2001-2003 Yamaha T50 Outboard Service & Repair Manual

SUPPLEMENTARY SERVICE MANUAL F50 T50 F60 T60 6C1-28197-1N-1X LIT-18616-03-28

Preface This Supplementary Service Manual has been prepared to introduce new service and new data information for F50D, T50D, F60D, and T60D. For complete information on service procedures, it is necessary to use this supplementary service manual along with the following manual. F50D, T50D, F60D, and T60D SERVICE MANUAL: LIT-18616-02-85 (6C1-28197-1G-11) Important information Particularly important information is distinguished in this manual by the following notations: The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! EWM00000 A WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury. ECM00000 A NOTICE indicates special precautions that must be taken to avoid damages to the outboard motor or other property. TIP: A TIP provides key information to make procedures easier or clearer. F50D, T50D, F60D, T60D SUPPLEMENTARY SERVICE MANUAL ©2010 by Yamaha Motor Corporation, U.S.A. 1st Edition, September 2010 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in U.S.A. LIT-18616-03-28

General information GEN INFO 0 Specification SPEC 1 Technical features and description TECH FEA 2 Rigging information RIG GING 3 Troubleshooting TRBL SHTG 4 Electrical system ELEC 5 Fuel system FUEL 6 Power unit POWR 7 Lower unit LOWR 8 Bracket unit BRKT 9 Maintenance MNT 10 Index Appendix A Supplementary contents

General information Safety while working ......................................................... 1 Rotating part ................................................................................... 1 Hot part ........................................................................................... 1 Electric shock ................................................................................. 1 Propeller ......................................................................................... 1 Handling of gasoline ....................................................................... 1 Ventilation ...................................................................................... 1 Self-protection ................................................................................ 2 Working with crane ......................................................................... 2 Handling of gas torch ..................................................................... 2 Part, lubricant, and sealant ............................................................ 2 Handling of sealant ......................................................................... 3 Special service tool ........................................................................ 3 Tightening torque ........................................................................... 3 Non-reusable part ........................................................................... 3 Disassembly and assembly ........................................................... 3 How to use this manual ......................................................... 4 Manual format ................................................................................ 4 Abbreviation ................................................................................... 5 Lubricant, sealant, and thread locking agent ...................... 6 Symbol ........................................................................................... 6 Special service tool ................................................................ 7 Specification Model feature ..........................................................................9 Model designation .......................................................................... 9 Serial number ................................................................................. 9 Model data ............................................................................10 Dimension and weight .................................................................. 10 Performance ................................................................................. 10 Power unit .................................................................................... 10 Lower unit ..................................................................................... 11 Bracket unit .................................................................................. 11 Fuel and oil requirement ............................................................... 11 Battery requirement ...................................................................... 12 PTT fluid requirement ................................................................... 12

0 1 2 3 4 5 6 7 8 9 10 A Electrical system technical data .........................................12 Ignition timing control system ....................................................... 12 Fuel injection control system ........................................................ 12 Engine speed control system ....................................................... 13 Charging system .......................................................................... 13 Gauge/sensor ............................................................................... 14 Y-COP .......................................................................................... 14 Fuel system technical data .................................................15 Fuel system .................................................................................. 15 Power unit technical data ....................................................15 Cylinder head assembly ............................................................... 15 Lower unit technical data ....................................................16 Lower unit assembly..................................................................... 16 Specified tightening torque .................................................17 Rigging information ...................................................................... 17 Electrical system .......................................................................... 17 Power unit .................................................................................... 17 Lower unit ..................................................................................... 17 Tiller handle model ....................................................................... 17 Bracket unit .................................................................................. 18 General tightening torque ...................................................18 Technical features and description Y-COP ....................................................................................19 Rigging information Outboard motor installation ................................................20 Dimension .............................................................................21 Exterior F50T, F60T ..................................................................... 21 Exterior F50T, F60T (model with optional tiller handle) ............... 22 Exterior T50T, T60T ..................................................................... 23 Exterior T50T, T60T (model with optional tiller handle) ............... 24 Clamp bracket .............................................................................. 25

Installing Y-COP (optional) .................................................26 Registering the receiver ID to the ECM ........................................ 26 System diagram ...................................................................27 Single outboard motor application ................................................ 27 Troubleshooting YDIS .......................................................................................29 Feature ......................................................................................... 29 Hardware requirement .................................................................. 29 Function........................................................................................ 30 Connecting the communication cable to the outboard motor ....... 31 Trouble code table........................................................................ 31 Outboard motor troubleshooting........................................32 Troubleshooting the power unit using the YDIS ........................... 32 Trouble code and checking step .................................................. 32 Troubleshooting the power unit (trouble code not detected) ........ 33 Electrical system Electrical component and wiring harness routing ............34 Starboard...................................................................................... 34 Front ............................................................................................. 36 Tiller handle (optional) .................................................................. 38 Circuit diagram .....................................................................40 ECM coupler layout ..............................................................41 Y-COP (optional) ..................................................................42 Checking Y-COP .......................................................................... 43 Checking the buzzer ..................................................................... 43 Checking the Y-COP main wiring harness ................................... 43 Checking the button cell battery ................................................... 44 Command Link Multifunction Meter sensor ......................45 Checking the water pressure sensor (optional) ............................ 45 Checking the speed sensor (optional) .......................................... 46

0 1 2 3 4 5 6 7 8 9 10 A Fuel system Fuel filter assembly ..............................................................48 Removing the fuel filter assembly ................................................ 48 Checking the fuel filter assembly.................................................. 48 Installing the fuel filter assembly .................................................. 49 Power unit Power unit assembly ...........................................................50 Installing the power unit ................................................................ 50 Oil pump ................................................................................53 Cylinder block ......................................................................54 Installing the crankshaft journal bearing ....................................... 54 Lower unit Shimming ..............................................................................55 Shimming workflow ...................................................................... 55 Shimming check sheet ................................................................. 56 Measuring the forward gear backlash and reverse gear backlash before disassembly ....................................................... 58 Shimming ..................................................................................... 61 Shim location ................................................................................ 61 Selecting the pinion shim (T3) ..................................................... 62 Pinion shim (T3) selection table ................................................... 65 Measuring the forward gear backlash .......................................... 67 Adjusting the forward gear shim (T1) thickness ........................... 67 Forward gear shim (T1) selection chart ........................................ 69 Measuring the reverse gear backlash .......................................... 71 Adjusting the reverse gear shim (T2) thickness ........................... 71 Reverse gear shim (T2) selection chart ....................................... 73

0 1 2 3 4 5 6 7 8 9 10 A Shimming (high thrust model) ............................................75 Shimming workflow ...................................................................... 75 Shimming check sheet ................................................................. 76 Measuring the forward gear backlash before disassembly .......... 77 Shimming ..................................................................................... 78 Shim location ................................................................................ 78 Selecting the pinion shim (T3) ...................................................... 79 Measuring the forward gear backlash .......................................... 80 Adjusting the forward gear shim (T1) thickness ........................... 80 Forward gear shim (T1) selection chart ........................................ 81 Bracket unit Tiller handle (optional) .........................................................83 Disassembling the tiller handle..................................................... 86 Assembling the tiller handle ......................................................... 87 Electrical component (optional) .........................................91 Disassembling the electrical component ...................................... 92 Assembling the electrical component ........................................... 92 Maintenance Outline ...................................................................................94 Maintenance interval chart 1 ........................................................ 94 Maintenance interval chart 2 ........................................................ 95 Appendix Wiring diagram .....................................................................98 How to use the wiring diagram ..................................................... 98 Engine control unit and fuel unit ................................................... 98 Ignition unit ................................................................................. 100 Charging unit and starting unit ................................................... 102 Control unit ................................................................................. 104

1 0 1 2 3 4 5 6 7 8 9 10 A General information Safety while working To prevent an accident or injury and to pro- vide quality service, observe the following safety procedures. Rotating part • Hands, feet, hair, jewelry, clothing, personal flotation device straps, and so on, can become entangled with internal rotating parts of the engine, resulting in serious injury or death. • Keep the top cowling installed whenever possible. Do not remove or install the top cowling when the engine is running. • Only operate the engine with the top cowling removed according to the specific instructions in the manual. Keep hands, feet, hair, jewelry, clothing, personal flotation device straps, and so on, away from any exposed moving parts. Hot part During and after operation, engine parts are hot enough to cause burns. Do not touch any parts under the top cowling until the engine has cooled. Electric shock Do not touch any electrical parts while starting or operating the engine. Otherwise, shock or electrocution could result. Propeller Do not hold the propeller with your hands when loosening or tightening the propeller nut. Handling of gasoline • Gasoline is highly flammable. Keep gasoline and all flammable products away from heat, sparks, and open flames. • Gasoline is poisonous and can cause injury or death. Handle gasoline with care. Never siphon gasoline by mouth. If you swallow some gasoline, inhale a lot of gasoline vapor, or get some gasoline in your eyes, see your doctor immediately. If gasoline spills on your skin, wash with soap and water. If gasoline spills on your clothing, change your clothes. Ventilation • Gasoline vapor and exhaust gas are heavier than air and extremely poisonous. If gasoline vapor or exhaust gas is inhaled in large quantities, it may cause loss of con- sciousness and death within a short time. • When test running an engine indoors (for example, in a water tank) make sure to do so where adequate ventilation can be main- tained.

2 Self-protection • Protect your eyes by wearing safety glasses or safety goggles during all opera- tions involving drilling and grinding, or when using an air compressor. • Protect your hands and feet by wearing pro- tective gloves and safety shoes when necessary. Working with crane • Outboard motors weighing 18.0 kg (39.7 lb) and over must be carried by a crane. • Use the wire ropes of adequate strength, and lift up the outboard motor using the three-point suspension. • If the outboard motor does not have three or more points to be suspended, support it using additional ropes, or the like, so that the outboard motor can be lifted and carried in a stable manner. Handling of gas torch • Improper handling of a gas torch may result in burns. For information on the proper handling of the gas torch, see the operation manual issued by the manufacturer. • When using a gas torch, keep it away from the gasoline and oil, to prevent a fire. • Components become hot enough to cause burns. Do not touch any hot components directly. Part, lubricant, and sealant Use only genuine Yamaha parts, lubricants, and sealants, or those recommended by Yamaha, when servicing or repairing the outboard motor.

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2001-2003 Yamaha T50 Outboard Service & Repair Manual

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