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Manuals
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Yamaha Manuals
Outboard Motor
F300F
Service manual
Yamaha F300F Service Manual
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
Table of Contents
General Information
Model Information
Model Name Designation
Applicable Model
General Feature
Important Safety and Service Information
Rotating Parts
Hot Parts
Electric Shock
Propeller
Handling of Gasoline
Ventilation
Parts, Lubricants, and Sealants
Self-Protection
Handling of Gas Torch
Lifting Outboard Motors
Handling of Lubricants and Sealants
Special Service Tools
Tightening Torque
Non-Reusable Parts
Disassembly and Assembly
Disposal of Used Components and Chemicals
How to Use this Manual
Manual Format
Abbreviation
Conditions When Testing and Adjusting
Color Code
Specified Tightening Torque
General Tightening Torque
Symbol
Specification Symbol
Lubricant, Sealant, and Thread Locking Agent Symbol
Special Service Tool
Specification
Specification Data
External Dimensions
Clamp Bracket Dimensions
Technical Feature and Description
Technical Feature and Description
Electronic Control System
Electrical Components
Fail-Safe
Crate Top Cover
Rigging Information
Bracket Unit
SBW (Steer by Wire) System
System Diagram
Structure
Operation
Outboard Motor Manual Steering Method
PTT Sensor
PTT Totaltilt
Bushing of the Drive Shaft
Upper Case
Lower Unit
Split-Type Drive Shaft
Reverse Thrust
Engine ECM
Fuel System
High-Pressure Fuel Pump Control
Low-Pressure Fuel Pump Control
PTT Protection Control
Fuel Diagram
Lubrication Diagram
Lubrication System
Cooling Diagram
Cooling System
Intake and Exhaust Diagram
Intake and Exhaust System
Fuel Hose and Blowby Hose
Hose Routing
Pressure Regulator Hose, Vapor Gas Hose, and Intake Air Pressure Sensor Hose
Cooling Water Hose
Rigging Information 0
Rigging Information
Important Reminder on Rigging
Outboard Motor Mounting Instructions
Crate Handling
Crate Top Cover Symbol Description
Uncrating
Uncrating Procedure
Installing the Outboard Motor
Outboard Motor Mounting
Installing the Battery Cable
Installing the Main Wire Harness
Installing the Rigging Grommet
Rigging Grommet Description
Rigging Grommet Mounting
Installing the Isolator Lead
Installing the SCU Communication Lead
Optional Equipment
Battery Installation
Single Outboard Motor Application (Single Station)
System Diagram
Twin Outboard Motor Application (Single Station)
Triple Outboard Motor Application (Single Station)
Quad Outboard Motor Application (Single Station)
Single Outboard Motor Application (Dual Station)
Twin Outboard Motor Application (Dual Station)
Triple Outboard Motor Application (Dual Station)
Quad Outboard Motor Application (Dual Station)
Digital Electronic Control
Digital Electronic Control System Reset
Setting the Tilt Limiter
Tilt Limiter
Clearing the Tilt Limiter
Calibration (6X9 Digital Electronic Control)
CL5 Display Calibration
Configuring the Number of Outboard Motors
Deactivating the Tilt Limiter
Accessing the Calibration Menu
Steering Sensor
Toe Adjust
Adjustment Settings
Lock to Lock
Friction Set
Battery Cable Length
Rigging Recommendation
Propeller Selection
Troubleshooting 0
Connecting the Communication Cable
Ydis
ECM Reprogramming
Outboard Motor Troubleshooting
Troubleshooting Procedure
Troubleshooting the Power Unit Using the YDIS
Trouble Code and Checking Step
Troubleshooting Procedure (Trouble Code Not Detected)
Troubleshooting the Power Unit
Troubleshooting the PTT Unit
Troubleshooting the Lower Unit
Electrical System
Fuse Holder
Bottom Cowling
ECM Coupler Layout
Checking the Electrical Component
Measuring the Peak Voltage
Checking the Engine ECM Circuit
Checking the ETV and TPS
Checking the OCV
Checking the Fuel Injector
Checking the Low-Pressure Fuel Pump and High-Pressure Fuel Pump
Checking the High-Pressure Fuel Pump Relay
Checking the Ignition Coil
Checking the Engine Shut-Off Switch
Checking the Power Switch
Starter Motor
Removing the Starter Motor
Disassembling the Starter Motor
Checking the Starter Motor Pinion
Checking the Armature (Starter Motor)
Assembling the Starter Motor
PTT System
Fuel System 0
Fuel System
Disconnecting the Quick Connector
Reducing the Fuel Pressure
Measuring the Fuel Pressure
Checking the Pressure Regulator
Fuel Filter Assembly
Checking the Fuel Cup Assembly
Checking the Fuel Filter Assembly
Checking the Fuel Filter Element
Removing the Fuel Filter Assembly
Assembling the Fuel Filter
Checking the Primer Pump
Installing the Fuel Filter
Intake Manifold
Checking the Intake Manifold
Installing the Intake Manifold
Installing the Intake Silencer
Etv
Checking the ETV
Checking the Intake Air Pressure Sensor
Installing the ETV and Surge Tank
Canister
Checking the Canister
Checking the Canister Check Valve
Installing the Canister
Low-Pressure Fuel Pump
Installing the Low-Pressure Fuel Pump
Vapor Separator and Vapor Shut-Off Valve
Checking the Vapor Shut-Off Valve
Draining the Fuel
Installing the Vapor Separator
Vapor Separator and High-Pressure Fuel Pump
Checking the Check Valve
Checking the High-Pressure Fuel Pump
Checking the Vapor Separator
Assembling the Vapor Separator
Fuel Injector
Checking the Fuel Rail
Installing the Fuel Injector
Power Unit
Power Unit
Checking the Compression Pressure
Checking the Oil Pressure
Checking the Pulser Coil Air Gap
Checking the Valve Clearance
Adjusting the Valve Clearance
Power Unit Assembly
Removing the Power Unit
Installing the Power Unit
Flywheel Magneto
Installing the Flywheel Magneto
Removing the Flywheel Magneto
Wire Harness
Installing the Wire Harness
Fuse Box
Junction Box
Installing the Junction Box
Installing the Rectifier/Regulator/Isolator
Starter Motor
Installing the Starter Motor
Engine ECM
Ignition Coil and Spark Plug
Checking the Spark Plug
Shift Actuator
Assembling the Shift Actuator Assembly
Installing the Shift Actuator Assembly
Timing Belt
Removing the Timing Belt
Checking the Timing Belt
Installing the Timing Belt
Camshaft
Removing the Camshaft, VCT Assembly, and Driven Sprocket
Checking the Camshaft
Checking the Sprocket
Checking the Valve Lifter
Checking the Camshaft Journal Oil Clearance
Checking the Camshaft Journal Outside Diameter and Camshaft Journal Inside Diameter
Installing the Camshaft, VCT Assembly, and Driven Sprocket
Cylinder Head
Disassembling the Cylinder Head
Removing the Cylinder Head
Checking the Cylinder Head
Checking the Cylinder Head Bolt
Checking the Valve Spring
Checking the Valve
Checking the Valve Guide
Replacing the Valve Guide
Checking the Valve Seat
Refacing the Valve Seat
Assembling the Cylinder Head
Checking the Cylinder Head Anode
Installing the Cylinder Head
Oil Cooler and Oil Pump Assembly
Checking the Oil Cooler
Checking the Oil Cooler Anode
Checking the Oil Pump
Removing the Oil Filter
Assembling the Oil Pump
Installing the Oil Cooler
Installing the Oil Pump Assembly
Installing the Oil Filter
Cylinder Block Sensor and Switch
Checking the Cooling Water Cover Anode
Checking the Thermostat
Installing the Thermostat
Installing the Cooling Water Cover
Installing the Knock Sensor
Installing the Pulley Bracket
Cylinder Block
Disassembling the Cylinder Block
Checking the Cylinder Bore
Checking the Piston Diameter
Checking the Piston Clearance
Checking the Piston Ring
Checking the Piston Ring End Gap
Checking the Piston Pin Boss Inside Diameter
Checking the Piston Ring Groove
Checking the Piston Ring Side Clearance
Checking the Connecting Rod Small End Inside Diameter and Big End Inside Diameter
Checking the Piston Pin Diameter
Checking the Connecting Rod Big End Side Clearance
Checking the Crankshaft
Checking the Big End Oil Clearance
Checking the Crankcase Bolt
Selecting the Crankshaft Pin Bearing
Crankshaft Pin Bearing Selection Table
Checking the Journal Oil Clearance
Selecting the Crankshaft Journal Bearing
Crankshaft Journal Bearing Selection Table
Assembling the Cylinder Block
Checking the Cylinder Block Anode
Lower Unit 0
Lower Unit
Assembling the Propeller (Shift Dampener System [SDS] Propeller)
Checking the Propeller
Disassembling the Propeller (Shift Dampener System [SDS] Propeller)
Propeller
Removing the Propeller
Installing the Propeller
Lower Unit
Checking the Lower Unit Anode
Removing the Lower Unit
Checking the Lower Unit for Leakage
Installing the Lower Unit
Extension (Except for X-Transom Model)
Assembling the Extension
Checking the Extension
Installing the Extension
Water Pump and Shift Rod
Checking the Intermediate Drive Shaft
Checking the Shift Rod
Checking the Water Pump
Removing the Water Pump and Shift Rod
Assembling the Water Pump Housing
Installing the Shift Rod
Installing the Water Pump
Propeller Shaft Housing (Regular Rotation Model)
Removing the Propeller Shaft Housing Assembly
Disassembling the Propeller Shaft Assembly
Disassembling the Propeller Shaft Housing Assembly
Disassembling the Reverse Gear
Assembling the Propeller Shaft Assembly
Checking the Dog Clutch
Checking the Propeller Shaft
Checking the Propeller Shaft Housing
Checking the Reverse Gear
Assembling the Propeller Shaft Housing Assembly
Assembling the Reverse Gear
Installing the Propeller Shaft Housing Assembly
Drive Shaft and Lower Case (Regular Rotation Model)
Disassembling the Drive Shaft
Disassembling the Oil Seal Housing
Removing the Drive Shaft
Removing the Forward Gear
Disassembling the Forward Gear
Checking the Drive Shaft
Checking the Forward Gear
Checking the Pinion
Disassembling the Lower Case
Assembling the Drive Shaft
Checking the Lower Case
Assembling the Forward Gear
Assembling the Lower Case
Assembling the Oil Seal Housing
Installing the Forward Gear
Shimming (Regular Rotation Model)
Shimming Workflow
Shimming Check Sheet
Shimming Procedure
Shim Location
Selecting the Forward Gear Shim (T1) and Reverse Gear Shim (T2)
Selecting the Pinion Shim (T3)
Measuring the Forward Gear Backlash and Reverse Gear Backlash
Selecting the Propeller Shaft Shim (T4)
Propeller Shaft Housing (Counter Rotation Model)
Disassembling the Forward Gear
Disassembling the Propeller Shaft Housing Assembly
Removing the Propeller Shaft Housing Assembly
Assembling the Propeller Shaft Housing and Forward Gear
Checking the Dog Clutch
Checking the Forward Gear
Checking the Propeller Shaft
Checking the Propeller Shaft Housing
Installing the Propeller Shaft Housing Assembly
Drive Shaft and Lower Case (Counter Rotation Model)
Removing the Drive Shaft
Removing the Reverse Gear
Shimming (Counter Rotation Model)
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Table of
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Chapters
Table of Contents
3
Technical Feature and Description
28
Rigging Information 0
61
Troubleshooting 0
115
Fuel System 0
198
Power Unit
230
Lower Unit 0
323
Bracket Unit
391
Maintenance 0
445
Table of Contents
Troubleshooting
Troubleshooting
115
Outboard motor troubleshooting
119
Troubleshooting procedure (trouble code not detected)
136
Troubleshooting the PTT unit
142
Troubleshooting the lower unit
143
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