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Yamaha Manuals
Outboard Motor
F115A
Service manual
Table Of Contents - Yamaha F115A Service Manual
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Also See for F115A
:
Service manual
(713 pages)
,
Owner's manual
(124 pages)
,
Rigging manual
(329 pages)
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Table Of Contents
710
page
of
710
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/
710
Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
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Table of Contents
Model Indication
4
How To Use This Manual
4
Important Information
8
Symbols
12
General Information
12
Specifications
12
Periodic Inspections And Adjustments
12
Table Of Contents
14
Identification
18
Serial Number
18
Starting Serial Numbers
18
Safety While Working
20
Fire Prevention
20
Ventilation
20
Self-Protection
20
Oils, Greases And Sealing Fluids
20
Good Working Practices
22
Disassembly And Assembly
24
Special Tools
26
Measuring
26
Outillage Special
27
Removing And Installing
30
General Specifications
38
Maintenance Specifications
42
Power Unit
42
Dimensions
42
D'entretien
43
Wartungsdaten
43
Motorblock
43
Mantenimiento
43
Unidad Del Motor
43
Unidad Inferior
51
Sistema Eléctrico
51
Dimensiones
57
Tightening Torques
62
Specified Torques
62
Torsión De Apriete
65
General Torques
66
Torsiones Generales
67
Maintenance Interval Chart
72
Top Cowling
76
Checking The Top Cowling Fit
76
Fuel System
76
Checking The Fuel Line
76
Checking The Fuel Filter
78
Measuring The Fuel Pressure (High-Pressure Fuel Line)
78
Control System
80
Checking And Adjusting The Throttle Body Pickup Timing
80
Adjusting The Shift Cable
82
Adjusting The Throttle Cable
84
Adjusting The Throttle Position Sensor
86
Synchronizing The Throttle Valves
88
Throttle Position Sensor Output Voltage
88
Vacuum Gauge Set
88
Adjusting The Throttle Position Sensor (When Disassembling Or Replacing The Throttle Body)
92
Cooling System
94
Checking The Cooling Water Discharge
94
Checking The Engine Oil Level
94
Replacing The Engine Oil/Oil Filter
94
Checking The Timing Belt
96
Adjusting The Valve Clearance
98
Measurement Steps
100
Mesure
101
Power Trim And Tilt System
104
Checking The Power Trim And Tilt Fluid Level
104
Adjusting The Trim Sensor Cam
106
Einstellung Der Trimmsensor-Nocke
107
Lower Unit
108
Checking The Gear Oil Level
108
Changing And Checking The Gear Oil
108
Checking The Lower Unit (For Air Leaks)
112
Checking The Anodes
112
General
112
Checking The Battery
114
Checking The Spark Plugs
116
Compression Pressure Measurement
118
Oil Pressure Measurement
120
Lubrication Points
122
Intake Silencer
130
Removing/Installing The Intake Silencer
130
Removing/Installing The Intake Assembly
134
Removing/Installing The Throttle Body
138
Removing/Installing The Control Unit
140
Removing/Installing The High-Pressure Fuel Line
144
Reducing The Fuel Pressure (High-Pressure Fuel Line)
148
Checking The Pressure Regulator
150
Removing/Installing The Fuel Injectors
152
Disassembling/Assembling The Fuel Injectors
154
Removing/Installing The Fuel Hoses
156
Removing/Installing The Vapor Separator
158
Disassembling/Assembling The Vapor Separator
160
Disassembling/Assembling The High-Pressure Fuel Pump
162
Removing/Installing The Pressure Regulator
164
Removing/Installing The Idle Speed Control Assembly
166
Disassembling/Assembling The Idle Speed Control Assembly
170
Disassembling/Assembling The Fuel Rail
172
Disassembling/Assembling The Intake Manifold
174
Removing/Installing The Throttle Position Sensor
176
Installing The Throttle Position Sensor
178
Removing/Installing The Low-Pressure Fuel Line
180
Disassembling/Assembling The Low-Pressure Fuel Line
184
Disassembling/Assembling The Fuel Filter
186
Disassembling/Assembling The Fuel Pump
188
Checking The Fuel Pumps
190
Removing/Installing The Flywheel Magnet Assembly
196
Removing The Flywheel Magnet Assembly
198
Installing The Flywheel Magnet Assembly
200
Disconnecting/Connecting The Control Cable
202
Disconnecting/Connecting The Leads
206
Removing/Installing The Power Unit
210
Removing/Installing The Stator Coil Assembly
212
Removing/Installing The Timing Belt
214
Removing The Driven Sprocket
218
Removing/Installing The Drive Sprocket
218
Installing The Driven Sprocket
220
Installing The Timing Belt
220
Removing/Installing The Ignition Coils And Starter Motor
222
Ecm And Junction Box Assembly
224
Removing/Installing The Cdi Unit And Junction Box Assembly
224
Disassembling/Assembling The Junction Box Assembly
230
Removing/Installing The Cylinder Head Cover
234
Removing/Installing The Camshafts
236
Checking The Camshaft
238
Installing The Camshaft
238
Removing/Installing The Cylinder Head Assembly
240
Checking The Thermostat
244
Removing/Installing The Valves
246
Checking The Valve
250
Checking The Valve Spring
252
Checking The Cylinder Head
252
Checking The Valve Guide
252
Checking The Valve Seat
254
Installing The Valve
256
Removing/Installing The Oil Filter And Exhaust Cover
258
Installing The Oil Filter
264
Crankshaft And Piston/Connecting Rod Assembly Removing/Installing The Crankshaft And Piston/Connecting Rod Assembly
266
Checking The Cylinder Block
270
Checking The Piston
270
Calculating The Piston-To-Cylinder Clearance
272
Checking The Piston Ring
272
Checking The Crankshaft
274
Checking The Main-Bearing Oil Clearance
274
Checking The Connecting Rod Big-End Oil Clearance
280
Installing The Piston Ring
286
Installing The Piston
288
Zusammenbauen
293
Removing/Installing The Lower Unit
302
Lower Unit (Regular Rotation Models)
302
Removing The Propeller
306
Checking The Propeller
306
Installing The Propeller
306
Removing/Installing The Water Pump
308
Water Pump (Regular Rotation Models)
308
Checking The Impeller Housing
312
Checking The Impeller And Impeller Housing Cup
312
Checking The Woodruff Key
312
Installing The Impeller And Impeller Housing
312
Removing/Installing The Shift Rod Assembly
314
Removing The Shift Rod Assembly
316
Removing/Installing The Propeller Shaft Housing Assembly
318
Disassembling/Assembling The Propeller Shaft Housing
322
Disassembling/Assembling The Propeller Shaft Assembly
324
Removing The Propeller Shaft Housing Assembly
326
Disassembling The Propeller Shaft Housing
326
Checking The Reverse Gear
328
Checking The Bearing
328
Checking The Propeller Shaft Housing
328
Checking The Dog Clutch
330
Checking The Propeller Shaft
330
Assembling The Propeller Shaft Housing
330
Assembling The Reverse Gear
330
Installing The Propeller Shaft Housing Assembly
332
Removing/Installing The Drive Shaft
334
Removing The Drive Shaft
338
Disassembling The Drive Shaft Housing Assembly
338
Disassembling The Forward Gear Assembly
338
Checking The Pinion
340
Checking The Drive Shaft
340
Checking The Drive Shaft Housing
340
Checking The Bearings
340
Assembling The Drive Shaft Housing Assembly
342
Installing The Drive Shaft
344
Disassembling/Assembling The Lower Case Assembly
346
Disassembling The Lower Case Assembly
348
Checking The Drive Shaft Sleeve
348
Checking The Needle Bearing
348
Assembling The Lower Case Assembly
348
Counter Rotation Models
368
Disassembling/Assembling The Propeller Shaft Housing Assembly
372
Disassembling/Assembling The Front Propeller Shaft Assembly
376
Removing The Forward Gear Assembly
378
Checking The Forward Gear
382
Checking The Propeller Shafts
382
Assembling The Forward Gear
384
Assembling The Propeller Shaft Housing Assembly
384
Installing The Forward Gear Assembly
386
Selecting The Pinion Shims
422
Selecting The Forward Gear Shims
426
Selecting The Reverse Gear Shim
428
Backlash
432
Measuring The Forward Gear Backlash
432
Measuring The Reverse Gear Backlash
434
Shimming (Counter Rotation Models) (For Usa And Canada)
440
Shimming (Counter Rotation Models) (For Worldwide)
454
Bracket Unit
476
Removing/Installing The Steering Friction
480
Steering Handle (Option)
480
Removing/Installing The Steering Handle
482
Disassembling/Assembling The Steering Handle
486
Disassembling/Assembling The Steering Handle Sub Assembly
492
Removing/Installing The Bottom Cowling
504
Removing/Installing The Upper Case Assembly
510
Disassembling/Assembling The Upper Case Assembly
514
Disassembling/Assembling The Oil Pan
520
Removing/Installing The Clamp Brackets
526
Removing/Installing The Steering Arm
530
Disassembling/Assembling The Swivel Bracket Assembly
532
Removing/Installing The Power Trim And Tilt Unit
536
Removing The Power Trim And Tilt Unit
540
Bleeding The Power Trim And Tilt Unit
540
Removing/Installing The Reservoir And Power Trim And Tilt Motor
544
Checking The Reservoir
546
Checking The Gear Pump Housing Filter
546
Installing The Power Trim And Tilt Motor
548
Filling The Reservoir
550
Measuring The Hydraulic Pressure
554
Removing/Installing The Tilt Ram Assembly And Gear Pump Unit
560
Removing The Tilt Ram End Screw
564
Removing The Gear Pump Unit
564
Disassembling The Gear Pump Unit
564
Checking The Tilt Ram
566
Checking The Gear Pump Unit
566
Assembling The Gear Pump Unit
568
Installing The Gear Pump Unit
570
Installing The Tilt Ram Assembly
570
Removing/Installing The Trim Ram Assemblies And Free Piston
574
Removing The Trim Ram End Screws
576
Removing The Free Piston
576
Checking The Trim Rams
578
Checking The Free Piston
578
Checking The Trim Ram Cylinders
578
Installing The Free Piston
578
Installing The Trim Rams
580
Electrical Systems
584
Electrical Components (Port View)
588
Electrical Components (Starboard View)
590
Electrical Components (Front View)
592
Electrical Components (Aft View)
594
Electrical Components (Top View)
596
Wire Harness
598
Electrical Components Analysis
602
Digital Circuit Tester
602
Measuring The Peak Voltage
602
Peak Voltage Adaptor
602
Measuring A Low Resistance
604
Ignition System
606
Checking The Fuses
608
Measuring The Ignition Coil Assembly
608
Checking The Ignition Spark Gap
610
Measuring The Ignition System Peak Voltage
612
Ignition Control System
616
Measuring The Pulser Coil Output Peak Voltage
618
Measuring The Engine Cooling Water Temperature Sensor Resistance
618
Checking The Oil Pressure Switch Continuity
620
Measuring The Throttle Position Sensor
622
Fuel Control System
624
Checking The Fuel Injectors
628
Starting System
630
Checking The Starter Relay
632
Checking The Shift Position Switch Continuity
634
Disassembling/Assembling The Starter Motor
636
Removing The Starter Motor Pinion
642
Checking The Starter Motor Pinion
642
Checking The Armature
642
Measuring The Brushes
644
Checking The Magnetic Switch Relay
646
Charging System
648
Measuring The Lighting Coil Output Peak Voltage
650
Measuring The Rectifier/Regulator Output Peak Voltage
650
Checking The Power Trim And Tilt Relay
654
Checking The Trailer Switch Continuity
656
Measuring The Trim Sensor Resistance
656
Disassembling/Assembling The Power Trim And Tilt Motor
658
Removing The Stator
662
Removing The Brush
662
Checking The Brush
662
Power Trim And Tilt Motor
664
Installing The Brush
666
Installing The Armature
666
Installing The Stator
666
Trouble Analysis
668
Trouble Analysis Chart
670
Self-Diagnosis
674
Diagnosis Code Indication
674
Diagnosis The Electronic Control System
674
Diagnosis Code Chart
675
Trouble Shooting For Electric Fuel Injection
676
Wiring Diagram
706
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Table of Contents
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This manual is also suitable for:
F115y
Fl115a
Lf115y
Fl115y
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