Yamaha 60 FETOL — инструкция по снятию магнитного маховика с двигателя [175/204]

Содержание

• English p.1
• G 60f 70b 75c 90a p.1
• Notice p.2
• How to use this manual p.3
• Manual format p.3
• An index to contents is provided on the first page of each section p.3
• Model indication p.3
• The illustrations p.3
• 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 p.3
• These have been kept to a minimum however when you are referred to another section of the manual you are told the page number to go to p.3
• Some illustrations in this manual may differ from the model you have this is because the procedure described may relate to several models though only one may be illustrated the name of the model described will be mentioned in the description p.3
• References p.3
• Multiple models are shown in this manual these indications are noted as follows p.3
• To help you identify components and understand the correct procedures of disassembly and assembly exploded diagrams are provided steps in the procedures are numbered thus 1 2 3 parts shown in the illustrations are identified thus p.3
• To assist you to find your way about this manual the section title and major heading is given at the head of every page p.3
• Board motor p.4
• Specifications p.4
• A caution indicates special precautions that must be taken to avoid damage to the out p.4
• Warnings cautions and notes p.4
• Warning p.4
• These are given in bold type at each procedure it is not necessary to leave the section deal ing with the procedure in order to look up the specifications it is important to note the differences in specifications of models where a procedure relates to more than one model the main differences in specifications will be shown in the following table p.4
• Operator a bystander or a person inspecting or repairing the outboard motor p.4
• A note provides key information to make procedures easier or clearer p.4
• The safety alert symbol means attention become alert your safety is involved p.4
• Failure to follow warning instructions could result in severe injury or death to the machine p.4
• Caution p.4
• Attention is drawn to the various warnings cautions and notes which distinguish important information in this manual in the following ways p.4
• Insp adj fuel p.5
• Gen info spec p.5
• Trbl anls p.5
• 2 3 4 5 6 7 8 9 p.9
• Chapter 1 general information p.9
• General information p.9
• Gen info p.9
• Starting serial numbers p.10
• Serial number p.10
• Identification p.10
• Gen info p.10
• Oils greases and sealing fluids p.11
• Fire prevention p.11
• Ventilation p.11
• Self protection p.11
• Safety while working p.11
• Gen info p.11
• Good working practices p.12
• Gen info p.12
• Safety while working p.12
• Disassembly and assembly p.13
• Safety while working p.13
• Gen info p.13
• Special tools p.14
• Gen info p.14
• Special tools p.15
• Measuring p.15
• Gen info p.15
• Special tools p.16
• Gen info p.16
• Special tools p.17
• Removal and installation p.17
• Gen info p.17
• Special tools p.18
• Gen info p.18
• Gen info p.19
• Special tools p.19
• Chapter 2 specifications p.21
• Specifications p.21
• 2 3 4 5 6 7 8 9 p.21
• General specification p.22
• General specification p.23
• For c60er 60fed c60tr 60fet c75tr 90aehd 90aed c90tr 90aet p.24
• For c60er c60tr c75tr p.24
• Yamalube two cycle outboard motor oil is recommended in usa yamalube 1 is recommended in canada p.24
• Pump octane number research octane motor octane 2 p.24
• General specification p.24
• Gear case lube is recommended in usa p.24
• Forward neutral reverse p.24
• General specification p.25
• Engine p.26
• Maintenance specifications p.26
• Maintenance specifications p.27
• Electrical p.28
• Maintenance specifications p.28
• Maintenance specifications p.29
• Maintenance specifications p.30
• Except for p75th 75cehto 90aehd p.31
• Maintenance specifications p.31
• For p60th 60fehto p75th 75cehto p.31
• Dimension p.31
• Maintenance specifications p.32
• Tightening torque p.33
• General torque specifications p.34
• Tightening torque general torque specifications p.34
• Periodic inspection and adjustment p.35
• Insp adj p.35
• Chapter 3 periodic inspection and adjustment p.35
• 2 3 4 5 6 7 8 9 p.35
• Periodic service p.36
• Maintenance schedule p.36
• Insp adj p.36
• Periodic service p.37
• Insp adj p.37
• Battery p.37
• Periodic service p.38
• Insp adj p.38
• Carburetor link adjustment p.38
• Carburetor p.38
• Periodic service p.39
• Insp adj p.39
• Fuel tank and fuel line p.39
• Fuel filter p.39
• Cylinder head bolts engine mounting bolts and flywheel nut p.39
• Gear oil p.40
• Idle speed p.40
• Periodic service p.40
• Insp adj p.40
• Periodic service p.41
• Insp adj p.41
• Ignition timing adjustment p.41
• Periodic service p.42
• Insp adj p.42
• Periodic service p.43
• Insp adj p.43
• Caution p.43
• Periodic service p.44
• Insp adj p.44
• Oil injection pump p.45
• Insp adj p.45
• Caution p.45
• Periodic service p.45
• Periodic service p.46
• Insp adj p.46
• Checking the oil level warning system p.46
• Caution p.46
• Power trim and tilt fluid ptt model p.47
• Periodic service p.47
• Oil pump link adjustment p.47
• Insp adj p.47
• Caution p.47
• Spark plug p.48
• Propeller p.48
• Periodic service p.48
• Insp adj p.48
• Greasing points p.49
• Insp adj p.49
• Periodic service p.49
• Fuel system p.51
• 2 3 4 5 6 7 8 9 p.51
• Chapter 4 fuel system p.51
• Fuel system p.52
• Exploded diagram p.52
• Fuel system p.53
• Fuel line p.53
• Removal p.54
• Fuel system p.54
• Cleaning and inspection p.54
• Fuel system p.55
• Installation p.56
• Fuel system p.56
• Exploded diagram except for c60er c60tr c75tr p.57
• Carburetor p.57
• Exploded diagram for c60er c60tr c75tr p.58
• Carburetor p.58
• Warning p.59
• Removal and disassembly p.59
• Caution p.59
• Carburetor p.59
• Inspection p.60
• Carburetor p.60
• Carburetor p.61
• Carburetor p.62
• Assembly p.62
• Caution p.63
• Carburetor p.63
• Installation p.64
• Carburetor p.64
• Oil injection system p.65
• Exploded diagram p.65
• Oil injection system oil injection model p.65
• Oil injection system p.66
• Removal p.67
• Oil injection system p.67
• Installation p.67
• Cleaning and inspection p.67
• Oil injection system p.68
• Caution p.68
• Power unit p.70
• Chapter 5 power unit p.70
• 2 3 4 5 6 7 8 9 p.71
• Exploded diagram p.72
• Exploded diagram p.73
• Removal p.74
• Preparation for overhaul removal p.74
• Preparation for overhaul p.74
• Removal p.75
• Disassembly p.76
• Inspection p.77
• Cylinder head p.77
• Caution p.77
• Cylinder block p.78
• Inspection p.78
• Piston p.79
• Inspection p.79
• Piston ring p.80
• Inspection p.80
• Caution p.80
• Inspection p.81
• Piston pin and small end bearing p.81
• Crankshaft p.81
• Reed valve p.82
• Inspection p.82
• Thermostat p.83
• Inspection p.83
• Crank main bearing p.83
• Inspection p.84
• Driven gear oil injection pump drive p.84
• Drive gear oil injection pump drive p.84
• Piston and piston ring p.85
• Caution p.85
• Bearing oil seal and o ring p.85
• Assembly and adjustment p.85
• Small end bearings and piston assembly p.86
• Caution p.86
• Assembly and adjustment p.86
• Assembly and adjustment p.87
• Connecting rod big end bearing assembly 75 80 90 hp p.87
• Assembly and adjustment p.88
• Oil seal housing p.88
• Crank cylinder assembly 50 60 70 hp p.88
• Caution p.88
• Crank cylinder assembly 75 80 90 hp p.89
• Assembly and adjustment p.89
• Cylinder head and exhaust cover p.90
• Assembly and adjustment p.90
• Intake manifold p.91
• Fuel system and electrical system p.91
• Drainage hose p.91
• Assembly and adjustment p.91
• Installation p.92
• Chapter 6 lower unit p.93
• 2 3 4 5 6 7 8 9 p.93
• Lower unit p.93
• Exploded diagram p.94
• Exploded diagram for 50geto c60er c60tr 60fet oceania c75tr 90aehd 90aed c90tr 90aet p.94
• Exploded diagram except for 50geto c60er c60tr 60fet oceania c75tr 90aehd 90aed c90tr 90aet p.95
• Exploded diagram p.95
• Preparation for removal disassembly p.96
• Preparation for removal p.96
• Disassembly p.96
• Disassembly p.97
• Disassembly p.98
• Disassembly p.99
• Disassembly p.100
• Disassembly p.101
• Gear case p.102
• Claw washer p.102
• Bearing housing p.102
• Ring nut p.102
• Inspection p.102
• Water pump housing p.103
• Oil seal housing water pump housing p.103
• Inspection p.103
• Impeller p.103
• Bearing p.103
• Propeller trim tab anode p.104
• Inspection p.104
• Drive shaft sleeve p.104
• Drive and propeller shaft p.104
• Clutch dog and components p.104
• Propeller shaft housing p.105
• Assembly and adjustment p.105
• Gear case p.106
• Assembly and adjustment p.106
• Assembly and adjustment p.107
• Assembly and adjustment p.108
• Assembly and adjustment p.109
• Shim selection for usa and canada p.110
• Shim selection p.110
• Shim selection for usa and canada p.111
• Shim selection for usa and canada p.112
• Shim selection for usa and canada p.113
• Shim selection for usa and canada p.114
• Shim selection except for usa and canada p.115
• Shim selection except for usa and canada p.116
• Shim selection except for usa and canada p.117
• Shim selection p.118
• Measuring the backlash p.118
• Shim selection p.119
• Determine the shim size according to the chart p.120
• Slowly turn the drive shaft in and out and read the dial gauge when the drive shaft stops in each direction p.120
• Shim selection p.120
• Reverse gear 1 install a propeller on the propeller shaft with the front facing backward fit the nut and tighten p.120
• Nut propeller 5 nm 0 m kg 3 ft lb p.120
• Water pump installation p.121
• Shim selection p.121
• Installation p.122
• Installation p.123
• Lower unit leakage check p.124
• Installation p.124
• Caution p.124
• Chapter 7 bracket unit p.125
• Bracket unit p.125
• 2 3 4 5 6 7 8 9 p.125
• Exploded diagram p.126
• Bracket unit p.126
• Upper casing 50 60 70 hp p.127
• Bracket unit p.127
• Bracket unit p.128
• 80 90 hp p.128
• Bracket unit p.129
• Bottom cowling p.129
• Bracket unit p.130
• Bracket unit manual tilt model p.131
• Bracket unit p.131
• Bracket unit p.132
• Bracket short transom p.132
• Bracket unit p.133
• Bracket long transom p.133
• Disassembly p.134
• Caution p.134
• Bracket unit p.134
• Removal p.134
• Inspection p.134
• Warning p.135
• Bracket unit p.135
• Assembly p.135
• Power trim and tilt unit p.136
• Hydraulic tilt unit p.136
• Warning p.136
• Removal p.136
• Inspection p.136
• Hydraulic tilt unit power trim and tilt unit p.136
• Power trim and tilt unit p.137
• Exploded diagram short transom 6h308 p.137
• Power trim and tilt unit p.138
• Disassembly p.139
• Caution p.139
• Power trim and tilt unit p.139
• Warning p.140
• Power trim and tilt unit p.140
• Power trim and tilt unit p.141
• Inspection p.141
• Assembly p.141
• Power trim and tilt unit p.142
• Manual valve 3 nm 0 m kg 2 ft lb p.142
• Main valve 10 nm 1 m kg 7 ft lb p.142
• Install the up relief valve with a new o ring and tighten the locking bolt to the specified torque p.142
• Install the manual valve in the body with new o rings p.142
• Install a new o ring on the shuttle pis ton insert the piston into the body then install the main valves with new o rings p.142
• Power trim and tilt unit p.143
• Power trim and tilt unit p.144
• Power trim and tilt unit p.145
• Exploded diagram long transom 6h1 15 62f 02 p.145
• Power trim and tilt unit p.146
• Power trim and tilt unit p.147
• Disassembly p.147
• Caution p.147
• Warning p.148
• Power trim and tilt unit p.148
• Power trim and tilt unit p.149
• Inspection p.149
• Assembly p.149
• Note feed oil into each pipe p.150
• Manual valve 3 nm 0 m kg 2 ft lb p.150
• Main valve 11 nm 1 m kg 8 ft lb p.150
• Lock nut delivery pipe 15 nm 1 m kg 11 ft lb p.150
• Install the tilt cylinder and the delivery pipes p.150
• Install the manual valve in the body with new o rings p.150
• Install a new o ring on the shuttle pis ton and insert the piston into the body then install the main valves with new o rings p.150
• Power trim and tilt unit p.150
• Valve lock screw 4 nm 0 m kg 2 ft lb screw 4 nm 0 m kg 2 ft lb p.151
• Power trim and tilt unit p.151
• Install the up relief valve and the valve lock screw with new o rings and tighten the screw to the specified torque p.151
• Fit a new o ring and the back up ring on the trim piston fit new o rings and a new oil seal on the end screw and install the complete trim piston in the cylinder fill the cylinder with hydraulic fluid and install and tighten the end screw to the specified torque p.151
• End screw trim cylinder 160 nm 16 m kg 115 ft lb p.151
• Cylinder end screw wrench yb 6175 1a 90890 6548 p.151
• Atf automatic transmission fluid p.151
• Power trim and tilt unit p.152
• Power trim and tilt unit p.153
• Hydraulic fluid pressure test p.153
• Filling with hydraulic fluid and air bleeding p.153
• Power trim and tilt unit p.154
• Caution p.154
• Power trim and tilt unit p.155
• Installation p.155
• Power trim and tilt motor p.156
• Inspection p.156
• Disassembly p.156
• Power trim and tilt motor p.157
• Power trim and tilt motor p.158
• Assembly p.158
• Electrical systems p.160
• Chapter 8 electrical systems p.160
• 2 3 4 5 6 7 8 9 p.161
• Electrical components p.162
• 60 70 hp p.162
• Electrical components p.163
• 80 90 hp p.163
• Check that all leads and connectors are properly connected p.164
• Electrical wiring p.164
• 60 70 hp p.164
• P75th 75cehto 90aehd p.164
• P60th 60fehto p.164
• Electrical wiring p.165
• 60 70 hp p.165
• Electrical wiring p.166
• 80 90 hp p.166
• Electrical wiring p.167
• 80 90 hp p.167
• Wiring diagram p.168
• 60 70 hp p.168
• Wiring diagram p.169
• C60er c60tr p.169
• 80 90 hp p.170
• Wiring diagram p.170
• Wiring diagram p.171
• P60th 60fehto p.172
• Wiring diagram p.172
• Wiring diagram p.173
• Remote control box p.173
• Digital meter p.173
• Removal p.174
• Magneto base p.174
• Caution p.174
• Removal p.175
• Caution p.175
• Inspection p.176
• Electrical analysis p.176
• Caution p.176
• Warning p.177
• Ignition spark gap p.177
• Electrical analysis p.177
• Cdi system peak voltage p.177
• Electrical analysis p.178
• Electrical analysis p.179
• Electrical analysis p.180
• Replacement of spark plug cap p.181
• Electrical analysis p.181
• Crank position sensor p.181
• Starter relay p.182
• Power trim and tilt relay p.182
• Electrical analysis p.182
• Electrical analysis p.183
• Trailer switch p.183
• Fuse rating 20a p.184
• Check the continuity of the rectifier reg ulator p.184
• Rectifier regulator p.184
• Never connect the rectifier regulator directly to the battery to check continuity p.184
• If continuity is not as specified replace the rectifier regulator p.184
• Electrical analysis p.184
• When testing disconnect the battery ter minals p.184
• When resistance is measured at less than 100 ω it can be said that there is continu ity p.184
• The digital tester cannot be used for this inspection p.184
• Referring to the diagram check the con tinuity of the fuse if the fuse is blown replace with a fuse of correct rating p.184
• Rectifier regulator check p.184
• Thermo switch p.185
• Fuel enrichment valve p.185
• Electrical analysis p.185
• Oil injection system oil injection model p.186
• Electrical analysis p.186
• 60 70 hp marking 6h3 16 unit ω p.187
• Oil level sensor resistance p.187
• Oil level sensor p.187
• Indicates that the pointer deflects once and returns to p.187
• Electrical analysis p.187
• Remove the circlip and disassemble the oil level sensor p.187
• Referring to the illustrations and tables check the continuity and resistance p.187
• Oil level sensor resistance p.188
• Float sw 1 sw 2 both off p.188
• Electrical analysis p.188
• The bottom p.188
• Strainer cover 2 float magnet 3 plate 4 gasket p.188
• Place the float with the magnet side upward p.188
• Indicates that the pointer deflects once and returns to p.188
• Float sw on a 5 8 mm 0 3 0 5 in p.188
• Float sw 2 on b 42 45 mm 1 7 1 8 in p.188
• Discontinuity p.188
• Assemble the plate which has a hole at p.188
• Assemble as shown in the diagram p.188
• 80 90 hp marking 6h1 15 unit ω p.188
• Wiring harness p.189
• Caution p.189
• Oil level warning lamp l e d p.189
• Electrical analysis p.189
• Electrical analysis p.190
• Engine stop switch p60th 60fehto p75th 75cehto 90aehd p.190
• Bracket p.190
• Battery p.190
• Electrical analysis installation p.191
• Neutral switch p60th 60fehto p75th 75cehto 90aehd 90tr 90aeto b90tr 90aeto p.191
• Main switch p60th 60fehto p75th 75cehto 90aehd p.191
• Installation p.191
• Flywheel magneto p.191
• Disconnect the cables and remove the starter motor p.192
• Starter motor p.192
• Removal p.192
• Note push the pinion stopper by hand toward the pinion and remove the clip p.192
• Disassembly p.192
• Using a piece of steel wire separate the brush springs and remove the brushes from the brush holders p.192
• Remove the yoke assembly by lightly tapping it with a plastic hammer and remove the armature p.192
• Remove the two through bolts and pull out the front cover lightly tapping it with a plastic hammer if necessary p.192
• Remove the starter clutch using a screw driver pry off the clip p.192
• Starter motor p.193
• Inspection p.193
• Starter motor p.194
• Starter motor p.195
• Assembly 50 60 70 hp p.195
• Starter motor p.196
• Installation 50 60 70 hp p.196
• Assembly 75 80 90 hp p.196
• Starter motor p.197
• Installation 75 80 90 hp p.197
• Trouble analysis p.199
• Trouble analysis chart p.200
• Trouble analysis p.200
• Trbl anls p.200
• Trouble analysis p.201
• Trbl anls p.201
• Trouble analysis p.202
• Trbl anls p.202