Yamaha F60 Service Manual

SERVICE MANUAL29209869W-28197-3D-1XSUPPLEMENTARYF60A

GEN INFOGeneral information369W3D1XIdentification1Applicable modelsThis manual covers the following models.Serial numberThe outboard motor serial numb

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Wiring diagramF60AEHT1 Battery2 Engine start switch3 Starter motor4 Power trim and tilt motor5 Power trim and tilt relay6 Engine shut-off switch7 Star

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Wiring diagramF60AET1 Battery2 Starter motor3 Power trim and tilt motor4 Power trim and tilt relay5 Starter relay6 Fuse (20 A)7 Trim sensor8 Prime Sta

YAMAHA MOTOR CO., LTD.Printed in the NetherlandsJul. 2001 – 1.3 × 1 CR(F60AEHT, F60AET)(E)

69W3D1X4Features and benefits1Power unitBased on the power unit of the field-proven F50, newly designed parts have been adopted in thevarious areas to

GEN INFOGeneral information569W3D1XOil pumpThe size of the oil pump rotor has been enlarged to increase the oil discharge volume. As a result,reliable

69W3D1X6Although the main jet specification numbers of the F50 differed between cylinders, the F60 usesmain jets with the same specification number fo

GEN INFOGeneral information769W3D1XLower unitDrive shaftThe drive shaft has been machined to accommodate the high power output. The portion thatmounts

69W3D1X8Forward gear bearingThe size of the forward gear bearing has been increased to accommodate the high power output ofthe F60. With this increase

GEN INFOGeneral information969W3D1XBracket unitPTT (Power trim and tilt) unitBased on the 62Y type PTT unit of the F50, the internal valve and power t

69W3D1X10Steering frictionThe F60 tiller handle models use a newly developed, compact steering friction.1Steering frictionElectrical unitStarter motor

GEN INFOGeneral information1169W3D1XTechnical tips1CarburetorPower nozzleThe power nozzle is activated when the engine is operating at high speeds. To

69W3D1X12PTT (Power Trim and Tilt) unitShuttle pistonA ball type shut-off construction is used for both the up-shuttle and down-shuttle pistons. The b

NOTICEThis Supplementary Service Manual has been prepared to introduce new service and new datainformation for the F60 which is based on the F50. For

GEN INFOGeneral information1369W3D1XPropeller selection1The performance of a boat and outboardmotor will be critically affected by the sizeand type of

69W3D1X14Predelivery checks1To make the delivery process smooth andefficient, the predelivery checks should becompleted as explained below.Checking th

GEN INFOGeneral information1569W3D1XNOTE:The optimum mounting height is affected bythe combination of the boat and the outboardmotor. To determine the

69W3D1X16Checking the gearshift and throttle operation1. Check that the gearshift operatessmoothly when the remote control leveror shift lever is shif

GEN INFOGeneral information1769W3D1XChecking the cooling watger pilot hole1. Start the engine, and then check thatcooling water is discharged from the

69W3D1X18General specifications2Item UnitModelF60AEHT F60AETDimensionOverall length mm (in) 1,339 (52.7) 706 (27.8)Overall width mm (in) 384 (15.1)Ove

SPECSpecifications1969W3D1X* PON: Pump Octane Number (Research Octane Number + Motor Octane Number)/2RON: Research Octane NumberFuel and oilFuel type

69W3D1X20Maintenance specifications2Power unitItem UnitModelF60AEHT F60AETPower unitMinimum compression pressure*kPa (kgf/cm2, psi)880 (8.8, 125)Lubri

SPECSpecifications2169W3D1XPiston ringsTop ringDimension 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 (i

69W3D1X22Face 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 (

ContentsGeneral information1GEN INFOSpecifications2SPECPeriodic checks and adjustments3CHK ADJFuel system4FUELPower unit5POWRLower unit6LOWRBracket un

SPECSpecifications2369W3D1XCrankcase main journal bearing thicknessYellow mm (in) 1.502–1.506 (0.0591–0.0593)Red mm (in) 1.498–1.502 (0.0590–0.0591)Pi

69W3D1X24Lower unitElectricalItem UnitModelF60AEHT F60AETGear backlashPinion-to-forward gear mm (in) 0.18–0.54 (0.0071–0.0212)Pinion-to-reverse gear m

SPECSpecifications2569W3D1XIgnition control systemOil pressure switchON ↔ OFFkPa (kgf/cm2, psi)29.4–58.8 (0.294–0.588, 4.181–8.361)Thermoswitch (Gy/B

69W3D1X26Power trim and tilt systemTrim sensorSetting resistanceΩ 9–11Resistance (P – B)Ω 9–288.3Fluid type ATF Dexron IIBrushesStandard length mm (in

SPECSpecifications2769W3D1XDimensionsExteriorL3L6L7H9 H5H2H7H1H11H4H3C1B6L5L8L9L4A3A2H6H10H8L2 L1L10W2W6A1 W5W1S69W2150

69W3D1X28Symbol UnitModelF60AEHTL1 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)

SPECSpecifications2969W3D1XExteriorL6L7W5W1A1H9H2H7H1H11H4H3C1B6L5L9L4A3A2H6H10H8L8L2L1L10S69W2160

69W3D1X30Symbol UnitModelF60AETL1 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

SPECSpecifications3169W3D1XClamp bracketSymbol UnitModelF60AEHT F60AETB1 mm (in) 126 (5.0)B2 mm (in) 249 (10.0)B3 mm (in) 163.5 (6.4)B4 mm (in) 50.8 (

69W3D1X32Tightening torques2Specified torquesPart to be tightened Thread sizeTightening torquesN·mkgf·mft·lbPower unitFlywheel magnet nut — 160 16 116

69W3D1XGeneral informationHow to use this manual... 1Manual format...

SPECSpecifications3369W3D1XGeneral torquesThis chart specifies tightening torques forstandard fasteners with a standard ISOthread pitch. Tightening to

69W3D1X34Special service tools3Digital tachometer90890-06760Compression gauge90890-03160Drive shaft holder 490890-06518Pinion nut holder90890-06505Soc

CHK ADJPeriodic checks and adjustments3569W3D1XDial gauge set90890-01252Magnet base90890-06705

69W3D1X36Maintenance interval chart3Use the following chart as a guideline for general maintenance.Adjust the maintenance intervals according to the o

CHK ADJPeriodic checks and adjustments3769W3D1XTop cowling3Checking the top cowling1. Check the fitting by pushing the cowlingwith both hands. Adjust

69W3D1X384. Check the thermostat valve opening atthe specified water temperatures.Replace if out of specification.5. Install the thermostat, new gaske

CHK ADJPeriodic checks and adjustments3969W3D1XLubrication1. Apply water resistant grease to the areasshown.NOTE:Apply grease to the grease nipple unt

69W3D1X40Hose routing4Fuel and blowby hoses1Blowby hose2Hose (acceleration pump-to-carburetor)3Fuel hose (fuel joint-to-fuel filter)4Fuel hose (fuel f

FUELFuel system4169W3D1XCooling water hose1Pilot water hose2Flushing hoseÈFlushing device modelÉView in direction of arrowS69W4020

69W3D1X42Fuel line and fuel filter4No. Part name Q’ty Remarks1 Fuel joint 12Bolt 1 M6 × 25 mm3 Seal 14 Fuel hose 1 Fuel joint-to-fuel filter5Bolt 1 M8

69W3D1XSpecificationsGeneral specifications... 18Maintenance specific

FUELFuel system4369W3D1XCarburetor unit4No. Part name Q’ty Remarks1 Acceleration pump 12Screw 3 ø5 × 9 mm3Link rod 14Hose 15Hose 46Link rod 17 Clip 1N

69W3D1X44Adjusting 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 p

POWRPower unit4569W3D1XPower unit5

69W3D1X46È Flushing device modelNo. Part name Q’ty Remarks1 Power trim and tilt relay 12Bolt 1 M8 × 16 mm3 Black battery cable 14 Wiring harness 1 10-

POWRPower unit4769W3D1X

69W3D1X48No. Part name Q’ty Remarks1Bracket 12 Starter motor 13 Spark plug cap 44 Ignition coil 25 Wiring harness 16 Thermoswitch 17 Holder 18Bolt 1 M

POWRPower unit4969W3D1X

69W3D1X50È Tightening sequenceNo. Part name Q’ty Remarks1 Cylinder head 12Plate 13 Cylinder head cover 14Bolt 7 M6 × 20 mm5 Cylinder head cover gasket

POWRPower unit5169W3D1X

69W3D1X52No. Part name Q’ty Remarks1 Rocker arm assembly 82 Rocker arm shaft 13 Cylinder head 14 Exhaust valve 45 Intake valve 46 Camshaft 17 Valve co

69W3D1XPower unitPower unit... 45Checking the com

POWRPower unit5369W3D1X

69W3D1X54È Tightening sequenceNo. Part name Q’ty Remarks1 Oil filter 12 Crankshaft 13 Bolt 10 M8 × 82 mm4 Bolt 10 M6 × 35 mm5 Crankcase 16 Oil seal 1N

POWRPower unit5569W3D1XChecking the compression pressure1. Start the engine, warm it up for 5 min-utes, and then turn it off.2. Remove the lock plate

69W3D1X56Checking the cylinder bore1. Measure the cylinder bore (D1–D6) atmeasuring points a, b, and c, and indirection d (D1, D3, D5), which is paral

LOWRLower unit5769W3D1XDrive shaft and lower case6

69W3D1X58No. Part name Q’ty Remarks1 Drive shaft 12 Oil seal 1Not reusable3 Oil seal housing 14 O-ring 1Not reusable5 Circlip 16 Shift rod 17 O-ring 1

LOWRLower unit5969W3D1XRemoving the drive shaft1. Remove the drive shaft assembly andpinion, and then pull out the forwardgear.Disassembling the forwa

69W3D1X60Shimming6Drive shaft and lower case / Shimming

LOWRLower unit6169W3D1XShimmingNOTE:• Shimming is not required when assemblingthe original lower case and inner parts.• Shimming is required when asse

69W3D1X62Example:If “T1” is 0.45 mm, then the forward gearshim is 0.42 mm.If “T1” is 0.60 mm, then the forward gearshim is 0.58 mm.Shimming

69W3D1XElectrical systemsWiring harness ... 85Ignition an

BRKTBracket unit6369W3D1XTiller handle7

69W3D1X64No. Part name Q’ty Remarks1 Tiller handle assembly 12 Tiller handle wiring harness 13Grommet 14 Clip 15 Throttle cable 16Plate 17Bolt 3 M6 ×

BRKTBracket unit6569W3D1XBottom cowling7

69W3D1X66No. Part name Q’ty Remarks1 Bottom cowling 12 Rubber seal 13 Washer 14 Bushing 25 Shift rod bracket 16Bolt 17Spring 18Ball 19 Shift rod 110 F

BRKTBracket unit6769W3D1XUpper case7

69W3D1X68No. Part name Q’ty Remarks1 Muffler assembly 12 Upper case 13 Muffler seal 14 Rubber seal 15 Dowel pin 26Grommet 17Damper 18Screw 2 ø5 × 16 m

BRKTBracket unit6969W3D1X

69W3D1X70No. Part name Q’ty Remarks1 Oil seal 1Not reusable2 Exhaust guide 13Grommet 14 Anode 15 Cover 16Bolt 1 M6 × 20 mm7 Cover 18Bolt 19 Gasket 1No

BRKTBracket unit7169W3D1XDisassembling the oil pan1. Remove the muffler 1, plate 2, andexhaust manifold 3 from the oil pan 4.2. Remove the oil pan 4 a

69W3D1X727. Tighten the oil pan bolts 7 then exhaustmanifold bolts 8, and then tighten themto the specified torque.8. Install the plate 9 and the muff

GEN INFOGeneral information169W3D1XHow to use this manual1Manual formatThe format of this manual has been designed to make service procedures clear an

BRKTBracket unit7369W3D1X4. Install the upper and lower mountingbolts into the swivel bracket 6 simulta-neously.5. Install the upper mounting nut 7 an

69W3D1X74Clamp brackets7No. Part name Q’ty Remarks1 Swivel bracket assembly 12Screw 2 ø6 × 15 mm3 Trim sensor 14 Trim sensor coupler 15 Plastic tie 1N

BRKTBracket unit7569W3D1XAdjusting the trim sensor1. Fully tilt the outboard motor up, and thensupport it with the tilt stop lever 1. WARNINGAfter til

69W3D1X76Swivel bracket and steering arm7No. Part name Q’ty Remarks1 Steering arm 12 Washer 13 Bushing 14 O-ring 2Not reusable5 Bushing 26 Swivel brac

BRKTBracket unit7769W3D1XPower trim and tilt unit7No. Part name Q’ty Remarks1 Power trim and tilt unit 12 Plastic tie 3Not reusable3 PTT motor lead 24

69W3D1X78No. Part name Q’ty Remarks1Bolt 2 M5 × 8 mm2 Relief valve bracket 13Bolt 3 M6 × 40 mm4 Valve lock screw 15 Up-relief spring 16 Valve support

BRKTBracket unit7969W3D1XNo. Part name Q’ty Remarks1Bolt 2 M5 × 20 mm2 Washer 23Bracket 14 O-ring 2Not reusable5 Spacer 26Spring 27 Valve pin 28Ball 2

69W3D1X80No. Part name Q’ty Remarks19 Shaft 120 Driven gear 121 Ball 222 Shuttle piston 123 Valve plate 124 Plate 125 Gear pump housing 1Power trim an

BRKTBracket unit8169W3D1XNo. Part name Q’ty Remarks1Screw 3 ø5 × 20 mm2Yoke 13 O-ring 1Not reusable4 Armature 15 Washer 16 Bushing 17Screw 2 ø4 × 12 m

69W3D1X82Disassembling the gear pump1. Remove the manual valve 1 and gearpump 2.2. Remove the relief valve bracket 3, thenthe relief valve seal 4 and

69W3D1X2SymbolsThe symbols below are designed to indicate the content of a chapter.General informationSpecificationsPeriodic checks and adjustmentsFue

BRKTBracket unit8369W3D1X4. Check the main valves for dirt or residue.Clean if necessary.5. Check the absorber valves for dirt or res-idue. Clean if n

69W3D1X847. Install the filters H and gear pump I byinstalling the bolts J, then tighteningthem to the specified torque.8. Install the manual valve K

ELECElectrical systems– +8569W3D1XWiring harness8Connect to:1Engine start switch or remote control box extension2Power trim and tilt relay3Ground4Star

69W3D1X86Ignition and ignition control system81Spark plug2Ignition coil3Charge coil4Pulser coil5Engine start switch6Engine shut-off switch710-pin coup

ELECElectrical systems– +8769W3D1X1Thermoswitch2Oil pressure switch3CDI unit4Oil pressure warning indicator5Overheat warning indicator6Warning indicat

69W3D1X88Checking the spark plug caps1. Remove the spark plug caps from thespark plug wires by turning the capscounterclockwise.2. Measure the spark p

ELECElectrical systems– +8969W3D1XStarting system81Fuse210-pin coupler3Engine start switch4Starter motor5Battery6Neutral switch7Starter relayÈTiller h

69W3D1X90Starter motor8No. Part name Q’ty Remarks1 Clip 12 Pinion stopper 13Spring 14 Starter motor pinion 15 Upper bracket 16 Washer 1 17Shim — As re

ELECElectrical systems– +9169W3D1XChecking the armature1. Check the armature axial free play.Replace the washers and shim(s) 3 ifout of specification.

69W3D1X922. Check the brush holder for continuity.Replace if out of specifications.Brush length limit a:10.0 mm (0.39 in)Brush assembly continuityBrus