F100B

F100C

SERVICE MANUAL
290429 60C-28197-5D-11

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 NOTICE

This manual has been prepared by Yamaha 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 Yamaha 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.

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.

F100B, F100C
SERVICE MANUAL
©2001 by Yamaha Motor Co., Ltd.
1st Edition, June 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

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 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

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 GEN
INFO
General information

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

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

Safety while working......................................................................................1-3

Fire prevention........................................................................................... 1-3
Ventilation..................................................................................................1-3
Self-protection ........................................................................................... 1-3
Parts, lubricants, and sealants ..................................................................1-3
Good working practices .............................................................................1-4
Disassembly and assembly ....................................................................... 1-4

Identification...................................................................................................1-5
Applicable models .....................................................................................1-5
Serial number ............................................................................................ 1-5

Features and benefits .................................................................................... 1-6

Power unit..................................................................................................1-6
Ignition system......................................................................................... 1-11
Bracket unit and the PTT unit .................................................................. 1-13
Cooling system ........................................................................................ 1-14
Lower unit ................................................................................................1-15

Technical tips ...............................................................................................1-16

Carburetor ...............................................................................................1-16
Acceleration pump...................................................................................1-17
Ignition system......................................................................................... 1-18
Ignition timing control............................................................................... 1-18
Lubrication system...................................................................................1-20
Cooling system ........................................................................................ 1-21
PTT (power trim and tilt) unit (F100B) .....................................................1-22
PTT (power trim and tilt) unit (F100C) .....................................................1-24

Propeller selection ....................................................................................... 1-25

Propeller size........................................................................................... 1-25
Selection.................................................................................................. 1-25

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 Predelivery checks ......................................................................................1-25
Checking the fuel system ........................................................................1-25
Checking the gear oil............................................................................... 1-26
Checking the engine oil ...........................................................................1-26
Checking the battery................................................................................ 1-26
Checking the outboard motor mounting position ..................................... 1-26
Checking the remote control cables ........................................................ 1-27
Checking the steering system .................................................................1-27
1
Checking the gearshift and throttle operation..........................................1-27
Checking the tilt system...........................................................................1-28
Checking the engine start switch and engine stop switch/
engine shut-off switch ............................................................................1-28
Checking the pilot water outlet ................................................................1-28
2
Test run ................................................................................................... 1-28
Break-in ................................................................................................... 1-29
After test run ............................................................................................ 1-29
3
4
5
6
7
8
9
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 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.”

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 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

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 GEN
INFO General information
Safety while working 1

To prevent an accident or injury and to

ensure quality service, follow the safety pro-
cedures provided below.

Fire prevention
Gasoline is highly flammable.
Keep gasoline and all flammable products
away from heat, sparks, and open flames.

Parts, lubricants, and sealants

Use only genuine Yamaha parts, lubricants,
and sealants or those recommended by
Yamaha, when servicing or repairing the out-
board motor.

Ventilation
Gasoline vapor and exhaust gas are heavier
than air and extremely poisonous. If inhaled
in large quantities they may cause loss of
consciousness and death within a short time.
When test running an engine indoors (e.g., in
Under normal conditions, the lubricants men-
a water tank) be sure to do so where ade-
tioned in this manual should not harm or be
quate ventilation can be maintained.
hazardous to your skin. However, you should
follow these precautions to minimize any risk
when working with lubricants.

1. Maintain good standards of personal and

industrial hygiene.

2. Change and wash clothing as soon as

possible if soiled with lubricants.

3. Avoid contact with skin. Do not, for

Self-protection example, place a soiled rag in your
pocket.
Protect your eyes by wearing safety glasses
or safety goggles during all operations involv-
4. Wash hands and any other part of the
ing drilling and grinding, or when using an air
body thoroughly with soap and hot water
compressor.
after contact with a lubricant or lubricant
Protect your hands and feet by wearing pro-
soiled clothing has been made.
tective gloves and safety shoes when neces-
sary. 5. To protect your skin, apply a protective
cream to your hands before working on
the outboard motor.

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 Safety while working
6. Keep a supply of clean, lint-free cloths for
wiping up spills, etc.

Good working practices

Special tools
Use the recommended special tools to pro-
tect parts from damage. Use the right tool in
1
the right manner—do not improvise.

3. Install bearings with the manufacture

2
identification mark in the direction indi-
cated in the installation procedure. In
addition, be sure to lubricate the bearings
liberally. 3
4. Apply a thin coat of water-resistant
grease to the lip and periphery of an oil
Tightening torques
Follow the tightening torque specifications
provided throughout the manual. When tight-
seal before installation.

5. Check that moving parts operate nor-

4
ening nuts, bolts, and screws, tighten the mally after assembly.

5
large sizes first, and tighten fasteners starting
in the center and moving outward.
Non-reusable parts
Always use new gaskets, seals, O-rings, cot-
ter pins, circlips, etc., when installing or
assembling parts.

6
7
Disassembly and assembly
1. Use compressed air to remove dust and
8
dirt during disassembly.

2. Apply engine oil to the contact surfaces

of moving parts before assembly. 9
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 GEN
INFO General information
Identification 1

NOTE:
Applicable models If the serial number label is removed, VOID
This manual covers the following models. marks will appear on the label.
Applicable models
F100BET, F100CET Approved Starting
Model name
model code serial No.
Serial number L: 000101–
The outboard motor serial number is F100BET 60C
X: 200101–
stamped on a label attached to the port
L: 000101–
clamp bracket. F100CET 60D
X: 200101–

S60C1090

È F100B
É F100C

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

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 Identification / Features and benefits
Features and benefits 1

Power unit
The F100B and F100C have been developed on the bases of the F100A, which has been recog-
nized as being environmentally friendly, with established emission control, and which has received
high marks as an efficiently superior model with a high fuel economy.
Blowby gas, which is discharged from the engine, is returned to the intake silencer and reburned to
purify the exhaust gas.
1
The intake passage and exhaust passage have been arranged around the engine to make the
entire engine compact. When compared to a small, 2-stroke, V4 engine it is compact like an in-line,
three cylinder engine.
2
3
4
5
6
:
7
8
:

: S60C1250

1 Silencer È Intake
2 Carburetor É Exhaust gas
Ê Blowby gas

9
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 GEN
INFO General information
Piston and connecting rod
The piston pin has been installed by shrink fitting it to the small end of the connecting rod, as a
result, a circlip is not used to install the piston pin.
The top ring has been nitrided and the second ring has been chrome plated for use with leaded gas-
oline.
The connecting rod and end cap are processed as a single unit. After being heat treated, the single
unit is struck and the connecting rod and end cap are split apart as shown in the illustration. To
increase accuracy during installation, the connecting rod and end cap that were processed together
are always installed as a set.
The hollow volume at the top of the pistons has been made larger and the compression ration has
been lowered to increase reliability and durability.

F100B, F100C

F100A

S60C1270

1 Top ring 6 Large hollow volume

2 Second ring 7 Compression ratio (8.9)
3 Oil ring 8 Small hollow volume
4 Connecting rod 9 Compression ratio (9.6)
5 Connecting rod end cap

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 Features and benefits
New plastic-region tightening bolts
To tighten the plastic-region tightening bolts, tighten them to the specified torque, and then tighten
them to the specified angle. By tightening the bolts to the specified angle, they are contracted to a

1
more accurate torque, making periodic maintenance checks and adjustments to, as well as addi-
tional tightening of the bolt unnecessary.
The cylinder head bolts, connecting rod bolts, and crankcase bolts have adopted this method to
help better control torque accuracy.

2
3
4
5
6
7
8
1 Specified torque 4 Cylinder head bolt
2 Specified angle 5 Crankcase journal bolt
3 Connecting rod bolt
9
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 GEN
INFO General information
Fuel pump and fuel filter
The fuel pump found in the F115A has been adopted. Although the quantity of parts has been
reduced and the necessary servicing time has been decreased as well, the ability of the fuel pump
to supply sufficient fuel has been retained.
A water separation fuel filter has been adopted. When water is mixed with fuel, it is separated and
precipitated at the bottom of the filter to prevent it from flowing to the carburetors. As water gathers
in the fuel cup, the red float inside the cup begins to rise, indicating that the accumulation of water is
taking place. After water has gathered in the fuel cup, the fuel filter can be disassembled to dispose
of the water.

S60C1290

1 Fuel pump
2 Fuel filter
3 Red float

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 Features and benefits
Hour meter
A newly developed hour meter is incorporated on the F100B and F100C. The hour meter makes it
possible to check the hours of operation of the outboard motor, which can be used to keep track of

1
periodic checks and adjustments.
When the engine switch is turned to ON, all LED on the display will illuminate for two seconds, and
then the hours of operation will be displayed.
A signal from the Rectifier Regulator, via the green and white (G/W) lead, is sent to the hour meter
as the hours of operation accumulation.

2
The hours of operation cannot be deleted.

3
4
5
6
S60C1300
7
1 Hour meter 6 Fuse
2
3
4
5
Grand (B)
Battery (Y)
Engine start switch
Starter motor
7
8
9
Rectifier Regulator
Flywheel magnet
Signal (G/W) 8
9
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 GEN
INFO General information
Ignition system
A CDI system has been incorporated. The CDI unit uses three signals (i.e., crankshaft position,
engine revolution, and throttle position) to determine the optimum ignition timing.
Engine speed is controlled by the CDI unit to prevent damage to the engine when the engine tem-
perature sensor detects that the engine temperature (i.e., water temperature) is too high, or when
the oil pressure switch detects that the oil pressure is too low, or when the engine idle speed is too
high.
In addition, when the engine overheats or when there is low oil pressure, the warning lamp flashes
and the buzzer sounds.
If the throttle position sensor and engine temperature sensor malfunction, the engine ignition timing
is set by the CDI unit to prevent damage to the engine.

1 Oil pressure switch 5 Throttle position sensor

2 Puler coil 6 Engine temperature sensor
3 Lighting coil 7 Ignition coils
4 CDI unit 8 Fuel pump

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 Features and benefits
At low speeds, the exhaust gas flows into the water wall through a hole on the side of the exhaust
guide.

1
2
:
3
È Exhaust gas flow at low speeds
:
S60C1330
4
É Exhaust gas flow at high speeds

An identification mark has been stamped on the exhaust manifold and exhaust chamber.
5
6
7
8
1
2
Identification mark “C”
Exhaust manifold
9
3 Exhaust chamber
4 Identification mark “D”

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 GEN
INFO General information
Bracket unit and the PTT unit
F100B uses the bracket unit of 2-stroke, V4 outboard motor and F100C uses that of F100A.
In addition, the PTT unit has been adopted from the F100A as well.
The F100B uses the one found on the proven 2-stroke, V4, and V6 outboard motors. This PTT unit
has been constructed to feature a single tilt cylinder and two trim cylinders.
The PTT unit of the F100C has been adopted from the proven F100A. This PTT unit consists of a
single cylinder for both tilt and trim functions, making the unit compact and lightweight.

Oil pump
The oil pump has been installed directly above the oil pan and to the exhaust guide.
In addition, the oil pump is operated directly by the drive shaft, therefore proper oil delivery can be
achieved.

1 Oil pump 3 IN
2 OUT 4 Oil pan

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 Features and benefits
Cooling system
A high capacity water pump and a large cylinder head water jacket have been incorporated to
enable better cooling.

1
A pressure control valve (PCV) has also been incorporated to control the cooling water pressure,
which in turn helps prevent water leakage from the power unit. When the cooling water pressure
becomes too high, the PCV opens and the cooling water flows through a bypass passage to the
upper case.
An additional water inlet, located in front of the trim tab, allows cooling water to flow into the exhaust
passage in the lower unit during high-speed operation. This extra cooling water properly cools the
high-temperature exhaust gas before it exits through the propeller boss, helping to prevent the rub-
ber parts in the propeller boss from being damaged by high gas temperatures. 2
3
4
5
6
7
1 Water pump È Cooling water
2 Pressure control valve (PCV)
3 Trim tab
É Exhaust gas
Ê Exhaust gas/Cooling water mixture
8
9
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 GEN
INFO General information
Water pump
The water pump has been hard chrome plated to prevent wear from muddy water. By hard chrome
plating the water pump, wear resistance has been enhanced, and as a result, the time necessary
between part changes or maintenance has been extended.

89ø
58ø

F100B F100C S60C1390

1 Blue identification paint

Lower unit
The lower unit of the F100C does not contain a reverse gear shim. Therefore, it is not necessary to
set the position of a shim for the reverse gear.

Gear ratio
F100A 2.31 (30/13)
F100B 2.15 (28/13)
F100C 2.31 (30/13)

F100C F100B
S60C1410

1 No reverse gear shim

2 Reverse gear shim

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 Features and benefits
Technical tips 1

Carburetor
Prime start
To facilitate the starting of a cold engine, an air-fuel mixture that is richer than normal is required.
For this reason, the Prime Start system has been adopted in the F100B and F100C. In the Prime
Start system, the thermo heater plunger is in a position that fully opens the fuel enrichment valve
while the engine is being started. Thus, fuel enrichment is achieved during the starting of the
1
engine, and continues while the engine is being warmed up. Once the engine is started, a signal is
sent from the pulser coil to the CDI, and from the CDI to the Prime Start to allow the wax to expand.
The expanded wax moves the thermo heater plunger in the direction to close the enrichment valve.
As a result, the volume of fuel that passes through the fuel enrichment valve decreases. A few min-
utes after the engine has started, the thermo heater plunger completely closes the fuel enrichment
2
valve, thus ending the fuel enrichment by the Prime Start system.

3
4
5
6
7
8
1
2
3
Prime Start
Carburetor #1/#3
Carburetor #2/#4
È Air
É Fuel
Ê Air-fuel mixture
9
4 Fuel enrichment valve
5 Thermo heater plunger

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 GEN
INFO General information
Acceleration pump
The function of the acceleration pump is to ensure a smooth acceleration by preventing the air-fuel
mixture from becoming temporarily lean in case the throttle valve is opened suddenly. When the
throttle valve is opened suddenly, a large volume of air is introduced into the engine. However,
because fuel is heavier than air, it is not possible to supply the volume of fuel that is necessary for
the large volume of air that has been introduced. Thus, because it is not possible to achieve the air-
fuel mixture that is required by the engine, bucking or hesitation results. For this reason, the acceler-
ation pump temporarily increases the fuel volume in order to adjust the air-fuel mixture to a ratio that
is necessary for the engine in case the throttle valve is opened suddenly.

Operation
When the throttle is opened suddenly, diaphragm (via the link that is connected to the throttle lever)
operates to pressurize the air in the dashpot. The pressurized air distributed to the carburetors by
passing through the in-line, one-way valve that is connected to the carburetors. The pressurized
and distributed air then utilizes the passage of the main air jet to flow into the main nozzle. The pres-
sure of the air helps suck fuel from the main jet, which increases the fuel in the main nozzle, and
thus achieves fuel enrichment.

1 Throttle lever link rod 7 Main jet

2 Diaphragm 8 Carburetor #4 (cutaway view)
3 In-line, one-way valve 9 Dashpot
4 To carburetor #1 0 Throttle lever
5 To carburetor #2 A Carburetor #4 (side view)
6 To carburetor #3

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 Technical tips
Ignition system
The computer controlled CDI system has three basic modes of operation: starting, warm-up, and
normal operation.

Ignition timing control

Starting mode
Ignition timing is fixed at 10° BTDC. The starting mode cuts off when the engine has been started
1
and the engine speed is over 600 r/min.

Warm-up mode
The engine speed is kept at approximately 1,100 r/min by the computer. The four main situations,
based on the cooling water temperature, that this mode operates in are as follows:
2
1.
2.
3.
4.
Below 0 °C (32 °F), this mode lasts approximately 300 seconds.
From 0 °C (32 °F)–20 °C (68 °F), this mode lasts approximately 180 seconds.
From 20 °C (68 °F)–40 °C (104 °F), this mode lasts approximately 120 seconds.
Over 40 °C (104 °F), this mode does not operate.
3
The warm-up mode will cut off if the engine speed exceeds 4,000 r/min.

Normal operation
This mode operates between 5° ATDC and 35° BTDC. The ignition timing is automatically adjusted
4
by the computer. The computer receives three signals (i.e, crankshaft position, engine revolution,
and throttle position) every five microseconds, and then adjusts the ignition timing accordingly.
Two pulser coils send signals to the computer which then determines the crankshaft position and
engine revolution.
The throttle position sensor also sends signals to the computer which then determines the throttle
5
position. The microcomputer uses these three signals to determine the proper ignition timing.

Fail-safe controls
When the engine start switch is turned on, both low oil pressure and overheat warning lights will turn
6
on. After the engine is started and the engine operates normally, the warning lights will turn off.
This ignition system incorporates three Fail-safe controls that are described below.

• Over-revolution control
Over 6,150 r/min, the ignition to either cylinder #1 or #4 is cut. At 6,175 r/min, the ignition to
7
both cylinders #1 and #4 is cut. Over 6,200 r/min, the ignition to both cylinders #1 and #4, and

8
either #2 or #3 is cut. Over 6,225 r/min, the ignition to cylinders #1, #2, #3, and #4 is cut.
• Overheating control
From 0–2,000 r/min (after starting the engine), this mode will not operate for 60 seconds.
From 2,000 r/min, it will not operate for 21 seconds.
When the cooling water temperature is 95 °C (203 °F) or above, this mode starts. The buzzer
will sound and the warning light will turn on. Ignition to cylinders #1 and #4 will cut off and the
engine speed will gradually lower to approximately 2,000 r/min.
This mode will stop when the cooling water temperature is 79 °C (174 °F) and the throttle is
fully closed. The buzzer will then stop and the warning light will turn off.
9
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 GEN
INFO General information
• Low oil pressure control
Three seconds after starting the engine this mode does not operate.
When the oil pressure switch turns on oil pressure is 150 kPa (1.5 kg/cm2, 21.3 psi) or below,
this mode starts. The buzzer will sound and the warning light will turn on. Ignition to cylinders
#1 and #4 will cut off and the engine speed will gradually lower to approximately 2,000 r/min.
This mode will stop when the oil pressure is 150 kPa (1.5 kg/cm2, 21.3 psi) or above and the
throttle is fully closed. The buzzer will then stop and the warning light will turn off.

Throttle position sensor

If the throttle position sensor is faulty, the ignition timing will automatically be fixed at 10° BTDC.

Engine temperature sensor

If the engine temperature sensor is faulty, the ignition timing will automatically be fixed at 10° BTDC.

Dual engine control system

This control system is used when two outboard motors are installed, along with a dual switch panel.
If the overheating or low oil pressure protection control modes on one of the two outboard motors is
activated, the same protection control mode on the other engine will be activated as well. However,
on the other engine, the warning light will not light and the buzzer will not sound.

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 Technical tips
Lubrication system

Pressure fed

Crankcase Cylinder head

Splash
Return 1
Sleeve

Piston
Intake and exhaust valves Camshaft
2
Crankshaft pin
Camshaft journal
3
Crankshaft journal
4
Main gallery Oil pressure switch 5
Return route

Return route
• Low oil pressure warning

• Oil pressure
regulation
Oil filter

Oil pump with relief valve

• Filtration of foreign objects

• Suction/pressure feeding
6
of oil

Oil strainer
• Prevention of air suction
• Filtration of large foreign objects
7
Oil pan
• Oil sump
• Oil cooling
8
S60C1450

9
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 GEN
INFO General information
Cooling system

Cooling water
inlet

Water pump
Discharge

Oil pan

Pilot water
Flushing device Exhaust cover outlet

Cylinder
Cylinder head
Pressure control Exhaust
valve (PCV) pipe
Thermostat

Upper case
(water wall)

Discharge
Trim tab
water inlet

Propeller boss

Discharge S60C1460

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 Technical tips
PTT (power trim and tilt) unit (F100B)
The circuit of the PTT unit and the location of its major components are shown in the illustration
below.

1
2
3
4
5
1 Lower chamber shuttle valve E Passage to upper chamber of trim cylinders
6
2 Up-relief valve F Passage to lower chambers of tilt cylinder and
3
4
5
6
Pump chamber
Down-check valve
Check valve
Tilt ram
trim cylinders
G Passage to upper chamber of tilt cylinder
H Thermal valve
I Manual valve
7
7 Trim and tilt housing J Lower chamber check valve
8 Reservoir K Upper chamber check valve
9
0
A
B
Filter screen
Shock valve
Passage to reservoir
Free piston check valve
L Upper chamber shuttle valve
M Up-intake valve
N Pump
O Down-intake valve
8
C Trim ram P Motor

9
D Shock return valve

60C5D11 1-22

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 GEN
INFO General information
Component identification

Description Notes
Up-relief valve PTT fluid flows upward above 10.8 MPa (110 kg/cm2,
1,500 psi).
Down-check valve PTT fluid flows easily to the left while some fluid flows to
the right through a small restriction.
Lower chamber check valve PTT fluid flows easily downward.
Lower chamber shuttle valve PTT fluid flows easily upward, pressure on top causes
valve to move down.
Upper chamber check valve PTT fluid flows easily downward.
Upper chamber shuttle valve PTT fluid flows easily upward, pressure on top causes
valve to move down.
Manual valve Port side, clockwise to release
Free piston check valve PTT fluid flows easily downward.
Shock valve PTT fluid flows downward above 16.7 MPa (170 kg/cm2,
2,420 psi).
Shock return valve PTT fluid flows easily upward.
Check valve PTT fluid flows easily to the right while a restriction allows
some flow to the left.
Thermal valve PTT fluid flows to the left above 18.6 MPa (190 kg/cm2,
2,700 psi).
Down-intake valve PTT fluid flows easily downward.
Up-intake valve PTT fluid flows easily downward.

1-23 60C5D11

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 Technical tips
PTT (power trim and tilt) unit (F100C)
The circuit of the PTT unit and the location of its major components are shown in the illustration
below.

1
2
3
4
5
1 PTT cylinder 9 Main valve
S60C1480
6
2 Free piston 0 Up-flow side
3
4
5
6
Pressure-release valves
Check valve
Tilt piston
Trim piston
A
B
C
D
Shuttle piston
Down-flow side
Gear pump
Up-relief valve
7
7 Ram E Down-relief valve
8 Manual valve F Reservoir

8
9
60C5D11 1-24

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 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 motor. 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 12 5/8 × 21 - K
motor.
13 × 19 - K
Propeller size 13 × 23 - K
The size of the propeller is indicated on the 13 × 25 - K
Aluminum
propeller blade or outside of the propeller 13 1/4 × 17 - K
boss. 13 1/2 × 15 - K
13 5/8 × 13 - K
14 × 11 - K
× - 13 × 17 - K
13 × 19 - K
13 × 21 - K
13 × 23 - K Stainless
13 × 25 - K
S60C1110
13 1/2 × 14 - K
13 1/2 × 16 - K

Predelivery checks 1

To make the delivery process smooth and

× - efficient, the predelivery checks should be
completed as explained below.

Checking the fuel system

S60C1120 1. Check that the fuel hoses are securely
connected and that the fuel tank is full
with fuel.

S60C1125

1-25 60C5D11

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 Propeller selection / Predelivery checks

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.
1
Recommended engine oil:
4-stroke motor oil
API: SE, SF, SG, or SH
2
SAE: 10W-30, 10W-40, or
20W-40
Oil capacity:
Without oil filter replacement:
4.5 L (4.8 US qt, 4.0 Imp qt)
3
S60C1130

CAUTION:
This is a 4-stroke engine. Never use pre-
mixed fuel.
Checking the battery
1. Check the capacity, electrolyte level, and
specified gravity of the battery.
4
5
Battery capacity: 70–100 Ah
Checking the gear oil Minimum cold cranking performance:
1. Check the gear oil level. 380 A
Electrolyte specific gravity:
1.28 at 20 °C (68 °F)

2. Check that the positive and negative bat-

tery leads are securely connected. 6
Checking the outboard motor

S60C1140
mounting position
1. Check the position of the anti-cavitation
plate.
7
Checking the engine oil
1. Check the oil level.

8
9
2. Check that the clamp brackets are
S60C1150
secured with the clamp bolts.

60C5D11 1-26

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 GEN
INFO General information
Checking the remote control cables Checking the steering system
1. Set the remote control lever to the neu- 1. Check the steering friction for proper
tral position and fully close the throttle adjustment.
lever/throttle grip.

2. Check that the throttle control lever 1

touches the fully closed stopper a.

2. Check that the steering operates

smoothly.
S60C1170

3. Check that the set pin b is in the center

of the shift bracket and aligned with the
alignment mark c on the bracket.

S60C1200

S60C1180

3. Check that there is no interference with

wires or hoses when the outboard motor
S60C1190
is steered.

Checking the gearshift and throttle

CAUTION: operation
The shift/throttle cable joint must be 1. Check that the gearshift operates
screwed in a minimum of 8.0 mm (0.31 in) smoothly when the remote control lever
d. or shift lever is shifted from neutral into
forward or reverse.

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 Predelivery checks
2. Check that the throttle operates smoothly 3. Check that the engine turns off when the
when the remote control lever or throttle engine stop switch is pushed or the
grip is shifted from the fully closed posi- engine shut-off cord is pulled from the
tion to the fully open position a.

1
engine shut-off switch.

N
F R

2
3
S60C1210 S60C1220

4
Checking the tilt system
1. Check that the outboard motor tilts up
Checking the pilot water outlet
1. Start the engine, and then check that
5
and down smoothly when operating the cooling water is discharged from the pilot
power trim and tilt unit.

2. Check that there is no abnormal noise

produced when the outboard motor is
water outlet.

6
tilted up or down.

3. Check that there is no interference with

wires and hoses when the tilted-up out-
board motor is steered.
7
8
4. Check that the trim meter points down
when the outboard motor is tilted all the
way down. Test run
1. Start the engine, and then check that the
Checking the engine start switch and gearshift operates smoothly.
engine stop switch/engine shut-off
switch
1. Check that the engine starts when the
engine start switch is turned to START.
2. Check the engine idle speed after the
engine has been warmed up. 9
3. Operate at trolling speed.
2. Check that the engine turns off when the
engine start switch is turned to OFF.

60C5D11 1-28

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 GEN
INFO General information
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: S60C1234
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-
0 1 2 10
mately half throttle.

S60C1240
45˚
È Hour

After test run

1. Check for water in the gear oil.

2. Check for fuel leakage in the cowling.

S60C1232 3. After a test run and while the engine is at

idle, flush the cooling water passage with
2. One hour b at 3,000 r/min or 3/4 throttle fresh water using the flushing kit.
and one minute out of every ten at full
throttle.

S60C1233

3. Eight hours c at any speed, however,

avoid running at full speed for more than
five minutes.

1-29 60C5D11

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 SPEC

Specifications

General specifications................................................................................... 2-1

Maintenance specifications ..........................................................................2-3

Power unit..................................................................................................2-3
1
Lower unit ..................................................................................................2-6
Electrical .................................................................................................... 2-7
Dimensions................................................................................................2-9

Tightening torques....................................................................................... 2-14

2
Specified torques.....................................................................................2-14

3
General torques....................................................................................... 2-16

4
5
6
7
8
9
60C5D11

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 SPEC
Specifications
General specifications 2

Model
Item Unit
F100BET F100CET
Dimension
Overall length mm (in) 825 (32.5)
Overall width mm (in) 486 (19.1)
Overall height
(L) mm (in) 1,595 (62.8) 1,582 (62.3)
(X) mm (in) 1,722 (67.8) 1,710 (67.3)
Boat transom height
(L) mm (in) 508 (20.0)
(X) mm (in) 635 (25.0)
Weight
(with aluminum propeller)
(L) kg (lb) 182.5 (402.4) 172.0 (379.3)
(X) kg (lb) 187.2 (412.8) 176.0 (388.1)
Performance
Maximum output kW (hp) 73.6 (100.0)
at 5,500 r/min
Full throttle operating range r/min 5,000–6,000
Maximum fuel consumption L (US gal, 31.0 (8.19, 6.82)
lmp gal)/hr
at 6,000 r/min
Power unit
Type In-line, 4-stroke, DOHC, 16 valves
Cylinder quantity 4
Displacement cm3 (cu. in) 1,596 (97.4)
Bore × stroke mm (in) 79.0 × 81.4 (3.11 × 3.20)
Compression ratio 8.90
Carburetor quantity 4
Control system Remote control (Tiller handle)
Starting system Electric
Ignition control system Microcomputer (CDI)
Ignition timing Degree ATDC 5–BTDC 20
Alternator output V, A 12, 10
Enrichment system Prime Start
Choke valve control —
Spark plugs LFR5A-11 (NGK)
Cooling system Water
Exhaust system Through propeller boss
Lubrication system Wet sump

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 General specifications
Model
Item Unit
F100BET F100CET
Fuel and oil
Fuel type
Fuel rating
Engine oil type
Engine oil grade
RON*

API
Unleaded gasoline/leaded gasoline
84
4-stroke motor oil
SE, SF, SG, or SH
1
SAE 10W-30 or 10W-40
Engine oil quantity
(with oil filter replacement) L
(US qt, lmp qt)
4.7 (5.0, 4.1) 2
(without oil filter replacement) L 4.5 (4.8, 4.0)

3
(US qt, lmp qt)
Gear oil type Hypoid gear oil
Gear oil grade API GL-4
SAE 90
Gear oil quantity L 0.785 (0.83, 0.69) 0.670 (0.71, 0.59)

Bracket
Trim angle
(at 12 degree boat transom)
(US qt, lmp qt)

Degree –4–16
4
Tilt-up angle Degree 70
Steering angle
Drive unit
Gearshift positions
Degree 30 + 30

F-N-R
35 + 35
5
Gear ratio 2.15 (28/13) 2.31 (30/13)
Reduction gear type
Clutch type
Propeller shaft type
Propeller direction
Spiral bevel gear
Dog clutch
Spline
Clockwise
6
(rear view)
Propeller identification mark
Electrical
Battery capacity Ah
K

70–100
7
Minimum cold cranking A 380

8
performance
* RON: Research Octane Number

9
60C5D11 2-2

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 SPEC
Specifications
Maintenance specifications 2

Power unit
Model
Item Unit
F100BET F100CET
Power unit
Minimum compression kPa 670 (6.7, 95)
pressure* (kgf/cm2, psi)
Lubrication oil pressure kPa (kgf/cm2, 520 (5.2, 74)
(reference data) psi) at
850 r/min
Cylinder heads
Warpage limit mm (in) 0.1 (0.04)

(lines indicate straightedge

position)
Cylinder head journal inside mm (in) 25.00–25.02 (0.9843–0.9850)
diameter
Cylinders
Bore size mm (in) 79.00–79.02 (3.1103–3.1110)
Taper limit mm (in) 0.08 (0.0031)
Out-of-round limit mm (in) 0.08 (0.0031)
Pistons
Piston diameter (D) mm (in) 78.93–78.94 (3.1075–3.1078)
Measuring point (H) mm (in) 13 (0.5)
Piston-to-cylinder clearance mm (in) 0.07–0.08 (0.0028–0.0031)
Oversize piston
1st mm (in) + 0.25 (0.0098)
Oversize piston diameter mm (in) 79.18–79.19 (3.1173–3.1177)
Piston pins
Outside diameter mm (in) 17.997–18.000 (0.7085–0.7087)
Piston rings
Top ring
Dimension B mm (in) 1.17–1.19 (0.0461–0.0468)
Dimension T mm (in) 2.80–3.00 (0.1103–0.1181)
End gap mm (in) 0.15–0.35 (0.0060–0.0137)
Side clearance mm (in) 0.04–0.08 (0.0016–0.0031)
* Measuring conditions:
Ambient temperature 20 °C (68 °F), wide open throttle, with plugs disconnected from all cylinders.
The figures are for reference only.

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 Maintenance specifications
Model
Item Unit
F100BET F100CET
2nd ring
Dimension B
Dimension T
End gap
Side clearance
mm (in)
mm (in)
mm (in)
mm (in)
1.47–1.49 (0.0579–0.0586)
3.00–3.20 (0.1182–0.1259)
0.70–0.90 (0.0276–0.0354)
0.03–0.07 (0.0012–0.0027)
1
Oil ring
Dimension B
Dimension T
End gap
mm (in)
mm (in)
mm (in)
2.38–2.48 (0.0938–0.0976)
2.40 (0.0945)
0.20–0.70 (0.0079–0.0275)
2
Side clearance mm (in) 0.03–0.15 (0.0012–0.0059)
Camshafts
Intake (A)
Exhaust (A)
Intake and
mm (in)
mm (in)
mm (in)
37.22–37.38 (1.4654–1.4716)
36.90–37.06 (1.4528–1.4590)
29.92–30.08 (1.1780–1.1842)
3
exhaust (B)
Camshaft journal diameter
Camshaft journal oil clearance
Maximum camshaft runout
mm (in)
mm (in)
mm (in)
24.96–24.98 (0.9827–0.9834)
0.02–0.06 (0.0008–0.0023)
0.1 (0.004)
4
Valves
Valve clearance (cold)
Intake
Exhaust
Head diameter (A)
mm (in)
mm (in)
0.20 ± 0.03 (0.008 ± 0.001)
0.34 ± 0.03 (0.013 ± 0.001)
5
Intake mm (in) 29.0–29.2 (1.142–1.150)
Exhaust

Face width (B)

mm (in) 24.0–24.2 (0.945–0.953)
6
Intake mm (in) 2.00–2.43 (0.0787–0.0957)

7
Exhaust mm (in) 2.28–2.71 (0.0898–0.1067)
Seat contact width (C)
Intake mm (in) 1.2–1.6 (0.047–0.063)
Exhaust mm (in) 1.2–1.6 (0.047–0.063)
Margin thickness (D)
Intake
Exhaust
Stem diameter
mm (in)
mm (in)
0.8–1.2 (0.031–0.047)
1.0–1.4 (0.039–0.055) 8
Intake mm (in) 5.97–5.99 (0.2350–0.2358)

9
Exhaust mm (in) 5.96–5.97 (0.2347–0.2350)
Guide inside diameter
Intake and exhaust mm (in) 6.01–6.02 (0.2367–0.2370)
Stem-to-guide clearance
Intake mm (in) 0.02–0.05 (0.0008–0.0019)
Exhaust mm (in) 0.04–0.06 (0.0016–0.0023)
Stem runout limit mm (in) 0.01 (0.0004)

60C5D11 2-4

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 SPEC
Specifications
Model
Item Unit
F100BET F100CET
Valve springs
Free length mm (in) 53.20 (2.0945)
Minimum free length mm (in) 52.25 (2.0570)
Tilt limit mm (in) 2.6 (0.10)
Connecting rods
Small-end inside diameter mm (in) 17.97–17.98 (0.7075–0.7078)
Big-end inside diameter mm (in) 47.03–47.04 (1.8514–1.8518)
Crank pin oil clearance mm (in) 0.023–0.035 (0.0010–0.0013)
Big-end bearing thickness
Yellow mm (in) 1.499–1.506 (0.0590–0.0593)
Green mm (in) 1.506–1.513 (0.0593–0.0596)
Blue mm (in) 1.513–1.520 (0.0596–0.0598)
Red mm (in) 1.520–1.527 (0.0598–0.0601)
Crankshaft
Crankshaft journal
Diameter mm (in) 47.984–48.000 (1.8892–1.8897)
Crank pin
Diameter mm (in) 43.982–44.000 (1.7315–1.7322)
Runout limit mm (in) 0.03 (0.0012)
Crankcase
Crankshaft main journal oil mm (in) 0.024–0.044 (0.0010–0.0017)
clearance
Upper crankcase main journal
bearing thickness
Green mm (in) 2.992–2.999 (0.1178–0.1181)
Blue mm (in) 2.999–3.006 (0.1181–0.1183)
Red mm (in) 3.006–3.013 (0.1183–0.1186)
Lower crankcase main journal
bearing thickness
Yellow mm (in) 3.010–3.017 (0.1185–0.1188)
Green mm (in) 3.017–3.024 (0.1188–0.1191)
Blue mm (in) 3.024–3.031 (0.1191–0.1193)
Red mm (in) 3.031–3.038 (0.1193–0.1196)
#3 main journal bearing
thickness (upper)
Green mm (in) 2.992–2.999 (0.1178–0.1181)
Blue mm (in) 2.999–3.006 (0.1181–0.1183)
Red mm (in) 3.006–3.013 (0.1183–0.1186)

2-5 60C5D11

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 Maintenance specifications
Model
Item Unit
F100BET F100CET
Oil pump
Discharge
at 100 °C (212 °F) with
10W-30 engine oil
Thermostats
L (US gal,
Imp gal)/min
at 1,000 r/min
5.9 (1.56, 1.30)
1
Opening temperature °C (°F) 50 (122)
Fully open temperature
Valve open lower limit
Fuel pump
°C (°F)
mm (in)
60 (140)
4.3 (0.17) 2
Discharge L (US gal, 100 (26.4, 22)

3
Imp gal)/hr
at 6,000 r/min
Pressure kPa 26–98 (0.26–0.98, 3.7–13.9)
(kgf/cm2, psi)
Carburetor
ID mark
Main jet
Main air jet
Pilot jet
#
#
#
60C00
128
75
42
4
Pilot air jet # 85
Midrange jet
Pilot screw
Float height
#
turns out
mm (in)
40
1 1/2–2 1/2
12.5–15.5 (0.49–0.61)
5
Engine idle speed r/min 800–900

Lower unit

Item Unit
F100BET
Model
F100CET
6
Gear backlash
Pinion-to-forward gear

Pinion-to-reverse gear
mm (in)

mm (in)
0.19–0.53
(0.007–0.021)
0.86–1.26
0.13–0.47
(0.005–0.019)
—
7
(0.034–0.050)
Pinion shims
Forward gear shims
Reverse gear shims
mm
mm
mm
0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50
0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50
0.10, 0.12, 0.15, 0.18,
0.30, 0.40, 0.50
—
8
9
60C5D11 2-6

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 SPEC
Specifications
Electrical
Model
Item Unit
F100BET F100CET
Ignition system
Ignition timing
(engine idle speed) Degree ATDC ± 5
Pulser coil output peak voltage
(W/R – B)
(*1)
at cranking 1 V 3.5
at cranking 2(*1) V 2.5
at 1,500 r/min V 9.0
at 3,500 r/min V 14.0
Pulser coil resistance(*2) Ω 445–545
(W/R – B)
CDI unit output peak voltage
(B/O – B, B/W – B)
at cranking (loaded) V 124
at 1,500 r/min V 125
at 3,500 r/min V 126
Spark plug gap mm (in) 11 (0.4)
Ignition control system
Oil pressure switch kPa 150 (1.5, 21.3)
(kgf/cm2, psi)
Thermo sensor resistance
at 20 °C (68 °F) kΩ 2.54
at 40 °C (104 °F) kΩ 1.15
at 60 °C (140 °F) kΩ 0.59
at 80 °C (176 °F) kΩ 0.32
Starter motor
Type Sliding gear
Output kW 1.4
Cranking time limit Second 30
Brushes
Standard length mm (in) 15.5 (0.61)
Wear limit mm (in) 9.5 (0.37)
Commutator
Standard diameter mm (in) 29.0 (1.14)
Wear limit mm (in) 28.0 (1.10)
Mica
Standard undercut mm (in) 0.5 (0.02)
Wear limit mm (in) 0.2 (0.01)
(*1)
Cranking 1: unloaded
Cranking 2: loaded
(*2)
The figures are for reference only.

2-7 60C5D11

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 Maintenance specifications
Model
Item Unit
F100BET F100CET
Charging system
Fuse
Lighting coil output peak
voltage
at cranking (*1)
(W – W)
A

V
20, 30

7.0
1
at 1,500 r/min(*1) V 38
at 3,500 r/min(*1)
Lighting coil resistance(*2)
(W – W)
V
Ω
91
0.32–0.48 2
Rectifier Regulator output

3
peak voltage (R – B)
at 1,500 r/min(*1) V 17.5
at 3,500 r/min(*1) V 19.0
Charging current V, A at 12, 20
6,000 r/min
Enrichment control system
Prime Start 4
Plunger minimum length a
Power trim and tilt system
Trim sensor
mm (in) 15.0 (0.59)
5
Setting resistance Ω 9–11
Resistance
Fluid type
Brushes
Standard length
(P – B) Ω

mm (in) 9.8 (0.39)

9–378.8
ATF Dexron II

—
6
Wear limit mm (in) 4.8 (0.19) —
Commutator
Standard diameter
Wear limit
mm (in)
mm (in)
22 (0.87)
21 (0.83)
—
—
7
Mica

(*1)
(*2)
Standard undercut
Unloaded
The figures are for reference only.
mm (in) 1.35 (0.05) —

8
9
60C5D11 2-8

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 SPEC
Specifications
Dimensions
Exterior

T1 W5

W1

A1

L7 L6

L2 L1
L10

H9
H2

H7 H10

L8
H8
B6
H4
A2
H1 C3

H3 H6

L5
H11
A3
L9
L4 S60C2150

2-9 60C5D11

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 Maintenance specifications
Model
Symbol Unit
F100BET F100CET
L1 mm (in) 664 (26.1) 647 (25.5)
L2
L3
L4
L5 (L)
mm (in)
mm (in)
mm (in)
mm (in)
161 (6.3)

631 (24.8)
69 (2.7)
—
171 (6.7)

574 (22.6)
65 (2.6)
1
(X) mm (in) 76 (3.0)
L6

L7
(L)
(X)
mm (in)
mm (in)
mm (in)
1,005 (39.6)
1,122 (44.2)
536 (21.1)
998 (39.3)
1,115 (43.9)
528 (20.8)
2
L8 mm (in) 158 (6.2) 164 (6.5)
L9

L10
H1
(L)
(X)

(L)
mm (in)
mm (in)
mm (in)
mm (in)
25 (1.0)
25 (1.0)
75 (3.0)
929 (36.6)
27 (1.1)
27 (1.1)
62 (2.4)
917 (36.1)
3
(X) mm (in) 1,056 (41.6) 1,040 (40.9)
H2
H3
H4 (L)
mm (in)
mm (in)
mm (in)
667 (26.3)

516 (20.3)
191 (7.5)
666 (26.2)

537 (21.1)
4
(X) mm (in) 643 (25.3) 664 (26.1)
H5
H6

H7
(L)
(X)
mm (in)
mm (in)
mm (in)
mm (in)
776 (30.6)
854 (33.6)
388 (15.3)
—
767 (30.2)
844 (33.2)
366 (14.4)
5
H8 mm (in) 14 (0.6) 27 (1.1)
H9
H10
H11
mm (in)
mm (in)
mm (in)
877 (34.5)
44 (1.7)
25 (1.0)
856 (33.7)
48 (1.9)
24 (0.9)
6
W1 mm (in) 243 (9.6) 240 (9.4)
W2
W3
W4
W5
mm (in)
mm (in)
mm (in)
mm (in) 384 (15.1)
—
—
—
405 (15.9)
7
W6 mm (in) —
A1
A2
A3
Degree
Degree
Degree
30
70
4
35
8
T1 mm (in) 660 (26.0)

9
60C5D11 2-10

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 SPEC
Specifications
Exterior (Tiller handle model)

L3
A1 W5

W2
W1

W6

L7 L6

L2 L1

L10

H9
H5
H2

H7
H10

H8
B6
H4

H1 A2
C3 H6
H3

L5
L8
H11

A3

L9 L4
S60C2160

2-11 60C5D11

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 Maintenance specifications
Model
Symbol Unit
F100BET F100CET
L1 mm (in) 664 (26.1) 651 (25.6)
L2
L3
L4
L5 (L)
mm (in)
mm (in)
mm (in)
mm (in)
316 (12.4)
832 (32.8)
631 (24.8)
69 (2.7)
268.3 (10.5)
792.7 (31.2)
574 (22.6)
65 (2.6)
1
(X) mm (in) 76 (3.0)
L6

L7
(L)
(X)
mm (in)
mm (in)
mm (in)
1,005 (39.6)
1,122 (44.2)
536 (21.1)
998 (39.3)
1,115 (43.9)
528 (20.8)
2
L8 mm (in) 294 (11.6) 270.5 (10.6)
L9

L10
H1
(L)
(X)

(L)
mm (in)
mm (in)
mm (in)
mm (in)
25 (1.0)
25 (1.0)
75 (3.0)
929 (36.6)
27 (1.1)
27 (1.1)
62 (2.4)
917 (36.1)
3
(X) mm (in) 1,056 (41.6) 1,040 (40.9)
H2
H3
H4 (L)
mm (in)
mm (in)
mm (in)
667 (26.3)

516 (20.3)
191 (7.5)
666 (26.2)

537 (21.1)
4
(X) mm (in) 643 (25.3) 664 (26.1)
H5
H6

H7
(L)
(X)
mm (in)
mm (in)
mm (in)
mm (in)
748 (29.4)
776 (30.6)
854 (33.6)
388 (15.3)
743.2 (29.3)
767 (30.2)
844 (33.2)
366 (14.4)
5
H8 mm (in) 105 (4.1) 76.3 (3.0)
H9
H10
H11
mm (in)
mm (in)
mm (in)
877 (34.5)
44 (1.7)
25 (1.0)
856 (33.7)
48 (1.9)
24 (0.9)
6
W1 mm (in) 243 (9.6) 240 (9.4)
W2
W3
W4
W5
mm (in)
mm (in)
mm (in)
mm (in) 384 (15.1)
93 (3.7)
—
—
405 (15.9)
7
W6 mm (in) 574 (22.6) 610.1 (24.0)
A1
A2
A3
Degree
Degree
Degree
30
70
4
35
8
T1 mm (in) —

9
60C5D11 2-12

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 SPEC
Specifications
Clamp bracket

Model
Symbol Unit
F100BET F100CET
B1 mm (in) 125.4 (4.9)
B2 mm (in) 254 (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) 367 (14.4) 347 (13.7)
B7 mm (in) —
B8 mm (in) —
B9 mm (in) 18.5 (0.7)
C2 mm (in) —
C3 mm (in) 82 (3.2) 80 (3.1)
D1 mm (in) 13 (0.5)
D2 mm (in) 55.5 (2.2)

2-13 60C5D11

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 Tightening torques
Tightening torques 2

Specified torques
Tightening torques

Power unit
Part to be tightened

Flywheel magnet nut

Thread size

—
N·m

186
kgf·m

18.6
ft·lb

135
1
Negative battery lead bolt M8 9 0.9 6.5
Positive battery lead nut
Power unit bolt
Apron bolt
Drive sprocket nut
—
M10
M6
—
9
42
4
265
0.9
4.2
0.4
26.5
6.5
30
2.9
192
2
Tensioner bolt M10 39 3.9 28
Driven sprocket bolt
Cover screw
Hour meter screw
M10
M6
—
60
4
2
6.0
0.4
0.2
43
2.9
1.4
3
Ignition coil bolt M6 8 0.8 5.8
Ground lead bolt
Oil pressure switch
Oil pressure switch lead bolt
Cylinder head cover bolt
M6
—
M4
M6
8
8
2
8
0.8
0.8
0.2
0.8
5.8
5.8
1.4
5.8
4
Breather cover screw M4 2 0.2 1.4
Fuel pump bracket bolt

Camshaft cap bolt

1st
2nd
M7

M7
17
8
17
1.7
0.8
1.7
12
5.8
12
5
Spark plug — 25 2.5 18

6
1st 14 1.4 10
M8
2nd 28 2.8 20
Cylinder head bolt 1st 15 1.5 11
2nd M10 30 3.0 22
3rd Turn 90°

Exhaust cover bolt

Oil filter
1st
2nd
M6

—
6
12
18
0.6
1.2
1.8
4.3
8.7
13
7
Plug M14 23 2.3 17

8
1st 14 1.4 10
M8
2nd 28 2.8 20
Crankcase bolt
1st 19 1.9 14
M10
2nd Turn 60°
1st 18 1.8 13

9
Connecting rod cap bolt M8
2nd Turn 90°

60C5D11 2-14

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 SPEC
Specifications
Tightening torques
Part to be tightened Thread size
N·m kgf·m ft·lb
Lower unit (F100B)
Check screw — 7 0.7 5.1
Lower unit bolt M10 39 3.9 28
Drain screw — 7 0.7 5.1
Propeller nut — 55 5.5 40
Trim tab bolt M10 42 4.2 30
Ring nut — 103 10.3 74
Pinion nut — 93 9.3 67
Water inlet cover screw — 4 0.4 2.9
Lower unit (F100C)
Check screw — 7 0.7 5.1
Lower unit bolt M10 39 3.9 28
Drain screw — 7 0.7 5.1
Propeller nut — 34 3.4 25
Ring nut — 103 10.3 74
Pinion nut — 93 9.3 67
Water inlet cover screw — 5 0.5 3.6
Bracket unit
Tiller handle assembly nut — 37 3.7 27
Engine shut-off switch nut — 4 0.4 2.9
Engine start switch nut — 4 0.4 2.9
Tiller handle bracket bolt M10 37 3.7 27
Oil pump assembly bolt M6 11 1.1 8.0
Oil pump cover screw M6 4 0.4 2.9
Upper mount nut — 53 5.3 38
F100B — 73 7.3 53
Lower mount nut
F100C — 53 5.3 38
Upper mount bolt M8 26 2.6 19
Muffler assembly bolt M8 20 2.0 14
Baffle plate screw M6 4 0.4 2.9
Oil strainer bolt M6 11 1.1 8.0
Oil pan bolt M6 11 1.1 8.0
Exhaust manifold bolt M6 11 1.1 8.0
Clamp bracket self-locking nut — 15 1.5 11
Trim sensor screw M6 2 0.2 1.4

2-15 60C5D11

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 Tightening torques
Tightening torques
Part to be tightened Thread size
N·m kgf·m ft·lb
Power trim and tilt unit (F100B)
Reservoir bolt
Reservoir cap
PTT motor bolt
Manual valve
M6
—
M6
—
5
5
7

3
0.5
0.7
0.5
0.3
3.6
5.1
3.6
2.2
1
Gear pump assembly bolt M8 9 0.9 6.5
Gear pump bolt
Tilt cylinder end screw
Tilt piston nut
M5
—
—
6
130
100
0.6
13
10
4.3
94
72
2
Trim cylinder end screw — 80 8.0 58
Power trim and tilt unit (F100C)
Tilt cylinder end screw
Reservoir cap
Pump housing assembly
—
—
—
90
7
9
9.0
0.7
0.9
65
5.1
6.5
3
Trim cylinder end screw — 80 8.0 58
Tilt piston bolt
Gear pump bolt
Main valve
M12
M6
—
85
8
11
8.5
0.8
1.1
61
5.8
8.0
4
Manual valve — 2 0.2 1.4
Manual valve seat
Electrical unit
Throttle position sensor screw
—

—
4

4
0.4

0.4
2.9

2.9
5
General torques
This chart specifies tightening torques for
standard fasteners with a standard ISO
thread pitch. Tightening torque specifications
for special components or assemblies are
6
provided in applicable sections of this man-
ual. To avoid warpage, tighten multi-fastener
assemblies in a crisscross fashion and pro-
gressive stages until the specified torque is
7
reached. Unless otherwise specified, torque
specifications require clean, dry threads.
Components should be at room temperature.

General torque
8
Nut (A) Bolt (B) specifications

9
N·m kgf·m ft·lb
8 mm M5 5 0.5 3.6
10 mm M6 8 0.8 5.8
12 mm M8 18 1.8 13
14 mm M10 36 3.6 25
17 mm M12 43 4.3 31

60C5D11 2-16

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 SPEC
Specifications
— MEMO —

2-17 60C5D11

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 CHK
ADJ
Periodic checks and adjustments

Special service tools .....................................................................................3-1

Maintenance interval chart............................................................................3-2 1

Top cowling .................................................................................................... 3-4
Checking the top cowling...........................................................................3-4
Checking the hour meter ...........................................................................3-4

Fuel system .................................................................................................... 3-4

2
Checking the fuel joint and fuel hoses (fuel joint-to-carburetor) ................ 3-4
Checking the fuel filter ............................................................................... 3-4

Power unit....................................................................................................... 3-5

Checking the engine oil .............................................................................3-5
3
Changing the engine oil.............................................................................3-5
Checking the timing belt ............................................................................3-7
Replacing the timing belt ...........................................................................3-7
Checking the valve clearance.................................................................... 3-7
Checking the spark plugs ..........................................................................3-7
4
Checking the thermostat............................................................................3-8
Checking the cooling water passage.........................................................3-8

Control system ............................................................................................... 3-9

Checking the throttle cable operation ........................................................3-9
5
Checking the gearshift operation............................................................. 3-10
Checking the engine idle speed ..............................................................3-10
Checking the ignition timing..................................................................... 3-11

Power trim and tilt unit ................................................................................ 3-12

6
Checking the power trim and tilt operation .............................................. 3-12
Checking the power trim and tilt fluid level .............................................. 3-12

Lower unit ..................................................................................................... 3-13

Checking the gear oil level ...................................................................... 3-13
7
Changing the gear oil .............................................................................. 3-13
Checking the lower unit (for air leakage) ................................................. 3-14
Checking the propeller............................................................................. 3-14 8
General..........................................................................................................3-14
Checking the anodes............................................................................... 3-14
Checking the battery................................................................................ 3-15
Lubrication ...............................................................................................3-16 9
60C5D11

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 CHK
ADJ Periodic checks and adjustments
Special service tools 3

Oil filter wrench

90890-01426

Digital tachometer
90890-06760

Timing light
90890-03141

Leakage tester
90890-06762

3-1 60C5D11

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 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
1

(every 30 months)

(every 5 years)
1000 hours
(3 months)

(6 months)
100 hours

200 hours

500 hours
(Break-in)
Refer to

10 hours

50 hours

(1 year)
Item Remarks
page

Top cowling
Top cowling fit Check/adjust 3-4
2
Fuel system
Fuel joint and fuel hoses
Fuel filter
Fuel tank(*1)
Check
Check/replace
Clean
3-4
3-4
—
3
Power unit

4
Ignition timing Check 3-11
Engine oil Check/change 3-5
Oil filter Change 3-5
Oil pump Check 7-17,
7-59
Timing belt(*2)
Valve clearance
Spark plugs
Check/replace
Check/adjust
Clean/adjust/replace
3-7
5-6
3-7
5
Piston rings Check/replace 5-41

6
Thermostat Check 3-8
Pressure control valve Check —
Oil leakage Check/replace —
Flywheel magnet nut Check —
Carburetor(*3) Check —
Motor exterior
Cooling water passage(*4)
Control system
Carburetor link
Check
Clean

Check/adjust
—
—

4-17
7
Throttle cable Check/adjust 3-9
Shift cable
Engine idle speed
Power trim and tilt unit
Check/adjust
Check/adjust
3-10
3-10 8
Power trim and tilt unit Check 3-12

9
60C5D11 3-2

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 CHK
ADJ Periodic checks and adjustments
Initial Every

(every 30 months)

(every 5 years)
1000 hours
(3 months)

(6 months)
100 hours

200 hours

500 hours
(Break-in)
Refer to

10 hours

50 hours

(1 year)
Item Remarks
page

Lower unit
Gear oil Change 3-13
Impeller/Woodruff key Check/replace 6-8,
6-36
Oil seals Check/replace —
Drive shaft Check/replace 6-18,
6-46
Propeller Check 3-14
General
Anodes/Trim tab Check/replace 3-14
Battery Check/charge 3-15
Wiring and connectors Adjust/reconnect —
Nuts and bolts(*5) Tighten —
Lubrication points Lubricate 3-16
Rubber seals Replace —
Bearings Check/replace —
Exhaust system Check/replace —
deterioration

NOTE:
(*1) If equipped with a portable fuel tank.
(*2) Be sure to replace the timing belt every 1,000 hours of operation or every five years.
(*3) Do not adjust the carburetor if it is operating correctly.
(*4) The engine should be flushed with fresh water after operating in salt, turbid, or muddy water.
(*5) Do not retighten the cylinder head and crankcase bolts.

3-3 60C5D11

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 Maintenance interval chart / Top cowling / Fuel system
Top cowling 3

Checking the top cowling

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

1
Fuel system
S60C3730

3
2
Checking the fuel joint and fuel

2. Loosen the bolts 1.

S60C3010 hoses (fuel joint-to-carburetor)
1. Remove the plate 1, and then check the
fuel hose connections and fuel joint 2 for
leaks. Replace if necessary. Also, check
3
3. Move the hook 2 up or down slightly to the fuel filter 3, fuel pump 4, and carbu-
adjust its position. retor 5 for leaks, and the fuel hoses for
leaks and deterioration. Replace if nec-
essary.
4
5
6
S60C3020

NOTE:
• To loosen the fitting, move the hook toward
the seal.

7
• To tighten the fitting, move the hook away
from the seal.

4. Tighten the bolts.

5. Check the fitting again and, if necessary,

repeat steps 2–4.

Checking the hour meter

Checking the fuel filter
S60C3030

8
1. Check the fuel filter element 1 for dirt
1. Turn the engine start switch to ON.

9
and residue and check the fuel filter cup
2 for foreign substances and cracks.
2. Check that the total hours of operation Clean with straight gasoline and replace
are displayed after the entire LED 1 has the cup if necessary.
been illuminated for two seconds.
Replace if LED does not illuminate.

60C5D11 3-4

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 CHK
ADJ Periodic checks and adjustments

NOTE:
• Change the oil if it appears milky or black.
• 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.

Changing the engine oil

1. Remove the engine oil dipstick and oil
filler cap 1.

NOTE:
Be sure not to spill any fuel when removing
the fuel filter cup.
S60C3060

Power unit 3

2. Place a drain pan under the drain hole,

Checking the engine oil
and then remove the drain bolt 2 and let
1. Place the outboard motor in an upright
the oil drain completely.
position.

2. Remove the engine oil dipstick, wipe it

clean, and then insert it back into the oil
filler hole.

3. Remove the dipstick again to check the

oil level, and the oil for discoloration and
its viscosity.

S60C3050 S60C3070

3-5 60C5D11

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 Fuel system / Power unit

E
1
2
NOTE:
To extract and change the oil through the dip-
stick hole a, you can use an oil changer 3
3
S60C3090
like the one shown in the illustration.

3. Place a rag under the oil filter, and then

remove the filter.
4
5
S60C3100

S60C3080
Oil filter wrench: 90890-01426 6
Oil filter wrench: 90890-01426 Oil filter: 18 N·m (1.8 kgf·m, 13 ft·lb)
7
T.
R.

NOTE: 6. Install the drain bolt, and then tighten it to

the specified torque.

8
Be sure to clean up any oil spills.

Drain bolt:
4. Apply a thin coat of engine oil to the O- 28 N·m (2.8 kgf·m, 20 ft·lb)
T.
R.

ring of the new oil filter.

5. Install the oil filter, and then tighten it to

the specified torque. 9
60C5D11 3-6

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 CHK
ADJ Periodic checks and adjustments
7. Pour the specified amount of the recom- Checking the valve clearance
mended engine oil into the oil filler hole.
NOTE:
Recommended engine oil: For checking procedures, see Chapter 5,
4-stroke motor oil “Checking the valve clearance”.
API: SE, SF, SG, or SH
SAE: 10W-30, 10W-40, or 20W-40
Oil quantity: Checking the spark plugs
With oil filter replacement: 1. Remove the cover.
4.7 L (5.0 US qt, 4.1 Imp qt)
2. Disconnect the high-tension cords, and
Without oil filter replacement:
then remove the spark plugs.
4.5 L (4.8 US qt, 4.0 Imp qt)
3. Clean the electrodes 1 with a spark plug
8. Install the oil filler cap and dipstick, and cleaner or wire brush. Replace the spark
then start the engine and warm it up for 5 plug if necessary.
minutes.

9. Turn the engine off, and then check the

oil level and correct it if necessary.

Checking the timing belt

1. Remove the flywheel magnet cover.

2. While turning the flywheel magnet clock-

wise, check the interior a and the exte-
rior b of the timing belt for cracks,
damage, or wear. Replace if necessary. 4. Check the electrodes for erosion and
excessive carbon or other deposits, and
the gasket for damage. Replace the
spark plug if necessary.

5. Check the spark plug gap a. Adjust if out

of specification.

CAUTION:
Do not turn the flywheel magnet counter-
clockwise, otherwise the valve system
may be damaged.

Replacing the timing belt Specified spark plug:

LFR5A-11 (NGK)
NOTE: Spark plug gap a:
For replacement procedures, see Chapter 5,
1.0–1.1 mm (0.039–0.043 in)
“Removing the timing belt and sprockets”.

3-7 60C5D11

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 Power unit
6. Install the spark plug, tighten it finger
tight b, then to the specified torque with
a spark plug wrench c.

1
5. Check the thermostat valve opening at
S60C3330

2
the specified water temperatures.
Replace if out of specification.
Spark plug:
25 N·m (2.5 kgf·m, 18 ft·lb) 3
T.
R.

Checking the thermostat

1. Remove the flywheel magnet cover.

2. Disconnect the cooling water hose 1,

and then remove the thermostat cover 2
4
and thermostat 3.

Water
temperature
Valve lift a 5
0 mm (0 in)–
50 °C (122 °F)

above
60 °C (140 °F)
(When the valve
begins to open.)
more than
4.3 mm (0.17 in)
6
6. Install the thermostat, new gasket, ther-
mostat cover, and then connect the cool-
ing water hose.
7
7. Install the flywheel magnet cover.

S60C3320
Checking the cooling water passage
1. Check the cooling water inlet cover 1
and cooling water inlet 2 for clogs.
8
3. Suspend the thermostat in a container of Clean if necessary.
water.

4. Place a thermometer in the water and

slowly heat the water.
9
60C5D11 3-8

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 CHK
ADJ Periodic checks and adjustments
Control system 3

Checking the throttle cable operation

1. Check that the throttle control lever 1
touches the fully closed stopper a when
the remote control lever is in neutral or
the throttle grip is fully closed. Adjust the
throttle cable length, if necessary, as fol-
lows.
S60C3370

S60C3390

S60C3350
2. Loosen the locknut 2, remove the clip
3, and then disconnect the throttle cable
joint 4.

S60C3360

È F100B
É F100C
S60C3400

2. Place the lower unit in water, and then

start the engine. 3. Contact the throttle control lever 1 with
the fully closed stopper a.
3. Check for water flow at the cooling water
outlet. If there is no water flow, check the 4. Adjust the position of the throttle cable
cooling water passage inside the out- joint until its hole is aligned with the set
board motor. pin b on the throttle control lever.

3-9 60C5D11

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 Power unit / Control system

1
CAUTION:
S60C3420 S60C3440

5. Adjust the position of the shift cable joint

2
The throttle cable joint must be screwed until its hole is aligned with the set pin.
in a minimum of 8.0 mm (0.31 in) c.

5. Connect the cable joint, install the clip,

and then tighten the locknut.
3
6. Check the throttle cable for smooth oper-
ation and adjust the cable length, if nec-
essary, repeating steps 2–6.
S60C3420
4
Checking the gearshift operation
1. Check that the gearshift operates
smoothly when shifting from neutral into
forward or reverse. Adjust the shift cable
CAUTION:
The shift cable joint must be screwed in a
minimum of 8.0 mm (0.31 in) c.
5
length if necessary.

2. Set the gearshift to the neutral position.

3. Loosen the locknut 1, remove the clip

2, and then disconnect the shift cable
6. Connect the cable joint, install the clip,
and then tighten the locknut.

7. Check the gearshift for smooth operation

6
joint 3. and adjust the shift cable length, if nec-
essary, repeating steps 3–6.

Checking the engine idle speed

7
NOTE:
Be sure to check the engine idle speed
before adjusting the pilot screw.

1. Start the engine and warm it up for 5 min-

8
utes.

4. Align the set pin a in the center of the

shift bracket and with the alignment mark
b on the bracket.
2. Attach the special service tool to high-
tension cord #1 1, and then check the
engine idle speed. Adjust if out of specifi-
9
cation.

60C5D11 3-10

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 CHK
ADJ Periodic checks and adjustments
3. Attach the special service tool to high-
tension cord #1 1.

S60C3450

S60C3470
Digital tachometer: 90890-06760

Engine idle speed: 800–900 r/min

3. Turn the throttle stop screw 2 in direc-

tion a or b until the specified engine
idle speed is obtained.
S60C3480

Timing light: 90890-03141

4. Check that the ignition timing mark (–5°)

a on the flywheel magnet is aligned with
the pointer b. Check the ignition system
and ignition control system if necessary.
S60C3460

NOTE:
30
• To increase the idle speed, turn the throttle 20
10 TDC -10

stop screw in direction a.

• To decrease the idle speed, turn the throttle
stop screw in direction b.

4. After adjusting the idle speed, rev the

engine a few times and let it idle for at S60C3490

least 15 seconds to check the stability of

the engine. Ignition timing: ATDC 5°

Checking the ignition timing

1. Start the engine and warm it up for 5 min-
utes.

2. Attach the special service tool to high-

tension cord #1, and then check the
engine idle speed.

3-11 60C5D11

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 Control system / Power trim and tilt unit
Power trim and tilt unit 3

Checking the power trim and tilt WARNING

operation After tilting up the outboard motor, be

1
sure to support it with the tilt stop lever.
1. Fully tilt the outboard motor up and down
Otherwise, the outboard motor could sud-
a few times and check the entire trim and
denly lower if the power trim and tilt unit
tilt range for smooth operation. Check the
should lose fluid pressure.
power trim and tilt fluid level if necessary.

NOTE:
Be sure to listen to the winding sound of the
PTT motor for smooth operation.
2. Remove the reservoir cap 2, and then
check the fluid level in the reservoir. 2
3
2. Fully tilt the outboard motor up, and then
support it with the tilt stop lever 1 to
check the lock mechanism of the lever.

S60C3520 4
È F100B
S60C3510 5
É F100C

Checking the power trim and tilt fluid

level
1. Fully tilt the outboard motor up, and then È F100B
É F100C
S60C3530 6
support it with the tilt stop lever 1.
NOTE:
If the fluid is at the correct level, the fluid
should overflow out of the filler hole when the
cap is removed.
7
3. If necessary, add sufficient fluid of the
recommended type until it overflows out
of the filler hole.
8
S60C3510

9
È F100B Recommended power trim and tilt
É F100C fluid:
ATF Dexron II

60C5D11 3-12

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 CHK
ADJ Periodic checks and adjustments
4. Install the reservoir cap, and then tighten 2. Place a drain pan under the drain screw
it to the specified torque. 1, remove the drain screw, then the
check screw 2 to drain the oil.
Reservoir cap:
7 N·m (0.7 kgf·m, 5.1 ft·lb)
T.
R.

Lower unit 3

Checking the gear oil level

1. Fully tilt the outboard motor down.

2. Remove the check screw 1, and then

check the gear oil level in the lower case.

3. Check the oil for metal, discoloration, and

its viscosity. Check the internal parts of
the lower case if necessary.
S60C3540
4. Insert the gear oil tube or gear oil pump
NOTE: into the drain hole and slowly fill the gear
If the oil is at the correct level, the oil should oil until oil flows out of the check hole and
overflow out of the check hole when the no air bubbles are visible.
check screw is removed.

3. If necessary, add sufficient gear oil of the

recommended type until it overflows out
of the check hole.

Recommended gear oil:

Hypoid gear oil
SAE: 90 S60C3560

4. Install the check screw, and then tighten

it to the specified torque.

Check screw:
7 N·m (0.7 kgf·m, 5.1 ft·lb)
T.
R.

Changing the gear oil

1. Tilt the outboard motor up slightly.

S60C3570

3-13 60C5D11

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 Power trim and tilt unit / Lower unit / General
3. If pressure drops below specification,
Recommended gear oil: check the drive shaft and propeller shaft
Hypoid gear oil oil seals for damage.
SAE: 90
Oil quantity:
F100B:
0.785 L (0.83 US qt, 0.69 Imp qt)
Checking the propeller
1. Check the propeller blades and splines
for cracks, damage, or wear. Replace if
1
F100C: necessary.

2
0.670 L (0.71 US qt, 0.59 Imp qt)

5. Install the check screw, quickly install the

drain screw, and then tighten them to the
specified torque.

Check and drain screw:

7 N·m (0.7 kgf·m, 5.1 ft·lb) 3
T.
R.

S60C3590
Checking the lower unit
(for air leakage)
1. Remove the check screw 1, and then
install the special service tool.
General
Checking the anodes
1. Check the anodes and trim tab for
3

4
scales, grease, or oil. Clean if necessary.

5
6
Leakage tester: 90890-06762

2. Apply the specified pressure to check

7
whether the lower unit can hold it for at
least 10 seconds.

CAUTION:
Do not over pressurize the lower unit, oth-
S60C3600
8
erwise the oil seals may be damaged.

Lower unit holding pressure:

100 kPa (1.0 kgf/cm2, 14 psi)
9
60C5D11 3-14

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 CHK
ADJ Periodic checks and adjustments
Checking the battery
1. Check the battery electrolyte level. If the
level is at or below the minimum level
mark a, add distilled water until the level
is between the maximum and minimum
level marks.

S60C3610

S60C3650

2. Check the specific gravity of the electro-

lyte. Fully charge the battery if out of
S60C3620
specification.

S60C3630

S60C3640

È F100B
É F100C

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

2. Replace the anodes and trim tab if

excessively eroded.

3-15 60C5D11

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 General
Lubrication
WARNING 1. Apply water resistant grease to the areas
Battery electrolyte is dangerous; it con- shown.

1
tains sulfuric acid which is poisonous and
highly caustic.
Always follow these preventive measures: A
• Avoid bodily contact with electrolyte as
it can cause severe burns or permanent

2
eye injury.
• Wear protective eye gear when handling
or working near batteries.
Antidote (EXTERNAL):
S60C3660
• SKIN – Wash with water.
• EYES – Flush with water for 15 minutes
and get immediate medical attention.
Antidote (INTERNAL):
• Drink large quantities of water or milk
A
3
followed with milk of magnesia, beaten
egg, or vegetable oil. Get immediate
medical attention.
Batteries generate explosive, hydrogen
gas. Always follow these preventive mea-
4
S60C3670
sures:
• Charge batteries in a well-ventilated
area.
• Keep batteries away from fire, sparks or
open flames (e.g., welding equipment,
A 5
lighted cigarettes).
• DO NOT SMOKE when charging or han-
dling batteries.
KEEP BATTERIES AND ELECTROLYTE
OUT OF REACH OF CHILDREN. A
6
S60C3680

NOTE:
• Batteries vary per manufacturer. The pro-
cedures mentioned in this manual may not
A
A
7
always apply, therefore, consult the instruc-
tion manual of the battery.
• Disconnect the negative lead first, then the
positive lead.
8
A S60C3690

Electrolyte specific gravity:

1.280 at 20 °C (68 °F)
9
60C5D11 3-16

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 CHK
ADJ Periodic checks and adjustments
2. Apply corrosion resistant grease to the
areas shown.

S60C3695

S60C3700

S60C3710

È F100B
É F100C

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

3-17 60C5D11

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 FUEL

Fuel system

Special service tools .....................................................................................4-1

Hose routing ...................................................................................................4-2

Fuel, blowby, and cooling water hoses......................................................4-2
1
Fuel line and fuel filter ................................................................................... 4-3

Fuel pump ....................................................................................................... 4-5

Checking the fuel pump.............................................................................4-7
2
Disassembling the fuel pump .................................................................... 4-8
Checking the diaphragm and valves .........................................................4-8
Assembling the fuel pump ......................................................................... 4-8

Throttle control............................................................................................... 4-9

3
Carburetor..................................................................................................... 4-13
Checking the check valve........................................................................4-15
Checking the fuel filters ...........................................................................4-15
Checking the carburetor ..........................................................................4-15
4
Checking the Prime Start.........................................................................4-16
Assembling the carburetor....................................................................... 4-17
Adjusting the throttle link rod ................................................................... 4-17
Adjusting the throttle position sensor.......................................................4-18
Adjusting the pilot screw..........................................................................4-19
5
Synchronizing the carburetors.................................................................4-20

6
7
8
9
60C5D11

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 FUEL
Fuel system
Special service tools 4

Vacuum/pressure pump gauge set Vacuum gauge (digital)

90890-06756 (commercially obtainable)

Digital tachometer Vacuum gauge (4 analog meters)

90890-06760 (commercially obtainable)

Vacuum gauge Vacuum gauge adaptor

90890-03159 (commercially obtainable)

Test harness (3 pins)

90890-06757

Digital circuit tester

90890-03174

4-1 60C5D11

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 Special service tools / Hose routing
Hose routing 4

Fuel, blowby, and cooling water hoses

1
2
3
4
5
6
7
S60C4010
8
1
2
3
4
Blowby hose
Fuel hose (fuel pump-to-carburetor)
Fuel hose (fuel filter-to-fuel pump)
Fuel hose (fuel joint-to-fuel filter)
9 Pilot water hose
9
5 Fuel hose (carburetor-to-carburetor)
6 Hose (acceleration pump-to-carburetor)
7 Hose (carburetor-to-carburetor)
8 Cooling water hose

60C5D11 4-2

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 FUEL
Fuel system
Fuel line and fuel filter 4

10 N • m (1.0 kgf • m, 7.2 ft • Ib)

T.
R.
8
7

13
7
7
11
8

8 10 14
9
7

15
7
7
13 17
11
10
16
9
12 1
21
15
26 22

20

2
19
27 3 18
25
4
5
6
24

29
15
28

23

S60C4030

4-3 60C5D11

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 Fuel line and fuel filter
No. Part name Q’ty Remarks
1 Fuel pump 1
2 Body 1
3
4
5
Fuel filter element
Float
O-ring
1
1
1 Not reusable
1
2 × 36.2 mm
6
7
8
Fuel filter cup
Clip
Fuel joint
1
9
3
2
9 Bolt 2 M6 × 12 mm
10
11
12
Washer
Clamp
Clamp
2
2
1
3
13 Fuel hose 2 Fuel joint-to-fuel joint
14
15
16
Fuel hose
Plastic tie
O-ring
1
2
1
Fuel pump-to-fuel joint
Not reusable
Not reusable
4
17 Bolt 2 M6 × 30 mm
18

19
Fuel hose

Plastic tie
1

2
Fuel pump-to-fuel filter
12.5 × 300 mm
Not reusable
5
20 Bolt 1 M6 × 16 mm
21
22
23
Bracket
Nut
Fuel hose
1
1
1 Fuel filter-to-fuel joint
12.5 × 950 mm
6
7
24 Plate 1
25 Bolt 1 M6 × 25 mm
26 Bolt 2 M6 × 25 mm
27 Grommet retaining plate 1

8
28 Plastic tie 1 Not reusable
29 Fuel joint 1

9
60C5D11 4-4

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 FUEL
Fuel system
Fuel pump 4

4 N • m (0.4 kgf • m, 2.9 ft • Ib)

T.
R.
1

14
13

12
11 2

10 11 15

12

13
14

6
5 8

S60C4040

4-5 60C5D11

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 Fuel pump
No. Part name Q’ty Remarks
1 Screw 3 M6 × 35 mm
2 Cover 1
3
4
5
Fuel pump body 2
Fuel pump body 1
Plunger
1
1
1
1
6 Spring 1
7
8
9
Nut
Spring
Pin
3
1
1
2
10 Diaphragm 1
11
12
13
Nut
Spring
Valve
2
2
2
3
14 Screw 2
15 Gasket 1 Not reusable
4
5
6
7
8
9
60C5D11 4-6

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 FUEL
Fuel system
Checking the fuel pump
NOTE:
1. Install the special service tool onto the
• Make sure that air does not escape from
fuel pump as shown.
the opposite side of the fuel pump.
• To eliminate any gaps between the fuel
pump valves and the fuel pump body 2, and
to ensure a better seal, make sure that the
inside of the fuel pump is moist with gaso-
line.

Fuel pump pressure a:

50 kPa (0.5 kgf/cm2, 7.1 psi)
Fuel pump negative pressure b:
30 kPa (0.3 kgf/cm2, 4.3 psi)

S60C4050

Vacuum/pressure pump gauge set:

90890-06756

2. Apply the specified pressure to each fuel

pump port.

3. If air flow is reversed, check the dia-

phragm for tears and the valves for
cracks. Replace if necessary.

CAUTION:
Do not over pressurize the fuel pump, oth-
erwise excessive pressure may cause air
leakage.

4-7 60C5D11

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 Fuel pump
Disassembling the fuel pump Checking the diaphragm and valves
1. Disassemble the fuel pump as shown. 1. Check the diaphragm 1 for tears and the
valves 2 for cracks. Replace if neces-

1
sary.

2
3
S60C4090

S60C4060 Assembling the fuel pump

1. Align the plunger and diaphragm installa-
2. Push down on the plunger and the dia- tion holes a, and then install the plunger
phragm, turn the fuel pump body 1 1
approximately 90° to a position where the
pin 2 can be removed easily, and then
remove the pin.
into the diaphragm.

2. Push down on the plunger and the dia-

phragm, and then install the pin 1.
4
5
6
7
3. Turn the fuel pump body 1 2 approxi-
mately 90°, and then push down on the
plunger several times to make sure that
the pin does not come out.

8
3. Slowly let up on the plunger and dia-
phragm, and then remove them.
9
60C5D11 4-8

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 FUEL
Fuel system
Throttle control 4

1
7
8

13
14
15 16 20
17 4 9
10
21 11
12
19

18

6 2

23
22

S60C4120

4-9 60C5D11

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 Throttle control
No. Part name Q’ty Remarks
1 Throttle cam 1
2 Throttle link rod 1
3
4
5
Throttle position sensor
Bracket
Throttle control lever
1
1
1
1
6 Bracket 1
7
8
9
Washer
Spring
Washer
1
1
1
2
10 Wave washer 1
11
12
13
Collar
Bolt
Bolt
1
1
1
M6 × 35 mm
M6 × 12 mm
3
14 Washer 1
15
16
17
Wave washer
Washer
Collar
1
1
1
4
18 Bolt 2 M6 × 25 mm
19
20
21
Collar
Pin
Spacer
1
1
1
5
22 Screw 2 M5 × 25 mm
23 Screw 2 M5 × 10 mm
6
7
8
9
60C5D11 4-10

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 FUEL
Fuel system

1617 18
15

2
3
12
11 4

19 20
21 24

14 20
13
22
5 9
10 23

1
6
7

25
21
25

21 26
25 27

22
25
25

23
28
S60C4130

4-11 60C5D11

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 Throttle control
No. Part name Q’ty Remarks
1 Silencer 1
2 Carburetor assembly 1
3
4
5
Intake manifold
Acceleration pump
Blowby hose
1
1
1
1
6 Bolt 8 M6 × 20 mm
7
8
Bolt
O-ring
3
4
M8 × 60 mm
Not reusable
3.5 × 47.7 mm
2
9 Gasket 1
10
11
12
Bolt
Spacer
O-ring
8
4
4
M6 × 120 mm

Not reusable
3
13 Fuel hose 2 Carburetor-to-carburetor
14
15
16
Link lever
O-ring
Spacer
1
4
4
Not reusable 4
17 O-ring 4 Not reusable

5
2.4 × 44.5 mm
18 Bolt 5 M8 × 35 mm
19 Fuel filter 4
20 Clip 8

6
21 Fuel hose 2 Carburetor-to-fuel pump
10 × 120 mm
22 Fuel hose 1 Carburetor-to-fuel pump
10 × 180 mm
23 Fuel hose 1 Carburetor-to-fuel pump

24
25
Screw
Hose
2
7
10 × 350 mm
M6 × 15 mm
Carburetor-to-carburetor
7
26 Hose 1 Carburetor-to-acceleration pump
27
28
Hose
Check valve
2
1
Check valve-to-carburetor
8
9
60C5D11 4-12

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 FUEL
Fuel system
Carburetor 4

2 5
6
7

1 3

4 1 8
9

10

11
1 14
18 14
15
20 16 12 13
17
21
19

22

23
24

25

26

27
28

29
S60C4140

4-13 60C5D11

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 Carburetor
No. Part name Q’ty Remarks
1 Carburetor body 1
2 Screw 3 M4 × 10 mm
3
4
5
Cover
Gasket
Spring
1
1
1
Not reusable 1
6 O-ring 1 Not reusable
7
8
9
Pilot screw
Prime Start
Screw
1
1
1 M4 × 10 mm
2
10 Bracket 1
11
12
13
O-ring
Body
Screw
1
1
3
Not reusable

M5 × 16 mm
3
14 O-ring 4 Not reusable
15
16
17
O-ring
Valve seat
Needle valve
1
1
1
Not reusable
4
18 Pilot jet 1
19
20
21
Plug
Main nozzle
Main jet
1
1
1
5
22 Screw 1 M4 × 8 mm
23
24
25
Float
Float pin
Gasket
1
1
1 Not reusable
6
26 Float chamber 1
27
28
29
O-ring
Drain screw
Screw
1
1
4
Not reusable

M4 × 14 mm
7
È Carburetors #1 and #3
É Carburetor #2
Ê Carburetor #4 8
9
60C5D11 4-14

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 FUEL
Fuel system
Checking the check valve Checking the carburetor
1. Install the special service tool onto the 1. Check the air and fuel passages, and jets
check valve. for dirt and foreign matter. Clean the car-
buretor body with a petroleum based sol-
vent if necessary.

2. Blow compressed air into all passages

and jets.

CAUTION:
• Direct the compressed air downward,
otherwise cleaning solvent may be
Vacuum/pressure pump gauge set: blown into your eyes or small parts of
90890-06756 the carburetor may be blown off.
• Do not use steel wire for cleaning the
2. Apply pressure to each check valve port. jets, otherwise the jet diameters may be
Replace if necessary. enlarged, which may seriously affect
performance.
NOTE:
Make sure that no air comes out of the oppo-
site side of the check valve. 3. Check the main jet 1, pilot jet 2, and
main nozzle 3 for dirt or residue. Clean if
necessary.
Checking the fuel filters
1. Check the fuel filters for dirt or residue.
Clean if necessary.

S60C4180

S60C4160

4-15 60C5D11

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 Carburetor
4. Check the pilot screw and needle valve
for bends or wear. Replace if necessary. NOTE:
• The float should be resting on the needle
valve 5, but not compressing it.
• Take measurements at the end of the float
opposite its pivoted side. 1
Float height a:
12.5–15.5 mm (0.49–0.61 in)

Checking the Prime Start

1. Measure the length of the Prime Start
2
plunger.

2. Connect the positive Prime Start blue (L)

lead and the negative Prime Start black
(B) lead to a battery as shown.
3
5. Check the float for deterioration. Replace
3. Measure the plunger length a after
applying power for 5 minutes. Replace if
out of specification.
4
it necessary.

5
6
S60C4190
Prime Start plunger minimum length
6. Measure the float height a. Adjust the
float height by bending the tab 4 if out of
specification.
a:
15.0 mm (0.59 in) 7
8
S60C4200
9
60C5D11 4-16

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 FUEL
Fuel system
Assembling the carburetor
1. Install the main nozzle 1, main jet 2,
pilot jet 3, plug 4, and valve seat 5 to
the carburetor body as shown.

S60C4240

Pilot screw setting:

1 1/2–2 1/2 turns out

Adjusting the throttle link rod

1. Set the throttle control lever to the fully
closed position.

2. Check that the mark a on the throttle

cam aligns with the center of the link
lever b as shown.
S60C4220

2. Install the needle valve 6, float 7, float

pin 8, and screw 9 as shown, and then
check the float for smooth operation.

3. Contact the throttle control lever 1 with

the fully closed stopper 2.

S60C4230 4. Check that the throttle is fully closed, and

that the fully closed mark a on the throt-
NOTE: tle cam 3 is aligned with the center of
• Place the needle valve in the valve seat the link lever b.
when installing the float to the carburetor
body.
• Fit the float pin into the slit on the carbure-
tor body and lock it with the screw.

3. Install the pilot screw 0, turn it in until it

is lightly seated, then out the specified
number of turns.

4-17 60C5D11

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 Carburetor
4. Loosen the screws 2.
NOTE:
Make sure that there is complete clearance
between the throttle cam roller 4 and the
cam surface.

5. Adjust the length of the throttle link rod

1
5, and then tighten the nut 6 securely.

6. Move the throttle control lever 1 to

check that the throttle valve opens and
closes smoothly. Also, check that the
S60C4280 2
5. Adjust the position of the throttle position
throttle cam roller 4 moves freely to the
sensor 3 until the specified voltage is
fully open position c on the throttle cam
3.

7. Set the throttle to the fully closed position

obtained.

Throttle position sensor output

3
voltage:
and check that the fully closed mark a
Pink (P) – Orange (O)
aligns with the center of the link lever b.

NOTE:
Make sure that there is no interference
0.68–0.72 V

6. Tighten the screws 2.

4
between the throttle control lever 1 and the
throttle position sensor lead 7.

Adjusting the throttle position

5
sensor
1. Connect the test harness (3 pins) and
digital circuit tester.

P
6
O 7
S60C4270

Digital circuit tester: 90890-03174

8
Test harness (3 pins): 90890-06757

2. Start the engine and warm it up for 5 min-

utes to check the stability of the engine.
9
3. Contact the throttle control lever 1 with
the fully closed stopper.

60C5D11 4-18

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 FUEL
Fuel system
Adjusting the pilot screw 4. Turn the throttle stop screw 3 in direc-
1. Start the engine and warm it up for 5 min- tion c or d until the specified engine
utes to check the stability of the engine. idle speed is obtained.
Adjust the pilot screw if necessary.

2. Attach the special service tool to high-

tension cord #1 1.

S60C4310

NOTE:
• To increase the idle speed, turn the throttle
S60C4290 stop screw in direction c.
• To decrease the idle speed, turn the throttle
stop screw in direction d.
Digital tachometer: 90890-06760

5. After adjusting the idle speed, rev the

3. Turn the pilot screws 2 in direction a engine a few times and let it idle for at
until the engine idle speed has least 15 seconds to check the stability of
decreased to approximately 40 r/min, the engine. Adjust the carburetor syn-
then in direction b 3/4 turn. chronization if necessary.

S60C4300

Engine idle speed: 800–900 r/min

4-19 60C5D11

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 Carburetor
Synchronizing the carburetors
1. Start the engine and warm it up for 5 min-
#1
utes to check the stability of the engine.

2. Attach the special service tool to high-

tension cord #1 1.
#2

#3
1
#4
2
S60C4290 3
S60C4330
Digital tachometer: 90890-06760

3. Remove all of the plugs 2 and attach the

special service tool and adapters to the
Vacuum gauge (digital)
(commercially obtainable) 3:
Vacuum gauge (4 analog meters)
4
carburetor assembly as shown. (commercially obtainable) 4:

#1
Vacuum gauge adaptor
(commercially obtainable) 5:

4. Adjust the idle speed to 1,000 r/min by

5
turning the throttle stop screw 5 on car-

#2
buretor #4 in direction a or b.
6
#3

#4
7
S60C4320 NOTE:
S60C4340

• To increase idle speed, turn the throttle

8
stop screw in direction a.

9
Vacuum gauge: 90890-03159 • To decrease idle speed, turn the throttle
stop screw in direction b.

5. Measure the vacuum pressure of carbu-

retor #4.

60C5D11 4-20

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 FUEL
Fuel system
6. Turn the throttle valve adjusting screws
6 to adjust the vacuum pressure of car-
buretors #1, #2, and #3 to the same vac-
uum variation as carburetor #4.

#1

#2

#3

#4

S60C4350

7. Adjust the engine idle speed to specifica-

tion.

Engine idle speed: 800–900 r/min

8. After adjusting the idle speed, rev the

engine a few times and let it idle for at
least 15 seconds to check that the vac-
uum pressure of carburetors #1, #2, and
#3 stays within 50 mmHg (67 mbar, 1.97
inHg) of carburetor #4, and to check the
stability of the engine.

4-21 60C5D11

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 POWR

Power unit

Special service tools .....................................................................................5-1

Power unit....................................................................................................... 5-3

Checking the valve clearance.................................................................... 5-6
1
Checking the compression pressure .........................................................5-9
Checking the oil pressure ..........................................................................5-9
Removing the power unit.........................................................................5-10

Timing belt and sprockets...........................................................................5-12

2
Removing the timing belt and sprockets.................................................. 5-17

3
Checking the timing belt and sprockets...................................................5-18
Installing the timing belt and sprockets....................................................5-18

Cylinder head ...............................................................................................5-21

Removing the cylinder head .................................................................... 5-25

4
Checking the valve springs...................................................................... 5-26
Checking the valves ................................................................................ 5-26
Checking the valve guides....................................................................... 5-27
Replacing the valve guides...................................................................... 5-28
Checking the valve seat ..........................................................................5-28
Refacing the valve seat ...........................................................................5-29
Checking the camshaft ............................................................................5-31
Checking the cylinder head ..................................................................... 5-32
Installing the valves ................................................................................. 5-33
Installing the cylinder head ...................................................................... 5-34
5
Cylinder body ...............................................................................................5-36
Removing and installing the oil filter ........................................................ 5-39
Disassembling the cylinder body ............................................................. 5-39
6
Checking the piston diameter .................................................................. 5-40
Checking the cylinder bore ...................................................................... 5-40
Checking the piston clearance ................................................................5-41
Checking the piston rings ........................................................................5-41
Checking the piston ring grooves ............................................................ 5-42
Checking the piston ring side clearance.................................................. 5-42
7
Checking the crankshaft ..........................................................................5-42
Checking the crankshaft pin oil clearance ............................................... 5-43
Selecting the connecting rod big end bearing .........................................5-44
Checking the crankshaft main journal oil clearance ................................5-45
Selecting the crankshaft main journal bearing.........................................5-47
8
Assembling the cylinder body.................................................................. 5-48
Installing the power unit...........................................................................5-51

9
60C5D11

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 POWR
Power unit
Special service tools 5

Compression gauge Valve spring compressor

90890-03160 90890-04019

Compression gauge adaptor Valve spring compressor attachment

90890-06563 90890-06320

Flywheel holder Valve guide remover/installer

90890-06522 90890-04064

Flywheel puller Valve guide reamer

90890-06521 90890-04066

Crankshaft holder 20 Valve seat cutter holder

90890-06552 90890-06553

5-1 60C5D11

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 Special service tools

1
Valve seat cutter
90890-06315, 90890-06324, 90890-06326,
90890-06328, 90890-06555
2
3
Crank stand alignment
90890-03107
4
5
Oil filter wrench
90890-01426

6
Piston slider
7
90890-06530

8
9
60C5D11 5-2

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 POWR
Power unit
Power unit 5

4
186 N • m (18.6 kgf • m, 135 ft • lb)

T.
R.
5
E 2

1 3

9 N • m (0.9 kgf • m, 6.5 ft • Ib)

T.
R.
21
17
14
10
8

13 15 16 18
19
9
11 18
12
19 20
25

26

27

28
29

30
22

31

32
23
33
34 24
S60C5010

5-3 60C5D11

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 Power unit
No. Part name Q’ty Remarks
1 Flywheel magnet 1
2 Bolt 2 M8 × 20 mm
3
4
5
Cover
Nut
Washer
1
1
1
1
6 Woodruff key 1
7
8
9
Engine oil dipstick
Bolt
Plate
1
1
1
M6 × 25 mm 2
10 Cover 1
11
12
13
Plastic tie
Pilot water hose
Bolt
1
1
1
Not reusable
10 × 330 mm
M8 × 16 mm
3
14 Negative battery lead 1
15
16
17
Nut
Washer
Positive battery lead
1
1
1
4
18 PTT motor lead 2
19
20
21
Washer
Nut
Wiring harness
2
2
1
5
22 Throttle cable 1
23
24
Shift cable
Fuel hose
1
1 Fuel filter-to-fuel joint
12.5 × 950 mm
6
25 Bolt 2 M6 × 25 mm
26
27
28
Retaining plate
Bolt
Plate
1
1
1
M6 × 20 mm 7
29 Grommet 1
30
31
32
Bolt
Clamp
Clip
1
1
2
M6 × 20 mm
8
33 Bolt 1 M6 × 25 mm
34 Plate 1
9
60C5D11 5-4

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 POWR
Power unit

2 3 7
1
3 9
4 9
3
9

5 LT
572
9

6 42 N • m (4.2 kgf • m, 30 ft • Ib)

T.
R.
8
LT
572 7 4 N • m (0.4 kgf • m, 2.9 ft • Ib)

T.
R.
S60C5030

No. Part name Q’ty Remarks

1 Power unit 1
2 Gasket 1
3 Dowel pin 2
4 Bolt 5 M6 × 16 mm
5 Nut 2
6 Apron 1
7 Bolt 2 M8 × 35 mm
8 Bolt 2 M6 × 40 mm
9 Bolt 6 M10 × 130 mm

5-5 60C5D11

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 Power unit
Checking the valve clearance 3. Loosen the tensioner bolt 5, and then
1. Remove the flywheel magnet cover 1, remove the timing belt 6, driven sprock-
cover 2, disconnect the high-tension ets 7, and cylinder head cover 8.
cords 3 and fuel hoses 4, and then
remove the spark plugs.
1
2
S60C3220

2. Turn the flywheel magnet clockwise and

3
align the TDC mark a on the flywheel

4
magnet with the pointer b, and check
that “ ” marks c and d on the driven
sprockets are aligned. S60C3230

4. Install the driven sprockets 7 and timing

belt 6, and then tighten the tensioner
bolt 5.
5
6
7
8
S60C3120 S60C3240

CAUTION:
Do not turn the flywheel magnet counter-
5. Check the intake valve clearance for cyl-
inders #1 and #2, and the exhaust valve
clearance for cylinders #1 and #3. Adjust
9
clockwise, otherwise the valve system
may be damaged. if out of specification.

60C5D11 5-6

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 POWR
Power unit
6. Turn the flywheel magnet 360° clock-
wise. Valve clearance:
Intake e:
CAUTION: 0.20 ± 0.03 mm (0.008 ± 0.001 in)
Do not turn the flywheel magnet counter- Exhaust f:
clockwise, otherwise the valve system 0.34 ± 0.03 mm (0.013 ± 0.001 in)
may be damaged.
8. Adjust the valve clearance if out of speci-
fication. Loosen the tensioner bolt 5,
7. Check the intake valve clearance for cyl- and then remove the timing belt 6,
inders #3 and #4, and the exhaust valve driven sprockets 7, camshaft caps 9,
clearance for cylinders #2 and #4. Adjust and camshafts 0.
if out of specification.

EX IN

#1

#2

#3

#4

S60C3260

NOTE:
Do not mix the valve train parts. Keep them
organized in their proper groups.

9. Remove the valve pad A from the valve

lifter B using a thin screwdriver.
S60C3250

NOTE:
• Check the valve clearance when the engine
is cold.
• Note the measurement.

S60C3270

5-7 60C5D11

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 Power unit
10. Measure the valve pad thickness with a
micrometer.
Select the necessary valve pad by calcu-

1
lating its thickness with the following for-
mula.

Necessary valve pad thickness =

Removed valve pad thickness + Measured

2
valve clearance – Specified valve
clearance

Example:
If the “Removed valve pad thickness” is 2.10
mm, the “Checked valve clearance” is 0.30
mm and the “Specified valve clearance” is
0.20 mm, then the necessary valve pad thick-
ness = 2.10 + 0.30 – 0.20 = 2.20 mm
3
11. Install the necessary valve pad into the
valve lifter.

12. Install the camshafts, camshaft caps,

driven sprockets, and timing belt, and
S60C3280
4
then tighten the tensioner bolt.

Camshaft cap bolt:

1st: 8 N·m (0.8 kgf·m, 5.8 ft·lb)
CAUTION:
• Do not turn the flywheel magnet coun-
terclockwise, otherwise the valve sys-
5
T.
R.

2nd: 17 N·m (1.7 kgf·m, 12 ft·lb) tem may be damaged.

• Do not remove the ignition timing
13. Check the valve clearance. Adjust if nec-
essary.
pointer.

17. Install the timing belt, and then tighten

6
14. Loosen the tensioner bolt, and then
the tensioner bolt finger tight.

7
remove the timing belt and driven sprock-
ets. 18. Turn the flywheel magnet clockwise two
turns, and then check that the alignment
15. Install the cylinder head cover and driven
marks are aligned.
sprockets.

Cylinder head cover:

8 N·m (0.8 kgf·m, 5.8 ft·lb)
19. Tighten the tensioner bolt to the specified
torque.
8
T.
R.

Driven sprocket: Tensioner bolt:

60 N·m (6.0 kgf·m, 43 ft·lb) 39 N·m (3.9 kgf·m, 28 ft·lb)
T.
R.

16. Check that the TDC mark a on the fly-

wheel magnet is aligned with the pointer
b, and that “ ” marks c and d on the
20. Install the spark plugs, and then connect
the high-tension cords and fuel hoses.
9
driven sprockets are aligned. Adjust if Spark plug:
necessary. 25 N·m (2.5 kgf·m, 18 ft·lb)
T.
R.

60C5D11 5-8

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 POWR
Power unit
21. Install the cover and flywheel magnet 5. If the compression pressure is below
cover. specification and the compression pres-
sure for each cylinder is unbalanced, add
Checking the compression pressure a small amount of engine oil to the cylin-
1. Start the engine, warm it up for 5 min- der, and then check the pressure again.
utes, and then turn it off.
NOTE:
2. Remove the clip from the engine shut-off • If the compression pressure increases,
switch on the remote control box or tiller check the piston and piston rings for wear.
handle. Replace if necessary.
• If the compression pressure does not
3. Remove the cover and all spark plugs, increase, check the valve clearance, valve,
and then install the special service tools valve seat, cylinder sleeve, cylinder head
to each spark plug hole. gasket, and cylinder head. Adjust or
replace if necessary.

Checking the oil pressure

1. Start the engine, warm it up for 5 min-
utes, and then turn it off.

2. Remove the flywheel magnet cover and

oil pressure switch, and then install an oil
S60C5040 pressure gauge 1 to the oil pressure
switch installation hole.
CAUTION:
Before removing the spark plugs, well to
clear out any dirt or dust that may fall into
the cylinder.

Compression gauge 1:
90890-03160
Compression gauge adapter 2:
90890-06563

NOTE:
4. Fully open the throttle, crank the engine Use a pressure gauge with an adapter that
until the reading on the compression has a 1/8 pitch thread.
gauge stabilizes, and then check the
compression pressure.
3. Check the oil pressure. Check the oil
Minimum compression pressure: pump, oil suction pipe, and oil strainer if
670 kPa (6.7 kgf/cm2, 95.3 psi) out of specification.

Oil pressure:
520 kPa (5.2 kgf/cm2, 74 psi) at
idle speed (850 r/min)

5-9 60C5D11

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 Power unit
Removing the power unit
NOTE:
1. Remove the flywheel magnet cover and
Apply force to the crankshaft end until the fly-
flywheel magnet.
wheel magnet comes off the tapered portion
of the crankshaft.

Flywheel holder 1: 90890-06522

1
Flywheel puller 2: 90890-06521

2. Remove the retaining plate 1 and clamp

2, and then disconnect the throttle cable
3 and shift cable 4. Remove the grom-
2
met 5 and disconnect the fuel hose 6.

3
4
5
S60C5090
6
7
CAUTION:
• Before removing the power unit, discon-
nect the battery terminals.
• Apply force in the direction of the
8
arrows shown, to prevent the flywheel
holder from slipping off easily.
• To prevent damage to the engine or
tools, screw in the flywheel puller set
bolts evenly and completely so that the
9
flywheel puller plate is parallel to the fly-
wheel magnet.

60C5D11 5-10

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 POWR
Power unit
3. Disconnect the pilot water hose 7 and
remove the engine oil dipstick 8 and
cover 9.

S60C5100

4. Disconnect the battery leads 0, wiring

harness A, and PTT motor leads B.

S60C5120

S60C5110

5. Remove the apron C and power unit by

removing the bolts D.

5-11 60C5D11

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 Power unit / Timing belt and sprockets
Timing belt and sprockets 5

1
1
3
4

6
5
2
2 N · m (0.2 kgf · m, 1.4 ft · Ib)
T.
R.

7
3
8
14

4 N · m (0.4 kgf · m, 2.9 ft · Ib)

10 11
12
4
T.
R.

No.
9

Part name
13

Q’ty Remarks
S60C5130

5
1 Screw 1 M4 × 10 mm
2
3
4
Bolt
Lighting coil
Bolt
3
1
4
M6 × 30 mm

M6 × 30 mm
6
5 Lighting coil base 1
6
7
8
Dowel pin
Cover
Screw
1
1
2
7
9 Screw 3 M6 × 20 mm
10
11
12
Neutral switch
Plate
Bracket
1
1
1
Tiller handle model
Tiller handle model
Tiller handle model
8
13 Bolt 2 M6 × 14 mm Tiller handle model
14 Hour meter 1
9
60C5D11 5-12

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 POWR
Power unit

15
-00
241
-46
67F

60 N · m (6.0 kgf · m, 43 ft · Ib)

T.
R.
21 23
22
E
19 24
27 25
20 26 E
18
17
265 N · m (26.5 kgf · m, 192 ft · lb)
T.
R.

E
29
28
16

30
4 (B)
39 N · m (3.9 kgf · m, 28 ft · Ib) 3 (B/W)
T.
R.

31
R

1
3 5 6

4
14 7
13

12 9
10

8
12 9
2
11

8 N · m (0.8 kgf · m, 5.8 ft · Ib) 8 N · m (0.8 kgf · m, 5.8 ft · Ib)

T.

T.
R.

R.

S60C5140

5-13 60C5D11

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 Timing belt and sprockets
No. Part name Q’ty Remarks
1 Starter motor 1
2 Ignition coil 2
3
4
5
Starter motor lead
Starter motor lead
Washer
1
1
2
Black/white
Black 1
6 Nut 2
7
8
9
Bolt
Bolt
Ground lead
3
1
3
M8 × 45 mm
M6 × 20 mm 2
10 Ignition coil lead 2
11
12
13
Bolt
Spark plug cap
Screw
4
4
5
M6 × 30 mm
3
14 Cover 1
15
16
17
Timing belt
Drive sprocket
Driven sprocket
1
1
2
4
18 Clip 1
19
20
21
Cooling water hose
Plastic tie
Bolt
1
1
2
Not reusable
M6 × 16 mm
5
22 Bracket 1
23
24
25
Bolt
Washer
Pin
2
2
2
M10 × 35 mm
6
26 Spring 1
27
28
29
Bolt
Tensioner
Nut
1
1
1
M10 × 45 mm
7
30 Retaining plate 1
31 Woodruff key 1
8
9
60C5D11 5-14

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 POWR
Power unit

8 N ¥ m (0.8 kgf ¥ m, 5.8 ft ¥ Ib)

T
.
R
.
2 N ¥ m (0.2 kgf ¥ m, 1.4 ft ¥ Ib)
8

T
.
R
.
9
7

10

12

11 17
13 18
16

19

15
4
14

20
2 23
22

21

25

24
24

5
28

26
3

25 27

S60C5150

5-15 60C5D11

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 Timing belt and sprockets
No. Part name Q’ty Remarks
1 Cover 1
2 Starter relay 1
3
4
5
Power trim and tilt relay
CDI unit
Rectifier Regulator
2
1
1
1
6 Wiring harness 1
7
8
9
Oil pressure switch
Bolt
Oil pressure switch lead
1
1
1
M4 × 8 mm 2
10 Bolt 2 M6 × 12 mm
11
12
13
Thermo sensor coupler
Ground lead
Starter relay lead
1
3
1
3
14 PTT relay lead 2
15
16
17
Bolt
Bolt
Collar
1
1
4
M6 × 12 mm
M6 × 20 mm 4
18 Grommet 4
19
20
21
Bolt
CDI unit coupler
Bolt
4
2
1
M6 × 28 mm

M6 × 20 mm
5
22 Ground lead 2
23
24
25
Hour meter coupler
Bolt
Hour meter lead
1
2
2
M6 × 12 mm 6
26 Bolt 3 M6 × 16 mm
27
28
Rectifier Regulator lead
Bolt
1
2 M6 × 25 mm 7
8
9
60C5D11 5-16

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 POWR
Power unit
Removing the timing belt and
NOTE:
sprockets • Use a deep socket 2 (M46) for this proce-
1. Set the cylinder #1 piston position to
dure.
TDC of the compression stroke by align-
• Do not turn the camshaft when loosening
ing “ ” marks a and b on the driven
the drive sprocket nut.
sprockets, and the hole c on the retain-
ing plate with the notch d on the cylinder
block. Crankshaft holder 20 3:
90890-06552

3. Disconnect the cooling water hose 4.

4. Remove the bracket 5, spring 6, ten-

sioner 7, and timing belt 8 from the
driven sprocket side.

S60C5160

CAUTION:
Do not turn the drive sprocket counter-
clockwise, otherwise the valve system
may be damaged.

2. Loosen the drive sprocket nut 1.

S60C5180

5. Loosen the driven sprocket bolts 9 and

remove the driven sprockets 0.

S60C5170

S60C5190

5-17 60C5D11

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 Timing belt and sprockets
2. Check the drive sprocket 1 and driven
NOTE: sprockets 2 for cracks, damage, or
Do not turn the camshaft when loosening the wear. Replace if necessary.
driven sprocket bolt.

Flywheel holder: 90890-06522

1
6. Remove the nut 1, drive sprocket A,
retaining plate B, and Woodruff key C. 2
S60C5220

Installing the sprockets and timing

belt
1. Check that “ ” marks a and b on the
3
driven sprockets 1 are aligned, and then
tighten the bolts 2.

4
5
6
E S60C5230

2. Install the retaining plate 3, Woodruff

key 4, drive sprocket 5, and nut 6, and
S60C5200
then tighten the nut.

Checking the timing belt and

sprockets
1. Check the interior and exterior of the tim-
7
ing belt for cracks, damage, or wear.
Replace if necessary.

8
9
60C5D11 5-18

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 POWR
Power unit

CAUTION:
• Do not twist, turn inside out, or bend the
timing belt beyond the maximum limit of
25 mm (1.0 in) e, otherwise it may be
damaged.
• Do not get oil or grease on the timing
S60C5240 belt.

3. Check that the hole c on the retaining

plate is aligned with the notch d on the 5. Install the tensioner 8, spring 9, and
cylinder block. bolts, and then tighten the bolts finger
tight.

S60C5250

4. Install the timing belt 7 from the drive

sprocket side with its part number in the
upright position.
S60C5280

6. Take up the timing belt slack by turning

241
-00
the drive sprocket clockwise at least two
-46
67F
full turns.

CAUTION:
Do not turn the sprockets counterclock-
wise, otherwise the valve system may be
damaged.

S60C5260

5-19 60C5D11

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 Timing belt and sprockets
7. Tighten the tensioner bolts to the speci-
fied torque. Flywheel holder: 90890-06522

Driven sprocket bolt 2:

60 N·m (6.0 kgf·m, 43 ft·lb)
1

T.
R.
10. Tighten the drive sprocket nut 6 to the
specified torque, and then install the
breather hose. 2
3
Tensioner bolt 0:
S60C5290

NOTE:
S60C5310
4
39 N·m (3.9 kgf·m, 28 ft·lb) • Use a deep socket A (M46) for this proce-
T.
R.

8. Turn the drive sprocket two turns, and

then check that the alignment marks are
aligned.
dure.
• Install the timing belt, and then tighten the
drive sprocket nut 6 so that the drive
sprocket and the driven sprocket do not
5
move out of the TDC position.
CAUTION:
Do not turn the sprockets counterclock-
wise, otherwise the valve system may be
damaged.
Crankshaft holder 20 B:
90890-06552
6
9. Tighten the driven sprocket bolt 2 to the Drive sprocket nut 6:
265 N·m (26.5 kgf·m, 192 ft·lb) 7
T.
R.

specified torque.

8
S60C5300
9
60C5D11 5-20

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 POWR
Power unit
Cylinder head 5

4
GM

1st 8 N • m (0.8 kgf • m, 5.8 ft • lb)

T.
2nd 17 N • m (1.7 kgf • m, 12 ft • lb)

R.
E 14
3
3
M

12 5
E
4
E 4
M
E

4
E 4 15
2 N • m (0.2 kgf • m, 1.4 ft • Ib)
T.
R.

4
GM 13 2 17 N • m (1.7 kgf • m, 12 ft • Ib)
T.
R.

E E
11
1st 8 N • m (0.8 kgf • m, 5.8 ft • lb)
6
T.

2nd 17 N • m (1.7 kgf • m, 12 ft • lb)

R.

LT
7 271

10
E

8 N • m (0.8 kgf • m, 5.8 ft • Ib)

T.
R.

S60C5320

5-21 60C5D11

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 Cylinder head
No. Part name Q’ty Remarks
1 Cylinder head cover 1
2 Camshaft 2
3
4
5
Camshaft cap
Camshaft cap
Fuel pump bracket
2
8
1
1
6 Oil filler cap 1
7
8
9
O-ring
Bolt
Gasket
1
14
1
3.1 × 30.6 mm
M6 × 30 mm
Not reusable
2
10 Breather cover 1
11
12
13
Screw
Bolt
Bolt
8
4
16
M4 × 8 mm
M7 × 48 mm
M7 × 37 mm
3
14 Oil seal 2 Not reusable
15 Bolt

È Tightening sequence
2 M7 × 48 mm
4
5
6
7
8
9
60C5D11 5-22

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 POWR
Power unit

1st 15 N • m (1.5 kgf • m, 11 ft • lb)

2nd 30 N • m (3.0 kgf • m, 22 ft • lb)
T.
R.

3nd 90°

25 N • m (2.5 kgf • m, 18 ft • Ib)

T.
R.
7

8
9

E
E

1 5
4

10
11

12 16
15
13
14
A

LT
271

22 23 6
21
20
19 3
18
17 24
E
23 E
22
21 1st 14 N • m (1.4 kgf • m, 10 ft • lb)
T.

2nd 28 N • m (2.8 kgf • m, 20 ft • lb)

R.

20
E
19
18
E
17
S60C5330

5-23 60C5D11

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 Cylinder head
No. Part name Q’ty Remarks
1 Cylinder head 1
2 Exhaust valve 8
3
4
5
Intake valve
Cylinder head gasket
Dowel pin
8
1
2
Not reusable 1
6 Bolt 5 M8 × 55 mm
7
8
9
Bolt
Cover
Thermostat
2
1
1
M6 × 25 mm
2
10 Bolt 10 M10 × 143 mm
11
12
13
Spark plug
Bolt
Bolt
4
4
2
M8 × 25 mm
M6 × 20 mm
3
14 Cover 2
15
16
17
Anode
Grommet
Valve pad
2
2
16
4
18 Valve lifter 16
19
20
21
Valve cotter
Spring retainer
Valve spring
32
16
16
5
22 Spring seat 16
23
24
Stem seal
Valve guide
16
16
Not reusable
Not reusable 6
È Tightening sequence

7
8
9
60C5D11 5-24

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 POWR
Power unit
Removing the cylinder head
1. Check that the camshaft dowel pin holes
a are in the position shown in the illus-
tration. Adjust if necessary.

S60C5340 S60C5360

2. Remove the cylinder head cover. 5. Remove the cylinder head bolts in the
sequence shown.
3. Remove the camshaft cap bolts in the
sequence shown.

S60C5370

S60C5350 CAUTION:
Do not scratch or damage the mating sur-
4. Remove camshaft caps 1 and 2, cam- faces of the cylinder head and cylinder
shaft (intake) 3, camshaft (exhaust) 4, body.
and fuel pump bracket 5.

NOTE:
Use a T-type TORX socket (T55) to remove
the cylinder head bolts (M10).

6. Remove the valve pads 6 and valve lift-

ers 7.

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 Cylinder head
Checking the valve springs
1. Measure the valve spring free length a.
Replace if out of specification.

1
NOTE:
S60C5380

Do not mix the valve train parts. Keep them

2
organized in their proper groups.

7. Remove the intake valve and exhaust

valves.
Valve spring free length limit a:
52.25 mm (2.057 in) 3
2. Measure the valve spring tilt b. Replace
if out of specification.

4
5
Valve spring tilt limit b:
2.6 mm (0.1 in)
6
NOTE:
Checking the valves
1. Check the valve face for pitting or wear.
Replace if necessary.
7
• Be sure to keep the valves, springs, and 2. Measure the valve margin thickness a.
other parts in the order as they were
removed.
• When replacing the valve, also replace the
valve guide and stem seal.
Replace if out of specification.
8
Valve spring compressor 8:
90890-04019
Valve spring compressor attachment
9
9:
90890-06320

60C5D11 5-26

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 POWR
Power unit
Checking the valve guides
Valve margin thickness a:
Intake: NOTE:
0.8–1.2 mm (0.031–0.047 in) • Use the valve guide clearance calculation
Exhaust: method or the valve runout measurement
1.0–1.4 mm (0.039–0.055 in) method to check the valve guides.
• Before checking the valve guide make sure
3. Measure the valve stem diameter b. that the valve stem diameter is within spec-
Replace if out of specification. ification.

1. Measure the valve guide inside diameter

a.

Valve stem diameter b:

S60C5450
Intake:
5.97–5.99 mm
Valve guide inside diameter limit a:
(0.2350–0.2358 in)
6.01–6.02 mm (0.2367–0.2370 in)
Exhaust:
5.96–5.97 mm
(0.2347–0.2350 in) 2. Calculate the valve stem-to-valve guide
clearance as follows. Replace the valve
guide if out of specification.
4. Measure the valve stem runout. Replace
if out of specification.
Valve stem-to-valve guide clearance
= valve guide inside diameter – valve
stem diameter:
Intake:
0.02–0.05 mm
(0.0008–0.0019 in)
Exhaust:
0.04–0.06 mm
(0.0016–0.0023 in)

Valve stem runout:

Intake: 0.01 mm (0.0004 in)
Exhaust: 0.01 mm (0.0004 in)

5-27 60C5D11

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 Cylinder head
Replacing the valve guides
1. Remove the valve guide 1 by striking
the special service tool from the combus-

1
tion chamber side.

NOTE:
• Turn the valve guide reamer clockwise to
2
ream the valve guide.

Valve guide remover/installer:

90890-04064
• Do not turn the reamer counterclockwise
when removing the reamer. 3
4
2. Install the new valve guide 2 by striking Valve guide reamer: 90890-04066
the special tool from the camshaft side to
the specified position a. 4. Measure the valve guide inside diameter.
Replace the valve guide if out of specifi-
cation.

Valve guide inside diameter:

6.01–6.02 mm (0.2367–0.2370 in)
5
Checking the valve seat
1. Eliminate carbon deposits from the valve
with a scraper. 6
NOTE: 2. Apply a thin, even layer of Mechanic’s

7
• Before installing the valve guide, mark its blueing dye (Dykem) onto the valve seat.
installation position b as shown.
• Apply engine oil to the surface of the new 3. Lap the valve slowly on the valve seat
valve guide. with a valve lapper (commercially obtain-
able) as shown.

Valve guide position a:

11.5 mm (0.45 in) 8
Valve guide remover/installer:
90890-04064

3. Insert the special service tool into the

9
valve guide 2, and then ream the valve S60C5500

guide.

60C5D11 5-28

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 POWR
Power unit
4. Measure the valve seat contact width a Refacing the valve seat
where the blueing dye is adhered to the 1. Reface the valve seat with the valve seat
valve face. Reface the valve seat if the cutter.
valve is not seated properly or if the valve
seat contact width is out of specification.
Replace the valve guide if the valve seat
contact is uneven.

Valve seat cutter holder:

90890-06553
Valve seat cutter:
30° (intake): 90890-06326
30° (exhaust): 90890-06328
45° (intake and exhaust):
90890-06555
60° (intake): 90890-06324
60° (exhaust): 90890-06315

2. Cut the surface of the valve seat with a

45° cutter by turning the cutter clockwise
until the valve seat face has become
smooth.

Valve seat contact width a:

Intake: S60C5540
1.2–1.6 mm (0.047–0.063 in)
Exhaust:
1.2–1.6 mm (0.047–0.063 in)

a Slag or rough surface

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 Cylinder head
6. If the valve seat contact area is too wide
CAUTION: and situated in the center of the valve
Do not over cut the valve seat. Be sure to face, use a 30° cutter to cut the top edge

1
turn the cutter evenly downward at a pres- of the valve seat, a 60° cutter to cut the
sure of 40–50 N (4–5 kgf, 8.8–11 lbf) to bottom edge to center the area and set
prevent chatter marks. its width.

3. Use a 30° cutter to adjust the contact

width of the top edge of the valve seat.
2
b Previous contact width
3
30° 7. If the valve seat contact area is too nar-

b Previous contact width

4. Use a 60° cutter to adjust the contact

S60C5560
row and situated near the top edge of the
valve face, use a 30° cutter to cut the top
edge of the valve seat. If necessary, use
4
a 45° cutter to center the area and set its
width of the bottom edge of the valve

5
width.
seat.

6
60°

b Previous contact width

5. Use a 45° cutter to adjust the contact

S60C5570
b Previous contact width
7
width of the valve seat to specification.

8
45°
9
S60C5580

b Previous contact width

c Specified contact width

60C5D11 5-30

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 POWR
Power unit
8. If the valve seat contact area is too nar- Checking the camshaft
row and situated near the bottom edge of 1. Measure the cam lobe. Replace if out of
the valve face, use a 60° cutter to cut the specification.
bottom edge of the valve seat. If neces-
sary, use a 45° cutter to center the area
and set its width.

Cam lobe a:
Intake:
b Previous contact width 37.22–37.38 mm
(1.4654–1.4716 in)
9. Apply a thin, even layer of lapping com- Exhaust:
pound onto the valve seat, and then lap 36.90–37.06 mm
the valve using a valve lapper (commer- (1.4528–1.4590 in)
cially obtainable). Cam lobe b:
Intake:
29.92–30.08 mm
(1.1780–1.1842 in)
Exhaust:
29.92–30.08 mm
(1.1780–1.1842 in)

2. Measure the camshaft runout. Replace if

S60C5500 out of specification.

CAUTION:
Do not get the lapping compound on the
valve stem and valve guide.

10. After every lapping procedure, be sure to

clean off any remaining lapping com-
pound from the cylinder head and the
valve.

11. Check the valve seat contact area of the Camshaft runout limit:
valve again. 0.1 mm (0.004 in)

5-31 60C5D11

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 Cylinder head
3. Measure the camshaft journal diameter Checking the cylinder head
c and cylinder head journal inside diam- 1. Eliminate carbon deposits from the com-
eter d. Replace the camshaft and cylin- bustion chambers and check for deterio-

1
der head if out of specification. ration.

2. Check the cylinder head warpage using a

straightedge 1 and thickness gauge 2
in five directions as shown. Replace if out

2
of specification.

3
S60C5640

Camshaft journal diameter c:

24.96–24.98 mm
(0.9827–0.9834 in)
Camshaft cap inside diameter d:
25.00–25.02 mm
(0.9843–0.9850 in) 4
4. Calculate the camshaft oil clearance e
as follows. Replace the camshaft and
cylinder head as a set if out of specifica-
tion. 5
e = d – c:
0.02–0.06 mm (0.0008–0.0023 in)

S60C5650
6
Cylinder head warpage limit:
0.1 mm (0.004 in)
7
8
9
60C5D11 5-32

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 POWR
Power unit
Installing the valves
1. Install the new valve stem seal 1 to the
valve guide.

S60C5660

2. Install the valve 2, spring seat 3, valve

spring 4, and spring retainer 5 in the
sequence shown, and then attach the
special service tool. S60C5680

4. Lightly tap the spring retainer with a plas-

tic hammer to set the valve cotter
securely.

S60C5690

5. Install the valve pads and valve lifters.

Valve spring compressor 6:

90890-04019
Valve spring compressor attachment
7:
90890-06320

3. Compress the valve spring, and then

install the valve cotter 8 using a thin
screwdriver with a small amount of
grease applied to it.

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 Cylinder head
Installing the cylinder head 2. Install the camshaft (intake) 1 and cam-
1. Tighten the cylinder head bolts to the shaft (exhaust) 2 with the new oil seals
specified torques, in the specified stages, 3.

1
and in the sequence detailed in the spec-
ification box.
M

M
E
2
E
3
S60C5710 4
E S60C5700 3. Check that the camshaft dowel pin holes

CAUTION:
Do not reuse the cylinder head gasket,
always replace it with a new one.
a are in the position shown in the illus-
tration. Adjust if necessary.
5
NOTE:
• Apply engine oil to the cylinder head bolts
before installation.
6
• Use a T-type TORX socket (T55) to install
the cylinder head bolts (M10).

Cylinder head bolt (M10):

S60C5340
7
1st 1–0:
T.
R.

8
15 N·m (1.5 kgf·m, 11 ft·lb)
2nd A–J:
30 N·m (3.0 kgf·m, 22 ft·lb)
3rd P–Y: 90°
Cylinder head bolt (M8):
1st K–O:
14 N·m (1.4 kgf·m, 10 ft·lb)
2nd Z–_:
28 N·m (2.8 kgf·m, 20 ft·lb)
9
60C5D11 5-34

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 POWR
Power unit
4. Install the camshaft caps in the proper
position as shown and with the stamped
numbers facing upside down.

1 1 1
A6 A1
A1

6 1

7 2

A 2 A 2

7 2

8 3

A 2 A 2

8 3

9 4

A 2 A 2

9 4

10 5

A 2 A 2

10 5
5

A 2

S60C5730

5. Tighten the camshaft cap bolts to the

specified torques in two stages and in the
sequence shown.

NOTE:
Apply engine oil to the camshaft cap bolts
before installation.

Camshaft cap bolt:

1st: 8 N·m (0.8 kgf·m, 5.8 ft·lb)
T.
R.

2nd: 17 N·m (1.7 kgf·m, 12 ft·lb)

6. Install the fuel pump bracket.

Fuel pump bracket:

17 N·m (1.7 kgf·m, 12 ft·lb)
T.
R.

7. Install the cylinder head cover.

Cylinder head cover:

8 N·m (0.8 kgf·m, 5.8 ft·lb)
T.
R.

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 Cylinder body
Cylinder body 5

1st 19 N • m (1.9 kgf • m, 14 ft • lb)

1
T.

2nd 60°
R.

14
15
E

12

16 3 1
14
E

6
E

2
10

3
5
15 9
2 8
E

11 4 UP

11

4
17 E E
E
7
11
1st 14 N • m (1.4 kgf • m, 10 ft • lb) 13
11
T.

2nd 28 N • m (2.8 kgf • m, 20 ft • lb)

R.

1st 18 N • m (1.8 kgf • m, 13 ft • lb)

11
T.

5
E R.
2nd 90°
S60C5760

No. Part name Q’ty Remarks

1 Crankshaft 1
2
3
4
Crankcase
Cylinder body
Piston and connecting rod
1
1
4
6
5 Connecting rod cap 4
6
7
Connecting rod bearing
Bolt
8
8 Not reusable
M8 × 38 mm
7
8 Oil ring 4

8
9 Second ring 4
10 Top ring 4
11 Main bearing 10
12 Oil seal 1 Not reusable

9
13 Oil seal 1 Not reusable
14 Bolt 4 M6 × 25 mm
15 Bracket 2
16 Bolt 10 M10 × 135 mm
17 Bolt 10 M8 × 55 mm

60C5D11 5-36

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 POWR
Power unit

23 N • m (2.3 kgf • m, 17 ft • Ib)

T.
R.

4
3

6
7
8
10 11 9

12
13
14
18 15
19
18 N • m (1.8 kgf • m, 13 ft • Ib) 20 16 17
T.
R.

E
E
23 21
2
22
1st 6 N • m (0.6 kgf • m, 4.3 ft • lb) LT
572
T.

2nd 12 N • m (1.2 kgf • m, 8.7 ft • lb)

R.

S60C5750

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 Cylinder body
No. Part name Q’ty Remarks
1 Exhaust cover 1
2 Oil filter 1
3
4
5
Gasket
Bolt
Gasket
1
1
1
Not reusable

Not reusable
1
6 Gasket 1 Not reusable
7
8
9
Thermo sensor
Retainer
Bolt
1
1
2 M6 × 16 mm
2
10 Clamp 1
11
12
13
Bolt
Gasket
Grommet
1
1
1
M6 × 10 mm
Not reusable 3
14 Pressure control valve 1
15
16
17
Spring
Cover
Bolt
1
1
3
4
18 Grommet 1
19
20
21
Anode
Cover
Bolt
1
1
2 M8 × 25 mm
5
22 Bolt 1 M6 × 20 mm
23 Bolt

È Tightening sequence
18 M6 × 30 mm
6
7
8
9
60C5D11 5-38

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 POWR
Power unit
Removing and installing the oil filter
1. Place a rag under the oil filter, and then Oil filter: 18 N·m (1.8 kgf·m, 13 ft·lb)

T.
R.
remove the filter.

Disassembling the cylinder body

1. Remove the exhaust cover bolts in the
sequence shown.

S60C5770

Oil filter wrench: 90890-01426

NOTE:
Be sure to clean up any oil spills.

2. Apply a thin coat of engine oil to the O-

ring of the new oil filter.

3. Install the oil filter, and then tighten it to S60C5800

the specified torque.
2. Remove the crankcase bolts in the
sequence shown.

S60C5780

S60C5810
Oil filter wrench: 90890-01426

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 Cylinder body
Checking the cylinder bore
NOTE:
1. Measure the cylinder bore (D1–D6) at
Do not remove the ignition timing pointer
measuring points a, b, and c, and in
from the crankcase.

1
direction d (D1, D3, D5), which is parallel
to the crankshaft, and direction e (D2,
3. Remove the connecting rod bolts and the D4, D6), which is at a right angle to the
connecting rod caps. crankshaft.

2
NOTE:
• Be sure to keep the bearings in the order as
they were removed, and to note the bearing D2 D1
color of the bearing.
• After removing the connecting rods, mark D4 D3
each cylinder for identification.

4. Remove the crankshaft, oil seals, and the

D6 D5

S60C5830
3
piston assemblies. a 20 mm (0.8 in)

4
b 70 mm (2.8 in)
Checking the piston diameter c 120 mm (4.7 in)
1. Measure the piston outside diameter at
the specified measuring point. Replace if Cylinder bore (D1–D6):
out of specification. 79.00–79.02 mm
(3.1103–3.1110 in)

2. Calculate the taper limit. Replace or

rebore the cylinder body if out of specifi-
5
cation.

Taper limit:
D1–D5 (direction d)
D2–D6 (direction e)
6
0.08 mm (0.0031 in)

Piston diameter a:
78.93–78.94 mm
(3.1075–3.1078 in)
3. Calculate the out-of-round limit. Replace
or rebore the cylinder body if out of spec-
ification.
7
Measuring point b:

8
13 mm (0.5 in) up from the bottom Out-of-round limit:
of the piston skirt D2–D1 (measuring point a)
Oversize piston diameter: D6–D5 (measuring point c)
79.18–79.19 mm 0.08 mm (0.0031 in)
(3.1174–3.1177 in)
Oversize 1: +0.25 mm (0.0098 in)

9
60C5D11 5-40

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 POWR
Power unit
Checking the piston clearance
1. Rebore the cylinder or replace the piston
and piston rings as a set, or the cylinder
body, or all parts if out of specification.

Piston clearance:
0.07–0.08 mm (0.0028–0.0031 in)

Checking the piston rings

1. Check the piston ring dimensions of B
and T. Replace if out of specification.

S60C5850

Piston ring dimensions:

Top ring a: Piston ring end gap e:
B: 1.17–1.19 mm Top ring:
(0.0461–0.0468 in) 0.15–0.35 mm
T: 2.8–3.0 mm (0.111–0.118 in) (0.0060–0.0137 in)
Second ring b: Second ring:
B: 1.47–1.49 mm 0.70–0.90 mm
(0.0579–0.0586 in) (0.0276–0.0354 in)
T: 3.00–3.20 mm Oil ring:
(0.1182–0.1259 in) 0.20–0.70 mm
Oil ring c: (0.0079–0.0275 in)
B: 2.38–2.48 mm
(0.0938–0.0976 in)
T: 2.40 mm (0.0945 in)

2. Level the piston ring 1 in the cylinder

with the piston crown.

Measuring point d: 20 mm (0.8 in)

3. Check the piston ring end gap e at the

specified measuring point. Replace if out
of specification.

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 Cylinder body
Checking the piston ring grooves
1. Measure the piston ring grooves. Piston ring side clearance:
Replace the piston if out of specification. Top ring a:
0.04–0.08 mm
(0.0016–0.0031 in)
Second ring b:
0.03–0.07 mm
1
(0.0012–0.0027 in)
Oil ring c:
0.03–0.15 mm
(0.0012–0.0059 in) 2
Checking the crankshaft

S60C5860
1. Measure the crankshaft journal diameter
a, crank pin diameter b, and crank pin
width c. Replace the crankshaft if out of
specification.
3
Piston ring groove:
Top ring a:
1.23–1.25 mm
(0.0485–0.0492 in)
4
Second ring b:
1.52–1.54 mm
(0.0599–0.0606 in)
Oil ring c:
2.51–2.53 mm
5
(0.0989–0.0996 in)

Checking the piston ring side

clearance
6
1. Measure the piston ring side clearance.

7
Replace the piston and piston rings as a
set if out of specification.

Crankshaft journal diameter a:

8
47.984–48.000 mm

9
(1.8892–1.8897 in)
Crank pin diameter b:
43.982–44.000 mm
(1.7315–1.7322 in)
Crank pin width c:
S60C5870 21.00–21.07 mm
(0.8268–0.8295 in)

60C5D11 5-42

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 POWR
Power unit
2. Measure the crankshaft runout. Replace 3. Put a piece of Plastigauge® (PG-1) onto
the crankshaft if out of specification. the crank pin, parallel to the crankshaft.

S60C5900

Crank stand alignment: NOTE:

90890-03107 Be sure not to put the Plastigauge (PG-1)
over the oil hole in the crank pin of the crank-
shaft.
Crankshaft runout limit:
0.03 mm (0.0012 in)
4. Install the connecting rod to the crank pin
Checking the crankshaft pin oil 3.
clearance
1. Clean the bearings and the connecting
rod.

2. Install the upper half of the bearing into

the connecting rod 1 and the lower half
into the connecting rod cap 2.

S60C5A10

NOTE:
Make sure that the large, flat side a on the
S60C5960
connecting rod faces towards the flywheel
side of the crankshaft.
CAUTION:
Install the bearings in their original posi-
tions.

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 Cylinder body
5. Tighten the connecting rod bolts to the
specified torques in two stages. Crank pin oil clearance:
0.023–0.035 mm
(0.0010–0.0013 in)

Selecting the connecting rod big end

bearing
1
1. When replacing the connecting rod bear-
ing, select the suitable bearing as fol-
lows.

2. Measure the connecting rod big end

2
inside diameter a.

3
NOTE:
• Reuse the connecting rod bolts.
• Do not turn the connecting rod until the
crank pin oil clearance measurement has
been completed.
4
• Make a mark on the connecting rod bolts S60C5980

5
and connecting rod caps, and then tighten
the bolts 90° from the mark. NOTE:
• Use a E-type TORX socket (E10) to install Reuse the connecting rod bolts.
the connecting rod bolts.

Connecting rod big end inside

Connecting rod bolt:
1st: 18 N·m (1.8 kgf·m, 13 ft·lb)
diameter a:
47.03–47.04 mm 6
T.
R.

2nd: 90° (1.8514–1.8518 in)

7
6. Remove the connecting rod cap and
measure the width of the compressed
Plastigauge (PG-1) on each crank pin.
Replace the connecting rod bearing if out
of specification.

8
9
60C5D11 5-44

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 POWR
Power unit
3. Check the crank pin mark on the crank-
shaft 2. Connecting rod bearing selection table
(20 °C [68 °F])
4. Select the suitable color b for the con- Connecting rod big
necting rod bearing from the table. end diameters – Upper Lower
crank pin bearing bearing
diameters (mm)
3.025–3.027 Yellow Yellow
3.028–3.034 Yellow Green*
3.035–3.041 Green Green
(#1) 3.042–3.049 Green Blue*
3.050–3.057 Blue Blue
3.058–3.063 Blue Red*
(#2)

CAUTION:
(#3) The (*) mark indicates that the color of the
upper and lower bearings are different.

(#4)
7. If the measurement value is more than
S60C5A45 the maximum value (3.063 mm), replace
the crankshaft, connecting rod, or both.

Checking the crankshaft main

journal oil clearance
1. Clean the bearings, main journals, and
bearing portions of the crankcase and
cylinder body.

2. Place the cylinder body upside down on

S60C5A65 a bench.

5. Subtract the crank pin diameters (#1–#4)

from the connecting rod big end diame-
ters (#1–#4).

NOTE:
The crank pin diameters (#1–#4) can be
determined by the stamped value as
described below.
Crank pin diameter = 43.900 + (stamped
value/1,000)
Example: #1 = 92 → 43.992

6. Select the suitable bearing from the table

below according to the calculated values.

5-45 60C5D11

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 Cylinder body
3. Install half of the bearings (grooved bear- 5. Install the remaining half of the bearings
ings) 1 and the crankshaft into the cylin- (plain bearings) 3 into the crankcase.
der body 2.

1
S60C5925
2
6. Install the crankcase onto the cylinder

S60C5910
body and apply engine oil onto the
threads of the crankcase bolts. 3
7. Tighten the crankcase bolts to the speci-
fied torques in two stages and in the

4
CAUTION:
Install the bearings in their original posi- sequence shown.
tions.

NOTE:
Install the unified thrust bearing at the posi-
tion a shown. 5
4. Put a piece of Plastigauge (PG-1) on
each main journal parallel to the crank-
shaft.
60°
6
7
S60C5930

NOTE:
NOTE:
• Do not move the crankshaft until the main
journal oil clearance measurement has
8
Do not put the Plastigauge (PG-1) over the been completed.

9
oil hole in the main journals of the crankshaft. • Make a mark on the crankcase and crank-
case bolts, and then tighten the M10 bolts
60° from the mark.

60C5D11 5-46

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 POWR
Power unit
3. Select the suitable color a for the main
Crankcase bolt (M10): bearing from the table.
1st: 19 N·m (1.9 kgf·m, 14 ft·lb)
T.
R.

2nd: 60°
Crankcase bolt (M8): (#1) (#2) (#3) (#4) (#5)
1st: 14 N·m (1.4 kgf·m, 10 ft·lb)
2nd: 28 N·m (2.8 kgf·m, 20 ft·lb)

8. Remove the crankcase and measure the

width of the compressed Plastigauge
(PG-1) on each main journal. Replace
S60C5A40
the main bearing if out of specification.

#1

#2

#3

#4

#5
S60C5A50

Crankshaft main journal oil

clearance:
0.024–0.044 mm
(0.0010–0.0017 in)

Selecting the crankshaft main

journal bearing
1. When replacing the main bearing, select S60C5A60
the suitable bearing as follows.
4. Subtract crankshaft journal diameters
2. Check the crankshaft journal mark on the #1–#5 from cylinder body journal diame-
crankshaft 1 and the cylinder body mark ters #1–#5.
on the cylinder body 2.
NOTE:
Cylinder body journal diameters (#1–#5) and
crankshaft journal diameters (#1–#5) can be
determined by the stamped value as
described below.
Crankshaft journal diameter = 47.900 +
(stamped value/1,000)
Example: #1 = 92 → 47.992
Cylinder body journal diameter = 54.000 +
(stamped value/1,000)
Example: #1 = 32 → 54.032

5-47 60C5D11

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 Cylinder body
5. Select the suitable bearing from the table Assembling the cylinder body
below according to the calculated values. 1. Install the oil ring 1, second ring 2, and
top ring 3 to the piston with the “T” mark
Crankshaft bearing selection table

1
a on the piston rings facing upward.
(20 °C [68 °F])
Cylinder body Bearing 2. Offset the piston ring end gaps as
Bearing
journal diameters – (cylinder shown.
(crankcase
crankshaft journal side)/thrust
side)

2
diameters (mm) bearing 45° 45°
#3 #2
6.023–6.026 Green Yellow* UP

6.027–6.034 Blue Green*

6.035–6.042 Blue Blue
#5 #1,#4 #5

3
6.043–6.049 Red Blue* #4
6.050–6.058 Red Red #3
#2
#1
CAUTION:

4
• The (*) mark indicates that the color of
E
the upper and lower bearings are differ-
ent. S60C5A70
• Be sure to install the main bearings in
the middle of the cylinder body and CAUTION:

5
crankcase journal so they do not block Do not scratch the piston or break the pis-
the oil holes. ton rings.

NOTE: NOTE:
Crankshaft bearing #3 is a thrust bearing. After installing the piston rings, check that

6. If the difference between the cylinder

body journal diameter and crankshaft
they move smoothly.

3. Install the upper half of the bearing into

6
journal diameter is more than the maxi- the connecting rod 4 and the lower half
mum value (6.058 mm), replace the
crankshaft.
into the connecting rod cap 5.
7
8
9
E
S60C5A80

60C5D11 5-48

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 POWR
Power unit
6. Set the crankshaft 8, and oil seals 9
CAUTION: and 0 into the cylinder body as shown.
Install the bearings in their original posi-
tion.

4. Install the piston with the “UP” mark on

the piston crown facing towards the fly-
wheel magnet.

S60C5A90

S60C5B20
NOTE:
Apply engine oil to the sides of the piston
assembly. 7. Install the connecting rod cap 5 to the
connecting rod, and then tighten the new
connecting rod bolts A to the specified
torques in two stages.
Piston slider: 90890-06530

5. Install half of the bearings (grooved bear-

ings) 6 into the cylinder body 7.
E

S60C5B10 S60C5B30

NOTE: CAUTION:
Install the unified thrust bearing at the posi- Do not reuse the connecting rod bolts,
tion b shown. always replace them with new ones.

5-49 60C5D11

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 Cylinder body
10. Install the crankcase bolts, and then
NOTE: tighten them to the specified torques in
• Make sure that the large, flat side c of the two stages and in the sequence shown.
connecting rod faces towards the flywheel
magnet side of the crankshaft.
• Apply engine oil to the connecting rod cap
and connecting rod bolt.
1
Connecting rod bolt A:
1st: 18 N·m (1.8 kgf·m, 13 ft·lb)
2
T.
R.

2nd: 90°

60°
8. Install half of the bearings (plain bear-
ings) B into the crankcase.

9. Apply Gasket Maker® to the mating sur-

face of the crankcase.
3
GM

S60C5930 4
CAUTION:
The oil seals must be installed before
tightening the crankcase bolts.
5
NOTE:

6
Apply engine oil to the crankcase bolts before
installation.
E
S60C5B40

Crankcase bolt (M10):

NOTE: 1st: 19 N·m (1.9 kgf·m, 14 ft·lb)
T.

7
R.

Do not get any Gasket Maker on the journal 2nd: 60°

bearings. Crankcase bolt (M8):
1st: 14 N·m (1.4 kgf·m, 10 ft·lb)
2nd: 28 N·m (2.8 kgf·m, 20 ft·lb)

8
9
60C5D11 5-50

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 POWR
Power unit
11. Install the new gasket and exhaust cover,
and then tighten the bolts to the specified
torques in two stages and in the
sequence shown.

S60C5B50

LT
Exhaust cover bolt: 572

1st: 6 N·m (0.6 kgf·m, 4.3 ft·lb)

T.
R.

2nd: 12 N·m (1.2 kgf·m, 8.7 ft·lb)

Installing the power unit

1. Install the dowel pins 1 and gasket 2. LT
572 S60C5B60
2. Install the power unit 3 by installing bolts
4 and 5, then tightening them to the Mounting bolt 4 5:
specified torque. 42 N·m (4.2 kgf·m, 30 ft·lb)
T.
R.

3. Install the apron 6. 4. Connect the battery leads 7, wiring har-

ness 8, and PTT motor leads 9.

S60C5B70

5-51 60C5D11

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 Cylinder body
5. Connect the pilot water hose 0 and 9. Install the Woodruff key G.
install the engine oil dipstick A.

1
2
S60C5C10

10. Install the flywheel magnet and flywheel

3
magnet cover.

S60C5B80

6. Connect the shift cable B and throttle

4
cable C, and then adjust their lengths.
For adjustment procedures, see Chapter
3, “Checking the throttle cable opera-
tion,” and “Checking the gearshift opera-
tion.”
5
7. Connect the fuel hose D.

8. Install the grommet E and retaining plate

F.
CAUTION:
Apply force in the direction of the arrows
shown, to prevent the flywheel holder
6
from slipping off easily.

NOTE:
Apply engine oil to the flywheel magnet nut
before installation.
7
Flywheel holder: 90890-06522 8
Flywheel magnet nut:
186 N·m (18.6 kgf·m, 135 ft·lb)
9
T.
R.

S60C5B90

60C5D11 5-52

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 LOWR

Lower unit

Special service tools .....................................................................................6-1

Lower unit (F100B)......................................................................................... 6-4

Removing the lower unit ............................................................................6-7
Removing the water pump and shift rod.................................................... 6-8
Checking the water pump and shift rod .....................................................6-8

Propeller shaft housing (F100B)...................................................................6-9

Removing the propeller shaft housing assembly..................................... 6-11
Disassembling the propeller shaft housing.............................................. 6-11
Disassembling the propeller shaft assembly ...........................................6-12
Checking the propeller shaft housing ......................................................6-12
Checking the propeller shaft.................................................................... 6-13
Assembling the propeller shaft assembly ................................................ 6-13
Assembling the propeller shaft housing...................................................6-13

Drive shaft and lower case (F100B)............................................................ 6-15

Removing the drive shaft.........................................................................6-17
Disassembling the drive shaft housing ....................................................6-17
Disassembling the forward gear ..............................................................6-17
Disassembling the lower case .................................................................6-18
Checking the pinion and forward gear.....................................................6-18
Checking the bearings............................................................................. 6-18
Checking the drive shaft ..........................................................................6-18
Checking the lower case .........................................................................6-19
Assembling the lower case...................................................................... 6-19
Assembling the forward gear................................................................... 6-19
Assembling the drive shaft housing......................................................... 6-20
Installing the drive shaft...........................................................................6-20
Installing the propeller shaft housing .......................................................6-21
Installing the water pump and shift rod....................................................6-22
Installing the lower unit ............................................................................6-23

Shimming (F100B)........................................................................................ 6-25

Shimming.................................................................................................6-26
Selecting the pinion shims....................................................................... 6-26
Selecting the forward gear shims ............................................................ 6-27
Selecting the reverse gear shims ............................................................ 6-28

Backlash (F100B) ......................................................................................... 6-29

Measuring the forward and reverse gear backlash .................................6-29

Lower unit (F100C)....................................................................................... 6-31

Removing the lower unit ..........................................................................6-35
Removing the water pump and shift rod.................................................. 6-36
Checking the water pump and shift rod ...................................................6-36

60C5D11

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 Propeller shaft housing (F100C).................................................................6-37
Removing the propeller shaft housing assembly..................................... 6-39
Disassembling the propeller shaft housing.............................................. 6-39
Disassembling the propeller shaft assembly ...........................................6-40
Checking the propeller shaft housing ......................................................6-40
Checking the propeller shaft.................................................................... 6-40
Assembling the propeller shaft assembly ................................................ 6-41
Assembling the propeller shaft housing...................................................6-41
1
Drive shaft and lower case (F100C)............................................................ 6-43
Removing the drive shaft.........................................................................6-45
Disassembling the drive shaft.................................................................. 6-45
Disassembling the forward gear ..............................................................6-45
2
Disassembling the lower case .................................................................6-46
Checking the pinion and forward gear.....................................................6-46
Checking the bearings............................................................................. 6-46
Checking the drive shaft ..........................................................................6-46
Checking the lower case .........................................................................6-47
3
Assembling the lower case...................................................................... 6-47
Assembling the forward gear................................................................... 6-48
Assembling the drive shaft ...................................................................... 6-48
Installing the drive shaft...........................................................................6-48
Installing the propeller shaft housing .......................................................6-49
4
Installing the water pump and shift rod....................................................6-49
Installing the lower unit ............................................................................6-51

Shimming (F100C)........................................................................................ 6-53

Shimming.................................................................................................6-54
5
Selecting the pinion shims....................................................................... 6-54
Selecting the forward gear shims ............................................................ 6-55
Selecting the reverse gear shims ............................................................ 6-56

Backlash (F100C) ......................................................................................... 6-56

6
Measuring the forward gear backlash .....................................................6-56

7
8
9
60C5D11

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 LOWR
Lower unit
Special service tools 6

Ring nut wrench 3 Bearing separator

90890-06511 90890-06534

Ring nut wrench extension Stopper guide stand

90890-06513 90890-06538

Bearing housing puller claw L Bearing puller

90890-06502 90890-06535
Bearing puller claw 1
90890-06536
Bearing puller claw 2
90890-06537

Stopper guide plate

90890-06501

Needle bearing attachment

90890-06609, 90890-06610, 90890-06611,
90890-06612, 90890-06653
Ball bearing attachment
90890-06631, 90890-06633, 90890-06636
Center bolt
90890-06504

6-1 60C5D11

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 Special service tools

1
Driver rod LL Pinion nut holder
90890-06605
Driver rod L3
90890-06652
90890-06505

2
Socket adapter 2
3
90890-06507
Driver rod SS
90890-06604 4
Bearing outer race puller
5
90890-06523
Bearing depth plate
90890-06603
6
Driver rod SL
90890-06602
7
Bearing inner race attachment
90890-06639, 90890-06641, 90890-06643,
90890-06661, 90890-06662
8
Bearing outer race attachment
90890-06620, 90890-06621, 90890-06623,
90890-06626, 90890-06628
9
Drive shaft holder 5
90890-06519

60C5D11 6-2

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 LOWR
Lower unit

Driver rod LS Backlash indicator

90890-06606 90890-06706

Pinion height gauge Magnet base plate

90890-06702 90890-07003

Digital caliper Dial gauge set

90890-06704 90890-01252

Shimming plate Magnet base

90890-06701 90890-06705

Shift rod push arm

90890-06052

6-3 60C5D11

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 Special service tools / Lower unit (F100B)
Lower unit (F100B) 6

1
9 42 N • m (4.2 kgf • m, 30 ft • Ib)

T.
R.
7 N • m (0.7 kgf • m, 5.1 ft • Ib)
T.
R.

10 55 N • m (5.5 kgf • m, 40 ft • Ib)

T.
R.
16

3
M
A
6

12
2
6
2
4

1
5
14 15
13
17

3
18

LT
572
7

11 LT
572
4
5
8

5
D 39 N • m (3.9 kgf • m, 28 ft • Ib)
T.
R.

39 N • m (3.9 kgf • m, 28 ft • Ib) S60C6005

T.
R.

No. Part name Q’ty Remarks

1 Lower unit 1
2
3
4
Plastic tie
Hose
Check screw
1
1
1
Not reusable
7 × 145 mm 6
5 Gasket 2 Not reusable
6
7
8
Dowel pin
Bolt
Drain screw
2
6
1
M10 × 45 mm 7
9 Grommet 1
10
11
12
Bolt
Bolt
Spacer
1
1
1
M10 × 45 mm
M10 × 70 mm 8
13 Propeller 1
14
15
16
Washer
Washer
Cotter pin
1
1
1 Not reusable
9
17 Propeller nut 1
18 Trim tab 1

60C5D11 6-4

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 LOWR
Lower unit

10 11
12

13
LT
572

14
A 15

16

17
A
18

2 19
20

3 8 A 21

4 LT 22
572
5

6 23

7 1
24 24

S60C6025

6-5 60C5D11

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 Lower unit (F100B)
No. Part name Q’ty Remarks
1 Shift rod assembly 1
2 Oil seal 1 Not reusable
3
4
Oil seal housing
O-ring
1
1 Not reusable
3.1 × 64.6 mm
1
5 Spring 1
6
7
8
Circlip
Shift rod
Bolt
1
1
3 M6 × 20 mm
2
9 Woodruff key 1
10
11
12
Bolt
Cover
Seal
4
1
1
M8 × 45 mm
3
13 Water pump housing 1
14

15
16
O-ring

Insert cartridge
O-ring
1

1
1
Not reusable
2.5 × 42 mm

Not reusable
4
2.5 × 91.5 mm
17
18
19
Collar
Spacer
Washer
1
1
2
5
20 Wave washer 1
21
22
23
Impeller
Outer plate cartridge
Gasket
1
1
1 Not reusable
6
24 Dowel pin 2

7
8
9
60C5D11 6-6

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 LOWR
Lower unit
Removing the lower unit
1. Drain the gear oil. For draining proce-
dures, see Chapter 3, “Changing the
gear oil.”

2. Set the gearshift to the neutral position,

and place a block of wood between the
anti-cavitation plate and propeller to keep
the propeller from turning, and then
remove the propeller nut and propeller.

S60C6015

5. Loosen the bolts, and then remove the

lower unit from the upper case.
WARNING
Do not hold the propeller with your hands
when loosening or tightening it. Be sure
to remove the battery leads from the bat-
teries and the engine shut-off switch. Put
a block of wood between the anti-cavita-
tion plate and propeller to keep the pro-
peller from turning.

3. Disconnect the speedometer hose 1.

4. Mark the trim tab 2 at the area shown,

and then remove it.

S60C6020

NOTE:
Check that there is no oil on the spline and
check it for rust or wear. Check the oil pump
if necessary.

6-7 60C5D11

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 Lower unit (F100B)
Removing the water pump and shift 2. Check the impeller 1 and insert car-
rod tridge 2 for cracks or wear. Replace if
1. Remove the water pump assembly and necessary.
shift rod assembly 1.

1
2
S60C6040

3. Check the Woodruff key 3 and the

groove a on the drive shaft for wear.
Replace if necessary.
3
4
S60C6045
5
Checking the water pump and shift 4. Check the shift rod for cracks or wear.
rod
1. Check the pump housing for deforma-
tion. Replace if necessary.
Replace if necessary.
6
7
S60C6035
S60C6050

8
9
60C5D11 6-8

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 LOWR
Lower unit
Propeller shaft housing (F100B) 6

9 13 11 16
14 17

8 12 10 12 15

17

16

11 12
10
9 14 15
103 N • m (10.3 kgf • m, 74 ft • lb)
13

T.
8

R.
D

2
4
7
D 6
5

24

E
19 23
18
A
E

22
21
20

S60C6085

6-9 60C5D11

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 Propeller shaft housing (F100B)
No. Part name Q’ty Remarks
1 Propeller shaft assembly 1
2 Propeller shaft housing assembly 1
3
4
5
Reverse gear shim
Washer
Straight key
—
2
1
As required
1
6 Claw washer 1
7
8
9
Ring nut
Shift rod joint
Ball
1
1
2
2
10 Slider 1
11
12
13
Ball
Ball
Spring
2
2
1
3
14 Dog clutch 1
15
16
17
Cross pin
Spring
Propeller shaft
1
1
1
4
18 Reverse gear 1
19
20
21
Thrust washer
Ball bearing
O-ring
1
1
1 Not reusable
5
5.5 × 97.8 mm
22
23
24
Propeller shaft housing
Needle bearing
Oil seal
1
1
2 Not reusable
6
7
8
9
60C5D11 6-10

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 LOWR
Lower unit
Removing the propeller shaft Disassembling the propeller shaft
housing assembly housing
1. Straighten the claw washer tabs a, and 1. Remove the reverse gear and thrust
then remove the ring nut and claw washer.
washer.

Ring nut wrench 3 1: 90890-06511

Ring nut wrench extension 2:
90890-06513
Bearing separator 1: 90890-06534
2. Pull out the propeller shaft housing Stopper guide plate 2: 90890-06501
assembly. Stopper guide stand 3:
90890-06538
Bearing puller 4: 90890-06535
Bearing puller claw 1 5:
90890-06536

NOTE:
Install the bearing separator 1 between the
reverse gear and thrust washer completely.

Bearing housing puller claw L 3:

90890-06502
Stopper guide plate 4: 90890-06501
Center bolt 5: 90890-06504

6-11 60C5D11

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 Propeller shaft housing (F100B)
2. Remove the ball bearing. Disassembling the propeller shaft
assembly
1. Remove the spring 1, and then remove
the cross pin 2, dog clutch 3, slider,
and spring.
1
2
Stopper guide plate 6: 90890-06501
Stopper guide stand 7:
90890-06538
Bearing puller 8: 90890-06535
Bearing puller claw 1 9: Checking the propeller shaft housing
3
90890-06536 1. Clean the propeller shaft housing using a

3. Remove the oil seals and needle bear-

ing.
soft brush and cleaning solvent, and then
check it for cracks. Replace if necessary.
4
5
2. Check the teeth and dogs of the reverse
6
Needle bearing attachment 0: gear for cracks or wear. Replace the
90890-06653
Driver rod L3 A: 90890-06652
gear if necessary.
7
8
S60C6125

9
60C5D11 6-12

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 LOWR
Lower unit
3. Check the bearings for pitting or rum- Assembling the propeller shaft
bling. Replace if necessary. assembly
1. Install the dog clutch 1 as shown.

S60C6130

Checking the propeller shaft

1. Check the propeller shaft for bends or
wear. Replace if necessary.

Assembling the propeller shaft

housing
1. Install the needle bearing into the propel-
ler shaft housing to the specified depth.

2. Check the dog clutch, shift rod joint, and

shift slider for cracks or wear. Replace if
necessary.

NOTE:
• Install the needle bearing with the manufac-
ture identification mark a facing toward the
oil seal (propeller side).
• When using the driver rod, do not strike the
special tool in a manner that will force the
stopper b out of place.

Driver rod SS 1: 90890-06604

Needle bearing attachment 2:
90890-06610
Bearing depth plate 3: 90890-06603

6-13 60C5D11

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 Propeller shaft housing (F100B)

Depth c: NOTE:
24.75–25.25 mm (0.97–0.99 in) Install the ball bearing with the manufacture
identification mark e facing outward (propel-
2. Apply grease to the new oil seals, and
then install them into the propeller shaft
housing to the specified depth.
ler side).

Bearing inner race attachment 9:

1
90890-06661

4. Install the reverse gear assembly to the

propeller shaft housing using a press.
2
3
NOTE:
Install an oil seal halfway into the propeller
shaft housing, then the other oil seal. 4
Bearing outer race attachment 4:
90890-06628
Driver rod LS 5: 90890-06606 5
Depth d:
4.75–5.25 mm (0.19–0.21 in)

3. Install the thrust washer 6 and ball bear-

ing 7 to the reverse gear 8 using a
Bearing inner race attachment 0:
6
90890-06661
press.

7
8
9
60C5D11 6-14

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 LOWR
Lower unit
Drive shaft and lower case (F100B) 6

6-15 60C5D11

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 Drive shaft and lower case (F100B)
No. Part name Q’ty Remarks
1 Drive shaft 1
2 Sleeve 1
3
4
5
Cover
Oil seal
Bolt
1
2
4
Not reusable
M8 × 25 mm
1
6 Drive shaft housing 1
7
8
Needle bearing
O-ring
1
1 Not reusable
3 × 60.5 mm
2
9 Pinion shim — As required
10
11
12
Thrust bearing
Seal
Plate
1
1
1
3
13 Joint 1
14

15
16
Plastic tie

Hose
Joint
2

1
1
Not reusable
7 × 80 mm
4
5
17 Nut 1
18 Water inlet cover 2
19 Lower case 1
20 Screw 1

6
21 Nut 1
22 Pinion 1
23 Needle bearing 1
24 Forward gear shim — As required

7
25 Bearing outer race 1 Not reusable
26 Taper roller bearing 1 Not reusable
27 Needle bearing 1
28 Forward gear 1

8
9
60C5D11 6-16

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 LOWR
Lower unit
Removing the drive shaft Disassembling the forward gear
1. Remove the drive shaft assembly and 1. Remove the taper roller bearing from the
pinion, and then pull out the forward forward gear using a press.
gear.

S60C6200

S60C6190

CAUTION:
Drive shaft holder 5 1: 90890-06519 Do not reuse the bearing, always replace
Pinion nut holder 2: 90890-06505 it with a new one.
Socket adapter 2 3: 90890-06507

Disassembling the drive shaft Bearing separator 1: 90890-06534

Bearing inner race attachment 2:
housing
90890-06641
1. Remove the cover, oil seals, and needle
bearing.
2. Remove the needle bearing from the for-
ward gear.

Needle bearing attachment 1:

90890-06610
Driver rod L3 2: 90890-06652 CAUTION:
Do not reuse the bearing, always replace
it with a new one.

Stopper guide plate 3: 90890-06501

Stopper guide stand 4:
90890-06538
Bearing puller 5: 90890-06535
Bearing puller claw 1 6:
90890-06536

6-17 60C5D11

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 Drive shaft and lower case (F100B)
Disassembling the lower case Checking the pinion and forward
1. Remove the taper roller bearing outer gear
race and shim(s). 1. Check the teeth of the pinion, and the
teeth and dogs of the forward gear for
cracks or wear. Replace if necessary.
1
2
NOTE:
Install the claws as shown.
Checking the bearings
S60C6220
3
Bearing outer race puller 1: 1. Check the bearings for pitting or rum-
90890-06523
Outer race puller claw A 2:
90890-06532
bling. Replace if necessary.

4
2. Remove the needle bearing.

5
Checking the drive shaft
S60C6225

1. Check the drive shaft for bends or wear.

6
Replace if necessary.

Ball bearing attachment 3:

90890-06636
7
Driver rod LL 4: 90890-06605

8
S60C6230

9
60C5D11 6-18

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 LOWR
Lower unit
Checking the lower case 2. Install the original shim(s) and taper roller
1. Check the skeg and torpedo for cracks or bearing outer race.
damage. Replace if necessary.

S60C6235
CAUTION:
Assembling the lower case Add or remove shims, if necessary, when
1. Install the needle bearing into the lower replacing the forward gear or lower case.
case to the specified depth.

Bearing outer race attachment 4:

90890-06620
Driver rod LL 5: 90890-06605

Assembling the forward gear

1. Install the new needle bearing into the
forward gear to the specified depth.

NOTE:
• Install the needle bearing with the manufac-
ture identification mark a facing upward.
• When using the driver rod, do not strike the
special tool in a manner that will force the
stopper b out of place.

Driver rod SL 1: 90890-06602

Needle bearing attachment 1:
Needle bearing attachment 2:
90890-06612
90890-06609
Driver rod L3 2: 90890-06652
Bearing depth plate 3: 90890-06603

Depth a: 2.5–3.5 mm (0.10–0.14 in)

Depth c: 184.0 mm (7.24 in)

6-19 60C5D11

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 Drive shaft and lower case (F100B)
2. Install the new taper roller bearing into 2. Apply grease to the new oil seals, and
the forward gear using a press. then install them into the drive shaft
housing to the specified depth.

1
2
Bearing inner race attachment 3:
90890-06661

Assembling the drive shaft housing

NOTE:
Install an oil seal halfway into the drive shaft
housing, then the other oil seal.
3
1. Install the needle bearing into the drive
shaft housing to the specified depth. Ball bearing attachment 4:
90890-06633
Driver rod LS 5: 90890-06606
4
Depth c:
0.25–0.75 mm (0.01–0.03 in)

Installing the drive shaft

5
1. Install the forward gear to the lower case.

NOTE:
When using the driver rod, do not strike the
2. Install the drive shaft housing 1 to the
drive shaft 2.
6
special tool in a manner that will force the

7
stopper a out of place.

Needle bearing attachment 1:

90890-06610
Driver rod SS 2: 90890-06604
Bearing depth plate 3: 90890-06603

Depth b:
8
5.75–6.25 mm (0.23–0.25 in) 3. Install the drive shaft assembly, pinion,
and pinion nut, and then tighten the nut
to the specified torque.
9
60C5D11 6-20

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 LOWR
Lower unit
3. Install the original shim(s) 4 and propel-
ler shaft housing assembly 5 into the
lower case, and then install the straight
key 6, claw washer 7, and ring nut 8.

4. Tighten the nut to the specified torque.

S60C6270

NOTE:
Install the drive shaft by lifting it up slightly,
then aligning it with the pinion and the spline
of the drive shaft.

Drive shaft holder 5 3:

490890-06519
Pinion nut holder 4: 90890-06505
Socket adapter 2 5: 90890-06507

Pinion nut:
93 N·m (9.3 kgf·m, 67 ft·lb)
T.
R.

4. Tighten the housing bolt.

Installing the propeller shaft housing

1. Install the washers 1 and propeller shaft
assembly 2 into the propeller shaft
housing assembly 3. NOTE:
Secure the ring nut by bending one tab a
2. Apply grease to the new O-rings.
into the slot in the ring nut and the other tabs
toward the propeller shaft housing assembly.

Ring nut wrench 3 9: 90890-06511

Ring nut wrench extension 0:
90890-06513

Ring nut 8:
103 N·m (10.3 kgf·m, 74 ft·lb)
T.
R.

6-21 60C5D11

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 Drive shaft and lower case (F100B)
Installing the water pump and shift 3. Install the Woodruff key into the drive
rod shaft.
1. Install the shift rod assembly 1.
4. Align the groove on the impeller 5 with
A

LT
the Woodruff key 6, and then install it to
the drive shaft. 1
572

2
3
5. Install the washers 7, wave washer 8,
spacer 9, and collar 0 to the drive shaft.

4
2. Install the new gasket 2, outer plate car-
S60C6055
5
tridge 3, and dowel pins 4.

NOTE:
• The collar and spacer should fit together
firmly.
6
• While pulling the drive shaft up, install the
collar with some appropriate tool a that fits
over the drive shaft as shown. 7
8
9
60C5D11 6-22

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 LOWR
Lower unit
6. Install the O-ring A and insert cartridge
B into the pump housing C. NOTE:
• When installing the pump housing, apply
grease to the inside of the housing, and
then turn the drive shaft clockwise while
A
pushing down the pump housing.
• Align the cover H projection d with the
hole e in the pump housing.

Installing the lower unit

S60C6075 1. Set the gearshift to the neutral position at
the lower unit.
NOTE:
Align the insert cartridge projections b with
the holes c in the pump housing. N

7. Install the O-ring D and pump housing

assembly E into the lower case, tighten
the bolts F, and then install the seal G
and cover H.

S60C6275

LT
572

2. Install the two dowel pins 1 to the lower

unit.

3. Install the lower unit to the upper case,

and then tighten the bolts to the specified
S60C6080 torque.

6-23 60C5D11

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 Drive shaft and lower case (F100B)
5. Install the propeller and propeller nut,
and then tighten the nut finger tight.
Place a block of wood between the anti-

1
cavitation plate and propeller to keep the
propeller from turning, and then tighten
the nut to the specified torque.

2
3
LT
572
LT
572

S60C6285
4
Mounting bolt:
39 N·m (3.9 kgf·m, 28 ft·lb)
5
T.
R.

4. Install the trim tab 2 to its original posi-

tion, and then connect the speedometer
hose 3.

WARNING
6
Do not hold the propeller with your hands
when loosening or tightening it. Be sure
to remove the battery leads from the bat-
teries and the engine shut-off switch. Put
a block of wood between the anti-cavita-
7
tion plate and propeller to keep the pro-
peller from turning.

NOTE:
8
If the grooves in the propeller nut 4 do not

9
align with the cotter pin hole, tighten the nut
until they are aligned.

S60C6290 Propeller nut 4:

55 N·m (5.5 kgf·m, 40 ft·lb)
T.
R.

60C5D11 6-24

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 LOWR
Lower unit
Shimming (F100B) 6

B3

T3

A3 B4

59.0

F
R P

T1 B1 34.0 A2 T2
A1 B2
15.8

S60C6305

6-25 60C5D11

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 Shimming (F100B)
Shimming
Pinion nut:
NOTE: 93 N·m (9.3 kgf·m, 67 ft·lb)

T.
R.
• 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
3. Measure the distance (M4) between the
shimming tool and the pinion as shown. 1
inner part(s).

Selecting the pinion shims

1. Install the drive shaft 1 to the shimming
2
tools.

3
Digital caliper 4: 90890-06704

4. Install the thrust bearing 5 to the drive

shaft housing 6, and then measure the
4
housing height (M3) as shown.

5
6
NOTE:
• Select the shim thickness (T3) by using the
specified measurement(s) and the calcula-
5. Calculate the pinion shim thickness (T3)
as shown in the examples below. 7
tion formula.
• Install the shimming tool to the drive shaft
so that the shaft is at the center of the hole.
• Tighten the wing nuts another 1/4 of a turn
after they contact the fixing plate 2.
R-1
F+5
P+2 8
Pinion height gauge 3:
90890-06702 S60C6330 9
2. Install the pinion and pinion nut, and then
tighten the nut to the specified torque.

60C5D11 6-26

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 LOWR
Lower unit

NOTE:
“P” is the deviation of the lower case dimen-
sion from standard. The “P” mark a is
stamped on the trim tab mounting surface of
the lower case in 0.01 mm units. If the “P”
mark is unreadable, assume that “P” is zero
and check the backlash when the unit is
assembled.

Calculation formula:
Pinion shim thickness (T3) =
62.50 + P/100 – M3 – M4

Example: NOTE:
If “M3” is 46.85 mm and “M4” is 15.12 mm • Select the shim thickness (T1) by using the
and “P” is (–5), then specified measurement(s) and the calcula-
T3 = 62.50 + (–5)/100 – 46.85 – 15.12 mm tion formula.
= 62.50 – 0.05 – 46.85 – 15.12 mm • Measure the bearing outer race at three
= 0.48 mm points to find the height average.

6. Select the pinion shim(s) (T3) as follows.

Shimming plate 2: 90890-06701
Calculated numeral Digital caliper 3: 90890-06704
Rounded numeral
at 1/100 place
1, 2 0 2. Calculate the forward gear shim thickness
3, 4, 5 2 (T1) as shown in the examples below.
6, 7, 8 5
9, 10 8
F+5
R-1 P+2
Available shim thicknesses:
0.10, 0.12, 0.15, 0.18, 0.30, 0.40, and
0.50 mm

Example:
S60C6345
If “T3” is 0.44 mm, then the pinion shim is
0.42 mm. NOTE:
If “T3” is 0.48 mm, then the pinion shim is “F” is the deviation of the lower case dimen-
0.45 mm. sion from standard. The “F” mark a is
stamped on the trim tab mounting surface of
Selecting the forward gear shims the lower case in 0.01 mm units. If the “F”
1. Turn the taper roller bearing outer race mark unreadable, assume that “F” is zero
1 two or three times to seat the rollers, and check the backlash when the unit is
and then measure the bearing height assembled.
(M1) as shown.

6-27 60C5D11

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 Shimming (F100B)

Calculation formula: NOTE:

Forward gear shim thickness (T1) = • Select the shim thickness (T2) by using the
24.60 + F/100 – M1 specified measurement(s) and the calcula-

Example:
If “M1” is 24.10 mm and “F” is (+5), then
tion formula.
• Measure the reverse gear at three points to
find the height average.
• Remove the O-ring when the measure-
1
T1 = 24.60 + (+5)/100 – 24.10 mm
ment.

2
= 24.60 + 0.05 – 24.10 mm
= 0.55 mm
Shimming plate 2: 90890-06701
3. Select the forward gear shim(s) (T1) as
Digital caliper 3: 90890-06704
follows.

Calculated numeral
at 1/100 place
1, 2
Rounded numeral

0
2. Calculate the reverse gear shim thick-
ness (T2) as shown in the examples
below.
3
3, 4, 5 2
6, 7, 8
9, 10
5
8
R-1
F+5
P+2
4
Available shim thicknesses:
0.10, 0.12, 0.15, 0.18, 0.30, 0.40, and
0.50 mm

Example:
S60C6360
5
If “T1” is 0.55 mm, then the forward gear NOTE:
shim is 0.52 mm.
If “T1” is 0.60 mm, then the forward gear
shim is 0.58 mm.
“R” is the deviation of the lower case dimen-
sion from standard. The “R” mark a is
stamped on the trim tab mounting surface of
the lower case in 0.01 mm units. If the “R”
6
Selecting the reverse gear shims mark unreadable, assume that “R” is zero
1. Turn the reverse gear 1 two or three
times, and then measure the reverse
gear height (M2) as shown.
and check the backlash when the unit is
assembled. 7
Calculation formula:
Reverse gear shim thickness (T2) =
M2 – 27.40 – R/100

Example:
8
If “M2” is 27.95 mm and “R” is (+2), then
T2 = 27.95 – 27.40 – (+2)/100 mm
= 27.95 – 27.40 – 0.02 mm
= 0.53 mm 9
60C5D11 6-28

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 LOWR
Lower unit
3. Select the reverse gear shim(s) (T2) as 3. Install the special service tool so that it
follows. pushes against the propeller shaft.

Calculated numeral
Rounded numeral
at 1/100 place
1, 2 2
3, 4, 5 5
6, 7, 8 8
9, 10 10

Available shim thicknesses:

0.10, 0.12, 0.15, 0.18, 0.30, 0.40, and
NOTE:
0.50 mm Tighten the center bolt while turning the drive
shaft until the drive shaft can no longer be
Example: turned.
If “T2” is 0.53 mm, then the reverse gear
shim is 0.55 mm.
If “T2” is 0.50 mm, then the reverse gear Bearing housing puller claw L 1:
shim is 0.50 mm. 90890-06502
Stopper guide plate 2: 90890-06501
Backlash (F100B) 6
Center bolt 3: 90890-06504
Measuring the forward and reverse
gear backlash 4. Install the backlash indicator onto the
1. Remove the water pump assembly. drive shaft (22.4 mm [0.88 in] in diame-
ter), then the dial gauge onto the lower
2. Set the gearshift to the neutral position. unit.

5. Set the lower unit upside down.

Shift rod push arm: 90890-06052

NOTE:
Install the dial gauge so that the plunger a
contacts the mark b on the backlash indica-
tor.

6-29 60C5D11

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 Shimming (F100B) / Backlash (F100B)

Backlash indicator 4: 90890-06706 NOTE:

Magnet base plate 5: 90890-07003 Tighten the propeller nut B while turning the
Dial gauge set 6: 90890-01252 drive shaft until the drive shaft can no longer
Magnet base 7: 90890-06705

6. Slowly turn the drive shaft clockwise and

be turned.

10. Slowly turn the drive shaft clockwise and

1
counterclockwise and measure the back- counterclockwise, and measure the

2
lash when the drive shaft stops in each backlash when the drive shaft stops in
direction. each direction.

Forward gear backlash:

0.19–0.53 mm (0.007–0.021 in)

7. Add or remove shims if out of specifica-

tion. 3
Forward gear
Shim thickness

4
backlash
Less than To be decreased by
0.19 mm (0.007 in) (0.36 – M) × 0.58

More than To be increased by

(M – 0.36) × 0.58

5
0.53 mm (0.021 in)

M: Measurement
Reverse gear backlash:
Available shim thicknesses: 0.86–1.26 mm (0.034–0.050 in)
0.10, 0.12, 0.15, 0.18, 0.30, 0.40, and
0.50 mm

8. Remove the special service tools from

11. Add or remove shims if out of specifica-
tion.

Reverse gear
6
the propeller shaft. Shim thickness
backlash
9. Apply a load to the reverse gear by
installing the propeller 8, the spacer 9
(without the washer 0), then the washer
Less than
0.86 mm (0.034 in)
More than
To be increased by
(1.06 – M) × 0.58
To be decreased by
7
A as shown. (M – 1.06) × 0.58
1.26 mm (0.050 in)

M: Measurement

Available shim thicknesses:

8
0.10, 0.12, 0.15, 0.18, 0.30, 0.40, and
0.50 mm

12. Remove the special service tools, and

then install the water pump assembly.
9
60C5D11 6-30

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 LOWR
Lower unit
Lower unit (F100C) 6

7 N • m (0.7 kgf • m, 5.1 ft • Ib)

T.
R.

9
2

3
34 N • m (3.4 kgf • m, 25 ft • Ib)

T.
R.
10 17
A 18
16
M
LT
8 572
8
4
5
15

14
13

11
12
D

5
7 LT
6 572

7 N • m (0.7 kgf • m, 5.1 ft • Ib)

T.
R.

39 N • m (3.9 kgf • m, 28 ft • Ib)

T.
R.

S60C6385

6-31 60C5D11

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 Lower unit (F100C)
No. Part name Q’ty Remarks
1 Lower unit 1
2 Plastic tie 1 Not reusable
3
4
5
Hose
Check screw
Gasket
1
1
2
7 × 200 mm

Not reusable
1
6 Bolt 4 M10 × 40 mm
7
8
9
Drain screw
Dowel pin
Grommet
1
2
1
2
10 Bolt 1 M8 × 45 mm
11
12
13
Trim tab
Bolt
Spacer
1
1
1
M8 × 60 mm 3
14 Propeller 1
15
16
17
Washer
Spacer
Propeller nut
1
1
1
4
18 Cotter pin 1 Not reusable

5
6
7
8
9
60C5D11 6-32

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 LOWR
Lower unit

8
9
10 11
LT
572
12 LT

13 572
A
A
2 4 14
3
A
15
LT

5 572
16
A
6 17
18
A

19
17
7 20
1
21

22

A
23
24

25

S60C6400

6-33 60C5D11

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 Lower unit (F100C)
No. Part name Q’ty Remarks
1 Shift rod 1
2 O-ring 1 Not reusable

3
4
Oil seal
Bolt
1
2
1.9 × 10.6 mm
Not reusable
M6 × 16 mm
1
5 Oil seal housing 1
6

7
8
O-ring

Circlip
Screw
1

1
2
Not reusable
3.1 × 55.6 mm
2
3
9 Cover 1
10 Bolt 2 M8 × 75 mm
11 Bolt 2 M8 × 50 mm
12 Seal 1

4
13 Water pump housing 1
14 Inner plate cartridge 1
15 Insert cartridge 1
16 Impeller 1

5
17 Dowel pin 2
18 Gasket 1 Not reusable
19 Outer plate cartridge 1
20 Gasket 1 Not reusable

6
21 Oil seal housing 1
22 O-ring 1 Not reusable
3.1 × 52.4 mm
23 Gasket 1 Not reusable
24 Oil seal 2 Not reusable
25 Woodruff key 1
7
8
9
60C5D11 6-34

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 LOWR
Lower unit
Removing the lower unit
1. Drain the gear oil. For draining proce-
dures, see Chapter 3, “Changing the
gear oil.”

2. Set the gearshift to the neutral position,

and place a block of wood between the
anti-cavitation plate and propeller to keep
the propeller from turning, and then
remove the propeller nut and propeller.

S60C6390

5. Loosen the bolts, and then remove the

lower unit from the upper case.
WARNING
Do not hold the propeller with your hands
when loosening or tightening it. Be sure
to remove the battery leads from the bat-
teries and the engine shut-off switch. Put
a block of wood between the anti-cavita-
tion plate and propeller to keep the pro-
peller from turning.

3. Disconnect the speedometer hose 1.

4. Mark the trim tab 2 at the area shown,

and then remove it.

S60C6395

NOTE:
Check that there is no oil on the spline and
check it for rust or wear. Check the oil pump
if necessary.

6-35 60C5D11

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 Lower unit (F100C)
Removing the water pump and shift 2. Check the impeller 1, inner plate car-
rod tridge 2 and insert plate cartridge 3 for
1. Remove the water pump assembly and cracks or wear. Replace if necessary.
shift rod assembly 1.

1
2
S60C6415

3. Check the Woodruff key 4 and the

groove a on the drive shaft for wear.
Replace if necessary.
3
S60C6405
4
NOTE:
Pull up the shift rod assembly a little a to dis-
connect it from the shift slider 2, turn it clock-
wise 90° b, and then remove it.
S60C6420
5
4. Check the shift rod for cracks or wear.
Checking the water pump and shift
rod
1. Check the pump housing for deforma-
Replace if necessary.
6
tion. Replace if necessary.

7
S60C6425

8
S60C6410

9
60C5D11 6-36

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 LOWR
Lower unit
Propeller shaft housing (F100C) 6

9 7
3 5

4 3 6
8 6
9

8
103 N • m (10.3 kgf • m, 74 ft • lb)

T.
R.
7
3
D
5
D
4
13
12

2
11
10
1

20 20

A
D

E
15
A
14 19
E

18
17
16
S60C6460

6-37 60C5D11

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 Propeller shaft housing (F100C)
No. Part name Q’ty Remarks
1 Propeller shaft assembly 1
2 Propeller shaft housing assembly 1
3
4
5
Ball
Slider
Shift plunger
2
1
1
1
6 Cross pin 1
7
8
9
Dog clutch
Spring
Propeller shaft
1
1
1
2
10 Washer 1
11
12
13
Straight key
Claw washer
Ring nut
1
1
1
3
14 Reverse gear 1
15
16
17
Thrust washer
Ball bearing
O-ring
1
1
1 Not reusable
4
5.5 × 97.8 mm
18
19
20
Propeller shaft housing
Needle bearing
Oil seal
1
1
2 Not reusable
5
6
7
8
9
60C5D11 6-38

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 LOWR
Lower unit
Removing the propeller shaft
housing assembly
1. Straighten the claw washer tabs a, and
then remove the ring nut and claw
washer.

Bearing separator 1: 90890-06534

Ring nut wrench 3 1: 90890-06511 Stopper guide plate 2: 90890-06501
Ring nut wrench extension 2: Stopper guide stand 3:
90890-06513 90890-06538
Bearing puller 4: 90890-06535
2. Pull out the propeller shaft housing Bearing puller claw 1 5:
assembly. 90890-06536

NOTE:
Install the bearing separator 1 between the
reverse gear and thrust washer completely.

2. Remove the ball bearing.

Bearing housing puller claw L 3:

90890-06502
Stopper guide plate 4: 90890-06501
Center bolt 5: 90890-06504

Disassembling the propeller shaft

housing Stopper guide plate 6: 90890-06501
1. Remove the reverse gear and thrust Stopper guide stand 7:
washer. 90890-06538
Bearing puller 8: 90890-06535
Bearing puller claw 1 9:
90890-06536

3. Remove the oil seals and needle bear-

ing.

6-39 60C5D11

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 Propeller shaft housing (F100C)
2. Check the teeth and dogs of the reverse
gear for cracks or wear. Replace the
gear if necessary.

1
2
S60C6125

Needle bearing attachment 0:

90890-06612
3. Check the bearings for pitting or rum-
bling. Replace if necessary. 3
Driver rod L3 A: 90890-06652

Disassembling the propeller shaft

assembly
1. Remove the spring 1, and then remove
4
the cross pin 2, dog clutch 3, slider,
and shift plunger 4.
S60C6130 5
Checking the propeller shaft

6
1. Check the propeller shaft for bends or
wear. Replace if necessary.

Checking the propeller shaft housing

1. Clean the propeller shaft housing using a
7
soft brush and cleaning solvent, and then
check it for cracks. Replace if necessary.
8
9
60C5D11 6-40

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 LOWR
Lower unit
2. Check the dog clutch and shift slider for
cracks or wear. Replace if necessary.

Assembling the propeller shaft

assembly
1. Install the dog clutch as shown. NOTE:
• Install the needle bearing with the manufac-
ture identification mark a facing toward the
oil seal (propeller side).
• When using the driver rod, do not strike the
special tool in a manner that will force the
stopper b out of place.

Driver rod SS 1: 90890-06604

Needle bearing attachment 2:
90890-06612
Bearing depth plate 3: 90890-06603

Depth c:
25.0–25.5 mm (0.98–1.00 in)
NOTE:
Install the dog clutch 1 with the “F” mark a
2. Apply grease to the new oil seals, and
facing toward the shift slider.
then install them into the propeller shaft
housing to the specified depth.
Assembling the propeller shaft
housing
1. Install the needle bearing into the propel-
ler shaft housing to the specified depth.

6-41 60C5D11

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 Propeller shaft housing (F100C)
4. Install the reverse gear assembly to the
NOTE: propeller shaft housing using a press.
Install an oil seal halfway into the propeller
shaft housing, then the other oil seal.

Ball bearing attachment 4:

90890-06633
1
Driver rod LS 5: 90890-06606

Depth d: 4.5–5.5 mm (0.18–0.22 in)

2
3. Install the thrust washer 6 and ball bear-
ing 7 to the reverse gear 8 using a
press. 3
Bearing outer race attachment 0:
4
90890-06623

5
NOTE:
6
Install the ball bearing with the manufacture
identification mark e facing outward (propel-
ler side).
7
Ball bearing attachment 9:

8
90890-06631

9
60C5D11 6-42

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 LOWR
Lower unit
Drive shaft and lower case (F100C) 6

6-43 60C5D11

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 Drive shaft and lower case (F100C)
No. Part name Q’ty Remarks
1 Drive shaft 1
2 Taper roller bearing 1 Not reusable
3
4
5
Bearing outer race
Pinion shim
Sleeve
—
1

1
Not reusable
As required 1
6 Hose 1 7 × 300 mm
7
8
9
Plastic tie
Joint
Nut
1
1
1
Not reusable
2
10 Water inlet cover 2
11
12
13
Screw
Seal
Plate
1
1
1
3
14 Forward gear shim — As required
15
16
17
Bearing outer race
Taper roller bearing
Needle bearing
1
1
1
Not reusable
Not reusable 4
18 Forward gear 1
19
20
21
Needle bearing
Pinion
Nut
1
1
1
5
22 Lower case 1

6
7
8
9
60C5D11 6-44

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 LOWR
Lower unit
Removing the drive shaft Disassembling the forward gear
1. Remove the drive shaft assembly and 1. Remove the taper roller bearing from the
pinion, and then pull out the forward forward gear using a press.
gear.

S60C6525

S60C6190

CAUTION:
Drive shaft holder 5 1: 90890-06519 Do not reuse the bearing, always replace
Pinion nut holder 2: 90890-06505 it with a new one.
Socket adapter 2 3: 90890-06507

Disassembling the drive shaft Bearing separator 1: 90890-06534

1. Install the pinion nut 1, tighten it finger
tight, and then remove the drive shaft
bearing 2 using a press. 2. Remove the needle bearing from the for-
ward gear.

CAUTION:
CAUTION:
• Do not press the drive shaft threads a
directly. Do not reuse the bearing, always replace
• Do not reuse the bearing, always it with a new one.
replace it with a new one.
Stopper guide plate 2: 90890-06501
Bearing inner race attachment 3: Stopper guide stand 3:
90890-06639 90890-06538
Bearing puller 4: 90890-06535
Bearing puller claw 2 5:
90890-06537

6-45 60C5D11

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 Drive shaft and lower case (F100C)
Disassembling the lower case 3. Remove the needle bearing.
1. Remove the taper roller bearing outer
race and shim(s).

1
2
Needle bearing attachment 7:
90890-06611
NOTE:
Install the claws as shown.
Driver rod L3 8: 90890-06652

Checking the pinion and forward

3
Bearing outer race puller 1: gear
90890-06523
Outer race puller claw A 2:
90890-06532
1. Check the teeth of the pinion, and the
teeth and dogs of the forward gear for
cracks or wear. Replace if necessary.
4
2. Remove the drive shaft bearing outer
race, shim(s), and drive shaft sleeve.
5
S60C6220
6
Checking the bearings

NOTE:
Install the claws as shown.
1. Check the bearings for pitting or rum-
bling. Replace if necessary.
7
Stopper guide plate 3: 90890-06501
Stopper guide stand 4:
90890-06538
8
Bearing puller 5: 90890-06535
Bearing puller claw 1 6:
90890-06536

Checking the drive shaft

S60C6545
9
1. Check the drive shaft for bends or wear.
Replace if necessary.

60C5D11 6-46

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 LOWR
Lower unit

Depth c:
187.6–188.6 mm (7.39–7.43 in)

2. Install the sleeve, original shim(s), and

drive shaft bearing outer race.

Checking the lower case

1. Check the skeg and torpedo for cracks or
damage. Replace if necessary.

CAUTION:
Add or remove shims, if necessary, when
replacing the pinion or lower case.

Assembling the lower case

1. Install the needle bearing into the lower NOTE:
case to the specified depth. • Apply the gear oil to the inside and outside
of the sleeve.
• Install the sleeve by facing the projection d
forward.

Bearing outer race attachment 4:

90890-06626
Driver rod LS 5: 90890-06606

3. Install the original shim(s) and taper roller

bearing outer race.
NOTE:
• Install the needle bearing with the manufac-
ture identification mark a facing upward.
• When using the driver rod, do not strike the
special tool in a manner that will force the
stopper b out of place.

Driver rod SL 1: 90890-06602

Needle bearing attachment 2:
90890-06611
Bearing depth plate 3: 90890-06603

6-47 60C5D11

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 Drive shaft and lower case (F100C)
Assembling the drive shaft
CAUTION: 1. Install the new drive shaft bearing into
Add or remove shims, if necessary, when the drive shaft using a press.

1
replacing the forward gear or lower case.

Bearing outer race attachment 6:

90890-06621
Driver rod LL 7: 90890-06605

Assembling the forward gear

1. Install the new needle bearing into the
2
forward gear to the specified depth.

Bearing inner race attachment 1:

90890-06643 3
Installing the drive shaft
1. Install the forward gear to the lower case.

2. Install the drive shaft assembly, pinion,

and pinion nut, and then tighten the nut
4
to the specified torque.

Needle bearing attachment 1:

90890-06609
Driver rod L3 2: 90890-06652
5
Depth a: 1.2 mm (0.05 in)
6
2. Install the new taper roller bearing into S60C6270

7
the forward gear using a press.
NOTE:
Install the drive shaft by lifting it up slightly,
then aligning it with the pinion and the spline
of the drive shaft.

Drive shaft holder 5 1:

90890-06519
8
Pinion nut holder 2: 90890-06505
Socket adapter 2 3: 90890-06507

Bearing inner race attachment 3:

90890-06662
Pinion nut:
93 N·m (9.3 kgf·m, 67 ft·lb)
9
T.
R.

60C5D11 6-48

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 LOWR
Lower unit
Installing the propeller shaft housing
1. Install the washer 1, propeller shaft
assembly 2, into the propeller shaft
housing assembly 3.

2. Apply grease to the new O-rings.

NOTE:
Secure the ring nut by bending one tab a
into the slot in the ring nut and the other tabs
toward the propeller shaft housing assembly.

Ring nut wrench 3 8: 90890-06511

Ring nut wrench extension 9:
90890-06513

3. Install the propeller shaft housing assem- Ring nut 7:

bly 4 into the lower case, and then 103 N·m (10.3 kgf·m, 74 ft·lb)
T.
R.

install the straight key 5, claw washer

6, and ring nut 7. Installing the water pump and shift
rod
4. Tighten the nut to the specified torque.
1. Install the shift rod assembly 1.

LT
572

S60C6430

6-49 60C5D11

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 Drive shaft and lower case (F100C)

NOTE:
Install the shift rod assembly into the lower
case, turn it counterclockwise 90° a, and
then push it down b to connect it to the shift
slider 2. A
1
2. Install the new oil seals into the oil seal
housing as shown.
2
3
Ball bearing attachment 3:
90890-06636 S60C6440
4
Driver rod LS 4: 90890-06606

3. Install the new O-ring 5.

4. Install the new gasket 6, oil seal housing

5. Install the Woodruff key into the drive
shaft.

6. Align the groove on the impeller 0 with

5
7, new gasket 8, and outer plate car- the Woodruff key A, and then install it to
tridge 9. the drive shaft.

6
7
8
9
60C5D11 6-50

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 LOWR
Lower unit
7. Install the insert cartridge B and inner Installing the lower unit
plate cartridge C into the pump housing 1. Set the gearshift to the neutral position at
D. the power unit and lower unit.

S60C6450

NOTE:
Align the insert cartridge projections c with
the holes d in the pump housing.
S60C6275

8. Install the new gasket E, pump housing

assembly F, and dowel pins G to the
lower case.

9. Install and tighten the bolts H.

LT LT
572 572
2. Install the two dowel pins 1 to the lower
unit.
A

3. Install the lower unit to the upper case,

and then tighten the bolts to the specified
torque.

S60C6455

NOTE:
When installing the pump housing, apply
grease to the inside of the housing, and then
turn the drive shaft clockwise while pushing
down the pump housing.

6-51 60C5D11

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 Drive shaft and lower case (F100C)
5. Install the propeller and propeller nut,
and then tighten the nut finger tight.
Place a block of wood between the anti-

1
cavitation plate and propeller to keep the
propeller from turning, and then tighten
the nut to the specified torque.
M

2
3
LT
572
S60C6585
4
Mounting bolt:
39 N·m (3.9 kgf·m, 28 ft·lb)
5
T.
R.

4. Install the trim tab 2 to its original posi-

tion, and then connect the speedometer
hose 3.

WARNING
6
Do not hold the propeller with your hands
LT
572
when loosening or tightening it. Be sure
to remove the battery leads from the bat-
teries and the engine shut-off switch. Put
a block of wood between the anti-cavita-
7
tion plate and propeller to keep the pro-
peller from turning.

NOTE:
8
If the grooves in the propeller nut 4 do not

9
align with the cotter pin hole, tighten the nut
until they are aligned.

S60C6590 Propeller nut 4:

34 N·m (3.4 kgf·m, 25 ft·lb)
T.
R.

60C5D11 6-52

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 LOWR
Lower unit
Shimming (F100C) 6

6-53 60C5D11

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 Shimming (F100C)
Shimming 2. Install the pinion and pinion nut, and then
tighten the nut to the specified torque.
NOTE:
• Shimming is not required when assembling Pinion nut:
the original lower case and inner parts. 93 N·m (9.3 kgf·m, 67 ft·lb)
1

T.
R.
• Shimming is required when assembling the
original inner parts and a new lower case. 3. Measure the distance (M) between the
• Shimming is required when replacing the shimming tool and the pinion as shown.
inner part(s).

Selecting the pinion shims

1. Install the drive shaft and drive shaft
2
bearing 1 to the shimming tools.

3
NOTE:
Measure the pinion at three points to find the
clearance average.
4
Digital caliper 4: 90890-06704

4. Calculate the pinion shim thickness (T3)

5
as shown in the examples below.

F +5
6
NOTE:
• Select the shim thickness (T3) by using the
specified measurement(s) and the calcula-
R
P +5
7
tion formula.

8
S60C6620
• Install the shimming tool to the drive shaft
so that the shaft is at the center of the hole. NOTE:
• Tighten the wing nuts another 1/4 of a turn “P” is the deviation of the lower case dimen-
after they contact the fixing plate 2. sion from standard. The “P” mark a is
stamped on the trim tab mounting surface of

Pinion height gauge 3:

90890-06702
the lower case in 0.01 mm units. If the “P”
mark is unreadable, assume that “P” is zero
and check the backlash when the unit is
assembled.
9
60C5D11 6-54

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 LOWR
Lower unit

Calculation formula:
Pinion shim thickness (T3) =
M – 31.50 mm – P/100

Example:
If “M” is 32.10 mm and “P” is (+5), then
T3 = 32.10 – 31.50 – (+5)/100 mm
= 0.60 – 0.05 mm = 0.55 mm
If “M” is 32.10 mm and “P” is (–5), then
T3 = 32.10 – 31.50 – (–5)/100 mm
= 0.60 + 0.05 mm = 0.65 mm

5. Select the pinion shim(s) (T3) as follows.

Calculated numeral NOTE:

Rounded numeral • Select the shim thickness (T1) by using the
at 1/100 place
0, 1 2 specified measurement(s) and the calcula-
tion formula.
2, 3, 4 5
• Measure the bearing outer race at three
5, 6, 7 8 points to find height average.
8, 9 10

Shimming plate 2: 90890-06701

Available shim thicknesses: Digital caliper 3: 90890-06704
0.10, 0.12, 0.15, 0.18, 0.30, 0.40, and
0.50 mm 2. Calculate the forward gear shim thickness
(T1) as shown in the examples below.
Example:
If “T3” is 0.55 mm, then the pinion shim is
0.58 mm.
If “T3” is 0.65 mm, then the pinion shim is
0.68 mm. F +5

Selecting the forward gear shims R

1. Turn the taper roller bearing outer race P +5

1 two or three times to seat the rollers,

and then measure the bearing height (M) S60C6635

as shown.
NOTE:
“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 unreadable, assume that “F” is zero
and check the backlash when the unit is
assembled.

6-55 60C5D11

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 Shimming (F100C) / Backlash (F100C)
Backlash (F100C) 6

Calculation formula:
Measuring the forward gear backlash
Forward gear shim thickness (T1) =
1. Remove the water pump assembly.
24.50 + F/100 – M

Example:
If “M” is 24.00 mm and “F” is (+5), then
2. Set the gearshift to the neutral position.
1
T1 = 24.50 + (+5)/100 – 24.00 mm

2
= 0.50 + 0.05 mm = 0.55 mm
If “M” is 24.00 mm and “F” is (–5), then
T1 = 24.50 + (–5)/100 – 24.00 mm
= 0.50 – 0.05 mm = 0.45 mm

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

Calculated numeral
Rounded numeral Shift rod push arm: 90890-06052
at 1/100 place
1, 2
3, 4, 5
6, 7, 8
0
2
5
3. Install the special service tool so that it
pushes against the propeller shaft.
4
9, 10 8

Available shim thicknesses:

0.10, 0.12, 0.15, 0.18, 0.30, 0.40, and
0.50 mm
5
Example:
If “T1” is 0.55 mm, then the forward gear
shim is 0.52 mm.
If “T1” is 0.45 mm, then the forward gear
6
NOTE:
shim is 0.42 mm.

7
Tighten the universal puller or center bolt
while turning the drive shaft until the drive
Selecting the reverse gear shims shaft can no longer be turned.
NOTE:
The F100C does not contain reverse gear Bearing housing puller claw L 1:
shims, therefore shimming is not necessary. 90890-06502
Stopper guide plate 2: 90890-06501
Center bolt 3: 90890-06504
8
9
60C5D11 6-56

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 LOWR
Lower unit
4. Install the backlash indicator onto the 6. Add or remove shims if out of specifica-
drive shaft (20 mm [0.79 in] in diameter), tion.
then the dial gauge onto the lower unit.
Forward gear
Shim thickness
backlash
Less than To be decreased by
0.13 mm (0.005 in) (0.30 – M) × 0.56

More than To be increased by

0.47 mm (0.019 in) (M – 0.30) × 0.56

M: Measurement

Available shim thicknesses:

0.10, 0.12, 0.15, 0.18, 0.30, 0.40, and
0.50 mm

7. Remove the special service tools, and

then install the water pump assembly.

NOTE:
Install the dial gauge so that the plunger a
contacts the mark b on the backlash indica-
tor.

Backlash indicator 4: 90890-06706

Magnet base plate 5: 90890-07003
Dial gauge set 6: 90890-01252
Magnet base 7: 90890-06705

5. Slowly turn the drive shaft clockwise and

counterclockwise and measure the back-
lash when the drive shaft stops in each
direction.

Forward gear backlash:

0.13–0.47 mm (0.005–0.019 in)

6-57 60C5D11

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 BRKT

Bracket unit

Special service tools .....................................................................................7-1

Tiller handle .................................................................................................... 7-3 1

Bottom cowling .............................................................................................. 7-9

Upper case (F100B)......................................................................................7-11

Disassembling the oil pump..................................................................... 7-17
Checking the oil pump ............................................................................. 7-17
2
Assembling the oil pump .........................................................................7-17
Disassembling the oil pan........................................................................7-18
Checking the oil strainer ..........................................................................7-18
Assembling the oil pan ............................................................................7-18
Installing the upper case..........................................................................7-20
3
Swivel bracket and steering arm (F100B) .................................................. 7-21
Removing the steering arm ..................................................................... 7-23
Installing the steering arm ....................................................................... 7-23 4
Clamp brackets (F100B) .............................................................................. 7-25
Removing the clamp brackets .................................................................7-27
Installing the clamp brackets ................................................................... 7-27
Adjusting the trim sensor cam .................................................................7-28
5
Power trim and tilt unit (F100B) .................................................................. 7-29
Removing the power trim and tilt unit ......................................................7-30

Tilt cylinder and trim cylinder (F100B).......................................................7-31

6
Disassembling the tilt cylinder and trim cylinders .................................... 7-32

7
Checking the reservoir............................................................................. 7-33
Checking the tilt cylinder and trim cylinder .............................................. 7-33
Assembling the trim rams ........................................................................7-33
Installing the trim rams ............................................................................7-34
Assembling the tilt ram ............................................................................7-35
Installing the tilt ram................................................................................. 7-36

Gear pump (F100B) ......................................................................................7-37

Disassembling the gear pump .................................................................7-39
8
Checking the valves ................................................................................ 7-39
Checking the filters .................................................................................. 7-39
Checking the gear pump .........................................................................7-40
Assembling the pump housing ................................................................7-40
Installing the pump housing..................................................................... 7-41
9
60C5D11

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 BRKT
Power trim and tilt motor (F100B) ..............................................................7-42
Disassembling the power trim and tilt motor............................................7-44
Checking the power trim and tilt motor ....................................................7-45
Assembling the power trim and tilt motor ................................................ 7-46
Installing the power trim and tilt motor.....................................................7-47

Bleeding the power trim and tilt unit (F100B)............................................7-48

Not installed............................................................................................. 7-48
Checking the hydraulic pressure ............................................................. 7-49
Installing the power trim and tilt unit ........................................................ 7-51
Built-in...................................................................................................... 7-52

Upper case (F100C)......................................................................................7-53

Disassembling the oil pump..................................................................... 7-59
Checking the oil pump ............................................................................. 7-59
Assembling the oil pump .........................................................................7-59
Disassembling the oil pan........................................................................7-60
Checking the oil strainer ..........................................................................7-60
Assembling the oil pan ............................................................................7-60
Installing the upper case..........................................................................7-62

Swivel bracket and clamp brackets (F100C) ............................................. 7-63

Removing the steering arm ..................................................................... 7-64
Installing the steering arm ....................................................................... 7-64

Clamp brackets (F100C) .............................................................................. 7-65

Removing the clamp brackets .................................................................7-67
Installing the clamp brackets ................................................................... 7-67
Adjusting the trim sensor cam .................................................................7-68

Power trim and tilt unit (F100C) .................................................................. 7-69

Removing the power trim and tilt unit ......................................................7-70
Installing the power trim and tilt unit ........................................................ 7-70

Tilt cylinder and trim cylinder (F100C).......................................................7-71

Disassembling the tilt cylinder .................................................................7-75
Disassembling the trim cylinder...............................................................7-75
Checking the tilt cylinder and trim cylinder .............................................. 7-75
Assembling the trim cylinder.................................................................... 7-76
Assembling the tilt cylinder ...................................................................... 7-78

Gear pump (F100C) ......................................................................................7-80

Disassembling the gear pump .................................................................7-83
Checking the valves ................................................................................ 7-83
Checking the filters .................................................................................. 7-84
Checking the gear pump .........................................................................7-84
Assembling the gear pump...................................................................... 7-84

60C5D11

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 Power trim and tilt motor (F100C) ..............................................................7-86
Checking the power trim and tilt motor ....................................................7-87
Assembling the power trim and tilt motor ................................................ 7-87

Bleeding the power trim and tilt unit (F100C)............................................7-88

Not installed............................................................................................. 7-88
Built-in...................................................................................................... 7-89
1
Power trim and tilt electrical system.......................................................... 7-90
Checking the fuse....................................................................................7-91
Checking the power trim and tilt relay .....................................................7-91
Checking the power trim and tilt switch/trailer switch ..............................7-91
2
Checking the trim sensor.........................................................................7-91

3
4
5
6
7
8
9
60C5D11

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 BRKT
Bracket unit
Special service tools 7

Bearing inner race attachment Cylinder-end screw wrench

90890-06662 90890-06544

Up relief fitting Digital circuit tester

90890-06773 90890-03174

Down relief fitting

90890-06774

Hydraulic pressure gauge

90890-06776

Trim & tilt wrench

90890-06548

7-1 60C5D11

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 Special service tools
— MEMO —

1
2
3
4
5
6
7
8
9
60C5D11 7-2

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 BRKT
Bracket unit
Tiller handle 7

7-3 60C5D11

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 Tiller handle
No. Part name Q’ty Remarks
1 Tiller handle assembly 1
2 Wiring harness extension 1
3
4
5
Engine start switch lead
PTT switch coupler
Throttle cable
1
1
1
1
6 Bolt 1 M6 × 20 mm
7
8
9
Clamp
Shift cable
Clip
1
1
1
2
10 Nut 2
11
12
13
Cover
Bolt
Plate
1
1
1
M6 × 25 mm 3
14 Bolt 2 M6 × 25 mm
15
16
17
Retaining plate
Bolt
Plate
1
1
1
M6 × 25 mm 4
18 Friction plate 1
19
20
21
Friction piece
Nut
Collar
2
2
2
5
22 Bolt 2
23
24
25
Bolt
Nut
Washer
2
1
1
6
26 Bracket 1
27
28
29
Nut
Steering lock shaft
Steering lock knob
2
1
1
7
30 Washer 2

8
9
60C5D11 7-4

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 BRKT
Bracket unit

7-5 60C5D11

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 Tiller handle
No. Part name Q’ty Remarks
1 Tiller handle sub assembly 1
2 Screw 2 M6 × 10 mm
3
4
5
Shift lever cover
Bolt
Shift lever
1
1
1
M8 × 40 mm 1
6 Bushing 1
7
8
9
Washer
Bushing
Nut
1
2
1
2
10 Engine shut-off switch 1
11
12
13
Nut
Washer
Bracket
1
1
1
3
14 Collar 1
15
16
17
Wave washer
Washer
Bolt
1
1
1 M10 × 80 mm
4
18 Connector 2
19
20
21
Engine start switch housing
Engine start switch
Nut
1
1
1
5
22 Bolt 1 M6 × 25 mm
23
24
25
Screw
Bolt
Cover
1
1
1
M6 × 20 mm 6
26 Power trim and tilt switch 1
27
28
29
Screw
Screw
Throttle grip
7
2
1
M6 × 16 mm
M6 × 40 mm 7
30 Screw 1 M5 × 25 mm
31
32
33
Washer
Spring
Bushing
1
1
1
8
9
60C5D11 7-6

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 BRKT
Bracket unit

7-7 60C5D11

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 Tiller handle
No. Part name Q’ty Remarks
1 Tiller handle 1
2 Cotter pin 1 Not reusable
3
4
5
Friction adjusting knob
Grommet
Plastic tie
1
1
2 Not reusable
1
6 Cable clamp 1
7
8
9
Stay
Bolt
Throttle cable
1
1
1
M6 × 14 mm
Short
2
10 Clip 1
11
12
13
Throttle arm
Throttle arm shaft
Shift cable
1
1
1 Long
3
14 Shift cable bracket 1
15
16
17
Bolt
Clip
Frame
1
1
1
M6 × 20 mm
4
18 Screw 2 M5 × 14 mm
19
20
21
Bolt
Spring housing
Spring
1
1
1
M6 × 14 mm
5
22 Actuator 1
23
24
25
Roller
Bushing
Shift arm
1
1
1
6
26 Bolt 2 M6 × 30 mm
27
28
29
Throttle shaft
Friction piece
Nut
1
1
1
7
8
9
60C5D11 7-8

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 BRKT
Bracket unit
Bottom cowling 7

4
5
6
7
8
A
9
17
10
3
A
12
16
9
A
15

1 14
24 25 A
12 26
11 27
28 29
13 23
30
18 A

18 22 32
34 31
19 20
21
33
34

35
A

38
36
37

S60C7030

7-9 60C5D11

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 Bottom cowling
No. Part name Q’ty Remarks
1 Shift rod 1
2 Bottom cowling 1
3
4
5
Shift rod bracket
Bolt
Spring
1
1
1
1
6 Ball 1
7
8
9
Cotter pin
Washer
Bushing
1
1
2
Not reusable
2
10 Bolt 2 M6 × 25 mm
11
12
13
Grommet
Clip
Shift rod lever
1
2
1
3
14 Washer 1
15
16
17
Shift bracket
Bushing
Bolt
1
1
2 M6 × 40 mm
4
18 Bolt 4 M6 × 20 mm
19
20
21
Bracket
Trailer switch
Pilot water hose
1
1
1
5
22 Hook 2
23
24
25
Spring
Bolt
Washer
2
2
2
M6 × 12 mm 6
26 Lever 2
27
28
29
Wave washer
Bushing
Bolt
2
2
4 M6 × 30 mm
7
30 Plate 2
31
32
33
Bushing
Cowling lock lever
Bolt
2
2
4 M8 × 35 mm
8
34 Grommet 2
35
36
37
Grommet
Clamp
Bolt
1
1
1 M6 × 30 mm
9
38 Rubber seal 1

60C5D11 7-10

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 BRKT
Bracket unit
Upper case (F100B) 7

5 4
6
LT
572 4 N • m (0.4 kgf • m, 2.9 ft • Ib)

T.
R.
7

11 N • m (1.1 kgf • m, 8.0 ft • Ib)

T.
R.

8
10
A
9
10
E
2

13 12
E 12 14
13
A

11

53 N • m (5.3 kgf • m, 38 ft • Ib) 15

T.
R.

22

20 LT
572

23

17 18
16
19 21
A
73 N • m (7.3 kgf • m, 53 ft • lb) 18
T.
R.

S60C7040

7-11 60C5D11

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 Upper case (F100B)
No. Part name Q’ty Remarks
1 Upper case assembly 1
2 Oil pump body 1
3
4
5
Oil seal
Oil seal
Bolt
1
1
6
Not reusable
Not reusable
M6 × 45 mm
1
6 Screw 6 M6 × 10 mm
7
8
9
Cover
Gasket
Shaft
1
1
1
Not reusable 2
10 O-ring 2 Not reusable
11
12
13
Oil seal
Dowel pin
O-ring
1
2
2
Not reusable

Not reusable
3
1.9 × 22.9 mm
14
15
16
Damper
Nut
Nut
2
2
2
4
17 Washer 2
18
19
20
Ground lead
Grease nipple
Washer
1
1
2
5
21 Bolt 1 M6 × 10 mm
22
23
Mount cover
Bolt
2
4 M10 × 40 mm 6
7
8
9
60C5D11 7-12

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 BRKT
Bracket unit

7
T.
R. 26 N • m (2.6 kgf • m, 19 ft • Ib)
5 3

LT A

572 4
8 6
9
20 N • m (2.0 kgf • m, 14 ft • Ib)

T.
R.
LT
572

10
11
A

12

13
A 15
16
4 N • m (0.4 kgf • m, 2.9 ft • Ib)
17
T.
R.

14
17

A
A
20 18
23
19
24 21
22 S60C7045

7-13 60C5D11

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 Upper case (F100B)
No. Part name Q’ty Remarks
1 Muffler assembly 1
2 Upper case 1
3
4
5
Bolt
Washer
Plate
2
2
1
M12 × 193 mm
1
6 Upper mount 1
7
8
9
Bolt
Grommet
Bolt
3
1
4
M8 × 45 mm

M8 × 40 mm
2
10 Muffler seal 1
11
12
13
Rubber seal
Gasket
Screw
1
1
2
Not reusable
M6 × 15 mm
3
14 Baffle plate 1
15
16
17
Damper
Grommet
Dowel pin
1
1
2
4
18 Bolt 2 M14 × 235 mm
19
20
21
Washer
Rubber washer
Lower mount
2
2
2
5
22 Washer 2
23
24
Drive shaft bushing
Circlip
1
1 6
7
8
9
60C5D11 7-14

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 BRKT
Bracket unit

3
2

4
5
11 N • m (1.1 kgf • m, 8.0 ft • Ib)
6

T.
R.
LT
572
7

LT
572

9 10
11 13
12
A
LT
572

11 N • m (1.1 kgf • m, 8.0 ft • Ib)

T.
R.

14
15

16
20 16
LT
21 18 572

17

A
22
LT
572
23 19 S60C7050

7-15 60C5D11

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 Upper case (F100B)
No. Part name Q’ty Remarks
1 Exhaust guide 1
2 Dowel pin 2
3
4
5
Gasket
Gasket
Oil strainer
1
1
1
Not reusable
Not reusable 1
6 Collar 3
7
8
9
Bolt
Bolt
Oil pan
3
12
1
M6 × 25 mm
M6 × 25 mm 2
10 Gasket 1 Not reusable
11
12
13
Exhaust manifold
Bolt
Exhaust seal
1
4
1
M6 × 70 mm 3
14 Gasket 2 Not reusable
15
16
17
Plate
Dowel pin
Bolt
1
2
6 M6 × 30 mm
4
18 Muffler 1
19
20
21
Bolt
Spacer
Grommet
1
1
1
M6 × 50 mm
5
22 Pipe 1
23 Rubber seal 1
6
7
8
9
60C5D11 7-16

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 BRKT
Bracket unit
Disassembling the oil pump
1. Remove oil seals 1 and 2, the cover 3,
gasket 4, shaft 5, and O-rings 6.

S60C7060

Bearing inner race attachment:

90890-06662

2. Install the new oil seal 3 into the oil

pump body 4.

D
d

T
A

S60C7055

Checking the oil pump

1. Check the shaft for cracks or wear.
Replace if necessary.

S60C7065

S60C7280
NOTE:
2. Check the oil seal and O-ring for tears. Use a general pipe with the specified mea-
Replace if necessary. surements.

3. Check the oil passage for dirt or residue.

General pipe 5:
Clean if necessary.
D = 43 mm (1.69 in)
d = 40 mm (1.57 in)
Assembling the oil pump
T = 30 mm (1.18 in)
1. Install the new oil seal 1 into the cover
2.

7-17 60C5D11

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 Upper case (F100B)
3. Install the O-rings 6 into the shaft 7.

4. Install the gasket 8 and the cover 2,

and then tighten the screws to the speci-
fied torque.
1
2
A
3
A
E

4
E

S60C7070
5
Oil pump cover screw:
4 N·m (0.4 kgf·m, 2.9 ft·lb)
6
T.
R.

S60C7075

Disassembling the oil pan Checking the oil strainer

1. Remove the muffler 1 and plate 2 from 1. Check the oil strainer for dirt and residue.
the oil pan 3.

2. Remove the exhaust manifold 4 from

the oil pan 3.
Clean if necessary.

Assembling the oil pan

7
1. Install the gaskets onto the exhaust
guide 1.
3. Remove the oil pan 3 from the exhaust
guide 5.

4. Remove the oil strainer 6.

2. Install the oil strainer 2 and bolts, and
then tighten the bolts to the specified
8
torque.

9
60C5D11 7-18

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 BRKT
Bracket unit
7. Install the water pipe 9.

S60C7080 A

Oil strainer bolt:

11 N·m (1.1 kgf·m, 8.0 ft·lb)
T.
R.

3. Install the oil pan 3 and then tighten the

bolts finger tight. LT
572

4. Install the exhaust manifold 4 and bolts,

and then tighten the bolts finger tight. S60C7090

A 8. Install the muffler assembly 0 by insert-

ing the tip of the water pipe A into the
LT
joint hole a of the upper case.
572
9. Install the muffler assembly bolts B, and
then tighten them to the specified torque.

LT
572

LT
572
A

S60C7085

A
5. Tighten the exhaust manifold bolts 5,
then the oil pan bolts 6, and then tighten
them to the specified torques.

Exhaust manifold bolt 5:

11 N·m (1.1 kgf·m, 8.0 ft·lb)
T.
R.

Oil pan bolt 6:

11 N·m (1.1 kgf·m, 8.0 ft·lb)

6. Install the plate 7 and the muffler 8 into S60C7095

the oil pan.

7-19 60C5D11

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 Upper case (F100B)
6. Install the upper mounting nut 7 and
Muffler assembly bolt B: lower mounting nut 8, and then tighten
20 N·m (2.0 kgf·m, 14 ft·lb)
T.

them to the specified torques.

R.

Installing the upper case

1. Install the upper mount 1 and bolts 2
into the upper case.
NOTE:
Before tightening the lower mounting nut, be
sure to connect the ground lead to the lower
mounting bolt.
1
2. Install the bolts 3, and then tighten them
to the specified torque. 7. Install the oil pump assembly 9.
2
LT
572 A 3
4
Upper mount bolt 3:
26 N·m (2.6 kgf·m, 19 ft·lb)
S60C7100

5
T.
R.

A
S60C7110
3. Install the lower mounts 4 to the upper
case. Upper mounting nut 7:
53 N·m (5.3 kgf·m, 38 ft·lb)
6
T.
R.

4. Install the mount cover 5. Lower mounting nut 8:

73 N·m (7.3 kgf·m, 53 ft·lb)
Oil pump bolt 0:
11 N·m (1.1 kgf·m, 8.0 ft·lb) 7
A

8
9
LT
572

S60C7105

5. Install the upper and lower mounting

bolts into the swivel bracket 6 simulta-
neously.

60C5D11 7-20

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 BRKT
Bracket unit
Swivel bracket and steering arm (F100B) 7

10

11
A

3
A
12
13

A 15

A
17

13
21
22 19 14
20
19 4
18
23
A 16
3

A A

5
6
7
8

S60C7115

7-21 60C5D11

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 Swivel bracket and steering arm (F100B)
No. Part name Q’ty Remarks
1 Steering arm 1
2 Washer 1
3
4
5
Bushing
Swivel bracket
O-ring
2
1
1 Not reusable
1
5.6 × 48.2 mm
6
7
8
Bushing
Washer
Steering yoke
1
1
1
2
9 Circlip 1
10
11
12
Steering hook
Nut
Starboard tilt stop lever
1
2
1
3
13 Bushing 2
14
15
16
Port tilt stop lever
Nut
Trim stopper
1
2
2 M10 × 27 mm
4
17 Pin 2
18
19
20
Tilt stop lever joint
Bushing
Collar
1
2
1
5
21 Spring 1
22
23
Spring holder
Bolt
1
1 M6 × 10 mm 6
7
8
9
60C5D11 7-22

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 BRKT
Bracket unit
Removing the steering arm 3. Install the bushing 5, O-ring 6, bushing
1. Remove the circlip 1. 7, and washer 8 onto the swivel
bracket.
2. Remove the steering yoke 2 by striking
it with a plastic hammer.

S60C7120

3. Remove the steering arm from the swivel

bracket by pulling the arm off the bracket.

Installing the steering arm

1. Install the washer 1 and bushing 2 onto
the steering arm 3.

2. Place the swivel bracket 4 in an upright

position, and then install the steering arm
onto the swivel bracket.

7-23 60C5D11

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 Swivel bracket and steering arm (F100B)
4. Install the steering arm 3 into the steer-
ing yoke 9 by aligning the center a of
the yoke with the center b of the steer-

1
ing arm.

5. Install the circlip 0.

2
3
S60C7145

4
6. Inject grease into the grease nipple until
grease comes out from both the upper
5
and lower bushings c.

6
A

7
S60C7140

8
9
60C5D11 7-24

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 BRKT
Bracket unit
Clamp brackets (F100B) 7

15 N • m (1.5 kgf • m, 11 ft • Ib)

T.
R.

2 N • m (0.2 kgf • m, 1.4 ft • Ib)

T.
R.

24

S60C7150

7-25 60C5D11

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 Clamp brackets (F100B)
No. Part name Q’ty Remarks
1 Swivel bracket assembly 1
2 Starboard clamp bracket 1
3
4
5
Port clamp bracket
Self-locking nut
Grease nipple
1
1
6
1
6 Ground lead 1
7
8
9
Washer
Screw
Washer
1
1
2
M6 × 11 mm 2
10 Bushing 2
11
12
13
Trim sensor
Screw
Trim sensor cam
1
2
1
M6 × 15 mm 3
14 Screw 1 M6 × 24 mm
15
16
17
Clamp
Ground lead
Bolt
1
1
1 M6 × 20 mm
4
18 Anode 1
19
20
21
Bracket
Ground lead
Bolt
2
1
4 M6 × 30 mm
5
22 Through tube 1
23
24
Bolt
Cap
1
1
M8 × 20 mm
6
7
8
9
60C5D11 7-26

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 BRKT
Bracket unit
Removing the clamp brackets
1. Remove the power trim and tilt unit. For
removal procedures, see “Removing the
power trim and tilt unit” in this chapter.

2. Remove the anode 1.

LT
3. Loosen the self-locking nuts 2, bolt 3, 271

cap 4, and then remove clamp brackets

5 and 6. S60C7160

4. Remove the trim sensor 7. NOTE:

Adjust the trim sensor after installing the
power trim and tilt unit.

2. Assemble the clamp brackets and the

swivel bracket by installing the anode 2,
bolt 3, and self-locking nuts 4, then
tightening them to the specified torque.

Installing the clamp brackets

1. Install the trim sensor 1 onto the swivel
bracket assembly.

7-27 60C5D11

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 Clamp brackets (F100B)

Self-locking nut 4: Trim sensor resistance:

15 N·m (1.5 kgf·m, 11 ft·lb) Pink (P) – Black (B)
T.
R.

9–11 Ω at 20 °C (68 °F)

3. Install the power trim and tilt unit. For
installation procedures, see “Installing
the power trim and tilt unit” in this chap-
4. Tighten the screw 1. 1
ter. Trim sensor cam screw 1:

2
2 N·m (0.2 kgf·m, 1.4 ft·lb)

T.
R.
4. Inject grease into all grease nipples until
grease comes out from the bushings a. 5. Fully tilt the outboard motor up, and then
support it with the tilt stop lever.
A

3
A
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

S60C7170
should lose fluid pressure.

6. Measure the trim sensor resistance.

4
Check the trim sensor if out of specifica-
tion.

Trim sensor resistance:

Pink (P) – Black (B)
5
238.8–378.8 Ω at 20 °C (68 °F)
A

S60C7175 6
Adjusting the trim sensor cam
1. Fully tilt the outboard motor down.

2. Loosen the screw 1. 7

3. Adjust the position of the trim sensor cam
2 until the specified resistance is
obtained.
8
B

P
Gy
9
S60C7185

60C5D11 7-28

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 BRKT
Bracket unit
Power trim and tilt unit (F100B) 7

No. Part name Q’ty Remarks

1 Power trim and tilt unit 1
2 PTT motor lead 2
3 Shaft 1
4 Plastic tie 3 Not reusable
5 Circlip 1
6 Bolt 2 M8 × 16 mm
7 Washer 2
8 Shaft 1
9 Bushing 6
10 Bolt 1 M6 × 10 mm
11 Ground lead 1

7-29 60C5D11

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 Power trim and tilt unit (F100B)
Removing the power trim and tilt unit
1. Fully tilt the outboard motor up, and then
support it with the tilt stop lever 1.

1
2
WARNING
After tilting up the outboard motor, be
sure to support it with the tilt stop lever.
3
Otherwise, the outboard motor could sud-
denly lower if the power trim and tilt unit
should lose fluid pressure. NOTE:
To remove the power trim and tilt unit, lower
the tilt ram slightly.
4
NOTE:
If the power trim and tilt does not operate,
loosen the manual valve and tilt the outboard
motor up manually. 5
2. Loosen the plastic ties 2, and then pull
out the PTT motor lead 3.

3. Remove the bolt 4 and disconnect the

ground lead 5.
6
4. Remove the circlip 6, then the shaft 7.

5. Loosen the bolts 8, and then remove the

shaft 9.
7
6. Remove the power trim and tilt unit 0.
8
9
60C5D11 7-30

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 BRKT
Bracket unit
Tilt cylinder and trim cylinder (F100B) 7

130 N • m (13 kgf • m, 94 ft • lb)

T.
R.

1
A 13
16
15
13
14
15
16
18 19
17 A

18
7
8 9
19
4 7
10
100 N • m (10 kgf • m, 72 ft • lb) 8
T.
R.

5 5 2 80 N • m (8.0 kgf • m, 58 ft • Ib)

T.
R.
6 6
12 11
3
11
12

S60C7365

No. Part name Q’ty Remarks

1 Tilt ram 1
2 Trim piston assembly 2
3 Cylinder body 1
4 Free piston 1
5 Backup ring 1
6 O-ring 1 Not reusable
7 Dust seal 2 Not reusable
8 Seal 2 Not reusable
9 Trim cylinder end screw 2
10 O-ring 2 Not reusable
11 Backup ring 2
12 O-ring 2 Not reusable
13 Dust seal 1 Not reusable
14 Tilt cylinder end screw 1
15 O-ring 1 Not reusable
16 O-ring 1 Not reusable
17 Tilt piston 1
18 O-ring 1 Not reusable
19 O-ring 1 Not reusable

7-31 60C5D11

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 Tilt cylinder and trim cylinder (F100B)
Disassembling the tilt cylinder and
trim cylinders
1. Hold the power trim and tilt unit 1 in a
vise using aluminum plates a on both
sides.
1
Trim & tilt wrench: 90890-06548
S60C7435

2
S60C7425

2. Loosen the tilt cylinder end screw 2, and

5. Drain the power trim and tilt fluid.

6. Install the trim cylinder end screws 4

3
then remove it. and tighten them finger tight.

4
5
S60C7430

WARNING
Make sure that the rams are fully
extended before removing the end screw.
NOTE:
Cover the tilt cylinder with a clean cloth 5. 6
7. Remove the free piston 6.

Trim & tilt wrench: 90890-06548 7

3. Drain the fluid.

4. Loosen the trim cylinder end screws 3,

and then remove them. 8
WARNING
Never look into the tilt cylinder opening
because the free piston and power trim
9
and tilt fluid may be expelled out force-
fully.

60C5D11 7-32

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 BRKT
Bracket unit

NOTE:
To remove the free piston, blow compressed
air through the hole a while holding down
the cloth.

8. Remove the trim piston assemblies.

Checking the reservoir

1. Check the reservoir for cracks. Replace if
necessary. 4. Check the trim and tilt rams for bends or
excessive corrosion. Polish with #400–
600 grit sandpaper if there is light rust or
replace if necessary.

Checking the tilt cylinder and trim

cylinder S60C7460
1. Check the power trim and tilt unit for
cracks or corrosion. Replace if neces- Assembling the trim rams
sary. 1. Install the new seal 1 and dust seal 2
into the trim cylinder end screw 3.
2. Check the inner walls of the cylinder
body for scratches. Replace if necessary. 2. Install the new O-ring 4 onto the end
screw.

3. Install the backup ring 5 and new O-ring

6 to the trim ram 7.

4. Install the trim ram into the end screw.

3. Check the outer surface of the tilt piston

and free piston for scratches. Replace if
necessary.

7-33 60C5D11

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 Tilt cylinder and trim cylinder (F100B)
Installing the trim rams 5. Fill the trim cylinders c with the recom-
1. Hold the cylinder body 1 in a vise using mended fluid to the correct level as
aluminum plates a on both sides. shown.

1
2
S60C7500

2. Add the specified amount of the recom-

mended fluid through the cylinder body
hole b.
6. Add a small amount of the recommended
fluid though cylinder body holes d, e,
and f.
3
4
5
Recommended power trim and tilt

6
Recommended power trim and tilt
fluid: fluid:
ATF Dexron II ATF Dexron II
Fluid quantity:
30 cm3 (1.0 US oz, 1.1 Imp oz) 7. Install the trim piston assembly into the

3. Install the new O-ring 2 and backup ring

3 to the free piston 4.
trim cylinder, and then tighten the trim
cylinder end screw 5 to the specified
torque. 7
4. Push the free piston 4 into the tilt cylin-
der until it bottoms out.

8
S60C7525 9
60C5D11 7-34

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 BRKT
Bracket unit
4. Install new O-rings 6 and 7 into the tilt
WARNING piston 8.
Do not push the trim rams down while
installing them into the trim cylinders. 5. Install the balls 9, absorber valve pins
Otherwise, the power trim and tilt fluid 0, and spring A as shown.
may spurt out from the unit.
6. Install the tilt piston 8, washer B, and
nut C to the tilt ram 5, and then tighten
the nut to the specified torque.
Trim & tilt wrench: 90890-06548

Trim cylinder end screw 5:

80 N·m (8.0 kgf·m, 58 ft·lb)
T.
R.

Assembling the tilt ram

1. Install the new dust seal 1, and O-rings
2 and 3 into the tilt cylinder end screw
4.

A Tilt piston nut C:

100 N·m (10 kgf·m, 72 ft·lb)
T.
R.

S60C7565

2. Install the tilt cylinder end screw 4 to the

tilt ram 5.

3. Hold the tilt ram end in a vise using alu-

minum plates on both sides.

7-35 60C5D11

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 Tilt cylinder and trim cylinder (F100B)
Installing the tilt ram
1. Fill the tilt cylinder a with the recom- WARNING
mended fluid to the correct level as To prevent the power trim and tilt fluid

1
shown. from spurting out due to internal pres-
sure, the tilt ram should be kept at full
2. Add a small amount of the recommended length.
fluid through the cylinder body hole b as
shown.
NOTE:
Place the tilt cylinder end screw at the bottom
of the tilt ram and install the tilt piston assem-
bly into the tilt cylinder.
2
Trim & tilt wrench: 90890-06548
3
Trim cylinder end screw:

4
130 N·m (13 kgf·m, 94 ft·lb)

T.
R.
Recommended power trim and tilt
fluid:
ATF Dexron II

3. Install the tilt piston assembly into the tilt

cylinder, and then tighten the tilt cylinder
end screw 1 to the specified torque. 5
6
7
8
S60C7590 9
60C5D11 7-36

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 BRKT
Bracket unit
Gear pump (F100B) 7

7-37 60C5D11

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 Gear pump (F100B)
No. Part name Q’ty Remarks
1 Manual valve 1
2 Bolt 2 M5 × 16 mm
3
4
5
Ball
Shuttle piston
O-ring
2
2
2 Not reusable
1
6 Main valve 2
7
8
9
Ball
Bolt
Bolt
2
1
2
M8 × 85 mm
M8 × 24 mm
2
10 Circlip 1
11
12
13
O-ring
O-ring
Backup ring
1
1
1
Not reusable
Not reusable 3
14 Spring 1
15
16
17
Absorber valve pin
Ball
Up-relief valve seat
1
1
1
4
18 O-ring 1 Not reusable
19
20
21
O-ring
Ball
Pin
5
1
1
Not reusable
5
22 Valve seat 1
23
24
25
Down-relief valve
O-ring
Filter
1
1
2
Not reusable 6
26 Valve pin 1

7
8
9
60C5D11 7-38

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 BRKT
Bracket unit
Disassembling the gear pump 2. Check the valve seat 1, down-relief
1. Remove the main valves 1. valve 2, and valve pin 3 for dirt or resi-
due. Clean if necessary.

S60C7470

3. Check the shuttle pistons 4, main valves

S60C7420 5, and up-relief valve seat 6 for dirt or
residue. Clean if necessary.
WARNING
Never look into the pump housing open-
ing because the main valves and power
trim and tilt fluid may be expelled out
forcefully.

NOTE:
To remove the main valves, cover the pump
housing with a clean cloth 2, and then blow S60C7475

compressed air through holes a and b

while holding the cloth down. Checking the filters
1. Check the gear pump filter 1 and down-
relief valve filters 2 for dirt or residue.
Checking the valves Clean if necessary.
1. Check the operation of the tilt piston
absorber valves and the valves for dirt or
residue. Clean if necessary.

S60C7480

7-39 60C5D11

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 Gear pump (F100B)
Checking the gear pump 4. Install the balls (3.18 mm [0.125 in]) 9,
1. Check the gear pump assembly for dam- shuttle pistons 0, and balls (4.76 mm
age or excessive wear. Replace if neces- [0.187 in]) A into the gear pump.

1
sary.

2
3
S60C7490

Assembling the pump housing

1. Install the new O-ring 1, up-relief valve
seat 2, ball (3.18 mm [0.125 in]) 3,
absorber valve pin 4, and spring 5 into
the pump housing.
4
CAUTION:
Install all components in their original
direction and position for proper assem-
bly and operation.
5
6
NOTE:
Apply grease to the balls and shuttle pistons
to prevent them from falling out of the gear
2. Install the new O-rings 6 onto the main pump.
valves 7.

3. Install the main valves 7 and pump

gears 8 into the pump housing.
5. Install the gear pump B to the pump
housing, and then tighten the bolts C to
the specified torque.
7
NOTE:
Tighten the bolts evenly and make sure that
the pump gears turn smoothly. 8
Gear pump bolt C:
6 N·m (0.6 kgf·m, 4.3 ft·lb)
9
T.
R.

60C5D11 7-40

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 BRKT
Bracket unit
6. Install the new O-ring D to the down- 5. Install the manual valve A to the pump
relief valve E. housing, tighten it to the specified torque,
and then install the circlip B.
7. Install the filters F and down-relief valve
E into the pump housing as shown.

Installing the pump housing

1. Install the ball 1 and pin 2 into the valve
seat 3. Pump housing bolt 7:
9 N·m (0.9 kgf·m, 6.5 ft·lb)
T.
R.
2. Install the valve seat 3, new O-rings 4, Manual valve A:
and valve pin 5 into the cylinder body. 3 N·m (0.3 kgf·m, 2.2 ft·lb)

6. Install the new O-ring C and reservoir D

to the cylinder body, and then tighten the
bolts E to the specified torque.

7. Install the new O-ring F into the reser-

voir cap G, and then tighten the reservoir
cap finger tighten to the reservoir.

NOTE:
When installing the valve seat assembly,
make sure that the pin is on the tilt cylinder
side as shown.

3. Install the pump housing 6 to the cylin-

der body, and then tighten the bolts 7 to S60C7560

the specified torque.

Reservoir bolt E:
4. Install the new O-rings 8 and 9, and 5 N·m (0.5 kgf·m, 3.6 ft·lb)
T.
R.

backup ring 0 to the manual valve A.

7-41 60C5D11

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 Gear pump (F100B) / Power trim and tilt motor (F100B)
Power trim and tilt motor (F100B) 7

1
2
3
4
No. Part name Q’ty Remarks
5
1 Power trim and tilt motor 1
2
3
4
Reservoir
Reservoir cap
O-ring
1
1
1 Not reusable
6
5 O-ring 1 Not reusable
6
7
8
Bolt
Bolt
O-ring
3
4
1
M6 × 13 mm
M6 × 35 mm
Not reusable
7
9 Filter 1
10 Joint 1
8
9
60C5D11 7-42

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 BRKT
Bracket unit

No. Part name Q’ty Remarks

1 Screw 3 M4 × 15 mm
2 Yoke 1
3 Armature 1
4 O-ring 1 Not reusable
5 Screw 2 M4 × 10 mm
6 Brush holder 1
7 Brush 2 1
8 Brush 1 1
9 Brush holder 1
10 Brush spring 2
11 PTT motor base 1
12 Oil seal 1 Not reusable

7-43 60C5D11

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 Power trim and tilt motor (F100B)
Disassembling the power trim and
tilt motor
1. Remove the PTT motor screws.

2. Remove the lead holder 1 and spacer

2 from the yoke 3, and then slide them
towards the leads.
1
CAUTION:
2
Do not touch the bimetal a, otherwise the

3
operation of the breaker may be affected.

NOTE:
Hold the brush with a screwdriver as shown,
and then disconnect the PTT motor lead

4
CAUTION:
(blue).
• Keep the PTT motor leads inside the
yoke.
• Do not allow grease or oil to contact the
commutator.

NOTE:
Place a clean cloth over the end of the arma-
5
ture shaft and carefully pull the armature from

6
the yoke with a pair of pliers as shown.

3. Remove the screws 4, disconnect the

PTT motor leads 5, and then remove
the brush holders 6 and brushes 7.

7
8
S60C7640

9
60C5D11 7-44

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 BRKT
Bracket unit
Checking the power trim and tilt 4. Check the armature coil for continuity.
motor Replace if out of specifications.
1. Check the commutator for dirt or foreign
substances. Clean with #600 grit sand-
paper if necessary.

2. Check the commutator undercut for dirt

or foreign substances. Clean with com-
pressed air if necessary.

3. Measure the commutator diameter a.

Replace if out of specification.

Armature coil continuity

Commutator segments b Continuity

Segment-laminations c No continuity
Segment-shaft d No continuity

5. Check the brush for continuity. Replace if

there is no continuity.

Commutator diameter limit a:

21 mm (0.83 in)

CAUTION:
Do not touch the bimetal e, otherwise the
operation of the breaker may be affected.

7-45 60C5D11

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 Power trim and tilt motor (F100B)
6. Measure the brush length. Replace if out Assembling the power trim and tilt
of specification. motor
1. Install the oil seal 1 into the motor base
2 as shown.

1
2
Brush length limit f:
4.8 mm (0.19 in)

7. Check the base for cracks or damage.

2. Install the brush holders 3, brushes 4,
PTT motor leads 5, and screws 6 to the
3
Replace if necessary. motor base as shown.

8. Check the bearing 1 and oil seal for

damage or wear. Replace the PTT motor
base if necessary.
4
5
S60C7680
3. Install the brush springs into the motor
base, and push the brushes 4 into the
holders, and then install the armature 7.
6
7
8
4. Install the new O-ring and yoke 8 to the
motor base.
9
60C5D11 7-46

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 BRKT
Bracket unit
3. Remove all of the air bubbles with a
syringe or suitable tool.

NOTE:
Turn the joint with a screwdriver, and then
remove any air between the pump gear teeth.

4. Install the new O-ring 3, power trim and

tilt motor 4, and then tighten the bolts 5
to the specified torque.
NOTE:
Place a clean cloth over the end of the arma-
ture shaft, hold the shaft with a pair of pliers
as shown, then carefully slide the yoke onto
the armature.

Installing the power trim and tilt

motor
1. Install the filter 1 and joint 2 into the
pump housing.
NOTE:
Align the armature shaft with the recess in
the joint.

PTT motor bolt 5:

5 N·m (0.5 kgf·m, 3.6 ft·lb)
T.
R.

5. Remove the reservoir cap.

6. Fill the reservoir b with the recom-

mended fluid to the brim of the filler hole
2. Fill the pump housing a with the recom-
as shown.
mended fluid to the correct level as
shown.

Recommended power trim and tilt

fluid:
Recommended power trim and tilt
ATF Dexron II
fluid:
ATF Dexron II

7-47 60C5D11

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 Power trim and tilt motor (F100B) / Bleeding the power trim and tilt unit (F100B)
7. Install the reservoir cap, and then tighten 2. Place the power trim and tilt unit in an
it to the specified torque. upright position.

Reservoir cap: 3. Check the fluid level in the reservoir.

7 N·m (0.7 kgf·m, 5.1 ft·lb)
1
T.
R.

NOTE:
The fluid level should be at the brim of the
Bleeding the power trim and tilt filler hole.
unit (F100B)

2
7

Not installed
1. Tighten the manual valve 1 by turning it 4. If necessary, add sufficient fluid of the
recommended type to the correct level.
clockwise.
Recommended power trim and tilt
fluid:
ATF Dexron II

5. Install the reservoir cap.

3
6. Connect the PTT motor leads 2 to the
battery terminals.
4
S60C7615
5
6
7
Ram PTT motor lead
Battery
8
terminal

Up

Down
Blue (L)
Green (G)
Green (G)
+
-
+
9
Blue (L) -

60C5D11 7-48

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 BRKT
Bracket unit
7. Reverse the PTT motor leads between 4. Remove the manual valve 2, and install
the battery terminals to fully extend the the up relief fitting 3 and hydraulic pres-
tilt ram and trim rams, and then reverse sure gauge 4, and then tighten them to
them again to fully retract the rams. the specified torques.

NOTE:
• Repeat this procedure so that the rams go
up and down four to five times (be sure to
wait a few seconds before switching the
leads).
• The sound of the power trim and tilt motor
will change when the rams are fully
extended.
• If the rams do not move up and down eas-
ily, push and pull on the rams to assist
operation.

8. Check the fluid level again when the

rams are fully extended. Add sufficient
fluid, if necessary, and then repeat step
7.

NOTE:
Repeat this procedure until the fluid remains
at the correct level. NOTE:
Be sure to remove the manual valve, and
then quickly attach the special tools before
Checking the hydraulic pressure
any fluid comes out.
1. Check the hydraulic pressure. Check the
internal parts if out of specification.
Up relief fitting 3: 90890-06773
2. Fully extend the power trim and tilt rams. Hydraulic pressure gauge 4:
90890-06776
3. Remove the circlip 1.

Up relief fitting:
4 N·m (0.4 kgf·m, 2.9 ft·lb)
T.
R.

Hydraulic pressure gauge:

9 N·m (0.9 kgf·m, 6.5 ft·lb)

7-49 60C5D11

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 Bleeding the power trim and tilt unit (F100B)
5. Connect the PTT motor leads to the bat- 7. After measuring the hydraulic pressure,
tery terminals to fully retract the trim and remove the special tools and quickly
tilt rams. attach the down relief fitting 5.

1
2
Hydraulic pressure gauge 4:
90890-06776
Down relief fitting 5: 90890-06774
3
T.
R.
Hydraulic pressure gauge:
9 N·m (0.9 kgf·m, 6.5 ft·lb)
Down relief fitting:
4 N·m (0.4 kgf·m, 2.9 ft·lb)
4
Ram

Up
PTT motor lead

Blue (L)
Battery
terminal
+
8. Reverse the PTT motor leads between
the battery terminals to fully retract the
trim and tilt rams, and then measure the
5
Green (G) - hydraulic pressure.

Down
Green (G)
Blue (L)
+
-
Hydraulic pressure (down):
5.9–8.8 MPa (60–90 kgf/cm2) 6
6. Reverse the PTT motor leads between 9. After measuring the hydraulic pressure,
the battery terminals to fully extend the
trim and tilt rams, and then measure the
hydraulic pressure.
connect the PTT motor leads to the bat-
tery terminals to fully extend the trim and
tilt rams. 7
Hydraulic pressure (up):
7.9–9.8 MPa (80–100 kgf/cm2)

8
9
60C5D11 7-50

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 BRKT
Bracket unit
10. Remove the special tools. Installing the power trim and tilt unit
1. Fully tilt the outboard motor up, and then
11. Install the manual valve and circlip. support it with the tilt stop lever 1.

S60C7705

12. Remove the reservoir cap, and then WARNING

check the fluid level in the reservoir.
After tilting up the outboard motor, be
sure to support it with the tilt stop lever.
13. If necessary, add fluid of the recom-
Otherwise, the outboard motor could sud-
mended type to the correct level.
denly lower if the power trim and tilt unit
should lose fluid pressure.

2. Install the shaft 2 and bolts 3 onto both

clamp brackets together with the power
trim and tilt unit 4.

3. Install the tilt ram upper end into the

swivel bracket with the shaft 5 and cir-
clip 6.
NOTE:
4. Connect the ground lead 7.
The fluid level should be at the brim of the
filler hole.

Recommended power trim and tilt

fluid:
ATF Dexron II

14. Install the reservoir cap.

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 Bleeding the power trim and tilt unit (F100B)
Built-in 8. If necessary, add sufficient fluid of the
1. Loosen the manual valve by turning it recommended type to the correct level.
counterclockwise until it cannot be turned

1
further.

S60C7715
2
NOTE:

2. Fully tilt the outboard motor up, and then

release it and let it lower by its own
The fluid level should be at the brim of the
filler hole. 3
weight four to five times. Recommended power trim and tilt
3. Tighten the manual valve by turning it
clockwise.
fluid:
ATF Dexron II

9. Install the reservoir cap.

4
4. Let the fluid settle for 5 minutes.

5. Push and hold the power trim and tilt

switch in the up position until the out-
board motor is fully tilted up.
NOTE:
Repeat this procedure until the fluid remains
at the correct level.
5
6. Support the outboard motor with the tilt
stop lever, and then let the fluid settle for
5 minutes.

WARNING
6
7
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.

7. Remove the reservoir cap 1, and then

check the fluid level in the reservoir.
8
9
60C5D11 7-52

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 BRKT
Bracket unit
Upper case (F100C) 7

3
11 N • m (1.1 kgf • m, 8.0 ft • Ib)
T.
R.

4
6
5
4 N • m (0.4 kgf • m, 2.9 ft • Ib)

T.
R.
LT
7
572

10 A
9
10
E
2 12
13
12 14
13
E

11

53 N • m (5.3 kgf • m, 38 ft • Ib) 15

T.
R.

20

16 17 18
19 21
A
18
53 N • m (5.3 kgf • m, 38 ft • Ib)
T.
R.

S60C7190

7-53 60C5D11

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 Upper case (F100C)
No. Part name Q’ty Remarks
1 Upper case assembly 1
2 Oil pump body 1
3
4
5
Oil seal
Oil seal
Bolt
1
1
6
Not reusable
Not reusable
M6 × 45 mm
1
6 Screw 6 M6 × 10 mm
7
8
9
Cover
Gasket
Shaft
1
1
1
Not reusable 2
10 O-ring 2 Not reusable
11
12
13
Oil seal
Dowel pin
O-ring
1
2
2
Not reusable

Not reusable
3
1.9 × 22.9 mm
14
15
16
Damper
Nut
Nut
2
2
2
4
17 Washer 2
18
19
20
Ground lead
Grease nipple
Washer
1
1
2
5
21 Bolt 1 M6 × 10 mm

6
7
8
9
60C5D11 7-54

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 BRKT
Bracket unit

26 N • m (2.6 kgf • m, 19 ft • Ib)

7
5
T.
R.

LT 3
572
A
4
8 6 9
20 N • m (2.0 kgf • m, 14 ft • Ib)

T.
R.
LT
572

10

A
11
12
4 N • m (0.4 kgf • m, 2.9 ft • Ib)
T.
R.

13

A 15 14
16
17

17

25
A
A
LT

23 18 572

24 19 26
20
21
22 S60C7195

7-55 60C5D11

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 Upper case (F100C)
No. Part name Q’ty Remarks
1 Muffler assembly 1
2 Upper case 1
3
4
5
Bolt
Washer
Plate
2
4
1
M12 × 194 mm
1
6 Upper mount 1
7
8
9
Bolt
Grommet
Bolt
3
1
4
M8 × 45 mm

M8 × 40 mm
2
10 Muffler seal 1
11
12
13
Rubber seal
Gasket
Screw
1
1
2
Not reusable
M6 × 15 mm
3
14 Baffle plate 1
15
16
17
Damper
Grommet
Dowel pin
1
1
2
4
18 Bolt 2 M12 × 200 mm
19
20
21
Washer
Rubber washer
Lower mount
4
2
2
5
22 Washer 2
23
24
25
Drive shaft bushing
Circlip
Mount cover
1
1
2
6
26 Bolt 4 M10 × 40 mm

7
8
9
60C5D11 7-56

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 BRKT
Bracket unit

3
4
5
11 N • m (1.1 kgf • m, 8.0 ft • Ib)
6

T.
R.
LT
572 7

LT
572

9
11 N • m (1.1 kgf • m, 8.0 ft • Ib)
T.
R.

11 10

12 13
LT
572
A
11 N • m (1.1 kgf • m, 8.0 ft • Ib)
T.
R.

14
15

20
16
16
LT
572
21 A
18 17

22
LT
19 572
S60C7200

7-57 60C5D11

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 Upper case (F100C)
No. Part name Q’ty Remarks
1 Exhaust guide 1
2 Dowel pin 2
3
4
5
Gasket
Gasket
Oil strainer
1
1
1
Not reusable
Not reusable 1
6 Collar 3
7
8
9
Bolt
Bolt
Oil pan
3
12
1
M6 × 25 mm
M6 × 25 mm 2
10 Gasket 1 Not reusable
11
12
13
Exhaust manifold
Bolt
Exhaust seal
1
4
1
M6 × 70 mm 3
14 Gasket 2 Not reusable
15
16
17
Plate
Dowel pin
Bolt
1
2
6 M6 × 30 mm
4
18 Muffler 1
19
20
21
Bolt
Grommet
Pipe
1
1
1
M6 × 50 mm
5
22 Rubber seal 1

6
7
8
9
60C5D11 7-58

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 BRKT
Bracket unit
Disassembling the oil pump
1. Remove oil seals 1 and 2, the cover 3,
gasket 4, shaft 5, and O-rings 6.

S60C7060

Bearing inner race attachment:

90890-06662

2. Install the new oil seal 3 into the oil

pump body 4.

D
d

T
A

S60C7055

Checking the oil pump

1. Checking the shaft for cracks or wear.
Replace if necessary.

S60C7065

S60C7280
NOTE:
2. Check the oil seal and O-ring for tears. Use a general pipe with the specified mea-
Replace if necessary. surements.

3. Check the oil passage for dirt or residur.

General pipe 5:
Clean if necessary.
D = 43 mm (1.69 in)
d = 40 mm (1.57 in)
Assembling the oil pump
T = 30 mm (1.18 in)
1. Install the new oil seal 1 into the cover
2.

7-59 60C5D11

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 Upper case (F100C)
3. Install the O-rings 6 into the shaft 7.

4. Install the gasket 8 and cover 2, and

then tighten the cover screws to the
specified torque.
1
2
A
3
S60C7205

A
E
Checking the oil strainer
1. Check the oil strainer for dirt and residue.
Clean if necessary.
4
E

S60C7070
Assembling the oil pan
1. Install the gaskets onto the exhaust
guide 1.
5
2. Install the oil strainer 2 and bolts, and
Oil pump cover screw:
4 N·m (0.4 kgf·m, 2.9 ft·lb)
then tighten the bolts to the specified
torque.
6
T.
R.

Disassembling the oil pan

1. Remove the muffler 1 and plate 2 from
the oil pan 3.

2. Remove the exhaust manifold 4 from

the oil pan 3.
7
3. Remove the oil pan 3 from the exhaust
guide 5.

4. Remove the oil strainer 6. Oil strainer bolt:

S60C7080
8
11 N·m (1.1 kgf·m, 8.0 ft·lb)
T.
R.

9
60C5D11 7-60

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 BRKT
Bracket unit
3. Install the oil pan 3 and then tighten the
bolts finger tight.

4. Install the exhaust manifold 4 and bolts,

and then tighten the bolts finger tight.

5. Tighten the exhaust manifold bolts 5,

then the oil pan bolts 6.

6. Install the plate 7 and the muffler 8 into

A
the oil pan.

7. Install the water pipe 9.

8. Install the muffler assembly 0 by insert-

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

9. Install the muffler assembly bolts B, and 572

then tighten them to the specified torque.

A
S60C7210

LT
572

LT LT

572 572
A

S60C7085

S60C7215

Muffler assembly bolt B:

20 N·m (2.0 kgf·m, 14 ft·lb)
T.
R.

7-61 60C5D11

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 Upper case (F100C)
Installing the upper case 6. Install the upper mounting nut 7 and
1. Install the upper mount 1 and bolts 2 lower mounting nut 8, and then tighten
into the upper case. them to the specified torques.

2. Install the bolts 3, and then tighten them

to the specified torque.
NOTE:
Before tightening the lower mounting nut, be
sure to connect the ground lead to the lower
mounting bolt.
1
LT
572 A
7. Install the oil pump assembly 9.
2
3
Upper mount bolt 3:
S60C7100
4
26 N·m (2.6 kgf·m, 19 ft·lb)
T.
R.

3. Install the lower mounts 4 to the upper

case. 5
4. Install the mount cover 5. S60C7225

Upper mounting nut 7:

53 N·m (5.3 kgf·m, 38 ft·lb)
6
T.
R.

Lower mounting nut 8:

53 N·m (5.3 kgf·m, 38 ft·lb)
Oil pump bolt 0:
11 N·m (1.1 kgf·m, 8.0 ft·lb) 7
A

8
LT
572

S60C7220

5. Install the upper and lower mounting

bolts into the swivel bracket 6 simulta-
neously.
9
60C5D11 7-62

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 BRKT
Bracket unit
Swivel bracket and clamp brackets (F100C) 7

10
11
1

A
2
3
4
A
5
6
12 15
18
13
14 15
A

A
16 5
3 mm (0.12 in) 17 4
A
7
8

9 S60C7230

No. Part name Q’ty Remarks

1 Steering arm 1
2 Washer 1
3 Bushing 1
4 O-ring 2 Not reusable
3.8 × 36.5 mm
5 Bushing 2
6 Swivel bracket 1
7 Washer 1
8 Steering yoke 1
9 Circlip 1
10 Steering hook 1
11 Nut 2
12 Tilt stop lever joint 1
13 Pin 1
14 Bushing 2
15 Spring 1
16 Spring holder 1
17 Bolt 1 M6 × 10 mm
18 Tilt stop lever 1

7-63 60C5D11

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 Swivel bracket and clamp brackets (F100C)
Removing the steering arm
1. Remove the circlip 1.

2. Remove the steering yoke 2 by striking

it with a plastic hammer.
1
A

S60C7245

4. Install the steering arm 5 into the steer-

2
ing yoke 0 by aligning the center a of
the yoke with the center b of the steer-
ing arm.

5. Install the circlip A.

3
4
S60C7235

3. Remove the steering arm from the swivel

bracket by pulling the arm off the bracket.

5
Installing the steering arm
1. Install the washer 1, bushing 2, O-ring
3, and bushing 4 onto the steering arm A

5.

6
2. Place the swivel bracket 6 in an upright
position, and then install the steering arm
S60C7250
onto the swivel bracket.

6. Inject grease into the grease nipple until

7
grease comes out from both the upper
and lower bushings c.
A

A
8
3. Install the bushing 7, O-ring 8, and
S60C7240
9
washer 9 onto the swivel bracket.
S60C7255

60C5D11 7-64

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 BRKT
Bracket unit
Clamp brackets (F100C) 7

15 N • m (1.5 kgf • m, 11 ft • Ib)

T.
R.

4 2

5
6

LT
572
9 21
7
8 10
22
5
A
1

A 11 8
11 7 3
A
12 14
13

15
3 N • m (0.3 kgf • m, 2.2 ft • Ib)
T.
R.

2 N • m (0.2 kgf • m, 1.4 ft • Ib)

T.
R.

16

17

18

19
20

S60C7260

7-65 60C5D11

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 Clamp brackets (F100C)
No. Part name Q’ty Remarks
1 Swivel bracket assembly 1
2 Starboard clamp bracket 1
3
4
5
Port clamp bracket
Self-locking nut
Ground lead
1
1
1
1
6 Screw 1 M6 × 12 mm
7
8
9
Washer
Bushing
Screw
2
2
2 M6 × 16 mm
2
10 Trim sensor 1
11
12
13
Grease nipple
Trim sensor cam
Screw
2
1
1 M6 × 25 mm
3
14 Clamp 2
15
16
17
Bolt
Plate
Anode
1
1
1
M6 × 10 mm
4
18 Ground lead 1
19
20
21
Bolt
Bolt
Through tube
2
2
1
M6 × 14 mm
M6 × 16 mm 5
22 Bolt 1 M8 × 20 mm

6
7
8
9
60C5D11 7-66

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 BRKT
Bracket unit
Removing the clamp brackets
NOTE:
1. Remove the power trim and tilt unit. For
Adjust the trim sensor after installing the
removal procedures, see “Removing the
power trim and tilt unit.
power trim and tilt unit” in this chapter.

2. Remove the anode 1. 2. Assemble the clamp brackets and the

swivel bracket by installing the anode 2,
3. Loosen the self-locking nuts 2 and bolt
bolt 3, and self-locking nuts 4, then
3, and then remove clamp brackets 4
tightening the nuts to the specified
and 5.
torque.
4. Remove the trim sensor 6.
LT
572

S60C7270

S60C7265
Self-locking nut 4:
15 N·m (1.5 kgf·m, 11 ft·lb)
T.
R.

Installing the clamp brackets

1. Install the trim sensor 1 onto the swivel
bracket assembly. 3. Install the power trim and tilt unit. For
installation procedures, see “Installing
the power trim and tilt unit” in this chap-
ter.

LT
271

S60C7160

7-67 60C5D11

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 Clamp brackets (F100C)
4. Inject grease into both grease nipples 5. Fully tilt the outboard motor up, and then
until grease comes out from the bushings support it with the tilt stop lever.
a.
WARNING
After tilting up the outboard motor, be
sure to support it with the tilt stop lever.
Otherwise, the outboard motor could sud-
1
denly lower if the power trim and tilt unit

2
should lose fluid pressure.

A 6. Measure the trim sensor resistance.

S60C7275 Check the trim sensor if out of specifica-

3
tion.
Adjusting the trim sensor cam
1. Fully tilt the outboard motor down. Trim sensor resistance:
Pink (P) – Black (B)
2. Loosen the screw 1. 238.8–378.8 Ω at 20 °C (68 °F)

3. Adjust the position of the trim sensor cam

2 until the specified resistance is
obtained.
4
B

Gy
5
P

S60C7185
6
Trim sensor resistance:
Pink (P) – Black (B)
9–11 Ω at 20 °C (68 °F) 7
4. Tighten the screw 1.

Trim sensor cam screw 1:

2 N·m (0.2 kgf·m, 1.4 ft·lb) 8
T.
R.

9
60C5D11 7-68

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 BRKT
Bracket unit
Power trim and tilt unit (F100C) 7

4 5 A
A

7 8 8 7
3

1
9
4 10

A
12 11
11 12 13

6
4
A
A

S60C7720

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 Circlip 3
5 Shaft 1
6 Shaft 1
7 Bushing 2
8 Bushing 2
9 Ground lead 1
10 Bolt 1 M6 × 10 mm
11 Bushing 2
12 Bushing 2
13 Spacer 1

7-69 60C5D11

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 Power trim and tilt unit (F100C)
Removing the power trim and tilt unit
NOTE:
1. Fully tilt the outboard motor up, and then
To remove the power trim and tilt unit, lower
support it with the tilt stop lever 1.
the tilt ram slightly.

Installing the power trim and tilt unit

1. Fully tilt the outboard motor up, and then
1
support it with the tilt stop lever 1.

2
S60C7750

WARNING
After tilting up the outboard motor, be
sure to support it with the tilt stop lever.
3
Otherwise, the outboard motor could sud- S60C7975
denly lower if the power trim and tilt unit
should lose fluid pressure. 2. Install the shaft 2 and circlips 3 onto
both clamp brackets together with the
power trim and tilt unit 4.
4
NOTE:
If the power trim and tilt does not operate,
loosen the manual valve and tilt the outboard
motor up manually.
3. Install the tilt ram upper end into the
swivel bracket with the shaft 5 and cir-
clip 6.
5
2. Loosen the plastic ties 2, and then pull 4. Connect the ground lead 7.
out the PTT motor lead 3.

3. Remove the bolt 4 and disconnect the

ground lead 5.
A
A 6
4. Remove the circlips 6, then shafts 7
and 8.

5. Remove the power trim and tilt unit 9.

7
A

A A S60C7980
8
S60C7755
9
60C5D11 7-70

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 BRKT
Bracket unit
Tilt cylinder and trim cylinder (F100C) 7

90 N • m (9.0 kgf • m, 65 ft • Ib)

T.
R.
3

13
15 16
14
15
16
17
17
18
19
20 20
21

6 22
1
7 N • m (0.7 kgf • m, 5.1 ft • Ib)
T.
R.

7
5

2 12

11
LT
10 7 N • m (0.7 kgf • m, 5.1 ft • Ib)
T.
R.

572
9 9 N • m (0.9 kgf • m, 6.5 ft • Ib) S60C7725
T.
R.

7-71 60C5D11

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 Tilt cylinder and trim cylinder (F100C)
No. Part name Q’ty Remarks
1 Power trim and tilt motor 1
2 Pump housing assembly 1
3
4
5
Tilt cylinder end screw
Trim cylinder assembly
Tilt cylinder assembly
1
1
1
1
6 Bolt 4 M6 × 20 mm
7
8
9
O-ring
Joint
Bolt
1
1
3
Not reusable

M6 × 75 mm
2
10 Reservoir cap 1
11

12
O-ring

O-ring
1

4
Not reusable
1.9 × 12.6 mm
Not reusable
3
1.5 × 8.5 mm

4
13 Ball 6
14 O-ring 1 Not reusable
15 Free piston 1
16 Valve seal 1

5
17 Circlip 1
18 Circlip 1 Not reusable
19 Trim cylinder base 1
20 Spring 2

6
21 Plate 1
22 Circlip 1

7
8
9
60C5D11 7-72

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 BRKT
Bracket unit

18
19
20

21 2

4
1 3
5
7
6
4
5
7

8
22 8
9
23 11
10
24
26 11 9
27
28 12
29 25 80 N • m (8.0 kgf • m, 58 ft • Ib)
T.
R.

13
23
14
30 30
24
31 14
15 16
32
LT
17
271 16
85 N • m (8.5 kgf • m, 61 ft • Ib)
T.
R.

17

S60C7730

7-73 60C5D11

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 Tilt cylinder and trim cylinder (F100C)
No. Part name Q’ty Remarks
1 Trim cylinder 1
2 Tilt ram 1
3
4
5
Dust seal
Backup ring
O-ring
1
1
1
Not reusable

Not reusable
1
2.4 × 22.6 mm
6
7
8
Tilt cylinder end screw
O-ring
Backup ring
1
1
1
Not reusable 2
9 O-ring 1 Not reusable

3
2.4 × 22.6 mm
10 Trim cylinder end screw 1
11 O-ring 1 Not reusable
12 Plate 1

4
13 Filter 1
14 O-ring 1 Not reusable
15 Trim piston 1
16 Backup ring 1

5
17 O-ring 1 Not reusable
18 Ball 5
19 Absorber valve pin 5
20 Spring 5

6
21 Plate 1
22 Ball 1
23 O-ring 1 Not reusable
3.5 × 35.7 mm
24 Backup ring 1
25
26
27
Tilt piston
Ball
Absorber valve pin
1
4
4
7
28 Spring 4
29
30
31
Pin
Pin
Washer
4
2
1
8
32 Bolt 1 M12 × 45 mm

9
60C5D11 7-74

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 BRKT
Bracket unit
Disassembling the tilt cylinder
1. Hold the power trim and tilt unit 1 in a
vise using aluminum plates a on both
sides.

a a
NOTE:
Place the trim cylinder in the vise horizon-
S60C7760
tally.

2. Loosen the tilt cylinder end screw 2, and 2. Loosen the trim cylinder end screw 2,
then remove it. and then remove it.

WARNING
Make sure that the ram is fully extended
before removing the end screw.

CAUTION:
Cylinder-end screw wrench:
90890-06544 Do not damage the check valve b when
loosening the end screw.
3. Drain the fluid.
Cylinder-end screw wrench:
Disassembling the trim cylinder 90890-06544
1. Hold the trim cylinder 1 in a vise using
aluminum plates a on both sides.
Checking the tilt cylinder and trim
cylinder
1. Check the power trim and tilt unit for
cracks or corrosion. Replace if neces-
sary.

2. Check the inner walls of the trim cylinder

and tilt cylinder for scratches. Replace if
necessary.

7-75 60C5D11

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 Tilt cylinder and trim cylinder (F100C)

1
3. Check the outer surface of the tilt piston 4. Install the backup ring 5 and O-rings 6
2
and free piston for scratches. Replace if and 7 into the trim cylinder end screw
necessary. 8.

3
4
4. Check the tilt ram for bends or excessive
corrosion. Polish with #400–600 grit
5. Install the trim cylinder end screw onto
the tilt ram.
5
sandpaper if there is light rust or replace
if necessary.

6
S60C7870
7
6. Install O-rings 9 and 0, and backup ring

Assembling the trim cylinder

1. Install the new dust seal 1 into the tilt
A onto the trim piston B.

7. Install the balls C, absorber valve pins

D and springs E into the trim piston, and
8
cylinder end screw 2.
then install the plate F and trim piston to
2. Install the O-ring 3 onto the end screw.

3. Install the tilt ram 4 into the end screw.

the trim cylinder G.
9
60C5D11 7-76

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 BRKT
Bracket unit
8. Install the filter H and plate I to the trim
cylinder. Tilt piston T:
85 N·m (8.5 kgf·m, 61 ft·lb)

T.
R.
13. Install the trim cylinder onto the tilt ram.

14. Hold the trim cylinder G in a vise using

aluminum plates a on both sides.

NOTE:
S60C7875
Place the trim cylinder in the vise horizon-
tally.
9. Install the backup ring J and O-ring K
into the tilt piston L.
15. Install the trim cylinder end screw 8, and
10. Install balls M and N, the absorber valve then tighten it to the specified torque.
pin O, springs P, pins Q and R, and
washer S into the tilt piston.

11. Hold the tilt ram end in a vise using alu-

minum plates on both sides.

12. Install the tilt piston to the tilt ram by

installing the bolt T, then tightening it to
the specified torque.

CAUTION:
Do not damage the check valve b when
tightening the end screw.

Cylinder-end screw wrench:

90890-06544

7-77 60C5D11

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 Tilt cylinder and trim cylinder (F100C)

Trim cylinder end screw 8:

80 N·m (8.0 kgf·m, 58 ft·lb)
T.
R.

Assembling the tilt cylinder

1. Install the valve seal 1 and the circlip 2
into the free piston 3 as shown.
1
2
2. Install the free piston into the trim cylin-
der 4 by installing the circlip 5.

LT
572 3
S60C7905

3. Install the trim cylinder base 6, springs

T.
R.
Pump housing bolt C:
9 N·m (0.9 kgf·m, 6.5 ft·lb)
Reservoir cap D:
4
7, and plate 8 into the trim cylinder with 7 N·m (0.7 kgf·m, 5.1 ft·lb)

5
the circlip 9.
6. Hold the power trim E in a vise using
aluminum plates a on both sides.

6
4. Install the O-rings 0 and pump housing
assembly A to the tilt cylinder B by
S60C7910
7
installing the bolts C, then tightening
them to the specified torque.

5. Install the reservoir cap D to the speci-

fied torque.
8
9
60C5D11 7-78

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 BRKT
Bracket unit
7. Fill the reservoir with the recommended 10. Install the balls I into the trim cylinder,
fluid to the correct level as shown. and then insert the trim cylinder into the
tilt cylinder B.

Recommended power trim and tilt

fluid: NOTE:
ATF Dexron II Apply grease to the balls to prevent them
from falling out of the cylinder.
8. Install the joint F and power trim and tilt
motor G by installing the bolts H, then Recommended power trim and tilt
tightening them to the specified torque. fluid:
ATF Dexron II

11. Pull the tilt ram until it is fully extended,

install the tilt cylinder end screw J, and
then tighten it to the specified torque.

Cylinder-end screw wrench:

S60C7920
90890-06544

PTT motor bolt H:

7 N·m (0.7 kgf·m, 5.1 ft·lb) Tilt cylinder end screw J:
T.
R.

90 N·m (9.0 kgf·m, 65 ft·lb)

T.
R.

9. Add fluid of the recommended type to the

first level at the bottom of the tilt cylinder
B.

7-79 60C5D11

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 Tilt cylinder and trim cylinder (F100C) / Gear pump (F100C)
Gear pump (F100C) 7

3
8 N • m (0.8 kgf • m, 5.8 ft • Ib) 4
1
T.
R.
2
12 10 5
1 13 6

2
14 11
10
11 15 7

8
9

7
2.2 mm
(0.087 in)
3
3
4
5
6
8
4
9

No. Part name Q’ty Remarks

S60C7735

5
1 Gear pump 1
2
3
4
Bolt
Cap
Down-relief spring
3
1
1
M6 × 35 mm
6
5 Absorber valve pin 1
6
7
8
Ball
Relief valve seat
O-ring
1
1
1 Not reusable
7
1.5 × 13.7 mm

8
9 Filter 1
10 Filter 2
11 O-ring 2 Not reusable
12 Down-relief spring 1

9
13 Valve support pin 1
14 Relief valve seal 1
15 O-ring 2 Not reusable

60C5D11 7-80

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 BRKT
Bracket unit

11 N • m (1.1 kgf • m, 8.0 ft • Ib)

T.
R.

17 16 12

20 13
11

10
21
18
19
22
23
24
25
14

11
4 N • m (0.4 kgf • m, 2.9 ft • Ib)
T.
R.

2 N • m (0.2 kgf • m, 1.4 ft • Ib)

T.
R.

15
9
8
7 13
6
5
4 12
3
11 N • m (1.1 kgf • m, 8.0 ft • Ib)
2
T.
R.

S60C7740

7-81 60C5D11

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 Gear pump (F100C)
No. Part name Q’ty Remarks
1 Circlip 1
2 Manual valve 1
3

4
O-ring

Manual release spring

1

1
Not reusable
2.4 × 22.6 mm 1
5 Manual release pin 1
6
7
8
Circlip
Ball
Manual valve seat
1
1
1
2
9 O-ring 1 Not reusable

3
1.5 × 8.5 mm
10 Pump housing 1
11 Main valve 2
12 O-ring 2 Not reusable

4
13 O-ring 2 Not reusable
14 Shuttle piston 1
15 O-ring 1 Not reusable
1.9 × 12.6 mm
16 Main valve 1
17
18
19
O-ring
O-ring
O-ring
1
1
1
Not reusable
Not reusable
Not reusable
5
20 Valve seat 2
21
22
23
Spring
Relief valve seat
O-ring
1
1
1 Not reusable
6
1.9 × 10.6 mm
24
25
Filter
O-ring
1
1 Not reusable
1.9 × 9.6 mm
7
8
9
60C5D11 7-82

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 BRKT
Bracket unit
Disassembling the gear pump
1. Remove the gear pump 1.

2. Remove the relief valve seat 2 and relief

valve seal 3.

S60C7790

Checking the valves

1. Check the operation of the check valve
a of the trim cylinder end screw and the
valve for dirt or residue. Clean if neces-
sary.

S60C7780

3. Remove the manual valve 4 and manual

valve seat 5.

2. Check the operation of the trim piston

absorber valves 1 and tilt piston
absorber valves 2, and the valves for
dirt or residue. Clean if necessary.

S60C7785

4. Remove the main valves 6 and shuttle

piston 7.

5. Remove the main valve 8 and relief S60C7815

valve seat 9.

7-83 60C5D11

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 Gear pump (F100C)
Checking the gear pump
1. Check the gear pump for damage.
Replace if necessary.

1
3. Check main valves 3 and 4 for dirt or
2
residue. Clean if necessary. S60C7835

4. Check the manual valve seat 5 and

relief valve seat 6 for dirt or residue.
Clean if necessary.
Assembling the gear pump
1. Install the shuttle piston 1 and main
valves 2, and then tighten the valves to
3
the specified torque.

2. Install the relief valve seat 3, valve seats

4, and main valve 5, and then tighten
the valve to the specified torque.
4
S60C7825
5
Checking the filters
1. Check the filters for dirt or residue. Clean
if necessary. 6
S60C7840 7
Main valve 2 and 5:
11 N·m (1.1 kgf·m, 8.0 ft·lb)

8
T.
R.

S60C7830

9
60C5D11 7-84

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 BRKT
Bracket unit
3. Install the manual valve seat 6, and then
tighten it to the specified torque. Depth a: 2.2 mm (0.087 in)
4. Install the manual valve 7, and then
tightening it to the specified torque. 7. Install the gear pump B by installing the
bolts C, then tightening them to the
specified torque.

S60C7845

Manual valve seat 6: S60C7855

4 N·m (0.4 kgf·m, 2.9 ft·lb)
T.
R.

Manual valve 7: Gear pump bolt C:

2 N·m (0.2 kgf·m, 1.4 ft·lb) 8 N·m (0.8 kgf·m, 5.8 ft·lb)
T.
R.

5. Install the relief valve seal 8, relief valve

seat 9, and absorber valve pin 0.

6. Tighten the cap A into the relief valve

seat to the specified depth a.

S60C7850

7-85 60C5D11

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 Gear pump (F100C) / Power trim and tilt motor (F100C)
Power trim and tilt motor (F100C) 7

8
1

2 3
8
9
1
4
A
10

11
2
8

5 10 12
3
11
6
7
13
4
No.
A

Part name Q’ty

14 A

Remarks
S60C7945

5
1 Screw 3 M5 × 12 mm
2
3
4
Washer
Yoke
O-ring
3
1
1 Not reusable
6
5 Armature 1
6
7
8
Screw
Washer
Screw
1
1
3
M4 × 10 mm

M4 × 10 mm
7
9 Circuit breaker 1
10
11
12
Brush
Brush spring
Brush holder
2
2
1
8
13 PTT motor base 1
14 Oil seal 1 Not reusable
9
60C5D11 7-86

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 BRKT
Bracket unit
Checking the power trim and tilt 4. Check the circuit breaker for continuity.
motor Replace if there is no continuity.
1. Check the commutator for dirt or foreign
substances. Clean with #600 grit sand-
paper if necessary.

S60C7950

5. Check the base for cracks or damage.

Replace if necessary.

2. Check the commutator undercut for dirt 6. Check the oil seal 1 for damage or wear.
or foreign substances. Clean with com- Replace if necessary.
pressed air if necessary.

3. Check the armature coil for continuity.

Replace if out of specifications.

Assembling the power trim and tilt

motor
1. Install the oil seal 1 into the motor base
2 as shown.

A S60C7965

Armature coil continuity 2. Install the springs 3 into the motor base
2, then the brush holder 4 into the
Commutator segments a Continuity
motor base together with the brushes 5
Segment-laminations b No continuity and circuit breaker 6.
Segment-shaft c No continuity

7-87 60C5D11

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 Power trim and tilt motor (F100C) / Bleeding the power trim and tilt unit (F100C)
3. Install the armature 7, O-ring 8, and
yoke 9. NOTE:
The fluid level should be at the brim of the
filler hole.

4. If necessary, add sufficient fluid of the

recommended type to the correct level.
1
A
Recommended power trim and tilt
fluid:
ATF Dexron II 2
5. Install the reservoir cap.

6. Connect the PTT motor leads 2 to the

battery terminals.
3
A

Bleeding the power trim and tilt

S60C7970
4
unit (F100C)

5
7

Not installed
1. Close the manual valve 1 by turning it
clockwise.

Battery
6
Tilt ram PTT motor lead
terminal

Up
Blue (L)
Green (G)
Green (G)
+
-
+
7
Down
Blue (L) -

7. Reverse the PTT motor leads between

the battery terminals to fully extend the
tilt ram, and then reverse them again to
8
fully retract the ram.
S60C7935

2. Place the power trim and tilt unit in an

9
upright position.

3. Check the fluid level in the reservoir.

60C5D11 7-88

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 BRKT
Bracket unit

NOTE: WARNING
• Repeat this procedure so that the tilt ram
After tilting up the outboard motor, be
goes up and down four to five times (be
sure to support it with the tilt stop lever.
sure to wait a few seconds before switching
Otherwise, the outboard motor could sud-
the leads).
denly lower if the power trim and tilt unit
• The sound of the power trim and tilt motor
should lose fluid pressure.
will change when the tilt ram is fully
extended.
7. Remove the reservoir cap 1, and then
check the fluid level in the reservoir.
8. Check the fluid level again when the tilt
ram is fully extended. Add sufficient fluid, 8. If necessary, add sufficient fluid of the
if necessary, and then repeat step 7. recommended type to the correct level.
NOTE:
Repeat this procedure until the fluid remains
at the correct level.

Built-in
1. Loosen the manual valve by turning it
counterclockwise until it cannot be turned
further.
S60C7985

NOTE:
The fluid level should be at the brim of the
filler hole.

Recommended power trim and tilt

fluid:
ATF Dexron II
S60C7745

9. Install the reservoir cap.

2. Fully tilt the outboard motor up, and then
release it and let it lower by its own NOTE:
weight four to five times. Repeat this procedure until the fluid remains
at the correct level.
3. Tighten the manual valve by turning it
clockwise.

4. Let the fluid settle for 5 minutes.

5. Push and hold the power trim and tilt

switch in the up position until the out-
board motor is fully tilted up.

6. Support the outboard motor with the tilt

stop lever, and then let the fluid settle for
5 minutes.

7-89 60C5D11

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 Bleeding the power trim and tilt unit (F100C) / Power trim and tilt electrical system
Power trim and tilt electrical system 7

1
2
3
L L Sb G
Sb

Lg
Sb

Lg
4
Lg

Lg
Sb
R
5
6
G Gy B B
Lg
R
B B
Gy

Sb

B B
R R
P R R
Gy
B 7
P

B
P Gy
S60C7990
8
1 Power trim and tilt motor È Tiller handle model
2

9
Power trim and tilt relay
3 Trailer switch B : Black
4 Power trim and tilt switch G : Green
5 Fuse (30 A) Gy : Gray
6 Fuse (20 A) L : Blue
7 10-P coupler Lg : Light green
8 Trim sensor P : Pink
9 Battery R : Red
Sb : Sky blue

60C5D11 7-90

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 BRKT
Bracket unit
Checking the fuse Checking the power trim and tilt
1. Check the fuse for continuity. Replace if switch/trailer switch
there is no continuity. 1. Check the power trim and tilt
switch/trailer switch for continuity.
Replace if out of specification.

Lead color

Switch Sky blue Light green

Red (R)
position (Sb) (Lg)
Up
S60C7995 Free
Down
Checking the power trim and tilt
relay Checking the trim sensor
1. Connect the digital circuit tester between 1. Measure the trim sensor resistance.
power trim and tilt relay terminals 1 and Replace if out of specification.
2.

2. Connect the light green (Lg) lead or sky

blue (Sb) lead 3 to the positive battery
terminal and the black (B) lead 4 to the
negative battery terminal as shown.

3. Check for continuity between terminals

1 and 2. Replace if there is no continu-
ity.

4. Disconnect the black (B) lead 4. Check Trim sensor resistance:

for continuity between terminals 1 and Pink (P) – Black (B)
2. Replace if there is continuity. 9–11 Ω at 20 °C (68 °F) a
238.8–378.8 Ω at 20 °C (68 °F) b

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

S60C7A05

7-91 60C5D11

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 – +
ELEC

Electrical systems

Special service tools .....................................................................................8-1

Checking the electrical components............................................................ 8-2

Measuring the peak voltage ...................................................................... 8-2
1
Measuring the lower resistance.................................................................8-2

Electrical components................................................................................... 8-3

Starboard and port views...........................................................................8-3
Front and rear views.................................................................................. 8-4
2
Tiller handle model .................................................................................... 8-5

Wiring harness ............................................................................................... 8-6

Ignition system and ignition control system............................................... 8-7

3
Checking the ignition spark gap ................................................................8-8
Checking the high-tension cords ............................................................... 8-8
Checking the ignition coil...........................................................................8-9
Checking the CDI unit................................................................................ 8-9
Checking the pulser coil ..........................................................................8-10
4
Checking the throttle position sensor ......................................................8-10
Checking the thermo sensor.................................................................... 8-11
Checking the oil pressure switch ............................................................. 8-11
Checking the engine start switch............................................................. 8-12
Checking the engine shut-off switch........................................................ 8-12
5
Starting system ............................................................................................ 8-13
Checking the fuse....................................................................................8-14
Checking the wiring harness (10 pins) ....................................................8-14
Checking the starter relay........................................................................8-14
6
Checking the neutral switch..................................................................... 8-14

Starter motor ................................................................................................8-15

Removing the starter motor pinion .......................................................... 8-17
Checking the starter motor pinion............................................................ 8-17
7
Checking the armature ............................................................................8-17
Checking the brushes.............................................................................. 8-18
Checking the relay assembly................................................................... 8-19
Checking the starter motor operation ......................................................8-19 8
Charging system .......................................................................................... 8-20
Checking the lighting coil.........................................................................8-21
Checking the Rectifier Regulator............................................................. 8-21
9
60C5D11

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ELEC
Electrical systems
Special service tools 8

Ignition tester Test harness (3 pins)

90890-06754 90890-06757

Digital circuit tester Vacuum/pressure pump gauge set

90890-03174 90890-06756

Peak voltage adaptor

90890-03172

Test harness (6 pins)

90890-06772

Test harness (3 pins)

90890-06770

8-1 60C5D11

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 Special service tools / Checking the electrical components
Checking the electrical Measuring the lower resistance
components 8
When measuring a resistance of 10 Ω or less
Measuring the peak voltage with the digital circuit tester, the correct mea-

1
surement cannot be obtained because of the
NOTE: internal resistance of the tester. To obtain the
Before troubleshooting the peak voltage, correct value, subtract the internal resistance
check that all electrical connections are tight from the displayed measurement.
and free from corrosion, and that the battery

2
is fully charged to 12 V. Correct value =
displayed measurement – internal
The condition of the ignition system can be resistance
determined by measuring the peak voltage.
Cranking speed is effected by many factors,
NOTE:
such as fouled or weak spark plugs, or a
weak battery. If one of these factors is
present, the peak voltage will be lower than
specification. In addition, if the peak voltage
Obtain the internal resistance of the digital
circuit tester by connecting both of its probes
and checking the display.
3
is lower than specification the engine will not
operate properly.
4
DC V

5
WARNING
When checking the peak voltage, do not
S60C8010

6
touch any of the connections of the digital
tester leads.

NOTE:
7
• Use the peak voltage adaptor with the digi-

8
tal circuit tester.
• When measuring the peak voltage, set the
selector on the digital circuit tester to the
DC voltage mode.
• Connect the positive pin on the peak volt-
age adaptor to the positive terminal of the
digital circuit tester.
9
60C5D11 8-2

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ELEC
Electrical systems
Electrical components 8

Starboard and port views

S60C8020

1 Ignition coils 9 Throttle position sensor

2 Thermo sensor
3 Starter motor
4 Fuse
5 Starter relay
6 Power trim and tilt relays
7 Oil pressure switch
8 Prime Start

8-3 60C5D11

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 Electrical components
Front and rear views

1
2
3
4
5
6
7
S60C8030 8
1 CDI unit È Tiller handle model
2

9
Starter relay
3 Power trim and tilt relays
4 Rectifier Regulator
5 Neutral switch (tiller handle model)
6 Spark plug
7 High-tension cords
8 Ignition coils

60C5D11 8-4

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ELEC
Electrical systems
Tiller handle model

S60C8040

1 Engine start switch

2 Engine start switch harness
3 Engine shut-off switch
4 Engine shut-off switch connector
5 Power trim and tilt switch
6 PTT switch lead
7 Neutral switch
8 Wiring harness extension
9 Connector assembly

8-5 60C5D11

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 Electrical components / Wiring harness
Wiring harness 8

R W R
Y

1
L B R
Y P

2
P B P O

P/B P/W
O Lg Sb Br
B/Y P/W
B Lg Sb
B

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

3
Br Y
P B

P/B P/W
B
Sb Lg

B/Y

4
R

OPB
B
BB BB P P/W B/Y P/W
O Y P/B P
B
L
W
R
Y
R R

R R

R
G
B
5
P/W W
Y

6
P
Sb
Lg
Br

L B Y
P/W
P/B

R
Lg
B/Y Sb
B
Sb Lg

7
Sb Lg Br
Y

S60C8050

8
Connect to: A Trailer switch or power trim B : Black
1 Oil pressure switch and tilt switch Br : Brown
2 Throttle position sensor B Starter relay G : Green
3 Ground C Power trim and tilt relays L : Blue
4 CDI unit D Thermo sensor Lg : Light green
5 CDI unit E Prime Start O : Orange
6
7
8
9
Hour meter
Rectifier Regulator
Starter relay
Remote control box or wiring
P
R
Sb
W
: Pink
: Red
: Sky blue
: White
9
harness extension Y : Yellow
0 Warning indicator or wiring B/Y : Black/yellow
harness extension P/B : Pink/black
P/W : Pink/white

60C5D11 8-6

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ELEC
Electrical systems
Ignition system and ignition control system 8

G/W

P/W
P
B/Y B

W
B/Y

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

B
B

S60C8060

1 Spark plugs 0 Fuse (30 A) B : Black B/Y : Black/yellow

2 Ignition coils A Oil pressure switch Br : Brown G/W : Green/white
3 Throttle position B Thermo sensor G : Green P/W : Pink/white
sensor C Engine start switch O : Orange W/B : White/black
4 Pulser coils D Engine shut-off P : Pink W/R : White/red
5 10-P coupler switch R : Red
6 CDI unit W : White
7 Lighting coil È Tiller handle model Y : Yellow
8 Rectifier Regulator B/O : Black/orange
9 Battery B/W : Black/white

8-7 60C5D11

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 Ignition system and ignition control system
Checking the ignition spark gap
1. Remove the cover and disconnect the WARNING
spark plug caps from the spark plugs. • Do not touch any of the connections of

1
the spark gap tester leads.
2. Connect a spark plug cap to the special • Do not let sparks leak out of the
service tool. removed spark plug caps.
• Keep flammable gas or liquids away,
since this test can produce sparks.

Checking the high-tension cords

1. Remove the high-tension cords from the
2
ignition coil.

S60C8070
2. Measure the high-tension cord resis-
tance. Replace if out of specification. 3
Ignition tester: 90890-06754

3. Set the spark gap length on the adjusting

knob.
4
S60C8100 5
High-tension cord resistance:

6
#1: 4.5–10.7 kΩ
#2: 3.3–8.0 kΩ
#3: 3.7–8.9 kΩ
#4: 4.3–10.2 kΩ

Ignition spark gap: 11 mm (0.4 in)

4. Crank the engine and observe the spark

7
through the discharge window of the
spark gap tester. Check the ignition coil if
out of specification.
8
OK

9
S60C8090

60C5D11 8-8

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ELEC
Electrical systems
Checking the ignition coil Checking the CDI unit
1. Remove the high-tension cords from the 1. Measure the CDI unit output peak volt-
ignition coil. age. If below specification, measure the
Rectifier Regulator output peak voltage
2. Measure the ignition coil resistance. and pulser coil output peak voltage.
Replace if out of specification. Replace the CDI unit if the output peak
voltage of the Rectifier Regulator and
B/W
pulser coil is above specification.

B/W

S60C8110

Ignition coil resistance:

Primary coil:
Black/white (B/W) – Black (B)
0.08–0.11 Ω at 20 °C (68 °F)
Secondary coil: S60C8120
3.5–4.7 kΩ at 20 °C (68 °F)
Digital circuit tester: 90890-03174
Peak voltage adaptor: 90890-03172
Test harness (6 pins): 90890-06772

CDI unit output peak voltage:

Black/orange (B/O) – Black (B)
Black/white (B/W) – Black (B)
Loaded
r/min
Cranking 1,500 3,500
DC V 124 125 126

8-9 60C5D11

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 Ignition system and ignition control system
Checking the pulser coil
1. Measure the pulser coil output peak volt- Pulser coil output peak voltage:
age. Replace the pulser coil if below White/red (W/R) – Black (B)
White/black (W/B) – Black (B)

1
specification.
Unloaded Loaded
r/min
Cranking 1,500 3,500
DC V 3.5 2.5 9.0 14.0

Pulser coil resistance (use as

reference):
White/red (W/R) – Black (B)
2
White/black (W/B) – Black (B)
445–545 Ω at 20 °C (68 °F)

Checking the throttle position

sensor
3
1. Start the engine and warm it up 5 min-
utes to check the stability of the engine.

2. Measure the throttle position sensor

input voltage. Replace the CDI unit if out
4
of specification.

S60C8140
3. Measure the throttle position sensor out-
put voltage. Replace the CDI unit if out of
specification.
5
NOTE:
• Use the peak voltage adaptor with the digi-
tal circuit tester.
• When measuring the peak voltage, set the
selector on the digital circuit tester to the
6
DC voltage mode.

Digital circuit tester: 90890-03174

Peak voltage adaptor: 90890-03172
7
Test harness (6 pins): 90890-06772

8
S60C8160 9
Test harness (3 pins): 90890-06757

60C5D11 8-10

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ELEC
Electrical systems
Checking the oil pressure switch
Throttle position sensor input 1. Connect the special service tool to the oil
voltage: pressure switch.
Red (R) – Orange (O)
5V 2. Slowly operate the special service tool.
Throttle position sensor output
voltage:
Pink (P) – Orange (O)
0.48–5.25 V

NOTE:
Make sure that the throttle position sensor
output voltage is within specification when
the throttle is fully closed and fully open.

Checking the thermo sensor

1. Place the thermo sensor in a container of
water and slowly heat the water.

3. Check the switch for continuity at the

specified pressure. Replace if there is no
continuity.

Vacuum/pressure pump gauge set:

90890-06756

Specified oil pressure:

150 kPa (1.5 kgf/cm2, 21.3 psi)

S60C8170

2. Measure the thermo sensor resistance.

Replace if out of specification.

Thermo sensor resistance:

at 20 °C (68 °F): 2.45 kΩ
at 40 °C (104 °F): 1.15 kΩ
at 60 °C (140 °F): 0.59 kΩ
at 80 °C (176 °F): 0.32 kΩ

8-11 60C5D11

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 Ignition system and ignition control system
Checking the engine start switch
1. Check the engine start switch for continu- Lead color
ity. Replace if there is no continuity. White (W) Black (B)
Remove the lock
plate a
Install the lock
plate b
1
Push the button c

2
Lead color

Switch White Black Red Yellow Brown

3
position (W) (B) (R) (Y) (Br)
OFF
ON
START
4
Checking the engine shut-off switch
1. Check the engine shut-off switch for con-
tinuity. Replace if there is no continuity.
5
6
7
8
9
60C5D11 8-12

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ELEC
Electrical systems
Starting system 8

1 Fuse (30 A) B : Black

2 Fuse (20 A) Br : Brown
3 Starter motor R : Red
4 Starter relay W : White
5 Battery Y : Yellow
6 10-pin coupler B/W : Black/white
7 Neutral switch
8 Engine start switch

È Tiller handle model

8-13 60C5D11

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 Starting system
Checking the fuse Checking the neutral switch
1. Check the fuse for continuity. Replace if 1. Check the neutral switch for continuity.
there is no continuity. Replace if there is no continuity.

1
2
S60C8220

Checking the wiring harness

(10 pins)
1. Check the wiring harness for continuity. Free
Lead color
Brown (Br) Brown (Br) 3
Replace if there is no continuity. Push

Checking the starter relay

1. Connect the digital circuit tester leads to
the starter relay terminals.
4
2. Connect the brown (Br) lead to the posi-
tive battery terminal.

3. Connect the black (B) lead to the nega-

5
tive battery terminal.

4. Check for continuity between the starter

relay terminals. Replace if there is no
continuity.
6
5. Check that there is no continuity between
the starter relay terminals after discon-
necting the brown or black lead. Replace
if there is continuity.
7
8
9
60C5D11 8-14

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ELEC
Electrical systems
Starter motor 8

1
2
3

4
5

16
6

17 7 26
A

27

18 10
11
28

12

19
29
20

21
13
22
A
14
23

15
24

25

S60C8250

8-15 60C5D11

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 Starter motor
No. Part name Q’ty Remarks
1 Clip 1
2 Pinion stopper 1
3
4
5
Starter motor pinion
Spring
Bolt
1
1
2 M6 × 52 mm
1
6 Housing 1
7
8
9
Rubber seal
Bearing
Clutch assembly
1
1
1
2
10 E-clip 1 Not reusable
11
12
13
Thrust washer
Center bracket
Pinion shaft
1
1
1
3
14 Planetary gear 3
15
16
17
Outer gear
Plate
Armature
1
1
1
4
18 Stator 1
19
20
21
Brush assembly
Brush holder assembly
Plate
1
1
1
5
22 Thrust washer 1
23
24
25
Lower bracket
Screw
Bolt
1
2
2
M4 × 14 mm
M6 × 120 mm
6
26 Shift lever 1
27
28
29
Spring
Relay assembly
Nut
1
1
1
7
8
9
60C5D11 8-16

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ELEC
Electrical systems
Removing the starter motor pinion Checking the armature
1. Slide the pinion stopper 1 down as 1. Check the commutator for dirt. Clean
shown, and then remove the clip 2. with #600 grid sandpaper and com-
pressed air if necessary.

S60C8260

NOTE:
Remove the clip with a thin screwdriver. 2. Measure the commutator diameter.
Replace the armature if out of specifica-
tion.
Checking the starter motor pinion
1. Check the pinion teeth for cracks or
wear. Replace if necessary.

Commutator diameter limit:

S60C8270
28.0 mm (1.10 in)
2. Check for smooth operation. Replace if
necessary.

NOTE:
Turn the pinion clockwise to check that it
operates smoothly and turn it counterclock-
wise to check that it locks in place.

8-17 60C5D11

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 Starter motor
3. Measure the commutator undercut a. Checking the brushes
Replace the armature if out of specifica- 1. Measure the brush length. Replace the
tion. brush assembly if out of specification.

1
2
Commutator undercut limit a:
0.2 mm (0.01 in)
Brush length limit a:
9.5 mm (0.37 in) 3
4. Check the armature for continuity. 2. Check the brush holder assembly for
Replace if out of specifications. continuity. Replace if out of specifica-
tions.
4
5
Armature continuity
Brush continuity
S60C8340
6
Commutator segments b Continuity
Segment –
Armature core c
Segment –
No continuity

No continuity
Brush 1 – Brush 2 No continuity
7
Armature shaft d

8
9
60C5D11 8-18

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ELEC
Electrical systems
Checking the relay assembly
1. Connect the tester leads between the
relay terminals as shown.

2. Connect the positive battery terminal to

the black and white (B/W) lead.

3. Connect the negative battery terminal to

the starter motor body.

B/W

S60C8350

CAUTION:
• Do not connect the battery for more than
one second, otherwise the relay may be
damaged.
• Do not connect the positive battery ter-
minal the position a shown.

4. Check that there is continuity between

the relay terminals. Replace if there is no
continuity.

5. Check that there is no continuity after the

negative battery terminal is removed.
Replace if there is continuity.

NOTE:
The starter motor pinion should be pushed
out while the relay is on.

Checking the starter motor operation

1. Check the operation of the starter motor
after installing it to the power unit.

8-19 60C5D11

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 Starter motor / Charging system
Charging system 8

1
B R G G G/W G/W
2
G/W W

G
W G
W 3
4
G
W
G W

B
5
B
B/W
B
6
S60C8360
7
1

8
Lighting coil B : Black
2 Rectifier Regulator G : Green
3 Fuse (30 A) R : Red
4 Battery W : White
5 Starter motor G/W : Green/white
6 Starter relay

9
60C5D11 8-20

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 – +
ELEC
Electrical systems
Checking the lighting coil Checking the Rectifier Regulator
1. Measure the lighting coil output peak 1. Measure the Rectifier Regulator output
voltage. Replace the lighting coil if below peak voltage. If below specification, mea-
specification. sure the lighting coil output peak voltage.
Replace the Rectifier Regulator if the out-
put peak voltage of the lighting coil is
above specification.

S60C8130

Digital circuit tester: 90890-03174

Peak voltage adaptor: 90890-03172 S60C8150

Test harness (3 pins): 90890-06770

Digital circuit tester: 90890-03174
Peak voltage adaptor: 90890-03172
Lighting coil output peak voltage:
White (W) – White (W)
Unloaded Loaded Rectifier Regulator output peak
r/min voltage:
Cranking 1,500 3,500
Red (R) – Black (B)
DC V 7.5 8.0 15.5 15.5
Unloaded
r/min
1,500 3,500
Lighting coil resistance (use as
DC V 17.5 19.0
reference):
White (W) – White (W)
0.32–0.48 Ω at 20 °C (68 °F) NOTE:
Disconnect the output lead (red lead) of the
Rectifier Regulator when measuring the out-
put peak voltage.

8-21 60C5D11

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 TRBL
SHTG
Troubleshooting

Power unit....................................................................................................... 9-1

Bracket unit .................................................................................................. 9-11 1

Electrical systems........................................................................................ 9-15

2
3
4
5
6
7
8
9
62Y5A11

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 TRBL
SHTG Troubleshooting

NOTE:
• To diagnose a mechanical malfunction, use the troubleshooting charts pertaining to the trouble
located in this chapter. Also, when checking and maintaining the outboard motor, see Chapters 4–
8, to check the part necessary to carry out safety maintenance.
• Check that all electrical connections are tight and free from corrosion, and that the battery is fully
charged to 12 V.

Power unit 9

Symptom: Engine does not crank.

• Check the starting system.
• Check the power unit.

Check that the gearshift is in the

neutral position.

Is the gearshift No
Set it to the neutral position.
in neutral?
Yes

Check the neutral switch for

continuity.

Is there conti- No
Replace the neutral switch.
nuity?
Yes

Check the engine start switch

for continuity.

Is there conti- No
Replace the engine start switch.
nuity?
Yes

Check the engine shut-off

switch for continuity.

Continued on next page.

9-1 62Y5A11

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 Power unit

1
Is there conti- Yes Replace the engine shut-off
nuity? switch.
No

Check the fuse for continuity.

2
Is there conti- No
Replace the fuse.

3
nuity?
Yes

Check the wiring harnesses for

continuity.

Is there conti-
nuity?
No
Replace the wiring harnesses.
4
Yes

Listen for the operation sound

of the starter relay.
5
Can the oper-
ation sound
be heard?
Yes
No
Replace the starter relay. 6
Check the starter motor opera-
tion.
7
Good operat- No

8
Replace the starter motor.
ing condition?
Yes

Check the power unit.

9
62Y5A11 9-2

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 TRBL
SHTG Troubleshooting
Symptom: Engine cranks, but will not start.
• Check the ignition system.
• Check the fuel system.
• Check the compression pressure of the power unit.

Check that the spark plugs pro-

WARNING
duce sparks. • Do not touch any of the connections of
the spark gap tester leads.
• Do not let sparks leak out of the
removed spark plug caps.
• Keep flammable gas or liquids away,
since this test can produce sparks.

Yes Check the ignition spark using

Are there sparks?
the spark gap tester.
No

Check the condition of the spark Below the

Yes Check the ignition
plugs. spark gap
system output peak
specification?
voltage.
No

Check the ignition coil.

Wet spark plugs? No

Check the fuel system.

Yes

Start the engine using dried or

new spark plugs.

Continued on next page.

9-3 62Y5A11

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 Power unit

1
Does the No Check the compression pres-
engine start? sure of the combustion chamber.
Yes

Out of specifi- Yes

Check the condition of the spark

cation?
No 2
Failure in starting operation
plugs again.

Wet spark plugs?

No
Failure in starting operation
Check the valve
clearance.
3
Yes

Check the fuel system.

Adjust the valve
clearance.
Yes Out of specifi-
cation?
4
No

Check the cylinder head, cylin-

der body, and piston assembly. 5
6
7
8
9
62Y5A11 9-4

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 TRBL
SHTG Troubleshooting
Symptom: Engine can be started, but does not remain on.
• Check the fuel system.
• Check the ignition system.
• Check the compression pressure of the power unit.

(Fuel system)

Check that the fuel vent screw of the fuel tank is open.

Is the vent No
Open the fuel vent screw.
screw open?
Yes

Check for water or residue in

the fuel filter.

Water or resi- No Check the fuel hose for kinks or

due? fuel leakage.
Yes

Clean the fuel system from the Kinks or fuel No

fuel tank to the fuel filter. leakage?
Yes
Check the fuel
Replace the respective parts.
pump operation.

Check the carbure- Yes Good operat-

tors. ing condition?
No
Replace the fuel
pump.

9-5 62Y5A11

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 Power unit
(Ignition system)

1
Check the ignition spark gap using the spark gap tester.

Out of specifi- No Check the ignition system out-

cation? put peak voltage.
Yes

Replace the spark plug.

2
3
(Compression pressure) 4
Check that there is no secondary air intake on the contact surfaces of
the intake manifold and crankcase.

Is there air Yes

5
Replace the respective seals.
intake?
No

Check the compression pres-

6
sure of the combustion chamber.

7
8
9
62Y5A11 9-6

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 TRBL
SHTG Troubleshooting
Symptom: The engine idle speed is not steady, but increases or decreases.
• Check the carburetors.
• Check the air intake system.
• Check the ignition system.

Check the operation of the

throttle cable and link rods.

Good operat- No Adjust the throttle cable and link

ing condition? rods.
Yes
Check the operation of the car-
buretor throttle valves by
removing the throttle cable and
link rods.

Do the valves Yes

close simul- Check the ignition timing.
taneously?
Check the second-
No
ary air intake on the
Check and disassemble the car- Out of specifi- No O-ring and manifold
buretors, and then clean them if cation? plate, and the gas-
necessary. kets of the vacuum
Yes check bolts.

Replace the CDI unit.

9-7 62Y5A11

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 Power unit
Symptom: Engine does not accelerate when the throttle is opened quickly.
The engine turns off when the throttle is opened quickly.
Acceleration is tardy and the engine is likely to stop at any moment.

1
• Check the carburetors.
• Check the ignition system.
• Check the compression pressure of the power unit.

Check the throttle cable opera-

tion.

Do the carbu-
2
retor throttle No
valves close
simulta-
neously?
Yes
Adjust the throttle cable.

3
Disassemble the carburetor and
check the internal parts for
clogs, debris, or wear. 4
Clogs, debris, No Check the ignition system and
or wear?
Yes
the compression pressure of the
engine.
5
Clean the carburetor or replace
the respective parts.

6
7
8
9
62Y5A11 9-8

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 TRBL
SHTG Troubleshooting
Symptom: Engine can run, but engine speed will not increase.
Overheat warning indicator is on.
Oil pressure warning indicator is on.
Warning indicator is on and buzzer is sounding.
• Check the water cooling system.
• Check the lubricating system.

(Cooling system)

Check the water inlet for clogs

or debris.

Check that cooling water is dis-

No charged from the pilot water
Clogs or debris?
outlet.
Yes

Is water dis- No
Clean the water inlet.
charged?
Yes
Check the water
pump impeller.

Check the water Yes

Check the thermostat operation. Good condition?
passage.
No

No Replace the impel-

Good condition? Replace the thermostat.
ler.
Yes

Check the thermo sensor.

No
Good condition? Replace the thermo sensor.

Yes

Replace the CDI unit.

9-9 62Y5A11

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 Power unit
(Lubricating system)

Check the engine oil level.

1
At specified No Add engine oil to the correct
level? level.
Yes

Check the oil pressure.

2
Out of specifi-
cation?
Yes Check the oil pump for debris or
oil leaks.
3
No

Debris or leaks?
No Check the oil pas-
sage. 4
Yes

Check the oil pressure switch.

Clean or replace the respective
parts.
5
No

6
Good condition? Replace the oil pressure switch.

Yes

Replace the CDI unit.

7
8
9
62Y5A11 9-10

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 TRBL
SHTG Troubleshooting
Bracket unit 9

Symptom: Power trim and tilt unit does not operate.

Listen for the operation sound

of the power trim and tilt relay.

Can the oper- Check the voltage between each terminal.

No
ation sound • Between the sky blue (Sb) lead and black (B) lead.
be heard? • Between the light green (Lg) lead and black (B) lead.
Yes

Can 12 V be No Check for continuity

obtained? between the battery,
relays, and switch.
Yes

Listen for the operation sound Replace the power trim and tilt
of the power trim and tilt motor. relay.

Can the oper- Check the voltage between the

No
ation sound blue (L) lead and green (G)
be heard? lead.
Yes

Can 12 V be No Replace the power

obtained? trim and tilt relay.
Yes

Check that the manual valve is Check the power trim and tilt
closed. motor.

No
Is it closed? Close the valve.

Yes

Check the power trim and tilt

fluid level.

Continued on next page.

9-11 62Y5A11

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 Bracket unit

At specified
level?
Yes
No
Add fluid to the correct level.
1
Measure the hydraulic pressure.
(for F100B)

Out of specifi- No Check the power trim and tilt

2
cation? unit for leaks.
Yes
Disassemble the power trim and
tilt unit, and then check the filter
3
for debris or dirt.

Debris or dirt?
Yes
Clean or replace the filters.
4
5
No

Check the fluid passages for

clogs or debris.

Clogs or debris?

No
Yes
Clean the passages.
6
7
Check the internal parts (valves,
pistons, gears, etc.).

8
9
62Y5A11 9-12

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 TRBL
SHTG Troubleshooting
Symptom: Power trim and tilt unit does not hold the outboard motor up.

Check that the manual valve is

closed.

No
Is it closed? Close the valve.

Yes

Check the power trim and tilt

fluid level.

At specified No
Add fluid to the correct level.
level?
Yes
Disassemble the power trim and
tilt unit, and then check the fil-
ters for debris or dirt.

Yes
Debris or dirt? Clean or replace the filters.

No

Check the fluid passages for

clogs or debris.

Yes
Clogs or debris? Clean the passages.

No

Check the internal parts (valves,

pistons, gear, etc.).

9-13 62Y5A11

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 Bracket unit
Symptom: Shift mechanism of the forward gear and reverse gear does not operate properly.

1
Check the shift cable operation.

Good operat- No Check the shift cables and links

ing condition? of the remote control box.
Yes

Check the operation of the shift

rod.
2
Good operat-
ing condition?
No Check the detent of the bottom
cowling.
3
Yes
Check the condition of the shift
rod connection between the
lower case and upper case.
4
Connected
properly?
Yes
No
Replace the shift rod.
5
Disassemble the lower case,
and then check the operation of
the dog clutch. 6
Good operat- No
ing condition?
Yes
Replace the respective parts.

7
Check the forward gear and
reverse gear.

8
9
62Y5A11 9-14

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SHTG Troubleshooting
Electrical systems 9

Symptom: Battery becomes weaker quickly.

• Check the charging system.

Measure the output peak voltage of the lighting coil.

Out of specifi- Yes

Replace the lighting coil.
cation?
No

Measure the Rectifier Regulator

output peak voltage.

Out of specifi- Yes

Replace the Rectifier Regulator.
cation?
No
Replace the battery, and then
check the voltage of all electri-
cal equipment on your boat.

9-15 62Y5A11

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 A. Checking the brushes............................... 8-18
Checking the camshaft ............................. 5-31
Acceleration pump ....................................1-17
Checking the carburetor ........................... 4-15
Adjusting the pilot screw ...........................4-19
Checking the CDI unit................................. 8-9

1
Adjusting the throttle link rod.....................4-17
Checking the check valve......................... 4-15
Adjusting the throttle position sensor ........4-18
Checking the compression pressure .......... 5-9
Adjusting the trim sensor cam......... 7-28, 7-68
Checking the cooling water passage.......... 3-8
After test run .............................................1-29
Checking the crankshaft ........................... 5-42
Applicable models.......................................1-5
Checking the crankshaft main journal oil

2
Assembling the carburetor ........................4-17
clearance ................................................ 5-45
Assembling the cylinder body ...................5-48
Checking the crankshaft pin oil
Assembling the drive shaft........................6-48
clearance ................................................ 5-43
Assembling the drive shaft housing ..........6-20
Checking the cylinder bore ....................... 5-40
Assembling the forward gear .......... 6-19, 6-48
Checking the cylinder head ...................... 5-32
Assembling the fuel pump...........................4-8
Assembling the gear pump .......................7-84
Assembling the lower case ............. 6-19, 6-47
Assembling the oil pan.................... 7-18, 7-60
Assembling the oil pump................. 7-17, 7-59
Checking the diaphragm and valves .......... 4-8
Checking the drive shaft ..................6-18, 6-46
Checking the electrical components........... 8-2
Checking the engine idle speed ............... 3-10
3
Checking the engine oil .....................1-26, 3-5
Assembling the power trim and tilt

4
Checking the engine shut-off switch......... 8-12
motor............................................. 7-46, 7-87
Checking the engine start switch.............. 8-12
Assembling the propeller shaft
Checking the engine start switch and
assembly....................................... 6-13, 6-41
engine stop switch/engine shut-off
Assembling the propeller shaft
switch...................................................... 1-28
housing ......................................... 6-13, 6-41
Checking the filters ..........................7-39, 7-84
Assembling the pump housing..................7-40
Assembling the tilt cylinder .......................7-78
Assembling the tilt ram..............................7-35
Assembling the trim cylinder .....................7-76
Checking the fuel filter ................................ 3-4
Checking the fuel filters ............................ 4-15
Checking the fuel joint and fuel hoses
(fuel joint-to-carburetor) ............................ 3-4
5
Assembling the trim rams .........................7-33
Checking the fuel pump.............................. 4-7

B.
Backlash (F100B) .....................................6-29
Backlash (F100C) .....................................6-56
Checking the fuel system ......................... 1-25
Checking the fuse............................7-91, 8-14
Checking the gear oil................................ 1-26
Checking the gear oil level ....................... 3-13
6
Bleeding the power trim and tilt unit Checking the gear pump .................7-40, 7-84

7
(F100B) ...................................................7-48 Checking the gearshift and throttle
Bleeding the power trim and tilt unit operation................................................. 1-27
(F100C)...................................................7-88 Checking the gearshift operation.............. 3-10
Bottom cowling............................................7-9 Checking the high-tension cords ................ 8-8
Bracket unit ...............................................9-11 Checking the hour meter ............................ 3-4

8
Bracket unit and the PTT unit ...................1-13 Checking the hydraulic pressure .............. 7-49
Break-in.....................................................1-29 Checking the ignition coil............................ 8-9
Built-in ............................................. 7-52, 7-89 Checking the ignition spark gap ................. 8-8
Checking the ignition timing...................... 3-11
C. Checking the lighting coil.......................... 8-21
Checking the lower case .................6-19, 6-47

9
Carburetor....................................... 1-16, 4-13
Changing the engine oil ..............................3-5 Checking the lower unit (for air leakage) .. 3-14
Changing the gear oil................................3-13 Checking the neutral switch...................... 8-14
Charging system .......................................8-20 Checking the oil pressure ........................... 5-9
Checking the anodes ................................3-14 Checking the oil pressure switch .............. 8-11
Checking the armature..............................8-17 Checking the oil pump .....................7-17, 7-59
Checking the battery ....................... 1-26, 3-15 Checking the oil strainer ..................7-18, 7-60
Checking the bearings .................... 6-18, 6-46

60C5D11 i-1

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 Index
Checking the outboard motor mounting Clamp brackets (F100B)........................... 7-25
position....................................................1-26 Clamp brackets (F100C) .......................... 7-65
Checking the pilot water outlet..................1-28 Control system............................................ 3-9
Checking the pinion and forward Cooling system ................................1-14, 1-21
gear............................................... 6-18, 6-46 Cylinder body............................................ 5-36
Checking the piston clearance..................5-41 Cylinder head ........................................... 5-21
Checking the piston diameter ...................5-40
Checking the piston ring grooves..............5-42 D.
Checking the piston ring side clearance ...5-42
Dimensions................................................. 2-9
Checking the piston rings..........................5-41
Disassembling the cylinder body .............. 5-39
Checking the power trim and tilt fluid
Disassembling the drive shaft................... 6-45
level.........................................................3-12
Disassembling the drive shaft housing ..... 6-17
Checking the power trim and tilt
Disassembling the forward gear ......6-17, 6-45
motor............................................. 7-45, 7-87
Disassembling the fuel pump ..................... 4-8
Checking the power trim and tilt
Disassembling the gear pump .........7-39, 7-83
operation .................................................3-12
Disassembling the lower case .........6-18, 6-46
Checking the power trim and tilt relay.......7-91
Disassembling the oil pan................7-18, 7-60
Checking the power trim and tilt
Disassembling the oil pump.............7-17, 7-59
switch/trailer switch .................................7-91
Disassembling the power trim and tilt
Checking the Prime Start ..........................4-16
motor ...................................................... 7-44
Checking the propeller ..............................3-14
Disassembling the propeller shaft
Checking the propeller shaft ........... 6-13, 6-40
assembly .......................................6-12, 6-40
Checking the propeller shaft
Disassembling the propeller shaft
housing ......................................... 6-12, 6-40
housing ..........................................6-11, 6-39
Checking the pulser coil............................8-10
Disassembling the tilt cylinder .................. 7-75
Checking the Rectifier Regulator ..............8-21
Disassembling the tilt cylinder and trim
Checking the relay assembly ....................8-19
cylinders ................................................. 7-32
Checking the remote control cables..........1-27
Disassembling the trim cylinder................ 7-75
Checking the reservoir ..............................7-33
Disassembly and assembly ........................ 1-4
Checking the spark plugs............................3-7
Drive shaft and lower case (F100B) ......... 6-15
Checking the starter motor operation........8-19
Drive shaft and lower case (F100C) ......... 6-43
Checking the starter motor pinion .............8-17
Checking the starter relay .........................8-14
Checking the steering system...................1-27 E.
Checking the thermo sensor .....................8-11 Electrical ..................................................... 2-7
Checking the thermostat .............................3-8 Electrical components ................................ 8-3
Checking the throttle cable operation .........3-9 Electrical systems..................................... 9-15
Checking the throttle position sensor........8-10
Checking the tilt cylinder and trim F.
cylinder.......................................... 7-33, 7-75 Features and benefits................................. 1-6
Checking the tilt system ............................1-28 Fire prevention............................................ 1-3
Checking the timing belt..............................3-7 Front and rear views................................... 8-4
Checking the timing belt and sprockets ....5-18 Fuel line and fuel filter ................................ 4-3
Checking the top cowling ............................3-4 Fuel pump................................................... 4-5
Checking the trim sensor ..........................7-91 Fuel system ................................................ 3-4
Checking the valve clearance ............. 3-7, 5-6 Fuel, blowby, and cooling water hoses....... 4-2
Checking the valve guides ........................5-27
Checking the valve seat............................5-28
Checking the valve springs .......................5-26
G.
Gear pump (F100B).................................. 7-37
Checking the valves...............5-26, 7-39, 7-83
Gear pump (F100C) ................................. 7-80
Checking the water pump and
General..................................................... 3-14
shift rod ........................................... 6-8, 6-36
General specifications ................................ 2-1
Checking the wiring harness (10 pins)......8-14
General torques........................................ 2-16

i-2 60C5D11

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 Good working practices ..............................1-4 P.
Parts, lubricants, and sealants ................... 1-3
H. Power trim and tilt electrical system ......... 7-90

1
Hose routing................................................4-2 Power trim and tilt motor (F100B)............. 7-42
How to use this manual...............................1-1 Power trim and tilt motor (F100C) ............ 7-86
Power trim and tilt unit .............................. 3-12
I. Power trim and tilt unit (F100B) ................ 7-29
Identification................................................1-5 Power trim and tilt unit (F100C)................ 7-69
Power unit.....................1-6, 2-3, 3-5, 5-3, 9-1
Ignition system ................................ 1-11, 1-18
Ignition system and ignition control
system.......................................................8-7
Ignition timing control ................................1-18
Predelivery checks ................................... 1-25
Propeller selection .................................... 1-25
Propeller shaft housing (F100B)................. 6-9
Propeller shaft housing (F100C)............... 6-37
2
Installing the clamp brackets........... 7-27, 7-67
Propeller size............................................ 1-25

3
Installing the cylinder head .......................5-34
Installing the drive shaft .................. 6-20, 6-48 PTT (power trim and tilt) unit (F100B) ...... 1-22
Installing the lower unit ................... 6-23, 6-51 PTT (power trim and tilt) unit (F100C) ...... 1-24
Installing the power trim and tilt motor ......7-47
Installing the power trim and tilt R.
unit ................................................ 7-51, 7-70 Refacing the valve seat ............................ 5-29
Installing the power unit ............................5-51
Installing the propeller shaft
housing ......................................... 6-21, 6-49
Installing the pump housing ......................7-41
Removing and installing the oil filter ......... 5-39
Removing the clamp brackets .........7-27, 7-67
Removing the cylinder head ..................... 5-25
Removing the drive shaft.................6-17, 6-45
4
Installing the sprockets and timing belt .....5-18 Removing the lower unit ....................6-7, 6-35
Installing the steering arm............... 7-23, 7-64
Installing the tilt ram ..................................7-36
Installing the trim rams..............................7-34
Installing the upper case ................. 7-20, 7-62
Removing the power trim and tilt
unit.................................................7-30, 7-70
Removing the power unit.......................... 5-10
Removing the propeller shaft housing
5
Installing the valves...................................5-33 assembly .......................................6-11, 6-39

L.
Installing the water pump and
shift rod ......................................... 6-22, 6-49
Removing the starter motor pinion ........... 8-17
Removing the steering arm .............7-23, 7-64
Removing the timing belt and sprockets... 5-17
Removing the water pump and
6
Lower unit ................................1-15, 2-6, 3-13 shift rod............................................6-8, 6-36

7
Lower unit (F100B) .....................................6-4 Replacing the timing belt ............................ 3-7
Lower unit (F100C) ...................................6-31 Replacing the valve guides....................... 5-28
Lubrication ................................................3-16
Lubrication system ....................................1-20 S.
Safety while working................................... 1-3
M.
Maintenance interval chart..........................3-2
Maintenance specifications.........................2-3
Manual format .............................................1-1
Selecting the connecting rod big end bearing .
5-44
Selecting the crankshaft main journal bearing.
5-47
8
Measuring the forward and reverse gear Selecting the forward gear shims ....6-27, 6-55

9
backlash..................................................6-29 Selecting the pinion shims...............6-26, 6-54
Measuring the forward gear backlash.......6-56 Selecting the reverse gear shims ....6-28, 6-56
Measuring the lower resistance ..................8-2 Selection................................................... 1-25
Measuring the peak voltage........................8-2 Self-protection ............................................ 1-3
Serial number ............................................. 1-5
Shimming.........................................6-26, 6-54
N. Shimming (F100B).................................... 6-25
Not installed .................................... 7-48, 7-88 Shimming (F100C) ................................... 6-53

60C5D11 i-3

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 Index
Special service
tools ....................3-1, 4-1, 5-1, 6-1, 7-1, 8-1
Specified torques ......................................2-14
Starboard and port views ............................8-3
Starter motor .............................................8-15
Starting system .........................................8-13
Swivel bracket and clamp brackets
(F100C)...................................................7-63
Swivel bracket and steering arm
(F100B) ...................................................7-21
Symbols ......................................................1-2
Synchronizing the carburetors ..................4-20

T.
Technical tips ............................................1-16
Test run.....................................................1-28
Throttle control ............................................4-9
Tightening torques ....................................2-14
Tiller handle ................................................7-3
Tiller handle model......................................8-5
Tilt cylinder and trim cylinder (F100B) ......7-31
Tilt cylinder and trim cylinder (F100C) ......7-71
Timing belt and sprockets .........................5-12
Top cowling.................................................3-4

U.
Upper case (F100B)..................................7-11
Upper case (F100C) .................................7-53

V.
Ventilation ...................................................1-3

W.
Wiring harness ............................................8-6

i-4 60C5D11

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 Wiring diagram
F100BET, F100CET
1 Battery Color code
2 Power trim and tilt motor B : Black
3 Starter motor Br : Brown
4 Starter relay G : Green
5 Power trim and tilt relay Gr : Gray
6 Rectifier Regulator L : Blue
7 Lighting coil Lg : Light green
8 Pulser coil O : Orange
9 Ignition coil P : Pink
0 Spark plug R : Red
A Throttle position sensor Sb : Sky blue
B Trim sensor W : White
C CDI unit Y : Yellow
D Oil pressure switch B/O : Black/orange
E Prime Start B/W : Black/white
F Hour meter B/Y : Black/yellow
G Fuse (30A) G/R : Green/red
H Fuse (20A) G/W : Green/white
I Neutral switch P/B : Pink/black
J Trailer switch P/W : Pink/white
K Power trim and tilt switch W/B : White/black
L Trim sensor W/R : White/red
M Engine stop switch
N Engine start switch

È Tiller handle model

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 YAMAHA MOTOR CO., LTD.
Printed in the Netherlands
Jun. 2001 – 0.5 × 1 CR
(F100BET, F100CET)
(E)

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 F100BET, F100CET
B

Br

G/W W G
B
B G/W Gy
W
G W L
G
G G W W B Lg
B B B W
B/W O

P
Br B G/W R B
R

Sb
B Gy
W
#1
B/W
Y
L
L
#4 B/O
Sb B
B B/W

#2 B/Y
B Gy R B B/W
B G/R
G
G
B G/W
#3
Lg P/B
B P/W

W/R B W/B W/B

B/W W/R
B/O

B G Y W/B
B
B B/W B/O
W/R
Y

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

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

B O
Br B G/W Y
Y P
R W
Y R
P/B
W B R Y Br P/W
OFF B P O
ON G/R G/W P/B
START P/W R
W B L B
B Br
W W B R Y Br G/R G/W

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

Sb Lg

L B

W O P/B B Sb R Lg
Sb R Lg UP L B L B
Sb Lg
B O B FREE
Gy UP
DOWN
FREE
P Sb
B
DOWN
Sb Lg Sb R Lg
L B L B
Lg Sb R Lg
P Gy Sb R
W P/B
Sb Sb
R R
Lg Lg
Lg R Lg R Sb

S60CWD01

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