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Outboard Motor
F150A
Yamaha F150A Service Manual
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0-8
Special service tool
0
1
2
3
4
5
6
7
8
9
10
A
Special service tool
F
or all mar
kets e
xcept U
.S.A. and Canada.
Special ser
vice tools with part numbers 90890-06883 and FIM20000ME are
distributed b
y the
Marine Ser
vice Division.
Special service tools with par
t numbers other than 90890-06883 and
FIM20000ME are distributed
by
the P
ar
ts Division.
Drilling plate
90890-06783
YDIS 2 starter kit
90890-06883
Diagnostic flash
90890-06873
Digital cir
cuit tester
90890-03189
P
eak v
oltage adapter B
90890-03172
T
est harness (3 pins)
90890-06869
V
acuum/pressure pump gau
ge set
90890-06945
T
est harness (3 pins)
90890-06847
******
******
**
*
12
14
Table of Contents
Table of Contents
3
Specification
2
Table of Contents
3
General Information
5
Safety While Working
6
Rotating Part
6
Hot Part
6
Electric Shock
6
Propeller
6
Handling of Gasoline
6
Ventilation
6
Self-Protection
7
Working with Crane
7
Handling of Gas Torch
7
Part, Lubricant, and Sealant
7
Handling of Sealant
8
Special Service Tool
8
Tightening Torque
8
Non-Reusable Part
8
Disassembly and Assembly
8
How to Use this Manual
9
Manual Format
9
Abbreviation
10
Lubricant, Sealant, and Thread Locking Agent
11
Symbol
11
Special Service Tool
13
Specification 1
22
Model Feature
24
General Feature
24
Model Name Designation
25
Serial Number
26
Model Data
27
Dimension and Weight
27
Performance
27
Power Unit
28
Lower Unit
28
Bracket Unit
28
Fuel and Oil Requirement
29
Battery Requirement
29
PTT Fluid Requirement
29
Electrical Technical Data
30
Ignition Timing Control System
30
Fuel Injection Control System
31
Engine Speed Control System
31
PTT System
31
Charging System
32
Starting System
32
Y-COP (Standard for European Market and Optional for Oceanian Market)
32
Gauge/Sensor
33
Fuel System Technical Data
34
Fuel System
34
Power Unit Technical Data
35
Power Unit
35
Cylinder Head Assembly
35
Crankcase Assembly
36
Lower Unit Technical Data
38
Lower Unit Assembly (Regular Rotation Model)
38
Lower Unit Assembly (Counter Rotation Model)
38
Bracket Unit Technical Data
39
PTT System
39
Specified Tightening Torque
40
Electrical System
40
Fuel System
40
Power Unit
41
Lower Unit (Regular Rotation Model)
42
Lower Unit (Counter Rotation Model)
42
Bracket Unit
42
General Tightening Torque
43
PTT Unit
43
Technical Feature and Description 2
44
Electronic Control System
46
Engine ECM Component
48
Engine Speed Control
50
Fail-Safe Control
51
Additional Features
52
Y-COP (Standard for European Market and Optional for Oceanian Market)
52
Tilt Limiter (F150A, FL150A [Optional for European and Oceanian Markets])
53
Ydis
54
Overview
54
New Functions
55
Logging
56
Power Unit System
57
Shimless Valve Lifter
57
Fuel System
58
Fuel Diagram
58
Vapor Gas Diagram
59
Lubrication System
60
Lubrication Diagram
60
Cooling System
61
Cooling Diagram
61
Intake and Exhaust System
62
Intake and Exhaust Diagram
62
Lower Unit
63
Propeller (SDS)
63
PTT Unit
64
Trim-Up and Tilt-Up Function
64
Trim-Down and Tilt-Down Function
65
Trim Ram Retraction When Tilting the Outboard Motor up
66
Rigging Information 3
68
Important Reminder on Rigging
70
Outboard Motor Mounting Instructions
70
Crate Handling
71
Crate Top Cover Pictograph Description
71
Uncrating
72
Uncrating Procedure
72
External Dimensions
74
F150A, Fl150A, F150B, Fl150B
74
Clamp Bracket
75
Outboard Motor Mounting
76
Installing the Outboard Motor
76
Rigging Grommet Mounting
78
Rigging Grommet Description
78
Installing the Shift Cable
78
Installing the Throttle Cable
80
Installing the 6Y8 Multifunction Meter Harness
81
Installing the Conventional Gauge Harness
81
Installing the Main Wiring Harness
82
Installing the Rigging Grommet
82
Optional Equipment
83
Installing the Isolator Lead
83
Installing the Water Pressure Sensor
83
Installing the Speed Sensor
84
Installing the Tilt Limiter
85
Setting the Tilt Limiter
87
Deactivating the Tilt Limiter
89
Y-COP (Standard for European Market and Optional for Oceanian Market)
89
Installing Y-COP
89
Registering the Receiver ID to the ECM
89
Battery Installation
91
Battery Wiring Without House (Accessory) Battery
91
Battery Wiring with House (Accessory) Battery
94
System Diagram
98
Single Outboard Motor Application (6Y8 Multifunction Meter)
98
Single Outboard Motor Application (Conventional Gauge)
100
Twin Outboard Motor Application (6Y8 Multifunction Meter)
102
Twin Outboard Motor Application (Conventional Gauge)
104
Rigging Recommendation
106
Extension Length Recommendation for Battery Cable
106
Propeller Selection
107
Propeller Size
107
Selection
107
Troubleshooting 4
111
Ydis
113
Function
113
Connecting the Communication Cable
116
Outboard Motor Troubleshooting
117
Troubleshooting Procedure
117
Troubleshooting the Power Unit Using the YDIS
117
Trouble Code and Checking Step
119
Troubleshooting the Power Unit Using the Diagnostic Flash Indicator
121
Troubleshooting the Power Unit (Trouble Code Not Detected)
122
Troubleshooting the PTT Unit
127
Troubleshooting the Lower Unit
128
Electrical System 5
130
Electrical Component and Wiring Harness Routing
132
Port
132
Junction Box Assembly
134
Rear
136
Top
137
Bottom Cowling
138
ECM Circuit
140
Circuit Diagram
140
ECM Coupler Layout
142
Checking the Electrical Component
143
Using the YDIS
143
Measuring the Peak Voltage
143
Using the Digital Tester
144
Engine Control Unit and Component
144
Checking the Main Relay
144
Checking the Engine ECM Circuit
145
Checking the TPS
146
Checking the ISC Valve
146
Checking the Oil Pressure Sensor
147
Fuel Control Unit and Component
147
Checking the Water Detection Switch
147
Checking the Fuel Injector
148
Checking the High-Pressure Fuel Pump
149
Checking the Vapor Shut-Off Valve
149
Charging Unit and Component
150
Checking the Lighting Coil (Stator Assembly)
150
Checking the Rectifier Regulator
150
Ignition Unit and Component
152
Checking the Ignition Spark
152
Checking the Spark Plug Wire
152
Checking the Ignition Coil
152
Checking the Pulser Coil
153
Checking the Air Temperature Sensor
154
Checking the Air Pressure Sensor
155
Checking the Engine Temperature Sensor
155
Checking the Thermoswitch
156
Checking the Shift Cut-Off Switch
157
Checking the Shift Position Switch
157
Checking the Engine Shut-Off Switch
158
Starting Unit and Component
158
Checking the Starter Relay
158
Checking the Engine Start Switch
159
Y-COP (Standard for European Market and Optional for Oceanian Market)
160
Checking Y-COP
161
Checking the Buzzer
161
Checking the Y-COP Main Wiring Harness
161
Checking the Button Cell Battery
162
Starter Motor
164
Removing the Starter Motor
166
Checking the Starter Motor Pinion
166
Disassembling the Starter Motor
166
Checking the Armature (Starter Motor)
168
Checking the Brush Holder
168
Assembling the Starter Motor
169
Installing the Starter Motor
170
6Y8 Multifunction Meter Sensor
171
Checking the Water Pressure Sensor (Optional)
171
Checking the Speed Sensor (Optional)
171
PTT System
172
Checking the PTT Relay
172
Checking the PTT Switch (on Bottom Cowling)
173
Checking the Trim Sensor
173
Checking the Tilt Limiter (Optional)
174
Fuel System 6
176
Hose Routing
178
Fuel Hose
178
Air Hose, Pressure Regulator Hose, and Vapor Gas Hose
179
Blowby Hose and Cooling Water Hose
181
Fuel Line
182
Reducing the Fuel Pressure
182
Measuring the Fuel Pressure
182
Checking the Pressure Regulator
182
Fuel Filter
184
Removing the Fuel Filter Assembly
185
Checking the Fuel Filter Assembly
185
Disassembling the Fuel Filter Assembly
186
Checking the Fuel Filter Element
186
Checking the Fuel Cup Assembly
186
Checking the Primer Pump
186
Assembling the Fuel Filter Assembly
186
Installing the Fuel Filter Assembly
187
Fuel Pump
188
Removing the Fuel Pump Assembly
190
Checking the Fuel Pump Assembly
190
Disassembling the Fuel Pump Assembly
191
Checking the Diaphragm and Valve
191
Assembling the Fuel Pump Assembly
191
Installing the Fuel Pump Assembly
192
Canister and Vapor Shut-Off Valve
194
Removing the Canister
195
Removing the Vapor Shut-Off Valve
195
Checking the Canister
195
Checking the Vapor Shut-Off Valve
196
Installing the Vapor Shut-Off Valve
196
Installing the Canister
196
Intake Silencer
198
Throttle Link
199
Removing the Throttle Link
200
Checking the Throttle Link
200
Installing the Throttle Link
200
Throttle Body
202
Removing the Throttle Body Assembly
203
Checking the TPS
203
Installing the Throttle Body Assembly
203
Throttle Body and Throttle Link Adjustment
204
Adjusting the Throttle Link
204
Fuel Injector
207
Removing the Fuel Injector
208
Removing the Fuel Cooler
208
Checking the Fuel Rail and Fuel Injector
209
Installing the Fuel Cooler
209
Installing the Fuel Injector
210
Intake Manifold and Vapor Separator
211
Draining the Fuel
214
Removing the Intake Manifold
214
Removing the Vapor Separator
214
Checking the Fuel Filter
215
Checking the Intake Manifold
215
Checking the Air Pressure Sensor
215
Checking the ISC Valve
215
Installing the Vapor Separator
216
Installing the Intake Manifold
217
Vapor Separator and High-Pressure Fuel Pump
219
Disassembling the Vapor Separator
220
Checking the High-Pressure Fuel Pump
220
Checking the Vapor Separator
220
Assembling the Vapor Separator
221
Power Unit 7
223
Default Chapter
224
Power Unit
224
Power Unit (Check and Adjustment)
226
Checking the Compression Pressure
226
Checking the Oil Pressure
226
Checking the Valve Clearance
226
Adjusting the Valve Clearance
228
Power Unit Assembly
230
Removing the Power Unit
232
Installing the Power Unit
234
Flywheel Magnet
237
Removing the Flywheel Magnet
238
Removing the Stator Assembly
238
Installing the Stator Assembly
239
Installing the Flywheel Magnet
240
Timing Belt
241
Removing the Timing Belt
242
Removing the Drive Sprocket
242
Checking the Timing Belt
242
Installing the Drive Sprocket
242
Installing the Timing Belt
243
Starter Motor
245
Removing the Starter Motor
246
Installing the Starter Motor
246
Rectifier Regulator and Ignition Coil
248
Removing the Rectifier Regulator
250
Removing the Ignition Coil
250
Checking the Spark Plug
250
Installing the Ignition Coil
251
Installing the Rectifier Regulator
251
Fuse Box
252
Wiring Harness
253
Removing the Wiring Harness
255
Installing the Wiring Harness
256
Camshaft
258
Removing the Driven Sprocket and Camshaft
260
Checking the Driven Sprocket
260
Checking the Camshaft
260
Installing the Driven Sprocket and Camshaft
261
Cylinder Head
263
Removing the Cylinder Head
265
Disassembling the Cylinder Head
265
Checking the Valve Lifter
265
Checking the Cylinder Head
266
Checking the Valve Spring
266
Checking the Valve
266
Checking the Valve Guide
267
Replacing the Valve Guide
267
Checking the Valve Seat
268
Refacing the Valve Seat
268
Checking the Cylinder Head and Cylinder Block Anode
270
Assembling the Cylinder Head
270
Installing the Cylinder Head
271
Exhaust Cover
273
Removing the Exhaust Cover
275
Checking the PCV
275
Checking the Thermostat
275
Checking the Exhaust Cover Anode
275
Installing the Exhaust Cover
276
Cylinder Block (F150A, FL150A)
277
Removing the Oil Pump Assembly
279
Removing the Oil Filter Bracket
279
Removing the Balancer Assembly
279
Disassembling the Oil Pump
279
Checking the Oil Pump
279
Assembling the Oil Pump
279
Installing the Oil Pump Assembly
280
Installing the Balancer Assembly
280
Installing the Oil Filter Bracket
281
Cylinder Block (F150B, FL150B)
283
Removing the Oil Pump Assembly
285
Removing the Oil Filter Bracket
285
Removing the Crankcase Cover
285
Disassembling the Oil Pump
285
Checking the Oil Pump
285
Assembling the Oil Pump
285
Installing the Oil Pump Assembly
285
Installing the Crankcase Cover
285
Installing the Oil Filter Bracket
285
Crankcase
286
Disassembling the Cylinder Block
288
Checking the Piston Diameter
289
Checking the Cylinder Bore
289
Checking the Piston Ring
289
Checking the Piston Ring End Gap
290
Checking the Piston Ring Groove
290
Checking the Piston Ring Side Clearance
290
Checking the Piston Pin Boss Inside Diameter
290
Checking the Piston Pin Diameter
291
Checking the Connecting Rod Small End Inside Diameter and Big End Inside Diameter
291
Checking the Connecting Rod Big End Side Clearance
291
Checking the Crankshaft
291
Checking the Big End Oil Clearance
292
Selecting the Crankpin Bearing
293
Crankpin Bearing Selection Table
295
Checking the Journal Oil Clearance
296
Selecting the Crankshaft Journal Bearing
297
Crankshaft Journal Bearing Selection Table
299
Assembling the Cylinder Block
300
Lower Unit 8
304
Default Chapter
306
Lower Unit
306
Lower Unit
308
(Regular Rotation Model, L-Transom Model)
308
Removing the Lower Unit
310
Disassembling the Propeller (SDS Propeller)
310
Checking the Propeller
310
Checking the Lower Unit Anode
310
Assembling the Propeller (SDS Propeller)
311
Lower Unit
311
Removing the Lower Unit
315
Disassembling the Propeller (SDS Propeller)
315
Checking the Propeller
315
Checking the Lower Unit Anode
315
Assembling the Propeller (SDS Propeller)
315
Water Pump and Shift Rod (Regular Rotation Model)
316
Removing the Water Pump and Shift Rod
318
Disassembling the Water Pump Housing
318
Checking the Water Pump and Shift Rod
318
Assembling the Water Pump Housing
319
Propeller Shaft Housing (Regular Rotation Model)
320
Removing the Propeller Shaft Housing Assembly
322
Disassembling the Propeller Shaft Assembly
322
Disassembling the Propeller Shaft Housing Assembly
323
Checking the Propeller Shaft
323
Checking the Dog Clutch
323
Checking the Propeller Shaft Housing
323
Checking the Reverse Gear
323
Assembling the Propeller Shaft Assembly
324
Assembling the Propeller Shaft Housing Assembly
324
Drive Shaft and Lower Case (Regular Rotation Model)
326
Removing the Drive Shaft
328
Disassembling the Drive Shaft Housing
328
Disassembling the Forward Gear
328
Disassembling the Lower Case
329
Checking the Pinion
329
Checking the Forward Gear
329
Checking the Drive Shaft
329
Checking the Lower Case
330
Assembling the Forward Gear
330
Assembling the Drive Shaft Housing
330
Assembling the Lower Case
331
Installing the Drive Shaft
332
Installing the Propeller Shaft Housing Assembly
333
Installing the Shift Rod
334
Installing the Water Pump
334
Checking the Lower Unit for Air Leakage
335
Installing the Lower Unit (L-Transom Model)
336
Installing the Lower Unit (X-Transom Model)
337
Shimming (Regular Rotation Model)
339
Shimming Workflow
339
Shimming Check Sheet
340
Measuring the Forward Gear Backlash and Reverse Gear Backlash before Disassembly
342
Shimming Procedure
345
Shim Location
345
Selecting the Pinion Shim (T3)
346
Measuring the Forward Gear Backlash
348
Adjusting the Forward Gear Shim Thickness (T1)
348
Measuring the Reverse Gear Backlash
350
Adjusting the Reverse Gear Shim Thickness (T2)
350
Lower Unit
352
Removing the Lower Unit
354
Disassembling the Propeller (SDS Propeller)
354
Checking the Propeller
354
Checking the Lower Unit Anode
354
Assembling the Propeller (SDS Propeller)
354
Lower Unit
354
Removing the Lower Unit
357
Disassembling the Propeller (SDS Propeller)
357
Checking the Propeller
357
Checking the Lower Unit Anode
357
Assembling the Propeller (SDS Propeller)
357
Water Pump and Shift Rod (Counter Rotation Model)
358
Removing the Water Pump and Shift Rod
360
Disassembling the Water Pump Housing
360
Checking the Water Pump and Shift Rod
360
Assembling the Water Pump Housing
360
Propeller Shaft Housing (Counter Rotation Model)
361
Removing the Propeller Shaft Housing Assembly
363
Disassembling the Propeller Shaft Housing Assembly
363
Disassembling the Forward Gear
363
Checking the Propeller Shaft
364
Checking the Dog Clutch
364
Checking the Propeller Shaft Housing
364
Checking the Forward Gear
364
Assembling the Propeller Shaft Housing Assembly and Forward Gear
364
Drive Shaft and Lower Case (Counter Rotation Model)
367
Removing the Drive Shaft
369
Removing the Reverse Gear
369
Disassembling the Drive Shaft Housing
369
Disassembling the Reverse Gear
369
Disassembling the Lower Case
369
Checking the Pinion
370
Checking the Reverse Gear
370
Checking the Drive Shaft
370
Checking the Lower Case
370
Assembling the Reverse Gear
370
Assembling the Lower Case
370
Assembling the Drive Shaft Housing
371
Installing the Reverse Gear
371
Installing the Drive Shaft
371
Installing the Propeller Shaft Housing Assembly
371
Installing the Shift Rod
371
Installing the Water Pump
371
Checking the Lower Unit for Air Leakage
371
Installing the Lower Unit (L-Transom Model)
371
Installing the Lower Unit (X-Transom Model)
372
Shimming (Counter Rotation Model)
373
Shimming Workflow
373
Measuring the Forward Gear Backlash and Reverse Gear Backlash before Disassembly
376
Shimming Procedure
379
Shim Location
379
Selecting the Pinion Shim (T3)
380
Selecting the Propeller Shaft Shim (T4)
380
Measuring the Forward Gear Backlash
381
Adjusting the Forward Gear Shim Thickness (T2)
381
Measuring the Reverse Gear Backlash
383
Adjusting the Reverse Gear Shim Thickness (T1)
383
Bracket Unit 9
386
Default Chapter
390
Removing the Shift Rod and Shift Bracket
390
Disassembling the Shift Bracket
390
Assembling the Shift Bracket
390
Installing the Shift Rod and Shift Bracket
391
PTT Switch and Cowling Lock Lever
393
Installing the Flushing Hose
395
Removing the Cowling Lock Lever
395
Removing the Flushing Hose
395
Removing the PTT Switch
395
Installing the Cowling Lock Lever
396
Installing the PTT Switch
396
Upper Case and Mounts
401
Removing the Upper Case
402
Installing the Upper Case
402
Upper Case
404
Disassembling the Upper Case
405
Checking the Drive Shaft Bushing
405
Assembling the Upper Case
405
Oil Pan and Exhaust Manifold
407
Disassembling the Oil Pan and Exhaust Manifold
409
Checking the Oil Pan and Exhaust Manifold
409
Checking the Oil Strainer
409
Assembling the Oil Pan and Exhaust Manifold
409
Removing the Steering Arm
412
Installing the Steering Arm
412
Clamp Bracket and Swivel Bracket
415
Removing the Clamp Bracket
417
Checking the Clamp Bracket Anode
417
Installing the Clamp Bracket
417
Adjusting the Trim Sensor Cam
419
Removing the PTT Unit
421
Checking the Hydraulic Pressure
422
Bleeding the PTT Unit
424
Installing the PTT Unit
426
PTT Cylinder
428
Removing the Tilt Ram and Trim Ram
430
Disassembling the Tilt Ram
431
Disassembling the Trim Ram
431
Checking the Tilt Cylinder and Trim Cylinder
431
Checking the Absorber Valve
431
Assembling the Tilt Ram
431
Assembling the Trim Ram
432
Installing the Trim Ram
433
Installing the Tilt Ram
433
PTT Motor
435
Removing the Reservoir
437
Removing the PTT Motor
437
Disassembling the PTT Motor
437
Checking the Armature (PTT Motor)
438
Checking the Brush
438
Checking the Reservoir
439
Assembling the PTT Motor
439
Installing the PTT Motor
440
Installing the Reservoir
440
Removing the Gear Pump Assembly
444
Disassembling the Gear Pump Housing
444
Disassembling the Gear Pump
444
Checking the Gear Pump
445
Checking the Gear Pump Housing
445
Checking the Valve Seal
445
Checking the Filter
445
Assembling the Gear Pump
446
Assembling the Gear Pump Housing
447
Installing the Gear Pump Assembly
448
Maintenance 10
450
Outline
452
Maintenance Interval Chart 1
452
Predelivery Check
455
Checking the Battery
455
Checking the Cooling Water Pilot Hole
456
Checking the Engine Oil Level
456
Checking the Main Switch/Stop Switch/Choke Switch
456
Checking the Fuel Line
457
Checking the Gear Oil Level
457
Checking the Shift Link/Shift Cable and Throttle Link/ Throttle Cable/Throttle Pick-Up Timing
457
Checking the Outboard Motor Mounting Height
457
Checking the Power Trim and Tilt Unit
458
Checking the Steering System
458
Checking the Throttle Cable and Shift Cable
458
Test Run
458
Break-In
459
After Test Run
459
General Periodic Maintenance
459
Checking the Anode
459
Checking the Battery
459
Checking the Cooling Water Inlet
459
Checking the Cooling Water Pilot Hole
460
Checking the Engine Idle Speed/Noise
460
Changing the Engine Oil
460
Checking the Engine Oil Level
461
Replacing the Oil Filter
461
Checking the Exhaust Guide/Exhaust Manifold
462
Checking the Main Switch/Stop Switch/Choke Switch
462
Checking the Fuel Filter
462
Checking the Fuel Pump
462
Checking for Fuel Leakage/Oil Leakage
462
Changing the Gear Oil
462
Checking the Gear Oil Level
463
Greasing Points
463
Checking the PCV
465
Checking the Propeller/Propeller Nut/Cotter Pin
465
Checking the PTT Fluid Level
465
Checking the Power Trim and Tilt Unit Operation
465
Index
467
Appendix
477
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Owner's Manual
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Yamaha F150A Specifications
General
Brand
Yamaha
Model
F150A
Category
Outboard Motor
Language
English
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