Page 1 F50D FT50C SERVICE MANUAL 60A-28197-5L-11...
Page 2: Important Information
Yamaha equipment. It has been written to suit the needs of persons who have the Bronze Technical Certiﬁcate of YTA (Yamaha Technical Academy) marine or the equivalent basic understanding of the mechanical and electrical concepts and procedures inherent in the work, for without such knowledge attempted repairs or ser- vice to the equipment could render it unsafe or unﬁt for use.
Page 3 Contents General information INFO Speciﬁcation SPEC TECH Technical features and description Rigging information GING TRBL Troubleshooting SHTG Electrical system ELEC Fuel system FUEL Power unit POWR Lower unit LOWR Bracket unit BRKT Maintenance Index Appendix...
Page 5: Table Of Contents
INFO General information Safety while working ............. 0-1 Rotating part................0-1 Hot part..................0-1 Electric shock ................0-1 Propeller ..................0-1 Handling of gasoline ..............0-1 Ventilation................... 0-1 Self-protection ................0-2 Working with crane ..............0-2 Handling of burner ..............0-2 Part, lubricant, and sealant............
Page 6: Safety While Working
INFO General information Safety while working Handling of gasoline Gasoline is highly ﬂammable. Keep gaso- To prevent an accident or injury and to line and all ﬂammable products away from ensure quality service, follow the safety pro- heat, sparks, and open ﬂames. cedures provided below.
Page 7: Self-Protection
Use a wire rope of adequate strength, and Yamaha, when servicing or repairing the out- lift up the outboard motor with the three board motor. point suspension.
Page 8: Special Service Tool
INFO General information Special service tool Disassembly and assembly Use the recommended special service tools Use compressed air to remove dust and to work safety, and to protect parts from dam- dirt during disassembly. age. Apply engine oil to the contact surfaces of moving parts before assembly.
Page 9: How To Use This Manual
(see 5 in the ﬁgure below for an example page). TIP: For troubleshooting procedures, see Chapter 4, “Troubleshooting”. LOWR Lower unit Lower unit (F50D) 35 N·m (3.5 kgf·m, 25.8 ft·lb) LOWR Lower unit Removing the drive shaft and shift...
Page 10: Abbreviation
INFO General information Abbreviation The following abbreviations are used in this service manual. Abbreviation Description ABYC American Boat and Yacht Council American Petroleum Institute Automatic Transmission Fluid American Wire Gauge BTDC Before Top Dead Center Cold Cranking Ampere Capacitor Discharge Ignition Centerline D model Hydro tilt model...
Page 11: Sealant And Locking Agent
Sealant and locking agent Symbol Symbols in an exploded diagram or illustration indicate the grade of lubricant and the lubrication point. Symbol Name Application Yamaha 4-stroke motor oil Lubricant Gear oil Lubricant Water resistant grease Lubricant (Yamaha grease A) Molybdenum disulﬁde grease...
Page 12: Special Service Tool
Name Application ThreeBond 1401 Sealant Special service tool For all markets except for U.S.A. and Canada. Special tools with Yamaha parts number (90890-*****) are distributed by Parts Division. Drilling plate Test harness (2 pins) 90890-06783 90890-06867 Vacuum/pressure pump gauge set...
Page 13 Sealant and locking agent / Special service tool Test harness (3 pins) Flywheel puller 90890-06870 90890-06521 Test harness (4 pins) Crankshaft holder 18 90890-06871 90890-06562 Digital tachometer Valve spring compressor 90890-06760 90890-04019 Compression gauge Valve spring compressor attachment 90890-03160 90890-06320 Flywheel holder Valve guide remover/installer 90890-06522...
Page 14 INFO General information Valve guide reamer Valve seat cutter 45° 90890-06804 90890-06555 Valve lapper Valve seat cutter 60° 90890-04101 90890-06323 Valve seat cutter holder Valve seat cutter 60° 90890-06316 90890-06315 Valve seat cutter 30° Bearing outer race attachment 90890-06326 90890-06626 Valve seat cutter 30°...
Page 15 Special service tool Oil ﬁlter wrench Center bolt 90890-01426 90890-06504 Piston slider Bearing separator 90890-06529 90890-06534 Shift rod push arm Stopper guide stand 90890-06052 90890-06538 Stopper guide plate Bearing puller assembly 90890-06501 90890-06535 Bearing housing puller claw S Driver rod L3 90890-06564 90890-06652 0-10...
Page 16 INFO General information Needle bearing attachment Needle bearing attachment 90890-06614 90890-06607 Driver rod SS Drive shaft holder 4 90890-06604 90890-06518 Bearing depth plate Pinion nut holder 90890-06603 90890-06715 Bearing inner race attachment Bearing inner race attachment 90890-06653 90890-06641 Bearing inner race attachment Magnet base plate 90890-06639 90890-07003...
Page 17 Special service tool Bearing inner race attachment Leakage tester 90890-06644 90890-06840 Bearing outer race attachment Backlash indicator 90890-06622 90890-06706 Handle stopper Driver rod LL EU0-23814-30 90890-06605 Dial gauge set Driver rod SL 90890-01252 90890-06602 Magnet base Bearing outer race attachment 90890-06844 90890-06627 0-12...
Page 18 INFO General information Pinion height gauge set Ball bearing attachment 90890-06668 90890-06655 Ring nut wrench 3 Bearing inner race attachment 90890-06511 90890-06661 Ring nut wrench extension Needle bearing attachment 90890-06513 90890-06611 Bearing housing puller claw L Bearing inner race attachment 90890-06502 90890-06662 Needle bearing attachment...
Page 19 Special service tool Bearing outer race attachment Timing light 90890-06621 90890-03141 Pinion height gauge set 90890-06669 Bearing outer race attachment 90890-06628 Needle bearing attachment 90890-06615 Cylinder-end screw wrench 90890-06568 0-14...
Page 20 INFO General information — MEMO — 0-15...
Page 21 ............ 1-13 PTT system ................1-13 Special tightening torque ............1-14 Fuel system ................1-14 Power unit ................1-14 Lower unit (F50D)..............1-15 Lower unit (FT50C) ..............1-15 Bracket unit ................1-15 PTT unit..................1-16 General tightening torque ............1-16...
Page 22: Model Features
Specification Model features General feature FT50C and F50D Overall Features 4 carburetors with acceleration pump, in line 4, SOHC, 8 valves, 0.935 L (56.1 ci) engine More resistant to leaded, sulfurous and low octane fuel More resistant in muddy water...
Page 23: Model Designation
F50DET 1000984– clamp bracket. FT50CET 1008356– FT50CED 1008518– FT50CEHD 1008391– YAMAHA MOTOR CO., LTD. MADE IN JAPAN PAYS D'ORIGINE JAPON 1 Model name 2 Approved model code 3 Transom height 4 Serial number...
Page 24: Model Data
SPEC Specification Model data Dimension and weight Model Item Unit F50DET FT50CET FT50CED FT50CEHD 1373.0 Overall length mm (in) 718.0 (28.3) (54.2) Overall width mm (in) 361.0(14.2) Overall height 1395.0 mm (in) 1436.0 (56.5) (54.9) 1550.0 1550.0 mm (in) — —...
Page 25: Fuel And Oil Requirement
Model data Fuel and oil requirement Model Item Unit F50DET FT50CET FT50CED FT50CEHD Fuel type Regular unleaded gasoline Fuel minimum rating Engine oil Engine oil grade (*1) SE, SF, SG, SH, SJ, or SL 5W-30, 10W-30, or 10W-40 Engine oil quantity (Oil pan capacity) L (US qt, without oil ﬁlter replacement...
Page 26: Lower Unit
SPEC Specification Lower unit Model Item Unit F50DET FT50CET FT50CED FT50CEHD Gear shift positions F-N-R 1.85 Gear ratio 2.31 (30/13) (24/13) Reduction gear type Spiral bevel gear Clutch type Dog clutch Propeller shaft type Spline Propeller direction (rear view) Clockwise Propeller mark Bracket unit Model...
Page 27: Electrical Technical Data
Model data / Electrical technical data Electrical technical data Ignition timing control system Model Item Unit F50DET FT50CET FT50CED FT50CEHD Spark plug mm (in) 0.8–0.9 (0.03–0.04) Cap resistance kΩ 3.8–6.3 Ignition coil Primary coil resistance (*1) Ω at 20 °C (68 °F) 0.1–0.2 Secondary coil resistance (*1)
Page 28: Engine Speed Control System
SPEC Specification Engine speed control system Model Item Unit F50DET FT50CET FT50CED FT50CEHD Oil pressure switch Speciﬁed oil pressure 29.4–68.6 (0.29–0.69, 4.26–9.95) (kgf/cm , psi) Charging system Model Item Unit F50DET FT50CET FT50CED FT50CEHD Lighting coil Resistance (*1) Ω at 20°C (68°F) 1.2–1.8 Output peak voltage (*1) at cranking (unloaded)
Page 29: Fuel System Technical Data
Electrical technical data / Fuel system technical data Fuel system technical data Fuel system Model Item Unit F50DET FT50CET FT50CED FT50CEHD Fuel joint Holding pressure Positive pressure 50.0 (0.50, 7.3) (kgf/cm , psi) Fuel ﬁlter assembly Holding pressure Positive pressure 200.0 (2.0, 29.0) (kgf/cm , psi)
Page 30: Power Unit Technical Data
SPEC Specification Power unit technical data Power unit Model Item Unit F50DET FT50CET FT50CED FT50CEHD Cylinder Minimum compression pres- 840.0 (8.4, 121.8) sure (*1) (kgf/cm , psi) Engine oil Oil pressure (*2) at 60 °C (140 °F) with SL 10W-30 engine oil and at 160.0 (1.6, 23.2) (kgf/cm , psi)
Page 31: Crankcase Assembly
Power unit technical data Model Item Unit F50DET FT50CET FT50CED FT50CEHD Camshaft Cam lobe height Intake mm (in) 30.888–30.988 (1.2161–1.2200) Exhaust mm (in) 30.824–30.924 (1.2135–1.2175) Cam lobe width Intake mm (in) 25.950–26.050 (1.0217–1.0256) Exhaust mm (in) 25.950–26.050 (1.0217–1.0256) Journal diameter #1 mm (in) 36.925–36.945 (1.4537–1.4545) Journal diameter #2, #3, #4...
Page 32 SPEC Specification Model Item Unit F50DET FT50CET FT50CED FT50CEHD Piston ring Top ring Type Barrel Dimension height (B) mm (in) 1.170–1.190 (0.0461–0.0469) Dimension width (T) mm (in) 2.250–2.450 (0.0886–0.0965) End gap (*1) mm (in) 0.150–0.300 (0.0059–0.0118) Side clearance mm (in) 0.040–0.080 (0.0016–0.0032) 2nd ring Type...
Page 33 Power unit technical data Model Item Unit F50DET FT50CET FT50CED FT50CEHD Crankcase Crankshaft journal oil clear- mm (in) 0.012–0.036 (0.0005–0.0014) ance Crankshaft bearing thick- mm (in) ness (*1) Upper Green mm (in) 1.490–1.494 (0.0587–0.0588) Pink mm (in) 1.494–1.498 (0.0588–0.0590) mm (in) 1.498–1.502 (0.0590–0.0591) Yellow mm (in)
Page 34: Lower Unit Technical Data
SPEC Specification Lower unit technical data Lower unit assembly Model Item Unit F50DET FT50CET FT50CED FT50CEHD Lower unit 70.0 Holding pressure 100.0 (1.0, 14.5) (kgf/cm , psi) (0.7,10.2) Pinion-to-forward gear 0.18–0.53 Backlash mm (in) (0.007– 0.12–0.45 (0.005–0.018) 0.021) Pinion-to-reverse gear 0.71–1.06 Backlash mm (in)
Page 35: Special Tightening Torque
Lower unit technical data / Bracket unit technical data / Special tightening torque Special tightening torque Fuel system Tightening torques Part to be tightened Thread size N·m kgf·m ft·lb Fuel ﬁlter nut — 13.3 Fuel ﬁlter cup — Fuel pump screw Fuel pump valve screw Acceleration pump screw Prime Start bracket screw...
Page 36: Lower Unit (F50D)
Thread size N·m kgf·m ft·lb 11.1 Crankcase bolt 22.1 Crankcase bolt Connecting rod bolt — 12.5 Lower unit (F50D) Tightening torques Part to be tightened Thread size N·m kgf·m ft·lb Gear oil drain screw — Gear oil check screw —...
Page 37: Ptt Unit
Special tightening torque / General tightening torque PTT unit Tightening torques Part to be tightened Thread size N·m kgf·m ft·lb Gear pump bracket bolt Relief valve bracket bolt Gear pump bolt PTT motor bolt Tilt piston bolt 45.0 Trim cylinder end screw —...
Page 38 SPEC Specification — MEMO — 1-17...
Page 39 TECH Technical features and description Electronic control system ............2-1 CDI unit with microcomputer ............2-1 Ignition system ................2-2 Ignition timing control ..............2-4 Fuel system .................. 2-7 Four carburetors ................. 2-7 Starting system (Prime Start) ............. 2-8 Carburetor operation ..............2-9 Acceleration pump..............
Page 40: Tech Fea
TECH Technical features and description Electronic control system CDI unit with microcomputer The ignition system consists of a ﬂywheel magnet, stator assembly, pulser coil, thermoswitch, oil pressure switch, CDI unit, and ignition coil. The CDI unit contains a built-in microcomputer that determines the ignition timing separately for acceleration and for normal operation, based on sig- nals received from the pulser coil, thermoswitch, and oil pressure switch.
Page 41: Ignition System
Electronic control system Ignition system In order to determine the optimal ignition timing that is necessary for the proper operation of the engine, the built-in microcomputer in the CDI unit detects the signals from various types of sensors and controls the ignition timing in accordance with a control map that is based on those signals. The microcomputer also effects controls to protect the engine against overheating, over revolution, and oil pressure drops, as well as to control alert devices.
Page 42 TECH Technical features and description Pulser coil The pulser coil transmits the pulser signals, which are generated in the pulser coil in accordance with the rotation of the ﬂywheel magnet, to the CDI unit. Among the two protrusions that are pro- vided for generating signals, one is used for cylinders #1 and #4, and the other for cylinders #2 and #3, thus enabling the pulser coil to simultaneously ignite two cylinders.
Page 43: Ignition Timing Control
Electronic control system Ignition timing control Control circuit diagram Operation Detection Microcomputer Ignition timing control Engine start Positive start Engine temperature (optimized ignition timing) Quick acceleration Acceleration Engine speed Engine speed control Over revolution Alert buzzer (in remote control Damage prevention Low oil pressure Oil pressure unit)
Page 44 TECH Technical features and description Starting control When starting the engine, the timing is set to BTDC 5° until the crankshaft speed maintains 600 r/min for 2 seconds or longer. 1 Cylinder identiﬁcation protrusion 7 Starting signal (5° BTDC) for cylinders #1 2 Protrusion for cylinders #1 and #4 and #4 3 Pulser coil...
Page 45 Electronic control system Acceleration control This control is activated when the throttle valve is opened suddenly. If the engine speed increases more than the speciﬁed ﬁgures, the control of the ignition timing transfers to the acceleration map. Thereafter, the control of the ignition timing transfers gradually to the control map before accelera- tion.
Page 46: Fuel System
TECH Technical features and description Fuel system Four carburetors Prime Start has been adopted for the starting system to further increase starting performance and serviceability. Furthermore, the acceleration pump and the dashpot have been integrated to simplify construction and to ease serviceability. The four carburetors can be accurately and easily adjusted due to the simple construction of the links.
Page 47: Starting System (Prime Start)
To facilitate the starting of a cold engine, a richer air-fuel mixture than normal is required. For this reason, the Prime Start system has been used in the F50D and FT50C. When the engine is cold, the fuel is delivered from the fully opened fuel enrichment valve. As a result, starting of a cold engine is facilitated.
Page 48: Carburetor Operation
TECH Technical features and description Carburetor operation å ∫ ç å Idle and low speed operation 6 Pilot jet ∫ Medium speed operation 7 Main jet ç High-speed operation 8 Pilot air jet 1 Pilot screw 9 Main air jet 2 Pilot outlet 0 Throttle valve a Air...
Page 49: Acceleration Pump
Fuel system Acceleration pump The function of the acceleration pump is to ensure a smooth acceleration by preventing the air-fuel mixture from becoming temporarily lean in case the throttle valve is opened suddenly. When the throttle is opened suddenly, diaphragm 1 (via the link that is connected to the throttle lever) operates to pressurize the air in the pump chamber.
Page 50: Lubrication System
TECH Technical features and description Lubrication system Oil ﬂow Block diagram for lubrication Crankcase Cylinder head Sleeve IN and EX valve Camshaft Piston Spray lubrication Connecting rod Rocker arm Cam journal Crankshaft Crank journal Rocker shaft Main gallery Oil pressure switch Oil filter Relief valve Oil pump...
Page 51: Ptt Unit
Lubrication system / PTT unit PTT unit PTT unit consists of an up-main valve, a down-main valve, an up-relief valve, a single cylinder, and a single ram, which control both trim and tilt functions. PTT cylinder has been integrated with the gear pump housing, the reservoir tank, and the PTT motor in order to achieve a smaller and more compact unit.
Page 52 TECH Technical features and description Trim-up function The gear pump 6 pumps PTT ﬂuid to the up-main valve 7. As a result, the ﬂuid pressure opens the up-shuttle piston 9 causing the ﬂuid to ﬂow into the lower part of the PTT cylinder 1. At the same time, vacuum from the gear pump 6 opens the down-main valve 4 and down-shuttle piston 0, which causes ﬂuid from the upper part of the PTT cylinder 1 to return to the gear pump 6, and also sucks ﬂuid in through the reservoir 8.
Page 53 PTT unit Tilt-up function When the trim cylinder 5 tops out, the check valve 4 is pushed down by the end screw wall 3. This causes allowing the PTT ﬂuid to ﬂow from the upper part of the trim cylinder 5, through the down-shuttle piston q and the down-main valve 7, and back to the gear pump 8.
Page 54 TECH Technical features and description Tilt-down function The gear pump 6 pumps the PTT ﬂuid to the down-main valve 5. As a result, ﬂuid pressure opens the down-main valve 5 and the down-shuttle piston q, which causes ﬂuid to ﬂow into the upper part of the trim cylinder 3 and forces the tilt piston t down.
Page 55 PTT unit Stopping condition When the PTT switch is not pushed (released), the gear pump does not pump the ﬂuid, the up-main valve and the down-main valve are closed, and the PTT ﬂuid pressure in the system remains con- stant. This allows the ram to maintain its position until the PTT ﬂuid ﬂows through the system again. When the outboard motor hits something in the water The check valve of the trim cylinder 2 and the tilt piston absorber 4 of the tilt piston 5 help to pre- vent internal damage to the PTT unit and help to protect the bracket and lower unit from damage in...
Page 56 TECH Technical features and description — MEMO — 2-17...
Page 57 GING Rigging information Outboard motor installation ............ 3-1 Dimensions .................. 3-2 Exterior F50DET................. 3-2 Exterior FT50CET ..............3-3 Exterior FT50CED ..............3-4 Exterior FT50CEHD ..............3-5 Clamp bracket L-transom model ..........3-6 Clamp bracket X-transom model ..........3-7 Crate top cover pictograph description .......
Page 58: Rigging Information
Improper mounting of the outboard motor could result in hazardous conditions such as poor handling, loss of control, or ﬁre hazards. Consult your dealer or a Yamaha trained per- son experienced in proper rigging should mount the motor.
Page 59: Dimensions
Outboard motor installation / Dimensions Dimensions Exterior F50DET mm (in) 933 (36.7) 407 (16.0) 148 (5.8) 576 (22.7) 142 (5.6) 63 (2.5) 0.6 (0.02) 532 (20.9)
Page 60: Exterior Ft50Cet
GING Rigging information Exterior FT50CET mm (in) L: 407 (16.0) L: 989 (38.9) X: 406 (16.0) X: 1095 (43.1) L: 148 (5.8) L: 576 (22.7) X: 147 (5.8) X: 577 (22.7) L: 142 (5.6) X: 141 (5.6) L: 63 (2.5) X: 62 (2.4) L: 560 (22.1) X: 561 (22.1)
Page 61: Exterior Ft50Ced
Dimensions Exterior FT50CED mm (in) 989 (38.9) 397 (15.6) 149 (5.9) 576 (22.7) 142 (5.6) 63 (2.5) 0.8 (0.03) 560 (22.0)
Page 62: Exterior Ft50Cehd
GING Rigging information Exterior FT50CEHD mm (in) L: 797 (31.4) X: 796 (31.3) L: 397 (15.6) L: 989 (38.9) X: 396 (15.6) X: 1092 (43.0) L: 272 (10.7) L: 576 (22.7) L: 189 (7.4) X: 271 (10.7) X: 577 (22.7) L: 63 (2.5) X: 188 (7.4) X: 62 (2.4)
Page 63: Clamp Bracket L-Transom Model
Dimensions Clamp bracket L-transom model mm (in) 180 (7.1) 180 (7.1) 163.5 (6.4) 163.5 (6.4) 69 (2.7) 13 (0.5) 13 (0.5) 126 (5.0) 126 (5.0) 139 (5.5) 139 (5.5)
Page 64: Clamp Bracket X-Transom Model
GING Rigging information Clamp bracket X-transom model mm (in) 180 (7.1) 180 (7.1) 163.5 (6.4) 163.5 (6.4) 69 (2.7) 13 (0.5) 13 (0.5) 126 (5.0) 126 (5.0) 139 (5.5) 139 (5.5)
Page 65: Crate Top Cover Pictograph Description
Dimensions / Crate top cover pictograph description Crate top cover pictograph description The following pictographs are important sign to handle the crate. Read the notice and understand what pictographs mean to avoid a damage to the product when handling, transporting, and/or keeping the crate. Care handling indication Lifting fork insert position Water avoidance indication...
Page 66: Uncrate Procedure
GING Rigging information 7. Remove the skeg holder 4. Uncrate procedure 1. Check the crate for shipping damage. 2. Remove the top cover. 3. Remove all bolts from the bottom plate, and remove the frame. NOTICE: Be careful not to cause any damage to the outboard motor.
Page 67: Mounting The Outboard Motor
Uncrate procedure / Mounting the outboard motor Mounting the outboard motor 2. Adjust the outboard motor so the height of the anti-cavitation plate e is equal to Proper mounting of the outboard motor will or slightly above the bottom of the boat mean better performance, maximum reliabil- transom.
Page 68: Tiller Handle Installation
GING Rigging information Boat transom Mounting bolt thickness (D) M12 × 115 mm 55–65 mm (2.17–2.56 in) (4.53 in) M12 × 130 mm 65–75 mm (2.56–2.95 in) (5.12 in) M12 × 150 mm 75–95 mm (2.95–3.74 in) (5.91 in) TIP: The second hole from the clamp bracket top is recommended for the upper mounting bolt.
Page 69: Installing The Steering Friction Assembly
Mounting the outboard motor / Tiller handle installation / Wiring harness connection 2. Remove the bolts 5 and retaining plate Installing the steering friction assembly 1. Install the friction piece assembly 1 and steering friction assembly 2 to the bracket. 2.
Page 70: Control Cable Installation
GING Rigging information å å H model 4. Connect the gauge harness 6 to the ∫ R model coupler b. (R model) Control cable installation Installing the shift cable (rod) and throttle cable 1. Install the grommet 1 onto the shift cable (rod) 2 and throttle cable 3, and install the cable guide 4 to the groove of the shift cable 2 (R model) and throttle...
Page 71 Wiring harness connection / Control cable installation ∫ 5. Adjust the shift cable joint 5 to the pin c of shift lever. NOTICE: The shift cable joint must be screwed in a minimum of 8.0 mm (0.31 in) d. å H model ∫...
Page 72: Remote Control Box Installation
GING Rigging information 8. Check that the throttle lever q on the throttle body assembly contacts e the throttle stop screw w. Remote control box installation See “Remote control box operation manual” or “Rigging guide”. 9. Adjust the cable joint 9 to the pin f of the throttle cam.
Page 73: Battery Wiring Without House (Accessory) Battery
Control cable installation / Remote control box installation / Installing the battery Battery wiring without house (accessory) battery When using a dual battery installation, a negative battery cable must be installed between the both engine batteries. This cable must be sized equivalent to the engine battery cables or larger AWG cable size in accordance with ABYC speciﬁcations.
Page 74 GING Rigging information 3-17...
Page 75: System Diagram
System diagram 3-18...
Page 76: Rigging Recommendations
GING Rigging information Rigging recommendations Extension length recommendation of battery cable Exceeding the recommended extension length of battery cable may cause poor electrical system performance or damage. To extend the length of battery cables, follow the requirements in the tables for your battery capacity, cable size, and atmosphere temperature.
Page 77: Propeller Selection
Use the following information as a guide for selecting a propeller that meets the operating F50D conditions of the boat and the outboard motor. Propeller size (in) Material 10 ×...
Page 78 GING Rigging information FT50C Propeller size (in) Material 12 5/8 × 21 - K 13 × 19 - K 13 × 23 - K 13 × 25 - K 13 1/4 × 17- K Aluminum 13 1/2 × 15 - K 13 5/8 ×...
Page 79 TRBL SHTG Troubleshooting Troubleshooting the outboard motor ........4-1 Troubleshooting procedure ............4-1 Troubleshooting table format............4-1 Troubleshooting the power unit ..........4-2 Troubleshooting the PTT unit ............. 4-7 Troubleshooting the lower unit ........... 4-8...
Page 80 TRBL SHTG Troubleshooting Troubleshooting the outboard motor Troubleshooting procedure Perform the troubleshooting as described in the following tables. TIP: Make sure that fresh fuel of the speciﬁed type has been used. Make sure that the battery is fully charged. Make sure to check that the couplers, connectors, and battery terminals are securely connected. When checking the input voltage of a part, the coupler or connector must be disconnected.
Page 81 Troubleshooting the outboard motor...
Page 82 TRBL SHTG Troubleshooting...
Page 83 Troubleshooting the outboard motor...
Page 84 TRBL SHTG Troubleshooting...
Page 85 Troubleshooting the outboard motor...
Page 86 TRBL SHTG Troubleshooting...
Page 87 Troubleshooting the outboard motor...
Page 88 TRBL SHTG Troubleshooting — MEMO —...
Page 89 ELEC Electrical system Electrical component and wiring harness routing .... 5-1 Port view..................5-1 Starboard view ................5-4 Bow view (D model) ..............5-5 Bow view (PTT model) ............... 5-7 Top view ..................5-9 Bottom cowling (PTT model) ............ 5-10 Tiller handle................
Page 90: Electrical System
ELEC Electrical system Electrical component and wiring harness routing Port view å ´ ∂ ç ∫ 1 Lighting coil coupler 9 Oil pressure switch 2 Rectiﬁer Regulator coupler 0 Ignition coil #2, #3 lead (Black) 3 Charge coil coupler q Thermoswitch 4 Pulser coil coupler w Ignition coil #2, #3 5 Thermoswitch connector (Black)
Page 91 Electrical component and wiring harness routing å ´ ∂ ç ∫ u Spark plug wire #3 j Hour meter i Spark plug wire #4 k Rectiﬁer Regulator o Ignition coil #1, #4 connector p Ignition coil #1, #4 lead (Black) å...
Page 92 ELEC Electrical system å ´ ∂ ç ∫ ∂ Install the ground lead to the bracket. ´ Fasten the leads with the plastic tie.
Page 93: Starboard View
Electrical component and wiring harness routing Starboard view å 1 Prime Start #3 2 Prime Start #1 3 Prime Start connectors 4 CDI unit 5 Prime Start coupler å Fasten the Prime Start connectors and intake silencer with the plastic tie.
Page 94: Bow View (D Model)
ELEC Electrical system Bow view (D model) ´ å ∫ ∂ ç 1 Starter motor q Prime Start lead 2 Starter relay w Negative battery cable 3 Starter motor lead 4 Fuse holder lead (Red) å Fasten the leads except for the fuse holder 5 Starter relay connector (Brown) lead (Red), with the plastic tie.
Page 95 Electrical component and wiring harness routing ´ å ∫ ∂ ç ∂ Insert the 10-pin main wiring harness cou- pler to the holder, and then fasten with the plastic tie. ´ Install the Prime Start lead onto the holder on the intake silencer.
Page 96: Bow View (Ptt Model)
ELEC Electrical system Bow view (PTT model) © å ƒ ∫ ´ ç ∂ 1 Starter motor q Alert indicator lead 2 Starter relay w PTT relay ground lead (Black) 3 Starter motor lead e PTT motor lead (Blue) 4 Fuse holder lead (Red) r PTT relay lead (Black) 5 Starter relay connector (Brown) t PTT relay...
Page 97 Electrical component and wiring harness routing © å ƒ ∫ ´ ç ∂ a Prime Start lead ∂ Install the wiring harness ground leads s Negative battery cable and PTT relay ground lead to the bracket. ´ Fasten the PTT switch lead and starter å...
Page 98: Top View
ELEC Electrical system Top view å 1 Stator assembly 2 Pulser coil lead 3 Pulser coil 4 Charge coil lead 5 Lighting coil lead å Fasten the pulser coil lead to the boss on the magnet base with the plastic tie. Cut off the surplus of the plastic tie, leaving 10 mm a.
Page 99: Bottom Cowling (Ptt Model)
Electrical component and wiring harness routing Bottom cowling (PTT model) å ∫ 1 PTT switch ∫ Fasten the leads except for the fuse holder 2 PTT switch coupler lead (Red), wiring harness ground lead 3 Trim sensor coupler (Black) and starter relay lead (Brown) with 4 PTT motor lead connector (Light green) the plastic tie.
Page 100: Tiller Handle
ELEC Electrical system Tiller handle ç ∫ å å Pass the engine start switch lead and 1 Neutral switch connector 2 Neutral switch engine shut-off switch lead through the 3 Neutral switch lead (to starter relay) grommet. 4 Alert indicator coupler ∫...
Page 101: Checking The Electrical Component
Electrical component and wiring harness routing / Checking the electrical component / Ignition unit and components Checking the electrical TIP: component Before measuring the peak voltage, check all wiring for proper connection and corro- Measuring the peak voltage sion, and check that the battery is fully charged.
Page 102: Checking The Spark Plug Cap
ELEC Electrical system Checking the ignition coil 1. Disconnect the ignition coil connector and terminal. 2. Remove the spark plug caps from the spark plug wires by turning the caps counterclockwise. 3. Measure the ignition coil resistance. Replace if out of speciﬁcation. TIP: Do not remove the clip from the engine shut-off switch.
Page 103: Checking The Charge Coil
Ignition unit and components Checking the charge coil 1. Disconnect the charge coil coupler a, and then connect the test harness 1. Test harness (2 pins) 1: 90890-06867 2. Measure the charge coil output peak voltage. Replace the stator assembly if below speciﬁcation.
Page 104: Checking The Cdi Unit
ELEC Electrical system 4. Measure the charge coil resistance. TIP: Replace the stator assembly if out of To prevent the engine from starting when speciﬁcation. cranking it, make sure to disconnect all spark plug caps. Charge coil resistance (reference data): Do not remove the clip from the engine Brown (Br)–Blue (L) shut-off switch.
Page 105: Checking The Oil Pressure Switch
Ignition unit and components 3. Turn the engine off. 2. Turn the engine start switch to “START”, and then measure the input voltage (CDI 4. Remove the thermoswitch. unit end). Replace the CDI unit if below speciﬁcation. 5. Place the thermoswitch in a container of water and slowly heat the water.
Page 106: Checking The Alert Indicator
ELEC Electrical system Oil pressure switch continuity: Oil pressure switch terminal c– Ground (switch body) Oil pressure Continuity 49.0 kPa (0.490 kgf/cm 7.105 psi) below 49.0 kPa (0.490 kgf/cm 7.105 psi) above TIP: Oil pressure switch continuity: Apply the pressure to the oil pressure Pink (P)–Ground switch gradually.
Page 107: Checking The Prime Start
Ignition unit and components LED1 3. Connect the Yellow/Red (Y/R) lead to the positive penlight battery terminal (1.5 V) and connect the Pink/White (P/W) lead to the negative terminal, and then check that the oil pressure alert indicator comes on. Replace the alert indicator if it does not come on.
Page 108: Checking The Engine Shut-Off Switch
ELEC Electrical system ∫ START å H model ∫ R model Engine start switch continuity: Terminal Switch Engine start switch input voltage: position Terminal a–Terminal b 12.0 V (battery voltage) 3. Check the engine start switch for continu- START ity at the 10-pin main wiring harness cou- pler.
Page 109: Checking The Hour Meter
Ignition unit and components å START ∫ START Throttle sensor adjusting lead (3 pins) 1: 90890-06857 2. Turn the engine start switch to “ON”, and then measure the input voltage at the hour meter coupler a. Check the wiring harness if below speciﬁcation. Hour meter input voltage: Yellow (Y)–Black (B) 12.0 V (battery voltage)
Page 110: Starting Unit And Components Checking The Fuse
ELEC Electrical system TIP: To prevent the engine from starting when cranking it, make sure to disconnect all spark plug caps. Measure the input voltage while the engine is cranking. 4. Turn the engine start switch to “OFF”, and then disconnect the special service tool 1.
Page 111: Checking The Neutral Switch
Ignition unit and components / Starting unit and components 8. Install the starter relay 3, and then con- nect the positive battery lead 2, starter motor lead 1, starter relay lead connec- tor a, and ground lead b. To route and connect the wirings, see “Electrical com- ponent and wiring harness routing”...
Page 112 ELEC Electrical system Neutral switch continuity: ∫ Terminal Switch position Free e (“F” or “R”) Pushed f (“N”) 5. Connect the neutral switch lead connec- tors (Br). 6BC80890 å H model ∫ R model Neutral switch input voltage: Brown (Br) a–Brown (Br) b 12.0 V (battery voltage) 3.
Page 113: Starter Motor
Starting unit and components / Starter motor Starter motor 7 N·m (0.7 kgf·m, 5.2 ft·lb) Part name Q’ty Remarks Pinion stopper Starter motor pinion Cover Washer kit — Armature Washer t = 0.3 mm Stator Brush holder assembly Brush set Brush spring Washer Spring washer...
Page 114: Removing The Starter Motor
ELEC Electrical system Removing the starter motor Removing the starter motor pinion 1. Slide the pinion stopper 1 down, and 1. Remove the starter motor from the power then remove the clips 2, pinion stopper unit. See “Starter motor” (7-15). 1, spring, and pinion 3.
Page 115: Checking The Armature
Starter motor 2. Measure the commutator diameter a. Replace if below speciﬁcation. TIP: The number of the parts of the washer set 4 and each thickness vary depending on the part. Digital caliper 1: 90890-06704 2. Remove the screws 7, and then remove the brush holder assembly 8 from the Standard diameter a: 33.0 mm (1.30 in) bracket 9.
Page 116: Checking The Brush Holder And Brush
ELEC Electrical system 2. Measure the length f of each brush. 4. Check armature continuity. Replace if out of speciﬁcation. Replace the brush assembly or brush holder assembly if below speciﬁcation. Armature continuity: Brush standard length f: 17.0 mm (0.67 in) Wear limit g: 10.0 mm (0.39 in) Checking the brush holder and Assembling the starter motor...
Page 117: Installing The Starter Motor
Starter motor / Charging unit and components Installing the starter motor 1. Install the starter motor to the power unit. See “Starter motor” (7-15). Charging unit and components Checking the lighting coil 1. Disconnect the lighting coil coupler a, and then connect the test harness 1 to the lighting coil coupler.
Page 118: Checking The Rectifier Regulator
ELEC Electrical system Lighting coil output peak voltage (reference data): Green (G)–Green (G) Unloaded Br L r/min Cranking 1500 3500 DC V 11.9 42.0 90.0 TIP: To prevent the engine from starting when cranking it, make sure to disconnect all Rectiﬁer Regulator output peak voltage spark plug caps.
Page 119 Charging unit and components 0.453 V 0.451 V 0.784 V 0.447 V 0.453 V 0.800 V 0.445 V 0.444 V TIP: Make sure to set the measurement range m, and display the testing diode mode n by pushing the “SHIFT” switch p when check- OL: Indicates on overload ing the Rectiﬁer Regulator continuity.
Page 120 ELEC Electrical system — MEMO — 5-31...
Page 121 FUEL Fuel system Hose routing ................6-1 Fuel hose and blowby hose............6-1 Cooling water hose..............6-3 Fuel ﬁlter ..................6-4 Checking the fuel joint ..............6-6 Checking the fuel filter assembly..........6-6 Fuel pump ..................6-7 Checking the fuel pump.............. 6-8 Disassembling the fuel pump .............
Page 122: Fuel System
FUEL Fuel system Hose routing Fuel hose and blowby hose 1 Fuel hose (fuel joint-to-fuel ﬁlter) q Hose (#2 carburetor-to-#3 carburetor) 2 Fuel hose (fuel ﬁlter-to-fuel pump) from Prime Start plunger 3 Fuel hose (fuel pump-to-carburetor) w Hose (acceleration pump-to-#1 carbure- 4 Fuel hose (fuel pump-to-carburetor) tor) 5 Fuel hose (joint-to-#4 carburetor)
Page 123 Hose routing u Blowby hose (cylinder head cover-to-joint f Acceleration pump g Carburetor #1 hose) h Carburetor #2 i Blowby joint hose o Blowby hose (joint hose-to-intake silencer) k Carburetor #3 m Carburetor #4 a Fuel joint b Fuel ﬁlter c Fuel pump d Fuel hose joint (#2 carburetor-to-#3 carburetor)
Page 124: Cooling Water Hose
FUEL Fuel system Cooling water hose 1 Cooling water hose (exhaust cover-to-joint) 2 Cooling water hose 3 Cooling water hose (joint-to-exhaust guide) a Joint b Cooling water pilot hole c Hose clamp...
Page 125: Fuel Filter
Hose routing / Fuel filter Fuel ﬁlter 2.5 N·m (0.3 kgf·m, 1.8 ft·lb) Part name Q’ty Remarks Retaining plate M6 × 20 mm Bolt Fuel joint Fuel ﬁlter assembly Fuel ﬁlter cup O-ring Fuel ﬁlter element Fuel pump assembly M6 × 25 mm Bolt Seal Fuel hose...
Page 126 FUEL Fuel system 2.5 N·m (0.3 kgf·m, 1.8 ft·lb) Part name Q’ty Remarks Clip M6 × 30 mm Bolt Bracket O-ring Plastic tie...
Page 127: Checking The Fuel Joint
Fuel filter Checking the fuel joint 1. Check the fuel joint. Replace if cracked or damaged. 2. Connect the special service tool 1 to the fuel joint outlet a. 3. Apply the speciﬁed positive pressure. Replace the fuel joint if the speciﬁed pressure cannot be maintained for at least 10 seconds.
Page 128 FUEL Fuel system Fuel pump 2 N·m (0.2 kgf·m, 1.5 ft·lb) 0.5 N·m (0.1 kgf·m, 0.4 ft·lb) 0.5 N·m (0.1 kgf·m, 0.4 ft·lb) Part name Q’ty Remarks M5 × 44 mm Screw Cover Fuel pump body 2 Fuel pump body 1 Plunger Spring Spring...
Page 129: Fuel Pump
Fuel pump Checking the fuel pump 1. Connect the special service tool 1 to the fuel pump inlet a. 2. Cover the fuel pump outlets b with rub- ber plugs 2, and then apply the speci- ﬁed positive pressure. Check that there is no air leakage.
Page 130: Checking The Diaphragm And Valve
FUEL Fuel system 3. Remove the plunger 2, spring 5, 6, 2. Push down on the plunger 4, install the and diaphragm 7 from fuel pump body 1 pin 6, and then turn fuel pump body 1 5 approximately 90°. Checking the diaphragm and valve 1.
Page 131 Fuel pump Fuel pump screw 9: 2 N·m (0.2 kgf·m, 1.5 ft·lb) TIP: Moisten the inside of the fuel pump with gasoline to ensure a good seal. Assemble the fuel pump so that tab a on the diaphragm is positioned on the opposite side of the fuel inlet and outlets c.
Page 132: Intake Silencer
FUEL Fuel system Intake silencer 8 N·m (0.8 kgf·m, 5.9 ft·lb) 29 25 3 N·m (0.3 kgf·m, 2.2 ft·lb) Part name Q’ty Remarks Carburetor Intake silencer Plastic tie Blowby hose M6 × 90 mm Bolt Collar O-ring Plate O-ring O-ring Joint Insulator Dowel...
Page 133 Intake silencer 8 N·m (0.8 kgf·m, 5.9 ft·lb) 29 25 3 N·m (0.3 kgf·m, 2.2 ft·lb) Part name Q’ty Remarks Holder Prime Start lead M6 × 30mm Bolt Collar Acceleration pump M5 × 10mm Screw Link rod Hose Hose Hose Hose Throttle link rod Link rod...
Page 134: Carburetor Unit
FUEL Fuel system Carburetor unit 2 N·m (0.2 kgf·m, 1.5 ft·lb) 2 N·m (0.2 kgf·m, 1.5 ft·lb) 2 N·m (0.2 kgf·m, 1.5 ft·lb) 2 N·m (0.2 kgf·m, 1.5 ft·lb) 3 N·m (0.3 kgf·m, 2.2 ft·lb) Part name Q’ty Remarks Carburetor body assembly #1/#2/#3/#4 M4 ×...
Page 135 Carburetor unit 2 N·m (0.2 kgf·m, 1.5 ft·lb) 2 N·m (0.2 kgf·m, 1.5 ft·lb) 2 N·m (0.2 kgf·m, 1.5 ft·lb) 2 N·m (0.2 kgf·m, 1.5 ft·lb) 3 N·m (0.3 kgf·m, 2.2 ft·lb) Part name Q’ty Remarks Fuel hose Float chamber-to-body #1, #3 Prime Start #1/#3 M4 ×...
Page 136: Removing The Carburetor
FUEL Fuel system Removing the carburetor 5. Check the ﬂoat. Replace if there is crack or deform. 1. Removing the carburetors from the power unit. See “Intake silencer” (6-11). 6. Measure the ﬂoat height a. Replace the ﬂoat or needle valve 1, if out of speciﬁ- Disassembling the carburetor cation.
Page 137: Assembling The Carburetor
Carburetor unit Prime Start plunger length a after supply- ing power (reference data): 24.6 mm (0.97 in) at 20 °C (68 °F) TIP: Assembling the carburetor Hook the needle valve 6 into the slot a on 1. Install the main nozzle 1, a new O-ring the ﬂoat 7, and then install it into the valve 2, plug 3, pilot jet 4, and main jet 5 to seat b.
Page 138: Synchronizing The Carburetor
4. Adjust the engine idle speed to 1000 r/min by turning the throttle stop screw 4 7. Adjust the engine idle speed to the spec- in direction b or c. iﬁcation by turning the throttle stop screw Engine idle speed: F50D: 800–900 r/min FT50C: 900–1000 r/min 6-17...
Page 139: Adjusting The Throttle Link Rod
Carburetor unit 8. After adjusting the idle speed, rev the engine a few times and let it idle to check the stability of the engine. Adjusting the throttle link rod 1. Push the throttle control lever 1 to the fully open position, and then measure the gap a between the carburetor throttle lever 2 and carburetor stopper 3.
Page 140 POWR Power unit Power unit (check and adjustment) ........7-1 Checking the compression pressure .......... 7-1 Checking the oil pressure ............7-1 Checking the pulser coil air gap ..........7-2 Adjusting the pulser coil air gap ..........7-2 Checking the valve clearance ............ 7-2 Flywheel magnet .................
Page 141 Camshaft and valve ..............7-30 Disassembling the cylinder head..........7-32 Checking the valve spring ............7-33 Checking the valve ..............7-33 Checking the valve guide ............7-34 Replacing the valve guide ............7-34 Checking the valve seat ............7-35 Refacing the valve seat ............7-35 Checking the rocker arm and rocker arm shaft ......
Page 142: Power Unit
7. If the compression pressure is below Engine idle speed: speciﬁcation or the compression pres- F50D: 800–900 r/min sure for each cylinder is unbalanced, add FT50C: 900–1000 r/min a small amount of engine oil to the cylin- 4. Measure the oil pressure. Check for oil...
Page 143: Checking The Pulser Coil Air Gap
Power unit (check and adjustment) Oil pressure (reference data): 160.0 kPa (1.6 kgf/cm , 23.2 psi) at 60 °C (140 °F) with SL 10W-30 engine oil and at 900 r/min TIP: The actual oil pressure may vary depending on the temperature and viscosity of the engine oil.
Page 144 POWR Power unit 6. Check the intake valve clearance c for 3. Turn the ﬂywheel magnet clockwise and align the “1” mark a on the driven cylinders #3 and #4, and the exhaust sprocket with the “▲” mark b on the cyl- valve clearance d for cylinders #2 and inder head.
Page 145: Flywheel Magnet
Power unit (check and adjustment) / Flywheel magnet Flywheel magnet 157 N·m (15.7 kgf·m, 115.8 ft·lb) 3 N·m (0.3 kgf·m, 2.2 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb) Part name Q’ty Remarks Flywheel magnet Stator assembly Cover Grommet Grommet Washer M6 ×...
Page 146: Removing The Flywheel Magnet
POWR Power unit Removing the ﬂywheel magnet Do not turn the ﬂywheel magnet counter- clockwise, otherwise the water pump impeller 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 “▲”...
Page 147: Installing The Flywheel Magnet
Flywheel magnet TIP: Installing the ﬂywheel magnet Make sure to remove any grease from the 1. Install the dowels 1, base assembly 2, tapered portion d of the crankshaft and the and then connect the pulser coil coupler inner surface e of the ﬂywheel magnet. Apply engine oil to the thread f of the ﬂy- wheel magnet nut and upper and lower sur- 2.
Page 148 POWR Power unit Wiring harness å 3.4 N·m (0.3 kgf·m, 2.5 ft·lb) å å H model Part name Q’ty Remarks PTT relay PTT model Battery cable M8 × 16 mm Bolt Grommet Spring washer Positive battery lead PTT relay positive lead PTT model Fuse holder lead Clip...
Page 149 Wiring harness å 3.4 N·m (0.3 kgf·m, 2.5 ft·lb) å å H model Part name Q’ty Remarks PTT model Spring washer PTT model M6 × 20 mm/PTT model Bolt Retaining plate M6 × 20 mm Bolt Shift cable R model Shift rod H model Cable guide...
Page 150: Removing The Control Cable, Hose And Wire Lead
POWR Power unit 3. Disconnect the fuel hose 5. Removing the control cable, hose and wire lead 1. Remove the bolts 1 and retaining plate 2. 4. Remove the plastic tie 6, corrugate tube 7, fuse holder 8, and then disconnect the battery cables 9, PTT relay lead 2.
Page 151: Install The Wire Lead, Hose, And Cable
Wiring harness 10. Remove the shift rod bolts r and plate t (R model) or neutral switch y (H model), and then remove the clip u. å 7. Disconnect the PTT switch coupler f and trim sensor coupler g. (PTT model) ∫...
Page 152 POWR Power unit ∫ å R model 5. Connect the gauge coupler c (R model) ∫ H model or alert indicator coupler (H model). 2. Install the PTT relay 7, and then tighten the bolts 8. 6. Connect the ground lead d and PTT motor leads e and f (PTT model).
Page 153 Wiring harness Starter relay terminal nut: 3.4 N·m (0.3 kgf·m, 2.5 ft·lb) 8. Connect the fuel hose q. 9. Install the throttle cable and shift cable (rod). See “Installing the shift cable (rod) and throttle cable” (3-13). 7-12...
Page 154 POWR Power unit Power unit assembly 21 N·m (2.1 kgf·m, 15.5 ft·lb) Part name Q’ty Remarks Power unit Dipstick Gasket Dowel M6 × 16 mm Bolt M8 × 80 mm Bolt Apron M6 × 24 mm Screw 7-13...
Page 155: Power Unit Assembly
Power unit assembly Removing the power unit Installing the power unit 1. Extract the engine oil. 1. Clean the power unit mating surface, and install the dowels 1 and a new gasket 2. Remove the apron 1. TIP: Make sure to check the shift rod is properly installed onto the bottom cowling before installing the power unit.
Page 156: Starter Motor
POWR Power unit Starter motor 8 N·m (0.8 kgf·m, 5.9 ft·lb) 30 N·m (3.0 kgf·m, 22.1 ft·lb) 7 N·m (0.7 kgf·m, 5.2 ft·lb) 2 N·m (0.2 kgf·m, 1.5 ft·lb) 30 N·m (3.0 kgf·m, 22.1 ft·lb) Part name Q’ty Remarks Bracket Starter motor Spark plug cap Ignition coil...
Page 157 Starter motor 8 N·m (0.8 kgf·m, 5.9 ft·lb) 30 N·m (3.0 kgf·m, 22.1 ft·lb) 7 N·m (0.7 kgf·m, 5.2 ft·lb) 2 N·m (0.2 kgf·m, 1.5 ft·lb) 30 N·m (3.0 kgf·m, 22.1 ft·lb) Part name Q’ty Remarks Spring washer M8 × 45 mm Bolt Hour meter M6 ×...
Page 158: Throttle Link And Throttle Cam
POWR Power unit Throttle link and throttle cam Part name Q’ty Remarks Throttle link rod Throttle cam Throttle control lever Bushing Cotter pin Clip Bushing M6 × 20 mm Bolt Spring Collar Bracket M6 × 25 mm Bolt Shift rod lever M6 ×...
Page 159: Timing Belt
Throttle link and throttle cam / Timing belt Timing belt 150 N·m (15.0 kgf·m, 110.6 ft·lb) 38 N·m (3.8 kgf·m, 28.0 ft·lb) 25 N·m (2.5 kgf·m, 18.4 ft·lb) 8 N·m (0.8 kgf·m, 5.9 ft·lb) Part name Q’ty Remarks Timing belt Drive sprocket Driven sprocket Bolt...
Page 160: Removing The Timing Belt And Sprocket
POWR Power unit Removing the timing belt and sprocket 1. Set the cylinder #1 piston position to TDC of the compression stroke by align- ing the “1” mark a on the driven sprocket with the “▲” mark b on the cylinder head.
Page 161: Checking The Timing Belt And Sprocket
Timing belt Installing the sprocket and timing belt 1. Check that the “1” mark a on the driven sprocket 1 is aligned with the “▲” mark b on the cylinder head, and then tighten the bolt 2 temporarily. 2. Install the retaining plate 3, Woodruff key 4, drive sprocket 5, retaining plate 3, and nut 6.
Page 162 POWR Power unit 4. Install the spring 7. 5. Hook the spring 7 to the slot e on the 8, and then temporarily tensioner tighten it with the bolt 9. 8. Tighten the driven sprocket bolt 2 to the speciﬁed torque. 6.
Page 163 Timing belt Crankshaft holder 18 r: 90890-06562 11. Tighten the tensioner bolts to the speci- fied torque. Drive sprocket nut 6: Tensioner bolt 9: 150 N·m (15.0 kgf·m, 110.6 ft·lb) 8 N·m (0.8 kgf·m, 5.9 ft·lb) Tensioner bolt (adjusting bolt) 0: TIP: 25 N·m (2.5 kgf·m, 18.4 ft·lb) Use a deep socket t (42 mm) for this proce-...
Page 164: Exhaust Cover
POWR Power unit Exhaust cover 6 N·m (0.6 kgf·m, 4.4 ft·lb) 12 N·m (1.2 kgf·m, 8.9 ft·lb) Part name Q’ty Remarks Exhaust cover Gasket Thermostat Gasket Cover M6 × 35 mm Bolt Clamp Grommet Anode Cover Plate M6 × 20 mm Bolt M5 ×...
Page 165: Removing The Exhaust Cover
Exhaust cover Removing the exhaust cover Checking the exhaust cover anode 1. Remove the exhaust cover bolts 1 in the 1. Check the anode. Clean if there are sequence numbers ( , , ···). scales, grease, or oil appeared or replace if excessively eroded.
Page 166 POWR Power unit Exhaust cover bolt 4: 1st: 6 N·m (0.6 kgf·m, 4.4 ft·lb) 2nd: 12 N·m (1.2 kgf·m, 8.9 ft·lb) 7-25...
Page 167: Cylinder Head
Exhaust cover / Cylinder head Cylinder head 23 N·m (2.3 kgf·m, 17.0 ft·lb) 47 N·m (4.7 kgf·m, 34.7 ft·lb) 18 N·m (1.8 kgf·m, 13.3 ft·lb) 6 N·m (0.6 kgf·m, 4.4 ft·lb) 12 N·m (1.2 kgf·m, 8.9 ft·lb) Part name Q’ty Remarks Cylinder head Oil pump assembly...
Page 168 POWR Power unit 23 N·m (2.3 kgf·m, 17.0 ft·lb) 47 N·m (4.7 kgf·m, 34.7 ft·lb) 18 N·m (1.8 kgf·m, 13.3 ft·lb) 6 N·m (0.6 kgf·m, 4.4 ft·lb) 12 N·m (1.2 kgf·m, 8.9 ft·lb) Part name Q’ty Remarks M6 × 20 mm Bolt O-ring O-ring...
Page 169: Removing The Cylinder Head
Cylinder head Removing the cylinder head 1. Remove the cylinder head cover bolts 1, and then remove the cylinder head cover 2 and gasket. 3. Remove the oil pump assembly 7. 2. Remove the cylinder head bolts 3, 4 in the sequence numbers ( , , ···).
Page 170 POWR Power unit Cylinder head bolt (M9) 8: 2. Install the dowels 5, a new gasket 6, 1st: 23 N·m (2.3 kgf·m, 17.0 ft·lb) and cylinder head 7. 2nd: 47 N·m (4.7 kgf·m, 34.7 ft·lb) Cylinder head bolt (M6) 9: 3.
Page 171 Cylinder head / Camshaft and valve Camshaft and valve 13.5 N·m (1.4 kgf·m, 10.0 ft·lb) Part name Q’ty Remarks Rocker arm Rocker arm shaft Cylinder head Exhaust valve Intake valve Camshaft Valve cotter Spring retainer Valve spring Spring seat Valve seal Circlip Valve guide Retaining bolt...
Page 172 POWR Power unit 13.5 N·m (1.4 kgf·m, 10.0 ft·lb) Part name Q’ty Remarks Rocker arm retainer e > f Tensioner a > b Stopper c > d Rocker arm retainer Adjusting screw 7-31...
Page 173: Camshaft And Valve
Camshaft and valve Disassembling the cylinder head 1. Loosen the locknut 1 and adjusting screw 2. 2. Remove the bolts 3 in the sequence numbers (z, x, ···), and then remove 4. Remove the intake valve and exhaust the rocker arm retainers 4, 5, stoppers valves.
Page 174: Checking The Valve Spring
POWR Power unit Checking the valve spring 1. Measure the valve spring free length a. Replace if below speciﬁcation. Valve margin thickness a: Intake: 0.600–1.000 mm (0.0236–0.0394 in) Exhaust: Degital caliper 1: 90890-06704 0.700–1.100 mm (0.0276–0.0433 in) 3. Measure the valve stem diameter b. Valve spring free length a: Replace if out of speciﬁcation.
Page 175: Checking The Valve Guide
Camshaft and valve Valve stem runout: Intake: 0.030 mm (0.0012 in) Exhaust: 0.030 mm (0.0012 in) Checking the valve guide Before checking a valve guide, make sure that the valve stem diameter is within speciﬁ- cation. 1. Measure the valve guide inside diameter a.
Page 176: Checking The Valve Seat
POWR Power unit 4. Measure the valve seat contact width a where the blueing dye is adhered to the valve face. Reface the valve seat if the valve is not seated properly or if the valve seat contact width is out of speciﬁcation. Replace the valve guide if the valve seat contact width is uneven.
Page 177: Valve Seat Cutter
Camshaft and valve 3. Use a 30° cutter to adjust the contact width of the top edge of the valve seat. 30˚ 30˚ 45˚ 60˚ Valve seat cutter holder: 90890-06316 b Previous contact width Valve seat cutter: 4. Use a 60° cutter to adjust the contact 30°...
Page 178: Checking The Rocker Arm And Rocker Arm Shaft
POWR Power unit 7. If the valve seat contact area is too wide and situated in the center of the valve face, use a 30° cutter to cut the top edge of the valve seat, a 60° cutter to cut the bottom edge to center the area and set its width.
Page 179: Checking The Camshaft
Camshaft and valve Rocker arm inside diameter b: Camshaft runout: 16.000–16.018 mm (0.6299–0.6306 in) 0.030 mm (0.0012 in) Rocker arm shaft outside diameter c: 3. Measure the camshaft journal diameter 15.971–15.991 mm (0.6288–0.6296 in) c. Replace the camshaft if out of speciﬁ- cation.
Page 180: Installing The Valve
POWR Power unit Valve spring compressor 6: 90890-04019 Valve spring compressor attachment 7: 90890-06320 Cylinder head warpage limit: 0.10 mm (0.0039 in) TIP: Face the ﬁne pitch side a of the valve spring Installing the valve toward the spring seat. 1.
Page 181: Installing The Camshaft
Camshaft and valve Installing the camshaft 1. Install a new oil seal 1. Installing the rocker arm assembly 1. Install the valve adjusting screw 1 and locknut 2 onto the rocker arm 3 tempo- rarily. 2. Assemble the rocker arm assemblies, and rocker arm shaft 4, tensioners 5, rocker arm retainers 6, 7, and stoppers 8 by installing the bolts 9.
Page 182 POWR Power unit TIP: Make sure that the arrow marks a on the tensioners 5 are facing up. Make sure that the rocker arm retainer 7 and stoppers 8 are assembled facing in the direction shown. 3. Install the rocker arm shaft assembly to the cylinder head, and then tighten the bolts 9 to the speciﬁed torque and in the sequence numbers ( ,...
Page 183 Camshaft and valve / Cylinder block Cylinder block 40 N·m (4.0kgf·m, 29.5 ft·lb) 18 N·m (1.8 kgf·m, 13.3 ft·lb) 6 N·m (0.6 kgf·m, 4.4 ft·lb) 12 N·m (1.2 kgf·m, 8.9 ft·lb) 15 N·m (1.5 kgf·m, 11.1 ft·lb) 6 N·m (0.6 kgf·m, 4.4 ft·lb) 30 N·m (3.0 kgf·m, 22.1 ft·lb) 17 N·m (1.7 kgf·m, 12.5 ft·lb) Part name...
Page 184 POWR Power unit 40 N·m (4.0kgf·m, 29.5 ft·lb) 18 N·m (1.8 kgf·m, 13.3 ft·lb) 6 N·m (0.6 kgf·m, 4.4 ft·lb) 12 N·m (1.2 kgf·m, 8.9 ft·lb) 15 N·m (1.5 kgf·m, 11.1 ft·lb) 6 N·m (0.6 kgf·m, 4.4 ft·lb) 30 N·m (3.0 kgf·m, 22.1 ft·lb) 17 N·m (1.7 kgf·m, 12.5 ft·lb) Part name Q’ty...
Page 185: Cylinder Block
Cylinder block Disassembling the cylinder block 1. Place a rag under the oil ﬁlter, and then remove the ﬁlter using a 64 mm (2.5 in) oil ﬁlter wrench. Oil ﬁlter wrench: 90890-01426 3. Remove the connecting rod cap bolts 4 and connecting rod caps a, and then 2.
Page 186: Checking The Piston Diameter
POWR Power unit Piston diameter a: 62.950–62.965 mm (2.4783–2.4789 in) Measuring point b: 5.0 mm (0.20 in) up from the bottom of the piston skirt Oversize piston diameter: Oversize 1: +0.25 mm (0.01 in) Oversize 2: +0.50 mm (0.02 in) TIP: Make sure to keep the crankshaft bearings in Checking the cylinder bore...
Page 187: Checking The Piston Ring End Gap
Cylinder block Piston ring end gap (reference data) a: Top ring: 0.150–0.300 mm (0.0059–0.0118 in) Second ring: 0.300–0.500 mm (0.0118–0.0197 in) Oil ring: 0.200–0.700 mm (0.0079–0.0276 in) Measuring point b: 20.0 mm (0.8 in) Checking the piston ring groove Piston ring dimensions: 1.
Page 188: Checking The Piston Pin Boss Inside Diameter
POWR Power unit Piston pin diameter: 15.965–15.970 mm (0.6285–0.6287 in) Checking the connecting rod small Piston ring side clearance: end and big end inside diameter Top ring a: 1. Measure the connecting rod small end 0.040–0.080 mm (0.0016–0.0032 in) inside diameter a and big end inside Second ring b: diameter b.
Page 189: Checking The Crankshaft
Cylinder block Connecting rod big end side clearance a: Crankshaft runout: 0.030 mm (0.0012 in) 0.050–0.220 mm (0.0020–0.0087 in) Checking the crankshaft journal oil Checking the crankshaft clearance 1. Measure the crankshaft journal diameter 1. Clean the bearings, crankshaft journals, a, crankpin diameter b, and crankpin and bearing portions of the crankcase width c.
Page 190 POWR Power unit TIP: Do not put the Plastigauge (PG-1) over the oil hole in the crankshaft journal. 4. Install the remaining half of the bearings into the crankcase. TIP: Crankcase bolt (M8) 5: Install the protrusion of the bearing into the 1st: 15 N·m (1.5 kgf·m, 11.1 ft·lb) groove in the crankcase.
Page 191: Checking The Crankpin Oil Clearance
Cylinder block 5. Tighten the connecting rod bolts 3 to the Checking the crankpin oil clearance speciﬁed torques in 2 stages. 1. Clean the bearings and connecting rod. 2. Install the crankpin bearings 1 into the connecting rod 2. TIP: Install the bearings in their original posi- tions.
Page 192: Selecting The Crankshaft Journal Bearing
POWR Power unit Selecting the crankshaft journal Crankshaft Cylinder Bearing bearing journal mark block mark color 1. When replacing the crankshaft journal bearing, select the suitable bearing as Yellow follows. 2. Check the crankshaft journal mark a on the crankshaft 1 and the cylinder block Pink mark b on the cylinder block 2.
Page 193: Assembling The Cylinder Block
Cylinder block Connecting Crankpin Bearing rod mark/ mark a color c color b 1/Red Yellow 1/Red 2/Blue 2/Blue Pink 3/Yellow TIP: 3/Yellow Green Face the alignment mark a on the con- necting rod 2 in the same direction as the 4.
Page 194 POWR Power unit TIP: After installing the piston rings, check that they move smoothly. 4. Install the crankpin bearings 8 into the connecting rod 9. NOTICE: Install the bearings in their original position. TIP: Install the protrusion e of the bearing into the groove on the connecting rod.
Page 195 Cylinder block Crankshaft journal bearing installation position (reference data): h #1: 14.200–14.800 mm (0.5591–0.5827 in) k #2: 95.400–96.000 mm (3.7559–3.7795 in) m #3: 167.400–168.000 mm (6.5905–6.6142 in) n #4: 239.400–240.000 mm (9.4252–9.4488 in) p #5: 16.600 mm (0.6535 in) 7. Set the crankshaft w, and oil seal e and r into the cylinder block.
Page 196 POWR Power unit 10. Install the crankcase y and then tighten the bolts u and i to the speciﬁed torques in 2 stages and in the sequence numbers ( , , ···). Crankcase bolt (M8) u: 1st: 15 N·m (1.5 kgf·m, 11.1 ft·lb) 2nd: 30 N·m (3.0 kgf·m, 22.1 ft·lb) Crankcase bolt (M6) i: 1st: 6 N·m (0.6 kgf·m, 4.4 ft·lb)
Page 197 Checking the dog clutch ............. 8-8 Assembling the propeller shaft housing assembly ..... 8-8 Assembling the propeller shaft assembly ........8-9 Drive shaft and lower case (F50D) ........8-10 Removing the drive shaft and shift rod assembly..... 8-12 Disassembling the drive shaft assembly ........8-12 Disassembling the forward gear ..........
Page 198 LOWR Shimming (F50D) ..............8-21 Shimming workflow ..............8-21 Shimming check sheet ............. 8-22 Removing the water pump ............8-24 Measuring the forward gear and reverse gear backlash before disassembly..............8-24 Shimming ................. 8-26 Shim location ................8-27 Selecting the pinion shim (T3) ..........8-28 Pinion shim (T3) selection table ..........
Page 199 Drive shaft and lower case (FT50C) ........8-53 Removing the drive shaft............8-55 Disassembling the drive shaft ..........8-55 Disassembling the forward gear ..........8-55 Disassembling the lower case ..........8-55 Checking the pinion and forward gear........8-56 Checking the drive shaft ............8-56 Checking the lower case ............
Page 200: Lower Unit
LOWR Lower unit Lower unit (F50D) 35 N·m (3.5 kgf·m, 25.8 ft·lb) 9 N·m (0.9 kgf·m, 6.6 ft·lb) 9 N·m (0.9 kgf·m, 6.6 ft·lb) 40 N·m (4.0 kgf·m, 29.5 ft·lb) Part name Q’ty Remarks Lower unit Plastic tie Hose M10 × 40 mm...
Page 201 Lower unit (F50D) 35 N·m (3.5 kgf·m, 25.8 ft·lb) 9 N·m (0.9 kgf·m, 6.6 ft·lb) 9 N·m (0.9 kgf·m, 6.6 ft·lb) 40 N·m (4.0 kgf·m, 29.5 ft·lb) Part name Q’ty Remarks Trim tab M8 × 25 mm Bolt...
Page 202: Removing The Lower Unit
LOWR Lower unit Removing the lower unit Make sure to disconnect the battery cables from the battery and remove the clip from the engine shut-off switch. When removing the lower unit with the power unit installed, make sure to sus- pend the outboard motor.
Page 203 Lower unit (F50D) / Propeller shaft housing (F50D) Propeller shaft housing (F50D) 15 N·m (1.5 kgf·m, 11.1 ft·lb) Part name Q’ty Remarks Spacer Grommet M8 × 30 mm Bolt Water pump housing Insert cartridge Impeller O-ring Outer plate cartridge Gasket...
Page 204 LOWR Lower unit 15 N·m (1.5 kgf·m, 11.1 ft·lb) Part name Q’ty Remarks Shift plunger Washer M8 × 25 mm Bolt Reverse gear Reverse gear shim — Ball bearing O-ring O-ring Propeller shaft housing Needle bearing Oil seal...
Page 205: Propeller Shaft Housing (F50D)
Propeller shaft housing (F50D) Removing the water pump Removing the propeller shaft 1. Remove the water pump housing 1, housing assembly insert cartridge 2, and impeller 3. 1. Remove the bolts 1 from the lower case. 2. Remove the Woodruff key 4, outer plate cartridge 5, gasket 6, and dowels 7.
Page 206: Disassembling The Propeller Shaft Assembly
LOWR Lower unit Disassembling the propeller shaft Stopper guide plate 2: 90890-06501 assembly Stopper guide stand 3: 90890-06538 1. Remove the spring 1, and then remove Bearing puller assembly 4: 90890-06535 the cross pin 2 and dog clutch 3. 3. Remove the oil seals 5 with needle 2.
Page 207: Checking The Dog Clutch
Propeller shaft housing (F50D) Installation depth a: 20.0–23.5 mm (0.79–0.93 in) TIP: Install the needle bearing with the manufac- ture identiﬁcation mark b facing toward the oil seal (propeller side). When using the driver rod, do not strike the special service tool in a manner that will force the stopper c out of place.
Page 208: Assembling The Propeller Shaft Assembly
LOWR Lower unit TIP: Bearing inner race attachment 9: Align the hole b in the dog clutch 1 with the 90890-06639 hole c in the propeller shaft 2. TIP: Install the ball bearing with the manufacture 2. Install the spring 3 and slider 4 into the identiﬁcation mark e facing toward the pro- propeller shaft 2.
Page 209 Propeller shaft housing (F50D) / Drive shaft and lower case (F50D) Drive shaft and lower case (F50D) 74 N·m (7.4 kgf·m, 54.6 ft·lb) Part name Q’ty Remarks Drive shaft Oil seal housing assembly Taper roller bearing Pinion shim — Sleeve...
Page 210 LOWR Lower unit 74 N·m (7.4 kgf·m, 54.6 ft·lb) Part name Q’ty Remarks Oil seal Plate O-ring Circlip Shift rod Shift cam Screw Water inlet cover Hose Plastic tie Joint Seal Plate Lower case 8-11...
Page 211: Drive Shaft And Lower Case (F50D)
Drive shaft and lower case (F50D) Removing the drive shaft and shift Disassembling the drive shaft rod assembly assembly 1. Loosen the pinion nut 1. 1. Install the pinion nut 1, tighten it tempo- rarily and then remove the taper roller bearing 2.
Page 212: Disassembling The Lower Case
LOWR Lower unit Disassembling the lower case 3. Heat the installation area of the taper roller bearing outer race in the lower case with a gas torch, and then remove Use heat-resistant gloves, otherwise the taper roller bearing outer race 5, burns could result.
Page 213: Checking The Lower Case
Drive shaft and lower case (F50D) Bearing inner race attachment 1: Draive shaft runout: 0.2 mm (0.008 in) 90890-06644 Checking the lower case Installing the shift rod 1. Check the skeg, anti-cavitation plate and 1. Install new O-rings 1, 2, plate 3, a new torpedo.
Page 214 LOWR Lower unit Do not reuse the original bearing, replace it with a new one. 1. Heat the installation area of the taper roller bearing outer race in the lower case with a gas torch, and then install the original shim(s) 1 and a new taper roller bearing outer race 2.
Page 215: Installing The Drive Shaft
Drive shaft and lower case (F50D) 4. Heat the installation area of the taper roller bearing outer race in the lower case with a gas torch, and then install the drive shaft sleeve 8, original shim(s) 9, and a new tapper roller bearing outer race 0.
Page 216: Installing The Propeller Shaft Housing Assembly
LOWR Lower unit 2. Install the shift plunger 4 and propeller shaft housing assembly into the lower case. 3. Tighten the bolts 5 to the speciﬁed torque. 3. Tighten the pinion nut 4 to the speciﬁed torque. Propeller shaft housing bolt 5: 15 N·m (1.5 kgf·m, 11.1 ft·lb) Drive shaft holder 4 0: 90890-06518 Pinion nut holder q: 90890-06715...
Page 217: Checking The Lower Unit For Air Leakage
Drive shaft and lower case (F50D) 5. Install a new O-ring 8 and water pump housing assembly 9 into the lower unit, and then tighten the bolts 0. Then install the grommet q and spacer w. NOTICE: turn drive shaft counterclockwise, otherwise the water pump impeller may be damaged.
Page 218: Installing The Lower Unit
LOWR Lower unit 2. Apply the speciﬁed pressure to check whether the lower unit can hold it for at least 10 seconds. NOTICE: Do not over pressurize the lower unit, otherwise the oil seals may be damaged. Lower unit holding pressure: 70.0 kPa (0.7 kgf/cm , 10.2 psi) 3.
Page 219 Drive shaft and lower case (F50D) 8. Fill the lower unit with gear oil to the cor- rect level. Recommended gear oil: Hypoid gear oil API: GL-4 SAE: 90 Gear oil quantity: 0.43 L (0.45 US qt, 0.38 Imp qt) 9.
Page 220: Shimming (F50D)
LOWR Lower unit Shimming (F50D) Shimming workﬂow Remove the water pump assembly and oil seal housing. Measure the backlash before disassembly. Within specification? Shimming is not required. Disassemble the lower unit. Select the pinion shims (T3). Assemble the lower unit.
Page 221 Shimming (F50D) Shimming check sheet Checking the external appearance The deviation of the lower case dimension from standard. Serial number Remarks Measuring the pinion height (mm) Measurements Measurement point 1 Measurement point 2 Measurement point 3 Measurement point 4 Average...
Page 222 LOWR Lower unit Measuring the reverse gear backlash (mm) Measurements Before disassembly After disassembly Measurement point 1 Measurement point 2 Measurement point 3 Measurement point 4 Average Truncated average (BL2) Adjusting the forward gear shim thickness (T1) Measure the thickness of each forward gear shim (T1) in 2 places. (mm) Number of shim(s) Subtotal...
Page 223: Removing The Water Pump
Shimming (F50D) 5. Tighten the center bolt 4 to the speciﬁed Removing the water pump torque while holding the drive shaft not to 1. Remove the water pump assembly. See turn. “Removing the water pump” (8-6). 2. Remove the oil seal housing assembly.
Page 224 LOWR Lower unit 9. Install the special service tools 7, 8, 9, and put another special service tool 0 on the handle stopper 6 to apply load. Magnet base plate 7: 90890-07003 Dial gauge set 8: 90890-01252 TIP: Magnet base 9: 90890-06844 Measure the backlash at 4 points: c, d, Pinion height gauge set 0: 90890-06668 e, and f, turning the drive shaft 180°...
Page 225: Shimming
Shimming (F50D) 13. Check that the forward gear backlash 18. Check that the reverse gear backlash average is within speciﬁcation. average is within speciﬁcation. Forward gear backlash: Reverse gear backlash: 0.18– 0.53 mm (0.007– 0.021 in) 0.71–1.06 mm (0.028– 0.042 in)
Page 226: Shim Location
LOWR Lower unit Shim location 8-27...
Page 227: Selecting The Pinion Shim (T3)
Shimming (F50D) 3. Check the gap a between the pinion 4 Selecting the pinion shim (T3) and the special service tool 1. NOTICE: Spray anti-rust lubricant on the bearing When tightening the pinion nut 5, before installation. Do not apply gear oil to check that the drive shaft rotates the parts.
Page 228 LOWR Lower unit 10. Measure the gap between the pinion 4 6. Place the pinion facing upward and hold and the special service tool 1. When it in the upright position. measuring the gap, insert the end of the 7. Turn the drive shaft 10 times or more to thickness gauge straight into the gap at seat the taper roller bearing.
Page 229 Shimming (F50D) Available shim thicknesses; 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, and 0.50 mm Example: (M) = 0.19 (P) = –3 (T3) = 0.60 mm from the “Pinion shim (T3) selection table”. Pinion height measurement (M) 0.18 0.19 0.20 Stamped value on the lower case 0.60...
Page 230: Pinion Shim (T3) Selection Table
LOWR Lower unit Pinion shim (T3) selection table (mm) å 0.05 0.06 0.07 0.08 0.09 0.10 0.11 0.12 0.13 0.14 0.15 0.16 0.30 0.32 0.32 0.35 0.35 0.35 0.38 0.38 0.38 0.40 0.40 0.42 0.32 0.32 0.35 0.35 0.35 0.38 0.38 0.38 0.40...
Page 231 Shimming (F50D) (mm) å 0.29 0.30 0.31 0.32 0.33 0.34 0.35 0.36 0.37 0.38 0.39 0.40 0.55 0.55 0.58 0.58 0.58 0.60 0.60 0.62 0.62 0.65 0.65 0.65 0.55 0.58 0.58 0.58 0.60 0.60 0.62 0.62 0.65 0.65 0.65 0.68 0.58...
Page 232: Measuring The Forward Gear Backlash
LOWR Lower unit Measuring the forward gear backlash 6. Measure the forward gear backlash. See “Measuring the forward gear and reverse Spray anti-rust lubricant on the gear and gear backlash before disassembly” bearings before installation. Do not apply (8-24) step 1–step 12. gear oil to the parts.
Page 233 Shimming (F50D) TIP: TIP: If the shim thickness adjustment value is Use the least number of shims to achieve positive, the current shim thickness must be the required shim thickness. increased by that amount and, if the value If the calculated shim thickness cannot be...
Page 234 LOWR Lower unit 8-35...
Page 235: Measuring The Reverse Gear Backlash
Shimming (F50D) Measuring the reverse gear backlash TIP: Spray anti-rust lubricant on the gear and Do not reuse a shim if it is deformed or bearings before installation. Do not apply scratched. gear oil to the parts. Otherwise, correct measurements cannot be obtained.
Page 236 LOWR Lower unit TIP: TIP: If the shim thickness adjustment value is Use the least number of shims to achieve positive, the current shim thickness must be the required shim thickness. increased by that amount and, if the value If the calculated shim thickness cannot be is negative, the current shim thickness must obtained with a combination of the available be decreased by that amount.
Page 237 Shimming (F50D) 8-38...
Page 238 LOWR Lower unit 8-39...
Page 239: Lower Unit (Ft50C)
Shimming (F50D) / Lower unit (FT50C) Lower unit (FT50C) 35 N·m (3.5 kgf·m, 25.8 ft·lb) 40 N·m (4.0 kgf·m, 29.5 ft·lb) 40 N·m (4.0 kgf·m, 29.5 ft·lb) 9 N·m (0.9 kgf·m, 6.6 ft·lb) Part name Q’ty Remarks Lower unit Plastic tie...
Page 240 LOWR Lower unit 35 N·m (3.5 kgf·m, 25.8 ft·lb) 40 N·m (4.0 kgf·m, 29.5 ft·lb) 9 N·m (0.9 kgf·m, 6.6 ft·lb) 40 N·m (4.0 kgf·m, 29.5 ft·lb) Part name Q’ty Remarks Trim tab Dowel Extension X transom Washer X transom Spring washer X transom X transom...
Page 241: Removing The Lower Unit
Lower unit (FT50C) Removing the lower unit Make sure to disconnect the battery cables from the battery and remove the clip from the engine shut-off switch. When removing the lower unit with the power unit installed, make sure to sus- pend the outboard motor.
Page 242 LOWR Lower unit ∫ å L transom ∫ X transom TIP: When disassembling the lower unit measure the backlash before disassembly. See “Mea- suring the forward gear backlash before dis- assembling” (8-67). 8-43...
Page 243 Lower unit (FT50C) / Water pump and shift rod (FT50C) Water pump and shift rod (FT50C) Part name Q’ty Remarks Oil seal Oil seal housing O-ring Circlip Shift rod O-ring M6 × 16 mm Bolt Woodruff key M8 × 55 mm Bolt M8 ×...
Page 244 LOWR Lower unit Part name Q’ty Remarks Dowel Gasket Oil seal housing O-ring Oil seal 8-45...
Page 245: Removing The Water Pump And Shift Rod
Water pump and shift rod (FT50C) Removing the water pump and shift TIP: When removing the shift rod, slightly lift it up, 1. Remove the water pump housing 1, and then pull it up by turning it 90° counter- gasket 2, insert cartridge 3, and impel- clockwise.
Page 246 LOWR Lower unit Propeller shaft housing (FT50C) 103 N·m (10.3 kgf·m, 76.0 ft·lb) Part name Q’ty Remarks Ball Slider Shift plunger Cross pin Dog clutch Spring Propeller shaft Washer Straight key Claw washer Ring nut Reverse gear Thrust washer Ball bearing O-ring Propeller shaft housing Needle bearing...
Page 247 Propeller shaft housing (FT50C) 103 N·m (10.3 kgf·m, 76.0 ft·lb) Part name Q’ty Remarks Oil seal 8-48...
Page 248: Removing The Propeller Shaft Housing Assembly
LOWR Lower unit Removing the propeller shaft housing assembly Make sure to remove the shift rod, before removing the propeller shaft housing assem- bly from the lower case. 1. Unbend the one claw 1 of the claw washer. Stopper guide plate 8: 90890-06501 Bearing housing puller claw L 9: 90890-06502 Center bolt 0: 90890-06504...
Page 249: Checking The Propeller Shaft Housing
Propeller shaft housing (FT50C) Driver rod L3 8: 90890-06652 Needle bearing attachment 9: 90890-06612 Checking the propeller shaft housing 1. Check the propeller shaft housing. Replace if corroded, cracked, or dam- aged. Checking the reverse gear Bearing separator 1: 90890-06534 1.
Page 250 LOWR Lower unit Driver rod LS 4: 90890-06606 Ball bearing attachment 5: 90890-06655 Installation depth d: 4.5–5.0 mm (0.18–0.20 in) 3. Install the thrust washer 6 and a new ball bearing 7 onto the reverse gear 8. Driver rod SS 1: 90890-06604 Needle bearing attachment 2: 90890-06612 Bearing depth plate 3: 90890-06603...
Page 251: Assembling The Propeller Shaft Assembly
Propeller shaft housing (FT50C) 5. After installing the reverse gear assem- bly, check that the reverse gear rotates smoothly. 6. Install a new O-ring q. 3. Install the cross pin 6 and spring 7. Assembling the propeller shaft assembly 1. Install the dog clutch 1 with the “F” mark a facing toward the forward gear onto the propeller shaft 2.
Page 252 LOWR Lower unit Drive shaft and lower case (FT50C) 94 N·m (9.4 kgf·m, 69.3 ft·lb) Part name Q’ty Remarks Drive shaft Taper roller bearing Pinion shim — Sleeve Hose Plastic tie Joint Water inlet cover Screw Seal Plate Forward gear shim —...
Page 253: Drive Shaft And Lower Case (Ft50C)
Drive shaft and lower case (FT50C) 94 N·m (9.4 kgf·m, 69.3 ft·lb) Part name Q’ty Remarks Pinion Lower case 8-54...
Page 254: Removing The Drive Shaft
LOWR Lower unit Removing the drive shaft 1. Loosen the pinion nut 1. Bearing inner race attachment 3: 90890-06639 Drive shaft holder 4 2: 90890-06518 Pinion nut holder 3: 90890-06715 Disassembling the forward gear 1. Remove the taper roller bearing from the 2.
Page 255: Checking The Pinion And Forward Gear
Drive shaft and lower case (FT50C) 1. Remove the needle bearing. Needle bearing attachment 1: 90890-06611 Driver rod L3 2: 90890-06652 Checking the pinion and forward 2. Heat the installation area of the taper gear roller bearing outer race in the lower 1.
Page 256: Assembling The Forward Gear
LOWR Lower unit Assembling the forward gear Assembling the lower case 1. Install a new taper roller bearing into the forward gear. NOTICE: Do not reuse the Use heat-resistant gloves, otherwise bearing, always replace it with a new burns could result. one.
Page 257 Drive shaft and lower case (FT50C) 2. While holding the special service tool 3, TIP: strike the tool to check that the taper Install a new needle bearing with the manu- roller bearing outer race is installed prop- facture identiﬁcation mark b facing upward. erly.
Page 258: Installing The Drive Shaft
LOWR Lower unit 2. Tighten the pinion nut 4 to the speciﬁed torque. Driver rod LL 3: 90890-06605 Bearing outer race attachment q: Drive shaft holder 4 5: 90890-06518 90890-06626 Pinion nut holder 6: 90890-06715 Installing the drive shaft Pinion nut 4: 1.
Page 259: Installing The Shift Rod
Drive shaft and lower case (FT50C) Installing the shift rod 1. Set the gear shift to the “N” position, and then install the shift rod 1, new O-rings 2, 3, oil seal housing 4, and a new oil seal 5. 4.
Page 260: Installing The Water Pump
LOWR Lower unit Needle bearing attachment 4: 4. Install the insert cartridge 8 and grom- 90890-06641 met 9 into the water pump housing 0. Driver rod L3 5: 90890-06652 Installation depth a: 4.0–4.5 mm (0.16–0.17 in) Installing the water pump 1.
Page 261: Checking The Lower Unit For Air Leakage
Drive shaft and lower case (FT50C) Installing the lower unit TIP: When installing the water pump housing, apply grease to the inside of the insert car- Do not hold the propeller with your tridge, and then turn the drive shaft clockwise hands when loosening or tightening it.
Page 262 LOWR Lower unit 6. Install the lower unit to the upper case, Lower unit mounting nut 9 and bolt 0: and then tighten the lower unit mounting 40 N·m (4.0 kgf·m, 29.5 ft·lb) bolts 6 and 7 to the speciﬁed torque. (L transom) 7.
Page 263: Shimming (Ft50C)
Drive shaft and lower case (FT50C) / Shimming (FT50C) Shimming (FT50C) Shimming workﬂow Remove the water pump assembly and oil seal housing. Measure the backlash before disassembly. Within specification? Shimming is not required. Disassemble the lower unit. Select the pinion shims (T3). Assemble the lower unit.
Page 264 LOWR Lower unit Shimming check sheet Checking the external appearance The deviation of the lower case dimension from standard. Serial number Remarks Measuring the pinion height (mm) Measurements Measurement point 1 Measurement point 2 Measurement point 3 Measurement point 4 Average Truncated average (M) Measuring the forward gear backlash...
Page 265: Shimming Workflow
Shimming (FT50C) Adjusting the forward gear shim thickness (T1) Measure the thickness of each forward gear shim (T1) in 2 places. (mm) Number of shim(s) Subtotal 0.10 0.12 0.15 0.18 0.30 0.40 0.50 Total 8-66...
Page 266: Removing The Water Pump
LOWR Lower unit Removing the water pump 1. Remove the water pump assembly, shift rod assembly, oil seal housing assembly. See “Removing the water pump and shift rod” (8-46). Measuring the forward gear backlash before disassembly 1. Set the gear shift in “N” position. Center bolt 4 (shimming): 5 N·m(0.5 kgf·m, 3.7 ft·lb) 6.
Page 267 Shimming (FT50C) Magnet base plate 7: 90890-07003 Dial gauge set 8: 90890-01252 Magnet base 9: 90890-06844 Pinion height gauge set 0: 90890-06669 TIP: Measure the backlash at 4 points: c, d, 10. Slowly turn the drive shaft clockwise and e, and f, turning the drive shaft 180° counterclockwise, and then measure the clockwise after each measurement.
Page 268: Shimming
LOWR Lower unit 13. Check that the forward gear backlash average is within speciﬁcation. Forward gear backlash: 0.12–0.45 mm (0.005–0.018 in) TIP: Adjust the shim thicknesses if the forward gear backlash is out of speciﬁcation. 14. Remove the special service tools, and then install the oil seal housing assembly, shift rod assembly, and water pump assembly.
Page 269: Shim Location
Shimming (FT50C) Shim location 8-70...
Page 270: Selecting The Pinion Shim (T3)
LOWR Lower unit 3. Check the gap a between the pinion 4 Selecting the pinion shim (T3) and the special service tool 1. NOTICE: Spray anti-rust lubricant on the bearing When tightening the pinion nut 5, before installation. Do not apply gear oil to check that the drive shaft rotates the parts.
Page 271 Shimming (FT50C) 10. Measure the gap between the pinion 4 6. Place the pinion facing upward and hold and the special service tool 1. When it in the upright position. measuring the gap, insert the end of the 7. Turn the drive shaft 10 times or more to thickness gauge straight into the gap at seat the taper roller bearing.
Page 272 LOWR Lower unit 12. Determine the pinion shim thickness (T3) in the “Pinion shim (T3) selection tables” according to the truncated average (M) and the deviation (P) stamped on the lower case. Available shim thicknesses; 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, and 0.50 mm Example: (M) = 0.19...
Page 273: Pinion Shim (T3) Selection Table
Shimming (FT50C) Pinion shim (T3) selection table (mm) å 0.05 0.06 0.07 0.08 0.09 0.10 0.11 0.12 0.13 0.14 0.15 0.16 0.30 0.32 0.32 0.35 0.35 0.35 0.38 0.38 0.38 0.40 0.40 0.42 0.32 0.32 0.35 0.35 0.35 0.38 0.38 0.38 0.40 0.40...
Page 274 LOWR Lower unit (mm) å 0.29 0.30 0.31 0.32 0.33 0.34 0.35 0.36 0.37 0.38 0.39 0.40 0.55 0.55 0.58 0.58 0.58 0.60 0.60 0.62 0.62 0.65 0.65 0.65 0.55 0.58 0.58 0.58 0.60 0.60 0.62 0.62 0.65 0.65 0.65 0.68 0.58 0.58...
Page 275: Measuring The Forward Gear Backlash
Shimming (FT50C) Measuring the forward gear backlash Forward gear backlash: Spray anti-rust lubricant on the gear and 0.12–0.45 mm (0.005–0.018 in) bearings before installation. Do not apply gear oil to the parts. Otherwise, correct Adjusting the forward gear shim measurements cannot be obtained. Keep the parts free of foreign material, thickness (T1) such as dirt and lint.
Page 276 LOWR Lower unit TIP: TIP: If the shim thickness adjustment value is Use the least number of shims to achieve positive, the current shim thickness must be the required shim thickness. increased by that amount and, if the value If the calculated shim thickness cannot be is negative, the current shim thickness must obtained with a combination of the available be decreased by that amount.
Page 277 Shimming (FT50C) 8-78...
Page 278 BRKT Bracket unit Tiller handle (removing) ............9-1 Tiller handle (disassembling) ..........9-3 Checking the throttle cable and shift rod ........9-6 Assembling the tiller handle ............9-6 Lubricating the throttle gear............9-7 Shift rod and bottom cowling ..........9-8 Upper case and mounts ............
Page 279 Gear pump (disassembling) ..........9-38 Disassembling the gear pump ..........9-40 Checking the valve ..............9-41 Checking the filter..............9-41 Checking the gear pump ............9-41 Assembling the gear pump............9-41 PTT cylinder ................9-44 Disassembling the tilt cylinder ..........9-46 Disassembling the trim cylinder..........
Page 280 BRKT Bracket unit Tiller handle (removing) 13 N·m (1.3 kgf·m, 9.6 ft·lb) 38 N·m (3.8 kgf·m, 28.0 ft·lb) Part name Q’ty Remarks Tiller handle assembly M8 × 35 mm Bolt Friction piece Wing nut Friction rod Washer Link rod M6 × 30 mm Bolt Washer Grommet...
Page 281 Tiller handle (removing) 13 N·m (1.3 kgf·m, 9.6 ft·lb) 38 N·m (3.8 kgf·m, 28.0 ft·lb) Part name Q’ty Remarks Steering friction assembly Shift rod 1 Shift rod 2 Washer Clip Cable joint Bolt Housing Collar Engine start switch M6 × 30 mm Screw Housing M6 ×...
Page 282 BRKT Bracket unit Tiller handle (disassembling) 11 N·m (1.1 kgf·m, 8.1 ft·lb) 38 N·m (3.8 kgf·m, 28.0 ft·lb) Part name Q’ty Remarks Tiller handle Throttle cable Gear Throttle shaft Case M6 × 25 mm Bolt Friction piece Washer Wing nut M6 ×...
Page 283 Tiller handle (disassembling) 11 N·m (1.1 kgf·m, 8.1 ft·lb) 38 N·m (3.8 kgf·m, 28.0 ft·lb) Part name Q’ty Remarks M6 × 16 mm Bolt Shift arm guide Shift arm Shift knob Bushing Spring Ball Washer Clip Collar Washer Washer M12 × 70 mm Bolt Washer Bushing...
Page 284 BRKT Bracket unit 11 N·m (1.1 kgf·m, 8.1 ft·lb) 38 N·m (3.8 kgf·m, 28.0 ft·lb) Part name Q’ty Remarks Washer Plastic washer Wave washer Bracket Gasket Cover M5 × 12 mm Screw Grease nipple M6 × 8 mm Screw...
Page 285 Tiller handle (disassembling) Checking the throttle cable and shift 1. Check the throttle cable and shift rod for smooth operation. 2. Check the inner wire and outer wire of the throttle cable. Replace if the outer wire is bent or damaged, or the rubber seals are damaged.
Page 286 BRKT Bracket unit Locknut d: 11 N·m (1.1 kgf·m, 8.1 ft·lb) Lubricating the throttle gear 1. Apply grease into the grease nipple until TIP: grease comes out from the screw hole Check that the fully closed mark e of the indicator is aligned with the mark f on the tiller handle.
Page 287 Tiller handle (disassembling) / Shift rod and bottom cowling Shift rod and bottom cowling 24 N·m (2.4 kgf·m, 17.7 ft·lb) 20 37 13 21 22 12 Part name Q’ty Remarks Bottom cowling Detent bolt Spring Ball Bracket Cotter pin Washer Bushing Shift rod Grommet...
Page 288 BRKT Bracket unit 24 N·m (2.4 kgf·m, 17.7 ft·lb) 20 37 13 21 22 12 Part name Q’ty Remarks Collar Pilot water outlet Plastic tie Collar Grommet Bushing Joint Cowling lock lever Cotter pin Cotter pin M6 × 12 mm/PTT model Bolt Bracket PTT model...
Page 289 Shift rod and bottom cowling 24 N·m (2.4 kgf·m, 17.7 ft·lb) 20 37 13 21 22 12 Part name Q’ty Remarks M6 × 24 mm/PTT model Screw Rubber seal Hose Grommet D model Plug D model Grommet R model 9-10...
Page 290 BRKT Bracket unit Upper case and mounts 24 N·m (2.4 kgf·m, 17.7 ft·lb) 42 N·m (4.2 kgf·m, 31.0 ft·lb) Part name Q’ty Remarks Washer M8 × 30 mm Bolt Upper mount Plate L transom M8 × 175 mm Bolt M12 × 160 mm Bolt Grommet Ground lead...
Page 291 Upper case and mounts 24 N·m (2.4 kgf·m, 17.7 ft·lb) 42 N·m (4.2 kgf·m, 31.0 ft·lb) Part name Q’ty Remarks Rubber washer Lower mount Washer Grease nipple Plate X transom Oil seal 9-12...
Page 292 BRKT Bracket unit 6. Remove the bolts e, washers r, rubber Removing the upper case washers t, lower mounts y, and wash- 1. Drain the remained engine oil. ers u. 2. Disconnect the ground lead 1. 3. Remove the upper mounting nuts 2 and lower mounting nuts 3 from the bracket assembly, and then remove the upper case assembly 4.
Page 293 Upper case and mounts 4. Install the end of the springs w into the Upper mounting nut u: groove of the housings e and ground 24 N·m (2.4 kgf·m, 17.7 ft·lb) lead r, and then tighten the bolts t. Lower mounting nut i: 42 N·m (4.2 kgf·m, 31.0 ft·lb) 5.
Page 294 BRKT Bracket unit Upper case 21 N·m (2.1 kgf·m, 15.5 ft·lb) Part name Q’ty Remarks Upper case Rubber seal Rubber seal Dowel Rubber seal Guide M5 × 16 mm Screw Bafﬂe plate M8 × 30 mm Bolt Bushing Circlip Stud bolt X transom 9-15...
Page 295 Upper case Disassembling the upper case 1. Remove the bolts 1, and then remove the mufﬂer assembly 2 from the upper case. Shaft 7 (reference): Diameter a: 20 mm (0.8 in) Length: 370 mm (14.6 in) Checking the drive shaft bushing 1.
Page 296 BRKT Bracket unit 2. Install the bafﬂe plate 5 and guide 6. 3. Install a new rubber seal 7 into the upper case. 4. Install the mufﬂer assembly 8 by insert- ing the tip of the water pipe 9 into the rubber seal 7.
Page 297 Upper case / Oil pan and exhaust manifold Oil pan and exhaust manifold 18 N·m (1.8 kgf·m, 13.3 ft·lb) Part name Q’ty Remarks Exhaust guide Grommet Anode Cover M5 × 12 mm Bolt Cover M6 × 20 mm Bolt Gasket Dowel M6 ×...
Page 298 BRKT Bracket unit 18 N·m (1.8 kgf·m, 13.3 ft·lb) Part name Q’ty Remarks M6 × 25 mm Bolt Mufﬂer Washer Pipe Rubber seal Gasket Relief valve Bolt M6 × 25 mm Bolt M6 × 16 mm Oil strainer Gasket Drain bolt Damper 9-19...
Page 299 Oil pan and exhaust manifold 4. Remove the oil strainer 5. Disassembling the oil pan 1. Remove the mufﬂer 1 from the oil pan. 5. Remove the gasket 6 and relief valve 2. Remove the exhaust manifold 2 from the oil pan 3. 3.
Page 300 BRKT Bracket unit 3. Install the oil strainer 6, and then tighten the bolts 5 and 7. 7. Tighten the exhaust manifold bolts y to the speciﬁed torque, and then tighten the oil pan bolts q. Manifold bolt y: 11 N·m (1.1 kgf·m, 8.1 ft·lb) 8.
Page 301 Oil pan and exhaust manifold / Steering arm, swivel bracket, and clamp brackets Steering arm, swivel bracket, and clamp brackets 23 N·m (2.3 kgf·m, 17.0 ft·lb) 3 N·m (0.3 kgf·m, 2.2 ft·lb) 20 N·m (2.0 kgf·m, 14.8 ft·lb) 2 N·m (0.2 kgf·m, 1.5 ft·lb) 16 15 26 25 3 N·m (0.3 kgf·m, 2.2 ft·lb)
Page 302 BRKT Bracket unit 23 N·m (2.3 kgf·m, 17.0 ft·lb) 3 N·m (0.3 kgf·m, 2.2 ft·lb) 20 N·m (2.0 kgf·m, 14.8 ft·lb) 2 N·m (0.2 kgf·m, 1.5 ft·lb) 16 15 26 25 3 N·m (0.3 kgf·m, 2.2 ft·lb) 3 N·m (0.3 kgf·m, 2.2 ft·lb) Part name Q’ty Remarks...
Page 303 Steering arm, swivel bracket, and clamp brackets 23 N·m (2.3 kgf·m, 17.0 ft·lb) 3 N·m (0.3 kgf·m, 2.2 ft·lb) 20 N·m (2.0 kgf·m, 14.8 ft·lb) 2 N·m (0.2 kgf·m, 1.5 ft·lb) 16 15 26 25 3 N·m (0.3 kgf·m, 2.2 ft·lb) 3 N·m (0.3 kgf·m, 2.2 ft·lb) Part name Q’ty...
Page 304 BRKT Bracket unit Removing the steering arm Installing the steering arm 1. Remove the circlip 1, and then remove 1. Install the washer 1, bushing 2, 3, and the steering yoke 2. a new O-ring 4 onto the steering arm 5. 2.
Page 305 Steering arm, swivel bracket, and clamp brackets 4. Install the steering yoke 0 making sure it 7. Apply grease into the grease nipple w is facing the same direction as the steer- until it comes out from both the upper ing arm 5 (aligning a with b).
Page 306 BRKT Bracket unit 4. Remove the spring 7, hook 8, and pins TIP: Make sure to install the distance collar 4 and tilt stop levers 5 so that they are facing in the 5. Remove the tilt stop levers 0, distance same direction (aligning b with c).
Page 307 Steering arm, swivel bracket, and clamp brackets 3. Fully tilt the swivel bracket up, and then support it with the tilt stop lever 1. 4. Loosen the cam screws 2. 5. Adjust the position of the trim sensor 3, and then tighten the screws 2 to the speciﬁed torque.
Page 308 BRKT Bracket unit PTT unit Part name Q’ty Remarks PTT unit Plastic tie M8 × 17 mm Bolt Washer Circlip Shaft Bushing Collar Tilt pin Collar Collar Shaft 9-29...
Page 309 PTT unit Removing the PTT unit After tilting the swivel bracket up, make sure to support it with the tilt stop lever. Otherwise, the swivel bracket could sud- denly lower if the PTT unit should lose ﬂuid pressure. When removing the PTT unit with the power unit installed, make sure to sus- pend the outboard motor.
Page 310 BRKT Bracket unit 2. Install the bushings 2 and collar 3 to the PTT unit and swivel bracket. 3. Install the upper end of the PTT unit into the swivel bracket, and then install the upper mount shaft 4 and circlip 5. 4.
Page 311 PTT unit / PTT motor PTT motor 4 N·m (0.4 kgf·m, 3.0 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb) Part name Q’ty Remarks PTT motor assembly M5 × 20 mm Screw Yoke O-ring Armature Washer Bushing M4 × 12 mm Screw Wire lead Brush 1...
Page 312 BRKT Bracket unit 4 N·m (0.4 kgf·m, 3.0 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb) Part name Q’ty Remarks O-ring Joint 9-33...
Page 313 PTT motor Disassembling the PTT motor 1. Remove the bolts 1, and then remove the york 2, armature 3, and PTT motor base 4. 2. Measure the commutator diameter a. Replace if below speciﬁcation. 2. Remove the screws 5, and then remove Digital caliper 1: 90890-06704 the brush holder assembly 6 from the PTT motor base.
Page 314 BRKT Bracket unit 4. Check the circuit breaker for continuity. Replace if there are no continuity. 2. Install the circuit breaker 4 onto brush 1 5 together with the brush holder 6 and 5. Check the PTT motor base. Replace if connect the wire lead 7.
Page 315 PTT motor / Gear pump (removing) Gear pump (removing) 5.3 N·m (0.5 kgf·m, 3.9 ft·lb) 7 N·m (0.7 kgf·m, 5.2 ft·lb) 2 N·m (0.2 kgf·m, 1.5 ft·lb) Part name Q’ty Remarks Gear pump assembly M5 × 8 mm Bolt Relief valve bracket L transom Screw L transom...
Page 316 BRKT Bracket unit 5.3 N·m (0.5 kgf·m, 3.9 ft·lb) 7 N·m (0.7 kgf·m, 5.2 ft·lb) 2 N·m (0.2 kgf·m, 1.5 ft·lb) Part name Q’ty Remarks Filter O-ring Manual valve Circlip Relief valve bracket X transom Valve lock screw X transom Up-relief spring X transom Valve support pin...
Page 317 Gear pump (removing) / Gear pump (disassembling) Gear pump (disassembling) 5.3 N·m (0.5 kgf·m, 3.9 ft·lb) Part name Q’ty Remarks M5 × 20 mm Bolt Washer Gear pump bracket O-ring Spacer Spring Absorber valve pin Ball Manual release spring Spring Down-main valve O-ring Main valve seal...
Page 318 BRKT Bracket unit 5.3 N·m (0.5 kgf·m, 3.9 ft·lb) Part name Q’ty Remarks Up-relief valve X transom Ball X transom 9-39...
Page 319 Gear pump (disassembling) Disassembling the gear pump å Make sure that the PTT ram is fully extended when removing the gear pump, otherwise ﬂuid can spurt out from the unit due to internal pressure. When disassembling the gear pump with the cylinder installed, do not push the PTT ram down, otherwise ﬂuid can ∫...
Page 320 BRKT Bracket unit Checking the gear pump 1. Check the drive gear a, driven gear b, and shaft c. Replace the gear pump assembly, if damaged or worn. Assembling the gear pump Checking the valve 1. Check the down-main valve 1 and up- main valve 2.
Page 321 Gear pump (disassembling) 10. Install the relief valve bracket z, and then tighten the bolts x to the speciﬁed torque. å ∫ 6. Install the balls w, absorber valve pins e, springs r, spacers t, and new O- rings y into the gear pump cover e. 7.
Page 322 BRKT Bracket unit Recommended PTT ﬂuid: ATF Dexron 2 15. Install the PTT motor % and then tighten the bolts ^ to the speciﬁed torque. Gear pump bolt m: 7 N·m (0.7 kgf·m, 5.2 ft·lb) Manual valve .: 2 N·m (0.2 kgf·m, 1.5 ft·lb) Reservoir cap @: 7 N·m (0.7 kgf·m, 5.2 ft·lb) PTT motor bolt ^:...
Page 323 Gear pump (disassembling) / PTT cylinder PTT cylinder 80 N·m (8.0 kgf·m, 59.0 ft·lb) 90 N·m (9.0 kgf·m, 66.4 ft·lb) 61 N·m (6.1 kgf·m, 45.0 ft·lb) 7 N·m (0.7 kgf·m, 5.2 ft·lb) Part name Q’ty Remarks PTT ram assembly Ball Snap ring Trim cylinder base Spring...
Page 324 BRKT Bracket unit 80 N·m (8.0 kgf·m, 59.0 ft·lb) 90 N·m (9.0 kgf·m, 66.4 ft·lb) 61 N·m (6.1 kgf·m, 45.0 ft·lb) 7 N·m (0.7 kgf·m, 5.2 ft·lb) Part name Q’ty Remarks Trim cylinder O-ring Backup ring O-ring Free piston 9-45...
Page 325 PTT cylinder Disassembling the tilt cylinder Make sure that the PTT ram is fully extended before removing the tilt cylinder end screw otherwise ﬂuid can spurt out from the unit due to internal pressure. 1. Hold the PTT unit 1 in a vise using alu- minum plates a on both sides.
Page 326 BRKT Bracket unit Assembling the trim cylinder Do not use a rag when assembling the PTT unit because dust and particles on the PTT unit components can lead to poor performance. Do not reuse the O-rings, always replace them with new ones. 1.
Page 327 PTT cylinder 5. Install the balls 0 into the trim cylinder Trim cylinder end screw b: 3, and then install the trim cylinder 3 80 N·m (8.0 kgf·m, 59.0 ft·lb) into the tilt cylinder q. Assembling the tilt cylinder 1. Install the free piston 1 and a new O- ring 2 into the trim cylinder 3, and then install the snap ring 4.
Page 328 BRKT Bracket unit 4. If the ﬂuid level is below the correct level, add sufﬁcient recommended ﬂuid to the correct level. Recommended PTT ﬂuid: ATF Dexron 2 5. Install the reservoir cap. 6. Connect the PTT motor leads a to the battery terminals to fully retract the PTT ram.
Page 329 PTT cylinder / PTT electrical system Battery PTT motor lead terminal Blue (L) Green (G) TIP: If the PTT ram does not move up and down easily, push and pull the PTT ram to assist operation. 8. Check the ﬂuid level when the PTT ram is fully extended.
Page 330 BRKT Bracket unit 5. Connect the digital circuit tester between Terminal color PTT relay terminals b and c. Switch position 6. Connect the positive battery lead to the Sky blue (Sb) lead, and the negative bat- Free tery lead to the Black (B) lead. 7.
Page 331 PTT electrical system / Hydro tilt unit Hydro tilt unit Part name Q’ty Remarks Hydro tilt M8 × 17 mm Bolt Washer Tilt pin Bushing Circlip Shaft Collar Collar Collar Shaft 9-52...
Page 332 BRKT Bracket unit Removing the hydro tilt unit After tilting the swivel bracket up, make sure to support it with the tilt stop lever. Otherwise, the swivel bracket could sud- denly lower if the hydro tilt unit should lose gas pressure. When removing the hydro tilt unit with the power unit installed, make sure to suspend the outboard motor.
Page 333 Hydro tilt unit 2. Install the bushings 2 and collar 3 to the hydro tilt unit and swivel bracket. 3. Install the upper end of the hydro tilt unit into the swivel bracket, and then install the upper mount shaft 4 and circlips 5. 4.
Page 334 BRKT Bracket unit — MEMO — 9-55...
Page 335 Maintenance Outline ..................10-1 Maintenance chart 1 ..............10-2 Maintenance chart 2 ..............10-3 Predelivery check ..............10-4 Checking the battery ..............10-4 Checking the engine start switch and engine shut-off switch ... 10-4 Checking the engine oil level............ 10-5 Checking the fuel system ............
Page 336: Maintenance
Maintenance Outline To ensure long product life, Yamaha strongly recommends the speciﬁed periodic check and main- tenance to be performed according to the maintenance interval chart. If replacement parts are necessary, use only genuine Yamaha parts of equivalent design and quality.
Page 337: Maintenance Chart 1
Fuel ﬁlter Check/replace 10-15 Fuel line Check/replace 10-15 Fuel pump Check/replace Fuel/oil leakage Check 10-15 Gear oil Change 10-15 Check/replace Impeller/water pump (F50D) housing 8-46 (FT50C) Replace Impeller/water pump (F50D) housing 8-46 (FT50C) Lubrication points Lubricate 10-16 Propeller/propeller nut/ Check/replace 10-17...
Page 338: Maintenance Chart 2
(5 years) Wiring harness connec- Check/replace tions/lead coupler con- — nections Water inlet Check 10-10 Yamaha meter/gauge Check — Yamaha fuel tank Check/replace — — : Not applicable Maintenance chart 2 Every Refer Item Actions to page 1000 hours Exhaust guide/...
Page 339: Predelivery Check
Outline / Predelivery check Predelivery check To make the delivery process smooth and efﬁcient, the predelivery checks should be completed as explained below. Checking the battery Battery electrolyte is dangerous; it con- tains sulfuric acid which is poisonous and highly caustic. Always follow these preventive measures: 2.
Page 340: Checking The Engine Oil Level
Maintenance ∫ START å H model ∫ R model Recommended engine oil: 4-stroke motor oil with combination of 3. Check that the engine turns off when the the following SAE and API oil classiﬁ- clip is removed from the engine shut-off cation.
Page 341: Checking The Gear Oil Level
Predelivery check Checking the PTT system 1. Check that the outboard motor tilts up and down smoothly when operating the PTT unit. 2. Check that there is no abnormal noise produced when the outboard motor is tilted up or down. 3.
Page 342: Checking The Gear Shift And Throttle Operation
Maintenance Checking the gear shift and throttle operation 1. Check that the gear shift operates smoothly when the shift lever is shifted from the “N” to “F” or “R” position. (H model) Check that the gear shift operates smoothly when the remote control lever is shifted from the “N”...
Page 343: Checking The Steering System
Predelivery check Checking the steering system Checking the cooling water pilot hole 1. Check the steering friction for proper adjustment. (H model) 1. Start the engine, check that cooling water is discharged from the cooling water pilot hole. TIP: To increase the friction, move the steering friction screw 1 in direction a.
Page 344: Test Run
Maintenance 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. å 3. Operate at trolling speed. 4. Run the outboard motor according to the break-in procedure.
Page 345: Checking The Battery
ç ∂ å å D model ∫ PTT model ∫ ç F50D ∂ FT50C TIP: Replace the anodes if excessively eroded. In addition, check the ground lead. If it is necessary to disassemble the out- board motor to check an anode, refer to the applicable disassembly procedure in this manual.
Page 346: Checking The Top Cowling
∫ 2. Loosen the bolts 1. 3. Move the hook 2 up or down slightly to adjust its position. å F50D ∫ FT50C TIP: Mark a the trim tab 2 at the area shown, and then remove it. 4. Place the lower unit in water, and then start the engine.
Page 347: Checking The Engine Idle Speed
General periodic maintenance 5. Check the ﬁtting again. Engine idle speed: F50D: 800–900 r/min 6. Check the air intake duct. Clean if there FT50C: 900–1000 r/min are obstructions. 4. Turn the throttle stop screw b in direc- tion c or d until the speciﬁed engine idle speed is obtained.
Page 348: Changing The Engine Oil
Maintenance TIP: If the oil appears milky or dirty, check for and repair the cause, and then change the oil. If the engine oil is below the lower level mark a, add sufﬁcient oil until the level is between a and b. Changing the engine oil Change the engine oil after the ﬁrst 20 hours of operation or 3 months, and every...
Page 349: Replacing The Oil Filter
General periodic maintenance 11. Start the engine and make sure that the low oil pressure alert indicator remains off. Also, make sure that there are no oil leaks. NOTICE: If the low oil pressure alert indicator comes on or if there are oil leaks, stop the engine and ﬁnd the cause.
Page 350: Checking The Fuel Filter
Maintenance Checking the fuel ﬁlter 1. Check the fuel ﬁlter element 1. Clean if there is dirt or residue and replace if damaged. 2. Check the fuel ﬁlter cup 2. Clean with straight gasoline if there are foreign sub- stances and replace if cracked. Changing the gear oil Never get under the lower unit while it is tilted.
Page 351: Lubrication
API: GL-4 SAE: 90 Gear oil quantity: F50D: 0.43 L (0.45 US qt, 0.38 Imp qt) FT50C: 0.67 L (0.71 US qt, 0.59 Imp qt) 7. Install new gaskets and gear oil check screw 4, and quickly install the gear oil drain screw 3, and then tighten them to the specified torque.
Page 352: Checking The Propeller
Maintenance å å H model TIP: Apply grease to the grease nipple until it ﬂows from the bushings a. 2. Apply low temperature resistant grease to the areas shown. 3. Apply anti-corrosion grease to the areas shown. Checking the propeller 1.
Page 353: Checking The Ptt Fluid Level
General periodic maintenance Checking the PTT ﬂuid level 1. Fully tilt the outboard motor up, and then support it with the tilt stop lever 1. WARNING! After tilting the outboard motor up, make sure to support it with the tilt stop lever. Otherwise, the outboard motor could suddenly lower if the PTT unit should lose ﬂuid pressure.
Page 354: Adjusting The Shift Cable
Maintenance 3. Adjust the position of the throttle cable joint until its hole is aligned with the pin c on the throttle cam. NOTICE: The throttle cable joint must be screwed in a minimum of 8.0 mm (0.31 in) d. 3.
Page 355: Checking The Spark Plug
General periodic maintenance Checking the spark plug Checking the thermostat 1. Remove the cover 1, thermostat cover 1. Disconnect the spark plug caps and 2 and thermostat 3. NOTICE: Do not remove the spark plugs. reuse the gasket 4, always replace it 2.
Page 356: Checking The Timing Belt
Maintenance Replacing the timing belt Do not turn the ﬂywheel magnet coun- terclockwise, otherwise the water pump impeller may be damaged. Do not turn the ﬂywheel magnet or the driven sprockets when the timing belt is not installed. Otherwise the pistons and valves will collide with each other and be damaged.
Page 357 General periodic maintenance 7. Install a new timing belt 3 onto the drive sprocket 7, and then install it onto the driven sprocket 8. Then loosen the bolt 6 1/2 turn. 8. Turn the crankshaft clockwise fully twice, 4. Install the spring 4. and then check that the “1”...
Page 358: Checking The Ignition Timing
2. Start the engine and warm it up for 10 minutes. 3. Check the engine idle speed. Engine idle speed: F50D: 800–900 r/min FT50C: 900–1000 r/min 4. Check that the “T” mark b on the ﬂy- wheel magnet is aligned with the base pointer c on the base assembly.
Page 359 Index CDI unit with microcomputer ...... 2-1 Changing the engine oil......10-13 Abbreviation ..........0-5 Changing the gear oil ......10-15 Acceleration pump ........2-10 Charging system......... 1-7 Adjusting the dashpot .......6-18 Charging unit and components....5-28 Adjusting the forward gear shim Checking the alert indicator ......
Page 360 Disassembling the tilt cylinder ....9-46 Checking the steering system....10-8 Disassembling the trim cylinder....9-46 Checking the thermostat ......10-20 Disassembling the upper case ....9-16 Checking the thermoswitch.......5-15 Disassembly and assembly ......0-3 Drive shaft and lower case (F50D) ... 8-10...
Page 361 Fuel pump ...........6-7 Intake silencer .......... 6-11 Fuel system........ 1-8, 1-14, 2-7 Fuel system technical data ......1-8 Lower unit ........... 1-5 Lower unit (F50D)......1-15, 8-1 Gear pump (disassembling)......9-38 Lower unit (FT50C)......1-15, 8-40 Gear pump (removing)......9-36 Lower unit assembly......... 1-13 General feature ...........1-1...
Page 362 Selecting the crankpin bearing ....7-51 Propeller............0-1 Selecting the crankshaft journal Propeller selection ........3-20 bearing............ 7-51 Propeller shaft housing (F50D) ....8-4 Selecting the pinion shim (T3) ..8-28, 8-71 Propeller shaft housing (FT50C)....8-47 Selection........... 3-20 Propeller size ..........3-20 Self-protection ..........0-2 PTT cylinder..........9-44...
Page 363 Index Tightening torque ........0-3 Tiller handle ..........5-11 Tiller handle (disassembling) ......9-3 Tiller handle (removing) ......9-1 Tiller handle installation ......3-11 Timing belt ..........7-18 Top view............5-9 Troubleshooting procedure ......4-1 Troubleshooting table format ......4-1 Troubleshooting the lower unit....4-8 Troubleshooting the outboard motor...4-1 Troubleshooting the power unit....4-2 Troubleshooting the PTT unit......4-7 Uncrate procedure ........3-9 Upper case..........9-15...
Page 365 Appendix Wiring diagram ................A-1 How to use the wiring diagram ........... A-1 F50DET, FT50CET ..............A-2 FT50CEHD, FT50CED ............... A-4...
Page 366: Wiring Diagram
Wiring diagram How to use the wiring diagram Composition of the wiring diagrams The wiring diagram consists of two sheets. One is for F50DET and FT50CET, the other for FT50CEHD and FT50CED. Legend symbols in the wiring diagrams 1 Double colors wire. 2 No wire connector.
Page 368 YAMAHA MOTOR CO., LTD. Printed in Japan Aug. 2008 – 0.5 × 1 n Printed on recycled paper...
Page 369 F50DET, FT50CET Lighting coil Starter motor Prime Start Charge coil CDI unit Rectifier Regulator Starter relay Battery Pulser coil PTT relay Fuse (20A) PTT motor Thermoswitch Oil pressure switch Spark plug Ignition coil PTT switch Trim sensor Sb R Lg FREE DOWN Hour meter...
Page 370 Color Code : Black : Brown : Green : Blue : Orange : Pink : Red : White : Yellow P/B : Pink/Black P/W : Pink/White B/O : Black/Orange B/W : Black/White G/W : Green/White Gy/B : Gray/Black Y/B : Yellow/Black Y/R : Yellow/Red W/B : White/Black W/R : White/Red...
Page 371 FT50CEHD, FT50CED Lighting coil Starter motor Prime Start Charge coil CDI unit Rectifier Regulator Starter relay Battery Pulser coil Neutral switch Thermoswitch Oil pressure switch Fuse (20A) Engine start switch Engine shut-off switch START Spark plug Ignition coil Alert indicator Hour meter...

This manual is also suitable for:

Ft50c

Yamaha F50D Servise Manual

Gen Info General Information

Safety While Working

How to Use this Manual

Sealant and Locking Agent

Special Service Tool

Spec Speciﬁcation

Model Features

Model Data

Electrical Technical Data

Fuel System Technical Data

Power Unit Technical Data

Lower Unit Technical Data

Bracket Unit Technical Data

Special Tightening Torque

General Tightening Torque

Tech Fea/Tech Fea

Technical Features and Description

Electronic Control System

Tech Fea

Fuel System

Lubrication System

PTT Unit

Rig Ging Rigging Information

Outboard Motor Installation

Rigging Information

Dimensions

Crate Top Cover Pictograph Description

Uncrate Procedure

Mounting the Outboard Motor

Tiller Handle Installation

Wiring Harness Connection

Control Cable Installation

Remote Control Box Installation

Installing the Battery

System Diagram

Rigging Recommendations

Propeller Selection

Elec Electrical System

Electrical Component and Wiring Harness Routing

Electrical System

Checking the Electrical Component

Ignition Unit and Components Checking the Ignition Spark

Starting Unit and Components Checking the Fuse

Starter Motor

Charging Unit and Components

Fuel Fuel System

Fuel System

Hose Routing

Fuel Filter

Fuel Pump

Intake Silencer

Carburetor Unit

Powr Power Unit

Power Unit

Power Unit (Check and Adjustment)

Flywheel Magnet

Power Unit Assembly

Starter Motor

Throttle Link and Throttle Cam

Timing Belt

Exhaust Cover

Cylinder Head

Camshaft and Valve

Cylinder Block

Lowr Lower Unit

Lower Unit (F50D)

Lower Unit

Propeller Shaft Housing (F50D)

Drive Shaft and Lower Case (F50D)

Shimming (F50D)

Lower Unit (FT50C)

Drive Shaft and Lower Case (FT50C)

Shimming (FT50C)

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Summary of Contents for Yamaha F50D