1986-1998 Yamaha 60HP Enduro 2 Stroke Outboard Repair Manual

1986 - 1995 OUTBOARD / MOTEUR HORS-BORD SERVICE MANUAL / MANUEL D’ATELIER Model : E60ELD, E60ELF, E60ELG, E60ELH, E60ELHP, E60ELHQ, E60ELHR, E60ELHS, E60ELHT, E60ELJ, E60LD, E60LF, E60LG, E60LH, E60LJ, E60MLHP, E60MLHQ, E60MLHR, E60MLHS, E60MLHT 6K5281977100 *6K5281977100*

E60J, E60EJ SERVICE MANUAL © 1986 by Yamaha Motor Co., Ltd. 1st edition, MAY 1986 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited. Printed in JAPAN

EXTERNAL ViEW F

NOTICE HOW TO USE THiS MANUAL This manual was written by the Yamaha Motor Company primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to put an entire mechanic,s education into one manual, so it is assumed that persons using this book to perform maintenance and repairs on Yamaha outboard motors have a basic under- standing of the mechanical concepts and procedures inherent in outboard motors repair technology. Without such knowledge, attempted repairs Or service to this model may render it unfit to use and/or unsafe. Yamaha Motor Co., Ltd. is continually striving to improve all models manufactured by Yamaha. Modifications :and significant changes in specifications or procedures will be forwarded to all Authorized Yamaha dealers and will, where ap- plicable, appear in future editions of this manual. SE RVICE DEPT. OVERSEAS MARKETING DIVISION MARINE OPERATIONS YAMAHA MOTOR CO., LTD. PARTICULARLY IMPORTANT IN FORMA- TION This material is distinguished by the following notation. NOTE : A NOTE provides key information to make procedures easier or clearer. A CAUTION indicates special procedures that must be followed to avoid damage to the outboard motors. Ig 7 El Tr l A WARNING indicates special procedures that must be followed to avoid injury to a outboard motors operator or person inspecting or repair- ing the outboard motors. MANUAL FORMAT All of the procedures in this manual are organiz- ed in a sequential, step-by-step format. The information has been complied to provide the mechanic with an easy to read, handy re- ference that contains comprehensive explana- tions of all disassembly, repair, assembly, and inspection operations. In this revised format, the condition of a faulty component will precede an arrow symbol and the course of action required will follow the symbol, e.g., Bearings Pitting/Damage --> Replace. EXPLODED DIAGRAM Each chapter provides exploded diagrams before each disassembly section for ease in identifying correct disassembly and assembly procedures. OPERATING SEQUENCE Part numbers ( ~, (~, (~...) in this manual indicate the sequence of disassembly, assembly, and inspection procedures.

GEN I-1! ® CARB INSP ADJ Pow. h • ow. I ELEoI, RCOL ~;~.~ STRT ® ® @ @ @ @ ® @ ± @ (~) @ ® ® l SYMBOL MARKS (Refer to the illustration) Symbol marks (~ to (~ are designed as thumb tabs to indicate the chapter's number and con- tent. (~ General information {~ Periodic inspections and adjustments (~) Fuel system and carburetion (~ Power head overhaul ~) Lower unit overhaul (~ Electrical system Recoil starter (~ Appendices Symbol marks (~ to (~ are used to identify the specifications appearing in the text. Recommended oil (~ Recommended grease @ Tightening torque @ Wear limit (~ Engine speed ~) Resistance Symbot marks (~ to gram indicate grade of of lubrication point. (~ in the exploded dia- lubricant and location Apply 2-stroke outboard motor oil Gear oil Apply YAMAHA GREASE A (Water resistant grease) Apply YAMAHA GREASE C (Antifreeze grease) Apply YAMAHA GREASE D (Anticorrosion grease) Apply YAMAHA GREASE E (Wear resistant grease) Symbol marks @ to @ in the exploded diagram indicate grade of sealing agent and location of sealing agent point. @ Apply YAMAHA bond No.4 @ Apply LOC TtTE No.572 @ Apply Screw lock

.~:~ iNDEX GENERAL INFO RMATION GEN |NFO PERiODiC iNSPECTiONS AND ADJUSTMENTS INSP ADJ FUEL SYSTEM AND I ~; ~ F - U - EL CARBURETION CARS POWER HEAD OVERHAUL LOWER UNiT OVE RHAUL 1 LOWR ELECTRICAL SYSTEM RECOIL STARTER .COL | r m STRT ,., APPENDICES

CHAPTE R 1 GENERAL INFORMATION GEN INFO i OUTBOARD MOTOR IDENTIFICATION .......................... 1- 1 MODEL AND SERIAL NUMBER .............................. 1- 1 ENGINE SERIAL NUMBER .................................. 1- 1 IMPORTANT INFORMATION ................................... 1- 2 ALL REPLACEMENT PARTS ................................. 1- 2 GASKET AND SEALS ...... ................................. 1- 2 CIRCLIPS ............................................ .... 1- 2 LOCK WASHERS AND COTTER PINS ............. ............. 1- 2 BEARINGS AND OIL SEALS ................................. 1- 3 TECHNICAL FEATURES ....................................... 1- 4 POWER UNIT ............................................. 1- 4 ELECTRICAL ............................................. 1- 9 LOWER UNIT ............................................. 1-12 COOLING SYSTEM ......................................... 1-17 SPECIAL TOOLS .............................................. 1-18 FOR TUNE-UP ............................................ 1-18 FOR ENGINE SERVICE ..................................... 1-19 FOR LOWER UNIT SERVICE ................................ 1-20 FOR ELECTRICAL COMPONENTS ............................ 1-25 FOR RIGGING ............................................ 1-25 SEALING AGENTS AND LUBRICANTS ........................... 1-26 SEALING AGENTS ......................................... 1-26 LUBRICANTS ............................................. 1-26 COOLING SYSTEM ............................................ 1-28 PROPELLER AND PROPELLER SELECTION ....................... 1-29 FUNCTION OF THE PROPELLER ............................. 1-29 MOVEMENT OF THE PROPELLER IN THE WATER .............. 1-29 PROPELLER PITCH ......................... ' .............. 1-30 PROPELLER SELECTION ................................... 1-31

I °'" INFO I OUTBOARD MOTOR IDENTI FICATION GENERAL INFORMATION OUTBOARD MOTOR TION IDENTIFICA- ','A~A.A Mo'lro, co., ,~D. / MAeE IN JAPAN \ / .,, MODEL AND SERIAL NUMBER The model and serial number plate is attached to the port side clamp bracket. (~Number plate Starting serial number: E60 SJ : 000101 LJ : 300101 ~ E60E SJ : 200101 LJ : 500101 (~ Model name (~ Approved model No. ~) Transam height (~) Serial number ENGINE SERIAL NUMBER The engine serial number is stamped on the plate attached to the cylinder body. (~Engine serial number NOTE ." Designs and specifications are subject to change without notice. 1-1

IMPORTANT INFORMATION GEN INFO IMPORTANT iNFORMATION ALL REPLACEMENT PARTS 1. Use only genuine Yamaha parts for all re- placements. Use oil and/or grease recommended by Yamaha for assembly and adjustment. Other brands may be similar in function and appearance, but inferior in quality. GASKETS AND SEALS 1. All gaskets and seals should be replaced when an engine is overhauled. All gasket surfaces and oil seal lips must be cleaned. 2. Properly oil all mating parts and bearings during reassembly. ® CIRCLIPS 1. All circlips should be inspected carefully before reassembly. Always replace piston pin clips after one use. Replace distorted circlips. When installing a circlip, make sure that the sharp edged corner is positioned opposite to the thrust it receives. See the sectional view below. (~ Th rust ~)Circlip (~ Shaft (~Sharp edged corner LOCK WASHERS AND COTTER PINS 1. All lock washers and cotter pins must be replaced when they are removed. Lock tab(s) should be bent along the bolts or nut hexagon after the bolts or nut has been properly tightened. ~)Cotter pin 1-2

INFO[ IMPORTANT INFORMATION BEARINGS AND OIL SEALS 1. Install the bearing(s) with their manufac- turer's marks or numbers facing outward. (In other words, the stamped letters must be on the side exposed to view). When installing bearings liberally oil the bearings. ~) Bearing Do not use compressed air to spin the bearings dry. This causes damage to the bearing surfaces. 2. Install the oil seal(s), apply a light coating of water resistant grease to outside diameter of the oil seal(s). (~Oil seal 1-3

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1986-1998 Yamaha 60HP Enduro 2 Stroke Outboard Repair Manual

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