Yamaha FL115Y Manuals

Manuals and User Guides for Yamaha FL115Y. We have 1 Yamaha FL115Y manual available for free PDF download: Service Manual

Yamaha FL115Y Service Manual

Yamaha FL115Y Service Manual (710 pages)

Brand: Yamaha | Category: Outboard Motor | Size: 13.69 MB

Table of Contents

How to Use this Manual
4
Model Indication
4
Important Information
8
General Information
12
Periodic Inspections and Adjustments
12
Specifications
12
- Symbols
  12
- Table of Contents
  14
- General Information
  16
- Identification
  18
Chapter 1

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
  - Specifications
    36
  - General Specifications
    38
  - Dimensions
    42
  - Maintenance Specifications
    42
  - Power Unit
    42
  - D'entretien
    43
  - Mantenimiento
    43
  - Motorblock
    43
  - Unidad del Motor
    43
  - Wartungsdaten
    43
  - Sistema Eléctrico
    51
  - Unidad Inferior
    51
  - Dimensions
    56
  - Dimensiones
    57
  - Specified Torques
    62
  - Tightening Torques
    62
  - Torsión de Apriete
    65
  - General Torques
    66
  - Torsiones Generales
    67
- Periodic Inspections and Adjustments
  68
Chapter 3

72
- Maintenance Interval Chart
  72
- Top Cowling
  76
- Checking the Top Cowling Fit
  76
- Fuel System
  76
- Power Unit
  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
  - Checking the Power Trim and Tilt Fluid Level
    104
  - Power Trim and Tilt System
    104
  - Adjusting the Trim Sensor Cam
    106
  - Einstellung der Trimmsensor-Nocke
    107
  - Changing and Checking the Gear Oil
    108
  - Checking the Gear Oil Level
    108
  - Lower Unit
    108
  - Checking the Anodes
    112
  - Checking the Lower Unit (for Air Leaks)
    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
CHAPTER 4 Removing/Installing the Intake Silencer

130
Chapter 5

198
- Removing the Flywheel Magnet Assembly
  198
- Installing the Flywheel Magnet Assembly
  200
- Disconnecting/Connecting the Control Cable
  202
- Power Unit
  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
- Lower Unit
  290
  - Zusammenbauen
    293
  - Removing/Installing the Lower Unit
    302
Chapter 6

302
- Lower Unit (Regular Rotation Models)
  302
- Bracket Unit
  476
  - Removing/Installing the Steering Friction
    480
  - Steering Handle (Option)
    480
Chapter 7

482
- Removing/Installing the Steering Handle
  482
- Disassembling/Assembling the Steering Handle
  486
- 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
  - Digital Circuit Tester
    602
  - Electrical Components Analysis
    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
  - Checking the Fuses
    618
  - Measuring the Engine Cooling Water Temperature Sensor Resistance
    618
  - Measuring the Pulser Coil Output Peak Voltage
    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
  - Checking the Armature
    642
  - Checking the Starter Motor Pinion
    642
    
    Removing the Starter Motor Pinion
    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
  - Checking the Brush
    662
  - Removing the Brush
    662
  - Removing the Stator
    662
  - Power Trim and Tilt Motor
    664
  - Installing the Brush
    666
  - Installing the Armature
    666
  - Installing the Stator
    666
- Trouble Analysis
  668
Chapter 9

670
- Trouble Analysis Chart
  670
  - Diagnosis Code Indication
    674
  - Diagnosis the Electronic Control System
    674
  - Self-Diagnosis
    674
  - Diagnosis Code Chart
    675
  - Trouble Shooting for Electric Fuel Injection
    676
  - Wiring Diagram
    706

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