Yamaha f60a(Supl)

SERVICE MANUAL292098 69W-28197-3D-1X

SUPPLEMENTARY

F60A

NOTICE

This Supplementary Service Manual has been prepared to introduce new service and new datainformation for the F60 which is based on the F50. For complete information on service procedures,it is necessary to use this Supplementary Service Manual together with the following manual.

Important information 1

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

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY ISINVOLVED!

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

CAUTION:A CAUTION indicates special precautions that must be taken to avoid damage to the out-board motor.

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

F50A, FT50B, FT50C SERVICE MANUAL: 62Y-28197-3A-11

F60ASUPPLEMENTARY SERVICE MANUAL

©2001 by Yamaha Motor Co., Ltd.1st Edition, July 2001

All rights reserved.Any reprinting or unauthorized use without the written permission of

Yamaha Motor Co., Ltd. is expressly prohibited.

Printed in the Netherlands

Contents

General information 1GEN INFO

Specifications 2SPEC

Periodic checks and adjustments 3CHK ADJ

Fuel system 4FUEL

Power unit 5POWR

Lower unit 6LOWR

Bracket unit 7BRKT

Electrical systems 8ELEC

Troubleshooting 9TRBL SHTG

Index

– +

69W3D1X

General information

How to use this manual .................................................................................... 1Manual format............................................................................................... 1Symbols........................................................................................................ 2

Identification...................................................................................................... 3Applicable models ........................................................................................ 3Serial number ............................................................................................... 3

Features and benefits ....................................................................................... 4Power unit..................................................................................................... 4Carburetors................................................................................................... 5Lower unit ..................................................................................................... 7Bracket unit................................................................................................... 9Electrical unit .............................................................................................. 10

Technical tips .................................................................................................. 11Carburetor .................................................................................................. 11PTT (Power Trim and Tilt) unit ................................................................... 12

Propeller selection.......................................................................................... 13Propeller size.............................................................................................. 13Selection..................................................................................................... 13

Predelivery checks ......................................................................................... 14Checking the fuel system ........................................................................... 14Checking the gear oil.................................................................................. 14Checking the engine oil .............................................................................. 14Checking the battery................................................................................... 14Checking the outboard motor mounting height........................................... 14Checking the shift/throttle cables................................................................ 15Checking the steering system .................................................................... 15Checking the gearshift and throttle operation............................................. 16Checking the tilt system.............................................................................. 16Checking the engine start switch and engine stop switch/engine shut-off switch ............................................................................... 16

Checking the cooling water pilot hole ......................................................... 17Test run ...................................................................................................... 17Break-in ...................................................................................................... 17After test run ............................................................................................... 17

69W3D1X

Specifications

General specifications.................................................................................... 18

Maintenance specifications ........................................................................... 20Power unit................................................................................................... 20Lower unit ................................................................................................... 24Electrical ..................................................................................................... 24Dimensions................................................................................................. 27

Tightening torques.......................................................................................... 32Specified torques........................................................................................ 32General torques.......................................................................................... 33

Periodic checks and adjustments

Special service tools ...................................................................................... 34

Maintenance interval chart............................................................................. 36

Top cowling ..................................................................................................... 37Checking the top cowling............................................................................ 37

Fuel system ..................................................................................................... 37Checking the fuel filter ................................................................................ 37

Power unit........................................................................................................ 37Checking the thermostat............................................................................. 37

General............................................................................................................. 38Checking the anodes.................................................................................. 38Lubrication .................................................................................................. 39

Fuel system

Hose routing.................................................................................................... 40Fuel and blowby hoses............................................................................... 40Cooling water hose..................................................................................... 41

Fuel line and fuel filter .................................................................................... 42

Carburetor unit ................................................................................................ 43Adjusting the dashpot (acceleration pump) ................................................ 44

69W3D1X

Power unit

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

Lower unit

Drive shaft and lower case............................................................................. 57Removing the drive shaft............................................................................ 59Disassembling the forward gear ................................................................. 59Assembling the forward gear...................................................................... 59Installing the drive shaft.............................................................................. 59

Shimming......................................................................................................... 60Shimming.................................................................................................... 61Selecting the forward gear shims ............................................................... 61

Bracket unit

Tiller handle..................................................................................................... 63

Bottom cowling ............................................................................................... 65

Upper case....................................................................................................... 67Disassembling the oil pan........................................................................... 71Assembling the oil pan ............................................................................... 71Installing the upper case............................................................................. 72

Clamp brackets ............................................................................................... 74Adjusting the trim sensor ............................................................................ 75

Swivel bracket and steering arm ................................................................... 76

Power trim and tilt unit ................................................................................... 77Disassembling the gear pump .................................................................... 82Checking the valves ................................................................................... 82Assembling the gear pump......................................................................... 83Checking the trim sensor............................................................................ 84

69W3D1X

Electrical systems

Wiring harness ................................................................................................ 85

Ignition and ignition control system ............................................................. 86Checking the spark plug caps .................................................................... 88Checking the pulser coil air gap ................................................................. 88Checking the engine start switch................................................................ 88

Starting system ............................................................................................... 89

Starter motor ................................................................................................... 90Checking the armature ............................................................................... 91Checking the brushes................................................................................. 91

Wiring diagram

GEN INFO General information

1 69W3D1X

How to use this manual 1

Manual formatThe 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.2 Tightening torque specifications are provided in the exploded diagrams and after a numbered

step with tightening instructions.3 Symbols are used to indicate important aspects of a procedure, such as the grade of lubricant

and lubrication point.4 The components list consist of parts and part quantities, as well as bolt, screw, O-ring, and hose

dimensions.5 Service points regarding removal, checking, and installation are shown in individual illustrations

to explain the relevant procedure.

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

69W3D1X 2

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

General information

Specifications

Periodic checks and adjustments

Fuel system

Power unit

Lower unit

Bracket unit

Electrical systems

Troubleshooting

GENINFO

SPEC

CHKADJ

FUEL

POWR

LOWR

BRKT

ELEC

TRBLSHTG

– +

Symbols 1 to 6 indicate specific data.

1 Special tool2 Specified oil or fluid3 Specified engine speed4 Specified tightening torque

5 Specified measurement6 Specified electrical value

(resistance, voltage, electric current)

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

7 Apply Yamaha 4-stroke motor oil8 Apply water resistant grease (Yamaha grease A)9 Apply molybdenum disulfide grease

0 Apply corrosion resistant grease (Yamaha grease D)

A Apply low temperature resistant grease (Yamaha grease C)

Symbols B to G in an exploded diagram indicate the type of sealant or locking agent and the appli-cation point.

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

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

1 2 3 4 5 6

T R..

7 8 9 0 A

EA M D C

B C D E F G

GM 4271

LT

242

LT

572

LTSS

How to use this manual

123456789


3 69W3D1X

Identification 1

Applicable modelsThis manual covers the following models.

Serial numberThe outboard motor serial number isstamped on a label attached to the portclamp bracket.

1 Model name2 Approved model code3 Transom height4 Serial number

Applicable models

F60AEHTF60AET

Model nameApproved

model codeStarting

serial No.

F60AEHT69W

L: 500101–

F60AET L: 400101–

69W3D1X 4

Features and benefits 1

Power unitBased on the power unit of the field-proven F50, newly designed parts have been adopted in thevarious areas to attain 60 horsepower. The newly designed parts include the intake valves, exhaustvalves, cylinder head, pistons, and the intake silencer.

Cylinder headThe shape of the combustion chamber has been changed to increase its capacity.The diameter of the intake and exhaust valves have been enlarged to increase output.

1 Combustion chamber2 Intake valve3 Exhaust valve

S69W1200F50 F60

F60F50

83.5 mm(3.29 in)

84.1 mm(3.31 in)

84.0 mm(3.31 in)

84.8 mm(3.34 in)

30.0 mm (1.18 in) 26.0 mm (1.02 in) 32.0 mm (1.26 in) 26.7 mm (1.05 in)

Identification / Features and benefits


5 69W3D1X

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

1 Rotor2 Embossed letters for identification

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

Oil discharge volume

F50 21.5 L (5.68 US gal, 0.22 Imp gal)/min

F60 23.5 L (6.21 US gal, 5.17 Imp gal)/min

Comparison chart of carburetor bores

Throttle valve Venturi

F50 ø27 ø22

F60 ø30 ø25

S69W1210

22 mm (0.87 in) 24 mm (0.94 in)

F50 F60

S69W1220F50 F60

Ø27

Ø22

Ø30

Ø25

69W3D1X 6

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

È Air

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

1 Power nozzle2 Fuel inletÈ Air-fuel mixture

S69W1230F50 F60:

Comparison chart of main jet diameters

Cylinder #1 #2 #3 #4

F50 #124 #126 #116 #114

F60 #124 #124 #124 #124

:S69W1240

Features and benefits


7 69W3D1X

Lower unitDrive shaftThe drive shaft has been machined to accommodate the high power output. The portion thatmounts to the pinion gear has been machined with involute splines to increase durability. A sectionof the midspan of the drive shaft has been reduced to 14.4 mm (0.57 in) to prevent the drive shaftfrom breaking under impact loads. In addition, two grooves are provided on the drive shaft for iden-tification purposes.

1 Grooves for identification2 Involute splines3 Angled splines

S69W1250

95.5 mm(3.76 in)

Ø14.4

F50:F60:

69W3D1X 8

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

1 Forward gear bearing2 Grooves for identification3 Forward gear

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

Bearing comparison chart

Forward gear bearing Forward gear

F50 22.2 mm (0.87 in) 18.5 mm (0.73 in)

F60 26.0 mm (1.02 in) 23.2 mm (0.91 in)

S69W1260

26.0 mm(1.02 in)

23.2 mm(0.91 in)



9 69W3D1X

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

1 PTT motor2 Identification mark3 Tilt piston absorber4 Tilt and trim cylinder5 Manual valve

6 Up-relief valve7 Down-relief valve8 Gear pumpÈ Shut-off pressure of the F60 valvesÉ Shut-off pressure of the F50 valves

Specified PTT motor output

F50A 12 V 0.15 kW

F60A 12 V 0.20 kW

69W

-00

S69W1270

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


3.3 MPa [34 kgf/cm2] (2.0 MPa [20.4 kgf/cm2])


69W3D1X 10

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

1 Steering friction

Electrical unitStarter motorThe starter motor uses six magnets and four brushes to enhance its operating torque.

1 Bearing2 Starter relay3 Neutral switch4 Engine start switch

5 Magnet6 Brush7 Starter motor8 Battery

S69W1280

S69W1290F50 F60

Operating torque

F50 2.74 N·m (0.27 kgf·m, 2.0 ft·lb)

F60 3.50 N·m (0.35 kgf·m, 2.5 ft·lb)



11 69W3D1X

Technical tips 1

CarburetorPower nozzleThe 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. Thepower nozzle supplies a richer fuel mixture at high engine speed to realize the optimal air-fuel ratioto produce output.

1 Throttle valve2 Power nozzleÈ AirÉ Air-fuel mixtureÊ Fuel

:

:

:

S69W1300

69W3D1X 12

PTT (Power Trim and Tilt) unitShuttle pistonA ball type shut-off construction is used for both the up-shuttle and down-shuttle pistons. The balltype realizes a reliable shut-off operation and high shut-off pressure.

1 Ball

F50

F60S69W1310

Technical tips


13 69W3D1X

Propeller selection 1

The performance of a boat and outboardmotor will be critically affected by the sizeand type of propeller you choose. Propellersgreatly affect boat speed, acceleration,engine life, fuel economy, and even boatingand steering capabilities. An incorrect choicecould adversely affect performance andcould also seriously damage the engine.Use the following information as a guide forselecting a propeller that meets the operatingconditions of the boat and the outboardmotor.

Propeller sizeThe size of the propeller is indicated on thepropeller blade or outside of the propellerboss.

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

SelectionWhen the engine speed is at the full throttleoperating range (5,000–6,000 r/min), theideal propeller for the boat is one that pro-vides maximum performance in relation toboat speed and fuel consumption.

S69W1030

× -

S69W1040

× -

S69W1050

× -

Propeller size (in) Material

10 × 15 - G

Aluminum

10 3/8 × 13 - G

10 5/8 × 12 - G

10 3/4 × 16 - G

11 × 15 - G

11 5/8 × 11 - G

11 3/4 × 10 - G

12 1/4 × 8 - G

12 1/4 × 9 - G

10 1/4 × 14 - G

Stainless

10 1/4 × 15 - G

10 1/4 × 16 - G

10 5/8 × 13 - G

11 1/2 × 13 - G

11 3/4 × 12 - G

12 × 11 - G

69W3D1X 14

Predelivery checks 1

To make the delivery process smooth andefficient, the predelivery checks should becompleted as explained below.

Checking the fuel system 1. Check that the fuel hoses are securely

connected and that the fuel tank is fullwith fuel.

CAUTION:This is a 4-stroke engine. Do not use pre-mixed fuel and 2-stroke outboard motoroil.

Checking the gear oil1. Check the gear oil level.

Checking the engine oil1. Check the oil level.

NOTE:• If the engine oil is above the maximum level

mark a, drain sufficient oil until the level isbetween a and b.

• If the engine oil is below the minimum levelmark b, add sufficient oil until the level isbetween a and b.

Checking the battery1. Check the capacity, electrolyte level, and

specified gravity of the battery.

2. Check that the red and black batterycables are securely connected.

Checking the outboard motor mounting height1. Check that the anti-cavitation plate is

aligned with the bottom of the boat. If themounting height is too high, cavitationwill occur and propulsion will be reduced.Also, the engine speed will increaseabnormally and cause the engine tooverheat. If the mounting height is toolow, water resistance will increase andreduce engine efficiency.

S69W1070

Recommended engine oil:API: SE, SF, SG, or SHSAE: 10W-30, 10W-40, or 20W-40

Oil capacity:Without oil filter replacement:

2.0 L (2.1 US qt, 1.8 Imp qt)

Battery capacity: 12 V, 70–100 Ah

Propeller selection / Predelivery checks


15 69W3D1X

NOTE:The optimum mounting height is affected bythe combination of the boat and the outboardmotor. To determine the optimum mountingheight, test run the outboard motor at differ-ent heights.

2. Check that the clamp brackets aresecured with the clamp bolts.

Checking the shift/throttle cables1. Set the remote control lever or shift lever

to the neutral position and fully close thethrottle lever or throttle grip.

2. Check that the set pin a is aligned withthe alignment mark b. Adjust if neces-sary.

3. Check that the alignment mark c isaligned with the mark d. Adjust if neces-sary.

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

Checking the steering system1. Check the steering friction for proper

adjustment.

2. Check that the steering operatessmoothly.

È Tiller handle modelÉ Remote control model

3. Check that there is no interference withwires or hoses when the outboard motoris steered.

S69W1110

È

É

69W3D1X 16

Checking the gearshift and throttle operation1. Check that the gearshift operates

smoothly when the remote control leveror shift lever is shifted from neutral intoforward or reverse.

2. Check that the throttle operates smoothlywhen the remote control lever or throttlegrip is shifted from the fully closed posi-tion to the fully open position a.


Checking the tilt system1. Check that the outboard motor tilts up

and down smoothly when operating thepower trim and tilt unit.

2. Check that there is no abnormal noiseproduced when the outboard motor istilted up or down.

3. Check that there is no interference withwires and hoses when the tilted-up out-board motor is steered.

4. Check that the trim meter points downwhen the outboard motor is tilted all theway down.

Checking the engine start switch and engine stop switch/engine shut-off switch1. Check that the engine starts when the

engine start switch is turned to START.

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

3. Check that the engine turns off when theengine stop switch is pushed or theengine shut-off cord is pulled from theengine shut-off switch.


È

S69W1150

FN

R

É

È

S69W1170

É

Predelivery checks


17 69W3D1X

Checking the cooling watger pilot hole1. Start the engine, and then check that

cooling water is discharged from thecooling water pilot hole.

Test run1. Start the engine, and then check that the

gearshift operates smoothly.

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

3. Operate at trolling speed.

4. Run the outboard motor for one hour at2,000 r/min or at half throttle, then foranother hour at 3,000 r/min or at 3/4throttle.

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

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

Break-inDuring the test run, perform the break-inoperation in the following three stages. 1. One hour a at 2,000 r/min or at approxi-

mately half throttle.

2. One hour b at 3,000 r/min or 3/4 throttleand one minute out of every ten at fullthrottle.

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

È Hour

After test run1. Check for water in the gear oil.

2. Check for fuel leakage in the cowling.

3. After a test run and while the engine is atidle, flush the cooling water passage withfresh water using the flushing kit.

S69W1190

0 1 2 10

69W3D1X 18

General specifications 2

Item UnitModel

F60AEHT F60AETDimension

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

(L) mm (in) 1,415 (55.7)Boat transom height

(L) mm (in) 508 (20.0)Weight

(with aluminum propeller)(L) kg (lb) 120.0 (265) 114.0 (251)

PerformanceMaximum output kW (hp)

at 5,500 r/min44.1 (60.0)

Full throttle operating range r/min 5,000–6,000Maximum fuel consumption L (US gal,

lmp gal)/hr at 6,000 r/min

19.5 (5.15, 4.29)

Power unitType In-line, 4-stroke, OHC, 8 valvesCylinder quantity 4Displacement cm3 (cu. in) 996 (60.8)Bore × stroke mm (in) 65.0 × 75.0 (2.56 × 2.95)Compression ratio 9.5Carburetor quantity 4Control system Tiller handle Remote controlStarting system ElectricIgnition control system Microcomputer (CDI)Ignition timing Degree TDC 0–BTDC 25Alternator output V, A 12, 10Enrichment system Prime StartSpark plugs DPR5EA-9Cooling system WaterExhaust system Through propeller bossLubrication system Wet sump

123456789

Predelivery checks / General specifications

SPECSpecifications

19 69W3D1X

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

Fuel and oilFuel type Regular unleaded gasolineFuel rating PON*

RON8691

Engine oil type 4-stroke motor oilEngine oil grade API

SAESE, SF, SG, or SH

10W-30, 10W-40, or 20W-40Engine oil quantity

(with oil filter replacement) L (US qt, lmp qt)

2.2 (2.3, 1.9)

(without oil filter replacement) L (US qt, lmp qt)

2.0 (2.1, 1.8)

Gear oil type Hypoid gear oilGear oil grade API

SAEGL-4

90Gear oil quantity L

(US qt, lmp qt)0.43 (0.45, 0.38)

BracketTrim angle (at 12 degree boat transom)

Degree –4 to 16

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

Drive unitGearshift positions F-N-RGear ratio 1.85 (24/13)Reduction gear type Spiral bevel gearClutch type Dog clutchPropeller shaft type SplinePropeller direction

(rear view)Clockwise

Propeller identification mark GElectrical

Battery capacity V, Ah 12, 70–100

Item UnitModel

F60AEHT F60AET

69W3D1X 20

Maintenance specifications 2

Power unit

Item UnitModel

F60AEHT F60AETPower unit

Minimum compression pressure*

kPa (kgf/cm2, psi)

880 (8.8, 125)

Lubrication oil pressure (reference data)

kPa (kgf/cm2, psi) at 900 r/min

110 (1.1, 16)

Cylinder headsWarpage limit mm (in) 0.1 (0.004)

(lines indicate straightedge position)Cylinder head journal inside diameter

mm (in) 37.00–37.02 (1.4567–1.4575)

CylindersBore size mm (in) 65.00–65.01 (2.5591–2.5594)Taper limit mm (in) 0.08 (0.0031)Out-of-round limit mm (in) 0.01 (0.0004)

PistonsPiston diameter (D) mm (in) 64.95–64.96 (2.5571–2.5574)Measuring point (H) mm (in) 5 (0.2)Piston-to-cylinder clearance mm (in) 0.035–0.065 (0.0014–0.0025)Piston pin boss bore size mm (in) 15.974–15.985 (0.6289–0.6293)Oversize piston

1st mm (in) +0.25 (0.0098)2nd mm (in) +0.50 (0.0196)

Oversize piston diameter1st mm (in) 65.20–65.21 (2.5669–2.5673)2nd mm (in) 65.45–65.46 (2.5768–2.5771)

Piston pinsOutside diameter mm (in) 15.965–15.970 (0.6285–0.6287)

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

General specifications / Maintenance specifications

SPECSpecifications

21 69W3D1X

Piston ringsTop 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 ringDimension B mm (in) 1.47–1.49 (0.0578–0.0586)Dimension T mm (in) 2.60–2.80 (0.1024–0.1102)End gap mm (in) 0.30–0.50 (0.0118–0.0196)Side clearance mm (in) 0.02–0.06 (0.0008–0.0023)

Oil ringDimension B mm (in) 2.36–2.48 (0.0929–0.0976)Dimension T mm (in) 2.75 (0.1083)End gap mm (in) 0.20–0.70 (0.0079–0.0275)Side clearance mm (in) 0.04–0.18 (0.0016–0.0070)

CamshaftsIntake (A) mm (in) 30.89–30.99 (1.2161–1.2200)Exhaust (A) mm (in) 30.82–30.92 (1.2135–1.2175)Intake and exhaust (B)

mm (in) 25.95–26.05 (1.0217–1.0256)

Camshaft journal diameter#1 mm (in) 36.93–36.94 (1.4539–1.4543)#2, #3, #4 mm (in) 36.94–36.95 (1.4543–1.4547)

Camshaft journal oil clearance#1 mm (in) 0.06–0.10 (0.0023–0.0039)#2, #3, #4 mm (in) 0.05–0.09 (0.0020–0.0035)

Maximum camshaft runout mm (in) 0.04 (0.0016)Rocker arm shafts

Outside diameter mm (in) 15.98–15.99 (0.6291–0.6295)Rocker arms

Inside diameter mm (in) 16.00–16.01 (0.6299–0.6303)Valves

Valve clearance (cold)Intake mm (in) 0.20 ± 0.05 (0.008 ± 0.002)Exhaust mm (in) 0.30 ± 0.05 (0.012 ± 0.002)

Head diameter (A)Intake mm (in) 31.9–32.1 (1.2560–1.2637)Exhaust mm (in) 26.6–26.8 (1.0472–1.0551)

Item UnitModel

F60AEHT F60AET

69W3D1X 22

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) 1.0–1.4 (0.0394–0.0551)

Stem diameterIntake mm (in) 5.48–5.49 (0.2157–0.2161)Exhaust mm (in) 5.46–5.47 (0.2150–0.2153)

Guide inside diameterIntake and exhaust mm (in) 5.50–5.51 (0.2165–0.2169)

Stem-to-guide clearanceIntake mm (in) 0.01–0.03 (0.0004–0.0012)Exhaust mm (in) 0.03–0.05 (0.0012–0.0020)

Stem runout limitIntake mm (in) 0.05 (0.0020)Exhaust mm (in) 0.03 (0.0012)

Valve springsFree length mm (in) 39.85 (1.5689)Minimum free length mm (in) 37.85 (1.4901)Tilt limit mm (in) 1.7 (0.067)

Connecting rodsSmall-end inside diameter mm (in) 15.985–15.998 (0.6293–0.6298)Big-end inside diameter mm (in) 36.000–36.024 (1.4173–1.4183)Crankpin oil clearance mm (in) 0.016–0.040 (0.0006–0.0015)Big-end bearing thickness

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

CrankshaftCrankshaft journal

Diameter mm (in) 42.984–43.000 (1.6923–1.6929)Crankpin

Diameter mm (in) 32.984–33.000 (1.2986–1.2992)Runout limit mm (in) 0.04 (0.0016)

CrankcaseCrankcase main journal inside diameter

mm (in) 46.000–46.024 (1.8110–1.8120)

Crankshaft main journal oil clearance

mm (in) 0.012–0.036 (0.0005–0.0014)

Item UnitModel

F60AEHT F60AET

Maintenance specifications

SPECSpecifications

23 69W3D1X

Crankcase main journal bearing thickness

Yellow mm (in) 1.502–1.506 (0.0591–0.0593)Red mm (in) 1.498–1.502 (0.0590–0.0591)Pink mm (in) 1.494–1.498 (0.0588–0.0590)Green mm (in) 1.490–1.494 (0.0587–0.0588)

Oil pumpType TrochoidOuter rotor-to-housing clearance

mm (in) 0.09–0.15 (0.0035–0.0059)

Outer rotor-to-inner rotor clearance limit

mm (in) below 0.12 (0.0047)

Rotor-to-cover clearance mm (in) 0.03–0.08 (0.0012–0.0031)Thermostat

Opening temperature °C (°F) 60 (140)Fully open temperature °C (°F) 70 (158)

Valve open lower limit mm (in) 3.0 (0.12)Fuel pump

Discharge L (US gal, Imp gal)/hr

at 6,000 r/min

70 (18.5, 15.4)

Pressure kPa (kgf/cm2, psi)

49 (0.49, 7.0)

Plunger stroke mm (in) 5.85–9.65 (0.2303–0.3799)Carburetor

ID mark 69W00Main jet # 124Pilot jet # 39Pilot screw turns out 1 3/4–2 3/4Float height mm (in) 5.2 (0.20)Engine idle speed r/min 800–900

Item UnitModel

F60AEHT F60AET

69W3D1X 24

Lower unit

Electrical

Item UnitModel

F60AEHT F60AETGear 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 mm 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50Forward gear shims mm 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50Reverse gear shims mm 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50

Item UnitModel

F60AEHT F60AETIgnition system

Ignition timing(engine idle speed) Degree TDC 0

Charge coil output peak voltage (L – Br)

at cranking (unloaded) V 159at cranking (loaded) V 164at 1,500 r/min (loaded) V 168at 3,500 r/min (loaded) V 126

Charge coil resistance(*1) (L – Br)

Ω 272–408

Pulser coil output peak voltage(W/R – W/B)

at cranking (unloaded) V 9.5at cranking (loaded) V 5.5at 1,500 r/min (loaded) V 11.0at 3,500 r/min (loaded) V 15.5

Pulser coil resistance(*1) (W/R – W/B)

Ω 396–594

CDI unit output peak voltage(B/O – B, B/W – B)

at cranking (unloaded) V 131at cranking (loaded) V 141at 1,500 r/min (loaded) V 150at 3,500 r/min (loaded) V 112

Spark plug gap mm (in) 0.9 (0.035)(*1) The figures are for reference only.


SPECSpecifications

25 69W3D1X

Ignition control systemOil pressure switch

ON ↔ OFFkPa

(kgf/cm2, psi)29.4–58.8 (0.294–0.588, 4.181–8.361)

Thermoswitch (Gy/B – B)OFF → ON °C (°F) 76–84 (169–183)ON → OFF °C (°F) 63–77 (145–170)

Starter motorType BendixOutput kW 1.1Cranking time limit Second 30Brushes

Standard length mm (in) 17.0 (0.67)Wear limit mm (in) 10.0 (0.39)

CommutatorStandard diameter mm (in) 33.0 (1.30)Wear limit mm (in) 32.0 (1.26)

MicaStandard undercut mm (in) 0.5–0.8 (0.02–0.03)Wear limit mm (in) 0.2 (0.01)

Charging systemFuse A 20Lighting coil output peak voltage (G – G)

at cranking (unloaded) V 14.0at 1,500 r/min (unloaded) V 38at 3,500 r/min (unloaded) V 86

Lighting coil resistance(*1) (G – G)

Ω 1.2–1.8

Rectifier Regulator output peak voltage (R – B)

at 1,500 r/min (unloaded) V 22at 3,500 r/min (unloaded) V 27

Enrichment control systemPrime Start

Plunger extended length a mm (in) 24.6 (0.97)(*1) The figures are for reference only.

Item UnitModel

F60AEHT F60AET

69W3D1X 26

Power trim and tilt systemTrim sensor

Setting resistance Ω 9–11Resistance (P – B) Ω 9–288.3

Fluid type ATF Dexron IIBrushes

Standard length mm (in) 10 (0.39)Wear limit mm (in) 3.5 (0.14)

CommutatorStandard diameter mm (in) 22.0 (0.87)Wear limit mm (in) 21.0 (0.83)

MicaStandard undercut mm (in) 1.5 (0.06)

Item UnitModel

F60AEHT F60AET


SPECSpecifications

27 69W3D1X

DimensionsExterior

L3

L6L7

H9 H5

H2

H7

H1

H11

H4

H3

C1

B6

L5L8

L9 L4

A3

A2

H6

H10

H8

L2 L1

L10

W2

W6

A1 W5

W1

S69W2150

69W3D1X 28

Symbol UnitModel

F60AEHTL1 mm (in) 584 (23.0)L2 mm (in) 226 (8.9)L3 mm (in) 755 (29.7)L4 mm (in) 533 (21.0)L5 (L) mm (in) 97 (3.8)

(X) mm (in) —L6 (L) mm (in) 932 (36.7)

(X) mm (in) —L7 mm (in) 417 (16.4)L8 mm (in) 164 (6.5)L9 (L) mm (in) 0 (0)

(X) mm (in) —L10 mm (in) 62 (2.4)H1 (L) mm (in) 870 (34.3)

(X) mm (in) —H2 mm (in) 545 (21.5)H3 mm (in) 175 (6.9)H4 (L) mm (in) 527 (20.7)

(X) mm (in) —H5 mm (in) 758 (29.8)H6 (L) mm (in) 708 (27.9)

(X) mm (in) —H7 mm (in) 354 (13.9)H8 mm (in) 37 (1.5)H9 mm (in) 759 (29.9)H10 mm (in) 49 (1.9)H11 (L) mm (in) 24 (0.9)

(X) mm (in) —W1 mm (in) 192 (7.6)W2 mm (in) 124 (4.9)W3 mm (in) —W4 mm (in) —W5 mm (in) 360 (14.2)W6 mm (in) 645 (25.4)A1 Degree 40A2 Degree 69A3 Degree 4T1 mm (in) —


SPECSpecifications

29 69W3D1X

Exterior

L6L7

W5W1

A1

H9

H2

H7

H1

H11

H4

H3

C1

B6

L5

L9 L4

A3

A2

H6

H10

H8

L8

L2

L1

L10

S69W2160

69W3D1X 30

Symbol UnitModel

F60AETL1 mm (in) 584 (23.0)L2 mm (in) 122 (4.8)L3 mm (in) —L4 mm (in) 533 (21.0)L5 (L) mm (in) 97 (3.8)

(X) mm (in) —L6 (L) mm (in) 932 (36.7)

(X) mm (in) —L7 mm (in) 417 (16.4)L8 mm (in) 147 (5.8)L9 (L) mm (in) 0 (0)

(X) mm (in) —L10 mm (in) 62 (2.4)H1 (L) mm (in) 870 (34.3)

(X) mm (in) —H2 mm (in) 545 (21.5)H3 mm (in) 175 (6.9)H4 (L) mm (in) 527 (20.7)

(X) mm (in) —H5 mm (in) —H6 (L) mm (in) 708 (27.9)

(X) mm (in) —H7 mm (in) 354 (13.9)H8 mm (in) 22.5 (0.9)H9 mm (in) 759 (29.9)H10 mm (in) 49 (1.9)H11 (L) mm (in) 24 (0.9)

(X) mm (in) —W1 mm (in) 192 (7.6)W2 mm (in) —W3 mm (in) —W4 mm (in) —W5 mm (in) 360 (14.2)W6 mm (in) —A1 Degree 40A2 Degree 69A3 Degree 4T1 mm (in) —


SPECSpecifications

31 69W3D1X

Clamp bracket

Symbol UnitModel

F60AEHT F60AETB1 mm (in) 126 (5.0)B2 mm (in) 249 (10.0)B3 mm (in) 163.5 (6.4)B4 mm (in) 50.8 (2.0)B5 mm (in) 180 (7.1)B6 mm (in) 350 (13.8)B7 mm (in) —B8 mm (in) —B9 mm (in) 18.5 (0.7)C1 mm (in) 69 (2.7)C2 mm (in) —D1 mm (in) 13 (0.5)D2 mm (in) 60.5 (2.4)

B5

B3

B4

B9B9B9

D1

D1B1

B6

C1

B8

B2

D2

S69W2170

69W3D1X 32

Tightening torques 2

Specified torques

Part to be tightened Thread sizeTightening torques

N·m kgf·m ft·lbPower unitFlywheel magnet nut — 160 16 116Stator base screw M6 4 0.4 2.9Cover screw M6 3 0.3 2.2Red battery cable nut — 4 0.4 2.9Oil pressure switch — 9 0.9 6.5Oil pressure switch lead screw — 2 0.2 1.4Ignition coil bolt M6 7 0.7 5.1Starter motor bolt M8 30 3.0 22Starter motor terminal nut — 9 0.9 6.5Power unit bolt M8 21 2.1 15Tensioner bolt — 8 0.8 5.8Tensioner adjusting bolt M8 25 2.5 18Drive sprocket nut — 140 14 101Driven sprocket bolt M10 38 3.8 28Spark plug — 18 1.8 13

Cylinder head bolt

1stM6

6 0.6 4.32nd 12 1.2 8.71st

M923 2.3 17

2nd 47 4.7 34Oil pump screw M6 4 0.4 2.9Rocker shaft bolt M8 18 1.8 13Oil filter — 18 1.8 13Oil drain bolt M14 17 1.7 12

Exhaust cover bolt1st

M66 0.6 4.3

2nd 12 1.2 8.7

Crankcase bolt

1stM6

6 0.6 4.32nd 12 1.2 8.71st

M815 1.5 11

2nd 30 3.0 22

Connecting rod cap bolt1st

—6 0.6 4.3

2nd 17 1.7 12Lower unitCheck screw — 9 0.9 6.5Lower unit bolt M10 40 4.0 29Drain screw — 9 0.9 6.5Propeller nut — 35 3.5 25Water inlet cover screw — 5 0.5 3.6Pinion nut M17 75 7.5 54

Maintenance specifications / Tightening torques

SPECSpecifications

33 69W3D1X

General torquesThis chart specifies tightening torques forstandard fasteners with a standard ISOthread pitch. Tightening torque specificationsfor special components or assemblies areprovided in applicable sections of this man-ual. To avoid warpage, tighten multi-fastenerassemblies in a crisscross fashion and pro-gressive stages until the specified torque isreached. Unless otherwise specified, torquespecifications require clean, dry threads. Components should be at room temperature.

Bracket unitTiller handle assembly nut — 37 3.7 27Engine shut-off switch nut — 2 0.2 1.4Tiller handle bracket nut — 38 3.8 27Engine start switch nut — 5 0.5 3.7Tiller handle bracket bolt M5 7 0.7 5.1Friction plate bolt M6 8 0.8 5.8Friction plate self-locking nut — 4 0.4 2.9Upper mount nut — 24 2.4 17Lower mount nut — 42 4.2 30Clamp bracket self-locking nut — 23 2.3 17Power trim and tiltTilt cylinder end screw — 90 9.0 65PTT motor bolt M5 4 0.4 2.9Reservoir cap — 7 0.7 5.1Trim cylinder end screw — 80 8.0 58Tilt piston bolt M12 61 6.1 44Relief valve bracket bolt M5 5 0.5 3.6Gear pump assembly bolt M6 5 0.5 3.6Gear pump bracket bolt M5 5 0.5 3.6Electrical unitPulser coil screw — 4 0.4 2.9Starter motor nut — 9 0.9 6.5

Part to be tightened Thread sizeTightening torques

N·m kgf·m ft·lb

Nut (A) Bolt (B)General torque specifications

N·m kgf·m ft·lb8 mm M5 5 0.5 3.610 mm M6 8 0.8 5.812 mm M8 18 1.8 1314 mm M10 36 3.6 2517 mm M12 43 4.3 31

69W3D1X 34

Special service tools 3

Digital tachometer90890-06760

Compression gauge90890-03160

Drive shaft holder 490890-06518

Pinion nut holder90890-06505

Socket adapter 190890-06506

Bearing separator90890-06534

Bearing inner race attachment90890-06643

Shimming plate90890-06701

Digital caliper90890-06704

Digital circuit tester90890-03174

Tightening torques / Special service tools

123456789

CHK ADJ Periodic checks and adjustments

35 69W3D1X

Dial gauge set90890-01252

Magnet base90890-06705

69W3D1X 36

Maintenance interval chart 3

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

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

operation in addition to the items in the maintenance interval chart.

Item RemarksInitial Every

10 hours (Break-in)

50 hours (3 months)

100 hours (6 months)

200 hours (1 year)

Top cowlingTop cowling fit CheckFuel systemFuel joint and fuel hoses CheckFuel filter Check/replaceFuel tank CleaningPower unitEngine oil ChangeOil filter ChangeTiming belt CheckValve clearance Check/adjustSpark plugs Clean/adjust/replaceThermostat CheckWater leakage CheckMotor exterior CheckExhaust leakage CheckCooling water passage CleanControl systemThrottle cable Check/adjustShift cable Check/adjustEngine idle speed AdjustIgnition timing CheckPower trim and tilt unitPower trim and tilt unit CheckLower unitGear oil ChangeLower unit leakage CheckPropeller CheckGeneralAnodes Check/replaceBattery Check every 1 monthWiring and connectors Adjust/reconnectNuts and bolts TightenLubrication points Lubricate

Special service tools / Maintenance interval chart


37 69W3D1X

Top cowling 3

Checking the top cowling1. Check the fitting by pushing the cowling

with both hands. Adjust if necessary.

2. Loosen the nuts 1.

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

NOTE:• To loosen the fitting, move the hook in

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

direction b.

4. Tighten the nuts.

5. Check the fitting again and, if necessary,repeat steps 2–4.

Fuel system 3

Checking the fuel filter1. Check the fuel filter element 1 for dirt

and residue and check the fuel filter cup2 for foreign substances and cracks.Clean with straight gasoline and replacethe cup if necessary.

NOTE:Be sure not to spill any fuel when removingthe fuel filter cup.

Power unit 3

Checking the thermostat1. Remove the cover 1, thermostat cover

2, and thermostat 3.

2. Suspend the thermostat in a container ofwater.

3. Place a thermometer in the water andslowly heat the water.

S69W3010

S69W3020

S69W3040

32

1

69W3D1X 38

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

5. Install the thermostat, new gasket, ther-mostat cover, and cover.

General 3

Checking the anodes1. Check the anodes and trim tab for

scales, grease, or oil. Clean if necessary.

CAUTION:Do not oil, grease, or paint the anodes,otherwise they will be ineffective.

2. Replace the anodes and trim tab ifexcessively eroded.

Water temperature

Valve lift a

60 °C (140 °F) Valve begins to lift

above 70 °C (158 °F)

more than 3.0 mm (0.12 in)

S69W3050

S69W3110

Top cowling / Fuel system / Power unit / General


39 69W3D1X

Lubrication1. Apply water resistant grease to the areas

shown.

NOTE:Apply grease to the grease nipple until itflows from the bushings a.

2. Apply corrosion resistant grease to theareas shown.

S69W3120

AA

S69W3150

AA

69W3D1X 40

Hose routing 4

Fuel and blowby hoses

1 Blowby hose2 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)

General / Hose routing

123456789

FUELFuel system

41 69W3D1X

Cooling water hose

1 Pilot water hose2 Flushing hose

È Flushing device modelÉ View in direction of arrow

S69W4020

69W3D1X 42

Fuel line and fuel filter 4

No. Part name Q’ty Remarks

1 Fuel joint 1

2 Bolt 1 M6 × 25 mm

3 Seal 1

4 Fuel hose 1 Fuel joint-to-fuel filter

5 Bolt 1 M8 × 14 mm

6 Nut 1

7 Bracket 1

8 Body 1

9 Fuel filter element 1

10 Float 1

11 O-ring 1 Not reusable

12 Cup 1

13 Fuel hose 2 Fuel pump-to-carburetor

14 Fuel hose 1 Fuel filter-to-fuel pump

15 Fuel pump 1


17 Bracket 1

18 Bolt 2 M6 × 30 mm

Hose routing / Fuel line and fuel filter

FUELFuel system

43 69W3D1X

Carburetor unit 4


1 Acceleration pump 1

2 Screw 3 ø5 × 9 mm

3 Link rod 1

4 Hose 1

5 Hose 4

6 Link rod 1

7 Clip 1 Not reusable

69W3D1X 44

Adjusting the dashpot (acceleration pump)1. Start the engine and warm it up for 5 min-

utes.

2. Check that the engine speed at the oper-ation point of the dashpot is within speci-fication.

3. Attach the special service tool to sparkplug wire #1 1.

4. Open the throttle cam 2 slowly, andcheck the engine speed when the accel-eration pump stopper 3 comes into con-tact with point a.

5. If out of specification, adjust the dashpotuntil the specified engine speed isobtained.

6. Open the throttle cam 2 slowly, andcheck that the acceleration pump stopper3 comes in contact with point a.

7. Turn the adjusting screw 4 in or out untilthe specified engine speed is obtained.

8. Open and close the throttle cam a fewtimes, and then check that the enginespeed at the operation point of the dash-pot is within specification. Adjust if nec-essary.

Digital tachometer: 90890-06760

Engine speed: 2,000–2,200 r/min

S69W4050

1

Carburetor unit

POWRPower unit

45 69W3D1X

Power unit 5

69W3D1X 46

È Flushing device model


1 Power trim and tilt relay 1

2 Bolt 1 M8 × 16 mm

3 Black battery cable 1

4 Wiring harness 1 10-pin coupler

5 Grommet 1

6 Nut 1

7 Spring washer 1

8 Red battery cable 1

9 PTT relay positive lead 1

10 Fuse holder lead 1

11 Clip 1

12 Warning indicator coupler 1 Tiller handle model

13 PTT switch coupler 1

14 Plastic tie 1 Not reusable

15 Pilot water hose 1

16 Bolt 2 M6 × 20 mm

17 Neutral switch 1 Tiller handle model

18 Plate 1 Remote control model

19 Neutral switch lead 2 Tiller handle model

20 Ground lead 3

21 Bolt 1 M6 × 12 mm

22 PTT relay lead 2

23 Nut 2

24 Spring washer 2

25 PTT motor lead 2 Green, blue

26 Bolt 2 M6 × 20 mm


28 Flushing hose 1

Power unit

123456789

POWRPower unit

47 69W3D1X

69W3D1X 48


1 Bracket 1

2 Starter motor 1

3 Spark plug cap 4

4 Ignition coil 2

5 Wiring harness 1

6 Thermoswitch 1

7 Holder 1

8 Bolt 1 M6 × 12 mm

9 Ground lead 3

10 Bolt 1 M6 × 12 mm

11 Oil pressure switch 1

12 Oil pressure switch lead 1

13 Screw 1

14 Ignition coil lead 2

15 Bolt 4 M6 × 30 mm

16 Thermoswitch lead 2

17 Rectifier Regulator coupler 1

18 CDI unit coupler 1

19 Bolt 2 M8 × 25 mm

20 Bolt 3 M8 × 35 mm

21 Nut 1

22 Spring washer 1

23 Starter motor lead 1

24 Spring washer 1

25 Nut 1

26 Bolt 1 M8 × 45 mm

27 Oil pressure switch lead 1

28 Starter relay lead 1

Power unit

POWRPower unit

49 69W3D1X

69W3D1X 50

È Tightening sequence


1 Cylinder head 1

2 Plate 1

3 Cylinder head cover 1

4 Bolt 7 M6 × 20 mm

5 Cylinder head cover gasket 1 Not reusable

6 Bolt 10 M9 × 95 mm

7 Spark plug 4

8 Bolt 5 M6 × 25 mm

9 Dowel pin 2

10 Cylinder head gasket 1 Not reusable

11 Grommet 4

12 Anode 4

13 Cover 4

14 Bolt 4

15 Cover 4

16 Bolt 4

17 O-ring 1 Not reusable1.9 × 36.8 mm



20 Bolt 4 M6 × 40 mm

21 Housing 1

22 Drive shaft 1

23 Pin 1

24 Inner rotor 1

25 Outer rotor 1

26 Gasket 1 Not reusable

27 Cover 1

28 Screw 2 ø6 × 20 mm

29 Engine hanger 1

30 Bolt 2 M6 × 20 mm

31 Screw 4 ø4 × 10 mm


33 Oil filler cap 1

Power unit

POWRPower unit

51 69W3D1X

69W3D1X 52


1 Rocker arm assembly 8

2 Rocker arm shaft 1

3 Cylinder head 1

4 Exhaust valve 4

5 Intake valve 4

6 Camshaft 1

7 Valve cotter 16

8 Spring retainer 8

9 Valve spring 8

10 Spring seat 8

11 Stem seal 8 Not reusable

12 Valve guide 8 Not reusable

13 Retaining bolt 1


15 Oil seal 1 Not reusable

16 Bolt 5 M8 × 22 mm

17 Rocker arm retainer 2

18 Tensioner 2

19 Rocker arm retainer 1

20 Stopper guide 2

Power unit

POWRPower unit

53 69W3D1X

69W3D1X 54

È Tightening sequence


1 Oil filter 1

2 Crankshaft 1

3 Bolt 10 M8 × 82 mm

4 Bolt 10 M6 × 35 mm

5 Crankcase 1


7 Main bearing 10


9 Connecting rod bearing 8

10 Connecting rod cap 4

11 Bolt 8

12 Dowel pin 2

13 Cylinder block 1

14 Connecting rod 4

15 Piston pin clip 8 Not reusable

16 Piston pin 4

17 Piston 4

18 Oil ring 4

19 Second ring 4

20 Top ring 4


22 Exhaust cover 1

23 Thermostat 1


25 Cover 1

26 Clamp 2

27 Grommet 1

28 Anode 1

29 Cover 1

30 Cover 1

31 Bolt 1 M6 × 20 mm

32 Bolt 1 M5 × 12 mm

33 Bolt 12 M6 × 35 mm

Power unit

POWRPower unit

55 69W3D1X

Checking the compression pressure1. Start the engine, warm it up for 5 min-

utes, and then turn it off.

2. Remove the lock plate from the engineshut-off switch on the remote control boxor tiller handle.

3. Remove all spark plugs, and then installthe special service tools to each sparkplug hole.

CAUTION:Before removing the spark plugs, removeany dirt or dust that may fall into the cylin-der.

4. Fully open the throttle manually, crankthe engine until the reading on the com-pression gauge stabilizes, and thencheck the compression pressure.

5. If the compression pressure is belowspecification and the compression pres-sure for each cylinder is unbalanced, adda small amount of engine oil to the cylin-der, and then check the pressure again.

NOTE:• If the compression pressure increases,

check the piston and piston rings for wear.Replace if necessary.

• If the compression pressure does notincrease, check the valve clearance, valve,valve seat, cylinder sleeve, cylinder headgasket, and cylinder head. Adjust orreplace if necessary.

Checking the oil pressure1. Remove the cover.

2. Remove the oil pressure switch, and theninstall an oil pressure gauge 1 to the oilpressure switch installation hole.

NOTE:Use a pressure gauge with an adapter thathas a 1/8 pitch thread.

3. Start the engine and warm it up for 5 min-utes.

4. Check the oil pressure. Check the oilpump, relief valve, oil filter, and oilstrainer if out of specification.

Compression gauge 1:90890-03160

Minimum compression pressure (reference data):

880 kPa (8.8 kgf/cm2, 125 psi)

Oil pressure (reference data):110 kPa (1.1 kgf/cm2, 16 psi) at idle speed (900 r/min)

69W3D1X 56

Checking the cylinder bore1. Measure the cylinder bore (D1–D6) at

measuring points a, b, and c, and indirection d (D1, D3, D5), which is parallelto the crankshaft, and direction e (D2,D4, D6), which is at a right angle to thecrankshaft.

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

2. Calculate the taper limit. Replace orrebore the cylinder block if out of specifi-cation.

3. Calculate the out-of-round limit. Replaceor rebore the cylinder block if out of spec-ification.

Checking the piston ring grooves1. Measure the piston ring grooves.

Replace the piston if out of specification.

Cylinder bore (D1–D6):65.00–65.01 mm(2.5591–2.5594 in)

Taper limit:D1–D5 (direction d)D2–D6 (direction e)

0.08 mm (0.0031 in)

Out-of-round limit:D2–D1 (measuring point a)D6–D5 (measuring point c)

0.01 mm (0.0004 in)

S69W5080

D1D2

D3D4

D5D6

Piston ring groove:Top ring a:

1.21–1.23 mm (0.0476–0.0484 in)

Second ring b:1.51–1.53 mm (0.0594–0.0602 in)

Oil ring c:2.52–2.54 mm (0.0992–0.0999 in)

Power unit

LOWRLower unit

57 69W3D1X

Drive shaft and lower case 6

69W3D1X 58


1 Drive shaft 1


3 Oil seal housing 1


5 Circlip 1

6 Shift rod 1


8 Taper roller bearing 1 Not reusable

9 Bearing outer race 1 Not reusable

10 Pinion shim — As required

11 Sleeve 1

12 Washer 1

13 Oil seal housing 1



16 Seal 1

17 Plate 1

18 Hose 1


20 Joint 1

21 Nut 1

22 Water inlet cover 2

23 Screw 1

24 Shift cam 1

25 Needle bearing 1

26 Pinion 1

27 Nut 1

28 Forward gear shim — As required

29 Bearing outer race 1 Not reusable

30 Taper roller bearing 1 Not reusable

31 Forward gear 1

32 Lower case 1

33 Cover 1


35 Check screw 1


37 Drain screw 1

Drive shaft and lower case

123456789

LOWRLower unit

59 69W3D1X

Removing the drive shaft1. Remove the drive shaft assembly and

pinion, and then pull out the forwardgear.

Disassembling the forward gear1. Remove the taper roller bearing from the

forward gear using a press.

CAUTION:Do not reuse the bearing, always replaceit with a new one.

Assembling the forward gear1. Install the new taper roller bearing into

the forward gear using a press.

Installing the drive shaft1. Install the forward gear, then the drive

shaft assembly, pinion, and pinion nut,and then tighten the nut to the specifiedtorque.

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

Bearing splitter plate 1: (commercially obtainable)Bearing separator 1: 90890-06534

S69W6020

S69W6030

Bearing inner race attachment 1:90890-06643

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

T R..

Pinion nut:75 N·m (7.5 kgf·m, 54 ft·lb)

S69W6020

69W3D1X 60

Shimming 6

Drive shaft and lower case / Shimming

LOWRLower unit

61 69W3D1X

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).

Selecting the forward gear shims1. Turn the taper roller bearing outer race

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

NOTE:• Select the shim thickness (T1) by using the

specified measurement(s) and the calcula-tion formula.

• Measure the bearing outer race at threepoints to find the height average.

2. Calculate the forward gear shim thickness(T1) as shown in the examples below.

NOTE:“F” is the deviation of the lower case dimen-sion from standard. The “F” mark a isstamped on the trim tab mounting surface ofthe lower case in 0.01 mm units. If the “F”mark is unreadable, assume that “F” is zeroand check the backlash when the unit isassembled.

Example:If “M” is 26.06 mm and “F” is (+1), thenT1 = 26.50 + (+1)/100 – 26.06 mm

= 26.50 + 0.01 – 26.06 mm = 0.45 mm

3. Select the forward gear shim(s) (T1) asfollows.

Shimming plate 2: 90890-06701Digital caliper 3: 90890-06704

Calculation formula:Forward gear shim thickness (T1) = 26.50 + F/100 – M

Calculated numeral at 1/100 place

Rounded numeral

1, 2 0

3, 4, 5 2

6, 7, 8 5

9, 10 8

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

69W3D1X 62

Example:If “T1” is 0.45 mm, then the forward gearshim is 0.42 mm.If “T1” is 0.60 mm, then the forward gearshim is 0.58 mm.

Shimming

BRKTBracket unit

63 69W3D1X

Tiller handle 7

69W3D1X 64


1 Tiller handle assembly 1

2 Tiller handle wiring harness 1

3 Grommet 1

4 Clip 1

5 Throttle cable 1

6 Plate 1

7 Bolt 3 M6 × 25 mm

8 Bolt 1 M8 × 16 mm

9 Black battery cable 1

10 Cable guide 1

11 Grommet 1

12 Nut 1 M6 × 35 mm

13 Washer 1

14 Red battery cable 1

15 Connector 1

16 Clip 1

17 Shift cable 1

18 Cover 1

19 Screw 3 ø6 × 35 mm

20 PTT switch coupler 1

21 PTT switch coupler 1 Tiller handle model

22 Plastic tie 1

23 Nut 2

24 Bolt 1 M5 × 20 mm

25 Bracket 1

26 Friction lock shaft 1

27 Collar 2

28 Washer 2

29 Friction lock lever 1

30 Friction piece 2

31 Friction plate 1

32 Washer 2

33 Bolt 2

34 Nut 1

35 Washer 1

36 Self-locking nut 1

Tiller handle

123456789

BRKTBracket unit

65 69W3D1X

Bottom cowling 7

69W3D1X 66


1 Bottom cowling 1

2 Rubber seal 1

3 Washer 1

4 Bushing 2

5 Shift rod bracket 1

6 Bolt 1

7 Spring 1

8 Ball 1

9 Shift rod 1

10 Flushing device 1 Flushing device model

11 Bracket 1 Flushing device model

12 Bolt 1 M6 × 16 mm / Flushing device model

13 Screw 2 ø6 × 20 mm / Flushing device model

14 Flushing hose 1 Flushing device model

15 Bolt 4 M6 × 30 mm

16 Grommet 4

17 Collar 4

18 Grommet 1

19 PTT motor lead 1

20 Trim sensor coupler 1

21 Screw 1 ø6 × 25 mm

22 Bolt 2 M6 × 20 mm

23 Bracket 1

24 Power trim and tilt switch 1

25 Warning indicator 1 Tiller handle model

26 Screw 1 ø6 × 14 mm / Tiller handle model

27 Pilot water hose 1

28 Collar 2

29 Grommet 2

30 Cowling lock lever 1

31 Washer 1

32 Wave washer 1

33 Bushing 2

34 Lever 1

35 Bolt 1 M6 × 12 mm

36 Spring 1

37 Hook 1

38 Bolt 1 M6 × 20 mm

Bottom cowling

BRKTBracket unit

67 69W3D1X

Upper case 7

69W3D1X 68


1 Muffler assembly 1

2 Upper case 1

3 Muffler seal 1

4 Rubber seal 1

5 Dowel pin 2

6 Grommet 1

7 Damper 1


9 Baffle plate 1

10 Bolt 4 M8 × 30 mm

11 Drive shaft bushing 1

12 Circlip 1

13 Ground lead 1


15 Cap 2

16 Bolt 2 M12 × 170 mm

17 Washer 2

18 Rubber washer 2

19 Washer 2

20 Lower mount 2

21 Washer 2

22 Mount cover 2

23 Bolt 4 M8 × 30 mm

24 Bolt 2 M8 × 175 mm

25 Plate 1

26 Bolt 3 M8 × 30 mm

27 Upper mount 1

28 Nut 2

29 Grease nipple 1

30 Washer 2

31 Nut 2

32 Cover 1

33 Bolt 2 M8 × 20 mm

Upper case

BRKTBracket unit

69 69W3D1X

69W3D1X 70



2 Exhaust guide 1

3 Grommet 1

4 Anode 1

5 Cover 1

6 Bolt 1 M6 × 20 mm

7 Cover 1

8 Bolt 1



11 Relief valve housing 1

12 Relief valve 1

13 Spring 1

14 Cotter pin 1 Not reusable

15 Bolt 2 M6 × 25 mm

16 Bolt 2 M6 × 16 mm

17 Oil strainer 1

18 Bolt 1 M6 × 25 mm


20 Pipe 1

21 Rubber seal 1

22 Dowel pin 2

23 Bolt 10 M6 × 25 mm

24 Drain bolt 1


26 Oil pan 1


28 Exhaust manifold 1

29 Bracket 1

30 Washer 3

31 Bolt 3 M6 × 50 mm



34 Plate 1

35 Muffler 1

36 Bolt 6 M6 × 25 mm

Upper case

BRKTBracket unit

71 69W3D1X

Disassembling the oil pan1. Remove the muffler 1, plate 2, and

exhaust manifold 3 from the oil pan 4.

2. Remove the oil pan 4 and the exhaustguide 5.

3. Remove the oil strainer 6 and the reliefvalve housing 7.

Assembling the oil pan1. Install the gaskets onto the exhaust

guide 1.

2. Install the relief valve assembly 2 byinstalling the bolts, then tightening themfinger tight.

3. Install the oil strainer 3 by installing thebolts.

4. Install the water pipe 4.

5. Install the oil pan 5 and bolts, and thentighten the bolts finger tight.

6. Install the exhaust manifold 6 and bolts,and then tighten the bolts finger tight.

69W3D1X 72

7. Tighten the oil pan bolts 7 then exhaustmanifold bolts 8, and then tighten themto the specified torque.

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

9. Install the muffler assembly A by insert-ing the tip of the water pipe 4 into thejoint hole a of the upper case.

10. Tighten the upper case bolts B, and thentighten them to the specified torque.

Installing the upper case1. Install the upper mount 1 and bolts 2

into the upper case.

2. Install the lower mounts 3 and bolts 4into the upper case.

3. Install the mount covers 5.T R.

.

Exhaust manifold bolt 8:10 N·m (1.0 kgf·m, 7.2 ft·lb)

S69W7100

LT

572

LT

572

T R..

Upper case bolt B:21 N·m (2.1 kgf·m, 15 ft·lb)

Upper case

BRKTBracket unit

73 69W3D1X

4. Install the upper and lower mountingbolts into the swivel bracket 6 simulta-neously.

5. Install the upper mounting nut 7 andlower mounting nut 8, and then tightenthem to the specified torque.

6. Install the cover 9.

T R..

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)

69W3D1X 74

Clamp brackets 7


1 Swivel bracket assembly 1


3 Trim sensor 1

4 Trim sensor coupler 1


6 Self-locking nut 2

7 Cap 2

8 Bolt 4 M6 × 25 mm

9 Anode 2

10 Port clamp bracket 1

11 Washer 2

12 Bushing 2

13 Through tube 1

14 Ground lead 1

15 Grease nipple 1


17 Starboard clamp bracket 1

18 Bracket 1

Upper case / Clamp brackets

BRKTBracket unit

75 69W3D1X

Adjusting the trim sensor1. Fully tilt the outboard motor up, and then

support it with the tilt stop lever 1.

WARNINGAfter tilting up the outboard motor, besure to support it with the tilt stop lever.Otherwise, the outboard motor could sud-denly lower if the power trim and tilt unitshould lose fluid pressure.

2. Loosen the cam screws 2.

3. Adjust the position of the trim sensor 3,and then tighten the screws 2 fingertight.

4. Fully tilt the outboard motor down.

5. Measure the trim sensor resistance.Repeat steps 1–5 if out of specification.

6. Tighten the screws 2.

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

WARNINGAfter tilting up the outboard motor, besure to support it with the tilt stop lever.Otherwise, the outboard motor could sud-denly lower if the power trim and tilt unitshould lose fluid pressure.

8. Measure the trim sensor resistance.Check the trim sensor if out of specifica-tion.

Trim sensor resistance:Pink (P) – Black (B)

9–11 Ω at 20 °C (68 °F)


168.3–288.3 Ω at 20 °C (68 °F)

69W3D1X 76

Swivel bracket and steering arm 7


1 Steering arm 1

2 Washer 1

3 Bushing 1


5 Bushing 2

6 Swivel bracket 1

7 Bushing 2

8 Port tilt stop lever 1

9 Circlip 1

10 Steering yoke 1

11 Bushing 1

12 Bushing 2

13 Tilt stop lever joint 1

14 Spring holder 1

15 Bolt 1 M6 × 10 mm

16 Spring 1

17 Pin 2 Not reusable

18 Starboard tilt stop lever 1

Clamp brackets / Swivel bracket and steering arm

BRKTBracket unit

77 69W3D1X

Power trim and tilt unit 7


1 Power trim and tilt unit 1


3 PTT motor lead 2

4 Washer 2

5 Bolt 2 M8 × 16 mm

6 Circlip 1

7 Shaft 1

8 Bushing 2

9 Collar 1

10 Tilt pin 1

11 Collar 1

12 Collar 1

13 Shaft 1

69W3D1X 78


1 Bolt 2 M5 × 8 mm

2 Relief valve bracket 1

3 Bolt 3 M6 × 40 mm

4 Valve lock screw 1

5 Up-relief spring 1

6 Valve support pin 1


8 Ball 1

9 Down-relief spring 1

10 Valve support pin 1

11 Relief valve seal 1

12 Filter 1


14 Spacer 2

15 Filter 2


17 Manual valve 1

18 Circlip 1

Power trim and tilt unit

BRKTBracket unit

79 69W3D1X


1 Bolt 2 M5 × 20 mm

2 Washer 2

3 Bracket 1


5 Spacer 2

6 Spring 2

7 Valve pin 2

8 Ball 2

9 Manual release spring 1

10 Ball 2

11 Gear pump cover 1

12 Spring 2

13 Shuttle piston 1


15 Valve seal 2

16 Circlip 2

17 Pin 2

18 Drive gear 1

69W3D1X 80


19 Shaft 1

20 Driven gear 1

21 Ball 2

22 Shuttle piston 1

23 Valve plate 1

24 Plate 1

25 Gear pump housing 1


BRKTBracket unit

81 69W3D1X



2 Yoke 1


4 Armature 1

5 Washer 1

6 Bushing 1


8 Lead 1

9 Brush 2 1

10 Brush 1 1

11 Brush holder 1

12 Circuit breaker 1

13 Brush spring 2

14 PTT motor base 1


69W3D1X 82

Disassembling the gear pump1. Remove the manual valve 1 and gear

pump 2.

2. Remove the relief valve bracket 3, thenthe relief valve seal 4 and ball 5.

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

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

5. Remove the drive gear A and drivengear B.

Checking the valves1. Check the operation of the check valve

a of the trim cylinder end screw andcheck the valve for dirt or residue. Cleanif necessary.

2. Check the operation of the tilt pistonabsorber valve and check for dirt or resi-due. Clean if necessary.

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


BRKTBracket unit

83 69W3D1X

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

5. Check the absorber valves for dirt or res-idue. Clean if necessary.

Assembling the gear pump1. Install the drive gear 1, driven gear 2,

shaft 3, and pins 4 into the gear pumphousing 5.

2. Install the balls 6 and shuttle pistons 7into the gear pump housing 5.

3. Install the gear pump cover 8.

4. Install the balls 9, manual release spring0 and bracket A by installing the boltsB, then tightening them to the specifiedtorque.

5. Install the relief valve seal C, ball D, andfilter E.

6. Install the relief valve bracket F byinstalling the bolts G, then tighteningthem to the specified torque.

S69W7280

S69W7290

S69W7300

T R..

Gear pump bracket bolt B:5 N·m (0.5 kgf·m, 3.6 ft·lb)

69W3D1X 84

7. Install the filters H and gear pump I byinstalling the bolts J, then tighteningthem to the specified torque.

8. Install the manual valve K and reservoircap L.

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

10. Install the joint M and power trim and tiltmotor N by installing the bolts O, thentightening them to the specified torque.

Checking the trim sensor 1. Measure the trim sensor resistance.

Replace if out of specification.

NOTE:Turn the lever 1 and measure the resistanceas it gradually changes.

T R..

Relief valve bracket bolt G:5 N·m (0.5 kgf·m, 3.6 ft·lb)

T R..

Gear pump bolt J:7 N·m (0.7 kgf·m, 5.1 ft·lb)

Recommended power trim and tilt fluid:

ATF Dexron II

T R..

PTT motor bolt O:4 N·m (0.4 kgf·m, 2.9 ft·lb)


9–11 Ω at 20 °C (68 °F) a 168.3–288.3 Ω at 20 °C (68 °F) b


ELECElectrical systems

– +

85 69W3D1X

Wiring harness 8

Connect to:1 Engine start switch or

remote control box extension

2 Power trim and tilt relay3 Ground4 Starter relay5 Red battery cable6 Prime Start

7 Warning indicator8 CDI unit9 Power trim and tilt

switch0 Rectifier RegulatorA ThermoswitchB Ignition coilC Oil pressure switch

B : BlackBr : BrownG : GreenL : BlueLg : Light greenP : PinkR : RedSb : Sky blueW : White

Y : YellowB/O : Black/orangeB/W : Black/whiteP/B : Pink/blackP/W : Pink/whiteY/B : Yellow/blackY/R : Yellow/red

Lg Lg SbSb

R

R

B B B

Br R

YYG

BBB

B

Y PL

P

G

LgSb

Y/RP/BP/W

Lg

LgLg

Sb

SbSb

Br

BrR

P

B B B

R

RL Y P

L BP R R G B

B B B BP

LgSb

Y Y G G

W

BY

WG

P/W P/W B/O

B/OB/W

Y/R Y/R B/WP/B P/B

Y/B Y/B

Y/B

B/O

B/W

RG

Lg

P

BrB

Sb

Y/B

P/B

Y/R

P/W

B/W

Y/B

B/O

Y/R

P/WP/B

Lg

R

Sb

L B

PW

B R

G

Y

L

Y

W

S69W8010

69W3D1X 86

Ignition and ignition control system 8

1 Spark plug2 Ignition coil3 Charge coil4 Pulser coil5 Engine start switch6 Engine shut-off switch7 10-pin coupler8 CDI unit

È Tiller handle model

B : BlackBr : BrownL : BlueO : OrangeW : WhiteB/O : Black/orangeB/W : Black/whiteW/B : White/blackW/R : White/red

Wiring harness / Ignition and ignition control system

123456789


– +

87 69W3D1X

1 Thermoswitch2 Oil pressure switch3 CDI unit4 Oil pressure warning indicator5 Overheat warning indicator6 Warning indicator


B : BlackP : PinkGy/B : Gray/blackP/B : Pink/blackP/W : Pink/whiteY/B : Yellow/blackY/R : Yellow/red

69W3D1X 88

Checking the spark plug caps1. Remove the spark plug caps from the

spark plug wires by turning the capscounterclockwise.

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

Checking the pulser coil air gap1. Turn the flywheel clockwise to align the

projection of the flywheel with the pulsercoil projection.

2. Measure the gap between both projec-tions with a thickness gauge. Adjust if outof specification.

3. Remove the flywheel magnet nut and fly-wheel magnet.

4. Loosen the pulser coil screws, adjust thepulser coil 1 position, and then tightenthe screws finger tight.

5. Install the flywheel magnet, and thencheck the gap and, if necessary, repeatsteps 3–5.

6. Tighten the pulser coil screws and fly-wheel magnet nut to the specifiedtorques.

Checking the engine start switch1. Check the engine start switch for continu-

ity. Replace if there is no continuity.

Spark plug cap resistance (reference data):

5 kΩ

S69W8060

Pulser coil air gap a:0.5–1.0 mm (0.020–0.039 in)

T R..

Pulser coil screw:4 N·m (0.4 kgf·m, 2.9 ft·lb)

Flywheel magnet nut:160 N·m (16 kgf·m, 116 ft·lb)

Lead color

Switch position

White (W)

Black (B)

Red (R)

Pink (P)

Brown (Br)

OFF

ON

START

Ignition and ignition control system


– +

89 69W3D1X

Starting system 8

1 Fuse2 10-pin coupler3 Engine start switch4 Starter motor5 Battery6 Neutral switch7 Starter relay


B : BlackBr : BrownR : Red

OFF

W B R P Br

ON

START

N

S

M

RBr

Br

Br

RRR

R

B

B

B

BB

B

B

R R

Br Br

Br

S69W8090E

69W3D1X 90

Starter motor 8


1 Clip 1

2 Pinion stopper 1

3 Spring 1

4 Starter motor pinion 1

5 Upper bracket 1

6 Washer 1 1

7 Shim — As required

8 Washer 2 1

9 Armature 1

10 Washer 2

11 Stator 1

12 Brush holder assembly 1

13 Brush set 1


15 Nut 1

16 Lower bracket 1

17 Screw 2 ø4 × 12 mm

18 Bolt 2 M6 × 120 mm

S69W8100

12

3

4

5

9

10

6

7

8

11

12

13

16

18

14

15

17

T R..

7 N • m (0.7 kgf • m, 5.1 ft • Ib)

Starting system / Starter motor


– +

91 69W3D1X

Checking the armature1. Check the armature axial free play.

Replace the washers and shim(s) 3 ifout of specification.

2. Check the commutator for dirt. Cleanwith #600 grid sandpaper and com-pressed air if necessary.

3. Measure the commutator diameter.Replace the armature if out of specifica-tion.

4. Measure the commutator undercut a.Replace the armature if out of specifica-tion.

5. Check the armature for continuity.Replace if out of specifications.

Checking the brushes1. Measure the brush length. Replace the

brush assembly if out of specification.

Dial gauge set 1: 90890-01252Magnet base 2: 90890-06705

Free play limit: 0.6 mm (0.024 in)

Diameter limit: 32.0 mm (1.26 in)

Commutator undercut limit:0.2 mm (0.01 in)

Armature continuity

Commutator segments b Continuity

Segment – Armature core c

No continuity

Segment – Armature shaft d

No continuity

69W3D1X 92

2. Check the brush holder for continuity.Replace if out of specifications.

Brush length limit a:10.0 mm (0.39 in)

Brush assembly continuity

Brush 1 – Brush assembly holder 4

ContinuityBrush 2 – Brush assembly holder 3

Brush 1 – Brush 2

No continuityBrush 1 – Brush assembly holder 3

Brush 2 – Brush assembly holder 4

S69W8170

Starter motor

Wiring diagramF60AEHT

1 Battery2 Engine start switch3 Starter motor4 Power trim and tilt motor5 Power trim and tilt relay6 Engine shut-off switch7 Starter relay8 Neutral switch9 Fuse (20 A)0 Warning indicatorA Power trim and tilt switchB Prime StartC Oil pressure switchD CDI unitE ThermoswitchF Charge coilG Pulser coilH Lighting coilI Rectifier RegulatorJ Ignition coilK Spark plugL Trim sensor

Color codeB : BlackBr : BrownG : GreenGy : GrayL : BlueLg : Light greenO : OrangeP : PinkR : RedSb : Sky blueW : WhiteY : YellowB/O : Black/orangeB/W : Black/whiteG/W : Green/whiteGy/B : Gray/blackP/B : Pink/blackP/W : Pink/whiteW/B : White/blackW/R : White/redY/B : Yellow/blackY/R : Yellow/red

Wiring diagramF60AET

1 Battery2 Starter motor3 Power trim and tilt motor4 Power trim and tilt relay5 Starter relay6 Fuse (20 A)7 Trim sensor8 Prime Start9 Oil pressure switch0 CDI unitA ThermoswitchB Charge coilC Pulser coilD Lighting coilE Rectifier RegulatorF Power trim and tilt switchG Ignition coilH Spark plug

È To remote controlÉ To warning indicatorÊ To trim meter

Color codeB : BlackBr : BrownG : GreenGy : GrayL : BlueLg : Light greenO : OrangeP : PinkR : RedSb : Sky blueW : WhiteY : YellowB/O : Black/orangeB/W : Black/whiteG/W : Green/whiteGy/B : Gray/blackP/B : Pink/blackP/W : Pink/whiteW/B : White/blackW/R : White/redY/B : Yellow/blackY/R : Yellow/red

YAMAHA MOTOR CO., LTD.

Printed in the NetherlandsJul. 2001 – 1.3 × 1 CR(F60AEHT, F60AET)

(E)

Sb R Lg

UP

FREE

DOWN

Sb R Lg

UP

FREE

DOWN

RBW P Br

OFF

ON

ST

F60AEHT

Gy

B

P

P/B

LgLg SbSb

RR

Y/R

P/W

Y/B

P/W

P/W

Y/R

B/O

Y/R

B/O B/W

B/W

Y/B

Y/B

P/B

P/B

SbSb Lg

R

Sb

R

Sb

R

Lg

Lg

R

W

Sb

P

Br B

LgG

P

R

W

B Br

Y

W/BW/R

G/W

G G

G

Br L

R

G/W

B

L

G

BR

BB

B

Y

Y

P O B

B

B

BB

B

B

O

B

RRR

W

W

W

BB

B

P

R

WP

GY

BR

R

O

B

BGGYY

L

L

L

B

B

B

B B B Y

P P

L

L

Y L Y L

R

R

R

R

G L

Br

Br

Br

Br

W

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

L W

P B

Y/R B/W

B/W

Y/B P/WY/R P/B

Y/B P/WY/RP/B

B/O

P/BY/B P/W B/O

P/B B/W Gy/B

Gy/B

W/RW/R

W/R

W/B

W/B

G/W

G/W G/W

Sb

SbLgLgSbSb

SbLg

Lg

Br

Br

L

G G G

GG

G BG L R

R B G

Br

Br

Br

#2

#3

#1

#4

Sb

RLg Sb

SbSb

Sb

PB

Gy

LgLgLg

LgRSb

Lg

S69WWD01E

Y

Y

L

L

B

OP W

B

W

L

Sb

P/B

Y/B

P/W

Y/R

B

Br

G

Gy

L

Lg

O

P

R

Sb

W

Y

B/O

B/W

G/W

Gy/B

P/B

P/W

W/B

W/R

Y/B

Y/R

Sb R Lg

UP

FREE

DOWN

F60AET

Gy

B

P

P/B

Y/R

P/W

Y/B

P/W

P/W

Y/R

B/O

Y/R

B/O B/W

B/W

Y/B

Y/B

P/B

P/B

Sb

R

Sb

R

Lg

Lg

R

W

Sb

P

Br B

LgG

Y

W/BW/R

G/W

G G

G

Br L

R

G/W

B

L

G

BR

BB

B

Y

Y

P O B

B

B

BB

B

B

O

B

R

WP

GY

BR

O

B

BGGYY

L

L

L

B

B

B

B B B Y

P P

L

L

Y L Y L

R

R

R

R

G L

Br

Br

W

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

L W

P B

Y/R B/W

B/W

Y/B P/WY/R P/B

B/O

P/BY/B P/W B/O

P/B B/W Gy/B

Gy/B

W/RW/R

W/R

W/B

W/B

G/W

G/W G/W

Sb

SbLgLgSbSb

SbLg

Lg

Br

Br

L

G G G

GG

G BG L R

R B G

Br

Br

#2

#3

#1

#4

SbPB

Gy Lg

S69WWD03E

B

Br

G

Gy

L

Lg

O

P

R

Sb

W

Y

B/O

B/W

G/W

Gy/B

P/B

P/W

W/B

W/R

Y/B

Y/R

Y

Y

L

L

B

OP W

B

W

L

Sb

RLg Sb

Yamaha f60a(Supl)

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