Yamaha 50G / 60F / 70B / 75C / 90A Outboard Service & Repair Manual

6H2-28197-Z9-11 SERVICE MANUAL 50G, 60F, 70B, 75C, 90A

E NOTICE This manual has been prepared by the Yamaha Motor Company Ltd. 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 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* 50G, 60F, 70B, 75C, 90A SERVICE MANUAL 1999 Yamaha Motor Co., Ltd. 1st Edition, February 1999 No part of this publication may be 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.

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 50GETO 60FEHTO 60FED 60FEDO 60FET 60FETO 70BEDO 70BETO USA and Canada name — P60TH C60ER — C60TR — — 70TR Indication 50GETO 60FEHTO 60FED 60FEDO 60FET 60FETO 70BEDO 70BETO Model name 75CET 75CETO 75CEHTO 80AETO 90AEHD 90AED 90AET 90AETO USA and Canada name C75TR 75TR P75TH — — — C90TR 90TR B90TR Indication 75CET 75CETO 75CEHTO 80AETO 90AEHD 90AED 90AET 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 50GETO 60FEHTO 60FED 60FEDO 60FET 60FETO 70BEDO 70BETO USA and Canada name — P60TH C60ER — C60TR — — 70TR Control system Remote control Manual control Remote control Tilt system Power trim and tilt Manual tilt Power trim and tilt Manual tilt Power trim and tilt Lubrication system Oil injection Pre-mixed Oil injection Pre-mixed Oil injection Model name 75CET 75CETO 75CEHTO 80AETO 90AEHD 90AED 90AET 90AETO USA and Canada name C75TR 75TR P75H — — — C90TR 90TR B90TR Control system Remote control Manual control Remote control Manual control Remote control Tilt system Power trim and tilt Manual tilt Power trim and tilt Lubrication system Pre-mixed Oil injection Pre-mixed 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 serial number of the outboard motor is stamped on a plate attached to the port side of the clamp bracket. 1 Serial number NOTE: For USA model: As an anti-theft measure, a special label on which the outboard motor serial number is stamped is bonded to the port side of the clamp bracket. The label is specially treated so that peeling it off causes cracks across the serial number. 1 Model name 2 Approved model No. 3 Transom height 4 Serial number STARTING SERIAL NUMBERS The starting serial number blocks are as follows: Model Approved model No. Serial number Model Approved model No. Serial number World- wide USA Canada World- wide USA Canada 50GETO — — 62F L: 400805 ~ 70BEDO — — 6H3 L: 402029 ~ 60FEHTO P60TH P60TH 6H2 L: 551924 ~ 70BETO 70TR 70TR L: 491824 ~ X: 750186 ~ X: 731262 ~ 60FED — C60ER S: 001118 ~ 75CET C75TR C75TR 6H0 L: 001251 ~ L: 305624 ~ 75CETO — 75TR L: 951540 ~ 60FEDO — — S: 100850 ~ 75CEHTO P75TH — L: 900371 ~ L: 407212 ~ 80AETO — — L: 457543 ~ 60FET C60TR C60TR S: 050474 ~ X: 851331 ~ L: 357665 ~ 90AEHD — — 6H1 L: 320132 ~ X: 710231 ~ 90AED — — L: 401108 ~ 60FETO — — S: 150756 ~ 90AET C90TR C90TR L: 354053 ~ L: 472180 ~ 90AETO 90TR B90TR 90TR L: 498690 ~ X: 732000 ~ X: 856313 ~

Yamaha 50G / 60F / 70B / 75C / 90A Outboard Service & Repair Manual

You're Reading a Preview

Recently Viewed