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F100B
Yamaha F100B Service Manual
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FUEL
Fuel system
4-1
60C5D11
Special service tools
4
Vacuum/pressure pump gauge se
t
90890-06756
Digital tachometer
90890-06760
Vacuum gauge
90890-03159
Test harness (3 pins)
90890-06757
Digital circuit tester
90890-03174
Vacuum gauge (digital)
(commercially obtainable)
Vacuum gauge (4 analog meters)
(commercially obtainable)
Vacuum gauge adaptor
(commercially obtainable)
71
73
Table of Contents
Gen Info General Information
4
Default Chapter
2
Important Information
2
Table of Contents
4
How to Use this Manual
6
Manual Format
6
Symbols
7
Safety While Working
8
Fire Prevention
8
Ventilation
8
Self-Protection
8
Parts, Lubricants, and Sealants
8
Good Working Practices
9
Disassembly and Assembly
9
Identification
10
Applicable Models
10
Serial Number
10
Features and Benefits
11
Power Unit
11
Ignition System
16
Bracket Unit and the PTT Unit
18
Cooling System
19
Lower Unit
20
Technical Tips
21
Carburetor
21
Acceleration Pump
22
Ignition System
23
Ignition Timing Control
23
Lubrication System
25
Cooling System
26
General Information
26
PTT (Power Trim and Tilt) Unit (F100B)
27
PTT (Power Trim and Tilt) Unit (F100C)
29
Predelivery Checks
30
Checking the Fuel System
30
Checking the Gear Oil
31
Checking the Engine Oil
31
Checking the Battery
31
Checking the Outboard Motor Mounting Position
31
Checking the Remote Control Cables
32
Checking the Steering System
32
Checking the Gearshift and Throttle Operation
32
Checking the Tilt System
33
Checking the Engine Start Switch and Engine Stop Switch/Engine Shut-Off Switch
33
Checking the Pilot Water Outlet
33
Test Run
33
Break-In
34
After Test Run
34
Propeller Selection
30
Propeller Size
30
Selection
30
Spec Specifications
35
Default Chapter
36
General Specifications
36
General Specifications
38
Maintenance Specifications
38
Power Unit
38
Lower Unit
41
Electrical
42
Dimensions
44
Tightening Torques
51
Specifications
38
Spec Specifications - Memo -
53
Chk Adj
54
Special Service Tools
54
Periodic Checks and Adjustments
54
Maintenance Interval Chart
55
Top Cowling
57
Checking the Top Cowling
57
Checking the Hour Meter
57
Fuel System
57
Checking the Fuel Joint and Fuel Hoses (Fuel Joint-To-Carburetor)
57
Checking the Fuel Filter
57
Power Unit
58
Checking the Engine Oil
58
Changing the Engine Oil
58
Checking the Timing Belt
60
Replacing the Timing Belt
60
Checking the Valve Clearance
60
Checking the Spark Plugs
60
Checking the Thermostat
61
Checking the Cooling Water Passage
61
Control System
62
Checking the Throttle Cable Operation
62
Checking the Gearshift Operation
63
Checking the Engine Idle Speed
63
Checking the Ignition Timing
64
Power Trim and Tilt Unit
65
Checking the Power Trim and Tilt Operation
65
Checking the Power Trim and Tilt Fluid Level
65
Lower Unit
66
Checking the Gear Oil Level
66
Changing the Gear Oil
66
Checking the Lower Unit (for Air Leakage)
67
Checking the Propeller
67
General
67
Checking the Anodes
67
Checking the Battery
68
Lubrication
69
Fuel Fuel System
71
Special Service Tools
72
Fuel System
72
Hose Routing
73
Fuel, Blowby, and Cooling Water Hoses
73
Fuel Line and Fuel Filter
74
Fuel Pump
76
Checking the Fuel Pump
78
Disassembling the Fuel Pump
79
Checking the Diaphragm and Valves
79
Assembling the Fuel Pump
79
Fuel System
80
Throttle Control
80
Carburetor
84
Checking the Check Valve
86
Checking the Fuel Filters
86
Checking the Carburetor
86
Checking the Prime Start
87
Assembling the Carburetor
88
Adjusting the Throttle Link Rod
88
Adjusting the Throttle Position Sensor
89
Adjusting the Pilot Screw
90
Synchronizing the Carburetors
91
Powr Power Unit
93
Special Service Tools
94
Power Unit
94
Power Unit
96
Checking the Valve Clearance
99
Power Unit
101
Checking the Compression Pressure
102
Checking the Oil Pressure
102
Removing the Power Unit
103
Timing Belt and Sprockets
105
Removing the Timing Belt and Sprockets
110
Checking the Timing Belt and Sprockets
111
Cylinder Head
114
Removing the Cylinder Head
118
Checking the Valve Springs
119
Checking the Valves
119
Checking the Valve Guides
120
Replacing the Valve Guides
121
Checking the Valve Seat
121
Refacing the Valve Seat
122
Checking the Camshaft
124
Checking the Cylinder Head
125
Installing the Valves
126
Installing the Cylinder Head
127
Cylinder Body
129
Removing and Installing the Oil Filter
132
Disassembling the Cylinder Body
132
Checking the Piston Diameter
133
Checking the Cylinder Bore
133
Checking the Piston Clearance
134
Checking the Piston Rings
134
Checking the Piston Ring Grooves
135
Checking the Piston Ring Side Clearance
135
Checking the Crankshaft
135
Checking the Crankshaft Pin Oil Clearance
136
Selecting the Connecting Rod Big End Bearing
137
Checking the Crankshaft Main Journal Oil Clearance
138
Selecting the Crankshaft Main Journal Bearing
140
Assembling the Cylinder Body
141
Installing the Power Unit
144
Lowr Lower Unit
146
Special Service Tools
148
Lower Unit (F100B)
151
Removing the Lower Unit
154
Removing the Water Pump and Shift Rod
155
Checking the Water Pump and Shift Rod
155
Propeller Shaft Housing (F100B)
156
Removing the Propeller Shaft Housing Assembly
158
Disassembling the Propeller Shaft Housing
158
Disassembling the Propeller Shaft Assembly
159
Checking the Propeller Shaft Housing
159
Checking the Propeller Shaft
160
Assembling the Propeller Shaft Assembly
160
Assembling the Propeller Shaft Housing
160
Drive Shaft and Lower Case (F100B)
162
Removing the Drive Shaft
164
Disassembling the Drive Shaft Housing
164
Disassembling the Forward Gear
164
Disassembling the Lower Case
165
Checking the Pinion and Forward Gear
165
Checking the Bearings
165
Checking the Drive Shaft
165
Checking the Lower Case
166
Assembling the Lower Case
166
Assembling the Forward Gear
166
Assembling the Drive Shaft Housing
167
Installing the Drive Shaft
167
Installing the Propeller Shaft Housing
168
Installing the Water Pump and Shift Rod
169
Installing the Lower Unit
170
Shimming (F100B)
172
Shimming
173
Selecting the Pinion Shims
173
Selecting the Forward Gear Shims
174
Selecting the Reverse Gear Shims
175
Backlash (F100B)
176
Measuring the Forward and Reverse Gear Backlash
176
Lower Unit (F100C)
178
Removing the Lower Unit
182
Removing the Water Pump and Shift Rod
183
Checking the Water Pump and Shift Rod
183
Propeller Shaft Housing (F100C)
184
Removing the Propeller Shaft Housing Assembly
186
Disassembling the Propeller Shaft Housing
186
Disassembling the Propeller Shaft Assembly
187
Checking the Propeller Shaft Housing
187
Checking the Propeller Shaft
187
Assembling the Propeller Shaft Assembly
188
Assembling the Propeller Shaft Housing
188
Drive Shaft and Lower Case (F100C)
190
Removing the Drive Shaft
192
Disassembling the Drive Shaft
192
Disassembling the Forward Gear
192
Disassembling the Lower Case
193
Checking the Pinion and Forward Gear
193
Checking the Bearings
193
Checking the Drive Shaft
193
Checking the Lower Case
194
Assembling the Lower Case
194
Assembling the Forward Gear
195
Assembling the Drive Shaft
195
Installing the Drive Shaft
195
Installing the Propeller Shaft Housing
196
Installing the Water Pump and Shift Rod
196
Installing the Lower Unit
198
Shimming (F100C)
200
Shimming
201
Selecting the Pinion Shims
201
Selecting the Forward Gear Shims
202
Selecting the Reverse Gear Shims
203
Backlash (F100C)
203
Measuring the Forward Gear Backlash
203
Brkt Bracket Unit
205
Bracket Unit
208
Special Service Tools
208
Tiller Handle
210
Bottom Cowling
216
Upper Case (F100B)
218
Disassembling the Oil Pump
224
Checking the Oil Pump
224
Assembling the Oil Pump
224
Disassembling the Oil Pan
225
Checking the Oil Strainer
225
Assembling the Oil Pan
225
Installing the Upper Case
227
Swivel Bracket and Steering Arm (F100B)
228
Removing the Steering Arm
230
Installing the Steering Arm
230
Clamp Brackets (F100B)
232
Removing the Clamp Brackets
234
Installing the Clamp Brackets
234
Adjusting the Trim Sensor Cam
235
Power Trim and Tilt Unit (F100B)
236
Removing the Power Trim and Tilt Unit
237
Tilt Cylinder and Trim Cylinder (F100B)
239
Disassembling the Tilt Cylinder and Trim Cylinders
239
Checking the Reservoir
240
Checking the Tilt Cylinder and Trim Cylinder
240
Assembling the Trim Rams
240
Installing the Trim Rams
241
Assembling the Tilt Ram
242
Installing the Tilt Ram
243
Gear Pump (F100B)
244
Disassembling the Gear Pump
246
Checking the Valves
246
Checking the Filters
246
Checking the Gear Pump
247
Assembling the Pump Housing
247
Installing the Pump Housing
248
Disassembling the Power Trim and Tilt Motor
251
Checking the Power Trim and Tilt Motor
252
Assembling the Power Trim and Tilt Motor
253
Installing the Power Trim and Tilt Motor
254
Bleeding the Power Trim and Tilt Unit (F100B)
255
Not Installed
255
Checking the Hydraulic Pressure
256
Installing the Power Trim and Tilt Unit
258
Built-In
259
Upper Case (F100C)
260
Disassembling the Oil Pump
266
Checking the Oil Pump
266
Assembling the Oil Pump
266
Disassembling the Oil Pan
267
Checking the Oil Strainer
267
Assembling the Oil Pan
267
Installing the Upper Case
269
Swivel Bracket and Clamp Brackets (F100C)
271
Removing the Steering Arm
271
Installing the Steering Arm
271
Clamp Brackets (F100C)
272
Removing the Clamp Brackets
274
Installing the Clamp Brackets
274
Adjusting the Trim Sensor Cam
275
Power Trim and Tilt Unit (F100C)
276
Removing the Power Trim and Tilt Unit
277
Installing the Power Trim and Tilt Unit
277
Tilt Cylinder and Trim Cylinder (F100C)
278
Disassembling the Tilt Cylinder
282
Disassembling the Trim Cylinder
282
Checking the Tilt Cylinder and Trim Cylinder
282
Assembling the Trim Cylinder
283
Assembling the Tilt Cylinder
285
Gear Pump (F100C)
287
Disassembling the Gear Pump
290
Checking the Valves
290
Checking the Filters
291
Checking the Gear Pump
291
Assembling the Gear Pump
291
Power Trim and Tilt Motor (F100C)
293
Power Trim and Tilt Motor (F100C)
294
Checking the Power Trim and Tilt Motor
294
Assembling the Power Trim and Tilt Motor
294
Bleeding the Power Trim and Tilt Unit (F100C)
295
Not Installed
295
Built-In
296
Power Trim and Tilt Electrical System
297
Checking the Fuse
298
Checking the Power Trim and Tilt Relay
298
Checking the Power Trim and Tilt Switch/Trailer Switch
298
Checking the Trim Sensor
298
Elec Electrical Systems
299
Special Service Tools
300
Electrical Systems
300
Checking the Electrical Components
301
Measuring the Peak Voltage
301
Measuring the Lower Resistance
301
Electrical Components
302
Starboard and Port Views
302
Front and Rear Views
303
Tiller Handle Model
304
Wiring Harness
305
Ignition System and Ignition Control System
306
Checking the Ignition Spark Gap
307
Checking the High-Tension Cords
307
Checking the Ignition Coil
308
Checking the CDI Unit
308
Checking the Pulser Coil
309
Checking the Throttle Position Sensor
309
Checking the Thermo Sensor
310
Checking the Oil Pressure Switch
310
Checking the Engine Start Switch
311
Checking the Engine Shut-Off Switch
311
Starting System
312
Checking the Fuse
313
Checking the Wiring Harness (10 Pins)
313
Checking the Starter Relay
313
Checking the Neutral Switch
313
Starter Motor
314
Removing the Starter Motor Pinion
316
Checking the Starter Motor Pinion
316
Checking the Armature
316
Checking the Brushes
317
Checking the Relay Assembly
318
Checking the Starter Motor Operation
318
Electrical Systems
312
Starter Motor
314
Charging System
319
Checking the Lighting Coil
320
Checking the Rectifier Regulator
320
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Yamaha F100B Specifications
General
Brand
Yamaha
Model
F100B
Category
Outboard Motor
Language
English
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