2004-2005 Yamaha 60hp 70hp 90hp 2 Stroke Outboard Service & Repair Manual

60C 70C 90C SERVICE MANUAL 6H2-28197-1F-11 LIT-18616-02-66 *LIT186160266*

E NOTICE This manual has been prepared by Yamaha primarily for use by Yamaha dealers and their trained mechanics when performing 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 render it unsafe or unfit for use. Because Yamaha has a policy of continuously improving its products, 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 succes- sive editions of this manual. 60C, 70C, 90C SERVICE MANUAL ©2003 by Yamaha Motor Corporation, USA 1st Edition, October 2003 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, USA is expressly prohibited. Printed in USA LIT-18616-02-66

E A50000-0 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 in a sequential, 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. MODEL INDICATION Multiple models are shown in this manual. These indications are noted as follows. 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, exploded diagrams are provided. Steps in the procedures are numbered thus: 1), 2), 3). Parts shown in the illustrations are identified thus: 1 , 2 , 3 . REFERENCES These have been kept to a minimum, however, when you are referred to another section of the manual, you are told the page number to go to. Model name 60FETO 70BETO 90AETO USA and Canada name 60TR 70TR 90TR Indication 60FETO 70BETO 90AETO

E SPECIFICATIONS These are given in bold type at 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 the following table. 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 ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! WARNING 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. CAUTION: 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. Model name 60FETO 70BETO 90AETO USA and Canada name 60TR 70TR 90TR Control system Remote control Tilt system Power trim and tilt Lubrication system Oil injection

E A50001-1-4 SYMBOLS Symbols 1 to 9 are designed as thumb- tabs to indicate the content of a chapter. 1 General Information 2 Specifications 3 Periodic Inspection and Adjustment 4 Fuel System 5 Power Unit 6 Lower Unit 7 Bracket Unit 8 Electrical Systems 9 Trouble Analysis Symbols 0 to F indicates specific data: 0 Special service tool A Specified liquid B Specified grease C Specified engine speed D Specified torque E Specified measurement F Specified electrical value [Resistance (Ω), Voltage (V), Electric current (A)] Symbol G to J in an exploded diagram indicate grade of lubricant and location of lubrication point: G Apply engine oil H Apply gear oil I Apply molybdenum disulfide oil J Apply water resistant grease (Yamaha marine grease A, Yamaha marine grease) Symbols K to N in an exploded diagram indicate grade of sealing or locking agent, and location of application point: K Apply Gasket Maker ® L Apply LOCTITE ® No. 271 (Red LOCTITE) M Apply LOCTITE ® No. 242 (Blue LOCTITE) N Apply LOCTITE ® No. 572 NOTE: In this manual, the above symbols may not be used in every case. 1 2 3 4 5 6 7 8 9 0 A B C D E F G H I J K L M N GEN INFO SPEC INSP ADJ FUEL POWR LOWR BRKT – + ELEC TRBL ANLS T R . . E G M A GM 271 LT 242 LT 572 LT

E INDEX GENERAL INFORMATION 1 SPECIFICATIONS 2 SPEC PERIODIC INSPECTION AND ADJUSTMENT 3 FUEL SYSTEM 4 FUEL POWER UNIT 5 POWR LOWER UNIT 6 LOWR BRACKET UNIT 7 BRKT ELECTRICAL SYSTEMS 8 ELEC TROUBLE ANALYSIS 9 GEN INFO INSP ADJ – + TRBL ANLS A30000-0

E 1 2 3 4 5 6 7 8 9 GEN INFO CHAPTER 1 GENERAL INFORMATION IDENTIFICATION ............................................................................................ 1-1 SERIAL NUMBER ..................................................................................... 1-1 STARTING SERIAL NUMBERS ............................................................... 1-1 SAFETY WHILE WORKING ............................................................................ 1-2 FIRE PREVENTION ................................................................................... 1-2 VENTILATION........................................................................................... 1-2 SELF-PROTECTION.................................................................................. 1-2 OILS, GREASES AND SEALING FLUIDS................................................ 1-2 GOOD WORKING PRACTICES ................................................................ 1-3 DISASSEMBLY AND ASSEMBLY ........................................................... 1-4 SPECIAL TOOLS ............................................................................................. 1-5 MEASURING ............................................................................................ 1-6 REMOVAL AND INSTALLATION ............................................................ 1-8

1-1 GEN INFO E IDENTIFICATION A60000-1* IDENTIFICATION SERIAL NUMBER The outboard motor serial number is stamped on a label attached to the port clamp bracket. 1 Model name 2 Approved model code 3 Transom height 4 Serial number STARTING SERIAL NUMBERS The starting serial number blocks are as follows: Model name Approved model code Starting serial No. 60TR 6H2 L: 1003093 ~ 70TR 6H3 L: 1002818 ~ 90TR 6H1 L: 1007591 ~

1-2 GEN INFO E SAFETY WHILE WORKING SAFETY WHILE WORKING The procedures given in this manual are those recommended by Yamaha to be fol- lowed by Yamaha dealers and their mechanics. FIRE PREVENTION Gasoline (petrol) is highly flammable. Petroleum vapor is explosive if ignited. Do not smoke while handling and keep it 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 gases are 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- pressed air, when grinding or when doing any operation which may cause particles to fly off. 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, grease and sealing fluids or those recommended by Yamaha.

1-3 GEN INFO E SAFETY WHILE WORKING Under normal conditions of use, there should be no hazards from the use of the lubricants mentioned in this manual. How- ever, safety is all-important and by adopt- ing good safety practices, any risk is minimized. A summary of the most important precautions is as follows: 1. While working, maintain good stan- dards of personal and industrial hygiene. 2. Clothing which has become contaminated with lubricants should be changed as soon as practicable, and laundered before further use. 3. Avoid skin contact with lubricants; do not, for example, place a soiled wiping- rag in one’s pocket. 4. Hands, and any other part of the body which have been in contact with lubricants or lubricant-contaminated clothing, should be thoroughly washed with hot water and soap as soon as practicable. 5. To protect the skin, the application of a suitable barrier cream to the hands before working is recommended. 6. A supply of clean, lint-free cloths should be available for wiping purposes. GOOD WORKING PRACTICES 1. The right tools Use the special tools that are advised to protect parts from damage. Use the right tool in the right manner - don’t improvise. 2. Tightening torque Follow the torque tightening instructions. When tightening bolts, nuts and screws, tighten the larger sizes first, and tighten inner-positioned fixings before outer-positioned ones.

2004-2005 Yamaha 60hp 70hp 90hp 2 Stroke Outboard Service & Repair Manual

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