unit

Minimum compression kPa 340 pressure (*1) at electric starter (kgf/cm2, psi) (3.4, 49)

Cylinder head

Warpage limit mm (in) 0.1 (0.0039)

(lines indicate straightedge position)

Cylinder

Bore size mm (in) 82.000–82.020 (3.2283–3.2291)

Piston

Piston diameter (D) mm (in) 81.935–81.955 (3.2258–3.2266) Measuring point (H) mm (in) 20.0 (0.79) Piston clearance mm (in) 0.065–0.070 (0.0026–0.0028) (reference data) Piston pin boss bore mm (in) 19.904–19.915 (0.7836–0.7841) Oversize piston

1st mm (in) 0.25 (0.010) 2nd mm (in) 0.50 (0.020)

Oversize piston diameter

1st mm (in) 82.185–82.205 (3.2356–3.2364) 2nd mm (in) 82.435–82.455 (3.2455–3.2463)

Piston pin

Outside diameter mm (in) 19.895–19.900 (0.7833–0.7835)

55DEHD 75AEHD 75AED 75AET

Model

(*1) Measuring conditions:

Ambient temperature 20°C (68°F), wide open throttle, with spark plugs removed from all cylinders. The figures are for reference only.

2-5

6885J11

+ 239 hidden pages

Yamaha 55D, 75A, 85A Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

General information

How to use this manual

Safety while working

Identification

Special service tool

Propeller selection

Predelivery check

Specification

General specification

Maintenance specification