F60A

SUPPLEMENTARY SERVICE MANUAL

292098 69W-28197-3D-1X

NOTICE
This Supplementary Service Manual has been prepared to introduce new service and new data information for the F60 which is based on the F50. For complete information on service procedures, it is necessary to use this Supplementary Service Manual together with the following manual. F50A, FT50B, FT50C SERVICE MANUAL: 62Y-28197-3A-11

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.

F60A SUPPLEMENTARY SERVICE MANUAL 2001 by Yamaha Motor Co., Ltd. 1st Edition, July 2001 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited. Printed in the Netherlands

Contents General information Specifications Periodic checks and adjustments Fuel system Power unit Lower unit Bracket unit Electrical systems Troubleshooting Index
GEN INFO

SPEC

CHK ADJ

FUEL

POWR

LOWR

BRKT
+

ELEC

TRBL SHTG

1 2 3 4 5 6 7 8 9

General information
How to use this manual .................................................................................... 1 Manual format............................................................................................... 1 Symbols........................................................................................................ 2 Identification...................................................................................................... 3 Applicable models ........................................................................................ 3 Serial number ............................................................................................... 3 Features and benefits ....................................................................................... 4 Power unit..................................................................................................... 4 Carburetors................................................................................................... 5 Lower unit ..................................................................................................... 7 Bracket unit................................................................................................... 9 Electrical unit .............................................................................................. 10 Technical tips .................................................................................................. 11 Carburetor .................................................................................................. 11 PTT (Power Trim and Tilt) unit ................................................................... 12 Propeller selection .......................................................................................... 13 Propeller size.............................................................................................. 13 Selection..................................................................................................... 13 Predelivery checks ......................................................................................... 14 Checking the fuel system ........................................................................... 14 Checking the gear oil.................................................................................. 14 Checking the engine oil .............................................................................. 14 Checking the battery................................................................................... 14 Checking the outboard motor mounting height........................................... 14 Checking the shift/throttle cables................................................................ 15 Checking the steering system .................................................................... 15 Checking the gearshift and throttle operation............................................. 16 Checking the tilt system.............................................................................. 16 Checking the engine start switch and engine stop switch/ engine shut-off switch ............................................................................... 16 Checking the cooling water pilot hole ......................................................... 17 Test run ...................................................................................................... 17 Break-in ...................................................................................................... 17 After test run ............................................................................................... 17

69W3D1X

Specifications
General specifications.................................................................................... 18 Maintenance specifications ........................................................................... 20 Power unit................................................................................................... 20 Lower unit ................................................................................................... 24 Electrical ..................................................................................................... 24 Dimensions................................................................................................. 27 Tightening torques.......................................................................................... 32 Specified torques........................................................................................ 32 General torques.......................................................................................... 33

Periodic checks and adjustments

Special service tools ...................................................................................... 34 Maintenance interval chart............................................................................. 36 Top cowling ..................................................................................................... 37 Checking the top cowling............................................................................ 37 Fuel system ..................................................................................................... 37 Checking the fuel filter ................................................................................ 37 Power unit........................................................................................................ 37 Checking the thermostat............................................................................. 37 General............................................................................................................. 38 Checking the anodes.................................................................................. 38 Lubrication .................................................................................................. 39

Fuel system
Hose routing .................................................................................................... 40 Fuel and blowby hoses............................................................................... 40 Cooling water hose..................................................................................... 41 Fuel line and fuel filter .................................................................................... 42 Carburetor unit ................................................................................................ 43 Adjusting the dashpot (acceleration pump) ................................................ 44

69W3D1X

Power unit
Power unit........................................................................................................ 45 Checking the compression pressure .......................................................... 55 Checking the oil pressure ........................................................................... 55 Checking the cylinder bore ......................................................................... 56 Checking the piston ring grooves ............................................................... 56

Lower unit
Drive shaft and lower case............................................................................. 57 Removing the drive shaft............................................................................ 59 Disassembling the forward gear ................................................................. 59 Assembling the forward gear...................................................................... 59 Installing the drive shaft.............................................................................. 59 Shimming......................................................................................................... 60 Shimming.................................................................................................... 61 Selecting the forward gear shims ............................................................... 61

Bracket unit
Tiller handle ..................................................................................................... 63 Bottom cowling ............................................................................................... 65 Upper case....................................................................................................... 67 Disassembling the oil pan........................................................................... 71 Assembling the oil pan ............................................................................... 71 Installing the upper case............................................................................. 72 Clamp brackets ............................................................................................... 74 Adjusting the trim sensor ............................................................................ 75 Swivel bracket and steering arm ................................................................... 76 Power trim and tilt unit ................................................................................... 77 Disassembling the gear pump .................................................................... 82 Checking the valves ................................................................................... 82 Assembling the gear pump......................................................................... 83 Checking the trim sensor............................................................................ 84

69W3D1X

Electrical systems
Wiring harness ................................................................................................ 85 Ignition and ignition control system ............................................................. 86 Checking the spark plug caps .................................................................... 88 Checking the pulser coil air gap ................................................................. 88 Checking the engine start switch................................................................ 88 Starting system ............................................................................................... 89 Starter motor ................................................................................................... 90 Checking the armature ............................................................................... 91 Checking the brushes................................................................................. 91 Wiring diagram

69W3D1X

GEN INFO
Manual format

General information
1

How to use this manual

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. 1 Parts are shown and detailed in an exploded diagram and are listed in the components list. 2 Tightening torque specifications are provided in the exploded diagrams and after a numbered step with tightening instructions. 3 Symbols are used to indicate important aspects of a procedure, such as the grade of lubricant and lubrication point. 4 The components list consist of parts and part quantities, as well as bolt, screw, O-ring, and hose dimensions. 5 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.

69W3D1X

How to use this manual

Symbols
The symbols below are designed to indicate the content of a chapter. General information Fuel system Bracket unit

GEN INFO
Specifications

FUEL
Power unit

BRKT
Electrical systems

SPEC

POWR

ELEC

Periodic checks and adjustments Lower unit

Troubleshooting

CHK ADJ

LOWR

TRBL SHTG

Symbols 1 to 6 indicate specific data.

1 2 3 4
T.

5
R.

1 2 3 4

Special tool Specified oil or fluid Specified engine speed Specified tightening torque

5 Specified measurement 6 Specified electrical value (resistance, voltage, electric current)

Symbols 7 to A in an exploded diagram indicate the grade of lubricant and the lubrication point.
7 8
A

9
M

0
D

A
C

E
7 Apply Yamaha 4-stroke motor oil 8 Apply water resistant grease (Yamaha grease A) 9 Apply molybdenum disulfide grease 0 Apply corrosion resistant grease (Yamaha grease D) A Apply low temperature resistant grease (Yamaha grease C)

Symbols B to G in an exploded diagram indicate the type of sealant or locking agent and the application point.
B
GM

E
LT LT

F
LT

G
SS

1 2 3 4 5 6 7 8 9

271

242

572

B Apply Gasket Maker C Apply Yamabond No. 4 D Apply LOCTITE No. 271 (Red)
69W3D1X

E Apply LOCTITE No. 242 (Blue) F Apply LOCTITE No. 572 G Apply silicon sealant

GEN INFO
Identification

General information
1

Applicable models
This manual covers the following models. Applicable models F60AEHT F60AET

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

1 2 3 4

Model name Approved model code Transom height Serial number

Model name F60AEHT F60AET

Approved model code 69W

Starting serial No. L: 500101 L: 400101

69W3D1X

Identification / Features and benefits Features and benefits

Power unit
Based on the power unit of the field-proven F50, newly designed parts have been adopted in the various areas to attain 60 horsepower. The newly designed parts include the intake valves, exhaust valves, cylinder head, pistons, and the intake silencer. Cylinder head The shape of the combustion chamber has been changed to increase its capacity. The diameter of the intake and exhaust valves have been enlarged to increase output.
1

F50

F60

83.5 mm (3.29 in)

84.1 mm (3.31 in)

84.0 mm (3.31 in)

84.8 mm (3.34 in)

30.0 mm (1.18 in)

F50

26.0 mm (1.02 in)

32.0 mm (1.26 in)

F60

26.7 mm (1.05 in)

S69W1200

1 Combustion chamber 2 Intake valve 3 Exhaust valve

69W3D1X

GEN INFO

General information

Oil pump The size of the oil pump rotor has been enlarged to increase the oil discharge volume. As a result, reliable lubrication has been realized.

22 mm (0.87 in)

24 mm (0.94 in)

F50

F60

S69W1210

1 Rotor 2 Embossed letters for identification Oil discharge volume F50 F60 21.5 L (5.68 US gal, 0.22 Imp gal)/min 23.5 L (6.21 US gal, 5.17 Imp gal)/min

Carburetors
To achieve the high power output of the F60, the carburetor bores have been enlarged.

27

22

F50

30

F60

25
S69W1220

Comparison chart of carburetor bores Throttle valve F50 F60 27 30 Venturi 22 25

69W3D1X

Features and benefits

Although the main jet specification numbers of the F50 differed between cylinders, the F60 uses main jets with the same specification number for all four cylinders due to the change in shape of the intake silencer.

F50

F60

:
S69W1230

Air Comparison chart of main jet diameters Cylinder F50 F60 #1 #124 #124 #2 #126 #124 #3 #116 #124 #4 #114 #124

Power nozzle The F60 uses a power nozzle in its carburetors. This nozzle provides a rich air-fuel mixture to ensure the proper output when operating at high engine speeds.

S69W1240

1 Power nozzle 2 Fuel inlet Air-fuel mixture

69W3D1X

GEN INFO
Lower unit

General information

Drive shaft The drive shaft has been machined to accommodate the high power output. The portion that mounts to the pinion gear has been machined with involute splines to increase durability. A section of the midspan of the drive shaft has been reduced to 14.4 mm (0.57 in) to prevent the drive shaft from breaking under impact loads. In addition, two grooves are provided on the drive shaft for identification purposes.

14.4

95.5 mm (3.76 in)

F60:

F50:

S69W1250

1 Grooves for identification 2 Involute splines 3 Angled splines

69W3D1X

Features and benefits

Forward gear bearing The size of the forward gear bearing has been increased to accommodate the high power output of the F60. With this increase, the coupling length of the forward gear has been extended as well. In addition, two grooves are provided on the forward gear for identification purposes.

26.0 mm (1.02 in)

23.2 mm (0.91 in)

S69W1260

1 Forward gear bearing 2 Grooves for identification 3 Forward gear Bearing comparison chart Forward gear bearing F50 F60 22.2 mm (0.87 in) 26.0 mm (1.02 in) Forward gear 18.5 mm (0.73 in) 23.2 mm (0.91 in)

Propeller The propeller of the F60 has been newly designed (69W series). The strength of the propeller blades and the slipping resistance of the damper have been increased. The 11-, 13-, and 15-inch propellers of the currently used 663 series will be gradually replaced by the 69W series.

69W3D1X

GEN INFO
Bracket unit

General information

PTT (Power trim and tilt) unit Based on the 62Y type PTT unit of the F50, the internal valve and power trim and tilt motor have been changed. The construction of the valves has been changed to increase the shut-off pressure. The unit limits the movement of the outboard motor, which has increased in size with the increase in its power output, and secures it in place.

31 MPa [316 kgf/cm2] (31 MPa [316 kgf/cm2])

69W-00

18 MPa [184 kgf/cm2] (14 MPa [143 kgf/cm2]) 12 MPa [122 kgf/cm2] (10 MPa [102 kgf/cm2]) 3.3 MPa [34 kgf/cm2] (2.0 MPa [20.4 kgf/cm2])

S69W1270

Specified PTT motor output

F50A F60A 1 2 3 4 5 12 V 0.15 kW 12 V 0.20 kW 6 7 8 Up-relief valve Down-relief valve Gear pump Shut-off pressure of the F60 valves Shut-off pressure of the F50 valves

PTT motor Identification mark Tilt piston absorber Tilt and trim cylinder Manual valve

69W3D1X

Features and benefits

Steering friction The F60 tiller handle models use a newly developed, compact steering friction.

S69W1280

1 Steering friction

Electrical unit
Starter motor The starter motor uses six magnets and four brushes to enhance its operating torque.

F50

F60
S69W1290

1 2 3 4

Bearing Starter relay Neutral switch Engine start switch Operating torque F50 F60 2.74 Nm (0.27 kgfm, 2.0 ftlb) 3.50 Nm (0.35 kgfm, 2.5 ftlb)

5 6 7 8

Magnet Brush Starter motor Battery

69W3D1X

10

GEN INFO
Technical tips
Carburetor

General information
1

Power nozzle The power nozzle is activated when the engine is operating at high speeds. To reduce the fuel consumption rate and the pollution of the exhaust gases, the carburetors of the F60 are set lean. Therefore, the air-fuel mixture becomes lean at high engine speeds, when greater output is needed. The power nozzle supplies a richer fuel mixture at high engine speed to realize the optimal air-fuel ratio to produce output.

: : :
S69W1300

1 2

Throttle valve Power nozzle Air Air-fuel mixture Fuel

11

69W3D1X

Technical tips
PTT (Power Trim and Tilt) unit
Shuttle piston A ball type shut-off construction is used for both the up-shuttle and down-shuttle pistons. The ball type realizes a reliable shut-off operation and high shut-off pressure.

F50

F60
S69W1310

1 Ball

69W3D1X

12

GEN INFO

General information
1

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.

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

Selection
When the engine speed is at the full throttle operating range (5,0006,000 r/min), the ideal propeller for the boat is one that provides maximum performance in relation to boat speed and fuel consumption. Propeller size (in) 10 15 - G 10 3/8 13 - G 10 5/8 12 - G 10 3/4 16 - G 11 15 - G 11 5/8 11 - G 11 3/4 10 - G 12 1/4 8 - G Aluminum Material

Propeller size
The size of the propeller is indicated on the propeller blade or outside of the propeller boss.

12 1/4 9 - G 10 1/4 14 - G 10 1/4 15 - G 10 1/4 16 - G 10 5/8 13 - G Stainless

S69W1030

11 1/2 13 - G 11 3/4 12 - G 12 11 - G

S69W1040

S69W1050

13

69W3D1X

Propeller selection / Predelivery checks Predelivery checks

1

Checking the engine oil

1. Check the oil level.

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 above the maximum level mark a, drain sufficient oil until the level is between a and b. 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: API: SE, SF, SG, or SH SAE: 10W-30, 10W-40, or 20W-40 Oil capacity: Without oil filter replacement: 2.0 L (2.1 US qt, 1.8 Imp qt)

CAUTION:
This is a 4-stroke engine. Do not use premixed fuel and 2-stroke outboard motor oil.

Checking the battery

1. Check the capacity, electrolyte level, and specified gravity of the battery. Battery capacity: 12 V, 70100 Ah

Checking the gear oil

1. Check the gear oil level. 2. Check that the red and black battery cables are securely connected.

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.

S69W1070

69W3D1X

14

GEN INFO

General information

S69W1110

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.

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

Checking the steering system

1. Check the steering friction for proper adjustment. 2. Check that smoothly.

Checking the shift/throttle 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. Adjust if necessary. 3. Check that the alignment mark c is aligned with the mark d. Adjust if necessary.

the

steering

operates

Tiller handle model Remote control model

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

15

69W3D1X

Predelivery checks
Checking the gearshift and throttle operation
1. Check that the gearshift operates smoothly when the remote control lever or shift lever is shifted from neutral into forward or reverse. 2. Check that the throttle operates smoothly when the remote control lever or throttle grip is shifted from the fully closed position to the fully open position a.

Checking the engine start switch and engine stop switch/engine shut-off 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. 3. Check that the engine turns off when the engine stop switch is pushed or the engine shut-off cord is pulled from the engine shut-off switch.

N F R

S69W1150

Tiller handle model Remote control model

S69W1170

Checking the tilt system

1. Check that the outboard motor tilts up and down smoothly when operating the power trim and tilt unit. 2. Check that there is no abnormal noise produced when the outboard motor is tilted up or down. 3. Check that there is no interference with wires and 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.

Tiller handle model Remote control model

69W3D1X

16

GEN INFO

General information

Checking the cooling watger pilot hole

1. Start the engine, and then check that cooling water is discharged from the cooling water pilot hole.
0 1 2 10

S69W1190

Hour

After test run

1. Check for water in the gear oil. 2. Check for fuel leakage in the cowling.

Test run
1. Start the engine, and then check that the gearshift 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 one 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.

3. After a test run and while the engine is at idle, flush the cooling water passage with fresh water using the flushing kit.

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 one minute out of every ten at full throttle. 3. Eight hours c at any speed, however, avoid running at full speed for more than five minutes.

17

69W3D1X

Predelivery checks / General specifications General specifications

Item Dimension Overall length Overall width Overall height (L) Boat transom height (L) Weight (with aluminum propeller) (L) Performance Maximum output Full throttle operating range Maximum fuel consumption Unit mm (in) mm (in) mm (in) mm (in) Model F60AEHT 1,339 (52.7) 384 (15.1) 1,415 (55.7) 508 (20.0) F60AET 706 (27.8)
2

kg (lb) kW (hp) at 5,500 r/min r/min L (US gal, lmp gal)/hr at 6,000 r/min

120.0 (265) 44.1 (60.0)

114.0 (251)

5,0006,000 19.5 (5.15, 4.29)

Power unit Type Cylinder quantity Displacement Bore stroke Compression ratio Carburetor quantity Control system Starting system Ignition control system Ignition timing Alternator output Enrichment system Spark plugs Cooling system Exhaust system Lubrication system

cm3 (cu. in) mm (in)

Degree V, A

In-line, 4-stroke, OHC, 8 valves 4 996 (60.8) 65.0 75.0 (2.56 2.95) 9.5 4 Tiller handle Remote control Electric Microcomputer (CDI) TDC 0BTDC 25 12, 10 Prime Start DPR5EA-9 Water Through propeller boss Wet sump

1 2 3 4 5 6 7 8 9
18

69W3D1X

SPEC
Item Fuel and oil Fuel type Fuel rating Engine oil type Engine oil grade

Specifications
Unit Model F60AEHT F60AET

PON* RON API SAE

Regular unleaded gasoline 86 91 4-stroke motor oil SE, SF, SG, or SH 10W-30, 10W-40, or 20W-40 2.2 (2.3, 1.9) 2.0 (2.1, 1.8) Hypoid gear oil GL-4 90 0.43 (0.45, 0.38)

L (US qt, lmp qt) (without oil filter replacement) L (US qt, lmp qt) Gear oil type Gear oil grade API SAE Gear oil quantity L (US qt, lmp qt) Bracket Trim angle Degree (at 12 degree boat transom) Tilt-up angle Degree Steering angle Degree Drive unit Gearshift positions Gear ratio Reduction gear type Clutch type Propeller shaft type Propeller direction (rear view) Propeller identification mark Electrical Battery capacity V, Ah

Engine oil quantity (with oil filter replacement)

4 to 16 69 40 + 40 F-N-R 1.85 (24/13) Spiral bevel gear Dog clutch Spline Clockwise G 12, 70100

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

19

69W3D1X

General specifications / Maintenance specifications Maintenance specifications

Power unit
Item Power unit Minimum compression pressure* Lubrication oil pressure (reference data) Cylinder heads Warpage limit Unit kPa (kgf/cm2, psi) kPa (kgf/cm2, psi) at 900 r/min mm (in) Model F60AEHT 880 (8.8, 125) 110 (1.1, 16) F60AET
2

0.1 (0.004)

(lines indicate straightedge position) Cylinder head journal inside diameter Cylinders Bore size Taper limit Out-of-round limit Pistons Piston diameter (D) Measuring point (H) Piston-to-cylinder clearance Piston pin boss bore size Oversize piston 1st 2nd Oversize piston diameter 1st 2nd Piston pins Outside diameter

mm (in)

37.0037.02 (1.45671.4575)

mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in)

65.0065.01 (2.55912.5594) 0.08 (0.0031) 0.01 (0.0004) 64.9564.96 (2.55712.5574) 5 (0.2) 0.0350.065 (0.00140.0025) 15.97415.985 (0.62890.6293) +0.25 (0.0098) +0.50 (0.0196) 65.2065.21 (2.56692.5673) 65.4565.46 (2.57682.5771) 15.96515.970 (0.62850.6287)

* Measuring conditions: Ambient temperature of 20 C (68 F), with throttle fully open, and spark plugs removed from all cylinders The figures are for reference only.

69W3D1X

20

SPEC
Item

Specifications
Unit Model F60AEHT F60AET

Piston rings Top ring Dimension B Dimension T End gap Side clearance 2nd ring Dimension B Dimension T End gap Side clearance Oil ring Dimension B Dimension T End gap Side clearance Camshafts Intake (A) Exhaust (A) Intake and exhaust (B) Camshaft journal diameter #1 #2, #3, #4 Camshaft journal oil clearance #1 #2, #3, #4 Maximum camshaft runout Rocker arm shafts Outside diameter Rocker arms Inside diameter Valves Valve clearance (cold) Intake Exhaust Head diameter (A) Intake Exhaust

mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in)

1.171.19 (0.04610.0468) 2.302.50 (0.09060.0984) 0.150.30 (0.00600.0118) 0.020.06 (0.00080.0023) 1.471.49 (0.05780.0586) 2.602.80 (0.10240.1102) 0.300.50 (0.01180.0196) 0.020.06 (0.00080.0023) 2.362.48 (0.09290.0976) 2.75 (0.1083) 0.200.70 (0.00790.0275) 0.040.18 (0.00160.0070) 30.8930.99 (1.21611.2200) 30.8230.92 (1.21351.2175) 25.9526.05 (1.02171.0256)

mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in)

36.9336.94 (1.45391.4543) 36.9436.95 (1.45431.4547) 0.060.10 (0.00230.0039) 0.050.09 (0.00200.0035) 0.04 (0.0016) 15.9815.99 (0.62910.6295) 16.0016.01 (0.62990.6303)

mm (in) mm (in) mm (in) mm (in)

0.20 0.05 (0.008 0.002) 0.30 0.05 (0.012 0.002) 31.932.1 (1.25601.2637) 26.626.8 (1.04721.0551)

21

69W3D1X

Maintenance specifications
Item Face width (B) Intake Exhaust Seat contact width (C) Intake Exhaust Margin thickness (D) Intake Exhaust Stem diameter Intake Exhaust Guide inside diameter Intake and exhaust Stem-to-guide clearance Intake Exhaust Stem runout limit Intake Exhaust Valve springs Free length Minimum free length Tilt limit Connecting rods Small-end inside diameter Big-end inside diameter Crankpin oil clearance Big-end bearing thickness Yellow Red Pink Green Crankshaft Crankshaft journal Diameter Crankpin Diameter Runout limit Crankcase Crankcase main journal inside diameter Crankshaft main journal oil clearance
69W3D1X

Unit mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in)

Model F60AEHT F60AET

1.982.40 (0.07800.0945) 2.162.79 (0.08500.1098) 1.31.5 (0.05120.0590) 1.31.5 (0.05120.0590) 0.81.2 (0.03150.0472) 1.01.4 (0.03940.0551) 5.485.49 (0.21570.2161) 5.465.47 (0.21500.2153) 5.505.51 (0.21650.2169) 0.010.03 (0.00040.0012) 0.030.05 (0.00120.0020) 0.05 (0.0020) 0.03 (0.0012) 39.85 (1.5689) 37.85 (1.4901) 1.7 (0.067) 15.98515.998 (0.62930.6298) 36.00036.024 (1.41731.4183) 0.0160.040 (0.00060.0015) 1.5001.504 (0.05910.0592) 1.4961.500 (0.05890.0591) 1.4921.496 (0.05870.0589) 1.4881.492 (0.05860.0587)

mm (in) mm (in) mm (in) mm (in) mm (in)

42.98443.000 (1.69231.6929) 32.98433.000 (1.29861.2992) 0.04 (0.0016) 46.00046.024 (1.81101.8120) 0.0120.036 (0.00050.0014)

22

SPEC
Item

Specifications
Unit Model F60AEHT F60AET

Crankcase main journal bearing thickness Yellow Red Pink Green Oil pump Type Outer rotor-to-housing clearance Outer rotor-to-inner rotor clearance limit Rotor-to-cover clearance Thermostat Opening temperature Fully open temperature

mm (in) mm (in) mm (in) mm (in)

1.5021.506 (0.05910.0593) 1.4981.502 (0.05900.0591) 1.4941.498 (0.05880.0590) 1.4901.494 (0.05870.0588) Trochoid 0.090.15 (0.00350.0059) below 0.12 (0.0047) 0.030.08 (0.00120.0031) 60 (140) 70 (158)

mm (in) mm (in) mm (in) C (F) C (F)

Valve open lower limit Fuel pump Discharge

mm (in) L (US gal, Imp gal)/hr at 6,000 r/min kPa (kgf/cm2, psi) mm (in)

3.0 (0.12) 70 (18.5, 15.4)

Pressure Plunger stroke Carburetor ID mark Main jet Pilot jet Pilot screw Float height Engine idle speed

49 (0.49, 7.0) 5.859.65 (0.23030.3799) 69W00 124 39 1 3/42 3/4 5.2 (0.20) 800900

# # turns out mm (in) r/min

23

69W3D1X

Maintenance specifications
Lower unit
Item Gear backlash Pinion-to-forward gear Pinion-to-reverse gear Pinion shims Forward gear shims Reverse gear shims Unit mm (in) mm (in) mm mm mm Model F60AEHT F60AET

0.180.54 (0.00710.0212) 0.711.07 (0.02800.0421) 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50

Electrical
Item Ignition system Ignition timing (engine idle speed) Charge coil output peak voltage (L Br) at cranking (unloaded) at cranking (loaded) at 1,500 r/min (loaded) at 3,500 r/min (loaded) Charge coil resistance(*1) (L Br) Pulser coil output peak voltage (W/R W/B) at cranking (unloaded) at cranking (loaded) at 1,500 r/min (loaded) at 3,500 r/min (loaded) Pulser coil resistance(*1) (W/R W/B) CDI unit output peak voltage (B/O B, B/W B) at cranking (unloaded) at cranking (loaded) at 1,500 r/min (loaded) at 3,500 r/min (loaded) Spark plug gap
(*1)

Unit

Model F60AEHT F60AET

Degree

TDC 0

V V V V

159 164 168 126 272408

V V V V

9.5 5.5 11.0 15.5 396594

V V V V mm (in)

131 141 150 112 0.9 (0.035)

The figures are for reference only.

69W3D1X

24

SPEC
Item

Specifications
Unit kPa (kgf/cm2, psi) C (F) C (F) Model F60AEHT F60AET

Ignition control system Oil pressure switch ON OFF Thermoswitch (Gy/B B) OFF ON ON OFF Starter motor Type Output Cranking time limit Brushes Standard length Wear limit Commutator Standard diameter Wear limit Mica Standard undercut Wear limit Charging system Fuse Lighting coil output peak voltage (G G) at cranking (unloaded) at 1,500 r/min (unloaded) at 3,500 r/min (unloaded) Lighting coil resistance(*1) (G G) Rectifier Regulator output peak voltage (R B) at 1,500 r/min (unloaded) at 3,500 r/min (unloaded) Enrichment control system Prime Start

29.458.8 (0.2940.588, 4.1818.361)

7684 (169183) 6377 (145170) Bendix 1.1 30 17.0 (0.67) 10.0 (0.39) 33.0 (1.30) 32.0 (1.26) 0.50.8 (0.020.03) 0.2 (0.01) 20

kW Second mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) A

V V V

14.0 38 86 1.21.8

V V

22 27

Plunger extended length a

(*1)

mm (in)

24.6 (0.97)

The figures are for reference only.

25

69W3D1X

Maintenance specifications
Item Power trim and tilt system Trim sensor Setting resistance Resistance (P B) Fluid type Brushes Standard length Wear limit Commutator Standard diameter Wear limit Mica Standard undercut Unit Model F60AEHT F60AET

911 9288.3 ATF Dexron II 10 (0.39) 3.5 (0.14) 22.0 (0.87) 21.0 (0.83) 1.5 (0.06)

mm (in) mm (in) mm (in) mm (in) mm (in)

69W3D1X

26

SPEC
Dimensions
Exterior

Specifications

L3 A1 W5

W2

W1

W6

L7 L2 L10 L1

L6

H9 H5 H2 H7 H10

H8 H4 H1

B6

C1 H3 L5 L8 A2

H6

H11 A3 L9 L4

S69W2150

27

69W3D1X

Maintenance specifications
Symbol L1 L2 L3 L4 L5 L6 L7 L8 L9 L10 H1 H2 H3 H4 H5 H6 H7 H8 H9 H10 H11 W1 W2 W3 W4 W5 W6 A1 A2 A3 T1 Unit mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) Degree Degree Degree mm (in) Model F60AEHT 584 (23.0) 226 (8.9) 755 (29.7) 533 (21.0) 97 (3.8) 932 (36.7) 417 (16.4) 164 (6.5) 0 (0) 62 (2.4) 870 (34.3) 545 (21.5) 175 (6.9) 527 (20.7) 758 (29.8) 708 (27.9) 354 (13.9) 37 (1.5) 759 (29.9) 49 (1.9) 24 (0.9) 192 (7.6) 124 (4.9) 360 (14.2) 645 (25.4) 40 69 4

(L) (X) (L) (X)

(L) (X) (L) (X)

(L) (X) (L) (X)

(L) (X)

69W3D1X

28

SPEC
Exterior

Specifications

A1

W5

W1

L7 L8 L10 L2 L1

L6

H9 H2 H7 H10

H8 H4 H1

B6

C1 H3 L5 A2

H6

H11 A3 L9 L4
S69W2160

29

69W3D1X

Maintenance specifications
Symbol L1 L2 L3 L4 L5 L6 L7 L8 L9 L10 H1 H2 H3 H4 H5 H6 H7 H8 H9 H10 H11 W1 W2 W3 W4 W5 W6 A1 A2 A3 T1 Unit mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) Degree Degree Degree mm (in) Model F60AET 584 (23.0) 122 (4.8) 533 (21.0) 97 (3.8) 932 (36.7) 417 (16.4) 147 (5.8) 0 (0) 62 (2.4) 870 (34.3) 545 (21.5) 175 (6.9) 527 (20.7) 708 (27.9) 354 (13.9) 22.5 (0.9) 759 (29.9) 49 (1.9) 24 (0.9) 192 (7.6) 360 (14.2) 40 69 4

(L) (X) (L) (X)

(L) (X) (L) (X)

(L) (X) (L) (X)

(L) (X)

69W3D1X

30

SPEC
Clamp bracket

Specifications

B5 B3

B4 B9 B9 B9 B2 D1 B6

C1

D2

B1 B8

D1

S69W2170

Symbol B1 B2 B3 B4 B5 B6 B7 B8 B9 C1 C2 D1 D2

Unit mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in)

Model F60AEHT 126 (5.0) 249 (10.0) 163.5 (6.4) 50.8 (2.0) 180 (7.1) 350 (13.8) 18.5 (0.7) 69 (2.7) 13 (0.5) 60.5 (2.4) F60AET

31

69W3D1X

Maintenance specifications / Tightening torques Tightening torques

Specified torques
Part to be tightened Power unit Flywheel magnet nut Stator base screw Cover screw Red battery cable nut Oil pressure switch Oil pressure switch lead screw Ignition coil bolt Starter motor bolt Starter motor terminal nut Power unit bolt Tensioner bolt Tensioner adjusting bolt Drive sprocket nut Driven sprocket bolt Spark plug Cylinder head bolt Oil pump screw Rocker shaft bolt Oil filter Oil drain bolt Exhaust cover bolt 1st 2nd 1st 2nd 1st 2nd 1st 2nd 1st 2nd 1st 2nd Thread size M6 M6 M6 M8 M8 M8 M10 M6 M9 M6 M8 M14 M6 M6 M8 M10 M17 Tightening torques Nm kgfm ftlb 160 4 3 4 9 2 7 30 9 21 8 25 140 38 18 6 12 23 47 4 18 18 17 6 12 6 12 15 30 6 17 9 40 9 35 5 75 16 0.4 0.3 0.4 0.9 0.2 0.7 3.0 0.9 2.1 0.8 2.5 14 3.8 1.8 0.6 1.2 2.3 4.7 0.4 1.8 1.8 1.7 0.6 1.2 0.6 1.2 1.5 3.0 0.6 1.7 0.9 4.0 0.9 3.5 0.5 7.5 116 2.9 2.2 2.9 6.5 1.4 5.1 22 6.5 15 5.8 18 101 28 13 4.3 8.7 17 34 2.9 13 13 12 4.3 8.7 4.3 8.7 11 22 4.3 12 6.5 29 6.5 25 3.6 54
2

Crankcase bolt

Connecting rod cap bolt Lower unit Check screw Lower unit bolt Drain screw Propeller nut Water inlet cover screw Pinion nut

69W3D1X

32

SPEC

Specifications
Part to be tightened Thread size M5 M6 M5 M12 M5 M6 M5 Tightening torques Nm kgfm ftlb 37 2 38 5 7 8 4 24 42 23 90 4 7 80 61 5 5 5 4 9 3.7 0.2 3.8 0.5 0.7 0.8 0.4 2.4 4.2 2.3 9.0 0.4 0.7 8.0 6.1 0.5 0.5 0.5 0.4 0.9 27 1.4 27 3.7 5.1 5.8 2.9 17 30 17 65 2.9 5.1 58 44 3.6 3.6 3.6 2.9 6.5

Bracket unit Tiller handle assembly nut Engine shut-off switch nut Tiller handle bracket nut Engine start switch nut Tiller handle bracket bolt Friction plate bolt Friction plate self-locking nut Upper mount nut Lower mount nut Clamp bracket self-locking nut Power trim and tilt Tilt cylinder end screw PTT motor bolt Reservoir cap Trim cylinder end screw Tilt piston bolt Relief valve bracket bolt Gear pump assembly bolt Gear pump bracket bolt Electrical unit Pulser coil screw Starter motor nut

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. Nut (A) 8 mm 10 mm 12 mm 14 mm 17 mm Bolt (B) M5 M6 M8 M10 M12 General torque specifications Nm kgfm ftlb 5 0.5 3.6 8 0.8 5.8 18 1.8 13 36 3.6 25 43 4.3 31

33

69W3D1X

Tightening torques / Special service tools Special service tools

3

Digital tachometer 90890-06760

Bearing separator 90890-06534

Compression gauge 90890-03160

Bearing inner race attachment 90890-06643

Drive shaft holder 4 90890-06518

Shimming plate 90890-06701

Pinion nut holder 90890-06505

Digital caliper 90890-06704

Socket adapter 1 90890-06506

Digital circuit tester 90890-03174

1 2 3 4 5 6 7 8 9
34

69W3D1X

CHK ADJ

Periodic checks and adjustments

Dial gauge set 90890-01252

Magnet base 90890-06705

35

69W3D1X

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 Item Top cowling Top cowling fit Fuel system Fuel joint and fuel hoses Fuel filter Fuel tank Power unit Engine oil Oil filter Timing belt Valve clearance Spark plugs Thermostat Water leakage Motor exterior Exhaust leakage Cooling water passage Control system Throttle cable Shift cable Engine idle speed Ignition timing Power trim and tilt unit Power trim and tilt unit Lower unit Gear oil Lower unit leakage Propeller General Anodes Battery Wiring and connectors Nuts and bolts Lubrication points Remarks Every
10 hours 50 hours 100 hours 200 hours (Break-in) (3 months) (6 months) (1 year)
3

Check Check Check/replace Cleaning Change Change Check Check/adjust Clean/adjust/replace Check Check Check Check Clean Check/adjust Check/adjust Adjust Check Check Change Check Check Check/replace Check Adjust/reconnect Tighten Lubricate

every 1 month

NOTE: Flush the engine with fresh water after operating in salt water, or turbid or muddy water. If leaded gasoline is used regularly, check the engine valves and related parts every 300 hours of operation in addition to the items in the maintenance interval chart.

69W3D1X

36

CHK ADJ
Top cowling

Periodic checks and adjustments

3

Checking the top cowling

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

NOTE: Be sure not to spill any fuel when removing the fuel filter cup.
S69W3010

2. Loosen the nuts 1. 3. Move the hook 2 up or down slightly to adjust its position.

Power unit
Checking the thermostat

1. Remove the cover 1, thermostat cover 2, and thermostat 3.

S69W3020

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 24.

1
S69W3040

2. Suspend the thermostat in a container of water. 3. Place a thermometer in the water and slowly heat the water.

Fuel system
Checking the fuel filter

1. Check the fuel filter element 1 for dirt and residue and check the fuel filter cup 2 for foreign substances and cracks. Clean with straight gasoline and replace the cup if necessary.

37

69W3D1X

Top cowling / Fuel system / Power unit / General

S69W3050

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

Water temperature 60 C (140 F) above 70 C (158 F)

Valve lift a Valve begins to lift more than 3.0 mm (0.12 in)

5. Install the thermostat, new gasket, thermostat cover, and cover.

General
Checking the anodes

1. Check the anodes and trim tab for scales, grease, or oil. Clean if necessary.
S69W3110

CAUTION:
Do not oil, grease, or paint the anodes, otherwise they will be ineffective. 2. Replace the anodes and trim tab if excessively eroded.

69W3D1X

38

CHK ADJ
Lubrication

Periodic checks and adjustments

1. Apply water resistant grease to the areas shown.

S69W3120

S69W3150

NOTE: Apply grease to the grease nipple until it flows from the bushings a. 2. Apply corrosion resistant grease to the areas shown.

39

69W3D1X

General / Hose routing Hose routing

Fuel and blowby hoses
4

1 2 3 4 5 6 7

Blowby hose Hose (acceleration pump-to-carburetor) Fuel hose (fuel joint-to-fuel filter) Fuel hose (fuel filter-to-fuel pump) Fuel hose (fuel pump-to-carburetor) Hose (carburetor-to-carburetor) Hose (acceleration pump-to-acceleration pump)

1 2 3 4 5 6 7 8 9
40

69W3D1X

FUEL

Fuel system

Cooling water hose

S69W4020

1 Pilot water hose 2 Flushing hose Flushing device model View in direction of arrow

41

69W3D1X

Hose routing / Fuel line and fuel filter Fuel line and fuel filter
4

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Fuel joint Bolt Seal Fuel hose Bolt Nut Bracket Body

Part name

Qty 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 2 M6 30 mm
Not reusable Not reusable

Remarks M6 25 mm Fuel joint-to-fuel filter M8 14 mm

Fuel filter element Float O-ring Cup Fuel hose Fuel hose Fuel pump O-ring Bracket Bolt

Fuel pump-to-carburetor Fuel filter-to-fuel pump

69W3D1X

42

FUEL
Carburetor unit

Fuel system
4

No. 1 2 3 4 5 6 7 Screw Link rod Hose Hose Link rod Clip

Part name Acceleration pump

Qty 1 3 1 1 4 1 1
Not reusable

Remarks 5 9 mm

43

69W3D1X

Carburetor unit
Adjusting the dashpot (acceleration pump)
1. Start the engine and warm it up for 5 minutes. 2. Check that the engine speed at the operation point of the dashpot is within specification. 3. Attach the special service tool to spark plug wire #1 1. 5. If out of specification, adjust the dashpot until the specified engine speed is obtained. 6. Open the throttle cam 2 slowly, and check that the acceleration pump stopper 3 comes in contact with point a. 7. Turn the adjusting screw 4 in or out until the specified engine speed is obtained.

S69W4050

Digital tachometer: 90890-06760 4. Open the throttle cam 2 slowly, and check the engine speed when the acceleration pump stopper 3 comes into contact with point a.

8. Open and close the throttle cam a few times, and then check that the engine speed at the operation point of the dashpot is within specification. Adjust if necessary.

Engine speed: 2,0002,200 r/min

69W3D1X

44

POWR
Power unit

Power unit
5

45

69W3D1X

Power unit
No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 Bolt Black battery cable Wiring harness Grommet Nut Spring washer Red battery cable PTT relay positive lead Fuse holder lead Clip Warning indicator coupler PTT switch coupler Plastic tie Pilot water hose Bolt Neutral switch Plate Neutral switch lead Ground lead Bolt PTT relay lead Nut Spring washer PTT motor lead Bolt Plastic tie Flushing hose Part name Power trim and tilt relay Qty 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 2 3 1 2 2 2 2 2 2 1 Green, blue M6 20 mm
Not reusable Not reusable

Remarks M8 16 mm 10-pin coupler

Tiller handle model

M6 20 mm Tiller handle model Remote control model Tiller handle model M6 12 mm

Flushing device model

1 2 3 4 5 6 7 8 9
46

69W3D1X

POWR

Power unit

47

69W3D1X

Power unit
No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 Bracket Starter motor Spark plug cap Ignition coil Wiring harness Thermoswitch Holder Bolt Ground lead Bolt Oil pressure switch Oil pressure switch lead Screw Ignition coil lead Bolt Thermoswitch lead Rectifier Regulator coupler CDI unit coupler Bolt Bolt Nut Spring washer Starter motor lead Spring washer Nut Bolt Oil pressure switch lead Starter relay lead Part name Qty 1 1 4 2 1 1 1 1 3 1 1 1 1 2 4 2 1 1 2 3 1 1 1 1 1 1 1 1 M8 45 mm M8 25 mm M8 35 mm M6 30 mm M6 12 mm M6 12 mm Remarks

69W3D1X

48

POWR

Power unit

49

69W3D1X

Power unit
No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 Plate Cylinder head cover Bolt Cylinder head cover gasket Bolt Spark plug Bolt Dowel pin Cylinder head gasket Grommet Anode Cover Bolt Cover Bolt O-ring O-ring O-ring Bolt Housing Drive shaft Pin Inner rotor Outer rotor Gasket Cover Screw Engine hanger Bolt Screw O-ring Oil filler cap Part name Cylinder head Qty 1 1 1 7 1 10 4 5 2 1 4 4 4 4 4 4 1 1 1 4 1 1 1 1 1 1 1 2 1 2 4 1 1 M6 20 mm 4 10 mm
Not reusable Not reusable Not reusable Not reusable

Remarks

M6 20 mm
Not reusable

M9 95 mm M6 25 mm

1.9 36.8 mm
Not reusable

1.8 17.1 mm
Not reusable

1.2 13.9 mm M6 40 mm

6 20 mm

Tightening sequence

69W3D1X

50

POWR

Power unit

51

69W3D1X

Power unit
No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Part name Rocker arm assembly Rocker arm shaft Cylinder head Exhaust valve Intake valve Camshaft Valve cotter Spring retainer Valve spring Spring seat Stem seal Valve guide Retaining bolt Gasket Oil seal Bolt Rocker arm retainer Tensioner Rocker arm retainer Stopper guide Qty 8 1 1 4 4 1 16 8 8 8 8 8 1 1 1 5 2 2 1 2
Not reusable Not reusable Not reusable Not reusable

Remarks

M8 22 mm

69W3D1X

52

POWR

Power unit

53

69W3D1X

Power unit
No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 Oil filter Crankshaft Bolt Bolt Crankcase Oil seal Main bearing Oil seal Connecting rod bearing Connecting rod cap Bolt Dowel pin Cylinder block Connecting rod Piston pin clip Piston pin Piston Oil ring Second ring Top ring Gasket Exhaust cover Thermostat Gasket Cover Clamp Grommet Anode Cover Cover Bolt Bolt Bolt Part name Qty 1 1 10 10 1 1 10 1 8 4 8 2 1 4 8 4 4 4 4 4 1 1 1 1 1 2 1 1 1 1 1 1 12 M6 20 mm M5 12 mm M6 35 mm
Not reusable Not reusable Not reusable Not reusable Not reusable

Remarks

M8 82 mm M6 35 mm

Tightening sequence

69W3D1X

54

POWR

Power unit
NOTE: If the compression pressure increases, check the piston and piston rings for wear. Replace if necessary. If the compression pressure does not increase, check the valve clearance, valve, valve seat, cylinder sleeve, cylinder head gasket, and cylinder head. Adjust or replace if necessary.

Checking the compression pressure

1. Start the engine, warm it up for 5 minutes, and then turn it off. 2. Remove the lock plate from the engine shut-off switch on the remote control box or tiller handle. 3. Remove all spark plugs, and then install the special service tools to each spark plug hole.

Checking the oil pressure

1. Remove the cover. 2. Remove the oil pressure switch, and then install an oil pressure gauge 1 to the oil pressure switch installation hole.

CAUTION:
Before removing the spark plugs, remove any dirt or dust that may fall into the cylinder. Compression gauge 1: 90890-03160 4. Fully open the throttle manually, crank the engine until the reading on the compression gauge stabilizes, and then check the compression pressure. Minimum compression pressure (reference data): 880 kPa (8.8 kgf/cm2, 125 psi) 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.

NOTE: Use a pressure gauge with an adapter that has a 1/8 pitch thread. 3. Start the engine and warm it up for 5 minutes. 4. Check the oil pressure. Check the oil pump, relief valve, oil filter, and oil strainer if out of specification. Oil pressure (reference data): 110 kPa (1.1 kgf/cm2, 16 psi) at idle speed (900 r/min)

55

69W3D1X

Power unit
Checking the cylinder bore
1. Measure the cylinder bore (D1D6) at measuring points a, b, and c, and in direction d (D1, D3, D5), which is parallel to the crankshaft, and direction e (D2, D4, D6), which is at a right angle to the crankshaft.

D2 D4 D6

D1 D3 D5
S69W5080

a 20 mm (0.8 in) b 60 mm (2.4 in) c 100 mm (3.9 in)

Cylinder bore (D1D6): 65.0065.01 mm (2.55912.5594 in) 2. Calculate the taper limit. Replace or rebore the cylinder block if out of specification. Taper limit: D1D5 (direction d) D2D6 (direction e) 0.08 mm (0.0031 in) 3. Calculate the out-of-round limit. Replace or rebore the cylinder block if out of specification. Out-of-round limit: D2D1 (measuring point a) D6D5 (measuring point c) 0.01 mm (0.0004 in)

Piston ring groove: Top ring a: 1.211.23 mm (0.04760.0484 in) Second ring b: 1.511.53 mm (0.05940.0602 in) Oil ring c: 2.522.54 mm (0.09920.0999 in)

Checking the piston ring grooves

1. Measure the piston ring grooves. Replace the piston if out of specification.

69W3D1X

56

LOWR

Lower unit
6

Drive shaft and lower case

57

69W3D1X

Drive shaft and lower case

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 Drive shaft Oil seal Oil seal housing O-ring Circlip Shift rod O-ring Taper roller bearing Bearing outer race Pinion shim Sleeve Washer Oil seal housing O-ring Oil seal Seal Plate Hose Plastic tie Joint Nut Water inlet cover Screw Shift cam Needle bearing Pinion Nut Forward gear shim Bearing outer race Taper roller bearing Forward gear Lower case Cover Gasket Check screw Gasket Drain screw Part name Qty 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Not reusable Not reusable Not reusable Not reusable Not reusable Not reusable Not reusable Not reusable Not reusable Not reusable

Remarks

As required

As required
Not reusable Not reusable

1 2 3 4 5 6 7 8 9
58

69W3D1X

LOWR

Lower unit

Removing the drive shaft

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

Bearing inner race attachment 1: 90890-06643

S69W6020

Drive shaft holder 4 1: 90890-06518 Pinion nut holder 2: 90890-06505 Socket adapter 1 3: 90890-06506

Installing the drive shaft

1. Install the forward gear, then the drive shaft assembly, pinion, and pinion nut, and then tighten the nut to the specified torque.

Disassembling the forward gear

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

S69W6020

S69W6030

Drive shaft holder 4 1: 90890-06518 Pinion nut holder 2: 90890-06505 Socket adapter 1 3: 90890-06506 Pinion nut: 75 Nm (7.5 kgfm, 54 ftlb)

CAUTION:
Do not reuse the bearing, always replace it with a new one. Bearing splitter plate 1: (commercially obtainable) Bearing separator 1: 90890-06534
T.

R.

Assembling the forward gear

1. Install the new taper roller bearing into the forward gear using a press.

59

69W3D1X

Drive shaft and lower case / Shimming Shimming

6

69W3D1X

60

LOWR
Shimming

Lower unit

NOTE: Shimming is not required when assembling the original lower case and inner parts. Shimming is required when assembling the original inner parts and a new lower case. Shimming is required when replacing the inner part(s).

Selecting the forward gear shims

1. Turn the taper roller bearing outer race 1 two or three times to seat the rollers, and then measure the bearing height (M) as shown.

NOTE: F is the deviation of the lower case dimension from standard. The F mark a is stamped on the trim tab mounting surface of the lower case in 0.01 mm units. If the F mark is unreadable, assume that F is zero and check the backlash when the unit is assembled. Calculation formula: Forward gear shim thickness (T1) = 26.50 + F/100 M Example: If M is 26.06 mm and F is (+1), then T1 = 26.50 + (+1)/100 26.06 mm = 26.50 + 0.01 26.06 mm = 0.45 mm 3. Select the forward gear shim(s) (T1) as follows. Calculated numeral at 1/100 place 1, 2 Rounded numeral 0 2 5 8

NOTE: Select the shim thickness (T1) by using the specified measurement(s) and the calculation formula. Measure the bearing outer race at three points to find the height average. Shimming plate 2: 90890-06701 Digital caliper 3: 90890-06704 2. Calculate the forward gear shim thickness (T1) as shown in the examples below.

3, 4, 5 6, 7, 8 9, 10

Available shim thicknesses: 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, and 0.50 mm

61

69W3D1X

Shimming
Example: If T1 is 0.45 mm, then the forward gear shim is 0.42 mm. If T1 is 0.60 mm, then the forward gear shim is 0.58 mm.

69W3D1X

62

BRKT
Tiller handle

Bracket unit
7

63

69W3D1X

Tiller handle
No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 Part name Tiller handle assembly Tiller handle wiring harness Grommet Clip Throttle cable Plate Bolt Bolt Black battery cable Cable guide Grommet Nut Washer Red battery cable Connector Clip Shift cable Cover Screw PTT switch coupler PTT switch coupler Plastic tie Nut Bolt Bracket Friction lock shaft Collar Washer Friction lock lever Friction piece Friction plate Washer Bolt Nut Washer Self-locking nut Qty 1 1 1 1 1 1 3 1 1 1 1 1 1 1 1 1 1 1 3 1 1 1 2 1 1 1 2 2 1 2 1 2 2 1 1 1 M5 20 mm Tiller handle model 6 35 mm M6 35 mm M6 25 mm M8 16 mm Remarks

1 2 3 4 5 6 7 8 9
64

69W3D1X

BRKT
Bottom cowling

Bracket unit
7

65

69W3D1X

Bottom cowling
No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 Rubber seal Washer Bushing Shift rod bracket Bolt Spring Ball Shift rod Flushing device Bracket Bolt Screw Flushing hose Bolt Grommet Collar Grommet PTT motor lead Trim sensor coupler Screw Bolt Bracket Power trim and tilt switch Warning indicator Screw Pilot water hose Collar Grommet Cowling lock lever Washer Wave washer Bushing Lever Bolt Spring Hook Bolt Part name Bottom cowling Qty 1 1 1 2 1 1 1 1 1 1 1 1 2 1 4 4 4 1 1 1 1 2 1 1 1 1 1 2 2 1 1 1 2 1 1 1 1 1 M6 20 mm M6 12 mm Tiller handle model 6 14 mm / Tiller handle model 6 25 mm M6 20 mm Flushing device model Flushing device model M6 16 mm / Flushing device model 6 20 mm / Flushing device model Flushing device model M6 30 mm Remarks

69W3D1X

66

BRKT
Upper case

Bracket unit
7

67

69W3D1X

Upper case
No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 Upper case Muffler seal Rubber seal Dowel pin Grommet Damper Screw Baffle plate Bolt Drive shaft bushing Circlip Ground lead Screw Cap Bolt Washer Rubber washer Washer Lower mount Washer Mount cover Bolt Bolt Plate Bolt Upper mount Nut Grease nipple Washer Nut Cover Bolt Part name Muffler assembly Qty 1 1 1 1 2 1 1 2 1 4 1 1 1 1 2 2 2 2 2 2 2 2 4 2 1 3 1 2 1 2 2 1 2 M8 20 mm M8 30 mm M8 30 mm M8 175 mm M12 170 mm 6 8 mm M8 30 mm 5 16 mm Remarks

69W3D1X

68

BRKT

Bracket unit

69

69W3D1X

Upper case
No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 Oil seal Exhaust guide Grommet Anode Cover Bolt Cover Bolt Gasket Gasket Relief valve housing Relief valve Spring Cotter pin Bolt Bolt Oil strainer Bolt Gasket Pipe Rubber seal Dowel pin Bolt Drain bolt O-ring Oil pan Gasket Exhaust manifold Bracket Washer Bolt Gasket Gasket Plate Muffler Bolt Part name Qty 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 1 1 1 1 1 2 10 1 1 1 1 1 1 3 3 1 2 1 1 6 M6 25 mm M6 50 mm
Not reusable Not reusable Not reusable Not reusable Not reusable Not reusable Not reusable Not reusable

Remarks

M6 20 mm

M6 25 mm M6 16 mm M6 25 mm
Not reusable

M6 25 mm

69W3D1X

70

BRKT

Bracket unit

Disassembling the oil pan

1. Remove the muffler 1, plate 2, and exhaust manifold 3 from the oil pan 4.

3. Install the oil strainer 3 by installing the bolts.

2. Remove the oil pan 4 and the exhaust guide 5. 3. Remove the oil strainer 6 and the relief valve housing 7. 4. Install the water pipe 4. 5. Install the oil pan 5 and bolts, and then tighten the bolts finger tight. 6. Install the exhaust manifold 6 and bolts, and then tighten the bolts finger tight.

Assembling the oil pan

1. Install the gaskets onto the exhaust guide 1. 2. Install the relief valve assembly 2 by installing the bolts, then tightening them finger tight.

71

69W3D1X

Upper case
10. Tighten the upper case bolts B, and then tighten them to the specified torque.

7. Tighten the oil pan bolts 7 then exhaust manifold bolts 8, and then tighten them to the specified torque.
T.

Exhaust manifold bolt 8: 10 Nm (1.0 kgfm, 7.2 ftlb)

Upper case bolt B: 21 Nm (2.1 kgfm, 15 ftlb)

R.

8. Install the plate 9 and the muffler 0 to the oil pan.

9. Install the muffler assembly A by inserting the tip of the water pipe 4 into the joint hole a of the upper case.
69W3D1X

T.

R.

Installing the upper case

1. Install the upper mount 1 and bolts 2 into the upper case. 2. Install the lower mounts 3 and bolts 4 into the upper case. 3. Install the mount covers 5.

LT

572

S69W7100

72

BRKT

Bracket unit
Upper mounting nut 7: 24 Nm (2.4 kgfm, 17 ftlb) Lower mounting nut 8: 42 Nm (4.2 kgfm, 30 ftlb)

T.

R.

4. Install the upper and lower mounting bolts into the swivel bracket 6 simultaneously. 5. Install the upper mounting nut 7 and lower mounting nut 8, and then tighten them to the specified torque. 6. Install the cover 9.

73

69W3D1X

Upper case / Clamp brackets Clamp brackets

7

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Screw Trim sensor

Part name Swivel bracket assembly

Qty 1 2 1 1 1 2 2 4 2 1 2 2 1 1 1 1 1 1 6 8 mm M6 25 mm
Not reusable

Remarks 6 15 mm

Trim sensor coupler Plastic tie Self-locking nut Cap Bolt Anode Port clamp bracket Washer Bushing Through tube Ground lead Grease nipple Screw Starboard clamp bracket Bracket

69W3D1X

74

BRKT

Bracket unit
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. 8. Measure the trim sensor resistance. Check the trim sensor if out of specification. Trim sensor resistance: Pink (P) Black (B) 168.3288.3 at 20 C (68 F)

Adjusting the trim sensor

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

WARNING
After tilting up the outboard motor, be sure to support it with the tilt stop lever. Otherwise, the outboard motor could suddenly lower if the power trim and tilt unit should lose fluid pressure. 2. Loosen the cam screws 2. 3. Adjust the position of the trim sensor 3, and then tighten the screws 2 finger tight. 4. Fully tilt the outboard motor down. 5. Measure the trim sensor resistance. Repeat steps 15 if out of specification. Trim sensor resistance: Pink (P) Black (B) 911 at 20 C (68 F) 6. Tighten the screws 2.

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

75

69W3D1X

Clamp brackets / Swivel bracket and steering arm Swivel bracket and steering arm
7

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Washer Bushing O-ring Bushing

Part name Steering arm

Qty 1 1 1 2 2 1 2 1 1 1 1 2 1 1 1 1 2 1
Not reusable Not reusable

Remarks

Swivel bracket Bushing Port tilt stop lever Circlip Steering yoke Bushing Bushing Tilt stop lever joint Spring holder Bolt Spring Pin Starboard tilt stop lever

M6 10 mm

69W3D1X

76

BRKT

Bracket unit
7

Power trim and tilt unit

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 Plastic tie

Part name Power trim and tilt unit PTT motor lead Washer Bolt Circlip Shaft Bushing Collar Tilt pin Collar Collar Shaft

Qty 1 3 2 2 2 1 1 2 1 1 1 1 1 M8 16 mm
Not reusable

Remarks

77

69W3D1X

Power trim and tilt unit

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Bolt

Part name Relief valve bracket Bolt Valve lock screw Up-relief spring Valve support pin O-ring Ball Down-relief spring Valve support pin Relief valve seal Filter O-ring Spacer Filter O-ring Manual valve Circlip

Qty 2 1 3 1 1 1 1 1 1 1 1 1 2 2 2 1 1 1
Not reusable Not reusable Not reusable

Remarks M5 8 mm M6 40 mm

69W3D1X

78

BRKT

Bracket unit

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Bolt Washer Bracket O-ring Spacer Spring Valve pin Ball

Part name

Qty 2 2 1 2 2 2 2 2 1 2 1 2 1 1 2 2 2 1
Not reusable Not reusable

Remarks M5 20 mm

Manual release spring Ball Gear pump cover Spring Shuttle piston O-ring Valve seal Circlip Pin Drive gear

79

69W3D1X

Power trim and tilt unit

No. 19 20 21 22 23 24 25 Shaft Driven gear Ball

Part name

Qty 1 1 2 1 1 1 1

Remarks

Shuttle piston Valve plate Plate Gear pump housing

69W3D1X

80

BRKT

Bracket unit

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Screw Yoke O-ring Armature Washer Bushing Screw Lead Brush 2 Brush 1

Part name

Qty 3 1 1 1 1 1 2 1 1 1 1 1 2 1 1
Not reusable Not reusable

Remarks 5 20 mm

4 12 mm

Brush holder Circuit breaker Brush spring PTT motor base Oil seal

81

69W3D1X

Power trim and tilt unit

Disassembling the gear pump
1. Remove the manual valve 1 and gear pump 2. 5. Remove the drive gear A and driven gear B.

Checking the valves

1. Check the operation of the check valve a of the trim cylinder end screw and check the valve for dirt or residue. Clean if necessary. 2. Remove the relief valve bracket 3, then the relief valve seal 4 and ball 5.

3. Remove the bracket 6, then the balls 7.

2. Check the operation of the tilt piston absorber valve and check for dirt or residue. Clean if necessary.

4. Remove the gear pump cover 8, then the shuttle pistons 9 and balls 0.

3. Check the up-relief valve and down-relief valve for dirt or residue. Clean if necessary.

69W3D1X

82

BRKT

Bracket unit

S69W7280

4. Check the main valves for dirt or residue. Clean if necessary.

4. Install the balls 9, manual release spring 0 and bracket A by installing the bolts B, then tightening them to the specified torque.

S69W7290

5. Check the absorber valves for dirt or residue. Clean if necessary.

Gear pump bracket bolt B: 5 Nm (0.5 kgfm, 3.6 ftlb)

S69W7300

5. Install the relief valve seal C, ball D, and filter E. 6. Install the relief valve bracket F by installing the bolts G, then tightening them to the specified torque.

T.

R.

Assembling the gear pump

1. Install the drive gear 1, driven gear 2, shaft 3, and pins 4 into the gear pump housing 5. 2. Install the balls 6 and shuttle pistons 7 into the gear pump housing 5. 3. Install the gear pump cover 8.

83

69W3D1X

Power trim and tilt unit

Relief valve bracket bolt G: 5 Nm (0.5 kgfm, 3.6 ftlb) 10. Install the joint M and power trim and tilt motor N by installing the bolts O, then tightening them to the specified torque.

7. Install the filters H and gear pump I by installing the bolts J, then tightening them to the specified torque. 8. Install the manual valve K and reservoir cap L.

9. Fill the reservoir with the recommended fluid to the correct level a as shown.

69W3D1X

T.

R.
T.

PTT motor bolt O: 4 Nm (0.4 kgfm, 2.9 ftlb)

Checking the trim sensor

1. Measure the trim sensor resistance. Replace if out of specification. Gear pump bolt J: 7 Nm (0.7 kgfm, 5.1 ftlb)

T.

R.

R.

NOTE: Turn the lever 1 and measure the resistance as it gradually changes. Trim sensor resistance: Pink (P) Black (B) 911 at 20 C (68 F) a 168.3288.3 at 20 C (68 F) b

Recommended power trim and tilt fluid: ATF Dexron II

84

ELEC

Electrical systems
8

Wiring harness

B G L L B/W Y Y L P Y/B P/B W P G G Y Y Y/R P/W B B/O B B B P

G Lg

R Y W B/W

P Br B

Sb

B/O

B BB R Lg Lg Sb Sb Br Sb Lg R Sb Lg

P/W P/B Y/R Y/B Y/B Y/R

P/B

P/W

R Lg Lg Lg Sb R Br P G W B Y Sb Sb R B B B Br L Y P

P/W P/B Y/R Y/B

P/B P/W L B B/O Y/B Y/R P W B/W

R Lg Sb

G B

Y Y G G

B B B

B/O B/W

S69W8010

7 1 Engine start switch or 8 9 remote control box extension 2 Power trim and tilt relay 0 A 3 Ground B 4 Starter relay C 5 Red battery cable 6 Prime Start

Connect to:

Warning indicator CDI unit Power trim and tilt switch Rectifier Regulator Thermoswitch Ignition coil Oil pressure switch

B Br G L Lg P R Sb W

: Black : Brown : Green : Blue : Light green : Pink : Red : Sky blue : White

Y B/O B/W P/B P/W Y/B Y/R

: Yellow : Black/orange : Black/white : Pink/black : Pink/white : Yellow/black : Yellow/red

85

69W3D1X

Wiring harness / Ignition and ignition control system Ignition and ignition control system
8

1 2 3 4 5 6 7 8

Spark plug Ignition coil Charge coil Pulser coil Engine start switch Engine shut-off switch 10-pin coupler CDI unit

B Br L O W B/O B/W W/B W/R

: Black : Brown : Blue : Orange : White : Black/orange : Black/white : White/black : White/red

1 2 3 4 5 6 7 8 9
86

Tiller handle model

69W3D1X

ELEC

Electrical systems

1 2 3 4 5 6

Thermoswitch Oil pressure switch CDI unit Oil pressure warning indicator Overheat warning indicator Warning indicator

B P Gy/B P/B P/W Y/B Y/R

: Black : Pink : Gray/black : Pink/black : Pink/white : Yellow/black : Yellow/red

Tiller handle model

87

69W3D1X

Ignition and ignition control system

Checking the spark plug caps
1. Remove the spark plug caps from the spark plug wires by turning the caps counterclockwise. Pulser coil air gap a: 0.51.0 mm (0.0200.039 in) 3. Remove the flywheel magnet nut and flywheel magnet. 4. Loosen the pulser coil screws, adjust the pulser coil 1 position, and then tighten the screws finger tight.

2. Measure the spark plug cap resistance. Replace if out of specification.

5. Install the flywheel magnet, and then check the gap and, if necessary, repeat steps 35. 6. Tighten the pulser coil screws and flywheel magnet nut to the specified torques. Spark plug cap resistance (reference data): 5 k Pulser coil screw: 4 Nm (0.4 kgfm, 2.9 ftlb) Flywheel magnet nut: 160 Nm (16 kgfm, 116 ftlb)

T.

R.

Checking the pulser coil air gap

1. Turn the flywheel clockwise to align the projection of the flywheel with the pulser coil projection. 2. Measure the gap between both projections with a thickness gauge. Adjust if out of specification.

Checking the engine start switch

1. Check the engine start switch for continuity. Replace if there is no continuity. Lead color Switch White Black Red position (W) (B) (R) OFF ON START Pink Brown (Br) (P)

S69W8060

69W3D1X

88

ELEC

Electrical systems
8

Starting system

W OFF ON START

Br

R Br

Br R R R Br R
N

Br

M S

B B

Br

Br

S69W8090E

1 2 3 4 5 6 7

Fuse 10-pin coupler Engine start switch Starter motor Battery Neutral switch Starter relay

B Br R

: Black : Brown : Red

Tiller handle model

89

69W3D1X

Starting system / Starter motor Starter motor

1 2 3 4 5 11
8

6 7 8 14 13 15 9
7 N m (0.7 kgf m, 5.1 ft Ib)
T.

12

R.

16

10

17 18
S69W8100

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Clip

Part name Pinion stopper Spring Starter motor pinion Upper bracket Washer 1 Shim Washer 2 Armature Washer Stator Brush holder assembly Brush set O-ring Nut Lower bracket Screw Bolt

Qty 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 2 2 4 12 mm M6 120 mm
Not reusable

Remarks

As required

69W3D1X

90

ELEC

Electrical systems
Diameter limit: 32.0 mm (1.26 in) 4. Measure the commutator undercut a. Replace the armature if out of specification.

Checking the armature

1. Check the armature axial free play. Replace the washers and shim(s) 3 if out of specification.

Dial gauge set 1: 90890-01252 Magnet base 2: 90890-06705 Commutator undercut limit: 0.2 mm (0.01 in) 5. Check the armature for continuity. Replace if out of specifications.

Free play limit: 0.6 mm (0.024 in) 2. Check the commutator for dirt. Clean with #600 grid sandpaper and compressed air if necessary.

Armature continuity 3. Measure the commutator diameter. Replace the armature if out of specification. Commutator segments b Segment Armature core c Segment Armature shaft d Continuity No continuity No continuity

Checking the brushes

1. Measure the brush length. Replace the brush assembly if out of specification.

91

69W3D1X

Starter motor

Brush length limit a: 10.0 mm (0.39 in) 2. Check the brush holder for continuity. Replace if out of specifications.

S69W8170

Brush assembly continuity Brush 1 Brush assembly holder 4 Brush 2 Brush assembly holder 3 Brush 1 Brush 2 Brush 1 Brush assembly holder 3 Brush 2 Brush assembly holder 4 No continuity

Continuity

69W3D1X

92

Wiring diagram F60AEHT

1 2 3 4 5 6 7 8 9 0 A B C D E F G H I J K L Battery Engine start switch Starter motor Power trim and tilt motor Power trim and tilt relay Engine shut-off switch Starter relay Neutral switch Fuse (20 A) Warning indicator Power trim and tilt switch Prime Start Oil pressure switch CDI unit Thermoswitch Charge coil Pulser coil Lighting coil Rectifier Regulator Ignition coil Spark plug Trim sensor

Color code
B Br G Gy L Lg O P R Sb W Y B/O B/W G/W Gy/B P/B P/W W/B W/R Y/B Y/R : Black : Brown : Green : Gray : Blue : Light green : Orange : Pink : Red : Sky blue : White : Yellow : Black/orange : Black/white : Green/white : Gray/black : Pink/black : Pink/white : White/black : White/red : Yellow/black : Yellow/red

Wiring diagram F60AET

1 2 3 4 5 6 7 8 9 0 A B C D E F G H Battery Starter motor Power trim and tilt motor Power trim and tilt relay Starter relay Fuse (20 A) Trim sensor Prime Start Oil pressure switch CDI unit Thermoswitch Charge coil Pulser coil Lighting coil Rectifier Regulator Power trim and tilt switch Ignition coil Spark plug

Color code
B Br G Gy L Lg O P R Sb W Y B/O B/W G/W Gy/B P/B P/W W/B W/R Y/B Y/R : Black : Brown : Green : Gray : Blue : Light green : Orange : Pink : Red : Sky blue : White : Yellow : Black/orange : Black/white : Green/white : Gray/black : Pink/black : Pink/white : White/black : White/red : Yellow/black : Yellow/red

To remote control To warning indicator To trim meter

YAMAHA MOTOR CO., LTD. Printed in the Netherlands Jul. 2001 1.3 1 CR
(F60AEHT, F60AET)

(E)

F60AEHT

B B B Br G Gy Y L Y L Br L G B Br R Y R L G L Br Y L B/O Y/R B Sb B /W Y/B Br L W/R W/B G G G G /W G /W B G L R B P Sb Y/R P/B W B/W Gy/B W/R Br B W/B L Y/B P/W O B/O W/R W/B G G G L Lg O P R Sb W Y B/O G/W P/W Y B P/W B L Y/R B/O B B Sb Lg Lg Lg Sb Sb R P W Lg G R P P L B B R Br Y L Y/B P/W Y/R P/B P W B/O B/W B L B R B P/B Y/B B/W G/W G Gy/B L O P P/B W W Br L W/R W/B G G G /W R B B/W G /W Gy/B P/B P/W W /B W /R Y/B Y/R

Br

R B G B

Y W R B Br Sb Lg P W G Y

P Sb B Br Br B

B Gy P B Y Y G G B B B P Gy

W OFF ON ST

Br

Y/B P/W Y/R P/B

B B

#2
W W W Y/B B B B Br P R P/B P/W R P/B P/W Sb Lg Y/R Lg Sb R B/W B/O O O

#3
B

#1 Sb R
Lg

Sb R UP FREE DOWN
Sb R

Lg

Lg

Y/B

Y/R

Sb

UP FREE DOWN
Lg Sb Sb R Lg

#4
B

Lg

Lg

Sb

Sb

Lg Sb R Lg

Lg Sb R Sb R Lg

Sb

Y/B

P/B

Y/R

P/W

S69WWD01E

F60AET

B B B Br G Gy Y L Y L Br L G B R Y R Br L G L Y L B/O Y/R B Sb B /W Y/B Br L W/R W/B G G G G /W G /W B G L R B P Sb Y/R P/B W B/W Gy/B W/R Br B W/B L Y/B P/W O B/O W/R W/B G G G L Lg O P R Sb W Y B/O G/W P/W Y B P/W B L Y/R B/O B B Sb Lg Lg Lg Sb Sb G Lg R P P L B B R Br Y L Y/B P/W Y/R P/B P W B/O B/W B L B R B P/B Y/B B/W G/W G Gy/B L O P P/B W W Br L W/R W/B G G G /W R B B/W G /W Gy/B P/B P/W W /B W /R Y/B Y/R

L R

R B G B

Y W R B Br Sb Lg P W G Y

P Sb Br B

Y Y

G G

B B B

Y/B P/W Y/R P/B

B B

#2
B/W B/O Y/B Y/R Lg Sb R O O

#3
B

P/B P/W

Sb Lg R R

#1 Sb R
Lg

Lg

Sb B Gy P B Gy

UP FREE DOWN

#4
B

Lg R Sb

S69WWD03E