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F100D
Yamaha F100D Service Manual
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POWR
Power unit
5-1
6D93G11
Special service tools
5
Compression gauge
90890-03160
Compression gauge extension M14
90890-06563
Flywheel holder
90890-06522
Flywheel puller
90890-06521
Crankshaft holder 20
90890-06552
Valve spring compressor
90890-04019
Valve spring compressor attachment
90890-06320
Valve guide remover/installer 5.9
90890-04064
Valve guide reamer 6.0
90890-04066
Valve seat cutter holder
90890-06553
69
71
Table of Contents
Gen Info General Information
5
Default Chapter
2
Important Information
2
Table of Contents
5
How to Use this Manual
6
Manual Format
6
Symbols
7
Contents
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 Model
10
Serial Number
10
Propeller Selection
10
Propeller Size
10
Selection
11
Predelivery Checks
11
Checking the Fuel System
11
Checking the Engine Oil Level
11
Checking the Gear Oil Level
12
Checking the Battery
12
Checking the Outboard Motor Mounting Height
12
Checking the Remote Control Cables
12
Checking the Steering System
13
Checking the Gear Shift and Throttle Operation
13
Checking the Power Trim and Tilt System
13
Checking the Engine Start Switch and Engine Stop Lanyard Switch
13
Checking the Cooling Water Pilot Hole
14
Test Run
14
Break-In
14
After Test Run
14
Spec Specifications
15
General Specifications
16
Specifications
16
Maintenance Specification
18
Power Unit
18
Lower Unit
21
Electrical
21
Dimensions
24
Tightening Torques
26
Specified Torques
26
General Torques
28
Chk Adj/Chk Adj
29
Periodic Checks and Adjustments
30
Special Service Tools
30
Chk Adj
30
Maintenance Interval Chart
31
Top Cowling
32
Checking the Top Cowling
32
Fuel System
32
Checking the Fuel Joint and Fuel Hoses (Fuel Joint-To-Fuel Injector)
32
Checking the Fuel Filter
32
Power Unit
33
Checking the Engine Oil
33
Changing the Engine Oil Using an Oil Changer
33
Changing the Engine Oil by Draining It
33
Replacing the Oil Filter
34
Checking the Timing Belt
35
Checking the Spark Plugs
35
Checking the Thermostat
36
Checking the Cooling Water Passage
37
Control System
37
Checking the Engine Idle Speed
37
Adjusting the Throttle Link and Throttle Cable
37
Checking the Gear Shift Operation
39
Bracket Unit
40
Checking the Power Trim and Tilt Operation
40
Checking the Power Trim and Tilt Fluid Level
40
Lower Unit
41
Checking the Gear Oil Level
41
Changing the Gear Oil
41
Checking the Lower Unit for Air Leakage
42
Checking the Propeller
42
General
43
Checking the Anodes
43
Checking the Battery
43
Lubricating the Outboard Motor
44
Fuel Fuel System
47
Fuel System
48
Special Service Tools
48
Hose Routing
49
Fuel and Blowby Hoses
49
Fuel Filter and Fuel Pump
50
Checking the Fuel Pump
52
Disassembling the Fuel Pump
52
Checking the Diaphragm and Valves
53
Assembling the Fuel Pump
53
Intake Manifold
54
Checking the Throttle Position Sensor
56
Installing the Throttle Position Sensor
56
Checking the Idle Speed Control
56
Vapor Separator
59
Reducing the Fuel Pressure
60
Disconnecting the Quick Connector
60
Measuring the Fuel Pressure
60
Checking the Pressure Regulator
61
Draining the Fuel
62
Removing the Fuel Hose Clamp
63
Installing the Fuel Hose Clamp
63
Disassembling the Vapor Separator
63
Checking the Vapor Separator
63
Assembling the Vapor Separator
64
Adjusting the Float
64
Canister
66
Checking the Canister
67
Powr Power Unit
68
Special Service Tools
71
Power Unit
72
Checking the Compression Pressure
72
Checking the Oil Pressure
72
Checking the Valve Clearance
79
Replacing the Timing Belt
82
Removing the Power Unit
85
Removing the Timing Belt and Sprockets
86
Checking the Timing Belt and Sprockets
87
Installing the Sprockets and Timing Belt
87
Throttle Link
89
Ecm
90
Junction Box
91
Cylinder Head
93
Removing the Cylinder Head
95
Checking the Valve Lifters
96
Checking the Valve Springs
96
Checking the Valves
96
Checking the Valve Guides
97
Replacing the Valve Guides
97
Checking the Valve Seat
98
Refacing the Valve Seat
99
Checking the Camshafts
101
Checking the Cylinder Head
101
Installing the Valves
102
Installing the Cylinder Head
103
Exhaust Cover
106
Removing the Exhaust Cover
108
Checking the Pressure Control Valve
108
Installing the Pressure Control Valve
108
Installing the Exhaust Cover
108
Cylinder Block
109
Disassembling the Cylinder Block
110
Checking the Piston Diameter
110
Checking the Cylinder Bore
111
Checking the Piston Clearance
111
Checking the Piston Rings
111
Checking the Piston Ring Grooves
112
Checking the Piston Ring Side Clearance
112
Checking the Connecting Rod Big End Side Clearance
112
Checking the Crankshaft
113
Checking the Crankpin Oil Clearance
113
Selecting the Connecting Rod Bearing
115
Checking the Crankshaft Journal Oil Clearance
116
Selecting the Main Bearing
117
Assembling the Power Unit
119
Installing the Power Unit
121
Lowr Lower Unit
123
Special Service Tools
124
Lower Unit
124
Lower Unit
126
Removing the Lower Unit
131
Removing the Water Pump and Shift Rod
132
Disassembling the Oil Seal Housing
132
Checking the Water Pump and Shift Rod
132
Propeller Shaft Housing
133
Removing the Propeller Shaft Housing Assembly
134
Disassembling the Propeller Shaft Assembly
134
Disassembling the Propeller Shaft Housing
134
Checking the Propeller Shaft Housing
135
Checking the Propeller Shaft
135
Assembling the Propeller Shaft Assembly
135
Assembling the Propeller Shaft Housing
136
Drive Shaft and Lower Case
138
Removing the Drive Shaft
140
Disassembling the Drive Shaft
140
Disassembling the Forward Gear
140
Disassembling the Lower Case
140
Checking the Pinion and Forward Gear
141
Checking the Bearings
141
Checking the Drive Shaft
141
Checking the Lower Case
141
Assembling the Lower Case
142
Assembling the Forward Gear
142
Assembling the Drive Shaft
143
Installing the Drive Shaft
143
Installing the Propeller Shaft Housing
143
Installing the Water Pump and Shift Rod
144
Installing the Lower Unit
145
Shimming
148
Selecting the Pinion Shims
149
Selecting the Forward Gear Shims
150
Backlash
151
Measuring the Forward Gear Backlash
151
Brkt Bracket Unit
154
Bracket Unit
156
Special Service Tools
156
Shift Rod
157
Bottom Cowling
158
Upper Case
161
Removing the Upper Case
167
Disassembling the Oil Pump
167
Checking the Oil Pump
167
Assembling the Oil Pump
167
Disassembling the Upper Case
168
Checking the Drive Shaft Bushing
168
Disassembling the Oil Pan
168
Checking the Oil Strainer
169
Assembling the Oil Pan
169
Assembling the Upper Case
170
Installing the Upper Case
170
Steering Arm
172
Removing the Steering Arm
173
Installing the Steering Arm
173
Clamp Brackets and Swivel Bracket
174
Removing the Clamp Brackets
176
Installing the Clamp Brackets
176
Adjusting the Trim Sensor
176
Power Trim and Tilt Unit
178
Removing the Power Trim and Tilt Unit
179
Power Trim and Tilt Motor
180
Disassembling the Power Trim and Tilt Motor
182
Checking the Power Trim and Tilt Motor
182
Assembling the Power Trim and Tilt Motor
184
Gear Pump
185
Disassembling the Gear Pump
188
Checking the Gear Pump
188
Assembling the Gear Pump
188
Tilt Cylinder and Trim Cylinder
190
Disassembling the Trim Cylinder
193
Disassembling the Tilt Cylinder
193
Checking the Tilt Cylinder and Trim Cylinder
194
Checking the Valves
194
Assembling the Tilt Cylinder
194
Assembling the Power Trim and Tilt Unit
196
Bleeding the Power Trim and Tilt Unit
198
Installing the Power Trim and Tilt Unit
199
Bleeding the Power Trim and Tilt Unit (Built-In)
199
Power Trim and Tilt Electrical System
200
Checking the Fuse
200
Checking the Power Trim and Tilt Relay
200
Checking the Power Trim and Tilt Switch
201
Checking the Trim Sensor
202
Elec Electrical Systems
203
Special Service Tools
204
Electrical Systems
204
Checking the Electrical Components
205
Measuring the Peak Voltage
205
Measuring the Lower Resistance
205
Electrical Components
206
Port View
206
Starboard View
207
Bow View
208
Top View
209
Ignition and Ignition Control System
210
Checking the Ignition Spark
210
Checking the Spark Plug Wires
210
Checking the Ignition Coils
210
Checking the ECM
211
Checking the Pulser Coils
211
Checking the Sensor Assembly
211
Checking the Cooling Water Temperature Sensor
212
Checking the Oil Pressure Switch
212
Checking the Shift Position Switch
212
Checking the Main and Fuel Pump Relay (Main Control)
213
Fuel Control System
213
Checking the Injectors
213
Checking the Electric Fuel Pump
213
Checking the Main and Fuel Pump Relay (Fuel Control)
214
Starting System
214
Checking the Fuses
214
Checking the Starter Relay
214
Starter Motor
216
Disassembling the Starter Motor
218
Checking the Starter Motor Pinion
218
Checking the Armature
218
Checking the Brushes
219
Checking the Magnet Switch
219
Checking the Starter Motor Operation
219
Charging System
219
Checking the Stator Coil
219
Checking the Rectifier Regulator
220
Trbl Shtg Troubleshooting
221
Special Service Tools
222
Trbl Shtg
222
Troubleshooting
222
Yamaha Diagnostic System
222
Power Unit
226
Bracket Unit
234
Electrical Systems
238
Diagnosing the Electronic Control System
239
Self-Diagnosis
239
Other manuals for Yamaha F100D
Owner's Manual
100 pages
4
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Yamaha F100D Specifications
General
Brand
Yamaha
Model
F100D
Category
Outboard Motor
Language
English
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