Selva Dorado 60 EFI Manuel de service

YAMAHA MOTOR CO., LTD.F4A/F4Goldfish 4Dorado 60 EFIDorado 50 EFISERVICE MANUAL

GEN INFOGeneral information1-56C13G11Serial numberThe outboard motor serial number isstamped on a label attached to the portclamp bracket.1Model name2

POWRPower unit5-96C13G115No. Part name Q’ty Remarks1 Rectifier Regulator 12Bolt 2 M6 × 25 mm3 Spark plug 44 Spark plug wire 45 Holder 16 Ignition coil

6C13G115-101234567895No. Part name Q’ty Remarks1 Starter motor 12Bolt 3 M8 × 45 mm3Screw 1 ø4 × 5 mm4Cap 15 Starter relay 16Bolt 2 M6 × 10 mm7Cap 28 H

POWRPower unit5-116C13G115No. Part name Q’ty Remarks1Bracket 12 Junction box 13ECM 14 Main and fuel pump relay 15 Power trim and tilt relay 16 Cover 1

6C13G115-121234567895No. Part name Q’ty Remarks18 Bolt 2 M6 × 20 mm19 Holder 120 Bolt 1 M6 × 14 mm21 Bolt 2 M8 × 25 mm22 Bolt 1 M6 × 20 mm23 Grommet 1

POWRPower unit5-136C13G115No. Part name Q’ty Remarks1 Throttle cam 12 Throttle control lever 13Bracket 14 Lever 15 Washer 16 Bushing 17 Clip 18Bolt 2

6C13G115-14123456789Removing the power unitNOTE:It is recommended to loosen the flywheelmagnet nut before removing the power unit toimprove working ef

POWRPower unit5-156C13G1110. Remove the power unit by removing thebolts B.11. Remove the flywheel magnet, then theWoodruff key.CAUTION:To prevent dama

6C13G115-16123456789NOTE:• Use a deep socket 2 for this procedure.• Make sure that the camshaft does not turnwhen loosening the drive sprocket nut.3.

POWRPower unit5-176C13G11Installing the timing belt and sprocketsCAUTION:Do not turn the drive sprocket or thedriven sprocket when the timing belt isn

6C13G115-18123456789CAUTION:• Do not damage the timing belt duringinstallation.• Do not twist, turn inside out, or bend thetiming belt beyond the maxi

6C13G11 1-6123456789Outline of features 1New electronic fuel injected Dorado 50 EFI and 60 EFI outboard motors have a mainly redesigned fuel and int

POWRPower unit5-196C13G11Cylinder head5No. Part name Q’ty Remarks1 Cylinder head 12Screw 6 ø4 × 20 mm3Plate 14 Engine hanger 15Bolt 2 M6 × 20 mm6Gaske

6C13G115-201234567895No. Part name Q’ty Remarks18 Dowel 219 Gasket 1Not reusable20 Grommet 221 Bolt 5 M6 × 25 mm22 Oil pump assembly 123 Bolt 4 M6 × 4

POWRPower unit5-216C13G115No. Part name Q’ty Remarks1Camshaft 12 Oil seal 1Not reusable3Gasket 1Not reusable4 Retaining bolt 15 Washer 76 Rocker arm a

6C13G115-221234567895No. Part name Q’ty Remarks18 Stopper guide 119 Tensioner 120 Stopper guide 121 Tensioner 1Cylinder head

POWRPower unit5-236C13G11Removing the cylinder head1. Remove the cylinder head cover.2. Remove the cylinder head bolts in thesequence shown.CAUTION:Do

6C13G115-241234567896. Remove the intake and exhaust valves.NOTE:Be sure to keep the valves, springs, andother parts in the order as they wereremoved.

POWRPower unit5-256C13G113. Measure the valve stem diameter b.Replace if out of specification.4. Measure the valve stem runout. Replaceif above specif

6C13G115-26123456789NOTE:Apply engine oil to the surface of the newvalve guide.3. Insert the special service tool into thevalve guide 2, and then ream

POWRPower unit5-276C13G114. Measure the valve seat contact width awhere the blueing dye is adhered to thevalve face. Reface the valve seat if thevalve

6C13G115-28123456789b Previous contact width4. Use a 60° cutter to adjust the contactwidth of the bottom edge of the valveseat.b Previous contact widt

GEN INFOGeneral information1-76C13G11Features and benefits1Fuel systemA pressure regulator is built into the vapor separator to obtain compact and sim

POWRPower unit5-296C13G119. Apply a thin, even layer of lapping com-pound onto the valve seat, and then lapthe valve using a valve lapper (commer-cial

6C13G115-301234567893. Measure the camshaft journal diametersc and d, and cylinder head journalinside diameter e. Replace the camshaftand cylinder hea

POWRPower unit5-316C13G11Checking the oil pump1. Measure the oil pump rotor clearancesas shown. Replace if out of specification.Installing the valves1

6C13G115-321234567894. Lightly tap the valve spring retainer witha plastic hammer to set the valve cottersecurely.Installing the camshaft1. Install a

POWRPower unit5-336C13G112. Assemble the rocker arm assemblies 1and rocker arm shaft 2, and then installthe tensioners 3 and stopper guides 4to the ro

6C13G115-34123456789Installing the cylinder head1. Install the driven sprocket, and thencheck that the “ 1” mark a on thedriven sprocket 1 is aligned

POWRPower unit5-356C13G11Exhaust cover5No. Part name Q’ty Remarks1 Cooling water temperature sensor 12Gasket 1Not reusable3Bolt 1 M6 × 14 mm4 Holder 1

6C13G115-361234567895No. Part name Q’ty Remarks18 Cover 119 Bolt 1 M5 × 12 mm20 Plate 121 Bolt 1 M6 × 20 mm22 Joint 123 Hose 124 Hose 125 Joint 126 Ho

POWRPower unit5-376C13G11Cylinder block5No. Part name Q’ty Remarks1Bolt 10 M8 × 82 mm2Bolt 10 M6 × 35 mm3 Crankcase 14 Main bearing 105Bolt 8 M6 × 30

6C13G115-38123456789Disassembling the cylinder block1. Remove the thermostat cover andexhaust cover by removing the bolts inthe sequence shown.2. Remo

6C13G111-8123456789Solenoid valveJust after the engine is stopped, the cooling water supply is also stopped and the heat is conductedto the vapor sepa

POWRPower unit5-396C13G11Checking the piston diameter1. Measure the piston outside diameter atthe specified measuring point. Replace ifout of specific

6C13G115-401234567892. Level the piston ring 1 in the cylinderwith a piston crown.3. Check the piston ring end gap d at thespecified measuring point.

POWRPower unit5-416C13G11Checking the piston ring side clearance1. Measure the piston ring side clearance.Replace the piston and piston rings as aset

6C13G115-42123456789Checking the crankshaft1. Measure the crankshaft journal diametera, crankpin diameter b, and crankpinwidth c. Replace the cranksha

POWRPower unit5-436C13G113. Put a piece of Plastigauge (PG-1) ontothe crankpin, parallel to the crankshaft.NOTE:Be sure not to put the Plastigauge (PG

6C13G115-441234567893. Select the suitable color b for the con-necting rod bearing from the table.Checking the crankshaft journal oil clearance1. Clea

POWRPower unit5-456C13G116. Install the crankcase onto the cylinderblock.7. Apply engine oil to the threads of thecrankcase bolts, and then tighten th

6C13G115-46123456789Assembling the power unit1. Assemble the piston 1, connecting rod2, piston pin 3, and piston pin clips 4.NOTE:• Face the embossed

POWRPower unit5-476C13G115. Install the piston with the “UP” mark onthe piston crown facing towards the fly-wheel magnet.NOTE:Apply engine oil to the

6C13G115-48123456789NOTE:• Align the alignment marks g on the con-necting rod cap and connecting rod.• Apply engine oil to the connecting rod boltsbef

GEN INFOGeneral information1-96C13G11Electronic control systemThe electronic control system is built up by the sensors and the ECM (Electric control M

POWRPower unit5-496C13G1114. Install the oil filter, and then tighten it tothe specified torque using the oil filterwrench.NOTE:Apply a thin coat of e

6C13G115-501234567897. Install the PTT switch coupler, PTT motorleads, and battery leads.8. Connect the throttle cable 6, shift cable7, and throttle l

LOWR6C13G11Lower unitSpecial service tools ...6-1Lower unit

6C13G11123456789Lower unit (FT50, FT60)...6-28Removing the lower unit...

LOWRLower unit6-16C13G11Special service tools6Bearing housing puller claw L90890-06502Bearing housing puller claw S90890-06564Stopper guide plate90890

6C13G116-2123456789Ball bearing attachment90890-06655Driver rod LS90890-06606Bearing inner race attachment90890-06639, 90890-06641, 90890-06643, 90890

LOWRLower unit6-36C13G11Shift rod push arm90890-06052Pinion height gauge90890-06710Pinion height gauge plate B90890-06712Digital caliper90890-06704Shi

6C13G116-4123456789Ring nut wrench 390890-06511Ring nut wrench extension90890-06513Special service tools

LOWRLower unit6-5 6C13G11Lower unit 6No. Part name Q’ty Remarks1 Lower unit 12 Check screw 13Gasket 2Not reusable4Drain screw 15 Bolt 4 M10 × 40 mm6 D

6C13G11 6-61234567896No. Part name Q’ty Remarks1 Cover 12Seal 13Bolt 4 M8 × 30 mm4 Water pump housing 15 Insert cartridge 16 Impeller 17O-ring 1Not re

6C13G111-10123456789ECM (Electric Control Module)This engine is controlled by the ECM to obtain precision combustion under various operations, andcan

LOWRLower unit6-76C13G11Removing the lower unit1. Drain the gear oil.2. Set the gear shift to the neutral position,and place a block of wood between t

6C13G11 6-8123456789Propeller shaft housing 6No. Part name Q’ty Remarks1 Shift plunger 12 Dog clutch 13Cross pin 14Spring 15 Shift slider 16Spring 17

LOWRLower unit6-96C13G11Removing the propeller shaft housing assembly1. Remove the bolts, and then pull out thepropeller shaft housing assembly.2. Rem

6C13G11 6-10123456789Checking the propeller shaft housing1. Clean the propeller shaft housing using asoft brush and cleaning solvent, and thencheck it

LOWRLower unit6-116C13G112. Apply grease to new oil seals, and theninstall them into the propeller shaft hous-ing to the specified depth.NOTE:Install

6C13G11 6-12123456789Drive shaft and lower case 6No. Part name Q’ty Remarks1Seal 12 Oil seal housing 13O-ring 1Not reusable4 Oil seal 2Not reusable5 W

LOWRLower unit6-136C13G116No. Part name Q’ty Remarks18 Screw 1 ø5 × 28 mm19 Cooling water inlet cover 220 Nut 121 Joint 122 Plastic tie 1Not reusable2

6C13G11 6-14123456789Removing the drive shaft1. Remove the drive shaft assembly andpinion, and then pull out the forwardgear.Disassembling the drive s

LOWRLower unit6-156C13G11Disassembling the lower case1. Remove the taper roller bearing outerrace and shim(s).NOTE:Install the claws as shown.2. Remov

6C13G11 6-16123456789Checking the lower case1. Check the skeg and torpedo for cracks ordamage. Replace the lower case if nec-essary.Assembling the oil

GEN INFOGeneral information1-116C13G11Variable trolling RPM switch (optional)This device is an optional equipment for tiller handle model.The idling a

LOWRLower unit6-176C13G113. Install the sleeve, original shim(s), andtaper roller bearing outer race.CAUTION:Add or remove shim(s), if necessary, ifre

6C13G11 6-18123456789Installing the oil seal housing1. Install a new O-ring 1, the oil seal hous-ing 2, and the seal 3.Installing the propeller shaft

LOWRLower unit6-196C13G11Installing the water pump1. Install a new gasket 1, the outer platecartridge 2, and dowels 3.2. Install the Woodruff key into

6C13G11 6-201234567892. Align the center of the set pin a with thealignment mark b on the bracket.3. Install the two dowels 1 into the lowerunit.4. In

LOWRLower unit6-216C13G116. Install the propeller and propeller nut,and then tighten the nut finger tight.Place a block of wood between the anti-cavit

6C13G11 6-22123456789Shimming 6Drive shaft and lower case / Shimming

LOWRLower unit6-236C13G11ShimmingNOTE:• Shimming is not required when assemblingthe original lower case and inner parts.• Shimming is required when as

6C13G11 6-24123456789Example:If “M3” is 11.70 mm and “P” is (+5), then T3 = 11.70 – 11.30 – (+5)/100 mm = 0.40 – 0.05 mm = 0.35 mm5. Select the pinion

LOWRLower unit6-25 6C13G112. Calculate the forward gear shim thick-ness (T1) as shown in the examplesbelow.NOTE:“F” is the deviation of the lower case

6C13G11 6-261234567893. Install the special service tools so that itpushes against the propeller shaft.NOTE:Tighten the center bolt while turning the

6C13G11 1-12123456789Propeller selection 1The performance of a boat and outboardmotor will be critically affected by the sizeand type of propeller you

LOWRLower unit6-276C13G118. Apply a load to the reverse gear byinstalling the propeller 8 (without thewasher 9 and 0), then the spacer A asshown.NOTE:

6C13G11 6-28123456789Lower unit (FT50, FT60) 6No. Part name Q’ty Remarks1 Lower unit 12Hose 13 Check screw 14Gasket 2Not reusable5 Dowel 26 Bolt 4 M10

LOWRLower unit6-296C13G116No. Part name Q’ty Remarks18 Stud bolt 4 X-transom model19 Bolt 1 M8 × 185 mm/X-transom model20 Dowel 2 X-transom model21 Ex

6C13G116-301234567896No. Part name Q’ty Remarks1O-ring 1Not reusable2Bolt 2 M6 × 16 mm3 Oil seal 1Not reusable4 Oil seal housing 15O-ring 1Not reusabl

LOWRLower unit6-316C13G11Removing the lower unit1. Drain the gear oil.2. Set the gear shift to the neutral position,and place a block of wood between

6C13G116-32123456789NOTE:Pull up the shift rod assembly a little a to dis-connect it from the shift slider 2, turn it coun-terclockwise 90° b, and the

LOWRLower unit6-336C13G11Propeller shaft housing (FT50, FT60)6No. Part name Q’ty Remarks1 Slider 12 Shift plunger 13Cross pin 14 Dog clutch 15Spring 1

6C13G116-34123456789Removing the propeller shaft housing assembly1. Straighten the claw washer tabs a, andthen remove the ring nut and clawwasher.2. P

LOWRLower unit6-356C13G112. Remove the ball bearing.CAUTION:Do not reuse the bearing, always replaceit with a new one.3. Remove the oil seals and need

6C13G116-36123456789NOTE:• Install the needle bearing with the manufac-ture identification mark a facing toward theoil seal (propeller side).• When us

GEN INFOGeneral information1-136C13G11Predelivery checks1To make the delivery process smooth andefficient, the predelivery checks should becompleted a

LOWRLower unit6-376C13G11Drive shaft and lower case (FT50, FT60)6No. Part name Q’ty Remarks1 Drive shaft 12 Taper roller bearing 1Not reusable3 Pinion

6C13G116-381234567896No. Part name Q’ty Remarks18 Pinion 119 Nut 120 Lower case 121 Oil seal housing 122 O-ring 1Not reusable23 Oil seal 1Not reusabl

LOWRLower unit6-396C13G11Removing the drive shaft1. Remove the drive shaft assembly andpinion, and then pull out the forwardgear.Disassembling the dri

6C13G116-40123456789Disassembling the lower case1. Remove the taper roller bearing outerrace and shim(s).NOTE:Install the claws as shown.2. Remove the

LOWRLower unit6-416C13G11Assembling the lower case1. Install the needle bearing into the lowercase to the specified depth.NOTE:• Install the needle be

6C13G116-421234567892. Install the new needle bearing into theforward gear to the specified depth.Assembling the drive shaft1. Install a new drive sha

LOWRLower unit6-436C13G113. Install the propeller shaft housing assem-bly 4 into the lower case, and theninstall the straight key 5, claw washer6, and

6C13G116-441234567893. Install a new O-ring 5, onto the oil sealhousing 7.4. Install a new gasket 6, the oil seal hous-ing 7, a new gasket 8, and the

LOWRLower unit6-456C13G112. Align the alignment mark a on the bush-ing with the alignment mark b on thebracket.3. Install the dowels 1 into the lower

6C13G116-461234567896. Install the propeller and propeller nut,and then tighten the nut finger tight.Place a block of wood between the anti-cavitation

6C13G111-14123456789Checking the outboard motor mounting height1. Check that the anti-cavitation plate isaligned with the bottom of the boat. If themo

LOWRLower unit6-476C13G11Shimming (FT50, FT60)6

6C13G116-48123456789ShimmingNOTE:• Shimming is not required when assemblingthe original lower case and inner parts.• Shimming is required when assembl

LOWRLower unit6-496C13G114. Calculate the pinion shim thickness (T3)as shown in the examples below.NOTE:“P” is the deviation of the lower case dimen-s

6C13G116-50123456789NOTE:“F” is the deviation of the lower case dimen-sion from standard. The “F” mark a isstamped on the trim tab mounting surface of

LOWRLower unit6-516C13G114. Install the backlash indicator onto thedrive shaft (18 mm [0.71 in] in diameter),then the dial gauge onto the lower unit.N

6C13G116-52123456789— MEMO —Backlash (FT50, FT60)

BRKT6C13G11Bracket unitSpecial service tools ...7-1Tiller handle...

6C13G11123456789Tilt cylinder and trim cylinder...7-40Disassembling the trim cylinde

BRKTBracket unit7-16C13G11Special service tools7Bearing puller assembly90890-06535Bearing puller claw 190890-06536Stopper guide stand90890-06538Stoppe

6C13G117-2123456789Tiller handle7No. Part name Q’ty Remarks1 Tiller handle assembly 12Grommet 13Nut 24 Clip 15 Throttle cable 16 Retaining plate 17Bol

NOTICEThis manual has been prepared by Selva primarily for use by Selva dealers and their trainedmechanics when performing maintenance procedures and

GEN INFOGeneral information1-156C13G112. Check that the steering operatessmoothly.ÈTiller handle model ÉRemote control model3. Check that there is no

BRKTBracket unit7-36C13G117No. Part name Q’ty Remarks18 Collar 1 Short19 Washer 120 Friction piece 121 Collar 1 Long22 Friction piece 123 Steering loc

6C13G117-41234567897No. Part name Q’ty Remarks1 Tiller handle sub assembly 12Screw 2 ø6 × 10 mm3 Shift lever cover 14Bolt 1 M8 × 40 mm5 Shift lever 16

BRKTBracket unit7-56C13G117No. Part name Q’ty Remarks18 Grease nipple 119 Engine start switch housing 120 Engine start switch 121 Nut 122 Bolt 1 M6 ×

6C13G117-61234567897No. Part name Q’ty Remarks1 Tiller handle 12 Cotter pin 1Not reusable3 Friction adjusting knob 14Grommet 15 Plastic tie 1Not reusa

BRKTBracket unit7-76C13G117No. Part name Q’ty Remarks18 Screw 2 ø5 × 10 mm19 Bolt 1 M6 × 14 mm20 Spring housing 121 Spring 122 Actuator 123 Roller 124

6C13G117-8123456789Checking the throttle cable and shift cable1. Check the operation of the throttle cableand shift cable.2. Check the inner wire and

BRKTBracket unit7-96C13G11Bottom cowling7No. Part name Q’ty Remarks1 Washer 12 Bushing 13Bracket 14 Bushing 15Bolt 1 M5 × 14 mm6 Shift rod 17 Bushing

6C13G117-101234567897No. Part name Q’ty Remarks18 Bolt 1 M6 × 25 mm19 Fuel joint 120 Seal 121 Bottom cowling assembly 122 Bolt 1 M6 × 20 mm23 Holder 1

BRKTBracket unit7-116C13G117No. Part name Q’ty Remarks1 Seal 1 Tiller handle model2 Warning indicator 1 Tiller handle model3 Collar 1 Tiller handle mo

6C13G117-121234567897No. Part name Q’ty Remarks18 Cowling lock lever 119 Washer 120 Wave washer 121 Bushing 122 Bolt 4 M6 × 30 mm23 Grommet 424 Collar

6C13G111-16123456789Checking the engine start switch and engine stop lanyard switch1. Check that the engine starts when theengine start switch is turn

BRKTBracket unit7-136C13G11Upper case7No. Part name Q’ty Remarks1 Upper case assembly 12Nut 23 Bolt 2 M12 × 170 mm4 Washer 25Bolt 3 M8 × 30 mm6 Upper

6C13G117-141234567897No. Part name Q’ty Remarks18 Bolt 4 M8 × 30 mm19 Screw 1 ø6 × 7 mm20 Cover 1 High thrust model21 Bolt 2 M8 × 20 mm, High thrust m

BRKTBracket unit7-156C13G117No. Part name Q’ty Remarks1 Muffler assembly 12 Rubber seal 13Grommet 14 Dowel 25 Upper case 16 Drive shaft bushing 17 Cir

6C13G117-161234567897No. Part name Q’ty Remarks1 Exhaust guide 12 Oil seal 1Not reusable3Hose 14 Joint 15 Housing 16Gasket 1Not reusable7 Oil strainer

BRKTBracket unit7-176C13G117No. Part name Q’ty Remarks18 Rubber seal 119 Gasket 1Not reusable20 Plate 121 Dowel 222 Grommet 123 Pipe 124 Gasket 1Not r

6C13G117-18123456789Removing the upper case1. Place a drain pan under the drain hole,and then remove the drain bolt and letthe oil drain completely.2.

BRKTBracket unit7-196C13G11Assembling the oil pan1. Install a new gasket 1 onto the exhaustguide 2.2. Install the oil strainer 3, a new gasket,and the

6C13G117-201234567898. Install the muffler assembly A by insert-ing the tip of the cooling water pipe Binto the joint hole b of the upper case.9. Inst

BRKTBracket unit7-216C13G11Installing the upper case1. Install the upper and lower mountingbolts into the swivel bracket 1 simulta-neously.2. Install

6C13G117-22123456789Steering arm7No. Part name Q’ty Remarks1 Steering arm 12 Washer 13 Bushing 14O-ring 2Not reusable5 Bushing 26 Swivel bracket assem

GEN INFOGeneral information1-176C13G11Test run1. Start the engine, and then check that thegear shift operates smoothly.2. Check the engine idle speed

BRKTBracket unit7-236C13G11Removing the steering arm1. Remove the circlip 1.2. Remove the steering yoke 2 by strikingit with a plastic hammer.3. Remov

6C13G117-24123456789Steering arm

BRKTBracket unit7-256C13G11Clamp brackets and swivel bracket7No. Part name Q’ty Remarks1 Swivel bracket assembly 12Screw 2 ø6 × 16 mm/Power trim and t

6C13G117-261234567897No. Part name Q’ty Remarks1 Swivel bracket 12 Bushing 13 Tilt stop lever 14 Bushing 15 Collar 2 Distance a: 30.3–30.4 mm (1.19–1.

BRKTBracket unit7-276C13G11Removing the clamp brackets1. Remove the power trim and tilt or hydrotilt. For removal procedure, see “Remov-ing the power

6C13G117-28123456789 WARNINGAfter tilting up the outboard motor, besure to support it with the tilt stop lever.Otherwise, the outboard motor could sud

BRKTBracket unit7-296C13G11Power trim and tilt unit7No. Part name Q’ty Remarks1 Power trim and tilt unit 1 Power trim and tilt model2 Hydro tilt unit

6C13G117-30123456789Removing the power trim and tilt unit/hydro tilt unit1. Fully tilt the outboard motor up, and thensupport it with the tilt stop le

BRKTBracket unit7-316C13G11Power trim and tilt motor7No. Part name Q’ty Remarks1Stator 12Screw 3 ø5 × 20 mm3O-ring 1Not reusable4 Bearing 2Not reusabl

6C13G117-32123456789Disassembling the power trim and tilt motor1. Remove the power trim and tilt motor, O-ring, and joint from the power trim and tilt

6C13G11SPEC123456789SpecificationsGeneral specifications...2-1Maintena

BRKTBracket unit7-336C13G113. Measure the commutator diameter.Replace if below specification.4. Check the armature for continuity.Replace if out of sp

6C13G117-341234567896. Install the stator onto the motor base.NOTE:Place a clean cloth over the end of the arma-ture shaft, hold it with a pair of pli

BRKTBracket unit7-356C13G11Gear pump7No. Part name Q’ty Remarks1 Gear pump assembly 12Spacer 23Pin 14 Lever 15Bolt 1 M3 × 16 mm6Bolt 1 M3 × 35 mm7Spri

6C13G117-361234567897No. Part name Q’ty Remarks18 Washer 119 Spring 120 Washer 121 Up-relief valve seat 122 Bolt 2 M5 × 25 mm23 O-ring 1Not reusable24

BRKTBracket unit7-376C13G117No. Part name Q’ty Remarks1 Manual release spring 12Ball 23Bracket 14Bolt 1 M3 × 5 mm5Bolt 2 M5 × 6 mm6 Washer 27O-ring 2N

6C13G117-38123456789Disassembling the gear pump1. Remove the manual valve, then the gearpump and filters.2. Remove the relief valve seat caps, thenthe

BRKTBracket unit7-396C13G113. Install the gear pump cover 4, then thepins 5.4. Install the adapters 6 into the gear pumpcover.5. Install the balls 7 i

6C13G117-40123456789Tilt cylinder and trim cylinder7No. Part name Q’ty Remarks1 Tilt piston assembly 12O-ring 1Not reusable3O-ring 1Not reusable4O-rin

BRKTBracket unit7-416C13G11Disassembling the trim cylinder1. Hold the power trim and tilt unit 1 in avise using aluminum plates a on bothsides.2. Loos

6C13G117-42123456789Checking the tilt cylinder and trim cylinder1. Check the inner walls of the trim cylinderand tilt cylinder for scratches. Replace

SPECSpecifications2-1 6C13G11General specifications 2Item Unit ModelDorado 50 EFI DimensionOverall length mm (in) 706 (27.8)1,339 (52.7)706 (27.8)Over

BRKTBracket unit7-436C13G116. Install the backup ring and new O-ringinto the tilt piston 3.7. Install balls 4 and 5, absorber valvepin, spring, pins,

6C13G117-44123456789Assembling the power trim and tilt unit1. Hold the trim cylinder in a vise using alu-minum plates on both sides.2. Install the fil

BRKTBracket unit7-456C13G117. Install the balls 6 into the tilt cylinder,and then insert the tilt cylinder into thetrim cylinder 7.NOTE:Apply grease t

6C13G117-461234567895. Install the reservoir cap, and then tightenit to the specified torque.6. Connect the PTT motor leads to the bat-tery terminals

BRKTBracket unit7-476C13G116. Route the PTT motor leads through thehole, and then install the plastic tie.7. Connect the ground lead to the bottom oft

6C13G117-481234567897. Remove the reservoir cap 2, and thencheck the fluid level in the reservoir.NOTE:If the fluid is at the correct level, the fluid

BRKTBracket unit7-496C13G112. Connect the digital circuit tester betweenpower trim and tilt relay terminals 2 and3.3. Connect the light green (Lg) lea

6C13G117-50123456789Checking the trim sensor1. Measure the trim sensor resistance.Replace if out of specification.NOTE:Turn the lever 1 and measure th

ELEC– +6C13G11Electrical systemsSpecial service tools ...8-1Checking

6C13G11123456789Starting system...8-15Checking the fuses...

6C13G11 2-2123456789(*1)RON: Research Octane NumberPON: Pump Octane Number = (RON + Motor Octane Number)/2(*2)Meeting both API and SAE requirements(*3

ELECElectrical systems– +8-16C13G11Special service tools8Ignition tester90890-06754Digital circuit tester90890-03174Peak voltage adapter B90890-03172T

6C13G118-2123456789Checking the electrical components8Measuring the peak voltageNOTE:Before troubleshooting the peak voltage,check that all electrical

ELECElectrical systems– +8-36C13G11Electrical components8Port view1Power trim and tilt relay2Starter motor3Oil pressure switch4Cooling water temperatu

6C13G118-4123456789Bow view1 Sensor assembly (intake air temperature and intake air pressure)2 ECM3 Fuse (20 A) (ECM, ignition coil, electric fuel pum

ELECElectrical systems– +8-56C13G11Starboard view1Fuel injector2ECM3Throttle position sensor4Idle speed control5Sensor assembly (intake air temperatur

6C13G118-6123456789Top view1 Solenoid valve2 Rectifier Regulator3 Spark plug4 Ignition coil5 Power trim and tilt switch (remote control model)6 Oil pr

ELECElectrical systems– +8-76C13G11Tiller handle model1Shift position switch2Neutral switch (tiller handle model)3Warning indicator (tiller handle mod

6C13G118-8123456789Ignition and ignition control system8Checking the ignition spark1. Disconnect the spark plug caps from thespark plugs.2. Connect a

ELECElectrical systems–+8-96C13G113. Measure the ignition coil resistance.Replace if out of specification.Checking the ECM1. Disconnect an ignition co

6C13G118-10123456789Checking the pulser coil air gap1. Remove the flywheel magnet cover.2. Turn the flywheel magnet clockwise toalign the projection o

SPECSpecifications2-36C13G11Item UnitModelF60CEHT F60CET FT60DETDimensionOverall length mm (in) 1,339 (52.7) 706 (27.8)Overall width mm (in) 384 (15.1

ELECElectrical systems– +8-116C13G114. Check the switch for no continuity at thespecified pressure. Replace if there iscontinuity.Checking the cooling

6C13G118-121234567892. Connect the digital circuit tester leads tothe relay terminals 2 and 3.3. Connect the positive battery terminal tothe main and

ELECElectrical systems– +8-136C13G11Checking the warning indicators (tiller handle model)1. Connect a positive penlight battery termi-nal (1.5 V) to t

6C13G118-14123456789NOTE:After the engine start switch is turned to ON,the electric fuel pump will operate for 3 sec-onds.Checking the main and fuel p

ELECElectrical systems– +8-156C13G11Starting system8Checking the fuses1. Check the fuses for continuity. Replace ifthere is no continuity.Checking the

6C13G118-16123456789Starter motor8No. Part name Q’ty Remarks1 Clip 12 Pinion stopper 13 Starter motor pinion 14Spring 15Bolt 2 M6 × 35 mm6 Housing 17

ELECElectrical systems– +8-176C13G118No. Part name Q’ty Remarks18 Brush assembly 119 Brush spring 420 Brush holder 121 Plate 122 Washer 123 Bracket 12

6C13G118-18123456789Disassembling the starter motor1. Slide the pinion stopper 1 down asshown, and then remove the clip 2.NOTE:Remove the clip with a

ELECElectrical systems– +8-196C13G114. Check the armature for continuity.Replace if out of specifications.Checking the brushes1. Measure the brush len

6C13G118-20123456789Charging system8Checking the stator coil1. Disconnect the stator coil coupler.2. Connect the test harness (6 pins) to thestator co

6C13G112-4123456789(*1)RON: Research Octane NumberPON: Pump Octane Number = (RON + Motor Octane Number)/2(*2)Meeting both API and SAE requirements(*3)

ELECElectrical systems– +8-216C13G11— MEMO —

6C13G11TRBLSHTG123456789TroubleshootingSpecial service tools ...9-1

TRBLSHTGTroubleshooting9-16C13G11Special service tools9Diagnostic System60V-85300-02Diagnostic System60V-WS853-02Diagnostic flash indicator B90890-068

6C13G119-2123456789Diagnostic System 9IntroductionFeaturesThe newly developed Diagnostic System provides quicker detection and analysis of enginemalfu

TRBLSHTGTroubleshooting9-36C13G11Hardware requirementsMake sure that your computer meets the following requirements before using this software.Compute

6C13G119-4123456789Connecting the communication cable to the outboard motorBow viewS6C190103-pin communication couplerDiagnostic System

TRBLSHTGTroubleshooting9-56C13G11Self-diagnosis9Diagnosing the electronic control system1. Connect the special service tool to theoutboard motor as sh

6C13G119-6123456789Code Symptom1Normal15Incorrect cooling water temperature sensor signal18Incorrect throttle position sensor signal19 Incorrect batte

TRBLSHTGTroubleshooting9-76C13G11NOTE:• Before troubleshooting the outboard motor, check the mounting and rigging of the outboard motor.Also, make sur

6C13G119-8123456789YesNoCheck the wiring harness for continuity.YesRepair or replace the wiring har-ness.NoDisassemble and check the starter motor.Rep

SPECSpecifications2-5 6C13G11Maintenance specification 2Power unitItem Unit ModelDorado 50 EFI Power unitMinimum compression pressure(*1) kPa (kgf/cm2

TRBLSHTGTroubleshooting9-96C13G11Ignition systemCheck the condition of the spark plugs.Clean, adjust, or replace the spark plugs.NoCheck the ignition

6C13G119-10123456789YesRepair or replace the spark plug wire.NoGood condition?Check the ECM output peak voltage.Check the main and fuel pump relay (ma

TRBLSHTGTroubleshooting9-116C13G11Fuel systemCheck the electric fuel pump operation.YesNoYesNoReplace the electrical fuel pump.Repair or replace the d

6C13G119-12123456789Check the ignition system and compression pressure.NoYesReplace the needle valve.Is the needle valve bent or worn?Check the fuel f

TRBLSHTGTroubleshooting9-136C13G11Symptom 2: Engine speed at wide open throttle is low, engine speed decreases, or enginestalls (poor acceleration or

6C13G119-14123456789Ignition systemYesOut of specification?NoCheck the ignition system, fuel system, lubrication system, or cooling system.Check the v

TRBLSHTGTroubleshooting9-156C13G11Replace the engine stop lan-yard switch.YesNoIs there continuity?Check the resistance of each ignition coil.YesRepai

6C13G119-16123456789Fuel systemContinued on next page.Check the fuel filters for clogs, dirt, or water and the hoses for leaks.YesNoRepair or replace

TRBLSHTGTroubleshooting9-176C13G11Lubrication systemNoYesReplace the needle valve.Is the needle valve bent or worn?Check the ignition system, lubri-ca

6C13G119-18123456789Cooling systemCheck the oil pump for debris or oil leaks.YesNoCheck the oil passage.Debris or leaks?YesNoClean or replace the defe

6C13G11 2-61234567892nd piston ringDimension B mm (in) 1.47–1.49 (0.0579–0.0587)Dimension T mm (in) 2.60–2.80 (0.1024–0.1102)End gap mm (in) 0.30–0.50

TRBLSHTGTroubleshooting9-196C13G11Symptom 3: Engine speed not stable at low speeds or hunting occurs.Check the water pump.Replace the cooling water te

6C13G119-20123456789Ignition systemCheck the condition of the spark plugs.Clean, adjust, or replace the spark plugs.NoCheck the ignition spark using t

TRBLSHTGTroubleshooting9-216C13G11Fuel systemCheck the fuel pump dia-phragm.Check the vapor separator nee-dle valve.YesNoReplace the diaphragm.Replace

6C13G119-22123456789Power trim and tilt unit9Symptom 1: Power trim and tilt unit does not operate.Check the power trim and tilt motor operation.Can th

TRBLSHTGTroubleshooting9-236C13G11Symptom 2: Power trim and tilt unit does not hold the outboard motor up.YesNoCheck the power trim and tilt fluid lev

6C13G11i-1123456789IndexA.Adjusting the float ...4-19Adjusting the friction plate...7-8Adjus

Indexi-26C13G11Checking the main and fuel pump relay (main control)...8-11Checking the neutral switch (tiller h

6C13G11i-3123456789IndexE.ECM (Electric Control Module) ...1-10Electrical ... 2-9, 2-15Electrica

Indexi-46C13G11Removing the water pump and shift rod ...6-31Replacing the oil filter...

6C13G11i-5123456789Index— MEMO —

ContentsGeneral information1GEN INFOSpecifications2SPECPeriodic checks and adjustments3CHK ADJFuel system4FUELPower unit5POWRLower unit6LOWRBracket un

SPECSpecifications2-7 6C13G11Stem diameterIntake mm (in) 5.475–5.490 (0.2156–0.2161)Exhaust mm (in) 5.460–5.475 (0.2150–0.2156)Guide inside diameterIn

Wiring diagramF50FED, F50FEHT, F50FET, FT50GET, F60CEHT, F60CET, FT60DET1 Ignition coil2 Spark plug3 Power trim and tilt switch (tiller handle)4 Power

F50FED, F50FEHT, F50FET, FT50GET, F60CEHTF60CET, FT60DETSb R LgUPFREEDOWN43211 21 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 241 2 3 4

6C13G11 2-8123456789Lower unitOil pumpType TrochoidOuter rotor-to-housing clearancemm (in) 0.09–0.15 (0.0035–0.0059)Outer rotor-to-inner rotor clearan

SPECSpecifications2-9 6C13G11ElectricalItem Unit ModelDorado 50 EFI Ignition and ignition control systemIgnition timing range(*1)Degree ATDC 10-BTDC 2

6C13G11 2-10123456789Starter motorType Sliding gearOutput kW 1.4Cranking time limit Second 30BrushesStandard length mm (in) 15.5 (0.61)Wear limit mm (

SPECSpecifications2-116C13G11Power unitItem UnitModelF60CEHT F60CET FT60DETPower unitMinimum compression pressure(*1) kPa (kgf/cm2, psi)960 (9.6, 139.

6C13G112-121234567892nd piston ringDimension B mm (in) 1.47–1.49 (0.0579–0.0587)Dimension T mm (in) 2.60–2.80 (0.1024–0.1102)End gap mm (in) 0.30–0.50

SPECSpecifications2-136C13G11Stem diameterIntake mm (in) 5.475–5.490 (0.2156–0.2161)Exhaust mm (in) 5.460–5.475 (0.2150–0.2156)Guide inside diameterIn

6C13G112-14123456789Lower unitOil pumpType TrochoidOuter rotor-to-housing clearancemm (in) 0.09–0.15 (0.0035–0.0059)Outer rotor-to-inner rotor clearan

SPECSpecifications2-156C13G11ElectricalItem UnitModelF60CEHT F60CET FT60DETIgnition and ignition control systemIgnition timing range(*1)Degree ATDC 10

6C13G112-16123456789Starter motorType Sliding gearOutput kW 1.4Cranking time limit Second 30BrushesStandard length mm (in) 15.5 (0.61)Wear limit mm (i

SPECSpecifications2-17 6C13G11DimensionsExterior(Remote control model)A: Hydro tilt model (For Europe)B: Power trim and tilt modelS6C12030mm (in)A: 63

6C13G11 2-18123456789(Tiller handle model)Power trim and tilt modelS6C12020Emm (in)40˚192 (7.6)188 (7.4)360 (14.2)192 (7.6)759 (29.9)645 (25.4)354 (14

SPECSpecifications2-196C13G11FT50, FT60X: For OceaniaS6C12010mm (in)40˚192 (7.6)188 (7.4)360 (14.2)192 (7.6)759 (29.9)354 (13.9)62 (2.4)22 (0.9)191 (7

6C13G112-20123456789Clamp bracketS6C12070mm (in)13 (0.5)180 (7.1)163.5 (6.4)254.0 (10.0)55.5 (2.2)350 (13.8)163.5 (6.4)126 (5.0)126 (5.0)180 (7.1)13 (

SPECSpecifications2-216C13G11Tightening torques2Specified torquesPart to be tightened Thread sizeTightening torquesN·mkgf·mft·lbFuel systemFuel filter

6C13G11 2-22123456789Cylinder head bolt1stM6 60.64.42nd 12 1.2 8.91st M912 1.2 8.92nd 23 2.3 17.03rd 90°Spark plug — 17 1.7 12.5Cooling water temperat

SPECSpecifications2-236C13G11Bracket unitRetaining plate bolt M6 10 1.0 7.4Tiller handle nut — 37 3.7 27.3Self-locking nut — 40.43.0Engine stop lanyar

6C13G112-24123456789General torquesThis chart specifies tightening torques forstandard fasteners with a standard ISOthread pitch. Tightening torque sp

SPECSpecifications2-256C13G11— MEMO —

6C13G11CHK ADJ123456789Periodic checks and adjustmentsSpecial service tools ...

6C13G11GEN INFO123456789General informationHow to use this manual...1-1M

CHK ADJPeriodic checks and adjustments3-16C13G11Special service tools3Digital tachometer90890-06760Leakage tester90890-06840Oil filter wrench90890-014

6C13G113-2123456789Maintenance interval chart3Use the following chart as a guideline for general maintenance.Adjust the maintenance intervals accordin

CHK ADJPeriodic checks and adjustments3-36C13G11Top cowling3Checking the top cowling1. Check the fitting by pushing the cowlingwith both hands. Adjust

6C13G113-41234567892. Remove the oil dipstick, wipe it clean,and then insert it back into the dipstickhole.3. Remove the oil dipstick again to checkth

CHK ADJPeriodic checks and adjustments3-56C13G112. Remove the oil dipstick and oil filler cap1.3. Place a drain pan under the drain hole,and then remo

6C13G113-61234567895. Pour the specified amount of the recom-mended engine oil into the oil filler hole.6. Install the oil filler cap and oil dipstick

CHK ADJPeriodic checks and adjustments3-76C13G113. Loosen the flywheel magnet nut.CAUTION:Apply force in the direction of the arrowsshown to prevent t

6C13G113-81234567898. Install a new timing belt 3 onto the drivesprocket, then onto the driven sprocketwith its part number in the upright posi-tion.C

CHK ADJPeriodic checks and adjustments3-96C13G112. Clean the electrodes 1 with a spark plugcleaner or wire brush. Replace the sparkplug if necessary.3

6C13G11 3-101234567895. Install the thermostat, gasket, and cover.Checking the cooling water passage1. Check the cooling water inlet cover 1and coolin

GEN INFOGeneral information1-16C13G11How to use this manual1Manual formatThe format of this manual has been designed to make service procedures clear

CHK ADJPeriodic checks and adjustments3-116C13G113. Loosen the locknut 1, and then adjustthe throttle link rod length a.4. Align the alignment mark b

6C13G113-1212345678910. Adjust the position of the throttle cablejoint until its hole is aligned with the setpin.NOTE:Pull the throttle cable towards

CHK ADJPeriodic checks and adjustments3-136C13G115. Adjust the position of the shift cable jointuntil its hole is aligned with the set pin. WARNINGThe

6C13G113-14123456789Checking the power trim and tilt fluid level1. Fully tilt the outboard motor up, and thensupport it with the tilt stop lever 1. WA

CHK ADJPeriodic checks and adjustments3-15 6C13G113. If necessary, add sufficient gear oil of therecommended type until it overflows outof the check h

6C13G113-161234567892. Apply the specified pressure to checkthat the pressure is maintained in thelower unit for at least 10 seconds.CAUTION:Do not ov

CHK ADJPeriodic checks and adjustments3-17 6C13G11CAUTION:Do not oil, grease, or paint the anodes orthe trim tab, otherwise they will be ineffec-tive.

6C13G113-18123456789Lubricating the outboard motor1. Apply water resistant grease to the areasshown.NOTE:Apply grease to the grease nipple until itflo

CHK ADJPeriodic checks and adjustments3-196C13G112. Apply low temperature resistant greaseto the area shown.3. Apply corrosion resistant grease to the

6C13G11FUEL123456789Fuel systemSpecial service tools ...4-1Hose rout

6C13G111-2123456789SymbolsThe symbols below are designed to indicate the content of a chapter.General informationSpecificationsPeriodic checks and adj

FUELFuel system4-16C13G11Special service tools4Vacuum/pressure pump gauge set90890-06756Fuel pressure gauge90890-06786Fuel pressure gauge adapter B908

6C13G114-2123456789Hose routing4Fuel and blowby hoses1 Blowby hose2 Fuel hose (fuel joint-to-fuel filter)3 Fuel hose (fuel filter-to-fuel pump)4 Fuel

FUELFuel system4-36C13G11Cooling water pilot hoses1Cooling water pilot hose (fuel cooler to fuel cooler)2Cooling water pilot hose (fuel cooler to fuel

6C13G114-4123456789Fuel filter and fuel pump4No. Part name Q’ty Remarks1 Fuel pump assembly 12Bolt 2 M6 × 30 mm3 Fuel hose 14 Holder 15Strainer 16O-ri

FUELFuel system4-56C13G114No. Part name Q’ty Remarks1Screw 4 ø5 × 43 mm2 Cover 13Seal 1Not reusable4 Fuel pump body 2 assembly 15 Diaphragm 16Pin 17Sp

6C13G114-6123456789Checking the fuel pump1. Disconnect the fuel hoses from the fuelpump.2. Connect the special service tool to thefuel pump inlet.3. C

FUELFuel system4-76C13G11Checking the diaphragm and valves1. Check the diaphragm for tears and thevalves for cracks. Replace if necessary.Assembling t

6C13G114-8123456789Intake manifold4No. Part name Q’ty Remarks1 Blowby hose 12 Holder 13Hose 14Bolt 2 M6 × 35 mm5Bolt 3 M6 × 45 mm6Bolt 5 M8 × 40 mm7 I

FUELFuel system4-96C13G114No. Part name Q’ty Remarks1 Fuel rail 12Gasket 1Not reusable3 Idle speed control 14Screw 2 ø5 × 13 mm5 Wiring harness 16O-ri

6C13G114-101234567894No. Part name Q’ty Remarks18 Link rod 119 Gasket 1Not reusable20 Intake manifold 121 Fuel injector 422 O-ring set 4Not reusable23

GEN INFOGeneral information1-36C13G11Safety while working1To prevent an accident or injury and toensure quality service, follow the safety pro-cedures

FUELFuel system4-11 6C13G11Checking the throttle position sensor1. Check the throttle position sensor outputvoltage using the DiagnosticSystem. If the

6C13G114-12123456789Vapor separator4No. Part name Q’ty Remarks1 Vapor separator 12 Collar 33Grommet 34Bolt 3 M6 × 30 mm5 Cooling water pilot hose 16Bo

FUELFuel system4-136C13G114No. Part name Q’ty Remarks1Hose 12 Joint 13Hose 14 Fuel hose 15 Holder 16 Fuel hose 17Hose 18Screw 6 ø5 × 14 mm9 Cover asse

6C13G114-141234567894No. Part name Q’ty Remarks18 O-ring 1Not reusable19 Drain hose 120 Drain screw 121 O-ring 1Not reusable22 Float chamber 123 Fuel

FUELFuel system4-156C13G114No. Part name Q’ty Remarks1 Cover 12 Pressure regulator 13Bolt 2 M6 × 12 mm4O-ring 1Not reusable5 Joint screw 16O-ring 1Not

6C13G114-16123456789Disconnecting the quick connector1. Wrap the quick connector with a rag, andthen rotate the quick connector tab 1 tothe stopper po

FUELFuel system4-176C13G113. Turn the engine start switch to ON, andthen measure the fuel pressure within 3seconds. WARNINGBefore measuring the fuel p

6C13G114-18123456789 WARNING• Before measuring the fuel pressure,make sure that the drain screw is tight-ened securely.• Do not loosen the drain screw

FUELFuel system4-196C13G115. Remove the needle valve and other com-ponents.Checking the vapor separator1. Check the needle valve for bends orwear. Rep

6C13G114-201234567892. Adjust the lever c of the float by bendingit until the float height d is within specifi-cation.NOTE:When adjusting the float he

6C13G111-41234567896. Keep a supply of clean, lint-free cloths forwiping up spills, etc.Good working practicesSpecial service toolsUse the recommended

POWR6C13G11Power unitSpecial service tools ...5-1Power unit...

6C13G11123456789Cylinder block ...5-37Disassembling the cyl

POWRPower unit5-16C13G11Special service tools5Compression gauge90890-03160Flywheel holder90890-06522Flywheel puller90890-06521Crankshaft holder 189089

6C13G115-2123456789Valve seat cutter90890-06312, 90890-06315, 90890-06323,90890-06327, 90890-06328, 90890-06555Bearing outer race attachment90890-0662

POWRPower unit5-36C13G11Power unit5Checking the compression pressure1. Start the engine, warm it up for 5 min-utes, and then turn it off.2. Remove the

6C13G115-4123456789Checking the valve clearanceCAUTION:Do not turn the flywheel magnet counter-clockwise, otherwise the valve systemmay be damaged.1.

POWRPower unit5-56C13G117. Check the intake valve clearance for cyl-inders #3 and #4, and the exhaust valveclearance for cylinders #2 and #4. Adjustif

6C13G115-61234567895No. Part name Q’ty Remarks1 Power unit 12 Oil dipstick 13Gasket 1Not reusable4 Dowel 25Bolt 2 M6 × 16 mm6Bolt 8 M8 × 80 mm7 Apron

POWRPower unit5-76C13G115No. Part name Q’ty Remarks1Nut 12 Washer 13 Flywheel magnet 14Bolt 3 M6 × 30 mm5 Stator coil 16 Stator coil bracket 17Bolt 4

6C13G115-81234567895No. Part name Q’ty Remarks1 Timing belt 12 Nut 1 Width across flats: 41 mm (1.6 in)3 Retaining plate 14 Drive sprocket 15 Bolt 1 M