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Yamaha FT60D Service Manual

Yamaha FT60D
305 pages
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F50F
FT50G
F60C
FT60D
SERVICE MANUAL
6C1-28197-3G-11
290551

Table of Contents

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Yamaha FT60D Specifications

General IconGeneral
Engine Type4-stroke
Starting SystemElectric
Cylinder ConfigurationIn-line 4
Full Throttle RPM Range5000-6000 rpm
Displacement996 cc
Maximum Output60 hp
Fuel SystemEFI
Weight114 kg
Bore x Stroke65 x 75 mm
Alternator Output at W.O.T.17 Amp

Summary

NOTICE

Important information

General Information

How to use this manual

Explains the manual's format, symbols, and usage guidelines.

Manual format

Details the structure and presentation of information within the manual.

Safety while working

Outlines essential safety procedures for preventing accidents and injuries during service.

Identification

Details model identification, applicable models, and serial number information.

Outline of features

Describes the new electronic fuel injected F50 and F60 outboard motors' design.

Features and benefits

Highlights key features like the fuel system, solenoid valve, and electronic control systems.

Propeller selection

Guides the choice of propeller size and type for optimal boat and outboard motor performance.

Predelivery checks

Lists essential checks to ensure smooth and efficient delivery of the outboard motor.

Symbols

Test Run and Break-in Procedures

Specifications

General specifications

Provides overall specifications including dimensions, weight, performance, and power unit details.

Maintenance specification

Details critical maintenance values for power unit, cylinder head, pistons, and more.

Tightening torques

Lists specified tightening torques for various parts and assemblies.

Dimensions

Presents exterior dimensions for different models and configurations.

Periodic checks and adjustments

Special service tools

Lists essential specialized tools required for maintenance and checks.

Maintenance interval chart

Outlines recommended maintenance intervals for various components and systems.

Top cowling checks

Describes how to check and adjust the fitting of the top cowling.

Fuel system checks

Details checks for fuel joints, hoses, and the fuel filter.

Power unit checks

Covers checks for engine oil, timing belt, spark plugs, and thermostat.

Control system checks

Explains checks for idle speed, throttle link, and gear shift operations.

Bracket unit checks

Includes checks for power trim/tilt and hydro tilt operations.

Lower unit checks

Covers checks for gear oil level and air leakage.

General checks

Includes checks for anodes, battery, and propeller.

Fuel system

Special service tools

Lists specialized tools for fuel system diagnostics and repairs.

Hose routing

Illustrates the routing of fuel, blowby, and cooling water pilot hoses.

Fuel filter and fuel pump

Provides an exploded view and details for servicing the fuel filter and pump assembly.

Intake manifold

Shows the components of the intake manifold, including fuel rail and throttle body.

Vapor separator

Details the exploded view and procedures for servicing the vapor separator.

Power unit

Special service tools

Lists specialized tools for power unit diagnostics and repairs.

Power unit service

Covers procedures for checking compression pressure and oil pressure.

Cylinder head service

Details procedures for removing, inspecting, and servicing the cylinder head components.

Cylinder block service

Outlines procedures for disassembling and checking the cylinder block and its internal parts.

Exhaust cover service

Provides an exploded view and details for servicing the exhaust cover assembly.

Lower unit

Special service tools

Lists specialized tools required for lower unit servicing.

Lower unit service (F50, F60)

Details procedures for removing, disassembling, and checking the F50/F60 lower unit.

Lower unit service (FT50, FT60)

Details procedures for removing, disassembling, and checking the FT50/FT60 lower unit.

Shimming procedures

Guides on selecting and installing shims for proper gear alignment.

Backlash measurement

Explains how to measure and adjust gear backlash.

Bracket unit

Special service tools

Lists specialized tools for bracket unit servicing.

Tiller handle

Details the assembly, lubrication, and adjustment of the tiller handle.

Bottom cowling

Provides an exploded view and procedures for servicing the bottom cowling.

Upper case

Details the exploded view and procedures for servicing the upper case.

Steering arm

Covers the removal and installation of the steering arm and its components.

Clamp brackets and swivel bracket

Explains the removal, installation, and adjustment of clamp brackets and swivel bracket.

Power trim and tilt unit

Details the removal, disassembly, checking, and assembly of the power trim and tilt unit.

Gear pump

Outlines procedures for disassembling, checking, and assembling the gear pump.

Tilt cylinder and trim cylinder

Covers disassembly, checking, and assembly of the tilt and trim cylinders.

Electrical systems

Special service tools

Lists specialized tools for electrical system diagnostics.

Checking electrical components

Details procedures for measuring peak voltage and lower resistance.

Electrical components views

Provides visual identification of electrical components from different views.

Ignition and ignition control system

Covers checks for ignition spark, spark plug wires, ignition coils, ECM, and pulser coil.

Fuel control system

Details checks for fuel injectors, electric fuel pump, and solenoid valve.

Starting system

Covers checks for fuses and the starter relay.

Starter motor

Provides an exploded view and disassembly/checking procedures for the starter motor.

Charging system

Covers checks for the stator coil and rectifier regulator.

Troubleshooting

Special service tools

Lists specialized tools for troubleshooting.

Yamaha Diagnostic System

Introduces the diagnostic system, its features, functions, and hardware requirements.

Self-diagnosis

Explains how to diagnose electronic control system malfunctions using flash patterns.

Power unit troubleshooting

Provides diagnostic flowcharts for engine starting issues.

Fuel system troubleshooting

Offers troubleshooting steps for fuel system related problems.

Power trim and tilt unit troubleshooting

Guides on troubleshooting issues with the power trim and tilt unit operation.

Index

Wiring Diagram

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