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F4B
Yamaha F4B Service Manual
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0-5
GEN
INFO
General information
Abbreviation
The f
ollowing abbre
viations are used in this service manual.
Abbre
viation
Description
API
American P
etroleum Institute
BTDC
Bef
ore T
op Dead Center
CCA
Cold Cranking Ampere
CDI
Capacitor Discharge Ignition
EN
European Norm (European standard)
FF
o
r
w
a
r
d
IEC
International Electrotechnical Commission
N
Neutral
OHV
Ov
erhead V
alve
POR
T
P
o
r
t side
RR
e
v
e
r
s
e
R
ON
Research Octane Number
STBD
Starboard side
TDC
T
op Dead Center
9
11
Table of Contents
Table of Contents
5
Rotating Part
6
Hot Part
6
Electric Shock
6
Propeller
6
Handling of Gasoline
6
Ventilation
6
Safety While Working
6
Handling of Sealant
7
Special Service Tool
7
Working with Crane
7
Part, Lubricant, and Sealant
7
Self-Protection
7
Tightening Torque
8
Non-Reusable Part
8
Disassembly and Assembly
8
How to Use this Manual
9
Manual Format
9
Abbreviation
10
Symbol
11
Lubricant, Sealant, and Thread Locking Agent
11
Special Service Tool
12
Spec Specification 1
17
General Feature
18
Model Feature
18
Specification
18
Model Designation
19
Serial Number
19
Dimension and Weight
20
Model Data
20
Performance
20
Power Unit
20
Bracket Unit
21
Fuel and Oil Requirement
21
Lower Unit
21
Charging System (Optional for European Market)
22
Electrical Technical Data
22
Fuel System
22
Fuel System Technical Data
22
Ignition Timing Control System
22
Manual Starter
23
Power Unit
23
Power Unit Technical Data
23
Cylinder Head Assembly
24
Crankcase Assembly
25
Lower Unit Assembly
26
Lower Unit Technical Data
26
Fuel System
27
Power Unit
27
Specified Tightening Torque
27
Bracket Unit
28
General Tightening Torque
28
Tech Fea
29
Engine Control System
30
Outline
30
Tech Fea
30
Technical Features and Description
30
CDI Unit
31
Ignition Timing Control
31
Ignition Cut-Off Control
32
Outline
33
Power Unit System
33
Automatic Decompressor
34
Blowby Gas Reburning System
35
Lighting Coil (Optional for European Market)
36
Fuel System
37
Outline
37
Carburetor
38
Built-In Primer Pump
41
Lubrication System
42
Oil Pump and Engine Oil Flow
42
Outline
42
Outline
43
Reverse Lock System
43
Tilt System
43
Lubrication Diagram
44
Cooling Flow Diagram
45
Intake and Exhaust Flow Diagram
46
Rig Ging Rigging Information 3
47
Outboard Motor Installation
48
Rigging Information
48
Dimension
49
Exterior F4BMH, F5AMH, F6CMH
49
Clamp Bracket
50
Outboard Motor Mounting
51
Uncrating Procedure
51
Installing the Charging System (Optional for European Market)
52
Installing the Battery (Optional for European Market)
53
Battery Requirement
54
Propeller Selection
54
Propeller Size
54
Rigging Recommendations
54
Selection
54
Elec Electrical System 5
59
Electrical Component and Wiring Harness Routing
60
Electrical System
60
Port
60
Top
61
Checking the Electrical Component
62
Measuring the Peak Voltage
62
Using the Digital Tester
62
Charging Unit and Component
63
Checking the Lighting Coil (Optional for European Market)
63
Checking the Rectifier Regulator (Optional for European Market)
63
Checking the Ignition Spark
64
Checking the Spark Plug Cap
64
Ignition Unit and Component
64
Checking the Engine Shut-Off Switch
65
Fuel Fuel System 6
67
Fuel Hose
68
Fuel System
68
Hose Routing
68
Blowby Hose, Oil Return Hose, and Cooling Water Hose
69
Fuel Tank
70
Removing the Fuel Tank
72
Removing the Primer Pump
72
Checking the Fuel Joint
73
Checking the Fuel Strainer
73
Checking the Fuel Strainer (Tank Side)
73
Checking the Fuel Tank
73
Checking the Primer Pump
74
Installing the Primer Pump
74
Installing the Fuel Tank
75
Intake Silencer
77
Removing the Carburetor
79
Removing the Throttle Cable and Throttle Link
79
Installing the Carburetor
80
Installing the Throttle Cable and Throttle Link
80
Adjusting the Throttle Cable and Throttle Link
81
Carburetor
83
Checking the Carburetor
85
Disassembling the Carburetor
85
Assembling the Carburetor
86
Fuel Pump
88
Checking the Fuel Pump
89
Disassembling the Fuel Pump
89
Removing the Fuel Pump
89
Assembling the Fuel Pump
90
Checking the Diaphragm and Valve
90
Installing the Fuel Pump
91
Powr Power Unit 7
92
Checking the CDI Unit Air Gap
94
Checking the Compression Pressure
94
Checking the Ignition Timing
94
Power Unit
94
Power Unit (Check and Adjustment)
94
Adjusting the CDI Unit Air Gap
95
Checking the Valve Clearance
95
Adjusting the Valve Clearance
96
Manual Starter
98
Checking the Manual Starter
100
Disassembling the Manual Starter
100
Removing the Manual Starter
100
Assembling the Manual Starter
101
Checking the Spiral Spring
101
Adjusting the Start-In-Gear Protection Cable
103
Installing the Manual Starter
103
Measuring the Starter Rope
103
Power Unit Assembly
104
Removing the Power Unit
105
Installing the Power Unit
107
Flywheel Magnet
111
Installing the Flywheel Magnet
112
Removing the Flywheel Magnet
112
Crankcase
115
Removing the Crankcase
116
Removing the Oil Pump
116
Removing the Oil Seal Housing
116
Checking the Crankcase
117
Checking the Rotor Assembly
117
Checking the Oil Seal Housing
118
Checking the Oil Strainer
118
Installing the Crankcase
118
Installing the Oil Pump
119
Installing the Oil Seal Housing
119
Cylinder Head
120
Disassembling the Cylinder Head
122
Removing the Cylinder Head
122
Checking the Cylinder Head
123
Checking the Push Rod
123
Checking the Rocker Arm
123
Checking the Valve Spring
123
Checking the Valve
124
Checking the Valve Guide
124
Checking the Valve Seat
125
Replacing the Valve Guide
125
Refacing the Valve Seat
126
Checking the Spark Plug
128
Checking the Thermostat
128
Checking the Thermostat Cover Anode
128
Assembling the Cylinder Head
129
Installing the Cylinder Head
130
Cylinder Block
132
Checking the Piston Diameter
133
Disassembling the Cylinder Block
133
Checking the Cylinder Bore
134
Checking the Piston Ring
134
Checking the Piston Ring End Gap
134
Checking the Connecting Rod Small End Inside Diameter and Big End Inside Diameter
135
Checking the Piston Pin Boss Inside Diameter
135
Checking the Piston Pin Diameter
135
Checking the Piston Ring Groove
135
Checking the Piston Ring Side Clearance
135
Checking the Connecting Rod Oil Clearance
136
Checking the Crankshaft
136
Checking the Camshaft
137
Checking the Cylinder Block
137
Assembling the Cylinder Block
138
Checking the Valve Lifter
138
Lowr Lower Unit 8
141
Lower Unit
143
Lower Unit
144
Removing the Lower Unit (L-Transom Model)
144
Removing the Lower Unit (S-Transom Model)
144
Checking the Lower Unit Anode
145
Checking the Propeller
145
Disassembling the Extension (L-Transom Model)
145
Water Pump and Shift Rod
146
Checking the Shift Rod
147
Checking the Water Pump
147
Removing the Water Pump and Shift Rod
147
Propeller Shaft Housing
148
Checking the Propeller Shaft
149
Disassembling the Propeller Shaft Assembly
149
Disassembling the Propeller Shaft Housing Assembly
149
Removing the Propeller Shaft Housing Assembly
149
Assembling the Propeller Shaft Assembly
150
Assembling the Propeller Shaft Housing Assembly
150
Checking the Dog Clutch
150
Checking the Propeller Shaft Housing
150
Checking the Reverse Gear
150
Drive Shaft and Lower Case
151
Checking the Forward Gear
152
Checking the Pinion
152
Disassembling the Lower Case
152
Removing the Drive Shaft
152
Assembling the Lower Case
153
Checking the Drive Shaft
153
Checking the Lower Case
153
Installing the Drive Shaft
154
Installing the Propeller Shaft Housing Assembly (L-Transom Model)
154
Installing the Propeller Shaft Housing Assembly (S-Transom Model)
154
Installing the Water Pump and Shift Rod
155
Assembling the Extension (L-Transom Model)
156
Checking the Lower Unit for Air Leakage
156
Installing the Lower Unit (S-Transom Model)
157
Installing the Lower Unit (L-Transom Model)
158
Brkt Bracket Unit 9
161
Assembling the Tiller Handle
164
Bracket Unit
164
Disassembling the Tiller Handle
164
Tiller Handle
164
Bottom Cowling
167
Assembling the Bottom Cowling
169
Disassembling the Bottom Cowling
169
Upper Case and Shift Lever
170
Removing the Shift Lever
172
Removing the Upper Case
172
Checking the Upper Case
173
Installing the Upper Case
173
Installing the Shift Lever
175
Clamp Bracket
176
Assembling the Clamp Bracket
178
Disassembling the Clamp Bracket
178
Mnt Maintenance 10
181
Maintenance
182
Maintenance Interval Chart
182
Outline
182
Checking the Battery (Optional for European Market)
184
Checking the Cooling Water Pilot Hole
184
Checking the Engine Oil Level
184
Predelivery Check
184
Checking the Engine Shut-Off Switch
185
Checking the Fuel System
185
Checking the Gear Oil Level
185
Checking the Gear Shift and Throttle Operation
185
Checking the Outboard Motor Mounting Height
186
Checking the Steering System
186
Checking the Throttle Cable
186
Break-In
187
Checking the Tilt System
187
Starting the Engine
187
Test Run
187
After Test Run
188
Checking the Anode
188
Checking the Battery (Optional for European Market)
188
Checking the Cooling Water Passage
188
Checking the Engine Idle Speed
188
General Periodic Maintenance
188
Changing the Engine Oil
189
Changing the Gear Oil
190
Checking the Engine Oil Level
190
Checking the Engine Shut-Off Switch
190
Checking the Fuel Joint and Fuel Hoses (Fuel Joint to Carburetor)
190
Checking the Fuel Strainer
190
Checking the Gear Oil Level
191
Checking the Ignition Timing
191
Lubricating the Outboard Motor
191
Adjusting the Throttle Link Rod and Throttle Cable
192
Checking the Propeller
192
Checking the Spark Plug
192
Checking the Spark Plug Cap
192
Checking the Thermostat
192
Checking the Top Cowling
192
Checking the Valve Clearance
192
Checking the Water Pump
193
Other manuals for Yamaha F4B
Owner's Manual
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Yamaha F4B Specifications
General
Brand
Yamaha
Model
F4B
Category
Outboard Motor
Language
English
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