![Yamaha F150 [263/313] 2 3 4 5 6 7 8 9](/img/pdf.png)
Yamaha F150 [263/313] 2 3 4 5 6 7 8 9
![Yamaha F150 [263/313] 2 3 4 5 6 7 8 9](/views2/1241096/page263/bg107.png)
63P3F11
8-4
1
2
3
4
5
6
7
8
9
Junction box assembly
1
ECM
2
Power trim and tilt relay
3
Starter relay
4
Diode
5
Fuse (30 A)
6
Main relay
7
Fuse (20 A)
8
Fuse (50 A)
9
Intake air temperature sensor
S63P8020
1
9
8
7
6
5
4
3
2
Electrical components
Содержание
- English 1
- Caution 2
- Important information 2
- Notice 2
- Warning 2
- Bracket unit 3
- Contents 3
- Electrical systems 3
- Fuel system 3
- General information 3
- Lower unit 3
- Periodic checks and adjustments 3
- Power unit 3
- Specifications 3
- Troubleshooting 3
- Gen info 4
- General information 4
- 2 3 4 5 6 7 8 9 5
- Caution 6
- Disassembling the drive shaft 6
- Disassembling the forward gear 6
- Gen info 6
- How to use this manual 6
- Manual format 6
- Removing the drive shaft 6
- 2 3 4 5 6 7 8 9 7
- Chk adj 7
- Gen info 7
- Symbols 7
- Trbl shtg 7
- Fire prevention 8
- Gen info 8
- Parts lubricants and sealants 8
- Safety while working 8
- Self protection 8
- Ventilation 8
- 2 3 4 5 6 7 8 9 9
- Disassembly and assembly 9
- Good working practices 9
- Applicable models 10
- Gen info 10
- Identification 10
- Serial number 10
- 2 3 4 5 6 7 8 9 11
- Crankshaft and cylinder 11
- Features and benefits 11
- Balancer 12
- Gen info 12
- Piston and piston ring 12
- 2 3 4 5 6 7 8 9 13
- Connecting rod 13
- Cylinder head cover 13
- 1 cylinder 14
- 2 cylinder 14
- 3 cylinder 14
- 4 cylinder 14
- Gen info 14
- Initial injection timing btdc10 14
- Intake system 14
- 2 3 4 5 6 7 8 9 15
- Top cowling 15
- E type power trim and tilt unit 16
- Gen info 16
- 2 3 4 5 6 7 8 9 17
- Cooling system 17
- Gen info 18
- Lubrication system 18
- Fuel system 20
- Gen info 20
- Electronic control system 22
- Gen info 22
- Technical tips 22
- 2 3 4 5 6 7 8 9 23
- Fail safe control 23
- Gen info 24
- Warning control 24
- 2 3 4 5 6 7 8 9 25
- Fuel pump control 25
- Over revolution control 25
- Shift cut control 25
- Gen info 26
- Propeller selection 26
- Propeller size 26
- Selection 26
- 2 3 4 5 6 7 8 9 27
- Caution 27
- Checking the battery 27
- Checking the engine oil level 27
- Checking the fuel system 27
- Checking the gear oil level 27
- Predelivery checks 27
- Caution 28
- Checking the outboard motor mounting height 28
- Checking the remote control cables 28
- Gen info 28
- 2 3 4 5 6 7 8 9 29
- Checking the engine start switch and engine stop lanyard switch 29
- Checking the gear shift and throttle operation 29
- Checking the power trim and tilt system 29
- Checking the steering system 29
- After test run 30
- Break in 30
- Checking the cooling water pilot hole 30
- Gen info 30
- Test run 30
- Specifications 31
- General specifications 32
- 2 3 4 5 6 7 8 9 33
- Maintenance specification 34
- Power unit 34
- 2 3 4 5 6 7 8 9 35
- 2 3 4 5 6 7 8 9 37
- Lower unit 37
- Electrical 38
- 2 3 4 5 6 7 8 9 39
- Dimensions 40
- Exterior 40
- Specifications 40
- 2 3 4 5 6 7 8 9 41
- Clamp bracket 41
- Maintenance specification 41
- Specified torques 42
- Tightening torques 42
- 2 3 4 5 6 7 8 9 43
- General torques 44
- 2 3 4 5 6 7 8 9 45
- Chk adj 45
- Periodic checks and adjustments 45
- Chk adj 46
- Special service tools 46
- 2 3 4 5 6 7 8 9 47
- Maintenance interval chart 47
- Checking the fuel filter 48
- Checking the fuel joint and fuel hoses fuel joint to fuel injector 48
- Checking the top cowling 48
- Chk adj 48
- Fuel system 48
- Top cowling 48
- 2 3 4 5 6 7 8 9 49
- Changing the engine oil using an oil changer 49
- Checking the engine oil 49
- Power unit 49
- Changing the engine oil by draining it 50
- Chk adj 50
- Replacing the oil filter 50
- 2 3 4 5 6 7 8 9 51
- Checking the spark plugs 51
- Checking the timing belt 51
- Checking the valve clearance 51
- Replacing the timing belt 51
- Checking the thermostat 52
- Chk adj 52
- 2 3 4 5 6 7 8 9 53
- Adjusting the throttle link and throttle cable 53
- Checking the cooling water passage 53
- Checking the engine idle speed 53
- Control system 53
- Chk adj 54
- 2 3 4 5 6 7 8 9 55
- Adjusting the throttle link and throttle cable operation using a thickness gauge 55
- Caution 55
- Caution 56
- Checking the gear shift operation 56
- Chk adj 56
- 2 3 4 5 6 7 8 9 57
- Caution 57
- Checking the ignition timing 57
- Checking the gear oil level 58
- Checking the power trim and tilt fluid level 58
- Checking the power trim and tilt operation 58
- Chk adj 58
- Lower unit 58
- Power trim and tilt unit 58
- Warning 58
- 2 3 4 5 6 7 8 9 59
- Changing the gear oil 59
- Caution 60
- Checking the anodes 60
- Checking the lower unit for air leakage 60
- Checking the propeller 60
- Chk adj 60
- General 60
- 2 3 4 5 6 7 8 9 61
- Caution 61
- Checking the battery 61
- Lubricating the outboard motor 61
- Warning 61
- Chk adj 62
- 2 3 4 5 6 7 8 9 63
- Fuel system 63
- Special service tools 64
- 2 3 4 5 6 7 8 9 65
- Fuel and blowby hoses 65
- Hose routing 65
- Fuel filter fuel pump and intake silencer 66
- 2 3 4 5 6 7 8 9 67
- 3 8 7 6 67
- Fuel filter fuel pump and intake silencer 67
- Fuel system 68
- 2 3 4 5 6 7 8 9 69
- Checking the fuel pumps 70
- Disassembling a fuel pump 70
- 2 3 4 5 6 7 8 9 71
- Assembling a fuel pump 71
- Checking the diaphragm and valves 71
- Intake assembly and vapor separator 72
- 2 3 4 5 6 7 8 9 73
- Intake assembly and vapor separator 73
- 6 5 4 3 74
- Fuel system 74
- 2 3 4 5 6 7 8 9 75
- 6 5 4 3 75
- Intake assembly and vapor separator 75
- Checking the pressure regulator 76
- Measuring the fuel pressure 76
- Warning 76
- 2 3 4 5 6 7 8 9 77
- Checking the check valve 77
- Warning 77
- Checking the vapor separator 78
- Reducing the fuel pressure 78
- Warning 78
- 2 3 4 5 6 7 8 9 79
- Caution 79
- Synchronizing the throttle valves 79
- Adjusting the throttle position sensor 80
- 2 3 4 5 6 7 8 9 81
- Adjusting the throttle position sensor when disassembling or replacing the throttle body 81
- Power unit 84
- 2 3 4 5 6 7 8 9 85
- Special service tools 86
- 2 3 4 5 6 7 8 9 87
- Power unit 88
- 2 3 4 5 6 7 8 9 89
- Power unit 89
- Power unit 90
- 2 3 4 5 6 7 8 9 91
- Power unit 91
- 10 678 92
- 13 12 15 92
- Power unit 92
- 10 678 93
- 13 12 15 93
- 2 3 4 5 6 7 8 9 93
- Power unit 93
- Power unit 94
- 2 3 4 5 6 7 8 9 95
- Power unit 95
- Caution 96
- Checking the compression pressure 96
- Checking the oil pressure 96
- 2 3 4 5 6 7 8 9 97
- Checking the oil pressure sensor 97
- Checking the valve clearance 97
- 2 3 4 5 6 7 8 9 99
- 2 3 4 5 6 7 8 9 101
- Caution 101
- Replacing the timing belt 101
- Caution 102
- 2 3 4 5 6 7 8 9 103
- Caution 103
- Removing the power unit 103
- 2 3 4 5 6 7 8 9 105
- Caution 105
- Removing the oil filter 105
- Removing the timing belt and sprockets 105
- Checking the timing belt and sprockets 106
- Installing the sprockets and timing belt 106
- 2 3 4 5 6 7 8 9 107
- Cylinder head 108
- Power unit 108
- 2 3 4 5 6 7 8 9 109
- Cylinder head 109
- 2 3 4 5 6 7 8 9 111
- 2 3 4 5 6 7 8 9 113
- Caution 113
- Checking the valve springs 113
- Removing the cylinder head 113
- Checking the valve guides 114
- Checking the valves 114
- 2 3 4 5 6 7 8 9 115
- Replacing the valve guides 115
- Checking the valve seat 116
- Refacing the valve seat 116
- 2 3 4 5 6 7 8 9 117
- Caution 117
- Caution 118
- Checking the camshaft 118
- 2 3 4 5 6 7 8 9 119
- Checking the cylinder head 119
- Installing the valves 119
- Caution 120
- Installing the cylinder head 120
- 2 3 4 5 6 7 8 9 121
- Checking the pressure control valve 122
- Installing the pressure control valve 122
- Removing the exhaust cover 122
- 2 3 4 5 6 7 8 9 123
- Cylinder block 123
- Cylinder head cylinder block 123
- Power unit 124
- 2 3 4 5 6 7 8 9 125
- Cylinder block 125
- Checking the balancer assembly 126
- Checking the piston diameter 126
- Disassembling the cylinder block 126
- 2 3 4 5 6 7 8 9 127
- A b c d 127
- Checking the cylinder bore 127
- Checking the piston clearance 127
- Checking the piston rings 127
- Checking the connecting rod big end side clearance 128
- Checking the piston ring grooves 128
- Checking the piston ring side clearance 128
- 2 3 4 5 6 7 8 9 129
- Checking the crankshaft 129
- Checking the crankpin oil clearance 130
- 2 3 4 5 6 7 8 9 131
- Selecting the connecting rod bearing 131
- Checking the crankshaft main journal oil clearance 132
- 2 3 4 5 6 7 8 9 133
- Selecting the crankshaft main bearing 133
- Assembling the oil pump 134
- Checking the oil pump 134
- Disassembling the oil pump 134
- 2 3 4 5 6 7 8 9 135
- Assembling the pistons and cylinder block 135
- Caution 135
- 2 3 4 5 6 7 8 9 137
- Caution 137
- 2 3 4 5 6 7 8 9 139
- Installing the power unit 140
- 2 3 4 5 6 7 8 9 141
- Caution 142
- Lower unit 144
- 2 3 4 5 6 7 8 9 145
- Special service tools 146
- 2 3 4 5 6 7 8 9 147
- 2 3 4 5 6 7 8 9 149
- Lower unit regular rotation model 149
- Special service tools lower unit regular rotation model 149
- Lower unit 150
- 2 3 4 5 6 7 8 9 151
- Lower unit regular rotation model 151
- Lower unit 152
- 2 3 4 5 6 7 8 9 153
- Removing the lower unit 153
- Removing the water pump and shift rod 153
- Warning 153
- Checking the water pump and shift rod 154
- 2 3 4 5 6 7 8 9 155
- Lower unit regular rotation model propeller shaft housing regular rotation model 155
- Propeller shaft housing regular rotation model 155
- Lower unit 156
- 2 3 4 5 6 7 8 9 157
- Disassembling the propeller shaft assembly 157
- Disassembling the propeller shaft housing 157
- Removing the propeller shaft housing assembly 157
- Checking the propeller shaft 158
- Checking the propeller shaft housing 158
- 2 3 4 5 6 7 8 9 159
- Assembling the propeller shaft assembly 159
- Assembling the propeller shaft housing 159
- 2 3 4 5 6 7 8 9 161
- Drive shaft and lower case regular rotation model 161
- Propeller shaft housing regular rotation model drive shaft and lower case regular rotation model 161
- Caution 162
- Disassembling the drive shaft housing 162
- Disassembling the forward gear 162
- Disassembling the lower case 162
- Removing the drive shaft 162
- 2 3 4 5 6 7 8 9 163
- Checking the bearings 163
- Checking the drive shaft 163
- Checking the lower case 163
- Checking the pinion and forward gear 163
- Assembling the drive shaft housing 164
- Assembling the forward gear 164
- Assembling the lower case 164
- Caution 164
- 2 3 4 5 6 7 8 9 165
- Caution 165
- Installing the drive shaft 165
- Caution 166
- Installing the propeller shaft housing 166
- Installing the water pump and shift rod 166
- 2 3 4 5 6 7 8 9 167
- Installing the lower unit 168
- 2 3 4 5 6 7 8 9 169
- Warning 169
- Lower unit 170
- Shimming regular rotation model 170
- 2 3 4 5 6 7 8 9 171
- Selecting the pinion shims 171
- Shimming 171
- Selecting the forward gear shims 172
- 2 3 4 5 6 7 8 9 173
- Selecting the reverse gear shims 173
- Backlash regular rotation model 174
- Measuring the forward and reverse gear backlash 174
- 2 3 4 5 6 7 8 9 175
- 2 3 4 5 6 7 8 9 177
- Backlash regular rotation model lower unit counter rotation model 177
- Lower unit counter rotation model 177
- Lower unit 178
- 2 3 4 5 6 7 8 9 179
- Lower unit counter rotation model 179
- Lower unit 180
- 2 3 4 5 6 7 8 9 181
- Removing the lower unit 181
- Removing the water pump and shift rod 181
- Warning 181
- Checking the water pump and shift rod 182
- 2 3 4 5 6 7 8 9 183
- Lower unit counter rotation model propeller shaft housing counter rotation model 183
- Propeller shaft housing counter rotation model 183
- Lower unit 184
- 2 3 4 5 6 7 8 9 185
- Disassembling the forward gear 185
- Disassembling the propeller shaft assembly 185
- Removing the propeller shaft housing assembly 185
- Assembling the propeller shaft housing 186
- Checking the propeller shaft 186
- Checking the propeller shaft housing 186
- Disassembling the propeller shaft housing 186
- 2 3 4 5 6 7 8 9 187
- Caution 187
- 2 3 4 5 6 7 8 9 189
- Drive shaft and lower case counter rotation model 189
- Propeller shaft housing counter rotation model drive shaft and lower case counter rotation model 189
- Lower unit 190
- 2 3 4 5 6 7 8 9 191
- Disassembling the drive shaft housing 191
- Disassembling the lower case 191
- Disassembling the reverse gear 191
- Removing the drive shaft 191
- Assembling the lower case 192
- Caution 192
- Checking the bearings 192
- Checking the drive shaft 192
- Checking the lower case 192
- Checking the pinion and reverse gear 192
- 2 3 4 5 6 7 8 9 193
- Assembling the drive shaft housing 193
- Assembling the reverse gear 193
- Caution 194
- Installing the drive shaft 194
- Installing the propeller shaft housing 194
- 2 3 4 5 6 7 8 9 195
- Caution 195
- Installing the water pump and shift rod 195
- 2 3 4 5 6 7 8 9 197
- Installing the lower unit 197
- Warning 198
- 2 3 4 5 6 7 8 9 199
- Drive shaft and lower case counter rotation model shimming counter rotation model 199
- Shimming counter rotation model 199
- Selecting the pinion shims 200
- Shimming 200
- 2 3 4 5 6 7 8 9 201
- Selecting the reverse gear shims 201
- Selecting the forward gear shims 202
- 2 3 4 5 6 7 8 9 203
- Selecting the propeller shaft shims 203
- 2 3 4 5 6 7 8 9 205
- Backlash counter rotation model 205
- Measuring the forward and reverse gear backlash 205
- 2 3 4 5 6 7 8 9 207
- 2 3 4 5 6 7 8 9 209
- Bracket unit 209
- Special service tools 210
- 2 3 4 5 6 7 8 9 211
- Bottom cowling 211
- Bracket unit 212
- 15 1413 213
- 19 23 24 22 213
- 2 3 4 5 6 7 8 9 213
- Bottom cowling 213
- 15 1413 214
- 19 23 24 22 214
- Bracket unit 214
- 2 3 4 5 6 7 8 9 215
- Bottom cowling upper case steering arm swivel bracket and clamp brackets 215
- Upper case steering arm swivel bracket and clamp brackets 215
- Bracket unit 216
- 15 14 13 1211 217
- 2 3 4 5 6 7 8 9 217
- 20 21 22 217
- Upper case steering arm swivel bracket and clamp brackets 217
- 15 14 13 1211 218
- 20 21 22 218
- Bracket unit 218
- 2 3 4 5 6 7 8 9 219
- Upper case steering arm swivel bracket and clamp brackets 219
- 2 3 4 5 6 7 8 9 221
- Assembling the oil pan 221
- Checking the oil strainer 221
- Disassembling the oil pan 221
- Draining the engine oil 221
- 2 3 4 5 6 7 8 9 223
- Installing the steering arm 223
- Removing the steering arm 223
- Installing the upper case 224
- 2 3 4 5 6 7 8 9 225
- Clamp brackets 225
- Upper case steering arm swivel bracket and clamp brackets clamp brackets 225
- Bracket unit 226
- 2 3 4 5 6 7 8 9 227
- Adjusting the trim sensor cam 227
- Installing the clamp brackets 227
- Removing the clamp brackets 227
- Warning 228
- 2 3 4 5 6 7 8 9 229
- Power trim and tilt unit 229
- 2 3 4 5 6 7 8 9 231
- Power trim and tilt unit 231
- 11 12 13 14 232
- 16 17 18 19 232
- 4 5 6 7 232
- 11 12 13 14 233
- 16 17 18 19 233
- 2 3 4 5 6 7 8 9 233
- 4 5 6 7 233
- Bracket unit 234
- 2 3 4 5 6 7 8 9 235
- Removing the power trim and tilt unit 236
- Warning 236
- 2 3 4 5 6 7 8 9 237
- Checking the hydraulic pressure 237
- 2 3 4 5 6 7 8 9 239
- Caution 239
- Disassembling the power trim and tilt motor 239
- Caution 240
- Checking the power trim and tilt motor 240
- 2 3 4 5 6 7 8 9 241
- Caution 241
- Assembling the power trim and tilt motor 242
- Caution 242
- Removing the reservoir 242
- 2 3 4 5 6 7 8 9 243
- Disassembling the gear pump housing 243
- Assembling the gear pump housing 244
- Caution 244
- Checking the gear pump 244
- Warning 244
- 2 3 4 5 6 7 8 9 245
- Caution 246
- Disassembling the tilt cylinder and trim cylinder 246
- Warning 246
- 2 3 4 5 6 7 8 9 247
- Checking the tilt cylinder and trim cylinder 247
- Assembling the tilt piston and trim pistons 248
- 2 3 4 5 6 7 8 9 249
- Assembling the power trim and tilt unit 249
- Caution 250
- 2 3 4 5 6 7 8 9 251
- Caution 251
- Bleeding the power trim and tilt unit 252
- 2 3 4 5 6 7 8 9 253
- Caution 253
- Installing the power trim and tilt unit 253
- Bleeding the power trim and tilt unit built in 254
- Warning 254
- 2 3 4 5 6 7 8 9 255
- D c b a 0 9 8 7 6 5 4 3 2 e f g 255
- Power trim and tilt electrical system 255
- Power trim and tilt unit power trim and tilt electrical system 255
- Checking the fuse 256
- Checking the power trim and tilt relay 256
- Checking the power trim and tilt switch 256
- 2 3 4 5 6 7 8 9 257
- Checking the trim sensor 257
- 2 3 4 5 6 7 8 9 259
- Electrical systems 259
- Special service tools 260
- 2 3 4 5 6 7 8 9 261
- Checking the electrical components 261
- Measuring the lower resistance 261
- Measuring the peak voltage 261
- Electrical components 262
- Port view 262
- 2 3 4 5 6 7 8 9 263
- Junction box assembly 263
- Aft view 264
- 2 3 4 5 6 7 8 9 265
- Top view 265
- S63p8190 266
- Wiring harness 266
- 2 3 4 5 6 7 8 9 267
- 3 4 5 6 7 8 9 0 a b c d 268
- 30 21 24 268
- 31 33 34 268
- 5 4 3 2 1 268
- Electrical systems 268
- Ignition and ignition control system 268
- 2 3 4 5 6 7 8 9 269
- 3 4 5 6 7 8 9 0 a b c d 269
- 5 4 3 2 1 269
- B black g green o orange p pink r red y yellow b o black orange b w black white b y black yellow g b green black 269
- G r green red g y green yellow l g blue green l y blue yellow p g pink green p w pink white r y red yellow w b white black w r white red y g yellow green 269
- Ignition and ignition control system 269
- Checking the ignition coils 270
- Checking the ignition spark gap 270
- Checking the spark plug wires 270
- Warning 270
- 2 3 4 5 6 7 8 9 271
- Checking the ecm 271
- Checking the pulser coil 271
- Checking the engine temperature sensor 272
- Checking the intake air temperature sensor 272
- Checking the throttle position sensor 272
- 2 3 4 5 6 7 8 9 273
- Checking the neutral switch 273
- Checking the shift cut switch 273
- Checking the thermoswitch 273
- 18 19 20 274
- 3 4 5 6 7 8 9 0 a b c d 274
- 39 40 33 34 274
- 5 4 3 2 1 274
- Electrical systems 274
- Fuel control system 274
- 18 19 20 275
- 2 3 4 5 6 7 8 9 275
- 3 4 5 6 7 8 9 0 a b c d 275
- 39 40 33 34 275
- 5 4 3 2 1 275
- B black g green l blue o orange p pink r red y yellow b y black yellow g b green black g r green red 275
- Fuel control system 275
- G y green yellow p g pink green pu b purple black pu g purple green pu r purple red pu y purple yellow r y red yellow w b white black w r white red y g yellow green 275
- Checking the electric fuel pump 276
- Checking the injectors 276
- Checking the main relay 276
- 2 3 4 5 6 7 8 9 277
- Fuel control system starting system 277
- Starting system 277
- Checking the fuses 278
- Checking the starter relay 278
- 2 3 4 5 6 7 8 9 279
- 4 3 2 1 279
- Starter motor 279
- 4 3 2 1 280
- Electrical systems 280
- 2 3 4 5 6 7 8 9 281
- Checking the armature 281
- Checking the starter motor pinion 281
- Removing the starter motor pinion 281
- Caution 282
- Checking the brushes 282
- Checking the magnet switch 282
- Checking the starter motor operation 282
- 2 3 4 5 6 7 8 9 283
- Charging system 283
- Starter motor charging system 283
- Checking the rectifier regulator 284
- Checking the stator coil 284
- Troubleshooting 285
- Special service tools 286
- Trbl shtg 286
- 2 3 4 5 6 7 8 9 287
- Contents 287
- Features 287
- Introduction 287
- Yamaha diagnostic system 287
- Hardware requirements 288
- Trbl shtg 288
- Power unit 290
- Trbl shtg 290
- 2 3 4 5 6 7 8 9 291
- Trbl shtg 292
- Warning 292
- 2 3 4 5 6 7 8 9 293
- Trbl shtg 294
- 2 3 4 5 6 7 8 9 295
- Trbl shtg 296
- Warning 296
- 2 3 4 5 6 7 8 9 297
- Trbl shtg 298
- 2 3 4 5 6 7 8 9 299
- Trbl shtg 300
- 2 3 4 5 6 7 8 9 301
- Warning 301
- Trbl shtg 302
- 2 3 4 5 6 7 8 9 303
- Diagnosing the electronic control system 304
- Self diagnosis 304
- Trbl shtg 304
- 2 3 4 5 6 7 8 9 305
- Numerics 306
- 2 3 4 5 6 7 8 9 307
- 2 3 4 5 6 7 8 9 309
- Color code 310
- Wiring diagram f150aet fl150aet 310
- 12 13 14 313
- 16 17 18 19 313
- 18 19 20 313
- 2 3 4 7 8 9 313
- 2 3 4 8 9 313
- 30 21 23 24 313
- 38 39 40 31 33 34 313
- F150aet fl150aet 313
- Wiring diagram f150aet fl150aet 313
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