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Yamaha F60A Supplementary Service Manual
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Yamaha F60A Supplementary Service Manual

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F60A
SUPPLEMENTARY
SERVICE MANUAL
292098
69W-28197-3D-1X

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Summary of Contents for Yamaha F60A

  • Page 1 F60A SUPPLEMENTARY SERVICE MANUAL 292098 69W-28197-3D-1X...

  • Page 2: Important Information

    NOTE: A NOTE provides key information to make procedures easier or clearer. F60A SUPPLEMENTARY SERVICE MANUAL ©2001 by Yamaha Motor Co., Ltd. 1st Edition, July 2001 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd.
  • Page 3 Contents General information INFO Specifications SPEC Periodic checks and adjustments Fuel system FUEL Power unit POWR Lower unit LOWR Bracket unit BRKT – Electrical systems ELEC Troubleshooting TRBL SHTG Index...

  • Page 4: Table Of Contents

    General information How to use this manual ..................1 Manual format....................1 Symbols......................2 Identification...................... 3 Applicable models ..................3 Serial number ....................3 Features and benefits ..................4 Power unit..................... 4 Carburetors....................5 Lower unit ..................... 7 Bracket unit....................9 Electrical unit ....................
  • Page 5 Specifications General specifications..................18 Maintenance specifications ................20 Power unit....................20 Lower unit ....................24 Electrical ..................... 24 Dimensions....................27 Tightening torques..................32 Specified torques..................32 General torques..................33 Periodic checks and adjustments Special service tools ..................34 Maintenance interval chart................36 Top cowling .....................
  • Page 6 Power unit Power unit......................45 Checking the compression pressure ............55 Checking the oil pressure ................55 Checking the cylinder bore ................. 56 Checking the piston ring grooves ............... 56 Lower unit Drive shaft and lower case................57 Removing the drive shaft................59 Disassembling the forward gear ..............
  • Page 7 Electrical systems Wiring harness ....................85 Ignition and ignition control system ............. 86 Checking the spark plug caps ..............88 Checking the pulser coil air gap ..............88 Checking the engine start switch..............88 Starting system ....................89 Starter motor ....................90 Checking the armature ................

  • Page 8: General Information

    INFO General information How to use this manual Manual format The format of this manual has been designed to make service procedures clear and easy to under- stand. Use the information below as a guide for effective and quality service. 1 Parts are shown and detailed in an exploded diagram and are listed in the components list.

  • Page 9: Symbols

    Symbols 7 to A in an exploded diagram indicate the grade of lubricant and the lubrication point. 7 Apply Yamaha 4-stroke motor oil 0 Apply corrosion resistant grease 8 Apply water resistant grease (Yamaha grease A) (Yamaha grease D) 9 Apply molybdenum disulfide grease...

  • Page 10: Identification

    INFO General information Identification Applicable models This manual covers the following models. Applicable models F60AEHT F60AET Serial number outboard motor serial number stamped on a label attached to the port clamp bracket. 1 Model name 2 Approved model code 3 Transom height 4 Serial number Approved Starting...

  • Page 11: Features And Benefits

    Identification / Features and benefits Features and benefits Power unit Based on the power unit of the field-proven F50, newly designed parts have been adopted in the various areas to attain 60 horsepower. The newly designed parts include the intake valves, exhaust valves, cylinder head, pistons, and the intake silencer.

  • Page 12: Carburetors

    INFO General information Oil pump The size of the oil pump rotor has been enlarged to increase the oil discharge volume. As a result, reliable lubrication has been realized. 22 mm (0.87 in) 24 mm (0.94 in) S69W1210 1 Rotor 2 Embossed letters for identification Oil discharge volume 21.5 L (5.68 US gal, 0.22 Imp gal)/min...
  • Page 13 Features and benefits Although the main jet specification numbers of the F50 differed between cylinders, the F60 uses main jets with the same specification number for all four cylinders due to the change in shape of the intake silencer. S69W1230 È...

  • Page 14: Lower Unit

    INFO General information Lower unit Drive shaft The drive shaft has been machined to accommodate the high power output. The portion that mounts to the pinion gear has been machined with involute splines to increase durability. A section of the midspan of the drive shaft has been reduced to 14.4 mm (0.57 in) to prevent the drive shaft from breaking under impact loads.
  • Page 15 Features and benefits Forward gear bearing The size of the forward gear bearing has been increased to accommodate the high power output of the F60. With this increase, the coupling length of the forward gear has been extended as well. In addition, two grooves are provided on the forward gear for identification purposes.

  • Page 16: Bracket Unit

    (10 MPa [102 kgf/cm 3.3 MPa [34 kgf/cm (2.0 MPa [20.4 kgf/cm S69W1270 Specified PTT motor output F50A 12 V 0.15 kW F60A 12 V 0.20 kW 1 PTT motor 6 Up-relief valve 2 Identification mark 7 Down-relief valve 3 Tilt piston absorber...

  • Page 17: Electrical Unit

    Features and benefits Steering friction The F60 tiller handle models use a newly developed, compact steering friction. S69W1280 1 Steering friction Electrical unit Starter motor The starter motor uses six magnets and four brushes to enhance its operating torque. S69W1290 1 Bearing 5 Magnet 2 Starter relay...

  • Page 18: Technical Tips

    INFO General information Technical tips Carburetor Power nozzle The power nozzle is activated when the engine is operating at high speeds. To reduce the fuel con- sumption rate and the pollution of the exhaust gases, the carburetors of the F60 are set lean. There- fore, the air-fuel mixture becomes lean at high engine speeds, when greater output is needed.

  • Page 19: Ptt (Power Trim And Tilt) Unit

    Technical tips PTT (Power Trim and Tilt) unit Shuttle piston A ball type shut-off construction is used for both the up-shuttle and down-shuttle pistons. The ball type realizes a reliable shut-off operation and high shut-off pressure. S69W1310 1 Ball 69W3D1X...

  • Page 20: Propeller Selection

    INFO General information a Propeller diameter (in inches) Propeller selection b Propeller pitch (in inches) The performance of a boat and outboard c Propeller type (propeller mark) motor will be critically affected by the size and type of propeller you choose. Propellers Selection greatly affect boat speed, acceleration, When the engine speed is at the full throttle...

  • Page 21: Predelivery Checks

    Propeller selection / Predelivery checks Predelivery checks Checking the engine oil 1. Check the oil level. To make the delivery process smooth and efficient, the predelivery checks should be completed as explained below. Checking the fuel system 1. Check that the fuel hoses are securely connected and that the fuel tank is full with fuel.

  • Page 22: Checking The Shift/Throttle Cables

    INFO General information S69W1110 NOTE: CAUTION: The optimum mounting height is affected by The shift/throttle cable joint must be the combination of the boat and the outboard screwed in a minimum of 8.0 mm (0.31 in) motor. To determine the optimum mounting height, test run the outboard motor at differ- ent heights.

  • Page 23: Checking The Gearshift And Throttle Operation

    Predelivery checks Checking the gearshift and throttle Checking the engine start switch and operation engine stop switch/engine shut-off 1. Check that gearshift operates switch smoothly when the remote control lever 1. Check that the engine starts when the or shift lever is shifted from neutral into engine start switch is turned to START.

  • Page 24: Checking The Cooling Water Pilot Hole

    INFO General information Checking the cooling watger pilot hole 1. Start the engine, and then check that cooling water is discharged from the cooling water pilot hole. S69W1190 È Hour After test run 1. Check for water in the gear oil. 2.

  • Page 25: General Specifications

    Predelivery checks / General specifications General specifications Model Item Unit F60AEHT F60AET Dimension Overall length mm (in) 1,339 (52.7) 706 (27.8) Overall width mm (in) 384 (15.1) Overall height mm (in) 1,415 (55.7) Boat transom height mm (in) 508 (20.0) Weight (with aluminum propeller) kg (lb)
  • Page 26 SPEC Specifications Model Item Unit F60AEHT F60AET Fuel and oil Fuel type Regular unleaded gasoline Fuel rating PON* Engine oil type 4-stroke motor oil Engine oil grade SE, SF, SG, or SH 10W-30, 10W-40, or 20W-40 Engine oil quantity (with oil filter replacement) 2.2 (2.3, 1.9) (US qt, lmp qt) (without oil filter replacement)

  • Page 27: Maintenance Specifications

    General specifications / Maintenance specifications Maintenance specifications Power unit Model Item Unit F60AEHT F60AET Power unit Minimum compression 880 (8.8, 125) pressure* (kgf/cm , psi) Lubrication oil pressure 110 (1.1, 16) (reference data) (kgf/cm , psi) at 900 r/min Cylinder heads Warpage limit mm (in) 0.1 (0.004)
  • Page 28 SPEC Specifications Model Item Unit F60AEHT F60AET Piston rings Top ring Dimension B mm (in) 1.17–1.19 (0.0461–0.0468) Dimension T mm (in) 2.30–2.50 (0.0906–0.0984) End gap mm (in) 0.15–0.30 (0.0060–0.0118) Side clearance mm (in) 0.02–0.06 (0.0008–0.0023) 2nd ring Dimension B mm (in) 1.47–1.49 (0.0578–0.0586) Dimension T mm (in)
  • Page 29 Maintenance specifications Model Item Unit F60AEHT F60AET Face width (B) Intake mm (in) 1.98–2.40 (0.0780–0.0945) Exhaust mm (in) 2.16–2.79 (0.0850–0.1098) Seat contact width (C) Intake mm (in) 1.3–1.5 (0.0512–0.0590) Exhaust mm (in) 1.3–1.5 (0.0512–0.0590) Margin thickness (D) Intake mm (in) 0.8–1.2 (0.0315–0.0472) Exhaust mm (in)
  • Page 30 SPEC Specifications Model Item Unit F60AEHT F60AET Crankcase main journal bearing thickness Yellow mm (in) 1.502–1.506 (0.0591–0.0593) mm (in) 1.498–1.502 (0.0590–0.0591) Pink mm (in) 1.494–1.498 (0.0588–0.0590) Green mm (in) 1.490–1.494 (0.0587–0.0588) Oil pump Type Trochoid Outer rotor-to-housing mm (in) 0.09–0.15 (0.0035–0.0059) clearance Outer rotor-to-inner rotor mm (in)

  • Page 31: Lower Unit

    Maintenance specifications Lower unit Model Item Unit F60AEHT F60AET Gear backlash Pinion-to-forward gear mm (in) 0.18–0.54 (0.0071–0.0212) Pinion-to-reverse gear mm (in) 0.71–1.07 (0.0280–0.0421) Pinion shims 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50 Forward gear shims 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50 Reverse gear shims 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50 Electrical...
  • Page 32 SPEC Specifications Model Item Unit F60AEHT F60AET Ignition control system Oil pressure switch 29.4–58.8 (0.294–0.588, 4.181–8.361) ON ↔ OFF (kgf/cm , psi) Thermoswitch (Gy/B – B) OFF → ON °C (°F) 76–84 (169–183) ON → OFF °C (°F) 63–77 (145–170) Starter motor Type Bendix...
  • Page 33 Maintenance specifications Model Item Unit F60AEHT F60AET Power trim and tilt system Trim sensor Ω Setting resistance 9–11 Ω Resistance (P – B) 9–288.3 Fluid type ATF Dexron II Brushes Standard length mm (in) 10 (0.39) Wear limit mm (in) 3.5 (0.14) Commutator Standard diameter...

  • Page 34: Dimensions

    SPEC Specifications Dimensions Exterior A1 W5 H9 H5 S69W2150 69W3D1X...
  • Page 35 Maintenance specifications Model Symbol Unit F60AEHT mm (in) 584 (23.0) mm (in) 226 (8.9) mm (in) 755 (29.7) mm (in) 533 (21.0) mm (in) 97 (3.8) mm (in) — mm (in) 932 (36.7) mm (in) — mm (in) 417 (16.4) mm (in) 164 (6.5) mm (in)
  • Page 36 SPEC Specifications Exterior S69W2160 69W3D1X...
  • Page 37 Maintenance specifications Model Symbol Unit F60AET mm (in) 584 (23.0) mm (in) 122 (4.8) mm (in) — mm (in) 533 (21.0) mm (in) 97 (3.8) mm (in) — mm (in) 932 (36.7) mm (in) — mm (in) 417 (16.4) mm (in) 147 (5.8) mm (in) 0 (0)
  • Page 38 SPEC Specifications Clamp bracket S69W2170 Model Symbol Unit F60AEHT F60AET mm (in) 126 (5.0) mm (in) 249 (10.0) mm (in) 163.5 (6.4) mm (in) 50.8 (2.0) mm (in) 180 (7.1) mm (in) 350 (13.8) mm (in) — mm (in) — mm (in) 18.5 (0.7) mm (in)

  • Page 39: Tightening Torques

    Maintenance specifications / Tightening torques Tightening torques Specified torques Tightening torques Part to be tightened Thread size N·m kgf·m ft·lb Power unit Flywheel magnet nut — Stator base screw Cover screw Red battery cable nut — Oil pressure switch — Oil pressure switch lead screw —...

  • Page 40: General Torques

    SPEC Specifications Tightening torques Part to be tightened Thread size N·m kgf·m ft·lb Bracket unit Tiller handle assembly nut — Engine shut-off switch nut — Tiller handle bracket nut — Engine start switch nut — Tiller handle bracket bolt Friction plate bolt Friction plate self-locking nut —...

  • Page 41: Special Service Tools

    Tightening torques / Special service tools Special service tools Digital tachometer Bearing separator 90890-06760 90890-06534 Compression gauge Bearing inner race attachment 90890-03160 90890-06643 Drive shaft holder 4 Shimming plate 90890-06518 90890-06701 Pinion nut holder Digital caliper 90890-06505 90890-06704 Socket adapter 1 Digital circuit tester 90890-06506 90890-03174...
  • Page 42 Periodic checks and adjustments Dial gauge set 90890-01252 Magnet base 90890-06705 69W3D1X...

  • Page 43: Maintenance Interval Chart

    Special service tools / Maintenance interval chart Maintenance interval chart Use the following chart as a guideline for general maintenance. Adjust the maintenance intervals according to the operating conditions of the outboard motor. Initial Every Item Remarks 10 hours 50 hours 100 hours 200 hours (Break-in)

  • Page 44: Top Cowling

    Periodic checks and adjustments Top cowling Checking the top cowling 1. Check the fitting by pushing the cowling with both hands. Adjust if necessary. NOTE: Be sure not to spill any fuel when removing the fuel filter cup. S69W3010 2. Loosen the nuts 1. Power unit Checking the thermostat 3.

  • Page 45: General

    Top cowling / Fuel system / Power unit / General S69W3050 4. Check the thermostat valve opening at specified water temperatures. Replace if out of specification. Water Valve lift a temperature 60 °C (140 °F) Valve begins to lift above more than 70 °C (158 °F) 3.0 mm (0.12 in)

  • Page 46: Lubrication

    Periodic checks and adjustments Lubrication 1. Apply water resistant grease to the areas shown. S69W3120 S69W3150 NOTE: Apply grease to the grease nipple until it flows from the bushings a. 2. Apply corrosion resistant grease to the areas shown. 69W3D1X...

  • Page 47: Hose Routing

    General / Hose routing Hose routing Fuel and blowby hoses 1 Blowby hose 2 Hose (acceleration pump-to-carburetor) 3 Fuel hose (fuel joint-to-fuel filter) 4 Fuel hose (fuel filter-to-fuel pump) 5 Fuel hose (fuel pump-to-carburetor) 6 Hose (carburetor-to-carburetor) 7 Hose (acceleration pump-to-acceleration pump) 69W3D1X...

  • Page 48: Cooling Water Hose

    FUEL Fuel system Cooling water hose S69W4020 1 Pilot water hose 2 Flushing hose È Flushing device model É View in direction of arrow 69W3D1X...

  • Page 49: Fuel Line And Fuel Filter

    Hose routing / Fuel line and fuel filter Fuel line and fuel filter Part name Q’ty Remarks Fuel joint M6 × 25 mm Bolt Seal Fuel hose Fuel joint-to-fuel filter M8 × 14 mm Bolt Bracket Body Fuel filter element Float O-ring Not reusable...

  • Page 50: Carburetor Unit

    FUEL Fuel system Carburetor unit Part name Q’ty Remarks Acceleration pump ø5 × 9 mm Screw Link rod Hose Hose Link rod Clip Not reusable 69W3D1X...

  • Page 51: Adjusting The Dashpot (Acceleration Pump)

    Carburetor unit Adjusting the dashpot (acceleration 5. If out of specification, adjust the dashpot until the specified engine speed is pump) obtained. 1. Start the engine and warm it up for 5 min- utes. 6. Open the throttle cam 2 slowly, and check that the acceleration pump stopper 2.

  • Page 52: Power Unit

    POWR Power unit Power unit 69W3D1X...
  • Page 53 Power unit Part name Q’ty Remarks Power trim and tilt relay M8 × 16 mm Bolt Black battery cable Wiring harness 10-pin coupler Grommet Spring washer Red battery cable PTT relay positive lead Fuse holder lead Clip Warning indicator coupler Tiller handle model PTT switch coupler Plastic tie...
  • Page 54 POWR Power unit 69W3D1X...
  • Page 55 Power unit Part name Q’ty Remarks Bracket Starter motor Spark plug cap Ignition coil Wiring harness Thermoswitch Holder M6 × 12 mm Bolt Ground lead M6 × 12 mm Bolt Oil pressure switch Oil pressure switch lead Screw Ignition coil lead M6 ×...
  • Page 56 POWR Power unit 69W3D1X...
  • Page 57 Power unit Part name Q’ty Remarks Cylinder head Plate Cylinder head cover M6 × 20 mm Bolt Cylinder head cover gasket Not reusable M9 × 95 mm Bolt Spark plug M6 × 25 mm Bolt Dowel pin Cylinder head gasket Not reusable Grommet Anode...
  • Page 58 POWR Power unit 69W3D1X...
  • Page 59 Power unit Part name Q’ty Remarks Rocker arm assembly Rocker arm shaft Cylinder head Exhaust valve Intake valve Camshaft Valve cotter Spring retainer Valve spring Spring seat Stem seal Not reusable Valve guide Not reusable Retaining bolt Gasket Not reusable Oil seal Not reusable M8 ×...
  • Page 60 POWR Power unit 69W3D1X...
  • Page 61 Power unit Part name Q’ty Remarks Oil filter Crankshaft M8 × 82 mm Bolt M6 × 35 mm Bolt Crankcase Oil seal Not reusable Main bearing Oil seal Not reusable Connecting rod bearing Connecting rod cap Bolt Dowel pin Cylinder block Connecting rod Piston pin clip Not reusable...

  • Page 62: Checking The Compression Pressure

    POWR Power unit Checking the compression pressure NOTE: 1. Start the engine, warm it up for 5 min- • If the compression pressure increases, utes, and then turn it off. check the piston and piston rings for wear. Replace if necessary. 2.

  • Page 63: Checking The Cylinder Bore

    Power unit Checking the cylinder bore 1. Measure the cylinder bore (D –D ) at measuring points a, b, and c, and in direction d (D ), which is parallel to the crankshaft, and direction e (D ), which is at a right angle to the crankshaft.

  • Page 64: Lower Unit

    LOWR Lower unit Drive shaft and lower case 69W3D1X...
  • Page 65 Drive shaft and lower case Part name Q’ty Remarks Drive shaft Oil seal Not reusable Oil seal housing O-ring Not reusable Circlip Shift rod O-ring Not reusable Taper roller bearing Not reusable Bearing outer race Not reusable Pinion shim — As required Sleeve Washer...

  • Page 66: Removing The Drive Shaft

    LOWR Lower unit Removing the drive shaft 1. Remove the drive shaft assembly and pinion, and then pull out the forward gear. Bearing inner race attachment 1: 90890-06643 S69W6020 Installing the drive shaft Drive shaft holder 4 1: 90890-06518 1. Install the forward gear, then the drive Pinion nut holder 2: 90890-06505 shaft assembly, pinion, and pinion nut, Socket adapter 1 3: 90890-06506...

  • Page 67: Shimming

    Drive shaft and lower case / Shimming Shimming 69W3D1X...

  • Page 68: Shimming

    LOWR Lower unit Shimming NOTE: • Shimming is not required when assembling the original lower case and inner parts. • Shimming is required when assembling the original inner parts and a new lower case. • Shimming is required when replacing the inner part(s).
  • Page 69 Shimming Example: If “T1” is 0.45 mm, then the forward gear shim is 0.42 mm. If “T1” is 0.60 mm, then the forward gear shim is 0.58 mm. 69W3D1X...

  • Page 70: Bracket Unit

    BRKT Bracket unit Tiller handle 69W3D1X...
  • Page 71 Tiller handle Part name Q’ty Remarks Tiller handle assembly Tiller handle wiring harness Grommet Clip Throttle cable Plate M6 × 25 mm Bolt M8 × 16 mm Bolt Black battery cable Cable guide Grommet M6 × 35 mm Washer Red battery cable Connector Clip Shift cable...

  • Page 72: Bottom Cowling

    BRKT Bracket unit Bottom cowling 69W3D1X...
  • Page 73 Bottom cowling Part name Q’ty Remarks Bottom cowling Rubber seal Washer Bushing Shift rod bracket Bolt Spring Ball Shift rod Flushing device Flushing device model Bracket Flushing device model M6 × 16 mm / Flushing device model Bolt ø6 × 20 mm / Flushing device model Screw Flushing hose Flushing device model...

  • Page 74: Upper Case

    BRKT Bracket unit Upper case 69W3D1X...
  • Page 75 Upper case Part name Q’ty Remarks Muffler assembly Upper case Muffler seal Rubber seal Dowel pin Grommet Damper ø5 × 16 mm Screw Baffle plate M8 × 30 mm Bolt Drive shaft bushing Circlip Ground lead ø6 × 8 mm Screw M12 ×...
  • Page 76 BRKT Bracket unit 69W3D1X...
  • Page 77 Upper case Part name Q’ty Remarks Oil seal Not reusable Exhaust guide Grommet Anode Cover M6 × 20 mm Bolt Cover Bolt Gasket Not reusable Gasket Not reusable Relief valve housing Relief valve Spring Cotter pin Not reusable M6 × 25 mm Bolt M6 ×...

  • Page 78: Disassembling The Oil Pan

    BRKT Bracket unit Disassembling the oil pan 1. Remove the muffler 1, plate 2, and exhaust manifold 3 from the oil pan 4. 3. Install the oil strainer 3 by installing the bolts. 2. Remove the oil pan 4 and the exhaust guide 5.

  • Page 79: Installing The Upper Case

    Upper case 10. Tighten the upper case bolts B, and then tighten them to the specified torque. 7. Tighten the oil pan bolts 7 then exhaust manifold bolts 8, and then tighten them Upper case bolt B: to the specified torque. 21 N·m (2.1 kgf·m, 15 ft·lb) Exhaust manifold bolt 8: 10 N·m (1.0 kgf·m, 7.2 ft·lb)
  • Page 80 BRKT Bracket unit Upper mounting nut 7: 24 N·m (2.4 kgf·m, 17 ft·lb) Lower mounting nut 8: 42 N·m (4.2 kgf·m, 30 ft·lb) 4. Install the upper and lower mounting bolts into the swivel bracket 6 simulta- neously. 5. Install the upper mounting nut 7 and lower mounting nut 8, and then tighten them to the specified torque.

  • Page 81: Clamp Brackets

    Upper case / Clamp brackets Clamp brackets Part name Q’ty Remarks Swivel bracket assembly ø6 × 15 mm Screw Trim sensor Trim sensor coupler Plastic tie Not reusable Self-locking nut M6 × 25 mm Bolt Anode Port clamp bracket Washer Bushing Through tube Ground lead...

  • Page 82: Adjusting The Trim Sensor

    BRKT Bracket unit Adjusting the trim sensor WARNING 1. Fully tilt the outboard motor up, and then support it with the tilt stop lever 1. After tilting up the outboard motor, be sure to support it with the tilt stop lever. Otherwise, the outboard motor could sud- denly lower if the power trim and tilt unit should lose fluid pressure.

  • Page 83: Swivel Bracket And Steering Arm

    Clamp brackets / Swivel bracket and steering arm Swivel bracket and steering arm Part name Q’ty Remarks Steering arm Washer Bushing O-ring Not reusable Bushing Swivel bracket Bushing Port tilt stop lever Circlip Steering yoke Bushing Bushing Tilt stop lever joint Spring holder M6 ×...

  • Page 84: Power Trim And Tilt Unit

    BRKT Bracket unit Power trim and tilt unit Part name Q’ty Remarks Power trim and tilt unit Plastic tie Not reusable PTT motor lead Washer M8 × 16 mm Bolt Circlip Shaft Bushing Collar Tilt pin Collar Collar Shaft 69W3D1X...
  • Page 85 Power trim and tilt unit Part name Q’ty Remarks M5 × 8 mm Bolt Relief valve bracket M6 × 40 mm Bolt Valve lock screw Up-relief spring Valve support pin O-ring Not reusable Ball Down-relief spring Valve support pin Relief valve seal Filter O-ring Not reusable...
  • Page 86 BRKT Bracket unit Part name Q’ty Remarks M5 × 20 mm Bolt Washer Bracket O-ring Not reusable Spacer Spring Valve pin Ball Manual release spring Ball Gear pump cover Spring Shuttle piston O-ring Not reusable Valve seal Circlip Drive gear 69W3D1X...
  • Page 87 Power trim and tilt unit Part name Q’ty Remarks Shaft Driven gear Ball Shuttle piston Valve plate Plate Gear pump housing 69W3D1X...
  • Page 88 BRKT Bracket unit Part name Q’ty Remarks ø5 × 20 mm Screw Yoke O-ring Not reusable Armature Washer Bushing ø4 × 12 mm Screw Lead Brush 2 Brush 1 Brush holder Circuit breaker Brush spring PTT motor base Oil seal Not reusable 69W3D1X...

  • Page 89: Disassembling The Gear Pump

    Power trim and tilt unit 5. Remove the drive gear A and driven Disassembling the gear pump gear B. 1. Remove the manual valve 1 and gear pump 2. Checking the valves 1. Check the operation of the check valve a of the trim cylinder end screw and check the valve for dirt or residue.

  • Page 90: Assembling The Gear Pump

    BRKT Bracket unit S69W7280 4. Check the main valves for dirt or residue. Clean if necessary. 4. Install the balls 9, manual release spring 0 and bracket A by installing the bolts B, then tightening them to the specified torque. S69W7290 5.

  • Page 91: Checking The Trim Sensor

    Power trim and tilt unit 10. Install the joint M and power trim and tilt Relief valve bracket bolt G: motor N by installing the bolts O, then 5 N·m (0.5 kgf·m, 3.6 ft·lb) tightening them to the specified torque. 7.

  • Page 92: Electrical Systems

    – ELEC Electrical systems Wiring harness B B B Lg Lg Sb Sb Lg Sb B B B B B B Y Y G G S69W8010 7 Warning indicator Connect to: : Black : Yellow 8 CDI unit 1 Engine start switch or : Brown : Black/orange 9 Power trim and tilt...

  • Page 93: Ignition And Ignition Control System

    Wiring harness / Ignition and ignition control system Ignition and ignition control system 1 Spark plug : Black 2 Ignition coil : Brown 3 Charge coil : Blue 4 Pulser coil : Orange 5 Engine start switch : White 6 Engine shut-off switch : Black/orange 7 10-pin coupler B/W : Black/white...
  • Page 94 – ELEC Electrical systems 1 Thermoswitch : Black 2 Oil pressure switch : Pink 3 CDI unit Gy/B : Gray/black 4 Oil pressure warning indicator : Pink/black 5 Overheat warning indicator P/W : Pink/white 6 Warning indicator : Yellow/black : Yellow/red È...

  • Page 95: Checking The Spark Plug Caps

    Ignition and ignition control system Checking the spark plug caps Pulser coil air gap a: 1. Remove the spark plug caps from the 0.5–1.0 mm (0.020–0.039 in) spark plug wires by turning the caps counterclockwise. 3. Remove the flywheel magnet nut and fly- wheel magnet.

  • Page 96: Starting System

    – ELEC Electrical systems Starting system START S69W8090E 1 Fuse : Black 2 10-pin coupler : Brown 3 Engine start switch : Red 4 Starter motor 5 Battery 6 Neutral switch 7 Starter relay È Tiller handle model 69W3D1X...

  • Page 97: Starter Motor

    Starting system / Starter motor Starter motor m (0.7 kgf m, 5.1 ft • • • S69W8100 Part name Q’ty Remarks Clip Pinion stopper Spring Starter motor pinion Upper bracket Washer 1 Shim — As required Washer 2 Armature Washer Stator Brush holder assembly Brush set...

  • Page 98: Checking The Armature

    – ELEC Electrical systems Checking the armature 1. Check the armature axial free play. Diameter limit: 32.0 mm (1.26 in) Replace the washers and shim(s) 3 if out of specification. 4. Measure the commutator undercut a. Replace the armature if out of specifica- tion.
  • Page 99 Starter motor Brush length limit a: 10.0 mm (0.39 in) 2. Check the brush holder for continuity. Replace if out of specifications. S69W8170 Brush assembly continuity Brush 1 – Brush assembly holder 4 Continuity Brush 2 – Brush assembly holder 3 Brush 1 –...
  • Page 100 F60AEHT B/W Gy/B Y/B P/W G/W G/W Gy/B Gy/B Y/B P/W R B G Y/B P/W Lg Sb Sb R Sb R FREE FREE DOWN DOWN S69WWD01E...

  • Page 101: Wiring Diagram

    Wiring diagram F60AEHT 1 Battery Color code 2 Engine start switch : Black 3 Starter motor : Brown 4 Power trim and tilt motor : Green 5 Power trim and tilt relay : Gray 6 Engine shut-off switch : Blue 7 Starter relay : Light green 8 Neutral switch...
  • Page 102 F60AET B/W Gy/B Y/B P/W G/W G/W Gy/B Gy/B Y/B P/W R B G Y/B P/W Lg Sb Sb R FREE DOWN S69WWD03E...
  • Page 103 Wiring diagram F60AET 1 Battery Color code 2 Starter motor : Black 3 Power trim and tilt motor : Brown 4 Power trim and tilt relay : Green 5 Starter relay : Gray 6 Fuse (20 A) : Blue 7 Trim sensor : Light green 8 Prime Start : Orange...
  • Page 105 YAMAHA MOTOR CO., LTD. Printed in the Netherlands Jul. 2001 – 1.3 × 1 CR (F60AEHT, F60AET)

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