F50TLRB

@YAMAHA
396 Pgs
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LIT-19616-02-33
62Y-28I97-1A-I I
Contents
General information
How to use this manual..... Manual format........ Symbols
....1-1 ........1-1
.,_._,.1-2
ldentification
Applicable Serial
models number
I-5
.........1-5 ................1-5 ........1-6
Features and benefits
Acceleration pump
Propeller selection
.,,.,,1.32
Predelivery checks Checking the fuel system Checking the gear oi1.............. Checking the engine oil .............. Checking the battery.
Checking the remote control Checking the steering wheel/tiller
......1-33
............... 1-33 ........ 1-33
cables handle Checkingthegearshiftandthrottleoperation... Checking the tilt system....... Checking the engine start switch and engine stop switch/engine shut-off switch Checking the pilot water outlet ......... Test run Break-in After test run.............
62Y1411
Checkingtheoutboardmotormountingposition
....1-33 ...1-33 ..................1-34

.................. 1-34 .......... 1-34
....................1-34 ...........1-35
....... 1-35
.................1-35 ....1-35 ....1-36 ...1-36
General information
How to use this manual Manualformat
The format of this manual has been designed to make service procedures clear and easy to understand. Use the information below as a guide for effective and quality service. @ Parts are shown and detailed in an exploded diagram and are listed in the components list.
@ Tightening torque specifications are provided in the components list at the beginning of each
section and atter a numbered step with tightening instructions. @ Symbols are used to indicate important aspects of a procedure, such as the grade of lubricant and lubrication point. @ The components list consist of pads and pafi quantities, as well as bolt and screw dimensions. @ Service points regarding removal, checking, and installation are shown in individual illustrations to explain the relevant procedure. @ This service manual has two types of special service tools. Use part numbers that start with "Jr', "YB-", "YM-", "YS-", "YU-", "YW-", or "YX-" for USA and Canada. Use parts numbers that start with "90890-" for all other countries.
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2.3 1.8 0.6 1,2
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1-1
62Y141
How to use this manual

Symbols
The symbols below are designed to indicate the content of a chapter. General information Power unit
,RFI
Specifications
POWR -_
Lower unit
SPEC
tF
LowRl
Bracket unit
Periodic checks and adjustments
CHK ADJ
BRKT
ml
Fuelsystem
Symbols
Fltrl
point.
Electrical systems
O to @ in an exploded diagram indicate the grade of lubricant and the lubrication
o
O Apply Yamaha
@ @ @ @
Apply Apply Apply Apply
/,\
!,
-@l
4-stroke motor oil
-@l
-@l
-@l
water resistant grease (Yamaha grease A, Yamaha marine grease)

molybdenum disulfide grease anti-corrosion grease (Yamaha grease D) low temperature resistant grease (Yamaha grease C)
Symbols @ to @ in an exploded diagram indicate the type of sealant or locking agent and the application point.
@
@
Apply Yamabond
@) Appry LOCTTTE@
o
271
o
242
GI
572
@ Apply Gasket MakeP

No. 4
No.271 (Red LOCTTTE) Apply LOCTITE@ No.242 (Blue LOCTITE) @ @ Apply LOCTITE@ No. 572 @ Apply silicon sealant
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1-2
General information Safety while working To prevent an accident or injury and

to ensure quality service, follow the safety procedures provided below.
Fire prevention
Gasoline is highly flammable.
Keep gasoline and all flammable products

away from heat, sparks, and open flames.
s62Y1 120
Parts, lubricants, and sealants

Use only genuine Yamaha parts, lubricants,
and sealants or those recommended by Yamaha, when servicing or repairing the

outboard motor,
AMANI
Ventilation
Gasoline vapor and exhaust gas are heavier than air and extremely poisonous. lf inhaled in large quantities they may cause loss of consciousness and death within a short time. When test running an engine indoors (e.9., in a water tank) be sure to do so where adequate ventilation can be maintained.
s62Y1
30
Under normal conditions, the lubricants mentioned in this manual should not harm or be hazardous to your skin. However, you should follow these precautions to minimize any risk when working with lubricants.
1.
Maintain good standards of personal and industrial hygiene.
2. 3.
Self-protection
Protect your eyes by wearing safety glasses or safety goggles during all operations involving drilling and grinding, or when using an air compressor. Protect your hands and feet by wearing protective gloves and safety shoes when necessary.
4.
Change and wash clothing as soon as possible if soiled with lubricants.
Avoid contact with skin. example, place a soiled

pocket.
Do rag
not, for
in
your
Wash hands and any other part of the body thoroughly with soap and hot water after contact with a lubricant or lubricant
soiled clothing has been made.
5.
To protect your skin, apply a protective cream to your hands before working on
the outboard motor.
1-3
62Y141
Safety while working
6.
Keep a supply of clean, lint-f ree cloths for wiping up spills, etc.
Good working practices Specialtools Use the recommended special tools to
pro-
tect parts from damage. Use the right tool in the right manner-do not improvise.
s62Y1
1
00
lnstall bearings with a manufacture identification mark in the direction indicated in the installation procedure. ln addition, be sure to lubricate the bearings liberally.
thin coat of water-resistant grease to the lip and out periphery of an oil seal before installation.
Apply
Tightening torques Follow the tightening torque specifications 5' Check that moving parts operate normally after assembly. provided throughout the manual. When tightening nuts, bolts, and screws, tighten the
large sizes first, and tighten fasteners stafting in the cenler and moving outward.
Non-reusable parts
Always use new gaskets, seals, O-rings, cotter pins, circlips, etc., when installing or assembling parts.
(F:.
Qo
s2Y1
1
50
Disassembly and assembly
1. 2.
Use compressed air to remove dust and dirt during disassembly.
Apply engine oil to the contact surfaces of moving parts before assembly.
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1-4
ldentification
Applicable models
This manual covers the following models. Applicable models USA, Canada
FSOTH
lf the serial number label is removed, VOID marks will appear on the label.
Approved modelcode USA, Canada
FSOTH FSOTR
Worldwide
FSOAEHD
Model name
Starting serial No.
FSOAEHT F5OAED F5OAET FT5OBET FTSOCEHD

FTSOCED
62Y 64J
FsOTR T5OTR
L:451812L:421732-
TsOTR FsOAEHD F5OAEHT F5OAED
L;40685f
L:350505L:451812L:301090L:421626-
Worldwide
FTSOCET
62Y
Serial number
FSOAET
The outboard motor serial number is stamped on a label attached to the port
clamp bracket.
FTsOBET FT5OCEHD FT5OCED FTSOCET 64J
L;40685f
L: 650101-
L:550101L:450101-
@ Modelname @ Approved model code

@ Transom height @ Serialnumber
1-5
62Y141
ldentification / Features and benefits

Features and benefits Newly designed four carburetors
Newly designed four carburelors have been based on the current F504. Prime Start has been adopted for the starting system to further increase stafting performance and serviceability. Furthermore, the acceleration pump and the dashpot have been integrated to simplify construction and to ease serviceability. The four carburetors can be accurately and easily adjusted due to the simple construction of the links.
J\,
-t
t
*1
@ Prime Start @ Acceleration pump
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1-6
CDI unit with microcomputer

The ignition system consists of a flywheel, stator, pulser coil, thermoswitch, oil pressure switch, CDI unit, and igntion coil. The CDI unit contains a built-in microcomputer that determines the ignition timing separately for acceleration and for normal operation, based on signals received from the pulser coil, thermoswitch, and oil pressure switch.
,G.
\\\--<Ll
@ @ @ @
CDlunit
Flywheel Stator Pulser coil Thermoswitch @ @ lgnition coil @ Oilpressure switch
1-7
62Y141
Features and benefits

Lower unit
Higher class pinion and gears The lower unit of the new T50/FT50B, FT50C uses the same type of large gears that are used in the F100. The use of the same type of gears that are used in a higher class model provides ample durability, making it possible to accommodate a wider range of applications throughout the market.
TsO/FTsOB, FTSOC
Pinion
Model
Fonrrrard
gear
Diameter
(mm) 74 95
Reverse gear Number of teeth 24 30 Diameter

(mm) 75 95
1.8
Number of teeth
13 13
Diameter
(mm)
Number of teeth 24
30
Gear ratio
F50/F50A
T5O/FT5OB, FTSOC
45 46
2.3
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1-8
Shift slider type shift mechanism The T50/FT50B, FT50C has adopted the shift slider type shift mechanism. This shift mechanism enables a prompt engagement of the dog clutch regardless of the operating speed of the shift lever. Thus, smooth and positive shift operation has been made possible.
@ @ @ @
E E
Shift rod Propeller shaft Dog clutch Shift slider

Fonvard
Reverse
1-9
62Y141
Features and benefits / Technical tips
Technical tips
Carburetor
Starting system (Prime Start) To facilitate the starting of a cold engine, an air-fuel mixture that is richer than normal is required. For this reason, the Prime Staft system has been adopted in the F50iF50A, T50/FT50B, FT50C. ln the Prime Start system, the thermo heater plunger is in a position that fully opens the fuel enrichment valve while the engine is being started. Thus, fuel enrichment is achieved during the stailing of the engine, and continues while the engine is being warmed up. Once the engine starts, current flows from the lighting coil of the to the thermo heater, allowing the wax in the Prime Start unit to expand. The expanded wax moves the thermo heater plunger in the direction to close the enrichment valve. As a result, the volume of fuel that passes through the fuel enrichment valve decreases. A few minutes after the engine has started, the thermo heater plunger completely closes the fuel enrichment valve, thus ending the fuel enrichment by the Prime Stafi system.
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O
Prime Stan lntake manifold of the engne @ Thermo heater plunger @ Fuel enrichment valve @ To carburelor #2 ot #4
S62Y12lO
@ Carburetor @ lntake silencer
E nr E Fuel
@ Plunger movement
62Y141
1-10
l#11
c,
( v',
@ Prime Stan
E the E
enriched air-fuel mixture is delivered to cylinders #1 and #2 by the Prime Start system attached to carburetor #1. tfie enriched airjuel mixture is delivered to cylinders #3 and #4 by the Prime Start system attached to carburetor #3.
1-1
62Y141
Technical tips
Carburetor operation
1. ldle and low-speed operation Since the vacuum at the venturi is low when the throttle valve is opened slightly, the main nozzle does not supply any air-fuel mixture to the engine. When the engine is operating at idle, the fuel that passes through the pilot jet and the air that passes through the pilot air jet mix, enabling the air-fuel mixture that has been regulated by the pilot screw to be fed through the pilot outlet. Because the throttle valve opens slightly when the engine is operating at low speeds, air-fuel mixture also stas to be fed from the bypass holes.
tr
@ Pilot screw @ Pilot outlet @ Bypass holes @ Venturi @ Main nozzle @ Pilot jet @ Main jet @ Pilot air jet
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1
@ Main air jet @ Throttle valve
E Rr E Air-fuelmixture E Fuel
'l-12
General information
2. Medium speed operation When the throttle valve opens further, air-fuel mixture is fed from the pilot outlet and all the bypass holes. ln addition, air-fuel mixture is also supplied from the main nozzle in accordance with the opening angle of the throttle valve.
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J:@
@ @ @ @ @ @ @ @
Pilot screw Pilot outlet Bypass holes Venturi

Pilot jet Main jet
@ Main air jet @ Throttle valve
E Rr E Air-fuelmixture E Fuel
Main nozzle Pilot air jet

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1
1-13
Technical tips
3. High-speed operation When the throttle valve approaches its fully open position, the fuel that has been regulated by the main jet and the air that has been regulated by the main air jet are mixed in the main nozzle. The resultant mixture is then sprayed by the main nozzle into the venturi. The air-fuel mixture that is sprayed through the venturi is then fed into the engine.
$:I @,9 J:g
@ Pilot screw @ Pilot outlet @ Bypass holes @ Main nozzle @ Pilot jet @ Main jet @ Main air jet @ Throttle valve
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1
E Rir E Air-fuelmixture E Fuel
'l-14
General information
Acceleration pump
The function of the acceleration pump is to ensure a smooth acceleration by preventing the air-fuel mixture from becoming temporarily lean in case the throttle valve is opened suddenly. When the throttle valve is opened suddenly, a large volume of air is introduced into the engine. However, because fuel is heavier than air, it is not possible to supply the volume of fuel that is necessary for the large volume of air that has been introduced. Thus, because it is not possible to achieve the airfuel mixture that is required by the engine, bucking or hesitation results. For this reason, the acceleration pump temporarily increases the fuel volume in order to adjust the air-fuel mixture to a ratio that is necessary for the engine in case the throttle valve is opened suddenly.
Bypass hose Acceleration pump Pump chamber Diaphragm 1 Throttle lever @
@ @ @ @
E Airflow E Throttle valve opening direction

1-15
62Y141
1
Technical tips
Operation When the throttle is opened suddenly, diaphragm 1 (via the link that is connected to the throttle lever) operates to pressurize the air in the pump chamber. The pressurized air opens diaphragm 2, and becomes distributed to the carburetors by passing through the pipes that are connected to the carburetors. The pressurized and distributed air then utilizes the passage of the main air jet to flow into the main nozzle. The pressure of the air helps suck fuel from the main jet, which increases the fuel in the main nozzle, and thus achieves the fuel enrichment.
$
@
s62Y1 300
@ Main air jet @ Main nozzle @ Main jet @ Throttle valve @ Pilot screw @ Pilot outlet Pilot jet @ From acceleration pump @ Throttle valve closing @ Throttle valve opening
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1
@ Diaphragm 1 @ Diaphragm 2 @ To carburetors E Airflow
Throttle valve opening direction
1-16
General information
lgnition system
ln order to determine the optimal ignition timing that is necessary for the proper operation of the engine, the built-in microcomputer in the CDI unit detects the signals from various types of sensors and controls the ignition timing in accordance with a control map that is based on those signals. The microcomputer also effects controls to protect the engine against overheating, over-revolution, and oil pressure drops, as well as to controlwarning devices.
llG*< +
@
l5----+<-+
ll
@ @ @ @ @
Pulser coil Flywheel Charge coil
CDlunit
Microcomputer
@ lgnition coils #1 and #4 @ lgnition coils #2 and #3 @ Oilpressure switch @ Thermoswitch
Flywheel Three protrusions for the pulser coil are provided along the periphery of the flywheel. The purpose of these protrusions is for detecting the engine speed. Two of them are used for ignition signals, and one is used for identifying the cylinders, and these signals are transmitted to the microcomputer.
1-17
62Y141
Technical tips
Pulser coil The pulser coil transmits the pulser signals, which are generated in the pulser coil in accordance with the rotation of the flywheel, to the CDI unit. Among the two protrusions that are provided for generating signals, one is used for cylinders #1 and #4, and the other for cylinders #2 and #3, thus enabling the pulser coil to simultaneously ignite two cylinders. To provide ignition signals to the cylinders, the microcomputer determines the ignition cylinder and ignition timing. These are based on the cylinder identification signals generated by the protrusion for identifying cylinders, and on the pulser signals generated by the protrusions for generating ignition signals.
d
s62Y1320
@ Flywheel @ Rotating direction @ Protrusion for cylinders #1 and #4 @ Pulser coil @ Cylinder identification protrusion @ Protrusion for cylinders #2 and #3
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1-18
General information
lgnition timing control
Control circuit diagram
Operation
Engine start Acceleration
Detection
Microcomputer
lgnition liming control (optimized ignition timing) Engine speed conlrol
Over-revolution Low oil pressure Overheat
Warning buzzer (in remote-control unit) Warning lamp (low oil pressure) Warning lamp overheat)
r>
Damage prevention
Basic control The ignition timing is determined by using the map based on the engine speed (r/min). Then, ignition signals are output from the microcomputer in accordance with the ignition timing map so that ignition can take place at the optimal timing in relation to the engine speed. Then, the microcomputer corrects the ignition timing in accordance with the operating conditions of the engine as detected by the signals that are input from the engine temperature sensor and oil pressure sensor. The pulser signals that are output when the protrusions for cylinders #1 and #4, and for cylinders #2 and #3 pass by the pulser coil, are used to calculate the engine speed. ln addition, the pulser signals are used to determine the forecast starting position of the ignition timing.
s62Y1340
@ @ @ @ @
Cylinder identification protrusion Pulser coil Protrusion for cylinders #1 and #4 Protrusion for cylinders #2 and #3 Pulser coil signal
@ Cylinder identification signal
@ ldentification sgnal for cylinders #1 and #4 @ ldentification sgnal for cylinders #2 and #3 @ Rotating direction
1-19
62Y141
Technical tips
Starting control When starting the engine, the timing is set to r/min for two seconds or longer.
5'
BTDC until the crankshaft speed maintains 600
o@., +o
s62Y1 350
@ Cylinder identification protrusion
@ Starting signal (5' BTDC) for cylinders #1 and

#4
@ Protrusion for cylinders #1 and #4 @ Pulser coil @ Protrusion for cylinders #2 and #3 @ Pulser coil signal @ Cylinder identification signal
@ Starting signal (5' BTDC) for cylinders #2 and

#3
@ Rotating direction
Warm-up control After the starting control is completed, the control transfers to the ignition timing based on the warmup map for three minutes. From the time the three-minule warm-up control has been completed, the controltransfers to the normal map.
/\ \9
o
@
\ ,\
v/
/
. ,/ aa
li- /
@ lgnition timing (BTDC') @ Engine speed (x 1,000 r/min) @ Warm-up map @ Acceleration map @ Normalmap
s62Y1 360
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'l-20
General information
Acceleration control This control is activated when the throttle valve is opened suddenly. lf the engine speed increases more than the specified figures, the control of the ignition timing transfers to the acceleration map. Thereafter, the control of the ignition timing transfers gradually to the control map before acceleration. lf it was under warm-up control, the timing transfers to the warm-up control map, and if it was under normal control, the timing transfers to the normal control map. The control described above will be repeated if the engine is accelerated again. Over-revolution control This control operates by detecting the engine speed. lf the engine speed increases to over 6,200 r/min, the ignition of cylinders #1 and #4 is stopped in order to regulate the speed. lf the engine speed increases further to over 6,300 r/min, the ignition of cylinders #2 and #3 is also stopped. This controlwill not be deactivated until the engine speed drops below 6,200 r/min. Overheating control This control operates in accordance with the engine temperature, which is detected by the signal that is input from the thermoswitch. When the microcomputer detects via the thermoswitch signal that the engine temperature has increased to over 80 'C (176 "F), it outputs a signal to stop the ignition of cylinders #1 and #4, if the engine speed is over 2,000 r/min. Al the same time, the microcomputer issues a warning by operating the warning lamp and the warning buzzer. When the overheating control is activated, it will not be deactivated until the engine is stopped or the engine temperature decreases to under 70 "C (158 "F). The determination of overheating stops when the engine is stopped. However, untilthe engine temperature decreases to approximately 70 "C (158 "F) or below, the overheating controlwill be activated upon restarting the engine. Upon restarting, if the engine speed is under 2,000 r/min, the overheating control will not be activated lor 75 seconds. However, if the engine is operated al over 2,000 r/min for more than 25 seconds, the overheating controlwill be activated. Oil pressure control The oil pressure control operates in accordance with the signals from the oil pressure switch. The oil pressure is determined to have dropped if the engine continues to operate at over 2,000 r/min with an oil pressure of under 49 kPa (0.49 kgf/cm2,6.97 psi) for more than one second. When the oil pressure control is activated, the warning buzzer sounds and the warning lamp illuminates. lf the engine speed is over 2,000 r/min, the control stops the ignition of cylinders #1 and #4 so that the engine speed will not increase to over 2,000 r/min. Once an oil pressure drop is determined, this control will not be deactivated even if the oil pressure recuperates, until the engine is stopped.
1-21
62Y141
Technical tips
Power trim and
tilt
The newly designed power trim and tilt consists of an up-main valve, a down-main valve, an uprelief valve, a single cylinder, and a single ram, which control both trim and tilt functions. The power trim and tilt cylinder has been integrated with the gear pump housing, the reservoir tank, and the power trim and tilt motor in order to achieve a smaller and more compact unit.
Hydraulic system diagram
@ @ @ @ @ @ @ @ @
Power trim and tilt cylinder

Ram
Reseruoir
Manualvalve
Down-main valve Down-relief valve Hydraulic pump Up-relief valve Up-main valve
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'l-22
Power trim and tilt components
@ @ @ @ @ @ @ @ @ @
Cylinder
Ram
Check valve Down-main valve Down-relief valve Motor Gear pump Up-main valve Reservoir
Up-relief valve Up-shuttle piston Down-shutfle piston Trim cylinder base @ Free piston @ Tilt piston
@ @ @ @
Manualvalve
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1
1-23
Technical tips
Trim-up function The gear pump pumps power trim and tilt fluid to the up-main valve. As a result, the fluid pressure opens the up-shuttle piston causing the fluid to flow into the lower part of the power trim and tilt cylinder. At the same time, vacuum from the gear pump opens the down-main valve and down-shuttle piston, which causes fluid from the upper part of the power trim and tilt cylinder to return to the gear pump, and also sucks fluid in through the reseruoir. The pressurized fluid forces up the trim cylinder along with the tilt piston, free piston, and trim cylinder base. As the trim cylinder moves up, the ram extends and the outboard motor is trimmed up. The end of the trim range is when the trim cylinder tops out in the power trim and tilt cylinder. Trim-up function
@ Power trim and tilt cylinder @ Ram @ Trim cylinder @ Down-main valve @ Motor @ Gear pump @ Up-main valve @ Reseruoir
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1
@ @ @ @ @
E B
Up-shuttle piston Down-shuttle piston Free piston Trim cylinder base Tilt piston Return Seno
'l-24
General information
Trim-down function When the power trim and tilt switch is pressed to "Down", the motor turns the gear pump counterclockwise and the power trim and tilt fluid flows in the opposite direction to that of the trim-up func'
tion.
Tilt-up function
When the trim cylinder tops out, the check valve is pushed down by the end screw wall. This causes the ball in the check valve to move down, opening the fluid passage and allowing the power trim and tilt fluid to flow from the upper part of the trim cylinder, through the down-shuttle piston and the down-main valve, and back to the gear pump. ln addition, fluid is also sucked in through the reservoir and the pressurized fluid continues to flow into the lower part of the trim cylinder, pushing up the tilt piston and free piston, and further extending the ram. As the tilt piston moves up and off of the trim cylinder base, the base moves up and pushes the balls outward to fit into holes of the power trim and tilt cylinder. Once the balls have been fitted into the holes the trim cylinder base cannot move. The end of the tilt-up range is when the tilt piston tops out in the trim cylinder and the ram is fully extended. The tilt-up function operates when the fluid pressure is under 10 MPa (100 kgf/cm2, 1,423 psi). When the fluid pressure in the lower part of the trim cylinder increases to over 10 MPa (100 kgf/cm2, 1,423 psi), the up-relief valve opens and allows the pressurized fluid to flow into the reservoir. Thus, the tilt piston and free piston are not pushed up and the ram cannot be extend fufther.
1-25
62Y141
Technical tips
Tilt-up function
@ Power trim and tilt cylinder @ Ram @ End screw @ Check valve @ Trim cylinder @ Reservoir @ Down-main valve @ Gear pump @ Up-main valve
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1
@ @ @ @ @ @
E E E
Up-shufile piston Down-shuttle piston Trim cylinder base Free piston Tilt piston Balls Return Send Moving direction
'l-26
Circular flow
$:@
J:@
@ Power trim and tilt cylinder @ Ram

@ Trim cylinder
@ Gear pump
@ Free piston @ Tilt piston
@ Motor @ Reservoir @ Up-relief valve
E Return E Send
1-27
62Y141
Technical tips
Tilt-down function When the power trim and tilt switch is pressed to "Down", the motor turns the gear pump counterclockwise, thus pumping the power trim and tilt fluid to the down-main valve. As a result, fluid pressure opens the down-main valve and the down-shuttle piston, which causes fluid to flow into the upper part of the trim cylinder and forces the tilt piston down. When the tilt piston and the free piston reach the trim cylinder base, it pushes the base down, allowing the balls to move inward. Once the balls move in, the trim cylinder is then able to move down and power trim and tilt fluid continues to flow into the cylinder and pushes the trim cylinder down, along with the tilt piston and ram. The end of the tilt-down range is when the tilt piston and the free piston bottom out in the trim cylinder base. When the power trim and tilt fluid pushes the trim cylinder down further trim-down is started. The end of the trim-down range is when the trim cylinder arrives at the bottom of the power trim and tilt cylinder. Before the trim cylinder arrives at the bottom of the power trim and tilt cylinder, an amount of fluid equal to the volume of the ram is returned to the reservoir.
62Y141
'l-28
Tilt-down function
@ Power trim and tilt cylinder @ Ram

@ Trim cylinder
@ Down-shuttle piston @ Ball @ Trim cylinder base
@ @ @ @ @ @ @
Down-relief valve Down-main valve Gear pump Reservoir Up-relief valve Up-shuttle piston Up-main valve
@ Free piston @ Tilt piston @ Balls
E Return E Seno E Moving direction

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1
1-29
Technical tips
Stopping condition When the power trim and tilt switch is not pushed (released), the gear pump does not pump the fluid, the up-main valve and the down-main valve are closed, and the power trim and tilt fluid pressure in the system remains constant. This allows the ram to maintain its position until the power trim and tilt fluid flows through the system again. When the outboard motor hits something in the water The check valve of the trim cylinder and the tilt piston absorber of the tilt piston help to prevent internal damage to the power trim and tilt unit and help to protect the bracket and lower unit from damage in case the outboard motor hits something during operation. When the outboard motor hits something, highly pressurized fluid in the upper part of the power trim and tilt cylinder pushes down the check valve of the trim cylinder. At the same time, fluid pressure in the upper part of the trim cylinder increases and the tilt piston absorber is pushed down. As a result, the tilt piston and the ram are pushed up without the free piston. The tilt piston is stopped before reaching the top of the trim cylinder by the damper function of the tilt piston absorber to protect the power trim and tilt unit from damage.
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1-30
Damper function
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s62Y1430
b.
@ Power trim and tilt cylinder

@ Trim cylinder
@ Ram
@ Tilt piston absorber @ Tilt piston
@ Check valve @ Tlt piston absorber @ Tilt piston
E E
Send Moving direction
@ Free piston
1-31
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1
Technical tips / Propeller selection

Propeller selecton The performance of a boat and outboard
motor will be critically atfected by the size and type of propeller you choose. Propellers greatly atfect boat speed, acceleration, engine life, fuel economy, and even boating and steering capabilities. An incorrect choice could adversely affect performance and could also seriously damage the motor. Use the following information as a guide for selecting a propeller that meets the operating conditions of the boat and the outboard
motor.
Selection
When the engine speed is at the full throttle operating range (5,000-,000 r/min) an ideal propeller for the boat is one that provides maximum performance in relation to boat speed and fuel consumption.
F50/F504 Propeller size (in) Material Aluminum Aluminum Aluminum Aluminum Aluminum Aluminum Aluminum Aluminum Aluminum Aluminum Aluminum Stainless Stainless Stainless Stainless Stainless Stainless Stainless Stainless
10x15-G 101/4x14-G 103/8x13-G 105/8x12-G

103/4 x 16 - G 103/4 x 17 - G
Propeller size
The size of the propeller is indicated on the propeller blade or outside of the propeller
boss.
103/4x17-G
1O314x17 - G
13x19-K
1/8x13-G 1/4x14-G 11 3/8x12-G 115/8x11-G

11
11
121/4x9'G
101/4x14-G 101/4x15-G 101/4x16-G 105/8x13-G 11 1/4x14-G 11 1/2x13-G 113/4x12-G 12x11-G
TsO/FT5OB, FTSOC
103/4x17-G
6
@ Propeller diameter (in inches) @ Propeller pitch (in inches) @ Propeller type (propeller mark)
13x19-K
Propeller size (in)
Material Aluminum Aluminum Aluminum Aluminum Aluminum Aluminum Aluminum Aluminum
12518x21 -K
13x19-K 13x23-K 13x25-K 131/4x17 -K 131/2x15-K 135i8x13-K 14x11-K
62Y141
'l-32
General information Predelivery checks

To make the delivery process smooth and etficient, the predelivery checks should be
completed as explained below.
Checking the engine oil
1,
Check the oil level.
Checking the fuel system 1. Check that the fuel hoses are securely connected and that the fuel tank is full
with fuel.
. lf the engine oil is above the maximum level .

mark @, drain sufficient oil until the level is between @ and @. lf the engine oil is below the minimum level
NOTE:
mark @, add sufficient oil until the level is between @ and O.

Recommended engine oil: API: SE, SF, SG, SH SAE: 10W-30, 10W-40, or 20W-40
Oilcapacity: Without oil filter replacement: 2.O L (2.1 US qt, 1.8 lmp qt)
This is a 4-stroke engine. Never use premixed fuel.
Checking the battery
1.
Checking the gear oil
Check the capacity, electrolyte level, and specified gravity of the battery.
1.
Check the gear oil level.
Battery capacity: 70-100 Ah (252-360 kC) Minimum cold cranking performance: 380 A Electrolyte specif ic gravity: 1.28 at 20 "C (68 'F)
2.
Check that the positive and negative battery leads are securely connected.
1-33
62Y141
Predelivery checks
Checking the outboard motor mounting position
1.
Check the position of the anti'cavitation

plate.
The shifUthrottle cable joint must

@.
be
screwed in a minimum of 8.0 mm (0.31 in)
2.
Check that the clamp brackets are

secured with the clamp bolts.
Checking the steering wheel/tiller handle 1. Check the steering friction for proper
adjustment.
s2Y1 490
Checking the remote control cables
1.
Set the remote control lever to the neutral position and fully close the throttle
lever/throttle grip.
2. 3.
2.
Check the steering for smooth operation.
Check that the set pin @ is aligned with the alignment mark @. Adust if necessary.
Check that the alignment mark @ is aligned with the mark (D. Adjust if necessary.
s62Y1 540
3.
Check that there is no interference with wires or hoses when the outboard motor is steered.
Ghecking the gearshift and throttle operaton 1. Check that the gearshift operates
smoothly when shifting from neutral into forward and reverse.
62Y141
'l-34
2.
Check that the throttle control lever contacts the respective stoppers when the throttle control lever is closed or fully
open.
'n
Checking the pilot water outlet
1.
Check that cooling water is discharged from the pilot water outlet.
Checking the tilt system 1. Check that the outboard motor can be
smoothly tilted up and down by operating the power trim and tilt unit,
s62Y1570
2. 3. 4.
Check that there is no abnormal noise produced when the outboard motor is tilted up and down. Check that there is no interference with wires and hoses when the tilted-up motor is steered. Check that the trim meter points down when the outboard motor is tilted all the way down.
Test run 1. Start the engine, and then check for

smooth gearshift operation.
2.
Check the engine idle speed after the

engine has been warmed up.
3. 4.
Operate at trolling speed.
Checking the engine start switch and engine stop switch/engine shut-off switch 1. Check that the engine starts when the
engine start switch is turned to START. Check that the engine turns off when the engine staft switch is turned to OFF. Check that the engine turns off when the engine stop switch is pushed/engine shut-otf cord is pulled.
Run the outboard for one hour at 2,000 r/min or at half throttle, then for another hour at 3,000 r/min or at3/4 throle.
Check that the motor will not tilt up when shifting into reverse and that water will not flow in over the transom.
5.
The test run is part of the break-in operation.
1-35
62Y141
Predelivery checks
Break-in
ln the test run, the break-in operation is performed in the following three stages. 1. One hour @ at 2,000 r/min or at approximately half throttle. One hour (D at 3,000 r/min or 3/4 throttle and one minute out of every ten at full throttle.
Eight hours @ at any speed, however, avoid running at full speed for more than five minutes.
s62Y1580
Hour
After test run
1.
Check for water in the gear oil.
2. Check for fuel leakage in the cowling. 3. After a test run and while the engine is at
idle, flush the cooling water passage with fresh water using the flushing kit.
62Y141
1-36
MEMO
1-37
62Y141
Specif ications
General specif ications.
Mai ntenance specif
2-1
ications ....
2-12
Tightening
torques..... torques...... Generaltorques......

Specified
.,...,..,.2-29 ...2-29 .....2-31
62Y1411
Specifications
General specif ications
Model
Item USA Unit F5OAEHD
FSOTR
Canada
FsOTH F5OAEHT
FSOAED
FsOTR FsOAET
Dimension Overall length Overallwidth Overall height

(L)
mm (in) mm (in) mm (in) mm (in)
1,329 (52.3) 361 (14.2) 1,397 (55.0) 508 (20.0)
718 (28.3)
Boat transom height

(L)
Weight
(with aluminum propeller)
(L)
ks (lb)
kW (hp)
@ 5,500 r/min
108 (238)
112 (247)
104 (22e1
108 (238)
Performance Maximum output

Full throttle operating range Maximum fuel consumption
36,8 (s0)
r/min
5,000-,000
17.3 (4.57,3.81)
L (US gal, lmp gal)/hr @ 6,000 r/min
Power unit Type Cylinder quantity Displacement Bore x stroke Compression ratio Carburetor quantity Controlsystem Starting system lgnition control system lgnition timing Alternator output Enrichment system Choke valve control Spark plugs Cooling system Exhaust system Lubrication system
ln-line, 4-stroke, OHC, B valves

4
cm3 (cu. in)
mm (in)
935 (57.1) 63.0 x 75.0 (2.48 x 2.95) 9.3

4
Tiller handle
Remote control
Degree
Electric Microcomputer (CDl) TDC r 1.5-BTDC a5 + 1.5
V,A
12,10
Prime Start DPR6EA-e (NGK) Water Through propeller boss Wet sump
2-1
62Y141
General specifications
Model Item USA Unit FsOAEHD
FSOTR
Canada
F5OTH
FsOTR FSOAED FSOAET
FSOAEHT
Fueland oil Fueltype Fuelrating

Engine oiltype Engine oilgrade Engine oil quantity (with oil filter replacement)
(without oil filter replacement)
*PON
RON API
Regular unleaded gasoline 86

91
SAE
L
4-stroke molor oil SE, SF, SG, SH 10W-30, 10W-40, or 20W-40 2.2 (2.3,1.9) 2.0 (2.1,1.81 Hypoid gear oil GL-4 90 0.43 (0.45, 0.38)
(US qt, lmp qt)

L
(US qt, lmp qt)
Gear oiltype Gear oil grade Gear oil quantity
API
SAE
L
(US qt, lmp qt)
Bracket Trim angle (a|12 degree boat transom) Tilt-up angle Steering angle Drive unit Gear shift positions Gear ratio Reduction gear type Clutch type Propeller shaft type Propeller direction (rear view) Propeller identification mark Electrical Battery capacity Minimum cold cranking pedormance
RON: Research Octane Number
Degree Degree Degree
-+20
69
40+40
F.N.R 1.85 (24113)
Spiralbevelgear
Dog clutch
Spline Clockwise
G
Ah (kc) A
7G-100 (252-360) 380
* PON: Pump Octane Number (Research Octane Number + Motor Octane Number)/2
62Y141
2-2
Specifications
Model
Item USA Unit TsOTR TsOTR FTSOBET =TSOCEHD FTSOCED
Canada
FTsOCET
Dimension Overall length Overallwidth Overall height

(L)
718
(28.3)
1,384 (54.5)
718 (28.3)
361 (14.2) 1,436 (56.5) 508 (20.0)
Boat transom height

(L)
Weight
(with aluminum propeller)
(L)
ks (lb)
112 (247) 111.5 (246)
108 (238)
112 (247)
Performance Maximum output

Full throttle operating range
kw (hp)
@ 5,500 r/min
36.8 (50) 5,000--6,000 17.3 (4.57,3.81)
Maximum fuel consumption
r/min L (US gal,
lmp gal)/hr @ 6,000 r/min
Power unit Type Cylinder quantity Displacement Bore x stroke Compression ratio Carburetor quantity Controlsystem
Stafting system lgnition control system lgnition timing
ln-line, 4-stroke, OHC,8 valves

4
cm3 (cu, in)
mm (in)
935 (57,1) 63.0 x 75.0 (2.48 x 2.95) 9.3

4
Remote control
Degree
TDC r 1.5BTDC 35 1.5
Tiller Remote control handle Electric Microcomputer (CDl) TDC r 1.5-BTDC ag + 1.5 TDC r 1.s-BTDC 35 1.5 (Depending on market)
Alternator output Enrichment system Choke valve control Spark plugs Cooling system Exhaust system Lubrication system
V,A
12,10
Prime Start DPR6EA-e (NGK) Water Through propeller boss Wet sump
2-3
62Y141
General specifications
Model Item USA Unit TsOTR TsOTR
FTSOBET
Canada
FTSOCEHD FTSOCED
FTSOCET
Fueland oil Fueltype Fuelrating

Engine oiltype Engine oilgrade Engine oil quantity (with oil filter replacement)
(without oil filter replacement)
*PON
RON API
Regular unleaded gasoline 86

91
SAE
L
4-stroke molor oil SE, SF, SG, SH 10W-30, 10W-40, or 20W-40 2.2 (2.3,1.9) 2.0 (2.1,1.81 Hypoid gear oil GL-4 90 0.61 (0.64, 0.54)
(US qt, lmp qt)

L
(US qt, lmp qt)
Gear oiltype Gear oil grade Gear oil quantity
API
SAE
L
(US qt, lmp qt)
Bracket Trim angle (a|12 degree boat transom) Tilt-up angle Steering angle Drive unit Gear shift positions Gear ratio
Reduction gear type Clutch type Propeller shaft type Propeller direction (rear view) Propeller identification mark
Degree Degree Degree
-+20
69
40+40
F.N.R 2.31 (30/13)
2.33 (28t12)
Spiralbevelgear
Dog clutch
Spline Clockwise
Electrical
Battery capacity Minimum cold cranking performance RON: Research Octane Number
Ah (kc) A
7r100 (252-360)
380
* PON: Pump Octane Number (Research Octane Number + Motor Octane Number)/2
62Y141
2-4
Specifications
Maintenance specifications
Power unit
Model
Item USA
FSOTR FSOAEHD
Canada
Unit
FsOTH FSOAEHT
FsOTR FsOAED
FSOAET
Power unit Minimum compression pressure" Lubrication oil pressure at 55 "C (131 'F), with 10W-30 engine oil Cylinder heads Warpage limit
kPa
(kgf/cm2, psi)
840 (8.4,122) 100 (1.0, 14)
kPa
(kgf/cm2, psi) @ 900 r/min
mm (in)
0.03 (0.001)
(lines indicate straightedge position) Cylinder head journal inside diameter
mm (in)
37.00-37.02
(1
.4567 -1 .457 5)
Cylinders
Bore size Taper limit Out-of-round limit mm (in) mm (in) mm (in)
H
63.00-63.0 1 (2.480-2.481) 0.08 (0.003) 0.08 (0.003)

62.
Pistons
Piston diameter ,L9!+ Measuring point Piston-to-cylinder clearance Oversize piston diameter
'
(D) == (H) I
mm (in) mm (in) mm (in) mm (in) mm (in) mm (in)

1
95-62. 9 6 (2.47 8-2.47 9) 5 (0.2)
0.04-0,06 (0,001 6-0,0024)

+ 0.25 (0.001) + 0.50 (0.002) 5.965-1
5.
1st
2nd Piston pins Outside diameter Piston rings Top ring Dimension B Dimension T End gap Side clearance
970 (0.6285-0.6287)
mm mm mm mm
(in) (in) (in) (in)
(0.046-0.O47) 2.39-2.41 (0. 094-0. 095) 0. 1 5-0.30 (0.006-0.01 2)

1
.17-1.1
0.04-0.08 (0.002-0.003)
* Measuring conditions:
Ambient temperature 20 "C (68 'F), wide open throttle, with plugs disconnected from all cylinders. The figures are for reference only.
2-5
62Y141
FSOTR
Canada
F5OTH
FsOTR FSOAED FSOAET
FSOAEHT
1
2nd ring Dimension
[-l]t DimensionT l. r
End gap Side clearance
mm mm mm mm mm mm mm mm
(in) (in) (in) (in) (in) (in) (in) (in)
Oilring
.47-1.49 (0.058--0.059) 2.49-2.51 (0. 098{.099) 0.3H.50 (0.012-O.020) 0.03-0.07 (0.001 -0.003)
B l'------_r pimension T --i End gap

Dimension
n f--------r-T ln
2.3+2.46
(0.
092-0.097)
2.75 (0.108)
0.2H,70 (0.008{.028)
0.05-o. 1 9 (0.002-0.008)
Side clearance
Camshafts Intake (A) Exhaust (A) lntake and exhaust (B) Camshaft jou rnal diameter
#1
mm (in) mm (in) mm (in)
30.89-30.99 30.82-30. 9 2 25.95-26.05
61-1 .2200) (1 .21 35-1 .21 7 5) (1 .0217-1. 0256)

(1 .21
#2, #3, #4 Camshaft journal oil clearance

#1
mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in)
36.93-36.94 36.94-36.9s
(1 (1
.4539-1 .4543) .4543-1 .4547)
#2, #3, #4 Maximum camshaft runout
0.055-0. 1 00 (0.0022-0. 0039) 0.04s-0.090 (0.001 8-0. 003s) 0.04 (0.0016)

1
Rocker arm shatts Outside diameter Rocker arms lnside diameter Valves Valve clearance (cold) lntake Exhaust Head diameter (A) lntake Exhaust
Face width
5.98-1 5.99 (0.629 1 -0.6295) 6.00-1 6.01 (0.6299-0.6303)
0.20 0.05 (0.008 0.30 + 0.05 (0.012 29.9-30. 1

(1
.1
r r
0.002) 0.002)
.1
77-1
85)
25.9-26.1
(1 .O2O-1
.027)
lntake Exhaust lntake Exhaust
(B)
I |
\r." E<. i\.^
1 1
.84-2.97 (0.07 24.1 17) .98-3. 1 1 (0.0784.122)
Seat contact width (C)l
0.9-1.1 (0.035-0.043) 0.9-1.1 (0.035-0.043)
62Y141
2-6
Specifications
Model
Item USA Unit
FSOAEHD F5OTR
Canada
Margin thickness
lntake Exhaust
(D) \
FsOTH FSOAEHT
FsOTR
FSOAED FSOAET
mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm mm mm mm
(in) (in) (in) (in)
1
0.6-1.0 (0.024-0.039) 0.7-1.1 (0,028-0,043) 5.48-s.49 5.46-5.47

(O.21 57 -O.21 61 )
Stem diameter lntake Exhaust Guide inside diameter lntake and exhaust Stem-to-gu ide clearance lntake Exhaust Stem runout limit
-o
(0.2 1 50-0.2
53)
5.50-5.51 (0.21 65-0.21 69) -O.03 (0.000,1-0.001 2) 0.03-0.05 (0.001 2-0.0020) 0.03 (0.0012)
0.01
Valve springs Free length Minimum free length Tilt limit Connecting rods Small-end inside diameter Big-end inside diameter Crank pin oilclearance Big-end bearing thickness Yellow
Red
3e.85 (1.56e) 37.85 (1.4e0) 1.7 (0.07) 5.985-1 5.998 (0.6293-0.6298) 36.00136. 024 (1 .417 T1.41 83) 0.01 6-0.040 (0.0006-0.001 5) .500-1 .504 (0.0591-0.0592) .496-1 .500 (0.0589-0.0591 ) 1 .492-1.496 (0.0587--0.0589) 1 .488-1 .492 (0.0s864.0587)
1 1
Pink Green
Crankshaft
Crankshaft journal Diameter Crank pin Diameter Runout limit mm (in) mm (in) mm (in) mm (in) mm (in)
42.984-43.000
(1
.6923-1 .6929)
32.984-33.000 (1 .2986-1 .2992) 0.04 (0.0016)

46.00G-46. O24 (1.81
0.01
1
Crankcase Crankcase main journal inside diameter Crankshaft main journal oil clearance Crankcase main journal bearing thickness Yellow
Red
11
.81 20)
2-0.036 (0.0005-0.001 4)
Pink Green
mm mm mm mm
(in) (in) (in) (in)
.502-1 .506 (0.0591-0.0593) .498-1 .502 (0.0590-0.0591 ) 1 .494-1.498 (0.0588--0.0590) 1 .4911 .494 (0.05874.0588)
1 1
2-7
62Y141
FSOTR
Canada
F5OTH
FsOTR FSOAED FSOAET
FSOAEHT
Oil pump
Type Outer rotor-to-housing clearance Outer rotor-to-inner rotor clearance limit Rotor-to-cover clearance Trochoid mm (in) mm (in) mm (in)
0.09{,15 (0.001{.006)
0.01 -0.
1
0 (0.0004-0.0039)
0.03-0.08 (0.001 -0.003) 60 (140) 70 (158)
Thermostats
Opening temperature Fully open temperature
"c ('F) "c ("F)
Valve open lower limit
mm (in) L (US gal, lmp gal)/hr @ 6,000 r/min kPa

(kgf/cmz, psi) mm (in)
3.0 (0.12)
70 (18.5, 15.4)
Fuel pump Discharge
Pressure Plunger stroke
49 (0.49,7.0)
5,85-9.0s (0.23{.35)
62Y40 62Y30
Carburetor
lD mark (USA and Canada) lD mark (worldwide)
Main jet Pilot jet
Float height Enqine idle speed
# # mm (in)
r/min
#1: 124, #2: 126, #3:

39 + 0.5 (0.39 10.0 900
11
6, #4: 114
0.02)
50
62Y141
2-8
Specifications
Lower unit
Model
Item USA Unit
FSOAEHD F5OTR
Canada
FsOTH FSOAEHT
0.
1
FsOTR
FSOAED FSOAET
Gear backlash
Pinion-to-fonruard gear
Pinion-to-reverse gear Pinion shims Fonruard gear shims Reverse gear shims
mm (in) mm (in)
mm mm mm
8-0.54 (0.007-0.021 ) o.7 1 -1. 07 (0. 028-0.O42)

0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50
Electrical
Model
Item USA FsOTR
FSOTH FSOTR F5OAED
Canada
Unit F5OAEHD
F5OAEHT
FsOAET
lgnition system
lgnition timing (engine idle speed) Charge coil output peak
(L
Degree
TDC
1.5
voltage
B0 V V V V
C)
@ cranking 1(.t) @ cranking 2(.t)
144
137
@ 1,500 r/min @ 3,500 r/min Charge coil resistancef2)

(L
169
129
272408
Br)
Pulser coil output peak voltage
(wR-wB)
@ 1,500 r/min @ 3,500 r/min
V V V
6.3 3.5 7.4

11.2
Pulser coil resistance(.2)
(wR-wB)
CDI unit output peak voltage (B/O - B, BM/ - B) @ cranking 1(.t) @ cranking 2(.t) @ 1,500 r/min @ 3,500 r/min Spark plug gap
(.t) Cranking 1: unloaded
(.2)
396-594
V V V V mm (in)
126
1s0
151
116
0.e (0.035)
Cranking 2: loaded The figures are for reference only.

62Y141
1
2-9
FSOTR
Canada
F5OTH
FsOTR FSOAED FSOAET
FSOAEHT
lgnition control system

Oil pressure switch kPa
(kgf/cmz, psi) (Gy/B
50 (0.5, 7.11)
Thermoswitch
Starter motor
B)
OFF -+ ON ON + OFF Type Output Cranking time limit Brushes Standard length Wear limit Commutator Standard diameter Wear limit Mica Standard undercut Wear limit
"c ('F) "c ('F)
7644 (16$-183)
63-77 (145-170)
Bendix
KW
1.1
Second mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) A
30 16.0 (0.63) 12.0 (0.47) 33.0 (1.30) 31.0 (1.22)
0.8 (0.03) 0.2 (0.01)

20
Charging system
voltage
@ 1,500
@ 3,500
Fuse Lighting coil output peak

(G
G)
@ cranking(.t)
/i(.t) /i(.t)
V V V
11.9
42
127
Lightin g coil resistancef2)
1.2-1.8
(G-G)
Rectif ier Regulator output
peak
voltage
(R
@ 1,500
@ 3,500
/ift)
/i(.t)
B)
V V
A @ 5,000 r/min
18.9 19.5
10
Charging current
Enrichment control system

Prime Start
nger projection extended minimum lenqth @

Plu
mm (in)
24.6 (O.e7)
(.t) Unloaded
('2)
The figures are for reference only.
62Y141
2-10
Specifications
Model
Item Unit
FSOAEHD F5OTR
FsOTH FSOAEHT
FsOTR
FSOAED FSOAET
Power trim and tilt system Trim sensor Setting resistance
c)
Resistance
Fluid type Brushes Standard length Wear limit Commutator Standard diameter Wear limit Mica Standard undercut
11!7
10-278.3 ATF Dexron II
10 (0.3e) 3.5 (0.14)
(P
B)
o
mm (in) mm (in) mm (in) mm (in) mm (in)
22.0 (O.87) 21.0 (0.83) 1.5 (0.06)
2-11
62Y141
Power unit
Model Item USA T5OTR TsOTR
FTSOBET
Canada
Unit
FTSOCEHD FTSOCED 840 (8.4,122)
FTSOCET
Power unit Minimum compression pressure* Lubrication oil pressure at 55 "C (131 'F), with 10W-30 engine oil Cylinder heads Warpage limit
kPa
(kgf/cm2, psi)
kPa
(kgf/cm'z, psi) @ 900 r/min
100
(1
.0,14)
mm (in)
0.03 (0.001)
(lines indicate straightedge position) Cylinder head journal inside diameter
mm (in)
37.0137.0 2
(1
.4567-1 .457 5)
Cylinders
Bore size Taper limit Out-of-round limit mm (in) mm (in) mm (in)
H
63.00-63. 0 1 (2.4812. 481) 0.08 (0.003) 0.08 (0.003)

62.
Pistons
Piston diameter ,tgI+ Measuring point (H) Piston-to-cylinder clearance Oversize piston diameter
'
(D) == I
mm (in) mm (in) mm (in) mm (in) mm (in) mm (in)

1
95-62. 9 6 (2.47 e-2.47 9)
5 (0.2)
0.01-0.06 (0.00 1 6-0.0024) + 0.25 (0.001) + 0.50 (0.002)
1st
2nd
Piston pins
Outside diameter 5.965-1 s.970 (0.6285{ .6287)
Piston rings
Top ring Dimension B Dimension T End gap Side clearance mm mm mm mm
(in) (in) (in) (in)
1.17-1.1 9 (0.046--0.047)
2.39-2.41 (0. 094{.095) 0. 1 5-.0.30 (0.006-.0.01 2) 0.04-0.08 (0.002-0.003)
* Measuring conditions:
Ambient temperature 20'C (68 'F), wide open throttle, with plugs disconnecled from all cylinders. The figures are for reference only.
62Y141
2-12
Specifications
Model
Canada
FTsOCET
2nd ring Dimension B [__\-]B Dimension T End gap Side clearance Oil ring n |----------]-T Dimension B ls I ll r-r Dimension T -l End gap Side clearance Camshafts lntake (A) Exhaust (A) lntake and exhaust (B) Camshaft journal diameter
mm mm mm mm mm mm mm mm
(in) (in) (in) (in) (in) (in) (in) (in)
.47-1.49 (0.058-0.059) 2.49-2.s1 (0. 098-0. 099) 0.30-0.s0 (0.01 2-0.020) 0.03-0.07 (0.001 -0.003)
1
l'------r
2.3+2.46 (0.092-0.097)
2.75 (0.108)
l, r
0.210,70 (0.008-0.028)
0.05-0.
1
(0.002-0.008)
61-1 .22OO) (1 .21 35-1 .217 5)
(1 .21 (1
30.89-30.99 30.82-30. 92 25.95-26.05
.0217 -1.0256)
#1
#2, #3, #4 Camshaft journal oil clearance

#1
mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in)
36.93-36.94 36.94-36.95
0.055--0.
1
(1 (1
.4539-1 .4s43) .4543-1 .4547)
00 (0.0022--0.0039)
(0.00 1 8-0.003s)
#2, #3, #4 Maximum camshaft runout
0.04s{.090
0.04 (0.0016)
1
Rocker arm shafts Outside diameter Rocker arms lnside diameter Valves Valve clearance (cold) lntake Exhaust Head diameter (A) lntake Exhaust
Face width
5.98-1 5.99 (0.6291 -0.6295) 6.00-1 6.01 (0.6299-0.6303)
0.20 r 0.05 (0.008 0.002) 0.30 + 0.05 (0.012 r 0.002)
29.9-30.1 (1.1 77-1 .1 85) 25.9-26.1 (1 .020-1 .O27)
lntake Exhaust lntake Exhaust
(B)
I |
\r., t
I
1 1
.8+2.97
(0.07
.98-3. 1 1 (0.07
2-0j e-0j
17) 22)
Seat contact width (C)l
\;. 'r
0.9-1.1 (0.035-0.043) 0.9-1.1 (0.035-0.043)
2-13
62Y141
Model Item USA Unit TsOTR TsOTR
FTSOBET
Canada
FTSOCEHD FTSOCED
FTSOCET
Margin thickness (D)
lntake Exhaust
i\ #jo
mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm mm mm mm
(in) (in) (in) (in)
1
0.6-1.0 (0.024-0.039) 0.7-1.1 (0.028-0,043)

5.48-5.49 (0.21 57 -O.21 61) 5.46-5.47 (0.21 50-0.2 1 53) 5.50-5.51 (0.21 65--0.21 69)
0.01
Stem diameter lntake Exhaust Guide inside diameter lntake and exhaust Stem-to-guide clearance lntake Exhaust Stem runout limit
-0.03 (0.0004-0.001
2)
0.03-0.05 (0.001 2-0.0020) 0.03 (0.0012)

3e.85 (1.56e) 37.85 (1.4e0) 1.7 (0.07) 5.985-1 5.998 (0.6293--0.6298) 36.00136.024 (1 .4173-1.41 83) 0.01 6-0.040 (0.0006-0.001 5) .500-1 .504 (0.0591-0.0592) .496-1 .500 (0.0589-0.0591 ) 1 .492-1. 496 (0.0587-0. 0589) 1 .488-1 .492 (0,0586-0.0587)
1 1
Valve springs Free length Minimum free length Tilt limit Connecting rods Small-end inside diameter Big-end inside diameter Crank pin oil clearance Big-end bearing thickness Yellow
Red
Pink Green
Crankshaft
Crankshaft journal Diameter Crankshaft pin Diameter Runout limit mm (in) mm (in) mm (in) mm (in) mm (in)
42.98q-43.000
(1
.6923-1 .6929)
32.984-33.000 ( 1 .2986-1 .2992) 0.04 (0.0016)

46.00G-46.O24 (1.81 10-1 .8120)
0.01
Crankcase Crankcase main journal inside diameter Crankshaft main journal oil clearance Crankcase main journal bearing thickness Yellow
Red
2-0.036 (0.0005-0.001 4)
Pink Green
62Y141
mm mm mm mm
(in) (in) (in) (in)
1 1 1
.502-1 .506 (0.0591-0.0593) .498-1 .502 (0.059G-0.0591 )
.494-1.498 (0.0588-0.0590) 1 .4911 .494 (0.0587-0.0588)
2-14
Specifications
Model
Canada
FTsOCET
Oil pump Type Outer rotor-to-housing clearance Outer rotor-to-inner rotor clearance limit Rotor-to-cover clearance Thermostats Opening temperature Fully open temperature
Trochoid 0.09-0,1 5 (0.001 -0.006)

0.01 -o.
1
0 (0.0004.-0.0039)
0.03-0.08 (0.001 -0.003)

60 (140) 70 (1 58)
"c ('F)
'c
("F)
Valve open lower limit
mm (in) L (US gal, lmp gal)/hr @ 6,000 r/min kPa

(kgf/cmz, psi) mm (in)
3.0 (0.12) 70 (18.5, 15.4)
Fuel pump Discharge
Pressure Plunger stroke
49 (0.49,7.O1
5.85-9.0s (0.23-0.35)
62Y40 62Y30
Carburetor
lD mark (USA and Canada) lD mark (worldwide)
Main jet Pilot jet Float height Engine idle speed
# # mm (in)
r/min
62Y30, 62Y50 (for Brazil) #1: 124, #2: 126, #3: 1 1 6, #4: 114
39 10.0 + 0.s (0.39 r 0.02) 900 + 50
2-15
62Y141
Lower unit
Model Item USA T5OTR TsOTR
FTSOBET
Canada
Unit
FTSOCEHD FTSOCED
0.1
FTSOCET
Gear backlash
Pinion-to-fonruard gear
Pinion-to-reverse gear Pinion shims Forward qear shims
mm (in) mm (in)
mm mm
24.45
(0.005-.0.01 8)
o.71-1.1 1 (0.028-0.044) 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50
Electrical
Model Item USA Unit TsOTR TsOTR FT5OBET FT5OCEHD FT5OCED FT5OCET
Canada
lgnition system
lgnition timing (engine idle speed) Charge coiloutput peak
(L
Degree
TDC
1.5
voltage
Br)
@ 1,500 r/min @ 3,500 r/min
V V V V
144
137 169
129
Charge coil resistance(.2)
272-408
(L-Br)
Pulser coil output peak voltage
(wR - wB)
@ 1,500 r/min @ 3,500 r/min
V V V V
c)
6.3 3.5 7.4

11.2
Pulser coil resistance(.2)
(wR-wB)
V V V V mm (in)
396-594
CDI unit output peak voltage (B/O - B, BA/V - B) @ cranking 1(.t) @ cranking 2(.t) @ 1,500 r/min @ 3,500 r/min Spark plug gap
t't) Cranking 1: unloaded
('2)
126
150
151
116
0.e (0.035)
Cranking 2: loaded The figures are for reference only.
62Y141
2-16
Specifications
Model
Canada
FTsOCET
lgnition control system

Oil pressure switch kPa
(kgf/cmz, psi) (Gy/B
50 (0.5, 7.11)
Thermoswitch
Starter motor
B)
OFF -+ ON ON + OFF Type Output Cranking time limit Brushes Standard length Wear limit Commutator Standard diameter Wear limit Mica Standard undercut Wear limit
'c 'c
('F) ('F)
76-84 (1 6e-1 83) 6-77 (145-170)

Bendix
KW
1.1
Second mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) A
30 16.0 (0.63)
12.0 (O.47)
33.0 (1.30) 31.0 (1.22) 0.8 (0.03) 0.2 (0.01) 20
Charging system
voltage
@ 1,500
@ 3,500
Fuse Lighting coil output peak

(G
- G)
V V V
1
@ cranking(.t)
1.9
/i(.t) /i('t)
42
127
Lighting coil resistancec2)
1.2-1.8
(G-G)
Rectifier Regulator output peak (R @ 1,500 /ift) @ 3,500 /i(.t) Charging current
voltage
B)
V V
A @ 5,000 r/min
18.9 19.5
10
Enrichment control system

Prime Start
unger projection extended minimum lenqth @

Pl
mm (in)
24.6 (O.e7)
(.t) Unloaded
12)
The figures are for reference only.

62Y141
2-17
Model Item Unit TsOTR TsOTR
FTSOBET
FTSOCEHD FTSOCED
FTSOCET
Power trim and tilt system Trim sensor Setting resistance
(.)
Resistance
Fluid type Brushes Standard length Wear limit Commutator Standard diameter Wear limit Mica Standard undercut
11l.7
1278.3 ATF Dexron II
10 (0.39) 3.5 (0.14)
(P
B)
o
mm (in) mm (in) mm (in) mm (in) mm (in)
22.0 (0.87) 21.0 (0.83) 1.5 (0.06)
62Y141
2-18
Specifications
Dimensions
Exterior
L6
L1
tt
\/./ \ \./
/7
/ // /
//
s62Y2200
2-19
62Y141
Model
Symbol
Unit
FSOAEHD
FsOTH
FSOAEHT 576 (22.7) 223 (8.8) 753 (2e.6) 532 (20.e) e7 (3.8)
L1
L2 L3 L4 L5 (L)
(x)
(L)
mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) Degree Degree Degree mm (in)
e30 (36.6) 3e7 (1s.6) 247 (e.7)
932 (36.7) 407 (16.0) 245 (e.6)
(x)
L7 L8 L9 (L)
0.6 (0.02)
63 (2.5) 876 (34.5) 51e (20.4)
175 (6.9) 536 (21.1)
(x)
110
H1
(L)
(x)
H2 H3 H4 H5 H6 H7 H8 H9 H10
H11 W1 (L)
(L)
(x)
(L)
732 (28.8) 685 (27.0) 330 (13.0) 3e (1.5) 738 (2e.0) 44 (1.7) 24 (1.0)
181 (7.1) 124 (4.e)
711 (28.0) 327 (12.e)
(x)
45 (1.8)
733 (28.e)
(x)
w2
W3 W4 W5 W6
A1
345 (13.6) 643 (25.3) 40 63

65
A2 A3
T1
62Y141
2-20
Specifications
Exterior
T1
H10
86
-x
2-21
Symbol
Unit
FSOAED
L1
Model FsOTR FsOTR

FSOAET
T5OTR T5OTR
FTSOBET
L2 L3 L4 L5 (L)
(x)
(L)
576 (22.7) 142 (5.6)
532 (20.9) e7 (3.8) 930 (36.6) 397 (15,6)

14e (5.e)
560 (22.0)
e32 (36.7)
eeo (3e.0)
(x)
L7 L8 L9 (L)
0.6 (0.02)
407 (16,0) 148 (5.8) 0.8 (0.03)
(x)
110
H1
(L)
63 (2.5) 876 (34.5) 51e (20.4) 175 (6.e) 536 (21.1)
e17 (36.1)
(x)
H2 H3 H4 H5 H6 H7 H8 H9 H10
H11 W1 (L)
1e1 (7.5)
(L)
(x)
(L)
685 (27.0) 330 (13.0) 0.5 (0.02) 738 (29,1)
711 (28.O)
74e (2e.5)
(x)
327 (12.9) 3.5 (0.1) 733 (28,9) 44 (1.7)
24 (o.e)
181 (7.1)
28 (1.1)
(x)
w2
W3 W4 W5 W6
A1
s+ss.ol
40 63
4 65
A2 A3
T1
560 (22.0)
62Y141
2-22
Specifications
Exterior
L1
,,,,,,
1,,',,
L6
,- -,11- -
\ /l-t \/
-
---\
Hg'i', .
.,-/
I
s62Y2230
2-23
62Y141
Model
Symbol
Unit FTSOCEHD 576 (22.7) 272 (10.7) 797 (31.4) 560 (22.0) e7 (3.8)
L1
L2 L3 L4 L5 (L)
(x)
(L)
990 (39.0) 3e7 (1s.6)

18e (7.4) 0.8 (0.03)
(x)
L7 L8 L9 (L)
(x)
110
H1
(L)
63 (2.5) e17 (36.1) 51e (20.4)

191 (7.5) 536 (21.1)
(x)
H2 H3 H4 H5 H6 H7 H8 H9 H10
H11 W1 (L)
(L)
(x)
(L)
680 (26.8) 723 (28.5) 330 (13.0)

110 (4.3)
(x)
738 (2e.1) 44 (1.7) 28 (1 .1)

181 (7.1) 213 (8.4) 181 (7.1)
(x)
w2
W3 W4 W5 W6
A1
A2 A3
T1
345 (13.6) 738 (2e.1) 40 63
62Y141
2-24
Specifications
Exterior
T1
H10
86
-x
2-25
Model
Symbol
Unit
FTSOCED
FTsOCET 576 (22.7) 142 (5.6)
L1
L2 L3 L4 L5 (L)
(x)
(L)
560 (22.0) e7 (3.8) 990 (39.0) 3e7 (1s.6)

14e (5.e) 0.8 (0.03)
(x)
L7 L8 L9 (L)
(x)
110
H1
(L)
63 (2.5) e17 (36.1) 51e (20.4)

191 (7.5) 536 (21.1)
(x)
H2 H3 H4 H5 H6 H7 H8 H9 H10
H11 W1 (L)
(L)
(x)
(L)
723 (28.5)
(x)
sgos.ol
0.5 (0.02)
738 (2e.1) 44 (1.7) 28 (1 .1)
181 (7.1) 181 (7.1)
(x)
w2
W3 W4 W5 W6
A1
345 (13.6) 40 63
4
A2 A3
T1
560 (22.0)
62Y141
2-26
Specifications
Clamp bracket
D
Model Symbol
Unit
FSOAEHD
B1
F5OTR
FsOTH FSOAEHT
FsOTR
FSOAET
82
B3
84
B5 B6
87
B8 B9
c2 c3
D1
D2
mm mm mm mm mm mm mm mm mm mm mm mm mm
(in) (in) (in) (in) (in) (in) (in) (in) (in) (in) (in) (in) (in)
FsOAED (5.0) 126 254 (10.0) 163.5 (6.4) 50.8 (2.0) 180 (7.1)
355 (14.0) 13e (5.5) 18.5 (0.7) 6e (2.7) 13 (0.5) 55.5 (2.2)
62Y141
1
2-27
Clamp bracket
D
Model
Symbol
USA
Canada
Unit
B1
82
B3
84
B5 B6
87
B8 B9
c2 c3
D1
D2
62Y141
1
mm mm mm mm mm mm mm mm mm mm mm mm mm
(in) (in) (in) (in) (in) (in) (in) (in) (in) (in) (in) (in) (in)
TsOTR TsOTR FT5OBET FTSOCEHD FT5OCED 126 (5,0) 254 (10.0) 163.5 (6.4) 50.8 (2.0) 180 (7.1)
FT5OCET
355 (14.0)
13e (5.5) 18.5 (0.7)
6e (2.7)
13 (0.5) 55.5 (2.2)
2-28
Specifications Tightening torques

Specified torques
Part to be tightened
Thread size
Tightening torques
N.m 160 kgf.m
16
ft.rb 116
Power unit Flywheel magnet nut Stator base screw Cover screw Negative battery lead bolt Positive battery lead nut Oil pressure switch Oil pressure switch lead screw lgnition coil bolt Starter motor bolt Starter motor terminal nut Power unit bolt Tensioner bolt Tensioner adjusting bolt Drive sprocket nut Driven sprocket bolt Spark plug
1st
M6 M6 M8
4
3
I
7
9 2
M6 M8
30
7
21
B
o.4 0.3 0.9 o.7 0,9 o.2 o.7 3.0 o.7

2.1
2.9 2.2 6.5

5.1
6,5
1.4
5.1
22
5.1
M8 M8
M10
15
25 140 38
18 6 12
0.8 2.5
14
5.8
18
101
3.8
1.8
28
13
Cylinder head bolt
2nd
1st
M6
M9
0.6
1.2
4.3 8.7
17
2nd Adjusting screw locknut
23 47
14 18 18
2.3 4.7
1.4
1.8
34
10 13 13
Oilfilter
Drain bolt Exhaust cover bolt
1st
1.8
2nd
1st
M6 M6 M8
6 12 6 12 15
0.6
1.2
0.6
1.2
Crankcase bolt
2nd
1st
4.3 8.7 4.3 8.7

11
1,s
2nd
Connecting rod cap bolt
1st
30
6 17
3.0 0.6
1.7
22 4.3
12
5.1
2nd
Lower unit (F50/F504)

Check screw Lower unit bolt Drain screw Propeller nut Water inlet cover screw Pinion nut
7 M10
o.7
4.O
40
7
29
5.1
35
5
M17
75
o.7 3.5 0.5 7.5
25 3.6 54
2-29
62Y141
Tightening torques
Paft to be tightened Thread size Tightening torques N.m kgf.m fr.lb
7 M10
Lower unit (T50/FT50B, FT50C) Check screw Lower unit bolt Drain screw Propeller nut Ring nut Water inlet cover screw Pinion nut Bracket unit Tiller handle assembly nut (F50/F504) Engine shut-off switch nut (F50/F504) Tiller handle bracket nut (F50/F50A) Main switch nut (F50/F504) Friction wing nut (FT50C) Tiller handle assembly nut (FT50C) Throle cable (short) locknut (FT50C) Upper mount nut Lower mount nut Trim sensor screw Clamp bracket self-locking nut Power trim and tilt Tilt cylinder end screw PTT motor bolt Reseruoir cap Trim cylinder end screw Tilt piston bolt Relief valve bracket bolt Gear pump assembly bolt Gear pump bracket bolt Electrical unit Pulser coil screw Starter motor nut
40
7
35
105
5
0.7 4.0 o.7 3,5

10.5
5.1
29
5.1
25 76
0.5
9.5
3.6
69 27
M22
95
37
4
38
5 13
3.7 0.4 3.8 0.5

1.3
37 37 24 42
M6
2
23
90 4
3.7 3.7 2.4 4.2 0.2 2.3 9.0 o.4 0.65 8.0
6.1
2.9 27 3.7 9.4 27 27

17
30 1.4
17
65
M5
6.5 80
M12 M5 M6 M5
61
2.9 4.7
58
5.3 6.5 5.3

4
9
0.s3 0.65 0.s3 0.4 0.9
44 3.8 4.7 3.8 2.9 6.5
62Y141
2-30
Specifications
Generaltorques
This chart specifies tightening torques for standard fasteners with a standard ISO
thread pitch. Tightening torque specifications for special components or assemblies are provided in applicable sections of this manual. To avoid warpage, tighten multi-fastener
assemblies in a crisscross fashion and progressive stages until the specified torque is reached. Unless otherwise specified, torque specifications require clean, dry threads. Components should be at room temperature. Generaltorque specifications N.m kgf.m ft.lb 5 0.5 3.6 8 0.8 5.8
18 1.8 13
Nut (A)
Bolt (B)
M5 M6 M8 M10
Mt12
8mm
10 12 14 17 mm mm mm mm
36 43
3.6 4.3
25
31
T-]-
2-31
62Y141

Special service tools Maintenance interval Top cowling Checking the top
3-1
chart.........
............3-3
irirrri t
cowling......
1-4
............3-4
j-4 Fuel system Checking the fueljoint and fuel hoses (fueljoint-to-carburetor)................3-4 Checking the fuelfilter........... ...........3-5
Power unit............ Checking the engine oi|.............. Replacing the engine oi|.............. Checking the timing belt............ Replacing the timing be|t............ Checking the valve clearance... Checking the spark p1u9s......... Checking the thermostat.............. Checking the cooling water passa9e..............
.............,..3-5 ......3-5 .....3-5 .......3-7 ......3-7 ......3-10
......3-11
...3-12
...3-13 ...................3-13 ....3-13 ,.,.3-14 .....3-15 ...3-15 .......3-16 ........3-16 .................3-16
Control
system
Checking Checking Checking Checking
the throttle cable the gearshift the engine idle the ignition
operation............ operation speed timin9.........
Power trim and tilt unit Checking the power trim and tilt operation Checking the power trim and tilt fluid level .......... Lower unit Checking the gear oil level Replacing the gear oi1............... Checking the lower unit (for air leakage) Checking the prope11er................. General Checking the Checking the
.............3-17 ......3-17 ...........3-19 ...3-19
anodes battery. Lubrication
...3-19 ...3-20 ...................3-21
62Y141

Special service tools
Pressudge/vacuum tester Y8-35956-A
Oilfilter wrench
YU-38411
Flywheel magnet holder vB-06139
Oil filter wrench 90890-01426
Wq
Universal puller
YB-06117
Flywheel holder
90890-06522
@)
td-"
Inductive self-powered tachometer
YU-08036-B
Flywheel puller
90890-06521
Battery powered timing light YM-33277-A
Digital tachometer
90890-06760
3-1
62Y141
Timing light
90890-03141
Leakage tester 90890-06762
62Y141
3-2
Periodic checks and adjustments Maintenance nterval chart

Use the following chaft as a guideline for general maintenance. Adjust the maintenance intervals according to the operating conditions of the outboard.
lnitial
Item
Every
Remarks
10 hours (Break-in)
50 hours 100 hours 200 hours (3 months) (6 months) ('l year)
Referto page 3-4 3-4
Top cowling Top cowling fit Fuel system Fueljoint and fuel hoses Fuelfilter Fueltank Power unit Engine oil Oilfilter Timing belt Valve clearance Spark plugs Thermostat Water leakage Motor exterior Exhaust leakage Cooling water passage Control system Throttle cable Shift cable Engine idle speed lgnition timing Power trim and tilt unit Power trim and tilt Lower unit Gear oil Lower unit leakage Propeller General Anodes Battery Wiring and connectors Nuts and bolts Lubrication points
Check Check Check/replace Cleaning Change Change Check Check/adjust Clean/adjusVreplace Check Check Check Check Clean Check/adjust Check/adjust Adjust Check Check Change Check Check Check/replace Check
Checl</reconnect
o o o o o o o
o o
o
3-5 3-5 3-7
o
o
o o o o o
o o o
o
3-10
3-11
3-12
o o o o
o o
;
3-13 3-14 3-15 3-15 3-16 3-17 3-19 3-19 3-19
o o o o
o
o
o o
o
o o
O every
o o
1 month
3-20
Tighten Lubricate
o o
o o
""
. .
NOTE: lf operating in salt water, turbid or muddy water, flush the engine with fresh water after each use. lf leaded gasoline is used regularly, check the engine valves and related parts every 300 hours of operation in addition to the items in the maintenance interualchart.
3-3
62Y141
Maintenance interval chart / Top cowling / Fuel system Top cowling

Checking the top cowling
1.
Check the fitting by pushing the cowling with both hands. Adjust if necessary.
Fuel system Checking the fuel joint and fuel hoses (fuel joint-to-carburetor)
1.
Remove the plate @, and then check the fuel hose connections and fueljoint @ for leaks. Replace if necessary. Also, check the fuelfilter @, fuel pump @, and carburetor @ for leaks, and the fuel hoses for leaks and deterioration. Replace if necessary.
s62Y3010
Loosen the nuts and bolts @. Move the hook @ up or down slightly to adjust its position.
NOTE: To loosen the fitting, move the hook toward the seal. . To tighten the fitting, move the hook away from the seal.
4. 5.
Tighten the nuts and bolts. Check the fitting again and, if necessary, repeat steps 2-4.
62Y141
3-4

Checking the fuel filter
1,
Check the fuel filter element O for dirt and residue and check the fuel filter cup @ for foreign substances and cracks. Clean with straight gasoline and replace the cup if necessary.
E
NOTE:
B @
- O
. Replace the oil if it appears milky or black. . lf the engine oil is above the maximum level
.--@ O
@
mark @, drain sutficient oil until the level is between @ and @. lf the engine oil is below the minimum level
mark @, add sutficient oil until the level is between @ and @.
,ffi
E
E
FsO/FsOA TsO/FTsOB, FT5OC
Replacing the engine oil 1. Remove the engine oil dipstick and
filler cap @.
oil
NOTE:
Be sure not to spill any fuel when removing

the fuel filter cup.
Power unit
1. 2. 3.
Checking the engine oil

Place the outboard in an upright position.
Remove the engine oil dipstick, wipe it clean, and then insert it back into the oil filler hole.
Remove the dipstick again to check the oil level and the oil for discoloration, and its viscosity,
3-5
62Y141
Fuel system / Power unit
2.
Place a drain pan under the drain hole, and then remove the drain bolt @ and let the oil drain completely.
s62Y3080
3.
Place a rag under the oil filter, and then remove the filter.
s62Y31
Oilfilter wrench: YU-38411 / 90890-01426

Oil filter: 18 N.m (1.8 kgf.m, 13 ft.lb)
6.
Oilfilter wrench: YU-38411 / 90890-01426
NOTE: Be sure to clean up any oil spills.
lnstall the drain bolt, and then tighten it to the specified torque.
Drain bolt: 18 N.m (1.8 kgf.m, 13 ft.lb)
7.
Fill the specified engine oil into the oil

filler hole.
Apply a thin coat of the new engine oil to the O-ring of the new oilfilter.
5.
lnstall the oil filter, and then tighten it to

the specified torque,
Recommended engine oil: 4-stroke motor oil API: SE, SF, SG, or SH SAE: 10W-30, 10W-40, or 20W-40
62Y141
3-6

Oilquantity: With oil filter replacement: 2.2 L (2.3 US qt, 1 .9 lmp qt) Without oil filter replacement: 2.0 L (2.1 US qt, 1.8 lmp qt)
8.
9.
lnstall the oil filler cap and dipstick, and then start the engine and warm it up for 5 minutes. Turn the engine ofi, and then check the oil level and correct it if necessary.
Do not turn the flywheel magnet counterclockwise, otherwise the valve system
may be damaged.
1, Remove the flywheel magnet cover, 2. While turning the flywheel magnet clockwise, check the interior @ and the exterior (D of the timing belt for cracks, damage, or wear. Replace if necessary.
Checking the timing belt
2.
Remove the flywheel magnet.
s62Y3130
Do not turn the flywheel magnet counterclockwise, otherwise the valve system
may be damaged.
Replacing the timing belt
1.
Turn the flywheel magnet clockwise and align the "1" mark @ on the driven sprocket with the "\" mark @ on the cylinder head.
s62Y31 50
3-7
62Y141
Power unit
Flywheel magnet holder Q: YB-06139 Flywheel holder @: 90890-06522 Universal puller @: YB-06117 Flywheel puller @: 90890-06521
3.
4.
Disconnect the stator couplers @, and then remove the stator @. Disconnect the pulser coil coupler @,
and then remove the stator base @ with both collars @.
E
5.
Remove the breather hose bolts @ and tensioner @, then the timing belt @ from the driven sprocket side.
E E
for USA and Canada

forworldwide
Y-
^\v
4_
. Apply force in the direction of
.
the prevent the flywheel arrows shown, to holder from slipping off easily. To prevent damage to the engine or tools, screw in the flywheel puller set bolts evenly and completely so that the flywheel puller plate is parallel to the flywheel magnet.
/7
,//
NOTE: Apply force to the crankshaft end until the flywheel magnet comes off the tapered portion of the crankshaft.
62Y141
3-8
6.
Check that the "'1" mark @ on the driven sprocket is aligned with the "1" mark @
on the cylinder head, and that the
"f"
o Do not twist,
mark @ on the drive sprocket is aligned with the "" mark (D on the crankcase. Align if necessary.
turn inside out, or bend the timing belt beyond the maximum limit of 25 mm (1.0 in) @, otherwise it may be
damaged.
Do not get oil or grease on the timing

belt.
B. lnstall the tensioner and bolts, and then

tighten the bolts finger tight.
9.
Turn the driven sprocket clockwise two turns, and then check that the alignment
marks are aligned.
Do not turn the sprockets counterclockwisen otherwise the valve system may be
damaged. 10. Tighten the tensioner bolts to the specified torque.
Do not turn the sprockets counterclockwise, otherwise the valve system may be
damaged.
Tensioner bolt: I N.m (0.8 kgf.m, 5.8 ft.lb) Tensioner bolt (adjusting bolt): 25 N.m (2.5 kgf.m, 18 ft.lb)
7.
While pushing against the tensioner side of the belt, install the new timing belt from the drive sprocket side with its part number in the upright position.
11. lnstall the breather hose bolts, stator base with both collars and stator, and then connect the couplers.
Stator base screw: 4 N.m (0.4 kgf.m, 2.9 ft.lb)
12. lnstall the Woodruff key.
#5/ ffl
3-9
s62Y31 90
62Y141
Power unit
13. lnstall the flywheel magnet and flywheel magnet cover.
2.
Remove the spark plugs, fuel pump @,

and cylinder head cover @.
r
1[
#
Turn the flywheel clockwise and align the "1" mark @ on the driven sprocket with the "" mark @ on the cylinder head.
E B
For USA and Canada
Forworldwide
Apply force in the direction of the arrows shown, to prevent the flywheel holder from slipping off easily.
NOTE: Apply engine oil to the flywheel magnet nut before installation.
Do not turn the flywheel counterclockFlywheel magnet holder: YB-06139 Flywheel holder: 90890-06522 wisen otherwise the valve system may be
damaged.
Flywheelmagnet nut: 160 N.m (16 kgf .m, 1 16 ft.lb)
4.
Checking the valve clearance
Check the intake valve clearance for cylinders #1 and #2, and the exhaust valve clearance for cylinders #1 and #3, Adjust if necessary.
1.
Remove the flywheel magnet cover, and
then disconnect the high-tension cords

and blowby hose @.
62Y141
3-10
5.
Turn the flywheel clockwise and align the "4" mark @ on the driven sprocket with the "" mark (D on the cylinder head.
NOTE: Adjust the valve clearance when the engine is cold.
Valve clearance: lntake (D: 0.20 + 0.05 mm (0.008 Exhaust @: 0,30 t 0.05 mm (0.012
t 0.002 in) t 0.002 in)
7.
Do not turn the flywheel counterclockwisen otherwise the valve system may be
Loosen the locknut @, and then turn the adjusting screw @ until the specified valve clearance is obtained.
damaged.
Check the intake valve clearance for cylinders #3 and #4, and the exhaust valve clearance for cylinders #2 and #4. Adjust if out of specification. NOTE:
6,
. To decrease the valve .
clearance, turn the adjusting screw clockwise. To increase the valve clearance, turn the adjusting screw counterclockwise.
8.
Tighten the locknut, and then check the valve clearances. Adjust if necessary.
L Install the cylinder head cover, fuel

pump, and spark plugs.
10. Connect the blowby hose and high-tension cords, and then install the flywheel magnet cover.
Checking the spark plugs
1,
Disconnect the high-tension cords, and then remove the spark plugs.
3-11
62Y141
Power unit
2.
Clean the electrodes @ with a spark plug cleaner or wire brush. Replace the spark plug if necessary.
Spark plug: 18 N.m
(1
.8 kgf 'm, 13 t.lb)
Ghecking the thermostat
1.
Remove the cover @, thermostat cover @, and thermostat @.
s62Y3260
Check the electrodes for erosion and excessive carbon or other deposits, and the gasket for damage. Replace the
spark plug if necessary. Check the spark plug gap @. Adjust if out of specification.
Suspend the thermostat in a container of water.
Place a thermometer in the water and

s62Y3270
slowly heat the water.
Specified spark plug: DPR6EA-9 (NGK) Spark plug gap @: 0.9 mm (0.035 in)
5.
lnstall the spark plug, tighten it finger tight (0, then to the specified torque with a spark plug wrench O.
62Y141
3-12
4.
the
Check the thermostat valve opening at specified water temperatures. Replace if out of specification.
3.
Check for water flow at the cooling water outlet. lf there is no water flow, check the cooling water passage inside the outboard.
Water temperature below 60
Valve lift ( 0 mm (0 in) more than 3 mm (0.12 in)
Control system
Checking the throttle cable operation 1. Check that the throttle cam @ is at the
fully closed position @ when the remote control lever is in neutral or the throttle grip is fully closed. Adjust the throttle cable length if necessary as follows.
"c (140'F)
above 70'C (1 58 'F)
5.
lnstall the thermostat, new gasket, thermostat cover, and cover.
Ghecking the cooling water passage 1. Check the cooling water inlet cover @
and cooling water inlet for clogs. Clean if necessary.
2.
Loosen the locknut @, remove the clip @, and then disconnect the throttle cable joint @.
2.
Place the lower unit in water, and then

start the engine.
3-13
62Y141
Power unit / Control system

Align the alignment mark @ on the throttle cam @ with the alignment mark @ on the shift bracket.
4.
Adjust the position of the throttle cable joint until its hole is aligned with the set
pin @ on the throttle cam.
s62Y3340
4.
Align the set pin @ n tlre center of the shift bracket with the alignment mark (D on the bracket.
s62Y3350
Adjust the position of the shift cable joint until its hole is aligned with the set pin.
The throttle cable joint must be screwed in a minimum of 8.0 mm (0.31 n) @.

Connect the cable joint, install the clip, and then tighten the locknut.
Check the throttle cable for smooth operation and adjust the cable length, if necessary, repeating steps 2-6.
Checking the gearshift operation 1. Check that the gearshift operates

smoothly when shifting from neutral into fonruard and reverse. Adjust the shift cable length if necessary.
The shifl cable joint must be screwed in a minimum of 8.0 mm (0.31 n) @. Connect the cable joint, install the clip,
and then tighten the locknut.
7.
2. 3.
Set the gearshift to the neutral position.
Loosen the locknut @, remove the clip @, and then disconnect the shift cable joint @.
1
Check the gearshift for smooth operation and adjust the shift cable length, if necessary, repeating steps 3-6.
62Y141
3-14

Checking the engine idle speed
1,
Checking the ignition timing
Start the engine and warm it up for 5 minutes.
1,
Start the engine and warm it up for 5 min' utes.
2.
Attach the special seruice tool to hightension cord #1 @, and then check the
engine idle speed. Adjust if out of specification.
2.
Attach the special service tool to hightension cord #1 @, and then check the engine idle speed.
lnductive self-powered tachometer: YU-08036-B Digital tachometer: 90890-06760 Engine idle speed: 900
lnductive self-powered tachometer: YU-08036-B Digital tachometer: 90890-06760 Engine idle speed: 900 + 50 r/min
t 50 r/min
3.
3.
Turn the throttle stop screw @ in direction @ or @ until the specified engine idle speed is obtained.
Attach the special service tool to hightension cord #1 O.
o@
NOTE: To increase the idle speed, turn the throttle stop screw in direction @. . To decrease the idle speed, turn the throttle stop screw in direction (D.
4.
After adjusting the idle speed, rev the engine a few times and let it idle for at
least 15 seconds to check the stability of the engine.
Battery powered timing light: YM-33277-A Timing light: 90890-031 41
3-15
62Y141
Control system / Power trim and tilt unit
4.
Check that the TDC "T' mark @ on the flywheel magnet is aligned with the magnet base pointer @.
Checking the power trim and tilt fluid Ievel

lgnition timing: TDC + 1.5'
1.
Fully tilt the outboard up, and then support it with the tilt stop lever @.
Power trim and tilt unit Checking the power trim and tilt operation
1.
Fully tilt the outboard up and down a few times and check the entire trim and tilt range for smooth operation. Check the power trim and tilt fluid level if necessary.
tt ,'
-'-
t,
After tilting up the outboard, be sure to support it with the tilt stop lever. Otherwise, the outboard could suddenly lower if the power trim and tilt unit should lose fluid pressure.
2.
Remove the tilt pin .
NOTE: Be sure to listen to the winding sound of the PTT motor for smooth operation.
2.
Fully tilt the outboard up, and then support it with the tilt stop lever @ to check the lock mechanism of the lever.
1
62Y141
3-16
3.
Remove the reseruoir cap @, and then

check the fluid level in the reseruoir.
NOTE: The gear oil level should be at the brim of the check hole.
3.
lf necessary, add sufficient gear oil of the recommended type to the correct level.
Recommended gear oil: GEAR CASE LUBE (USA) or Hypoid gear oil
SAE:90
NOTE: The fluid level should be at the brim of the filler hole.
4.
lnstall the check screw, and then tighten it to the specified torque.
4. lf necessary, add sutficient fluid of the

recommended type to the correct level. Recommended power trim and tilt fluid: ATF Dexron II
Check screw: 7 N.m (0.7 kgf.m, 5.1 ft.lb)
Replacing the gear oil
1.
Fully tilt the outboard up, and then sup' port it with the tilt stop lever @.
5.
lnstall the reseruoir cap, and then tighten

it to the specified torque.
Reseruoir cap: B N.m (0.8 kgf.m, 5.8 ft.lb)
6. 1. 2.
lnstall the tilt pin to its original position.
Lower unit
Checking the gear oil level
Fully tilt the outboard down.
2.
Remove the tilt pin , and then install it in the upper tilt pin hole @.
Remove the check screw @, and then check the gear oil level in the lower case.
3.
Release the tilt stop lever and tilt the outboard down until it contacts the tilt pin.
3-17
62Y141
Power trim and tilt unit / Lower unit
4.
Place a drain pan under the drain screw @, remove the drain screw, then the check screw @ to drain the oil.
s62Y35s0
Recommended gear oil: GEAR CASE LUBE (USA)or Hypoid gear oil
Check the oilfor metal, discoloration, and viscosity. Check the internal parts of the lower case if necessary.
SAE:90
Oilquantity: F50/F50A: 0.43 L (0.45 US qt, 0.38 lmp qt)
TSO/FT5OB, FTSOC:
lnsert the gear oil tube or gear oil pump into the drain hole and slowly fillthe gear oil until oil flows out of the check hole and no air bubbles are visible.
0.61 L (0.64 US qt, 0.54 lmp qt)
7.
lnstall the check screw, quickly install the drain screw, and then tighten them to the specified torque.
Check and drain screw: 7 N.m (0.7 kgf.m,5.1 ft.lb)
62Y141
3-18

Checking the lower unit (for air Ieakage) 1. Remove the check screw @, and then
install the special service tool.
Checking the propeller
1,
Check the propeller blades and splines for cracks, damage, or wear. Replace if necessary.
General
Checking the anodes
1.
Check the anodes and trim tab for

scales, grease, or oil. Clean if necessary.
E E
For USA and Canada For worldwide
Pressu relvacuum tester: YB-35956-A
Leakage tester: 90890-06762
2.
Apply the specified pressure to check whether the lower unit can hold it for at
least 10 seconds.
Do not over pressurize the lower unit, otherwise the oil seals may be damaged. NOTE: Cover the check hole with a rag when removing the pressure/vacuum tester from the lower unit. Lower unit holding pressure: 100 kPa (1,0 kgf/cm2, 14 psi)
tr
3. lf pressure drops below specification,

check the drive shaft and propeller shaft oilseals for damage.
3-19
62Y141
Lower unit / General
E
@@@
2.
Check the specific gravity of the electrolyte. Fully charge the battery if out of specification.
E E E E
FT50C only EHD, ED models EHT, ET models Fso/F5oA only
Do not oil, grease, or paint the anodes, otherwise they will be ineffective.
Battery electrolyte is dangerous; it contains sulfuric acid which is poisonous and highly caustic. Always follow these preventive measures: . Avoid bodily contact with electrolyte as it can cause severe burns or permanent eye injury. . Wear protective eye gear when handling or working near batteries. Antidote (EXTERNAL): . SKIN - Wash with water. . EYES - Flush with water for 15 minutes and get immediate medical attention. Antidote (INTERNAL): . Drink large quantities of water or milk followed with milk of magnesia, beaten egg, or vegetable oil. Get immediate medical attention. Batteries generate explosive, hydrogen gas. Always follow these preventive measures: . Charge batteries in a well-ventilated
2.
1.
Replace
the anodes and trim tab if
. Kep batteries away from fire, sparks or

open flames (e.9., welding equipment, lighted cigarettes). o DO NOT SMOKE when charging or handling batteries. KEEP BATTERIES AND ELECTROLYTE
OUT OF REACH OF CHILDREN.
area.
excessively eroded.
Checking the battery

Check the battery electrolyte level. lf the
level is at or below the minimum level mark @, add distilled water untilthe level is between the maximum and minimum
level marks.
62Y141
3-20
Batteries vary per manufacturer. The procedures mentioned in this manual may not always apply, therefore, consult the instruction manual of the battery. Disconnect the negative lead first, then the positive lead.
Electrolyte specif ic g ravity: 1.280 at 20 "C (68 "F)
Lubrication
1.
Apply water resistant grease to the areas

shown.
E FsO/FsOA, TsO/FTsOB E rrsoc

3-21
62Y1411
General
Apply grease to the grease nipple until it
flows from the bushings @.
2.
Apply anti-corrosion grease to the areas shown.
62Y141
3-22
MEMO
3-23
62Y141
Fuel system
Special service tools Hose routing
4-1
........4-2
Fuel line
Fuel filter and fuel Checking the fuel Disassembling the fuel Checking the diaphragm and Assembling the fuel
pump pump......... pump valves pump.........
.....4-7
...........4-9 .,,..,,..,.4-9 .................4-10 .....4-10
4-11
Carburetor unit Carburetor
Disassembling the Checking the carburetor Checking the Prime Assembling the Adjusting the throttle link Synchronizing the Adjusting the dash-pot (acceleration
carburetor.. ,,..,,..,..,, Start........... carburetor.............. rod carburetors pump)
.......4-19 ..,.4-19
.....4-2O
...................4-2O ..........4-21
........4-23 ......4-24
62Y141
Fuel system
Digital tachometer
90890-06760 Pressu re/vacuum tester Y8-35956-A
Vacuum gauge 90890-03159
lnductive self-powered tachometer vu-08036.8
Carburetor synchronizer
YU-08030
d@
Vacuum/pressure pump gauge set
90890-06756 4-1
62Y141
1
Special service tools / Hose routing Hose routing

Fuel and blowby hoses
@ @ @ @ @ @
Blowby hose Hose (acceleration pump-to-carburetor) Fuel hose (fuel joint-to-fuel filter) Fuel hose (fuelfilter-to-fuel pump) Fuel hose (fuel pump-to-carburetor) Hose (carburetor-to-carburetor)
62Y141
4-2
Fuel system
Cooling water hose
ltodels with flushing device
4-3
62Y141
Hose routing
MEMO
62Y141
4-4
Fuel line
f-.-^
--l
4-5
62Y141
Fuel line
No.
1
Pat name
Q'ty
1 1 1 1 1 1 1
Remarks
Tightening torques Stage

N.m
kgtm
t.lb
Fueljoint
3 4
5
Fuelfilter Fuelfilter
Fuel pump Bolt
Seal
F50/F504
T5O/FTsOB, FTSOC
M6x25mm
Fuel joint-to-f uel filter
6 7
Fuel hose Clip Bolt

Nut
I I
10
11
3
1 1 1 1
M8x14mm
Bracket Fuel hose Fuel hose Clip Bolt O-ring
12 13 14 15 16
Fuel filter-to-fuel pump
2 3
Fuel pump-to-carbu retor
2
1
NFI
M6x30mm
62Y141
4-6
Fuel filter and fuel pump
4l
I ivzv tzR
lto--, _i iP_,
lig--'i ll6,-ul
L_ul-___l
178 (
1
4-7
62Y141

No.
1
Pat name
Fuel filter cup
Q'ty
1 1 1 1 1
Remarks

N.m
kgtm
t.lb
O-ring
Fuel filter element
3 4
5
Body Float Screw Cover Fuel pump body 2 Fuel pump body
Nut
1
6 7
4
1 1 1
M5x35mm
I I
10
11
4
1 1 1 1 1
Plunger Spring Spring

Pin
12 13 14 15 16 17
1B
Diaphragm Screw Valve

Nut Seal
2 2 2
1 1
M3x6mm
19
20
Gasket
E FsoiFsoA
E rsorrsoB,
FTSoc
62Y141
4-8
Fuel system Checking the fuel pump
1,
lnstall the special service tool onto the fuel pump as shown.
NOTE:
Make sure that air does not escape from

the opposite side of the fuel pump.
. To eliminate any gaps between the fuel

pump valves and the fuel pump body 2, and to ensure a better seal, make sure that the inside of the fuel pump is moist with gasoline.
Fuel pump pressure @: 50 kPa (0,5 kgf/cm2, 7.1 psi) Fuel pump negative pressure @: 30 kPa (0.3 kgf/cm2,4.3 psi)
Disassembling the fuel pump
1,
Disassemble the fuel pump as shown.
Pressu relvacuum tester: YB-35956-A Vacuum/pressure pump gauge set: 90890-06756 2.
Apply the specified pressure to each fuel pump port.
3.
lf air flow is reversed, check the diaphragm for tears and the valves for
cracks. Replace if necessary.
Do not over pressurize the fuel pumpo oth-
erwise excessive pressure may cause air leakage.
4-9
62Y141
2.
Push down on the plunger and the diaphragm, turn the fuel pump body 1 @ approximately 90" to a position where the pin can be removed easily, and then remove the pin.
2.
Push down on the plunger and the diaphragm, and then install the pin @.
s62Y41 40
*
.t.
Turn the fuel pump body 1 @ approximately 90o, and then push down on the plunger several times to make sure that the pin does not come out.
1>*
s62Y41 10
3.
1.
Slowly let up on the plunger and diaphragm, and then remove them.
4.
s62Y41 50
Checking the diaphragm and valves

Check the diaphragm O for tears and the valves @ for cracks. Replace if necessary.
Assemble the cover @, gasket @, and seal @ with the screws @, and then install the fuel pump.
d-
tN
s62V
d\.J b
Assembling the fuel pump
1.
Align the plunger and diaphragm installation holes @, and then installthe plunger into the diaphragm.
62Y141
4-10
Garburetor unit
'N
\/ [],
N
):'
)!
N\ l.'
[el
'g
\
\ 7
4-11
62Y141
Carburetor unit
No.
1
Pat name Carburetor assembly Clip Blowby hose Prime Start coupler Bolt Collar Throttle link rod O-ring lnsulator
Q'ty
1 1 1 1
Remarks Joint-to-silencer

N.m
kgtm
t.lb
3 4
5
2 2
1
M6x30mm
6 7
I I
10
11
I
1
Dowelpin
Bolt Fuel hose Clip Rivet
I
2
M6x25mm
12 13 14
2 2
62Y141
4-12
J""
ru
J."
4-13
62Y141
Carburetor unit
No.
1
Pat name Acceleration pump Screw Link rod

Hose Hose
Q'ty
1
Remarks

N.m
kgtm
t.lb
3
1 1
M5x9mm
Acceleration pump-toacceleration pump Acceleration pump-tocarburetor
3 4
5
4
1
Link rod
62Y141
4-14
Fuel system
o
a
o o o
14 12
s62Y41 90
4-15
62Y141
Carburetor unit
No.
1
Pat name Carburetor Silencer Plastic tie Blowby hose Bolt Collar O-ring Plate O-ring O-ring Joint Plastic tie Fuel hose Fuel hose
Q'ty 4
1 1 1
Remarks

N.m
kgtm
t.lb
3 4
5
[@!r
M6x90mm
Silencer-to-joint
I
B
6 7
4
1
I I
10
11
4 4
1
12 13 14
4
2
Carbu retor-to-carbu retor
Carburetor-to{uel pump
62Y141
4-16
Garburetor
2t
-p
,V
iE1
(.s
T/-\ \
---l
4-17
62Y141
1
Carburetor
No.
1
Pat name Carburetor body Screw Cover

Seal Pilot jet Main jet
Q'ty
1
Remarks

N.m
kgtm
t.lb
4
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
M4x13mm
3 4
5
6 7
Needle valve Main nozzle O-ring

Plug
I I
10
11
Float Screw Float pin Gasket Float chamber Drain screw O-ring Screw Fuel hose Prime Start Screw O-ring Bracket Body Screw Gasket
12 13 14 15 16 17
1B
M4x6mm
4
1 1 1 1 1 1
M4x13mm
Float chamber-to-body
19
20
21
M4x7mm
22 23 24 25 26
2
1
Caburetor#1: M4 x 17 mm Cauretor#S: M4 x 22mm
E E E
Carburetors #1 , #2, and #3 Carburetor #4 Carburetors #1 and #3
62Y141
4-18
Disassembling the carburetor

NOTE:
Before disassembling the carburetor, make sure to note the number of times the pilot screw is turned out from the seated position to its set position.
4.
w-,p .:j;:{W
--g
s62Y4230
Checking the carburetor
1.
Check the air and fuel passages and jets, for dirt and foreign matter. Clean the carburetor body with a petroleum based solvent if necessary.
Check the needle valve for bends or

wear, Replace if necessary,
2.
Blow compressed air into all passages

and jets.
s62Y4220
. Direct the compressed air downwardn

otherwise cleaning solvent may be blown into your eyes or small pafis of
. Do not use steel wire for cleaning the

iets, otherwise the jet diameters may be enlargedo which may seriously affect performance.
the carburetor may be blown off,
3.
Check the main jet O, pilot jet @, and main nozzle @ for dirt or residue. Clean if necessary.
4-19
62Y141
Carburetor
5.
Check the float for deterioration. Replace it necessary.
/. -,/ -tt
\/^ ' J-/-<z' ^
\ r\ I
Ut
s62Y4250
Prime Start plunger minimum length @: 24,6 mm (0.97 in)
Measure the float height @. Replace the float and needle valve, if out of specification, as a set.
Assembling the carburetor

NOTE: Before assembling the carburetor, make sure to turn the pilot screw the same number of times, as noted before disassembly, from the seated position to the set position.
1.
lnstall the main nozzle O, plug @, pilot jet @, and main jet @ to the carburetor
body as shown.
. .
NOTE:
@-
The float should be resting on the needle valve @, but not compressing it. Take measurements at the top of the float flange opposite its pivoted side.
Float height @: 10.0 t 0.5 mm (0.39
,'e
g--o

0.02 in)
Checking the Prime Start 1. Measure the length of the Prime Starl
plunger.
2. 3.
Connect the positive Prime Start blue (L) lead and the negative Prime Start black (B) lead to a battery as shown.
Measure the plunger length @ after applying power for 5 minutes. Replace if
out of specification.
62Y141
4-20
2.
lnstall the needle valve @, float @, float pin @, and screw @ as shown, and then the check the float for smooth operation.
Throttle link rod length @: 144 mm (5.67 in)
. .
NOTE:
Place the needle valve in the valve seat when installing the float to the carburetor
body.
Fit the float pin into the slit on the carburetor body and lock it with the screw.
Adjusting the throttle Iink rod
1.
Push the throttle control lever @ to the fully open position as shown, and then
measure the gap between the carburetor throttle lever @ and carburetor stopper
@.
2.
lf out of specification, adjust the throttle

link rod length.
Gap @: Less than 0.5 mm (0.02 in)
3.
Remove the throttle link rod @, adjust it to the specified length (D, and then install
it.
4-21
62Y141
Carburetor
4.
Push the throttle control lever @ to the fully open position as shown.
While pushing the carburetor throttle lever @ against the carburetor stopper
@, loosen, and then tighten the adjusting screw @.
62Y141
4-22
Synchronizing the carburetors
1,
Start the engine and warm it up for 5 minutes to check the stability of the engine.
2.
Attach the special seruice tool

high'tension cord #1 @.
to
the
lnductive self-powered tachometer: YU-08036-B Digital tachometer: 90890-06760
3.
Remove all of the plugs @ and attach the special service tool and adapters to the carburetor assembly as shown.
NOTE:
For best results, use a vacuum gauge @

(commercially obtainable) with four adapters like the one shown in the illustration.
4.
Adjust the idle speed to 1,000 r/min by turning the throttle stop screw @ on carburetor #4 in direction @ or (0.
o@
. To increase idle speed, turn the . To decrease idle speed, turn the
stop screw in direction (0.
Carbu retor synchron izer: YU-08030 Vacuum gauge: 90890-031 59
NOTE:
throttle throttle
stop screw in direction @.
4-23
62Y141
Carburetor
Measure the vacuum pressure of carburelor #4.
Turn the throttle valve adjusting screws @ to adjust the vacuum pressure of carburetors #1, #2, and #3 to the same vacuum variation as carburelor #4.
lnductive self-powered tachometer: YU.08036-B Digital tachometer: 90890-06760
3.
Open the throttle cam @ slowly, and

check the engine speed when the acceleration pump stopper @ comes into contact with point @.
s62Y4420
7.
Adjust the engine idle speed to specification.
Engine idle speed: 900
t 50 r/min
8.
After adjusting the idle speed, rev the engine a few times and let it idle for at least 15 seconds to check that the vacuum pressures stay within 50 mm Hg (67 m bar, 1,97 in Hg) and to check the
stability of the engine.
Adjusting the dash-pot (acceleration pump)
1.
Sta the engine and warm it up for 5 minutes, and then check the engine speed at the operation point of the dash-pot.
s62Y4440
Engine speed: 2,700 rlmin
2.
Attach the special service tool to hightension cord #1 @.
4.
lf out of specification, adjust the engine

speed at the operation point of dash-pot.
62Y141
4-24
Fuel system
Open the throttle cam @ slowly, and
check that the acceleration pump stopper @ comes in contact with point @. Turn the adjusting screw @ in or out until the specified engine speed is obtained.
s62Y4450
7.
Open and close the throttle cam a few times, and check the engine speed at the operation point of dash-pot again. Adjust if necessary.
4-25
62Y141
MEMO
62Y141
4-26
Power unit
Troubleshooting
Special service tools Power Checking the compression pressure Checking the oil pressure Removing the power unit............
.5-1
5-10 5-13 ...............5-25 ....5-26 ..................5-29 .,,,.,,.,5-31 ................... 5-32
Timing belt and
sprockets.
Removing the timing belt and Checking the timing belt and sprockets lnstalling the timing belt and
sprockets.,, sprockets...
...........5-32
5-35 ....................5-39 ......5-40 ....5-40
......5-41
Cylinder head
Removing the cylinder Checking the valve Checking the Checking the valve Replacing the valve guides. Checking the valve Refacing the valve Checking the rocker arms and rocker arm Checking the camshaft ....... Checking the cylinder head Checking the oil lnstalling the valves .... lnstalling the camshaft........ lnstalling the rocker arm lnstalling the cylinder head
head.......... springs....... valves guides........ seat........... seat...........
.........5-41
......5-42
shatt...
.......5-43 ................5-45 .........5-46 ...........5-47 .........5-47 ,..,,..,.5.48 .....5-49 ...5-49
pump.........
assemb|y............... ..........
62Y141
Cylinder body
Removing and installing the .......5-55 Disassembling the cylinder .............5-55 Checking the piston .....5-56 ..5-56 Checking the cylinder Checking the piston .......5-57 .....5-57 Checking the piston Checking the piston ring ......5-58 Checking the piston ring side .........5-58 Checking the piston pin boss bore ..........5-58 Checking the piston pin .....5-58 ......5-59 Checking the connecting rod small end inside Checking the connecting rod big end side c|earance..............................5-59 Checking the connecting rod ..........5-59 Checking the ...5-59 Checking the crankshaft main journal oil c|earance...,...,..,,..,,,.,,,,,.,,,.,,..5-60 Checkingthecrankshaftpinoilclearance................ ............5-61 ................5-62 Selecting the crankshaft main journal ...5-63 Selecting the connecting rod big end Assembling the cylinder ..................5-64 lnstalling the power .,,.,.5-67
oilfilter........... body.......... diameter.... bore........... clearance rin9s.......... grooves................ clearance... .......... ............. diameter bolt............ crankshaft.............. bearing...... bearing body.......... unit..,,..,,..,.
62Y141
Troubleshooting
Before troubleshooting the power unit, check that all electrical connections are tight and free from corrosion, and that the battery is fully charged to 12 V.
Symptom: Engine does not crank. . Check the starting system. . Check the power unit.
Check that the gearshift is in the neutral position.
Set it to the neutral position.
Check the neutral switch for continuity.
Replace the neutral switch,
Check the engine staft switch for continuity.
Replace the engine staft switch.
Check the engine shut-off switch for continuity.
Replace the engine shut-off switch.
Check the fuse for continuity.
Replace the fuse.
Continued oh next page.

5-1
62Y141
1
Troubleshooting
Check the wiring harnesses for continuity.
Replace the wiring harnesses.
Check operation of the starter motor pinion.
Does the pinion rotate?
Listen for the operation sound

of the starter relay.
Remove allspark plugs, and then the engine.
Check the starter motor.
Check the power unit.
Check that the combustion camber is filled with engine oil or gasoline.
62Y141
5-2
Symptom: Engine cracks, but will not start. . Check the ignition system.
. .
Check the fuel system, Check the compression pressure of power unit.
Check the ignition spark using the spark gap tester.
Do not touch any of
the connections of
Gheck the ignition system out-
put peak voltage.
Check the condition of the spark plugs.
the spark gap tester leads. . Do not let sparks leak out of the removed spark plug caps. o Kp flammable gas or liquids away, since this test can produce sparks.
Check the fuel system.
Start the engine using dried or new spark plugs.
Gheck the compression pressure of the combustion chamber.
Check the condition of the spark plugs again.
Failure in staing operation
Failure in staing operation
Check the fuel system.
Check the cylinder head, cylinger body, and piston assembly.
5-3
62Y141
Troubleshooting
Symptom: Engine can be staed, but does not remain on.
. . .
Check the fuel system. Check the ignition system. Check the compression pressure of power unit.
Check that the fuelvent screw of the fueltank is open.
ls the vent screw open?
Open the fuelvent screw.
Check for water or residue in the fuelfilter.
Check the fuel hose for kinks or fuel leakage.
Clean the fuel system from the fuel tank lo the fuel filter.
Replace the respective parts.
Replace the primary fuel pump.
62Y141
5-4
Check that there is no secondary air intake on the contact surfaces of the intake manifold and crankcase.
Replace the respective seals.
Check the compression pressure of the combustion chamber.
Check the ignition spark gap using the spark gap tester.
Check the ignition system output peak voltage.
Replace the spark plug.
5-5
62Y141
Troubleshooting
Symptom: The engine idle speed is not steady, but increases or decreases.
. . .
Check the carburetors. Check the air intake system. Check the ignition system. Check the operation of the carburetor throttle valves.
Check the ignition timing. Check the secondary air intake on the O-ring and manifold plate, and the gaskets of the vacuum check bolts. Replace the CDI unit.
Check the operation of the carburetor throttle valves by removing the throttle cables and link rods.
Check the throttle cable operation and lubricate it if necessary.
Check and disassemble the carburetors, and then clean them if necessary.
62Y141
5-6
Symptom: Engine does not accelerate when the throttle is opened quickly.
The engine turns off when the throttle is opened quickly. Acceleration is tardy and the engine is likely to stop at any moment. . Check the carburetors. . Check the ignition system. . Check the compression pressure of power unit. Check the throttle cable operation.
Do the carburetor throttle
valves close simultaneously?
Adjust the throttle cable.
Check the needle valve of the carburetor for debris or wear.
Check each jet of the carburetor for clogs or debris. Check the ignition system and the compression pressure of the engine. Clean or replace the respective
parts.
Clean the carburetor, or replace respective parts.
5-7
62Y141
Troubleshooting
Symptom: Engine can run, but engine speed will not increase.
Overheat warning indicator is on. Oil pressure warning indicator is on. Warning indicator is on and buzzer is sounding. . Check the water cooling system. . Check the lubricating system. Check the water inlet for clogs or debris. Check that cooling water is discharged from the pilot water outlet.
Clean the water inlet.
Check the thermostat operation.
Replace the thermostat.
Check the thermoswitch.
Replace the thermoswitch.
Replace the CDI unit.
62Y141
5-8
Check the engine oil level.
Add engine oilto the correct

level.
Check the oil pressure.
Check the oil pump for debris or wear.
Check the oil pressure switch.
Clean or replace the respective

parts.
Replace the oil pressure switch.
Replace the CDI unit.
5-9
62Y141
Special service tools Special service tools
Compression gauge
YU-33223-1
ff
Kroq
Valve guide remover YM-01122
Valve guide reamer YM-01196 Flywheel magnet holder

YB-06139
z
5-10
Valve seat cutter set YM-91043-C
Universal puller
YB-06117
Drive shaft needle bearing depth stop Y8-34473
Crankshaft holder Y8-06562
Oil filter wrench

YU-38411
Valve spring compressor YM-01253
62Y141
Piston ring compressor

YU-33294
Valve spring compressor 90890-04019
6 v-. a ,^Q\4\ r.{u.

-\\\
\\\\ \\\\ \)
\la\
Valve spring compressor attach ment 90890-06320
Compression gauge
90890-03160
Valve guide remover/installer 90890-06801 Flywheel holder

90890-06522
@^s) P-' ttt

Flywheel puller
90890-06521
Valve guide reamer 90890-06804
Valve seat cutter holder 90890-06316
Crankshaft holder 18
90890-06562
5-11
62Y141
eee
Valve seat cutter 90890-0631 5, 90890-06323, 90890-06326, 90890-06328, 90890-06555 Bearing outer race attachment 90890-06626
Oil filter wrench

90890-01426
Piston slider
90890-06529
62Y141
5-12
Power unit
t
.,D
s62Y5010
5-13
62Y141
Power unit
No.
1
Pat name
Q'ty
1 1 1
Remarks

N.m
kgtm
t.lb
Flywheelmagnet
Stator coil Cover Grommet
Nut
3 4
5
2
1 1
160
16
116
6 7
Washer Bolt Lighting coil coupler Charge coil coupler Stator base Pulser coil coupler Screw
3
1 1 1 1
M6x25mm
I I
10
11
12 13 14 15 16
4
2
1 1
M6x24mm
o.4
2.9
Dowelpin
Woodruff key Cover Screw
M6x35mm
0.3
2.2
62Y141
5-14
('
I I
it ri
t4
i/
t
I
2i ..' -a'
5-15
Power unit
No.
1
Pat name Throttle cable Shift cable Shift cable Fuel pump
Fuel filter assembly Fuel filter assembly
Q'ty
1 1 1 1 1 1 1
Remarks

N.m
kgtm
t.lb
F50/F504, T50/FT50B
FTSOC
3 4
5
F50/F50A
TsO/FTsOB, FTSOC
6 7
Carburetor assembly Bolt Plate Clip Clip Grommet Holder Holder Bolt O-ring Clip Fuel hose Bolt Clip Fuel hose Bolt O-ring
I I
10
11
3
1 1 1 1 1 1
M6x20mm
12 13 14 15 16 17
1B
F50/F504, T50/FT50B
FTsOC
2
1
2
2
1 1 1
19
20
21
Fuel f ilter-to-fuel joint
22 23 24 25 26 27 28 29 30
I
4
2
1 1 1
Dowelpin
Clip Blowby hose Prime Start coupler Bolt Collar Throttle link rod
2
2
1
M6x30mm
62Y141
5-16
] ,
l\ l
. ('*' '\-
\ |(
.l
\
L
V'
s62Y5030
5-17
62Y141
Power unit
No.
1
Pat name Power trim and tilt relay Bolt Negative battery lead Wiring harness extension Grommet
Nut
Q'ty
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Remarks EHT/ET models

N.m
9
kgtm
0.9
t.lb 6.5
M8x16mm
3 4
5
6 7
o.7
5.1
Spring washer Positive battery lead PTT relay positive lead Fuse holder lead Clip Warning indicator coupler Trailer switch coupler Plastic tie
Pilot water hose
I I
10
11
EHT/ET models
12 13 14 15 16 17
1B
EHD/EHT models EHT/ET models
Bolt
2
1 1
M6x20mm
Tiller handle models
Remote control models
Neutralswitch
Plate
19
Neutralswitch lead
Ground lead Bolt PTT relay lead
Nut
Tiller handle models
20
21
3
1
M6x12mm
EHT/ET models EHT/ET models EHT/ET models EHT/ET models Green, blue
22 23 24 25 26
2 2 2 2
Spring washer PTT motor lead Bolt
M6x20mm
EHT/ET models
62Y141
5-18
co
%/^
JF
cl :l ol ol =l o-l
slE
2<
5
(\I
ffil lal ll ll
o)
rf)
I
Power unit
No.
1
Pat name Bracket Starter motor Spark plug cap lgnition coil Wiring harness Thermoswitch Holder Bolt Ground lead Bolt Oil pressure switch Oil pressure switch lead Screw lgnition coil lead Bolt Thermoswitch lead
Rectif ier Regu lator coupler
Q'ty
1 1
Remarks

N.m
kgtm
t.lb
3 4
5
4 2
1 1 1 1
6 7
I I
10
11
M6x12mm M6x12mm
9
3
1 1 1 1
0.9 0.2 0.7
6.5
1.4
12 13 14 15 16 17
1B
4
2
1 1
M6x30mm
5.1
CDI unit coupler Bolt Bolt

Nut
19
2
3
1 1 1 1 1 1
20
21
M8x25mm M8x35mm
30
3.0
22
22 23 24 25 26
Spring washer Starter motor lead Spring washer

Nut
0.7 3.0
5.1
Bolt
M8x45mm
30
22
62Y141
5-20
ffiffi
s62Y5050
5-21
62Y141
Power unit
No.
1
Pat name Power unit Engine oildipstick Gasket
Q'ty
1 1 1
Remarks

N.m
kgtm
t.lb
3 4
5
Dowelpin
Bolt Bolt Apron Screw
Nut
2 2
B
1
6 7
M6x16mm MBxB0mm M6x24mm
21
2.1
15
I I
2 2
62Y141
5-22
d4 /,
(\1:
l^
19
5-23
62Y141
Power unit
No.
1
Pat name Throttle link rod Throttle cam Throttle control lever Clip Bushing Bolt Spring Collar Bracket Bolt Shift rod Bolt Bracket Spring Bolt
Q'ty
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Remarks

N.m
kgtm
t.lb
3 4
5
6 7
M6x20mm
I I
10
11
M6x30mm M6x30mm
12 13 14 15
62Y141
5-24
Checking the compression pressure 1, Start the engine, warm it up for 5 minutes, and then turn it otf.
. lf the compression . lf
NOTE:
2. 3.
Remove the clip from the engine shut-off switch on the remote control box or tiller handle.
Remove the all spark plugs, and then install the special service tool to each spark plug hole.
pressure increases, check the piston and piston rings for wear. Replace if necessary. the compression pressure does not increase, check the valve clearance, valve, valve seat, cylinder sleeve, cylinder head gasket, and cylinder head. Adjust or replace if necessary.
Checking the oil pressure 1. Start the engine, warm it up for 5

utes, and then turn it otf.
min-
2.
Remove the oil pressure switch, and then install an oil pressure gauge O to the oil pressure switch installation hole.
Before removing the spark plugs, blow compressed air in the spark plug well to clear out any dirt or dust that may fall into the cylinder.
Compression gauge @: YU-33223-1 / 90890-031 60
4.
Use a pressure gauge with an adapter with a 1/B pitch thread.
Fully open the throttle, crank the engine
until the reading on the compression gauge stabilizes, and then check the
compression pressure. Minimum compression pressure: 840 kPa (8.4 kgf/cm2, 122psi)
3.
Check the oil pressure. Check the oil pump, oil suction pipe, and oil strainer if
5. lf the compression pressure is below

specification and the compression pressure for each cylinder is unbalanced, add a small amount of engine oil to the cylinder, and then check the pressure again.
Oilpressure: 100 kPa (1.0 kgf/cm2, 14 psi) at idle speed (900150 r/min)
5-25
62Y141
Power unit
Removing the power unit
1.
Remove the flywheel magnet cover and flywheel magnet.
. Apply force in the direction of the arrows shown, to prevent the flywheel
. To prevent damage to the engine or toolso screw in the flywheel puller set
bolts evenly and completely so that the flywheel puller plate is parallelto the flywheel magnet.
NOTE: Apply force to the crankshaft end until the flywheel magnet comes off the tapered portion of the crankshaft.
holder from slipping off easily.
Flywheel magnet holder @: YB-06139 Flywheel holder O: 90890-06522 Universal puller @: YB-06117 Flywheel puller @: 90890-06521
tr
E E
for USA and Canada

forworldwide
62Y141
5-26
2.
Disconnect the throttle cable @ and shift cable/shift rod @.
5.
Remove the power trim and tilt relay @, shift rod @ and shift rod bolts @.
s62Y5081
3.
Disconnect the fuel hose @ and throttle link rod @.
6.
Remove the apron @.
@-_
s62Y5082
4.
Disconnect the battery leads @, 10-pin coupler @), PTT relay leads ) (EHT, ET), PTT motor leads @ (EHT, ET), ground lead @ (EHT, ET), warning indicator coupler @ (EHD, EHT), trailer switch coupler C) (EHT, ET), pilot water hose @, and flushing hose (models with
flushing device).
5-27
62Y141
Power unit
7.
Remove the power unit by removing the bolts @.
s62Y5085
62Y141
5-28
Timing belt and sprockets
@
@
ffi t_
g-'1
F-r
l.',_
\i
CN
\\ \U
,\t s\
*t
5-29
62Y141

No.
1
Pat name Timing belt Drive sprocket Driven sprocket Bolt Bolt Tensioner Spring
Nut
Q'ty
1 1 1 1 1 1 1 1
Remarks

N.m
kgtm
t.lb
3 4
5
I
M8x20mm
25
0.8 2.5
5.8
18
6 7
I I
10
11
140
14
101
Retaining plate Woodruff key Bolt Washer Bolt Blowby hose Clip
2
1 1 1
M10 x 40 mm
38
3.8
2A
12 13 14 15 16
2
1 1 1
M6x20mm
Dowelpin
62Y141
5-30
Removing the timing belt and sprockets 1. Set the cylinder #1 piston position to
TDC of the compression stroke by aligning the "1" mark @ on the driven sprocket with the mark (D on the cylinder
3.
Remove the tensioner @ and timing belt @ from the driven sprocket side.
""
head.
' {
Do not turn the drive sprocket counterclockwise, otherwise the valve system
may be damaged.
s62Y5140
2.
Remove the breather hose and loosen the drive sprocket nut O.
4.
Loosen the driven sprocket bolt @ and remove the driven sprocket @.
s62Y51 50
E E
s62Y5130
NOTE: Use a deep socket @ (M42) for this procedure. . Do not turn the camshaft when loosening the drive sprocket nut.
NOTE: Do not turn the camshaft when loosening the driven sprocket bolt.
Flywheel magnet holder: YB-06139 Flywheel holder: 90890-06522
Crankshaft holder @: YB-06562 Crankshaft holder 1B @: 90890-06562
5-31
62Y141
5.
Remove the nut @, retaining plates @, drive sprocket @, and Woodruff key @.
lnstalling the timing belt and sprockets
1.
Check that the "1" mark @ on the driven sprocket @ is aligned with the "" mark (D on the cylinder head, and then tighten the bolt ,
2.
s62Y51 55
lnstall the retaining plate @, Woodruff key @, drive sprocket @, retaining plate @, and nut @, and then tighten the nut.
Checking the timing belt and sprockets
1.
Check the interior and exterior of the timing belt for cracks, damage, or wear. Replace if necessary.
s62Y51 60
Check the drive sprocket O and driven sprocket @ for cracks, damage, or wear. Replace if necessary.
s62Y51 70
62Y141
5-32
3.
Check that the "!" mark @ on the retaining plate is aligned with the mark @ on the cylinder body,
"l"
5.
lnstall the tensioner @ and bolts, and

then tighten the bolts finger tight.
qc YM
{
4.
lnstall the new timing belt @ from the drive sprocket side with its part number in the upright position.
6.
Take up the timing belt slack by turning the drive sprocket clockwise at least two fullturns.
Do not turn the sprockets counterclockwise, otherwise the valve system may be damaged.
1 7.
Tighten the tensioner bolts to the specified torque.
t_j\l
'@'
ffi\\ -
/e\
qy
...a,
o Do not twisto turn inside out, or bend the
Tensioner bolt @: 8 N.m (0.8 kgf.m, 5.8 tt.lb) Tensioner bolt (adjusting bolt) @: 25 N.m (2.5 kgf.m, 18 t.lb)
timing belt beyond the maximum limit of 25 mm (1.0 in) @, otherwise it may be
8.
. Do not get oil or grease on the timing

belt.
damaged.
Turn the drive sprocket two turns, and then check that the alignment marks are
aligned.
5-33
62Y141

Do not turn the sprockets counterclockwiseo otherwise the valve system may be
damaged.
Crankshaft holder @: YB-06562 Crankshaft holder 18 @: 90890-06562 Drive sprocket nut @: 140 N.m (14 kgf.m, 100 t.lb)
Tighten lhe driven sprocket bolt @ to the specified torque.
E E
for USA and Canada

Forworldwide
Flywheel magnet holder: YB-06139 Flywheel holder: 90890-06522 Driven sprocket bolt : 38 N.m (3.8 kgf.m, 27ll.lb) 10. Tighten the drive sprocket nut @ to the specified torque, and then install the breather hose.
-\)- \--\-^ - \ \ ,-/ r' \z

^\
NOTE:
Use a deep socket @ (M42) for this procedure.
62Y141
5-34
Gylinder head
T
7
,-=@
\-
hT."A-@1-tt
")w.H',
\ IL-/'
5-35
62Y141
Cylinder head
No.
1
Pat name Cylinder head Oil pump Cylinder head cover Bolt Cylinder head cover gasket Bolt Spark plug Bolt
Q'ty
1 1 1
Remarks

N.m
kgtm
t.lb
3 4
5
7
1
M6x20mm
6 7
10
M9x95mm
1st
2nd
4
5
23 47
18
2.3 4.7
1.8
17
34
13
I I
10
11
M6x25mm
1st
6
12
0.6
1.2
2nd Dowelpin
Cylinder head gasket Grommet Anode Cover Bolt Cover Bolt O-ring O-ring 2
1
4.3 8.7
4 4 4 4 4 4
1 1 1
12 13 14 15 16 17 18 19
O'ring
Bolt Housing Drive shaft
Pin
20
21
4
1 1 1 1 1 1 1
M6x40mm
22 23 24 25 26 27 28
lnner rotor Outer rotor Gasket Cover Screw
M6x20mm
Tightening sequence
62Y141
5-36
lffiliEtl,o*",un,.
'
12,
@ /'
\r/
..'/
5-37
62Y141
Cylinder head
No.
1
Pat name Rocker arm assembly Rocker arm shaft Cylinder head Exhaust valve lntake valve Camshaft Valve cotter Spring retainer Valve spring Spring seat Stem seal Valve guide Retaining bolt Gasket
Q'ty
B
1 1
Remarks

N.m
kgtm
t.lb
3 4
5
4 4
1
6 7
16
I I
10
11
I I I I
B
1 1 1
12 13 14 15 16 17
1B
Oilseal
Bolt Rocker arm retainer Tensioner Rocker arm retainer
M8x22mm
2 2
1
19
62Y141
5-38
Removing the cylinder head
1,
Check that the camshaft dowel pin hole @ s n the position shown in the illustration. Adjust if necessary.
2.
Remove the cylinder head cover bolts in the sequence shown.

s62Y5270
4.
Remove the oil pump
O,
rocker arm
assembly @, and rocker arm shaft @.
s62Y5265
Remove the cylinder head bolts in the sequence shown.
5-39
62Y141
Cylinder head
5.
Remove the retaining bolt @, then the

camshaft @ by pulling it downward.
Valve spring compressor @: YM-01253 / 90890-04019 Valve spring compressor attachment @: 90890-06320
Checking the valve springs
1.
Measure the valve spring free length @. Replace if out of specification.
Valve spring free length limit @: 37.85 mm (1.490 in)
2.
Remove the valves.
Measure the valve spring tilt (. Replace if out of specification.
Valve spring tilt limit (D: 1.2 mm (0,07 in)
Checking the valves
1.
Check the valve face for pitting or wear. Replace if necessary.
s62Y5290
When replacing the valve, also replace the

valve guide and stem seal.
62Y141
5-40
2.
Measure the valve margin thickness @. Replace if out of specification.
Valve stem runout: lntake: 0.03 mm (0.0012 in) Exhaust: 0.03 mm (0.0012 in)
Checking the valve guides
1.
Measure the valve guide inside diameter @. Replace if out of specification.
Valve margin thickness @: lntake: 0.6-1.0 mm (0.024-0.039 in) Exhaust: O.7-1.1 mm (0.028-0.043 in)
3.
Measure the valve stem diameter (0.

Replace if out of specification. Valve guide inside diameter limit @: 5.50-5.51 mm (0.2165-O.2169 in)
Replacing the valve guides 1. Remove the valve guide @ by striking

the special seruice tool from the combustion chamber side.
Valve stem diameter (D: lntake: 5.48-5.49 mm (0.2157{.2161 in)

Exhaust:
5.46-5.47 mm (0.2150{.2153 in)
4.
Measure the valve stem runout. Replace if out of specification.
Valve guide remover: YM-01122 Valve guide remover/installer:

90890-06801
5-41
62Y141
Cylinder head
2.
lnstall the new valve guide @ by striking
4.
the special seruice tool from the camshatt side until the valve guide clip @
contacts the cylinder head.
Measure the valve guide inside diameter. Replace the valve guide if out of specification.
Valve guide inside diameter: 5.5f5.51 mm (0.2165-0.2169 in)
Checking the valve seat
1.
Eliminate carbon deposits from the valve with a scraper.
2. 3.
s62Y5370
Apply a thin, even layer of Mechanic's

blueing dye (Dykem) onto the valve seat.
Lap the valve slowly on the valve seat with a valve lapper (commercially obtainable) as shown.
Apply engine oil to the sudace of the new

valve guide.
Valve guide remover: YM-01122 Valve guide remover/installer;

90890-06801
3.
lnseft the special seruice tool into the

valve guide @, and then ream the valve guide.
Measure the valve seat contact width @ where the blueing dye is adhered to the valve face. Reface the valve seat if the valve is not seated properly or if the valve seat contact width is out of specification. Replace the valve guide if the valve seat contact is uneven.
. Turn the valve guide reamer cloclaruise

ream the valve guide.
NOTE:
to
s62Y541 0
. Do not turn the reamer counterclockwise

when removing the reamer.
Valve guide reamer: YM-o1196 i 90890-06804
62Y141
5-42
s62Y5420 s62Y5450
Valve seat contact width @: lntake: 0.9-1.1 mm (0.035-0.043 in) Exhaust: 0.9-1.1 mm (0.035-0.043 in)
@ Stag or rough sudace
Refacing the valve seat
Do not over cut the valve seat. Make sure
1.
Reface the valve seat with the valve seat cutter.
to turn the cutter evenly downward at a pressure of 4f50 N (4-5 kgf, 8.8-11 lbf)
to prevent chatter marks.
3.
.*f--_l.,g.u
s62Y5430
Use a 30o cutler to adjust the contact width of the top edge of the valve seat.
Valve seat cutter set: YM-91043-C Valve seat cutter holder: 90890-06316 Valve seat cutter: 30" (intake): 90890-06326 30" (exhaust): 90890-06328 45" (intake and exhaust): 90890-06555 60' (intake): 90890-06323 60" (exhaust): 90890-0631 5
(D Previous contact width
2.
Cut the surface of the valve seat with a 45o cutter by turning the cuer clockwise until the valve seal face has become smooth.
62Y141
1
5-43
Cylinder head
4.
Use a 60o cutter to adjust the contact width of the bottom edge of the valve
seat.
7.
lf the valve seat contact area is too narrow and situated near the top edge of the valve face, use a 30o cutter to cut the top edge of the valve seat. lf necessary, use a 45o cutter to center the area and set its width.
s62Y5461
@ Previous contact width
5.
Use a 45o cutter to adjust the contact

width of the valve seat to specification. (D Previous conlact width
5
8.
@ Previous conlact width
s62Y5470
lf the valve seat contact area is too narrow and situated near the bottom edge of the valve face, use a 60o cutter to cut the bottom edge of the valve seat. lf necessary, use a 45o cutter to center the area and set its width.
s62Y5462
@ Specified contact width
6.
lf the valve seat contact area is too wide and situated in the center of the valve face, use a 30o cutter to cut the top edge of the valve seat, a 60" cutter to cut the bottom edge to center the area and set
its width.
s62Y5480
9.
Apply a thin, even layer of lapping compound onto the valve seat, and then lap the valve using a valve lapper (commercially obtainable).
s2Y5490
62Y141
5-44
Do not get the lapping compound on the valve stem and valve guide.
10. After every lapping procedure, be sure to clean off any remaining lapping compound from the cylinder head and the valve. 11. Check the valve seat contact area of the valve again.
Cam lobe @: lntake:
30.8S-30.99 mm
(1
.2161-1.2200 in)
Checking the rocker arms and rocker arm shaft
Exhaust:
1.
30.82-30.92 mm
Cam lobe (D: lntake:
(1
.213*1.2175 in)
Check the rocker arms, rocker arm shaft, and rocker arm contact surface @ tor wear. Replace if necessary. Measure the rocker arms inside diameter @ and rocker arm shaft outside diameter @. Replace if out of specification.
25.95-26.05 mm
Exhaust:
(1
.0217-1.0256 in) .0217-1.0256 in)
2.
25.95-26.05 mm
(1
2.
Measure the camshaft runout. Replace if out of specification.
Rocker arm inside diameter (D: 16.0116.01 mm (0.62910.6303 in) Rocker arm shatt outside diameter @: 15.98-15.99 mm (0.6291-0.6295 in)
Camshaft runout limit: 0.04 mm (0.0016 in)
Ghecking the camshaft
1.
Measure the cam lobe. Replace if out of specification.
5-45
62Y141
Cylinder head
3.
Measure the camshaft journal diameter @ and cylinder head journal inside diameter (D. Replace the camshaft and cylinder head if out of specification.
Camshaft journal diameter @: #1: 36.93-36.94 mm (1.4539-1.4543 in) #2, #3, #4; 36.94-36.95 mm (1 .4543-1.4547 in) Cylinder head journal inside diameter CD: 37.00-37.02 mm (1 .4567-1.4575 in)
4.
Calculate the camshaft oil clearance @ as follows. Replace the camshaft and cylinder head as a set if out of specification.
Cylinder head warpage limit: 0.03 mm (0.001 in)
@=CD-@:
#1 :
0.0-0.10 mm (0.0022-0.0039 in)
#2, #3, #4;
0.05-0.09 mm (0.00184.0035 in)
Checking the cylinder head
1.
Eliminate carbon deposits from the combustion chambers and check for deterioration.
2.
Check the cylinder head warpage using a
straightedge @ and thickness gauge @ in five directions as shown. Replace if out of specification.
62Y141
5-46
Checking the oil pump 1, Measure the oil pump rotor clearances
as shown. Replace if out of specification.
r))
s62Y5590
2.
lnstall the valve @, spring seat @, valve spring @, and spring retainer @ in the sequence shown, and then attach the special service tool.
Clearance @: 0.09-0.15 mm (0.004{.006 in) Clearance (D: 0.01-0.10 mm (0.0004-0.0039 in) Clearance @: 0.03--0.08 mm (0.001-0.003 in)
Face the fine pitch side @ of the valve spring toward the spring seat.
lnstalling the valves
Valve spring compressor @: YM-01253 / 90890-04019 Valve spring compressor attachment @: 90890-06320
1.
lnstall the new valve stem seal @ to the valve guide, and then apply engine oil to the valve guide.
5-47
62Y141
Cylinder head
3.
Compress the valve spring, and then install the valve cotter @ using a thin screwdriver with a small amount of grease applied to it.
lnstalling the camshaft
1.
lnstall the new oil seal @.
e
E E
Drive shatt needle bearing depth stop:
Y8-34473
Bearing outer race attachment: 90890-06626 Lightly tap the spring retainer with a plastic hammer to set the valve cotter securely,
2.
lnstall the camshaft @ in the direction shown, then the retaining bolt @.
62Y141
5-48
lnstalling the rocker arm assembly
1,
3.
Check that the camshaft dowel pin hole @ s n the position shown in the illustration. Adjust if necessary.
lnstall the rocker arm shaft assembly to the cylinder head by installing the bolts, and then tighten them to the specified torque and in the sequence shown.
2.
Assembly the rocker arm @ and rocker arm shatt @, and the tensioner @, rocker arm retainer @ by installing the bolts.
Bolt: 1B N.m (1.8 kgf.m, 13 ft.lb)
lnstalling the cylinder head 1. lnstall the oil pump O by aligning the oil
pump drive shaft @ with the camshaft pin
@.
t-5;
f- /
Make sure that the arrow marks @ on the two tensioners are facing up.
5-49
62Y141
Cylinder head
2.
Tighten the cylinder head bolts to the

specified torques in two stages and in the sequence shown.
@ @ @
s62Y5670
Apply engine oil to the cylinder head bolts

(M9) before installation.
Cylinder head bolt (M9): 1st: 23 N'm (2.3 kgf.m, 17 ft.lb) 2nd:47 N.m (4.7 kgf.m, 34 ft.lb) Cylinder head bolt (M6): 1st: 6 N.m (0.6 kgf.m, 4.3 ft.lb) 2nd:12 N.m (1.2 kgf.m, 8.7 ft.lb)
3.
Tighten the cylinder head cover bolts in the sequence shown.
62Y141
5-50
Gylinder body
<>-.-15
2\3
Lffi
W 4 .1 7e ^w #@& 219r."
Yd zB
M;,
)Ja@,
c4
-R
'(
1u
26
@ ,%Jg
Y;{%lJ
Ju
5-51
62Y141
Cylinder body
No.
1
Pat name
Q'ty
1 1
Remarks

N.m
1B
kgtm
1,8 1.5
t.lb
13
Oilfilter
Crankshaft Bolt Bolt Crankcase
3 4
5
10 10
M8x82mm M6x35mm
1st
15
11
2nd
1st
30 6
12
3.0 0.6
1.2
22 4.3 8.7
2nd
1 1
6 7
Oilseal
Main bearing
10
1
I I
10
11
Oilseal
Connecting rod bearing Connecting rod cap Bolt
I
4
B
1st
6
17
0.6
1.7
4.3
12
2nd
12 13 14 15 16 17 18 19
Dowelpin
Cylinder body Connecting rod Piston pin clip Piston pin
Piston
2
1 1
2
1 1 1 1 1 1 1 1 1 1 1
Oil ring
Second ring
20
21
Top ring
Piston assembly Gasket Exhaust cover Thermostat Gasket Cover Bolt Clamp Bolt Grommet
22 23 24 25 26 27 28 29 30
2
1
M6x35mm
10
1
62Y141
5-52
lffiliEtl,o*",un,.
G>--1s
@tr:
@
\ 23 24ZS
W
1
w
@
o
@ @
5-53
62Y141
Cylinder body
No.
31
Pat name Anode Cover Cover Bolt Bolt Bolt
Q'ty
1 1 1 1 1
Remarks

N.m
kgtm
t.lb
32
33 34
35
36
10
M6x20mm M5x12mm M6x35mm
1st
6
12
0.6
1.2
2nd
4.3 8.7
Tightening sequence
62Y141
5-54
Removing and nstalling the oil filter 1, Place a rag under the oil filter, and then
remove the filter.
<-W-
Oil filter wrench: YU-38411 / 90890-01426
Oil filter wrench: YU-38411
/ 90890-01426
Oil filter: 18 N.m
(1
.8 kgf.m, 13 ft.lb)
NOTE: Be sure to clean up any oil spills. Apply a thin coat of the new engine oilto the O-ring of the new oilfilter.
Disassembling the cylinder body
1.
Remove the exhaust cover bolts in the

sequence shown.
lnstall the oil filter, and then tighten it to

the specified torque.
5-55
62Y141
Cylinder body
2.
Remove the crankcase bolts

sequence shown.
in
the
@@
CIc:::@
@rr@ @rr@
@o
@@
@@
Piston diameter @: 62.9s42.96 mm (2.472.479 in) Measuring point @: 5 mm (0.2 in) up from the bottom of the piston skirt Oversize piston diameter: Oversize 1: +0.25 mm (0.01 in) Oversize 2: +0.50 mm (0.02 in)
s2Ys7go
Checking the cylinder bore

Remove the connecting rod bolts and the piston assemblies.
1.
Measure the cylinder bore (D.'-Du) @ at
Remove the crankshaft, oil seals, and dowelpins.

Remove the piston pin clip O with pliers, and then remove the piston.
measuring points @, O and @, and in direction @, which is parallel to the

crankshaft, and direction @, which s at a right angle to the crankshaft.
Ghecking the piston diameter 1. Measure the piston outside diameter at

the specified measuring point. Replace if out of specification,
Cylinder bore @: 63.00{3.01 mm (2.4812.481 in)
62Y141
5-56
2.
Calculate the taper limit. Replace or rebore the cylinder body if out of specification.
Piston ring dimensions:
Taper limit = maximum of D.' or D, minimum of Du or D6: 0.08 mm (0.003 in)
3.
Calculate the out-of-round limit. Replace or rebore the cylinder body if out of specification.
2.
Top ring @: B:1.17-1.19 mm (0.046-0.047 T:2.39-2..41 mm (0.094-0.095 Second ring (D: B:1.47-1.49 mm (0.058-0.059 T:2.49-2.51 mm (0.098-0.099 Oil ring @: B:2.3-2.46 mm (0.092-0.097 T: 2.75 mm (0.108 in)
in) in) in) in) in)
Out-of'round limit = maximum of D1, D3, or Du - minimum of Dr, Do, or Du: 0.08 mm (0.003 in)
Level the piston ring Q n the cylinder with the piston crown of an inverted piston.
Checking the piston clearance
3.
1.
Rebore the cylinder or replace the piston and piston rings as a set or the cylinder body, or both if out of specification.
Check the piston ring end gap @ at the specified measuring point. Replace if out of specification.
Piston clearance: 0.04-O.06 mm (0.0016-0.0024 in)
Checking the piston rngs
1.
Check the piston ring @ dimensions of B and T. Replace if out of specification.
D= r,T,l
n r---------t (9-.--l t---------
6) Y
t-\= l.T,l
,-.,---
r.T,l
Piston ring end gap @: Top ring: 0.15-0.30 mm (0.006-0.012 in) Second ring: 0.30-0.50 mm (0.012-0.020 in) Oil ring: 0.204.70 mm (0.008-0.028 in) Measuring point @: 20 mm (0.8 in)
5-57
62Y141
Cylinder body
Checking the piston ring grooves 1. Measure the piston ring grooves,
Replace the piston if out of specification. Piston ring side clearance:
___l_
_l@
Top ring @: 0.04-0.08 mm (0.002-O.003 in) Second ring @: 0.03-0.07 mm (0.001{.003 in) Oil ring @: 0.05-0.19 mm (0.002-O.007 in)
___l_
L_lo
i-_'"
Checking the piston pin boss bore 1. Measure the piston pin boss bore.
Replace the piston if out of specification.
lPiston ring groove: Top ring @: 1.2Y1.25 mm (0.048-0.049 in) Second ring @: 1.52-1.54 mm (0.06G-0.061 in) Oil ring @: 2.51-2.53 mm (0.09f0.100 in)
s2Y5790
Piston pin boss bore: 15.97 4-15.985 mm (0.6289-0.6293 in)
Checking the piston ring side clearance
Checking the piston pin 1. Measure the piston
pin
diameter.
1.
Measure the piston ring side clearance. Replace the piston and piston rings as a set if out of specification.
Replace if out of specification.
@ @
Piston pin diameter: 1 5.965-1 5.970 mm (0.6285{.6287 in)
62Y141
5-58
Checking the connecting rod small end inside diameter 1. Measure the connecting rod small end
inside diameter @. Replace the connecting rod if out of specification. @
tf--]t
ml
o
mm (0.2 in)
l-----l,olmm
(0.+ n)
Connecting rod bolt thread diameter limit (difference between @ and (D): f0.1 mm (f0.004 in)
Checking the crankshaft

Connecting rod small end inside diameter @: 15,985-15.998 mm (0,62934.6298 in)
1.
Ghecking the connecting rod big end side clearance
Measure the crankshaft journal diameter @, crank pin diameter @, and crank pin width @. Replace the crankshaft if out of specification.
1,
Measure the connecting rod big end side
clearance @. Replace the connecting

rod or crankshaft, or both if out of specification.
Connecting rod big end side clearance @: 0.054.22 mm (0.002{.009 in)
Checking the connecting rod bolt
1.
Measure the connecting rod bolt thread diameter at the two points @ and @.
Calculate the ditference between @ and @. Replace if out of specification. Crankshaft journal diameter @: 42.98443.000 mm (1 .6923-1 .6929 in) Crank pin diameter @: 32.984-33.000 mm (1 .2986-1 .2992 in) Crank pin width @: 21 .000-21.070 mm (0.8268-0.8295 in)
2.
5-59
62Y141
Cylinder body
2.
Measure the crankshatt runout. Replace the crankshaft if out of specification.
s62Y5870
NOTE:
Crankshaft runout limit: 0.04 mm (0.0016 in)
Do not put the Plastigauge (PG-l) over the oil hole in the main journals of the crankshaft.
Checking the crankshaft main journal oil clearance
5.
lnstall the remaining half of the bearings into the crankcase.
1.
Clean the bearings, main journals, and bearing portions of the crankcase and cylinder body.
Place the cylinder body upside down on a bench.
NOTEr
lnsert the projection of the bearing into the

notch in the crankcase.
2. 3.
lnstall the crankcase onto the cylinder body and apply engine oil onto the
threads of the crankcase bolts.
7.
lnstall half of the bearings
O and the
crankshaft @ into the cylinder body @.
Tighten the crankcase bolts to the specified torques in two stages and in the sequence shown,
@rr@
lnstall the bearings in their original positions.
@@
@@
@i:r@
lnsert the projection @ of the bearing into the notch in the cylinder body.
4.
Put a piece of Plastigauge@ 1eC-t on each main journal parallel to the crankshaft.
62Y141
5-60
NOTE:
Do not move the crankshaft until the main journal oil clearance measurement has been completed.
Crankcase bolt (M8): 1st:15 N.m (1.5 kgf.m, 11 ft.lb) 2nd: 30 N.m (3.0 kgf.m, 22ttlb) Crankcase bolt (M6): 1st: 6 N.m (0.6 kgf.m, 4.3 ft'lb) 2nd:12 N.m (1.2 kgf.m, 8,7 ft.lb)
Install the bearings in their original positions.
lnsert the projection @ of the bearing into the slot on the cap and connecting rod.
3.
Put a piece of Plastigauge (PG-1) onto the crank pin, parallelto the crankshaft.
B. Remove the crankcase
and measure the
width of the compressed Plastigauge (PG-1) on each main journal. Replace

the main bearing if out of specification.
NOTE:
Be sure not to put the Plastigauge (PG-1) over the oil hole in the crank pin of the crankshatt.
Crankshaft main journal oil clearance: 0.012-0.036 mm (0.0005-0.0014 in)
4.
lnstall the connecting rod to the crank pin

@
Checking the crankshaft pin oil clearance 1. Clean the bearings and the connecting
rod.
2.
lnstall the upper half of the bearing into the connecting rod @ and the lower half into the connecting rod cap @.
5-61
62Y141
Cylinder body
.
NOTE:
Align the alignment marks (D on the connecting rod cap and connecting rod. Face the embossed "Y" mark on the connecting rod toward the flywheel side of the crankshaft. Tighten the connecting rod bolts to the specified torques in two stages.
Selecting the crankshaft main journal bearing
1. When replacing the main bearing,

the suitable bearing as follows.
select
Check the crankshaft journal mark on the crankshaft e and the cylinder body mark on the cylinder body @.
5.
Select the suitable color @ for the main bearing from the table.
NOTE: Do not turn the connecting rod until the crank
pin oil clearance measurement has

completed.
been
Connecting rod bolt: 1st: 6 N.m (0.6 kgf.m, 4.3 ft.lb) 2nd:17 N.m (1.7 kgf.m, 12 ft.lb)
6.
Remove the connecting rod cap and measure the width of the compressed Plastigauge (PG-1) on each crank pin. Replace the connecting rod bearing if out of specification.
s2Y5A1 0
Cylinder body mark A A

B B
Crankshaft journalmark A
B
Bearing color Yellow

Red
A
B
Crank pin oil clearance: 0,016-0,040 mm (0.0006-0.0015 in)
c c
A
B
Pink Green
62Y141
5-62
4.
When installing the main bearing, inse the projection of the main bearing into the slot on the cylinder body,
Remove any small metal particles and oil from the contact surfaces of the cylinder body and the main bearing.
5.
Measure the main journal oil clearance with a piece of Plastigauge (PG-1).
Crankshaft main journal oil clearance: 0.012-0.036 mm (0.00010.0014 in)
6,
lf the oil clearance is below specification,
check the main bearing color and clean the contact surface of the cylinder body and the main bearing, and then check the main journal oilclearance again.
7.
lf the oil clearance is over specification, install an oversized main bearing, and then check the main journal oil clearance
again.
Connecting rod cap mark/color

VRed VRed
Crank pin mark

A
B
Bearing color Yellow

Red
Selecting the connecting rod big end bearing
1.
When replacing the connecting rod bearing, select the suitable connecting rod bearing as follows.
Check the crank pin mark on the crankshaft @ and the connecting rod cap mark or painted color on the connecting rod @.
IVBlue IVBlue IIVYellow IIVYellow
A
B
A
B
Pink Green
4.
Select the suitable color @ for the connecting rod bearing from the table.
When installing the connecting rod bearing, insert the projection of the connecting rod bearing into the slot on the connecting rod.
Remove any small metal particles and oil from the contact surfaces of the connecting rod and the connecting rod bearing.
5.
Measure the crank pin oil clearance with a piece of Plastigauge (PG'1).
Crank pin oil clearance: 0.016-0.040 mm (0.00064.0015 in)
5-63
62Y141
Cylinder body
6.
lf the oil clearance is below specification, check the connecting rod bearing color and clean the contact surface of the connecting rod and the connecting rod bearing, and then check the crank pin oil clearance again.
3.
Ofiset the piston ring end gaps

shown.
as
7.
lf the oil clearance is over specification,

installan over-sized connecting rod bearing, and then check the crank pin oil clearance again.
Assembling the cylinder body
1.
Assemble the piston @, connecting rod @, piston pin @, and piston pin clips @.
Do not scratch the piston or break the pis-
ton rings.
After installing the piston rings, check that

they move smoothly.
4.
lnstall the upper half of the bearing into the connecting rod @ and the lower half into the connecting rod cap @.
. Face the embossed

.
NOTE:
"Y" mark @ on the connecting rod in the same direction as the "UP" mark (D on the piston. Always use new piston pin clips, and do not allow the piston pin clip end to align with the piston pin slot @.
lnstallthe oil ring @, second ring @, and top ring @ to the piston with the "T" mark @ on tne piston rings facing upward.
lnstall the bearings in their original position.

NOTEr
2.
lnsert the projection @ of the bearing into the slot on the cap and connecting rod.
62Y141
5-64
5.
lnstall the piston with the "UP" mark on the piston crown facing towards the flywheel.
7.
Set the crankshaft @, and oil seals @ and @ into the cylinder body as shown. Apply engine oil to the inner oil seal, jour' nal bearings, and connecting rod bearing.
E E
for USA and Canada for worldwide
8.
NOTE: Apply engine oil to side of the piston assemblv.
lnstall the connecting rod cap @ to the connecting rod, and then tighten the con' necting rod bolts @ to the specified torques in two stages. Apply engine oilto the connecting rod cap and connecting rod bolt.
Piston ring compressor: YU-33294 Piston slider: 90890-06529
6.
lnstall half of the bearings @ into the cylinder body @.
lnsert the projection @ of the bearing into the notch in the cylinder body.
5-65
62Y141
Cylinder body
NOTE: Align the alignment marks @ on the connecting rod cap and connecting rod.
Connecting rod bolt: 1st: 6 N.m (0.6 kgf.m, 4.3 ft.lb) 2nd:17 N.m (1.7 kgf.m, 12 ft.lb)
9.
@@ @@
lnstall half of the bearings @ into the

crankcase, then dowel pins @,
10.
Apply Gasket MakeP to the mating surface of the crankcase.
@rr@
@o
oo
s62Y5B1 0
The
oil seals must be installed before
tightening the crankcase bolts.

NOTE: Apply engine oil to the crankcase bolt (MB) before installation.
s62Y5490
. lnsert the projection @ of the bearing into . Do not get any Gasket Maker on the journal
bearings. the notch in the crankcase.
NOTE:
Crankcase bolt (MB): 1st: 15 N.m (1.5 kgf.m, 11ft.lb) 2nd:30 N.m (3.0 kgf.m, 22fl.lb) Crankcase bolt (M6): 1st: 6 N.m (0,6 kgf.m, 4.3 t.lb) 2nd:12 N.m (1.2 kgf.m, 8.7 ft'lb)
11. lnstall the crankcase bolts, and then tighten them to the specified torques in two stages and in the sequence shown.
62Y141
5-66
12. lnstall the new gasket and exhaust cover,
torques
and then tighten the bolts to the specified two stages and the sequence shown.
in
in
Exhaust cover bolt: 1st: 6 N.m (0.6 kgf.m, 4.3 ft.lb) 2nd:12 N.m (1.2 kgf.m, 8,7 ft.lb)
Mounting bolt @: 21 N.m (2.1 kgf.m, 15 ft.lb)
3. 1. 2.
lnstalling the power unit
lnstall the dowel pins @ and gasket @. lnstall the power unit @ by installing the
lnstall the apron @.
bolts @, then tightening them to the

specified torque.
@-_
5-67
62Y141
Cylinder body
4.
lnstall the shift rod bolts @, shift rod @

and power trim and tilt relay @.
6.
Connect the throttle link rod @ and fuel hose @.
Connect the flushing hose (models with flushing device), pilot water hose @,
trailer switch coupler
GD
(EHT, ET), warn-
ing indicator coupler @) (EHD, EHT), ground lead @ (EHT, ET), PTT motor
leads @ (EHT, ET), PTT relay leads @ (EHT, ET), 10-pin coupler @, and battery leads @.
s62Y5089
7.
Connect the shift cable/shift rod @ and throttle cable @, and then adjust their lengths. For adjustment procedures, see Chapter 3, "Checking the throttle cable operation," and "Checking the gearshift
operation."
62Y141
5-68
8.
lnstallthe Woodrutf key.

Flywheel magnet holder: YB-06139 Flywheel holder: 90890-06522 Flywheel magnet nut: 160 N.m (16 kgf.m, 116 ft'lb)
9,
lnstall the flywheel magnet and flywheel
E E
Apply force in the direction of the arrows shown, to prevent the flywheel holder from slipping off easily.
Apply engine oil to the flywheel magnet nut before installation.
5-69
62Y141
MEMO
62Y141
5-70
Lower unit
6-1
Removing the lower
unit............
.......6-9
Water pump and propeller shaft housing (F50/F504) .............6-1I Removing the water pump and propeller shaft housing assembly..........6-13 Disassembling the propeller shaft housin9................ ...........6-13 Disassemblingthepropellershaftassembly............. ...........6-14 Checking the water pump......... ......6-14 ................6-15 Checking the propeller shaft housing .6-15 Checking the propeller shatt Assembling the propeller shaft assembly ..........6-16 Assembling the propeller shaft housing...... .......6-16 lnstalling the propeller shaft housing .................6-18 lnstalling the water pump......... .......6-18 Drive shaft and lower case (F50/F504) Removing the drive shaft.......... Disassembling the drive shaft assembly Disassembling the forward gear Disassembling the lower case Checking the pinion and fonruard 9ear........... Checking the bearings Checking the drive shaft..... Checking the shift rod and shift cam Checking the lower case .......... Assembling the lower case Assembling the fonruard 9ear........... Assembling the drive shaft.......... lnstalling the drive shaft .................. lnstalling the lower unit...............
......6-23 ...........6-23 ..,...,.,...,....,. 6-23
........6-24 ....6-25 ................. 6-25

.................6-25 ......6-25 .........6-25 ..................6-27 ...6-27
Shimming (F50) (for USA and Canada)

Shimming.. Selecting the pinion Selecting the fonrard gear Selecting the reverse gear
6-31
Jil::
shims shims
.........6-32 .........6-32 ...6-33 ...6-34
Shimming (F504) (for worldwide
Shimming..
Selecting the pinion Selecting the fonrard gear shims Selecting the reverse gear shims
shims.........
...................6-36 .....6-36
62Y141
Backlash (F50/F504) ..........6-39 Measuring the fonuard and reverse gear backlash .................................6-39 Lower unit (T50/FT50B, FT50C) Removing the lower uni1............
............6-41 .....6-43
Water pump and shift rod (T50/FT50B, FT50C)................. .....6-45 Removing the water pump and shift rod..... .......6-47 .............6-47 Checking the water pump and shift rod lnstalling the water pump and shift rod..... .........6-48 Propeller shaft housing (50/FT50B, FT50C)................ ..........6-51 Removing the propeller shaft housing assembly... ...............6-53 Disassembling the propeller shaft housing................ ...........6-53 Disassembling the propeller shaft assemb|y............. ...........6-54 ................6-54 Checking the propeller shaft housing Checking the propeller shaft........ ...6-55 Assembling the propeller shaft assembly... .......6-55 Assembling the propeller shaft housing...... .......6-55 lnstalling the propeller shaft housing .................6-57 Drive shaft and lower case (T50/FT50B, FT50C) Removing the drive shaft.......... Disassembling the drive shaft.. Disassembling the fonruard gear........... Disassembling the lower case Checking the pinion and fonruard 9ear........... Checking the bearin9s................ Checking the drive shaft.......... Checking the lower case .......... Assembling the lower case........... Assembling the fonruard 9ear,.,.....,.. Assembling the drive shaft.......... lnstalling the drive shaft.......... lnstalling the lower unit............ ..6-59
......6-61 .......6-61
.............6-61 ........6-62 ....6-63 ....6-63 .......6-63 ......6-63
..6-63
..,,,.,,..,,..,,..6-65 ...6-66 ........6-66 .......6-66 ................6-69 ...................6-70 .....6-70 ...6-71
Shimming (T50) (for USA and
Canada) Selecting the pinion shims......... Selecting the forward gear shims Shimming.. Shimming..
Shimming (FT50B, FT50C) (for
worldwide)............ .................6-73 ...................6.-74 Selecting the pinion shims......... .....6-74 Selecting the forward gear shims ,..6-75
Backlash (T50/FT50B, FT50C).... ...........6-77 Measuring the fonruard and reverse gear backlash .................................6-77
62Y141
Bearing housing needle bearing installer

YB-06111
Bearing housing puller

YB-06207, YB-06234
Kruq
Universal puller vB-06I17
Oilseal installer
YB-06168
/\ -* \ -l-\-
\-\\\
-\e
Forward/reverse gear bearing installer Y8-06270-A
Slide hammer and adapters Y8-06096
Bearing cup installer

YB-06167
Bearing housing needle bearing remover

YB-06112, YB-06153
Drive shaft holder Y8-06049
Driver handle
Y8-06071
6-1
62Y141
Bearing splitter plate YB-06219
Pinion shim selecting tools YB-34432-8, Y 8-34432-9, YB-34432-1 04, YB-34432-1 1 A, YB-34432'17
Wp
Drive shaft needle bearing remover and installer YB-06063, YB-06155
Forward gear shim selecting tools YB-34446-1, YB-34446 -3, Y 8-34446-4, YB-34446-5, YB-34446 -7, Y 8'34446-1 5
btu
Drive shaft needle bearing depth stop YB-34473,YB.34474
Shift rod push arm

YB-06052
Drive shaft taper roller bearing cup installer YB-06110
Backlash indicator gauge

YB-06265
Forward gear bearing cup installer

YB-06109, YB-06276-B
Magnetic plate
YB-07003
62Y141
6-2
Dial gauge
YU-03097
Forward gear needle bearing and tapered roller bearing installer Y8-06200
Magnetic f lexible stand YU-3448I
Bearing housing puller claw

90890-06564
Bearing housing oilseal installer Y8-06269 Stopper guide plate

90890-06501
Gland nut wrench Y8-34447 Center bolt 90890-06504
Crank upper and lower seal installer v8-06244 Bearing separator

90890-06534
6-3
62Y141
Stopper guide stand

90890-06538
Driver rod SS 90890-06604
Bearing puller
90890-06535
Bearing depth plate

90890-06603
Bearing puller claw I

90890-06536
Bearing inner race attachment

90890-06639, 90890-06641, 90890-06643n 90890-06644, 90890-06661, 90890-06662
Needle bearing attachment

90890-06607, 90890-0661 0, 90890-0661 1, 90890-0661 2, 90890-0661 4, 90890-06653
Drive shaft holder 4

90890-06518
Driver rod L3 90890-06652
Pinion nut holder

90890-06s05
62Y141
6-4
Socket adapter 90890-06506
Driver rod LS 90890-06606
Bearing outer race puller

90890-06523
Driver rod LL
90890-06605
Outer race puller claw A

90890-06532
Pinion height gauge

90890-06702
Driver rod SL
90890-06602
Digitalcaliper
90890-06704
Bearing outer race attachment 90890-06621, 90890-06622, 90890-06626, 90890-06627
Shimming plate
90890-06701
6-5
62Y141
Shift rod push arm

90890-06052
Ring nut wrench 3

90890-0651
1
Backlash indicator
90890-06706
Ring nut wrench extension 90890-06s13
"a
\a)./
\
Magnet base plate
90890-07003 90890-06502
\?
Bearing housing puller claw L
Dial gauge set

90890-01252
Ball bearing attachment

90890-06655
Magnet base
90890.06705
Socket adapter 90890.06507
62Y141
6-6
Lower unit (F50/F50A)
fs
/,
s62Y6010
6-7
62Y141

No.
1
Pat name Lower unit Plastic tie

Hose
Q'ty
1 1 1 1
Remarks

N.m
kgtm
t.lb
3 4
5
Check screw Gasket Bolt Drain screw
7 M10 x 40 mm 40 7
0.7
4.O
5.1
2 4
1
6 7
29
5.1
o.7
I I
10
11
Dowelpin
Bolt Anode Bolt Thrust washer Propeller Washer Washer Cotter pin Propeller nut Trim tab Bolt
2
1 1 1 1 1 1 1 1 1 1 1
M8x35mm M8x60mm
12 13 14 15 16 17
1B
35
3.5
25
19
M8x20mm
62Y141
6-8
Removing the lower unit 1, Drain the gear oil, For draining procedures, see Chapter 3, "Replacing the
gear oil."
2.
Sel the gearshift to the neutral position, and place a block of wood between the
anti-cavitation plate and propeller to keep the propeller from turning, and then remove the propeller nut and propeller.
s62Y6020
Do not hold the propeller with your hands when loosening or tightening it. Be sure to remove the battery leads from the batteries and the engine shut-off switch. Put a block of wood between the cavitation plate and propeller to keep the propeller from turning.
Disconnect the speedometer hose O. Mark the trim tab @ at the area shown, and then remove it.
5.
Loosen the bolts, and then remove lhe lower unit from the upper case.
3. 4.
6-9
62Y141
MEMO
62Y141
6-10
Water pump and propeller shaft housing (F50/F504)
22
6-11
62Y141

No.
1
Pat name Propeller shaft assembly Propeller shaft housing assembly Spacer Grommet Bolt Water pump housing lnsert plate cartridge lmpeller
Q'ty
1 1
Remarks

N.m
kgtm
t.lb
3 4
5
1 1
4
1 1 1 1 1 1
M8x20mm
6 7
B
I
10
11
O'ring
Outer plate cartridge Gasket
12 13 14 15 16 17 18 19
Dowelpin
Woodruff key Slider Spring Cross pin
Dog clutch
2
1 1 1 1 1 1 1 1 1
Spring Propeller shatt Shift plunger Washer Bolt Reverse gear Reverse gear shim
20
21
22 23 24 25 26 27 28 29 30
2
1
M8x25mm
As required
Ballbearing O'ring O'ring

Propeller shaft housing Needle bearing
1 1
2
1 1
Oilseal
62Y141
6-12
1. 2.
E
Removing the water pump and propeller shaft housing assembly

Remove the water pump assembly.
tr
Remove the propeller shaft housing assembly by removing the bolts @, then pulling the housing out.
E E
For USA and Canada for worldwide
Slide hammer and adapters @: YB-06096 Bearing separator @: 90890-06534 Stopper guide plate @: 90890-06501 Stopper guide stand @: 90890-06538 Bearing puller @: 90890-06535 Bearing puller claw 1 @: 90890-06536 NOTE:
E E
lnstall the bearing separator @ between the reverse gear and propeller shaft housing completely, then the other special service tools.
Bearing housing puller @: YB-06234 Universal puller @: YB-061 17 Bearing housing puller claw @: 90890-06564 Stopper guide plate @: 90890-06501 Center bolt @: 90890-06504
2.
E
Remove the ball bearing.
Disassembling the propeller shaft housing
1.
E
Remove the reverse gear and shim(s).
6-13
62Y141
E E
For USA and Canada
Forworldwide
Slide hammer Stopper guide Stopper guide Bearing puller Bearing puller
and adapters @: YB-06096 plate @: 90890-06501 stand @: 90890-06538 @: 90890-06535 claw 1 @: 90890-06536
Checking the water pump 1. Check the pump housing for deformation. Replace if necessary.
3.
Remove the oil seals and needle bearing.
------ / \-/ \\ -,/

1
(o)
-
2.
Check the impeller @ and insert plate cartridge @ for cracks or wear. Replace if necessary.
s62Y6090
Bearing housing needle bearing remover @:
YB-06112 Needle bearing attachment @: 90890-06614 Driver handle @: YB-06071 Driver rod L3 @: 90890-06652
Disassembling the propeller shaft assembly
1.
Remove the spring @, then the cross pin @, dog clutch @, slider, and spring.
62Y141
6-14
3.
Check the Woodrutf key @ and the groove @ on the drive shaft for wear.
Replace if necessary,
s62Y6120
Checking the propeller shaft 1. Check the propeller shaft for bends or
wear. Replace if necessary.
Checking the propeller shaft housing
1.
Clean the propeller shaft housing using a soft brush and cleaning solvent, and then check it for cracks. Replace if necessary.
2.
s62Y61 25
Check the dog clutch and shift plunger for cracks or wear. Replace if necessary.
Check the teeth and dogs of the reverse gear for cracks or wear. Replace the gear if necessary.
s62Y61 15
Check the bearings for pitting or rumbling. Replace if necessary.
6-15
62Y141

Assembling the propeller shaft assembly
1.
lnstall the dog clutch as shown.
. lnstallthe
.
NOTE:
needle bearing with the manufacture identification mark @ facing toward the oil seal (propeller side). Do not strike the driver rod in a manner that willforce the stopper @ out of place.
Driver handle O: YB-06071 Bearing housing needle bearing installer @: YB-06111 Driver rod SS @: 90890-06604 Needle bearing attachment @: 90890-06614 Bearing depth plate @: 90890-06603
s62Y61 40
Deprh
O:3.0-3.5 mm (0.12-0.14
in)
NOTE: lnstall the dog clutch @ with the "F" mark @ facing toward the shift plunger.
Depth @:23.0-23.5 mm (0.91-0.93 in)
2.
E
Assembling the propeller shaft housing
Apply grease to the new oil seals, and then install them into the propeller shaft housing to the specified depth.
1.
lnstall the needle bearing into the propeller shaft housing to the specified depth.
s62Y61 45
E E E E
for USA and Canada
forworldwide
NOTE:
lnstall an oil seal halfway into the propeller shaft housing, then the other oil seal.
62Y141
6-16
Oil seal installer @: YB-06168 Driver handle @: YB-06071 Needle bearing attachment @; 90890-06653 Driver rod L3 @: 90890-06652 Depth @: 4.0-4.5 mm (0.16-0.18 in)
Fonruard/reverse gear bearing installer @:
YB-06270-A Bearing inner race attachment @: 90890-06639
4.
lnstall the reverse gear assembly to the propeller shaft housing using a press.
3.
lnstall the original shim(s) @ and ball bearing into the reverse gear using a
press.
s62Y61 75
E E
Bearing cup installer @: YB-06167 Needle bearing attachment @: 90890-06607
ffi or
Add remove shimsn if necessaryo when replacing the reverse gear or propeller shaft housing.
lnstall the ball bearing with the manufacture identification mark O facing outward (propeller side).
6-17
62Y141

lnstalling the propeller shaft housing 1. lnstall the washer @, propeller shaft
assembly @, and shift plunger @, into the propeller shaft housing assembly @.
2.
Apply grease to the new O-rings.
NOTE: Align the groove of the impeller @ with the Woodrutf key @.
lnstall the insert plate cartridge @ into

the water pump housing @.
s62Y61 B0
lnstall the propeller shaft housing assem-
bly into the lower case @, and then

tighten the bolts @.
NOTE: Align the projection @ of the insert plate cartridge with the hole @ in the pump housing.
NOTE: When installing the propeller shaft assembly, be sure not to drop the shift plunger @.
lnstalling the water pump
1.
lnstall the new gasket and outer plate

cartridge.
2.
3.
lnstall the Woodrutf key into the drive

shaft.
Apply grease to the impeller, and then

install it onto the drive shaft.
62Y141
6-18
5.
lnstall the O-ring @, pump housing assembly @, and dowel pins @ into the lower case, tighten the bolts @, and then installthe grommet @ and spacer @.
. .
When installing the pump housing, turn the drive shaft clockwise while pushing down the pump housing. Align the spacer projection @ with the hole @ n tne pump housing.
6-19
62Y141
MEMO
62Y141
6-20
lffil$-l ,o*",un,,
Drive shaft and lower case (F50/F50A)
15=@
\t
lL
1B
ine \)
Vrn
s/
I
I
,{'W
24
6-21
Drive shaft and lower case (F50/F504)

No.
1
Pat name Shift rod assembly Drive shaft
Q'ty
1 1 1 1 1 1 1 1 1 1
Remarks

N.m
kgtm
t.lb
3 4
5
Oilseal Oilseal housing

O-ring Circlip Shift rod O-ring
6 7
I I
10
11
Taper roller bearing

Bearing outer race Pinion shim Sleeve Oil seal housing assembly Washer
12 13 14 15 16 17
1B
1 1 1 1 1
Oilseal housing
O-ring
Oilseal
Seal
2
1 1 1 1 1 1
19
Plate
Hose
20
21
Plastic tie Joint

Nut
22 23 24 25 26 27 28 29 30
31
Water inlet cover

Screw Shift cam Needle bearing
Pinion
2
1 1 1 1 1
0.s
3.6
Nut Forward gear shim Bearing outer race
O:
17 mm
75
7.5
54
As required
1 1 1 1
32
33 34
Taper roller bearing Forward gear

Lower case
62Y141
6-22
Removing the drive shaft 1, Remove the drive shaft assembly and pinion, and then pull out the forward
gear.
tu
tr
E E
o Do
not press the drive shaft threaOs @ directly. Do not reuse the bearingo always replace it with a new one.
Bearing splitter plate @; YB-06219 Bearing inner race attachment @:

90890-06641
E E
Disassembling the forward gear
1.
Remove the taper roller bearing from the forward gear using a press.
Drive shaft holder @: YB-06049 Drive shaft holder 4 @: 90890-06518 Pinion nut holder @: 90890-06505 Socket adapter 1 @: 90890-06506
Disassembling the drive shaft assembly
1.
lnstall the pinion nut @, tighten it finger tight, and then remove the drive shaft bearing@usingapress.
Do not reuse the bearingn always replace it with a new one.

Bearing splitter plate @; YB-06219 Bearing separator @: 90890-06534
6-23
62Y141

Disassembling the lower case
1.
Remove the taper roller bearing outer race and shim(s).
E E
NOTE:
lnstallthe claw as shown.

Slide hammer Stopper guide Stopper guide Bearing puller Bearing puller and adapters @: YB-06096 plate @: 90890-06501 stand @: 90890-06538 @: 90890-06535 claw 1 @: 90890-06536
E E
For USA and Canada
3.
Remove the needle bearing.
Forworldwide
lnstallthe claw as shown.

Slide hammer and adapters @: YB-06096 Bearing outer race puller @: 90890-06523 Outer race puller claw A @: 90890-06532 Stopper guide stand @: 90890-06538
2.
Remove the drive shaft bearing outer

race, shim(s), and drive shaft sleeve.
Drive shaft needle bearing remover and installer @: YB-06063 Needle bearing attachment @: 90890-06614 Driver handle @: YB-06071 Driver rod L3 @: 90890-06652
4.
Remove the shift rod assembly and shift

cam.
62Y141
6-24
Checking the pinion and forward gear 1. Check the teeth of the pinion, and the teeth and dogs of the forward gear for cracks or wear. Replace the pinion or
gear if necessary.
562YO,
Checking the Iower case

1
Check the skeg and torpedo for cracks or damage. Replace if necessary.
Checking the bearings 1. Check the bearings for pitting or

bling. Replace if necessary.
rum-
Assembling the Iower case
1.
lnstall the shift rod assembly cam @ as shown.
Q and
shift
s62Y6265
Checking the drive shaft
1,
Check the drive shaft for bends or wear. Replace if necessary.
Checking the shift rod and shift cam 1, Check the shift rod and shift cam for
cracks or wear. Replace if necessary.
s62Y6280
lnstall the shift cam with lhe "UP" mark @ facing upward.
6-25
62Y141
2.
lnstall the needle bearing into the lower

case to the specified depth.
*!*
B
@-'1I
E E
for USA and Canada

Forworldwide
. lnstallthe
.
NOTE:
needle bearing with the manufacture identification mark O facing upward. When using the driver rod, do not strike the the special tool in a manner that will force the stopper @ out of place.
Add or remove shims, if necessary, when replacing the pinion or lower case.
NOTEr
.
Driver handle @: YB-06071 Drive shaft needle bearing remover and installer @:YB-06063 Drive shaft needle bearing depth stop @: YB-34474 Driver rod SL @: 90890-06602 Needle bearing attachment @: 90890-06614 Bearing depth plate @: 90890-06603 Depth (D: 1 32.5-1 33.0 mm (5.22-5.24 in) Depth @: 1 82.5-1 83.0 mm (7.19-7.21 in)
Apply gear oil to the inside and outside of the sleeve. lnstallthe sleeve with the projeclion O tacing fonruard.
Drive shaft taper roller bearing cup installer @: YB-06110
Bearing outer race attachment @: 90890-06627 Driver handle @: YB-06071 Driver rod LS @: 90890-06606
3.
lnstall the sleeve, original shim(s), and

bearing outer race.
62Y141
6-26
4.
lnstall the forward gear original shim(s) and taper roller bearing outer race.
Drive shaft taper roller bearing cup installer @: YB-06110 Bearing inner race attachment @:
90890-06639
Assembling the drive shaft
1.
Install the new drive shaft bearing into the drive shaft using a press.
Add or remove shims, if necessaryo when replacing the forward gear or lower case.
Fonivard gear bearing cup installer @:
s62Y6325
YB-06109 Bearing outer race attachment @: 90890-06622 Driver handle @: YB-06071 Driver rod LL @: 90890-06605
tr
I I
Assembling the forward gear
1.
lnstall the new taper roller bearing into the fonruard gear using a press.
#E
E B
for USA and Canada for worldwide
NOTE:
Use a special service tool or a general pipe

with the specified measurements.
General pipe @: D = 38 mm (1.49 in), d = 32 mm (1.26 in) Bearing inner race attachment @: 90890-06644
E E
6-27
62Y141
2.
E
lnstall the new oil seals to the oil seal

housing as shown.
tr
E E
tr
Drive shaft holder @: YB-06049 Drive shaft holder 4 @: 90890-06518 Pinion nut holder @: 90890-06505 Socket adapter 1 @: 90890-06506 Pinion nut: 75 N.m (7.5 kgf.m, 54 ft.lb)
lnstalling the lower unit
E E
for USA and Canada

Forworldwide
1.
Set the gearshift to the neutral position at power unit and lower unit.
Oil seal installer @: YB-06168 Driver handle @: YB-06071 Needle bearing attachment @: 90890-06653 Driver rod L3 @: 90890-06652
lnstalling the drive shaft
1.
lnstall the forward gear, then the drive shaft assembly, pinion, and pinion nut, and then tighten the nut to the specified
torque.
tu
62Y141
1
6-28
lnstall the two dowel pins

unit.
3,
Q to the lower
lnstall the lower unit to the upper case, and then tighten the bolts to the specified torque.
5.
lnstall the propeller and propeller nut,

tighten the nut finger tight. Place a block of wood between the anti-cavitation plate and propeller to keep the propeller from turning, and then tighten the nut to the specified torque.
Mounting bolt: 40 N.m (4.0 kgf.m, 29 ft.lb)
4.
lnstall the trim tab @ to its original position, and then connect the speedometer hose @.
6-29
62Y141
lf the grooves in the propeller nut @ do not align with the cotter pin hole, tighten the nut untilthey are aligned.
Propeller nut @: 35 N.m (3.5 kgf.m, 25 ft.lb)
62Y141
6-30
Shimming (F50) (for USA and Ganada)
'u
i-i
ll
i-i
i-
ir
6-31
62Y141

Shimming
NOTE: Shimming is not required when assembling the original lower case and inner parts. . Shimming is required when assembling the original inner parts and a new lower case. . Shimming is required when replacing the inner pafis.
Selecting the pinion shims 1. Calculate the specified value (M0)

shown in the examples below.
as
NOTE: NOTE: "P" is the deviation of the lower case dimenis stamped on the trim tab mounting surface of the lower case in 0,01 mm units. lf the "P"
lnstall the shim selecting tools to the drive shaft so that the shaft is at the center of the
hole.
sion from standard. The "P" mark @
mark is unreadable, assume that "P" is zero and check the backlash when the unit is assembled.
Specified value (M0) = 0.30 + P/100 mm Example: lf "P" is "+5", then M0 = 0.30 + (+5)/100 mm = 0.30 + 0.05 mm = 0.35 mm lf "P" is'L5", then M0 = 0,30 + (-5)/100 mm = 0,30- 0,05 mm = 0.25 mm
Pinion shim selecting tools: YB-34432-8 @), YB-34432-104 @), YB-34432-114 G), YB-34432-17 Q)
4.
lnstallthe pinion and pinion nut, and then tighten the nut to the specified torque.
Pinion nut: 75 N.m (7.5 kgf.m, 54 t.lb)
2.
3.
lnstall the drive shatt and drive shaft bearing @ to the shim selecting tools.
Attach the clamp @ to the gauge base using four bolts of appropriate sizes.
62Y141
6-32
5.
Measure the clearance (M) between the
shim selecting tool and the pinion as

shown,
Selecting the forward gear shims 1, Calculate the specified value (M0)
as
s62Y6370
NOTE: Measure the pinion at three points to find the clearance average.
6.
Select the pinion shims (T3).
NOTE: "F" is the deviation of the lower case dimension from standard. The "F" mark @ is stamped on the trim tab mounting surface of the lower case in 0.01 mm units. lf the "F" mark is unreadable, assume that "F" is zero and check the backlash when the unit is assembled.
Specified value (M0) = 0.95 + F/100 mm Example: lf "F" is "+5", then M0 = 0.95 + (+5)i100 mm = 0.95 + 0.05 mm NOTE:
= 1.00 mm
lf "F" is "-5", then M0 = 0.95 + (-5)/100 mm = 0.95 = 0.90 mm
The sum of T3 and M should not be more

than M0.
- 0.05 mm
Pinion shim thickness (T3) = M0
Available shim thicknesses: 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, and 0.50 mm
6-33
62Y141
2.
lnstall the taper roller bearing @ to the

shim selecting tools.
e *"^-{-N
ol
r@
NOTE:
M>

than M0.
Forward gear shim thickness
(Tl)
MO-M
NOTE: Tighten the nut four turns after it contacts the spring.
Available shim thicknesses: 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, and 0,50 mm
Selecting the reverse gear shims
1.
Forward gear shim selecting tools: Y 8-34446^1 , YB-34446-3 G), Y B-34446-4 @, YB-34446- 1 5 )
3.
Measure the clearance (M) between the gauge pin and press plate.
Measure the backlash to find the necessary shim thickness (T2). Add or remove shims if out of specification. For measuring procedures, see "Measuring the forward and reverse backlash" in this chapter.
s62Y6390
NOTE:
4.
Select the forward gear shims (T1).
Measure the backlash with the original shim(s). lf the original shim(s) is unavailable, start with a 0.50 mm shim.
62Y141
6-34
Shimming (F50A) (for worldwide)
'u
i-i
ll
i-i
i-
ir
6-35
62Y141
Shimming (F504) (for worldwide)

Shimming
NOTE: Shimming is not required when assembling the original lower case and inner parts. . Shimming is required when assembling the original inner parts and a new lower case. . Shimming is required when replacing the inner pafis.
3.
Measure the distance (M) between the shimming tool and the pinion as shown.
ffi#
#
4.
Selecting the pinion shims 1. lnstall the drive shaft and drive
bearing @ to the shimming tools.
ffi's62y645
shaft
Measure the pinion at three points to find the clearance average.
Digital caliper @: 90890-06704 Calculate the pinion shim thickness (T3) as shown in the examples below.
NOTE: "P" is the deviation of the lower case dimenNOTE: Select the shim thickness (T3) by using the specified measurement(s) and the calculation formula. . lnstall the shimming tool to the drive shaft so that the shaft is at the center of the hole. . Tighten the wing nuts another 1/4 turn afler they contact the fixing plate .
is
stamped on the trim tab mounting surface of
the lower case in 0.01 mm units. lf the "P" mark is unreadable, assume that "P" is zero and check the backlash when the unit is
assembled.
Pinion shim thickness (T3) =
M-11.30mm-P/100
Pinion height gauge @: 90890-06702
2.
Pinion nut: 75 N.m (7.5 kgf.m, 54 ft.lb)

62Y141
6-36
Example: lf "M" is "11 .70 mm" and "P" is "+5", then T3 = 1 1.70 - 1 1.30 - (+5)i100 mm = 0.40 - 0.05 fiffr = 0.35 mm lf "M" is "11 .70 mm" and "P" is "-5", then
T3 = 1 1.7O -
1.30
(-5)/100 mm
= 0.40 + 0.05 mm = 0.45 mm
5.
Select the pinion shim(s) (Tg) as follows. Rounded numeral

2
5
s62Y6430
Calculated numeral at 1/100 place
1,2
3,4,5 6,7,8
9, 10
I
10
Available shim thicknesses: 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, and 0.50 mm Example:
NOTE: Select the shim thickness (T1) by using the specified measurement(s) and the calculation formula, . Measure the bearing outer race at three points to find the height average.
lf "T3" is "0.44 mm", then the pinion shim is

0.45 mm.
Shimming plate @: 90890-06701 Digital caliper @: 90890-06704

0.40 mm.
2.
Calculate the forward gear shim thickness (T1) as follows.
Selecting the forward gear shims
1.
Turn the taper roller bearing outer race O two or three times to seat the rollers, and then measure the bearing height (M)
as shown.
s62Y6425
NOTE: "F" is the deviation of the lower case dimension from standard. The "F" mark @ is stamped on the trim tab mounting surface of the lower case in 0.01 mm units. lf the "F" mark is unreadable, assume that "F" is zero and check the backlash when the unit is assembled.
Fonruard gear shim thickness (T1) =
22.75+F/100-M
6-37
62Y141
1
Shimming (F504) (for worldwide)

Example: lf "M" is "22.45 mm" and "F' is "+5", then T1 = 22.75 + (+5)/100 -22.45mm = 0.30 + 0.05 mm = 0.35 mm lf "M" is "22.45 mm" and "F" is "-5", then NOTE:
Measure the backlash with the original shim(s). lf the original shim(s) is unavailable, start with a 0.50 mm shim.
T1 =22.75 + (-5)/1O0-22.45mm
= 0.30
0.05 fir = 0.25 mm
3.
Select the forward gear shim(s) (T1) as follows.

Rounded numeral
0 2 5
B
1,2
3,4,5 6,7,8
9, 10
lf
.Tf
is "0.45 mm", then fonruard gear shim
is 0.42 mm,
lf "T1" is "0.50 mm", then fonruard gear shim

is 0.48 mm.
Selecting the reverse gear shims 1. Measure the backlash to find the shim thickness (T2). Add or remove shims if
out of specification. For measuring procedures, see "Measuring the fonryard and reverse backlash" in this chapter.
62Y141
6-38
Backlash (F50/F504)
1. Remove the water pump assembly. 2. Set the gearshift to the neutral position.
E
Measuring the forward and reverse gear backlash
NOTE:
Tighten the universal puller or center bolt while turning the drive shaft until the drive
shaft can no longer be turned.
Bearing housing puller @: YB-06234 Universal puller @: YB-06117 Bearing housing puller claw @: 90890-06s64 Stopper guide plate @: 90890-06501 Center bolt @; 90890-06504
4.
E E
lnstall the backlash indicator onto the drive shaft (18 mm [0.71 in] in diameter), then the dial gauge onto the lower unit.
Shift rod push arm: YB-06052 Shift rod push arm: 90890-06052
3.
t-l
lnstall the special service tool so that it pushes against the propeller shaft.
lnstall the dial gauge so that the plunger @ contacts the mark (D on the backlash indicator.
E E
Backlash indicator gauge @: YB-06265 Backlash indicator @: 90890-06706 Magnetic plate @: YB-07003 Magnet base plate @: 90890-07003 Dial gauge @:YU-03097 Dial gauge set @: 90890-01252 Magnet flexible stand @: YU-34481 Magnet base @: 90890-06705
6-39
62Y141
Backlash (F50/F504)
5.
Slowly turn the drive shaft clockwise and counterclockwise and measure the backlash when the drive shaft stops in each direction.
9.
Slowly turn the drive shaft clockwise and counterclockwise and measuring the backlash when the drive shaft stops in each direction.
Forward gear backlash: 0.18-0.54 mm (0.007-0.021 in)
6.
Add or remove shims if out of specification.

Forward gear backlash Shim thickness To be decreased by
Less than 0.18 mm (0.007 in) More than 0.54 mm (0.021 in)
(0.36-M)x0.56
To be increased by
(M-0.36)x0.56
M: Measurement Available shim thicknesses: 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, and 0.50 mm
7.
8.
Remove the special service tools from the propeller shaft.
Apply a load to the reverse gear by installing the propeller @ without the spacer @, the washer @ backwards,
then the washer @ as shown.
Reverse gear backlash: 0.71-1.07 mm (0.028-0.042 in)
10. Add or remove shims if out of specification.

Reverse gear backlash Less than 0.71 mm (0.028 in) More than
1.07 mm (0.042 in)
s62Y6470
Shim thickness To be decreased by
(0.89-M)x0.56
To be increased by
(M-0.89)x0.56
Tighten the propeller nut @ while turning the drive shaft until the drive shaft can no longer be turned.
11. Remove the special service tools, and then install the water pump assembly.
62Y141
6-40
Lower unit (T50/FT50B, FT50C)
I
6-41
.@4
1B
62Y141

No.
1
Pat name Lower unit Plastic tie

Hose
Q'ty
1 1 1 1
Remarks

N.m
kgtm
t.lb
3 4
5
Check screw Gasket
0.7
5.1
2 2 4
1 1 1 1 1 1 1 1 1 1 1
6 7
Dowelpin
Bolt Drain screw Grommet Bolt Bolt Thrust washer Propeller Washer Washer Cotter pin Propeller nut Trim tab
M10 x 40 mm
40 7
4.O
29
5.1
I I
10
11
0.7
M10 x 45 mm,
O:
12 mm
M8x60mm
12 13 14 15 16 17
1B
35
3.5
25
62Y141
6-42
Removing the lower unit 1, Drain the gear oil, For draining procedures, see Chapter 3, "Replacing the
gear oil."
2.
Sel the gearshift to the neutral position, and place a block of wood between the
anti-cavitation plate and propeller to keep the propeller from turning, and then remove the propeller nut and propeller.
Disconnect the speedometer hose O. Mark the trim tab @ at the area shown, and then remove it.
5.
Loosen the bolts, and then remove lhe lower unit from the upper case.
3. 4.
6-43
62Y141
MEMO
62Y141
6-44
Water pump and shift rod (T50/FT50B, FT50C)
10-
14
{ {:--- 6 i 9 @--"
--l
@l
H*'
=-'
l,/ - .4v-13
|
#15
@-,0 l\
W-==ro
@=,
@-''
IP
,i
tw
6-45
62Y141
1

No.
1
Pat name Shift rod assembly
Q'ty
1 1 1 1 1 1 1
Remarks

N.m
kgtm
t.lb
3 4
5
Oilseal Oilseal housing

O-ring Circlip Shift rod O-ring Bolt Woodruff key Bolt Bolt Water pump housing Grommet Gasket
6 7
I I
10
11
2
1
2 2
1 1 1 1 1 1 1
12 13 14 15 16 17
1B
lnseft plate cartridge

lmpeller Outer plate cartridge Gasket
19
Dowelpin
Oil seal housing assembly Gasket
2
1 1 1 1
20
21
22 23 24
Oilseal housing
O-ring
Oilseal
62Y141
6-46
Removing the water pump and shift rod
2.
1.
Remove the water pump assembly and

shift rod assembly @.
Check the impeller @ and insert plate cartridge @ for cracks or wear. Replace if necessary.
s62Y6540
3.
Check the Woodruff key @ and the groove @ on the drive shaft for wear. Replace if necessary.
v
s62Y6530
Pull up the shift rod assembly a little @ to Osconnect it from the shift slider @, turn it counterclockwise 90'@, and then remove it.
4.
Check the shift rod for cracks or wear. Replace if necessary.
Checking the water pump and shift rod 1. Check the pump housing for deformation. Replace if necessary.
@(P
6-47
62Y141
1
-/
/-\

lnstalling the water pump and shift rod
tr
1.
lnstall the shift rod assembly @.
E E
?
J
I
H
i-rj
Bearing housing oil seal installer @: YB-06269 Driver handle @: YB-06071 Needle bearing attachment @: 90890-06610 Driver rod L3 @: 90890-06652
3.
lnstallthe new O-ring @.

lnstallthe new gasket @, oilseal housing @, new gasket @, and outer plate cartridge @.
4.
s62Y6555
NOTE:
lnstall the shift rod assembly into the lower case, turn it clockwise 90'@, and then push it down (D to connect it to the shift slider @. lnstall the new oil seals into the oil seal
housing as shown.
lnstall the Woodruff key into the drive

shaft.
62Y141
6-48
6.
Apply grease to the impeller, and then install it to the drive shaft.
lnstall the new gasket @, pump housing assembly @, and dowel pins @ to the lower case,
9.
lnstall and tighten the bolts @.
NOTE: Align the groove on the impeller @ with the Woodruff key @.
7.
lnstall the inse plate cartridge @ and grommet @ into the pump housing @.
Align the insert plate cartridge projection @

with the hole (D in the pump housing.
When installing the pump housing, turn the drive shaft clockwise while pushing down the pump housing.
6-49
62Y141
MEMO
62Y141
6-50
Propeller shaft housing (T50/FT50B, FT50C)
6-51
62Y141

No.
1
Pat name Propeller shaft assembly Propeller shaft housing assembly

Ball
Q'ty
1 1
Remarks

N.m
kgtm
t.lb
3 4
5
2
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Slider Shift plunger Cross pin

Dog clutch
6 7
B
Spring Propeller shaft Washer Straight key Claw washer Ring nut Reverse gear Thrust washer
I
10
11
12 13 14 15 16 17 18 19
105
10.5
76
Ballbearing
O-ring Propeller shaft housing Needle bearing
[@!r
nl
20
Oilseal
62Y141
6-52
Removing the propeller shaft housing assembly
1.
Straighten the claw washer tabs @, and claw washer.
then remove the ring nut and
Bearing housing puller @: YB-06207 Universal puller @: YB-06117 Bearing housing puller daw L @: 90890-06502 Stopper guide plate @: 90890-06501 Center bolt @: 90890-06504
Disassembling the propeller shaft housing 1. Remove the reverse gear and thrust
washer.
E
Gland nut wrench Q:YB-34447 Ring nut wrench 3 O: 90890-06511 Ring nut wrench extension @: 90890-06513
2.
Pull out the propeller shaft

assembly.
housing
E E
E E
for USA and Canada

For worldwide
Slide hammer and adapters O: YB-06096 Bearing separator @: 90890-06534 Stopper guide plate @: 90890-06501 Stopper guide stand @: 90890-06538 Bearing puller @: 90890-06535 Bearing puller claw 1 @: 90890-06536
6-53
62Y141

NOTE: lnstall the bearing separator @ between the reverse gear and thrust washer completely, then the other special service tools.
2.
E
Remove the ball bearing.
YB-06153 Needle bearing attachment @: 90890-06612 Driver handle @: YB-06071 Driver rod L3 @: 90890-06652
Disassembling the propeller shaft assembly
1.
Remove the spring @, and then remove the cross pin @, dog clutch @, slider and shift plunger.
tr
Checking the propeller shaft housing
1.
s62Y625
E E
For USA and Canada
forworldwide and adapters @: YB-06096 plate @: 90890-06501 stand @: 90890-06538 @: 90890-06535 claw 1 @: 90890-06536
Clean the propeller shaft housing using a soft brush and cleaning solvent, and then check it for cracks. Replace if necessary.
Slide hammer Stopper guide Stopper guide Bearing puller Bearing puller
3.
Remove the oil seals and needle bearing.
62Y141
6-54
2.
Check the teeth and dogs of the reverse gear for cracks or wear. Replace the gear if necessary.
S62Y66lO
Assembling the propeller shaft assembly
Check the bearings for pitting or rumbling. Replace if necessary.
1.
lnstall the dog clutch as shown.
S62Y6615
Checking the propeller shaft 1. Check the propeller shaft for bends or
NOTE: lnstall the dog clutch @ with the "F'mark @ facing toward the shift slider.
Assembling the propeller shaft housing
1.
lnstall the needle bearing into the propeller shaft housing to the specified depth.
2.
Check the dog clutch and shift slider for cracks or wear. Replace if necessary.
6-55
62Y141
tr
tr
E E
For USA and Canada
Forworldwide
E E
. lnstallthe
.
needle bearing with the manufacture identification mark @ facing toward the oil seal (propeller side), When using the driver rod, do not strike the special tool in a manner that will force the stopper @ out of place.
lnstall an oil seal halfway into the propeller shaft housing, then the other oil seal.
Bearing housing oil seal installer @: YB-06269 Driver handle @: YB-06071 Ball bearing attachment @: 90890-06655 Driver rod LS @: 90890-06606 Depth @:4.5-5.5 mm (0.18-0.22in)
Driver handle @: YB-06071

YB-061s3 Driver rod SS @: 90890-06604 Needle bearing attachment @: 90890-06612 Bearing depth plate @: 90890-06603 Depth @: 25.G-25.5 mm (0.98-1.00 in)
3.
E
lnstallthe thrust washer @ and ball bearO to the reverse gear @ using a press.
ing
2.
Apply grease to the new oil seals, and then install them into the propeller shaft
housing to the specified depth.
EI
E E
62Y141
1
6-56
NOTE:
lnstall the ball bearing with the manufacture identification mark @ facing outward (propeller side).
Drive shaft needle bearing depth stop @:
Y8-34473
Bearing inner race attachment @: 90890-06639
4.
lnstall the reverse gear assembly to the propeller shaft housing using a press.
3.
ff\
@, and ring nut @.
4.
s62Y6705
lnstallthe propeller shaft housing assem-
bly @ into the lower case, and then install the straight key @, claw washer
Tighten the nut to the specified torque.
Forward gear bearing cup installer @: YB-06109 Bearing inner race attachment @:
90890-06661
lnstalling the propeller shaft housing 1, lnstall the washer @, propeller shaft assembly @, into the propeller shaft
housing assembly @.
s62Y67 5
1
2.
Apply grease to the new O-rings.
NOTE: Secure the ring nut by bending one lab @ into the slot in the ring nut and the other tabs toward the propeller shaft housing assembly.
6-57
62Y141

Gland nut wrench @:YB-34447 Ring nut wrench 3 @: 90890-06511 Ring nut wrench extension @: 90890-06513 Ring nut @: 105 N.m (10.5 kgf.m, 76 ft.lb)
62Y141
6-58
Drive shaft and lower case (T50/FT50B, FT50C)
j
2
rc
l(' ./i r*l I," -/, z)i 6 ,l

872 .//l
t-$
$'
I I
4*-@
I'
s62Y6720
6-59
62Y141

No.
1
Pat name Drive shaft
Q'ty
1 1 1
Remarks

N.m
kgtm
t.lb

Bearing outer race Pinion shim Sleeve
Hose
3 4
5
As required
1 1 1 1 1
6 7
Plastic tie Joint

Nut
I I
10
11
Water inlet cover

Screw
Seal
2
1 1 1
0.5
3.6
12 13 14 15 16 17
1B
Plate Forward gear shim Bearing outer race
As required
1 1 1 1 1 1 1 1

Needle bearing Forward gear Needle bearing
Pinion
19
20
21
Nut Lower case
O:22
mm
95
9.5
69
22
62Y141
6-60
Removing the drive shaft 1, Remove the drive shaft assembly and pinion, and then pull out the forward
gear.
o Do
not press the drive shaft threaOs @ directly. Do not reuse the bearingn always replace it with a new one.
Bearing splitter plate @: YB-06219 Bearing inner race attachment @: 90890-06639
Disassembling the forward gear
1.
Remove the taper roller bearing from the forward gear using a press.
Drive shaft holder O: YB-06049 Drive shaft holder 4 @: 90890-06518 Pinion nut holder @: 90890-06505 Socket adapter 2 @: 90890-06507
Disassembling the drive shaft
1.
lnstall the pinion nut @, tighten it finger tight, and then remove the drive shaft bearing@usingapress.
E
Do not reuse the bearingn always replace it with a new one.
Bearing splitter plate @: YB-06219 Bearing separator @: 90890-06534
2.
E
Remove the needle bearing from the forward gear.
\
E E
For USA and Canada for worldwide
e
62Y141
1
6-61
tr
NOTE:
lnstallthe claws as shown.

Slide hammer and adapters @: YB-06096 Bearing outer race puller @: 90890-06523 Outer race puller claw A @: 90890-06532
2.
E E
For USA and Canada
Remove the drive shaft bearing outer

race, shim(s), and drive shaft sleeve.
Forworldwide
Do not reuse the bearing, always replace it with a new one.

Slide hammer Stopper guide Stopper guide Bearing puller Bearing puller and adapters @: YB-06096 plate @: 90890-06501 stand @: 90890-06538 @: 90890-06535 claw 1 @: 90890-06536
Disassembling the lower case
1.
Remove the taper roller bearing outer race and shim(s).
E E
NOTE:
lnstallthe claws as shown.

Slide hammer Stopper guide Stopper guide Bearing puller Bearing puller and adapters @: YB-06096 plate @: 90890-06501 stand @: 90890-06538 @: 90890'06535 claw 1 @: 90890-06536
E E
For USA and Canada
Forworldwide
62Y141
6-62
3.
Remove the needle bearing.
Checking the drive shaft
1,
Check the drive shaft for bends or wear. Replace if necessary.
YB-06153 Needle bearing attachment @:

90890-0661
1
Checking the lower case

1
Driver handle @: YB-06071 Driver rod L3 @: 90890-06652
Check the skeg and torpedo for cracks or damage. Replace if necessary.
Checking the pinion and forward gear 1. Check the teeth of the pinion, and the teeth and dogs of the forward gear for
cracks or wear. Replace if necessary.
s62Y6791
Assembling the Iower case
1.
lnstall the needle bearing into the lower

case to the specified depth.
Checking the bearings 1. Check the bearings for pitting or

bling. Replace if necessary.
rum-
6-63
62Y141
E E
For USA and Canada
Forworldwide
. lnstallthe
.
needle bearing with the manufacture identification mark @ facing upward. When using the driver rod, do not strike the special tool in a manner that will force the stopper (D out of place.
E E
Add or remove shimso if necessary, when replacing the pinion or lower case.
NOTE: Apply the gear oil to the inside and outside of the sleeve. . lnstallthe sleeve by facing the projection @ forward.
Driver handle O: YB-06071 Drive shaft needle bearing remover and installer ;YB-06155 Drive shaft needle bearing depth stop @:
Y8-34473
Driver rod SL @: 90890-06602 Needle bearing attachment @:
90890-0661
1
Bearing depth plate @: 90890-06603 Depth @: 136.4-188.6 mm (7.34-7.43in)
Crank upper and lower seal installer @:
Y8'06244
Bearing outer race attachment @: 90890-06626 Driver handle @: YB-06071 Driver rod LL @: 90890-06605
2.
lnstall the sleeve, original shim(s), and

drive shaft bearing outer race.
62Y141
6-64
3.
lnstallthe originalshim(s) and taper roller

bearing outer race.
A
(
s62Y681 5
E E
Fonruard gear needle bearing and tapered
A
)@"9*.
E E
roller bearing installer O: YB-06200 Bearing inner race attachment @: 90890-06662
2.
lnstall the new needle bearing into the

forward gear to the specified depth.
Add or remove shimsn if necessaryo when replacing the forward gear or |ower case.
Forward gear bearing cup installer @: YB-06276-B Driver handle @: YB-06071 Bearing outer race attachment @:
90890-06621
Driver rod LL @: 90890-06605
YB-06112 Needle bearing attachment @: 90890-06614 Driver handle @: YB-06071 Driver rod L3 @: 90890-06652 Depth @: 1.1 mm (0.04 in)
Assembling the forward gear
1.
lnstall the new taper roller bearing into

the fonruard gear using a press.
6-65
62Y141

Assembling the drive shaft
1.
lnstall the new drive shaft bearing into

the drive shaft using a press.
Drive shaft holder @: YB-06049 Drive shaft holder 4 @: 490890-06518 Pinion nut holder @: 90890-06505 Socket adapter 2 @: 90890-06507 Pinion nut: 95 N.m (9.5 kgf.m, 68 ft.lb)
lnstalling the Iower unit
1.
Set the gearshift to the neutral position at power unit and lower unit.
tr
{}
#t]
U
t6
SA
E E
For USA and Canada
Forworldwide
NOTE: Use the special seruice tool or a general pipe with the specified measurements.
General pipe @: D = 38 mm (1.49 in), d=32 mm (1.26 in) Bearing inner race attachment @: 90890-06643
lnstalling the drive shaft
1.
lnstall the forward gear, then the drive shaft assembly, pinion, and pinion nut, and then tighten the nut to the specified
torque.
62Y141
6-66
lnstall the two dowel pins

unit.
3,
Q to the lower
lnstall the lower unit to the upper case, and then tighten the bolts to the specified torque.
9
@
Y-Gl
572
--t
J
r
5.
lnstall the propeller and propeller nut,

tighten the nut finger tight. Place a block of wood between the anti-cavitation plate and propeller to keep the propeller from turning, and then tighten the nut to the specified torque.
Mounting bolt: 40 N.m (4.0 kgf.m, 29 ft.lb)
4.
lnstall the trim tab @ to its original position, and then connect the speedometer hose @.
s62Y651 5
6-67
62Y141
lf the grooves in the propeller nut @ do not align with the cotter pin hole, tighten the nut untilthey are aligned.
Propeller nut @: 35 N.m (3.5 kgf.m, 25 ft.lb)
62Y141
6-68
Shimming (T50) (for USA and Ganada)
I I I I I I I I I I
6-69
62Y141
Shimming (T50) (for USA and Canada)

Shimming
NOTE: Shimming is not required when assembling the original lower case and inner parts. . Shimming is required when assembling the original inner parts and a new lower case. . Shimming is required when replacing the inner pafi(s).
Selecting the pinion shims 1. Calculate the specified value (M0)

as
NOTE: NOTE: "P" is the deviation of the lower case dimenis stamped on the trim tab mounting surface of the lower case in 0,01 mm units. lf the "P"
lnstall the shim selecting tools to the drive shaft so that the shaft is at the center of the
hole.
mark unreadable, assume that "P" is zero and check the backlash when the unit is
assembled.
Pinion shim selecting tools: YB-34432-9 @), YB-34432-104 @), YB-34432-114 G), YB-34432-17 Q)
4.
Specified value (M0) = Q.2O + P/100 mm Example: lf "P" is "+5", then M0 = 0.20 + (+5)/100 mm = 0.20 + 0.05 mm = 0.25 mm lf "P" is'L5", then M0 = 0,20 + (-5)/100 mm = o.20- 0,05 mm = 0.15 mm
Pinion nut: 95 N.m (9.5 kgf.m, 69 t.lb)
2.
3.
lnstall the drive shatt and drive shaft bearing @ to the shim selecting tools.
Attach the clamp @ to the gauge base using four bolts of appropriate sizes.
62Y141
6-70
5.
Measure the clearance (M) between the
shim selecting tool and the pinion as

shown,
Selecting the forward gear shims 1, Calculate the specified value (M0)
as
s62Y6875
s62Y6885
NOTE: Measure the pinion at three points to find the clearance average.
6.
Select the pinion shims (T3).
NOTE: "F" is the deviation of the lower case dimension from standard. The "F' mark @ is stamped on the trim tab mounting surface of the lower case in 0.01 mm units. lf the "F" mark is unreadable, assume that "F" is zero and check the backlash when the unit is assembled.
Specified value (M0) = 1 .70 + F/100 mm Example: lf "F" is "+5", then M0 = 1 .70 + (+5)/100 mm = 1.70 + 0.05 mm
= 1.75 mm
NOTE: lf "F" is "-5", ther

than M0.
M0 = 1 .70 + (-5)/100 mm = = 1.65 mm
1.7O
- 0.05 mm
Pinion shim thickness (T3) = M0
6-71
62Y141
Shimming (T50) (for USA and Canada)
2.
lnstall the taper roller bearing @ to the

shim selecting tools.
4.
Select the fonruard gear shims (T1).
|,@
*$-N
@
T1
o,l
M>
NOTE:

than M0.
Forward gear shim thickness (T1) =
MO_M
Available shim thicknesses: 0,10, 0,12, 0.15, 0,18, 0.30, 0,40, and 0.50 mm
Tighten the nut four turns after it contacts the spring.
Forward gear shim selecting tools: Y 8-34446^1 , YB-34446-3 G), Y B-34446-5 @, YB-34446-7 )
3.
Measure the clearance (M) between the gauge pin and the press plate.
62Y141
6-72
Shimming (FT50B, FT50C) (for worldwide)
I I I I I I I I I I
6-73
62Y141

Shimming
NOTE: Shimming is not required when assembling the original lower case and inner parts. . Shimming is required when assembling the original inner parts and a new lower case. . Shimming is required when replacing the inner pafi(s).
3.
Measure the distance (M) between the shimming tool and the pinion as shown.
ffi#
#
4.
Selecting the pinion shims 1. lnstall the drive shaft and drive
bearing @ to the shimming tools.
ffi's62y6e5
shaft
Measure the pinion at three points to find the clearance average.
Digital caliper @: 90890-06704 Calculate the pinion shim thickness (T3) as shown in the examples below.
NOTE: "P" is the deviation of the lower case dimenNOTE: Select the shim thickness (T3) by using the specified measurement(s) and the calculation formula. . lnstall the shimming tool to the drive shaft so that the shaft is at the center of the hole. . Tighten the wing nuts another 1/4 of a turn after they contact the fixing plate @.
is
stamped on the trim tab mounting surface of
the lower case in 0.01 mm units. lf the "P" mark is unreadable, assume that "P" is zero and check the backlash when the unit is
assembled.
Pinion shim thickness (T3) = M - 31.50 mm - P/100
Pinion height gauge @: 90890-06702
2.
Pinion nut: 95 N.m (9.5 kgf.m, 69 ft.lb)

62Y141
6-74
Example: lf "M" is "32.10 mm" and "P" is "+5", then T3 = 32,10 - 31.50 - (+5)i100 mm = 0.60 - 0.05 fiffr = 0.55 mm lf "M" is "32j0 mm" and "P" is "-5", then T3 = 32.10 - 31 .50 - (-s)/100 mm = 0.60 + 0.05 mm = 0.65 mm
5.
Select the pinion shim(s) (Tg) as follows. Rounded numeral

2
5
s62Y6930
0,
2,3, 4
5,6,7 8,9
I
10
NOTE: Select the shim thickness (T1) by using the specified measurement(s) and the calculation formula, . Measure the bearing outer race at three points to find height average.

0.60 mm.
Shimming plate @: 90890-06701 Digital caliper @: 90890-06704

0.65 mm.
2.
Calculate the forward gear shim thickness (T1) as shown in the examples below.
Selecting the forward gear shims
1.
Turn the taper roller bearing outer race O two or three times to seat the rollers, and then measure the bearing height (M)
as shown.
s62Y6935
NOTE: "F" is the deviation of the lower case dimension from standard. The "F" mark @ is stamped on the trim tab mounting surface of the lower case in 0.01 mm units. lf the "F" mark unreadable, assume that "F" is zero and check the backlash when the unit is assembled.
Fonruard gear shim thickness (T1) =
24.50+F/100-M
6-75
62Y141
1

Example: lf "M" is "24.00 mm" and "F' is "+5", then T1 = 24.50 + (+5)/100 - 24.00 mm = 0.50 + 0.05 mm = 0.55 mm lf "M" is "24.00 mm" and "F" is "-5", then T1 = 24.50 + (-5)/100 - 24.00 mm = 0.50 - 0.05 fir = 0.45 mm
3.
Select the forward gear shim(s) (T1) as follows.

Rounded numeral
0 2 5
B
1,2
3,4,5 6,7,8
9, 10
lf "T1" is "0.45 mm", then the

shim is 0.42 mm.
fonruard gear
lf
"Tf
is "0.50 mm", then the fonruard gear
shim is 0.48 mm.
62Y141
6-76
Backlash (T50/FT50B, FT50C)
1. Remove the water pump assembly. 2. Set the gearshift to the neutral position.
Measuring the forward and reverse gear backlash
NOTE:
Tighten the universal puller or center bolt while turning the drive shaft until the drive
shaft can no longer be turned.
Bearing housing puller @: YB-06207 Universal puller @: YB-06117 Bearing housing puller daw L @: 90890-06s02 Stopper guide plate @: 90890-06501 Center bolt @; 90890-06504
4.
E E
lnstall the backlash indicator onto the drive shaft (18 mm [0.71 in] in diameter), then the dial gauge onto the lower unit.
Shift rod push arm: YB-06052 Shift rod push arm: 90890-06052
3.
E
lnstall the special service tool so that it pushes against the propeller shaft.
NOTE:
lnstall the dial gauge so that the plunger @ contacts the mark (D on the backlash indicator.
E E
6-77
62Y141
Backlash (T50/FT50B, FT50C)

Backlash indicator gauge @: YB-06265 Backlash indicator @: 90890-06706 Magnetic plate @: YB-07003 Magnet base plate @: 90890-07003 NOTE: Tighten the propeller nut @ while turning the drive shaft until the drive shatt can no longer be turned.
Dialgauge @:YU-03097 Dialgauge set @: 90890-01252 Magnet flexible stand @: YU-34481 Magnel base @: 90890'06705
9.
5.
Forward gear backlash: 0.12-0.45 mm (0.005-0.018 in)
6.
Add or remove shims if out of specification.

Forward gear backlash Shim thickness To be decreased by
Less than 0.12 mm (0.005 in) More than 0.45 mm (0.018 in)
(0.29-M)x0.57
To be increased by
(M-0.29)x0.57
7.
Remove the special seruice tools from the propeller shaft.

Apply a load to the reverse gear by installing the propeller @ without the spacer @, and washer @ and washer @ as shown.
Reverse gear backlash: 0.71-1.11 mm (0.028-0.044 in)
10. Check the pinion shim if out of specification, 11. Remove the special service tools, and then install the water pump assembly.
s62Y6965
62Y141
6-78
Bracket unit
Troubleshooting
Special service tools .7-1
Tiller handle (F50/F504, T50T508)
Checking the throttle cable and shift Assembling the tiller
cable.. handle........ rod handle..,..,,. operation
.7-5 ......7-15 ....7-15

..........7-17 ...........7-23 ....7-23
Tifler handle
(FT50G).
Checking the throttle cable and shift Assembling the tiller Lubricating the throttle gear
Bottom cowling
Checking the shift rod assembly
........7-29
7-31 .......7-39 ..,...,..,.7-39 .....7-39 ......7-41
Upper Disassembling the oil pan........ Checking the oil strainer and the relief valve Assembling the oil pan ....... lnstalling the upper case........... Clamp brackets Removing the clamp brackets lnstalling the clamp brackets Adjusting the trim sensor.......
7-43 ........7-45 ..........7-45 .........7-46
Swivel bracket and steering arm

lnstalling the steering arm
.........7-49
Power trim and tilt unit Removing the power trim and tilVhydro tilt
..............
.............7-53
Tilt cylinder and trim cylinder Trim cylinder

7-57
62Y141
Gear pump Disassembling the tilt cylinder Disassembling the trim cy1inder................. Disassembling the gear pump Checking the tilt cylinder and trim cylinder Check the valves Checking the filters Checking the gear pump ......... Assembling the gear pump......... Assembling the trim cylinder...... Assembling the tilt cylinder...... Bleeding the power trim and tilt (not installed).... Bleeding the power trim and tilt (built-in) Power trim and tilt motor... Checking the power trim and tilt motor.... Assembling the power trim and tilt motor lnstalling the power trim and ti1t.............. Power trim and tilt electrical system.. Checking the fuse..... Checking the power trim and tilt relay Checking the power trim and tilt switch/trailer Checking the trim sensor,..,,..
........7-63 ........7-63
........7-64 ........7-64 .........7-65 ......7-65 .......7-66 ....7-66 .....7-67 .......7-69 ..................7-7O ...........7-71 ...................7-73 ..........7-75 ..........7-76 ...........7-76 7-74
switch
...7-79 ...............7-79 ...........7-80 ,,..,..,.7-80
62Y141
Troubleshooting
Before troubleshooting the power trim and tilt unit, check that all electrical connections are tight and free from corrosion, and that the battery is fully charged to 12 V.
Symptom: Power trim and tilt unit does not operate.

Listen for the operation sound
of the power trim and tilt relay.
. .
Check the voltage between each terminal. Between the sky blue (Sb) lead and black (B) lead. Between the light green (Lg) lead and black (B) lead.
Gheck for continuity between the battery,
relay, and switch. Listen for the operation sound of the power trim and tilt motor. Replace the power trim and tilt
relay.
Check the voltage between the sky blue (Sb) lead and black (B)
lead.
Replace the power trim and tilt relay.
Check that the manual release plug is closed.
Check the power trim and tilt

motor.
Close the plug.
Check the power trim and tilt fluid level,
Add fluid to the correct level.
Disassemble the power trim and tilt unit, and then check it.
7-1
62Y141
Troubleshooting
Symptom: Power trim and tilt unit does not hold the outboard motor up.
Check that the manual release plug is closed.
Close the plug.
Check the power trim and tilt fluid level.
Add fluid to the correct level.
Disassemble the power trim and tilt unit, and then check it.
62Y141
7-2
Symptom: Shift mechanism of the forward gear and reverse gear does not operate properly.
Check the shift cable operation,
Check the shift cables and links

of the remote control box.
Check the operation of the shift

rod.
Gheck the detent of the bottom cowling.
Check the condition of the shift rod connection between the lower case and upper case.
Replace the shift rod.
Disassemble the lower case, and then check the shifting gear mechanism and the respective
parts.
7-3
62Y141
Troubleshooting / Special service tools

Trim and tilt cylinder wrench YB-06175-28
Cylinder-end screw wrench

90890-06544
62Y141
7-4
-l,,""n",un*
lffiTf
Tiller handle (F50/F50A, T50/FT50B)
20
la
=)
/rt
21
ll
7-5
Tiller handle (F50/F504, T50/FT50B)

No.
1
Pat name
Q'ty
1 1 1
Remarks

N.m
kgtm
t.lb
Tiller handle assembly Friction plate Tiller handle wiring harness Tiller handle wiring harness
Grommet Clip Throttle cable Plate Bolt Bolt Negative battery lead Cable guide Grommet
Nut
3 4
Models applicable for tachometer, trim meter or warning buzzer
1 1 1 1
6 7
I I
10
11
3
1 1 1 1 1 1 1 1 1 1
M6x20mm M8x16mm
0.9
6.5
12 13 14 15 16 17 18 19
0.7
5.1
Washer Positive battery lead Connector Clip Shift cable Plastic tie Cover Screw Trailer switch coupler PTT switch coupler Bolt Screw Collar Clamp
Nut
20
21
2
1
22 23 24 25 26 27 28 29 30
3
1 1 1 1 1 1
M6x35mm
Models with trailer switch
M6x35mm M6x25mm
2 2
37
3.7
27
Bolt
M6x16mm
62Y141
7-6
lffiTf
lr,""n",un*
20
la
=)
I
q/
22
V-^ {--t
21
7-7

No.
31
Pat name
Nut
Q'ty 2
2
Remarks

N.m
kgtm
t.lb
32
Collar Bolt Self-locking nut Bracket Steering lock shaft Steering lock knob Friction plate Friction piece
33 34
35
2
1 1 1 1 1
M8x50mm
36 37 38
39
62Y141
7-8
lffiTf
lr,""n",un*
7a i
1.
/'l -D4\ I ),
I
,r/,^/
l:
\\'r
\ [ \\ \ \-!-/
I
'.21" '1.
i
7-9
62Y141

No.
1
Pat name Tiller handle sub assembly Screw Shift lever cover Bolt Shift lever Bushing Washer Bushing
Nut
Q'ty
1
Remarks

N.m
kgtm
t.lb
2
1 1 1 1 1
M6x10mm M8x40mm
3 4
5
6 7
I I
10
11
2
1 1 1 1 1 1 1 1 1 1 1
4 38
0.4 3.8
2.9 27
Engine shut-otf switch Nut Washer Bracket Collar Wave washer Washer Bolt Clamp Screw Connector Engine start switch housing Engine start switch
Nut
12 13 14 15 16 17
1B
19
20
21
2
1
22 23 24 25 26 27 28 29 30
1 1 1 1 1 1 1
0.5
3.7
Bolt Screw Bolt Cover Power trim and tilt switch Screw Screw
M6x25mm M6x20mm
M6x16mm M6x16mm
62Y141
7-10
lffiTf
lr,""n",un*
7a i
1.
/'l -D4\ I ),
I
,r/,^/
l:
\\'r
\ [ \\ \ \-!-/
I
'.21" '1.
i
7-11
62Y141

No.
31
Pat name Screw Throttle grip Screw Washer Spring Bushing
Q'ty 2
1 1 1 1 1
Remarks

N.m
kgtm
t.lb
M6x40mm M5x25mm
32
33 34
35
36
62Y141
7-12
\
)
) -/
I $.
/
-/
21V
Li+f'i,#l
s62Y7030
7-13
62Y141

No.
1
Pat name
Q'ty
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Remarks

N.m
kgtm
t.lb
Tiller handle
Cotter pin Friction adjusting knob Grommet Plastic tie Cable clamp Stay Bolt Throttle cable Clip Throttle arm Throttle arm shaft Shift cable Shift cable bracket Bolt Clip Frame Screw Bolt Spring housing Spring Actuator Roller Bushing Shift arm Bolt Throttle shaft Friction piece
Nut
3 4
5
6 7
I I
10
11
M6x14mm
Short
12 13 14 15 16 17
1B
Long
M6x14mm
2
1 1 1 1 1 1 1
19
M5x14mm M6x14mm
20
21
22 23 24 25 26 27 28 29
2
1 1 1
M6x30mm
62Y141
7-14
Checking the throttle cable and shift cable
1.
Check the operation of the throttle cable and shift cable.
2.
Check the inner wire and outer wire of both cables for bends or damage, and the rubber seals for damage. Replace if necessary.
s62Y7040
Assembling the tiller handle 1. lnstall the throttle shaft @ and
throttle arm @ into the frame @. Align the mark @ of the fully closed position of the throttle shaft to the shaft holder. Align the mark @ of the fully closed position of the throttle arm to the indent of the frame.
Make sure that the throttle grip is fully closed when installing the throttle cable.
7-15
62Y141
MEMO
62Y141
7-16
Tiller handle (FT50C)
t4-_.fu$-rt
to-q$u
7-17
62Y141

No.
1
Pat name Bolt

Nut
Q'ty
1 1 1 1 1 1 1 1
Remarks

N.m
kgtm
t.lb
MBxS0mm
13 1.3
3 4
5
Wing nut Friction piece Bolt Friction rod Washer

Nut
9.4
M6x35mm
6 7
I I
10
11
Washer Link rod

Nut
2
1 1 1
12 13 14 15 16 17
1B
Plate Bolt Grommet Cable guide Grommet Plastic tie Battery lead
3
1 1 1
M6x20mm
2
1
62Y141
7-18
B-__
'\-a'
.'/
g
3
7-19
62Y141

No.
1
Pat name
Q'ty
1 1
Remarks

N.m
kgtm
t.lb
Tiller handle Tiller handle wiring harness

Clip Shift rod
Nut
3 4
5
1 1
2
1 1 1 1 1
37 M12 x 70 mm 37
3.7
27
6 7
B
Bushing Bolt Clip Throttle cable

Nut
I
10
11
3.7
27
Plastic washer
2 2
1 1 1 1 1 1 1 1 1 1
12 13 14 15 16 17 18 19
Metalwasher
Wave washer
Pin
Gear Throttle shaft Bolt Friction piece Wing nut Bolt Gasket Cover Bolt Bolt Grease nipple Case Bushing Spring Washer Throttle grip Screw
M6x25mm
20
21
M6x25mm
22 23 24 25 26 27 28 29 30
31
4
1 1 1 1 1 1 1 1
M5x14mm M6xBmm
M5x25mm
62Y141
7-20
g.--,
@--7
'-'5
-l(9
q
19
20
7-21
62Y141

No.
1
Pat name Bracket Bolt Bolt Shift arm guide

Nut
Q'ty
1
Remarks

N.m
kgtm
t.lb
2 2
1 1 1 1 1 1 1 1 1 1 1
3 4
5
M6x16mm M6x16mm
6 7
Washer Washer Bushing
I I
10
11
Tiller handle bracket

Nut
Bushing Engine stop switch Bolt Engine start switch housing Screw Connector Connector Engine start switch Screw Screw Collar
Ball
12 13 14 15 16 17 18 19
M6x20mm
1 1 1 1 1 1 1 1 1 1 1 1 1 1
M6x12mm
Black White
20
21
M6x30mm M6x25mm
22 23 24 25 26 27 28
Spring Shift arm Washer Shift grip Clip Shift rod
62Y141
7-22
Checking the throttle cable and shift rod
1.
Check the operation of the throttle cable and shift rod.
lnstall the throttle cable @ into the gear @ until the inner cable is engaged with the gear,
3.
2.
Turn the throttle shaft @ clockwise to

wind the inner cable around the gear @.
Check the inner wire, outer wire of the cable and rod for bends or damage, and the rubber seals for damage. Replace if necessary.
r i,:dt
Assembling the tiller handle
1.
lnstall the throttle shaft @ into the tiller handle @ by aligning the mark "" @ of the tiller handle with the screw hole @ of the throttle shaft.
NOTE: Make sure that the throttle grip is fully closed when installing the throttle cable.
Lubricating the throttle gear
1.
lnject grease into the grease nipple until grease comes out from the screw hole
@.
s62Y71 00
7-23
62Y141
MEMO
62Y141
7-24
Bottom cowling
V; g
,t1 4 5
l"
r;-X------/ v
\ 22 ..'
g-23
G^',.( ."I >/

f/'0,
s62Y7140
7-25
62Y141
Bottom cowling
No.
1
Pat name Shift rod assembly Bottom cowling Bolt Spring

Ball
Q'ty
1 1 1 1 1 1 1 1 1 1 1 1
Remarks

N.m
kgtm
t.lb
3 4
5
6 7
Shift rod bracket Cotter pin Washer Bushing Bushing Shift rod Grommet Rubber seal Bolt Grommet Screw Warning indicator Grommet Collar
Pilot water outlet
I I
10
11
12 13 14 15 16 17 18 19
4 4 4
1
M6x30mm M6x14mm
EHD/EHT models EHD/EHT models EHD/EHT models
1 1
4
1
20
21
Plastic tie Collar Grommet Bushing Joint Cowling lock lever

Pin
2
2
22 23 24 25 26 27 28 29 30
2 2
1 1 1
Cotter pin
Pin
2
1 1
Cotter pin
62Y141
7-26
ff
{*,1
*/
,.,g1 I
s2
7-27
62Y141
Bottom cowling
No.
31
Pat name Bolt Bracket Trailer switch PTT motor lead Trim sensor coupler Screw Grommet Flushing hose Adapter Bolt
Q'ty 2
1 1 1 1 1
Remarks Models with trailer switch Models with trailer switch Models with trailer switch EHT/ET models EHT/ET models

N.m
kgtm
t.lb
32
33 34
35
36 37
3B
M6x24mm
EHT/ET models
1 1
Models with flushing device Models with flushing device
39
40
M6x20mm
Models with flushing device
41
Rubber seal
Hose
1 1
42
62Y141
7-28
Checking the shift rod assembly operation
1.
Check the shift rod assembly and detent for smooth operation.
E E
FsO/F5OA, T5O/FTsOB
FT5OC
7-29
62Y141
Bottom cowling
MEMO
62Y141
7-30
Upper case
/4.
-,
s62Y71 70
7-31
62Y141
Upper case
No.
1
Pat name Upper case assembly

Nut Nut
Q'ty
1
Remarks

N.m 24 42
kgtm
2.4 4.2
t.lb
17
2 2 2
3
1 1
3 4
5
30
Washer Bolt Upper mount Plate Bolt
M8x30mm
6 7
I I
10
11
2 2 2 2
1
M8 x 175 mm M12
cap
Bolt Grommet Ground lead Screw Mount cover Bolt Mount housing Spring Washer Rubber washer Lower mount Washer Grease nipple
160 mm
12 13 14 15 16 17
1B
2 2 4 2 4 2
2 2
M8x25mm
19
20
21
2
1
22
62Y141
7-32
7-33
62Y141
Upper case
No.
1
Pat name Muffler assembly Upper case Mutfler seal Rubber seal
Q'ty
1 1 1 1
Remarks

N.m
kgtm
t.lb
3 4
5
Dowelpin
Grommet Guide Damper Screw Baffle plate Bolt Drive shaft bushing Circlip
2
1 1 1
6 7
FTsOC
I I
10
11
2
1
M5x16mm M8x30mm
4
1 1
12 13
62Y141
7-34
(F50/F50A, T50/FT50B)
/1
,/
rQ,'
t,[
.,J
14
[J,/ ,u-'f>/
r@l
,), ,'
7-35
62Y141
Upper case
No.
1
Pat name
Q'ty
1 1 1 1
Remarks

N.m
kgtm
t.lb
Oilseal
Exhaust guide Grommet Gasket
3 4
5
Dowelpin
Bolt Oil pan Gasket Exhaust manifold Bolt Gasket Bolt Muffler Gasket
Pipe
2
10
1 1 1
6 7
M6x25mm
I I
10
11
3
1
M6x50mm M6x25mm
12 13 14 15 16 17
1B
6
1 1 1 1 1 1
Rubber seal Gasket

Relief valve housing
19
Bolt Bolt Bolt
2 2
1 1 1 1 1
20
21
22 23 24 25
Oilstrainer
Relief valve
Spring Cotter pin
62Y141
7-36
-l,,""n",un*
lffiTf
(Fr50c)
ry
7-37
Upper case
No.
1
Pat name
Q'ty
1 1 1 1 1 1 1 1 1 1
Remarks

N.m
kgtm
t.lb
Oilseal
Exhaust guide Grommet Grommet Anode Cover Bolt Cover Bolt Gasket
3 4
5
6 7
I I
10
11
Dowelpin
Bolt Oil pan Gasket Exhaust manifold Bolt Gasket Gasket Bolt Mutfler Gasket
Pipe
2
10
1 1 1 1 1 1
12 13 14 15 16 17
1B
M6x25mm
M6x45mm
19
6
1 1 1 1 1 1
M6x25mm
20
21
22 23 24 25 26 27 28 29 30
31
Rubber seal Gasket

Relief valve housing
Bolt Bolt Bolt
2 2
1 1 1 1 1
Oilstrainer
Relief valve
Spring Cotter pin
32
62Y141
7-38
Disassembling the oil pan
1. 2. 3. 4.
Remove the muffler @ from the oil pan
Assembling the oil pan 1, lnstall the gaskets onto the

guide @.
exhaust
.
Remove the exhaust manifold @ from
the oil pan @. Remove the oil pan guide @.
2.
lnstall the relief valve assembly @ by installing the bolts, then tightening them
finger tight.
from the exhaust
Remove the oil strainer @ and the relief valve housing @.
3.
lnstall the oil strainer @ by installing the

bolts.
s62Y7i
E rrsoc
Checking the oil straner and the relief valve
1.
Check the oil strainer and relief valve for dirt and residue. Clean if necessary.
7-39
62Y141
Upper case
4.
lnstallthe water pipe @.

lnstall the oil pan @ and bolts, and then tighten the bolts finger tight.
lnstallthe exhaust manifold @ and bolts, and then tighten the bolts finger tight.
s62Y7245
lnstallthe muffler @ into the oil pan.
7.
Tighten the exhaust manifold

then the oil pan bolts @.
62Y141
7-40
9.
lnstall the muffler assembly @ by inserting the tip of the water pipe @ into the joint hole @ of the upper case,
s62Y7280
lnstalling the upper case
1.
lnstall the upper mount @ and bolts @ into the upper case, and then tighten the bolts @.
NOTE: Be sure to install the ground lead @ into the mount housing @.
2.
Set the lower mounts @ and bolts to the upper case.
lnstall the end of the spring @ into the groove of the mount housing @, and then tighten the bolts @,
7-41
62Y141
Upper case
4.
lnstall the upper and lower mounting bolts into the swivel bracket @ simultaneously.
lnstall the upper mounting nut @ and lower mounting nut @, and then tighten
them to the specified torques.
lnstall the cover @ by installing the

screw.
ev''
l(,
Upper mounting nut @: 24 N.m (2.4 kgf.m, 17 ft.lb) Lower mounting nut @: 42 N.m (4.2 kgf.m, 30 ft.lb)
62Y141
7-42
Glamp brackets
f' \
18
-0
#
B
s62Y7300
7-43
62Y141
Clamp brackets
No.
1
Pat name Swivel bracket assembly Screw Trim sensor Trim sensor coupler Plastic tie Self-locking nut
Q'ty
1 1
Remarks

N.m
2
kgtm
0.2
t.lb
1.4
EHT/ET models
M6x15mm
3 4
5
1 1 1
EHT/ET models EHT/ET models

23
6 7
B
2 2
1 1 1
2.3
17
cap
Bolt Anode Port clamp bracket Washer Bushing Through tube Bolt Anode Ground lead Grease nipple Screw Starboard clamp bracket
M6x25mm
I
10
11
2 2
1
12 13 14 15 16 17 18 19
2
1 1 1 1 1
M6x25mm
M6x8mm
62Y141
7-44
Removing the clamp brackets
1,
Remove the power trim and tilt or hydro For removing procedures, see "Removing the power trim and tilVhydro tilt'in this chapter.
NOTE:
tilt.
Adjust the trim sensor after installing the power lrim and tilt.
2.
2. 3.
Loosen the self-locking nuts @, and then remove clamp brackets @ and @. Remove the trim sensor @.
Assemble the clamp brackets and the swivel bracket by installing the self-lock' ing nuts @, then tightening them to the specified torque.
s62Y7
lnstalling the clamp brackets
1.
lnstall the trim sensor @ onto the port

clamp brackets.
Self-locking nut @: 23 N.m (2.3 kgf.m, 17 ft.lb)
3.
lnstall the power trim and tilt or hydro tilt. For installing procedures, see "lnstalling the power trim and tilf in this chapter.
7-45
62Y141
Clamp brackets
4.
lnject grease into both grease nipples until grease comes out from the bushings
@.
4.
Measure the trim sensor resistance. Repeat steps 1-5 if out of specification.
Adjusting the trim sensor
1.
Trim sensor setting resistance: Pink (P)- Black (B) 11 t7 at 20 "C (68 "F)
6.
Fully tilt the outboard up, and then support it with the tilt stop lever.
After tilting up the outboardo be sure to support it with the tilt stop lever. Otherwise, the outboard could suddenly lower if the power trim and tilt unit should lose fluid pressure.
After tilting up the outboard, be sure to support it with the tilt stop lever. Otherwise, the outboard could suddenly lower if the power trim and till unit should lose fluid pressure.
2. 3.
7.
Tighten the cam screws @ to the specified torque.
Trim sensor cam screw @: 2 N.m (0.2 kgf.m, 1.4 t.lb)
Loosen the cam screws @.
B.
Adjust the position of the trim sensor @, and then tighten the screws @ finger tight.
62Y141
7-46
16- - s
7-47
62Y141

No.
1
Pat name Steering arm Washer Bushing O-ring Bushing
Q'ty
1 1 1
Remarks

N.m
kgtm
t.lb
3 4
5
2 2
1 1 1 1 1 1 1 1 1 1 1 1
6 7
Swivelbracket
Bushing
Port tilt stop lever
I I
10
11
Circlip Steering yoke Bushing Bushing Tilt stop lever joint Spring holder Bolt Spring Bushing
Pin
12 13 14 15 16 17
1B
M6x10mm
2
1 1
19
Bushing Starboard tilt stop lever
20
62Y141
7-48
Removing the steering arm 1, Remove the circlip O.
2.
Remove the steering yoke @ by striking it with a plastic hammer.
4.
lnstall the steering arm @ into the steering yoke @ by aligning the center @ of the yoke with the center @ of the steering arm.
3. 1.
Remove the steering arm from the swivel bracket by pulling the arm off the bracket.
5.
lnstallthe circlip @.
lnstalling the steering arm

lnstall the washer @, bushing @, O-ring @, and bushing @ onto the steering arm
@.
2.
Place the swivel bracket @ in an upright position, and then installthe steering arm onto the swivel bracket.
s62Y7410
s62Y7390
3.
lnstall the bushing @, O-ring @, and bushing @ onto the swivel bracket.
7-49
62Y141
6.
lnject grease into the grease nipple until grease comes out from both the upper and lower bushings @.
62Y141
7-50
Power trim and tilt unit
rr"\
r-\ -\
-'n'
ln I \-/
14
s62Y7430
7-51
62Y141

No.
1
Pat name Power trim and tilt Hydro tilt Plastic tie PTT motor lead Washer Bolt Circlip Shaft Bushing Collar Tilt pin Collar Collar Shaft Bushing Circlip Shaft Collar
Q'ty
1 1
Remarks EHT/ET models EHD/ED models

N.m
kgtm
t.lb
3 4
5
3 2
2 2
1 1
6 7
MBxl6mm
EHT/ET models EHT/ET models EHT/ET models EHT/ET models
I I
10
11
2
1 1 1 1 1
12 13 14 15 16 17
1B
2 2
1 1
EHD/ED models EHD/ED models EHD/ED models EHD/ED models
62Y141
7-52
Removing the power trim and tilVhydro tilt
1.
2.
Loosen the plastic locking tie @, and then pull out the PTT motor lead @.
Remove the tilt pin @. Remove the circlip(s) @ and the shaft @. Loosen the bolt @, and then remove the shaft @. Remove the power trim and tilVhydro tilt
3. 4. 5.
6.
To remove the power trim and tilVhydro tilt,

lower the tilt rod slightly.
o.
7-53
62Y141
MEMO
62Y141
7-54
Tilt cylinder and trim cylinder
.1.-.G--O
ot
<l>-- 8
@=V
/ <9>--
9 10
1
1 11
O-o
{5
12 1
7-55
62Y141
Tilt cylinder and trim cylinder

No.
1
Pat name Power trim and tilt motor Tilt cylinder end screw Bolt O-ring Joint
Q'ty
1 1
Remarks

N.m 90
kgtm
9.0 0.4
t.lb 65 2.9
3 4
5
3
1 1 1
M5x20mm
6 7
O'ring
Ball
6
1 1 1 1 1 1
I I
10
11
O-ring Free piston Valve seal Circlip Circlip Trim cylinder base Spring Plate Circlip Tilt cylinder assembly
12 13 14 15 16 17
1B
2
1 1 1 1 1 1
O'ring
Reservoir cap Anode Bolt
19
6.5
0.65
4.7
20
21
M6x25mm
62Y141
7-56
Trim cylinder
o.@-tu
Zl- zz-
o-..-15
201
25
19
@-t, :\4=23
--trc
62Y141
1
@-ro
7-57
Trim cylinder
No.
1
Pat name
Q'ty
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Remarks

N.m
kgtm
t.lb
Tilt ram
Dust seal
3 4
5
Backup ring O-ring Tilt cylinder end screw
6 7
O'ring
Backup ring O-ring Trim cylinder end screw O-ring O-ring Trim piston O-ring Trim cylinder O-ring Backup ring
Ball
I I
10
11
80
8.0
58
12 13 14 15 16 17
1B
Tilt piston
Ball
19
4 4 4 4 2
1 1
20
21
Absorber valve pin Spring

Pin Pin
22 23 24 25
Washer Bolt
M12 x 45 mm
61
6.1
44
62Y141
7-58
Gear pump
t-=g
I
-3
'..J
-\-.^.--r'
l--^,--t
B-
7-59
62Y141
Gear pump
No.
1
Pat name Bolt

Relief valve bracket
Q'ty 2
2 3
1 1 1 1 1 1 1 1 1
Remarks

N.m
kgtm
0.53 0.65
t.lb 3.8 4.7
MSxBmm
5.3 6.5
3 4
5
Bolt Adapter Up-relief spring Valve support pin

Relief valve seal
M6x45mm
17.5 m (0.69 in)
6 7
I I
10
11
Down-relief spring Valve support pin

Relief valve seal
14.2mm (0.56 in)
Filter Gear pump O-ring Filter O-ring Manual release plug Circlip
12 13 14 15 16 17
2 2 2
1 1
62Y141
7-60
y ^ u--
I
a----o (.2
l,/p1
7-61
62Y141
Gear pump
No.
1
Pat name Bolt Washer Gear pump bracket O-ring Spring Spacer Down-shuttle piston Up-shuttle piston Manual release spring
Ball
Q'ty 2 2
1
Remarks

N.m
kgtm
0.53
t.lb 3,8
M5x20mm
5.3
3 4
5
2 2 2
2
1 1
6 7
I I
10
11
2
1 1 1 1 1
Gear pump cover Down-main valve O-ring Valve seal Circlip

Pin
12 13 14 15 16 17
1B
2
1 1 1
Drive gear Shaft Driven gear

Ball
19
20
21
2 2
1 1 1 1
Return spring Up-main valve Valve seal Circlip Gear pump housing
22 23 24 25
62Y141
7-62
Disassembling the tilt cylinder
1,
Hold the power trim and tilt O in a vise using aluminum plates @ on both sides.
NOTE:
Place the trim cylinder in the vise horizontally.
2.
Loosen the trim cylinder end screw @,

and then remove it.
2.
Loosen the tilt cylinder end screw @, and then remove it.
Do not damage the check valve (D when loosening the end screw.
Trim and tilt cylinder wrench: YB-06175-28 Cylinder-end screw wrench: 90890-06544
Make sure that the ram is fully extended before removing the end screw.
Trim and tilt cylinder wrench: YB-06175-28 Cylinder-end screw wrench : 90890-06544
3. Drain the fluid.

Disassembling the trim cylinder
1.
Hold the trim cylinder @ in a vise using aluminum plates @ on both sides.
7-63
62Y141
Gear pump
Disassembling the gear pump
1.
4. 5.
Remove the manual release plug @ and gear pump @.
Remove the gear pump cover @, then up-main valve @.
the down-main valve @ and
B t
Remove the drive gear @ and driven gear @.
O... -z_;>
q
O
@
{;ir\
'\@
--.--]
I
$N
2.
s62Y7540
Ghecking the tilt cylinder and trim
Remove the relief valve bracket @, then the down-relief valve @ and up-relief valve @.
cylinder
1.
Check the power trim and tilVhydro tilt for cracks or corrosion. Replace if necessary.
2.
Check the inner walls of the trim cylinder and tilt cylinder for scratches, Replace if necessary.
Remove the gear pump bracket @, then the down-shuttle piston @ and up-shuttle piston @.
62Y141
7-64
3.
Check the outer sudace of the tilt piston and free piston for scratches. Replace if necessary.
|-.,
I U
0
3.
s62Y7590
e
s62Y7620
Check the down-main valve @ and the up'main valve @ for dirt or residue. Clean if necessary.
Check the down-relief valve @, up-relief valve @, and shuttle pistons @ for dirt or residue. Clean if necessary.
4.
Check the tilt ram for bends or excessive corrosion. Polish with #400{00 grit sandpaper if there is light rust or replace if necessary.
4.
v
.
s62Y7600
d6
6) X
@@
s62Y7630
Check the valves
Checking the filters
1.
Check the operation of the check valve @ of the trim cylinder end screw and check the valve for dirt or residue. Clean if necessary.
1.
Check the gear pump filter @ and shuttle piston filters O for diil or residue. Clean if necessary.
s62Y7610
Check the operation of the tilt piston absorber valve and check for dirt or residue. Clean if necessary.
7-65
62Y141
Gear pump
Checking the gear pump
7.
1.
Check the drive gear @, driven gear @, and shaft @ for damage or excessive wear. Replace if necessary.
lnstall the gear pump bracket @ by installing the bolts @, then tightening
them to the specified torque.
*t, o
Mffi
s62Y7650
Assembling the gear pump
Gear pump bracket bolt @: 5.3 N.m (0.53 kgf.m, 3.8 ft.lb)
8.
1.
lnstall the drive gear @, driven gear @,

shaft @, and pins @ into the gear pump housing @.
lnstall the down-relief valve @, up-relief

valve @, and filter @.
2. 3. 4.
lnstall the balls @ into the gear pump

housing @.
9.
lnstall the relief valve bracket @ by installing the bolts @, then tightening
lnstall the down-main valve @ and upmain valve @,

lnstall the gear pump cover @.
Q.
--
a,
@
@
r--@ #o----..|
lnstallthe shuttle pistons @ into the gear pump cover @. lnstall the balls @ into the gear pump cover @ with the manual release spring
@.
Relief valve bracket bolt @: 5.3 N.m (0.53 kgf.m, 3.8 ft.lb)
62Y141
7-66
10. lnstall the filters @ and gear pump @ by installing the bolts @, then tightening
@=--g y-@
11. lnstall the manual release plug @ and reservoir cap .
V
(-
JV ?*
uv

PTT motor bolt @: 4 N.m (0.4 kgf.m, 2.9 ft.lb)
Gear pump bolt @: 6.5 N.m (0.65 kgf.m,
Assembling the trim cylinder 1, lnstall the dust seal O into the tilt cylinder
end screw @.
4.7ltlb)
12. Fill the reseruoir with the recommended fluid to the correct levelas shown.
2. 3.
lnstall the O-ring @ to the end screw. lnstall the tilt ram @ into the end screw.
Recommended power trim and tilt fluid: ATF Dexron II
13. lnstall the joint @ and power trim and tilt motor @ by installing the bolts @, then
tightening them to the specified torque.
7-67
62Y141
Gear pump
4.
lnstall the backup ring @ and O-rings @ and @ into the trim cylinder end screw
@.
9.
Hold the tilt ram end in a vise using aluminum plates on both sides.
10. lnstall the tilt piston to the tilt ram by installing the bolt, then tightening it to the specified torque.
s62Y7730
5.
lnstall the trim cylinder end screw onto

the tilt ram.
Tilt piston: 61 N.m (6.1 kgf.m, 44 ft.lb)
11. lnstall the trim cylinder onto the tilt ram.

s62Y7740
lnstall O-rings @ and @ onto the trim piston @, and then install the trim piston to the trim cylinder @.
12. Hold the trim cylinder @ in a vise using aluminum plates @ on both sides.
NOTE:
Place the trim cylinder in the vise horizontally.
s62Y7750
7. 8.
lnstall the backup ring @ and O-ring @ into the tilt piston @.
lnstall balls @ and @, absorber valve pin @, spring @, pins @ and @, and washer @ into the tilt piston.
1
62Y141
7-68
13. lnstallthe trim cylinder end screw @, and

then tighten it to the specified torque.
@
,u,
brlm
-/
\SN4.
s62Y7'oo
a vise using aluminum plates @ on both sides.

Hold the power trim @ and in
Do not damage the check valve @ when tightening the end screw.
Trim and tilt cylinder wrench: YB-06175-28 Cylinder-end screw wrench : 90890-06544
5.
s62Y7805
Add fluid of the recommended type to the first level at the bottom of tilt cylinder.
Trim cylinder end screw @: 80 N.m (8.0 kgf.m, 58 t.lb)
6.
Assembling the tilt cylinder
lnstall the balls @ into the trim cylinder, and then insert the trim cylinder into the tilt cylinder @.
1.
lnstall the valve seal @ and the circlip @ into the free piston @ as shown.
2.
lnstall the free piston into the trim cylinder @ by installing the circlip @.
NOTE:
Apply grease to the balls to prevent them from falling out of the cylinder.
3,
lnstall the trim cylinder base @, springs @, and plate @ into the trim cylinder with the circlip @.
7-69
62Y141
Gear pump
7.
lnstall the tilt cylinder end screw @, and then tighten it to the specified torque.
Trim and tilt cylinder wrench: YB-06175-28 Cylinder-end screw wrench: 90890-06544 Tilt cylinder end screw @: 90 N.m (9.0 kgf.m, 65 ft.lb)
Fully extend the tilt rod, and then add suf-
s62Y7840
2. 3.
ficient fluid of the recommended type to the correct level.
Place the power trim and tilt in an upright position. Check the fluid level in the reservoir.
lnstall the reservoir cap @.
NOTE: The fluid level should be at the brim of the filler hole.
4. lf necessary, add sufficient fluid of the

recommended type to the correct level. Recommended power trim and tilt fluid: ATF Dexron II
5.
lnstallthe reservoir cap.
Bleeding the power trm and tlt (not installed) 1. Close the manual release plug @
turning it clockwise.
by
62Y141
7-70
6.
Connect the PTT motor leads @ to the battery terminals.
Bleeding the power trm and tlt (built-in)
1.
1
G(L)
Loosen the manual release plug by turning it counterclockwise until it cannot be turned further.
-----t'
a..O
^a
ot',
s62Y7860
2.
Tilt rod
Up Down
PTT motor lead Blue (L) Green (G) Green (G) Blue (L)
Battery terminal
@
Fully tilt the outboard up, and then release it and let it lower by its own
weight four to five times. Tighten the manual release plug by turning it clockrrvise.
Let the fluid settle for 5 minutes.
o
@
3.
4. 5.
7.
Reverse the PTT motor leads between the battery terminals when the tilt ram is fully extended, and then reverse them again when it is fully compressed.
Push and hold the power trim and tilt switch in the up position until the out'
board is fully tilted up.
6.
.
.
NOTE:
Repeat this procedure so that the tilt ram goes up and down four to five times. The sound of the power trim and tilt motor will change when the tilt ram is fully extended. Check the fluid level again when the tilt ram is fully extended. Add sutficient fluid, if necessary, and then repeat step 7,
Support the outboard with the tilt stop lever, and then let the fluid settle for 5 minutes.
B.
After tilting up the outboard, be sure to support it with the tilt stop lever. Otherwise, the outboard could suddenly lower if the power trim and tilt unit should lose fluid pressure,
NOTE: Repeat this procedure until the fluid remains at the correct level.
7-71
62Y141
Gear pump
7.
Remove the reseruoir cap @, and then check the fluid level in the reservoir.
lf
necessary, add sufficient fluid of the recommended type to the correct level.
The fluid level should be at the brim of the filler hole.

lnstall the reservoir cap.
NOTE: Repeat this procedure until the fluid remains at the correct level.
62Y141
7-72
Power trim and tilt motor
7-73
62Y141

No.
1
Pat name Screw Yoke O-ring Armature Bushing Screw Wire lead Brush 2 Brush
1
Q'ty
3
1 1 1 1
Remarks

N.m
kgtm
t.lb
M5x20mm
3 4
5
6 7
2
1 1 1 1 1
M4x12mm
I I
10
11
Brush holder Circuit breaker Brush spring PTT motor base
12 13 14
2
1 1
Oilseal
62Y141
7-74
Checking the power trim and tilt motor
1.
Check the commutator for dirt or foreign substances. Clean with #600 grit sandpaper if necessary.
Armature coil continuity Commutator segments @ Segment-lam inations ( Segment-shaft

2.
CD
Continuity No continuity No continuity
Check the commutator undercut for diil or foreign substances, Clean with compressed air if necessary. Measure the commutator diameter @. Replace if out of specification.
5.
Check the circuit breaker for continuity. Replace if there is no continuity.
3.
s62Y7930
6.
Measure the brush length. Replace if out of specification.
Commutator diameter limit @: 21 mm (0.83 in)
4.
Check the armature coil for continuity.

Replace if out of specifications.
Brush length limit @: 3.5 mm (0.14 in)
7.
Check the base for cracks or damage. Replace if necessary,
7-75
62Y141
8.
Check the bushing @ for damage or

Assembling the power trim and tilt motor
1.
lnstall the oil seal @ and the bushing @

into the motor base @ as shown.
s62Y7980
lnstalling the power trim and tilt
1.
Fully tilf the outboard up, and then support it with the tilt stop lever @.
Attach the circuit breaker @ onto brush 1 @ together with the brush holder @ and connect the wire lead .
O__y
+'-@i9:
lnstall the springs @ into the motor base, then the brush holder into the motor base together with the brushes and circuit breaker.
4.
lnstall the armature

yoke @.
O, O-ring @, and
62Y141
7-76
lnstallthe shaft @ and bolts @ onto both clamp brackets together with the power trim and tilVhydro tilt @.
lnstall the tilt ram upper end into the swivel bracket with the shaft @ and circlip(s) @. lnstall the tilt pin .
s62Y7A10
7-77
62Y141
Power trim and tilt motor / Power trim and tilt electrical system Power trim and tilt electrical system
@ Power trim and tilt motor @ Power trim and tilt relay @ Trailer switch @ Power trim and tilt switch @ Fuse @ Battery
B G
Gy
L Lg
P
Black Green Gray

Blue
Light green Pink

Red
Trim sensor Models with trailer switch
sb
Sky blue
62Y141
7-78
Checking the fuse
1,
Check the fuse and fuse holder for continuity. Replace if there is no continuity.
Connect the light green (Lg) lead to the positive battery terminal and the black (B) lead to the negative battery terminal as shown.
4.
Check for continuity between terminals @ and @. Replace if there is no continu'

itv.
Checking the power trim and tilt relay 1. Check the power trim and tilt relay for
continuity. Replace if out of specification.
5.
s62Y7A50
Connect the digital circuit tester between power trim and tilt relay terminals @ and
@
6.
Connect the sky blue (Sb) lead to the positive battery terminal and the black (B) lead to the negative battery terminal as shown. Check for continuity between terminals @ and @. Replace if there is no continuity.
7.
e_9
tt
Power trim and tilt relay continuity Sky blue
Light green
(Sb)- Black (B) (Lg)- Black (B)
Continuity Continuity
No continuity
Terminal@ -Terminal@ Terminal@ -Terminal@
TerminalO -Terminal@ Terminal@ -Terminal@
2.
Connect the digital circuit tester between power trim and tilt relay terminals O and
@.
7-79
62Y141
Power trim and tilt electrical system

Checking the power trim and tilt switch/trailer switch switch/trailer switch
Trim sensor resistance: Pink (P)- Black (B) 10-278.3 at 20 "C (68 "F)
1. Check the power trim and
for
tilt continuity.
Replace if out of specification. Turn the lever @ and measure the resistance as it gradually changes.
Lead color Switch position

Up Free Down
Skyblue (sb)
Red (R)
Lightgreen
(Lg)
o_ ----o o_ ----o
Ghecking the trim sensor 1. Measure the trim sensor resistance.

Replace if out of specification.
62Y141
7-80
MEMO
7-81
62Y141
Electrical systems
Special service tools Checking the electrical components........... Measuring the peak voltage Measuring the lower resistance..
............8-4 .............8-4 ......8-4 ............8-5 .........8-5 ..,,,.,,,,,.,,,.,,..,,8-6 .....8-7 .........8-8 .............8-9 8-10
Electrical
Starboard and port Front Top Tiller handle model (F50/F504, T50/FT50B) Tiller handle model
components............... views......... view view (FT50C)
. . . .
Wiring harness lgnition system and lgnition control system...... Checking the ignition spark gap Checking the spark plug caps Checking the ignition coi1............. Checking the CDI unit............. Checking the charge coil ............ Checking the pulser coil ,,..,,..,.., Checking the pulser coilair gap ........... Checking the engine start switch Checking the engine shut-otf switch........
Checking the thermoswitch Checking the oil pressure
......... switch
....................8-I1 .,,..8-13 ........8-14 ...8-14 ........8-15 ....8-15 ,,.,.8-16 .............8-16 ....8-17 ..........8-17 ...8-18 ,,..8-18
..................8-19 ...8-2O ..............8-20 ....8-20 ....8-20
Starting
Checking Checking Checking Checking
system the fuse..... the wiring harness (10 pins) the neutral switch........ the starter re1ay........... pinion pinion......... armature................ brushes operation coi1............. Regulator
Starter motor
Removing the starter motor Checking the starter motor Checking the Checking the Checking the stafier motor
....................8-23 .............8-23 ...8-23
..8-24 ................8-24
...............8-25 ...8-26 ....8-26
Charging
system
Checking the lighting Checking the Rectifier
62Y141
Electrical systems Troubleshooting

Before troubleshooting the charging system, check that all electrical connections are tight and free from corrosion, and that the battery is fully charged to 12 V.
Symptom: Battery becomes weaker quickly. . Check the charging system.
Measure the output peak voltage of the lighting coil.
Replace the lighting coil,
Measure the Rectifier Regulator output peak voltage.
Replace the Rectifier Regulator.
Replace the battery, and then check the whole voltage of all electrical equipments on your
boat.
8-1
62Y141
Troubleshooting / Special service tools

t--..
!t
Dialgauge
YU-03097
Dynamic spark tester

YM-34487
Magnetic flexible stand

YU-34481
Digital multimeter
YU-34899-A
Test harness (3 pins)

YB-06770 Peak voltage adaptor
YU-39991
d\
il8fl
#ru
Test harness (2 pins) Y8-06767
Test harness (4 pins)

YB-06771
ffi
8-2
/K
Pressu relvacu um teste r Y8-35956-A
lgnition tester
90890-06754
62Y141
Electrical systems
ww
Digital circuit tester
90890-03174
&
Magnet base
90890-06705
tr
['nn
/K h / \v
Peak voltage adaptor 90890-03172
Test harness (3 pins) 90890-06770
[]n
ffi
/K
ftilflff
\K/o
90890-06756
i ?^ r-("lh
Vacuum/pressure pump gauge set
Dial gauge set 90890-01252
8-3
62Y141
Special service tools / Checking the electrical components Ghecking the electrical components
Measuring the peak voltage
The condition of the ignition system can be determined by measuring the peak voltage. Cranking speed is etfected by many factors, such as fouled or weak spark plugs, or a weak battery. lf one of these factors is present, the peak voltage will be lower than specification. ln addition, if the peak voltage is lower than specification the engine will not
operate properly.
Measuring the lower resistance

When measuring a resistance of 10 Q or less with the digital circuit tester, the correct measurement cannot be obtained because of the internal resistance of the tester. To obtain the correct value, subtract the internal resistance from the displayed measurement.
Correct value = displayed measurement resistance
internal
NOTE: Obtain the internal resistance of the digital circuit tester by connecting both of its probes and checking the display.
. Use the peak voltage

.
NOTE:
adaptor with the digital circuit tester. When measuring the peak voltage, set the selector on the digital circuit tester to the
DG voltage mode. Connect the positive pin on the peak voltage adaptor to the positive terminal of the digital circuit tester.
62Y141
8-4
Electrical systems Electrical components

Starboard and pofi views
@ @ @ @ @
Stalor
Pulser coil
@ Slarter relay @ Starter motor
CDlunit
lgnition coil
@ PTT switch coupler
Oilpressure switch @ Thermoswitch
Power trim and tilt model with tiller handle
@ Prime Start @ Rectifier Regulator
8-5
62Y141
Electrical components
Front view
Stator
Tller handle model
@ Pulser coil @ CDlunit @ Fuse @ Neutralswitch (tiller handle model) @ Starler relay @ Starter motor @ Power trim and tilt relay (power trim and tilt
model)
62Y141
8-6
Electrical systems
Top view
O Stator
@ @ @ @
Pulser coil
CDlunit
lgnition coil Starter motor @ Trailer switch
8-7
62Y141
Electrical components
Tiller handle model (F50/F504, T50/FT50B)
@ Engine starl switch @ Engine start switch harness @ Engine shut-off switch @ Engine shut-off switch connector @ Neutralswitch @ Battery lead @ Wiring harness extension
@) PTT switch lead
Applicable for tachometer, trim meter or warning buzzer model
@ Power trim and tilt switch
62Y141
8-8
Electrical systems
Tiller handle model (FT50C)
@ @ @ @ @ @
Engine Engine Engine Engine
start switch start switch harness shut-off switch shut-off switch connector
Neutralswitch
Battery lead
8-9
62Y141
Electrical components / Wiring harness Wiring harness
@ @
@ @
r
@@ @@
Connect to: @ Tiller handle main

switch or remote control box or wiring harness extension Power trim and tilt relay Ground Stafier relay Positive battery lead Prime Start
1
@ Warning indicator or
digital tachometer
E
B
Powertrim and tilt

model Black Brown Green
Blue
W B/O
B^/V
@ CDlunit
@ Power trim and tilt

switch or trailer switch @ Rectifier Regulator @ Thermoswitch @ lgnition coil @ Oilpressure switch
P/B
PA/V
Br
G L Lg
P
@
@ @
Y/B Y/R
White Black/orange Blackiwhite Pink/black Pink/white Yellow/black Yellow/red
Light green Pink

Red
@ @
Sb
Sky blue
62Y141
8-10
Electrical systems lgnition system and lgnition control system
@t
I
V/R WR WB
//R WR WB
H LBr H
d@
LBr
WB
(,
Spark plug lgnition coil Charge coil Pulser coil Engine start switch Engine shut-off switch @ 1O-pin coupler
@ @ @ @ @ @
Br L W BlO B^^/
Black Brown
Blue
White
Blacllorange
Black/white
@ CDlunit
WB WR
Whiteiblack
Whiteired
8-11
62Y141
lgnition system and lgnition control system
@@
@ Thermoswitch @ Oilpressure switch @ CDlunit
E Remote control model E tller handle model
B
G
@ Digitaltachometer @ Oil pressure warning

indicator @ Overheat warning indicator Remote controlbox @ Warning indicator
62Y141
1
Gy/B PlB
PA/V
YlB
Y/R
Black Green Red Yellow Green/black Pink/black Pink/white Yellow/black Yellow/red
8-12
Electrical systems
Checking the ignition spark gap
1,
Disconnect the spark plug caps from the spark plugs.
2.
Connect a spark plug cap to the special seruice tool.
562Y8
E E
4.
Crank the engine and observe the spark through the discharge window of the spark gap tester. Check the ignition coil if out of specification.
E E
Dynam ic spark teste r : Y l{l-34487
lgnition tester: 90890-06754
3.
Set the spark gap length on the adjusting knob.
E E
o Do not
touch any of the connections of the spark gap tester leads. Do not let sparks leak out of the removed spark plug caps. Kep flammable gas or liquids away, since ths test can produce sparks.
lgnition spark gap: 9 mm (0.35 in)
8-13
62Y141

Checking the spark plug caps
1.
Remove the spark plug caps from the high-tension cords by turning the caps counterclockwise.
r:::::::::::-::: l------------------{
s62YB1 70
Measure the spark plug cap resistance. Replace if out of specification.
lgnition coil resistance: Primary coil: Orange (O)- Black (B) 0.08-0.11 Q at 20'C (68 "F) Secondary coil: High-tension cord - High-tension cord 3.54.7 k at 20 "C (68 "F) Spark plug cap resistance:
3.75{.25
kO
Ghecking the ignition coil 1. Remove the spark plug caps from the high-tension cords by turning the caps
counterclockrvise.
2.
Measure the ignition coil resistance.

Replace if out of specification,
62Y141
8-14
Electrical systems
Checking the CDI unit 1, Measure the CDI unit output peak voltage. lf below specification, measure the
charge coil output peak voltage and the pulser coil output peak voltage. Replace the CDI unit if the output peak voltage of both coils is above specification.
CDI unit output peak voltage: Black/orange (B/O) - Black (B) Black/white (BAA/) - Black (B)
r/min
Unloaded
Loaded
1,500
151
Cranking 126
150
3,500
116
DCV
Checking the charge coil
1.
Measure the charge coil output peak voltif below specification.
age. Replace the stator coil
When checking the peak voltage do not touch any of the connections of the digital tester leads.
NOTE: Use the peak voltage adaptor with the digital circuit tester. . When measuring the peak voltage, set the selector on the digital circuit tester to the
NOTE: Use the peak voltage adaptor with the digi' tal circuit tester. . When measuring the peak voltage, set the selector on the digital circuit tester to the DC voltage mode.
DC voltage mode.
.
Digital multimeter: YU-34899-A Digital circuit tester: 90890-031 74 Peak voltage adaptor: YU-39991 / 90890-03172
8-15
62Y141

Digital multimeter: YU-34899-A Digital circuit tester: 90890-031 74 Peak voltage adaptor: YU-39991 / 90890-03172 Test harness (2 pins): YB-06767 / 90890-06767 Charge coil output peak voltage: Brown (Br)- Blue (L)
r/min
Unloaded

.
NOTE:
DC voltage mode.
Loaded
1,500 169
Cranking 144
137
3,500 129
DCV
Digital multimeter: YU-34899-A Digital circuit tester: 90890-031 74 Peak voltage adaptor: YU-39991 / 90890-03172 Test harness (2 pins): YB-06767 / 90890-06767 Pulser coil output peak voltage: White/red (W/R) - White/black (W/B)
r/min
Unloaded
Charge coil resistance (use as reference): Brown (Br)- Blue (L) 272408 Q at 20 "C (68 "F)
Loaded
1,500
Checking the pulser coil
Cranking 6.3 3.5
3,500
11.2
1.
Measure the pulser coil output peak voltage. Replace the pulser coil if below specification.
DCV
7.4
Pulser coil resistance (use as reference): White/red (W/R) - White/black (WB) 396-594 O at 20 "C (68'F)
Ghecking the pulser col air gap 1. Turn the flywheel clockwise to align the
projection of the flywheel with the pulser coil projection.
2.
Measure the gap between both projections with a thickness gauge @. Adjust if out of specification.
Pulser coil air gap: 0.5-1.0 mm (0.02G-0.039 in)
62Y141
8-16
Electrical systems
Remove the flywheel magnet nut and flywheel magnet. Switch
4.
Lead color White Black

position
Loosen the pulser coil screws, adjust the pulser coil @ position, and then tighten the screws finger tight.
(w)
(B)
Red (R)
Pink Browr
(P)
(Br)
OFF
ON
o-
o-
-
--o
START
Checking the engine shut-off swtch
1.
@
Check the engine shut-off switch for con' tinuity. Replace if there is no continuity.
@h
-H
5.
6,
Set the flywheel magnet and then check the gap again and, if necessary, repeat steps 3-5. Tighten the pulser coil screws and flywheel magnet nut to the specified torques.
Pulser coil screw: 4 N.m (0.4 kgf.m, 2.9 tt.lb) Flywheel magnet nut: 160 N.m (16 kgf.m, 116 ft.lb)
Checking the engine start switch
1.
Check the engine start switch for continuity. Replace if there is no continuity.
Lead color White (W) Remove the lock plate @

Black (B)
o_ ----o
Cr---{
lnstallthe lock
plate @
s62Y8250
Push the button @
8-17
62Y141

Checking the thermoswitch
1.
Place the thermoswitch in a container of water and slowly heat the water.
s2Y8270
Check the switch for continuity at the specified pressure. Replace if there is no continuity.
Pressure/vacuum tester: YB-35956-A Vacuum/pressure pump gauge set: 90890-06756 Specified oil pressure: 15 kPa (0.15 kgf/cm2, 2.13 psi)
Check the switch for continuity at the specified temperatures. Replace if out of
specification.
@ Temperature @ tme
@ No continuity @ Continuity
Thermoswitch continuity temperature: Pink (P) - Black (B)
@:76-84'C (164-183
@:6T77'C (145-170
"F) "F)
Ghecking the oil pressure switch
1.
Connect the special service tool to the oil pressure switch. Slowly operate the specialservice tool.
2.
62Y141
8-18
Electrical systems Starting system
@ Fuse
@ 10-pin coupler @ Engine start switch @ Starter motor @ Battery @ Neutralswitch
B Br R
: Black : Brown
:Red
Starter
relay
tller handle model
8-19
62Y141
Starting system
Checking the fuse
4.
Check for continuity between the starter
1.
Check the fuse and fuse holder for continuity. Replace if there is no continuity.
relay terminals. Replace if there is no

continuity. Check that there is no continuity between the starter relay terminals atter disconnecting the brown or black lead. Replace if there is continuity.
Checking the wiring harness (10 pins)
1. 1.
Check the wiring harness for continuity. Replace if there is no continuity.
Checking the neutral switch

Check the neutral switch for continuity. Replace if there is no continuity.
Lead color Brown (Br)

Free Push Brown (Br)
Checking the starter relay
1.
Connect the digital circuit tester leads to the starter relay terminals, Connect the brown (Br) lead to the positive battery terminal. Connect the black (B) lead to the negative battery terminal.
2. 3.
62Y141
8-20
Electrical systems Starter motor
10
-ffi
s62Y8350
8-21
62Y141
Starter motor
No.
1
Pat name Clip Pinion stopper Spring Starter motor pinion Upper bracket
Q'ty
1 1 1 1 1 1
Remarks

N.m
kgtm
t.lb
3 4
5
6 7
O'ring Washer
Shim
1
I I
10
11
As required
1 1 1 1 1 1 1 1 1 1 1
Washer 2 Armature Stator
12 13 14 15 16 17
1B
O'ring
Brush holder assembly Brush set O-ring Washer Spring washer
Nut
I
M4x12mm
M5 x 125 mm
0.9
6.5
19
Lower bracket Screw Bolt
20
21
2 2
62Y141
8-22
Electrical systems
Removing the stafier motor pinion 1, Slide the pinion stopper @ down as
shown, and then remove the clip @.
Dial gauge @:YU-03097 Dial gauge set @: 90890-01252 Magnetic flexible stand @: YU-34481
Checking the stater motor pinion 1. Check the pinion teeth for cracks or
Magnet base @: 90890-06705 Free play limit: 0.6 mm (0.024 in)
2.
Check the commutator for dirt. Clean with #600 grid sandpaper and compressed air if necessary.
2.
Check for smooth operation. Replace necessary.
3.
the commutator diameter. Replace the armature if out of specification.

Measure
NOTE:
Turn the pinion clockwise to check that it operates smoothly and turn it counterclockwise to check that it locks.
Checking the armature 1. Check the armature axial free play. Replace the washers and shim(s) @ if
Diameter limit: 31.0 mm (1.22in)
8-23
62Y141
Starter motor
4.
Measure the commutator undercut @. Replace the armature if out of specification.
Brush length limit @: 12.0 mm (0.47 in)
2.
Check the brush holder for continuity.

Commutator undercut limit: 0.2 mm (0.01 in) Brush assembly continuity
5.
Check
the
armature
for
continuity.
BrushO-Brush@ Brush@-Brush@ Brush@-Brush@ Brushholder@-Brush

assembly holder @
Continuity
No continuity
Checking the starter motor operaton
1.
Check the operation of the stafter motor after installing it to the power unit.
s62Y8430
Armature continuity
Commutatorsegments(D
Segment Armature core @ Segment Armature shaft @
Continuity
No continuity No continuity
Checking the brushes 1. Measure the brush length. Replace the

brush assembly if our of specification.
62Y141
8-24
Electrical systems
Gharging system
@ @ @ @
Lighting coil Rectifier Regulator Fuse Battery
B G
R
Black Green
Red
G^^/
Green/white
8-25
62Y141
Charging system
Checking the lighting coil 1. Measure the lighting coil output
peak voltage. Replace the stator coil if below specification. Lighting coil resistance (use as reference): Green (G) - Green (G) 1 .2-1.8 Q at 20 'C (68 "F)
Checking the Rectifier Regulator 1. Measure the Rectifier Regulator output

peak voltage. lf below specification, measure the lighting coil output peak voltage. Replace the Rectifier Regulator if the out-
put peak voltage of the lighting coil

above specification.
is
s62Y8470
NOTE: . Use the peak voltage adaptor with the digital circuit tester. . When measuring the peak voltage, set the selector on the digital circuit tester to the
DC voltage mode,
NOTE:

.
Digital multimeter: YU-34899-A Digital circuit tester: 90890-031 74 Peak voltage adaptor: YU-39991 / 90890-03172 Test harness (3 pins): YB-06770 / 90890-06770 Lighting coil output peak voltage: Green (G) - Green (G)
r/min
DC voltage mode.
Digital multimeter: YU'34899-A Digital circuit tester: 90890-031 74 Peak voltage adaptor: YU-39991 / 90890-03172 Test harness (4 pins):
Unloaded Cranking
1
YB-06771l 90890-06771
3,500
127
1,500 42
DCV
62Y141
1.9
8-26
Electrical systems
Rectifier Regulator output peak voltage: Red (R)- Black (B)
r/min
Unloaded
1,500 18.9
3,500
19.5
DCV
After starting the engine, disconnect the output lead (red lead) of the Rectifier Regulator when measuring the output peak voltage.
8-27
62Y141
MEMO
62Y141
8-28
lndex
A.
Acceleration pump ....... ... . ... . 1 -1 5 Adjusting the dash-pot (acceleration ............4-24 Adj usting the th rottle n k rod......... ............ 4-21 Adjusting the trim ......7-46 Aftertest ...........1-36 Applicable ...........1-5 Assembling the catbu retor,.,,.,......,.,..,. ..... 4-20 Assembling the cylinder body ................... 5-64 Assembling the drive shaft .............. 6-27, 6-66 Assembling the forward gear.......... 6-27, 6-65 Assembling the fuel pump.........................4-1 0 Assembling the gear pump ..,.,,.,......,.,..,.,. 7-66 Assembling the lower case ..,.,,.,..... 6-25, 6-63 Assembling the oil .......7-39 Assembling the power trim and tilt motor..7-76 Assembling the propeller shaft 6-16, 6-55 Assembling the propeller shaft
pump)
I i
sensor run.............. models........
Checking Checking inside Checking Checking Checking
diameter...............
clearance clearance
the connecting rod bolt,......,.,.., 5-59 the connecting rod small end .... 5-59 the cooling water passage........ 3-1 3 the crankshaft ........................... 5-59 the crankshaft main journal oil
.....,.,5-60
Checking the crankshaft pin oil ........5-61 Checking the cylinder bore ....................... 5-56 Checking the cylinder head ...................... 5-46 Checking the diaphragm and valves .,,.,... 4-10 Checking the drive shaft ..................6-25, 6-63 Checking the electrical components........... 8-4 Checking the engine idle speed ............... 3-15 Checking the engine oil .....................1-33, 3-5 Checking the engine shut-off switch,.,,.,... 8-17 Checking the engine start switch.............. 8-1 7 Checking the engine start switch and engine stop switch/engine shut-otf switch .......... 1-35 ...............7-65 Checking the Checking the fuel f ilter ..,.,,.,...,,.,.,....,.,,.,...,. 3-5 Checking the fueljoint and fuel hoses (fuel ........ 3-4 Checking the fuel pump.............................. 4-g ..... 1-33 Checking the fuel Checking the .7-79, 8-20 Checking the gear oi1................................ 1 -33 Checking the gear oil ...3-17 Checking the gear pump .......................... 7-66 Checking the gearshift and ............ 1-34 throttle Checking the gearshift operation .............. 3-1 4 Checking the ignition coi|.......................... 8-1 4 Checking the ignition spark gap ............... 8-13 Checking the ignition timin9...................... 3-1 5 Checking the lighting coi1.......................... 8-26 Checking the lower case .,.,,.,.,.,,.,...6-25, 6-63 Checking the lower unit (for air leakage).. 3-19 Checking the neutral switch...................... 8-20 Checking the oil pressu re ......................... 5-25 Checking the oil pressure switch .............. 8-18 ..........5-47 Checking the oil Checking the oil strainer and the relief ......7-39 Checking the outboard motor mounting ........... 1-34 Checking the pilot water outlet .,,.,......,.,.., 1-35 Checking the pinion and forward ..6-25, 6-63 piston clearance ................. 5-57 Checking the Checking the piston diameter................... 5-56 Checking the piston pn,.,,.,...,,.,.,....,.,,.,... 5-58
pan...
assembly..... housing
Assembling the tiller Assembling the tilt cy|inder ....................... 7-69 Assembling the trim cylinder ....... ..............7-67
handle
.6-16,6-55 7-15,7-23
filters
joint-to-carburetor) system fuse,.,.... level
B.
Backlash ............6-39 Backlash (T50/F[50B, FT50C) ................. 6-77 Bleeding the power trim and tilt (built-in),..7-71 Bleeding the power trim and tilt (not ....7-7O Bottom ..............7-25 ......1-36
(F50/F504)
installed).................. cowling........ Break-in.......
operation.....
c.
Carburetor... Carburetor unit.............. system valves.... anodes armature battery... bearings brushes camshaft
1-10,4-17
........4-11 CDI unit with microcomputer,.,...... .............. 1 -7 ...................8-25 Charging ...............7-65 Check the Checking the ............3-19 Checking the ..........8-23 Checking the 1-33, 3-20 Checking the 6-25, 6-63 ...........8-24 Checking the .........5-45 Checking the Checking the carburetor............................ 4-1 Checking the CD I unit .,.,.,,...,.,,.,......,.,..,.,. 8-1 5 Checking th charge coi|.,.,.,,.,.........,.,..,.,. 8-1 5 Checki ng the compression pressure......... 5-25 Checking the connecting rod big end side ........5-59
pump
valve
position
gear............
clearance
-1
62Y141
Checking Checking Checking Checking Checking
fluid
level
the the the the the
piston piston piston piston power
Checking the Checking the Checking Checking trailer Checking Checking Checking Checking the the
operation
switch
the
the the the
housing
Checking the Checking the Checking the Checking the Checking the rocker arm Checking the Checking the Checking Checking Checking Checking Checking Checking the the the the the the
shaft.....
operation
tiller
handle..
pin boss bore.,...,.,..,.5-58 ring grooves.............. 5-58 ring side clearance...5-58 rings.......................... 5-57 trim and tilt ..,..,.,.3-16 power trim and tilt motor .....7-75 power trim and tilt .........3-16 power trim and tilt re|ay.......7-79 power trim and tilt switchi ,.,.7-80 Prime Start............ .............. 4-2O ..........3-19 propeller shaft ........... 6-1 5, 6-55 propeller shaft ,6-15, 6-54 pulser coi1 ............................ 8-1 6 pulser coil air gap................8-16 Rectifier Regulator .............. 8-26 remote control cab|es.......... 1-34 rocker arms and .............5-45 shift rod and shift cam.........6-25 shift rod assembly .........7-29 spark plug caps.,.,..,.,..,...,.., 8-1 4 spark p1u9s.......................... 3-1 1 starter motor operation........ 8-24 starter motor pinion ............. 8-23 starter re|ay ......................... 8-20 steering wheel/
Checking the wiring harness (10 pins) ,.,., 8-20 Clamp ..............7-43 Control .............3-13 Cooling water ...............4-3 ............5-51 Cylinder .,.,..,.,..,5-35 Cylinder head
brackets....... system......... hose.. body............ .,.,..,...,
D.
Dimensions.
Disassembling Disassembling Disassembling Disassembling Disassembling Disassembling Disassembling Disassembling Disassembling Disassembling the the the the the the the the the the
......2-19
propeller
assembly housing
carburetor.,..,...,..,.,.,.., 4-1 9 cylinder body .............. 5-55 drive shaft ................... 6-61 drive shaft assembly ..6-23 forward gear......6-23, 6-61 fuel pump .,..,...,..,.,.,,.,.. 4-9 gear pump,...,..,.,. ....... 7 -64 lower case.........6-24, 6-62 oil pan......................... 7-39 propeller shaft
...................6-14,6-54
Disassembling the propeller shaft
..6-13, 6-53 Disassembling the tilt cylinder .................. 7-63 Disassembling the trim cyli nder................ 7-63 Disassembly and assemb|y................. ....... 1 -4 Drive shaft and lower case (F50/F504).,,.6-21 Drive shaft and lower case (T50/FT50B, ..........6-59
FT50C)
E.
.... 1-34
Electrical Electrical components

F.
....2-9,2-16
............8-5
Checking Checking Checking shift Checking Checking Checking trim Checking Checking Checking Checking Checking Checking Checking Checking Checking Checking Checking Checking
cable....
the thermostat ................. ..........3-1 2 the thermoswitch ....................... 8-1 the throttle cable and
....7-15 the throttle cable and shifl rod..,7-23

the throttle cable operation .......3-13 the tilt cylinder and
cylinder the tilt system

the the the the the the the the the the the
.....7-64
........1-35 timin g be|t..,.,..,....,.,..,...,..,.,.., 3-7 timing belt and sprockets....5-32 top ........3-4 trim ......7-80 valve clearance ................... 3-1 0 valve ,.,.5-41 valve seat............. ............... 5-42 valve ...5-40 ..........5-40 water pump ......................... 6-1 4 water pump and shift rod ....6-47
Features and .............1-6 Fire ........1-3 Front ........8-6 Fuel and blowby hoses.......... ..................... 4-2 Fuel filter and fuel pump .,..,.,..,. .................. 4-7 Fuel ..............4-5 Fuel ........3-4
benefits prevention................ view... line system
cowling sensor
G.
pump.. General.......
Gear
......7-59 ......3-19 ............2-31 ,.,.,..,.,1-4
guides
General specif ications .................. .............. 2-1
springs valves....
Generaltorques........ Good working practices
62Y141
i-2
lndex
H.
Hose ........4-2 How to use this manua|............................... 1 -1
routing
I.
ldentification lgnition system
."......1-5 ......................1-17 lgnition system and lgnition control
Power trim and tilt unit..,.,,.,...,,.,.,,...3-16, 7-51 Power unit........................2-5, 2-12, 3-5, 5-1 3 Predelivery ...............1-33 Propeller ................1-32 Propeller shaft housing (T50/FT50B, .,.,,.,..,6-51 Propeller ..........1-32
checks selection
FT50C) si2e,.,.,..,.,....
system.........
....8-11
R.
Refacing the valve seat ............................ 5-43 Removing and installing the oil fi|ter......... 5-55 Removing the clamp brackets .................. 7 -45 Removing the cylinder head ..................... 5-39 Removing the drive shaft.................6-23, 6-61 Removing the lower unit....................6-9, 6-43 Removing the power trim and tilV hydro ....7-53 Removing the power unit.......................... 5-26 Removing the propeller shaft housing
lgnition timing contro| ................................ 1 -1 lnstalling the camshaft .............................. 5-48 lnstalling the clamp brackets....... ..............7-45 lnstalling the cylinder head .,..,......,..,.,..,... 5-49 lnstalling the drive shaft .................. 6-28, 6-66 lnstalling the lower unit ...................6-28, 6-66 lnstalling the power trim and tilt ................7-76 lnstalling the power unit ............................ 5-67 lnstalling the propeller shaft
ti|t......
housing
.6-18,6-57
lnstalling lnstalling lnstalling lnstalling lnstalling lnstalling lnstalling
the rocker arm assembly ...........5-49 the steering arm .............. ...........7-49 the timing belt and sprockets.....5-32
the upper case,.,.,....... ...............7-41 the ...........5-47 the water pump .......................... 6-1 the water pump and shift rod.....6-48
assembly
........6-53
valves....
L.
Lower ....1-8, 2-9, 2-16, 3-17 Lower unit ............6-7 Lower unit (T50/FT50B, FT50C) ............... 6-41 Lubricatin g the throttle gear ............ ..........7 -23 ..,.,...3-21
unit (F50/F504)
Removing Removing Removing Removing propeller Removing Replacing Replacing Replacing Replacing
the stafier motor pinion .....,.,..,8-23 the steering arm ............. ......... 7-49 the timing belt and sprockets...5-31 the water pump and shaft housing assembly ........... 6-1 3 the water pump and shift rod,.. 6-47 lhe engine oi1 ............................. 3-5 the gear oi|............................... 3-1 7 the timing belt ............................ 3-7 the valve 9uides....................... 5-41
S.
Safety while working................................... Selecting the connecting rod big end
1
Lubrication
M.
-3
bearing..,.,.,. bearing........ ..........
.,.,5-63 ....5-62
Selecting the crankshaft main journal Selecting the fonrvard gear shims 6-33, 6-37, 6-71, 6-75 Selecting the pinion
Maintenance interval chart.......................... 3-3 Maintenance specifications..,.,,.,......,.., .......2-5
Manualformat.........
".."............1-1
Measuring the fonruard and reverse gear back|ash.................. . 6-39, 6-77 Measuring the lower resistance .................. 8-4 Measuring the peak vo|tage....,.,,.,...,..,.,...., 8-4
shims..........
6-32, 6-36, 6-70, 6-74
Selecting the reverse gear shims ....6-34, 6-38
N.
Newly designed four carburetors ................
1
-6
Selection..... ......1-32 .......1-3 Self-protection ................. number.................. ....... 1-5 Serial Shimming..., 6-32, 6-36, 6-70,6-74
Shimming (F50) (for USA and Canada) ...6-31 Shimming (F504) (for worldwide) ............. 6-35 Shimming (FT50B, FT50C) (for ... 6-73 Shimming (T50) (for USA and Canada) ,.,6-69
P.
Parts, lubricants, and sea|ants.................... 1 -3 Power trim and tlt ................ ..................... 1 -22 Power trim and tlt electrical system.,..,.,...7-78 Power trim and tilt motor...... .....................7 -73
worldwide).................
-3
62Y141
Specialservice tools ..................3-1, 4-1 , 5-10,
Specified ..................2-29 Starboard and port views ............................ 8-5 ..............8-21 Starter ,..,.,.,..,...,..,.,.8-19 Starting Swivel bracket and steeri ng arm...............7 -47
torques
6-1
,7-4, 8-2
motor........... system
Symbols
T.
..............1-2
Synchronizing the carburetors ............. ..... 4-23
Technicaltips.............. ..........1-10 Test run....... ......1-35 Tightening torques ................2-29

Tiller handle (F50/F504, T50/F[50B) ...,..,.,7-5 Tiller handle (FT50C) ............7-17 Tiller handle model
(F50/F50A,
T50/FT50B).
.......8-8
Tiller handle model (FT50C) ....................... 8-9

Tilt cylinder and trim cylinder .................... 7-55 Ti min g belt and sprockets .,..,...,..,...,..,.,..,. 5-29 Top ........3-4 Top ........8-7 Trim .....7-57 Troub|eshootin9 ...........................5-1, 7 -1, 8-1
cowling. view...... cylinder
U.
Upper
case..
......7-31
V.
Ventilation
vtf.
......"..".1-3
Water pump and propeller shaft housing
(F50/F504)..
....6-11
Water pump and shift rod (T50/FT50B, Wiring
FT50C)........ ...6-45 harness ..,.,.,..,.,..,...,..,8-10
62Y141
i-4
Wiring diagram
FSOAEHD, FSOAED, FTSOCEHD, FTSOCED
@ @ @ @ @ @
Battery Engine start switch Engine shut-off switch Starter motor Starter relay
Color code
B
Br
G
Black Brown Green

Blue
Neutralswitch
Fuse (20A)
o
P R
@ Prime Start
@ Warning indicator
Orange Pink
Red
@ CDlunit
@ Thermoswitch @ Oilpressure switch
W B/O
BA/V
@ @ @ @ @ @
Charge coil Pulser coil Lighting coil Rectifier Regulator lgnition coil Spark plug
EHD
Bt
GAtr
Gy/B
PlB
White Black/orange Black/white Black/yellow Green/white Gray/lclack Pink/black

Pinl</white
PAr
W/B W/R
White/black White/red
YlB
Y/R
YelloMllack YelloMred
@YAMAHA
YAMAHA MOTOR CORPORATION, USA
Printed in USA
Nov.2000-1.66x1CR
(FsoAEf, FT50BEr)
r

F50TLRB

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F50TLRB

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@YAMAHA

fftlllH ilfft ||il

tilll lltil iltil ililt tilil

Features and benefits

....1-33 ...1-33 ..................1-34

.................1-35 ....1-35 ....1-36 ...1-36

2.3 1.8 0.6 1,2

3, Femw th. hnrinr@ dlihing bh spnl s[e. Ofrmtds

4, Losn rh diwn rccxet bd ru. tb dtu. .rbt O.

Crbh tuldd @:YB.oG

How to use this manual

Periodic checks and adjustments

O to @ in an exploded diagram indicate the grade of lubricant and the lubrication

water resistant grease (Yamaha grease A, Yamaha marine grease)

@ Apply Gasket MakeP

General information Safety while working To prevent an accident or injury and

Keep gasoline and all flammable products

Parts, lubricants, and sealants

and sealants or those recommended by Yamaha, when servicing or repairing the

Maintain good standards of personal and industrial hygiene.

Change and wash clothing as soon as possible if soiled with lubricants.

Avoid contact with skin. example, place a soiled

Safety while working

Good working practices Specialtools Use the recommended special tools to

Disassembly and assembly

Use compressed air to remove dust and dirt during disassembly.

Starting serial No.

FSOAEHT F5OAED F5OAET FT5OBET FTSOCEHD

TsOTR FsOAEHD F5OAEHT F5OAED

FTsOBET FT5OCEHD FT5OCED FTSOCET 64J

@ Modelname @ Approved model code

ldentification / Features and benefits

@ Prime Start @ Acceleration pump

CDI unit with microcomputer

Flywheel Stator Pulser coil Thermoswitch @ @ lgnition coil @ Oilpressure switch

Features and benefits

Reverse gear Number of teeth 24 30 Diameter

Shift rod Propeller shaft Dog clutch Shift slider

Features and benefits / Technical tips

@ Carburetor @ lntake silencer

@ Main air jet @ Throttle valve

Pilot screw Pilot outlet Bypass holes Venturi

@ Main air jet @ Throttle valve

Main nozzle Pilot air jet

$:I @,9 J:g

E Rir E Air-fuelmixture E Fuel

Bypass hose Acceleration pump Pump chamber Diaphragm 1 Throttle lever @

E Airflow E Throttle valve opening direction

@ Diaphragm 1 @ Diaphragm 2 @ To carburetors E Airflow

Throttle valve opening direction

Pulser coil Flywheel Charge coil

@ lgnition coils #1 and #4 @ lgnition coils #2 and #3 @ Oilpressure switch @ Thermoswitch

Over-revolution Low oil pressure Overheat

@ Cylinder identification signal

BTDC until the crankshaft speed maintains 600

@ Cylinder identification protrusion

@ Starting signal (5' BTDC) for cylinders #1 and

@ Starting signal (5' BTDC) for cylinders #2 and

Hydraulic system diagram

Power trim and tilt cylinder

Power trim and tilt components

@ Power trim and tilt cylinder @ Ram

@ Free piston @ Tilt piston