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F450A 2022
Yamaha F450A 2022 Manuals
Manuals and User Guides for Yamaha F450A 2022. We have
1
Yamaha F450A 2022 manual available for free PDF download: Service Manual
Yamaha F450A 2022 Service Manual (592 pages)
Brand:
Yamaha
| Category:
Motorcycle
| Size: 37 MB
Table of Contents
Table of Contents
3
General Information
4
Model Information
5
Applicable Model
5
Model Name Designation
5
Important Safety and Service Information
7
Rotating Parts
7
Hot Parts
7
Electric Shock
7
Propeller
7
Handling of Gasoline
7
Ventilation
7
Self-Protection
7
Lifting Outboard Motors
8
Handling of Gas Torch
8
Parts, Lubricants, and Sealants
8
Handling of Lubricants and Sealants
8
Special Service Tools
9
Tightening Torque
9
Non-Reusable Parts
9
Disassembly and Assembly
9
Disposal of Used Components and Chemicals
9
How to Use this Manual
11
Conditions When Testing and Adjusting
11
Abbreviation
11
Color Code
12
Specified Tightening Torque
13
General Tightening Torque
13
Symbol
14
Specification Symbol
14
Lubricant, Sealant, and Thread Locking Agent Symbol
14
Special Service Tool
16
Specification
23
Specification Data
24
External Dimensions
25
Technical Feature and Description
28
Model Feature
29
General Feature
29
Model Comparison Table
30
Power Unit
31
Intake Silencer
32
Shift-Shock Reduction
32
Sleeveless Cylinder
33
Heat Exhaust Fan and Heat Vent
33
Direct Fuel Injection
34
Crankshaft
35
Camshaft
36
Cowlings
37
Bracket Unit
38
Upper Mount
39
SBW (Steer by Wire) System
40
System Diagram
41
Structure
43
Operation
44
Outboard Motor Manual Steering Method
45
PTT Unit
46
PTT Sensor
47
PTT Lead
48
PTT Totaltilt
48
Lower Unit
51
Lower Case
52
Gear Oil Changing Method
53
Reverse Thrust
55
Propeller (XTO-EC Series)
56
Engine ECM
56
Electrical System
57
Charging System (F400A/FL400A/XF400)
57
Charging System (F450A/FL450A/XF450)
58
Knocking Detection
61
Overheat Detection
61
Electronic Control System
62
Electrical Components
64
Fail-Safe
66
Fuel System
70
Fuel Diagram
70
High-Pressure Fuel Pump Control
73
Low-Pressure Fuel Pump Control
73
Vapor Separator
74
Fuel Strainer
75
Direct Injection Pump
76
Lubrication System
77
Lubrication Diagram
77
Dual Rotor Oil Pump
79
Oil Drain Plug
80
Cooling System
81
Cooling Diagram
81
Dual Water Pump
84
Engine Anode
85
Thermostat
86
Intake and Exhaust System
87
Intake and Exhaust Diagram
87
Hose Routing
88
Fuel Hose and Blowby Hose
88
Cooling Water Hose
89
Rigging Information
91
Important Reminder on Rigging
92
Outboard Motor Mounting Instructions
92
Crate Handling
93
Crate Top Cover Symbol Description
93
Uncrating
94
Uncrating Procedure (Outboard Motor Without Lower Unit)
94
Uncrating Procedure (Outboard Motor with Lower Unit)
95
Outboard Motor Mounting
99
Installing the Outboard Motor
99
Outboard Motor Mounting Height
103
Rigging Grommet Mounting
104
Rigging Grommet Description
104
Installing the Battery Cable
104
Installing the Main Wire Harness
104
Installing the Rigging Grommet
104
Connecting the Fuel Hose
105
Optional Equipment
106
Installing the Isolator Lead
106
Installing the SCU Communication Lead
106
Installing Y-COP
107
Battery Installation
108
Battery Wiring
110
System Diagram
116
Single Outboard Motor Application (Single Station)
116
Twin Outboard Motor Application (Single Station)
119
Triple Outboard Motor Application (Single Station)
122
Quad Outboard Motor Application (Single Station)
126
Quint Outboard Motor Application (Single Station)
130
Single Outboard Motor Application (Dual Station)
134
Twin Outboard Motor Application (Dual Station)
137
Triple Outboard Motor Application (Dual Station)
141
Quad Outboard Motor Application (Dual Station)
145
Quint Outboard Motor Application (Dual Station)
149
Digital Electronic Control
153
Digital Electronic Control System Reset
153
Tilt Limiter
154
Setting the Tilt Limiter
154
Clearing the Tilt Limiter
155
Deactivating the Tilt Limiter
155
Calibration (6X9 Digital Electronic Control)
157
CL5 Display Calibration
158
Configuring the Number of Outboard Motors
158
Accessing the Calibration Menu
158
Steering Sensor
159
Toe Adjust
161
Lock to Lock
163
Friction Set
165
Rigging Recommendation
167
Battery Cable Length
167
Extension Length Recommendation for Battery Cable
167
Propeller Selection
169
Propeller Size
169
Selection
170
Fuel Line Air Purging
172
Air Purging During Initial Priming
172
Troubleshooting
173
Ydis
174
Connecting the Communication Cable
174
ECM Reprogramming
176
Outboard Motor Troubleshooting
177
Troubleshooting Procedure
177
Troubleshooting the Power Unit Using the YDIS
177
Trouble Code and Checking Step
181
Troubleshooting Procedure (Trouble Code Not Detected)
198
Troubleshooting the Power Unit
198
Troubleshooting the PTT Unit
206
Troubleshooting the Lower Unit
208
Electrical System
210
Electrical Component and Wire Harness Routing
212
Port
212
Starboard
214
Rear
216
Front
218
Top
219
Fuse Holder (Electrical Management Box)
221
Bottom Cowling
222
ECM Circuit Diagram
223
ECM Coupler Layout
226
Checking the Electrical Component
229
Using the YDIS
229
Using the Digital Tester
229
Engine Control Unit and Component
230
Checking the Main Relay
230
Checking the Engine ECM Circuit
230
Checking the Electrical Management Box
231
Checking the ETV and TPS
232
Checking the ETV Motor Relay
233
Checking the SPS
233
Checking the Shift Actuator Relay
234
Checking the Shift Actuator
234
Checking the Cam Position Sensor
234
Checking the OCV
236
Checking the Oil Pressure Sensor
237
Checking the Water Pressure Sensor
237
Fuel Control Unit and Component
239
Checking the Injector Driver Circuit
239
Checking the Water Detection Switch
239
Checking the Fuel Injector
240
Checking the Low-Pressure Fuel Pump and High-Pressure Fuel Pump
240
Checking the Direct Injection Pump
241
Checking the Low-Pressure Fuel Pump Relay
242
Checking the High-Pressure Fuel Pump Relay
242
Checking the Fuel Pressure Sensor
243
Charging Unit and Component
245
Checking the Lighting Coil (Stator Assembly)
245
Checking the Rectifier/Regulator
245
Ignition Unit and Component
246
Checking the Ignition Spark
246
Checking the Ignition Coil
246
Checking the Crankshaft Position Sensor
246
Checking the Intake Air Pressure/Temperature Sensor
247
Checking the Engine Temperature Sensor
248
Checking the Thermo Sensor
249
Checking the Knock Sensor
250
Checking the Engine Shut-Off Switch (6X6)
250
Checking the Engine Shut-Off Switch (EKS)
250
Starting Unit and Component
252
Checking the Starter Relay
252
Checking the Engine Start Switch and Main Switch (6X6)
252
Checking the Engine Start/Stop Button (6X6)
252
Checking the Power Switch (EKS)
253
Checking the Start/Stop Button (EKS)
254
Checking Y-COP
255
Starter Motor
256
Removing the Starter Motor
257
Checking the Starter Motor Pinion
257
Disassembling the Starter Motor
257
Checking the Armature (Starter Motor)
258
Checking the Brush Holder
258
Assembling the Starter Motor
259
Installing the Starter Motor
260
Outboard Motor and Digital Electronic Control Connection
261
Checking the Extension Wire Harness
261
Checking the Main Harness
261
Steering Unit
263
Checking the Steering Actuator
263
PTT System
264
Fuel System
267
Fuel System Basic Procedure
268
Starting the Engine after Running out of Fuel
268
Reducing the Fuel Pressure
268
Disconnecting the Quick Connector
268
Measuring the Fuel Pressure
269
Fuel Filter Assembly
270
Checking the Fuel Filter Assembly
271
Checking the Fuel Filter Element
271
Checking the Fuel Cup Assembly
271
Checking the Primer Pump
271
Assembling the Fuel Filter
272
Installing the Fuel Filter
272
Low-Pressure Fuel Pump
273
Checking the Low-Pressure Fuel Pump
274
Checking the Feed Valve (Low-Pressure Fuel Pump)
274
Checking the Relief Valve (Low-Pressure Fuel Pump)
274
Installing the Low-Pressure Fuel Pump
275
Vapor Separator and High-Pressure Fuel Pump
276
Draining the Fuel
277
Removing the Vapor Separator
277
Checking the High-Pressure Fuel Pump
277
Assembling the Vapor Separator
277
Installing the Vapor Separator
278
Fuel Hose Assembly
279
Fuel Hose, Feed Valve, Relief Valve, and Fuel Strainer
280
Disassembling the Fuel Hose Assembly
281
Checking the Fuel Strainer
281
Checking the Relief Valve (High-Pressure Fuel Pump)
281
Checking the Feed Valve (High-Pressure Fuel Pump)
282
Checking the Fuel Pressure Sensor (High-Pressure Fuel Pump)
283
Assembling the Fuel Hose Assembly
283
Installing the Fuel Hose Assembly
284
Direct Injection Pump and Fuel Injector
285
Removing the Fuel Rail
286
Removing the Fuel Injector
286
Checking the Fuel Pressure Sensor (Direct Injection Pump)
286
Checking the Direct Injection Pump
286
Checking the Fuel Rail and Fuel Injector
286
Installing the Fuel Injector and Fuel Rail
287
Intake Manifold
291
Checking the Intake Manifold
293
Installing the Intake Manifold
293
Etv
295
Checking the ETV
296
Checking the Intake Air Pressure/Temperature Sensor
296
Installing the ETV and Surge Tank
296
Power Unit
298
Power Unit (Check and Adjustment)
301
Checking the Compression Pressure
301
Checking the Oil Pressure
301
Checking the Valve Clearance
301
Adjusting the Valve Clearance
303
Shroud Cover and Terminal Cover
305
Installing the Shroud Cover and Terminal Cover
306
Exhaust Joint (Outside)
307
Removing the Exhaust Joint Assembly
308
Disassembling the Exhaust Joint Assembly
308
Checking the Exhaust Joint
308
Checking the Exhaust Joint Anode
308
Checking the Water Pressure Sensor
308
Installing the Exhaust Joint Assembly
308
Exhaust Joint (Inside)
311
Removing the Exhaust Joint
312
Checking the Exhaust Joint
312
Checking the Exhaust Joint Anode
312
Installing the Exhaust Joint
312
Power Unit Assembly
313
Removing the Power Unit
315
Installing the Power Unit
317
Electrical Management Box
322
Installing the Electrical Management Box
323
Flywheel Magneto
324
Removing the Flywheel Magneto
325
Installing the Flywheel Magneto
325
Starter Motor and Extension Wire Harness
329
Installing the Starter Motor
329
Installing the Extension Wire Harness
329
Wire Harness
331
Removing the Wire Harness
331
Installing the Wire Harness
333
ECM, Injector Driver, and Rectifier/Regulator
338
Removing the Rectifier/Regulator
338
Checking the Rectifier/Regulator Anode
338
Installing the ECM and Injector Driver
338
Installing the Rectifier/Regulator
338
Ignition Coil and Spark Plug
340
Checking the Spark Plug
341
Installing the Ignition Coil and Spark Plug
341
Timing Belt
342
Removing the Timing Belt
343
Checking the Timing Belt
343
Installing the Timing Belt
343
Camshaft
346
Removing the Camshaft, VCT Assembly, and Driven Sprocket
348
Checking the Sprocket
349
Checking the Cam Chain
349
Checking the Cam Chain Tensioner
349
Checking the Valve Lifter
350
Checking the Camshaft
350
Checking the Camshaft Journal Oil Clearance
351
Checking the Camshaft Journal Outside Diameter and Camshaft Journal Inside Diameter
352
Installing the Camshaft, VCT Assembly, and Driven Sprocket
353
Cylinder Head
358
Removing the Cylinder Head
359
Disassembling the Cylinder Head
359
Checking the Cylinder Head
359
Checking the Cylinder Head Bolt
360
Checking the Valve Spring
360
Checking the Valve
361
Checking the Valve Guide
361
Replacing the Valve Guide
362
Checking the Valve Seat
363
Refacing the Valve Seat
363
Checking the Cylinder Head Anode
366
Checking the Cam Position Sensor
366
Checking the OCV
366
Assembling the Cylinder Head
366
Installing the Cylinder Head
368
Oil Pump Assembly
370
Removing the Oil Pump Assembly
371
Removing the Oil Filter
371
Installing the Oil Filler Neck and Relief Valve
371
Installing the Oil Pump Assembly
371
Installing the Oil Filter
371
Oil Cooler and Water Jacket
372
Checking the Thermostat
373
Checking the Oil Cooler Cover Anode and Water Jacket Anode
373
Installing the Cylinder Block Thermostat
373
Installing the Water Jacket Cover
373
Installing the Oil Cooler Cover
374
Cylinder Block Sensor
375
Checking the Cylinder Block Anode
376
Installing the Cylinder Block Anode
376
Installing the Cylinder Block Sensor
376
Cylinder Block
377
Disassembling the Cylinder Block
378
Checking the Piston Diameter
378
Checking the Cylinder Bore
379
Checking the Piston Clearance
379
Checking the Piston Ring
379
Checking the Piston Ring End Gap
380
Checking the Piston Ring Groove
380
Checking the Piston Ring Side Clearance
381
Checking the Piston Pin Boss Inside Diameter
381
Checking the Piston Pin Diameter
381
Checking the Connecting Rod Small End Inside Diameter and Big End Inside Diameter
382
Checking the Connecting Rod Big End Side Clearance
382
Checking the Crankshaft
382
Checking the Crankcase Bolt
383
Checking the Big End Oil Clearance
383
Selecting the Crankshaft Pin Bearing
385
Crankshaft Pin Bearing Selection Table
387
Checking the Journal Oil Clearance
388
Selecting the Crankshaft Journal Bearing
389
Crankshaft Journal Bearing Selection Table
391
Assembling the Cylinder Block
392
Lower Unit
398
Propeller and Water Inlet Cover
400
Removing the Propeller
401
Disassembling the Propeller (Shift Dampener System [SDS] Propeller)
401
Checking the Propeller
401
Assembling the Propeller (Shift Dampener System [SDS] Propeller)
401
Installing the Water Inlet
402
Installing the Propeller
402
Lower Unit
405
Removing the Lower Unit
405
Checking the Lower Unit Anode
405
Checking the Gear Oil Passage Check Valve
405
Checking the Lower Unit for Leakage
405
Installing the Lower Unit
406
Extension (Except for X-Transom Model)
408
Checking the Extension
409
Assembling the Extension
409
Installing the Extension
409
Water Pump and Shift Rod
410
Removing the Shift Rod (Regular Rotation Model)
411
Removing the Shift Rod (Counter Rotation Model)
411
Removing the Gear Oil Passage Check Valve
411
Checking the Water Pump
412
Checking the Shift Rod
412
Installing the Gear Oil Passage Check Valve
412
Assembling the Shift Rod Guide Plate
412
Assembling the Water Pump Housing
413
Installing the Water Pump and Shift Rod (Regular Rotation Model)
414
Installing the Water Pump and Shift Rod (Counter Rotation Model)
415
Propeller Shaft Housing (Regular Rotation Model)
417
Removing the Propeller Shaft Housing Assembly
418
Disassembling the Propeller Shaft Assembly
419
Disassembling the Reverse Gear
419
Disassembling the Propeller Shaft Housing Assembly
419
Checking the Propeller Shaft
420
Checking the Dog Clutch
420
Checking the Propeller Shaft Housing
420
Checking the Reverse Gear
421
Assembling the Propeller Shaft Assembly
421
Assembling the Reverse Gear
421
Assembling the Propeller Shaft Housing Assembly
422
Installing the Propeller Shaft Housing Assembly
424
Drive Shaft and Lower Case (Regular Rotation Model)
426
Removing the Drive Shaft
427
Disassembling the Drive Shaft
427
Disassembling the Forward Gear
428
Disassembling the Lower Case
428
Checking the Pinion
429
Checking the Forward Gear
429
Checking the Drive Shaft
429
Checking the Lower Case
429
Assembling the Lower Case
429
Assembling the Forward Gear
430
Assembling the Drive Shaft
430
Assembling the Oil Seal Housing
432
Installing the Forward Gear
433
Installing the Drive Shaft
433
Shimming (Regular Rotation Model)
435
Shimming Workflow
435
Shimming Check Sheet
436
Shimming Procedure
437
Shim Location
437
Selecting the Forward Gear Shim (T1) and Reverse Gear Shim (T2)
438
Selecting the Pinion Shim (T3)
438
Measuring the Forward Gear Backlash and Reverse Gear Backlash
440
Selecting the Propeller Shaft Shim (T4)
444
Propeller Shaft Housing (Counter Rotation Model)
447
Removing the Propeller Shaft Housing Assembly
448
Disassembling the Propeller Shaft Housing Assembly
448
Disassembling the Forward Gear
449
Checking the Propeller Shaft
449
Checking the Dog Clutch
450
Checking the Propeller Shaft Housing
450
Checking the Forward Gear
450
Assembling the Propeller Shaft Housing and Forward Gear
450
Installing the Propeller Shaft Housing Assembly
451
Drive Shaft and Lower Case (Counter Rotation Model)
453
Removing the Drive Shaft
454
Disassembling the Drive Shaft
454
Disassembling the Reverse Gear
454
Disassembling the Lower Case
454
Checking the Pinion
454
Checking the Reverse Gear
454
Checking the Drive Shaft
454
Checking the Lower Case
454
Assembling the Lower Case
454
Assembling the Reverse Gear
454
Assembling the Drive Shaft
455
Assembling the Oil Seal Housing
455
Installing the Reverse Gear
455
Installing the Drive Shaft
455
Shimming (Counter Rotation Model)
456
Shimming Workflow
456
Shimming Check Sheet
457
Shimming Procedure
458
Shim Location
458
Selecting the Reverse Gear Shim (T1) and Forward Gear Shim (T2)
459
Selecting the Pinion Shim (T3)
459
Selecting the Propeller Shaft Shim (T4)
459
Measuring the Forward Gear Backlash and Reverse Gear Backlash
461
Bracket Unit
467
Bottom Cowling Cover and Apron Cover
469
Installing the Bottom Cowling Cover
470
Bottom Cowling (PORT and STBD)
471
Removing the Bottom Cowling
473
Assembling the Bottom Cowling
473
Installing the Propeller Light Bracket
474
Installing the Bottom Cowling
475
Apron
476
Cooling Water Hose and Gear Oil Changing Hose
477
Removing the Cooling Water Hose (Oil Pan Side)
478
Installing the Gear Oil Changing Hose
478
Installing the Cooling Water Hose
480
Shift Actuator and Shift Rod
481
Installing the Shift Actuator and Shift Rod
482
Bottom Cowling (Front) and Flushing Hose
484
Assembling the Bottom Cowling (Front)
485
Installing the Bottom Cowling (Front)
485
Installing the Flushing Hose and PTT Switch
485
Upper Case Assembly and Mount
488
Removing the Upper Case Assembly
489
Installing the Upper Case Assembly
489
Exhaust Guide
493
Checking the Exhaust Guide
494
Installing the Exhaust Guide
494
Upper Case, Muffler, and Oil Pan
496
Disassembling the Upper Case
497
Checking the Upper Case
497
Checking the Muffler
497
Checking the PCV
497
Checking the Oil Pan and Oil Strainer
497
Assembling the Oil Pan
497
Assembling the Upper Case
498
Installing the Muffler and Upper Case
498
Steering Actuator and Steering Arm
500
Removing the Steering Actuator (with the Power Unit Installed)
501
Removing the Power Steering Unit (with the Power Unit Removed)
502
Removing the Steering Arm
503
Checking the Steering Arm and Steering Arm Joint
504
Installing the Steering Arm
504
Installing the Steering Actuator (with the Power Unit Removed)
505
Installing the Steering Actuator (with the Power Unit Installed)
507
Clamp Bracket and Swivel Bracket
510
Removing the Clamp Bracket
511
Checking the Clamp Bracket Anode
511
Assembling the Swivel Bracket
511
Installing the Clamp Bracket
511
PTT Unit
513
Removing the PTT Unit
514
Checking the PTT Motor Electric Current When the Relief Valve Operates
514
Bleeding the PTT Unit
516
Installing the PTT Unit
517
PTT Motor
520
Removing the Reservoir
521
Disassembling the PTT Motor
521
Checking the PTT Motor
521
Checking the Brush
522
Checking the Reservoir
522
Checking the Filter
522
Assembling the PTT Motor
522
Installing the Reservoir
523
Installing the PTT Motor
523
PTT Gear Pump
525
Disassembling the Gear Pump Assembly
527
Checking the Gear Pump
527
Checking the Gear Pump Housing
527
Checking the Filter
527
Assembling the Gear Pump Assembly
527
Installing the Gear Pump Assembly
529
PTT Cylinder
530
Removing the Tilt Ram
532
Removing the Trim Ram
532
Checking the Tilt Cylinder and Trim Cylinder
533
Checking the Absorber Valve
533
Assembling the Trim Ram
533
Assembling the Tilt Ram
533
Installing the Tilt Cylinder
534
Installing the Trim Ram
534
Installing the Tilt Ram
535
Maintenance
537
Maintenance Interval Chart
538
Checking the Battery
546
Checking the Cooling Water Pilot Hole
546
Checking the Engine Idle Speed
546
Checking the Engine Oil Level
547
Replacing the Oil Filter
550
Checking the Gear Oil Level
551
Greasing Points
556
Checking the PTT Fluid Level
557
Predelivery Check
559
Checking the Outboard Motor Mounting Height
562
Wiring Diagram
572
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