Yamaha F75F Manuals

Manuals and User Guides for Yamaha F75F. We have 1 Yamaha F75F manual available for free PDF download: Service Manual

Yamaha F75F Service Manual

Yamaha F75F Service Manual (344 pages)

Brand: Yamaha | Category: Outboard Motor | Size: 47 MB

Table of Contents

Table of Contents

3
- General Information
  4
- Model Information
  5
- Model Name Designation
  5
- Applicable Model
  5
- General Feature
  6
- 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
  8
- Lifting Outboard Motors
  8
- Handling of Gas Torch
  8
- Parts, Lubricants, and Sealants
  8
- Tightening Torque
  9
- Disassembly and Assembly
  9
- Special Service Tools
  9
- Non-Reusable Parts
  9
- Handling of Lubricants and Sealants
  9
- Disposal of Used Components and Chemicals
  10
- How to Use this Manual
  11
- Manual Format
  11
- Conditions When Testing and Adjusting
  12
- Abbreviation
  12
- Color Code
  12
- Symbol
  13
- General Tightening Torque
  13
- Specified Tightening Torque
  13
- Lubricant, Sealant, and Thread Locking Agent
  14
- Special Service Tool
  15
- Specification
  19
  - Specification Data
    20
  - External Dimensions
    20
  - Clamp Bracket Dimensions
    22
Technical Feature and Description

23
- Technical Feature and Description
  24
- Electronic Control System
  25
- Electrical Components
  26
- Electronic Fuel Injection Control
  28
- Ignition Timing Control
  30
- Engine Protection Control
  32
- Battery Removal Control
  33
- Fail-Safe
  33
- ISC Valve Control
  33
- Knock Control
  33
- Fuse Box
  35
- Self-Diagnosis of Power Supply Circuit
  35
- Trouble Code Detecting Conditions
  36
- Cable Clamp
  38
- Fuel Filter
  38
- Lifting the Outboard Motor
  38
- Oil Catch Tray
  38
- Rigging Grommet
  38
- Serviceability
  38
- Anode
  39
- Cylinder Block
  40
- Flywheel and Crankshaft
  40
- Overview
  40
- Power Unit System
  40
- Vapor Separator
  40
- Bracket Unit
  41
- Electrical System
  41
- Hour Meter (Tiller Handle Model)
  41
- Lower Unit
  41
- Overview
  41
- PTT Unit
  41
- Upper Case
  41
- Upper Mount, Lower Mount
  41
- Fuel System
  42
- Silencer
  42
- Fuel Diagram
  43
- High-Pressure Fuel Pump Control
  43
- Lubrication Diagram
  45
- Lubrication System
  45
- Cooling Diagram
  47
- Cooling System
  47
- Intake and Exhaust Diagram
  49
- Intake and Exhaust System
  49
- Fuel Hose
  50
- Hose Routing
  50
- Vapor Gas Hose and Blowby Hose
  51
- Cooling Water Hose
  52
Rigging Information 0

53
Troubleshooting 0

68
- Connecting the Communication Cable
  69
- Ydis
  69
- ECM Reprogramming
  71
- Outboard Motor Troubleshooting
  72
- Troubleshooting Procedure
  72
- Troubleshooting the Power Unit Using the YDIS
  72
- Trouble Code and Checking Step
  73
- Troubleshooting Procedure (Trouble Code Not Detected)
  75
- Troubleshooting the Power Unit
  76
- Troubleshooting the PTT Unit
  81
- Troubleshooting the Lower Unit
  82
  - Fuse Holder
    89
  - Bottom Cowling
    93
  - ECM Coupler Layout
    99
  - Checking the Electrical Component
    101
  - Measuring the Peak Voltage
    101
  - Checking the Fuel Injector
    107
  - Checking the High-Pressure Fuel Pump
    107
  - Checking the High-Pressure Fuel Pump Relay
    108
  - Checking the Rectifier/Regulator
    110
  - Checking the Hour Meter
    111
  - Checking the Intake Air Temperature Sensor
    114
  - Checking the Knock Sensor
    116
  - Checking the Shift Position Switch
    116
  - Starter Motor
    119
  - Assembling the Starter Motor
    122
  - PTT System
    124
  - Installing the Starter Motor
    124
Fuel System 0

128
- Disconnecting the Quick Connector
  130
- Reducing the Fuel Pressure
  130
- Measuring the Fuel Pressure
  131
- Fuel Filter
  133
- Fuel Tank
  134
- Checking the Fuel Cup Assembly
  135
- Checking the Fuel Filter Assembly
  135
- Checking the Fuel Filter Element
  135
- Removing the Fuel Filter Assembly
  135
- Assembling the Fuel Filter Assembly
  136
- Checking the Primer Pump
  136
- Installing the Fuel Filter Assembly
  136
- Fuel Pump Assembly
  137
- Checking the Fuel Pump Assembly
  138
- Checking the Fuel Strainer
  138
- Removing the Fuel Pump Assembly
  138
- Assembling the Fuel Pump Assembly
  139
- Checking the Diaphragm and Valve
  139
- Disassembling the Fuel Pump Assembly
  139
- Installing the Fuel Pump Assembly
  141
- Vapor Separator
  142
- Draining the Fuel
  143
- Installing the Vapor Separator
  143
- Removing the Vapor Separator
  143
- Vapor Separator and High-Pressure Fuel Pump
  144
- Assembling the Vapor Separator
  145
- Checking the Vapor Separator
  145
- Fuel Injector
  146
- Checking the Fuel Rail and Fuel Injector
  147
- Installing the Fuel Injector
  147
- Removing the Fuel Injector
  147
- Intake Silencer, Intake Manifold and Throttle Body
  148
- Checking the Intake Air Pressure/Temperature Sensor
  150
- Checking the Intake Manifold
  150
- Checking the Throttle Body
  150
- Installing the Intake Manifold
  150
- Installing the Throttle Body
  150
- Adjusting the Throttle Link Rod
  151
- Canister and Vapor Shut-Off Valve
  153
- Checking the Canister
  154
- Checking the Canister Check Valve
  154
- Checking the Vapor Shut-Off Valve
  154
- Installing the Vapor Shut-Off Valve and Canister
  155
Power Unit

156
- Power Unit
  157
- Checking the Compression Pressure
  159
- Checking the Oil Pressure
  159
- Checking the Pulser Coil Air Gap
  160
- Checking the Valve Clearance
  160
- Adjusting the Valve Clearance
  163
- Power Unit Assembly
  164
- Removing the Power Unit
  165
- Installing the Power Unit
  167
- Flywheel Magneto and Timing Belt
  170
- Checking the Timing Belt and Sprocket
  171
- Installing the Sprocket and Timing Belt
  171
- Removing the Flywheel Magneto
  171
- Removing the Timing Belt and Sprocket
  171
- Installing the Stator Assembly
  172
- Installing the Flywheel Magneto
  173
- Starter Motor
  174
- Rectifier/Regulator, Ignition Coil, and Spark Plug
  175
- Checking the Spark Plug
  176
- Installing the Ignition Coil, Rectifier/Regulator, and Spark Plug
  176
- Wire Harness
  177
- Wire Harness (Tiller Handle Model)
  177
- Wire Harness (Remote Control Model)
  178
- Installing the Wire Harness
  179
- Fuse Box
  180
- Throttle Control Lever
  181
- Installing the Throttle Control Lever
  182
- Oil Cooler
  183
- Checking the Crankcase Cover Anode
  184
- Checking the Thermostat
  184
- Installing the Crankcase Cover
  184
- Cylinder Head
  185
- Checking the Cylinder Head Anode
  186
- Checking the Cylinder Head Bolt
  186
- Installing the Cylinder Head
  186
- Removing the Cylinder Head
  186
- Camshaft and Valve
  188
- Checking the Cylinder Head
  189
- Disassembling the Cylinder Head
  189
- Checking the Valve
  190
- Checking the Valve Spring
  190
- Checking the Valve Guide
  191
- Replacing the Valve Guide
  191
- Checking the Valve Seat
  192
- Refacing the Valve Seat
  193
- Checking the Rocker Arm and Rocker Arm Shaft
  195
- Assembling the Cylinder Head
  196
- Checking the Camshaft
  196
- Cylinder Block
  200
- Assembling the Oil Pump
  201
- Checking the Cylinder Block Anode
  201
- Checking the Oil Pump
  201
- Removing the Oil Filter
  201
- Installing the Oil Pump Assembly
  202
- Installing the Oil Filter
  203
- Crankcase
  204
- Disassembling the Cylinder Block
  205
- Checking the Cylinder Bore
  206
- Checking the Piston Clearance
  206
- Checking the Piston Diameter
  206
- Checking the Piston Ring
  207
- Checking the Piston Ring End Gap
  207
- Checking the Piston Pin Boss Inside Diameter
  208
- Checking the Piston Ring Groove
  208
- Checking the Piston Ring Side Clearance
  208
- Checking the Connecting Rod Small End Inside Diameter and Big End In- Side Diameter
  209
- Checking the Piston Pin Diameter
  209
- Checking the Connecting Rod Big End Side Clearance
  210
- Checking the Crankshaft
  210
- Checking the Big End Oil Clearance
  211
- Selecting the Crankshaft Pin Bearing
  212
- Crankshaft Pin Bearing Selection Table
  214
- Checking the Journal Oil Clearance
  215
- Selecting the Crankshaft Journal Bearing
  216
- Crankshaft Journal Bearing Selection Table
  218
- Assembling the Cylinder Block
  219
Lower Unit 0

223
- Lower Unit
  224
- Checking the Lower Unit Anode
  226
- Checking the Propeller
  226
- Lower Unit
  226
- Removing the Lower Unit
  226
- Water Pump and Shift Rod
  227
- Assembling the Water Pump Housing
  228
- Checking the Water Pump and Shift Rod
  228
- Removing the Water Pump and Shift Rod
  228
- Propeller Shaft Housing
  229
- Disassembling the Propeller Shaft Assembly
  230
- Removing the Propeller Shaft Housing Assembly
  230
- Checking the Propeller Shaft
  231
- Disassembling the Propeller Shaft Housing Assembly
  231
- Assembling the Propeller Shaft Assembly
  232
- Assembling the Propeller Shaft Housing Assembly
  232
- Checking the Dog Clutch
  232
- Checking the Propeller Shaft Housing
  232
- Checking the Reverse Gear
  232
- Drive Shaft and Lower Case
  234
- Disassembling the Drive Shaft Housing
  235
- Disassembling the Forward Gear
  235
- Removing the Drive Shaft
  235
- Checking the Drive Shaft
  236
- Checking the Forward Gear
  236
- Checking the Pinion
  236
- Disassembling the Lower Case
  236
- Assembling the Drive Shaft Housing
  237
- Assembling the Forward Gear
  237
- Checking the Lower Case
  237
- Assembling the Lower Case
  238
- Installing the Drive Shaft
  239
- Installing the Propeller Shaft Housing Assembly
  240
- Installing the Shift Rod
  241
- Installing the Water Pump
  241
- Checking the Lower Unit for Air Leakage
  242
- Installing the Lower Unit
  242
- Shimming
  244
- Shimming Workflow
  244
- Shimming Check Sheet
  245
- Measuring the Forward Gear Backlash and Reverse Gear Backlash before Dis- Assembly
  247
- Shimming Procedure
  251
- Selecting the Pinion Shim (T3)
  252
- Measuring the Forward Gear Backlash
  254
- Adjusting the Forward Gear Shim Thickness (T1)
  255
- Measuring the Reverse Gear Backlash
  256
- Adjusting the Reverse Gear Shim Thickness (T2)
  257
- Bracket Unit
  260
  - Tiller Handle (Tiller Handle Model)
    262
  - Assembling the Tiller Handle
    264
  - Shift Rod and Shift Bracket
    269
  - PTT Switch and Cowling Lock Lever
    270
  - Assembling the Upper Case
    275
  - Checking the Drive Shaft Bushing
    277
  - Checking the Oil Strainer
    279
  - Steering Arm
    281
  - Removing the PTT Unit
    285
  - Bleeding the PTT Unit
    285
  - Clamp Bracket and Swivel Bracket
    288
  - Checking the Clamp Bracket Anode
    289
  - Installing the Clamp Bracket
    289
  - PTT Motor
    291
  - Checking the Armature (PTT Motor)
    292
  - Disassembling the PTT Motor
    292
  - Assembling the PTT Motor
    293
  - Checking the Brush
    293
  - PTT Gear Pump
    295
  - Checking the Gear Pump
    297
  - Assembling the Gear Pump Housing
    297
  - PTT Cylinder
    299
Maintenance 0

304
- Outline
  305
- Maintenance Interval Chart 1
  306
- Maintenance Interval Chart 2
  308
- Predelivery Check
  309
- Checking the Battery
  312
- Checking the Engine Oil Level
  312
- Checking the Cooling Water Pilot Hole
  313
- Checking the Gear Oil Level
  313
- Checking the Outboard Motor Mounting Height
  314
- General Periodic Maintenance
  315
- Changing the Engine Oil Using an Oil Changer
  319
- Checking the Cooling Water Inlet
  319
- Checking the Engine Idle Speed/Noise
  319
- Changing the Engine Oil by Removing the Drain Bolt
  320
- Changing the Gear Oil
  322
- Replacing the Oil Filter
  322
- Greasing Points
  324
- Greasing the Clamp Bracket Bolt (through Tube)
  324
- Checking the Power Trim and Tilt Unit Operation
  325
- Checking the PTT Fluid Level
  325
- Checking the Cowling Lock Lever
  326
Appendix

327
- Model Data
  328
- Specification
  328
- Electrical System Technical Data
  329
- Fuel System Technical Data
  331
- Power Unit Technical Data
  331
- Bracket Unit Technical Data
  333
- Lower Unit Technical Data
  333
- How to Use the Wiring Diagram
  334
- Wiring Diagram
  334
- Engine Control Unit, Fuel Unit, and Ignition Unit
  335
- Charging Unit, Starting Unit, and PTT Unit
  336
- Engine Control Unit, Fuel Unit, and Ignition Unit
  337
- Charging Unit, Starting Unit, and PTT Unit (Remote Control Model)
  338
- Control Unit
  339
- Pinion Shim (T3) Selection Table
  340
- Shim Selection Table and Chart
  340
- Forward Gear Shim (T1) Selection Chart
  341
- Reverse Gear Shim (T2) Selection Chart
  341
- List of Optional Parts
  342

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