F60A

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

This Supplementary Service Manual has been prepared to introduce new service and new data
information for the F60 which is based on the F50. For complete information on service procedures,
it is necessary to use this Supplementary Service Manual together with the following manual.

F50A, FT50B, FT50C SERVICE MANUAL: 62Y-28197-3A-11

Important information 1

Particularly important information is distinguished in this manual by the following notations:

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS
INVOLVED!

WARNING
Failure to follow WARNING instructions could result in severe injury or death to the machine
operator, a bystander, or a person inspecting or repairing the outboard motor.

CAUTION:
A CAUTION indicates special precautions that must be taken to avoid damage to the out-
board motor.

NOTE:
A NOTE provides key information to make procedures easier or clearer.

F60A
SUPPLEMENTARY SERVICE MANUAL
©2001 by Yamaha Motor Co., Ltd.
1st Edition, July 2001
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
Printed in the Netherlands
 Contents
General information GEN
INFO
1
Specifications
SPEC 2
Periodic checks and adjustments CHK
ADJ
3
Fuel system
FUEL 4
Power unit
POWR 5
Lower unit
LOWR 6
Bracket unit
BRKT 7
– +

Electrical systems
ELEC 8
Troubleshooting TRBL
SHTG
9
Index
 General information

How to use this manual .................................................................................... 1

Manual format............................................................................................... 1
Symbols........................................................................................................ 2

Identification...................................................................................................... 3
Applicable models ........................................................................................ 3
Serial number ............................................................................................... 3

Features and benefits ....................................................................................... 4

Power unit..................................................................................................... 4
Carburetors................................................................................................... 5
Lower unit ..................................................................................................... 7
Bracket unit................................................................................................... 9
Electrical unit .............................................................................................. 10

Technical tips .................................................................................................. 11

Carburetor .................................................................................................. 11
PTT (Power Trim and Tilt) unit ................................................................... 12

Propeller selection .......................................................................................... 13

Propeller size.............................................................................................. 13
Selection..................................................................................................... 13

Predelivery checks ......................................................................................... 14

Checking the fuel system ........................................................................... 14
Checking the gear oil.................................................................................. 14
Checking the engine oil .............................................................................. 14
Checking the battery................................................................................... 14
Checking the outboard motor mounting height........................................... 14
Checking the shift/throttle cables................................................................ 15
Checking the steering system .................................................................... 15
Checking the gearshift and throttle operation............................................. 16
Checking the tilt system.............................................................................. 16
Checking the engine start switch and engine stop switch/
engine shut-off switch ............................................................................... 16
Checking the cooling water pilot hole ......................................................... 17
Test run ...................................................................................................... 17
Break-in ...................................................................................................... 17
After test run ............................................................................................... 17

69W3D1X
 Specifications

General specifications.................................................................................... 18

Maintenance specifications ........................................................................... 20

Power unit................................................................................................... 20
Lower unit ................................................................................................... 24
Electrical ..................................................................................................... 24
Dimensions................................................................................................. 27

Tightening torques.......................................................................................... 32
Specified torques........................................................................................ 32
General torques.......................................................................................... 33

Periodic checks and adjustments

Special service tools ...................................................................................... 34

Maintenance interval chart............................................................................. 36

Top cowling ..................................................................................................... 37

Checking the top cowling............................................................................ 37

Fuel system ..................................................................................................... 37

Checking the fuel filter ................................................................................ 37

Power unit........................................................................................................ 37
Checking the thermostat............................................................................. 37

General............................................................................................................. 38
Checking the anodes.................................................................................. 38
Lubrication .................................................................................................. 39

Fuel system

Hose routing .................................................................................................... 40

Fuel and blowby hoses............................................................................... 40
Cooling water hose..................................................................................... 41

Fuel line and fuel filter .................................................................................... 42

Carburetor unit ................................................................................................ 43

Adjusting the dashpot (acceleration pump) ................................................ 44

69W3D1X
 Power unit

Power unit........................................................................................................ 45
Checking the compression pressure .......................................................... 55
Checking the oil pressure ........................................................................... 55
Checking the cylinder bore ......................................................................... 56
Checking the piston ring grooves ............................................................... 56

Lower unit

Drive shaft and lower case............................................................................. 57

Removing the drive shaft............................................................................ 59
Disassembling the forward gear ................................................................. 59
Assembling the forward gear...................................................................... 59
Installing the drive shaft.............................................................................. 59

Shimming......................................................................................................... 60
Shimming.................................................................................................... 61
Selecting the forward gear shims ............................................................... 61

Bracket unit

Tiller handle ..................................................................................................... 63

Bottom cowling ............................................................................................... 65

Upper case....................................................................................................... 67
Disassembling the oil pan........................................................................... 71
Assembling the oil pan ............................................................................... 71
Installing the upper case............................................................................. 72

Clamp brackets ............................................................................................... 74

Adjusting the trim sensor ............................................................................ 75

Swivel bracket and steering arm ................................................................... 76

Power trim and tilt unit ................................................................................... 77

Disassembling the gear pump .................................................................... 82
Checking the valves ................................................................................... 82
Assembling the gear pump......................................................................... 83
Checking the trim sensor............................................................................ 84

69W3D1X
 Electrical systems

Wiring harness ................................................................................................ 85

Ignition and ignition control system ............................................................. 86

Checking the spark plug caps .................................................................... 88
Checking the pulser coil air gap ................................................................. 88
Checking the engine start switch................................................................ 88

Starting system ............................................................................................... 89

Starter motor ................................................................................................... 90

Checking the armature ............................................................................... 91
Checking the brushes................................................................................. 91

Wiring diagram

69W3D1X
 GEN
INFO General information
How to use this manual 1

Manual format
The format of this manual has been designed to make service procedures clear and easy to under-
stand. Use the information below as a guide for effective and quality service.

1 Parts are shown and detailed in an exploded diagram and are listed in the components list.
2 Tightening torque specifications are provided in the exploded diagrams and after a numbered
step with tightening instructions.
3 Symbols are used to indicate important aspects of a procedure, such as the grade of lubricant
and lubrication point.
4 The components list consist of parts and part quantities, as well as bolt, screw, O-ring, and hose
dimensions.
5 Service points regarding removal, checking, and installation are shown in individual illustrations
to explain the relevant procedure.

NOTE:
For troubleshooting procedures, see Chapter 9, “Troubleshooting.”

1 69W3D1X
 How to use this manual
Symbols
The symbols below are designed to indicate the content of a chapter.
General information Fuel system Bracket unit
GEN
INFO FUEL BRKT 1
Specifications Power unit Electrical systems

SPEC POWR ELEC – +

2
Periodic checks and adjustments Lower unit Troubleshooting
CHK
ADJ LOWR TRBL
SHTG 3
Symbols 1 to 6 indicate specific data.

1 2 3 4
T.
R.

5 6
4
1
2
3
4
Special tool
Specified oil or fluid
Specified engine speed
Specified tightening torque
5 Specified measurement
6 Specified electrical value
(resistance, voltage, electric current)
5
Symbols 7 to A in an exploded diagram indicate the grade of lubricant and the lubrication point.

7 8 9 0 A
6
A M D C
E

7 Apply Yamaha 4-stroke motor oil

8 Apply water resistant grease (Yamaha grease A)
0 Apply corrosion resistant grease
(Yamaha grease D)
7
9 Apply molybdenum disulfide grease A Apply low temperature resistant grease
(Yamaha grease C)

Symbols B to G in an exploded diagram indicate the type of sealant or locking agent and the appli-
8
cation point.

B
GM
C
4
D
LT

271
E
LT

242
F
LT

572
G

SS
9
B Apply Gasket Maker® E Apply LOCTITE® No. 242 (Blue)
C Apply Yamabond No. 4 F Apply LOCTITE® No. 572
D Apply LOCTITE® No. 271 (Red) G Apply silicon sealant

69W3D1X 2
 GEN
INFO General information
Identification 1

Applicable models
This manual covers the following models.

Applicable models
F60AEHT
F60AET

Serial number
The outboard motor serial number is
stamped on a label attached to the port
clamp bracket.

1 Model name
2 Approved model code
3 Transom height
4 Serial number

Approved Starting
Model name
model code serial No.
F60AEHT L: 500101–
69W
F60AET L: 400101–

3 69W3D1X
 Identification / Features and benefits
Features and benefits 1

Power unit
Based on the power unit of the field-proven F50, newly designed parts have been adopted in the
various areas to attain 60 horsepower. The newly designed parts include the intake valves, exhaust
valves, cylinder head, pistons, and the intake silencer.

Cylinder head
The shape of the combustion chamber has been changed to increase its capacity.
The diameter of the intake and exhaust valves have been enlarged to increase output.

F50 F60

83.5 mm 84.1 mm 84.0 mm 84.8 mm

(3.29 in) (3.31 in) (3.31 in) (3.34 in)

30.0 mm (1.18 in) 26.0 mm (1.02 in) 32.0 mm (1.26 in) 26.7 mm (1.05 in)

F50 F60 S69W1200

1 Combustion chamber
2 Intake valve
3 Exhaust valve

69W3D1X 4
 GEN
INFO General information
Oil pump
The size of the oil pump rotor has been enlarged to increase the oil discharge volume. As a result,
reliable lubrication has been realized.

22 mm (0.87 in) 24 mm (0.94 in)

F50 F60 S69W1210

1 Rotor
2 Embossed letters for identification

Oil discharge volume

F50 21.5 L (5.68 US gal, 0.22 Imp gal)/min
F60 23.5 L (6.21 US gal, 5.17 Imp gal)/min

Carburetors
To achieve the high power output of the F60, the carburetor bores have been enlarged.
Ø27

Ø22

Ø25
Ø30

F50 F60
S69W1220

Comparison chart of carburetor bores

Throttle valve Venturi

F50 ø27 ø22
F60 ø30 ø25

5 69W3D1X
 Features and benefits
Although the main jet specification numbers of the F50 differed between cylinders, the F60 uses
main jets with the same specification number for all four cylinders due to the change in shape of the
intake silencer.

:
F50 F60 S69W1230

È Air
Comparison chart of main jet diameters

Cylinder #1 #2 #3 #4
F50 #124 #126 #116 #114
F60 #124 #124 #124 #124

Power nozzle
The F60 uses a power nozzle in its carburetors. This nozzle provides a rich air-fuel mixture to
ensure the proper output when operating at high engine speeds.

:
S69W1240

1 Power nozzle
2 Fuel inlet
È Air-fuel mixture

69W3D1X 6
 GEN
INFO General information
Lower unit
Drive shaft
The drive shaft has been machined to accommodate the high power output. The portion that
mounts to the pinion gear has been machined with involute splines to increase durability. A section
of the midspan of the drive shaft has been reduced to 14.4 mm (0.57 in) to prevent the drive shaft
from breaking under impact loads. In addition, two grooves are provided on the drive shaft for iden-
tification purposes.

Ø14.4

95.5 mm
(3.76 in)

F60: F50:

S69W1250

1 Grooves for identification

2 Involute splines
3 Angled splines

7 69W3D1X
 Features and benefits
Forward gear bearing
The size of the forward gear bearing has been increased to accommodate the high power output of
the F60. With this increase, the coupling length of the forward gear has been extended as well. In
addition, two grooves are provided on the forward gear for identification purposes.

26.0 mm
23.2 mm
(1.02 in)
(0.91 in)
S69W1260

1 Forward gear bearing

2 Grooves for identification
3 Forward gear
Bearing comparison chart

Forward gear bearing Forward gear

F50 22.2 mm (0.87 in) 18.5 mm (0.73 in)
F60 26.0 mm (1.02 in) 23.2 mm (0.91 in)

Propeller
The propeller of the F60 has been newly designed (69W series). The strength of the propeller
blades and the slipping resistance of the damper have been increased. The 11-, 13-, and 15-inch
propellers of the currently used 663 series will be gradually replaced by the 69W series.

69W3D1X 8
 GEN
INFO General information
Bracket unit
PTT (Power trim and tilt) unit
Based on the 62Y type PTT unit of the F50, the internal valve and power trim and tilt motor have
been changed. The construction of the valves has been changed to increase the shut-off pressure.
The unit limits the movement of the outboard motor, which has increased in size with the increase in
its power output, and secures it in place.

69W-00

31 MPa [316 kgf/cm2]

(31 MPa [316 kgf/cm2])

18 MPa [184 kgf/cm2]

(14 MPa [143 kgf/cm2])

12 MPa [122 kgf/cm2]

(10 MPa [102 kgf/cm2])

3.3 MPa [34 kgf/cm2]

(2.0 MPa [20.4 kgf/cm2])

S69W1270

Specified PTT motor output

F50A 12 V 0.15 kW
F60A 12 V 0.20 kW

1 PTT motor 6 Up-relief valve

2 Identification mark 7 Down-relief valve
3 Tilt piston absorber 8 Gear pump
4 Tilt and trim cylinder È Shut-off pressure of the F60 valves
5 Manual valve É Shut-off pressure of the F50 valves

9 69W3D1X
 Features and benefits
Steering friction
The F60 tiller handle models use a newly developed, compact steering friction.

S69W1280

1 Steering friction

Electrical unit
Starter motor
The starter motor uses six magnets and four brushes to enhance its operating torque.

F50 F60
S69W1290

1 Bearing 5 Magnet
2 Starter relay 6 Brush
3 Neutral switch 7 Starter motor
4 Engine start switch 8 Battery

Operating torque
F50 2.74 N·m (0.27 kgf·m, 2.0 ft·lb)
F60 3.50 N·m (0.35 kgf·m, 2.5 ft·lb)

69W3D1X 10
 GEN
INFO General information
Technical tips 1

Carburetor
Power nozzle
The power nozzle is activated when the engine is operating at high speeds. To reduce the fuel con-
sumption rate and the pollution of the exhaust gases, the carburetors of the F60 are set lean. There-
fore, the air-fuel mixture becomes lean at high engine speeds, when greater output is needed. The
power nozzle supplies a richer fuel mixture at high engine speed to realize the optimal air-fuel ratio
to produce output.

:
S69W1300

1 Throttle valve
2 Power nozzle
È Air
É Air-fuel mixture
Ê Fuel

11 69W3D1X
 Technical tips
PTT (Power Trim and Tilt) unit
Shuttle piston
A ball type shut-off construction is used for both the up-shuttle and down-shuttle pistons. The ball
type realizes a reliable shut-off operation and high shut-off pressure.

F50

F60
S69W1310

1 Ball

69W3D1X 12
 GEN
INFO General information
Propeller selection 1
a Propeller diameter (in inches)
b Propeller pitch (in inches)
The performance of a boat and outboard
c Propeller type (propeller mark)
motor will be critically affected by the size
and type of propeller you choose. Propellers Selection
greatly affect boat speed, acceleration, When the engine speed is at the full throttle
engine life, fuel economy, and even boating operating range (5,000–6,000 r/min), the
and steering capabilities. An incorrect choice ideal propeller for the boat is one that pro-
could adversely affect performance and vides maximum performance in relation to
could also seriously damage the engine. boat speed and fuel consumption.
Use the following information as a guide for
selecting a propeller that meets the operating Propeller size (in) Material
conditions of the boat and the outboard 10 × 15 - G
motor.
10 3/8 × 13 - G
Propeller size 10 5/8 × 12 - G
The size of the propeller is indicated on the 10 3/4 × 16 - G
propeller blade or outside of the propeller 11 × 15 - G Aluminum
boss. 11 5/8 × 11 - G
11 3/4 × 10 - G
12 1/4 × 8 - G
× - 12 1/4 × 9 - G
10 1/4 × 14 - G
10 1/4 × 15 - G
10 1/4 × 16 - G
10 5/8 × 13 - G Stainless
S69W1030
11 1/2 × 13 - G
11 3/4 × 12 - G
12 × 11 - G

× -

S69W1040

× -

S69W1050

13 69W3D1X

Predelivery checks
To make the delivery process smooth and
efficient, the predelivery checks should be
completed as explained below.
Checking the fuel system
1. Check that the fuel hoses are securely
connected and that the fuel tank is full
with fuel.
CAUTION:
This is a 4-stroke engine. Do not use pre-
mixed fuel and 2-stroke outboard motor
oil.
Checking the gear oil
1. Check the gear oil level.
S69W1070
69W3D1X
Propeller selection / Predelivery checks
1 Checking the engine oil
1. Check the oil level.
NOTE:
• If the engine oil is above the maximum level
mark a, drain sufficient oil until the level is
between a and b.
• If the engine oil is below the minimum level
mark b, add sufficient oil until the level is
between a and b.
Recommended engine oil:
API: SE, SF, SG, or SH
SAE: 10W-30, 10W-40, or 20W-40
Oil capacity:
Without oil filter replacement:
2.0 L (2.1 US qt, 1.8 Imp qt)
Checking the battery
1. Check the capacity, electrolyte level, and
specified gravity of the battery.
Battery capacity: 12 V, 70–100 Ah
2. Check that the red and black battery
cables are securely connected.
Checking the outboard motor
mounting height
1. Check that the anti-cavitation plate is
aligned with the bottom of the boat. If the
mounting height is too high, cavitation
will occur and propulsion will be reduced.
Also, the engine speed will increase
abnormally and cause the engine to
overheat. If the mounting height is too
low, water resistance will increase and
reduce engine efficiency.
14
 GEN
INFO General information

S69W1110

NOTE: CAUTION:
The optimum mounting height is affected by
The shift/throttle cable joint must be
the combination of the boat and the outboard
screwed in a minimum of 8.0 mm (0.31 in)
motor. To determine the optimum mounting
e.
height, test run the outboard motor at differ-
ent heights.
Checking the steering system
1. Check the steering friction for proper
2. Check that the clamp brackets are
adjustment.
secured with the clamp bolts.
2. Check that the steering operates
Checking the shift/throttle cables smoothly.
1. Set the remote control lever or shift lever
to the neutral position and fully close the È
throttle lever or throttle grip.

2. Check that the set pin a is aligned with

the alignment mark b. Adjust if neces-
sary.

3. Check that the alignment mark c is

aligned with the mark d. Adjust if neces-
sary.
É

È Tiller handle model

É Remote control model

3. Check that there is no interference with

wires or hoses when the outboard motor
is steered.

15 69W3D1X

Checking the gearshift and throttle
operation
1. Check that the gearshift operates
smoothly when the remote control lever
or shift lever is shifted from neutral into
forward or reverse.
2. Check that the throttle operates smoothly
when the remote control lever or throttle
grip is shifted from the fully closed posi-
tion to the fully open position a.
È
Predelivery checks
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.
2. Check that the engine turns off when the
engine start switch is turned to OFF.
3. Check that the engine turns off when the
engine stop switch is pushed or the
engine shut-off cord is pulled from the
engine shut-off switch.
È

É
N
F R
É

S69W1150

È Tiller handle model

É Remote control model S69W1170

È Tiller handle model

Checking the tilt system É Remote control model
1. Check that the outboard motor tilts up
and down smoothly when operating the
power trim and tilt unit.

2. Check that there is no abnormal noise

produced when the outboard motor is
tilted up or down.

3. Check that there is no interference with

wires and hoses when the tilted-up out-
board motor is steered.

4. Check that the trim meter points down

when the outboard motor is tilted all the
way down.

69W3D1X 16
 GEN
INFO General information
Checking the cooling watger pilot
hole
1. Start the engine, and then check that
cooling water is discharged from the
cooling water pilot hole.

0 1 2 10

S69W1190

È Hour

After test run

1. Check for water in the gear oil.

2. Check for fuel leakage in the cowling.

Test run
1. Start the engine, and then check that the
gearshift operates smoothly.
2. Check the engine idle speed after the
engine has been warmed up.
3. After a test run and while the engine is at
idle, flush the cooling water passage with
fresh water using the flushing kit.

3. Operate at trolling speed.

4. Run the outboard motor for one hour at

2,000 r/min or at half throttle, then for
another hour at 3,000 r/min or at 3/4
throttle.

5. Check that the outboard motor does not

tilt up when shifting into reverse and that
water does not flow in over the transom.

NOTE:
The test run is part of the break-in operation.

Break-in
During the test run, perform the break-in
operation in the following three stages.
1. One hour a at 2,000 r/min or at approxi-
mately half throttle.

2. One hour b at 3,000 r/min or 3/4 throttle

and one minute out of every ten at full
throttle.

3. Eight hours c at any speed, however,

avoid running at full speed for more than
five minutes.

17 69W3D1X
 Predelivery checks / General specifications
General specifications 2

Model
Item Unit
F60AEHT F60AET
Dimension
Overall length
Overall width
mm (in)
mm (in)
1,339 (52.7)
384 (15.1)
706 (27.8) 1
Overall height
(L)
Boat transom height
(L)
Weight
mm (in)

mm (in)
1,415 (55.7)

508 (20.0)
2
(with aluminum propeller)
(L)
Performance
Maximum output
kg (lb)

kW (hp)
120.0 (265)

44.1 (60.0)
114.0 (251)
3
at 5,500 r/min

4
Full throttle operating range r/min 5,000–6,000
Maximum fuel consumption L (US gal, 19.5 (5.15, 4.29)
lmp gal)/hr
at 6,000 r/min
Power unit
Type
Cylinder quantity
Displacement
Bore × stroke
cm3 (cu. in)
mm (in)
In-line, 4-stroke, OHC, 8 valves
4
996 (60.8)
65.0 × 75.0 (2.56 × 2.95)
5
Compression ratio 9.5
Carburetor quantity
Control system
Starting system
Tiller handle
4

Electric
Remote control 6
Ignition control system Microcomputer (CDI)
Ignition timing
Alternator output
Enrichment system
Spark plugs
Degree
V, A
TDC 0–BTDC 25
12, 10
Prime Start
DPR5EA-9
7
Cooling system Water
Exhaust system
Lubrication system
Through propeller boss
Wet sump 8
9
69W3D1X 18
SPEC
Specifications
Model
Item Unit
F60AEHT F60AET
Fuel and oil
Fuel type Regular unleaded gasoline
Fuel rating PON* 86
RON 91
Engine oil type 4-stroke motor oil
Engine oil grade API SE, SF, SG, or SH
SAE 10W-30, 10W-40, or 20W-40
Engine oil quantity
(with oil filter replacement) L 2.2 (2.3, 1.9)
(US qt, lmp qt)
(without oil filter replacement) L 2.0 (2.1, 1.8)
(US qt, lmp qt)
Gear oil type Hypoid gear oil
Gear oil grade API GL-4
SAE 90
Gear oil quantity L 0.43 (0.45, 0.38)
(US qt, lmp qt)
Bracket
Trim angle Degree –4 to 16
(at 12 degree boat transom)
Tilt-up angle Degree 69
Steering angle Degree 40 + 40
Drive unit
Gearshift positions F-N-R
Gear ratio 1.85 (24/13)
Reduction gear type Spiral bevel gear
Clutch type Dog clutch
Propeller shaft type Spline
Propeller direction Clockwise
(rear view)
Propeller identification mark G
Electrical
Battery capacity V, Ah 12, 70–100
* PON: Pump Octane Number (Research Octane Number + Motor Octane Number)/2
RON: Research Octane Number

19 69W3D1X
 General specifications / Maintenance specifications
Maintenance specifications 2

Power unit
Model
Item Unit
F60AEHT F60AET
Power unit
Minimum compression kPa 880 (8.8, 125)
pressure* (kgf/cm2, psi)
Lubrication oil pressure kPa 110 (1.1, 16)
(reference data) (kgf/cm2, psi)
at 900 r/min
Cylinder heads
Warpage limit mm (in) 0.1 (0.004)

(lines indicate straightedge

position)
Cylinder head journal inside mm (in) 37.00–37.02 (1.4567–1.4575)
diameter
Cylinders
Bore size mm (in) 65.00–65.01 (2.5591–2.5594)
Taper limit mm (in) 0.08 (0.0031)
Out-of-round limit mm (in) 0.01 (0.0004)
Pistons
Piston diameter (D) mm (in) 64.95–64.96 (2.5571–2.5574)
Measuring point (H) mm (in) 5 (0.2)
Piston-to-cylinder clearance mm (in) 0.035–0.065 (0.0014–0.0025)
Piston pin boss bore size mm (in) 15.974–15.985 (0.6289–0.6293)
Oversize piston
1st mm (in) +0.25 (0.0098)
2nd mm (in) +0.50 (0.0196)
Oversize piston diameter
1st mm (in) 65.20–65.21 (2.5669–2.5673)
2nd mm (in) 65.45–65.46 (2.5768–2.5771)
Piston pins
Outside diameter mm (in) 15.965–15.970 (0.6285–0.6287)
* Measuring conditions:
Ambient temperature of 20 °C (68 °F), with throttle fully open, and spark plugs removed from all
cylinders
The figures are for reference only.

69W3D1X 20
SPEC
Specifications
Model
Item Unit
F60AEHT F60AET
Piston rings
Top ring
Dimension B mm (in) 1.17–1.19 (0.0461–0.0468)
Dimension T mm (in) 2.30–2.50 (0.0906–0.0984)
End gap mm (in) 0.15–0.30 (0.0060–0.0118)
Side clearance mm (in) 0.02–0.06 (0.0008–0.0023)
2nd ring
Dimension B mm (in) 1.47–1.49 (0.0578–0.0586)
Dimension T mm (in) 2.60–2.80 (0.1024–0.1102)
End gap mm (in) 0.30–0.50 (0.0118–0.0196)
Side clearance mm (in) 0.02–0.06 (0.0008–0.0023)
Oil ring
Dimension B mm (in) 2.36–2.48 (0.0929–0.0976)
Dimension T mm (in) 2.75 (0.1083)
End gap mm (in) 0.20–0.70 (0.0079–0.0275)
Side clearance mm (in) 0.04–0.18 (0.0016–0.0070)
Camshafts
Intake (A) mm (in) 30.89–30.99 (1.2161–1.2200)
Exhaust (A) mm (in) 30.82–30.92 (1.2135–1.2175)
Intake and mm (in) 25.95–26.05 (1.0217–1.0256)
exhaust (B)
Camshaft journal diameter
#1 mm (in) 36.93–36.94 (1.4539–1.4543)
#2, #3, #4 mm (in) 36.94–36.95 (1.4543–1.4547)
Camshaft journal oil clearance
#1 mm (in) 0.06–0.10 (0.0023–0.0039)
#2, #3, #4 mm (in) 0.05–0.09 (0.0020–0.0035)
Maximum camshaft runout mm (in) 0.04 (0.0016)
Rocker arm shafts
Outside diameter mm (in) 15.98–15.99 (0.6291–0.6295)
Rocker arms
Inside diameter mm (in) 16.00–16.01 (0.6299–0.6303)
Valves
Valve clearance (cold)
Intake mm (in) 0.20 ± 0.05 (0.008 ± 0.002)
Exhaust mm (in) 0.30 ± 0.05 (0.012 ± 0.002)
Head diameter (A)
Intake mm (in) 31.9–32.1 (1.2560–1.2637)
Exhaust mm (in) 26.6–26.8 (1.0472–1.0551)

21 69W3D1X
 Maintenance specifications
Model
Item Unit
F60AEHT F60AET
Face width (B)
Intake mm (in) 1.98–2.40 (0.0780–0.0945)
Exhaust mm (in) 2.16–2.79 (0.0850–0.1098)
Seat contact width (C)
Intake mm (in) 1.3–1.5 (0.0512–0.0590)
Exhaust mm (in) 1.3–1.5 (0.0512–0.0590)
Margin thickness (D)
Intake mm (in) 0.8–1.2 (0.0315–0.0472)
Exhaust mm (in) 1.0–1.4 (0.0394–0.0551)
Stem diameter
Intake mm (in) 5.48–5.49 (0.2157–0.2161)
Exhaust mm (in) 5.46–5.47 (0.2150–0.2153)
Guide inside diameter
Intake and exhaust mm (in) 5.50–5.51 (0.2165–0.2169)
Stem-to-guide clearance
Intake mm (in) 0.01–0.03 (0.0004–0.0012)
Exhaust mm (in) 0.03–0.05 (0.0012–0.0020)
Stem runout limit
Intake mm (in) 0.05 (0.0020)
Exhaust mm (in) 0.03 (0.0012)
Valve springs
Free length mm (in) 39.85 (1.5689)
Minimum free length mm (in) 37.85 (1.4901)
Tilt limit mm (in) 1.7 (0.067)
Connecting rods
Small-end inside diameter mm (in) 15.985–15.998 (0.6293–0.6298)
Big-end inside diameter mm (in) 36.000–36.024 (1.4173–1.4183)
Crankpin oil clearance mm (in) 0.016–0.040 (0.0006–0.0015)
Big-end bearing thickness
Yellow mm (in) 1.500–1.504 (0.0591–0.0592)
Red mm (in) 1.496–1.500 (0.0589–0.0591)
Pink mm (in) 1.492–1.496 (0.0587–0.0589)
Green mm (in) 1.488–1.492 (0.0586–0.0587)
Crankshaft
Crankshaft journal
Diameter mm (in) 42.984–43.000 (1.6923–1.6929)
Crankpin
Diameter mm (in) 32.984–33.000 (1.2986–1.2992)
Runout limit mm (in) 0.04 (0.0016)
Crankcase
Crankcase main journal inside mm (in) 46.000–46.024 (1.8110–1.8120)
diameter
Crankshaft main journal oil mm (in) 0.012–0.036 (0.0005–0.0014)
clearance

69W3D1X 22
SPEC
Specifications
Model
Item Unit
F60AEHT F60AET
Crankcase main journal
bearing thickness
Yellow mm (in) 1.502–1.506 (0.0591–0.0593)
Red mm (in) 1.498–1.502 (0.0590–0.0591)
Pink mm (in) 1.494–1.498 (0.0588–0.0590)
Green mm (in) 1.490–1.494 (0.0587–0.0588)
Oil pump
Type Trochoid
Outer rotor-to-housing mm (in) 0.09–0.15 (0.0035–0.0059)
clearance
Outer rotor-to-inner rotor mm (in) below 0.12 (0.0047)
clearance limit
Rotor-to-cover clearance mm (in) 0.03–0.08 (0.0012–0.0031)
Thermostat
Opening temperature °C (°F) 60 (140)
Fully open temperature °C (°F) 70 (158)

Valve open lower limit mm (in) 3.0 (0.12)

Fuel pump
Discharge L (US gal, 70 (18.5, 15.4)
Imp gal)/hr
at 6,000 r/min
Pressure kPa 49 (0.49, 7.0)
(kgf/cm2, psi)
Plunger stroke mm (in) 5.85–9.65 (0.2303–0.3799)
Carburetor
ID mark 69W00
Main jet # 124
Pilot jet # 39
Pilot screw turns out 1 3/4–2 3/4
Float height mm (in) 5.2 (0.20)
Engine idle speed r/min 800–900

23 69W3D1X
 Maintenance specifications
Lower unit
Model
Item Unit
F60AEHT F60AET
Gear backlash
Pinion-to-forward gear mm (in) 0.18–0.54 (0.0071–0.0212)
Pinion-to-reverse gear mm (in) 0.71–1.07 (0.0280–0.0421)
Pinion shims mm 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50
Forward gear shims mm 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50
Reverse gear shims mm 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50

Electrical
Model
Item Unit
F60AEHT F60AET
Ignition system
Ignition timing
(engine idle speed) Degree TDC 0
Charge coil output peak
voltage (L – Br)
at cranking (unloaded) V 159
at cranking (loaded) V 164
at 1,500 r/min (loaded) V 168
at 3,500 r/min (loaded) V 126
Charge coil resistance(*1) Ω 272–408
(L – Br)
Pulser coil output peak voltage
(W/R – W/B)
at cranking (unloaded) V 9.5
at cranking (loaded) V 5.5
at 1,500 r/min (loaded) V 11.0
at 3,500 r/min (loaded) V 15.5
Pulser coil resistance(*1) Ω 396–594
(W/R – W/B)
CDI unit output peak voltage
(B/O – B, B/W – B)
at cranking (unloaded) V 131
at cranking (loaded) V 141
at 1,500 r/min (loaded) V 150
at 3,500 r/min (loaded) V 112
Spark plug gap mm (in) 0.9 (0.035)
(*1)
The figures are for reference only.

69W3D1X 24
SPEC
Specifications
Model
Item Unit
F60AEHT F60AET
Ignition control system
Oil pressure switch kPa 29.4–58.8 (0.294–0.588, 4.181–8.361)
ON ↔ OFF (kgf/cm2, psi)
Thermoswitch (Gy/B – B)
OFF → ON °C (°F) 76–84 (169–183)
ON → OFF °C (°F) 63–77 (145–170)
Starter motor
Type Bendix
Output kW 1.1
Cranking time limit Second 30
Brushes
Standard length mm (in) 17.0 (0.67)
Wear limit mm (in) 10.0 (0.39)
Commutator
Standard diameter mm (in) 33.0 (1.30)
Wear limit mm (in) 32.0 (1.26)
Mica
Standard undercut mm (in) 0.5–0.8 (0.02–0.03)
Wear limit mm (in) 0.2 (0.01)
Charging system
Fuse A 20
Lighting coil output peak
voltage (G – G)
at cranking (unloaded) V 14.0
at 1,500 r/min (unloaded) V 38
at 3,500 r/min (unloaded) V 86
Lighting coil resistance(*1) Ω 1.2–1.8
(G – G)
Rectifier Regulator output
peak voltage (R – B)
at 1,500 r/min (unloaded) V 22
at 3,500 r/min (unloaded) V 27
Enrichment control system
Prime Start

Plunger extended length a mm (in) 24.6 (0.97)

(*1)
The figures are for reference only.

25 69W3D1X
 Maintenance specifications
Model
Item Unit
F60AEHT F60AET
Power trim and tilt system
Trim sensor
Setting resistance Ω 9–11
Resistance (P – B) Ω 9–288.3
Fluid type ATF Dexron II
Brushes
Standard length mm (in) 10 (0.39)
Wear limit mm (in) 3.5 (0.14)
Commutator
Standard diameter mm (in) 22.0 (0.87)
Wear limit mm (in) 21.0 (0.83)
Mica
Standard undercut mm (in) 1.5 (0.06)

69W3D1X 26
SPEC
Specifications
Dimensions
Exterior

L3
A1 W5

W2
W1

W6

L7 L6
L2 L1
L10

H9 H5

H2
H7
H10

H8 B6

H4

H1 C1

H3 L5
H6
L8
A2

H11

A3

L9 L4

S69W2150

27 69W3D1X
 Maintenance specifications
Model
Symbol Unit
F60AEHT
L1 mm (in) 584 (23.0)
L2 mm (in) 226 (8.9)
L3 mm (in) 755 (29.7)
L4 mm (in) 533 (21.0)
L5 (L) mm (in) 97 (3.8)
(X) mm (in) —
L6 (L) mm (in) 932 (36.7)
(X) mm (in) —
L7 mm (in) 417 (16.4)
L8 mm (in) 164 (6.5)
L9 (L) mm (in) 0 (0)
(X) mm (in) —
L10 mm (in) 62 (2.4)
H1 (L) mm (in) 870 (34.3)
(X) mm (in) —
H2 mm (in) 545 (21.5)
H3 mm (in) 175 (6.9)
H4 (L) mm (in) 527 (20.7)
(X) mm (in) —
H5 mm (in) 758 (29.8)
H6 (L) mm (in) 708 (27.9)
(X) mm (in) —
H7 mm (in) 354 (13.9)
H8 mm (in) 37 (1.5)
H9 mm (in) 759 (29.9)
H10 mm (in) 49 (1.9)
H11 (L) mm (in) 24 (0.9)
(X) mm (in) —
W1 mm (in) 192 (7.6)
W2 mm (in) 124 (4.9)
W3 mm (in) —
W4 mm (in) —
W5 mm (in) 360 (14.2)
W6 mm (in) 645 (25.4)
A1 Degree 40
A2 Degree 69
A3 Degree 4
T1 mm (in) —

69W3D1X 28
SPEC
Specifications
Exterior

A1

W1
W5

L7 L6
L8 L1
L10
L2

H9

H2
H7
H10

H8 B6

H4

H1 C1

H3 L5
H6
A2

H11

A3

L9 L4
S69W2160

29 69W3D1X
 Maintenance specifications
Model
Symbol Unit
F60AET
L1 mm (in) 584 (23.0)
L2 mm (in) 122 (4.8)
L3 mm (in) —
L4 mm (in) 533 (21.0)
L5 (L) mm (in) 97 (3.8)
(X) mm (in) —
L6 (L) mm (in) 932 (36.7)
(X) mm (in) —
L7 mm (in) 417 (16.4)
L8 mm (in) 147 (5.8)
L9 (L) mm (in) 0 (0)
(X) mm (in) —
L10 mm (in) 62 (2.4)
H1 (L) mm (in) 870 (34.3)
(X) mm (in) —
H2 mm (in) 545 (21.5)
H3 mm (in) 175 (6.9)
H4 (L) mm (in) 527 (20.7)
(X) mm (in) —
H5 mm (in) —
H6 (L) mm (in) 708 (27.9)
(X) mm (in) —
H7 mm (in) 354 (13.9)
H8 mm (in) 22.5 (0.9)
H9 mm (in) 759 (29.9)
H10 mm (in) 49 (1.9)
H11 (L) mm (in) 24 (0.9)
(X) mm (in) —
W1 mm (in) 192 (7.6)
W2 mm (in) —
W3 mm (in) —
W4 mm (in) —
W5 mm (in) 360 (14.2)
W6 mm (in) —
A1 Degree 40
A2 Degree 69
A3 Degree 4
T1 mm (in) —

69W3D1X 30
SPEC
Specifications
Clamp bracket

B5
B3

B4

B9
B9
B9
B2 C1
D1
B6

D2

D1
B1
B8

S69W2170

Model
Symbol Unit
F60AEHT F60AET
B1 mm (in) 126 (5.0)
B2 mm (in) 249 (10.0)
B3 mm (in) 163.5 (6.4)
B4 mm (in) 50.8 (2.0)
B5 mm (in) 180 (7.1)
B6 mm (in) 350 (13.8)
B7 mm (in) —
B8 mm (in) —
B9 mm (in) 18.5 (0.7)
C1 mm (in) 69 (2.7)
C2 mm (in) —
D1 mm (in) 13 (0.5)
D2 mm (in) 60.5 (2.4)

31 69W3D1X
 Maintenance specifications / Tightening torques
Tightening torques 2

Specified torques
Tightening torques
Part to be tightened Thread size
N·m kgf·m ft·lb
Power unit
Flywheel magnet nut — 160 16 116
Stator base screw M6 4 0.4 2.9
Cover screw M6 3 0.3 2.2
Red battery cable nut — 4 0.4 2.9
Oil pressure switch — 9 0.9 6.5
Oil pressure switch lead screw — 2 0.2 1.4
Ignition coil bolt M6 7 0.7 5.1
Starter motor bolt M8 30 3.0 22
Starter motor terminal nut — 9 0.9 6.5
Power unit bolt M8 21 2.1 15
Tensioner bolt — 8 0.8 5.8
Tensioner adjusting bolt M8 25 2.5 18
Drive sprocket nut — 140 14 101
Driven sprocket bolt M10 38 3.8 28
Spark plug — 18 1.8 13
1st 6 0.6 4.3
M6
2nd 12 1.2 8.7
Cylinder head bolt
1st 23 2.3 17
M9
2nd 47 4.7 34
Oil pump screw M6 4 0.4 2.9
Rocker shaft bolt M8 18 1.8 13
Oil filter — 18 1.8 13
Oil drain bolt M14 17 1.7 12
1st 6 0.6 4.3
Exhaust cover bolt M6
2nd 12 1.2 8.7
1st 6 0.6 4.3
M6
2nd 12 1.2 8.7
Crankcase bolt
1st 15 1.5 11
M8
2nd 30 3.0 22
1st 6 0.6 4.3
Connecting rod cap bolt —
2nd 17 1.7 12
Lower unit
Check screw — 9 0.9 6.5
Lower unit bolt M10 40 4.0 29
Drain screw — 9 0.9 6.5
Propeller nut — 35 3.5 25
Water inlet cover screw — 5 0.5 3.6
Pinion nut M17 75 7.5 54

69W3D1X 32
 SPEC
Specifications
Tightening torques
Part to be tightened Thread size
N·m kgf·m ft·lb
Bracket unit
Tiller handle assembly nut — 37 3.7 27
Engine shut-off switch nut — 2 0.2 1.4
Tiller handle bracket nut — 38 3.8 27
Engine start switch nut — 5 0.5 3.7
Tiller handle bracket bolt M5 7 0.7 5.1
Friction plate bolt M6 8 0.8 5.8
Friction plate self-locking nut — 4 0.4 2.9
Upper mount nut — 24 2.4 17
Lower mount nut — 42 4.2 30
Clamp bracket self-locking nut — 23 2.3 17
Power trim and tilt
Tilt cylinder end screw — 90 9.0 65
PTT motor bolt M5 4 0.4 2.9
Reservoir cap — 7 0.7 5.1
Trim cylinder end screw — 80 8.0 58
Tilt piston bolt M12 61 6.1 44
Relief valve bracket bolt M5 5 0.5 3.6
Gear pump assembly bolt M6 5 0.5 3.6
Gear pump bracket bolt M5 5 0.5 3.6
Electrical unit
Pulser coil screw — 4 0.4 2.9
Starter motor nut — 9 0.9 6.5

General torques
This chart specifies tightening torques for
standard fasteners with a standard ISO General torque
thread pitch. Tightening torque specifications Nut (A) Bolt (B) specifications
for special components or assemblies are N·m kgf·m ft·lb
provided in applicable sections of this man- 8 mm M5 5 0.5 3.6
ual. To avoid warpage, tighten multi-fastener 10 mm M6 8 0.8 5.8
assemblies in a crisscross fashion and pro- 12 mm M8 18 1.8 13
gressive stages until the specified torque is 14 mm M10 36 3.6 25
reached. Unless otherwise specified, torque 17 mm M12 43 4.3 31
specifications require clean, dry threads.
Components should be at room temperature.

33 69W3D1X
 Tightening torques / Special service tools
Special service tools 3

1
Digital tachometer
90890-06760
Bearing separator
90890-06534
2
3
Compression gauge Bearing inner race attachment
90890-03160 90890-06643
4
5
Drive shaft holder 4 Shimming plate

6
90890-06518 90890-06701

Pinion nut holder Digital caliper

7
90890-06505 90890-06704

8
Socket adapter 1
90890-06506
Digital circuit tester
90890-03174
9
69W3D1X 34
 CHK
ADJ Periodic checks and adjustments

Dial gauge set

90890-01252

Magnet base
90890-06705

35 69W3D1X
 Special service tools / Maintenance interval chart
Maintenance interval chart 3

Use the following chart as a guideline for general maintenance.

Adjust the maintenance intervals according to the operating conditions of the outboard motor.
Initial Every
Item Remarks 10 hours 50 hours 100 hours 200 hours
(Break-in) (3 months) (6 months) (1 year)
Top cowling
Top cowling fit Check
Fuel system
Fuel joint and fuel hoses Check
Fuel filter Check/replace
Fuel tank Cleaning
Power unit
Engine oil Change
Oil filter Change
Timing belt Check
Valve clearance Check/adjust
Spark plugs Clean/adjust/replace
Thermostat Check
Water leakage Check
Motor exterior Check
Exhaust leakage Check
Cooling water passage Clean
Control system
Throttle cable Check/adjust
Shift cable Check/adjust
Engine idle speed Adjust
Ignition timing Check
Power trim and tilt unit
Power trim and tilt unit Check
Lower unit
Gear oil Change
Lower unit leakage Check
Propeller Check
General
Anodes Check/replace
Battery Check every 1 month
Wiring and connectors Adjust/reconnect
Nuts and bolts Tighten
Lubrication points Lubricate

NOTE:
• Flush the engine with fresh water after operating in salt water, or turbid or muddy water.
• If 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 interval chart.

69W3D1X 36
 CHK
ADJ Periodic checks and adjustments
Top cowling 3

Checking the top cowling

1. Check the fitting by pushing the cowling
with both hands. Adjust if necessary.

NOTE:
Be sure not to spill any fuel when removing
the fuel filter cup.
S69W3010

2. Loosen the nuts 1. Power unit 3

Checking the thermostat

3. Move the hook 2 up or down slightly to
1. Remove the cover 1, thermostat cover
adjust its position.
2, and thermostat 3.

3
2

S69W3020

NOTE:
• To loosen the fitting, move the hook in
direction a.
• To tighten the fitting, move the hook in
direction b.

1
4. Tighten the nuts. S69W3040

5. Check the fitting again and, if necessary, 2. Suspend the thermostat in a container of
repeat steps 2–4. water.

Fuel system 3
3. Place a thermometer in the water and
Checking the fuel filter slowly heat the water.
1. Check the fuel filter element 1 for dirt
and residue and check the fuel filter cup
2 for foreign substances and cracks.
Clean with straight gasoline and replace
the cup if necessary.

37 69W3D1X
 Top cowling / Fuel system / Power unit / General

S69W3050

4. Check the thermostat valve opening at

the specified water temperatures.
Replace if out of specification.

Water
Valve lift a
temperature
60 °C (140 °F) Valve begins to lift
above more than
70 °C (158 °F) 3.0 mm (0.12 in)

5. Install the thermostat, new gasket, ther-

mostat cover, and cover.

General 3

Checking the anodes

1. Check the anodes and trim tab for
scales, grease, or oil. Clean if necessary.
S69W3110

CAUTION:
Do not oil, grease, or paint the anodes,
otherwise they will be ineffective.

2. Replace the anodes and trim tab if

excessively eroded.

69W3D1X 38
 CHK
ADJ Periodic checks and adjustments
Lubrication
1. Apply water resistant grease to the areas
shown.

S69W3120

S69W3150

NOTE:
Apply grease to the grease nipple until it
flows from the bushings a.

2. Apply corrosion resistant grease to the

areas shown.

39 69W3D1X
 General / Hose routing
Hose routing 4

Fuel and blowby hoses

1
2
3
4
5
6
7
8
1
2
3
4
Blowby hose
Hose (acceleration pump-to-carburetor)
Fuel hose (fuel joint-to-fuel filter)
Fuel hose (fuel filter-to-fuel pump)
9
5 Fuel hose (fuel pump-to-carburetor)
6 Hose (carburetor-to-carburetor)
7 Hose
(acceleration pump-to-acceleration pump)

69W3D1X 40
 FUEL
Fuel system
Cooling water hose

S69W4020

1 Pilot water hose

2 Flushing hose

È Flushing device model

É View in direction of arrow

41 69W3D1X
 Hose routing / Fuel line and fuel filter
Fuel line and fuel filter 4

No. Part name Q’ty Remarks

1 Fuel joint 1
2 Bolt 1 M6 × 25 mm
3 Seal 1
4 Fuel hose 1 Fuel joint-to-fuel filter
5 Bolt 1 M8 × 14 mm
6 Nut 1
7 Bracket 1
8 Body 1
9 Fuel filter element 1
10 Float 1
11 O-ring 1 Not reusable
12 Cup 1
13 Fuel hose 2 Fuel pump-to-carburetor
14 Fuel hose 1 Fuel filter-to-fuel pump
15 Fuel pump 1
16 O-ring 1 Not reusable
17 Bracket 1
18 Bolt 2 M6 × 30 mm

69W3D1X 42
FUEL
Fuel system
Carburetor unit 4

No. Part name Q’ty Remarks

1 Acceleration pump 1
2 Screw 3 ø5 × 9 mm
3 Link rod 1
4 Hose 1
5 Hose 4
6 Link rod 1
7 Clip 1 Not reusable

43 69W3D1X

Adjusting the dashpot (acceleration
pump)
1. Start the engine and warm it up for 5 min-
utes.
2. Check that the engine speed at the oper-
ation point of the dashpot is within speci-
fication.
3. Attach the special service tool to spark
plug wire #1 1.
S69W4050
Digital tachometer: 90890-06760
4. Open the throttle cam 2 slowly, and
check the engine speed when the accel-
eration pump stopper 3 comes into con-
tact with point a.
Engine speed: 2,000–2,200 r/min
69W3D1X
Carburetor unit
5. If out of specification, adjust the dashpot
until the specified engine speed is
obtained.
6. Open the throttle cam 2 slowly, and
check that the acceleration pump stopper
3 comes in contact with point a.
7. Turn the adjusting screw 4 in or out until
the specified engine speed is obtained.
8. Open and close the throttle cam a few
times, and then check that the engine
speed at the operation point of the dash-
pot is within specification. Adjust if nec-
essary.
44
POWR
Power unit
Power unit 5

45 69W3D1X
 Power unit
No. Part name Q’ty Remarks
1 Power trim and tilt relay 1
2 Bolt 1 M8 × 16 mm
3
4
5
Black battery cable
Wiring harness
Grommet
1
1
1
10-pin coupler 1
6 Nut 1
7
8
9
Spring washer
Red battery cable
PTT relay positive lead
1
1
1
2
10 Fuse holder lead 1
11
12
13
Clip
Warning indicator coupler
PTT switch coupler
1
1
1
Tiller handle model 3
14 Plastic tie 1 Not reusable
15
16
17
Pilot water hose
Bolt
Neutral switch
1
2
1
M6 × 20 mm
Tiller handle model
4
18 Plate 1 Remote control model
19
20
21
Neutral switch lead
Ground lead
Bolt
2
3
1
Tiller handle model

M6 × 12 mm
5
22 PTT relay lead 2
23
24
25
Nut
Spring washer
PTT motor lead
2
2
2 Green, blue
6
26 Bolt 2 M6 × 20 mm
27
28
Plastic tie
Flushing hose
2
1
Not reusable
7
È Flushing device model

8
9
69W3D1X 46
POWR
Power unit

47 69W3D1X
 Power unit
No. Part name Q’ty Remarks
1 Bracket 1
2 Starter motor 1
3 Spark plug cap 4
4 Ignition coil 2
5 Wiring harness 1
6 Thermoswitch 1
7 Holder 1
8 Bolt 1 M6 × 12 mm
9 Ground lead 3
10 Bolt 1 M6 × 12 mm
11 Oil pressure switch 1
12 Oil pressure switch lead 1
13 Screw 1
14 Ignition coil lead 2
15 Bolt 4 M6 × 30 mm
16 Thermoswitch lead 2
17 Rectifier Regulator coupler 1
18 CDI unit coupler 1
19 Bolt 2 M8 × 25 mm
20 Bolt 3 M8 × 35 mm
21 Nut 1
22 Spring washer 1
23 Starter motor lead 1
24 Spring washer 1
25 Nut 1
26 Bolt 1 M8 × 45 mm
27 Oil pressure switch lead 1
28 Starter relay lead 1

69W3D1X 48
POWR
Power unit

49 69W3D1X
 Power unit
No. Part name Q’ty Remarks
1 Cylinder head 1
2 Plate 1
3 Cylinder head cover 1
4 Bolt 7 M6 × 20 mm
5 Cylinder head cover gasket 1 Not reusable
6 Bolt 10 M9 × 95 mm
7 Spark plug 4
8 Bolt 5 M6 × 25 mm
9 Dowel pin 2
10 Cylinder head gasket 1 Not reusable
11 Grommet 4
12 Anode 4
13 Cover 4
14 Bolt 4
15 Cover 4
16 Bolt 4
17 O-ring 1 Not reusable
1.9 × 36.8 mm
18 O-ring 1 Not reusable
1.8 × 17.1 mm
19 O-ring 1 Not reusable
1.2 × 13.9 mm
20 Bolt 4 M6 × 40 mm
21 Housing 1
22 Drive shaft 1
23 Pin 1
24 Inner rotor 1
25 Outer rotor 1
26 Gasket 1 Not reusable
27 Cover 1
28 Screw 2 ø6 × 20 mm
29 Engine hanger 1
30 Bolt 2 M6 × 20 mm
31 Screw 4 ø4 × 10 mm
32 O-ring 1 Not reusable
33 Oil filler cap 1

È Tightening sequence

69W3D1X 50
POWR
Power unit

51 69W3D1X
 Power unit
No. Part name Q’ty Remarks
1 Rocker arm assembly 8
2 Rocker arm shaft 1
3 Cylinder head 1
4 Exhaust valve 4
5 Intake valve 4
6 Camshaft 1
7 Valve cotter 16
8 Spring retainer 8
9 Valve spring 8
10 Spring seat 8
11 Stem seal 8 Not reusable
12 Valve guide 8 Not reusable
13 Retaining bolt 1
14 Gasket 1 Not reusable
15 Oil seal 1 Not reusable
16 Bolt 5 M8 × 22 mm
17 Rocker arm retainer 2
18 Tensioner 2
19 Rocker arm retainer 1
20 Stopper guide 2

69W3D1X 52
POWR
Power unit

53 69W3D1X
 Power unit
No. Part name Q’ty Remarks
1 Oil filter 1
2 Crankshaft 1
3 Bolt 10 M8 × 82 mm
4 Bolt 10 M6 × 35 mm
5 Crankcase 1
6 Oil seal 1 Not reusable
7 Main bearing 10
8 Oil seal 1 Not reusable
9 Connecting rod bearing 8
10 Connecting rod cap 4
11 Bolt 8
12 Dowel pin 2
13 Cylinder block 1
14 Connecting rod 4
15 Piston pin clip 8 Not reusable
16 Piston pin 4
17 Piston 4
18 Oil ring 4
19 Second ring 4
20 Top ring 4
21 Gasket 1 Not reusable
22 Exhaust cover 1
23 Thermostat 1
24 Gasket 1 Not reusable
25 Cover 1
26 Clamp 2
27 Grommet 1
28 Anode 1
29 Cover 1
30 Cover 1
31 Bolt 1 M6 × 20 mm
32 Bolt 1 M5 × 12 mm
33 Bolt 12 M6 × 35 mm

È Tightening sequence

69W3D1X 54
POWR
Power unit
Checking the compression pressure
1. Start the engine, warm it up for 5 min-
utes, and then turn it off.
2. Remove the lock plate from the engine
shut-off switch on the remote control box
or tiller handle.
3. Remove all spark plugs, and then install
the special service tools to each spark
plug hole.
NOTE:
• If the compression pressure increases,
check the piston and piston rings for wear.
Replace if necessary.
• If 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. Remove the cover.

2. Remove the oil pressure switch, and then

install an oil pressure gauge 1 to the oil
pressure switch installation hole.

CAUTION:
Before removing the spark plugs, remove
any dirt or dust that may fall into the cylin-
der.

Compression gauge 1:
90890-03160
4. Fully open the throttle manually, crank
the engine until the reading on the com-
pression gauge stabilizes, and then
check the compression pressure.
NOTE:
Use a pressure gauge with an adapter that
has a 1/8 pitch thread.
3. Start the engine and warm it up for 5 min-
utes.

Minimum compression pressure 4. Check the oil pressure. Check the oil
(reference data): pump, relief valve, oil filter, and oil
880 kPa (8.8 kgf/cm2, 125 psi) strainer if out of specification.

Oil pressure (reference data):

5. If the compression pressure is below
110 kPa (1.1 kgf/cm2, 16 psi) at
specification and the compression pres-
idle speed (900 r/min)
sure for each cylinder is unbalanced, add
a small amount of engine oil to the cylin-
der, and then check the pressure again.

55 69W3D1X
 Power unit
Checking the cylinder bore
1. Measure the cylinder bore (D1–D6) at
measuring points a, b, and c, and in
direction d (D1, D3, D5), which is parallel
to the crankshaft, and direction e (D2,
D4, D6), which is at a right angle to the
crankshaft.

D2 D1

D4 D3

D6 D5
Piston ring groove:
S69W5080 Top ring a:
a 20 mm (0.8 in) 1.21–1.23 mm
b 60 mm (2.4 in) (0.0476–0.0484 in)
c 100 mm (3.9 in) Second ring b:
1.51–1.53 mm
Cylinder bore (D1–D6): (0.0594–0.0602 in)
65.00–65.01 mm Oil ring c:
(2.5591–2.5594 in) 2.52–2.54 mm
(0.0992–0.0999 in)
2. Calculate the taper limit. Replace or
rebore the cylinder block if out of specifi-
cation.

Taper limit:
D1–D5 (direction d)
D2–D6 (direction e)
0.08 mm (0.0031 in)

3. Calculate the out-of-round limit. Replace

or rebore the cylinder block if out of spec-
ification.

Out-of-round limit:
D2–D1 (measuring point a)
D6–D5 (measuring point c)
0.01 mm (0.0004 in)

Checking the piston ring grooves

1. Measure the piston ring grooves.
Replace the piston if out of specification.

69W3D1X 56
LOWR
Lower unit
Drive shaft and lower case 6

57 69W3D1X
 Drive shaft and lower case
No. Part name Q’ty Remarks
1 Drive shaft 1
2 Oil seal 1 Not reusable
3
4
5
Oil seal housing
O-ring
Circlip
1
1
1
Not reusable 1
6 Shift rod 1
7
8
9
O-ring
Taper roller bearing
Bearing outer race
1
1
1
Not reusable
Not reusable
Not reusable
2
10 Pinion shim — As required
11
12
13
Sleeve
Washer
Oil seal housing
1
1
1
3
14 O-ring 1 Not reusable
15
16
17
Oil seal
Seal
Plate
2
1
1
Not reusable
4
18 Hose 1
19
20
21
Plastic tie
Joint
Nut
1
1
1
Not reusable
5
22 Water inlet cover 2
23
24
25
Screw
Shift cam
Needle bearing
1
1
1
6
26 Pinion 1
27
28
29
Nut
Forward gear shim
Bearing outer race
—
1

1
As required
Not reusable
7
30 Taper roller bearing 1 Not reusable
31
32
33
Forward gear
Lower case
Cover
1
1
1
8
34 Gasket 1 Not reusable
35
36
37
Check screw
Gasket
Drain screw
1
1
1
Not reusable 9
69W3D1X 58
LOWR
Lower unit
Removing the drive shaft
1. Remove the drive shaft assembly and
pinion, and then pull out the forward
gear.

Bearing inner race attachment 1:

90890-06643
S69W6020

Installing the drive shaft

Drive shaft holder 4 1: 90890-06518 1. Install the forward gear, then the drive
Pinion nut holder 2: 90890-06505 shaft assembly, pinion, and pinion nut,
Socket adapter 1 3: 90890-06506 and then tighten the nut to the specified
torque.
Disassembling the forward gear
1. Remove the taper roller bearing from the
forward gear using a press.

S69W6020

Drive shaft holder 4 1: 90890-06518

S69W6030 Pinion nut holder 2: 90890-06505
Socket adapter 1 3: 90890-06506
CAUTION:
Do not reuse the bearing, always replace Pinion nut:
it with a new one. 75 N·m (7.5 kgf·m, 54 ft·lb)
T.
R.

Bearing splitter plate 1:

(commercially obtainable)
Bearing separator 1: 90890-06534

Assembling the forward gear

1. Install the new taper roller bearing into
the forward gear using a press.

59 69W3D1X
 Drive shaft and lower case / Shimming
Shimming 6

69W3D1X 60
LOWR
Lower unit
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 part(s).

Selecting the forward gear shims NOTE:

1. Turn the taper roller bearing outer race
1 two or three times to seat the rollers,
and then measure the bearing height (M)
as shown.
“F” is the deviation of the lower case dimen-
sion from standard. The “F” mark a is
stamped on the trim tab mounting surface of
the lower case in 0.01 mm units. If the “F”
mark is unreadable, assume that “F” is zero
and check the backlash when the unit is
assembled.

Calculation formula:
Forward gear shim thickness (T1) =
26.50 + F/100 – M

Example:
If “M” is 26.06 mm and “F” is (+1), then
T1 = 26.50 + (+1)/100 – 26.06 mm
= 26.50 + 0.01 – 26.06 mm
= 0.45 mm

3. Select the forward gear shim(s) (T1) as

follows.

Calculated numeral
Rounded numeral
at 1/100 place
1, 2 0
NOTE:
3, 4, 5 2
• Select the shim thickness (T1) by using the
specified measurement(s) and the calcula- 6, 7, 8 5
tion formula. 9, 10 8
• Measure the bearing outer race at three
points to find the height average.
Available shim thicknesses:
0.10, 0.12, 0.15, 0.18, 0.30, 0.40, and
Shimming plate 2: 90890-06701 0.50 mm
Digital caliper 3: 90890-06704

2. Calculate the forward gear shim thickness

(T1) as shown in the examples below.

61 69W3D1X
 Shimming
Example:
If “T1” is 0.45 mm, then the forward gear
shim is 0.42 mm.
If “T1” is 0.60 mm, then the forward gear
shim is 0.58 mm.

69W3D1X 62
BRKT
Bracket unit
Tiller handle 7

63 69W3D1X
 Tiller handle
No. Part name Q’ty Remarks
1 Tiller handle assembly 1
2 Tiller handle wiring harness 1
3
4
5
Grommet
Clip
Throttle cable
1
1
1
1
6 Plate 1
7
8
9
Bolt
Bolt
Black battery cable
3
1
1
M6 × 25 mm
M8 × 16 mm 2
10 Cable guide 1
11
12
13
Grommet
Nut
Washer
1
1
1
M6 × 35 mm 3
14 Red battery cable 1
15
16
17
Connector
Clip
Shift cable
1
1
1
4
18 Cover 1
19
20
21
Screw
PTT switch coupler
PTT switch coupler
3
1
1
ø6 × 35 mm

Tiller handle model

5
22 Plastic tie 1
23
24
25
Nut
Bolt
Bracket
2
1
1
M5 × 20 mm 6
26 Friction lock shaft 1
27
28
29
Collar
Washer
Friction lock lever
2
2
1
7
30 Friction piece 2
31
32
33
Friction plate
Washer
Bolt
1
2
2
8
34 Nut 1
35
36
Washer
Self-locking nut
1
1 9
69W3D1X 64
BRKT
Bracket unit
Bottom cowling 7

65 69W3D1X
 Bottom cowling
No. Part name Q’ty Remarks
1 Bottom cowling 1
2 Rubber seal 1
3 Washer 1
4 Bushing 2
5 Shift rod bracket 1
6 Bolt 1
7 Spring 1
8 Ball 1
9 Shift rod 1
10 Flushing device 1 Flushing device model
11 Bracket 1 Flushing device model
12 Bolt 1 M6 × 16 mm / Flushing device model
13 Screw 2 ø6 × 20 mm / Flushing device model
14 Flushing hose 1 Flushing device model
15 Bolt 4 M6 × 30 mm
16 Grommet 4
17 Collar 4
18 Grommet 1
19 PTT motor lead 1
20 Trim sensor coupler 1
21 Screw 1 ø6 × 25 mm
22 Bolt 2 M6 × 20 mm
23 Bracket 1
24 Power trim and tilt switch 1
25 Warning indicator 1 Tiller handle model
26 Screw 1 ø6 × 14 mm / Tiller handle model
27 Pilot water hose 1
28 Collar 2
29 Grommet 2
30 Cowling lock lever 1
31 Washer 1
32 Wave washer 1
33 Bushing 2
34 Lever 1
35 Bolt 1 M6 × 12 mm
36 Spring 1
37 Hook 1
38 Bolt 1 M6 × 20 mm

69W3D1X 66
BRKT
Bracket unit
Upper case 7

67 69W3D1X
 Upper case
No. Part name Q’ty Remarks
1 Muffler assembly 1
2 Upper case 1
3 Muffler seal 1
4 Rubber seal 1
5 Dowel pin 2
6 Grommet 1
7 Damper 1
8 Screw 2 ø5 × 16 mm
9 Baffle plate 1
10 Bolt 4 M8 × 30 mm
11 Drive shaft bushing 1
12 Circlip 1
13 Ground lead 1
14 Screw 1 ø6 × 8 mm
15 Cap 2
16 Bolt 2 M12 × 170 mm
17 Washer 2
18 Rubber washer 2
19 Washer 2
20 Lower mount 2
21 Washer 2
22 Mount cover 2
23 Bolt 4 M8 × 30 mm
24 Bolt 2 M8 × 175 mm
25 Plate 1
26 Bolt 3 M8 × 30 mm
27 Upper mount 1
28 Nut 2
29 Grease nipple 1
30 Washer 2
31 Nut 2
32 Cover 1
33 Bolt 2 M8 × 20 mm

69W3D1X 68
BRKT
Bracket unit

69 69W3D1X
 Upper case
No. Part name Q’ty Remarks
1 Oil seal 1 Not reusable
2 Exhaust guide 1
3 Grommet 1
4 Anode 1
5 Cover 1
6 Bolt 1 M6 × 20 mm
7 Cover 1
8 Bolt 1
9 Gasket 1 Not reusable
10 Gasket 1 Not reusable
11 Relief valve housing 1
12 Relief valve 1
13 Spring 1
14 Cotter pin 1 Not reusable
15 Bolt 2 M6 × 25 mm
16 Bolt 2 M6 × 16 mm
17 Oil strainer 1
18 Bolt 1 M6 × 25 mm
19 Gasket 1 Not reusable
20 Pipe 1
21 Rubber seal 1
22 Dowel pin 2
23 Bolt 10 M6 × 25 mm
24 Drain bolt 1
25 O-ring 1 Not reusable
26 Oil pan 1
27 Gasket 1 Not reusable
28 Exhaust manifold 1
29 Bracket 1
30 Washer 3
31 Bolt 3 M6 × 50 mm
32 Gasket 1 Not reusable
33 Gasket 2 Not reusable
34 Plate 1
35 Muffler 1
36 Bolt 6 M6 × 25 mm

69W3D1X 70
BRKT
Bracket unit
Disassembling the oil pan
1. Remove the muffler 1, plate 2, and
exhaust manifold 3 from the oil pan 4.

3. Install the oil strainer 3 by installing the

bolts.

2. Remove the oil pan 4 and the exhaust

guide 5.

3. Remove the oil strainer 6 and the relief

valve housing 7.

4. Install the water pipe 4.

5. Install the oil pan 5 and bolts, and then

tighten the bolts finger tight.

6. Install the exhaust manifold 6 and bolts,

and then tighten the bolts finger tight.

Assembling the oil pan

1. Install the gaskets onto the exhaust
guide 1.

2. Install the relief valve assembly 2 by

installing the bolts, then tightening them
finger tight.

71 69W3D1X
 Upper case
10. Tighten the upper case bolts B, and then
tighten them to the specified torque.

7. Tighten the oil pan bolts 7 then exhaust

manifold bolts 8, and then tighten them
to the specified torque. Upper case bolt B:
21 N·m (2.1 kgf·m, 15 ft·lb)
T.
R.

Exhaust manifold bolt 8:

10 N·m (1.0 kgf·m, 7.2 ft·lb)
T.
R.

Installing the upper case

1. Install the upper mount 1 and bolts 2
8. Install the plate 9 and the muffler 0 to into the upper case.
the oil pan.
2. Install the lower mounts 3 and bolts 4
into the upper case.

3. Install the mount covers 5.

LT
572

S69W7100

9. Install the muffler assembly A by insert-

ing the tip of the water pipe 4 into the
joint hole a of the upper case.

69W3D1X 72
BRKT
Bracket unit

Upper mounting nut 7:

24 N·m (2.4 kgf·m, 17 ft·lb)

T.
R.
Lower mounting nut 8:
42 N·m (4.2 kgf·m, 30 ft·lb)

4. Install the upper and lower mounting

bolts into the swivel bracket 6 simulta-
neously.

5. Install the upper mounting nut 7 and

lower mounting nut 8, and then tighten
them to the specified torque.

6. Install the cover 9.

73 69W3D1X
 Upper case / Clamp brackets
Clamp brackets 7

No. Part name Q’ty Remarks

1 Swivel bracket assembly 1
2 Screw 2 ø6 × 15 mm
3 Trim sensor 1
4 Trim sensor coupler 1
5 Plastic tie 1 Not reusable
6 Self-locking nut 2
7 Cap 2
8 Bolt 4 M6 × 25 mm
9 Anode 2
10 Port clamp bracket 1
11 Washer 2
12 Bushing 2
13 Through tube 1
14 Ground lead 1
15 Grease nipple 1
16 Screw 1 ø6 × 8 mm
17 Starboard clamp bracket 1
18 Bracket 1

69W3D1X 74
BRKT
Bracket unit
Adjusting the trim sensor
1. Fully tilt the outboard motor up, and then
support it with the tilt stop lever 1.
WARNING
After tilting up the outboard motor, be
sure to support it with the tilt stop lever.
Otherwise, the outboard motor could sud-
denly lower if the power trim and tilt unit
should lose fluid pressure.

8. Measure the trim sensor resistance.

Check the trim sensor if out of specifica-
tion.

Trim sensor resistance:

WARNING Pink (P) – Black (B)
After tilting up the outboard motor, be 168.3–288.3 Ω at 20 °C (68 °F)
sure to support it with the tilt stop lever.
Otherwise, the outboard motor could sud-
denly lower if the power trim and tilt unit
should lose fluid pressure.

2. Loosen the cam screws 2.

3. Adjust the position of the trim sensor 3,

and then tighten the screws 2 finger
tight.

4. Fully tilt the outboard motor down.

5. Measure the trim sensor resistance.

Repeat steps 1–5 if out of specification.

Trim sensor resistance:

Pink (P) – Black (B)
9–11 Ω at 20 °C (68 °F)

6. Tighten the screws 2.

7. Fully tilt the outboard motor up, and then

support it with the tilt stop lever.

75 69W3D1X
 Clamp brackets / Swivel bracket and steering arm
Swivel bracket and steering arm 7

No. Part name Q’ty Remarks

1 Steering arm 1
2 Washer 1
3 Bushing 1
4 O-ring 2 Not reusable
5 Bushing 2
6 Swivel bracket 1
7 Bushing 2
8 Port tilt stop lever 1
9 Circlip 1
10 Steering yoke 1
11 Bushing 1
12 Bushing 2
13 Tilt stop lever joint 1
14 Spring holder 1
15 Bolt 1 M6 × 10 mm
16 Spring 1
17 Pin 2 Not reusable
18 Starboard tilt stop lever 1

69W3D1X 76
BRKT
Bracket unit
Power trim and tilt unit 7

No. Part name Q’ty Remarks

1 Power trim and tilt unit 1
2 Plastic tie 3 Not reusable
3 PTT motor lead 2
4 Washer 2
5 Bolt 2 M8 × 16 mm
6 Circlip 1
7 Shaft 1
8 Bushing 2
9 Collar 1
10 Tilt pin 1
11 Collar 1
12 Collar 1
13 Shaft 1

77 69W3D1X
 Power trim and tilt unit

No. Part name Q’ty Remarks

1 Bolt 2 M5 × 8 mm
2 Relief valve bracket 1
3 Bolt 3 M6 × 40 mm
4 Valve lock screw 1
5 Up-relief spring 1
6 Valve support pin 1
7 O-ring 1 Not reusable
8 Ball 1
9 Down-relief spring 1
10 Valve support pin 1
11 Relief valve seal 1
12 Filter 1
13 O-ring 2 Not reusable
14 Spacer 2
15 Filter 2
16 O-ring 1 Not reusable
17 Manual valve 1
18 Circlip 1

69W3D1X 78
BRKT
Bracket unit

No. Part name Q’ty Remarks

1 Bolt 2 M5 × 20 mm
2 Washer 2
3 Bracket 1
4 O-ring 2 Not reusable
5 Spacer 2
6 Spring 2
7 Valve pin 2
8 Ball 2
9 Manual release spring 1
10 Ball 2
11 Gear pump cover 1
12 Spring 2
13 Shuttle piston 1
14 O-ring 1 Not reusable
15 Valve seal 2
16 Circlip 2
17 Pin 2
18 Drive gear 1

79 69W3D1X
 Power trim and tilt unit

No. Part name Q’ty Remarks

19 Shaft 1
20 Driven gear 1
21 Ball 2
22 Shuttle piston 1
23 Valve plate 1
24 Plate 1
25 Gear pump housing 1

69W3D1X 80
BRKT
Bracket unit

No. Part name Q’ty Remarks

1 Screw 3 ø5 × 20 mm
2 Yoke 1
3 O-ring 1 Not reusable
4 Armature 1
5 Washer 1
6 Bushing 1
7 Screw 2 ø4 × 12 mm
8 Lead 1
9 Brush 2 1
10 Brush 1 1
11 Brush holder 1
12 Circuit breaker 1
13 Brush spring 2
14 PTT motor base 1
15 Oil seal 1 Not reusable

81 69W3D1X
 Power trim and tilt unit
Disassembling the gear pump 5. Remove the drive gear A and driven
1. Remove the manual valve 1 and gear gear B.
pump 2.

Checking the valves

1. Check the operation of the check valve
a of the trim cylinder end screw and
check the valve for dirt or residue. Clean
if necessary.
2. Remove the relief valve bracket 3, then
the relief valve seal 4 and ball 5.

2. Check the operation of the tilt piston

absorber valve and check for dirt or resi-
3. Remove the bracket 6, then the balls 7. due. Clean if necessary.

4. Remove the gear pump cover 8, then 3. Check the up-relief valve and down-relief
the shuttle pistons 9 and balls 0. valve for dirt or residue. Clean if neces-
sary.

69W3D1X 82
BRKT
Bracket unit

S69W7280

4. Check the main valves for dirt or residue.

Clean if necessary.

4. Install the balls 9, manual release spring

0 and bracket A by installing the bolts
B, then tightening them to the specified
torque.

S69W7290

5. Check the absorber valves for dirt or res-

idue. Clean if necessary.

Gear pump bracket bolt B:

5 N·m (0.5 kgf·m, 3.6 ft·lb)
T.
R.

5. Install the relief valve seal C, ball D, and

filter E.
S69W7300

6. Install the relief valve bracket F by

Assembling the gear pump installing the bolts G, then tightening
1. Install the drive gear 1, driven gear 2, them to the specified torque.
shaft 3, and pins 4 into the gear pump
housing 5.

2. Install the balls 6 and shuttle pistons 7

into the gear pump housing 5.

3. Install the gear pump cover 8.

83 69W3D1X
 Power trim and tilt unit
10. Install the joint M and power trim and tilt
Relief valve bracket bolt G: motor N by installing the bolts O, then
5 N·m (0.5 kgf·m, 3.6 ft·lb)
T.

tightening them to the specified torque.

R.

7. Install the filters H and gear pump I by

installing the bolts J, then tightening
them to the specified torque.

8. Install the manual valve K and reservoir

cap L.

PTT motor bolt O:

4 N·m (0.4 kgf·m, 2.9 ft·lb)
T.
R.

Checking the trim sensor

1. Measure the trim sensor resistance.
Replace if out of specification.

Gear pump bolt J:

7 N·m (0.7 kgf·m, 5.1 ft·lb)
T.
R.

9. Fill the reservoir with the recommended

fluid to the correct level a as shown.

NOTE:
Turn the lever 1 and measure the resistance
as it gradually changes.

Trim sensor resistance:

Recommended power trim and tilt Pink (P) – Black (B)
fluid: 9–11 Ω at 20 °C (68 °F) a
ATF Dexron II 168.3–288.3 Ω at 20 °C (68 °F) b

69W3D1X 84
 – +
ELEC
Electrical systems
Wiring harness 8

B R

B
G P

L L B
B/W B/O
B
B
Y
B
Y L P Y/B Y/R
P/B P/W
W P
G G Y Y

G R
Y
Lg
W

B/W
P Sb B/O
Br
B
B BB
Lg
R Br R Sb
Lg Lg Sb Sb Sb Lg

R
P/W P/B
Y/R Y/B
Y/B Y/R

P/B P/W
R

P/W P/B P/B P/W L B B/O

R Y/R Y/B Y/B Y/R P W B/W R Lg Sb R G B

Lg Sb B B B Br
Lg Sb L Y P B B B P B B/O
Y Y G G B/W
R
Lg
Sb
R
Br
P
G
W
B
Y

S69W8010

Connect to: 7 Warning indicator B : Black Y : Yellow

1 Engine start switch or 8 CDI unit Br : Brown B/O : Black/orange
remote control box 9 Power trim and tilt G : Green B/W : Black/white
extension switch L : Blue P/B : Pink/black
2 Power trim and tilt relay 0 Rectifier Regulator Lg : Light green P/W : Pink/white
3 Ground A Thermoswitch P : Pink Y/B : Yellow/black
4 Starter relay B Ignition coil R : Red Y/R : Yellow/red
5 Red battery cable C Oil pressure switch Sb : Sky blue
6 Prime Start W : White

85 69W3D1X
 Wiring harness / Ignition and ignition control system
Ignition and ignition control system 8

1
2
3
4
5
6
7
8
1 Spark plug B : Black
2

9
Ignition coil Br : Brown
3 Charge coil L : Blue
4 Pulser coil O : Orange
5 Engine start switch W : White
6 Engine shut-off switch B/O : Black/orange
7 10-pin coupler B/W : Black/white
8 CDI unit W/B : White/black
W/R : White/red
È Tiller handle model

69W3D1X 86
 – +
ELEC
Electrical systems

1 Thermoswitch B : Black
2 Oil pressure switch P : Pink
3 CDI unit Gy/B : Gray/black
4 Oil pressure warning indicator P/B : Pink/black
5 Overheat warning indicator P/W : Pink/white
6 Warning indicator Y/B : Yellow/black
Y/R : Yellow/red
È Tiller handle model

87 69W3D1X
 Ignition and ignition control system
Checking the spark plug caps
1. Remove the spark plug caps from the Pulser coil air gap a:
spark plug wires by turning the caps 0.5–1.0 mm (0.020–0.039 in)
counterclockwise.
3. Remove the flywheel magnet nut and fly-
wheel magnet.

4. Loosen the pulser coil screws, adjust the

pulser coil 1 position, and then tighten
the screws finger tight.

2. Measure the spark plug cap resistance.

Replace if out of specification.

5. Install the flywheel magnet, and then

check the gap and, if necessary, repeat
steps 3–5.

6. Tighten the pulser coil screws and fly-

wheel magnet nut to the specified
torques.
Spark plug cap resistance
(reference data): Pulser coil screw:
4 N·m (0.4 kgf·m, 2.9 ft·lb)
T.

5 kΩ
R.

Flywheel magnet nut:

Checking the pulser coil air gap 160 N·m (16 kgf·m, 116 ft·lb)
1. Turn the flywheel clockwise to align the
projection of the flywheel with the pulser Checking the engine start switch
coil projection. 1. Check the engine start switch for continu-
ity. Replace if there is no continuity.
2. Measure the gap between both projec-
tions with a thickness gauge. Adjust if out Lead color
of specification.
Switch White Black Red Pink Brown
position (W) (B) (R) (P) (Br)
OFF
ON
START

S69W8060

69W3D1X 88
 – +
ELEC
Electrical systems
Starting system 8

W B R P Br
OFF
ON R R
START

R
Br

Br Br

R R R

Br

R
N

B M

S B B

B
B

Br

Br

B B

S69W8090E

1 Fuse B : Black
2 10-pin coupler Br : Brown
3 Engine start switch R : Red
4 Starter motor
5 Battery
6 Neutral switch
7 Starter relay

È Tiller handle model

89 69W3D1X
 Starting system / Starter motor
Starter motor 8

1
2
3

4
5 11

6
7
12
8 14
13
15 7 N • m (0.7 kgf • m, 5.1 ft • Ib)

T.
R.
9
16

10 17
18

S69W8100

No. Part name Q’ty Remarks

1 Clip 1
2 Pinion stopper 1
3 Spring 1
4 Starter motor pinion 1
5 Upper bracket 1
6 Washer 1 1
7 Shim — As required
8 Washer 2 1
9 Armature 1
10 Washer 2
11 Stator 1
12 Brush holder assembly 1
13 Brush set 1
14 O-ring 1 Not reusable
15 Nut 1
16 Lower bracket 1
17 Screw 2 ø4 × 12 mm
18 Bolt 2 M6 × 120 mm

69W3D1X 90
 – +
ELEC
Electrical systems
Checking the armature
1. Check the armature axial free play. Diameter limit: 32.0 mm (1.26 in)
Replace the washers and shim(s) 3 if
out of specification.
4. Measure the commutator undercut a.
Replace the armature if out of specifica-
tion.

Dial gauge set 1: 90890-01252

Magnet base 2: 90890-06705

Commutator undercut limit:

Free play limit: 0.6 mm (0.024 in) 0.2 mm (0.01 in)

5. Check the armature for continuity.

2. Check the commutator for dirt. Clean Replace if out of specifications.
with #600 grid sandpaper and com-
pressed air if necessary.

Armature continuity
3. Measure the commutator diameter.
Replace the armature if out of specifica- Commutator segments b Continuity
tion. Segment –
No continuity
Armature core c
Segment –
No continuity
Armature shaft d

Checking the brushes

1. Measure the brush length. Replace the
brush assembly if out of specification.

91 69W3D1X
 Starter motor

Brush length limit a:

10.0 mm (0.39 in)

2. Check the brush holder for continuity.

Replace if out of specifications.

S69W8170

Brush assembly continuity

Brush 1 – Brush
assembly holder 4
Continuity
Brush 2 – Brush
assembly holder 3
Brush 1 – Brush 2
Brush 1 – Brush
assembly holder 3 No continuity
Brush 2 – Brush
assembly holder 4

69W3D1X 92
F60AEHT

Br
B
B G

Gy
Y L Y L
L L
Br

G G G Lg

B W/R W/B O
B Sb Y/R P/B W B/W Gy/B W/R Br
Br P Y/B P/W O B/O B W/B L G P
R
Y R
R
Br L G G/W G/W B Sb
L G L R
W/R W/B G G W
G L B Sb
Y L B/O B/W
Y
Br
Y/R Y/B
B/O

L Y G/W B/W
R Br
Br L W/R W/B G/W
P/W P/B
O W G Gy/B
Y P W G
B G/W P/B
P/W P/W
P/B
R B
B Y/R Y/B W/B
L
B/O
B/W W/R
B L G/W L
G Y/B
B B B R Br Y L
Gy/B B Y/R
Sb Lg
Y/B P/W P B/O B R B
Lg
Lg P P L Y/R P/B W B/W
Sb
Sb
R B G
R G R B
Lg Y
P
W R
W B
Br
Sb
Lg
P
P W
G
Sb Y
B Br B
Br
B

Gy
P
B

Y Y G G B B B
P Gy

W B R P Br Y/B P/W B
Y/R P/B
OFF B

ON
#2
ST W B/W O

B/O
W
W O
Y/B Y/R
B B Lg Sb R #3
B
B

Br P/B Sb
P/W
P Lg

R R #1
P/B P/W
Sb R Lg R
Sb R Lg
UP UP
Y/B FREE Sb Lg FREE
Y/R #4
DOWN DOWN B

Sb R Lg Lg Sb Sb Lg Lg Sb R Lg Sb Sb R Lg
Sb
Y/B P/B Y/R P/W
Sb Sb
R R
Lg Lg

R R R

S69WWD01E
Wiring diagram
F60AEHT
1 Battery Color code
2 Engine start switch B : Black
3 Starter motor Br : Brown
4 Power trim and tilt motor G : Green
5 Power trim and tilt relay Gy : Gray
6 Engine shut-off switch L : Blue
7 Starter relay Lg : Light green
8 Neutral switch O : Orange
9 Fuse (20 A) P : Pink
0 Warning indicator R : Red
A Power trim and tilt switch Sb : Sky blue
B Prime Start W : White
C Oil pressure switch Y : Yellow
D CDI unit B/O : Black/orange
E Thermoswitch B/W : Black/white
F Charge coil G/W : Green/white
G Pulser coil Gy/B : Gray/black
H Lighting coil P/B : Pink/black
I Rectifier Regulator P/W : Pink/white
J Ignition coil W/B : White/black
K Spark plug W/R : White/red
L Trim sensor Y/B : Yellow/black
Y/R : Yellow/red
F60AET

Br
B
B G

Gy
Y L Y L
L L
Br

G G G Lg

B W/R W/B O
B Sb Y/R P/B W B/W Gy/B W/R Br
P Y/B P/W O B/O B W/B L G P
R
Y R
R Br
Br L G G/W G/W B Sb
L G L R
W/R W/B G G W
G L B Sb
Y L B/O B/W
Y
Y/R Y/B
B/O

L Y G/W B/W
R
Br L W/R W/B G/W
P/W P/B
O W G Gy/B
Y P W G
B G/W P/B
P/W P/W
P/B
R B
B Y/R Y/B W/B
L
B/O
B/W W/R
B L G/W L
G Y/B
B B B R Br Y L
Gy/B B Y/R
Sb Lg
Y/B P/W P B/O B R B
Lg
Lg P P L Y/R P/B W B/W
Sb
Sb
R B G
G R B
Lg Y
W R
B
Br
Sb
Lg
P
P
W
G
Sb Y
Br B

Y Y G G B B B

Y/B P/W B
Y/R P/B
B

#2
B/W O

B/O

Lg Sb R O
Y/B Y/R
#3
B

P/B Sb
P/W
Lg
R #1
R
Sb R Lg
UP
Sb Lg FREE
B
#4
DOWN B

Gy Lg R Sb
P
B

P Gy

S69WWD03E
Wiring diagram
F60AET
1 Battery Color code
2 Starter motor B : Black
3 Power trim and tilt motor Br : Brown
4 Power trim and tilt relay G : Green
5 Starter relay Gy : Gray
6 Fuse (20 A) L : Blue
7 Trim sensor Lg : Light green
8 Prime Start O : Orange
9 Oil pressure switch P : Pink
0 CDI unit R : Red
A Thermoswitch Sb : Sky blue
B Charge coil W : White
C Pulser coil Y : Yellow
D Lighting coil B/O : Black/orange
E Rectifier Regulator B/W : Black/white
F Power trim and tilt switch G/W : Green/white
G Ignition coil Gy/B : Gray/black
H Spark plug P/B : Pink/black
P/W : Pink/white
È To remote control W/B : White/black
É To warning indicator W/R : White/red
Ê To trim meter Y/B : Yellow/black
Y/R : Yellow/red
 YAMAHA MOTOR CO., LTD.
Printed in the Netherlands
Jul. 2001 – 1.3 × 1 CR
(F60AEHT, F60AET)

(E)