Yamaha 60L, Supplementary Service Manual

Page 1: ...SERVICE MANUAL 292087 60L 28197 3D 1X SUPPLEMENTARY F200A FL200A https www boat manuals com ...

Page 2: ...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 F225A FL225A SERVICE MANUAL 69J...

Page 3: ...EN INFO Specifications 2 SPEC Periodic checks and adjustments 3 CHK ADJ Fuel system 4 FUEL Power unit 5 POWR Lower unit 6 LOWR Bracket unit 7 BRKT Electrical systems 8 ELEC Troubleshooting 9 TRBL SHTG Index https www boat manuals com ...

Page 4: ...ion 7 Predelivery checks 8 Checking the fuel system 8 Checking the gear oil 8 Checking the engine oil 8 Checking the battery 8 Checking the outboard motor mounting height 9 Checking the remote control cables 9 Checking the steering wheel 10 Checking the gearshift and throttle operation 10 Checking the tilt system 10 Checking the engine start switch and engine stop switch engine shut off switch 10 ...

Page 5: ...ice tools 27 Maintenance interval chart 28 Bracket unit Power trim and tilt unit 30 Assembling the gear pump 30 Electrical systems Fuel control system 31 Checking the fuel injector 31 Checking the low pressure fuel pump and high pressure fuel pump 32 Troubleshooting Yamaha Diagnostic System 33 Introduction 33 Getting started 33 Self diagnosis 42 Diagnosing the electronic control system 42 Index 44...

Page 6: ...nd 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 ...

Page 7: ...bols 7 to A in an exploded diagram indicate the grade of lubricant and the lubrication point 7 Apply Yamaha 4 stroke motor oil 8 Apply water resistant grease Yamaha grease A 9 Apply molybdenum disulfide grease 0 Apply corrosion resistant grease Yamaha grease D A Apply low temperature resistant grease Yamaha grease C Symbols B to G in an exploded diagram indicate the type of sealant or locking agen...

Page 8: ...l 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 Applicable models F200AET FL200AET Model name Approved model code Starting serial No F200AET 60L X 600101 FL200AET 60M X 600101 https www boat manuals com ...

Page 9: ...8 Power source for diagnosis lamp 36 Diagnosis signal 26 Personal computer Starboard bank Port bank Ground for power source 42 Ground for unit 32 Thermo switch 37 Neutral switch 31 6 Emergency engine stop switch 4 Shift cutoff switch 9 Oil pressure sensor 29 Power source for oil pressure sensor 10 Intake air temperature sensor 7 Engine temperature sensor 35 Ground for sensors 8 Intake air presssur...

Page 10: ...4 2 and 5 3 and 6 group injection TDC 720 180 120 TDC TDC TDC TDC Crankshaft angle Cylinder Cylinder 1 Cylinder 2 Cylinder 3 Cylinder 4 Cylinder 5 Cylinder 6 Ignition Injection Ignition Injection Ignition Injection Ignition Injection Ignition Injection Ignition Injection Compression Compression Compression Compression Compression Compression Intake Intake Intake Intake Intake Intake Combustion Exh...

Page 11: ...ssion Combustion Exhaust Intake Compression Expansion Compression Combustion Exhaust Intake Compression Intake Compression Combustion Exhaust Intake Compression Compression Combustion Exhaust Intake Compression Combustion Exhaust Compression Combustion Exhaust Intake Intake Intake Intake Combustion Exhaust Exhaust Combustion Exhaust Starting injection start timing standard position BTDC 70 S60L120...

Page 12: ...lade or outside of the propeller boss a Propeller diameter in inches b Propeller pitch in inches c Propeller type propeller mark Selection When the engine speed is at the full throttle operating range 5 000 6 000 r min the ideal propeller for the boat is one that pro vides maximum performance in relation to boat speed and fuel consumption S60L1030 S60L1040 S60L1050 Regular rotation model Propeller...

Page 13: ...OTE If the engine oil is above the maximum level mark H drain sufficient oil until the level is between H and L If the engine oil is below the minimum level mark L add sufficient oil until the level is between H and L Checking the battery 1 Check the capacity electrolyte level and specified gravity of the battery 2 Check that the red and black battery cables are securely connected S60L1060 S60L107...

Page 14: ...tion of the boat and the outboard motor To determine the optimum mounting height test run the outboard motor at differ ent heights 2 Check that the clamp brackets are secured with the clamp bolts Checking the remote control cables 1 Set the remote control lever to the neu tral position and fully close the throttle lever 2 Check that the throttle cam 1 is in its fully close position and the alignme...

Page 15: ...tboard 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 Checking the engine start ...

Page 16: ...n 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 ...

Page 17: ...7 4 14 5 Power unit Type V6 4 stroke DOHC 24 valves Cylinder quantity 6 Displacement cm3 cu in 3 352 204 5 Bore stroke mm in 94 0 80 5 3 70 3 17 Compression ratio 9 9 Control system Remote control Starting system Electric Ignition control system Microcomputer TCI Ignition timing Degree TDC BTDC 21 Alternator output V A 12 45 Spark plugs LFR5A 11 NGK Cooling system Water Exhaust system Through prop...

Page 18: ...quantity L US qt lmp qt 1 15 1 22 1 01 1 00 1 06 0 88 Bracket Trim angle at 12 degree boat transom Degree 3 16 Tilt up angle Degree 70 Steering angle Degree 32 32 Drive unit Gearshift positions F N R Gear ratio 2 00 30 15 Reduction gear type Spiral bevel gear Clutch type Dog clutch Propeller shaft type Spline Propeller direction rear view Clockwise Counterclockwise Propeller identification mark T ...

Page 19: ... H mm in 5 0 2 Piston to cylinder clearance mm in 0 075 0 080 0 0029 0 0031 Piston pin boss bore mm in 21 02 21 03 0 8276 0 8280 Piston pins Outside diameter mm in 21 00 0 827 Piston rings Top ring Dimension B mm in 1 17 1 19 0 0461 0 0468 Dimension T mm in 2 8 3 0 0 110 0 118 End gap mm in 0 15 0 30 0 0059 0 0118 Side clearance mm in 0 04 0 08 0 0016 0 0031 2nd ring Dimension B mm in 1 17 1 19 0 ...

Page 20: ...3 0 013 0 001 Head diameter A Intake mm in 34 85 35 15 1 3720 1 3839 Exhaust mm in 29 85 30 15 1 1752 1 1870 Face width B Intake mm in 2 11 0 0831 Exhaust mm in 2 43 0 0957 Seat contact width C Intake mm in 1 1 1 4 0 043 0 055 Exhaust mm in 1 4 1 7 0 055 0 067 Margin thickness D Intake mm in 0 7 0 028 Exhaust mm in 1 0 0 039 Stem diameter Intake mm in 5 477 5 492 0 2156 0 2162 Exhaust mm in 5 464 ...

Page 21: ...ameter mm in 62 968 62 992 2 4791 2 4800 Crankpin diameter mm in 49 976 50 000 1 9676 1 9685 Crankpin width mm in 21 50 21 55 0 8465 0 8484 Runout limit mm in 0 03 0 0012 Crankcase Crankshaft main journal oil clearance mm in 0 025 0 050 0 0010 0 0020 Upper crankcase main journal bearing thickness 1 mm in 2 494 2 500 0 0981 0 0984 2 mm in 2 498 2 504 0 0983 0 0986 3 mm in 2 502 2 508 0 0985 0 0987 ...

Page 22: ...open lower limit mm in 4 3 0 17 Engine speed Engine idle speed r min 650 750 Item Unit Model F200AET FL200AET Gear backlash Pinion to forward gear mm in 0 21 0 44 0 008 0 017 0 35 0 70 0 014 0 028 Pinion to reverse gear mm in 0 70 1 03 0 028 0 041 0 70 1 03 0 028 0 041 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 ...

Page 23: ... loaded V 260 Spark plug gap mm in 1 1 0 043 Ignition coil resistance Primary coil R Y B O R Y B Y R Y B W Ω 1 5 1 9 Secondary coil spark plug wire spark plug wire kΩ 19 6 35 4 Throttle position sensor output voltage P B mV 695 705 Oil pressure sensor output voltage engine idle speed O B V 3 8 Intake air temperature sensor resistance at 0 C 32 F kΩ 5 4 6 6 at 80 C 176 F kΩ 0 29 0 39 Engine tempera...

Page 24: ... Wear limit mm in 28 0 1 10 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 5 20 30 Stator coil output peak voltage G G at cranking unloaded V 10 at 1 500 r min unloaded V 42 at 3 500 r min unloaded V 93 G W G W at cranking unloaded V 9 0 at 1 500 r min unloaded V 34 at 3 500 r min unloaded V 78 Stator coil resistance 1 G G Ω 0 24 0 41 G W G W Ω 0 21...

Page 25: ...istance Ω 9 11 Resistance P B Ω 9 387 6 Fluid type ATF Dexron II Brushes Standard length mm in 12 0 0 47 Wear limit mm in 4 0 0 16 Commutator Standard diameter mm in 25 0 0 98 Item Unit Model F200AET FL200AET Maintenance specifications https www boat manuals com ...

Page 26: ...SPEC Specifications 21 60L3D1X Dimensions Exterior S60L2130 W5 A1 T1 W1 L7 H9 H1 H11 H2 H4 H3 H7 H8 H10 L8 L5 A2 H6 L9 L4 A3 12 C3 L2 L1 L10 L6 https www boat manuals com ...

Page 27: ... 2 0 L10 mm in 75 3 0 H1 X mm in 1 078 42 4 H2 mm in 727 28 6 H3 mm in 216 8 5 H4 X mm in 643 25 3 H5 mm in H6 X mm in 847 33 3 H7 mm in 361 14 2 H8 mm in 39 1 5 H9 mm in 880 34 6 H10 mm in 45 1 8 H11 X mm in 25 1 0 W1 mm in 317 12 5 W2 mm in W3 mm in W4 mm in W5 mm in 453 17 8 W6 mm in A1 Degree 32 A2 Degree 70 A3 Degree 3 T1 mm in 724 28 5 Maintenance specifications https www boat manuals com ...

Page 28: ...200AET B1 mm in 125 4 9 B2 mm in 254 10 0 B3 mm in 163 6 4 B4 mm in 51 2 0 B5 mm in 180 7 1 B6 mm in 411 16 2 B7 mm in B8 mm in B9 mm in 19 0 7 C2 mm in C3 mm in 79 3 1 D1 mm in 13 0 5 D2 mm in 56 2 2 S60L2140 B5 B6 B1 D1 D2 B2 C3 D1 B4 B9 B9 B9 B3 https www boat manuals com ...

Page 29: ... 8 0 8 5 8 Power unit bolt M9 M10 42 4 2 30 Flywheel magnet nut 240 24 174 PTT relay nut 4 0 4 2 9 Starter relay lead bolt M6 4 0 4 2 9 Battery cable nut 9 0 9 6 5 Starter motor bolt M8 29 2 9 21 Rectifier Regulator 1st M6 6 0 6 4 3 2nd 12 1 2 8 7 Link rod nut 4 0 4 2 9 Oil pressure sensor 18 1 8 13 Oil filter union bolt 34 3 4 25 Oil filter 18 1 8 13 Driven sprocket bolt M10 60 6 0 43 Timing belt...

Page 30: ...se stud bolt 1st M8 25 2 5 18 2nd 90 Crankcase bolt 1st M10 40 4 0 29 2nd 90 1st M8 14 1 4 10 2nd 28 2 8 20 Lower unit regular rotation model Trim tab bolt M10 43 4 3 31 Lower unit bolt M10 47 4 7 34 Propeller nut 55 5 5 40 Propeller shaft housing grease nipple 6 0 6 4 3 Propeller shaft housing bolt M8 30 3 0 22 Pinion nut 142 14 2 103 Lower unit counter rotation model Trim tab bolt M10 43 4 3 31 ...

Page 31: ... 2 2 16 Friction plate screw M6 4 0 4 2 9 Trim stopper nut 36 3 6 25 Power trim and tilt unit Power trim and tilt unit bolt M10 44 4 4 32 Reservoir bolt M8 18 1 8 13 Reservoir cap M12 7 0 7 5 1 Manual valve 2 0 2 1 4 Fluid pipe 15 1 5 11 Trim cylinder end screw 160 16 115 Trim piston bolt M8 38 3 8 27 Tilt ram 55 5 5 40 Tilt cylinder end screw 90 9 0 65 Tilt piston bolt M6 7 0 7 5 1 Gear housing b...

Page 32: ...astener assemblies in a crisscross fashion and pro gressive stages until the specified torque is reached Unless otherwise specified torque specifications require clean dry threads Components should be at room temperature Special service tools 2 Test harness 2 pins 90890 06861 Diagnostic flash indicator 4 90890 06795 Nut A Bolt B General torque specifications N m kgf m ft lb 8 mm M5 5 0 5 3 6 10 mm...

Page 33: ...ower unit Engine oil Check before each use Change Oil filter Change Oil pump Check Timing chain Check replace 1 000 hours or 5 years Chain tensioner Check replace Timing belt 2 Check replace Valve clearance Check adjust Spark plugs Clean adjust replace Thermostat Check Pressure control valve Check Flywheel magnet nut Check Motor exterior Check before each use Oil leakage Check Cooling water passag...

Page 34: ...t retighten the cylinder head and crankcase bolts Lower unit Gear oil Change Impeller Woodruff key Check replace 500 hours or 30 months Oil seals Check replace Propeller Check before each use General Anodes Trim tab Check replace Battery Check charge Wiring and connectors Adjust reconnect Nuts and bolts 4 Tighten Lubrication points Lubricate Item Remarks Initial Every 10 hours Break in 50 hours 3 ...

Page 35: ...and ball B into the gear housing 1 5 5 Install the filters C and gear pump D by installing the bolts E then tightening them to the specified torque 6 Install the manual valve F T R Gear pump bracket bolt 0 7 N m 0 7 kgf m 5 1 ft lb T R Up relief lock screw a height from the top of the gear housing 1 8 2 0 mm 0 071 0 079 in Down relief lock screw b depth from the top of the gear housing 1 5 2 0 mm ...

Page 36: ...If out of specification measure the fuel injector resistance 5 Measure the resistance of the fuel injec tors Replace if out of specification Digital circuit tester 90890 03174 Peak voltage adaptor 90890 03172 Test harness 2 pins 90890 06861 S60L8010 S60L8020 Fuel injector output peak voltage use as reference 1 Red yellow R Y Orange red O R 2 Red yellow R Y Orange black O B 3 Red yellow R Y Orange ...

Page 37: ...he high pressure fuel pump 2 Replace if there is no sound NOTE After the engine start switch is turned to ON the high pressure fuel pump will oper ate for 5 seconds Check the operation of the low pressure fuel pump 3 using the Stationary test of the Yamaha Diagnostic System Change step 3 and the note in the F225 service manual to that mentioned above S69J8300 S69J8310J Fuel control system 1 2 3 4 ...

Page 38: ...above NOTE The amount of memory and the amount of free space on the hard disk differs depending on the computer Using this software while there is not enough free space on the hard disk may cause errors and result in insufficient memory This software may not run properly on some laptop computers Getting started This section provides information on installing the Yamaha Diagnostic System under Wind...

Page 39: ...n then the CD ROM drive icon and then double click the Setup exe icon to start up the installer Fig 1 Fig 1 4 Click the Next button to start the installation process Fig 2 Fig 2 Yamaha Diagnostic System 1 2 3 4 5 6 7 8 9 https www boat manuals com ...

Page 40: ...ppears Click the Yes button to update this program or click the No button to quit the installation Fig 3 Fig 3 NOTE To quit the installation click the Cancel button The following dialog box appears Fig 4 To quit the installation program click the Exit Setup button To resume the installation click the Resume button Fig 4 https www boat manuals com ...

Page 41: ... button to start copying the program files NOTE To go back to the previous dialog box step 4 click the Back button To quit the installation click the Cancel button Fig 5 NOTE If the Yamaha Diagnostic System has already been installed onto your computer the following mes sage Fig 6 appears Fig 6 Yamaha Diagnostic System https www boat manuals com ...

Page 42: ...box appears Click the Finish button to quit the installation program Fig 8 NOTE Install the Database file before installing the Yamaha Diagnostic System otherwise the program will not operate correctly For installation procedures refer to UPDATING THE DATABASE on the next page https www boat manuals com ...

Page 43: ...e 1 Turn on your computer and start up Windows 95 Windows 98 Windows Me or Windows 2000 2 From the taskbar at the bottom of your computer screen click the Start button fig 9 point to Programs and then click Yamaha Diagnostic System to open the Yamaha Diagnostic Sys tem window Fig 10 Fig 9 Yamaha Diagnostic System https www boat manuals com ...

Page 44: ...ss any key to go to the first menu See fig 11 Fig 10 4 Click the Update database F1 button or press the F1 key on your keyboard Fig 11 Fig 11 NOTE Do not click the Starting service tool Enter button or press the Enter key on your keyboard until the database has been updated otherwise the program will not operate correctly https www boat manuals com ...

Page 45: ...computer s hard drive automati cally Any earlier version of the database saved on the hard drive will be overwritten 6 Click the OK button to start copying the database files Fig 12 Fig 12 NOTE If an error message appears and the program stops operating follow the error message Fig 13 Fig 13 Yamaha Diagnostic System https www boat manuals com ...

Page 46: ...Cancel button or press the Esc key on your key board Fig 14 NOTE Display the program and database information to check version Fig 15 To display information click the title in the first menu screen while pressing the Shift key or press the Enter key while pressing Shift key See fig 11 Fig 15 8 To quit the Yamaha Diagnostic System from the first menu see fig 11 press the Esc key on your keyboard ht...

Page 47: ...ample The flash pattern in the illus tration indicates code number 23 a Light on 0 33 second b Light off 4 95 seconds c Light off 0 33 second d Light off 1 65 seconds 4 If a flash pattern listed in the diagnosis code chart is displayed check the mal functioning part according to the flash pattern NOTE When more than one problem is detected the light of the diagnostic tester flashes in the pattern ...

Page 48: ...gnal 19 Incorrect battery voltage 23 Incorrect intake air temperature sensor signal 28 Incorrect neutral switch signal 29 Incorrect intake air pressure sensor signal 37 Incorrect idle speed control signal 39 Incorrect oil pressure sensor signal 45 Incorrect shift cut switch signal 46 Incorrect thermoswitch signal 44 Incorrect engine stop switch signal https www boat manuals com ...

Page 49: ...l 10 Checking the tilt system 10 D Diagnosing the electronic control system 42 Dimensions 21 E Electrical 18 Electronic control system 4 F Features and benefits 4 Fuel control system 31 Fuel injection control 6 G General specifications 12 General torques 27 Getting started 33 H How to use this manual 1 I Identification 3 Ignition and fuel injection timing 5 Introduction 33 L Lower unit 17 M Mainte...

Page 50: ... the information that is provided herein Applicable Service Manual 69J 28197 3D 11 290435 WRONG CORRECT P 2 7 Spark plug gap 11 mm 0 43 in Spark plug gap 1 1 mm 0 043 in P 9 1 Yamaha Diagnostic System upgrade 68F 2819K 10 Yamaha Diagnostic System upgrade 68F WS853 01 P 9 1 9 61 Diagnostic flash indicator 4 90890 06795 Diagnostic flash indicator 90890 06765 https www boat manuals com ...

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Page 52: ...or P Trim sensor Q Battery R Intake air temperature sensor S Main relay T Oil pressure sensor U Power trim and tilt switch È To warning indicator É To remote control Ê To trim meter Ë To computer Ì To diagnostic indicator Color code B Black Br Brown G Green Gy Gray L Blue Lg Light green O Orange P Pink R Red Sb Sky blue W White Y Yellow B O Black orange B W Black white B Y Black yellow Br W Brown ...

Page 53: ...https www boat manuals com ...

Page 54: ...YAMAHA MOTOR CO LTD Printed in the Netherlands Aug 2001 1 3 1 CR F200AET FL200AET E https www boat manuals com ...

Page 55: ... B P B Y B B Y B Y R B W R Y R Y R R B W R Y B Y B O R B W R Y P W P B L W G Lg R Y W Sb P B Br P B B P Gy W B W R W G W G B W R 1 1 4 6 4 2 3 6 5 2 3 5 1 2 3 4 5 6 1 2 3 4 5 6 B B R R Y R Y R Y R Y R Y R Y R R B B B B B B B B B B B B B B B B B B R Y R R Br Br Lg Sb Lg Sb Gy R R R B L 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 G Y G P W L W B Y B L Y O O O W G W B W R 16 17 18 19 20 21 22 23 24 25 26 27 ...

Page 56: ...O R Y B W L Y O R O Y O B Y G R Y R Y W B L W L W P B R Y G B P B B B B R 1 4 6 5 3 R B B B B B B O B P P B O P B B B Br B Sb Y G Br R Lg Sb Sb O Lg Lg W B G Y G B R Y R Y P W L W R B B Br G Gy L Lg O P R Sb W Y O R O Y P B P G P W R B R Y W B W G W R Y G B O B W B Y Br W G B G R G W G Y L R L W L Y O B S60LWD04 https www boat manuals com ...