2001-2009 Yamaha Outboard F60 F60A Engine Service & Repair Manual

SERVICE MANUAL 292098 69W-28197-3D-1X SUPPLEMENTARY F60A

NOTICE This Supplementary Service Manual has been prepared to introduce new service and new data information for the F60 which is based on the F50. For complete information on service procedures, it is necessary to use this Supplementary Service Manual together with the following manual. Important information 1 Particularly important information is distinguished in this manual by the following notations: 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. F50A, FT50B, FT50C SERVICE MANUAL: 62Y-28197-3A-11 F60A SUPPLEMENTARY SERVICE MANUAL ©2001 by Yamaha Motor Co., Ltd. 1st Edition, July 2001 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited. Printed in the Netherlands

Contents General information 1 GEN INFO Specifications 2 SPEC Periodic checks and adjustments 3 CHK ADJ Fuel system 4 FUEL Power unit 5 POWR Lower unit 6 LOWR Bracket unit 7 BRKT Electrical systems 8 ELEC Troubleshooting 9 TRBL SHTG Index – +

69W3D1X General information How to use this manual .................................................................................... 1 Manual format............................................................................................... 1 Symbols ........................................................................................................ 2 Identification ...................................................................................................... 3 Applicable models ........................................................................................ 3 Serial number ............................................................................................... 3 Features and benefits ....................................................................................... 4 Power unit ..................................................................................................... 4 Carburetors................................................................................................... 5 Lower unit ..................................................................................................... 7 Bracket unit ................................................................................................... 9 Electrical unit .............................................................................................. 10 Technical tips .................................................................................................. 11 Carburetor .................................................................................................. 11 PTT (Power Trim and Tilt) unit ................................................................... 12 Propeller selection .......................................................................................... 13 Propeller size .............................................................................................. 13 Selection ..................................................................................................... 13 Predelivery checks ......................................................................................... 14 Checking the fuel system ........................................................................... 14 Checking the gear oil .................................................................................. 14 Checking the engine oil .............................................................................. 14 Checking the battery................................................................................... 14 Checking the outboard motor mounting height ........................................... 14 Checking the shift/throttle cables................................................................ 15 Checking the steering system .................................................................... 15 Checking the gearshift and throttle operation ............................................. 16 Checking the tilt system.............................................................................. 16 Checking the engine start switch and engine stop switch/ engine shut-off switch ............................................................................... 16 Checking the cooling water pilot hole ......................................................... 17 Test run ...................................................................................................... 17 Break-in ...................................................................................................... 17 After test run ............................................................................................... 17

69W3D1X Specifications General specifications .................................................................................... 18 Maintenance specifications ........................................................................... 20 Power unit ................................................................................................... 20 Lower unit ................................................................................................... 24 Electrical ..................................................................................................... 24 Dimensions ................................................................................................. 27 Tightening torques.......................................................................................... 32 Specified torques ........................................................................................ 32 General torques .......................................................................................... 33 Periodic checks and adjustments Special service tools ...................................................................................... 34 Maintenance interval chart ............................................................................. 36 Top cowling ..................................................................................................... 37 Checking the top cowling............................................................................ 37 Fuel system ..................................................................................................... 37 Checking the fuel filter ................................................................................ 37 Power unit ........................................................................................................ 37 Checking the thermostat ............................................................................. 37 General ............................................................................................................. 38 Checking the anodes .................................................................................. 38 Lubrication .................................................................................................. 39 Fuel system Hose routing .................................................................................................... 40 Fuel and blowby hoses ............................................................................... 40 Cooling water hose ..................................................................................... 41 Fuel line and fuel filter .................................................................................... 42 Carburetor unit ................................................................................................ 43 Adjusting the dashpot (acceleration pump) ................................................ 44

69W3D1X Power unit Power unit ........................................................................................................ 45 Checking the compression pressure .......................................................... 55 Checking the oil pressure ........................................................................... 55 Checking the cylinder bore ......................................................................... 56 Checking the piston ring grooves ............................................................... 56 Lower unit Drive shaft and lower case ............................................................................. 57 Removing the drive shaft ............................................................................ 59 Disassembling the forward gear ................................................................. 59 Assembling the forward gear ...................................................................... 59 Installing the drive shaft .............................................................................. 59 Shimming ......................................................................................................... 60 Shimming.................................................................................................... 61 Selecting the forward gear shims ............................................................... 61 Bracket unit Tiller handle ..................................................................................................... 63 Bottom cowling ............................................................................................... 65 Upper case ....................................................................................................... 67 Disassembling the oil pan........................................................................... 71 Assembling the oil pan ............................................................................... 71 Installing the upper case............................................................................. 72 Clamp brackets ............................................................................................... 74 Adjusting the trim sensor ............................................................................ 75 Swivel bracket and steering arm ................................................................... 76 Power trim and tilt unit ................................................................................... 77 Disassembling the gear pump .................................................................... 82 Checking the valves ................................................................................... 82 Assembling the gear pump ......................................................................... 83 Checking the trim sensor ............................................................................ 84

69W3D1X Electrical systems Wiring harness ................................................................................................ 85 Ignition and ignition control system ............................................................. 86 Checking the spark plug caps .................................................................... 88 Checking the pulser coil air gap ................................................................. 88 Checking the engine start switch ................................................................ 88 Starting system ............................................................................................... 89 Starter motor ................................................................................................... 90 Checking the armature ............................................................................... 91 Checking the brushes ................................................................................. 91 Wiring diagram

GEN INFO General information 1 69W3D1X How to use this manual 1 Manual format The 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. 1 Parts are shown and detailed in an exploded diagram and are listed in the components list. 2 Tightening torque specifications are provided in the exploded diagrams and after a numbered step with tightening instructions. 3 Symbols are used to indicate important aspects of a procedure, such as the grade of lubricant and lubrication point. 4 The components list consist of parts and part quantities, as well as bolt, screw, O-ring, and hose dimensions. 5 Service points regarding removal, checking, and installation are shown in individual illustrations to explain the relevant procedure. NOTE: For troubleshooting procedures, see Chapter 9, “Troubleshooting.”

69W3D1X 2 Symbols The symbols below are designed to indicate the content of a chapter. General information Specifications Periodic checks and adjustments Fuel system Power unit Lower unit Bracket unit Electrical systems Troubleshooting GEN INFO SPEC CHK ADJ FUEL POWR LOWR BRKT ELEC TRBL SHTG – + Symbols 1 to 6 indicate specific data. 1 Special tool 2 Specified oil or fluid 3 Specified engine speed 4 Specified tightening torque 5 Specified measurement 6 Specified electrical value (resistance, voltage, electric current) Symbols 7 to A in an exploded diagram indicate the grade of lubricant and the lubrication point. 7 Apply Yamaha 4-stroke motor oil 8 Apply water resistant grease (Yamaha grease A) 9 Apply molybdenum disulfide grease 0 Apply corrosion resistant grease (Yamaha grease D) A Apply low temperature resistant grease (Yamaha grease C) Symbols B to G in an exploded diagram indicate the type of sealant or locking agent and the appli- cation point. B Apply Gasket Maker ® C Apply Yamabond No. 4 D Apply LOCTITE ® No. 271 (Red) E Apply LOCTITE ® No. 242 (Blue) F Apply LOCTITE ® No. 572 G Apply silicon sealant 1 2 3 4 5 6 T R . . 7 8 9 0 A E A M D C B C D E F G GM 4 271 LT 242 LT 572 LT SS How to use this manual 1 2 3 4 5 6 7 8 9

GEN INFO General information 3 69W3D1X Identification 1 Applicable models This manual covers the following models. 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 Applicable models F60AEHT F60AET Model name Approved model code Starting serial No. F60AEHT 69W L: 500101– F60AET L: 400101–

2001-2009 Yamaha Outboard F60 F60A Engine Service & Repair Manual

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