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LIT-19616-02-33 62Y-28I97-1A-I I

Contents

General information

How to use this manual..... ....1-1Manual format........ ........1-1Symbols .,_._,.1-2

ldentificationApplicable models .........1-5Serial number ................1-5

Features and benefits ........1-6

Acceleration pump

Propeller selection .,,.,,1.32

Predelivery checks ......1-33Checking the fuel system ............... 1-33Checking the gear oi1.............. ........ 1-33Checking the engine oil .............. ....1-33Checking the battery. ...1-33Checkingtheoutboardmotormountingposition ..................1-34Checking the remote control cables .................. 1-34Checking the steering wheel/tiller handle .......... 1-34Checkingthegearshiftandthrottleoperation... ....................1-34Checking the tilt system....... ...........1-35Checking the engine start switch andengine stop switch/engine shut-off switch ....... 1-35

Checking the pilot water outlet ......... .................1-35Test run ....1-35Break-in ....1-36After test run............. ...1-36

I-5

62Y1411

General information

How to use this manualManualformatThe 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.

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

@ Tightening torque specifications are provided in the components list at the beginning of eachsection and atter a numbered step with tightening instructions.

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

@ The components list consist of pads and pafi quantities, as well as bolt and screw dimensions.

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

@ This service manual has two types of special service tools. Use part numbers that start with "Jr',"YB-", "YM-", "YS-", "YU-", "YW-", or "YX-" for USA and Canada. Use parts numbers that startwith "90890-" for all other countries.

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1-1 62Y141 1

How to use this manual

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

General information

,RFüIÎSpecifications

SPEC I tFPeriodic checks and

CHKADJ

Fuelsystem

Power unit

POWR -_ELower unit

LowRl Èadjustments Bracket unit

BRKT

Electrical systemsml FltrlSymbols O to @ in an exploded diagram indicate the grade of lubricant and the lubrication point.

O Apply Yamaha 4-stroke motor oil

@ Apply water resistant grease (Yamaha grease A, Yamaha marine grease)

@ Apply molybdenum disulfide grease

@ Apply anti-corrosion grease (Yamaha grease D)

@ Apply low temperature resistant grease (Yamaha grease C)

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

@ Apply Gasket MakePØ Apply Yamabond No. 4

@) Appry LOCTTTE@ No.271 (Red LOCTTTE)

@ Apply LOCTITE@ No.242 (Blue LOCTITE)

@ Apply LOCTITE@ No. 572@ Apply silicon sealant

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@

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q@

Ào271

@ Io242

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62Y141 1 1-2

General information

Safety while workingTo prevent an accident or injury and toensure quality service, follow the safety pro-

cedures provided below.

Fire preventionGasoline is highly flammable.Keep gasoline and all flammable productsaway from heat, sparks, and open flames.

VentilationGasoline vapor and exhaust gas are heavierthan air and extremely poisonous. lf inhaledin large quantities they may cause loss ofconsciousness and death within a short time.When test running an engine indoors (e.9., in

a water tank) be sure to do so where ade-quate ventilation can be maintained.

Self-protectionProtect your eyes by wearing safety glassesor safety goggles during all operations involv-ing drilling and grinding, or when using an aircompressor.Protect your hands and feet by wearing pro-

tective gloves and safety shoes when neces-sary.

s62Y1 120

Parts, lubricants, and sealantsUse only genuine Yamaha parts, lubricants,and sealants or those recommended byYamaha, when servicing or repairing theoutboard motor,

AMANI

s62Y1 1 30

Under normal conditions, the lubricants men-tioned in this manual should not harm or behazardous to your skin. However, you shouldfollow these precautions to minimize any riskwhen working with lubricants.

1. Maintain good standards of personal andindustrial hygiene.

2. Change and wash clothing as soon aspossible if soiled with lubricants.

3. Avoid contact with skin. Doexample, place a soiled ragpocket.

Wash hands and any other part of thebody thoroughly with soap and hot waterafter contact with a lubricant or lubricantsoiled clothing has been made.

To protect your skin, apply a protectivecream to your hands before working onthe outboard motor.

not, forin your

4.

5.

1-3 62Y141 1

Safety while working6. Keep a supply of clean, lint-f ree cloths for

wiping up spills, etc.

Good working practicesSpecialtoolsUse the recommended special tools to pro-

tect parts from damage. Use the right tool inthe right manner-do not improvise.

Tightening torquesFollow the tightening torque specifications 5'

provided throughout the manual. When tight-ening nuts, bolts, and screws, tighten thelarge sizes first, and tighten fasteners staftingin the cenler and moving outward.Non-reusable partsAlways use new gaskets, seals, O-rings, cot-ter pins, circlips, etc., when installing orassembling parts.

lnstall bearings with a manufacture iden-tification mark in the direction indicated in

the installation procedure. ln addition, besure to lubricate the bearings liberally.

Apply a thin coat of water-resistantgrease to the lip and out periphery of anoil seal before installation.

Check that moving parts operate nor-mally after assembly.

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sô2Y1 1 50

Disassembly and assembly1. Use compressed air to remove dust and

dirt during disassembly.

2. Apply engine oil to the contact surfacesof moving parts before assembly.

s62Y1 1 00

1-462Y141 1

Applicable models

USA, Canada Worldwide

FSOTH

FsOTR

T5OTR

FSOAEHD

FSOAEHT

F5OAED

F5OAET

FT5OBET

FTSOCEHD

FTSOCED

FTSOCET

ldentificationApplicable modelsThis manual covers the following models.

Serial numberThe outboard motor serialstamped on a label attachedclamp bracket.

lf the serial number label is removed, VOIDmarks will appear on the label.

number isto the port

@ Modelname@ Approved model code@ Transom height

@ Serialnumber

1-5

Model nameApproved

modelcodeStarting

serial No.

USA, Canada

FSOTH62Y

L:451812-

FSOTR L:421732-TsOTR 64J L;40685f

Worldwide

FsOAEHD

62Y

L:350505-F5OAEHT L:451812-F5OAED L:301090-

FSOAET L:421626-FTsOBET

64J

L;40685fFT5OCEHD L: 650101-

FT5OCED L:550101-FTSOCET L:450101-

62Y141 1

ldentification / Features and benefits

Features and benefitsNewly designed four carburetorsNewly designed four carburelors have been based on the current F504. Prime Start has beenadopted for the starting system to further increase stafting performance and serviceability. Further-more, the acceleration pump and the dashpot have been integrated to simplify construction and toease serviceability. The four carburetors can be accurately and easily adjusted due to the simpleconstruction of the links.

@ Prime Start@ Acceleration pump

1-6

J\,t-ti*1\

\ì

62Y141 1

CDI unit with microcomputerThe ignition system consists of a flywheel, stator, pulser coil, thermoswitch, oil pressure switch, CDIunit, and ign¡tion coil. The CDI unit contains a built-in microcomputer that determines the ignitiontiming separately for acceleration and for normal operation, based on signals received from thepulser coil, thermoswitch, and oil pressure switch.

@ CDlunit@ Flywheel@ Stator@ Pulser coil@ Thermoswitch

@ lgnition coil@ Oilpressure switch

1-7

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62Y141 1

Features and benefits

Lower unitHigher class pinion and gearsThe lower unit of the new T50/FT50B, FT50C uses the same type of large gears that are used in theF100. The use of the same type of gears that are used in a higher class model provides ample dura-bility, making it possible to accommodate a wider range of applications throughout the market.

TsO/FTsOB, FTSOC

1-8

Pinion Fonrrrard gear Reverse gear

Gear ratioModel

Numberof teeth

Diameter(mm)

Numberof teeth

Diameter(mm)

Numberof teeth

Diameter(mm)

F50/F50A 13 45 24 74 24 75 1.8

T5O/FT5OB,FTSOC

13 46 30 95 30 95 2.3

62Y141 1

Shift slider type shift mechanismThe T50/FT50B, FT50C has adopted the shift slider type shift mechanism. This shift mechanismenables a prompt engagement of the dog clutch regardless of the operating speed of the shift lever.Thus, smooth and positive shift operation has been made possible.

@ Shift rod

@ Propeller shaft@ Dog clutch@ Shift sliderE Fon¡vard

E Reverse

1-9 62Y141 1

Features and benefits / Technical tips

Technical tipsCarburetorStarting system (Prime Start)To facilitate the starting of a cold engine, an air-fuel mixture that is richer than normal is required.For this reason, the Prime Staft system has been adopted in the F50iF50A, T50/FT50B, FT50C. lnthe Prime Start system, the thermo heater plunger is in a position that fully opens the fuel enrich-ment valve while the engine is being started. Thus, fuel enrichment is achieved during the stailing ofthe engine, and continues while the engine is being warmed up. Once the engine starts, currentflows from the lighting coil of the to the thermo heater, allowing the wax in the Prime Start unit toexpand. The expanded wax moves the thermo heater plunger in the direction to close the enrich-ment valve. As a result, the volume of fuel that passes through the fuel enrichment valve decreases.A few minutes after the engine has started, the thermo heater plunger completely closes the fuelenrichment valve, thus ending the fuel enrichment by the Prime Stafi system.

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@ Carburetor@ lntake silencerE n¡rE Fuel@ Plunger movement

O Prime Stanø lntake manifold of the eng¡ne

@ Thermo heater plunger

@ Fuel enrichment valve@ To carburelor #2 ot #4

62Y141 1

S62Y12¡lO

1-10

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@ Prime StanE the enriched air-fuel mixture is delivered to

cylinders #1 and #2 by the Prime Start systemattached to carburetor #1.

E tfie enriched airjuel mixture is delivered tocylinders #3 and #4 by the Prime Start systemattached to carburetor #3.

1-1 1 62Y141 1

Technical tipsCarburetor operation1. ldle and low-speed operationSince the vacuum at the venturi is low when the throttle valve is opened slightly, the main nozzledoes not supply any air-fuel mixture to the engine.When the engine is operating at idle, the fuel that passes through the pilot jet and the air that passesthrough the pilot air jet mix, enabling the air-fuel mixture that has been regulated by the pilot screwto be fed through the pilot outlet.Because the throttle valve opens slightly when the engine is operating at low speeds, air-fuel mix-ture also stañs to be fed from the bypass holes.

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@ Pilot screw@ Pilot outlet@ Bypass holes@ Venturi@ Main nozzle@ Pilot jet@ Main jet@ Pilot air jet

62Y141 1

@ Main air jet

@ Throttle valveE R¡r

E Air-fuelmixtureE Fuel

'l-12

General information2. Medium speed operationWhen the throttle valve opens further, air-fuel mixture is fed from the pilot outlet and all the bypassholes. ln addition, air-fuel mixture is also supplied from the main nozzle in accordance with theopening angle of the throttle valve.

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@ Pilot screw

@ Pilot outlet

@ Bypass holes

@ Venturi

@ Pilot jet@ Main jet@ Main nozzle@ Pilot air jet

1-13

@ Main air jet

@ Throttle valveE R¡r

E Air-fuelmixtureE Fuel

62Y141 1

Technical tips3. High-speed operationWhen the throttle valve approaches its fully open position, the fuel that has been regulated by themain jet and the air that has been regulated by the main air jet are mixed in the main nozzle. Theresultant mixture is then sprayed by the main nozzle into the venturi. The air-fuel mixture that issprayed through the venturi is then fed into the engine.

$:I@,9J:g

@ Pilot screw@ Pilot outlet@ Bypass holes

@ Main nozzle

@ Pilot jet@ Main jet@ Main air jet

@ Throttle valve

62Y141 1

E RirE Air-fuelmixtureE Fuel

'l-14

General information

Acceleration pumpThe function of the acceleration pump is to ensure a smooth acceleration by preventing the air-fuelmixture from becoming temporarily lean in case the throttle valve is opened suddenly. When thethrottle valve is opened suddenly, a large volume of air is introduced into the engine. However,because fuel is heavier than air, it is not possible to supply the volume of fuel that is necessary forthe large volume of air that has been introduced. Thus, because it is not possible to achieve the air-fuel mixture that is required by the engine, bucking or hesitation results. For this reason, the acceler-ation pump temporarily increases the fuel volume in order to adjust the air-fuel mixture to a ratio thatis necessary for the engine in case the throttle valve is opened suddenly.

@ Bypass hose@ Acceleration pump

@ Pump chamber@ Diaphragm 1

@ Throttle leverE AirflowE Throttle valve opening direction

1-15 62Y141 1

Technical tipsOperationWhen the throttle is opened suddenly, diaphragm 1 (via the link that is connected to the throttlelever) operates to pressurize the air in the pump chamber. The pressurized air opens diaphragm 2,

and becomes distributed to the carburetors by passing through the pipes that are connected to thecarburetors. The pressurized and distributed air then utilizes the passage of the main air jet to flowinto the main nozzle. The pressure of the air helps suck fuel from the main jet, which increases thefuel in the main nozzle, and thus achieves the fuel enrichment.

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s62Y1 300

@ Main air jet

@ Main nozzle@ Main jet@ Throttle valve@ Pilot screw@ Pilot outletØ Pilot jet@ From acceleration pump

@ Throttle valve closing@ Throttle valve opening

62Y141 1

@ Diaphragm 1

@ Diaphragm 2

@ To carburetorsE AirflowE Throttle valve opening direction

1-16

General information

lgnition systemln order to determine the optimal ignition timing that is necessary for the proper operation of theengine, the built-in microcomputer in the CDI unit detects the signals from various types of sensorsand controls the ignition timing in accordance with a control map that is based on those signals. Themicrocomputer also effects controls to protect the engine against overheating, over-revolution, andoil pressure drops, as well as to controlwarning devices.

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@

@ Pulser coil

@ Flywheel

@ Charge coil

@ CDlunit@ Microcomputer

FlywheelThree protrusions for the pulser coil are provided along the periphery of the flywheel. The purposeof these protrusions is for detecting the engine speed. Two of them are used for ignition signals, andone is used for identifying the cylinders, and these signals are transmitted to the microcomputer.

@ lgnition coils #1 and #4

@ lgnition coils #2 and #3

@ Oilpressure switch@ Thermoswitch

1-17 62Y141 1

Technical tipsPulser coilThe pulser coil transmits the pulser signals, which are generated in the pulser coil in accordancewith the rotation of the flywheel, to the CDI unit. Among the two protrusions that are provided forgenerating signals, one is used for cylinders #1 and #4, and the other for cylinders #2 and #3, thusenabling the pulser coil to simultaneously ignite two cylinders.To provide ignition signals to the cylinders, the microcomputer determines the ignition cylinder andignition timing. These are based on the cylinder identification signals generated by the protrusion foridentifying cylinders, and on the pulser signals generated by the protrusions for generating ignitionsignals.

ds62Y1320

@ Flywheel@ Rotating direction@ Protrusion for cylinders #1 and #4@ Pulser coil@ Cylinder identification protrusion

@ Protrusion for cylinders #2 and #3

62Y141 1 1-18

lgnition timing controlControl circuit diagram

Operation

Engine start

Acceleration

General information

Detection Microcomputer

lgnition liming control(optimized ignitiontiming)

Engine speed conlrolOver-revolution

Low oil pressure

Warning buzzer(in remote-controlunit) r> Damage prevention

OverheatWarning lamp(low oil pressure)

Warning lampoverheat)

Basic controlThe ignition timing is determined by using the map based on the engine speed (r/min). Then, igni-tion signals are output from the microcomputer in accordance with the ignition timing map so thatignition can take place at the optimal timing in relation to the engine speed. Then, the microcom-puter corrects the ignition timing in accordance with the operating conditions of the engine asdetected by the signals that are input from the engine temperature sensor and oil pressure sensor.The pulser signals that are output when the protrusions for cylinders #1 and #4, and for cylinders #2and #3 pass by the pulser coil, are used to calculate the engine speed. ln addition, the pulser sig-nals are used to determine the forecast starting position of the ignition timing.

@ Cylinder identification protrusion

@ Pulser coil@ Protrusion for cylinders #1 and #4@ Protrusion for cylinders #2 and #3@ Pulser coil signal

1-19

@ Cylinder identification signal@ ldentification s¡gnal for cylinders #1 and #4@ ldentification s¡gnal for cylinders #2 and #3@ Rotating direction

s62Y1340

62Y141 1

Technical tipsStarting controlWhen starting the engine, the timing is set to 5' BTDC until the crankshaft speed maintains 600r/min for two seconds or longer.

s62Y1 350

@ Starting signal (5' BTDC) for cylinders #1 and#4

@ Starting signal (5' BTDC) for cylinders #2 and#3

@ Rotating direction@ Cylinder identification signal

Warm-up controlAfter the starting control is completed, the control transfers to the ignition timing based on the warm-up map for three minutes. From the time the three-minule warm-up control has been completed, thecontroltransfers to the normal map.

6

s62Y1 360

@ lgnition timing (BTDC')@ Engine speed (x 1,000 r/min)@ Warm-up map@ Acceleration map@ Normalmap

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@ Cylinder identification protrusion

@ Protrusion for cylinders #1 and #4

@ Pulser coil@ Protrusion for cylinders #2 and #3

@ Pulser coil signal

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62Y141 1 'l-20

General informationAcceleration controlThis control is activated when the throttle valve is opened suddenly. lf the engine speed increasesmore than the specified figures, the control of the ignition timing transfers to the acceleration map.Thereafter, the control of the ignition timing transfers gradually to the control map before accelera-tion. lf it was under warm-up control, the timing transfers to the warm-up control map, and if it wasunder normal control, the timing transfers to the normal control map. The control described abovewill be repeated if the engine is accelerated again.Over-revolution controlThis control operates by detecting the engine speed. lf the engine speed increases to over 6,200r/min, the ignition of cylinders #1 and #4 is stopped in order to regulate the speed. lf the enginespeed increases further to over 6,300 r/min, the ignition of cylinders #2 and #3 is also stopped. Thiscontrolwill not be deactivated until the engine speed drops below 6,200 r/min.Overheating controlThis control operates in accordance with the engine temperature, which is detected by the signalthat is input from the thermoswitch. When the microcomputer detects via the thermoswitch signalthat the engine temperature has increased to over 80 'C (176 "F), it outputs a signal to stop the igni-tion of cylinders #1 and #4, if the engine speed is over 2,000 r/min. Al the same time, the microcom-puter issues a warning by operating the warning lamp and the warning buzzer. When theoverheating control is activated, it will not be deactivated until the engine is stopped or the enginetemperature decreases to under 70 "C (158 "F).The determination of overheating stops when the engine is stopped. However, untilthe engine tem-perature decreases to approximately 70 "C (158 "F) or below, the overheating controlwill be acti-vated upon restarting the engine. Upon restarting, if the engine speed is under 2,000 r/min, theoverheating control will not be activated lor 75 seconds. However, if the engine is operated al over2,000 r/min for more than 25 seconds, the overheating controlwill be activated.Oil pressure controlThe oil pressure control operates in accordance with the signals from the oil pressure switch. The oilpressure is determined to have dropped if the engine continues to operate at over 2,000 r/min withan oil pressure of under 49 kPa (0.49 kgf/cm2,6.97 psi) for more than one second. When the oilpressure control is activated, the warning buzzer sounds and the warning lamp illuminates. lf theengine speed is over 2,000 r/min, the control stops the ignition of cylinders #1 and #4 so that theengine speed will not increase to over 2,000 r/min. Once an oil pressure drop is determined, thiscontrol will not be deactivated even if the oil pressure recuperates, until the engine is stopped.

1-21 62Y141 1

Technical tipsPower trim and tiltThe newly designed power trim and tilt consists of an up-main valve, a down-main valve, an up-relief valve, a single cylinder, and a single ram, which control both trim and tilt functions.The power trim and tilt cylinder has been integrated with the gear pump housing, the reservoir tank,and the power trim and tilt motor in order to achieve a smaller and more compact unit.

Hydraulic system diagram

@ Power trim and tilt cylinder@ Ram

@ Reseruoir

@ Manualvalve@ Down-main valve

@ Down-relief valve@ Hydraulic pump

@ Up-relief valve@ Up-main valve

62Y141 1 'l-22

Power trim and tilt components

@ Cylinder

@ Ram

@ Check valve

@ Down-main valve

@ Down-relief valve

@ Motor

@ Gear pump

@ Up-main valve

@ Reservoir

@ Manualvalve

1-23

@ Up-relief valve

@ Up-shuttle piston

@ Down-shutfle piston

@ Trim cylinder base

@ Free piston

@ Tilt piston

62Y141 1

Technical tipsTrim-up functionThe gear pump pumps power trim and tilt fluid to the up-main valve. As a result, the fluid pressureopens the up-shuttle piston causing the fluid to flow into the lower part of the power trim and tilt cyl-inder. At the same time, vacuum from the gear pump opens the down-main valve and down-shuttlepiston, which causes fluid from the upper part of the power trim and tilt cylinder to return to the gearpump, and also sucks fluid in through the reseruoir.The pressurized fluid forces up the trim cylinder along with the tilt piston, free piston, and trim cylin-der base. As the trim cylinder moves up, the ram extends and the outboard motor is trimmed up.

The end of the trim range is when the trim cylinder tops out in the power trim and tilt cylinder.

Trim-up function


@ Trim cylinder@ Down-main valve@ Motor@ Gear pump

@ Up-main valve@ Reseruoir

62Y141 1

@ Up-shuttle piston

@ Down-shuttle piston

@ Free piston

@ Trim cylinder base@ Tilt pistonE ReturnB Seno

'l-24

General informationTrim-down functionWhen the power trim and tilt switch is pressed to "Down", the motor turns the gear pump counter-clockwise and the power trim and tilt fluid flows in the opposite direction to that of the trim-up func'tion.Tilt-up functionWhen the trim cylinder tops out, the check valve is pushed down by the end screw wall. This causesthe ball in the check valve to move down, opening the fluid passage and allowing the power trim andtilt fluid to flow from the upper part of the trim cylinder, through the down-shuttle piston and thedown-main valve, and back to the gear pump. ln addition, fluid is also sucked in through the reser-voir and the pressurized fluid continues to flow into the lower part of the trim cylinder, pushing up thetilt piston and free piston, and further extending the ram.As the tilt piston moves up and off of the trim cylinder base, the base moves up and pushes the ballsoutward to fit into holes of the power trim and tilt cylinder. Once the balls have been fitted into theholes the trim cylinder base cannot move.The end of the tilt-up range is when the tilt piston tops out in the trim cylinder and the ram is fullyextended.The tilt-up function operates when the fluid pressure is under 10 MPa (100 kgf/cm2, 1,423 psi).

When the fluid pressure in the lower part of the trim cylinder increases to over 10 MPa (100 kgf/cm2,1,423 psi), the up-relief valve opens and allows the pressurized fluid to flow into the reservoir. Thus,the tilt piston and free piston are not pushed up and the ram cannot be extend fufther.

1-25 62Y141 1

Technical tipsTilt-up function


@ End screw@ Check valve@ Trim cylinder@ Reservoir@ Down-main valve@ Gear pump

@ Up-main valve

62Y141 1

@ Up-shufile piston


@ Trim cylinder base@ Free piston

@ Tilt piston

@ BallsE ReturnE SendE Moving direction

'l-26

Circular flow

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@ Trim cylinder@ Motor@ Reservoir@ Up-relief valve

1-27

@ Gear pump

@ Free piston

@ Tilt pistonE ReturnE Send

62Y141 1

Technical tipsTilt-down functionWhen the power trim and tilt switch is pressed to "Down", the motor turns the gear pump counter-clockwise, thus pumping the power trim and tilt fluid to the down-main valve. As a result, fluid pres-sure opens the down-main valve and the down-shuttle piston, which causes fluid to flow into theupper part of the trim cylinder and forces the tilt piston down.When the tilt piston and the free piston reach the trim cylinder base, it pushes the base down, allow-ing the balls to move inward. Once the balls move in, the trim cylinder is then able to move downand power trim and tilt fluid continues to flow into the cylinder and pushes the trim cylinder down,along with the tilt piston and ram.The end of the tilt-down range is when the tilt piston and the free piston bottom out in the trim cylin-der base. When the power trim and tilt fluid pushes the trim cylinder down further trim-down isstarted. The end of the trim-down range is when the trim cylinder arrives at the bottom of the powertrim and tilt cylinder. Before the trim cylinder arrives at the bottom of the power trim and tilt cylinder,an amount of fluid equal to the volume of the ram is returned to the reservoir.

62Y141 1 'l-28

Tilt-down function

@ Power trim and tilt cylinder

@ Ram

@ Trim cylinder

@ Down-relief valve

@ Down-main valve

@ Gear pump

@ Reservoir

@ Up-relief valve

@ Up-shuttle piston

@ Up-main valve

1-29


@ Ball

@ Trim cylinder base

@ Free piston

@ Tilt piston

@ BallsE ReturnE SenoE Moving direction

62Y141 1

Technical tipsStopping conditionWhen the power trim and tilt switch is not pushed (released), the gear pump does not pump thefluid, the up-main valve and the down-main valve are closed, and the power trim and tilt fluid pres-sure in the system remains constant. This allows the ram to maintain its position until the power trimand tilt fluid flows through the system again.When the outboard motor hits something in the waterThe check valve of the trim cylinder and the tilt piston absorber of the tilt piston help to prevent inter-nal damage to the power trim and tilt unit and help to protect the bracket and lower unit from dam-age in case the outboard motor hits something during operation.When the outboard motor hits something, highly pressurized fluid in the upper part of the power trimand tilt cylinder pushes down the check valve of the trim cylinder. At the same time, fluid pressure in

the upper part of the trim cylinder increases and the tilt piston absorber is pushed down. As a result,the tilt piston and the ram are pushed up without the free piston. The tilt piston is stopped beforereaching the top of the trim cylinder by the damper function of the tilt piston absorber to protect thepower trim and tilt unit from damage.

62Y141 1 1-30

Damper function

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@ Power trim and tilt cylinder@ Trim cylinder@ Ram

@ Tilt piston absorber@ Tilt piston

@ Free piston

1-31

@ Check valve@ T¡lt piston absorber@ Tilt pistonE SendE Moving direction

s62Y1430

62Y141 1

Technical tips / Propeller selection

103/4x17-G

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ö öó1O314x17 - G

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Propeller select¡onThe performance of a boat and outboardmotor will be critically atfected by the sizeand type of propeller you choose. Propellersgreatly atfect boat speed, acceleration,engine life, fuel economy, and even boatingand steering capabilities. An incorrect choicecould adversely affect performance andcould also seriously damage the motor.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.

103/4x17-G

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@ Propeller diameter (in inches)@ Propeller pitch (in inches)@ Propeller type (propeller mark)

SelectionWhen the engine speed is at the full throttleoperating range (5,000-€,000 r/min) an idealpropeller for the boat is one that providesmaximum performance in relation to boatspeed and fuel consumption.

F50/F504

Propeller size (in) Material

10x15-G Aluminum

101/4x14-G Aluminum

103/8x13-G Aluminum

105/8x12-G Aluminum

103/4 x 16 - G Aluminum

103/4 x 17 - G Aluminum

11 1/8x13-G Aluminum



115/8x11-G Aluminum

121/4x9'G Aluminum

101/4x14-G Stainless




11 1/4x14-G Stainless

11 1/2x13-G Stainless


12x11-G Stainless

TsO/FT5OB, FTSOC

Propeller size (in) Material

12518x21 -K Aluminum

13x19-K Aluminum

13x23-K Aluminum

13x25-K Aluminum

131/4x17 -K Aluminum

131/2x15-K Aluminum

135i8x13-K Aluminum

14x11-K Aluminum

62Y141 1 'l-32

General information

Predelivery checksTo make the delivery process smooth andetficient, the predelivery checks should becompleted as explained below.

Checking the fuel system1. Check that the fuel hoses are securely

connected and that the fuel tank is fullwith fuel.

This is a 4-stroke engine. Never use pre-mixed fuel.

Checking the gear oil1. Check the gear oil level.

Checking the engine oil1, Check the oil level.

NOTE:. lf the engine oil is above the maximum level

mark @, drain sufficient oil until the level is

between @ and @.. lf the engine oil is below the minimum level

mark @, add sufficient oil until the level is

between @ and O.

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

Oilcapacity:Without oil filter replacement:

2.O L (2.1 US qt, 1.8 lmp qt)

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

specified gravity of the battery.

Battery capacity: 70-100 Ah (252-360 kC)Minimum cold cranking performance:

380 AElectrolyte specif ic gravity:

1.28 at 20 "C (68 'F)

2. Check that the positive and negative bat-tery leads are securely connected.

1-33 62Y141 1

Predelivery checks

Checking the outboard motormounting position1. Check the position of the anti'cavitation

plate.

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

sô2Y1 490

Checking the remote control cables1. Set the remote control lever to the neu-

tral position and fully close the throttlelever/throttle grip.

2. Check that the set pin @ is aligned withthe alignment mark @. Ad¡ust if neces-sary.

3. Check that the alignment mark @ isaligned with the mark (D. Adjust if neces-sary.

The shifUthrottle cable joint must bescrewed in a minimum of 8.0 mm (0.31 in)@.

Checking the steering wheel/tillerhandle1. Check the steering friction for proper

adjustment.

2. Check the steering for smooth operation.

s62Y1 540

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

Ghecking the gearshift and throttleoperat¡on1. Check that the gearshift operates

smoothly when shifting from neutral intoforward and reverse.

62Y141 1 'l-34

'ânIF

2. Check that the throttle control lever con-tacts the respective stoppers when thethrottle control lever is closed or fullyopen.

Checking the tilt system1. Check that the outboard motor can be

smoothly tilted up and down by operatingthe power trim and tilt unit,

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

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

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

Checking the engine start switch andengine stop switch/engine shut-offswitch1. Check that the engine starts when the

engine start switch is turned to START.

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

Check that the engine turns off when theengine stop switch is pushed/engineshut-otf cord is pulled.

Checking the pilot water outlet1. Check that cooling water is discharged

from the pilot water outlet.

s62Y1570

Test run1. Start the engine, and then check for

smooth gearshift operation.

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

Operate at trolling speed.

Run the outboard for one hour at 2,000r/min or at half throttle, then for anotherhour at 3,000 r/min or at3/4 throüle.

Check that the motor will not tilt up whenshifting into reverse and that water willnot flow in over the transom.

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

2.

3.

4.

5.

1-35 62Y141 1

Predelivery checksBreak-inln the test run, the break-in operation is per-formed in the following three stages.1. One hour @ at 2,000 r/min or at approxi-

mately half throttle.

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

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

s62Y1580

E 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.

62Y141 1 1-36

- MEMO -

1-37 62Y141 1

Specif ications

General specif ications.

Mai ntenance specif ications ....

2-1

2-12

Tightening torques..... .,...,..,.2-29Specified torques...... ...2-29Generaltorques...... .....2-31

62Y1411

Specifications

General specif ications

USACanada

Item Unit

ModelFSOTR

FsOTH FsOTR

F5OAEHD F5OAEHT FSOAED FsOAET

DimensionOverall length

OverallwidthOverall height

(L)

Boat transom height(L)

mm (in)

mm (in)

mm (in)

mm (in)

1,329 (52.3) 718 (28.3)

361 (14.2)

1,397 (55.0)

508 (20.0)

Weight(with aluminum propeller)

(L) ks (lb) 108 (238) 112 (247) 104 (22e1 108 (238)

PerformanceMaximum output

Full throttle operating rangeMaximum fuel consumption

kW (hp)@ 5,500 r/min

r/min

L (US gal,lmp gal)/hr

@ 6,000 r/min

36,8 (s0)

5,000-€,00017.3 (4.57,3.81)

Power unitTypeCylinder quantity

DisplacementBore x strokeCompression ratio

Carburetor quantity

ControlsystemStarting systemlgnition control systemlgnition timingAlternator outputEnrichment systemChoke valve controlSpark plugs

Cooling systemExhaust systemLubrication system

cm3 (cu. in)

mm (in)

DegreeV,A

ln-line, 4-stroke, OHC, B valves4

935 (57.1)

63.0 x 75.0 (2.48 x 2.95)9.34

Tiller handle Remote controlElectric

Microcomputer (CDl)TDC r 1.5-BTDC a5 + 1.5

12,10Prime Start

DPR6EA-e (NGK)

WaterThrough propeller boss

Wet sump

2-1 62Y141 1

General specifications

USA

CanadaItem Unit

Model

FSOTR

F5OTH FsOTR

FsOAEHD FSOAEHT FSOAED FSOAET

Fueland oilFueltypeFuelrating

Engine oiltypeEngine oilgrade

Engine oil quantity(with oil filter replacement)

(without oil filter replacement)

Gear oiltypeGear oil grade

Gear oil quantity

*PON

RON

APISAE

L

(US qt, lmp qt)

L

(US qt, lmp qt)

APISAE

L

(US qt, lmp qt)

Regular unleaded gasoline

8691

4-stroke molor oil

SE, SF, SG, SH10W-30, 10W-40, or 20W-40

2.2 (2.3,1.9)

2.0 (2.1,1.81

Hypoid gear oil

GL-490

0.43 (0.45, 0.38)

BracketTrim angle(a|12 degree boat transom)Tilt-up angleSteering angle

Degree

DegreeDegree

-+20

69

40+40Drive unit

Gear shift positions

Gear ratio

Reduction gear typeClutch typePropeller shaft typePropeller direction

(rear view)Propeller identification mark

F.N.R1.85 (24113)

SpiralbevelgearDog clutch

SplineClockwise

G

ElectricalBattery capacityMinimum cold crankingpedormance

Ah (kc)A

7G-100 (252-360)380

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

62Y141 1 2-2

Specifications

USA

CanadaItem Unit

ModelTsOTR

TsOTR

FTSOBET =TSOCEHD FTSOCED FTsOCET

DimensionOverall length

OverallwidthOverall height

(L)

Boat transom height(L)

mm (in)

mm (in)

mm (in)

mm (in)

718(28.3)

1,384(54.5)

718 (28.3)

361 (14.2)

1,436 (56.5)

508 (20.0)

Weight(with aluminum propeller)

(L) ks (lb) 112 (247) 111.5 (246) 108 (238) 112 (247)

PerformanceMaximum output

Full throttle operating rangeMaximum fuel consumption

kw (hp)

@ 5,500 r/min

r/min


@ 6,000 r/min

36.8 (50)

5,000--6,00017.3 (4.57,3.81)

Power unitTypeCylinder quantity

DisplacementBore x strokeCompression ratio

Carburetor quantity

Controlsystem

Stafting systemlgnition control systemlgnition timing

Alternator outputEnrichment systemChoke valve controlSpark plugs

Cooling systemExhaust systemLubrication system

cm3 (cu, in)

mm (in)

Degree

V,A

ln-line, 4-stroke, OHC,8 valves4

935 (57,1)

63.0 x 75.0 (2.48 x 2.95)9.34

Remotecontrol

Tillerhandle

Remote control

ElectricMicrocomputer (CDl)

TDC r 1.5-BTDC 35 I

1.5

TDC r 1.5-BTDC ag + 1.5TDC r 1.s-BTDC 35 I 1.5

(Depending on market)12,10

Prime Start

DPR6EA-e (NGK)

WaterThrough propeller boss

Wet sump

2-3 62Y141 1

General specifications

USA

CanadaItem Unit

Model

TsOTR

TsOTR

FTSOBET FTSOCEHD FTSOCED FTSOCET

Fueland oilFueltypeFuelrating

Engine oiltypeEngine oilgrade

Engine oil quantity(with oil filter replacement)

(without oil filter replacement)

Gear oiltypeGear oil grade

Gear oil quantity

*PON

RON

APISAE

L

(US qt, lmp qt)

L

(US qt, lmp qt)

APISAE

L

(US qt, lmp qt)

Regular unleaded gasoline

8691

4-stroke molor oil

SE, SF, SG, SH10W-30, 10W-40, or 20W-40

2.2 (2.3,1.9)

2.0 (2.1,1.81

Hypoid gear oil

GL-490

0.61 (0.64, 0.54)

BracketTrim angle(a|12 degree boat transom)Tilt-up angleSteering angle

Degree

DegreeDegree

-+20

69

40+40Drive unit

Gear shift positions

Gear ratio

Reduction gear typeClutch typePropeller shaft typePropeller direction

(rear view)Propeller identification mark

F.N.R2.33

(28t12)2.31 (30/13)

SpiralbevelgearDog clutch

SplineClockwise

ElectricalBattery capacityMinimum cold crankingperformance

Ah (kc)A

7r100 (252-360)380

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

62Y141 1 2-4

Specifications

USA

CanadaItem Unit

ModelFSOTR

FsOTH FsOTR

FSOAEHD FSOAEHT FsOAED FSOAET

Power unitMinimum compressionpressure"

Lubrication oil pressureat 55 "C (131 'F), with10W-30 engine oil

kPa(kgf/cm2, psi)

kPa(kgf/cm2, psi)

@ 900 r/min

840 (8.4,122)

100 (1.0, 14)

Cylinder headsWarpage limit

(lines indicate straightedgeposition)

Cylinder head journal insidediameter

mm (in)

mm (in)

0.03 (0.001)

37.00-37.02 (1 .4567 -1 .457 5)

CylindersBore sizeTaper limitOut-of-round limit

mm (in)

mm (in)

mm (in)

63.00-63.0 1 (2.480-2.481)0.08 (0.003)

0.08 (0.003)

Pistons == H

Piston diameter (D) ,L9!+Measuring point (H) I '

Piston-to-cylinder clearanceOversize piston diameter

1st

2nd

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

62. 95-62. 9 6 (2.47 8-2.47 9)

5 (0.2)

0.04-0,06 (0,001 6-0,0024)

+ 0.25 (0.001)

+ 0.50 (0.002)

Piston pinsOutside diameter mm (in) 1 5.965-1 5. 970 (0.6285-0.6287)

Piston ringsTop ring

Dimension B

Dimension TEnd gap

Side clearance

mm (in)

mm (in)

mm (in)

mm (in)

1 .17-1.1 I (0.046-0.O47)

2.39-2.41 (0. 094-0. 095)

0. 1 5-0.30 (0.006-0.01 2)

0.04-0.08 (0.002-0.003)

Maintenance specificationsPower unit

* Measuring conditions:Ambient temperature 20 "C (68 'F), wide open throttle, with plugs disconnected from all cylinders.The figures are for reference only.

2-5 62Y141 1

Maintenance specifications

USA

CanadaItem Unit

Model

FSOTR

F5OTH FsOTR


2nd ring

Dimension B [-l]tDimensionT l. r I

End gap

Side clearanceOilring n f--------r-T

Dimension B l'------_r lnpimension T i ---End gap

Side clearance

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

1 .47-1.49 (0.058--0.059)

2.49-2.51 (0. 098{.099)0.3H.50 (0.012-O.020)

0.03-0.07 (0.001 -0.003)

2.3+2.46 (0. 092-0.097)2.75 (0.108)

0.2H,70 (0.008{.028)0.05-o. 1 9 (0.002-0.008)

CamshaftsIntake (A)

Exhaust (A)

lntake andexhaust (B)

Camshaft jou rnal diameter#1

#2, #3, #4Camshaft journal oil clearance

#1

#2, #3, #4Maximum camshaft runout

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

30.89-30.99 (1 .21 61-1 .2200)30.82-30. 9 2 (1 .21 35-1 .21 7 5)

25.95-26.05 (1 .0217-1. 0256)

36.93-36.94 (1 .4539-1 .4543)

36.94-36.9s (1 .4543-1 .4547)

0.055-0. 1 00 (0.0022-0. 0039)

0.04s-0.090 (0.001 8-0. 003s)0.04 (0.0016)

Rocker arm shattsOutside diameter mm (in) 1 5.98-1 5.99 (0.629 1 -0.6295)

Rocker armslnside diameter mm (in) 1 6.00-1 6.01 (0.6299-0.6303)

ValvesValve clearance (cold)

lntakeExhaust

Head diameter (A)

lntakeExhaust

Face width (B) I Ilntake | \r."

Exhaust E<.Seat contact width (C)l

¡lntake i\.^Exhaust

=

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

0.20 È 0.05 (0.008 r 0.002)0.30 + 0.05 (0.012 r 0.002)

29.9-30. 1 (1 . 1 77-1 .1 85)

25.9-26.1 (1 .O2O-1 .027)

1 .84-2.97 (0.07 24.1 17)1 .98-3. 1 1 (0.0784.122)

0.9-1.1 (0.035-0.043)0.9-1.1 (0.035-0.043)

62Y141 1 2-6

Specifications

USA

CanadaItem Unit

ModelF5OTR

FsOTH FsOTR

FSOAEHD FSOAEHT FSOAED FSOAET

Margin thickness (D) |lntake \Exhaust

-ÌoStem diameterlntakeExhaust

Guide inside diameterlntake and exhaust

Stem-to-gu ide clearancelntakeExhaust

Stem runout limit

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

0.6-1.0 (0.024-0.039)0.7-1.1 (0,028-0,043)

5.48-s.49 (O.21 57 -O.21 61 )

5.46-5.47 (0.2 1 50-0.2 1 53)

5.50-5.51 (0.21 65-0.21 69)

0.01 -O.03 (0.000,1-0.001 2)

0.03-0.05 (0.001 2-0.0020)0.03 (0.0012)

Valve springsFree length

Minimum free length

Tilt limit

mm (in)

mm (in)

mm (in)

3e.85 (1.56e)37.85 (1.4e0)

1.7 (0.07)

Connecting rodsSmall-end inside diameterBig-end inside diameterCrank pin oilclearanceBig-end bearing thickness

YellowRed

PinkGreen

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

1 5.985-1 5.998 (0.6293-0.6298)

36.00136. 024 (1 .417 T1.41 83)

0.01 6-0.040 (0.0006-0.001 5)

1 .500-1 .504 (0.0591-0.0592)1 .496-1 .500 (0.0589-0.0591 )1 .492-1.496 (0.0587--0.0589)

1 .488-1 .492 (0.0s864.0587)Crankshaft

Crankshaft journal

DiameterCrank pin

DiameterRunout limit

mm (in)

mm (in)

mm (in)

42.984-43.000 (1 .6923-1 .6929)

32.984-33.000 (1 .2986-1 .2992)0.04 (0.0016)

CrankcaseCrankcase main journal insidediameterCrankshaft main journal oilclearanceCrankcase main journalbearing thickness

YellowRed

PinkGreen

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

46.00G-46. O24 (1.81 1 11 .81 20)

0.01 2-0.036 (0.0005-0.001 4)

1 .502-1 .506 (0.0591-0.0593)1 .498-1 .502 (0.0590-0.0591 )1 .494-1.498 (0.0588--0.0590)

1 .4911 .494 (0.05874.0588)

2-7 62Y141 1


USA

CanadaItem Unit

Model

FSOTR

F5OTH FsOTR


Oil pumpTypeOuter rotor-to-housingclearanceOuter rotor-to-inner rotorclearance limitRotor-to-cover clearance

mm (in)

mm (in)

mm (in)

Trochoid0.09{,15 (0.001{.006)

0.01 -0. 1 0 (0.0004-0.0039)

0.03-0.08 (0.001 -0.003)Thermostats

Opening temperatureFully open temperature

Valve open lower limit

"c ('F)"c ("F)

mm (in)

60 (140)

70 (158)

3.0 (0.12)

Fuel pumpDischarge

Pressure

Plunger stroke


@ 6,000 r/min

kPa(kgf/cmz, psi)

mm (in)

70 (18.5, 15.4)

49 (0.49,7.0)

5,85-9.0s (0.23{.35)Carburetor

lD mark (USA and Canada)lD mark (worldwide)

Main jet

Pilot jetFloat heightEnqine idle speed

##

mm (in)

r/min

62Y4062Y30

#1: 124, #2: 126, #3: 1 1 6, #4: 11439

10.0 + 0.5 (0.39 r 0.02)900 r 50

62Y141 1 2-8

SpecificationsLower unit

USA

CanadaItem Unit

ModelF5OTR

FsOTH FsOTR


Gear backlashPinion-to-fonruard gear

Pinion-to-reverse gear

Pinion shimsFonruard gear shimsReverse gear shims

mm (in)

mm (in)

mm

mm

mm

0. 1 8-0.54 (0.007-0.021 )

o.7 1 -1. 07 (0. 028-0.O42)0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.500.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.500.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50

Electrical

USA

CanadaItem Unit

ModelFsOTR

FSOTH FSOTR

F5OAEHD F5OAEHT F5OAED FsOAET

lgnition systemlgnition timing

(engine idle speed)Charge coil output peakvoltage (L - B0

@ cranking 1(.t)

@ cranking 2(.t)

@ 1,500 r/min

@ 3,500 r/min

Charge coil resistancef2)(L - Br)

Pulser coil output peak voltage(wR-wB)

@ cranking 1(.t)

@ cranking 2(.t)

@ 1,500 r/min

@ 3,500 r/min

Pulser coil resistance(.2)(wR-wB)

CDI unit output peak voltage(B/O - B, BM/ - B)

@ cranking 1(.t)

@ cranking 2(.t)

@ 1,500 r/min

@ 3,500 r/min

Spark plug gap

Degree

VVVVC)

V

VVVo

VVVV

mm (in)

TDC 1.5

144137

169

129272408

6.33.57.411.2

396-594

1261s0

151

116

0.e (0.035)(.t) Cranking 1: unloaded

Cranking 2: loaded(.2) The figures are for reference only.

2-9 62Y141 1


USA

CanadaItem Unit

Model

FSOTR

F5OTH FsOTR


lgnition control systemOil pressure switch

Thermoswitch (Gy/B - B)

OFF -+ ON

ON + OFF

kPa(kgf/cmz, psi)

"c ('F)

"c ('F)

50 (0.5, 7.11)

7644 (16$-183)63-77 (145-170)

Starter motorTypeOutputCranking time limitBrushes

Standard length

Wear limitCommutator

Standard diameterWear limit

MicaStandard undercutWear limit

KW

Second

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

Bendix1.1

30

16.0 (0.63)

12.0 (0.47)

33.0 (1.30)

31.0 (1.22)

0.8 (0.03)

0.2 (0.01)

Charging systemFuseLighting coil output peakvoltage (G - G)

@ cranking(.t)

@ 1,500 ¡/¡i¡(.t)@ 3,500 ¡/¡i¡(.t)

Lightin g coil resistancef2)(G-G)

Rectif ier Regulator outputpeak voltage (R - B)

@ 1,500 ¡/¡i¡ft)@ 3,500 ¡/¡i¡(.t)

Charging current

A

VVVo

VV

A @ 5,000 r/min

20

11.9

42127

1.2-1.8

18.9

19.5

10

Enrichment control systemPrime Start

Plu nger projection extendedminimum lenqth @

mm (in) 24.6 (O.e7)

(.t) Unloaded('2) The figures are for reference only.

62Y141 1 2-10

Specifications

Item Unit

ModelF5OTR

FsOTH FsOTR


Power trim and tilt systemTrim sensor

Setting resistanceResistance (P - B)

Fluid typeBrushes

Standard lengthWear limit

CommutatorStandard diameterWear limit

MicaStandard undercut

c)

o

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

11!710-278.3

ATF Dexron II

10 (0.3e)

3.5 (0.14)

22.0 (O.87)

21.0 (0.83)

1.5 (0.06)

2-11 62Y141 1

Maintenance specificationsPower unit

USA

CanadaItem Unit

Model

T5OTR

TsOTR


Power unitMinimum compressionpressure*

Lubrication oil pressureat 55 "C (131 'F), with10W-30 engine oil

kPa(kgf/cm2, psi)

kPa(kgf/cm'z, psi)

@ 900 r/min

840 (8.4,122)

100 (1 .0,14)

Cylinder headsWarpage limit

(lines indicate straightedgeposition)

Cylinder head journal insidediameter

mm (in)

mm (in)

0.03 (0.001)

37.0137.0 2 (1 .4567-1 .457 5)

CylindersBore sizeTaper limitOut-of-round limit

mm (in)

mm (in)

mm (in)

63.00-63. 0 1 (2.4812. 481)0.08 (0.003)

0.08 (0.003)

Pistons == H

Piston diameter (D) ,tgI+Measuring point (H) I '

Piston-to-cylinder clearanceOversize piston diameter

1st

2nd

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

62. 95-62. 9 6 (2.47 e-2.47 9)

5 (0.2)

0.0¿1-0.06 (0.00 1 6-0.0024)

+ 0.25 (0.001)

+ 0.50 (0.002)

Piston pinsOutside diameter mm (in) 1 5.965-1 s.970 (0.6285{ .6287)

Piston ringsTop ring

Dimension B

Dimension TEnd gap

Side clearance

mm (in)

mm (in)

mm (in)

mm (in)

1.17-1.1 9 (0.046--0.047)

2.39-2.41 (0. 094{.095)0. 1 5-.0.30 (0.006-.0.01 2)

0.04-0.08 (0.002-0.003)* Measuring conditions:

Ambient temperature 20'C (68 'F), wide open throttle, with plugs disconnecled from all cylinders.The figures are for reference only.

62Y141 1 2-12

Specifications

USA

CanadaItem Unit

ModelTsOTR

TsOTR


2nd ring

Dimension B [__\-]BDimension TEnd gap

Side clearanceOil ring

Dimension B

Dimension TEnd gap

Side clearance

n |----------]-Tl'------r lsll r-r Il, r -l

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

1 .47-1.49 (0.058-0.059)2.49-2.s1 (0. 098-0. 099)

0.30-0.s0 (0.01 2-0.020)0.03-0.07 (0.001 -0.003)

2.3+2.46 (0.092-0.097)2.75 (0.108)

0.210,70 (0.008-0.028)0.05-0. 1 I (0.002-0.008)

Camshaft journal diameter#1

#2, #3, #4Camshaft journal oil clearance

#1

#2, #3, #4Maximum camshaft runout

Camshaftslntake (A)

Exhaust (A)

lntake andexhaust (B)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

30.89-30.99 (1 .21 61-1 .22OO)

30.82-30. 92 (1 .21 35-1 .217 5)

25.95-26.05 (1 .0217 -1.0256)

36.93-36.94 (1 .4539-1 .4s43)36.94-36.95 (1 .4543-1 .4547)

0.055--0. 1 00 (0.0022--0.0039)

0.04s{.090 (0.00 1 8-0.003s)0.04 (0.0016)

Rocker arm shaftsOutside diameter mm (in) 1 5.98-1 5.99 (0.6291 -0.6295)

Rocker armslnside diameter mm (in) 1 6.00-1 6.01 (0.6299-0.6303)

ValvesValve clearance (cold)

lntakeExhaust

Head diameter (A)

lntakeExhaust

Face width (B) I Ilntake | \r.,

Exhaust ÐtSeat contact width (C)l

I

lntake \;.Exhaust Ê'r

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

0.20 r 0.05 (0.008 È 0.002)0.30 + 0.05 (0.012 r 0.002)

29.9-30.1 (1.1 77-1 .1 85)

25.9-26.1 (1 .020-1 .O27)

1 .8+2.97 (0.07 2-0j 17)1 .98-3. 1 1 (0.07 e-0j 22)

0.9-1.1 (0.035-0.043)0.9-1.1 (0.035-0.043)

2-13 62Y141 1


USA

CanadaItem Unit

Model

TsOTR

TsOTR


Margin thickness (D) I Ilntake i\

Exhaust #joStem diameter

lntakeExhaust

Guide inside diameterlntake and exhaust

Stem-to-guide clearancelntakeExhaust

Stem runout limit

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

0.6-1.0 (0.024-0.039)0.7-1.1 (0.028-0,043)

5.48-5.49 (0.21 57 -O.21 61)5.46-5.47 (0.21 50-0.2 1 53)

5.50-5.51 (0.21 65--0.21 69)

0.01 -0.03 (0.0004-0.001 2)

0.03-0.05 (0.001 2-0.0020)0.03 (0.0012)

Valve springsFree lengthMinimum free lengthTilt limit

mm (in)

mm (in)

mm (in)

3e.85 (1.56e)

37.85 (1.4e0)

1.7 (0.07)

Connecting rodsSmall-end inside diameterBig-end inside diameterCrank pin oil clearanceBig-end bearing thickness

YellowRed

PinkGreen

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

1 5.985-1 5.998 (0.6293--0.6298)

36.00136.024 (1 .4173-1.41 83)

0.01 6-0.040 (0.0006-0.001 5)

1 .500-1 .504 (0.0591-0.0592)1 .496-1 .500 (0.0589-0.0591 )

1 .492-1. 496 (0.0587-0. 0589)1 .488-1 .492 (0,0586-0.0587)

CrankshaftCrankshaft journal

DiameterCrankshaft pin

DiameterRunout limit

mm (in)

mm (in)

mm (in)

42.98q-43.000 (1 .6923-1 .6929)

32.984-33.000 ( 1 .2986-1 .2992)0.04 (0.0016)

CrankcaseCrankcase main journal insidediameterCrankshaft main journal oilclearanceCrankcase main journalbearing thickness

YellowRed

PinkGreen

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

46.00G-46.O24 (1.81 10-1 .8120)

0.01 2-0.036 (0.0005-0.001 4)

1 .502-1 .506 (0.0591-0.0593)1 .498-1 .502 (0.059G-0.0591 )

1 .494-1.498 (0.0588-0.0590)1 .4911 .494 (0.0587-0.0588)

62Y141 1 2-14

Specifications

USA

CanadaItem Unit

ModelTsOTR

TsOTR


Oil pumpTypeOuter rotor-to-housingclearanceOuter rotor-to-inner rotorclearance limitRotor-to-cover clearance

mm (in)

mm (in)

mm (in)

Trochoid0.09-0,1 5 (0.001 -0.006)

0.01 -o. 1 0 (0.0004.-0.0039)

0.03-0.08 (0.001 -0.003)Thermostats

Opening temperatureFully open temperature

Valve open lower limit

"c ('F)'c ("F)

mm (in)

60 (140)

70 (1 58)

3.0 (0.12)

Fuel pumpDischarge

Pressure

Plunger stroke


@ 6,000 r/min

kPa(kgf/cmz, psi)

mm (in)

70 (18.5, 15.4)

49 (0.49,7.O1

5.85-9.0s (0.23-0.35)Carburetor

lD mark (USA and Canada)lD mark (worldwide)

Main jet

Pilot jetFloat heightEngine idle speed

##

mm (in)

r/min

62Y4062Y30 62Y30, 62Y50 (for Brazil)

#1: 124, #2: 126, #3: 1 1 6, #4: 11439

10.0 + 0.s (0.39 r 0.02)900 + 50

2-15 62Y141 1

Maintenance specificationsLower unit

ItemUSA

CanadaUnit

Model

T5OTR

TsOTR


Gear backlashPinion-to-fonruard gear

Pinion-to-reverse gear

Pinion shimsForward qear shims

mm (in)

mm (in)

mm

mm

0.1 24.45 (0.005-.0.01 8)

o.71-1.1 1 (0.028-0.044)0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.500.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50

Electrical

USA

CanadaItem Unit

Model

TsOTR

TsOTR

FT5OBET FT5OCEHD FT5OCED FT5OCET

lgnition systemlgnition timing

(engine idle speed)Charge coiloutput peakvoltage (L - Br)

@ cranking 1(.t)

@ cranking 2(.t)

@ 1,500 r/min

@ 3,500 r/min

Charge coil resistance(.2)(L-Br)

Pulser coil output peak voltage(wR - wB)

@ cranking 1(.t)

@ cranking 2(.t)

@ 1,500 r/min

@ 3,500 r/min

Pulser coil resistance(.2)(wR-wB)

CDI unit output peak voltage(B/O - B, BA/V - B)

@ cranking 1(.t)

@ cranking 2(.t)

@ 1,500 r/min

@ 3,500 r/min

Spark plug gap

Degree

VVVVo

VVVVc)

VVVV

mm (in)

TDC r 1.5

144137

169

129272-408

6.33.57.411.2

396-594

126150

151

116

0.e (0.035)

t't) Cranking 1: unloadedCranking 2: loaded

('2) The figures are for reference only.

62Y141 1 2-16

Specifications

USA

CanadaItem Unit

ModelTsOTR

TsOTR


lgnition control systemOil pressure switch

Thermoswitch (Gy/B - B)

OFF -+ ON

ON + OFF

kPa(kgf/cmz, psi)

'c ('F)'c ('F)

50 (0.5, 7.11)

76-84 (1 6e-1 83)

6Ê-77 (145-170)Starter motor

TypeOutputCranking time limitBrushes

Standard lengthWear limit

CommutatorStandard diameterWear limit

MicaStandard undercutWear limit

KW

Second

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

Bendix1.1

30

16.0 (0.63)

12.0 (O.47)

33.0 (1.30)

31.0 (1.22)

0.8 (0.03)

0.2 (0.01)

Charging systemFuseLighting coil output peakvoltage (G - G)

@ cranking(.t)

@ 1,500 ¡/¡i¡(.t)@ 3,500 ¡/¡i¡('t)

Lighting coil resistancec2)(G-G)

Rectifier Regulator outputpeak voltage (R - B)

@ 1,500 ¡/¡i¡ft)@ 3,500 ¡/¡i¡(.t)

Charging current

A

VVVo

VV

A @ 5,000 r/min

20

1 1.9

42127

1.2-1.8

18.9

19.5

10

Enrichment control systemPrime Start

Pl unger projection extendedminimum lenqth @

mm (in) 24.6 (O.e7)

(.t) Unloaded12) The figures are for reference only.

2-17 62Y141 1


Item Unit

Model

TsOTR

TsOTR


Power trim and tilt systemTrim sensor

Setting resistanceResistance (P - B)

Fluid typeBrushes

Standard length

Wear limitCommutator

Standard diameterWear limit

MicaStandard undercut

(.)

o

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

11l.71È278.3

ATF Dexron II

10 (0.39)

3.5 (0.14)

22.0 (0.87)

21.0 (0.83)

1.5 (0.06)

62Y141 1 2-18

SpecificationsDimensionsExterior

L6L1

////¡/7

tt ./ /\ \/ /\./

s62Y2200

62Y141 12-19


Symbol Unit

Model

FsOTH

FSOAEHD FSOAEHT

L1

L2

L3

L4

L5 (L)

(x)(L)

(x)L7

L8

L9

110H1

(L)

(x)

(L)

(x)H2

H3

H4 (L)

(x)

(L)

(x)

H5

H6

H7

H8

H9

H10H11 (L)

(x)W1

w2W3W4W5W6A1

A2A3T1

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

DegreeDegreeDegreemm (in)

576 (22.7)

223 (8.8)

753 (2e.6)

532 (20.e)

e7 (3.8)

e30 (36.6) 932 (36.7)

3e7 (1s.6)

247 (e.7)407 (16.0)

245 (e.6)

0.6 (0.02)

63 (2.5)

876 (34.5)

51e (20.4)

175 (6.9)

536 (21.1)

732 (28.8)

685 (27.0) 711 (28.0)

330 (13.0)

3e (1.5)

738 (2e.0)

327 (12.e)

45 (1.8)

733 (28.e)

44 (1.7)

24 (1.0)

181 (7.1)

124 (4.e)

345 (13.6)

643 (25.3)40

63 65

:

62Y141 1 2-20

SpecificationsExterior

T1

H10 86 -x

/

2-21


Symbol Unit

Model

FsOTR T5OTR

FsOTR T5OTR

FSOAED FSOAET FTSOBET

L1

L2

L3

L4

L5 (L)

(x)(L)

(x)L7

L8

L9 (L)

(x)

(L)

(x)

110H1

H2

H3

H4

H5

H6

(L)

(x)

(L)

(x)H7

H8

H9

H10H11 (L)

(x)W1

w2W3W4W5W6A1

A2A3T1

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)


576 (22.7)

142 (5.6)

532 (20.9) 560 (22.0)

e7 (3.8)

930 (36.6) e32 (36.7) eeo (3e.0)

397 (15,6)

14e (5.e)407 (16,0)

148 (5.8)

0.6 (0.02) 0.8 (0.03)

63 (2.5)

876 (34.5) e17 (36.1)

51e (20.4)

175 (6.e) 1e1 (7.5)

536 (21.1)

685 (27.0) 711 (28.O) 74e (2e.5)

330 (13.0)

0.5 (0.02)

738 (29,1)

327 (12.9)

3.5 (0.1)

733 (28,9)

44 (1.7)

24 (o.e) 28 (1.1)

181 (7.1)

s+sãs.ol

4063 65

4

560 (22.0)

62Y141 1 2-22


,,,,,,

1,,',,

L1

L6

,- -,11- -l¡-t -/ \ \/---\

.,-/ I

Hg'i', .ó

s62Y2230

62Y141 12-23


Symbol Unit

Model

FTSOCEHD

L1

L2

L3

L4

L5 (L)

(x)(L)

(x)L7

L8

L9 (L)

(x)

(L)

(x)

110H1

H2

H3

H4 (L)

(x)

(L)

(x)

H5

H6

H7

H8

H9

H10H11 (L)

(x)W1

w2W3W4W5W6A1

A2A3T1

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)


576 (22.7)

272 (10.7)

797 (31.4)

560 (22.0)

e7 (3.8)

990 (39.0)

3e7 (1s.6)

18e (7.4)

0.8 (0.03)

63 (2.5)

e17 (36.1)

51e (20.4)

191 (7.5)

536 (21.1)

680 (26.8)

723 (28.5)

330 (13.0)

110 (4.3)

738 (2e.1)

44 (1.7)

28 (1 .1)

181 (7.1)

213 (8.4)

181 (7.1)

345 (13.6)738 (2e.1)

4063

i

62Y141 1 2-24


T1

H10 86 -x

/

2-25


Symbol Unit

Model

FTSOCED FTsOCET

L1

L2

L3

L4

L5 (L)

(x)(L)

(x)L7

L8

L9 (L)

(x)

(L)

(x)

110H1

H2

H3

H4 (L)

(x)

(L)

(x)

H5

H6

H7

H8

H9

H10H11 (L)

(x)W1

w2W3W4W5W6A1

A2A3T1

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)


576 (22.7)

142 (5.6)

560 (22.0)

e7 (3.8)

990 (39.0)

3e7 (1s.6)

14e (5.e)

0.8 (0.03)

63 (2.5)

e17 (36.1)

51e (20.4)

191 (7.5)

536 (21.1)

723 (28.5)

sgoãs.ol0.5 (0.02)

738 (2e.1)

44 (1.7)

28 (1 .1)

181 (7.1)

181 (7.1)

345 (13.6)

40634

560 (22.0)

62Y141 1 2-26

SpecificationsClamp bracket

D

Symbol Unit

ModelF5OTR

FsOTH FsOTR

FSOAEHD FSOAEHT FsOAED FSOAET

B1

82B3

84B5

B6

87B8

B9

c2c3D1

D2

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

126 (5.0)

254 (10.0)

163.5 (6.4)

50.8 (2.0)

180 (7.1)

355 (14.0)

13e (5.5)

18.5 (0.7)

6e (2.7)

13 (0.5)

55.5 (2.2)

2-27 62Y141 1

Maintenance specificationsClamp bracket

D

USA

CanadaSymbol Unit

Model

TsOTR

TsOTRFT5OBET FTSOCEHD FT5OCED FT5OCET

B1

82B3

84B5

B6

87B8

B9

c2c3D1

D2

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

126 (5,0)

254 (10.0)

163.5 (6.4)

50.8 (2.0)

180 (7.1)

355 (14.0)

13e (5.5)

18.5 (0.7)

6e (2.7)

13 (0.5)

55.5 (2.2)

62Y141 1 2-28

Specifications

Tightening torquesSpecified torques

Part to be tightened Thread sizeTightening torques

N.m kgf.m ft.rb

Power unitFlywheel magnet nut 160 16 116

Stator base screw M6 4 o.4 2.9Cover screw M6 3 0.3 2.2Negative battery lead bolt M8 I 0.9 6.5Positive battery lead nut 7 o.7 5.1

Oil pressure switch 9 0,9 6,5Oil pressure switch lead screw 2 o.2 1.4

lgnition coil bolt M6 7 o.7 5.1

Starter motor bolt M8 30 3.0 22Starter motor terminal nut 7 o.7 5.1

Power unit bolt M8 21 2.1 15

Tensioner bolt B 0.8 5.8Tensioner adjusting bolt M8 25 2.5 18

Drive sprocket nut 140 14 101

Driven 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 34Adjusting screw locknut 14 1.4 10

Oilfilter 18 1.8 13

Drain bolt 18 1.8 13

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,s 11

2nd 30 3.0 22

Connecting rod cap bolt1st 6 0.6 4.32nd 17 1.7 12

Lower unit (F50/F504)Check screw 7 o.7 5.1

Lower unit bolt M10 40 4.O 29Drain screw 7 o.7 5.1

Propeller nut 35 3.5 25Water inlet cover screw 5 0.5 3.6Pinion nut M17 75 7.5 54

2-29 62Y141 1

Tightening torques

Paft to be tightened Thread sizeTightening torques

N.m kgf.m fr.lbLower unit (T50/FT50B, FT50C)Check screw 7 0.7 5.1

Lower unit bolt M10 40 4.0 29

Drain screw 7 o.7 5.1

Propeller nut 35 3,5 25

Ring nut 105 10.5 76

Water inlet cover screw 5 0.5 3.6Pinion nut M22 95 9.5 69

Bracket unitTiller handle assembly nut (F50/F504) 37 3.7 27

Engine shut-off switch nut (F50/F504) 4 0.4 2.9Tiller handle bracket nut (F50/F50A) 38 3.8 27Main switch nut (F50/F504) 5 0.5 3.7Friction wing nut (FT50C) 13 1.3 9.4Tiller handle assembly nut (FT50C) 37 3.7 27Throüle cable (short) locknut (FT50C) 37 3.7 27Upper mount nut 24 2.4 17

Lower mount nut 42 4.2 30

Trim sensor screw M6 2 0.2 1.4

Clamp bracket self-locking nut 23 2.3 17

Power trim and tiltTilt cylinder end screw 90 9.0 65PTT motor bolt M5 4 o.4 2.9Reseruoir cap 6.5 0.65 4.7Trim cylinder end screw 80 8.0 58

Tilt piston bolt M12 61 6.1 44Relief valve bracket bolt M5 5.3 0.s3 3.8Gear pump assembly bolt M6 6.5 0.65 4.7Gear pump bracket bolt M5 5.3 0.s3 3.8Electrical unitPulser coil screw 4 0.4 2.9Starter motor nut 9 0.9 6.5

62Y141 1 2-30

Specifications

GeneraltorquesThis 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.

T--]-

Nut (A) Bolt (B)Generaltorquespecifications

N.m kgf.m ft.lb8mm10 mm

12 mm

14 mm

17 mm

M5

M6

M8

M10

Mt12

5

8

18

36

43

0.50.81.8

3.64.3

3.65.813

2531

2-31 62Y141 1

Periodic checks and adjustments

Special service tools

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

Top cowling 1-4ir¡¡ir¡¡rr¡i t

Checking the top cowling...... ............3-4

Fuel system j-4Checking the fueljoint and fuel hoses (fueljoint-to-carburetor)................3-4Checking the fuelfilter........... ...........3-5

Power unit............ .............,..3-5Checking the engine oi|.............. ......3-5Replacing the engine oi|.............. .....3-5Checking the timing belt............ .......3-7Replacing the timing be|t............ ......3-7Checking the valve clearance... ......3-10Checking the spark p1u9s......... ......3-11Checking the thermostat.............. ...3-12Checking the cooling water passa9e.............. ...3-13

Control system ...................3-13Checking the throttle cable operation............ ....3-13Checking the gearshift operation ,.,.3-14Checking the engine idle speed .....3-15Checking the ignition timin9......... ...3-15

Power trim and tilt unit .......3-16Checking the power trim and tilt operation ........3-16Checking the power trim and tilt fluid level .......... .................3-16

Lower unitChecking the gear oil level .............3-17Replacing the gear oi1............... ......3-17Checking the lower unit (for air leakage) ...........3-19Checking the prope11er................. ...3-19

GeneralChecking the anodes ...3-19Checking the battery. ...3-20Lubrication ...................3-21

3-1

62Y141 1



Pressudge/vacuum testerY8-35956-A

Oilfilter wrenchYU-38411

Flywheel magnet holdervB-06139

Oil filter wrench90890-01426

Flywheel holder90890-06522

@Æ)øtd-æ"

Flywheel puller90890-06521

WqUniversal pullerYB-06117

Inductive self-powered tachometerYU-08036-B

Battery powered timing lightYM-33277-A

3-1

Digital tachometer90890-06760

62Y141 1


Timing light90890-03141

Leakage tester90890-06762

62Y141 1 3-2

Item Remarkslnitial Every Referto

page10 hours(Break-in)

50 hours(3 months)

100 hours(6 months)

200 hours('l year)

Top cowlingTop cowling fit Check o o 3-4Fuel systemFueljoint and fuel hoses

FuelfilterFueltank

CheckCheck/replaceCleaning

o ooo

o

3-4

ïPower unitEngine oil

OilfilterTiming beltValve clearanceSpark plugs

ThermostatWater leakageMotor exteriorExhaust leakageCooling water passage

ChangeChangeCheckCheck/adjustClean/adjusVreplaceCheckCheckCheckCheckClean

o

oo

o

o

o

oooo

o

ooo

oooo

o

o

3-5

3-5

3-7

3-103-11

3-12

;Control systemThrottle cableShift cableEngine idle speedlgnition timing

Check/adjustCheck/adjustAdjustCheck

oo

o

oo

o

3-133-143-153-15

Power trim and tilt unitPower trim and tilt Check o o o 3-16Lower unitGear oil

Lower unit leakagePropeller

ChangeCheckCheck

o

o

o

oo

3-173-193-19

GeneralAnodesBatteryWiring and connectorsNuts and boltsLubrication points

Check/replaceCheckChecl</reconnect

TightenLubricate

o o 3-193-20

""

O every 1 month

oo o

oo


Maintenance ¡nterval chartUse the following chaft as a guideline for general maintenance.Adjust the maintenance intervals according to the operating conditions of the outboard.

NOTE:. lf operating in salt water, turbid or muddy water, flush the engine with fresh water after each use.. lf 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 interualchart.

3-3 62Y141 1

Maintenance interval chart / Top cowling / Fuel system

Top cowlingChecking the top cowling1. Check the fitting by pushing the cowling

with both hands. Adjust if necessary.

s62Y3010

Loosen the nuts and bolts @.

Move the hook @ up or down slightly toadjust its position.

NOTE:. To loosen the fitting, move the hook toward

the seal.. To tighten the fitting, move the hook away

from the seal.

Tighten the nuts and bolts.

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

Fuel systemChecking the fuel joint and fuelhoses (fuel joint-to-carburetor)1. Remove the plate @, and then check the

fuel hose connections and fueljoint @ forleaks. Replace if necessary. Also, checkthe fuelfilter @, fuel pump @, and carbu-retor @ for leaks, and the fuel hoses forleaks and deterioration. Replace if nec-essary.

4.

5.

62Y141 1 3-4


E

Checking the fuel filter1, Check the fuel filter element O for dirt

and residue and check the fuel filter cup

@ for foreign substances and cracks.Clean with straight gasoline and replacethe cup if necessary.

E FsO/FsOAE TsO/FTsOB, FT5OC

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

Power unitChecking the engine oil1. Place the outboard in an upright position.

2. Remove the engine oil dipstick, wipe itclean, and then insert it back into the oilfiller hole.

3. Remove the dipstick again to check theoil level and the oil for discoloration, andits viscosity,

NOTE:. Replace the oil if it appears milky or black.. lf the engine oil is above the maximum level

mark @, drain sutficient oil until the level is

between @ and @.. lf the engine oil is below the minimum level

mark @, add sutficient oil until the level is

between @ and @.

Replacing the engine oil1. Remove the engine oil dipstick and oil

filler cap @.

E

.--@O@

Æ

@

Bå

@-Æ O

,ffi

3-5 62Y141 1

Fuel system / Power unit2. Place a drain pan under the drain hole,

and then remove the drain bolt @ and letthe oil drain completely.

3. Place a rag under the oil filter, and thenremove the filter.

Oilfilter wrench: YU-38411 / 90890-01426

NOTE:Be sure to clean up any oil spills.

Apply a thin coat of the new engine oil tothe O-ring of the new oilfilter.

lnstall the oil filter, and then tighten it tothe specified torque,

s62Y31 1 5

Oilfilter wrench: YU-38411 / 90890-01426

Oil filter: 18 N.m (1.8 kgf.m, 13 ft.lb)

6. lnstall the drain bolt, and then tighten it tothe specified torque.

Drain bolt: 18 N.m (1.8 kgf.m, 13 ft.lb)

7. Fill the specified engine oil into the oilfiller hole.

Recommended engine oil:4-stroke motor oilAPI: SE, SF, SG, or SHSAE: 10W-30, 10W-40, or 20W-40

5.

s62Y3080

62Y141 1 3-6


Oilquantity:With oil filter replacement:

2.2 L (2.3 US qt, 1 .9 lmp qt)Without oil filter replacement:

2.0 L (2.1 US qt, 1.8 lmp qt)

8. lnstall the oil filler cap and dipstick, andthen start the engine and warm it up for 5minutes.

9. Turn the engine ofi, and then check theoil level and correct it if necessary.

Checking the timing belt1, Remove the flywheel magnet cover,

2. While turning the flywheel magnet clock-wise, check the interior @ and the exte-rior (D of the timing belt for cracks,damage, or wear. Replace if necessary.

s62Y3130

Do not turn the flywheel magnet counter-clockwise, otherwise the valve systemmay be damaged.

Replacing the timing belt1. Turn the flywheel magnet clockwise and

align the "1" mark @ on the drivensprocket with the "¡\" mark @ on the cyl-inder head.

Do not turn the flywheel magnet counter-clockwise, otherwise the valve systemmay be damaged.

2. Remove the flywheel magnet.

E

\

s62Y31 50

3-7 62Y141 1

Power unit

E

E for USA and CanadaE forworldwide

. Apply force in the direction of thearrows shown, to prevent the flywheelholder from slipping off easily.

. To prevent damage to the engine ortools, screw in the flywheel puller setbolts evenly and completely so that theflywheel puller plate is parallel to the fly-wheel magnet.

NOTE:Apply force to the crankshaft end until the fly-wheel magnet comes off the tapered portionof the crankshaft.

Flywheel magnet holder Q: YB-06139Flywheel holder @: 90890-06522Universal puller @: YB-06117Flywheel puller @: 90890-06521

3. Disconnect the stator couplers @, andthen remove the stator @.

Disconnect the pulser coil coupler @,and then remove the stator base @ withboth collars @.

Remove the breather hose bolts @ andtensioner @, then the timing belt @ fromthe driven sprocket side.

E

4.

5.

o^\vY-þ4_

,// //72

62Y141 1 3-8

Periodic checks and adjustments6. Check that the "'1" mark @ on the driven

sprocket is aligned with the "1" mark @on the cylinder head, and that the "f"mark @ on the drive sprocket is alignedwith the "¡" mark (D on the crankcase.Align if necessary.

Do not turn the sprockets counterclock-wise, otherwise the valve system may bedamaged.

7. While pushing against the tensioner sideof the belt, install the new timing belt fromthe drive sprocket side with its part num-ber in the upright position.

ffl #5/

o Do not twist, turn inside out, or bend thetiming belt beyond the maximum limit of25 mm (1.0 in) @, otherwise it may bedamaged.

. Do not get oil or grease on the timingbelt.

B. lnstall the tensioner and bolts, and thentighten the bolts finger tight.

9. Turn the driven sprocket clockwise twoturns, and then check that the alignmentmarks are aligned.

Do not turn the sprockets counterclock-wisen otherwise the valve system may bedamaged.

10. Tighten the tensioner bolts to the speci-fied torque.

Tensioner bolt:I N.m (0.8 kgf.m, 5.8 ft.lb)

Tensioner bolt (adjusting bolt):25 N.m (2.5 kgf.m, 18 ft.lb)

11. lnstall the breather hose bolts, statorbase with both collars and stator, andthen connect the couplers.

Stator base screw:4 N.m (0.4 kgf.m, 2.9 ft.lb)

12. lnstall the Woodruff key.

3-9

s62Y31 90

62Y141 1

Power unit13. lnstall the flywheel magnet and flywheel

magnet cover.

E For USA and CanadaB Forworldwide

Apply force in the direction of the arrowsshown, to prevent the flywheel holderfrom slipping off easily.

NOTE:Apply engine oil to the flywheel magnet nutbefore installation.

Flywheel magnet holder: YB-06139Flywheel holder: 90890-06522

Flywheelmagnet nut:160 N.m (16 kgf .m, 1 16 ft.lb)

Checking the valve clearance1. Remove the flywheel magnet cover, and

then disconnect the high-tension cordsand blowby hose @.

2. Remove the spark plugs, fuel pump @,and cylinder head cover @.

Turn the flywheel clockwise and align the"1" mark @ on the driven sprocket withthe "¡" mark @ on the cylinder head.

Do not turn the flywheel counterclock-wisen otherwise the valve system may bedamaged.

4. Check the intake valve clearance for cyl-inders #1 and #2, and the exhaust valveclearance for cylinders #1 and #3, Adjustif necessary.

E

¡r

1[#

62Y141 1 3-10


6,

5. Turn the flywheel clockwise and align the"4" mark @ on the driven sprocket withthe "¡" mark (D on the cylinder head.

Do not turn the flywheel counterclock-wisen otherwise the valve system may bedamaged.

Check the intake valve clearance for cyl-inders #3 and #4, and the exhaust valveclearance for cylinders #2 and #4. Adjustif out of specification.

NOTE:Adjust the valve clearance when the engineis cold.

Valve clearance:lntake (D:

0.20 + 0.05 mm (0.008 t 0.002 in)Exhaust @:

0,30 t 0.05 mm (0.012 t 0.002 in)

7. Loosen the locknut @, and then turn theadjusting screw @ until the specifiedvalve clearance is obtained.

NOTE:. To decrease the valve clearance, turn the

adjusting screw clockwise.. To increase the valve clearance, turn the

adjusting screw counterclockwise.

Tighten the locknut, and then check thevalve clearances. Adjust if necessary.

Install the cylinder head cover, fuelpump, and spark plugs.

10. Connect the blowby hose and high-ten-sion cords, and then install the flywheelmagnet cover.

Checking the spark plugs1, Disconnect the high-tension cords, and

then remove the spark plugs.

8.

L

3-11 62Y141 1

Power unit2. Clean the electrodes @ with a spark plug

cleaner or wire brush. Replace the sparkplug if necessary.

s62Y3260

Check the electrodes for erosion andexcessive carbon or other deposits, andthe gasket for damage. Replace thespark plug if necessary.

Check the spark plug gap @. Adjust if outof specification.

s62Y3270

Specified spark plug: DPR6EA-9 (NGK)

Spark plug gap @: 0.9 mm (0.035 in)

5. lnstall the spark plug, tighten it fingertight (0, then to the specified torque witha spark plug wrench O.

Spark plug: 18 N.m (1 .8 kgf 'm, 13 Ít.lb)

Ghecking the thermostat1. Remove the cover @, thermostat cover

@, and thermostat @.

Suspend the thermostat in a container ofwater.

Place a thermometer in the water andslowly heat the water.

62Y141 1 3-12

Periodic checks and adjustments4. Check the thermostat valve opening at

the specified water temperatures.Replace if out of specification.

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

Ghecking the cooling water passage1. Check the cooling water inlet cover @

and cooling water inlet for clogs. Clean ifnecessary.

2. Place the lower unit in water, and thenstart the engine.

3. Check for water flow at the cooling wateroutlet. lf there is no water flow, check thecooling water passage inside the out-board.

Control systemChecking the throttle cable operation1. Check that the throttle cam @ is at the

fully closed position @ when the remotecontrol lever is in neutral or the throttlegrip is fully closed. Adjust the throttlecable length if necessary as follows.

2. Loosen the locknut @, remove the clip

@, and then disconnect the throttle cablejoint @.

Water temperature Valve lift (Ð

below60 "c (140'F) 0 mm (0 in)

above70'C (1 58 'F)

more than3 mm (0.12 in)

3-13 62Y141 1

Power unit / Control system

4.

Align the alignment mark @ on the throt-tle cam @ with the alignment mark @ onthe shift bracket.

Adjust the position of the throttle cablejoint until its hole is aligned with the setpin @ on the throttle cam.

The throttle cable joint must be screwedin a minimum of 8.0 mm (0.31 ¡n) @.

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

Check the throttle cable for smooth oper-ation and adjust the cable length, if nec-essary, repeating steps 2-6.

Checking the gearshift operation1. Check that the gearshift operates

smoothly when shifting from neutral intofonruard and reverse. Adjust the shiftcable length if necessary.

2. Set the gearshift to the neutral position.

3. Loosen the locknut @, remove the clip

@, and then disconnect the shift cablejoint @.

62Y141 1

s62Y3340

Align the set pin @ ¡n tlre center of theshift bracket with the alignment mark (D

on the bracket.

Adjust the position of the shift cable jointuntil its hole is aligned with the set pin.

The shifl cable joint must be screwed in aminimum of 8.0 mm (0.31 ¡n) @.

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

Check the gearshift for smooth operationand adjust the shift cable length, if nec-essary, repeating steps 3-6.

4.

7.

s62Y3350

3-14

Periodic checks and adjustmentsChecking the engine idle speed1, Start the engine and warm it up for 5 min-

utes.

2. Attach the special seruice tool to high-tension cord #1 @, and then check theengine idle speed. Adjust if out of specifi-cation.

lnductive self-powered tachometer:YU-08036-B

Digital tachometer: 90890-06760

Engine idle speed: 900 t 50 r/min

3. Turn the throttle stop screw @ in direc-tion @ or @ until the specified engineidle speed is obtained.

NOTE:. To increase the idle speed, turn the throttle

stop screw in direction @.. To decrease the idle speed, turn the throttle

stop screw in direction (D.

4. After adjusting the idle speed, rev theengine a few times and let it idle for atleast 15 seconds to check the stability ofthe engine.

3-15

Checking the ignition timing1, Start the engine and warm it up for 5 min'

utes.

2. Attach the special service tool to high-tension cord #1 @, and then check theengine idle speed.



Engine idle speed: 900 + 50 r/min

3. Attach the special service tool to high-tension cord #1 O.

Battery powered timing light: YM-33277-ATiming light: 90890-031 41

(ùo@

62Y141 1

Control system / Power trim and tilt unit4. Check that the TDC "T' mark @ on the

flywheel magnet is aligned with the mag-net base pointer @.

lgnition timing: TDC + 1.5'

Power trim and tilt unitChecking the power trim and tiltoperation1. Fully tilt the outboard up and down a few

times and check the entire trim and tiltrange for smooth operation. Check thepower trim and tilt fluid level if necessary.

tt,'

-'- t,

NOTE:Be sure to listen to the winding sound of thePTT motor for smooth operation.

2. Fully tilt the outboard up, and then sup-port it with the tilt stop lever @ to checkthe lock mechanism of the lever.

62Y141 1

Checking the power trim and tilt fluidIevel1. Fully tilt the outboard up, and then sup-

port it with the tilt stop lever @.

After tilting up the outboard, be sure tosupport it with the tilt stop lever.Otherwise, the outboard could suddenlylower if the power trim and tilt unit shouldlose fluid pressure.

2. Remove the tilt pin Ø.

3-16

Periodic checks and adjustments3. Remove the reseruoir cap @, and then

check the fluid level in the reseruoir.

NOTE:The fluid level should be at the brim of thefiller hole.

4. lf necessary, add sutficient fluid of therecommended type to the correct level.

Recommended power trim and tilt fluid:ATF Dexron II

5. lnstall the reseruoir cap, and then tightenit to the specified torque.

Reseruoir cap: B N.m (0.8 kgf.m, 5.8 ft.lb)

6. lnstall the tilt pin to its original position.

Lower unitChecking the gear oil level1. Fully tilt the outboard down.

2. Remove the check screw @, and thencheck the gear oil level in the lower case.

NOTE:The gear oil level should be at the brim of thecheck hole.

3. lf necessary, add sufficient gear oil of therecommended type to the correct level.

Recommended gear oil:GEAR CASE LUBE (USA) or Hypoidgear oilSAE:90

4. lnstall the check screw, and then tightenit to the specified torque.

Check screw: 7 N.m (0.7 kgf.m, 5.1 ft.lb)

Replacing the gear oil1. Fully tilt the outboard up, and then sup'


Remove the tilt pin Ø, and then install it

in the upper tilt pin hole @.

Release the tilt stop lever and tilt the out-board down until it contacts the tilt pin.

2.

3.

3-17 62Y141 1

Power trim and tilt unit / Lower unit4. Place a drain pan under the drain screw

@, remove the drain screw, then thecheck screw @ to drain the oil.

Check the oilfor metal, discoloration, andviscosity. Check the internal parts of thelower case if necessary.

lnsert the gear oil tube or gear oil pumpinto the drain hole and slowly fillthe gearoil until oil flows out of the check hole andno air bubbles are visible.

Recommended gear oil:GEAR CASE LUBE (USA)or Hypoidgear oilSAE:90

Oilquantity:F50/F50A:

0.43 L (0.45 US qt, 0.38 lmp qt)

TSO/FT5OB, FTSOC:

0.61 L (0.64 US qt, 0.54 lmp qt)

7. lnstall the check screw, quickly install thedrain screw, and then tighten them to thespecified torque.

Check and drain screw:7 N.m (0.7 kgf.m,5.1 ft.lb)

s62Y35s0

62Y141 1 3-18

Periodic checks and adjustmentsChecking the lower unit(for air Ieakage)1. Remove the check screw @, and then

install the special service tool.

E For USA and CanadaE For worldwide

Pressu relvacuum tester: YB-35956-ALeakage tester: 90890-06762

2. Apply the specified pressure to checkwhether the lower unit can hold it for atleast 10 seconds.

Do not over pressurize the lower unit, oth-erwise the oil seals may be damaged.

NOTE:Cover the check hole with a rag when remov-ing the pressure/vacuum tester from thelower unit.

Lower unit holding pressure:100 kPa (1,0 kgf/cm2, 14 psi)

3. lf pressure drops below specification,check the drive shaft and propeller shaftoilseals for damage.

3-19

Checking the propeller1, Check the propeller blades and splines

for cracks, damage, or wear. Replace ifnecessary.

GeneralChecking the anodes1. Check the anodes and trim tab for

scales, grease, or oil. Clean if necessary.

tr

62Y141 1

Lower unit / General

E

E

E FT50C onlyE EHD, ED modelsE EHT, ET modelsE Fso/F5oA only

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

2. Replace the anodes and trim tab ifexcessively eroded.

Checking the battery1. Check the battery electrolyte level. lf the

level is at or below the minimum levelmark @, add distilled water untilthe levelis between the maximum and minimumlevel marks.

2. Check the specific gravity of the electro-lyte. Fully charge the battery if out ofspecification.

Battery electrolyte is dangerous; it con-tains sulfuric acid which is poisonous andhighly caustic.Always follow these preventive measures:. Avoid bodily contact with electrolyte as

it can cause severe burns or permanenteye injury.

. Wear protective eye gear when handlingor working near batteries.

Antidote (EXTERNAL):. SKIN - Wash with water.. EYES - Flush with water for 15 minutes

and get immediate medical attention.Antidote (INTERNAL):. Drink large quantities of water or milk

followed with milk of magnesia, beatenegg, or vegetable oil. Get immediatemedical attention.

Batteries generate explosive, hydrogengas. Always follow these preventive mea-sures:. Charge batteries in a well-ventilated

area.. Keêp batteries away from fire, sparks or

open flames (e.9., welding equipment,lighted cigarettes).

o DO NOT SMOKE when charging or han-dling batteries.

KEEP BATTERIES AND ELECTROLYTEOUT OF REACH OF CHILDREN.

@@@7

62Y141 1 3-20


. Batteries vary per manufacturer. The pro-

cedures mentioned in this manual may notalways apply, therefore, consult the instruc-tion manual of the battery.

. Disconnect the negative lead first, then thepositive lead.

Electrolyte specif ic g ravity:1.280 at 20 "C (68 "F)

Lubrication1. Apply water resistant grease to the areas

shown.

E FsO/FsOA, TsO/FTsOBE rrsoc

3-21 62Y1411

General

Apply grease to the grease nipple until itflows from the bushings @.

2. Apply anti-corrosion grease to the areasshown.

62Y141 1 3-22


- MEMO -

3-23 62Y141 1

Fuel system


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

Fuel line

Fuel filter and fuel pump .....4-7Checking the fuel pump......... ...........4-9Disassembling the fuel pump .,,..,,..,.4-9Checking the diaphragm and valves .................4-10Assembling the fuel pump......... .....4-10

Carburetor unit 4-11

CarburetorDisassembling the carburetor.. .......4-19Checking the carburetor ,,..,,..,..,, ..,.4-19Checking the Prime Start........... .....4-2OAssembling the carburetor.............. ...................4-2OAdjusting the throttle link rod ..........4-21Synchronizing the carburetors ........4-23Adjusting the dash-pot (acceleration pump) ......4-24

4-1

62Y141 1

Fuel system


Pressu re/vacuum testerY8-35956-A

lnductive self-powered tachometervu-08036.8

Carburetor synchronizerYU-08030

Digital tachometer90890-06760

Vacuum gauge90890-03159

d@Vacuum/pressure pump gauge set90890-06756

4-1 62Y141 1

Special service tools / Hose routing

Hose routingFuel and blowby hoses

@ Blowby hose

@ Hose (acceleration pump-to-carburetor)

@ Fuel hose (fuel joint-to-fuel filter)

@ Fuel hose (fuelfilter-to-fuel pump)

@ Fuel hose (fuel pump-to-carburetor)

@ Hose (carburetor-to-carburetor)

62Y141 1 4-2

Fuel systemCooling water hose

E lt¡odels with flushing device

4-3 62Y141 1

Hose routing

- MEMO -

62Y141 1 4-4

Fuel line

f-.-^ : --l

4-5 62Y141 1

Fuel line

No. PaÌt name Q'ty RemarksTightening torques

Stage N.m kgtm Ít.lb

1

2

3

4

5

6

7

II10

11

12

13

14

15

16

Fueljoint

FuelfilterFuelfilter

Fuel pump

Bolt

Seal

Fuel hose

Clip

Bolt

Nut

Bracket

Fuel hose

Fuel hose

Clip

Bolt

O-ring

1

1

1

1

1

1

1

3

1

1

1

1

2

3

2

1

F50/F504

T5O/FTsOB, FTSOC

M6x25mm

Fuel joint-to-f uel filter

M8x14mm

Fuel filter-to-fuel pump

Fuel pump-to-carbu retor

M6x30mmNFæIË

62Y141 1 4-6

Fuel filter and fuel pump

4lI

I ivzv ItzRlig--'ill6,-ullto--, 1

_i iP_, i

L_ul-___l

178

(

1

B

4-7 62Y141 1

Fuel filter and fuel pump



1

2

3

4

5

6

7

II10

11

12

13

14

15

16

17

1B

19

20

Fuel filter cup

O-ring

Fuel filter element

Body

Float

Screw

Cover

Fuel pump body 2

Fuel pump body 1

Nut

Plunger

Spring

Spring

Pin

Diaphragm

Screw

Valve

Nut

Seal

Gasket

1

1

1

1

1

4

1

1

1

4

1

1

1

1

1

2

2

2

1

1

M5x35mm

M3x6mm

E FsoiFsoAE rso¡rrsoB, FTSoc

62Y141 1 4-8

Fuel systemChecking the fuel pump1, lnstall the special service tool onto the

fuel pump as shown.

Pressu relvacuum tester: YB-35956-AVacuum/pressure pump gauge set:

90890-06756

Apply the specified pressure to each fuelpump port.

lf air flow is reversed, check the dia-phragm for tears and the valves forcracks. Replace if necessary.

Do not over pressurize the fuel pumpo oth-erwise excessive pressure may cause airleakage.

NOTE:. Make sure that air does not escape from

the opposite side of the fuel pump.. To eliminate any gaps between the fuel

pump valves and the fuel pump body 2, andto ensure a better seal, make sure that theinside of the fuel pump is moist with gaso-line.

Fuel pump pressure @:50 kPa (0,5 kgf/cm2, 7.1 psi)

Fuel pump negative pressure @:30 kPa (0.3 kgf/cm2,4.3 psi)

Disassembling the fuel pump1, Disassemble the fuel pump as shown.

2.

3.

4-9 62Y141 1

Fuel filter and fuel pump2. Push down on the plunger and the dia-

phragm, turn the fuel pump body 1 @approximately 90" to a position where thepin ø can be removed easily, and thenremove the pin.

à*

s62Y41 10

2. Push down on the plunger and the dia-phragm, and then install the pin @.

s62Y41 40

Turn the fuel pump body 1 @ approxi-mately 90o, and then push down on theplunger several times to make sure thatthe pin does not come out.

1>*

s62Y41 50

Assemble the cover @, gasket @, andseal @ with the screws @, and theninstall the fuel pump.

3. Slowly let up on the plunger and dia-phragm, and then remove them.

Checking the diaphragm and valves1. Check the diaphragm O for tears and the

valves @ for cracks. Replace if neces-sary.

s62V

Assembling the fuel pump1. Align the plunger and diaphragm installa-

tion holes @, and then installthe plungerinto the diaphragm.

.t.

4.

d-þtNd\.J b

62Y141 1 4-10

Garburetor unit

)!N):'

N\l.'

þ5

'g\

\7

'N\/

[],

[el

4-11 62Y141 1

Carburetor unit



1

2

3

4

5

6

7

II10

11

12

13

14

Carburetor assembly

Clip

Blowby hose

Prime Start coupler

Bolt

Collar

Throttle link rod

O-ring

lnsulator

Dowelpin

Bolt

Fuel hose

Clip

Rivet

1

1

1

1

2

2

1

I1

2

I2

2

2

Joint-to-silencer

M6x30mm

M6x25mmFuel pump-to-carbu retor

62Y141 1 4-12

J""

ruJ."

S

62Y141 14-13

Carburetor unit



1

2

3

4

5

6

Acceleration pump

Screw

Link rod

Hose

Hose

Link rod

1

3

1

1

4

1

M5x9mm

Acceleration pump-to-acceleration pump

Acceleration pump-to-carburetor

62Y141 1 4-14

Fuel system

14

12

oooo

ao

s62Y41 90

62Y141 14-15

Carburetor unit



1

2

3

4

5

6

7

II10

11

12

13

14

Carburetor

Silencer

Plastic tie

Blowby hose

Bolt

Collar

O-ring

Plate

O-ring

O-ring

Joint

Plastic tie

Fuel hose

Fuel hose

4

1

1

1

IB

4

1

4

4

1

7

4

2

[@!rSilencer-to-joint

M6x90mm

Carbu retor-to-carbu retor

Carburetor-to{uel pump

62Y141 1 4-16

Garburetor

2t -pT/-\(.s \,V

iE-

1

î

4-17

---l

62Y141 1

Carburetor



1

2

3

4

5

6

7

II10

11

12

13

14

15

16

17

1B

19

20

21

22

23

24

25

26

Carburetor body

Screw

Cover

Seal

Pilot jet

Main jet

Needle valve

Main nozzle

O-ring

Plug

Float

Screw

Float pin

Gasket

Float chamber

Drain screw

O-ring

Screw

Fuel hose

Prime Start

Screw

O-ring

Bracket

Body

Screw

Gasket

1

4

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

4

1

1

1

1

1

1

2

1

M4x13mm

M4x6mm

M4x13mmFloat chamber-to-body

M4x7mm

Caburetor#1: M4 x 17 mmCaóuretor#S: M4 x 22mm

E Carburetors #1 , #2, and #3E Carburetor #4E Carburetors #1 and #3

62Y141 1 4-18

Disassembling the carburetor

NOTE:Before disassembling the carburetor, makesure to note the number of times the pilotscrew is turned out from the seated positionto its set position.

Checking the carburetor1. Check the air and fuel passages and jets,

for dirt and foreign matter. Clean the car-buretor body with a petroleum based sol-vent if necessary.

2. Blow compressed air into all passagesand jets.

. Direct the compressed air downwardnotherwise cleaning solvent may beblown into your eyes or small pafis ofthe carburetor may be blown off,

. Do not use steel wire for cleaning theiets, otherwise the jet diameters may beenlargedo which may seriously affectperformance.

3. Check the main jet O, pilot jet @, andmain nozzle @ for dirt or residue. Clean ifnecessary.

4.

w-,p.:j;:ä{Wó --gô

Check the needle valve forwear, Replace if necessary,

s62Y4230

bends or

s62Y4220

4-19 62Y141 1

Carburetor

-tt \- /. r\ ^,/ I \/¿' ¿J-^ -/-<z'

Ut

5. Check the float for deterioration. Replaceit necessary.

s62Y4250

Measure the float height @. Replace thefloat and needle valve, if out of specifica-tion, as a set.

NOTE:. The float should be resting on the needle

valve @, but not compressing it.. Take measurements at the top of the float

flange opposite its pivoted side.

Float height @:10.0 t 0.5 mm (0.39 t 0.02 in)

Checking the Prime Start1. Measure the length of the Prime Starl

plunger.

2. Connect the positive Prime Start blue (L)

lead and the negative Prime Start black(B) lead to a battery as shown.

3. Measure the plunger length @ afterapplying power for 5 minutes. Replace if

out of specification.

Prime Start plunger minimum length @:24,6 mm (0.97 in)

Assembling the carburetor

NOTE:Before assembling the carburetor, make sureto turn the pilot screw the same number oftimes, as noted before disassembly, from theseated position to the set position.

1. lnstall the main nozzle O, plug @, pilotjet @, and main jet @ to the carburetorbody as shown.

g--oÕ

þ

@-ìc,'e

62Y141 1 4-20

2. lnstall the needle valve @, float @, floatpin @, and screw @ as shown, and thenthe check the float for smooth operation.

NOTE:. Place the needle valve in the valve seat

when installing the float to the carburetorbody.

. Fit the float pin into the slit on the carbure-tor body and lock it with the screw.

Adjusting the throttle Iink rod1. Push the throttle control lever @ to the

fully open position as shown, and thenmeasure the gap between the carburetorthrottle lever @ and carburetor stopper

@.

2. lf out of specification, adjust the throttlelink rod length.

Gap @: Less than 0.5 mm (0.02 in)

3. Remove the throttle link rod @, adjust itto the specified length (D, and then installit.

Throttle link rod length @:144 mm (5.67 in)

4-21 62Y141 1

Carburetor4. Push the throttle control lever @ to the

fully open position as shown.

While pushing the carburetor throttlelever @ against the carburetor stopper

@, loosen, and then tighten the adjustingscrew @.

62Y141 1 4-22

Synchronizing the carburetors1, Start the engine and warm it up for 5 min-

utes to check the stability of the engine.

2. Attach the special seruice tool to thehigh'tension cord #1 @.



3. Remove all of the plugs @ and attach thespecial service tool and adapters to thecarburetor assembly as shown.

Carbu retor synchron izer: YU-08030Vacuum gauge: 90890-031 59

NOTE:For best results, use a vacuum gauge @(commercially obtainable) with four adapterslike the one shown in the illustration.

Adjust the idle speed to 1,000 r/min byturning the throttle stop screw @ on car-buretor #4 in direction @ or (0.

NOTE:. To increase idle speed, turn the throttle

stop screw in direction @.. To decrease idle speed, turn the throttle

stop screw in direction (0.

4.

(ùo@

4-23 62Y141 1

Carburetor

7.

Measure the vacuum pressure of carbu-relor #4.

Turn the throttle valve adjusting screws

@ to adjust the vacuum pressure of car-buretors #1, #2, and #3 to the same vac-uum variation as carburelor #4.

Adjust the engine idle speed to specifica-tion.

Engine idle speed: 900 t 50 r/min

8. After adjusting the idle speed, rev theengine a few times and let it idle for atleast 15 seconds to check that the vac-uum pressures stay within 50 mm Hg(67 m bar, 1,97 in Hg) and to check thestability of the engine.

Adjusting the dash-pot(acceleration pump)1. Stañ the engine and warm it up for 5 min-

utes, and then check the engine speed atthe operation point of the dash-pot.

2. Attach the special service tool to high-tension cord #1 @.

lnductive self-powered tachometer:YU.08036-B


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

Engine speed: 2,700 rlmin

4. lf out of specification, adjust the enginespeed at the operation point of dash-pot.

s62Y4420

s62Y4440

62Y141 1 4-24

Fuel systemOpen the throttle cam @ slowly, andcheck that the acceleration pump stopper

@ comes in contact with point @.

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

7. Open and close the throttle cam a fewtimes, and check the engine speed at theoperation point of dash-pot again. Adjustif necessary.

s62Y4450

4-25 62Y141 1

- MEMO -

62Y141 1 4-26

Power unit

Troubleshooting

Special service tools 5-10

5-13PowerChecking the compression pressureChecking the oil pressure ...............5-25Removing the power unit............ ....5-26

Timing belt and sprockets. ..................5-29Removing the timing belt and sprockets.,, .,,,.,,.,5-31Checking the timing belt and sprockets ................... 5-32lnstalling the timing belt and sprockets... ...........5-32

Cylinder head 5-35Removing the cylinder head.......... ....................5-39Checking the valve springs....... ......5-40Checking the valves ....5-40Checking the valve guides........ ......5-41Replacing the valve guides. .........5-41Checking the valve seat........... ......5-42Refacing the valve seat........... .......5-43Checking the rocker arms and rocker arm shatt... ................5-45

.5-1

Checking the camshaft .......Checking the cylinder head .........5-46

.........5-47,..,,..,.5.48

Checking the oil pump......... ...........5-47lnstalling the valves ....lnstalling the camshaft........lnstalling the rocker arm assemb|y............... .....5-49lnstalling the cylinder head .......... ...5-49

62Y141 1

Cylinder bodyRemoving and installing the oilfilter........... .......5-55Disassembling the cylinder body.......... .............5-55Checking the piston diameter.... .....5-56Checking the cylinder bore........... ..5-56Checking the piston clearance .......5-57Checking the piston rin9s.......... .....5-57Checking the piston ring grooves................ ......5-58Checking the piston ring side clearance... .........5-58Checking the piston pin boss bore .......... ..........5-58Checking the piston pin ............. .....5-58Checking the connecting rod small end inside diameter ......5-59Checking the connecting rod big end side c|earance..............................5-59Checking the connecting rod bolt............ ..........5-59Checking the crankshaft.............. ...5-59Checking the crankshaft main journal oil c|earance...,...,..,,..,,,.,,,,,.,,,.,,..5-60Checkingthecrankshaftpinoilclearance................ ............5-61Selecting the crankshaft main journal bearing...... ................5-62Selecting the connecting rod big end bearing ...5-63Assembling the cylinder body.......... ..................5-64lnstalling the power unit..,,..,,..,. .,,.,.5-67

62Y141 1

TroubleshootingBefore troubleshooting the power unit, check that all electrical connections are tight and free fromcorrosion, and that the battery is fully charged to 12 V.

Symptom: Engine does not crank.. Check the starting system.. Check the power unit.

5-1

Check that the gearshift is in theneutral position.

Set it to the neutral position.

Check the neutral switch forcontinuity.

Replace the neutral switch,

Check the engine staft switchfor continuity.

Replace the engine staft switch.

Check the engine shut-offswitch for continuity.

Replace the engine shut-offswitch.

Check the fuse for continuity.

Replace the fuse.

Continued oh next page.

62Y141 1

Troubleshooting

Check the wiring harnesses forcontinuity.

Replace the wiring harnesses.

Check operation of the startermotor pinion.

Does the pin-ion rotate?

Listen for the operation soundof the starter relay.

Remove allspark plugs, andthen the engine.

Check the starter motor.

Check the power unit.

Check that the combustioncamber is filled with engine oilor gasoline.

62Y141 1 5-2

Symptom: Engine cracks, but will not start.. Check the ignition system.. Check the fuel system,. Check the compression pressure of power unit.

. Do not touch any ofthe connections ofthe spark gap testerleads.

. Do not let sparksleak out of theremoved spark plugcaps.

o Kêêp flammablegas or liquids away,since this test canproduce sparks.

Check the ignition spark using the spark gap tester.

Gheck the ignition system out-put peak voltage.

Check the condition of the sparkplugs.

Check the fuel system.

Start the engine using dried ornew spark plugs.

Gheck the compression pres-sure of the combustion chamber.

Check the condition of the sparkplugs again.

Failure in stañing operation

Failure in stañing operation

Check the fuel system.

Check the cylinder head,cylinger body, and pistonassembly.

5-3 62Y141 1

TroubleshootingSymptom: Engine can be staÊed, but does not remain on.. Check the fuel system.. Check the ignition system.. Check the compression pressure of power unit.

Check that the fuelvent screw of the fueltank is open.

ls the ventscrew open?

Open the fuelvent screw.

Check for water or residue inthe fuelfilter.

Check the fuel hose for kinks orfuel leakage.

Clean the fuel system from thefuel tank lo the fuel filter.

Replace the respective parts.

Replace the pri-mary fuel pump.

62Y141 1 5-4

Check that there is no secondary air intake on the contact surfaces ofthe intake manifold and crankcase.

Replace the respective seals.

Check the compression pres-sure of the combustion chamber.

Check the ignition spark gap using the spark gap tester.

Check the ignition system out-put peak voltage.

Replace the spark plug.

5-5 62Y141 1

Troubleshooting

Check the operation of the car-buretor throttle valves.

Check the ignition timing.

Check the second-ary air intake on theO-ring and manifoldplate, and the gas-kets of the vacuumcheck bolts.Check the operation of the car-

buretor throttle valves byremoving the throttle cables andlink rods.

Replace the CDI unit.

Check the throttle cable opera-tion and lubricate it if necessary.

Check and disassemble the car-buretors, and then clean them ifnecessary.

Symptom: The engine idle speed is not steady, but increases or decreases.. Check the carburetors.. Check the air intake system.. Check the ignition system.

62Y141 1 5-6

Symptom: Engine does not accelerate when the throttle is opened quickly.The engine turns off when the throttle is opened quickly.Acceleration is tardy and the engine is likely to stop at any moment.. Check the carburetors.. Check the ignition system.. Check the compression pressure of power unit.

Check the throttle cable opera-tion.

Do the carbu-retor throttlevalves closesimulta-neously?

Adjust the throttle cable.

Check the needle valve of thecarburetor for debris or wear.

Check each jet of the carburetorfor clogs or debris.

Check the ignitionsystem and thecompression pres-sure of the engine.

Clean the carburetor, or replacerespective parts.

Clean or replace the respectiveparts.

5-7 62Y141 1

TroubleshootingSymptom: Engine can run, but engine speed will not increase.Overheat warning indicator is on.Oil pressure warning indicator is on.Warning indicator is on and buzzer is sounding.. Check the water cooling system.. Check the lubricating system.

Check the water inlet for clogsor debris.

Check that cooling water is dis-charged from the pilot wateroutlet.

Clean the water inlet.

Check the thermostat operation.

Replace the thermostat.

Check the thermoswitch.

Replace the thermoswitch.


62Y141 1 5-8

Check the engine oil level.

Add engine oilto the correctlevel.

Check the oil pressure.

Check the oil pump for debris orwear.

Check the oil pressure switch. Clean or replace the respectiveparts.

Replace the oil pressure switch.


5-9 62Y141 1



ffCompression gaugeYU-33223-1

Flywheel magnet holderYB-06139

/Valve guide removerYM-01122zValve guide reamerYM-01196

Valve seat cutter setYM-91043-C

Drive shaft needle bearing depth stopY8-34473

Oil filter wrenchYU-38411

KroqUniversal pullerYB-06117

Crankshaft holderY8-06562

Valve spring compressorYM-01253

62Y141 1 5-10

Piston ring compressorYU-33294

Valve spring compressor90890-04019

Valve spring compressor attach ment90890-06320

Valve guide remover/installer90890-06801

Valve guide reamer90890-06804

Valve seat cutter holder90890-06316

@^s)øttt

P-'

Flywheel puller90890-06521

Flywheel holder90890-06522

Crankshaft holder 1890890-06562

5-11

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Compression gauge90890-03160

62Y141 1


eeeValve seat cutter90890-0631 5, 90890-06323, 90890-06326,90890-06328, 90890-06555

Bearing outer race attachment90890-06626

Oil filter wrench90890-01426

Piston slider90890-06529

62Y141 1 5-12

Power unit

1

(

t.,D

s62Y5010

62Y141 15-13

Power unit



1

2

3

4

5

6

7

II10

11

12

13

14

15

16

Flywheelmagnet

Stator coil

Cover

Grommet

Nut

Washer

Bolt

Lighting coil coupler

Charge coil coupler

Stator base

Pulser coil coupler

Screw

Dowelpin

Woodruff key

Cover

Screw

1

1

1

2

1

1

3

1

1

1

1

4

2

1

1

3

M6x25mm

M6x24mm

M6x35mm

160

4

3

16

o.4

0.3

116

2.9

2.2

62Y141 1 5-14

('I

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5-15

Power unit



1

2

3

4

5

6

7

II10

11

12

13

14

15

16

17

1B

19

20

21

22

23

24

25

26

27

28

29

30

Throttle cable

Shift cable

Shift cable

Fuel pump

Fuel filter assembly

Fuel filter assembly

Carburetor assembly

Bolt

Plate

Clip

Clip

Grommet

Holder

Holder

Bolt

O-ring

Clip

Fuel hose

Bolt

Clip

Fuel hose

Bolt

O-ring

Dowelpin

Clip

Blowby hose

Prime Start coupler

Bolt

Collar

Throttle link rod

1

1

1

1

1

1

1

3

1

1

1

1

1

1

2

1

2

2

1

1

1

I4

2

1

1

1

2

2

1

F50/F504, T50/FT50B

FTSOC

F50/F50A

TsO/FTsOB, FTSOC

M6x20mm

F50/F504, T50/FT50B

FTsOC

Fuel pump-to-carbu retor

Fuel f ilter-to-fuel joint

M6x30mm

62Y141 1 5-16

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s62Y5030

62Y141 15-17

Power unit



1

2

3

4

5

6

7

II10

11

12

13

14

15

16

17

1B

19

20

21

22

23

24

25

26

Power trim and tilt relay

Bolt

Negative battery lead

Wiring harness extension

Grommet

Nut

Spring washer

Positive battery lead

PTT relay positive lead

Fuse holder lead

Clip

Warning indicator coupler

Trailer switch coupler

Plastic tie

Pilot water hose

Bolt

Neutralswitch

Plate

Neutralswitch lead

Ground lead

Bolt

PTT relay lead

Nut

Spring washer

PTT motor lead

Bolt

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

2

1

1

2

3

1

2

2

2

2

2

EHT/ET models

M8x16mm

EHT/ET models

EHD/EHT models

EHT/ET models

M6x20mmTiller handle models

Remote control models

Tiller handle models

M6x12mmEHT/ET models

EHT/ET models

EHT/ET models

EHT/ET modelsGreen, blue


9

7

0.9

o.7

6.5

5.1

62Y141 1 5-18

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Power unit



1

2

3

4

5

6

7

II10

11

12

13

14

15

16

17

1B

19

20

21

22

23

24

25

26

Bracket

Starter motor

Spark plug cap

lgnition coil

Wiring harness

Thermoswitch

Holder

Bolt

Ground lead

Bolt

Oil pressure switch

Oil pressure switch lead

Screw

lgnition coil lead

Bolt

Thermoswitch lead

Rectif ier Regu lator coupler

CDI unit coupler

Bolt

Bolt

Nut

Spring washer

Starter motor lead

Spring washer

Nut

Bolt

1

1

4

2

1

1

1

1

3

1

1

1

1

2

4

2

1

1

2

3

1

1

1

1

1

1

M6x12mm

M6x12mm

M6x30mm

M8x25mmM8x35mm

M8x45mm

9

2

7

30

7

30

0.9

0.2

0.7

3.0

0.7

3.0

6.5

1.4

5.1

22

5.1

22

62Y141 1 5-20

ffiffi

s62Y5050

62Y141 15-21

Power unit



1

2

3

4

5

6

7

II

Power unit

Engine oildipstick

Gasket

Dowelpin

Bolt

Bolt

Apron

Screw

Nut

1

1

1

2

2

B

1

2

2

M6x16mmMBxB0mm

M6x24mm

21 2.1 15

62Y141 1 5-22

d4

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l^(\1:19

5-23 62Y141 1

Power unit



1

2

3

4

5

6

7

II10

11

12

13

14

15

Throttle link rod

Throttle cam

Throttle control lever

Clip

Bushing

Bolt

Spring

Collar

Bracket

Bolt

Shift rod

Bolt

Bracket

Spring

Bolt

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

M6x20mm

M6x30mm

M6x30mm

62Y141 1 5-24

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

utes, and then turn it otf.

2. Remove the clip from the engine shut-offswitch on the remote control box or tillerhandle.

3. Remove the all spark plugs, and theninstall the special service tool to eachspark plug hole.

Before removing the spark plugs, blowcompressed air in the spark plug well toclear out any dirt or dust that may fall intothe cylinder.

Compression gauge @:YU-33223-1 / 90890-031 60

4. Fully open the throttle, crank the engineuntil the reading on the compressiongauge stabilizes, and then check thecompression pressure.

Minimum compression pressure:840 kPa (8.4 kgf/cm2, 122psi)

5. lf 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:. lf the compression pressure increases,

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

. lf 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. Start the engine, warm it up for 5 min-

utes, and then turn it otf.

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

Use a pressure gauge with an adapter with a1/B pitch thread.

3. Check the oil pressure. Check the oilpump, oil suction pipe, and oil strainer ifout of specification.

Oilpressure:100 kPa (1.0 kgf/cm2, 14 psi) at idlespeed (900150 r/min)

5-25 62Y141 1

Power unitRemoving the power unit1. Remove the flywheel magnet cover and

flywheel magnet.


62Y141 1

. Apply force in the direction of thearrows shown, to prevent the flywheelholder from slipping off easily.

. To prevent damage to the engine ortoolso screw in the flywheel puller setbolts evenly and completely so that theflywheel puller plate is parallelto the fly-wheel magnet.

NOTE:Apply force to the crankshaft end until the fly-wheel magnet comes off the tapered portionof the crankshaft.

Flywheel magnet holder @: YB-06139Flywheel holder O: 90890-06522Universal puller @: YB-06117Flywheel puller @: 90890-06521

E

E

tr

5-26

3.

2. Disconnect the throttle cable @ and shiftcable/shift rod @.

Disconnect the fuel hose @ and throttlelink rod @.

s62Y5082

4. Disconnect the battery leads @, 10-pincoupler @), PTT relay leads €) (EHT,ET), PTT motor leads @ (EHT, ET),ground lead @ (EHT, ET), warning indi-cator coupler @ (EHD, EHT), trailerswitch coupler C) (EHT, ET), pilot waterhose @, and flushing hose (models withflushing device).

5. Remove the power trim and tilt relay @,shift rod @ and shift rod bolts @.

6. Remove the apron @.

@-_

s62Y5081

5-27 62Y141 1

Power unit7. Remove the power unit by removing the

bolts @.

s62Y5085

62Y141 1 5-28

Timing belt and sprockets

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62Y141 15-29




1

2

3

4

5

6

7

II10

11

12

13

14

15

16

Timing belt

Drive sprocket

Driven sprocket

Bolt

Bolt

Tensioner

Spring

Nut

Retaining plate

Woodruff key

Bolt

Washer

Bolt

Blowby hose

Clip

Dowelpin

1

1

1

1

1

1

1

1

2

1

1

1

2

1

1

1

M8x20mm

M10 x 40 mm

M6x20mm

I25

140

38

0.8

2.5

14

3.8

5.8

18

101

2A

62Y141 1 5-30

Removing the timing belt andsprockets1. Set the cylinder #1 piston position to

TDC of the compression stroke by align-ing the "1" mark @ on the driven sprocketwith the "¡" mark (D on the cylinderhead.

Do not turn the drive sprocket counter-clockwise, otherwise the valve systemmay be damaged.

2. Remove the breather hose and loosenthe drive sprocket nut O.

s62Y5130

NOTE:. Use a deep socket @ (M42) for this proce-

dure.. Do not turn the camshaft when loosening

the drive sprocket nut.

Crankshaft holder @: YB-06562Crankshaft holder 1B @: 90890-06562

3. Remove the tensioner @ and timing belt

@ from the driven sprocket side.

s62Y5140

Loosen the driven sprocket bolt @ andremove the driven sprocket @.

s62Y51 50


NOTE:Do not turn the camshaft when loosening thedriven sprocket bolt.


'þ{

4.

B

5-31 62Y141 1

Timing belt and sprockets5. Remove the nut @, retaining plates @,

drive sprocket @, and Woodruff key @.

s62Y51 55

Checking the timing belt andsprockets1. Check the interior and exterior of the tim-

ing belt for cracks, damage, or wear.Replace if necessary.

s62Y51 60

Check the drive sprocket O and drivensprocket @ for cracks, damage, or wear.Replace if necessary.

lnstalling the timing belt andsprockets1. Check that the "1" mark @ on the driven

sprocket @ is aligned with the "¡" mark(D on the cylinder head, and then tightenthe bolt Ø,

lnstall the retaining plate @, Woodruffkey @, drive sprocket @, retaining plate

@, and nut @, and then tighten the nut.

2.

62Y141 1

s62Y51 70

5-32

3. Check that the "¡!" mark @ on the retain-ing plate is aligned with the "l" mark @on the cylinder body,

lnstall the new timing belt @ from thedrive sprocket side with its part numberin the upright position.

/e\ \

ffi\\ - ...a,

tØ_j\l qy'@'

o Do not twisto turn inside out, or bend thetiming belt beyond the maximum limit of25 mm (1.0 in) @, otherwise it may bedamaged.

. Do not get oil or grease on the timingbelt.

qcYM

{

5. lnstall the tensioner @ and bolts, andthen tighten the bolts finger tight.

6. Take up the timing belt slack by turningthe drive sprocket clockwise at least twofullturns.

sprockets counterclock-the valve system may be

Tighten the tensioner bolts to the speci-fied torque.

Tensioner bolt @:8 N.m (0.8 kgf.m, 5.8 tt.lb)

Tensioner bolt (adjusting bolt) @:25 N.m (2.5 kgf.m, 18 Ít.lb)

8. Turn the drive sprocket two turns, andthen check that the alignment marks arealigned.

4.

Do not turn thewise, otherwisedamaged.

7.1

5-33 62Y141 1


Do not turn the sprockets counterclock-wiseo otherwise the valve system may bedamaged.

L Tighten lhe driven sprocket bolt @ to thespecified torque.

Crankshaft holder @: YB-06562Crankshaft holder 18 @: 90890-06562

Drive sprocket nut @:140 N.m (14 kgf.m, 100 Ít.lb)

E for USA and CanadaE Forworldwide


Driven sprocket bolt Ø:38 N.m (3.8 kgf.m, 27ll.lb)

10. Tighten the drive sprocket nut @ to thespecified torque, and then install thebreather hose.

NOTE:Use a deep socket @ (M42) for this proce-dure.

B

-^ -\á€)- \---\ ìØ- \ ,-/r' \z \ ^\

62Y141 1 5-34

Gylinder head

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T7

,-=@hT."A-@1-tt\ IL-/'\- ")w.H',

5-35 62Y141 1

Cylinder head



1

2

3

4

5

6

7

I

I10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

Cylinder head

Oil pump

Cylinder head cover

Bolt

Cylinder head covergasket

Bolt

Spark plug

Bolt

Dowelpin

Cylinder head gasket

Grommet

Anode

Cover

Bolt

Cover

Bolt

O-ring

O-ring

O'ring

Bolt

Housing

Drive shaft

Pin

lnner rotor

Outer rotor

Gasket

Cover

Screw

1

1

1

7

1

10

4

5

2

1

4

4

4

4

4

4

1

1

1

4

1

1

1

1

1

1

1

2

M6x20mm

M9x95mm

M6x25mm

M6x40mm

M6x20mm

1st2nd

1st2nd

2347

18

612

2.34.7

1.8

0.61.2

17

34

13

4.38.7

E Tightening sequence

62Y141 1 5-36

lffiliEtl,o*",un,.

' 12, ð-

Ð\r/ @ ..'/

/'

5-37 62Y141 1

Cylinder head



1

2

3

4

5

6

7

II10

11

12

13

14

15

16

17

1B

19

Rocker arm assembly

Rocker arm shaft

Cylinder head

Exhaust valve

lntake valve

Camshaft

Valve cotter

Spring retainer

Valve spring

Spring seat

Stem seal

Valve guide

Retaining bolt

Gasket

OilsealBolt

Rocker arm retainer

Tensioner

Rocker arm retainer

B

1

1

4

4

1

16

IIIIB

1

1

1

5

2

2

1

M8x22mm

62Y141 1 5-38

Removing the cylinder head1, Check that the camshaft dowel pin hole

@ ¡s ¡n the position shown in the illustra-tion. Adjust if necessary.

2. Remove the cylinder head cover bolts inthe sequence shown.

s62Y5265

Remove the cylinder head bolts in thesequence shown.

s62Y5270

Remove the oil pump O, rocker armassembly @, and rocker arm shaft @.

4.

5-39 62Y141 1

Cylinder head

5. Remove the retaining bolt @, then thecamshaft @ by pulling it downward.

Remove thevalves.

Valve spring compressor @:YM-01253 / 90890-04019

Valve spring compressor attachment @:90890-06320

Checking the valve springs1. Measure the valve spring free length @.

Replace if out of specification.

Valve spring free length limit @:37.85 mm (1.490 in)

2. Measure the valve spring tilt (þ. Replaceif out of specification.

Valve spring tilt limit (D: 1.2 mm (0,07 in)

Checking the valves1. Check the valve face for pitting or wear.

Replace if necessary.

s62Y5290

When replacing the valve, also replace thevalve guide and stem seal.

62Y141 1 5-40

2. Measure the valve margin thickness @.Replace if out of specification.

Valve margin thickness @:lntake: 0.6-1.0 mm (0.024-0.039 in)Exhaust: O.7-1.1 mm (0.028-0.043 in)

3. Measure the valve stem diameter (0.Replace if out of specification.

Valve stem diameter (D:

lntake:5.48-5.49 mm (0.2157{.2161 in)

Exhaust:5.46-5.47 mm (0.2150{.2153 in)

4. Measure the valve stem runout. Replaceif out of specification.

Valve stem runout:lntake: 0.03 mm (0.0012 in)Exhaust: 0.03 mm (0.0012 in)

Checking the valve guides1. Measure the valve guide inside diameter

@. Replace if out of specification.

Valve guide inside diameter limit @:5.50-5.51 mm (0.2165-O.2169 in)

Replacing the valve guides1. Remove the valve guide @ by striking

the special seruice tool from the combus-tion chamber side.

Valve guide remover: YM-01122Valve guide remover/installer:

90890-06801

5-41 62Y141 1

Cylinder head

2. lnstall the new valve guide @ by strikingthe special seruice tool from the cam-shatt side until the valve guide clip @contacts the cylinder head.

s62Y5370

Apply engine oil to the sudace of the newvalve guide.

Valve guide remover: YM-01122Valve guide remover/installer;

90890-06801

3. lnseft the special seruice tool into thevalve guide @, and then ream the valveguide.

NOTE:. Turn the valve guide reamer cloclaruise to

ream the valve guide.. Do not turn the reamer counterclockwise

when removing the reamer.

Valve guide reamer:YM-o1196 i 90890-06804

4. Measure the valve guide inside diameter.Replace the valve guide if out of specifi-cation.

Valve guide inside diameter:5.5f5.51 mm (0.2165-0.2169 in)

Checking the valve seat1. Eliminate carbon deposits from the valve

with a scraper.

2. Apply a thin, even layer of Mechanic'sblueing dye (Dykem) onto the valve seat.

3. Lap the valve slowly on the valve seatwith a valve lapper (commercially obtain-able) as shown.

Measure the valve seat contact width @where the blueing dye is adhered to thevalve face. Reface the valve seat if thevalve is not seated properly or if the valveseat contact width is out of specification.Replace the valve guide if the valve seatcontact is uneven.

s62Y541 0

62Y141 1 5-42

s62Y5420

Valve seat contact width @:lntake: 0.9-1.1 mm (0.035-0.043 in)Exhaust: 0.9-1.1 mm (0.035-0.043 in)

Refacing the valve seat1. Reface the valve seat with the valve seat

cutter.

.*Þf--_l.,Èg.ûu

s62Y5430

Valve seat cutter set: YM-91043-CValve seat cutter holder: 90890-06316Valve seat cutter:

30" (intake): 90890-0632630" (exhaust): 90890-0632845" (intake and exhaust): 90890-0655560' (intake): 90890-0632360" (exhaust): 90890-0631 5

2. Cut the surface of the valve seat with a45o cutter by turning the cuüer clockwiseuntil the valve seal face has becomesmooth.

5-43

s62Y5450

@ Stag or rough sudace

Do not over cut the valve seat. Make sureto turn the cutter evenly downward at apressure of 4f50 N (4-5 kgf, 8.8-11 lbf)to prevent chatter marks.

3. Use a 30o cutler to adjust the contactwidth of the top edge of the valve seat.

(D Previous contact width

62Y141 1

Cylinder head

4. Use a 60o cutter towidth of the bottomseat.

adjust the contactedge of the valve

s62Y5461

@ Previous contact width

5. Use a 45o cutter to adjust the contactwidth of the valve seat to specification.

s62Y5462

(D Previous contact width@ Specified contact width

6. lf the valve seat contact area is too wideand situated in the center of the valveface, use a 30o cutter to cut the top edgeof the valve seat, a 60" cutter to cut thebottom edge to center the area and setits width.

7. lf the valve seat contact area is too nar-row and situated near the top edge of thevalve face, use a 30o cutter to cut the topedge of the valve seat. lf necessary, usea 45o cutter to center the area and set itswidth.

5s62Y5470

(D Previous conlact width

8. lf the valve seat contact area is too nar-row and situated near the bottom edge ofthe valve face, use a 60o cutter to cut thebottom edge of the valve seat. lf neces-sary, use a 45o cutter to center the areaand set its width.

s62Y5480

@ Previous conlact width

9. Apply a thin, even layer of lapping com-pound onto the valve seat, and then lapthe valve using a valve lapper (commer-cially obtainable).

(D Previous contact width

62Y141 1

sô2Y5490

5-44

Do not get the lapping compound on thevalve stem and valve guide.

10. After every lapping procedure, be sure toclean off any remaining lapping com-pound from the cylinder head and thevalve.

11. Check the valve seat contact area of thevalve again.

Checking the rocker arms and rockerarm shaft1. Check the rocker arms, rocker arm shaft,

and rocker arm contact surface @ torwear. Replace if necessary.

2. Measure the rocker arms inside diameter@ and rocker arm shaft outside diameter@. Replace if out of specification.

Rocker arm inside diameter (D:

16.0116.01 mm (0.62910.6303 in)Rocker arm shatt outside diameter @:

15.98-15.99 mm (0.6291-0.6295 in)

Ghecking the camshaft1. Measure the cam lobe. Replace if out of

specification.

Cam lobe @:lntake:

30.8S-30.99 mm (1 .2161-1.2200 in)Exhaust:

30.82-30.92 mm (1 .213*1.2175 in)Cam lobe (D:

lntake:25.95-26.05 mm (1 .0217-1.0256 in)

Exhaust:25.95-26.05 mm (1 .0217-1.0256 in)

2. Measure the camshaft runout. Replace if

out of specification.

Camshaft runout limit: 0.04 mm (0.0016 in)

5-45 62Y141 1

Cylinder head

3. Measure the camshaft journal diameter@ and cylinder head journal inside diam-eter (D. Replace the camshaft and cylin-der head if out of specification.

Camshaft journal diameter @:#1: 36.93-36.94 mm (1.4539-1.4543 in)#2, #3, #4;

36.94-36.95 mm (1 .4543-1.4547 in)Cylinder head journal inside diameter CD:

37.00-37.02 mm (1 .4567-1.4575 in)

4. Calculate the camshaft oil clearance @as follows. Replace the camshaft andcylinder head as a set if out of specifica-tion.

@=CD-@:#1 : 0.0ô-0.10 mm (0.0022-0.0039 in)#2, #3, #4;

0.05-0.09 mm (0.00184.0035 in)

Checking the cylinder head1. Eliminate carbon deposits from the com-

bustion chambers and check for deterio-ration.

2. Check the cylinder head warpage using astraightedge @ and thickness gauge @in five directions as shown. Replace if outof specification.

Cylinder head warpage limit:0.03 mm (0.001 in)

62Y141 1 5-46

Checking the oil pump1, Measure the oil pump rotor clearances

as shown. Replace if out of specification.

Clearance @:0.09-0.15 mm (0.004{.006 in)

Clearance (D:

0.01-0.10 mm (0.0004-0.0039 in)Clearance @:

0.03--0.08 mm (0.001-0.003 in)

lnstalling the valves1. lnstall the new valve stem seal @ to the

valve guide, and then apply engine oil tothe valve guide.

2. lnstall the valve @, spring seat @, valvespring @, and spring retainer @ in thesequence shown, and then attach thespecial service tool.

Face the fine pitch side @ of the valve springtoward the spring seat.

Valve spring compressor @:YM-01253 / 90890-04019

Valve spring compressor attachment @:90890-06320

r))s62Y5590

5-47 62Y141 1

Cylinder head

3. Compress the valve spring, and theninstall the valve cotter @ using a thinscrewdriver with a small amount ofgrease applied to it.

Lightly tap the spring retainer with a plas-tic hammer to set the valve cottersecurely,

lnstalling the camshaft1. lnstall the new oil seal @.

E ForE For

USA and Canadaworldwide

Drive shatt needle bearing depth stop:Y8-34473

Bearing outer race attachment:90890-06626

2. lnstall the camshaft @ in the directionshown, then the retaining bolt @.

e

62Y141 1 5-48

lnstalling the rocker arm assembly1, Check that the camshaft dowel pin hole

@ ¡s ¡n the position shown in the illustra-tion. Adjust if necessary.

2. Assembly the rocker arm @ and rockerarm shatt @, and the tensioner @, rockerarm retainer @ by installing the bolts.

Make sure that the arrow marks @ on the twotensioners are facing up.

3. lnstall the rocker arm shaft assembly tothe cylinder head by installing the bolts,and then tighten them to the specifiedtorque and in the sequence shown.

Bolt: 1B N.m (1.8 kgf.m, 13 ft.lb)

lnstalling the cylinder head1. lnstall the oil pump O by aligning the oil

pump drive shaft @ with the camshaft pin

@.

þ

t-5;f-Ë /

5-49 62Y141 1

Cylinder head

2. Tighten the cylinder head bolts to thespecified torques in two stages and in thesequence shown.

s62Y5670

Apply engine oil to the cylinder head bolts(M9) before installation.

Cylinder head bolt (M9):1st: 23 N'm (2.3 kgf.m, 17 ft.lb)2nd:47 N.m (4.7 kgf.m, 34 ft.lb)

Cylinder head bolt (M6):1st: 6 N.m (0.6 kgf.m, 4.3 ft.lb)2nd:12 N.m (1.2 kgf.m, 8.7 ft.lb)

3. Tighten the cylinder head cover bolts in

the sequence shown.

@

@

@

62Y141 1 5-50

Gylinder body

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2\3 '( 1u 26

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62Y141 15-51

Cylinder body



1

2

3

4

5

6

7

II10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

Oilfilter

Crankshaft

Bolt

Bolt

Crankcase

OilsealMain bearing

Oilseal

Connecting rod bearing

Connecting rod cap

Bolt

Dowelpin

Cylinder body

Connecting rod

Piston pin clip

Piston pin

Piston

Oil ring

Second ring

Top ring

Piston assembly

Gasket

Exhaust cover

Thermostat

Gasket

Cover

Bolt

Clamp

Bolt

Grommet

1

1

10

10

1

1

10

1

I4

B

2

1

1

2

1

1

1

1

1

1

1

1

1

1

1

2

1

10

1

M8x82mm

M6x35mm

M6x35mm

1st2nd

1st2nd

1st2nd

1B

15

30

612

617

1,8

1.53.0

0.61.2

0.61.7

13

11

22

4.38.7

4.312

62Y141 1 5-52

lffiliEtl,o*",un,.

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@\ 23 24ZS

@tr:

Ww

1

G>--1s

@

o@

@

5-53 62Y141 1

Cylinder body



31

32

33

34

35

36

Anode

Cover

Cover

Bolt

Bolt

Bolt

1

1

1

1

1

10

M6x20mmM5x12mmM6x35mm 1st

2nd612

0.61.2

4.38.7

E Tightening sequence

62Y141 1 5-54

<-WÆ-

Removing and ¡nstalling the oil filter1, Place a rag under the oil filter, and then

remove the filter.

Oil filter wrench: YU-38411 / 90890-01426

NOTE:Be sure to clean up any oil spills.

Apply a thin coat of the new engine oiltothe O-ring of the new oilfilter.

lnstall the oil filter, and then tighten it tothe specified torque.

Oil filter wrench: YU-38411 / 90890-01426

Oil filter: 18 N.m (1 .8 kgf.m, 13 ft.lb)

Disassembling the cylinder body1. Remove the exhaust cover bolts in the

sequence shown.

5-55 62Y141 1

Cylinder body2. Remove the crankcase bolts in the

sequence shown.

@ @ sô2Ys7go

Remove the connecting rod bolts and thepiston assemblies.

Remove the crankshaft, oil seals, anddowelpins.

Remove the piston pin clip O with pliers,

and then remove the piston.

Ghecking the piston diameter1. Measure the piston outside diameter at

the specified measuring point. Replace ifout of specification,

Piston diameter @:62.9s42.96 mm (2.47ù2.479 in)

Measuring point @:5 mm (0.2 in) up from the bottom of thepiston skirt

Oversize piston diameter:Oversize 1: +0.25 mm (0.01 in)

Oversize 2: +0.50 mm (0.02 in)

Checking the cylinder bore1. Measure the cylinder bore (D.'-Du) @ at

measuring points @, O and @, and in

direction @, which is parallel to thecrankshaft, and direction @, which ¡s at aright angle to the crankshaft.

Cylinder bore @:63.00{3.01 mm (2.4812.481 in)

@@CIc:::@

@@@rr@

@@@rr@

@o

62Y141 1 5-56

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

Taper limit = maximum of D.' or D, -minimum of Du or D6:

0.08 mm (0.003 in)

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

Out-of'round limit = maximum of D1, D3, orDu - minimum of Dr, Do, or Du:

0.08 mm (0.003 in)

Checking the piston clearance1. Rebore the cylinder or replace the piston

and piston rings as a set or the cylinderbody, or both if out of specification.

Piston clearance:0.04-O.06 mm (0.0016-0.0024 in)

Checking the piston r¡ngs1. Check the piston ring @ dimensions of B

and T. Replace if out of specification.

at-\=l.T,l

2.

3.

Piston ring dimensions:Top ring @:

B:1.17-1.19 mm (0.046-0.047 in)T:2.39-2..41 mm (0.094-0.095 in)

Second ring (D:

B:1.47-1.49 mm (0.058-0.059 in)T:2.49-2.51 mm (0.098-0.099 in)

Oil ring @:B:2.3¿¡-2.46 mm (0.092-0.097 in)T: 2.75 mm (0.108 in)

Level the piston ring Q ¡n the cylinderwith the piston crown of an inverted pis-ton.

Check the piston ring end gap @ at thespecified measuring point. Replace if outof specification.

Piston ring end gap @:Top ring: 0.15-0.30 mm (0.006-0.012 in)Second ring:

0.30-0.50 mm (0.012-0.020 in)Oil ring: 0.204.70 mm (0.008-0.028 in)

Measuring point @: 20 mm (0.8 in)

6)YD=r,T,l

n r---------t(9-.--l t---------

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5-57 62Y141 1

Cylinder body

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

Replace the piston if out of specification.

Piston ring groove:Top ring @:

1.2Y1.25 mm (0.048-0.049 in)

Second ring @:1.52-1.54 mm (0.06G-0.061 in)

Oil ring @:2.51-2.53 mm (0.09f0.100 in)

Checking the piston ring sideclearance1. Measure the piston ring side clearance.

Replace the piston and piston rings as aset if out of specification.

Piston ring side clearance:Top ring @:

0.04-0.08 mm (0.002-O.003 in)Second ring @:

0.03-0.07 mm (0.001{.003 in)Oil ring @:

0.05-0.19 mm (0.002-O.007 in)

Checking the piston pin boss bore1. Measure the piston pin boss bore.

Replace the piston if out of specification.

Piston pin boss bore:15.97 4-15.985 mm (0.6289-0.6293 in)

Checking the piston pin1. Measure the piston pin diameter.


Piston pin diameter:1 5.965-1 5.970 mm (0.6285{.6287 in)

___l_I _l@

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sô2Y5790

@

@

62Y141 1 5-58

Checking the connecting rod smallend inside diameter1. Measure the connecting rod small end

inside diameter @. Replace the connect-ing rod if out of specification.

Connecting rod small end inside diameter@: 15,985-15.998 mm (0,62934.6298 in)

Ghecking the connecting rod big endside clearance1, Measure the connecting rod big end side

clearance @. Replace the connectingrod or crankshaft, or both if out of specifi-cation.

Connecting rod big end side clearance @:0.054.22 mm (0.002{.009 in)

Checking the connecting rod bolt1. Measure the connecting rod bolt thread

diameter at the two points @ and @.

2. Calculate the ditference between @ and@. Replace if out of specification.

l-----l,olmm (0.+ ¡n)

o

Connecting rod bolt thread diameter limit(difference between @ and (D):

f0.1 mm (f0.004 in)

Checking the crankshaft1. Measure the crankshaft journal diameter

@, crank pin diameter @, and crank pin

width @. Replace the crankshaft if out ofspecification.

Crankshaft journal diameter @:42.98443.000 mm (1 .6923-1 .6929 in)

Crank pin diameter @:32.984-33.000 mm (1 .2986-1 .2992 in)

Crank pin width @:21 .000-21.070 mm (0.8268-0.8295 in)

tf--]t mm (0.2 in)

ml@

5-59 62Y141 1

Cylinder body2. Measure the crankshatt runout. Replace

the crankshaft if out of specification.

s62Y5870

Crankshaft runout limit:0.04 mm (0.0016 in)

Checking the crankshaft mainjournal oil clearance1. Clean the bearings, main journals, and

bearing portions of the crankcase andcylinder body.

2. Place the cylinder body upside down ona bench.

3. lnstall half of the bearings O and thecrankshaft @ into the cylinder body @.

lnstall the bearings in their original posi-tions.

lnsert the projection @ of the bearing into thenotch in the cylinder body.

4. Put a piece of Plastigauge@ 1eC-t ¡ oneach main journal parallel to the crank-shaft.

62Y141 1

NOTE:Do not put the Plastigauge (PG-l) over theoil hole in the main journals of the crankshaft.

5. lnstall the remaining half of the bearingsinto the crankcase.

NOTErlnsert the projection of the bearing into thenotch in the crankcase.

lnstall the crankcase onto the cylinderbody and apply engine oil onto thethreads of the crankcase bolts.

Tighten the crankcase bolts to the speci-fied torques in two stages and in thesequence shown,

7.

Ø@

@@@rr@

@@@i:r@

5-60

NOTE:Do not move the crankshaft until the mainjournal oil clearance measurement has beencompleted.

Crankcase bolt (M8):1st:15 N.m (1.5 kgf.m, 11 ft.lb)2nd: 30 N.m (3.0 kgf.m, 22ttlb)

Crankcase bolt (M6):1st: 6 N.m (0.6 kgf.m, 4.3 ft'lb)2nd:12 N.m (1.2 kgf.m, 8,7 ft.lb)

B. Remove the crankcase and measure thewidth of the compressed Plastigauge(PG-1) on each main journal. Replacethe main bearing if out of specification.

Crankshaft main journal oil clearance:0.012-0.036 mm (0.0005-0.0014 in)

Checking the crankshaft pin oilclearance1. Clean the bearings and the connecting

rod.

2. lnstall the upper half of the bearing intothe connecting rod @ and the lower halfinto the connecting rod cap @.

Install the bearings in their original posi-tions.

lnsert the projection @ of the bearing into theslot on the cap and connecting rod.

3. Put a piece of Plastigauge (PG-1) ontothe crank pin, parallelto the crankshaft.

NOTE:Be sure not to put the Plastigauge (PG-1)over the oil hole in the crank pin of the crank-shatt.

lnstall the connecting rod to the crank pin

@

4.

5-61 62Y141 1

Cylinder body

5.

NOTE:. Align the alignment marks (D on the con-

necting rod cap and connecting rod.. Face the embossed "Y" mark on the con-

necting rod toward the flywheel side of thecrankshaft.

Tighten the connecting rod boltsspecified torques in two stages.

to the

NOTE:Do not turn the connecting rod until the crankpin oil clearance measurement has beencompleted.

Connecting rod bolt:1st: 6 N.m (0.6 kgf.m, 4.3 ft.lb)2nd:17 N.m (1.7 kgf.m, 12 ft.lb)

6. Remove the connecting rod cap andmeasure the width of the compressedPlastigauge (PG-1) on each crank pin.Replace the connecting rod bearing if outof specification.

Crank pin oil clearance:0,016-0,040 mm (0.0006-0.0015 in)

Selecting the crankshaft mainjournal bearing1. When replacing the main bearing, select

the suitable bearing as follows.

Check the crankshaft journal mark on thecrankshaft e and the cylinder body markon the cylinder body @.

Select the suitable color @ for the mainbearing from the table.

sô2Y5A1 0

Cylinderbody mark

Crankshaftjournalmark

Bearingcolor

A A Yellow

A BRed

B A

B BPink

c A

c B Green

62Y141 1 5-62

4. When installing the main bearing, inseñthe projection of the main bearing intothe slot on the cylinder body,

Remove any small metal particles and oilfrom the contact surfaces of the cylinderbody and the main bearing.

5. Measure the main journal oil clearancewith a piece of Plastigauge (PG-1).

Crankshaft main journal oil clearance:0.012-0.036 mm (0.00010.0014 in)

6, lf the oil clearance is below specification,check the main bearing color and cleanthe contact surface of the cylinder bodyand the main bearing, and then checkthe main journal oilclearance again.

7. lf the oil clearance is over specification,install an oversized main bearing, andthen check the main journal oil clearanceagain.

Selecting the connecting rod big endbearing1. When replacing the connecting rod bear-

ing, select the suitable connecting rodbearing as follows.

Check the crank pin mark on the crank-shaft @ and the connecting rod cap markor painted color on the connecting rod @.

Select the suitable color @ for the con-necting rod bearing from the table.

4. When installing the connecting rod bear-ing, insert the projection of the connect-ing rod bearing into the slot on theconnecting rod.

Remove any small metal particles and oilfrom the contact surfaces of the connect-ing rod and the connecting rod bearing.

5. Measure the crank pin oil clearance witha piece of Plastigauge (PG'1).

Crank pin oil clearance:0.016-0.040 mm (0.00064.0015 in)

Connectingrod cap

mark/color

Crank pin

markBearing

color

VRed A Yellow

VRed BRed

IVBlue A

IVBlue BPink

IIVYellow A

IIVYellow B Green

5-63 62Y141 1

Cylinder body6. lf the oil clearance is below specification,

check the connecting rod bearing colorand clean the contact surface of the con-necting rod and the connecting rod bear-ing, and then check the crank pin oilclearance again.

7. lf the oil clearance is over specification,installan over-sized connecting rod bear-ing, and then check the crank pin oilclearance again.

Assembling the cylinder body1. Assemble the piston @, connecting rod

@, piston pin @, and piston pin clips @.

NOTE:. Face the embossed "Y" mark @ on the

connecting rod in the same direction as the"UP" mark (D on the piston.

. Always use new piston pin clips, and do notallow the piston pin clip end to align with thepiston pin slot @.

2. lnstallthe oil ring @, second ring @, andtop ring @ to the piston with the "T" mark@ on tne piston rings facing upward.

62Y141 1

3. Ofiset the piston ring end gaps asshown.

Do not scratch the piston or break the pis-ton rings.

After installing the piston rings, check thatthey move smoothly.

lnstall the upper half of the bearing intothe connecting rod @ and the lower halfinto the connecting rod cap @.

lnstall the bearings in their original posi-tion.

NOTErlnsert the projection @ of the bearing into theslot on the cap and connecting rod.

4.

5-64

5. lnstall the piston with the "UP" mark onthe piston crown facing towards the fly-wheel.

E for USA and CanadaE for worldwide

NOTE:Apply engine oil to side of the piston assem-blv.

Piston ring compressor: YU-33294Piston slider: 90890-06529

6. lnstall half of the bearings @ into the cyl-inder body @.

lnsert the projection @ of the bearing into thenotch in the cylinder body.

7. Set the crankshaft @, and oil seals @and @ into the cylinder body as shown.Apply engine oil to the inner oil seal, jour'nal bearings, and connecting rod bear-ing.

8. lnstall the connecting rod cap @ to theconnecting rod, and then tighten the con'necting rod bolts @ to the specifiedtorques in two stages. Apply engine oiltothe connecting rod cap and connectingrod bolt.

5-65 62Y141 1

Cylinder body

9.

10.

NOTE:Align the alignment marks @ on the connect-ing rod cap and connecting rod.

Connecting rod bolt:1st: 6 N.m (0.6 kgf.m, 4.3 ft.lb)2nd:17 N.m (1.7 kgf.m, 12 ft.lb)

lnstall half of the bearings @ into thecrankcase, then dowel pins @,

Apply Gasket MakeP to the mating sur-face of the crankcase.

NOTE:. lnsert the projection @ of the bearing into

the notch in the crankcase.. Do not get any Gasket Maker on the journal

bearings.

11. lnstall the crankcase bolts, and thentighten them to the specified torques in

two stages and in the sequence shown.

s62Y5B1 0

The oil seals must be installed beforetightening the crankcase bolts.

NOTE:Apply engine oil to the crankcase bolt (MB)

before installation.

Crankcase bolt (MB):

1st: 15 N.m (1.5 kgf.m, 11ft.lb)2nd:30 N.m (3.0 kgf.m, 22fl.lb)

Crankcase bolt (M6):

1st: 6 N.m (0,6 kgf.m, 4.3 Ít.lb)2nd:12 N.m (1.2 kgf.m, 8.7 ft'lb)

Ø@

@@@ü@

@o@rr@oo

s62Y5490

62Y141 1 5-66

12. lnstall the new gasket and exhaust cover,and then tighten the bolts to the specifiedtorques in two stages and in thesequence shown.

Exhaust cover bolt:1st: 6 N.m (0.6 kgf.m, 4.3 ft.lb)2nd:12 N.m (1.2 kgf.m, 8,7 ft.lb)

lnstalling the power unit1. lnstall the dowel pins @ and gasket @.

2. lnstall the power unit @ by installing thebolts @, then tightening them to thespecified torque.

Mounting bolt @:21 N.m (2.1 kgf.m, 15 ft.lb)

3. lnstall the apron @.

@-_

5-67 62Y141 1

Cylinder body4. lnstall the shift rod bolts @, shift rod @

and power trim and tilt relay @.

Connect the flushing hose (models withflushing device), pilot water hose @,trailer switch coupler GD (EHT, ET), warn-ing indicator coupler @) (EHD, EHT),ground lead @ (EHT, ET), PTT motorleads @ (EHT, ET), PTT relay leads @(EHT, ET), 10-pin coupler @, and batteryleads @.

6. Connect the throttle link rod @ and fuelhose @.

s62Y5089

Connect the shift cable/shift rod @ andthrottle cable @, and then adjust theirlengths. For adjustment procedures, seeChapter 3, "Checking the throttle cableoperation," and "Checking the gearshiftoperation."

7.

62Y141 1 5-68

8. lnstallthe Woodrutf key.

9, lnstall the flywheel magnet and flywheel


Apply force in the direction of the arrowsshown, to prevent the flywheel holderfrom slipping off easily.

Apply engine oil to the flywheel magnet nutbefore installation.


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

5-69 62Y141 1

- MEMO -

62Y141 1 5-70

Lower unit


Removing the lower unit............ .......6-9

Water pump and propeller shaft housing (F50/F504) .............6-1IRemoving the water pump and propeller shaft housing assembly..........6-13Disassembling the propeller shaft housin9................ ...........6-13Disassemblingthepropellershaftassembly............. ...........6-14Checking the water pump......... ......6-14Checking the propeller shaft housing ................6-15Checking the propeller shatt .6-15Assembling the propeller shaft assembly ..........6-16Assembling the propeller shaft housing...... .......6-16lnstalling the propeller shaft housing .................6-18lnstalling the water pump......... .......6-18

Drive shaft and lower case (F50/F504)Removing the drive shaft.......... ......6-23Disassembling the drive shaft assembly ...........6-23Disassembling the forward gear ..,...,.,...,....,. 6-23Disassembling the lower case ........6-24Checking the pinion and fonruard 9ear........... ....6-25Checking the bearings ................. 6-25Checking the drive shaft.....Checking the shift rod and shift cam .................6-25Checking the lower case .......... ......6-25Assembling the lower case .........6-25Assembling the fonruard 9ear........... ..................6-27Assembling the drive shaft.......... ...6-27lnstalling the drive shaft ..................lnstalling the lower unit...............

Shimming (F50) (for USA and Canada) 6-31

6-1

Selecting the fonrard gear shims ...6-33Selecting the reverse gear shims ...6-34

Shimming (F504) (for worldwideShimming.. ...................6-36Selecting the pinion shims......... .....6-36

Shimming..Selecting the pinion Jil::

Selecting the fonrard gear shimsSelecting the reverse gear shims

.........6-32

.........6-32

62Y141 1

Backlash (F50/F504) ..........6-39Measuring the fonuard and reverse gear backlash .................................6-39

Lower unit (T50/FT50B, FT50C) ............6-41Removing the lower uni1............ .....6-43

Water pump and shift rod (T50/FT50B, FT50C)................. .....6-45Removing the water pump and shift rod..... .......6-47Checking the water pump and shift rod .............6-47lnstalling the water pump and shift rod..... .........6-48

Propeller shaft housing (Í50/FT50B, FT50C)................ ..........6-51Removing the propeller shaft housing assembly... ...............6-53Disassembling the propeller shaft housing................ ...........6-53Disassembling the propeller shaft assemb|y............. ...........6-54Checking the propeller shaft housing ................6-54Checking the propeller shaft........ ...6-55Assembling the propeller shaft assembly... .......6-55Assembling the propeller shaft housing...... .......6-55lnstalling the propeller shaft housing .................6-57

Drive shaft and lower case (T50/FT50B, FT50C) ..6-59Removing the drive shaft.......... ......6-61Disassembling the drive shaft.. .......6-61Disassembling the fonruard gear........... .............6-61Disassembling the lower case ........6-62Checking the pinion and fonruard 9ear........... ....6-63Checking the bearin9s................ ....6-63Checking the drive shaft.......... .......6-63Checking the lower case .......... ......6-63Assembling the lower case........... ..6-63Assembling the fonruard 9ear,.,.....,.. ..,,,.,,..,,..,,..6-65Assembling the drive shaft.......... ...6-66lnstalling the drive shaft.......... ........6-66lnstalling the lower unit............ .......6-66

Shimming (T50) (for USA and Canada) ................6-69Shimming.. ...................6-70Selecting the pinion shims......... .....6-70Selecting the forward gear shims ...6-71

Shimming (FT50B, FT50C) (for worldwide)............ .................6-73Shimming.. ...................6.-74Selecting the pinion shims......... .....6-74Selecting the forward gear shims ,..6-75

Backlash (T50/FT50B, FT50C).... ...........6-77Measuring the fonruard and reverse gear backlash .................................6-77

62Y141 1


Bearing housing pullerYB-06207, YB-06234

Universal pullervB-06I17

Bearing housing needle bearing installerYB-06111

Oilseal installerYB-06168

Forward/reverse gear bearing installerY8-06270-A

Bearing cup installerYB-06167

Drive shaft holderY8-06049

Kruq

€-*ñ \ /\-l¡-\- \-\-\\-\eSlide hammer and adaptersY8-06096

Bearing housing needle bearing removerYB-06112, YB-06153

Driver handleY8-06071

6-1 62Y141 1


Bearing splitter plateYB-06219

Drive shaft needle bearing remover andinstallerYB-06063, YB-06155

Drive shaft needle bearing depth stopYB-34473,YB.34474

Drive shaft taper roller bearing cupinstallerYB-06110

Forward gear bearing cup installerYB-06109, YB-06276-B

WpPinion shim selecting toolsYB-34432-8, Y 8-34432-9, YB-34432-1 04,YB-34432-1 1 A, YB-34432'17

btuForward gear shim selecting toolsYB-34446-1, YB-34446 -3, Y 8-34446-4,YB-34446-5, YB-34446 -7, Y 8'34446-1 5

Shift rod push armYB-06052

Backlash indicator gaugeYB-06265

Magnetic plateYB-07003

62Y141 1 6-2

I

Dial gaugeYU-03097

Magnetic f lexible standYU-3448I

Bearing housing oilseal installerY8-06269

Gland nut wrenchY8-34447

Crank upper and lower seal installerv8-06244

Forward gear needle bearing and taperedroller bearing installerY8-06200

Bearing housing puller claw90890-06564

Stopper guide plate90890-06501

Center bolt90890-06504

Bearing separator90890-06534

6-3 62Y141 1


Stopper guide stand90890-06538

Bearing puller90890-06535

Bearing puller claw I90890-06536

Needle bearing attachment90890-06607, 90890-0661 0, 90890-0661 1,

90890-0661 2, 90890-0661 4, 90890-06653

Driver rod L390890-06652

Driver rod SS90890-06604

Bearing depth plate90890-06603

Bearing inner race attachment90890-06639, 90890-06641, 90890-06643n90890-06644, 90890-06661, 90890-06662

Drive shaft holder 490890-06518

Pinion nut holder90890-06s05

62Y141 1 6-4

Socket adapter 1

90890-06506

Bearing outer race puller90890-06523

Outer race puller claw A90890-06532

Driver rod SL90890-06602

Bearing outer race attachment90890-06621, 90890-06622, 90890-06626,90890-06627

Driver rod LS90890-06606

Driver rod LL90890-06605

Pinion height gauge90890-06702

d

Digitalcaliper90890-06704

Shimming plate90890-06701

6-5 62Y141 1


Shift rod push arm90890-06052

Ring nut wrench 390890-0651 1

"a\a)./Ring nut wrench extension90890-06s13

\ \?Bearing housing puller claw L90890-06502

Backlash indicator90890-06706

Magnet base plate90890-07003

Dial gauge set90890-01252

Magnet base90890.06705

Ball bearing attachment90890-06655

Socket adapter90890.06507

62Y141 1 6-6

Lower unit (F50/F50A)

fsá/,

F

s62Y6010

62Y141 16-7

Lower unit (F50/F504)



1

2

3

4

5

6

7

II10

11

12

13

14

15

16

17

1B

19

Lower unit

Plastic tie

Hose

Check screw

Gasket

Bolt

Drain screw

Dowelpin

Bolt

Anode

Bolt

Thrust washer

Propeller

Washer

Washer

Cotter pin

Propeller nut

Trim tab

Bolt

1

1

1

1

2

4

1

2

1

1

1

1

1

1

1

1

1

1

1

M10 x 40 mm

M8x35mm

M8x60mm

M8x20mm

7

40

7

35

0.7

4.O

o.7

3.5

5.1

29

5.1

25

62Y141 1 6-8

Removing the lower unit1, Drain the gear oil, For draining proce-

dures, see Chapter 3, "Replacing thegear oil."

2. Sel the gearshift to the neutral position,and place a block of wood between theanti-cavitation plate and propeller to keepthe propeller from turning, and thenremove the propeller nut and propeller.

Do not hold the propeller with your handswhen loosening or tightening it. Be sureto remove the battery leads from the bat-teries and the engine shut-off switch. Puta block of wood between the cavitationplate and propeller to keep the propellerfrom turning.

Disconnect the speedometer hose O.

Mark the trim tab @ at the area shown,and then remove it.

Loosen the bolts, and then remove lhelower unit from the upper case.

5.

3.

4.

s62Y6020

6-9 62Y141 1

Lower unit (F50/F504)

- MEMO -

62Y141 1 6-10

Water pump and propeller shaft housing (F50/F504)

22

À

6-11 62Y141 1




1

2

3

4

5

6

7

B

I10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

Propeller shaft assembly

Propeller shaft housingassembly

Spacer

Grommet

Bolt

Water pump housing

lnsert plate cartridge

lmpeller

O'ring

Outer plate cartridge

Gasket

Dowelpin

Woodruff key

Slider

Spring

Cross pin

Dog clutch

Spring

Propeller shatt

Shift plunger

Washer

Bolt

Reverse gear

Reverse gear shim

Ballbearing

O'ring

O'ring

Propeller shaft housing

Needle bearing

Oilseal

1

1

1

1

4

1

1

1

1

1

1

2

1

1

1

1

1

1

1

1

1

2

1

1

1

2

1

1

2

M8x20mm

M8x25mm

As required

62Y141 1 6-12

Removing the water pump andpropeller shaft housing assembly1. Remove the water pump assembly.

2. Remove the propeller shaft housingassembly by removing the bolts @, thenpulling the housing out.


Bearing housing puller @: YB-06234Universal puller @: YB-061 17Bearing housing puller claw @:

90890-06564Stopper guide plate @: 90890-06501Center bolt @: 90890-06504

Disassembling the propeller shafthousing1. Remove the reverse gear and shim(s).

E

E For USA and CanadaE for worldwide

Slide hammer and adapters @: YB-06096Bearing separator @: 90890-06534Stopper guide plate @: 90890-06501Stopper guide stand @: 90890-06538Bearing puller @: 90890-06535Bearing puller claw 1 @: 90890-06536

NOTE:lnstall the bearing separator @ between thereverse gear and propeller shaft housingcompletely, then the other special servicetools.

2. Remove the ball bearing.

E

tr

E

6-13 62Y141 1


E

E For USA and CanadaE Forworldwide

Slide hammer and adapters @: YB-06096Stopper guide plate @: 90890-06501Stopper guide stand @: 90890-06538Bearing puller @: 90890-06535Bearing puller claw 1 @: 90890-06536

3. Remove the oil seals and needle bear-ing.

s62Y6090

Bearing housing needle bearing remover @:YB-06112

Needle bearing attachment @:90890-06614

Driver handle @: YB-06071Driver rod L3 @: 90890-06652

Disassembling the propeller shaftassembly1. Remove the spring @, then the cross pin

@, dog clutch @, slider, and spring.

Checking the water pump1. Check the pump housing for deforma-

tion. Replace if necessary.

Check the impeller @ and insert platecartridge @ for cracks or wear. Replaceif necessary.

2.

(o)1 ------ /\-/\\ -,/

-

62Y141 1 6-14

3. Check the Woodrutf key @ and thegroove @ on the drive shaft for wear.Replace if necessary,

Checking the propeller shaft housing1. Clean the propeller shaft housing using a

soft brush and cleaning solvent, and thencheck it for cracks. Replace if necessary.

s62Y61 25

Check the teeth and dogs of the reversegear for cracks or wear. Replace thegear if necessary.

s62Y61 15

Check the bearings for pitting or rum-bling. Replace if necessary.

s62Y6120

Checking the propeller shaft1. Check the propeller shaft for bends or

wear. Replace if necessary.

Check the dog clutch and shift plungerfor cracks or wear. Replace if necessary.

2.

6-15 62Y141 1


Assembling the propeller shaftassembly1. lnstall the dog clutch as shown.

NOTE:lnstall the dog clutch @ with the "F" mark @facing toward the shift plunger.

Assembling the propeller shafthousing1. lnstall the needle bearing into the propel-

ler shaft housing to the specified depth.

NOTE:. lnstallthe needle bearing with the manufac-

ture identification mark @ facing toward theoil seal (propeller side).

. Do not strike the driver rod in a manner thatwillforce the stopper @ out of place.

Driver handle O: YB-06071Bearing housing needle bearing installer @:

YB-06111Driver rod SS @: 90890-06604Needle bearing attachment @:

90890-06614Bearing depth plate @: 90890-06603

Deprh O:3.0-3.5 mm (0.12-0.14 in)

Depth @:23.0-23.5 mm (0.91-0.93 in)

2. Apply grease to the new oil seals, andthen install them into the propeller shafthousing to the specified depth.


NOTE:lnstall an oil seal halfway into the propellershaft housing, then the other oil seal.

E

s62Y61 40

s62Y61 45


62Y141 1 6-16

Oil seal installer @: YB-06168Driver handle @: YB-06071Needle bearing attachment @;

90890-06653Driver rod L3 @: 90890-06652

Depth @: 4.0-4.5 mm (0.16-0.18 in)

3. lnstall the original shim(s) @ and ballbearing into the reverse gear using apress.


shimsn if necessaryo whenreverse gear or propeller

lnstall the ball bearing with the manufactureidentification mark O facing outward (propel-ler side).

Fonruard/reverse gear bearing installer @:YB-06270-A

Bearing inner race attachment @:90890-06639

4. lnstall the reverse gear assembly to thepropeller shaft housing using a press.

Bearing cup installer @: YB-06167Needle bearing attachment @:

90890-06607

ffiAdd or removereplacing theshaft housing.

s62Y61 75

6-17 62Y141 1


lnstalling the propeller shaft housing1. lnstall the washer @, propeller shaft

assembly @, and shift plunger @, intothe propeller shaft housing assembly @.

2. Apply grease to the new O-rings.

s62Y61 B0

lnstall the propeller shaft housing assem-bly into the lower case @, and thentighten the bolts @.

NOTE:When installing the propeller shaft assembly,be sure not to drop the shift plunger @.

lnstalling the water pump1. lnstall the new gasket and outer plate

cartridge.

2. lnstall the Woodrutf key into the driveshaft.

3. Apply grease to the impeller, and theninstall it onto the drive shaft.

NOTE:Align the groove of the impeller @ with theWoodrutf key @.

lnstall the insert plate cartridge @ intothe water pump housing @.

NOTE:Align the projection @ of the insert plate car-tridge with the hole @ in the pump housing.

62Y141 1 6-18

5. lnstall the O-ring @, pump housingassembly @, and dowel pins @ into thelower case, tighten the bolts @, and theninstallthe grommet @ and spacer @.

. When installing the pump housing, turn thedrive shaft clockwise while pushing downthe pump housing.

. Align the spacer projection @ with the hole@ ¡n tne pump housing.

6-19 62Y141 1


- MEMO -

62Y141 1 6-20

lffil$-l ,o*",un,,Drive shaft and lower case (F50/F50A)

15=@

\t lLine\€)

1B

Vrns/

II

,{'W24

6-21

Drive shaft and lower case (F50/F504)



1

2

3

4

5

6

7

II10

11

12

13

14

15

16

17

1B

19

20

21

22

23

24

25

26

27

28

29

30

31

32

33

34

Shift rod assembly

Drive shaft

Oilseal

Oilseal housing

O-ring

Circlip

Shift rod

O-ring

Taper roller bearing

Bearing outer race

Pinion shim

Sleeve

Oil seal housing assembly

Washer

Oilseal housing

O-ring

OilsealSeal

Plate

Hose

Plastic tie

Joint

Nut

Water inlet cover

Screw

Shift cam

Needle bearing

Pinion

Nut

Forward gear shim

Bearing outer race


Forward gear

Lower case

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

2

1

1

1

1

1

1

2

1

1

1

1

1

1

1

1

1

O: 17 mm

As required

5

75

0.s

7.5

3.6

54

62Y141 1 6-22

tu

E

Removing the drive shaft1, Remove the drive shaft assembly and

pinion, and then pull out the forwardgear.


Drive shaft holder @: YB-06049Drive shaft holder 4 @: 90890-06518Pinion nut holder @: 90890-06505Socket adapter 1 @: 90890-06506

Disassembling the drive shaftassembly1. lnstall the pinion nut @, tighten it finger

tight, and then remove the drive shaftbearing@usingapress.


o Do not press the drive shaft threaOs @directly.

. Do not reuse the bearingo alwaysreplace it with a new one.

Bearing splitter plate @; YB-06219Bearing inner race attachment @:

90890-06641

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

forward gear using a press.

Do not reuse the bearingn always replaceit with a new one.

Bearing splitter plate @; YB-06219Bearing separator @: 90890-06534

tr

E

6-23 62Y141 1


Disassembling the lower case1. Remove the taper roller bearing outer

race and shim(s).


lnstallthe claw as shown.

Slide hammer and adapters @: YB-06096Bearing outer race puller @: 90890-06523Outer race puller claw A @: 90890-06532Stopper guide stand @: 90890-06538

2. Remove the drive shaft bearing outerrace, shim(s), and drive shaft sleeve.

E For worldwide

NOTE:lnstallthe claw as shown.


3. Remove the needle bearing.

Drive shaft needle bearing remover andinstaller @: YB-06063Needle bearing attachment @:

90890-06614Driver handle @: YB-06071Driver rod L3 @: 90890-06652

4. Remove the shift rod assembly and shiftcam.

E For USA and Canada

62Y141 1 6-24

Checking the pinion and forwardgear1. Check the teeth of the pinion, and the

teeth and dogs of the forward gear forcracks or wear. Replace the pinion orgear if necessary.

Checking the bearings1. Check the bearings for pitting or rum-

bling. Replace if necessary.

s62Y6265

Checking the drive shaft1, Check the drive shaft for bends or wear.


Checking the shift rod and shift cam1, Check the shift rod and shift cam for

cracks or wear. Replace if necessary.

562YO,

Checking the Iower case1 . Check the skeg and torpedo for cracks or

damage. Replace if necessary.

Assembling the Iower case1. lnstall the shift rod assembly Q and shift

cam @ as shown.

lnstall the shift cam with lhe "UP" mark @facing upward.

s62Y6280

6-25 62Y141 1


2. lnstall the needle bearing into the lowercase to the specified depth.


NOTE:. lnstallthe needle bearing with the manufac-

ture identification mark O facing upward.. When using the driver rod, do not strike the

the special tool in a manner that will forcethe stopper @ out of place.

Driver handle @: YB-06071Drive shaft needle bearing remover andinstaller @:YB-06063Drive shaft needle bearing depth stop @:

YB-34474Driver rod SL @: 90890-06602Needle bearing attachment @:


Depth (D:

Depth @:

1 32.5-1 33.0 mm (5.22-5.24 in)1 82.5-1 83.0 mm (7.19-7.21 in)

3. lnstall the sleeve, original shim(s), andbearing outer race.

Add or remove shims, if necessary, whenreplacing the pinion or lower case.

NOTEr. Apply gear oil to the inside and outside of

the sleeve.. lnstallthe sleeve with the projeclion O tac-

ing fonruard.

Drive shaft taper roller bearing cup installer

@: YB-06110Bearing outer race attachment @:

90890-06627Driver handle @: YB-06071Driver rod LS @: 90890-06606

@-'1I

Bô*!*

62Y141 1 6-26

Drive shaft taper roller bearing cup installer

@: YB-06110Bearing inner race attachment @:

90890-06639

Assembling the drive shaft1. Install the new drive shaft bearing into

the drive shaft using a press.

II

#-E

4. lnstall the forward gear original shim(s)and taper roller bearing outer race.

Add or remove shims, if necessaryo whenreplacing the forward gear or lower case.

Fonivard gear bearing cup installer @:YB-06109

Bearing outer race attachment @:90890-06622

Driver handle @: YB-06071Driver rod LL @: 90890-06605

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

the fonruard gear using a press.


6-27

E for USA and CanadaB for worldwide

NOTE:Use a special service tool or a general pipewith the specified measurements.

General pipe @:D = 38 mm (1.49 in), d = 32 mm (1.26 in)


Eo

s62Y6325

tr

E

62Y141 1


2. lnstall the new oil seals to the oil sealhousing as shown.


Oil seal installer @: YB-06168Driver handle @: YB-06071Needle bearing attachment @:

90890-06653Driver rod L3 @: 90890-06652

lnstalling the drive shaft1. lnstall the forward gear, then the drive

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



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

lnstalling the lower unit1. Set the gearshift to the neutral position at

power unit and lower unit.

tr

E

tr

tu

E

62Y141 1 6-28

3,

lnstall the two dowel pins Q to the lowerunit.

lnstall the lower unit to the upper case,and then tighten the bolts to the specifiedtorque.

Mounting bolt: 40 N.m (4.0 kgf.m, 29 ft.lb)

4. lnstall the trim tab @ to its original posi-tion, and then connect the speedometerhose @.

lnstall the propeller and propeller nut,tighten the nut finger tight. Place a blockof wood between the anti-cavitation plateand propeller to keep the propeller fromturning, and then tighten the nut to thespecified torque.

5.

J

6-29 62Y141 1



lf the grooves in the propeller nut @ do notalign with the cotter pin hole, tighten the nutuntilthey are aligned.

Propeller nut @:35 N.m (3.5 kgf.m, 25 ft.lb)

62Y141 1 6-30

Shimming (F50) (for USA and Ganada)

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6-31 62Y141 1

Shimming (F50) (for USA and Canada)

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 pafis.

Selecting the pinion shims1. Calculate the specified value (M0) as

shown in the examples below.

NOTE:"P" is the deviation of the lower case dimen-sion from standard. The "P" mark @ isstamped on the trim tab mounting surface ofthe lower case in 0,01 mm units. lf the "P"mark is unreadable, assume that "P" is zeroand check the backlash when the unit isassembled.

Specified value (M0) = 0.30 + P/100 mm

Example:lf "P" is "+5", thenM0 = 0.30 + (+5)/100 mm = 0.30 + 0.05 mm

= 0.35 mmlf "P" is'L5", thenM0 = 0,30 + (-5)/100 mm = 0,30- 0,05 mm

= 0.25 mm

2. lnstall the drive shatt and drive shaftbearing @ to the shim selecting tools.

3. Attach the clamp @ to the gauge baseusing four bolts of appropriate sizes.

62Y141 1

NOTE:lnstall the shim selecting tools to the driveshaft so that the shaft is at the center of thehole.

Pinion shim selecting tools:YB-34432-8 @), YB-34432-104 @),

YB-34432-114 G), YB-34432-17 Q)

4. lnstallthe pinion and pinion nut, and thentighten the nut to the specified torque.

Pinion nut: 75 N.m (7.5 kgf.m, 54 Ít.lb)

6-32

5. Measure the clearance (M) between theshim selecting tool and the pinion asshown,

s62Y6370

NOTE:Measure the pinion at three points to find theclearance average.

6. Select the pinion shims (T3).

NOTE:The sum of T3 and M should not be morethan M0.

Pinion shim thickness (T3) = M0 - M

Available shim thicknesses:0.10, 0.12, 0.15, 0.18, 0.30, 0.40, and0.50 mm

Selecting the forward gear shims1, Calculate the specified value (M0) as


NOTE:"F" is the deviation of the lower case dimen-sion from standard. The "F" mark @ is

stamped on the trim tab mounting surface ofthe lower case in 0.01 mm units. lf the "F"

mark is unreadable, assume that "F" is zeroand check the backlash when the unit isassembled.

Specified value (M0) = 0.95 + F/100 mm

Example:lf "F" is "+5", thenM0 = 0.95 + (+5)i100 mm = 0.95 + 0.05 mm

= 1.00 mmlf "F" is "-5", thenM0 = 0.95 + (-5)/100 mm = 0.95 - 0.05 mm

= 0.90 mm

6-33 62Y141 1

Shimming (F50) (for USA and Canada)

2. lnstall the taper roller bearing @ to theshim selecting tools.

NOTE:Tighten the nut four turns after it contacts thespring.

Forward gear shim selecting tools:Y 8-34446^1 Ø, YB-34446-3 G),Y B-34446-4 @, YB-34446- 1 5 €)

3. Measure the clearance (M) between thegauge pin and press plate.

s62Y6390

4. Select the forward gear shims (T1).


Forward gear shim thickness (Tl) =MO-M

Available shim thicknesses:0.10, 0.12, 0.15, 0.18, 0.30, 0.40, and0,50 mm

Selecting the reverse gear shims1. Measure the backlash to find the neces-

sary shim thickness (T2). Add or removeshims if out of specification. For measur-ing procedures, see "Measuring the for-ward and reverse backlash" in thischapter.

NOTE:Measure the backlash with the originalshim(s). lf the original shim(s) is unavailable,start with a 0.50 mm shim.


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62Y141 1 6-34

Shimming (F50A) (for worldwide)

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6-35 62Y141 1

Shimming (F504) (for worldwide)

Shimming




inner pafis.

Selecting the pinion shims1. lnstall the drive shaft and drive shaft

bearing @ to the shimming tools.

NOTE:. Select the shim thickness (T3) by using the

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

. lnstall the shimming tool to the drive shaftso that the shaft is at the center of the hole.

. Tighten the wing nuts another 1/4 turn aflerthey contact the fixing plate Ø.

Pinion height gauge @: 90890-06702



3. Measure the distance (M) between theshimming tool and the pinion as shown.

ffi## ffi's62y645

Measure the pinion at three points to find theclearance average.

Digital caliper @: 90890-06704

4. Calculate the pinion shim thickness (T3)as shown in the examples below.

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

Pinion shim thickness (T3) =M-11.30mm-P/100

62Y141 1 6-36

Example:lf "M" is "11 .70 mm" and "P" is "+5", thenT3 = 1 1.70 - 1 1.30 - (+5)i100 mm

= 0.40 - 0.05 fiìffr = 0.35 mmlf "M" is "11 .70 mm" and "P" is "-5", thenT3 = 1 1.7O - 1 1.30 - (-5)/100 mm

= 0.40 + 0.05 mm = 0.45 mm

5. Select the pinion shim(s) (Tg) as follows.


Example:lf "T3" is "0.44 mm", then the pinion shim is0.45 mm.lf "T3" is "0.39 mm", then the pinion shim is0.40 mm.

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

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

s62Y6425

s62Y6430


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

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

Shimming plate @: 90890-06701Digital caliper @: 90890-06704

2. Calculate the forward gear shim thick-ness (T1) as follows.


stamped on the trim tab mounting surface ofthe lower case in 0.01 mm units. lf the "F"mark is unreadable, assume that "F" is zeroand check the backlash when the unit isassembled.

Fonruard gear shim thickness (T1) =22.75+F/100-M

Calculated numeralat 1/100 place Rounded numeral

1,2 2

3,4,5 5

6,7,8 I9, 10 10

6-37 62Y141 1

Shimming (F504) (for worldwide)Example:lf "M" is "22.45 mm" and "F' is "+5", thenT1 = 22.75 + (+5)/100 -22.45mm

= 0.30 + 0.05 mm = 0.35 mmlf "M" is "22.45 mm" and "F" is "-5", thenT1 =22.75 + (-5)/1O0-22.45mm

= 0.30 - 0.05 fiìÍr = 0.25 mm

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


Example:lf .Tf is "0.45 mm", then fonruard gear shimis 0.42 mm,lf "T1" is "0.50 mm", then fonruard gear shimis 0.48 mm.

Selecting the reverse gear shims1. Measure the backlash to find the shim

thickness (T2). Add or remove shims ifout of specification. For measuring pro-

cedures, see "Measuring the fonryard andreverse backlash" in this chapter.

NOTE:Measure the backlash with the originalshim(s). lf the original shim(s) is unavailable,start with a 0.50 mm shim.


Calculated numeralat 1/100 place

Rounded numeral

1,2 0

3,4,5 2

6,7,8 5

9, 10 B

62Y141 1 6-38

Backlash (F50/F504)Measuring the forward and reversegear backlash1. Remove the water pump assembly.



Shift rod push arm: YB-06052Shift rod push arm: 90890-06052

3. lnstall the special service tool so that itpushes against the propeller shaft.


NOTE:Tighten the universal puller or center boltwhile turning the drive shaft until the driveshaft can no longer be turned.

Bearing housing puller @: YB-06234Universal puller @: YB-06117Bearing housing puller claw @:

90890-06s64Stopper guide plate @: 90890-06501Center bolt @; 90890-06504

4. lnstall the backlash indicator onto thedrive shaft (18 mm [0.71 in] in diameter),then the dial gauge onto the lower unit.

lnstall the dial gauge so that the plunger @contacts the mark (D on the backlash indica-tor.

Backlash indicator gauge @: YB-06265Backlash indicator @: 90890-06706Magnetic plate @: YB-07003Magnet base plate @: 90890-07003Dial gauge @:YU-03097Dial gauge set @: 90890-01252Magnet flexible stand @: YU-34481Magnet base @: 90890-06705

E

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6-39 62Y141 1

Backlash (F50/F504)

5. Slowly turn the drive shaft clockwise andcounterclockwise and measure the back-lash when the drive shaft stops in eachdirection.

Forward gear backlash:0.18-0.54 mm (0.007-0.021 in)

6. Add or remove shims if out of specifica-tion.

Forward gearbacklash

Shim thickness

Less than0.18 mm (0.007 in)

To be decreased by(0.36-M)x0.56

More than0.54 mm (0.021 in)

To be increased by(M-0.36)x0.56

M: Measurement


7. Remove the special service tools fromthe propeller shaft.

8. Apply a load to the reverse gear byinstalling the propeller @ without thespacer @, the washer @ backwards,then the washer @ as shown.

Tighten the propeller nut @ while turning thedrive shaft until the drive shaft can no longerbe turned.

9. Slowly turn the drive shaft clockwise andcounterclockwise and measuring thebacklash when the drive shaft stops ineach direction.

Reverse gear backlash:0.71-1.07 mm (0.028-0.042 in)


Reverse gearbacklash

Shim thickness





M: Measurement


11. Remove the special service tools, andthen install the water pump assembly.

s62Y6470

62Y141 1 6-40

Lower unit (T50/FT50B, FT50C)

I.@4

1B

62Y141 16-41




1

2

3

4

5

6

7

II10

11

12

13

14

15

16

17

1B

Lower unit

Plastic tie

Hose

Check screw

Gasket

Dowelpin

Bolt

Drain screw

Grommet

Bolt

Bolt

Thrust washer

Propeller

Washer

Washer

Cotter pin

Propeller nut

Trim tab

1

1

1

1

2

2

4

1

1

1

1

1

1

1

1

1

1

1

M10 x 40 mm

M10 x 45 mm, O: 12 mm

M8x60mm

7

40

7

35

0.7

4.O

0.7

3.5

5.1

29

5.1

25

62Y141 1 6-42

Removing the lower unit1, Drain the gear oil, For draining proce-

dures, see Chapter 3, "Replacing thegear oil."

2. Sel the gearshift to the neutral position,and place a block of wood between theanti-cavitation plate and propeller to keepthe propeller from turning, and thenremove the propeller nut and propeller.


Disconnect the speedometer hose O.

Mark the trim tab @ at the area shown,and then remove it.

Loosen the bolts, and then remove lhelower unit from the upper case.

5.

3.

4.

6-43 62Y141 1


- MEMO -

62Y141 1 6-44

Water pump and shift rod (T50/FT50B, FT50C)

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6-45 62Y141 1




1

2

3

4

5

6

7

II10

11

12

13

14

15

16

17

1B

19

20

21

22

23

24

Shift rod assembly

Oilseal

Oilseal housing

O-ring

Circlip

Shift rod

O-ring

Bolt

Woodruff key

Bolt

Bolt

Water pump housing

Grommet

Gasket

lnseft plate cartridge

lmpeller

Outer plate cartridge

Gasket

Dowelpin

Oil seal housing assembly

Gasket

Oilseal housing

O-ring

Oilseal

1

1

1

1

1

1

1

2

1

2

2

1

1

1

1

1

1

1

2

1

1

1

1

2

M6x16mm

M8x55mmM8x45mm

62Y141 1 6-46

Removing the water pump and shiftrod1. Remove the water pump assembly and

shift rod assembly @.

Pull up the shift rod assembly a little @ to O¡s-

connect it from the shift slider @, turn it coun-terclockwise 90'@, and then remove it.

Checking the water pump and shiftrod1. Check the pump housing for deforma-

tion. Replace if necessary.

2. Check the impeller @ and insert plate

cartridge @ for cracks or wear. Replaceif necessary.

s62Y6540

Check the Woodruff key @ and thegroove @ on the drive shaft for wear.Replace if necessary.

4. Check the shift rod for cracks or wear.Replace if necessary.

3.Iñ

s62Y6530

v

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@(P

6-47 62Y141 1


lnstalling the water pump and shiftrod1. lnstall the shift rod assembly @.

NOTE:lnstall the shift rod assembly into the lowercase, turn it clockwise 90'@, and then push

it down (D to connect it to the shift slider @.

lnstall the new oil seals into the oil sealhousing as shown.


Bearing housing oil seal installer @:YB-06269

Driver handle @: YB-06071Needle bearing attachment @:

90890-06610Driver rod L3 @: 90890-06652

lnstallthe new O-ring @.

lnstallthe new gasket @, oilseal housing

@, new gasket @, and outer plate car-tridge @.

lnstall the Woodruff key into the driveshaft.

tr

3.

4.

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s62Y6555

62Y141 1 6-48

6. Apply grease to the impeller, and theninstall it to the drive shaft.

NOTE:Align the groove on the impeller @ with theWoodruff key @.

7. lnstall the inseñ plate cartridge @ andgrommet @ into the pump housing @.

Align the insert plate cartridge projection @with the hole (D in the pump housing.

lnstall the new gasket @, pump housingassembly @, and dowel pins @ to thelower case,

lnstall and tighten the bolts @.

When installing the pump housing, turn thedrive shaft clockwise while pushing down thepump housing.

9.

6-49 62Y141 1


- MEMO -

62Y141 1 6-50

Propeller shaft housing (T50/FT50B, FT50C)

6-51 62Y141 1




1

2

3

4

5

6

7

B

I10

11

12

13

14

15

16

17

18

19

20

Propeller shaft assembly

Propeller shaft housingassembly

Ball

Slider

Shift plunger

Cross pin

Dog clutch

Spring

Propeller shaft

Washer

Straight key

Claw washer

Ring nut

Reverse gear

Thrust washer

Ballbearing

O-ring

Propeller shaft housing

Needle bearing

Oilseal

1

1

2

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

2

[@!rnËælË

105 10.5 76

62Y141 1 6-52

Removing the propeller shafthousing assembly1. Straighten the claw washer tabs @, and

then remove the ring nut and clawwasher.

Gland nut wrench Q:YB-34447Ring nut wrench 3 O: 90890-06511Ring nut wrench extension @:

90890-06513

2. Pull out the propeller shaft housingassembly.

E for USA and CanadaE For worldwide

Bearing housing puller @: YB-06207Universal puller @: YB-06117Bearing housing puller daw L @:

90890-06502Stopper guide plate @: 90890-06501Center bolt @: 90890-06504

Disassembling the propeller shafthousing1. Remove the reverse gear and thrust

washer.

E


Slide hammer and adapters O: YB-06096Bearing separator @: 90890-06534Stopper guide plate @: 90890-06501Stopper guide stand @: 90890-06538Bearing puller @: 90890-06535Bearing puller claw 1 @: 90890-06536

E

6-53 62Y141 1


tr

NOTE:lnstall the bearing separator @ between thereverse gear and thrust washer completely,then the other special service tools.

2. Remove the ball bearing.

E

s62Yô625

E For USA and CanadaE forworldwide


3. Remove the oil seals and needle bear-ing.




Disassembling the propeller shaftassembly1. Remove the spring @, and then remove

the cross pin @, dog clutch @, slider andshift plunger.

Checking the propeller shaft housing1. Clean the propeller shaft housing using a

soft brush and cleaning solvent, and thencheck it for cracks. Replace if necessary.

62Y141 1 6-54

2. Check the teeth and dogs of the reversegear for cracks or wear. Replace thegear if necessary.

Check the bearings for pittingbling. Replace if necessary.

S62Y66¿lO

or rum-

S62Y66¡15

Checking the propeller shaft1. Check the propeller shaft for bends or


2. Check the dog clutch and shift slider forcracks or wear. Replace if necessary.

Assembling the propeller shaftassembly1. lnstall the dog clutch as shown.

NOTE:lnstall the dog clutch @ with the "F'mark @facing toward the shift slider.

Assembling the propeller shafthousing1. lnstall the needle bearing into the propel-

ler shaft housing to the specified depth.

E

6-55 62Y141 1


trtr


. lnstallthe needle bearing with the manufac-ture identification mark @ facing toward theoil seal (propeller side),

. When using the driver rod, do not strike thespecial tool in a manner that will force thestopper @ out of place.

Driver handle @: YB-06071Bearing housing needle bearing remover @:

YB-061s3Driver rod SS @: 90890-06604Needle bearing attachment @:


Depth @: 25.G-25.5 mm (0.98-1.00 in) E

2. Apply grease to the new oil seals, andthen install them into the propeller shafthousing to the specified depth.

EI


lnstall an oil seal halfway into the propellershaft housing, then the other oil seal.

Bearing housing oil seal installer @:YB-06269

Driver handle @: YB-06071Ball bearing attachment @: 90890-06655Driver rod LS @: 90890-06606

Depth @:4.5-5.5 mm (0.18-0.22in)

3. lnstallthe thrust washer @ and ball bear-ing O to the reverse gear @ using apress.


62Y141 1 6-56

NOTE:lnstall the ball bearing with the manufactureidentification mark @ facing outward (propel-ler side).

Drive shaft needle bearing depth stop @:Y8-34473


4. lnstall the reverse gear assembly to thepropeller shaft housing using a press.

Forward gear bearing cup installer @:YB-06109


lnstalling the propeller shaft housing1, lnstall the washer @, propeller shaft

assembly @, into the propeller shafthousing assembly @.

2. Apply grease to the new O-rings.

s62Y6705

lnstallthe propeller shaft housing assem-bly @ into the lower case, and theninstall the straight key @, claw washer

@, and ring nut @.

Tighten the nut to the specified torque.

NOTE:Secure the ring nut by bending one lab @into the slot in the ring nut and the other tabstoward the propeller shaft housing assembly.

\

ff-3.

4.

s62Y67 1 5

6-57 62Y141 1


Gland nut wrench @:YB-34447Ring nut wrench 3 @: 90890-06511Ring nut wrench extension @:

90890-06513

Ring nut @: 105 N.m (10.5 kgf.m, 76 ft.lb)

62Y141 1 6-58

Drive shaft and lower case (T50/FT50B, FT50C)

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3

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s62Y6720

62Y141 16-59




1

2

3

4

5

6

7

II10

11

12

13

14

15

16

17

1B

19

20

21

22

Drive shaft


Bearing outer race

Pinion shim

Sleeve

Hose

Plastic tie

Joint

Nut

Water inlet cover

Screw

Seal

Plate

Forward gear shim

Bearing outer race


Needle bearing

Forward gear

Needle bearing

Pinion

Nut

Lower case

1

1

1

1

1

1

1

1

2

1

1

1

1

1

1

1

1

1

1

1

As required

As required

O:22 mm

5

95

0.5

9.5

3.6

69

62Y141 1 6-60

E

Removing the drive shaft1, Remove the drive shaft assembly and

pinion, and then pull out the forwardgear.

Drive shaft holder O: YB-06049Drive shaft holder 4 @: 90890-06518Pinion nut holder @: 90890-06505Socket adapter 2 @: 90890-06507

Disassembling the drive shaft1. lnstall the pinion nut @, tighten it finger

tight, and then remove the drive shaftbearing@usingapress.

E For USA and CanadaE for worldwide

o Do not press the drive shaft threaOs @directly.

. Do not reuse the bearingn alwaysreplace it with a new one.

Bearing splitter plate @: YB-06219Bearing inner race attachment @:

90890-06639

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

forward gear using a press.

Do not reuse the bearingn always replaceit with a new one.

Bearing splitter plate @: YB-06219Bearing separator @: 90890-06534

2. Remove the needle bearing from the for-ward gear.

E

\

e

I

6-61 62Y141 1


tr


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


Disassembling the lower case1. Remove the taper roller bearing outer

race and shim(s).


NOTE:lnstallthe claws as shown.

Slide hammer and adapters @: YB-06096Bearing outer race puller @: 90890-06523Outer race puller claw A @: 90890-06532

2. Remove the drive shaft bearing outerrace, shim(s), and drive shaft sleeve.


NOTE:lnstallthe claws as shown.

Slide hammer and adapters @: YB-06096Stopper guide plate @: 90890-06501Stopper guide stand @: 90890-06538Bearing puller @: 90890'06535Bearing puller claw 1 @: 90890-06536

62Y141 1 6-62

3. Remove the needle bearing.


Needle bearing attachment @:90890-0661 1


Checking the pinion and forwardgear1. Check the teeth of the pinion, and the

teeth and dogs of the forward gear forcracks or wear. Replace if necessary.

Checking the bearings1. Check the bearings for pitting or rum-

bling. Replace if necessary.

Checking the drive shaft1, Check the drive shaft for bends or wear.


Checking the lower case1 . Check the skeg and torpedo for cracks or

damage. Replace if necessary.

s62Y6791

Assembling the Iower case1. lnstall the needle bearing into the lower

case to the specified depth.

6-63 62Y141 1



. lnstallthe needle bearing with the manufac-ture identification mark @ facing upward.

. When using the driver rod, do not strike thespecial tool in a manner that will force thestopper (D out of place.

Driver handle O: YB-06071Drive shaft needle bearing remover andinstaller Ø;YB-06155Drive shaft needle bearing depth stop @:

Y8-34473Driver rod SL @: 90890-06602Needle bearing attachment @:

90890-0661 1

Bearing depth plate @: 90890-06603

Depth @: 136.4-188.6 mm (7.34-7.43in)

2. lnstall the sleeve, original shim(s), anddrive shaft bearing outer race.


Add or remove shimso if necessary, whenreplacing the pinion or lower case.

NOTE:. Apply the gear oil to the inside and outside

of the sleeve.. lnstallthe sleeve by facing the projection @

forward.

Crank upper and lower seal installer @:Y8'06244

Bearing outer race attachment @:90890-06626

Driver handle @: YB-06071Driver rod LL @: 90890-06605

62Y141 1 6-64

3. lnstallthe originalshim(s) and taper rollerbearing outer race.

dA

(Ð

s62Y681 5


Fonruard gear needle bearing and taperedroller bearing installer O: YB-06200Bearing inner race attachment @:

90890-06662

2. lnstall the new needle bearing into theforward gear to the specified depth.




Depth @: 1.1 mm (0.04 in)

ÊA)@"9*.


Add or remove shimsn if necessaryo whenreplacing the forward gear or |ower case.

Forward gear bearing cup installer @:YB-06276-B

Driver handle @: YB-06071Bearing outer race attachment @:

90890-06621Driver rod LL @: 90890-06605

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

the fonruard gear using a press.

6-65 62Y141 1


{}

I

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U

tr

Assembling the drive shaft1. lnstall the new drive shaft bearing into

the drive shaft using a press.

E


NOTE:Use the special seruice tool or a general pipewith the specified measurements.

General pipe @:D = 38 mm (1.49 in), d=32 mm (1.26 in)


lnstalling the drive shaft1. lnstall the forward gear, then the drive

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



lnstalling the Iower unit1. Set the gearshift to the neutral position at

power unit and lower unit.

SAt6

W

62Y141 1 6-66

3,

lnstall the two dowel pins Q to the lowerunit.

lnstall the lower unit to the upper case,and then tighten the bolts to the specifiedtorque.

Mounting bolt: 40 N.m (4.0 kgf.m, 29 ft.lb)

4. lnstall the trim tab @ to its original posi-tion, and then connect the speedometerhose @.

lnstall the propeller and propeller nut,tighten the nut finger tight. Place a blockof wood between the anti-cavitation plateand propeller to keep the propeller fromturning, and then tighten the nut to thespecified torque.

s62Y651 5

9@ --tY-Gl

I 572

5.

I

J

r

6-67 62Y141 1



lf the grooves in the propeller nut @ do notalign with the cotter pin hole, tighten the nutuntilthey are aligned.

Propeller nut @:35 N.m (3.5 kgf.m, 25 ft.lb)

62Y141 1 6-68

Shimming (T50) (for USA and Ganada)

I

I

I

I

I

I

I

I

I

I

6-69 62Y141 1

Shimming (T50) (for USA and Canada)

Shimming




inner pafi(s).

Selecting the pinion shims1. Calculate the specified value (M0) as


NOTE:"P" is the deviation of the lower case dimen-sion from standard. The "P" mark @ isstamped on the trim tab mounting surface ofthe lower case in 0,01 mm units. lf the "P"mark unreadable, assume that "P" is zeroand check the backlash when the unit isassembled.

Specified value (M0) = Q.2O + P/100 mm

Example:lf "P" is "+5", thenM0 = 0.20 + (+5)/100 mm = 0.20 + 0.05 mm

= 0.25 mmlf "P" is'L5", thenM0 = 0,20 + (-5)/100 mm = o.20- 0,05 mm

= 0.15 mm

2. lnstall the drive shatt and drive shaftbearing @ to the shim selecting tools.

3. Attach the clamp @ to the gauge baseusing four bolts of appropriate sizes.

62Y141 1

NOTE:lnstall the shim selecting tools to the driveshaft so that the shaft is at the center of thehole.

Pinion shim selecting tools:YB-34432-9 @), YB-34432-104 @),

YB-34432-114 G), YB-34432-17 Q)


Pinion nut: 95 N.m (9.5 kgf.m, 69 Ít.lb)

6-70

5. Measure the clearance (M) between theshim selecting tool and the pinion asshown,

s62Y6875

NOTE:Measure the pinion at three points to find theclearance average.

6. Select the pinion shims (T3).


Pinion shim thickness (T3) = M0 - M


Selecting the forward gear shims1, Calculate the specified value (M0) as


s62Y6885

NOTE:"F" is the deviation of the lower case dimen-sion from standard. The "F' mark @ is

stamped on the trim tab mounting surface ofthe lower case in 0.01 mm units. lf the "F"mark is unreadable, assume that "F" is zeroand check the backlash when the unit isassembled.

Specified value (M0) = 1 .70 + F/100 mm

Example:lf "F" is "+5", thenM0 = 1 .70 + (+5)/100 mm = 1.70 + 0.05 mm

= 1.75 mmlf "F" is "-5", therìM0 = 1 .70 + (-5)/100 mm = 1.7O - 0.05 mm

= 1.65 mm

6-71 62Y141 1

Shimming (T50) (for USA and Canada)

2. lnstall the taper roller bearing @ to theshim selecting tools.

4. Select the fonruard gear shims (T1).

T1

NOTE:The sumthan M0.

of T1 and M should not be more

Forward gear shim thickness (T1) =MO_M

Available shim thicknesses:0,10, 0,12, 0.15, 0,18, 0.30, 0,40, and0.50 mm

|,@o,l e*$-N@M>

É

Tighten the nut four turns after it contacts thespring.

Forward gear shim selecting tools:Y 8-34446^1 Ø, YB-34446-3 G),Y B-34446-5 @, YB-34446-7 €)

3. Measure the clearance (M) between thegauge pin and the press plate.

62Y141 1 6-72

Shimming (FT50B, FT50C) (for worldwide)

I

I

I

I

I

I

I

I

I

I

6-73 62Y141 1

Shimming (FT50B, FT50C) (for worldwide)

Shimming




inner pafi(s).

Selecting the pinion shims1. lnstall the drive shaft and drive shaft

bearing @ to the shimming tools.


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

. lnstall the shimming tool to the drive shaftso that the shaft is at the center of the hole.

. Tighten the wing nuts another 1/4 of a turnafter they contact the fixing plate @.

Pinion height gauge @: 90890-06702



3. Measure the distance (M) between theshimming tool and the pinion as shown.

ffi## ffi's62y6e5

Measure the pinion at three points to find theclearance average.

Digital caliper @: 90890-06704

4. Calculate the pinion shim thickness (T3)as shown in the examples below.

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

Pinion shim thickness (T3) =M - 31.50 mm - P/100

62Y141 1 6-74

Example:lf "M" is "32.10 mm" and "P" is "+5", thenT3 = 32,10 - 31.50 - (+5)i100 mm

= 0.60 - 0.05 fiìffr = 0.55 mmlf "M" is "32j0 mm" and "P" is "-5", thenT3 = 32.10 - 31 .50 - (-s)/100 mm

= 0.60 + 0.05 mm = 0.65 mm

5. Select the pinion shim(s) (Tg) as follows.


Example:lf "T3" is "0.59 mm", then the pinion shim is0.60 mm.lf "T3" is "0.64 mm", then the pinion shim is0.65 mm.

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

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

s62Y6930


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

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

Shimming plate @: 90890-06701Digital caliper @: 90890-06704

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

s62Y6935


stamped on the trim tab mounting surface ofthe lower case in 0.01 mm units. lf the "F"mark unreadable, assume that "F" is zeroand check the backlash when the unit isassembled.

Fonruard gear shim thickness (T1) =24.50+F/100-M

Calculated numeralat 1/100 place Rounded numeral

0, 1 2

2,3, 4 5

5,6,7 I8,9 10

6-75 62Y141 1

Shimming (FT50B, FT50C) (for worldwide)Example:lf "M" is "24.00 mm" and "F' is "+5", thenT1 = 24.50 + (+5)/100 - 24.00 mm

= 0.50 + 0.05 mm = 0.55 mmlf "M" is "24.00 mm" and "F" is "-5", thenT1 = 24.50 + (-5)/100 - 24.00 mm

= 0.50 - 0.05 fiìÍr = 0.45 mm

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


Example:lf "T1" is "0.45 mm", then the fonruard gearshim is 0.42 mm.lf "Tf is "0.50 mm", then the fonruard gearshim is 0.48 mm.

Calculated numeralat 1/100 place

Rounded numeral

1,2 0

3,4,5 2

6,7,8 5

9, 10 B

62Y141 1 6-76

E

Backlash (T50/FT50B, FT50C)Measuring the forward and reversegear backlash1. Remove the water pump assembly.



Shift rod push arm: YB-06052Shift rod push arm: 90890-06052

3. lnstall the special service tool so that itpushes against the propeller shaft.


NOTE:Tighten the universal puller or center boltwhile turning the drive shaft until the driveshaft can no longer be turned.

Bearing housing puller @: YB-06207Universal puller @: YB-06117Bearing housing puller daw L @:

90890-06s02Stopper guide plate @: 90890-06501Center bolt @; 90890-06504

4. lnstall the backlash indicator onto thedrive shaft (18 mm [0.71 in] in diameter),then the dial gauge onto the lower unit.

NOTE:lnstall the dial gauge so that the plunger @contacts the mark (D on the backlash indica-tor.

6-77 62Y141 1

Backlash (T50/FT50B, FT50C)

Backlash indicator gauge @: YB-06265Backlash indicator @: 90890-06706Magnetic plate @: YB-07003Magnet base plate @: 90890-07003Dialgauge @:YU-03097Dialgauge set @: 90890-01252Magnet flexible stand @: YU-34481Magnel base @: 90890'06705


Forward gear backlash:0.12-0.45 mm (0.005-0.018 in)


Forward gearbacklash

Shim thickness





M: Measurement


Remove the special seruice tools fromthe propeller shaft.

Apply a load to the reverse gear by install-ing the propeller @ without the spacer @,and washer @ and washer @ as shown.

NOTE:Tighten the propeller nut @ while turning thedrive shaft until the drive shatt can no longerbe turned.


Reverse gear backlash:0.71-1.11 mm (0.028-0.044 in)

10. Check the pinion shim if out of specifica-tion,

11. Remove the special service tools, andthen install the water pump assembly.

7.

s62Y6965

62Y141 1 6-78

Bracket unit

Troubleshooting


Tiller handle (F50/F504, T50ÆT508) .7-5Checking the throttle cable and shift cable.. ......7-15Assembling the tiller handle........ ....7-15

Tifler handle (FT50G). ..........7-17Checking the throttle cable and shift rod ...........7-23Assembling the tiller handle..,..,,. ....7-23Lubricating the throttle gear

Bottom cowlingChecking the shift rod assembly operation ........7-29

Upper 7-31Disassembling the oil pan........ .......7-39Checking the oil strainer and the relief valve ..,...,..,.7-39Assembling the oil pan ....... .....7-39lnstalling the upper case........... ......7-41

Clamp brackets 7-43Removing the clamp brackets ........7-45lnstalling the clamp brackets ..........7-45Adjusting the trim sensor....... .........7-46

Swivel bracket and steering arm

lnstalling the steering arm .........7-49

Power trim and tilt unitRemoving the power trim and tilVhydro tilt .............. .............7-53

Tilt cylinder and trim cylinder

Trim cylinder 7-57

.7-1

62Y141 1

Gear pumpDisassembling the tilt cylinder ........7-63Disassembling the trim cy1inder................. ........7-63Disassembling the gear pump ........7-64Checking the tilt cylinder and trim cylinder ........7-64Check the valves .........7-65Checking the filters ......7-65Checking the gear pump ......... .......7-66Assembling the gear pump......... ....7-66Assembling the trim cylinder...... .....7-67Assembling the tilt cylinder...... .......7-69Bleeding the power trim and tilt (not installed).... ..................7-7OBleeding the power trim and tilt (built-in) ...........7-71

Power trim and tilt motor... ...................7-73Checking the power trim and tilt motor.... ..........7-75Assembling the power trim and tilt motor ..........7-76lnstalling the power trim and ti1t.............. ...........7-76

Power trim and tilt electrical system.. 7-74Checking the fuse..... ...7-79Checking the power trim and tilt relay ...............7-79Checking the power trim and tilt switch/trailer switch ...........7-80Checking the trim sensor,..,,.. ,,..,..,.7-80

62Y141 1

TroubleshootingBefore troubleshooting the power trim and tilt unit, check that all electrical connections are tight andfree from corrosion, and that the battery is fully charged to 12 V.Symptom: Power trim and tilt unit does not operate.

7-1

Listen for the operation soundof the power trim and tilt relay.

Check the voltage between each terminal.. Between the sky blue (Sb) lead and black (B) lead.. Between the light green (Lg) lead and black (B) lead.

Gheck for continuitybetween the battery,relay, and switch.

Listen for the operation soundof the power trim and tilt motor.

Replace the power trim and tiltrelay.

Check the voltage between thesky blue (Sb) lead and black (B)lead.

Replace the powertrim and tilt relay.

Check that the manual releaseplug is closed.

Check the power trim and tiltmotor.

Close the plug.

Check the power trim and tiltfluid level,

Add fluid to the correct level.

Disassemble the power trim andtilt unit, and then check it.

62Y141 1

Troubleshooting

Check that the manual releaseplug is closed.

Close the plug.

Check the power trim and tiltfluid level.

Add fluid to the correct level.

Disassemble the power trim andtilt unit, and then check it.

Symptom: Power trim and tilt unit does not hold the outboard motor up.

62Y141 1 7-2

Symptom: Shift mechanism of the forward gear and reverse gear does not operate properly.

Check the shift cable operation,

Check the shift cables and linksof the remote control box.

Check the operation of the shiftrod.

Gheck the detent of the bottomcowling.

Check the condition of the shiftrod connection between thelower case and upper case.

Replace the shift rod.

Disassemble the lower case,and then check the shifting gearmechanism and the respectiveparts.

7-3 62Y141 1

Troubleshooting / Special service tools


Trim and tilt cylinder wrenchYB-06175-28

Cylinder-end screw wrench90890-06544

62Y141 1 7-4

lffiTìf -l,,""n",un*

Tiller handle (F50/F50A, T50/FT50B)

/rt

llì

20la=)

21

7-5

Tiller handle (F50/F504, T50/FT50B)



1

2

3

4

5

6

7

II10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

Tiller handle assembly

Friction plate

Tiller handle wiringharness


Grommet

Clip

Throttle cable

Plate

Bolt

Bolt

Negative battery lead

Cable guide

Grommet

Nut

Washer

Positive battery lead

Connector

Clip

Shift cable

Plastic tie

Cover

Screw

Trailer switch coupler

PTT switch coupler

Bolt

Screw

Collar

Clamp

Nut

Bolt

1

1

1

1

1

1

1

1

3

1

1

1

1

1

1

1

1

1

1

2

1

3

1

1

1

1

1

1

2

2

Models applicable fortachometer, trim meter orwarning buzzer

M6x20mmM8x16mm

M6x35mm

Models with trailer switch

M6x35mmM6x25mm

M6x16mm

9

7

37

0.9

0.7

3.7

6.5

5.1

27

62Y141 1 7-6

lffiTìf lr,""n",un*

20la=)

21

V-^{--t Iq/

r22

7-7




31

32

33

34

35

36

37

38

39

Nut

Collar

Bolt

Self-locking nut

Bracket

Steering lock shaft

Steering lock knob

Friction plate

Friction piece

2

2

2

1

1

1

1

1

2

M8x50mm

62Y141 1 7-8


o7a ià1.é

-D4\I \\'r

Æ\ì[ \\

\ \-!-/I

'.21"'1.

il

t ,r/,^/ l:/'l I ),

7-9 62Y141 1




1

2

3

4

5

6

7

II10

11

12

13

14

15

16

17

1B

19

20

21

22

23

24

25

26

27

28

29

30

Tiller handle sub assembly

Screw

Shift lever cover

Bolt

Shift lever

Bushing

Washer

Bushing

Nut

Engine shut-otf switch

Nut

Washer

Bracket

Collar

Wave washer

Washer

Bolt

Clamp

Screw

Connector

Engine start switchhousing

Engine start switch

Nut

Bolt

Screw

Bolt

Cover

Power trim and tilt switch

Screw

Screw

1

2

1

1

1

1

1

2

1

1

1

1

1

1

1

1

1

1

1

2

1

1

1

1

1

1

1

1

5

2

M6x10mm

M8x40mm

M6x25mm

M6x20mm

M6x16mmM6x16mm

4

38

5

0.4

3.8

0.5

2.9

27

3.7

62Y141 1 7-10


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-D4\I \\'r

Æ\ì[ \\

\ \-!-/I

'.21"'1.

il

7-11

t ,r/,^/ l:/'l I ),

62Y141 1




31

32

33

34

35

36

Screw

Throttle grip

Screw

Washer

Spring

Bushing

2

1

1

1

1

1

M6x40mm

M5x25mm

62Y141 1 7-12

\

)

/I$.

)

-/

-/ 21Vå i

Li+f'i,#l

s62Y7030

62Y141 17-13




1

2

3

4

5

6

7

II10

11

12

13

14

15

16

17

1B

19

20

21

22

23

24

25

26

27

28

29

Tiller handle

Cotter pin

Friction adjusting knob

Grommet

Plastic tie

Cable clamp

Stay

Bolt

Throttle cable

Clip

Throttle arm

Throttle arm shaft

Shift cable

Shift cable bracket

Bolt

Clip

Frame

Screw

Bolt

Spring housing

Spring

Actuator

Roller

Bushing

Shift arm

Bolt

Throttle shaft

Friction piece

Nut

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

2

1

1

1

1

1

1

1

2

1

1

1

M6x14mmShort

Long

M6x14mm

M5x14mmM6x14mm

M6x30mm

62Y141 1 7-14

Checking the throttle cable and shiftcable1. Check the operation of the throttle cable

and shift cable.

2. Check the inner wire and outer wire ofboth cables for bends or damage, andthe rubber seals for damage. Replace ifnecessary.

s62Y7040

Assembling the tiller handle1. lnstall the throttle shaft @ and throttle

arm @ into the frame @. Align the mark@ of the fully closed position of the throt-tle shaft to the shaft holder. Align themark @ of the fully closed position of thethrottle arm to the indent of the frame.

Make sure that the throttle grip is fully closedwhen installing the throttle cable.

7-15 62Y141 1


- MEMO -

62Y141 1 7-16

Tiller handle (FT50C)

t4-_.fu$-rt

to-q$u

7-17 62Y141 1




1

2

3

4

5

6

7

II10

11

12

13

14

15

16

17

1B

Bolt

Nut

Wing nut

Friction piece

Bolt

Friction rod

Washer

Nut

Washer

Link rod

Nut

Plate

Bolt

Grommet

Cable guide

Grommet

Plastic tie

Battery lead

1

1

1

1

1

1

1

1

2

1

1

1

3

1

1

1

2

1

MBxS0mm

M6x35mm

M6x20mm

13 1.3 9.4

62Y141 1 7-18

B-__¿

.'/'\-a'

I

g

3

7-19 62Y141 1




1

2

3

4

5

6

7

B

I10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

Tiller handle


Clip

Shift rod

Nut

Bushing

Bolt

Clip

Throttle cable

Nut

Plastic washer

Metalwasher

Wave washer

Pin

Gear

Throttle shaft

Bolt

Friction piece

Wing nut

Bolt

Gasket

Cover

Bolt

Bolt

Grease nipple

Case

Bushing

Spring

Washer

Throttle grip

Screw

1

1

1

1

2

1

1

1

1

1

2

2

1

1

1

1

1

1

1

1

1

1

4

1

1

1

1

1

1

1

1

M12 x 70 mm

M6x25mm

M6x25mm

M5x14mmM6xBmm

M5x25mm

37

37

3.7

3.7

27

27

62Y141 1 7-20

'-'5g.--,@--7

-l(9I

20

q19

7-21 62Y141 1




1

2

3

4

5

6

7

II10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

Bracket

Bolt

Bolt

Shift arm guide

Nut

Washer

Washer

Bushing

Tiller handle bracket

Nut

Bushing

Engine stop switch

Bolt

Engine start switchhousing

Screw

Connector

Connector

Engine start switch

Screw

Screw

Collar

Ball

Spring

Shift arm

Washer

Shift grip

Clip

Shift rod

1

2

2

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

M6x16mmM6x16mm

M6x20mm

M6x12mmBlack

White

M6x30mmM6x25mm

62Y141 1 7-22

Checking the throttle cable and shiftrod1. Check the operation of the throttle cable

and shift rod.

2. Check the inner wire, outer wire of thecable and rod for bends or damage, andthe rubber seals for damage. Replace ifnecessary.

Assembling the tiller handle1. lnstall the throttle shaft @ into the tiller

handle @ by aligning the mark "¡" @ ofthe tiller handle with the screw hole @ ofthe throttle shaft.

s62Y71 00

lnstall the throttle cable @ into the gear

@ until the inner cable is engaged withthe gear,

Turn the throttle shaft @ clockwise towind the inner cable around the gear @.

NOTE:Make sure that the throttle grip is fully closedwhen installing the throttle cable.

Lubricating the throttle gear1. lnject grease into the grease nipple until

grease comes out from the screw hole

@.

3.

Ær\i,:dtå

7-23 62Y141 1


- MEMO -

62Y141 1 7-24

Bottom cowling

,t1

V;g4

5

lÞ"

g-23\ 22 ..'r;-X------/v

G^',.(."Iú>//'0,

s62Y7140

f-

7-25 62Y141 1

Bottom cowling



1

2

3

4

5

6

7

II10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

Shift rod assembly

Bottom cowling

Bolt

Spring

Ball

Shift rod bracket

Cotter pin

Washer

Bushing

Bushing

Shift rod

Grommet

Rubber seal

Bolt

Grommet

Screw

Warning indicator

Grommet

Collar

Pilot water outlet

Plastic tie

Collar

Grommet

Bushing

Joint

Cowling lock lever

Pin

Cotter pin

Pin

Cotter pin

1

1

1

1

1

1

1

1

1

1

1

1

4

4

4

1

1

1

4

1

2

2

2

2

1

1

1

2

1

1

M6x30mm

M6x14mmEHD/EHT models

EHD/EHT models

EHD/EHT models

62Y141 1 7-26

ffÉì,.,g1 I

f s2 I{*,1*/

62Y141 17-27

Bottom cowling



31

32

33

34

35

36

37

3B

39

40

41

42

Bolt

Bracket

Trailer switch

PTT motor lead

Trim sensor coupler

Screw

Grommet

Flushing hose

Adapter

Bolt

Rubber seal

Hose

2

1

1

1

1

1

1

1

1

1

1

1




EHT/ET models

EHT/ET models


Models with flushingdevice

Models with flushingdevice

M6x20mmModels with flushingdevice

62Y141 1 7-28

Checking the shift rod assemblyoperation1. Check the shift rod assembly and detent

for smooth operation.

Ã

E FsO/F5OA, T5O/FTsOBE FT5OC

7-29 62Y141 1

Bottom cowling

- MEMO -

62Y141 1 7-30

Upper case

É/4. -,

s62Y71 70

62Y141 17-31

Upper case



1

2

3

4

5

6

7

II10

11

12

13

14

15

16

17

1B

19

20

21

22

Upper case assembly

Nut

Nut

Washer

Bolt

Upper mount

Plate

Bolt

capBolt

Grommet

Ground lead

Screw

Mount cover

Bolt

Mount housing

Spring

Washer

Rubber washer

Lower mount

Washer

Grease nipple

1

2

2

2

3

1

1

2

2

2

2

1

2

2

4

2

4

2

2

2

2

1

M8x30mm

M8 x 175 mm

M12 x 160 mm

M8x25mm

24

42

2.4

4.2

17

30

62Y141 1 7-32

62Y141 17-33

Upper case



1

2

3

4

5

6

7

II10

11

12

13

Muffler assembly

Upper case

Mutfler seal

Rubber seal

Dowelpin

Grommet

Guide

Damper

Screw

Baffle plate

Bolt

Drive shaft bushing

Circlip

1

1

1

1

2

1

1

1

2

1

4

1

1

FTsOC

M5x16mm

M8x30mm

62Y141 1 7-34

(F50/F50A, T50/FT50B)

/1 rQ,'

t,[

,/

14.,J

,),[J,/

,u-'f>/r@l

,'€

7-35 62Y141 1

Upper case



1

2

3

4

5

6

7

II10

11

12

13

14

15

16

17

1B

19

20

21

22

23

24

25

Oilseal

Exhaust guide

Grommet

Gasket

Dowelpin

Bolt

Oil pan

Gasket

Exhaust manifold

Bolt

Gasket

Bolt

Muffler

Gasket

Pipe

Rubber seal

Gasket

Relief valve housing

Bolt

Bolt

Bolt

OilstrainerRelief valve

Spring

Cotter pin

1

1

1

1

2

10

1

1

1

3

1

6

1

1

1

1

1

1

2

2

1

1

1

1

1

M6x25mm

M6x50mm

M6x25mm

M6x25mmM6x16mmM6x25mm

62Y141 1 7-36

lffiTìf -l,,""n",un*

(Fr50c)

ryß

7-37

Upper case



1

2

3

4

5

6

7

II10

11

12

13

14

15

16

17

1B

19

20

21

22

23

24

25

26

27

28

29

30

31

32

Oilseal

Exhaust guide

Grommet

Grommet

Anode

Cover

Bolt

Cover

Bolt

Gasket

Dowelpin

Bolt

Oil pan

Gasket

Exhaust manifold

Bolt

Gasket

Gasket

Bolt

Mutfler

Gasket

Pipe

Rubber seal

Gasket

Relief valve housing

Bolt

Bolt

Bolt

OilstrainerRelief valve

Spring

Cotter pin

1

1

1

1

1

1

1

1

1

1

2

10

1

1

1

1

1

1

6

1

1

1

1

1

1

2

2

1

1

1

1

1

M6x25mm

M6x45mm

M6x25mm

M6x25mmM6x16mmM6x25mm

62Y141 1 7-38

Disassembling the oil pan1. Remove the muffler @ from the oil pan

Ø.

2. Remove the exhaust manifold @ fromthe oil pan @.

3. Remove the oil pan ø from the exhaustguide @.

4. Remove the oil strainer @ and the reliefvalve housing @.

s62Y7i

E rrsoc

Checking the oil stra¡ner and therelief valve1. Check the oil strainer and relief valve for

dirt and residue. Clean if necessary.

Assembling the oil pan1, lnstall the gaskets onto the exhaust

guide @.

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

lnstall the oil strainer @ by installing thebolts.

3.

7-39 62Y141 1

Upper case4. lnstallthe water pipe @.

lnstall the oil pan @ and bolts, and thentighten the bolts finger tight.

lnstallthe exhaust manifold @ and bolts,and then tighten the bolts finger tight.

7. Tighten the exhaust manifoldthen the oil pan bolts @.

s62Y7245

L lnstallthe muffler @ into the oil pan.

62Y141 1 7-40

9. lnstall the muffler assembly @ by insert-ing the tip of the water pipe @ into thejoint hole @ of the upper case,

lnstalling the upper case1. lnstall the upper mount @ and bolts @

into the upper case, and then tighten thebolts @.

Set the lower mounts @ and bolts to theupper case.

lnstall the end of the spring @ into thegroove of the mount housing @, andthen tighten the bolts @,

NOTE:Be sure to install the ground lead @ into themount housing @.

2.

s62Y7280

7-41 62Y141 1

Upper case4. lnstall the upper and lower mounting

bolts into the swivel bracket @ simulta-neously.

lnstall the upper mounting nut @ andlower mounting nut @, and then tightenthem to the specified torques.

lnstall the cover @ by installing thescrew.

Upper mounting nut @:24 N.m (2.4 kgf.m, 17 ft.lb)

Lower mounting nut @:42 N.m (4.2 kgf.m, 30 ft.lb)

ev''l-(,

62Y141 1 7-42

Glamp brackets

A

5

Ie

fï'\ 18

N-0

#B

s62Y7300

62Y141 17-43

Clamp brackets



1

2

3

4

5

6

7

B

I10

11

12

13

14

15

16

17

18

19

Swivel bracket assembly

Screw

Trim sensor

Trim sensor coupler

Plastic tie

Self-locking nut

capBolt

Anode

Port clamp bracket

Washer

Bushing

Through tube

Bolt

Anode

Ground lead

Grease nipple

Screw

Starboard clamp bracket

1

1

1

1

1

2

2

1

1

1

2

2

1

2

1

1

1

1

1

EHT/ET modelsM6x15mmEHT/ET models

EHT/ET models

M6x25mm

M6x25mm

M6x8mm

2

23

0.2

2.3

1.4

17

62Y141 1 7-44

Removing the clamp brackets1, Remove the power trim and tilt or hydro

tilt. For removing procedures, see"Removing the power trim and tilVhydrotilt'in this chapter.

2. Loosen the self-locking nuts @, and thenremove clamp brackets @ and @.

3. Remove the trim sensor @.

s62Y7Í

lnstalling the clamp brackets1. lnstall the trim sensor @ onto the port

clamp brackets.

NOTE:Adjust the trim sensor after installing thepower lrim and tilt.

Assemble the clamp brackets and theswivel bracket by installing the self-lock'ing nuts @, then tightening them to thespecified torque.

Self-locking nut @:23 N.m (2.3 kgf.m, 17 ft.lb)

3. lnstall the power trim and tilt or hydro tilt.For installing procedures, see "lnstallingthe power trim and tilf in this chapter.

2.

7-45 62Y141 1

Clamp brackets4. lnject grease into both grease nipples

until grease comes out from the bushings@.

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


After tilting up the outboard, be sure tosupport it with the tilt stop lever.Otherwise, the outboard could suddenlylower if the power trim and till unit shouldlose fluid pressure.

Loosen the cam screws @.

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

Fully tilt the outboard down.

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

Trim sensor setting resistance:Pink (P)- Black (B)

11 t7 Ç¿ at 20 "C (68 "F)

6. Fully tilt the outboard up, and then sup-port it with the tilt stop lever.

After tilting up the outboardo be sure tosupport it with the tilt stop lever.Otherwise, the outboard could suddenlylower if the power trim and tilt unit shouldlose fluid pressure.

7. Tighten the cam screws @ to the speci-fied torque.

Trim sensor cam screw @:2 N.m (0.2 kgf.m, 1.4 Ít.lb)

B. Fully tilt the outboard down.

4.

2.

3.

62Y141 1 7-46


16- s-Ë

7-47 62Y141 1




1

2

3

4

5

6

7

II10

11

12

13

14

15

16

17

1B

19

20

Steering arm

Washer

Bushing

O-ring

Bushing

Swivelbracket

Bushing

Port tilt stop lever

Circlip

Steering yoke

Bushing

Bushing

Tilt stop lever joint

Spring holder

Bolt

Spring

Bushing

Pin

Bushing

Starboard tilt stop lever

1

1

1

2

2

1

1

1

1

1

1

1

1

1

1

1

1

2

1

1

M6x10mm

62Y141 1 7-48

Removing the steering arm1, Remove the circlip O.

2. Remove the steering yoke @ by strikingit with a plastic hammer.

3. Remove the steering arm from the swivelbracket by pulling the arm off the bracket.

lnstalling the steering arm1. lnstall the washer @, bushing @, O-ring

@, and bushing @ onto the steering arm

@.

2. Place the swivel bracket @ in an uprightposition, and then installthe steering armonto the swivel bracket.

3. lnstall the bushing @, O-ring @, andbushing @ onto the swivel bracket.

lnstall the steering arm @ into the steer-ing yoke @ by aligning the center @ ofthe yoke with the center @ of the steer-ing arm.

lnstallthe circlip @.

4.

5.

s62Y7410

s62Y7390

7-49 62Y141 1

Swivel bracket and steering arm6. lnject grease into the grease nipple until

grease comes out from both the upperand lower bushings @.

62Y141 1 7-50

Power trim and tilt unit

rr"\

IlnI \-/

r-\ -'n'ì-\

14

s62Y7430

62Y141 17-51




1

2

3

4

5

6

7

II10

11

12

13

14

15

16

17

1B

Power trim and tilt

Hydro tilt

Plastic tie

PTT motor lead

Washer

Bolt

Circlip

Shaft

Bushing

Collar

Tilt pin

Collar

Collar

Shaft

Bushing

Circlip

Shaft

Collar

1

1

3

2

2

2

1

1

2

1

1

1

1

1

2

2

1

1

EHT/ET models

EHD/ED models

MBxl6mmEHT/ET models

EHT/ET models

EHT/ET models

EHT/ET models

EHD/ED models

EHD/ED models

EHD/ED models

EHD/ED models

62Y141 1 7-52

Removing the power trim andtilVhydro tilt1. Fully tilt the outboard up, and then sup-



2.

3.

4.

5.

6.

Loosen the plastic locking tie @, andthen pull out the PTT motor lead @.

Remove the tilt pin @.

Remove the circlip(s) @ and the shaft @.

Loosen the bolt @, and then remove theshaft @.

Remove the power trim and tilVhydro tilto.

To remove the power trim and tilVhydro tilt,lower the tilt rod slightly.

7-53 62Y141 1


- MEMO -

62Y141 1 7-54


.1.¡-.G--Oot

I

<l>--@=-V/ <9>--

8

9

10

11

12

1

1

1O-o{5

7-55 62Y141 1




1

2

3

4

5

6

7

II10

11

12

13

14

15

16

17

1B

19

20

21

Power trim and tilt motor

Tilt cylinder end screw

Bolt

O-ring

Joint

O'ring

Ball

O-ring

Free piston

Valve seal

Circlip

Circlip

Trim cylinder base

Spring

Plate

Circlip

Tilt cylinder assembly

O'ring

Reservoir cap

Anode

Bolt

1

1

3

1

1

1

6

1

1

1

1

1

1

2

1

1

1

1

1

1

2

M5x20mm

M6x25mm

90

4

6.5

9.0

0.4

0.65

65

2.9

4.7

62Y141 1 7-56

Trim cylinder

- o-..-15

o.@-tu

@-t,:\4=23@-ro

--trc

19

201Zl-Ëzz-Å

62Y141 1

25

7-57

Trim cylinder



1

2

3

4

5

6

7

II10

11

12

13

14

15

16

17

1B

19

20

21

22

23

24

25

Tilt ram

Dust seal

Backup ring

O-ring

Tilt cylinder end screw

O'ring

Backup ring

O-ring

Trim cylinder end screw

O-ring

O-ring

Trim piston

O-ring

Trim cylinder

O-ring

Backup ring

Ball

Tilt piston

Ball

Absorber valve pin

Spring

Pin

Pin

Washer

Bolt

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

4

4

4

4

2

1

1 M12 x 45 mm

80

61

8.0

6.1

58

44

62Y141 1 7-58

Gear pump

t-=g

3

\

B-3

B-'..J

Il--^,--t-\-.^.--r'

7-59 62Y141 1

Gear pump



1

2

3

4

5

6

7

II10

11

12

13

14

15

16

17

Bolt

Relief valve bracket

Bolt

Adapter

Up-relief spring

Valve support pin

Relief valve seal

Down-relief spring

Valve support pin

Relief valve seal

Filter

Gear pump

O-ring

Filter

O-ring

Manual release plug

Circlip

2

2

3

1

1

1

1

1

1

1

1

1

2

2

2

1

1

MSxBmm

M6x45mm

17.5 m (0.69 in)

14.2mm (0.56 in)

5.3

6.5

0.53

0.65

3.8

4.7

62Y141 1 7-60

I^ ya----o (.2u--é l,/p1

7-61 62Y141 1

Gear pump



1

2

3

4

5

6

7

II10

11

12

13

14

15

16

17

1B

19

20

21

22

23

24

25

Bolt

Washer

Gear pump bracket

O-ring

Spring

Spacer

Down-shuttle piston

Up-shuttle piston

Manual release spring

Ball

Gear pump cover

Down-main valve

O-ring

Valve seal

Circlip

Pin

Drive gear

Shaft

Driven gear

Ball

Return spring

Up-main valve

Valve seal

Circlip

Gear pump housing

2

2

1

2

2

2

2

1

1

2

1

1

1

1

1

2

1

1

1

2

2

1

1

1

1

M5x20mm 5.3 0.53 3,8

62Y141 1 7-62

2.

Disassembling the tilt cylinder1, Hold the power trim and tilt O in a vise

using aluminum plates @ on both sides.

Loosen the tilt cylinder end screw @, andthen remove it.

Make sure that the ram is fully extendedbefore removing the end screw.

Trim and tilt cylinder wrench: YB-06175-28Cylinder-end screw wrench : 90890-06544

3. Drain the fluid.

Disassembling the trim cylinder1. Hold the trim cylinder @ in a vise using

aluminum plates @ on both sides.

NOTE:Place the trim cylinder in the vise horizon-tally.

2. Loosen the trim cylinder end screw @,and then remove it.

Do not damage the check valve (D whenloosening the end screw.

Trim and tilt cylinder wrench: YB-06175-28Cylinder-end screw wrench: 90890-06544

7-63 62Y141 1

Gear pump

Bt

Disassembling the gear pump1. Remove the manual release plug @ and

gear pump @.

s62Y7540

Remove the relief valve bracket @, thenthe down-relief valve @ and up-reliefvalve @.

Remove the gear pump bracket @, thenthe down-shuttle piston @ and up-shuttlepiston @.

O... -z_;>

à'\@{;i¡r\ I

4. Remove the gear pump cover @, thenthe down-main valve @ and up-mainvalve @.

5. Remove the drive gear @ and drivengear @.

q€O@ --.--]

\

$N2.

Ghecking the tilt cylinder and trimcylinder1. Check the power trim and tilVhydro tilt for

cracks or corrosion. Replace if neces-sary.

2. Check the inner walls of the trim cylinderand tilt cylinder for scratches, Replace ifnecessary.

Igç

Þ

62Y141 1 7-64

3. Check the outer sudace of the tilt piston

and free piston for scratches. Replace ifnecessary.

s62Y7590

Check the tilt ram for bends or excessivecorrosion. Polish with #400{00 gritsandpaper if there is light rust or replaceif necessary.

s62Y7600

Check the valves1. Check the operation of the check valve

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

s62Y7610

Check the operation of the tilt piston

absorber valve and check for dirt or resi-due. Clean if necessary.

s62Y7620

Check the down-main valve @ and theup'main valve @ for dirt or residue.Clean if necessary.

Check the down-relief valve @, up-reliefvalve @, and shuttle pistons @ for dirt orresidue. Clean if necessary.

¿.ØvÕChecking the filters1. Check the gear pump filter @ and shuttle

piston filters O for diil or residue. Clean ifnecessary.

|-.,eIU0

4.

3.

4.

d66)X

@@s62Y7630

7-65 62Y141 1

Gear pump

Checking the gear pump1. Check the drive gear @, driven gear @,

and shaft @ for damage or excessivewear. Replace if necessary.

s62Y7650

Assembling the gear pump1. lnstall the drive gear @, driven gear @,

shaft @, and pins @ into the gear pumphousing @.

2. lnstall the balls @ into the gear pumphousing @.

3. lnstall the down-main valve @ and up-main valve @,

4. lnstall the gear pump cover @.

lnstallthe shuttle pistons @ into the gearpump cover @.

lnstall the balls @ into the gear pumpcover @ with the manual release spring

@.

7. lnstall the gear pump bracket @ byinstalling the bolts @, then tighteningthem to the specified torque.

Gear pump bracket bolt @:5.3 N.m (0.53 kgf.m, 3.8 ft.lb)

lnstall the down-relief valve @, up-reliefvalve @, and filter @.

lnstall the relief valve bracket @ byinstalling the bolts @, then tighteningthem to the specified torque.

Relief valve bracket bolt @:5.3 N.m (0.53 kgf.m, 3.8 ft.lb)

o *t,

Mffi8.

9.

Q. --

r¡--@Ë#o----..- |

a,@O@

62Y141 1 7-66

10. lnstall the filters @ and gear pump @ byinstalling the bolts @, then tighteningthem to the specified torque.

11. lnstall the manual release plug @ andreservoir cap Ø.

uvØ

Gear pump bolt @:6.5 N.m (0.65 kgf.m, 4.7ltlb)

12. Fill the reseruoir with the recommendedfluid to the correct levelas shown.


13. lnstall the joint @ and power trim and tiltmotor @ by installing the bolts @, thentightening them to the specified torque.

@=--g y-@

JV?*(ô-V

PTT motor bolt @:4 N.m (0.4 kgf.m, 2.9 ft.lb)Ø

þ Assembling the trim cylinder1, lnstall the dust seal O into the tilt cylinder

end screw @.

2. lnstall the O-ring @ to the end screw.

3. lnstall the tilt ram @ into the end screw.

7-67 62Y141 1

Gear pump

5.

4. lnstall the backup ring @ and O-rings @and @ into the trim cylinder end screw

@.

lnstall the trim cylinder endthe tilt ram.

s62Y7730

screw onto

s62Y7740

lnstall O-rings @ and @ onto the trim pis-

ton @, and then install the trim piston tothe trim cylinder @.

s62Y7750

7. lnstall the backup ring @ and O-ring @into the tilt piston @.

8. lnstall balls @ and @, absorber valve pin

@, spring @, pins @ and @, and washer

@ into the tilt piston.

62Y141 1

9. Hold the tilt ram end in a vise using alu-minum plates on both sides.

10. lnstall the tilt piston to the tilt ram byinstalling the bolt, then tightening it to thespecified torque.

Tilt piston: 61 N.m (6.1 kgf.m, 44 ft.lb)

11. lnstall the trim cylinder onto the tilt ram.

12. Hold the trim cylinder @ in a vise usingaluminum plates @ on both sides.

NOTE:Place the trim cylinder in the vise horizon-tally.

7-68

13. lnstallthe trim cylinder end screw @, andthen tighten it to the specified torque.

Do not damage the check valve @ whentightening the end screw.

Trim and tilt cylinder wrench: YB-06175-28Cylinder-end screw wrench : 90890-06544

Trim cylinder end screw @:80 N.m (8.0 kgf.m, 58 Ít.lb)

Assembling the tilt cylinder1. lnstall the valve seal @ and the circlip @

into the free piston @ as shown.

2. lnstall the free piston into the trim cylin-der @ by installing the circlip @.

3, lnstall the trim cylinder base @, springs

@, and plate @ into the trim cylinder withthe circlip @.

Ø@ .ç,u, brlm -/

\SN- s62Y7'oo

4. Hold the power trim @ and in a viseusing aluminum plates @ on both sides.

s62Y7805

Add fluid of the recommended type to thefirst level at the bottom of tilt cylinder.

lnstall the balls @ into the trim cylinder,and then insert the trim cylinder into thetilt cylinder @.

NOTE:Apply grease to the balls to prevent themfrom falling out of the cylinder.


5.

6.

7-69 62Y141 1

Gear pump

L

7. lnstall the tilt cylinder end screw @, andthen tighten it to the specified torque.

Trim and tilt cylinder wrench: YB-06175-28Cylinder-end screw wrench: 90890-06544

Tilt cylinder end screw @:90 N.m (9.0 kgf.m, 65 ft.lb)

Fully extend the tilt rod, and then add suf-ficient fluid of the recommended type tothe correct level.

lnstall the reservoir cap @.


Bleeding the power tr¡m and t¡lt(not installed)1. Close the manual release plug @ by

turning it clockwise.

2. Place the power trim and tilt in an uprightposition.

3. Check the fluid level in the reservoir.

NOTE:The fluid level should be at the brim of thefiller hole.

4. lf necessary, add sufficient fluid of therecommended type to the correct level.


5. lnstallthe reservoir cap.

s62Y7840

62Y141 1 7-70

6. Connect the PTT motor leads @ to thebattery terminals.

G(L)

7. Reverse the PTT motor leads betweenthe battery terminals when the tilt ram isfully extended, and then reverse themagain when it is fully compressed.

NOTE:. Repeat this procedure so that the tilt ram

goes up and down four to five times.. The sound of the power trim and tilt motor

will change when the tilt ram is fullyextended.

B. Check the fluid level again when the tiltram is fully extended. Add sutficient fluid,if necessary, and then repeat step 7,

NOTE:Repeat this procedure until the fluid remainsat the correct level.

Bleeding the power tr¡m and t¡lt(built-in)1. Loosen the manual release plug by turn-

ing it counterclockwise until it cannot beturned further.

1Ï

2.

3.

4.

5.

s62Y7860

Fully tilt the outboard up, and thenrelease it and let it lower by its ownweight four to five times.

Tighten the manual release plug by turn-ing it clockrrvise.

Let the fluid settle for 5 minutes.

Push and hold the power trim and tiltswitch in the up position until the out'board is fully tilted up.

Support the outboard with the tilt stoplever, and then let the fluid settle for 5minutes.

After tilting up the outboard, be sure tosupport it with the tilt stop lever.Otherwise, the outboard could suddenlylower if the power trim and tilt unit shouldlose fluid pressure,

6.

-----t' a..O

^a ot',¿

Tilt rod PTT motor leadBatteryterminal

UpBlue (L) @

Green (G) oDown

Green (G) @

Blue (L)

7-71 62Y141 1

Gear pump7. Remove the reseruoir cap @, and then

check the fluid level in the reservoir.

lf necessary, add sufficient fluid of therecommended type to the correct level.

The fluid level should be at the brim of thefiller hole.


L lnstall the reservoir cap.

NOTE:Repeat this procedure until the fluid remainsat the correct level.

62Y141 1 7-72


7-73 62Y141 1




1

2

3

4

5

6

7

II10

11

12

13

14

Screw

Yoke

O-ring

Armature

Bushing

Screw

Wire lead

Brush 2

Brush 1

Brush holder

Circuit breaker

Brush spring

PTT motor base

Oilseal

3

1

1

1

1

2

1

1

1

1

1

2

1

1

M5x20mm

M4x12mm

62Y141 1 7-74

2.

3.

Checking the power trim and tiltmotor1. Check the commutator for dirt or foreign

substances. Clean with #600 grit sand-paper if necessary.

Check the commutator undercut for diilor foreign substances, Clean with com-pressed air if necessary.

Measure the commutator diameter @.Replace if out of specification.

Commutator diameter limit @:21 mm (0.83 in)

4. Check the armature coil for continuity.Replace if out of specifications.

5. Check the circuit breaker for continuity.Replace if there is no continuity.

s62Y7930

Measure the brush length. Replace if outof specification.

Brush length limit @: 3.5 mm (0.14 in)

7. Check the base for cracks or damage.Replace if necessary,

6.

Armature coil continuity

Commutator segments @ Continuity

Segment-lam inations (Ð No continuity

Segment-shaft CD No continuity

7-75 62Y141 1

Power trim and tilt motor8. Check the bushing @ for damage or


Assembling the power trim and tiltmotor1. lnstall the oil seal @ and the bushing @

into the motor base @ as shown.

Attach the circuit breaker @ onto brush 1

@ together with the brush holder @ andconnect the wire lead Ø.

O__yæ

ñ\

+'-@i9:Æ

lnstall the springs @ into the motor base,then the brush holder into the motor basetogether with the brushes and circuitbreaker.

lnstall the armature O, O-ring @, andyoke @.

4.

s62Y7980

lnstalling the power trim and tilt1. Fully tilf the outboard up, and then sup-



62Y141 1 7-76

lnstallthe shaft @ and bolts @ onto bothclamp brackets together with the powertrim and tilVhydro tilt @.

lnstall the tilt ram upper end into theswivel bracket with the shaft @ and cir-clip(s) @.

lnstall the tilt pin Ø.

s62Y7A10

7-77 62Y141 1

Power trim and tilt motor / Power trim and tilt electrical system

Power trim and tilt electrical system

@ Power trim and tilt motor@ Power trim and tilt relay@ Trailer switch@ Power trim and tilt switch@ Fuse@ BatteryØ Trim sensor

E Models with trailer switch

62Y141 1

BGGyLLgP

Rsb

BlackGreenGrayBlueLight greenPinkRedSky blue

7-78

Checking the fuse1, Check the fuse and fuse holder for conti-

nuity. Replace if there is no continuity.

Checking the power trim and tiltrelay1. Check the power trim and tilt relay for

continuity. Replace if out of specification.

2. Connect the digital circuit tester betweenpower trim and tilt relay terminals O and

@.

Connect the light green (Lg) lead to thepositive battery terminal and the black(B) lead to the negative battery terminalas shown.

Check for continuity between terminals

@ and @. Replace if there is no continu'itv.

s62Y7A50

Connect the digital circuit tester betweenpower trim and tilt relay terminals @ and

@

Connect the sky blue (Sb) lead to thepositive battery terminal and the black(B) lead to the negative battery terminalas shown.

Check for continuity between terminals

@ and @. Replace if there is no continu-ity.

4.

5.

6.

7.

e_9

tåt

Power trim and tilt relay continuity

Sky blue (Sb)- Black (B)Light green (Lg)- Black (B)

Continuity

Terminal@ -Terminal@Terminal@ -Terminal@

Continuity

TerminalO -Terminal@Terminal@ -Terminal@

No continuity

7-79 62Y141 1

Power trim and tilt electrical system

Checking the power trim and tiltswitch/trailer switch1. Check the power trim and tilt

switch/trailer switch for continuity.Replace if out of specification.

Ghecking the trim sensor1. Measure the trim sensor resistance.


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

10-278.3 Ç¿ at 20 "C (68 "F)

Turn the lever @ and measure the resistanceas it gradually changes.

Lead color

Switchposition

Skyblue(sb)

Red (R)Lightgreen

(Lg)

Up o_ ----oFree

Down o_ ----o

62Y141 1 7-80

- MEMO -

7-81 62Y141 1

Electrical systems


Checking the electrical components........... ............8-4Measuring the peak voltage .............8-4Measuring the lower resistance.. ......8-4

Electrical components............... ............8-5Starboard and port views......... .........8-5Front view ..,,,.,,,,,.,,,.,,..,,8-6Top view .....8-7Tiller handle model (F50/F504, T50/FT50B) . . . . .........8-8Tiller handle model (FT50C) .............8-9

Wiring harness 8-10

lgnition system and lgnition control system...... ....................8-I1Checking the ignition spark gap .,,..8-13Checking the spark plug caps ........8-14Checking the ignition coi1............. ...8-14Checking the CDI unit............. ........8-15Checking the charge coil ............ ....8-15Checking the pulser coil ,,..,,..,.., ,,.,.8-16Checking the pulser coilair gap ........... .............8-16Checking the engine start switch ....8-17Checking the engine shut-otf switch........ ..........8-17Checking the thermoswitch ......... ...8-18Checking the oil pressure switch ,,..8-18

Starting system ..................8-19Checking the fuse..... ...8-2OChecking the wiring harness (10 pins) ..............8-20Checking the neutral switch........ ....8-20Checking the starter re1ay........... ....8-20

Starter motorRemoving the starter motor pinion ....................8-23Checking the starter motor pinion......... .............8-23Checking the armature................ ...8-23Checking the brushes ..8-24Checking the stafier motor operation ................8-24

Charging system ...............8-25Checking the lighting coi1............. ...8-26Checking the Rectifier Regulator ....8-26

62Y141 1

Electrical systems

TroubleshootingBefore troubleshooting the charging system, check that all electrical connections are tight and freefrom corrosion, and that the battery is fully charged to 12 V.

Symptom: Battery becomes weaker quickly.. Check the charging system.

8-1

Measure the output peak voltage of the lighting coil.

Replace the lighting coil,

Measure the Rectifier Regulatoroutput peak voltage.

Replace the Rectifier Regulator.

Replace the battery, and thencheck the whole voltage of allelectrical equipments on yourboat.

62Y141 1

Troubleshooting / Special service tools


Dynamic spark testerYM-34487

Digital multimeterYU-34899-A

Peak voltage adaptorYU-39991

Test harness (2 pins)Y8-06767

Pressu relvacu um teste rY8-35956-A

t--..

!t

#ru

Magnetic flexible standYU-34481

il8fl

d\Test harness (3 pins)YB-06770

/KffiTest harness (4 pins)YB-06771

DialgaugeYU-03097

lgnition tester90890-06754

62Y141 1 8-2

Electrical systems

wwDigital circuit tester90890-03174

Dial gauge set90890-01252

Peak voltage adaptor90890-03172

[]nðN

áèTest harness (2 pins)90890-06767

i ß?^r-(Ë"lh\K/oVacuum/pressure pump gauge set90890-06756

tr&

Magnet base90890-06705

['nn/Kóàhç/ \v

Test harness (3 pins)90890-06770

ftilflff/Kffiè

Test harness (4 pins)90890-06771

8-3 62Y141 1

Special service tools / Checking the electrical components

Ghecking the electricalcomponentsMeasuring the peak voltageThe condition of the ignition system can bedetermined by measuring the peak voltage.Cranking speed is etfected by many factors,such as fouled or weak spark plugs, or aweak battery. lf one of these factors ispresent, the peak voltage will be lower thanspecification. ln addition, if the peak voltageis lower than specification the engine will notoperate properly.

NOTE:. Use the peak voltage adaptor with the digi-

tal circuit tester.. When measuring the peak voltage, set the

selector on the digital circuit tester to theDG voltage mode.

. Connect the positive pin on the peak volt-age adaptor to the positive terminal of thedigital circuit tester.

Measuring the lower resistanceWhen measuring a resistance of 10 Q or lesswith the digital circuit tester, the correct mea-surement cannot be obtained because of theinternal resistance of the tester.To obtain the correct value, subtract the inter-nal resistance from the displayed measure-ment.

Correct value =displayed measurement - internalresistance

NOTE:Obtain the internal resistance of the digitalcircuit tester by connecting both of its probesand checking the display.

62Y141 1 8-4

Electrical systems

Electrical componentsStarboard and pofi views

@ Stalor@ Pulser coil@ CDlunit@ lgnition coil@ Oilpressure switch@ Thermoswitch@ Prime Start@ Rectifier Regulator

8-5

@ Slarter relay@ Starter motor@ PTT switch coupler

E Power trim and tilt model with tiller handle

62Y141 1

Electrical componentsFront view

O Stator@ Pulser coil@ CDlunit@ Fuse@ Neutralswitch (tiller handle model)

@ Starler relay

@ Starter motor

@ Power trim and tilt relay (power trim and tiltmodel)

62Y141 1

E T¡ller handle model

8-6

Electrical systemsTop view

O Stator@ Pulser coil@ CDlunit@ lgnition coil@ Starter motor

@ Trailer switch

8-7 62Y141 1

Electrical componentsTiller handle model (F50/F504, T50/FT50B)

@ Engine starl switch@ Engine start switch harness@ Engine shut-off switch@ Engine shut-off switch connector@ Neutralswitch@ Battery lead

@ Wiring harness extension@) PTT switch lead

@ Power trim and tilt switch

62Y141 1

E Applicable for tachometer, trim meter orwarning buzzer model

8-8

Electrical systemsTiller handle model (FT50C)

@ Engine start switch@ Engine start switch harness@ Engine shut-off switch@ Engine shut-off switch connector@ Neutralswitch@ Battery lead

8-9 62Y141 1

Electrical components / Wiring harness

Wiring harness

É

@

@@

@

@ @@@

r

Connect to:

@ Tiller handle mainswitch or remotecontrol box or wiringharness extension

@ Power trim and tiltrelay

@ Ground@ Stafier relay

@ Positive battery lead@ Prime Start

62Y141 1

@ Warning indicator ordigital tachometer

@ CDlunit@ Power trim and tilt

switch or trailer switch@ Rectifier Regulator@ Thermoswitch@ lgnition coil@ Oilpressure switch

E Powertrim and tiltmodel

BlackBrownGreenBlueLight greenPinkRedSky blue

WhiteBlack/orangeBlackiwhitePink/blackPink/whiteYellow/blackYellow/red

BBrGLLgP

RSb

WB/OB^/VP/BPA/V

Y/BY/R

8-10

Electrical systems

lgnition system and lgnition control system

@t

I

WR

ÉWR

V/R WB

H//R WB

LBr

èd@HLBr

WB

(,

@

@ Spark plug

@ lgnition coil@ Charge coil@ Pulser coil@ Engine start switch@ Engine shut-off switch@ 1O-pin coupler@ CDlunit

BBrLWBlOB^^/WBWR

BlackBrownBlueWhiteBlacllorangeBlack/whiteWhiteiblackWhiteired

8-11 62Y141 1


@@

E Remote control modelE t¡ller handle model

@ Thermoswitch@ Oilpressure switch@ CDlunit@ Digitaltachometer@ Oil pressure warning

indicator@ Overheat warning

indicatorØ Remote controlbox@ Warning indicator

62Y141 1

BGR

Gy/BPlBPA/V

YlBY/R

BlackGreenRedYellowGreen/blackPink/blackPink/whiteYellow/blackYellow/red

8-12

Electrical systemsChecking the ignition spark gap1, Disconnect the spark plug caps from the

spark plugs.

2. Connect a spark plug cap to the specialseruice tool.


Dynam ic spark teste r : Y l{l-34487lgnition tester: 90890-06754

3. Set the spark gap length on the adjustingknob.

562Y8


4. Crank the engine and observe the sparkthrough the discharge window of thespark gap tester. Check the ignition coil ifout of specification.


o Do not touch any of the connections ofthe spark gap tester leads.

. Do not let sparks leak out of theremoved spark plug caps.

. Keêp flammable gas or liquids away,since th¡s test can produce sparks.

lgnition spark gap: 9 mm (0.35 in)

8-13 62Y141 1


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

high-tension cords by turning the capscounterclockwise.

r:::::::::::-:::l------------------{

s62YB1 70

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

Spark plug cap resistance: 3.75{.25 kO

Ghecking the ignition coil1. Remove the spark plug caps from the

high-tension cords by turning the capscounterclockr¡vise.

2. Measure the ignition coil resistance.Replace if out of specification,

lgnition coil resistance:Primary coil:

Orange (O)- Black (B)0.08-0.11 Q at 20'C (68 "F)

Secondary coil:High-tension cord - High-tension cord

3.54.7 kÇ¿ at 20 "C (68 "F)

62Y141 1 8-14

Electrical systemsChecking the CDI unit1, Measure the CDI unit output peak volt-

age. lf below specification, measure thecharge coil output peak voltage and thepulser coil output peak voltage. Replacethe CDI unit if the output peak voltage ofboth coils is above specification.

Checking the charge coil1. Measure the charge coil output peak volt-

age. Replace the stator coil if belowspecification.

When checkingtouch any of thetester leads.

the peak voltage do notconnections of the digital



selector on the digital circuit tester to theDC voltage mode.

Digital multimeter: YU-34899-ADigital circuit tester: 90890-031 74Peak voltage adaptor:

YU-39991 / 90890-03172



NOTE:. Use the peak voltage adaptor with the digi'



CDI unit output peak voltage:Black/orange (B/O) - Black (B)

Black/white (BAA/) - Black (B)

r/minUnloaded Loaded

Cranking 1,500 3,500

DCV 126 150 151 116

8-15 62Y141 1



YU-39991 / 90890-03172Test harness (2 pins):

YB-06767 / 90890-06767

Charge coil output peak voltage:Brown (Br)- Blue (L)



DCV 144 137 169 129

Charge coil resistance (use as reference):Brown (Br)- Blue (L)

272408 Q at 20 "C (68 "F)

Checking the pulser coil1. Measure the pulser coil output peak volt-

age. Replace the pulser coil if belowspecification.






YB-06767 / 90890-06767

Pulser coil output peak voltage:White/red (W/R) - White/black (W/B)



DCV 6.3 3.5 7.4 11.2

Pulser coil resistance (use as reference):White/red (W/R) - White/black (WB)

396-594 O at 20 "C (68'F)

Ghecking the pulser co¡l 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 ifout of specification.

Pulser coil air gap:

0.5-1.0 mm (0.02G-0.039 in)



62Y141 1 8-16

Electrical systems

4.

Remove the flywheel magnet nut and fly-wheel magnet.

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

5. Set the flywheel magnet and then checkthe gap again and, if necessary, repeatsteps 3-5.

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

Pulser coil screw:4 N.m (0.4 kgf.m, 2.9 tt.lb)

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

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

ity. Replace if there is no continuity.

Checking the engine shut-off sw¡tch1. Check the engine shut-off switch for con'

tinuity. Replace if there is no continuity.

Lead color

Switchposition

White(w)

Black(B)

Red(R)

Pink(P)

Browr(Br)

OFF o-ON o- -ÐSTART ô- --o

@ @hì-H

s62Y8250

Lead color

White (W) Black (B)

Remove the lockplate @

o_ ----o

lnstallthe lockplate @

Push the button @ Cr- ---{

8-17 62Y141 1


Checking the thermoswitch1. Place the thermoswitch in a container of

water and slowly heat the water.

ôôôôôô sô2Y8270

Check the switch for continuity at thespecified temperatures. Replace if out ofspecification.

@ Temperature@ t¡me@ No continuity@ Continuity

Thermoswitch continuity temperature:Pink (P) - Black (B)

@:76-84'C (164-183 "F)@:6T77'C (145-170 "F)

Ghecking the oil pressure switch1. Connect the special service tool to the oil

pressure switch.

2. Slowly operate the specialservice tool.

Check the switch for continuity at thespecified pressure. Replace if there is nocontinuity.

Pressure/vacuum tester: YB-35956-AVacuum/pressure pump gauge set:

90890-06756

Specified oil pressure:15 kPa (0.15 kgf/cm2, 2.13 psi)

62Y141 1 8-18

Electrical systems

Starting system

o

@ Fuse

@ 10-pin coupler@ Engine start switch@ Starter motor@ Battery@ NeutralswitchØ Starter relay

E t¡ller handle model

8-19

B : BlackBr : BrownR :Red

62Y141 1

Starting system

Checking the fuse1. Check the fuse and fuse holder for conti-

nuity. Replace if there is no continuity.

Checking the wiring harness(10 pins)1. Check the wiring harness for continuity.

Replace if there is no continuity.

Checking the neutral switch1. Check the neutral switch for continuity.

Replace if there is no continuity.

Checking the starter relay1. Connect the digital circuit tester leads to

the starter relay terminals,

2. Connect the brown (Br) lead to the posi-tive battery terminal.

3. Connect the black (B) lead to the nega-tive battery terminal.

4. Check for continuity between the starterrelay terminals. Replace if there is nocontinuity.

Check that there is no continuity betweenthe starter relay terminals atter discon-necting the brown or black lead. Replaceif there is continuity.

Lead color

Brown (Br) Brown (Br)

Free

Push o o

62Y141 1 8-20

Electrical systems

Starter motor

s62Y8350

62Y141 1

-ffi10

8-21

Starter motor



1

2

3

4

5

6

7

II10

11

12

13

14

15

16

17

1B

19

20

21

Clip

Pinion stopper

Spring

Starter motor pinion

Upper bracket

O'ring

Washer 1

Shim

Washer 2

Armature

Stator

O'ring

Brush holder assembly

Brush set

O-ring

Washer

Spring washer

Nut

Lower bracket

Screw

Bolt

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

2

2

As required

M4x12mmM5 x 125 mm

I 0.9 6.5

62Y141 1 8-22

Electrical systemsRemoving the stafier motor pinion1, Slide the pinion stopper @ down as

shown, and then remove the clip @.

Checking the sta¡ter motor pinion1. Check the pinion teeth for cracks or


2. Check for smooth operation. Replacenecessary.

NOTE:Turn the pinion clockwise to check that itoperates smoothly and turn it counterclock-wise to check that it locks.

Checking the armature1. Check the armature axial free play.

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

8-23

Dial gauge @:YU-03097Dial gauge set @: 90890-01252Magnetic flexible stand @: YU-34481Magnet base @: 90890-06705

Free play limit: 0.6 mm (0.024 in)

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

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

Diameter limit: 31.0 mm (1.22in)

3.

62Y141 1

Starter motor4. Measure the commutator undercut @.

Replace the armature if out of specifica-tion.

Commutator undercut limit:0.2 mm (0.01 in)

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

Checking the brushes1. Measure the brush length. Replace the

brush assembly if our of specification.

Brush length limit @: 12.0 mm (0.47 in)

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

Checking the starter motor operat¡on1. Check the operation of the stafter motor

after installing it to the power unit.

Brush assembly continuity

BrushO-Brush@ Continuity

Brush@-Brush@Brush@-Brush@Brushholder@-Brushassembly holder @

No continuity

s62Y8430

Armature continuity

Commutatorsegments(D Continuity

Segment -Armature core @

No continuity

Segment -Armature shaft @

No continuity

62Y141 1 8-24

Electrical systems

Gharging system

@ Lighting coil@ Rectifier Regulator

@ Fuse

@ Battery

BlackGreenRedGreen/white

BGRG^^/

8-25 62Y141 1

Charging system

Checking the lighting coil1. Measure the lighting coil output peak

voltage. Replace the stator coil if belowspecification.

Lighting coil resistance (use as reference):Green (G) - Green (G)

1 .2-1.8 Q at 20 'C (68 "F)

Checking the Rectifier Regulator1. Measure the Rectifier Regulator output

peak voltage. lf below specification, mea-sure the lighting coil output peak voltage.Replace the Rectifier Regulator if the out-put peak voltage of the lighting coil is

above specification.





selector on the digital circuit tester to theDC voltage mode,



YB-06770 / 90890-06770

Lighting coil output peak voltage:Green (G) - Green (G)

r/minUnloaded


DCV 1 1.9 42 127




Digital multimeter: YU'34899-ADigital circuit tester: 90890-031 74Peak voltage adaptor:


YB-06771l 90890-06771



s62Y8470

62Y141 1 8-26

Electrical systems

Rectifier Regulator output peak voltage:Red (R)- Black (B)

r/minUnloaded

1,500 3,500

DCV 18.9 19.5

After starting the engine, disconnect the out-put lead (red lead) of the Rectifier Regulatorwhen measuring the output peak voltage.

8-27 62Y141 1

- MEMO -

62Y141 1 8-28

lndex

A.Acceleration pump ....... ... . . ... . 1 -1 5Adjusting the dash-pot

(acceleration pump) ............4-24Adj usting the th rottle I i n k rod......... ............ 4-21Adjusting the trim sensor ......7-46Aftertest run.............. ...........1-36Applicable models........ ...........1-5Assembling the catbu retor,.,,.,......,.,..,. ..... 4-20Assembling the cylinder body ................... 5-64Assembling the drive shaft .............. 6-27, 6-66Assembling the forward gear.......... 6-27, 6-65Assembling the fuel pump.........................4-1 0Assembling the gear pump ..,.,,.,......,.,..,.,. 7-66Assembling the lower case ..,.,,.,..... 6-25, 6-63Assembling the oil pan... .......7-39Assembling the power trim and tilt motor..7-76Assembling the propeller shaftassembly..... 6-16, 6-55

Assembling the propeller shafthousing .6-16,6-55

Assembling the tiller handle 7-15,7-23Assembling the tilt cy|inder ....................... 7-69Assembling the trim cylinder ....... ..............7-67

B.Backlash (F50/F504) ............6-39Backlash (T50/F[50B, FT50C) ................. 6-77Bleeding the power trim and tilt (built-in),..7-71Bleeding the power trim and tilt

(not installed).................. ....7-7OBottom cowling........ ..............7-25Break-in....... ......1-36

c.Carburetor... 1-10,4-17Carburetor unit.............. ........4-11CDI unit with microcomputer,.,...... .............. 1 -7Charging system ...................8-25Check the valves.... ...............7-65Checking the anodes ............3-19Checking the armature ..........8-23Checking the battery... 1-33, 3-20Checking the bearings 6-25, 6-63Checking the brushes ...........8-24Checking the camshaft .........5-45Checking the carburetor............................ 4-1 IChecking the CD I unit .,.,.,,...,.,,.,......,.,..,.,. 8-1 5Checking thê charge coi|.,.,.,,.,.........,.,..,.,. 8-1 5Checki ng the compression pressure......... 5-25Checking the connecting rod big end sideclearance ........5-59

¡-1

Checking the connecting rod bolt,......,.,.., 5-59Checking the connecting rod small end

inside diameter............... .... 5-59Checking the cooling water passage........ 3-1 3Checking the crankshaft ........................... 5-59Checking the crankshaft main journal oilclearance .....,.,5-60

Checking the crankshaft pin oilclearance ........5-61

Checking the cylinder bore ....................... 5-56Checking the cylinder head ...................... 5-46Checking the diaphragm and valves .,,.,... 4-10Checking the drive shaft ..................6-25, 6-63Checking the electrical components........... 8-4Checking the engine idle speed ............... 3-15Checking the engine oil .....................1-33, 3-5Checking the engine shut-off switch,.,,.,... 8-17Checking the engine start switch.............. 8-1 7

Checking the engine start switch and enginestop switch/engine shut-otf switch .......... 1-35

Checking the filters ...............7-65Checking the fuel f ilter ..,.,,.,...,,.,.,....,.,,.,...,. 3-5Checking the fueljoint and fuel hoses

(fuel joint-to-carburetor) ........ 3-4Checking the fuel pump.............................. 4-gChecking the fuel system ..... 1-33

Checking the fuse,.,.... .7-79, 8-20Checking the gear oi1................................ 1 -33Checking the gear oil level ...3-17Checking the gear pump .......................... 7-66Checking the gearshift and

throttle operation..... ............ 1-34Checking the gearshift operation .............. 3-1 4Checking the ignition coi|.......................... 8-1 4Checking the ignition spark gap ............... 8-13Checking the ignition timin9...................... 3-1 5Checking the lighting coi1.......................... 8-26Checking the lower case .,.,,.,.,.,,.,...6-25, 6-63Checking the lower unit (for air leakage).. 3-19Checking the neutral switch...................... 8-20Checking the oil pressu re ......................... 5-25Checking the oil pressure switch .............. 8-18Checking the oil pump ..........5-47Checking the oil strainer and the

relief valve ......7-39Checking the outboard motor mountingposition ........... 1-34

Checking the pilot water outlet .,,.,......,.,.., 1-35Checking the pinion and

forward gear............ ..6-25, 6-63Checking the piston clearance ................. 5-57Checking the piston diameter................... 5-56Checking the piston p¡n,.,,.,...,,.,.,....,.,,.,... 5-58

62Y141 1

Checking the piston pin boss bore.,...,.,..,.5-58Checking the piston ring grooves.............. 5-58Checking the piston ring side clearance...5-58Checking the piston rings.......................... 5-57Checking the power trim and tiltfluid level ..,..,.,.3-16

Checking the power trim and tilt motor .....7-75Checking the power trim and tiltoperation .........3-16

Checking the power trim and tilt re|ay.......7-79Checking the power trim and tilt switchi

trailer switch ,.,.7-80Checking the Prime Start............ .............. 4-2O

Checking the propeller ..........3-19Checking the propeller shaft ........... 6-1 5, 6-55Checking the propeller shafthousing ,6-15, 6-54

Checking the pulser coi1 ............................ 8-1 6Checking the pulser coil air gap................8-16Checking the Rectifier Regulator .............. 8-26Checking the remote control cab|es.......... 1-34Checking the rocker arms and

rocker arm shaft..... .............5-45Checking the shift rod and shift cam.........6-25Checking the shift rod assemblyoperation .........7-29

Checking the spark plug caps.,.,..,.,..,...,.., 8-1 4Checking the spark p1u9s.......................... 3-1 1

Checking the starter motor operation........ 8-24Checking the starter motor pinion ............. 8-23Checking the starter re|ay ......................... 8-20Checking the steering wheel/tiller handle.. .... 1-34

Checking the thermostat ................. ..........3-1 2

Checking the thermoswitch ....................... 8-1 IChecking the throttle cable and

shift cable.... ....7-15Checking the throttle cable and shifl rod..,7-23Checking the throttle cable operation .......3-13Checking the tilt cylinder and

trim cylinder .....7-64Checking the tilt system ........1-35Checking the timin g be|t..,.,..,....,.,..,...,..,.,.., 3-7Checking the timing belt and sprockets....5-32Checking the top cowling ........3-4Checking the trim sensor ......7-80Checking the valve clearance ................... 3-1 0Checking the valve guides ,.,.5-41Checking the valve seat............. ............... 5-42Checking the valve springs ...5-40Checking the valves.... ..........5-40Checking the water pump ......................... 6-1 4Checking the water pump and shift rod ....6-47

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Checking the wiring harness (10 pins) ,.,., 8-20Clamp brackets....... ..............7-43Control system......... .............3-13Cooling water hose.. ...............4-3Cylinder body............ ............5-51Cylinder head .,.,..,..., .,.,..,.,..,5-35

D.Dimensions. ......2-19Disassembling the carburetor.,..,...,..,.,.,.., 4-1 9Disassembling the cylinder body .............. 5-55Disassembling the drive shaft ................... 6-61

Disassembling the drive shaft assembly ..6-23Disassembling the forward gear......6-23, 6-61Disassembling the fuel pump .,..,...,..,.,.,,.,.. 4-9Disassembling the gear pump,...,..,.,. ....... 7 -64Disassembling the lower case.........6-24, 6-62Disassembling the oil pan......................... 7-39Disassembling the propeller shaftassembly ...................6-14,6-54

Disassembling the propeller shafthousing ..6-13, 6-53

Disassembling the tilt cylinder .................. 7-63Disassembling the trim cyli nder................ 7-63Disassembly and assemb|y................. ....... 1 -4

Drive shaft and lower case (F50/F504).,,.6-21Drive shaft and lower case

(T50/FT50B, FT50C) ..........6-59

E.Electrical ....2-9,2-16Electrical components ............8-5

F.Features and benefits .............1-6Fire prevention................ ........1-3Front view... ........8-6Fuel and blowby hoses.......... ..................... 4-2Fuel filter and fuel pump .,..,.,..,. .................. 4-7Fuel line ..............4-5Fuel system ........3-4

G.Gear pump.. ......7-59General....... ......3-19General specif ications .................. .............. 2-1

Generaltorques........ ............2-31Good working practices ,.,.,..,.,1-4

i-2

lndex

H.Hose routing ........4-2How to use this manua|............................... 1 -1

I.ldentification ."......1-5lgnition system ......................1-17lgnition system and lgnition controlsystem......... ....8-11

lgnition timing contro| ................................ 1 -1 Ilnstalling the camshaft .............................. 5-48lnstalling the clamp brackets....... ..............7-45lnstalling the cylinder head .,..,......,..,.,..,... 5-49lnstalling the drive shaft .................. 6-28, 6-66lnstalling the lower unit ...................6-28, 6-66lnstalling the power trim and tilt ................7-76lnstalling the power unit ............................ 5-67lnstalling the propeller shafthousing .6-18,6-57

lnstalling the rocker arm assembly ...........5-49lnstalling the steering arm .............. ...........7-49lnstalling the timing belt and sprockets.....5-32lnstalling the upper case,.,.,....... ...............7-41lnstalling the valves.... ...........5-47lnstalling the water pump .......................... 6-1 Ilnstalling the water pump and shift rod.....6-48

L.Lower unit ....1-8, 2-9, 2-16, 3-17Lower unit (F50/F504) ............6-7Lower unit (T50/FT50B, FT50C) ............... 6-41Lubricatin g the throttle gear ............ ..........7 -23Lubrication ..,.,...3-21

M.Maintenance interval chart.......................... 3-3Maintenance specifications..,.,,.,......,.., .......2-5Manualformat......... ".."............1-1Measuring the fonruard and

reverse gear back|ash.................. . 6-39, 6-77Measuring the lower resistance .................. 8-4Measuring the peak vo|tage....,.,,.,...,..,.,...., 8-4

N.Newly designed four carburetors ................ 1 -6

P.Parts, lubricants, and sea|ants.................... 1 -3Power trim and t¡lt ................ ..................... 1 -22

Power trim and t¡lt electrical system.,..,.,...7-78Power trim and tilt motor...... .....................7 -73

¡-3

Power trim and tilt unit..,.,,.,...,,.,.,,...3-16, 7-51Power unit........................2-5, 2-12, 3-5, 5-1 3Predelivery checks ...............1-33Propeller selection ................1-32Propeller shaft housing

(T50/FT50B, FT50C) .,.,,.,..,6-51Propeller si2e,.,.,..,.,.... ..........1-32

R.Refacing the valve seat ............................ 5-43Removing and installing the oil fi|ter......... 5-55Removing the clamp brackets .................. 7 -45Removing the cylinder head ..................... 5-39Removing the drive shaft.................6-23, 6-61Removing the lower unit....................6-9, 6-43Removing the power trim and tilV

hydro ti|t...... ....7-53Removing the power unit.......................... 5-26Removing the propeller shaft housingassembly ........6-53

Removing the stafier motor pinion .....,.,..,8-23Removing the steering arm ............. ......... 7-49Removing the timing belt and sprockets...5-31Removing the water pump and

propeller shaft housing assembly ........... 6-1 3Removing the water pump and shift rod,.. 6-47Replacing lhe engine oi1 ............................. 3-5Replacing the gear oi|............................... 3-1 7Replacing the timing belt ............................ 3-7Replacing the valve 9uides....................... 5-41

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

Selecting the connecting rod big endbearing..,.,.,. .,.,5-63

Selecting the crankshaft main journal

bearing........ ....5-62Selecting the fonrvard gear

shims .......... 6-33, 6-37, 6-71, 6-75Selecting the pinionshims.......... 6-32, 6-36, 6-70, 6-74

Selecting the reverse gear shims ....6-34, 6-38Selection..... ......1-32Self-protection ................. .......1-3Serial number.................. ....... 1-5

Shimming..., 6-32, 6-36, 6-70,6-74Shimming (F50) (for USA and Canada) ...6-31Shimming (F504) (for worldwide) ............. 6-35Shimming (FT50B, FT50C)

(for worldwide)................. ... 6-73Shimming (T50) (for USA and Canada) ,.,6-69

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Specialservicetools ..................3-1, 4-1 , 5-10, 6-1 ,7-4, 8-2

Specified torques ..................2-29Starboard and port views ............................ 8-5Starter motor........... ..............8-21Starting system ,..,.,.,..,...,..,.,.8-19Swivel bracket and steeri ng arm...............7 -47Symbols ..............1-2Synchronizing the carburetors ............. ..... 4-23

T.Technicaltips.............. ..........1-10Test run....... ......1-35Tightening torques ................2-29Tiller handle (F50/F504, T50/F[50B) ...,..,.,7-5Tiller handle (FT50C) ............7-17Tiller handle model

(F50/F50A, T50/FT50B). .......8-8Tiller handle model (FT50C) ....................... 8-9Tilt cylinder and trim cylinder .................... 7-55Ti min g belt and sprockets .,..,...,..,...,..,.,..,. 5-29Top cowling. ........3-4Top view...... ........8-7Trim cylinder .....7-57Troub|eshootin9 ...........................5-1, 7 -1, 8-1

U.Upper case.. ......7-31

V.Ventilation ......"..".1-3

vtf.Water pump and propeller shaft housing(F50/F504).. ....6-11

Water pump and shift rod(T50/FT50B, FT50C)........ ...6-45

Wiring harness ..,.,.,..,.,..,...,..,8-10

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Wiring diagramFSOAEHD, FSOAED, FTSOCEHD, FTSOCED

@ Battery@ Engine start switch@ Engine shut-off switch@ Starter motor@ Starter relay@ NeutralswitchØ Fuse (20A)

@ Prime Start@ Warning indicator@ CDlunit@ Thermoswitch@ Oilpressure switch@ Charge coil@ Pulser coil@ Lighting coil@ Rectifier Regulator@ lgnition coil@ Spark plug

E EHD

Color codeBBrGLoPRWB/OBA/V

BtGAtrGy/BPlBPArW/BW/RYlBY/R

BlackBrownGreenBlueOrangePinkRedWhiteBlack/orangeBlack/whiteBlack/yellowGreen/whiteGray/lclackPink/blackPinl</whiteWhite/blackWhite/redYelloMl¡lackYelloMred

@YAMAHAYAMAHA MOTOR CORPORATION, USA

Printed in USANov.2000-1.66x1CR(FsoAEf, FT50BEr)

r ¡À\

f50tlrb

Documents

service manual

genuine yamaha parts

quality service

general information

i o gi572 q

manual format

safety procedures

service points