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1996 – 2010 Yamaha 50 60 70 75 80 90HP 2 Stroke Outboard Repair Manual – PDF DOWNLOAD
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1996 – 2010 Yamaha 50 60 70 75 80 90HP 2 Stroke Outboard Repair Manual
Model : 60TLRA, 60TLRX, 60TLRY, 60TLRZ, 75TLRA, 75TLRB, 75TLRV, 75TLRW, 75TLRX, 75TLRY, 75TLRZ, 90TJRV, 90TJRW, 90TJRX, 90TJRY, 90TJRZ, 90TLR, 90TLRA, 90TLRB, 90TLRC, 90TLRD, 90TLRF, 90TLRG, 90TLRH, 90TLRH (6H1C), 90TLRV, 90TLRW, 90TLRX, 90TLRY, 90TLRZ
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Description
1996 – 2010 Yamaha 50 60 70 75 80 90HP 2 Stroke Outboard Repair Manual
FILE DETAILS:
1996 – 2010 Yamaha 50 60 70 75 80 90HP 2 Stroke Outboard Repair Manual
LANGUAGE:ENGLISH
PAGES:408
DOWNLOADABLE:YES
FILE TYPE:PDF
TABLE OF CONTENTS:
1996 – 2010 Yamaha 50 60 70 75 80 90HP 2 Stroke Outboard Repair Manual
1996-2010 YAMAHA 50 60 70 75 80 90HP 2-STROKE OUTBOARDS.......................... 1 NOTICE....................................................................... 2 HOW TO USE MANUAL............................................................ 4 TABLE OF CONTENTS............................................................ 14 GENERAL INFORMATION.......................................................... 16 IDENTIFICATION........................................................... 18 SERIAL NUMBER........................................................ 18 STARTING SERIAL NUMBERS.............................................. 18 SAFETY WHILE WORKING..................................................... 20 FIRE PREVENTION...................................................... 20 VENTILATION.......................................................... 20 SELF-PROTECTION...................................................... 20 OILS, GREASES AND SEALING FLUIDS..................................... 20 GOOD WORKING PRACTICES............................................... 22 DISASSEMBLY AND ASSEMBLY............................................. 24 SPECIAL TOOLS............................................................ 26 MEASURING............................................................ 27 REMOVAL AND INSTALLATION............................................. 31 SPECIFICATIONS............................................................... 38 GENERAL SPECIFICATIONS................................................... 40 MAINTENANCE SPECIFICATIONS............................................... 48 ENGINE............................................................... 48 ELECTRICAL........................................................... 52 DIMENSION............................................................ 58 TIGHTENING TORQUE........................................................ 62 GENERAL TORQUE SPECIFICATIONS............................................ 64 PERIODIC INSPECTION AND ADJUSTMENT........................................... 66 MAINTENANCE SCHEDULE..................................................... 68 ANODE.................................................................... 68 BATTERY.................................................................. 72 CARBURETOR............................................................... 74 CARBURETOR LINK ADJUSTMENT............................................... 74 CYLINDER HEAD BOLTS, ENGINE MOUNTING BOLTS, AND FLYWHEEL NUT............. 76 FUEL FILTER.............................................................. 76 FUEL TANK AND FUEL LINE.................................................. 76 GEAR OIL................................................................. 78 IDLE-SPEED............................................................... 78 IGNITION TIMING ADJUSTMENT............................................... 80 TIMING PLATE POSITION ADJUSTMENT..................................... 80 THROTTLE SENSOR CONTROL LINK ADJUSTMENT.............................. 82 IGNITION TIMING ADJUSTMENT........................................... 84 PICK-UP TIMING ADJUSTMENT............................................ 86 OIL INJECTION PUMP....................................................... 88 OPERATIONAL TEST..................................................... 88 CHECKING THE OIL LEVEL WARNING SYSTEM.................................... 90 OIL PUMP LINK ADJUSTMENT................................................. 92 POWER TRIM AND TILT FLUID (P.T.T. model)................................. 92 PROPELLER................................................................ 94 SPARK PLUG............................................................... 94 GREASING POINTS.......................................................... 96 FUEL SYSTEM.................................................................. 98 FUEL SYSTEM..............................................................100 EXPLODED DIAGRAM.....................................................100 FUEL LINE............................................................102 REMOVAL..............................................................104 INSTALLTION..........................................................108 CLEANING AND INSPECTION..............................................104 CARBURETOR...............................................................110 EXPLODED DIAGRAM (Prime starter model)...............................110 EXPLODED DIAGRAM (Choke model).......................................112 REMOVAL AND DISASSEMBLY..............................................114 INSPECTION...........................................................116 ASSEMBLY.............................................................120 INSTALLATION.........................................................124 OIL-INJECTION SYSTEM (Oil injection model)...............................126 EXPLODED DIAGRAM.....................................................126 REMOVAL..............................................................130 CLEANING AND INSPECTION..............................................130 INSTALLATION.........................................................130 POWER UNIT...................................................................132 EXPLODED DIAGRAM.........................................................136 PREPARATION FOR OVERHAUL.................................................140 REMOVAL..................................................................140 DISASSEMBLY..............................................................144 INSPECTION...............................................................146 CYLINDER HEAD........................................................146 CYLINDER BLOCK.......................................................148 PISTON...............................................................150 PISTON RING..........................................................152 PISTON PIN AND SMALL END BEARING.....................................154 CRANKSHAFT...........................................................154 REED VALVE...........................................................156 THERMOSTAT...........................................................158 CRANK MAIN BEARING...................................................158 DRIVE GEAR (OIL INJECTION PUMP DRIVE)................................160 DRIVEN GEAR (OIL INJECTION PUMP DRIVE)...............................160 ASSEMBLY AND ADJUSTMENT..................................................162 BEARING, OIL SEAL AND O-RING.........................................162 PISTON AND PISTON RING...............................................162 SMALL END BEARINGS AND PISTON ASSEMBLY...............................164 CONNECTING ROD BIG END BEARING ASSEMBLY (75, 80, 90 hp)..............166 OIL SEAL HOUSING.....................................................168 CRANK CYLINDER ASSEMBLY (50, 60, 70 hp)..............................168 CRANK CYLINDER ASSEMBLY (75, 80, 90 hp)..............................170 CYLINDER HEAD AND EXHAUST COVER......................................172 DRAINAGE HOSE........................................................174 INTAKE MANIFOLD......................................................174 FUEL SYSTEM AND ELECTRICAL SYSTEM....................................174 INSTALLTION..............................................................176 LOWER UNIT...................................................................178 EXPLODED DIAGRAM.........................................................180 PREPARATION FOR REMOVAL..................................................182 DISASSEMBLY..............................................................182 INSPECTION...............................................................194 GEAR CASE............................................................194 BEARING HOUSING......................................................194 CLAW-WASHER..........................................................194 RING-NUT.............................................................194 WATER PUMP HOUSING...................................................196 IMPELLER.............................................................196 OIL-SEAL HOUSING (Water pump housing)................................196 GEAR.................................................................196 BEARING..............................................................196 CLUTCH DOG AND COMPONENTS............................................198 DRIVE AND PROPELLER SHAFT............................................198 DRIVESHAFT SLEEVE....................................................198 PROPELLER/TRIM TAB/ANODE.............................................198 ASSEMBLY AND ADJUSTMENT..................................................200 ASSEMBLY.............................................................200 SHIM SELECTION.......................................................210 MEASURING THE BACKLASH...............................................226 WATER PUMP INSTALLATION..............................................232 INSTALLATION.............................................................234 LOWER UNIT LEAKAGE CHECK.............................................238 BRACKET UNIT.................................................................240 BRACKET UNIT.............................................................242 EXPLODED DIAGRAM.....................................................242 REMOVAL..............................................................258 DISASSEMBLY..........................................................258 INSPECTION...........................................................258 ASSEMBLY.............................................................260 HYDRAULIC TILT UNIT......................................................262 INSPECTION...........................................................262 POWER TRIM AND TILT UNIT.................................................262 REMOVAL..............................................................262 EXPLODED DIAGRAM (Short transom [6H308]).............................264 DISASSEMBLY..........................................................268 INSPECTION...........................................................272 ASSEMBLY.............................................................272 EXPLODED DIAGRAM (Long transom [6H1-15], [62F-02])...................280 DISASSEMBLY..........................................................284 INSPECTION...........................................................288 ASSEMBLY.............................................................288 FILLING WITH HYDRAULIC FLUID AND AIR-BLEEDING........................296 HYDRAULIC FLUID PRESSURE TEST........................................296 INSTALLATION.........................................................300 P.T.T. MOTOR.............................................................302 DISASSEMBLY..........................................................302 INSPECTION...........................................................302 ASSEMBLY.............................................................306 ELECTRICAL SYSTEM............................................................308 ELECTRICAL COMPONENTS....................................................312 ELECTRICAL WIRING........................................................316 WIRING DIAGRAM...........................................................324 REMOTE CONTROL BOX...................................................334 REMOVAL..................................................................336 MAGNETO BASE.........................................................336 CLEANING, INSPECTION AND REPAIR..........................................340 TESTING THE C.D.I. SYSTEM (For U.S.A. and CANADA)....................340 PULSER COIL..........................................................352 CHARGE COIL..........................................................352 LIGHTING COIL........................................................354 IGNITION COIL........................................................354 REPLACEMENT OF SPARK-PLUG CAP (Standard type)........................356 C.D.I. UNIT..........................................................358 CRANK POSITION SENSOR................................................362 STARTER RELAY........................................................362 POWER TRIM AND TILT RELAY............................................362 POWER TRIM AND TILT SWITCH...........................................364 RECTIFIER REGULATOR..................................................366 FUSE.................................................................366 THERMOS-SWITCH.......................................................368 FUEL ENRICHMENT VALVE................................................368 OIL INJECTION SYSTEM (Oil injection model)...........................370 OIL-LEVEL SENSOR.....................................................372 OIL-LEVEL WARNING LAMP (L.E.D.)......................................376 WIRING HARNESS.......................................................376 BRACKET..............................................................378 BATTERY..............................................................378 ENGINE STOP SWITCH (P60TH/60FEMTO, P75TH/75CEHTO)....................378 MAIN SWITCH (P60TH/60FEMTO, P75TH/75CEHTO)...........................380 NEUTRAL SWITCH (P60TH/60FEMTO, P75TH/75CEHTO, 90TR/90AETO, B90TR)....380 INSTALLATION.............................................................380 FLYWHEEL MAGNETO.....................................................380 STARTER MOTOR............................................................382 REMOVAL..............................................................382 DISASSEMBLY..........................................................382 INSPECTION...........................................................384 ASSEMBLY (50, 60, 70 hp).............................................388 INSTALLATION (50, 60, 70 hp).........................................390 ASSEMBLY (75, 80, 90 hp).............................................390 INSTALLATION (75, 80, 90 hp).........................................392 TROUBLE ANALYSIS.............................................................394 TROUBLE ANALYSIS.........................................................396 TROUBLE ANALYSIS CHART...............................................396
DESCRIPTION:
1996 – 2010 Yamaha 50 60 70 75 80 90HP 2 Stroke Outboard Repair Manual
PREFACE:
This manual has been prepared by the Yamaha Motor Company primarily for use by Yamaha dealers and their trained mechanics when performing maintenance procedures and repairs to Yamaha equipment. It has been written to suit the needs of persons who have a basic understanding of the mechanical and electrical concepts and procedures inherent in the work, for without such knowledge attempted repairs or service to the equipment could render it unsafe or unfit for use.
Because the Yamaha Motor Company Ltd. has a policy of continuously improving its products, models may differ in detail from the descriptions and illustrations given in this publication. Use only the latest edition of this manual. Authorized Yamaha dealers are notified periodically of modifications and significant changes in specifications and procedures, and these are incorporated in successive editions of this manual.
MANUAL FORMAT
- This manual provides the mechanic with descriptions of the operations of disassembly. repair, assembly, adjustment and inspection. each of which is presented in a sequential, step-by-step procedure.
- To assist you to find your way about this manual, the Section Title and Major Heading is given at the head of every page.
- An Index to contents is provided on the first page of each Section.
1996 – 2010 YAMAHA 50 60 70 75 80 90HP 2 STROKE OUTBOARD REPAIR MANUAL – PDF DOWNLOAD:
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- This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
- This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
- Require some other service manual or have any queries: please WRITE to us at [email protected]
