1997 Yamaha 50 HP outboard service repair manual

1993 - 1998 OUTBOARD / MOTEUR HORS-BORD SERVICE MANUAL / MANUEL D’ATELIER Model : C75TLRW, P60TLHT, P60TLHU 6H228197Z311 *6H228197Z311*

1993 Outboard Model: P60S/70S Part: 6H228197Z311

A20000-O NOTICE This manual has been prepared by the Yamaha Motor Company primarily for use byYamaha dealers and their trained mechanics whenperforming maintenance procedures and repairs to Yamaha equipment. It has been written to suit the needs of persons who have a basic understanding of the mechanical and electrical concepts and procedures inherent in the work, for without such knowledge attempted repairs or service to the equipment could ren- der it unsafe or unfit for use. Because the Yamaha Motor Company Ltd. has a policy of continuously improving its prod- ucts, models may differ in detail from the descriptions and illustrations given in this publication. Use only the latest edition of this manual. Authorized Yamaha dealers are notified periodically of modifications and significant changes in specifications and procedures, and these are incorporated in successive editions of this manual. A10001-0 _ P60S/70S/90S 50G/60F/70B/80A/90A SERVICE MANUAL ©1993 Yamaha Motor Co., Ltd. 1st. Edition,November 1993 All rights reserved. No part of this publication maybe reproduced or transmitted in any form or by any means including photocopying and recording without the written permission of the copyright holder. Such written permission must also be obtained before any part of this publication is stored in a retrieval system of any nature. Printed in Japan P/N 6H2-28197-Z3-11

AS0000-0 HOW TO USE THIS MANUAL MANUAL FORMAT This manual provides the mechanic with descriptions of the operations of disassembly, repair, assembly, adjustment and inspection, each of which is presented inasequential, step-by-step procedure, To assist you to find your way about this manual, the Section Title and Major Heading is given at the head of every page. An Index to contents is provided on the first page of each Section. THE ILLUSTRATIONS Some illustrations in this manual may differ from the model you have. This is because the procedure described may relate to several models, though only one may be illustrated. (The name of the model described will be mentioned in the description.) To help you identify components and understand the correct procedures of disassembly and assembly, explodeddiagrams are provided. Steps in the procedures are numbered thus: 1), 2), 3). Partsshown in the illustrations are identifiedthus: O, (_),Q. REFERENCES These have been kepttoa minimum, however, when you are referred to another section of the manual, you are told the page numberto go to.

SPECIFICATIONS These are given in bold typeat each procedure. It is not necessary to leave the section deal- ing with the procedure in order to look up the specifications. It is important to note the differences in specifications of models. Where a procedure relates to more than one model, the main differences in specifications will be shown in a following table. For U.S.A. and CANADA) Model Item _-_, P60TH 70TR 90TR Control system Manual control Remote control Remote control Tilt system Power trim and tilt Power trim and tilt Power trim and tilt (Except for U.S.A. and CANADA) Model 50GEO 50GETO 6OFEO 6OFETO 70BEO Item Power trim Power trim Tilt system Manual tilt and tilt Manual tilt and tilt Manual tilt 70BETO 80AEO 80AETO 90AEO 90AETO Powertrim Powertrim Powertrim Manual tilt Manual tilt andtilt andtilt andtilt WARNINGS, CAUTIONS AND NOTES Attention is drawn to the various Warnings, Cautions and Notes which distinguish important information in this manual in the following ways. The Safety Alert Symbol means ATr'ENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! IF!_TAT!_'I ;t k_ IIL_ lei Failure to follow WARNING instructions could result in severe injury or death to the machine operator, a bystander, or a person inspecting or repairing the outboard motor. A CAUTION indicates special precautions that must be taken to avoid damage to the outboard motor. NOTE: A NOTE provides key information to make procedures easier or clearer. IMPORTANT: This part has been subjected tochange of specification during production.

_) (_) AS0001-1-4 ·, SYMBOLS - GEN INFO 'T SPEC _ Symbols Oto O are designed as thumb- tabs to indicatethe content of a chapter. (_ (_) (_) General Information (D Specifications INSP FUEL J_ QPeriodiclnspectionandAdjustment ADJ ®Fuel System O Power Unit O (_ _ Lower Unit O Bracket Unit _ p (_) Electrical System POWR LOWR _ (_) Trouble-shooting I ® ® I i _ BRKT _' ELEC, _"_ I - ® _ Symbols (_) to _) indicate specific data: i_ <_ (_) Special service tool TRBL ® Specified liquid SHTG · -...-. _) Specified grease (_) Specified engine speed @ =-'----- (_) ',-,"','--- (_) Specified torque ii_ (_) Specified measurement - _ _) Specified electrical value [Resistance (4), Voltage (V), Electric current _ iimmmmlmw_lm :(_ =, (_) -- (A)] '_--_ q_ _............._._ , 0 _ - Symbol (_) to _ in an exploded diagram indi- _ -- cate grade of lubricant and location of lubrica- _7) _) tion point: _ (_ Apply engine oil _) Apply gear oil _) Apply molybdenum disulfide oil (_ Apply water resistant grease (Yamaha :(_ (_ marine grease A, Yamaha marine grease) _ Symbols (_) to (_ in an exploded diagram indicate grade of sealing or locking agent, and location of application point: (_Apply Gasketmaker ® Apply LOCTITE ®No. 271 (Red LOCTITE) _ Apply LOCTITE ® No. 242 (Blue LOCTITE) 271 _) Apply LOCTITE ® No. 572 _ _ .L NOTE: _1_ Inthis manual, the above symbols may not 242 u572 be used in every case.

oooo.o INDEX 3.. GENERAL INFORMATION GEN INFO SPECIFICATIONS _g"p SPEC PERIODIC INSPECTION AND ADJUSTMENT i_-_ ADJ FUELSYSTEM E FUEL POWER UNIT G POWR BRACKET UNIT BRKT ELECTRICAL SYSTEM _ [_ ELEC TROU BLE-SHOOTING T_L SHTG

I GEN CHAPTER 1 GENERAL INFORMATION IOENTIFICATJON ........................................................................................... 1 - 1 SERIAL NUMBER .................................................................................... 1-1 ENGINE SERIAL NUMBER ..................................................................... '1-'1 S'_ART_NG SERIAL NUMBERS .............................................................. 1-1 SAFETY WHILE WORKING .......................................................................... 1-2 F_RE PREVF_ N'_ O N .................................................................................. '1-2 VE NT_ LA'_ O N ......................................................................................... 1-2 S E LF'PR O"FE_CT_ O N ................................................................................ 1-2 OILS, GREASESAND SEALING FLUIDS .............................................. 1-2 GOOD WORKING PRACTICES ............................................................... 1-3 DISASSEMBLY AND ASSEMBLY .......................................................... 1-4 SPECIAL TOOLS ........................................................................................... 1 '5 FOR TUNE-UP ......................................................................................... 1-5 FOR POWER UNIT SERVICE .................................................................. 1-6 FOR LOWER UNIT SERVICE .................................................................. 1-7 FOR P.T.T. SERVICE ............................................................................. 1-12

I GEN iNFOI I IDENTIFICATION A60000-1' · : ,.,, SERIAL NUMBER The serial number of the outboard motor is stamped on a plate attached to the port side of the clamp bracket. O Serial number NOTE: ForU.S.A. model: /(_) As an anti-theft measure, a special label on which the outboard motor serial number is r I Y ) _MAHAli_!!:.?:?!i;!!i.?!iifili?;?:??i!i'i;i:;: ? stamped is bonded to the port side of the ,, clamp bracket. The label is specially treated [iiiiiiiiiiiiiiiiii!ii:iiiPAYS '''''_*'_(_'-_ _!i};i!iiiii:JAPONiii!iiiil}i ii:i!;ii;!!i!il J SO that peeling it off causes cracksacross /YAMAHA M(_TOR CO., LTD, the serial number. /MADE IN J_PAN t' D'ORI_INE (_) Model name (_) Approved model No. -- O Transom height ® Serial number -_O,_ _mib_ ENGINE SERIAL NUMBER The engine serial number is stamped on the port side of the cylinder body. STARTING SERIAL NUMBERS iff The starting serial number blocks are as fol- lows: Model Approved Serial Number model No. 50GEe S: 100153 ~ L: 400424 ~ 62F 50GETO S: 200129 ~ L: 500871 ~ 60FEe S: 100793 ~ L: 406295 ~ 60FETe S: 150657 ~ 6H2 L: 465483 ~ UL: 730666 ~ P60THS L: 550832 ~* 70BEe S: 100216 ~ L: 401718 ~ 70BETO 6H3 S: 150329 ~ (70TRS} L: 483416 ~* UL: 730798 ~ 80AEO L: 401100 ~ 80AETO 6H0 L: 456637 ~ UL: 850765 ~ 90AEO L: 401067 ~ 90AETO 6H1 L: 486330 ~* (90TRS) UL: 854694 ~ 1-1 *: For U.S.A. and CANADA

I GEN INFO{ '_ { SAFETYWHILEWORKING SAFETY WHILE WORKING The procedures given in this manual are _ those recommended by Yamaha to be fol- lowed by Yamaha dealers and their mechanics. FIREPREVENTION _. Gasoline (petrol) is highly flammable. Petroleum vapor is explosive if ignited. Do not smoke while handling andkeepit away from heat, sparks, and open flames. VENTILATION Petroleum vapor is heavier than air and if _ .....,_ inhaled in large quantities will not support life.Engine exhaust gasesare harmful to __ breathe. When test-running an engine indoors, maintain good ventilation. SELF-PROTECTION Protect your eyes with suitable safety glasses or safety goggles when using com- t_, .. _ pressed air, when grinding or when doing any operation which may cause particles to · flyoff. Protect hands and feet by wearing safety gloves or protective shoes if appropriate to the work you are doing. OILS, GREASES AND SEALING FLUIDS Use only genuine Yamaha oils, greases and sealing fluids or those recommended by Yamaha. i 1-2

1997 Yamaha 50 HP outboard service repair manual

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