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Yamaha e60hmhd User Manual

Yamaha e60hmhd
488 pages
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F
ES
290377
69D-28197-ZA-C1
WORLDWIDE
E60HMHD
E60HWHD
E60HWD
USA, CANADA
E60MH
E60EH
WARTUNGSHANDBUCH
MANUAL DE SERVICIO
MANUEL D'ENTRETIEN
SERVICE MANUAL

Table of Contents

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Yamaha e60hmhd Specifications

General IconGeneral
BrandYamaha
Modele60hmhd
CategoryOutboard Motor
LanguageEnglish

Summary

NOTICE

SERVICE MANUAL

Official Yamaha service manual for dealers and trained mechanics, detailing maintenance and repair procedures.

HOW TO USE THIS MANUAL

MANUAL FORMAT

Describes the manual's sequential, step-by-step format, including disassembly, repair, assembly, and inspection explanations.

MODEL INDICATION

Details how specific models are referenced and indicated throughout the manual.

ILLUSTRATIONS

States that illustrations within the manual represent all designated models.

CROSS REFERENCES

Mentions cross references are kept to a minimum and direct to appropriate sections.

IMPORTANT INFORMATION

WARNING

Highlights critical safety information where non-compliance may lead to severe injury or death.

CAUTION

Indicates necessary precautions to prevent damage to the outboard motor.

NOTE

Provides supplementary information to enhance procedure clarity and ease of execution.

SYMBOLS

Chapter Indicators (Symbols ①-⑨)

Symbols used as thumb-tabs to denote the content of each chapter.

Specific Data Indicators (Symbols ⑩-⑱)

Symbols indicating specific data such as special tools, liquids, speeds, torque, and electrical values.

Exploded Diagram Indicators (Symbols ⑲-㉓)

Symbols used in exploded diagrams to identify lubricant grade, sealing agents, and application points.

CHAPTER 1 GENERAL INFORMATION

IDENTIFICATION

Details on serial numbers and model identification for the outboard motor.

SAFETY WHILE WORKING

Covers essential safety procedures for working with the equipment.

SPECIAL TOOLS

Lists and describes specific tools recommended by Yamaha for maintenance and assembly.

FEATURES AND BENEFITS

Highlights key improvements and advantages of the engine's design and components.

TECHNICAL TIPS

Provides expert advice and operational details on specific systems like the shift mechanism.

CHAPTER 2 SPECIFICATIONS

GENERAL SPECIFICATIONS

Provides overall technical data including dimensions, weight, performance metrics, and power unit details.

MAINTENANCE SPECIFICATIONS

Details specific maintenance data for various engine components, carburetor, and electrical systems.

DIMENSIONS

Presents detailed dimensional data for the outboard motor and bracket components.

TIGHTENING TORQUES

Specifies required torque values for fasteners in various assemblies like power unit, lower unit, and bracket.

CHAPTER 3 PERIODIC CHECK AND ADJUSTMENT

TOP COWLING

Details on checking and adjusting the fit of the top cowling.

FUEL SYSTEM

Covers checks for the fuel line and fuel filter condition.

CONTROL SYSTEM

Provides procedures for adjusting ignition timing, carburetors, throttle, and shift controls.

LOWER UNIT

Covers checks and procedures for gear oil level and lower unit integrity.

GENERAL

Includes general checks for anode, battery, spark plugs, and lubrication points.

CHAPTER 4 FUEL SYSTEM

FUEL LINE

Covers removal, installation, and checking of the fuel joint.

FUEL FILTER

Details disassembly, assembly, and checking procedures for the fuel filter.

FUEL PUMP

Covers disassembly, assembly, and checking procedures for the fuel pump.

CARBURETOR

Provides instructions for removing, installing, disassembling, and checking the carburetor.

CHAPTER 5 POWER UNIT

RECOIL STARTER ASSEMBLY

Covers removal, installation, disassembly, and assembly of the recoil starter.

STARTER PULLEY AND FLYWHEEL MAGNET ASSEMBLY

Details removal and installation procedures for the starter pulley and flywheel magnet assembly.

POWER UNIT

Covers removal and installation of electrical units and related parts for the power unit.

MAGNET BASE AND CONTROL LEVER

Provides steps for removing and installing the magnet base and its associated control lever.

INTAKE MANIFOLD AND REED VALVES

Covers removal, installation, and checking procedures for the intake manifold and reed valves.

CYLINDER HEAD

Details removal, installation, and checking procedures for the cylinder head assembly.

CHAPTER 6 LOWER UNIT

LOWER UNIT

Covers removal, installation, and checking of propeller, trim tab, and lower unit components.

SHIFT ROD ASSEMBLY

Details removal, installation, and checking of the shift rod and its related components.

PROPELLER SHAFT HOUSING ASSEMBLY

Covers disassembly, assembly, and checking of propeller shaft housing and assembly components.

SHIMMING (FOR USA AND CANADA)

Explains how to select pinion gear shims for USA and Canada models.

SHIMMING (EXCEPT FOR USA AND CANADA)

Explains how to select pinion gear shims for models outside the USA and Canada.

BACKLASH

Covers the measurement and adjustment procedures for both forward and reverse gear backlash.

CHAPTER 7 BRACKET UNIT

STEERING HANDLE ASSEMBLY

Covers removal, installation, and disassembly of the steering handle and friction bracket.

BOTTOM COWLING

Details removal and installation procedures for the bottom cowling assembly.

SHIFT ACTUATOR

Covers the disassembly and assembly procedures for the shift actuator.

UPPER CASE ASSEMBLY

Details removal, installation, and disassembly of the upper case assembly components.

STEERING ARM

Covers removal and installation procedures for the steering arm.

CLAMP BRACKETS

Covers removal, installation, and checking of clamp brackets and shock absorber.

CHAPTER 8 ELECTRICAL SYSTEMS

ELECTRICAL COMPONENT

Identification of electrical components with their corresponding wire color codes.

ELECTRICAL COMPONENTS ANALYSIS

Details analysis procedures for digital circuit testers, peak voltage, and low resistance measurements.

IGNITION SYSTEM

Covers checks for spark plugs, ignition coils, charge coil, pulser coil, and CDI unit.

IGNITION CONTROL SYSTEM

Provides wiring diagrams and checks for main switch, engine stop switch, thermo switch, and warning lamp.

STARTING SYSTEM

Covers checks for battery, fuse, wire harness, connections, switches, relay, and fuel enrichment valve.

STARTER MOTOR

Details disassembly, assembly, and checking procedures for the starter motor and its components.

CHARGING SYSTEM

Covers checks for battery, fuse, lighting coil, and rectifier/regulator.

CHAPTER 9 TROUBLE ANALYSIS

TROUBLE ANALYSIS

Provides a general overview of troubleshooting steps and items to check.

TROUBLE ANALYSIS CHART

A chart correlating trouble modes with elements to inspect and relevant chapters.

TROUBLE SHOOTING FOR PEAK VOLTAGE

Diagnostic steps for troubleshooting ignition system issues related to peak voltage.

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