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Yamaha
Outboard Motor
F100A
Yamaha F100A Service Manual
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8-29
–+
ELEC
E
POWER TRIM AND TILT (PTT) CONTROL SYSTEM
POWER TRIM AND TILT (PTT) CONTROL SYSTEM
B
Gy
P
UP
Sb
R
Lg
Lg
Lg
L
L
Lg
Lg
Sb
Sb
Sb
R
R
R
R
P
B
B
B
B
B
G
G
B
Sb
FREE
DOWN
O
B
B
Gy
Gy
P
P
UP
Sb
R
Lg
Lg
Lg
L
L
Lg
Lg
Lg
Lg
Lg
Sb
Sb
Sb
R
R
R
R
RR
B
R
BB
B
G
G
B
Sb
Sb
Sb
FREE
DOWN
O
O
N
S
M
R
30 (A)
20 (A)
1
2
2
3
4
7
8
5
5
6
1
PTT motor
2
PTT relays
3
Trailer switch
4
10P coupler
5
Fuses (20A, 30A)
6
Battery
7
Trim sensor
8
4P coupler
B
: Black
G
: Green
Gy
: Gray
L
: Blue
Lg
: Light green
O
: Orange
P
: Pink
R
: Red
Sb
: Sky blue
443
445
Table of Contents
Default Chapter
4
How to Use this Manual
4
Symbols
10
Inspection Periodique Et Reglage
11
Index
12
Table of Contents
13
General Information
14
Chapter 1
16
Identification
16
Serial Number
16
Starting Serial Numbers
16
Safety While Working
18
Fire Prevention
18
Ventilation
18
Self-Protection
18
Oils, Greases and Sealing Fluids
18
Good Working Practices
20
Disassembly and Assembly
22
Special Tools
24
Measuring
24
Outillage Special
25
Removal and Installation
26
Outillage Special
27
Specifications
32
General Specifications
34
Maintenance Specifications
38
Engine
38
Chapitre 2 Specifications D'entretien
39
Moteur
39
Bloc de Propulsion
45
Electrical
46
Systeme Electrique
47
Dimensions
50
Tightening Torques
52
Couples de Serrage
53
Antriebseinheit
53
Motor
53
Elektrische Anlage
55
General Tightening Torques
56
Torsión de Apriete General
57
Hose Routing
58
Enrutamiento de Mangueras
59
Periodic Inspection and Adjustment
60
Chapter 3
62
Maintenance Interval Chart
62
Cowling Hook
66
Fuel Filter Inspection
66
Fuel Line
66
Fuel System
66
Periodic Service Cowling
66
Carburetor Check and Adjustment
68
Control System
68
Carburetor Pickup Timing Check and Adjustment
72
Shift Cable Adjustment
74
Throttle Cable Adjustment
76
Cooling System
78
Cooling Water Flow
78
Engine Oil Level
78
Engine Oil/Oil Filter Replacement
78
Power Unit
78
Timing Belt
80
Valve Clearance Adjustment
82
Power Trim and Tilt (PTT) System
88
PTT Fluid
88
Gear Oil
90
Lower Unit
90
Anodes
92
General
92
Lower Unit Leakage Check
92
Battery
94
Spark Plugs
96
Compression Pressure Measurement
98
Oil Pressure Measurement
100
Lubrication Points
102
Fuel System
104
Systeme
105
Fuel Hose and Fuel Filter Exploded Diagram
106
Removal and Installation Chart
106
Fuel Pumps Exploded Diagram
110
Fuel Pump Inspection
116
Service Points
116
Control Unit Exploded Diagram
118
Intake Assy. Exploded Diagram
122
Carburetor Exploded Diagram
130
Carburetor Assembly
138
Carburetor Inspection
138
Power Unit
142
Moteur
143
Motor
143
Flywheel Magneto Exploded Diagram
146
Flywheel Magneto Removal
148
Service Points
148
Flywheel Magneto Installation
150
Power Unit Exploded Diagram
152
Removal and Installation Chart
152
Removal and Installation Chart
162
Stator Coil Assy. Exploded Diagram
162
Removal and Installation Chart
166
Timing Belt Exploded Diagram
166
Drive Sprocket Removal/Installation
170
Driven Sprocket Removal
170
Service Points
170
Driven Sprocket Installation
172
Timing Belt Installation
172
Ignition Coils and Starter Motor Exploded Diagram
174
Removal and Installation Chart
174
CDI Unit and Relays Exploded Diagram
176
Cylinder Head Cover Exploded Diagram
180
Removal and Installation Chart
180
Camshafts Exploded Diagram
184
Removal and Installation Chart
184
Camshaft Inspection
186
Camshaft Installation
186
Service Points
186
Cylinder Head Assy. Exploded Diagram
188
Removal and Installation Chart
188
Service Points
192
Thermostat Inspection
192
Valves Exploded Diagram
194
Valves
196
Service Points
198
Valve Inspection
198
Cylinder Head Inspection
200
Valve Guide Inspection
200
Valve Spring Inspection
200
Valve Seat Inspection
202
Valve Installation
204
Oil Filter and Exhaust Cover Exploded Diagram
206
Removal and Installation Chart
206
Oil Filter Installation
212
Service Points
212
Crankshaft and Piston/Connecting Rod Assy. Exploded Diagram
214
Removal and Installation Chart
214
Cylinder Block Inspection
218
Piston Inspection
218
Piston Ring Inspection
220
Piston-To-Cylinder Clearance
220
Crankshaft Inspection
222
Main-Bearing Oil Clearance
222
Connecting Rod Big-End Oil Clearance
228
Piston Ring Installation
234
Piston Installation
236
Lower Unit
238
Bloc de Propulsion
239
Lower Unit Exploded Diagram
242
Chapter 6
246
Propeller Removal
246
Propeller Inspection
246
Propeller Installation
246
Service Points
246
Water Pump Exploded Diagram
248
Impeller and Insert Cartridge Inspection
252
Impeller and Water Pump Housing Installation
252
Service Points
252
Water Pump Housing Inspection
252
Woodruff Key Inspection
252
Removal and Installation Chart
254
Shift Rod Exploded Diagram
254
Propeller Shaft Housing Assy. Exploded Diagram
256
Removal and Installation Chart
256
Service Points
256
Propeller Shaft Housing Assy. Disassembly
258
Propeller Shaft Housing Assy. Disassembly
260
Propeller Shaft Housing Assy. Removal
260
Bearing Inspection
262
Propeller Shaft Housing Inspection
262
Reverse Gear Inspection
262
Propeller Shaft Housing Assy. Assembly
264
Propeller Shaft Housing Installation
266
Propeller Shaft Assy. Exploded Diagram
268
Removal and Installation Chart
268
Dog Clutch Inspection
270
Propeller Shaft Inspection
270
Service Points
270
Shift Slider Inspection
270
Lower Case Exploded Diagram
272
Removal and Installation Chart
272
Drive Shaft Bearing Removal
276
Service Points
276
Forward Gear Bearing Installation
278
Forward Gear Bearing Removal
278
Drive Shaft Bearing Installation
280
Drive Shaft Installation
282
Shimming
284
Pinion Gear Shim
284
Shim Selection (for USA and Canada)
284
Forward Gear Shim
286
Pinion Gear Shim
292
Shim Selection (for Worldwide)
292
Forward Gear Shim
294
Measuring the Backlash
298
Forward Gear
300
Bracket Unit
302
Unite de Support
303
Shift Actuator Assy. Exploded Diagram
306
Bottom Cowling Exploded Diagram
310
Upper Case Assy. Exploded Diagram
316
Oil Pan Exploded Diagram
326
Steering Bracket Exploded Diagram
330
Clamp Bracket Exploded Diagram
334
Swivel Bracket Exploded Diagram
338
Power Trim and Tilt (PTT) Unit Exploded Diagram
340
PTT Motor, Pump Housing, and Tilt Cylinder Exploded Diagram
344
Tilt Rod Assy. Exploded Diagram
348
Cylinder End Screw Inspection
358
Tilt Rod Assy. and Inner Cylinder Removal
358
Tilt Rod Assy. and Inner Cylinder Installation
360
Pump Housing Exploded Diagram
362
Gear Pump Exploded Diagram
368
PTT Motor Exploded Diagram
372
Motor Inspection
376
PTT Motor Assembly
378
Air Bleeding
380
PTT Fluid Filling
380
PTT Unit
380
Electrical Systems
384
Equipement
385
Electrical Components (Starboard View)
388
Electrical Components (Port View)
390
Electrical Components (Front View)
392
Electrical Components (Rear View)
394
Wire Harness
396
Digital Circuit Tester
398
Electrical Analysis
398
Peak Voltage Adaptor
398
Peak Voltage Measurement
398
Test Harness
400
Ignition System
402
Ignition Spark Gap
404
Ignition System Peak Voltage
406
Spark Plug Lead Assy.
410
Ignition Control System
412
Engine Temperature Sensor
414
Oil Pressure Switch
414
Pick-Up Coils
414
Throttle Position Sensor (TPS)
416
Starting System
418
Fuses
420
Starter Relay
420
Wire Connections
420
Starter Motor Exploded Diagram
422
Armature Inspection
430
Pinion Gear Inspection
430
Pinion Gear Removal
430
Brush Holder Inspection
432
Starter Motor
432
Relay (Magnetic Switch)
434
Charging System
436
Charging System Peak Voltage
438
Enrichment Control System
440
Electrothermal Valve
442
Power Trim and Tilt (PTT) Control System
444
PTT Relays
446
Trailer Switch
448
Trim Sensor
448
Trouble Analysis
450
Trouble Analysis Chart
452
Antriebseinheit
457
Motorhalterung
457
Störungssuche
457
Trbl
459
Wiring Diagram
460
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Yamaha F100A Specifications
General
Brand
Yamaha
Model
F100A
Category
Outboard Motor
Language
English
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