Yamaha F50 Service Manual
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62Y3A11i-2 1 2 3 4 5 6 7 8 Checking the piston diameter ................... 5-56 Checking the piston pin............................. 5-58 Checking the piston pin boss bore ............ 5-58 Checking the piston ring grooves.............. 5-58 Checking the piston ring side clearance ... 5-58 Checking the piston rings.......................... 5-57 Checking the power trim and tilt fluid level ............................................ 3-16 Checking the power trim and tilt motor ..... 7-75 Checking the power trim and tilt operation ............................................ 3-16 Checking the power trim and tilt relay ....... 7-79 Checking the power trim and tilt switch/trailer switch ............................ 7-80 Checking the Prime Start .......................... 4-20 Checking the propeller .............................. 3-19 Checking the propeller shaft ........... 6-15 , 6-55 Checking the propeller shaft housing ......................................... 6-15 , 6-54 Checking the pulser coil ............................ 8-16 Checking the pulser coil air gap ................ 8-16 Checking the Rectifier Regulator .............. 8-26 Checking the remote control cables.......... 1-34 Checking the rocker arms and rocker arm shaft ...................................... 5-45 Checking the shift rod and shift cam ......... 6-25 Checking the shift rod assembly operation ................................................. 7-29 Checking the spark plug caps ................... 8-14 Checking the spark plugs.......................... 3-11 Checking the starter motor operation........ 8-24 Checking the starter motor pinion ............. 8-23 Checking the starter relay ......................... 8-20 Checking the steering wheel/ tiller handle.............................................. 1-34 Checking the thermostat ........................... 3-12 Checking the thermoswitch ....................... 8-18 Checking the throttle cable and shift cable ................................................ 7-15 Checking the throttle cable and shift rod... 7-23 Checking the throttle cable operation ....... 3-13 Checking the tilt cylinder and trim cylinder............................................. 7-64 Checking the tilt system ............................ 1-35 Checking the timing belt.............................. 3-7 Checking the timing belt and sprockets .... 5-32 Checking the top cowling ............................ 3-4 Checking the trim sensor .......................... 7-80 Checking the valve clearance ................... 3-10 Checking the valve guides ........................ 5-41 Checking the valve seat ............................ 5-42 Checking the valve springs ....................... 5-40 Checking the valves .................................. 5-40Checking the water pump ......................... 6-14 Checking the water pump and shift rod .... 6-47 Checking the wiring harness (10 pins) ..... 8-20 Clamp brackets......................................... 7-43 Control system.......................................... 3-13 Cooling water hose ..................................... 4-3 Cylinder body............................................ 5-51 Cylinder head ........................................... 5-35 D. Dimensions ............................................... 2-19 Disassembling the cylinder body .............. 5-55 Disassembling the drive shaft................... 6-61 Disassembling the drive shaft assembly .. 6-23 Disassembling the forward gear ......6-23 , 6-61 Disassembling the fuel pump ..................... 4-9 Disassembling the gear pump .................. 7-64 Disassembling the lower case .........6-24 , 6-62 Disassembling the oil pan......................... 7-39 Disassembling the propeller shaft assembly .......................................6-14 , 6-54 Disassembling the propeller shaft housing ..........................................6-13 , 6-53 Disassembling the tilt cylinder .................. 7-63 Disassembling the trim cylinder ................ 7-63 Disassembly and assembly ........................ 1-4 Drive shaft and lower case (F50/F50A) .... 6-21 Drive shaft and lower case (T50/FT50B, FT50C) .............................. 6-59 E. Electrical ............................................2-9, 2-16 Electrical components ................................ 8-5 F. Features and benefits ................................. 1-6 Fire prevention............................................ 1-3 Front view ................................................... 8-6 Fuel and blowby hoses ............................... 4-2 Fuel filter and fuel pump ............................. 4-7 Fuel line ...................................................... 4-5 Fuel system ................................................ 3-4 G. Gear pump................................................ 7-59 General ..................................................... 3-19 General specifications ................................ 2-1 General torques ........................................ 2-31 Good working practices .............................. 1-4
Index i-362Y3A11 H. Hose routing................................................ 4-2 How to use this manual............................... 1-1 I. Identification ................................................ 1-5 Ignition system .......................................... 1-17 Ignition system and Ignition control system..................................................... 8-11 Ignition timing control ................................ 1-19 Installing the camshaft .............................. 5-48 Installing the clamp brackets..................... 7-45 Installing the cylinder head ....................... 5-49 Installing the drive shaft .................. 6-28 , 6-66 Installing the lower unit ................... 6-28 , 6-66 Installing the power trim and tilt ................ 7-76 Installing the power unit ............................ 5-67 Installing the propeller shaft housing ......................................... 6-18 , 6-57 Installing the rocker arm assembly ........... 5-49 Installing the steering arm ......................... 7-49 Installing the timing belt and sprockets ..... 5-32 Installing the upper case ........................... 7-41 Installing the valves................................... 5-47 Installing the water pump .......................... 6-18 Installing the water pump and shift rod ..... 6-48 L. Lower unit ........................ 1-8, 2-9, 2-16, 3-17 Lower unit (F50/F50A) ................................ 6-7 Lower unit (T50/FT50B, FT50C) ............... 6-41 Lubricating the throttle gear ...................... 7-23 Lubrication ................................................ 3-21 M. Maintenance interval chart .......................... 3-3 Maintenance specifications ......................... 2-5 Manual format ............................................. 1-1 Measuring the forward and reverse gear backlash................... 6-39 , 6-77 Measuring the lower resistance .................. 8-4 Measuring the peak voltage ........................ 8-4 N. Newly designed four carburetors ................ 1-6 P. Parts, lubricants, and sealants .................... 1-3 Power trim and tilt ..................................... 1-22 Power trim and tilt electrical system.......... 7-78 Power trim and tilt motor ........................... 7-73Power trim and tilt unit .....................3-16 , 7-51 Power unit........................ 2-5 , 2-12, 3-5, 5-13 Predelivery checks ................................... 1-33 Propeller selection .................................... 1-32 Propeller shaft housing (T50/FT50B, FT50C) .............................. 6-51 Propeller size ............................................ 1-32 R. Refacing the valve seat ............................ 5-43 Removing and installing the oil filter ......... 5-55 Removing the clamp brackets .................. 7-45 Removing the cylinder head ..................... 5-39 Removing the drive shaft .................6-23 , 6-61 Removing the lower unit ....................6-9 , 6-43 Removing the power trim and tilt/ hydro tilt .................................................. 7-53 Removing the power unit .......................... 5-26 Removing the propeller shaft housing assembly ................................................ 6-53 Removing the starter motor pinion ........... 8-23 Removing the steering arm ...................... 7-49 Removing the timing belt and sprockets... 5-31 Removing the water pump and propeller shaft housing assembly ........... 6-13 Removing the water pump and shift rod ... 6-47 Replacing the engine oil ............................. 3-5 Replacing the gear oil ............................... 3-17 Replacing the timing belt ............................ 3-7 Replacing the valve guides....................... 5-41 S. Safety while working ................................... 1-3 Selecting the connecting rod big end bearing.................................................... 5-63 Selecting the crankshaft main journal bearing.................................................... 5-62 Selecting the forward gear shims ......................... 6-33 , 6-37, 6-71, 6-75 Selecting the pinion shims ......................... 6-32 , 6-36, 6-70, 6-74 Selecting the reverse gear shims ....6-34 , 6-38 Selection ................................................... 1-32 Self-protection ............................................ 1-3 Serial number ............................................. 1-5 Shimming..................... 6-32 , 6-36, 6-70, 6-74 Shimming (F50) (for USA and Canada) ... 6-31 Shimming (F50A) (for worldwide) ............. 6-35 Shimming (FT50B, FT50C) (for worldwide) ........................................ 6-73 Shimming (T50) (for USA and Canada) ... 6-69
62Y3A11i-4 1 2 3 4 5 6 7 8 Special service tools .................. 3-1 , 4-1, 5-10, 6-1, 7-4, 8-2 Specified torques ...................................... 2-29 Starboard and port views ............................ 8-5 Starter motor ............................................. 8-21 Starting system ......................................... 8-19 Swivel bracket and steering arm ............... 7-47 Symbols ...................................................... 1-2 Synchronizing the carburetors .................. 4-23 T. Technical tips ............................................ 1-10 Test run ..................................................... 1-35 Tightening torques .................................... 2-29 Tiller handle (F50/F50A, T50/FT50B) ......... 7-5 Tiller handle (FT50C) ................................ 7-17 Tiller handle model (F50/F50A, T50/FT50B) ............................ 8-8 Tiller handle model (FT50C) ....................... 8-9 Tilt cylinder and trim cylinder .................... 7-55 Timing belt and sprockets ......................... 5-29 Top cowling ................................................. 3-4 Top view...................................................... 8-7 Trim cylinder ............................................. 7-57 Troubleshooting ...........................5-1 , 7-1, 8-1 U. Upper case................................................ 7-31 V. Ventilation ................................................... 1-3 W. Water pump and propeller shaft housing (F50/F50A) .............................................. 6-11 Water pump and shift rod (T50/FT50B, FT50C)............................... 6-45 Wiring harness .......................................... 8-10
Wiring diagram F50AEHD, F50AED, FT50CEHD, FT50CED 1Battery 2Engine start switch 3Engine shut-off switch 4Starter motor 5Starter relay 6Neutral switch 7Fuse (20A) 8Prime Start 9Warning indicator 0CDI unit AThermoswitch BOil pressure switch CCharge coil DPulser coil ELighting coil FRectifier Regulator GIgnition coil HSpark plug IHour meter ÈEHD ÉOptionColor code B: Black Br : Brown G: Green L: Blue O : Orange P: Pink R: Red W: White Y : Yellow B/O : Black/orange B/W : Black/white B/Y : Black/yellow G/W : Green/white Gy/B : Gray/black P/B : Pink/black P/W : Pink/white W/B : White/black W/R : White/red Y/B : Yellow/black Y/R : Yellow/red
Wiring diagram F50TH/F50AEHT 1Battery 2Power trim and tilt motor 3Engine start switch 4Power trim and tilt relay 5Engine shut-off switch 6Starter motor 7Starter relay 8Neutral switch 9Fuse (20A) 0Warning indicator APrime Start BPower trim and tilt switch CCDI unit DThermoswitch ECharge coil FLighting coil GPulser coil HRectifier Regulator IOil pressure switch JTrailer switch KIgnition coil LSpark plug ÈWith trailer switch modelColor code B: Black Br : Brown G: Green L: Blue Lg : Light green O : Orange P: Pink R: Red Sb : Sky blue W: White Y : Yellow B/O : Black/orange B/W : Black/white B/Y : Black/yellow G/W : Green/white Gy/B : Gray/black P/B : Pink/black P/W : Pink/white W/B : White/black W/R : White/red Y/B : Yellow/black Y/R : Yellow/red
Wiring diagram (applicable for tachometer, trim meter or warning buzzer) F50TH/F50AEHT* 1Battery 2Power trim and tilt motor 3Power trim and tilt relay 4Starter motor 5Fuse (20A) 6Neutral switch 7Starter relay 8Prime Start 9CDI unit 0Charge coil ALighting coil BPulser coil CRectifier Regulator DThermoswitch EOil pressure switch FEngine start switch GEngine shut-off switch HPower trim and tilt switch ITrailer switch JTrim sensor KIgnition coil LSpark plugColor code B: Black Br : Brown G: Green L: Blue Lg : Light green O : Orange P: Pink R: Red Sb : Sky blue W: White Y : Yellow B/O : Black/orange B/W : Black/white B/Y : Black/yellow G/R : Green/red G/W : Green/white Gy/B : Gray/black P/B : Pink/black P/W : Pink/white W/B : White/black W/R : White/red Y/B : Yellow/black Y/R : Yellow/red
Wiring diagram F50TR/F50AET, T50TR/FT50BET, FT50CET 1Battery 2Power trim and tilt motor 3Power trim and tilt relay 4Starter motor 5Fuse (20A) 6Trim sensor 7Prime Start 8Starter relay 9CDI unit 0Charge coil ALighting coil BPulser coil CRectifier Regulator DThermoswitch EOil pressure switch FTrailer switch GIgnition coil HSpark plug IHour meter ÈOptionColor code B: Black Br : Brown G: Green Gr : Gray L: Blue Lg : Light green O : Orange P: Pink R: Red Sb : Sky blue W: White Y : Yellow B/O : Black/orange B/W : Black/white B/Y : Black/yellow G/W : Green/white Gy/B : Gray/black P/B : Pink/black P/W : Pink/white W/B : White/black W/R : White/red Y/B : Yellow/black Y/R : Yellow/red
YAMAHA MOTOR CO., LTD. Printed in the Netherlands Nov. 2000 – 1.4 × 1 CR(F50AEHD, F50AEHT, F50AED, F50AET, FT50BET, FT50CEHD, FT50CED, FT50CET)
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