Yamaha F50, F60 User Manual

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F50F

FT50G

F60C

FT60D

290551

SERVICE MANUAL

6C1-28197-3G-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:

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

WARNING

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.

CAUTION:

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.

F50F, FT50G, F60C, FT60D

SERVICE MANUAL

1st Edition, July 2004

Any reprinting or unauthorized use

without the written permission of

Yamaha Motor Co., Ltd. is expressly prohibited.

Printed in the Netherlands

General information

Specifications

Periodic checks and adjustments

Fuel system

Power unit

GEN

INFO

SPEC

CHK

ADJ

FUEL

POWR

1 2 3 4 5

Lower unit

Bracket unit

Electrical systems

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

Symbols.....................................................................................................1-2

Safety while working......................................................................................1-3

Fire prevention...........................................................................................1-3

Ventilation..................................................................................................1-3

Self-protection ...........................................................................................1-3

Parts, lubricants, and sealants ..................................................................1-3

Good working practices .............................................................................1-4

Disassembly and assembly .......................................................................1-4

1 2

Identification...................................................................................................1-4

Applicable models .....................................................................................1-4

Serial number ............................................................................................1-5

Outline of features .........................................................................................1-6

Features and benefits....................................................................................1-7

Fuel system ...............................................................................................1-7

Solenoid valve ...........................................................................................1-8

Electronic control system...........................................................................1-9

ECM (Electric Control Module) ................................................................1-10

Variable trolling RPM switch (optional)....................................................1-11

Propeller selection.......................................................................................1-12

Propeller size...........................................................................................1-12

Selection..................................................................................................1-12

Predelivery checks ......................................................................................1-13

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

Checking the engine oil level...................................................................1-13

Checking the gear oil level ......................................................................1-13

Checking the battery................................................................................1-13

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

Checking the remote control cables ........................................................1-14

Checking the steering system .................................................................1-14

Checking the gear shift and throttle operation.........................................1-15

Checking the power trim and tilt system..................................................1-15

Checking the hydro tilt system.................................................................1-15

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

Checking the cooling water pilot hole ......................................................1-16

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

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

After test run ............................................................................................1-17

3 4 5 6 7 8 9

6C13G11

GEN

INFO

General information

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.

Parts are shown and detailed in an exploded diagram and are listed in the components list.

Tightening torque specifications are provided in the exploded diagrams and after a numbered step with tightening instructions.

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

The components list consists of part names and part quantities, as well as bolt and screw dimensions.

Service points regarding removal, checking, and installation are shown in individual illustrations to explain the relevant procedure.

NOTE:

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

40 mm

10 45 mm

60 mm

LOWR

Lower unit

No. Part name Q’ty Remarks

1 Lower unit 1

2 Plastic tie 1

3Hose 1

4 Check screw 1

5 Gasket 2

6 Dowel pin 2

7 Bolt 4 M10

8 Drain screw 1

9Grommet 1

10 Bolt 1 M

11 Bolt 1 M8

12 Thrust washer 1

13 Propeller 1

14 Washer 1

15 Washer 1

16 Cotter pin 1

17 Propeller nut 1

18 Trim tab 1

6-5

Lower unit

Not reusable

62Y5A11

LOWR

Removing the drive shaft

1. Remove the drive shaft assembly and pinion, and then pull out the forward gear.

Disassembling the drive shaft

1. Install the pinion nut 1, tighten it finger tight, and then remove the drive shaft bearing 2 using a press.

CAUTION:

• Do not 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.

Lower unit

S62Y6850K

Drive shaft holder 4 1: 90890-06518 Pinion nut holder 2: 90890-06505 Socket adapter 2 3: 90890-06507

Bearing inner race attachment 3:

90890-06639

CAUTION:

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

Bearing separator 1: 90890-06534

2. Remove the needle bearing from the forward gear.

CAUTION:

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

Stopper guide plate 2: 90890-06501 Stopper guide stand 3:

90890-06538 Bearing puller 4: 90890-06535 Bearing puller claw 1 5:

90890-06536

S62Y6740K

1-1

6-19

62Y5A11

6C13G11

Symbols

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

How to use this manual

General information

GEN

INFO

Specifications

SPEC

Periodic checks and adjustments

CHK

ADJ

Symbols 1 to 6 indicate specific data.

123456

Fuel system

FUEL

Power unit

POWR

Lower unit

LOWR

Bracket unit

BRKT

Electrical systems

ELEC

Troubleshooting

–+

TRBL

SHTG

1 2 3 4

Special tool

Specified oil or fluid

Specified engine speed

Specified tightening torque

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

7890ABC

A M

E G

Apply Yamaha 4-stroke motor oil

Apply gear oil

Apply water resistant grease (Yamaha grease A)

Apply molybdenum disulfide grease

Symbols D to H in an exploded diagram indicate the type of sealant or locking agent and the application point.

DEFGH

271

Specified measurement

Specified electrical value

(resistance, voltage, electric current)

C I

Apply corrosion resistant grease

(Yamaha grease D) Apply low temperature resistant grease

(Yamaha grease C) Apply injector grease

242

572

5 6 7 8 9

Apply Gasket Maker

Apply LOCTITE 271 (red)

Apply LOCTITE 242 (blue)

6C13G11

Apply LOCTITE 572

Apply silicon sealant

1-2

GEN

INFO

General information

Safety while working

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

Fire prevention

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

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.

Parts, lubricants, and sealants

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.

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.

1-3

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.

6C13G11

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

Good working practices

Special service tools

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

Tightening torques

Follow 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 parts

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

Safety while working / Identification

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.

Identification

Applicable models

This manual covers the following models.

Applicable models

F50FED, F50FEHT, F50FET, FT50GET,

F60CEHT, F60CET, FT60DET

1 2 3 4

5 6

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.

6C13G11

(*)

Hydro tilt model (For Europe)

(*)

Tiller handle model (For Oceania)

7 8 9

1-4

GEN

INFO

Serial number

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

General information

S6C11010

Model name

Approved model code

Transom height

Serial number

Model name

Approved

model code

Starting

serial No.

F50FED

6C1 1000001–F50FEHT

F50FET

FT50GET 6C2 1000001–

F60CEHT

6C5 1000001–

F60CET

FT60DET 6C6 1000001–

(*)

Hydro tilt model (For Europe)

(*)

Tiller handle model (For Oceania)

1-5

6C13G11

Identification / Outline of features

Outline of features

New electronic fuel injected F50 and F60 outboard motors have a mainly redesigned fuel and intake system based on the carbureted F60 outboard motor.

Power unit

• Single throttle body, single throttle valve

• Multi-point injection system, group injection

(#1/#4 and #2/#3)

• Group ignition system (#1/#4 and #2/#3)

• Large plastic intake manifold

• Compact plastic fuel rail

• Modularized intake system components

• Vapor separator with built-in pressure regulator

• Solenoid valve

• Fuel cooler

• Aluminum rocker arm

Electrical

• Compact electronic fuel injection system

• Self-diagnosis system and Yamaha Diagnostic

System

• Variable trolling RPM switch (optional for tiller handle model)

• Throttle position sensor with learning function (adjustment free)

• Compact charging system at low rpm

• Compact fuel injectors

• Fuel filter with water separator

1 2 3 4 5 6

Clamp bracket/upper case

• 2-piece upper case

• Upper portion case with oil sump

• Big capacity water wall structure around muffler

• Idle exhaust labyrinth structure

• Exclusive clamp bracket for permanent mount-

ing

Lower unit

• Same lower drive unit as carbureted F60 model

6C13G11

S6C11120

1-6

7 8 9

GEN

INFO

General information

Features and benefits

Fuel system

A pressure regulator is built into the vapor separator to obtain compact and simple fuel delivery structure. A plastic fuel rail is used to prevent it from corrosion and for light weight. Fuel discharged from the pressure regulator returns to the vapor separator after cooling down through the fuel cooler. The fuel joint is used on the high pressure fuel hose to remove and/or install the intake unit easily.

Fuel filter (Optional) Fuel tank

Primer pump

Fuel filter with water separator

Fuel pump (Mechanical)

Fuel filter

Vapor separator

Electric fuel pump

Fuel cooler

Pressure regulator

injector

Fuel

Fuel rail

Fuel

injector

#2 #3 #4

Fuel

injector

Fuel

injector

S6C11130

1-7

6C13G11

Features and benefits

Solenoid valve

Just after the engine is stopped, the cooling water supply is also stopped and the heat is conducted to the vapor separator from the engine, causing birth of many fuel vapor gases. The vapor gases are fed into the intake silencer to reburn them. However, many vapor gases are sucked into the combustion chambers, causing a rich air and fuel mixture, which is difficult to restart the engine. So the solenoid valve has been used for better restarting engine while the engine is warm. The solenoid valve stops the vapor gases not to return into the intake silencer.

1 2 3

Fuel tank

Fuel filter

Fuel pump

Fuel cooler

Return fuel hose

Pressure regulator

Solenoid valve

To throttle body

Fuel injector

Electric fuel pump

Fuel filter

Fuel

Vapor gas

4 5 6 7 8

6C13G11

1-8

GEN

INFO

Electronic control system

The electronic control system is built up by the sensors and the ECM (Electric control Module). The ECM receives signals from the sensors and determines the air and fuel mixture (A/F), and ignition timing. Under various condition, the ECM gives the best-suitable engine operation. In addition, warning control, fail-safe control, a self-diagnosis function, etc., are equipped to increase reliability.

General information

Sensor assembly

(intake air temperature and intake air pressure) ECM

Throttle position sensor

Oil pressure switch

Cooling water temperature sensor

Pulser coil

S6C11150

1-9

6C13G11

Features and benefits

ECM (Electric Control Module)

This engine is controlled by the ECM to obtain precision combustion under various operations, and can realize high power output, low fuel consumption, and low emission. The ECM controls the ignition timing, fuel injection timing, and the fuel injection volume, and ensures that the optimum ignition timing and air and fuel ratio can be achieved in all operating conditions such as engine starting, normal operation, and quick acceleration.

The self-diagnosis function is incorporated into the ECM and can be easily found a malfunction point by a personal computer with the optional software installed.

Pulser coil

Power source for sensors

Throttle position sensor

Intake air pressure sensor

Cooling water pressure sensor

Ground for sensors

Intake air temperature sensor

Cooling water temperature sensor

Shift position switch

Fuel injectors #1, #4

Fuel injectors #2, #3

Ignition coil #1, #4

Ignition coil #2, #3

Idle speed control (S1)

Idle speed control (S2)

Idle speed control (S3)

Idle speed control (S4)

Tachometer

Oil pressure warning indicator Overheat

warning

indicator Check engine warning indicator

Buzzer/DES switch

Solenoid valve

Fuel pump relay

23 6 20 21

DES switch

OUTPUTINPUT

Main relay

Relay

2 3 4

5 6 7

6C13G11

Flywheel

magnet

Rectifier Regulator

– +

Battery

Engine stop lanyard switch

Oil pressure switch

Variable trolling RPM switch (UP)

Variable trolling RPM switch (DOWN)

Ground for ECM

Ground

Battery (+)

Engine start switch

Main relay

Diagnosis

Power for diagnosis lamp

Self-diagnosis

8 9

S6C11160

1-10

GEN

INFO

Variable trolling RPM switch (optional)

This device is an optional equipment for tiller handle model. The idling and/or trolling rpm can be controlled in the range of 620 through 900 r/min with 50 r/min interval. Especially for 620 through 700 r/min, the engine rpm is controlled with 40 r/min interval. Pushing and holding the switch changes rpm continuously at 50 r/min interval. If engine rpm reaches to the ends of specified range, the rpm is no longer changed.

CAUTION:

Do not modify the variable trolling RPM switch. Modification such as wire extension, disassembly, etc., can malfunction for the system and/ or damage the electrical components.

NOTE:

Variable trolling RPM switch kit P/N: 6C5-W8186-00

General information

Variable trolling RPM switch (optional)

S6C11170

1-11

6C13G11

Features and benefits / Propeller selection

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 on a propeller blade, on the propeller boss end.

× -

Selection

When the engine speed is at the full throttle operating range (5,000–6,000 r/min), the ideal propeller for the boat is one that provides maximum performance in relation to boat speed and fuel consumption.

F50, F60

Propeller size (in) Material

10 × 15 - G

10 1/4 × 14 - G

10 3/8 × 13 - G

10 5/8 × 12 - G

10 3/4 × 16 - G

10 3/4 × 17 - G

Aluminum

11 × 15 - G

11 1/8 × 13 - G

11 1/4 × 14 - G

11 3/8 × 12 - G

11 5/8 × 11 - G

12 1/4 × 9 - G

1 2 3 4

× -

S69W1030

S69W1040

10 1/4 × 14 - G

10 1/4 × 15 - G

10 1/4 × 16 - G

10 5/8 × 13 - G

Stainless

11 1/4 × 14 - G

11 1/2 × 13 - G

11 3/4 × 12 - G

12 × 11 - G

FT50, FT60

Propeller size (in) Material

14 × 11 - K Aluminum

5 6 7 8 9

Propeller diameter (in inches)

Propeller pitch (in inches)

Propeller type (propeller mark)

6C13G11

S69W1050

1-12

GEN

INFO

General information

Predelivery checks

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.

NOTE:

If the engine oil is below the minimum level mark b, add sufficient oil until the level is between a and b.

Recommended engine oil:

4-stroke motor oil

API: SE, SF, SG, SH, or SJ SAE: 10W-30 or 10W-40

Engine oil quantity:

Without oil filter replacement:

2.5 L (2.64 US qt, 2.20 Imp qt)

Checking the gear oil level

1. Check the gear oil level.

CAUTION:

This is a 4-stroke engine. Never use premixed fuel.

Checking the engine oil level

1. Check the engine oil level.

S6C11030

S60V1290

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 leads are securely connected.

1-13

6C13G11

Predelivery checks

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.

S6C11080

4. Check that the edge of a shift rod e is aligned with the alignment mark f on the bottom cowling.

1 2 3 4

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 clamp bolts.

Checking the remote control cables

1. Set the remote control lever or shift lever to the neutral position and fully close the throttle lever or throttle grip.

2. Check that the set pin a is aligned with the alignment mark b.

3. Check that the alignment mark c is aligned with the mark d.

S6C11090

WARNING

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

Checking the steering system

1. Check the steering friction for proper adjustment.

S6C11110

5 6 7 8

6C13G11

1-14

GEN

INFO

General information

2. Check that the steering operates smoothly.

Tiller handle model

Remote control model

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

S69J1210

Tiller handle model

Remote control model

Checking the power trim and tilt system

1. Check that the outboard motor tilts up and down smoothly when operating the power trim and tilt unit.

Checking the gear shift and throttle operation

1. Check that the gear shift operates smoothly when the remote control lever or shift lever is shifted from neutral to forward or reverse.

2. Check that the throttle operates smoothly when the throttle grip (tiller handle model) is turned from the fully closed position to the fully open position a. Check that the throttle operates smoothly when the remote control lever (remote control model) is shifted from forward or reverse to the fully open position a.

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.

Checking the hydro tilt system

1. Check that the outboard motor tilts up and down smoothly.

2. Fully tilt the outboard motor up, and then lock the tilt stop lever 1 to check the lock mechanism of the hydro tilt. Replace the hydro tilt unit if necessary.

1-15

6C13G11

Predelivery checks

S6C11100

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

Tiller handle model

Remote control model

3. Check that the engine turns off when the engine stop lanyard switch is pushed or engine stop lanyard is pulled from the engine stop lanyard switch.

OFF

START

S60V1070

Tiller handle model

Remote control model

Checking the cooling water pilot hole

1. Check that cooling water is discharged from the cooling water pilot hole.

5 6 7 8 9

6C13G11

1-16

GEN

INFO

General information

Test run

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

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

3. Operate at trolling speed.

4. Run the outboard motor for 1 hour at 2,000 r/min or at half throttle, then for another hour at 3,000 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.

After test run

1. Check for water in the gear oil.

2. Check for fuel leakage in the cowling.

3. Flush the cooling water passage with fresh water using the flushing kit and with the engine running at idle.

Break-in

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

1. One hour a at 2,000 r/min or at approximately half throttle

2. One hour b at 3,000 r/min or 3/4 throttle and 1 minute out of every 10 at full throttle

3. Eight hours c at any speed, however, avoid running at full speed for more than 5 minutes

210

Hour

1-17

S69J1240

6C13G11

SPEC

Specifications

General specifications...................................................................................2-1

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

Power unit..................................................................................................2-5

Lower unit ..................................................................................................2-8

Electrical ....................................................................................................2-9

Power unit................................................................................................2-11

Lower unit ................................................................................................2-14

Electrical ..................................................................................................2-15

Dimensions..............................................................................................2-17

Tightening torques.......................................................................................2-21

Specified torques.....................................................................................2-21

General torques.......................................................................................2-24

1 2 3 4 5 6 7 8 9

6C13G11

SPEC

Specifications

General specifications

1,339 (52.7)

114.0 (251)

Tiller

Model

706 (27.8)

110.0 (243)

Remote control

Item Unit

F50FED F50FEHT F50FET FT50GET

Dimension

Overall length mm (in) 706

(27.8) Overall width mm (in) 384 (15.1) Overall height

(L) mm (in) 1,415 (55.7) 1,455

(*1)

(X)

mm (in) — 1,569

Boat transom height

(L) mm (in) 508 (20.0)

(*1)

(X)

mm (in) — 635

Weight

(with aluminium propeller)

(L) kg (lb) 107.0

(236)

(*1)

(X)

kg (lb) — 119.0

Performance

Maximum output kW (hp) 36.8 (50.0) at 5,500 r/min Full throttle operating range r/min 5,000–6,000 Maximum fuel consumption L (US gal,

18.5 (4.89, 4.07) at 6,000 r/min

lmp gal)/hr

Engine idle speed r/min 700–800

Power unit

Type In-line, 4-stroke, SOHC, 8 valves Cylinder quantity 4 Total displacement cm

(cu. in) 996 (60.8) Bore × stroke mm (in) 65.0 × 75.0 (2.56 × 2.95) Compression ratio 9.50 Control system Remote

control

handle Starting system Electric Fuel system Fuel injection Ignition system TCI Advance system Micro computer Maximum generator output V, A 12, 16 Spark plug DPR6EB-9 (NGK) Cooling system Water Exhaust system Propeller boss Lubrication system Wet sump

(*1)

For Oceania

(57.3)

(61.8)

(25.0)

115.0 (254)

(262)

2-1

6C13G11

General specifications

Item Unit

Fuel and oil

Fuel type Regular unleaded gasoline Fuel minimum rating RON

Engine oil 4-stroke motor oil Engine oil grade

Engine oil quantity

(without oil filter replacement) L (US qt,

(with oil filter replacement) L (US qt,

Gear oil type Hypoid gear oil Gear oil grade

Gear oil quantity cm

Bracket unit

Trim angle (at 12° boat transom) Tilt-up angle Degree 67 69 Steering angle Degree 40 + 40

Drive unit

Gear shift positions F-N-R Gear ratio 1.85 (13/24) 2.31

Reduction gear type Spiral bevel gear Clutch type Dog clutch Propeller shaft type Spline Propeller direction (rear view) Clockwise Propeller identification mark G K

Electrical

Battery minimum capacity

CCA/EN A 430 20HR/IEC Ah 70

(*1)

RON: Research Octane Number PON: Pump Octane Number = (RON + Motor Octane Number)/2

(*2)

Meeting both API and SAE requirements

(*3)

CCA: Cold Cranking Ampere EN: European Norm (European standard) IEC: International Electrotechnical Commission

(*2)

API GL-4

(*3)

(*1)

PON

API

SAE

lmp qt)

SAE 90

(US oz,

lmp oz)

Degree –4 to 20

F50FED F50FEHT F50FET FT50GET

SE, SF, SG, SH, or SJ

10W-30 or 10W-40

430 (14.5, 15.2) 670

Model

90 86

2.5 (2.64, 2.20)

2.7 (2.85, 2.38)

(22.7,

23.6)

(13/30)

1 2 3 4 5 6 7 8 9

6C13G11

2-2

SPEC

Specifications

Item Unit

F60CEHT F60CET FT60DET

Model

Dimension

Overall length mm (in) 1,339 (52.7) 706 (27.8) Overall width mm (in) 384 (15.1) Overall height

(L) mm (in) 1,415 (55.7) 1,455 (57.3)

(*1)

(X)

mm (in) — 1,569 (61.8)

Boat transom height

(L) mm (in) 508 (20.0)

(*1)

(X)

mm (in) — 635 (25.0)

Weight

(with aluminium propeller)

(L) kg (lb) 114.0 (251) 110.0 (243) 115.0 (254)

(*1)

(X)

kg (lb) — 119.0 (262)

Performance

Maximum output kW (hp) 44.1 (60.0) at 5,500 r/min Full throttle operating range r/min 5,000–6,000 Maximum fuel consumption L (US gal,

20.0 (5.28, 4.40) at 6,000 r/min

lmp gal)/hr

Engine idle speed r/min 700–800

Power unit

Type In-line, 4-stroke, SOHC, 8 valves Cylinder quantity 4 Total displacement cm

(cu. in) 996 (60.8) Bore × stroke mm (in) 65.0 × 75.0 (2.56 × 2.95) Compression ratio 9.50 Control system Tiller handle Remote control Starting system Electric Fuel system Fuel injection Ignition system TCI Advance system Micro computer Maximum generator output V, A 12, 16 Spark plug DPR6EB-9 (NGK) Cooling system Water Exhaust system Propeller boss Lubrication system Wet sump

(*1)

For Oceania

2-3

6C13G11

General specifications

Item Unit

Fuel and oil

Fuel type Regular unleaded gasoline Fuel minimum rating RON

Engine oil 4-stroke motor oil Engine oil grade

Engine oil quantity

(without oil filter replacement) L (US qt,

(with oil filter replacement) L (US qt,

Gear oil type Hypoid gear oil Gear oil grade

Gear oil quantity cm

Bracket unit

Trim angle (at 12° boat transom)

Tilt-up angle Degree 69 Steering angle Degree 40 + 40

Drive unit

Gear shift positions F-N-R Gear ratio 1.85 (13/24) 2.31 (13/30) Reduction gear type Spiral bevel gear Clutch type Dog clutch Propeller shaft type Spline Propeller direction (rear view) Clockwise Propeller identification mark G K

Electrical

Battery minimum capacity

CCA/EN A 430 20HR/IEC Ah 70

(*1)

RON: Research Octane Number PON: Pump Octane Number = (RON + Motor Octane Number)/2

(*2)

Meeting both API and SAE requirements

(*3)

CCA: Cold Cranking Ampere EN: European Norm (European standard) IEC: International Electrotechnical Commission

(*2)

API GL-4

(*3)

(*1)

PON

API

SAE

lmp qt)

SAE 90

(US oz,

lmp oz)

Degree –4 to 20

F60CEHT F60CET FT60DET

SE, SF, SG, SH, or SJ

10W-30 or 10W-40

430 (14.5, 15.2) 670

Model

90 86

2.5 (2.64, 2.20)

2.7 (2.85, 2.38)

(22.7, 23.6)

1 2 3 4 5 6 7 8 9

6C13G11

2-4

SPEC

Specifications

Maintenance specification

Power unit

Item Unit

F50FED F50FEHT F50FET FT50GET

Power unit

Minimum compression pressure

Oil pressure

(*1)

(*2)

kPa

(kgf/cm2, psi)

(kgf/cm

, psi)

125 (1.25, 18.1) at engine idle speed

Cylinder head

Warpage limit mm (in) 0.10 (0.0039)

(lines indicate straightedge position) Journal inside diameter mm (in) 37.000–37.025 (1.4567–1.4577)

Cylinders

Bore size mm (in) 65.000–65.015 (2.5591–2.5596) Taper limit mm (in) 0.08 (0.0032) Out-of-round limit mm (in) 0.05 (0.0020)

Pistons

Piston diameter (D) mm (in) 64.950–64.965 (2.5571–2.5577) Measuring point (H) mm (in) 5.0 (0.20) Piston clearance mm (in) 0.035–0.065 (0.0014–0.0026) Piston pin boss bore mm (in) 15.974–15.985 (0.6289–0.6293) Oversize piston diameter

1st mm (in) 65.200–65.215 (2.5669–2.5675) 2nd mm (in) 65.450–65.465 (2.5768–2.5774)

Piston pins

Outside diameter mm (in) 15.965–15.970 (0.6285–0.6287)

Piston rings

Top ring

Dimension B mm (in) 1.17–1.19 (0.0461–0.0469) Dimension T mm (in) 2.30–2.50 (0.0905–0.0984) End gap mm (in) 0.15–0.30 (0.0059–0.0118) Side clearance mm (in) 0.02–0.06 (0.0008–0.0024)

(*1)

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

(*2)

The figures are for reference only.

Model

960 (9.6, 139.2)

2-5

6C13G11

Maintenance specification

Item Unit

2nd piston ring

Dimension B mm (in) 1.47–1.49 (0.0579–0.0587) Dimension T mm (in) 2.60–2.80 (0.1024–0.1102) End gap mm (in) 0.30–0.50 (0.0118–0.0197) Side clearance mm (in) 0.02–0.06 (0.0008–0.0024)

Oil ring

Dimension B mm (in) 2.36–2.48 (0.0929–0.0976) Dimension T End gap mm (in) 0.20–0.70 (0.0079–0.0276) Side clearance mm (in) 0.04–0.18 (0.0016–0.0071)

Camshaft

Intake (A) mm (in) 30.888–30.988 (1.2161–1.2200) Exhaust (A) mm (in) 30.824–30.924 (1.2135–1.2175) Intake and exhaust (B) Camshaft journal diameter

#1 Camshaft journal diameter

#2, #3, #4 Camshaft journal oil clearance mm (in) 0.045–0.090 (0.0018–0.0035) Camshaft runout limit mm (in) 0.03 (0.0012)

Rocker arm shaft

Rocker arm shaft outside diameter

Rocker arms

Rocker arm inside diameter mm (in) 16.000–16.018 (0.6299–0.6306)

Valves

Valve clearance (cold)

Intake mm (in) 0.20 Exhaust mm (in) 0.30

Head diameter (A)

Intake mm (in) 31.90–32.10 (1.256–1.264) Exhaust mm (in) 26.60–26.80 (1.047–1.055)

Face width (B)

Intake mm (in) 1.98–2.40 (0.078–0.094) Exhaust mm (in) 2.16–2.79 (0.085–0.110)

Seat contact width (C)

Intake and exhaust mm (in) 1.3–1.5 (0.051–0.059)

Margin thickness (D)

Intake mm (in) 0.8–1.2 (0.031–0.047) Exhaust mm (in) 1.0–1.4 (0.039–0.055)

(*1)

mm (in) 2.75 (0.1083)

mm (in) 25.950–26.050 (1.0216–1.0256)

mm (in) 36.925–36.945 (1.4537–1.4545)

mm (in) 36.935–36.955 (1.4541–1.4549)

mm (in) 15.971–15.991 (0.6288–0.6296)

F50FED F50FEHT F50FET FT50GET

Model

0.05 (0.008

0.05 (0.012

± ±

0.002)

1 2 3 4 5 6 7 8 9

(*1)

The figures are for reference only.

6C13G11

2-6

SPEC

Specifications

Item Unit

Stem diameter

Intake mm (in) 5.475–5.490 (0.2156–0.2161) Exhaust mm (in) 5.460–5.475 (0.2150–0.2156)

Guide inside diameter

Intake and exhaust mm (in) 5.500–5.512 (0.2165–0.2170)

Stem-to-guide clearance

Intake and exhaust mm (in) 0.025–0.052 (0.0010–0.0020)

Stem runout limit

Intake mm (in) 0.05 (0.0020) Exhaust mm (in) 0.03 (0.0012)

Valve springs

Free length mm (in) 39.85 (1.5689) Tilt limit mm (in) 1.7 (0.07)

Connecting rods

Small end inside diameter mm (in) 15.985–15.998 (0.6293–0.6298) Big end inside diameter mm (in) 36.000–36.024 (1.4173–1.4183) Connecting rod big end side clearance Crankpin oil clearance mm (in) 0.016–0.040 (0.0006–0.0016) Big end bearing thickness

Yellow mm (in) 1.500–1.504 (0.0591–0.0592) Red mm (in) 1.496–1.500 (0.0589–0.0591) Pink mm (in) 1.492–1.496 (0.0587–0.0589) Green mm (in) 1.488–1.492 (0.0586–0.0587)

Crankshaft

Crankshaft journal diameter mm (in) 42.984–43.000 (1.6923–1.6929) Crankpin diameter mm (in) 32.984–33.000 (1.2986–1.2992) Crankpin width mm (in) 21.000–21.070 (0.8268–0.8295) Runout limit mm (in) 0.03 (0.0012)

Crankcase

Crankshaft main journal oil clearance

Crankcase main journal bearing thickness

Yellow mm (in) 1.502–1.506 (0.0591–0.0592) Red mm (in) 1.498–1.502 (0.0590–0.0591) Pink mm (in) 1.494–1.498 (0.0588–0.0590) Green mm (in) 1.490–1.494 (0.0587–0.0588)

mm (in) 0.05–0.22 (0.0020–0.0087)

mm (in) 0.012–0.036 (0.0005–0.0014)

F50FED F50FEHT F50FET FT50GET

Model

2-7

6C13G11

Maintenance specification

Item Unit

Oil pump

Type Trochoid Outer rotor-to-housing

clearance Outer rotor-to-inner rotor clearance limit Rotor-to-cover clearance mm (in) 0.03–0.08 (0.0012–0.0031) Relief valve operating

pressure

Thermostat

Opening temperature °C (°F) 58–62 (136–144) Fully open temperature °C (°F) 70 (158) Valve open lower limit mm (in) 3.0 (0.12)

Lower unit

Item Unit

Gear backlash

Pinion-to-forward gear mm (in) 0.35–0.81 (0.0138–0.0319) 0.09–0.62

Pinion-to-reverse gear mm (in) 0.89–1.34 (0.0350–0.0528) — Pinion shims mm 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50 Forward gear shims mm 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50 Reverse gear shims mm 0.10, 0.12, 0.15, 0.18, 0.30, 0.40,

mm (in) 0.09–0.15 (0.0035–0.0059)

mm (in) 0.12 (0.0047)

kPa

(kgf/cm

, psi)

F50FED F50FEHT F50FET FT50GET

350–450 (3.5–4.5, 50.8–62.3)

F50FED F50FEHT F50FET FT50GET

Model

(0.0035–

0.0244)

0.50

1 2 3 4 5

—

6C13G11

7 8 9

2-8

SPEC

Electrical

Specifications

Item Unit

F50FED F50FEHT F50FET FT50GET

Model

Ignition and ignition control system

Ignition timing range

(*1)

Degree ATDC 10-BTDC 25 Spark plug gap mm (in) 0.8–0.9 (0.031–0.035) Ignition coil resistance

Primary coil (R – B/W)

at 20 °C (68 °F)

Ω

1.53–2.07

Secondary coil

at 20 °C (68 °F) k

Spark plug wire resistance k

Ω Ω

12.50–16.91

1.9–5.0

ECM output peak voltage

(B/R, B/W – ground) at cranking (loaded) V 240 at 1,500 r/min (loaded) V 290 at 3,500 r/min (loaded) V 300

Pulser coil output peak voltage

(W/R – W/B) at cranking (unloaded) V 7.9 at cranking (loaded) V 7.2 at 1,500 r/min (loaded) V 20.7 at 3,500 r/min (loaded) V 32.0

Pulser coil resistance

(*2)

Ω

396–594

(W/B – W/R)

Pulser coil air gap mm (in) 0.75 ± 0.25 (0.030 ± 0.010) Throttle position sensor

Output voltage (P – B) V 0.8–1.2 at engine idle speed

Sensor assembly resistance

at 20 °C (68 °F) k at 80 °C (176 °F) k

(*2)

Ω Ω

5.4–6.6

0.282–0.382

Cooling water temperature sensor resistance

at 20 °C (68 °F) k at 60 °C (140 °F) k at 100 °C (212 °F) k

(*2)

(B/Y – B)

Ω Ω Ω

2.439

0.589

0.193

Fuel control system

Fuel injector resistance

at 21 °C (70 °F)

Solenoid valve resistance

at 20 °C (68 °F)

(*1)

The actual ignition timing may vary according to environmental conditions.

The figures are for reference only and do not represent the ignition timing figures from the fully closed position to the fully open position of the throttle valve.

(*2)

The figures are for reference only.

(*2)

Ω

12.0

30.0–34.0

2-9

6C13G11

Maintenance specification

Item Unit

Starter motor

Type Sliding gear Output kW 1.4 Cranking time limit Second 30 Brushes

Standard length mm (in) 15.5 (0.61) Wear limit mm (in) 9.5 (0.37)

Commutator

Standard diameter mm (in) 29.0 (1.14) Wear limit mm (in) 28.0 (1.10)

Mica

Standard undercut mm (in) 0.8 (0.03) Wear limit mm (in) 0.2 (0.01)

Charging system

Fuse A 20, 30 Stator coil output peak voltage

(W – W) at cranking (unloaded) V 13.2 at 1,500 r/min (unloaded) V 42.2 at 3,500 r/min (unloaded) V 96.6

Stator coil resistance

at 20 °C (68 °F) (W – W)

Rectifier Regulator output peak voltage (R – B)

at 1,500 r/min (unloaded) V 13.0 at 3,500 r/min (unloaded) V 13.0

Power trim and tilt system

Trim sensor

Setting resistance (P – B) Resistance (P – B)

Fluid type ATF Dexron Brushes

Standard limit mm (in) 11.0 (0.43) Wear limit mm (in) 4.5 (0.18)

Commutator

Standard limit mm (in) 19.0 (0.75) Wear limit mm (in) 18.0 (0.71)

Mica

Standard undercut mm (in) 1.5 (0.06)

(*1)

The figures are for reference only.

(*1)

Ω

Ω Ω

F50FED F50FEHT F50FET FT50GET

Model

0.52–0.63

9–11

9–288.3

1 2 3 4 5 6

7 8 9

6C13G11

2-10

SPEC

Power unit

Specifications

Item Unit

F60CEHT F60CET FT60DET

Model

Power unit

Minimum compression pressure Oil pressure

(*1)

(*2)

kPa

(kgf/cm2, psi)

(kgf/cm

, psi)

960 (9.6, 139.2)

125 (1.25, 18.1) at engine idle speed

Cylinder head

Warpage limit mm (in) 0.10 (0.0039)

(lines indicate straightedge position)

Journal inside diameter mm (in) 37.000–37.025 (1.4567–1.4577)

Cylinders

Bore size mm (in) 65.000–65.015 (2.5591–2.5596) Taper limit mm (in) 0.08 (0.0032) Out-of-round limit mm (in) 0.05 (0.0020)

Pistons

1st mm (in) 65.200–65.215 (2.5669–2.5675) 2nd mm (in) 65.450–65.465 (2.5768–2.5774)

Piston pins

Outside diameter mm (in) 15.965–15.970 (0.6285–0.6287)

Piston rings

Top ring

Dimension B mm (in) 1.17–1.19 (0.0461–0.0469) Dimension T mm (in) 2.30–2.50 (0.0905–0.0984) End gap mm (in) 0.15–0.30 (0.0059–0.0118) Side clearance mm (in) 0.02–0.06 (0.0008–0.0024)

(*1)

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

(*2)

The figures are for reference only.

2-11

6C13G11

Maintenance specification

Item Unit

2nd piston ring

Dimension B mm (in) 1.47–1.49 (0.0579–0.0587) Dimension T mm (in) 2.60–2.80 (0.1024–0.1102) End gap mm (in) 0.30–0.50 (0.0118–0.0197) Side clearance mm (in) 0.02–0.06 (0.0008–0.0024)

Oil ring

Dimension B mm (in) 2.36–2.48 (0.0929–0.0976) Dimension T End gap mm (in) 0.20–0.70 (0.0079–0.0276) Side clearance mm (in) 0.04–0.18 (0.0016–0.0071)

Camshaft

Intake (A) mm (in) 30.888–30.988 (1.2161–1.2200) Exhaust (A) mm (in) 30.824–30.924 (1.2135–1.2175) Intake and exhaust (B) Camshaft journal diameter

#1 Camshaft journal diameter

#2, #3, #4 Camshaft journal oil clearance mm (in) 0.045–0.090 (0.0018–0.0035) Camshaft runout limit mm (in) 0.03 (0.0012)

Rocker arm shaft

Rocker arm shaft outside diameter

Rocker arms

Rocker arm inside diameter mm (in) 16.000–16.018 (0.6299–0.6306)

Valves

Valve clearance (cold)

Intake mm (in) 0.20 ± 0.05 (0.008 Exhaust mm (in) 0.30

Head diameter (A)

Intake mm (in) 31.90–32.10 (1.256–1.264) Exhaust mm (in) 26.60–26.80 (1.047–1.055)

Face width (B)

Intake mm (in) 1.98–2.40 (0.078–0.094) Exhaust mm (in) 2.16–2.79 (0.085–0.110)

Seat contact width (C)

Intake and exhaust mm (in) 1.3–1.5 (0.051–0.059)

Margin thickness (D)

Intake mm (in) 0.8–1.2 (0.031–0.047) Exhaust mm (in) 1.0–1.4 (0.039–0.055)

(*1)

mm (in) 2.75 (0.1083)

mm (in) 25.950–26.050 (1.0216–1.0256)

mm (in) 36.925–36.945 (1.4537–1.4545)

mm (in) 36.935–36.955 (1.4541–1.4549)

mm (in) 15.971–15.991 (0.6288–0.6296)

F60CEHT F60CET FT60DET

Model

0.002)

0.05 (0.012 ± 0.002)

1 2 3 4 5 6 7 8 9

(*1)

The figures are for reference only.

6C13G11

2-12

SPEC

Specifications

Item Unit

Stem diameter

Intake mm (in) 5.475–5.490 (0.2156–0.2161) Exhaust mm (in) 5.460–5.475 (0.2150–0.2156)

Guide inside diameter

Intake and exhaust mm (in) 5.500–5.512 (0.2165–0.2170)

Stem-to-guide clearance

Intake and exhaust mm (in) 0.025–0.052 (0.0010–0.0020)

Stem runout limit

Intake mm (in) 0.05 (0.0020) Exhaust mm (in) 0.03 (0.0012)

Valve springs

Free length mm (in) 39.85 (1.5689) Tilt limit mm (in) 1.7 (0.07)

Connecting rods

Yellow mm (in) 1.500–1.504 (0.0591–0.0592) Red mm (in) 1.496–1.500 (0.0589–0.0591) Pink mm (in) 1.492–1.496 (0.0587–0.0589) Green mm (in) 1.488–1.492 (0.0586–0.0587)

Crankshaft

Crankcase

Crankshaft main journal oil clearance

Crankcase main journal bearing thickness

Yellow mm (in) 1.502–1.506 (0.0591–0.0592) Red mm (in) 1.498–1.502 (0.0590–0.0591) Pink mm (in) 1.494–1.498 (0.0588–0.0590) Green mm (in) 1.490–1.494 (0.0587–0.0588)

mm (in) 0.05–0.22 (0.0020–0.0087)

mm (in) 0.012–0.036 (0.0005–0.0014)

F60CEHT F60CET FT60DET

Model

2-13

6C13G11

Maintenance specification

Item Unit

Oil pump

Type Trochoid Outer rotor-to-housing

clearance Outer rotor-to-inner rotor clearance limit Rotor-to-cover clearance mm (in) 0.03–0.08 (0.0012–0.0031) Relief valve operating

pressure

Thermostat

Opening temperature °C (°F) 58–62 (136–144) Fully open temperature °C (°F) 70 (158) Valve open lower limit mm (in) 3.0 (0.12)

Lower unit

Item Unit

Gear backlash

Pinion-to-forward gear mm (in) 0.35–0.81 (0.0138–0.0319) 0.09–0.62

mm (in) 0.09–0.15 (0.0035–0.0059)

mm (in) 0.12 (0.0047)

kPa

(kgf/cm

, psi)

F60CEHT F60CET FT60DET

350–450 (3.5–4.5, 50.8–62.3)

F60CEHT F60CET FT60DET

0.40, 0.50

Model

(0.0035–

0.0244)

1 2 3 4 5

—

6C13G11

7 8 9

2-14

SPEC

Electrical

Specifications

Item Unit

F60CEHT F60CET FT60DET

Model

Ignition and ignition control system

Ignition timing range

(*1)

Degree ATDC 10-BTDC 24 Spark plug gap mm (in) 0.8–0.9 (0.031–0.035) Ignition coil resistance

Primary coil (R – B/W)

at 20 °C (68 °F)

Ω

1.53–2.07

Secondary coil

at 20 °C (68 °F) k

Spark plug wire resistance k

Ω Ω

12.50–16.91

1.9–5.0

ECM output peak voltage

(B/R, B/W – ground) at cranking (loaded) V 240 at 1,500 r/min (loaded) V 290 at 3,500 r/min (loaded) V 300

Pulser coil output peak voltage

(W/B – W/R) at cranking (unloaded) V 7.9 at cranking (loaded) V 7.2 at 1,500 r/min (loaded) V 20.7 at 3,500 r/min (loaded) V 32.0

Pulser coil resistance

(*2)

Ω

396–594

(W/B – W/R)

Pulser coil air gap mm (in) 0.75 ± 0.25 (0.030 ± 0.010) Throttle position sensor

Output voltage (P – B) V 0.8–1.2 at engine idle speed

Sensor assembly resistance

at 20 °C (68 °F) k at 80 °C (176 °F) k

(*2)

Ω Ω

5.4–6.6

0.282–0.382

Cooling water temperature sensor resistance

at 20 °C (68 °F) k at 60 °C (140 °F) k at 100 °C (212 °F) k

(*2)

(B/Y – B)

Ω Ω Ω

2.439

0.589

0.193

Fuel control system

Fuel injector resistance

at 21 °C (70 °F)

Solenoid valve resistance

at 20 °C (68 °F)

(*1)

The actual ignition timing may vary according to environmental conditions.

The figures are for reference only and do not represent the ignition timing figures from the fully closed position to the fully open position of the throttle valve.

(*2)

The figures are for reference only.

(*2)

Ω

12.0

30.0–34.0

2-15

6C13G11

Maintenance specification

Item Unit

Starter motor

Type Sliding gear Output kW 1.4 Cranking time limit Second 30 Brushes

Standard length mm (in) 15.5 (0.61) Wear limit mm (in) 9.5 (0.37)

Commutator

Standard diameter mm (in) 29.0 (1.14) Wear limit mm (in) 28.0 (1.10)

Mica

Standard undercut mm (in) 0.8 (0.03) Wear limit mm (in) 0.2 (0.01)

Charging system

Fuse A 20, 30 Stator coil output peak voltage

(W – W) at cranking (unloaded) V 13.2 at 1,500 r/min (unloaded) V 42.2 at 3,500 r/min (unloaded) V 96.6

Stator coil resistance

at 20 °C (68 °F) (W – W)

Rectifier Regulator output peak voltage (R – B)

at 1,500 r/min (unloaded) V 13.0 at 3,500 r/min (unloaded) V 13.0

Power trim and tilt system

Trim sensor

Setting resistance (P – B) Resistance (P – B)

Fluid type ATF Dexron Brushes

Standard limit mm (in) 11.0 (0.43) Wear limit mm (in) 4.5 (0.18)

Commutator

Standard limit mm (in) 19.0 (0.75) Wear limit mm (in) 18.0 (0.71)

Mica

Standard undercut mm (in) 1.5 (0.06)

(*1)

The figures are for reference only.

(*1)

Ω

Ω Ω

F60CEHT F60CET FT60DET

Model

0.52–0.63

9–11

9–288.3

1 2 3 4 5 6

7 8 9

6C13G11

2-16

SPEC

Specifications

Dimensions

Exterior F50, F60 (Remote control model)

188 (7.4)

192 (7.6)

mm (in)

360 (14.2)192

(7.6)

A: 762 (30.0)

B: 759 (29.9)

A: 148 (5.8) B: 147 (5.8)

354 (13.9)

49 (1.9)

A: 406 (16.0) B: 417 (16.4)

122 (4.8)

A: 25 (1.0)

B: 22 (0.9)

A: 930 (36.6) B: 932 (36.7)

584 (23.0)

62 (2.4)

545 (21.5)

527 (20.7)

870 (34.3)

175 (6.9)

24 (0.9)

A: Hydro tilt model (For Europe) B: Power trim and tilt model

2-17

97 (3.8)

A: 63˚

B: 65˚

533 (21.0)

A: 682 (26.9)

B: 708 (27.9)

S6C12030

6C13G11

F50, F60 (Tiller handle model)

192 (7.6)

188 (7.4)

(*1)

Maintenance specification

mm (in)

360 (14.2)

(7.6)

192

124 (4.9)

645 (25.4)

759 (29.9)

354 (14.0)

755 (29.7)

417 (16.4)

226 (8.9)

2 3

932 (36.7)

584 (23.0)

164 (6.5)

62 (2.4)

758 (29.8)

545 (21.5)

49 (1.9)

527 (20.7)

870 (343)

175 (6.9)

24 (0.9)

Power trim and tilt model

(*1)

For Oceania

6C13G11

37 (1.5)

97 (3.8)

65˚

533 (21.0)

708 (27.9)

8 9

S6C12020E

2-18

SPEC

FT50, FT60

Specifications

188 (7.4)

192 (7.6)

mm (in)

360 (14.2)

192 (7.6)

759 (29.9)

354 (13.9)

417 (16.4)

147 (5.8)

122 (4.8)

62 (2.4)

22 (0.9)

L: 996 (39.2) X: 1,099 (43.3)

584 (23.0)

62 (2.4)

545 (21.5)

L: 910 (35.8)

X: For Oceania

2-19

L: 530 (20.9)

X: 644 (25.4)

X: 1,024 (40.3)

191 (7.5)

24 (0.9)

L : 98 (3.9)

X : 114 (4.5)

12˚

561 (22.1)

65˚

L: 746 (29.4)

X: 812 (32.0)

S6C12010

6C13G11

Clamp bracket

Maintenance specification

mm (in)

180 (7.1)

163.5 (6.4)

180 (7.1)

163.5 (6.4)

50.8 (2.0)

18.5 (0.7)

254.0 (10.0)

350 (13.8)

2 3 4

70.5 (2.78)

13 (0.5)

55.5 (2.2)

126 (5.0)126 (5.0)

13 (0.5)

6 7 8 9

S6C12070

6C13G11

2-20

SPEC

Specifications

Tightening torques

Specified torques

Part to be tightened Thread size

Fuel system

Fuel filter cup — 30.32.2 Fuel pump screw M5 3 0.3 2.2 Fuel pump valve screw M3 0.5 0.05 0.36 Idle speed control screw M5 4 0.4 3.0 Sensor assembly screw M5 4 0.4 3.0 Fuel cooler screw M6 3 0.3 2.2 Fuel rail mounting bolt M6 9 0.9 6.6 Throttle body mounting bolt M6 9 0.9 6.6 Pressure regulator bolt M6 5 0.5 3.7 Drain screw — 1.5 0.15 1.1 Joint screw — 40.43.0 Vapor separator cover screw M5 3 0.3 2.2 Plate screw M4 2 0.2 1.5

Power unit

Power unit mounting bolt M8 27 2.7 20.0 Shift position switch screw M4 2 0.2 1.5 Stator coil bracket bolt M6 4 0.4 3.0 Pulser coil bolt M5 4 0.4 3.0 Flywheel magnet nut M20 157 15.7 115.8 Starter motor bolt M8 29 2.9 21.4 Starter motor terminal nut M8 9 0.9 6.6 Starter relay lead bolt M6 4 0.4 3.0 Starter motor lead screw M4 2 0.2 1.5 Starter relay holder screw M6 3 0.3 2.2 Main and fuel pump relay screw M6 3 0.3 2.2 ECM cover screw M6 3 0.3 2.2 Self diagnosis connector screw M6 3 0.3 2.2 Ignition coil bolt M6 7 0.7 5.2 Oil filter — 18 1.8 13.3 PTT relay nut M6 4 0.4 3.0 PTT motor lead bolt M6 4 0.4 3.0 Positive battery lead nut M8 9 0.9 6.6 Drive sprocket nut M41 140 14.0 103.3 Driven sprocket bolt M10 38 3.8 28.0 Rocker arm lock nut M10 14 1.4 10.3 Rocker arm shaft bolt M8 18 1.8 13.3

Tightening torques

N·mkgf·mft·lb

2-21

6C13G11

Tightening torques

Part to be tightened Thread size

1st

2nd 12 1.2 8.9

Cylinder head bolt

Spark plug — 17 1.7 12.5 Cooling water temperature sensor — 23 2.3 17.0 Oil pressure switch — 80.85.9 Oil pressure switch lead bolt M4 2 0.2 1.5

Exhaust cover bolt

Exhaust cover plug

Oil filter union bolt — 40 4.0 29.5 Oil pump screw M6 4 0.4 3.0

Crankcase bolt

Connecting rod cap bolt

Lower unit (F50, F60)

Gear oil drain screw — 90.96.6 Gear oil check screw — 90.96.6 Lower case mounting bolt M10 39 3.9 28.8 Propeller nut M16 34 3.4 25.1 Ring nut — 103 10.3 76.0 Cooling water inlet cover screw — 40.43.0 Pinion nut M16 74 7.4 54.6 Propeller shaft housing bolt M8 16 1.6 11.8

Lower unit (FT50, FT60)

Gear oil drain screw — 90.96.6 Gear oil check screw — 90.96.6 Lower case mounting bolt (nut) M10 39 3.9 28.8 Propeller nut M16 34 3.4 25.1 Ring nut — 103 10.3 76.0 Cooling water inlet cover screw — 40.43.0 Pinion nut M16 93 9.3 68.6 Propeller shaft housing bolt M8 16 1.6 11.8

1st

2nd 23 2.3 17.0

3rd 90°

1st

2nd 12 1.2 8.9

1st

2nd 12 1.2 8.9

1st

2nd 30 3.0 22.1

1st

2nd 17 1.7 12.5

M14 23 2.3 17.0 M18 55 5.5 40.6

—

Tightening torques

N·mkgf·mft·lb

60.64.4

12 1.2 8.9

60.64.4

15 1.5 11.1

60.64.4

1 2 3 4 5 6 7 8 9

6C13G11

2-22

SPEC

Specifications

Part to be tightened Thread size

Bracket unit

Retaining plate bolt M6 10 1.0 7.4 Tiller handle nut — 37 3.7 27.3 Self-locking nut — 40.43.0 Engine stop lanyard switch nut — 20.21.5 Tiller handle bracket nut — 37 3.7 27.3 Tiller handle bracket bolt M12 37 3.7 27.3 Engine start switch nut — 40.43.0 Shift rod detent bolt — 18 1.8 13.3 PTT switch bracket bolt M6 10 1.0 7.4 Flushing hose adapter screw M6 2 0.2 1.5 Engine oil drain bolt M14 17 1.7 12.5 Muffler bolt M6 10 1.0 7.4 Exhaust manifold bolt M6 10 1.0 7.4 Oil pan bolt M8 27 2.7 20.0 Oil strainer bolt M6 10 1.0 7.4 Upper mounting nut M8 24 2.4 17.7 Self-locking nut — 22 2.2 16.2 Grease nipple — 30.32.2

Power trim and tilt unit

PTT motor bolt M5 4 0.4 3.0 Reservoir cap — 70.75.2 Manual valve — 20.21.5 Gear pump bolt M5 5 0.5 3.7 Lever bolt M3 3 0.3 2.2

Relief valve seat cap bolt

Gear pump housing bolt M5 5 0.5 3.7

Gear pump bracket bolt

Tilt cylinder end screw — 110 11.0 81.1 Trim cylinder end screw — 80 8.0 59.0 Tilt piston bolt M12 61 6.1 45.0

M4 4 0.4 3.0 M5 5 0.5 3.7

M3 3 0.3 2.2 M5 4 0.4 3.0

Tightening torques

N·mkgf·mft·lb

2-23

6C13G11

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 manual. To avoid warpage, tighten multi-fastener assemblies in a crisscross fashion and progressive stages until the specified torque is reached. Unless otherwise specified, torque specifications require clean, dry threads. Components should be at room temperature.

General torque

Nut (A) Bolt (B)

8 mm M5 5 0.5 3.6 10 mm M6 8 0.8 5.8 12 mm M8 18 1.8 13 14 mm M10 36 3.6 25 17 mm M12 43 4.3 31

specifications

N·mkgf·mft·lb

Tightening torques

1 2 3 4 5 6 7 8 9

6C13G11

2-24

SPEC

Specifications

— MEMO —

2-25

6C13G11

CHK

ADJ

Periodic checks and adjustments

Special service tools .....................................................................................3-1

Maintenance interval chart............................................................................3-2

Top cowling ....................................................................................................3-3

Checking the top cowling...........................................................................3-3

Fuel system ....................................................................................................3-3

Checking the fuel joint and fuel hoses (fuel joint-to-fuel injector) ..............3-3

Checking the fuel filter ...............................................................................3-3

Power unit.......................................................................................................3-3

Checking the engine oil level.....................................................................3-3

Changing the engine oil using an oil changer............................................3-4

Changing the engine oil by draining it .......................................................3-4

Replacing the oil filter ................................................................................3-5

Checking the timing belt ............................................................................3-6

Replacing the timing belt ...........................................................................3-6

Checking the spark plugs ..........................................................................3-8

Checking the thermostat............................................................................3-9

Checking the cooling water passage.......................................................3-10

Control system.............................................................................................3-10

Checking the engine idle speed ..............................................................3-10

Adjusting the throttle link and throttle cable.............................................3-10

Checking the gear shift operation............................................................3-12

1 2 3 4 5

Bracket unit ..................................................................................................3-13

Checking the power trim and tilt operation .............................................. 3-13

Checking the hydro tilt unit operation ......................................................3-13

Checking the power trim and tilt fluid level ..............................................3-14

Lower unit.....................................................................................................3-14

Checking the gear oil level ......................................................................3-14

Changing the gear oil ..............................................................................3-15

Checking the lower unit for air leakage ...................................................3-15

Checking the propeller.............................................................................3-16

General..........................................................................................................3-16

Checking the anodes...............................................................................3-16

Checking the battery................................................................................3-17

Lubricating the outboard motor................................................................3-18

6 7 8 9

6C13G11

CHK

ADJ

Periodic checks and adjustments

Special service tools

Digital tachometer 90890-06760

Leakage tester 90890-06840

Oil filter wrench 90890-01426

Flywheel holder 90890-06522

Flywheel puller 90890-06521

3-1

6C13G11

Special service tools / Maintenance interval chart

Maintenance interval chart

Use the following chart as a guideline for general maintenance. Adjust the maintenance intervals according to the operating conditions of the outboard motor.

Initial Every

Item Remarks

Anodes (external) Check/replace 3-16 Anodes (internal) Check/replace 3-16 Battery Check/charge 3-17 Cooling water passages Clean 3-10 Top cowling Check 3-3 Fuel filter

(can be disassembled) Fuel system Check 3-3 Fuel tank

(Yamaha portable tank) Gear oil Change 3-14 Lubrication points Lubricate 3-18 Engine idle speed (EFI models) Power trim and tilt unit Check 3-13 Propeller and cotter pin Check/replace 3-16 Shift link/shift cable Check/adjust 3-12 Thermostat Check 3-9 Throttle link/throttle cable/

throttle pick-up timing Water pump Check 6-7, 6-32 Engine oil Check/change 3-3 Oil filter Change 3-5 Spark plugs Clean/adjust/

Timing belt Check/replace 3-6 Valve clearance (OHC) Check/adjust 5-4

Check/replace 3-3

Check/clean —

Check/adjust 3-10

replace

10 hours

(1 month)

50 hours

(3 months)

100 hours

(6 months)

200 hours

(1 year)

Refer to

page

3-8

1 2 3 4 5 6 7

NOTE:

When operating in salt water, turbid or muddy water, the engine should be flushed with clean water after each use.

Every

Item Remarks

Timing belt Replace 3-6

6C13G11

500 hours

(2.5 years)

1,000 hours

(5 years)

Refer to

page

3-2

8 9

CHK

ADJ

Periodic checks and adjustments

Top cowling

Checking the top cowling

1. Check the fitting by pushing the cowling with both hands. Adjust if necessary.

S6C13010

2. Loosen the nuts 1.

3. Move the hook 2 up or down slightly to adjust its position.

2. Check the low-pressure fuel hose connections and fuel joint for leaks. Replace if necessary. Also, check the fuel filter 1, fuel pump 2, strainer 3, and fuel cooler

for leaks or deterioration. Replace if

necessary.

3. Check the high-pressure fuel hose connections for leaks. Replace if necessary. Also, check the vapor separator 5, fuel rail 6, fuel injectors 7, and pressure regulator 8 for leaks or deterioration. Replace if necessary.

S6D53020

NOTE:

• To loosen the fitting, move the hook in direction a.

• To tighten the fitting, move the hook in direction b.

4. Tighten the nuts.

5. Check the fitting again and, if necessary,

repeat steps 2–4.

Fuel system

Checking the fuel joint and fuel hoses (fuel joint-to-fuel injector)

1. Remove the flywheel magnet cover.

Checking the fuel filter

1. Check the fuel filter element 1 for dirt and residue and check the fuel filter cup

for foreign substances and cracks. Clean the cup with straight gasoline and replace the element if necessary.

S6C13030

NOTE:

Be sure not to spill any fuel when removing the fuel filter cup.

Power unit

Checking the engine oil level

1. Place the outboard motor in an upright position.

3-3

6C13G11

2. Remove the oil dipstick, wipe it clean, and then insert it back into the dipstick hole.

3. Remove the oil dipstick again to check the oil level and to check the oil for discoloration and its viscosity.

S6C11030

NOTE:

• Change the oil if it appears milky or dirty.

• If the engine oil is below the minimum level

mark b, add sufficient oil until the level is between a and b.

Changing the engine oil using an oil changer

1. Start the engine, warm it up, and then turn it off.

2. Remove the oil dipstick and oil filler cap

Top cowling / Fuel system / Power unit

4. Operate the oil changer to extract the oil.

NOTE:

Be sure to clean up any oil spills.

5. Pour the specified amount of the recommended engine oil into the oil filler hole.

Recommended engine oil:

4-stroke motor oil

API: SE, SF, SG, SH, or SJ SAE: 10W-30 or 10W-40

Engine oil quantity:

Without oil filter replacement:

2.5 L (2.64 US qt, 2.20 Imp qt)

6. Install the oil filler cap and oil dipstick, and then start the engine and warm it up for 5 minutes.

7. Turn the engine off, and then check the oil level and correct it if necessary.

S6C13330

1 2 3 4 5 6

S6C13050

3. Insert the tube of the oil changer 2 into the dipstick hole 3.

6C13G11

Changing the engine oil by draining it

1. Start the engine, warm it up, and then turn it off.

3-4

7 8 9

CHK

ADJ

Periodic checks and adjustments

2. Remove the oil dipstick and oil filler cap

S6C13050

3. Place a drain pan under the drain hole, and then remove the drain bolt 2 and gasket and let the oil drain completely.

S6C13060

7. Turn the engine off, and then check the oil level and correct it if necessary.

Replacing the oil filter

1. Extract the engine oil with an oil changer or drain it.

2. Place a rag under the oil filter, and then remove the oil filter using the oil filter wrench 1.

S6C13070

NOTE:

• Wait more than 5 minutes after turning the

engine off to replace the oil filter.

• Be sure to clean up any oil spills.

NOTE:

Be sure to clean up any oil spills.

4. Install the gasket and drain bolt, and then tighten it to the specified torque.

Engine oil drain bolt:

17 N·m (1.7 kgf·m, 12.5 ft·lb)

5. Pour the specified amount of the recommended engine oil into the oil filler hole.

Recommended engine oil:

4-stroke motor oil

API: SE, SF, SG, SH, or SJ SAE: 10W-30 or 10W-40

Engine oil quantity:

Without oil filter replacement:

2.5 L (2.64 US qt, 2.20 Imp qt)

6. Install the oil filler cap and oil dipstick, and then start the engine and warm it up for 5 minutes.

Oil filter wrench 1: 90890-01426

3. Apply a thin coat of engine oil to the Oring of the new oil filter.

4. Install the oil filter, and then tighten it to the specified torque using the oil filter wrench 1.

S6C13080

Oil filter:

18 N·m (1.8 kgf·m, 13.3 ft·lb)

3-5

6C13G11

5. Pour the specified amount of the recommended engine oil into the oil filler hole.

Recommended engine oil:

4-stroke motor oil

API: SE, SF, SG, SH, or SJ SAE: 10W-30 or 10W-40

Engine oil quantity:

With oil filter replacement:

2.7 L (2.85 US qt, 2.38 Imp qt)

6. Install the oil filler cap and oil dipstick, and then start the engine and warm it up for 5 minutes.

7. Turn the engine off, and then check the oil level and correct it if necessary.

Checking the timing belt

CAUTION:

Do not turn the flywheel magnet counterclockwise, otherwise the valve system may be damaged.

1. Remove the flywheel magnet cover.

2. Remove the solenoid valve.

Power unit

S6C13090

Timing belt slack a:

Within 14 mm (0.55 in)

Replacing the timing belt

CAUTION:

Do not turn the flywheel magnet counterclockwise, otherwise the valve system may be damaged.

1. Remove the flywheel magnet cover.

2. Turn the flywheel magnet clockwise and align the “ 1” mark a on the driven sprocket with the “” mark b on the cylinder head.

1 2 3 4 5

3. While turning the flywheel magnet clockwise, check the interior and the exterior of the timing belt for cracks, damage, or wear. Replace if necessary.

4. Turn the flywheel magnet clockwise to transfer the slack of the timing belt from port to starboard, and then lightly hold the flywheel magnet in place.

5. Slightly push the timing belt with your finger between the drive gear and driven gear, and then measure the belt slack. Replace the timing belt if above specification.

S6C15850

6 7 8 9

6C13G11

3-6

CHK

ADJ

Periodic checks and adjustments

3. Loosen the flywheel magnet nut.

CAUTION:

Apply force in the direction of the arrows shown to prevent the flywheel holder from slipping off easily.

Flywheel holder: 90890-06522

4. Remove the flywheel magnet, then the Woodruff key.

NOTE:

Apply force to the crankshaft end until the flywheel magnet comes off the tapered portion of the crankshaft.

Flywheel puller: 90890-06521

5. Disconnect the stator coil coupler and pulser coil coupler, and remove the stator coil assembly 1.

6. Remove the solenoid valve, and then remove the timing belt 2 from the driven sprocket, then from the drive sprocket.

CAUTION:

To prevent damage to the engine or tools, screw in the puller set bolts evenly and completely so that the puller plate is parallel to the flywheel magnet.

3-7

CAUTION:

Do not turn the drive sprocket or the driven sprocket when the timing belt is not installed. Otherwise the piston and valves will interfere with each other and be damaged.

7. 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 retaining plate is aligned with the “” mark d on the crankcase.

6C13G11

8. Install a new timing belt 3 onto the drive

sprocket, then onto the driven sprocket with its part number in the upright position.

Power unit

10. Install the solenoid valve and stator coil assembly, and connect the stator coil coupler and pulser coil coupler.

11. Install the Woodruff key, then the flywheel magnet.

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 installation.

1 2 3 4 5

CAUTION:

• Do not damage the timing belt during installation.

• Do not twist, turn inside out, or bend the timing belt beyond the maximum limit of 25 mm (1.0 in), otherwise it can be damaged.

• Do not get oil or grease on the timing belt.

9. Turn the drive sprocket clockwise two

turns, and then check that the alignment marks are aligned.

Flywheel holder: 90890-06522

Flywheel magnet nut:

157 N·m (15.7 kgf·m, 115.8 ft·lb)

12. Adjust the pulser coil air gap.

NOTE:

For adjustment procedures, see Chapter 8, “Checking the pulser coil air gap.”

13. Install the flywheel magnet cover.

Checking the spark plugs

1. Disconnect the spark plug wires, and then remove the spark plugs.

6 7 8 9

6C13G11

3-8

CHK

ADJ

2. Clean the electrodes 1 with a spark plug cleaner or wire brush. Replace the spark plug if necessary.

Periodic checks and adjustments

2. Suspend the thermostat in a container of water.

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 gap a. Adjust if out of specification.

Specified spark plug:

DPR6EB-9 (NGK)

Spark plug gap a:

0.8–0.9 mm (0.031–0.035 in)

3. Place a thermometer in the water and slowly heat the water.

S69J5E40

4. Check the thermostat valve opening at the specified water temperatures. Replace if out of specification.

5. Install the spark plugs, tighten them finger tight, then to the specified torque using a spark plug wrench.

Spark plug:

17 N·m (1.7 kgf·m, 12.5 ft·lb)

Checking the thermostat

1. Remove the cover 1, gasket, and thermostat 2.

3-9

6C13G11

Power unit / Control system

Water

temperature

58–62 °C

(136–144 °F)

above

70 °C (158 °F)

5. Install the thermostat, gasket, and cover.

Checking the cooling water passage

1. Check the cooling water inlet cover and cooling water inlet for clogs. Clean if necessary.

Valve lift a

0.05 mm

(0.0020 in)

(valve begins to lift)

more than

3.0 mm (0.12 in)

Control system

Checking the engine idle speed

1. Start the engine and warm it up for 5 minutes.

2. Attach the special service tool to spark plug wire #1 1, and then check the engine idle speed.

1 2

3 4

S6C13100

F50, F60

2. Place the lower unit in water, and then start the engine.

3. Check for water flow at the cooling water pilot hole. If there is no water flow, check the cooling water passage inside the outboard motor.

S6C13110

Digital tachometer: 90890-06760

Engine idle speed: 700–800 r/min

Adjusting the throttle link and throttle cable

1. Set the remote control lever to the neutral position and fully close the throttle lever. Set the throttle grip to the fully closed position.

2. Disconnect the throttle link rod from the throttle body and the throttle link.

5 6 7 8 9

6C13G11

3-10

CHK

ADJ

Periodic checks and adjustments

3. Loosen the locknut 1, and then adjust the throttle link rod length a.

S6C13120

Throttle link rod length a:

121 mm (4.76 in)

4. Align the alignment mark b on the throttle control lever with the alignment mark

on the bracket.

6. Contact the cam roller 2 on the throttle control lever to the throttle cam as shown, and then adjust the position of the throttle link rod until the joint 3 of the throttle link rod is aligned with the joint

of the control lever.

S6C13140

S6C13130

5. Connect the throttle link rod to the throttle body.

NOTE:

Connect the end of the throttle link rod that does not have a locknut to the throttle body.

S6C13150

7. Connect the throttle link rod to the throttle link, and then tighten the locknut.

8. Loosen the locknut 5, remove the clip

, and then disconnect the throttle cable

joint 7.

S6C13160

9. Adjust the throttle cam 8 until the alignment mark d on the throttle cam is aligned with the alignment mark e on the bracket.

3-11

6C13G11

Control system

12. Operate the throttle to check that the throttle valves fully close and fully open, and check that the throttle cam contacts the fully closed stopper when the throttle is in the fully closed position.

13. Check the throttle cable for smooth operation and, if necessary, repeat steps 1–

12.

S6C13170

10. Adjust the position of the throttle cable joint until its hole is aligned with the set pin.

NOTE:

Pull the throttle cable towards the set pin to remove any free play in the cable before adjusting the position of the throttle cable joint.

S6C13180

Checking the gear shift operation

1. Check that the gear shift operates smoothly when shifting it from neutral to forward or reverse. Adjust the shift cable length if necessary.

2. Set the gear shift to the neutral position.

3. Loosen the locknut 1, remove the clip

, and then disconnect the shift cable

joint 3.

S6C13190

4. Align the center of the set pin a with the alignment mark b on the bracket.

2 3 4 5 6 7

11. Connect the throttle cable joint, install the clip, and then tighten the locknut.

WARNING

The throttle cable joint must be screwed in a minimum of 8.0 mm (0.31 in) f.

6C13G11

8 9

S6C13200

3-12

CHK

ADJ

Periodic checks and adjustments

5. Adjust the position of the shift cable joint until its hole is aligned with the set pin.

S69J3370

WARNING

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

6. Connect the cable joint, install the clip, and then tighten the locknut.

7. Check the gear shift for smooth operation and, if necessary, repeat steps 3–6.

Bracket unit

Checking the power trim and tilt operation

1. Fully tilt the outboard motor up and down a few times and check the entire trim and tilt range for smooth operation. Check the power trim and tilt fluid level if necessary.

NOTE:

Be sure to listen to the winding sound of the power trim and tilt motor for smooth operation.

2. Fully tilt the outboard motor up, and then support it with the tilt stop lever 1 to check the lock mechanism of the lever.

S6C13300

Checking the hydro tilt unit operation

1. Fully tilt the outboard motor up and down

a few times and check the entire tilt range for smooth operation. Replace the hydro tilt unit if necessary.

3-13

2. Fully tilt the outboard motor up, and then support it with the tilt stop lever 1 to check the lock mechanism of the lever.

3. Fully tilt the outboard motor up, and then lock the tilt stop lever 2 to check the lock mechanism of the hydro tilt unit. Replace the hydro tilt unit if necessary.

6C13G11

Control system / Bracket unit / Lower unit

S6C13360

Checking the power trim and tilt fluid level

1. Fully tilt the outboard motor up, and then support it with the tilt stop lever 1.

S6C13300

WARNING

After tilting up the outboard motor, be sure to support it with the tilt stop lever. Otherwise, the outboard motor could suddenly lower if the power trim and tilt unit should lose fluid pressure.

NOTE:

If the fluid is at the correct level, the fluid should overflow out of the filler hole when the reservoir cap is removed.

3. If necessary, add sufficient fluid of the recommended type until it overflows out of the filler hole.

Recommended power trim and tilt fluid:

ATF Dexron II

4. Install the reservoir cap, and then tighten it to the specified torque.

Reservoir cap:

7 N·m (0.7 kgf·m, 5.2 ft·lb)

Lower unit

Checking the gear oil level

1. Fully tilt the outboard motor down.

2. Remove the check screw 1, and then check the gear oil level in the lower case.

1 2 3 4

5 6

2. Remove the reservoir cap 2, and then check the fluid level in the reservoir.

S60V3320

NOTE:

If the oil is at the correct level, the oil should overflow out of the check hole when the check screw is removed.

7 8 9

6C13G11

3-14

CHK

ADJ

3. If necessary, add sufficient gear oil of the recommended type until it overflows out of the check hole.

Recommended gear oil:

Hypoid gear oil API: GL-4 SAE: 90

4. Install the check screw, and then tighten it to the specified torque.

Gear oil check screw:

9 N·m (0.9 kgf·m, 6.6 ft·lb)

Changing the gear oil

1. Tilt the outboard motor up slightly.

2. Place a drain pan under the drain screw

, remove the drain screw, then the check screw 2 and let the oil drain completely.

Periodic checks and adjustments

3. Check the oil for metal and discoloration, and its viscosity. Check the internal parts of the lower case if necessary.

4. Insert a gear oil tube or gear oil pump into the drain hole and slowly fill the gear oil until oil flows out of the check hole and no air bubbles are visible.

Recommended gear oil:

Hypoid gear oil API: GL-4 SAE: 90

Gear oil quantity:

F50, F60:

430 cm

(14.5 US oz, 15.2 Imp oz)

FT50, FT60:

670 cm

(22.7 US oz, 23.6 Imp oz)

5. Install the check screw and quickly install the drain screw, and then tighten them to the specified torque.

Gear oil check screw and drain screw:

9 N·m (0.9 kgf·m, 6.6 ft·lb)

Checking the lower unit for air leakage

1. Remove the check screw 1, and then install the special service tool.

3-15

6C13G11

Lower unit / General

Leakage tester: 90890-06840

2. Apply the specified pressure to check that the pressure is maintained in the lower unit for at least 10 seconds.

CAUTION:

Do not over pressurize the lower unit, otherwise the oil seals can be damaged.

General

Checking the anodes

1. Check the anodes and trim tab for scales, grease, or oil. Clean if necessary.

1 2 3 4

NOTE:

Cover the check hole with a rag when removing the tester from the lower unit.

Lower unit holding pressure:

100 kPa (1.0 kgf/cm

3. If pressure drops below specification, check the drive shaft and propeller shaft oil seals for damage.

Checking the propeller

1. Check the propeller blades and splines for cracks, damage, or wear. Replace if necessary.

, 14.5 psi)

5 6

S6C13240

7 8

S6C13250

6C13G11

3-16

CHK

ADJ

Periodic checks and adjustments

S60C3640

Power trim and tilt model

Hydro tilt model

F50, F60

FT50, FT60

CAUTION:

Do not oil, grease, or paint the anodes or the trim tab, otherwise they will be ineffective.

NOTE:

If it is necessary to disassemble the outboard motor to check an anode, refer to the applicable disassembly procedure in this manual.

2. Replace the anodes or trim tab if excessively eroded.

Checking the battery

1. Check the battery electrolyte level. If the level is at or below the minimum level mark a, add distilled water until the level is between the maximum and minimum level marks.

WARNING

Battery electrolyte is dangerous; it contains sulfuric acid which is poisonous and highly caustic. Always follow these preventive measures:

• Avoid bodily contact with electrolyte as it can cause severe burns or permanent eye injury.

• Wear protective eye gear when handling or working near batteries.

Antidote (EXTERNAL):

• SKIN – Wash with water.

• EYES – Flush with water for 15 minutes

and get immediate medical attention.

Antidote (INTERNAL):

• Drink large quantities of water or milk followed with milk of magnesia, beaten egg, or vegetable oil. Get immediate medical attention.

Batteries generate explosive, hydrogen gas. Always follow these preventive measures:

• Charge batteries in a well-ventilated area.

• Keep batteries away from fire, sparks or open flames (e.g., welding equipment, lighted cigarettes).

• DO NOT SMOKE when charging or handling batteries.

KEEP BATTERIES AND ELECTROLYTE OUT OF REACH OF CHILDREN.

NOTE:

• Batteries vary per manufacturer. The procedures mentioned in this manual may not always apply, therefore, consult the instruction manual of the battery.

• Disconnect the negative battery lead first, then the positive battery lead.

S69J3620

2. Check the specific gravity of the electrolyte. Fully charge the battery if out of specification.

3-17

Electrolyte specific gravity:

1.280 at 20 °C (68 °F)

6C13G11

Lubricating the outboard motor

1. Apply water resistant grease to the areas shown.

S6C13270

General

1 2

S6C13290

NOTE:

Apply grease to the grease nipple until it

S6C17360

flows from the bushings a.

S6C17540

5 6 7

6C13G11

8 9

3-18

CHK

ADJ

2. Apply low temperature resistant grease to the area shown.

3. Apply corrosion resistant grease to the area shown.

Periodic checks and adjustments

S6C13280

3-19

6C13G11

FUEL

Fuel system

Special service tools .....................................................................................4-1

Hose routing...................................................................................................4-2

Fuel and blowby hoses..............................................................................4-2

Cooling water pilot hoses ..........................................................................4-3

Fuel filter and fuel pump ...............................................................................4-4

Checking the fuel pump.............................................................................4-6

Disassembling the fuel pump ....................................................................4-6

Checking the diaphragm and valves .........................................................4-7

Assembling the fuel pump .........................................................................4-7

Checking the fuel joint ...............................................................................4-7

Intake manifold...............................................................................................4-8

Checking the throttle position sensor ......................................................4-11

Installing the throttle position sensor .......................................................4-11

Checking the idle speed control ..............................................................4-11

Vapor separator............................................................................................4-12

Disconnecting the quick connector..........................................................4-16

Measuring the fuel pressure ....................................................................4-16

Checking the pressure regulator .............................................................4-17

Draining the fuel ......................................................................................4-18

Disassembling the vapor separator .........................................................4-18

Checking the vapor separator .................................................................4-19

Adjusting the float ....................................................................................4-19

Assembling the vapor separator..............................................................4-20

1 2 3 4 5 6

6C13G11

7 8 9

FUEL

Fuel system

Special service tools

Vacuum/pressure pump gauge set 90890-06756

Fuel pressure gauge 90890-06786

Fuel pressure gauge adapter B 90890-06942

4-1

6C13G11

Special service tools / Hose routing

Hose routing

Fuel and blowby hoses

2 3 4

Blowby hose

Fuel hose (fuel joint-to-fuel filter)

Fuel hose (fuel filter-to-fuel pump)

Fuel hose (fuel pump-to-strainer)

Fuel hose (strainer-to-vapor separator)

High-pressure fuel hose (vapor separator-to-fuel rail)

Fuel hose (pressure regulator-to-fuel cooler)

Fuel hose (fuel cooler-to-vapor separator)

S6C14010

5 6 7 8

6C13G11

4-2

FUEL

Fuel system

Cooling water pilot hoses

Cooling water pilot hose (fuel cooler to fuel cooler)

Cooling water pilot hose (fuel cooler to fuel joint)

Cooling water pilot hose (fuel joint to upper case)

Flushing hose (hose joint to fuel joint)

Cooling water pilot hose (fuel joint to water outlet joint)

Cooling water pilot hose (fuel cooler to fuel joint)

Cooling water pilot hose (water outlet joint to water outlet)

Cooling water pilot hose (water outlet joint to exhaust cover)

S6C14340

4-3

6C13G11

Hose routing / Fuel filter and fuel pump

Fuel filter and fuel pump

2 3

3 N

m (0.3 kgf

No. Part name Q’ty Remarks

1 Fuel pump assembly 1 2Bolt 2 M6 × 30 mm 3 Fuel hose 1 4 Holder 1 5Strainer 1 6O-ring 1 7Screw 1 ø6 × 14 mm 8Bolt 1 M8 × 16 mm

9Nut 1 10 Bracket 1 11 Fuel filter assembly 1 12 O-ring 1 13 Fuel filter element 1 14 O-ring 1 15 Float 1 16 Cup 1 17 Clamp 4

Not reusable

m, 2.2 ft

Ib)

S6C14320

5 6 7 8 9

6C13G11

4-4

FUEL

Fuel system

No. Part name Q’ty Remarks

1Screw 4 ø5 × 43 mm

2 Cover 1

3Seal 1

Not reusable

4 Fuel pump body 2 assembly 1

5 Diaphragm 1

6Pin 1

7Spring 1

8 Fuel pump body 1 1

9Nut 4 10 Spring 1 11 Plunger 1 12 Spring washer 4

4-5

6C13G11

Checking the fuel pump

1. Disconnect the fuel hoses from the fuel pump.

2. Connect the special service tool to the fuel pump inlet.

3. Cover the fuel pump outlet with a finger, and then apply the specified positive pressure. Check that there is no air leakage.

Fuel filter and fuel pump

S6C14070

NOTE:

Assemble the fuel pump valve to the fuel pump body, and moisten the inside of the fuel pump with gasoline to ensure a good seal.

S6C14050

Vacuum/pressure pump gauge set:

90890-06756

Specified pressure:

50 kPa (0.5 kgf/cm

4. Apply the specified negative pressure and check that there is no air leakage.

, 7.3 psi)

Specified pressure:

50 kPa (0.5 kgf/cm

Disassembling the fuel pump

1. Disassemble the fuel pump.

2. Push down on the plunger and the diaphragm, turn fuel pump body 1 approximately 90° to a position where the pin 2 can be removed easily, and then remove the pin.

, 7.3 psi)

4 5 6 7

S6C14060

Specified pressure:

30 kPa (0.3 kgf/cm

5. Connect the special service tool to the fuel pump outlet.

6. Apply the specified positive pressure and check that there is no air leakage. Disassemble the fuel pump if necessary.

6C13G11

, 4.4 psi)

8 9

3. Slowly let up on the plunger and diaphragm, and then remove them.

4-6

FUEL

Fuel system

Checking the diaphragm and valves

1. Check the diaphragm for tears and the valves for cracks. Replace if necessary.

Assembling the fuel pump

NOTE:

Clean the parts and soak the valves and the diaphragm in gasoline before assembly to obtain prompt operation of the fuel pump when starting the engine.

1. Align the plunger and diaphragm installation holes a, and then install the plunger into the diaphragm.

2. Push down on the plunger and the diaphragm, and then install the pin 1.

Checking the fuel joint

1. Check the fuel hose connector for cracks or damage.

2. Connect the special service tool to the fuel hose connector outlet.

3. Apply the specified pressure to check that the pressure is maintained for 10 seconds. Replace the fuel hose connector if necessary.

3. Turn fuel pump body 1 2 approximately 90°, and then push down on the plunger several times to make sure that the pin does not come out.

Vacuum/pressure pump gauge set:

90890-06756

Fuel hose connector holding pressure:

50 kPa (0.5 kgf/cm

, 7.3 psi)

NOTE:

Make sure that the gasket and diaphragm are kept in place through the assembly process.

4-7

6C13G11

Fuel filter and fuel pump / Intake manifold

Intake manifold

3 4

No. Part name Q’ty Remarks

1 Blowby hose 1 2 Holder 1 3Hose 1 4Bolt 2 M6 × 35 mm 5Bolt 3 M6 × 45 mm 6Bolt 5 M8 × 40 mm 7 Intake manifold assembly 1 8 Cooling water pilot hose 1

9 Pressure regulator hose 1 10 Dowel 2 11 Plastic tie 1

Not reusable

S6C14100

6 7 8

6C13G11

4-8

FUEL

Fuel system

4 N

m (0.4 kgf

m, 3.0 ft

Ib)

4 N

m (0.4 kgf

m, 3.0 ft

Ib)

9 N

m (0.9 kgf

m, 6.6 ft

Ib)

9 N

m (0.9 kgf

No. Part name Q’ty Remarks

1 Fuel rail 1

2Gasket 1

3 Idle speed control 1

4Screw 2 ø5 × 13 mm

5 Wiring harness 1

6O-ring 1

7Screw 2 ø5 × 13 mm

8 Sensor assembly 1

9O-ring 1 10 Collar 2 11 Grommet 2 12 Intake silencer 1 13 Screw 2 14 Throttle position sensor 1 15 O-ring 1 16 Bolt 3 M6 × 16 mm 17 Throttle body assembly 1

m, 6.6 ft

Ib)

Not reusable

S6C14110

4-9

6C13G11

Intake manifold

4 N

m (0.4 kgf

m, 3.0 ft

4 N

m (0.4 kgf

Ib)

m, 3.0 ft

Ib)

1 2

9 N

m (0.9 kgf

m, 6.6 ft

Ib)

9 N

m (0.9 kgf

No. Part name Q’ty Remarks

18 Link rod 1 19 Gasket 1 20 Intake manifold 1 21 Fuel injector 4 22 O-ring set 4 23 Clip 2 24 Bolt 2 M6 × 38 mm

m, 6.6 ft

Ib)

Not reusable

S6C14110

6 7 8 9

6C13G11

4-10

FUEL

Fuel system

Checking the throttle position sensor

1. Check the throttle position sensor output voltage using the Yamaha Diagnostic System. If the output voltage is out of specification, replace the throttle position sensor.

S6C14350

Throttle position sensor output voltage at engine idle speed:

0.8–1.2 V

NOTE:

• If the throttle position sensor output voltage is out of specification, reinstall the throttle position sensor.

• Measure the throttle position sensor output voltage using the Yamaha Diagnostic System.

• Do not turn the throttle stop screw a.

Checking the idle speed control

1. Check the operation of the idle speed

control using the Yamaha Diagnostic System.

Installing the throttle position sensor

1. Install the throttle position sensor 1 in a position where the output voltage is within specification.

S6C14310

Throttle position sensor output voltage at engine idle speed:

0.8–1.2 V

4-11

6C13G11

Intake manifold / Vapor separator

Vapor separator

2 3 4

No. Part name Q’ty Remarks

1 Vapor separator 1 2 Collar 3 3Grommet 3 4Bolt 3 M6 × 30 mm 5 Cooling water pilot hose 1 6Bolt 1 M6 × 15 mm 7 Corrugated tube 1

S6C14130

6 7 8

6C13G11

4-12

FUEL

Fuel system

WATER

FUEL

WATER

3 N

1.5 N

m (0.15 kgf

m, 1.1 ft

Ib)

4 N

m (0.4 kgf

No. Part name Q’ty Remarks

1Hose 1 2 Joint 1 3Hose 1 4 Fuel hose 1 5 Holder 1 6 Fuel hose 1 7Hose 1 8Screw 6 ø5 × 14 mm

9 Cover assembly 1 10 Gasket 1 11 Hose 1 12 Hose 1 13 Screw 2 ø6 × 14 mm 14 Fuel cooler 1 15 Hose 1 16 Fuel hose 1 17 Joint screw 1

m, 3.0 ft

Not reusable

m (0.3 kgf

Ib)

3 N

m, 2.2 ft

m (0.3 kgf

Ib)

m, 2.2 ft

Ib)

S6C14140

4-13

6C13G11

WATER

FUEL

WATER

3 N

m (0.3 kgf

3 N

m, 2.2 ft

m (0.3 kgf

Ib)

Vapor separator

m, 2.2 ft

Ib)

1 2 3 4 5

1.5 N

m (0.15 kgf

No. Part name Q’ty Remarks

18 O-ring 1 19 Drain hose 1 20 Drain screw 1 21 O-ring 1 22 Float chamber 1 23 Fuel pump damper 1 24 High-pressure fuel hose 1 25 Clamp 1 26 Hose 1 27 Solenoid valve 1 28 Clamp 2

m, 1.1 ft

Ib)

4 N

m (0.4 kgf

m, 3.0 ft

Not reusable

Ib)

S6C14140

6 7 8 9

6C13G11

4-14

FUEL

Fuel system

4 N

m (0.4 kgf

5 N

m, 3.0 ft

m (0.5 kgf

Ib)

m, 3.7 ft

Ib)

m (0.2 kgf

2 N

m, 1.5 ft

Ib)

2 N

m (0.2 kgf

m, 1.5 ft

Ib)

No. Part name Q’ty Remarks

1 Cover 1

2 Pressure regulator 1

3Bolt 2 M6 × 12 mm

4O-ring 1

Not reusable

5 Joint screw 1

6O-ring 1

Not reusable

7 Electric fuel pump 1

8Grommet 1

9 Collar 1 10 Filter 1 11 Screw 2 ø4 × 6 mm 12 Wiring harness 1 13 Float 1 14 Needle valve 1 15 Pin 1 16 Clip 1

Not reusable

S6C14360

4-15

6C13G11

Disconnecting the quick connector

1. Wrap the quick connector with a rag, and then rotate the quick connector tab 1 to the stopper position a.

S6C14240

WARNING

If the quick connector is removed suddenly, pressurized fuel could spray out. To gradually release the fuel pressure, be sure to remove the quick connector slowly.

Vapor separator

WARNING

Always reduce the fuel pressure in the fuel line before servicing the line or the fuel pipe. If the fuel pressure is not released, pressurized fuel could spray out.

Measuring the fuel pressure

1. Disconnect the quick connector from the fuel rail.

NOTE:

Before disconnecting the quick connector, release the fuel pressure.

2. Connect the special service tools as shown.

1 2 3 4

CAUTION:

• Do not rotate the quick connector tab past the stopper position a, otherwise it could be damaged.

• When the fuel hoses are disconnected, quickly remove the retainer 2 from the quick connector, otherwise the retainer can be lost.

2. Disconnect the quick connector 3 from

the fuel rail 4 directly.

S6C14250

S6C14260

WARNING

• When connecting the fuel pressure gauge, first cover the connection between the gauge and adapter with a clean, dry rag to prevent fuel from leaking out.

• Gently screw in the gauge until it is firmly connected.

Fuel pressure gauge 1:

90890-06786

Fuel pressure gauge adapter B 2:

90890-06942

5 6 7 8 9

6C13G11

4-16

FUEL

Fuel system

3. Turn the engine start switch to ON, and then measure the fuel pressure within 3 seconds.

WARNING

Before measuring the fuel pressure, make sure that the drain screw is tightened securely.

NOTE:

The fuel pressure decreases 3 seconds after the engine start switch is turned to ON.

Fuel pressure (reference data):

290 kPa (2.9 kgf/cm

, 41.2 psi)

4. Start the engine, warm it up for 5 minutes, and then measure the fuel pressure. If below specification, check the high-pressure fuel line and the vapor separator.

WARNING

• Do not loosen the drain screw while

measuring the fuel pressure. Loosening the drain screw can cause fuel to spray out creating a fire hazard.

• After measuring the fuel pressure, cover

the end of the hose with a clean, dry rag, point the hose downward, and then loosen the drain screw to drain the remaining fuel from the hose and gauge.

• When storing the fuel pressure gauge,

make sure that the drain screw is tightened securely.

NOTE:

Before disconnecting the quick connector, release the fuel pressure.

3. Connect the special service tools as shown.

4. Disconnect the pressure regulator hose, and then connect the special service tools to the pressure regulator.

S6C14160

WARNING

• When connecting the fuel pressure

gauge, first cover the connection between the gauge and adapter with a clean, dry rag to prevent fuel from leaking out.

• Gently screw in the gauge until it is

firmly connected.

Fuel pressure gauge: 90890-06786 Vacuum/pressure pump gauge set:

90890-06756

Fuel pressure gauge adapter B:

90890-06942

Fuel pressure (reference data):

230 kPa (2.3 kgf/cm

, 32.7 psi)

Checking the pressure regulator

1. Remove the cap.

2. Disconnect the quick connector from the fuel rail.

4-17

5. Start the engine and let it idle.

6. Check that the fuel pressure reduces when vacuum pressure is applied to the pressure regulator. If the fuel pressure does not reduce, replace the pressure regulator.

6C13G11

WARNING

• Before measuring the fuel pressure, make sure that the drain screw is tightened securely.

• Do not loosen the drain screw while measuring the fuel pressure. Loosening the drain screw can cause fuel to spray out creating a fire hazard.

• After measuring the fuel pressure, cover the end of the hose with a clean, dry rag, point the hose downward, and then loosen the drain screw to drain the remaining fuel from the hose and gauge.

• When storing the fuel pressure gauge, make sure that the drain screw is tightened securely.

Draining the fuel

1. Remove the cap 1.

Vapor separator

4. Drain the fuel from the vapor separator drain hose by pressing the valve using a thin screwdriver.

S6C14190

Disassembling the vapor separator

1. Remove the cap 1.

2. Cover the valve a of the vapor separator with a rag, and then press in the valve using a thin screwdriver to release the fuel pressure.

1 2 3 4

2. Cover the valve a of the vapor separator with a rag, and then press in the valve using a thin screwdriver to release the fuel pressure.

WARNING

Always reduce the fuel pressure in the high-pressure fuel line before servicing the line or the vapor separator. If the fuel pressure is not released, pressurized fuel may spray out.

S6C14180

3. Remove the float chamber.

4. Remove the float pin and float.

S6C14180

5 6 7 8

3. Place a container under the vapor separator drain hose, and then loosen the drain screw 2.

6C13G11

S6C14220

NOTE:

Remove the float pin in the direction of the arrow b shown.

4-18

FUEL

Fuel system

5. Remove the needle valve and other components.

Checking the vapor separator

1. Check the needle valve for bends or wear. Replace if necessary.

Float height c:

46.6 ± 1.0 mm (1.83 ± 0.04 in)

S6D54200

2. Check the float for deterioration. Replace if necessary.

3. Check the filter for dirt or residue. Clean if necessary.

4. Install the needle valve, float, and float pin, and then check the float for smooth operation.

S6C14210

NOTE:

• Do not reuse the float pin, always replace it

with a new one.

• Install the float pin in the direction of the

arrow a shown.

• Install the float pin with its tapered end

towards the punch mark b on the vapor separator cover.

6. Check the float height

as shown. Adjust the float height if out of specification.

S6C14200

NOTE:

The float should be resting on the needle valve, but not compressing it.

Float height d:

35.0 ± 1.0 mm (1.38 ± 0.04 in)

Adjusting the float

1. Adjust the stopper a of the float by bending it until the float height b is within specification.

5. Check the float height c as shown. Adjust the float height if out of specification.

4-19

6C13G11

Float height b:

46.6 ± 1.0 mm (1.83 ± 0.04 in)

2. Adjust the lever c of the float by bending it until the float height d is within specification.

NOTE:

When adjusting the float height, do not bend the lever e.

Vapor separator

1 2 3 4

Float height d:

35.0 ± 1.0 mm (1.38 ± 0.04 in)

Assembling the vapor separator

1. Install the float chamber.

2. Install all parts removed during dissasembly.

NOTE:

Be sure to connect and route the hoses correctly.

5 6 7 8

6C13G11

4-20

POWR

Power unit

Special service tools .....................................................................................5-1

Power unit.......................................................................................................5-3

Checking the compression pressure .........................................................5-3

Checking the oil pressure ..........................................................................5-3

Checking the valve clearance....................................................................5-4

Removing the power unit.........................................................................5-14

Removing the timing belt and sprockets..................................................5-15

Checking the timing belt and sprockets...................................................5-16

Installing the timing belt and sprockets....................................................5-17

Cylinder head ...............................................................................................5-19

Removing the cylinder head ....................................................................5-23

Checking the valve springs......................................................................5-24

Checking the valves ................................................................................5-24

Checking the valve guides.......................................................................5-25

Replacing the valve guides......................................................................5-25

Checking the valve seat ..........................................................................5-26

Refacing the valve seat ...........................................................................5-27

Checking the rocker arms and rocker arm shaft......................................5-29

Checking the camshaft ............................................................................5-29

Checking the cylinder head .....................................................................5-30

Checking the oil pump .............................................................................5-31

Installing the valves .................................................................................5-31

Installing the camshaft.............................................................................5-32

Installing the rocker arm shaft assembly .................................................5-32

Installing the oil pump..............................................................................5-33

Installing the cylinder head ......................................................................5-34

Exhaust cover ..............................................................................................5-35

6C13G11

Cylinder block ..............................................................................................5-37

Disassembling the cylinder block ............................................................5-38

Checking the piston diameter ..................................................................5-39

Checking the cylinder bore ......................................................................5-39

Checking the piston clearance ................................................................5-39

Checking the piston rings ........................................................................5-39

Checking the piston ring grooves ............................................................5-40

Checking the piston ring side clearance..................................................5-41

Checking the piston pin boss bore ..........................................................5-41

Checking the piston pin ...........................................................................5-41

Checking the connecting rod small end inside diameter ......................... 5-41

Checking the connecting rod big end side clearance..............................5-41

Checking the crankshaft ..........................................................................5-42

Checking the crankpin oil clearance........................................................5-42

Selecting the connecting rod bearing ......................................................5-43

Checking the crankshaft journal oil clearance .........................................5-44

Selecting the main bearings ....................................................................5-45

Assembling the power unit ......................................................................5-46

Installing the power unit...........................................................................5-49

1 2 3 4 5 6 7 8 9

6C13G11

POWR

Power unit

Special service tools

Compression gauge 90890-03160

Flywheel holder 90890-06522

Valve spring compressor attachment 90890-06320

Valve guide remover/installer 90890-06801

Flywheel puller 90890-06521

Crankshaft holder 18 90890-06562

Valve spring compressor 90890-04019

Valve guide installer 90890-06810

Valve guide reamer 90890-06804

Valve seat cutter holder 90890-06316

5-1

6C13G11

Valve seat cutter 90890-06312, 90890-06315, 90890-06323, 90890-06327, 90890-06328, 90890-06555

Bearing outer race attachment 90890-06626

Special service tools

1 2 3

Oil filter wrench 90890-01426

Piston slider 90890-06529

4 5 6 7 8

6C13G11

5-2

POWR

Power unit

Checking the compression pressure

1. Start the engine, warm it up for 5 minutes, and then turn it off.

2. Remove the clip from the engine stop lanyard switch.

3. Remove the spark plug caps and all spark plugs, and then install the special service tools into a spark plug hole.

NOTE:

• If the compression pressure increases, check the pistons and piston rings for wear. Replace if necessary.

• If the compression pressure does not increase, check the valve clearance, valves, valve seat, cylinder sleeve, cylinder head gasket, and cylinder head. Adjust or replace if necessary.

Checking the oil pressure

1. Place a rag under the oil pressure switch.

2. Remove the oil pressure switch, and then

install an oil pressure gauge 1 into the oil pressure switch installation hole.

CAUTION:

Before removing the spark plugs, blow compressed air in the spark plug well to clear out any dirt or dust that may fall into the cylinder.

Compression gauge 1:

90890-03160

4. Fully open the throttle, crank the engine until the reading on the compression gauge stabilizes, and then check the compression pressure.

Minimum compression pressure (reference data):

960 kPa (9.6 kgf/cm

5. If the compression pressure is below specification and the compression pressure for each cylinder is unbalanced, add a small amount of engine oil to the cylinder, and then check the pressure again.

, 139.2 psi)

NOTE:

Use a general pressure gauge.

3. Start the engine and warm it up for 5 minutes.

4. Check the oil pressure. Check the oil pump and oil strainer and check for oil leakage if below specification.

Oil pressure (reference data):

125 kPa (1.25 kgf/cm

, 18.1 psi)

at engine idle speed

5. Increase the engine speed, and then check the relief valve opening pressure.

NOTE:

The relief valve is installed in the oil pump.

5-3

6C13G11

Relief valve opening pressure (reference data):

350–450 kPa (3.5–4.5 kgf/cm

Checking the valve clearance

CAUTION:

Do not turn the flywheel magnet counterclockwise, otherwise the valve system may be damaged.

1. Remove the flywheel magnet cover, and then remove the blowby hose 1.

2. Remove the fuel pump 2 and fuel filter

, 50.8–62.3 psi)

Power unit

S6C15140

1 2 3

3. Disconnect the spark plug caps and remove the spark plugs and cylinder head cover 4.

4. Turn the flywheel magnet clockwise and align the “ 1” mark a on the driven sprocket with the “” mark b on the cylinder head.

S6C15130

5. Check the intake valve clearance for cylinders #1 and #2, and the exhaust valve clearance for cylinders #1 and #3. Adjust if out of specification.

6. Turn the flywheel magnet clockwise and align the “ 4” mark c on the driven sprocket with the “” mark b on the cylinder head.

4 5 6 7 8

6C13G11

5-4

POWR

Power unit

7. Check the intake valve clearance for cylinders #3 and #4, and the exhaust valve clearance for cylinders #2 and #4. Adjust if out of specification.

EX IN

NOTE:

• To decrease the valve clearance, turn the adjusting screw clockwise.

• To increase the valve clearance, turn the adjusting screw counterclockwise.

9. Tighten the rocker arm locknut to the

specified torque, and then check the valve clearance again. Adjust if necessary.

Rocker arm locknut 5:

14 N·m (1.4 kgf·m, 10.3 ft·lb)

10. Install the cylinder head cover, fuel

pump, fuel filter, spark plugs, spark plug caps, blowby hose, and flywheel magnet cover.

S6C15150

NOTE:

Check the valve clearance when the engine is cold.

Valve clearance (cold):

Intake d:

0.20 ± 0.05 mm (0.008 ± 0.002 in)

Exhaust e:

0.30 ± 0.05 mm (0.012 ± 0.002 in)

8. Loosen the rocker arm locknut 5, and then turn the adjusting screw 6 until the specified valve clearance is obtained.

S6C15160

5-5

6C13G11

Power unit

1 2 3

No. Part name Q’ty Remarks

1 Power unit 1 2 Oil dipstick 1 3Gasket 1 4 Dowel 2 5Bolt 2 M6 × 16 mm 6Bolt 8 M8 × 80 mm 7 Apron 1 8Screw 2 ø6 × 24 mm

9Nut 2 10 Flywheel magnet cover 1 11 Grommet 2 12 Neutral switch 1 Tiller handle model 13 Shift position switch 1 14 Bolt 2 M6 × 20 mm 15 Screw 2 ø4 × 16 mm 16 Plate 1 17 Collar 1

Not reusable

4 5 6 7 8 9

6C13G11

5-6

POWR

Power unit

No. Part name Q’ty Remarks

1Nut 1

2 Washer 1

3 Flywheel magnet 1

4Bolt 3 M6 × 30 mm

5 Stator coil 1

6 Stator coil bracket 1

7Bolt 4 M6 × 30 mm

8 Collar 2

9 Pulser coil 1 10 Bolt 2 M5 × 12 mm 11 Woodruff key 1 12 Bolt 1 M6 × 20 mm

5-7

6C13G11

Power unit

1 2 3

No. Part name Q’ty Remarks

1 Timing belt 1

2 Nut 1 Width across flats: 41 mm (1.6 in)

3 Retaining plate 1

4 Drive sprocket 1

5 Bolt 1 M10 × 35 mm

6 Washer 1

7 Driven sprocket 1

8 Dowel 1

9 Woodruff key 1

4 5 6 7 8

6C13G11

5-8

POWR

Power unit

7 N

m (0.7 kgf

No. Part name Q’ty Remarks

1 Rectifier Regulator 1

2Bolt 2 M6 × 25 mm

3 Spark plug 4

4 Spark plug wire 4

5 Holder 1

6 Ignition coil 2

7Bolt 4 M6 × 30 mm

8 Holder 2

9Bracket 1 10 Bracket 1 11 Cover 1 12 Holder 1

m, 5.2 ft

Ib)

17 N

m (1.7 kgf

m, 12.5 ft

Ib)

S6C15050

5-9

6C13G11

Yamaha F50, F60 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Contents

General information

Specifications

Periodic checks and adjustments

Fuel system

Power unit