15 hp 2004 4 stroke

SUPPLEMENTARY SERVICE MANUAL

66M-28197-ZA-1X

F15Z

LIT-18616-02-12

NOTICEThis Supplementary Service Manual has been prepared to introduce new service and data for the F15Z. For complete service information procedures, it is necessary to use this Supplementary Service Manual together with the following manual.

F15Z

SUPPLEMENTARY SERVICE MANUAL

©2000 by Yamaha Motor Corporation, U.S.A.

1st Edition, April 2000

All rights reserved. Any reprinting or

unauthorized use without the written

permission of Yamaha Motor Corporation, U.S.A.

is expressly prohibited.

Printed in USA

P/N LIT-18616-02-12

F15A (F15) SERVICE MANUAL: 66M-28197-Z7-11

HOW TO USE THIS MANUAL

MANUAL FORMAT

All of the procedures in this manual are organised in a sequential, step-by-step format. Theinformation has been compiled to provide the mechanic with an easy to read, handyreference that contains comprehensive explanations of all disassembly, repair, assembly, andinspection operations.In this revised format, the condition of a faulty component will precede an arrow symbol andthe course of action required will follow the symbol, e.g.,

•BearingsPitting/scratches Replace.

MODEL INDICATION

Multiple models are referred to in this manual and their model indications are noted asfollows.

ILLUSTRATIONS

The illustrations within this service manual represent all of the designated models.

CROSS REFERENCES

The cross references have been kept to a minimum. Cross references will direct you to theappropriate section or chapter.

Model name F15AEP F15AEHP

USA and Canada name F15PR F15PH

Indication F15AEP F15AEHP

IMPORTANT INFORMATION

In this Service Manual particularly important information is distinguished in the followingways.

The safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY ISINVOLVED!

WARNING

Failure to follow WARNING instructions could result in severe injury or death to the machine

operator, a bystander or a person inspecting or repairing the outboard motor.

CAUTION

A CAUTION indicates special precautions that must be taken to avoid damage to the

outboard motor.

NOTE:A NOTE provides key information to make procedures easier or clearer.

HOW TO USE THIS MANUAL

1 The main points regarding removing/installing and disassembly/assembly procedure are shown in the exploded views.

2 The numbers in the exploded views indicate the required sequence of the procedure and should be observed accordingly.

3 Symbols are used in the exploded views to indicate important aspects of the procedure.A list of meanings for these symbols is provided on the following page.

4 It is important to refer to the job instruction charts at the same time as the exploded views.These charts list the sequence that the procedures should be carried out in, as well as providing exploded on part names, quantities, dimensions and important points relating to each relevant task.Example:O-ring 39.5 x 2.5 mm: inside diameter (D) x ring diameter (d)

5 In addition to tightening torques, the dimensions of the bolts and screws are also mentioned.Example:

Bolt and screw size : bolt and screw diameter (D) x length (d)

6 In addition to the exploded views and job instruction charts, this manual provides individual illustrations when further explanations are required to explain the relevant procedure.

10 x 25 mm

SYMBOLS

Symbols 1 to 9 are designed as thumb-tabsto indicate the content of a chapter.

1 General information2 Specifications3 Periodic check and adjustment4 Fuel system5 Power unit6 Lower unit7 Bracket unit8 Electrical system9 Trouble analysis

Symbols : to E indicate specific data.: Special toolA Specified liquidB Specified engine speedC Specified torqueD Specified measurementE Specified electrical value

[Resistance (Ω), Voltage (V), Electrical current (A)]

Symbols F to H in an exploded diagramindicate the grade of lubricant and thelocation of the lubricant point.

F Apply Yamaha 4-stroke motor oilG Apply water resistant grease

(Yamaha grease A, Yamaha marine grease)

H Apply molybdenum disufied oil

Symbols I to N in an exploded diagramindicate the grade of the sealing or lockingagent and the location of the applicationpoint.I Apply Gasket Maker® J Apply Yamabond #4

(Yamaha bond number 4)K Apply LOCTITE® No.271 (Red LOCTITE)L Apply LOCTITE® No.242 (Blue LOCTITE)M Apply LOCTITE® No.572N Apply silicon sealant

1 2

3 4

5 6

7 8

9 :

A B

C D

E F

G H

I J

K L

M N

GENERAL INFORMATION

IDENTIFICATION................................................................................................. 1

SERIAL NUMBER ......................................................................................... 1STARTING SERIAL NUMBERS ................................................................... 1

SPECIAL TOOLS ................................................................................................. 2

REMOVAL AND INSTALLATION ................................................................ 2

SPECIFICATIONS

GENERAL SPECIFICATIONS.............................................................................. 3

MAINTENANCE SPECIFICATIONS.................................................................... 5

POWER UNIT................................................................................................ 5LOWER.......................................................................................................... 8ELECTRICAL ................................................................................................. 8DIMENSIONS ............................................................................................. 11

TIGHTENING TORQUES .................................................................................. 13

SPECIFIED TORQUES ................................................................................ 13GENERAL TORQUES ................................................................................. 14

PERIODIC INSPECTIONS AND ADJUSTMENT

MAINTENANCE INTERVAL CHART ................................................................ 15

POWER TILT SYSTEM...................................................................................... 16

CHECKING THE POWER TILT (PT) FLUID LEVEL .................................... 16

GENERAL .......................................................................................................... 16

CHECKING THE ANODE ............................................................................ 16

POWER UNIT

POWER UNIT .................................................................................................... 17

REMOVING/INSTALLING THE POWER UNIT 1 (F15AEP/F15PR) ........... 17REMOVING/INSTALLING THE POWER UNIT 1 (F15AEHP/F15PH) ........ 19

ELECTRICAL UNIT............................................................................................ 21

REMOVING/INSTALLING THE ELECTRICAL UNIT .................................. 21

CYLINDER HEAD AND OIL PUMP................................................................... 24

REMOVING/INSTALLING THE CYLINDER HEAD AND OIL PUMP ......... 24

OIL PUMP.......................................................................................................... 25

DISASSEMBLING/ASSEMBLING THE OIL PUMP ................................... 25

CAMSHAFT AND VALVE................................................................................. 26

REMOVING/INSTALLING THE CAMSHAFT AND VALVE ....................... 26CHECKING THE ROCKER ARM AND ROCKER ARM SHAFT .................. 28CHECKING THE CAMSHAFT..................................................................... 28REFACING THE VALVE SEAT ................................................................... 29INSTALLING THE CAMSHAFT OIL SEAL................................................. 30

OIL FILTER, THERMOSTAT AND EXHAUST COVER..................................... 31

DISASSEMBLING/ASSEMBLING THE OIL FILTER, THERMOSTAT AND EXHAUST COVER ............................................................................. 31

BRACKET UNIT

STEERING HANDLE ASSEMBLY (F15AEHP/F15PH) ..................................... 33

REMOVING/INSTALLING THE STEERING HANDLE ASSEMBLY........... 33DISASSEMBLING/ASSEMBLING THE STEERING HANDLE ASSEMBLY................................................................................................. 34INSTALLING THE PT SWITCH .................................................................. 36

BOTTOM COWLING ASSEMBLY .................................................................... 37

REMOVING/INSTALLING THE BOTTOM COWLING ASSEMBLY .......... 37

SWIVEL AND STEERING BRACKET................................................................ 40

REMOVING/INSTALLING THE SWIVEL AND STEERING BRACKET ...... 40

POWER TILT (PT) UNIT .................................................................................... 41

REMOVING/INSTALLING THE POWER TILT (PT) UNIT .......................... 41DISASSEMBLING/ASSEMBLING THE POWER TILT (PT) CYLINDER .... 43DISASSEMBLING THE POWER TILT (PT) CYLINDER ............................. 45ASSEMBLING THE POWER TILT (PT) CYLINDER ................................... 46DISASSEMBLING/ASSEMBLING THE VALVES AND PUMP 1 ............... 50INSTALLING THE RELIEF VALVE.............................................................. 52DISASSEMBLING/ASSEMBLING THE PT MOTOR.................................. 53REMOVING THE ARMATURE ................................................................... 54CHECKING THE PT MOTOR ...................................................................... 54CHECKING THE PT MOTOR ASSEMBLY ................................................. 56INSTALLING THE OIL SEAL ...................................................................... 56DISASSEMBLING/ASSEMBLING THE VALVES AND PUMP 2 ............... 57

CLAMP BRACKET............................................................................................. 59

REMOVING/INSTALLING THE CLAMP BRACKET ................................... 59

ELECTRICAL SYSTEM

ELECTRICAL COMPONENTS........................................................................... 61

TOP VIEW AND PORT SIDE VIEW ............................................................ 61FRONT VIEW (F15AEP/F15PH) .................................................................. 62FRONT VIEW (F15AEHP/F15PH) ............................................................... 63

STARTER MOTOR ............................................................................................ 64

DISASSEMBLING/ASSEMBLING THE STARTER MOTOR...................... 64REMOVING THE PINION NUT .................................................................. 66CHECKING THE PINION GEAR ................................................................. 66CHECKING THE ARMATURE .................................................................... 66CHECKING THE BRUSH HOLDER............................................................. 67

POWER TILT (PT) SYSTEM.............................................................................. 68

POWER TILT (PT) SYSTEM (F15AEP/F15PR) ........................................... 68POWER TILT (PT) SYSTEM (F15AEHP/F15PH) ........................................ 69CHECKING THE PT SWITCH ..................................................................... 70CHECKING THE TRAILER SWITCH ........................................................... 70CHECKING THE PT RELAY ........................................................................ 70

TROUBLE ANALYSIS

TROUBLE ANALYSIS ....................................................................................... 72

TROUBLE ANALYSIS CHART ................................................................... 72

IDENTIFICATION

1

IDENTIFICATION

SERIAL NUMBER

The outboard motor’s serial number is stamped on a label which is attached to the port clamp bracket.

NOTE:As an antitheft measure, a special label on which the outboard motor’s serial number is stamped is bonded to the port clamp bracket. The label is specially treated so that peeling it off causes cracks across the serial number.

1 Model name2 Approval model code3 Transom height4 Serial number

STARTING SERIAL NUMBERS

The starting serial number blocks are as follows:

Model name Applicable model code

Starting serial

numberWorld wide

USA/Canada

F15AEP F15PR 66M L:800141-F15AEHP F15PH 66M L:900111-

SPECIAL TOOLS

2

SPECIAL TOOLSUsing the correct special tools recommended by Yamaha, will aid the work and enable accurate assembly and tune-up.Improvising and using improper tools can damage the equipment.

NOTE: For U.S.A. and Canada, use part numbers

that start with “J-”, “YB-” “YM-”, “YU-” or “YW-”.

For other countries, use part numbers that start with “90890-”.

REMOVAL AND INSTALLATION

1 Power tilt wrench:

2 Oil seal attachment:

3 Driver rod:

4 Valve seat cutter set:

5 Valve seat cutter:

P/N. YB-0656090890-06560

P/N. YB-06112, YB-06196 ..............a90890-06614, 90890-06196....b

P/N. YB-06071 ................................a90890-06652...........................b

P/N. 90890-06803

P/N. 90890-06556

a2 b

a3 b

4 5

1

GENERAL SPECIFICATIONS

3


Item Unit

ModelWorld wide F15AEP F15AEHP

USA F15PR F15PHCanada F15PR F15PH

DIMENSION

Overall length mm (in) 643 (25.3) 1,001 (39.4)Overall width mm (in) 369 (14.5) 427 (16.8)Overall height mm (in) 1,207 (47.5) 1,207 (47.5)

WEIGHT

(with aluminum propeller) kg (lb) 54 (119.0) 55 (121.3)PERFORMANCE

Maximum output kW (hp) @ 5,000 r/min

11 (15)

Full throttle operating range r/min 4,500 - 5,500Maximum fuel consumption L (US gal, lmp

gal)/h @ 5,000 r/min

5.3 (1.39, 1.16)

POWER UNIT

Type 4 stroke, OHC, in-lineNumber of cylinders 2Displacement cm3 (cu. in) 323 (19.7)Bore x stroke mm (in) 59.0 x 59.0 (2.32 x 2.32)Compression ratio 9.19Compression pressure kPa (kg/cm2, psi) 961 (9.8, 139.4)Number of carburetors 1Control system Remote control Tiller controlStarting system Electric motorIgnition control system C.D.ILighting coil Single phaseLighting coil output V-A DC12-10 with rectifier/regulatorStarting enrichment Choke valveSpark plug DPR6EA-9Exhaust system Propeller hubLubrication system Wet sumpIgnition timing Degree (BTDC) 5 – 30

FUEL AND OIL

Fuel type Unleaded regular gasolineFuel rating PON (*1) 86

PON (*2) 91(*1) PON : Pump Octane Number(*2) RON : Research Octane Number


4

Item Unit



Engine oil type 4-stroke engine oilEngine oil grade API SE, SF, SE-SF, SE-SF-CC

SAE 10W-30, 10W-40Engine oil quantity

With oil filter cm3 (US oz, Imp oz) 1,200 (40.6, 42.2)Without oil filter cm3 (US oz, Imp oz) 1,000 (33.8, 35.2)

Gear oil type Hypoid gear oilGear oil grade SAE #90Gear oil quantity cm3 (US oz, Imp oz) 250 (8.45, 8.80)

BRACKET

Trim angle Degrees 8, 12, 16, 20Tilt-up angle Degrees 63Steering angle Degrees 40 + 40

DRIVE UNIT

Gear positions F - N - RGear ratio 2.08 (27:13)Gear type Spiral bevel gearPropeller direction (rear view) ClockwisePropeller drive system SplinePropeller series mark J

ELECTRICAL

Battery capacity Ah (kC) 40 (144)Cold cranking A 380

MAINTENANCE SPECIFICATIONS

5


POWER UNIT

Item Unit



CYLINDER HEAD

Warpage limit mm (in) 0.1 (0.004)CYLINDER

Bore mm (in) 59.000 - 59.015 (2.3228 - 2.3234)Taper limit mm (in) 0.08 (0.003)Out-of-round limit mm (in) 0.05 (0.002)Cylinder block inside diameter mm (in) A : Blue 38.033 - 38.040 (1.4974 - 1.4976)

B : Black 38.025 - 38.032 (1.4970 - 1.4973)C : Brown 38.016 - 38.024 (1.4967 - 1.4970)

CAMSHAFT

Intake (A) mm (in) 27.596 - 27.696 (1.0865 - 1.0904)Intake (B) mm (in) 23.95 - 24.05 (0.9429 - 0.9468)Exhaust (A) mm (in) 27.616 - 27.716 (1.0872 - 1.0912)Exhaust (B) mm (in) 23.95 - 24.05 (0.9429 - 0.9468)Cylinder head journal diameter (driven gear end)

mm (in) 17.973 - 17.984 (0.7076 - 0.7080)

Cylinder head journal diameter (center)

mm (in) 34.935 - 34.955 (1.3754 - 1.3762)

Oil pump housing journal diameter (oil pump end)

mm (in) 15.973 - 15.984 (0.6289 - 0.6293)

Camshaft round limit mm (in) 0.03 (0.001)TIMING BELT

Slack mm (in) 0 - 10 (0 - 0.4)ROCKER ARM SHAFT

Outside diameter mm (in) 12.941 - 12.951 (0.5095 - 0.5099)ROCKER ARM

Inside diameter mm (in) 13.000 - 13.018 (0.5118 - 0.5125)VALVES

Face angle Degree 90.5 - 91.5Valve clearance (cold)

Intake mm (in) 0.15 - 0.25 (0.006 - 0.010)Exhaust mm (in) 0.20 - 0.30 (0.008 - 0.012)

Head diameter (A)Intake mm (in) 27.9 - 28.1 (1.10 - 1.11)Exhaust mm (in) 21.9 - 22.1 (0.86 - 0.87)

Face width (B)Intake mm (in) 2.0 - 3.1 (0.079 - 0.122)Exhaust mm (in) 2.0 - 3.1 (0.079 - 0.122)


6

Item Unit



Seat width (C) mm (in) 0.6 - 0.8 (0.02 - 0.03)Margin thickness (D)


Stem outside diameterIntake mm (in) 5.475 - 5.490 (0.2155 - 0.2161)Exhaust mm (in) 5.460 - 5.475 (0.2150 - 0.2156)

Guide inside diameter mm (in) 5.500 - 5.512 (0.2165 - 0.2170)Stem-to-guide clearance


Stem runout limit mm (in) 0.016 (0.0006)VALVE SPRING

Free length mm (in) 34.4 (1.35)Free length limit mm (in) 32.7 (1.29)Set length mm/kg (in/lb) 25.4 / 11.0 (1.00 / 24.2)Tilt limit mm (in) 1.5 (0.06)

PISTON

Piston-to-cylinder clearance mm (in) 0.035 - 0.065 (0.0014 - 0.0026)Piston diameter (D)

Standard mm (in) 58.950 - 58.965 (2.3206 - 2.3215)Measuring point (H) mm (in) 5 (0.20)Pin boss inside diameter mm (in) 14.004 - 14.015 (0.5513 - 0.5518)Oversize piston diameter

1st (except for USA) mm (in) 59.25 (2.333)2nd mm (in) 59.50 (2.343)

PISTON PIN

Outside diameter mm (in) 13.996 - 14.000 (0.5510 - 0.5512)PISTON RINGS

Top ringType BarrelDimensions (B x T) mm (in) 1.2 x 2.25 (0.05 x 0.09)End gap (installed) mm (in) 0.15 - 0.30 (0.006 - 0.012)

Wear limit mm (in) 0.50 (0.020)Side clearance (installed) mm (in) 0.013 - 0.035 (0.0005 - 0.0013)

2nd ringType PlainDimensions (B x T) mm (in) 1.5 x 2.6 (0.06 x 0.10)End gap (installed) mm (in) 0.30 - 0.50 (0.012 - 0.020)

Wear limit mm (in) 0.70 (0.028)Side clearance (installed) mm (in) 0.02 - 0.04 (0.001 - 0.002)


7

Item Unit



Oil ringDimensions (B x T) mm (in) 2.4 x 2.45 (0.09 x 0.10)End gap (installed) mm (in) 0.2 - 0.7 (0.008 - 0.028)

Wear limit mm (in) 0.9 (0.04)CONNECTING ROD

Small end inside diameter mm (in) 14.015 - 14.029 (0.5518 - 0.5523)Big end oil clearance mm (in) 0.021 - 0.045 (0.0008 - 0.0018)

CRANKSHAFT

Crankshaft width mm (in) 126.70 - 126.90 (4.99 - 5.00)Crankshaft big end side clearance mm (in) 0.05 - 0.22 (0.002 - 0.009)Crankcase mark-bearing color A:Blue B:Black C:BrownCrankshaft journal clearance mm (in) 0.012 - 0.045 (0.0005 - 0.0018)Runout limit mm (in) 0.03 (0.0012)

THERMOSTAT

ID mark S60°CValve opening temperature °C (°F) 58 - 62 (136.4 - 143.6)Full-open temperature °C (°F) 70 (158)Valve lift mm (in) 3 (0.12)

FUEL PUMP

Discharge L (US gal, lmp gal)/h

@ 3,000 r/min

25 (6.60, 5.50)

Pressure kPa (kg/cm2, psi) 117.6 (1.2, 17.07)Diaphragm stroke mm (in) 2.4 - 4.8 (0.094 - 0.189)Plunger stroke mm (in) 3.52 - 6.57 (0.139 - 0.259)

OIL PUMP

Type Trochoid

Outer rotor-to-housing clearance a mm (in) 0.10 - 0.15 (0.004 - 0.006)Outer rotor-to-inner rotor clearanceb mm (in) 0.04 - 0.14 (0.002 - 0.006)Rotor-to-cover clearance c mm (in) 0.03 - 0.09 (0.001 - 0.004)Relief valve operating pressure kPa (kg/cm2, psi) 388 - 450 (3.88 - 4.50, 55.2 - 64.0)

CARBURETOR

ID mark 66M10Main jet # 104Pilot jet # 45Float height a mm (in) 9.5 - 10.5 (0.37 - 0.41)Idle speed r/min 900 - 1,000Trolling speed r/min 800 - 900


8

LOWER

ELECTRICAL

Item Unit



GEAR BACKLASH (SST indicator)

Pinion-forwardMinimum mm (in) 0.19 (0.007)Mid-point mm (in) 0.53 (0.02)Maximum mm (in) 0.86 (0.034)

Pinion-reverseMinimum mm (in) 0.95 (0.037)Mid-point mm (in) 1.30 (0.051)Maximum mm (in) 1.65 (0.064)

Pinion shim mm 1.13 / 1.2Forward shim mm 0.10 / 0.12 / 0.15 / 0.18 / 0.30 / 0.40 / 0.50Reverse shim mm 0.1 / 0.2 / 0.3 / 0.4 / 0.5

TEST PROPELLER

Test propeller Part no. YB - 1619 / 90890-01619Specific revolution r/min 5,200 - 5,400

Item Unit



IGNITION SYSTEM

Ignition timing Degree 5 - 30Charge coil output peak voltage (BTDC)

(Br-L)@ cranking 1 (500 r/min) open V 130@ cranking 2 (500 r/min) loaded V 130@ 1,500 r/min V 180@ 3,500 r/min V 180

Pulser coil output peak voltage(W/G-B)@ cranking 1 (500 r/min) open V 4.0@ cranking 2 (500 r/min) loaded V 3.5@ 1,500 r/min V 11.0@ 3,500 r/min V 23.0

CDI unit output peak voltage(O-B)@ cranking 1 (500 r/min) open V 120@ cranking 2 (500 r/min) loaded V 120@ 1,500 r/min V 165@ 3,500 r/min V 165

Spark plug gap mm (in) 0.9 (0.04)


9

Item Unit



Charge coil resistance (Br-L) Ω 272 - 408Pulser coil resistance (W/G-B) Ω 234 - 348Ignition coil resistance (O-B)

Primary Ω 0.16 - 0.24Secondary kΩ 3.92 - 5.88

IGNITION CONTROL SYSTEM

Oil pressure switch kPa (kg/cm2, psi) 14.7 (0.15, 2.13)Engine speed limiter

Rated timing r/min 6,200Ignition off r/min 6,800Reset r/min 6,000

STARTING SYSTEM

Fuse A 20STARTER MOTOR

Type BendixRating Second 30Output kW 1.1Brush length mm (in) 12.6 (0.5)

Limit mm (in) 6.4 (0.25)Commutator undercut mm (in) 2 (0.08)

Limit mm (in) 0.8 (0.03)CHARGING SYSTEM

Lighting coil output peak voltageV1 (G-G/W)@ cranking 1 (500 r/min) open V 6.5@ cranking 2 (500 r/min) loaded V 6.0@ 1,500 r/min V 21@ 3,500 r/min V 46

Rectifier output peak voltageV2 (R-B)@ cranking (500 r/min) open V 6.0@ 1,500 r/min V 20@ 3,500 r/min V 45

Charging current A@ r/min 10 @ 5,000Lighting coil resistance (G-G/W) Ω@20°C (68°F) 0.24 - 0.36


10

Item Unit



POWER TILT (PT) UNIT

Fluid type ATF Dexroin llBrush length mm (in) 6 (0.25)

Limit mm (in) 3 (0.12)Commutator diameter mm (in) 16.5 (0.65)

Limit mm (in) 15.5 (0.61)


11

DIMENSIONS

Symbol

Unit



L1 mm (in) 483 (19.0) 483 (19.0)L2 mm (in) 152 (6.0) 160 (6.3)L3 mm (in) – 517 (20.4)L4 mm (in) 363 (14.3) 363 (14.3)L6 mm (in) 840 (33.1) 840 (33.1)L7 mm (in) 308 (12.1) 308 (12.1)H1 mm (in) 835 (32.9) 835 (32.9)H2 mm (in) 372 (14.7) 372 (14.7)H3 mm (in) 135 (5.3) 135 (5.3)H4 mm (in) 570 (22.4) 570 (22.4)H6 mm (in) 641 (25.2) 641 (25.2)H7 mm (in) 261 (10.3) 261 (10.3)H8 mm (in) – 12 (0.5)H9 mm (in) 587 (23.1) 587 (23.1)W1 mm (in) 182 (7.2) 182 (7.2)W5 mm (in) 329 (13.0) 329 (13.0)W6 mm (in) – 575 (22.6)A1 Degree 40 40A2 Degree 63 63A3 Degree 12 12


12

Symbol

Unit



B1 mm (in) 95.3 (3.8)B2 mm (in) 92.4 (3.6)B3 mm (in) 95.3 (3.8)B4 mm (in) 94.5 (3.7)B5 mm (in) 111 (4.4)B6 mm (in) 326.7 (12.9)B9 mm (in) 18 (0.7)D1 mm (in) 8.3 (0.3)D2 mm (in) 10 (0.4)C1 mm (in) 40 (1.6)C2 mm (in) 66 (2.6)

TIGHTENING TORQUES

13

TIGHTENING TORQUES

SPECIFIED TORQUES

Part to be tightenedPart

nameThread

sizeQ’ty

Tightening torqueN•m kgfm ftlb

POWER UNIT

Power unit mounting Bolt M8 6 21 2.1 15.2Flywheel Nut M16 1 110 11.0 80Carburetor Bolt M6 2 10 1.0 7.2Oil filter – – 1 18 1.8 13Oil filter plug (cylinder block) – M20 1 40 4.0 29Spark plug – M12 2 18 1.8 13Drive sprocket Nut M28 1 55 5.5 39.8Driven sprocket Bolt M6 1 13 1.3 9.4Cylinder head cover Bolt M6 4 8 0.8 5.8

Cylinder head

1stBolt M8 6

15 1.5 10.82nd 30 3.0 221st

Bolt M6 36 0.6 4.5

2nd 12 1.2 8.7Valve adjusting screw – M6 4 14 1.4 10.0Oil pump Bolt M6 3 8 0.8 5.8Oil pump cover Screw M6 2 4 0.4 2.9

Exhaust cover1st

Bolt M6 76 0.6 4.5

2nd 12 1.2 8.7

Crankcase

1stBolt M8 4

15 1.5 10.82nd 30 3.0 221st

Bolt M6 66 0.6 4.5

2nd 12 1.2 8.7

Connecting rod1st

Bolt M7 410 1.0 7.2

2nd 22 2.2 16Anode cover Bolt M5 1 5 0.5 3.6Starter motor mounting Bolt M8 3 29 2.9 21LOWER UNIT

Propeller Nut M10 1 17 1.7 12.3Lower unit mounting Bolt M8 4 18 1.8 13Pinion gear nut Nut M8 1 25 2.5 18BRACKET

Tiller handle mounting (pivot) Nut M10 1 10 1.0 7.2Tiller handle mounting locknut (pivot) Nut M10 1 23 2.3 16.6Water flushing adapter Bolt M6 1 10 1.0 7.2Bottom cowling Bolt M6 4 8 0.8 5.8Steering friction piece Bolt M6 1 4 0.4 2.9Tilt stop lever Bolt M6 4 8 0.8 5.8Upper rubber mounting Nut M8 2 21 2.1 15

Lower rubber mountingBolt/Nut

M8 4 32 3.2 23

Clamp bracket Nut M22 2 12 1.2 8.7Clamp bracket - upper (PT) Bolt M8 2 24 2.4 17.7Clamp bracket - lower (PT) Bolt M8 2 18 1.8 13Upper casing Bolt M8 6 18 1.8 13Oil drain plug Bolt M14 1 27 2.7 19.5Exhaust manifold Bolt M6 2 11 1.1 8.0Water inlet cover Screw M5 1 5 0.5 3.6

TIGHTENING TORQUES

14

GENERAL TORQUES

This chart specifies tightening torques for standard fasteners with a standard ISO thread pitch. Tightening torque specifications for special components or assemblies are provided in applicable sections of this manual. To avoid warpage, tighten multifastener assemblies in a crisscross fashion and progressive stages until the specified tightening torque is reached. Unless otherwise specified, tightening torque specifications require clean, dry threads.Components should be at room temperature.

Part to be tightenedPart

nameThread

sizeQ’ty

Tightening torqueN•m kgfm ftlb

PT UNIT

Reservoir cap Bolt M10 1 5 0.5 3.6PT motor Bolt M5 4 5 0.5 3.6Cylinder end screw Screw M33 1 45 4.5 32Gear pump housing Bolt M5 6 5 0.5 3.6Tilt piston – M12 1 45 4.5 32ELECTRICAL

Starter motor Bolt M8 3 29 2.9 21Solenoid Screw M5 2 3 0.3 2.2Solenoid mount bracket Bolt M6 2 8 0.8 5.8Lighting coil Bolt M6 4 8 0.8 5.8Oil pressure switch Bolt – 1 8 0.8 5.8Rectifier/regulator Bolt M6 2 8 0.8 5.8Rectifier/regulator bracket Bolt M6 3 8 0.8 5.8Rectifier/regulator bracket ground Bolt M6 1 8 0.8 5.8

Nut (A) Bolt (B)General torque specifications

N•m kgf•m ftlb8 mm M5 5 0.5 3.610 mm M6 8 0.8 5.812 mm M8 18 1.8 1314 mm M10 36 3.6 2517 mm M12 43 4.3 31

MAINTENANCE INTERVAL CHART

15

MAINTENANCE INTERVAL CHARTUse the following chart as a guide to general maintenance intervals.Dependant on operating conditions, adjust the maintenance intervals accordingly.

Item RemarksInitial Every

10 hours (Brake-in)

50 hours (3 months)

100 hours (6 months)

200 hours (1 year)

TOP COWLING:

Water separator drain hole Check FUEL SYSTEM:

Fuel line Check Fuel filter Check/replace CONTROL SYSTEM:

Throttle cables Check/adjust Remote control throttle cable Check/adjust Throttle link lever Check/adjust Remote control shift cable Check/adjust Shift cable Check/adjust Engine idling speed Check/adjust Start-in-gear protection device Check/adjust POWER UNIT:

Engine oil Check/change Oil filter Replace Timing belt Check/replace Valve clearance Check/adjust Ignition timing Check Thermostat Check/replace Water leakage Check Motor exterior Check Exhaust leakage Check Cooling water passage Check/clean POWER TILT SYSTEM:

Power tilt fluid Check/change LOWER UNIT:

Gear oil Change Impeller Check Lower unit leakage Check Propeller Check GENERAL:

Anode Check Battery Check EVERY MONTHSpark plug Cleaning/

adjust/ replace

Wiring and connector Adjust/reconnect

Bolts and nuts Tighten Lubrication points Lubricate

POWER TILT SYSTEM/ GENERAL

16

POWER TILT SYSTEM/ GENERAL

CHECKING THE POWER TILT (PT)

FLUID LEVEL

WARNING

To prevent the hydraulic fluid from

spurting out due to internal pressure, the

outboard should be kept fully tilted up (the

tilt ram at full length) while slowly

removing the screw.

1. Check: Power tilt fluid level

Level is low Add fluid to the proper level.

Checking steps:

(1) Tilt up the outboard and lock it with tilt lock knob 1.

(2) Remove the reservoir cap 2.(3) Check that the fluid level is directly

below the fluid level checking hole a.

2. Add:

GENERAL

CHECKING THE ANODE

1. Check: Anode (engine) Anode (clamp bracket) Anode (lower unit)

Scales Clean.Oil/grease Clean.Excessive wear (half worn) damage Replace.

CAUTION:

Do not oil, grease, or paint the anode, or it

will not operate properly.

Recommended hydraulic fluid:

ATF Dexron ll

Reservoir cap:

5 N•m (0.5 kgf•m, 3.6ft•lb)

POWER UNIT

17

POWER UNIT

REMOVING/INSTALLING THE POWER UNIT 1 (F15AEP/F15PR)

Step Job/Part Q'ty Remarks1 Bolt 32 Fitting plate 13 Battery cables 14 Throttle cable 15 Shift cable 16 Shift link rod 17 PT motor lead 18 PT relay lead 29 Remote control lead 110 Fuse lead 111 Trailer switch lead 112 Fuel hose 113 Pilot water hose 1

Continued on next page.

POWER UNIT

18

Step Job/Part Q'ty Remarks14 Water flushing hose 1

For installation, reverse the removal procedure.

POWER UNIT

19

REMOVING/INSTALLING THE POWER UNIT 1 (F15AEHP/F15PH)

Step Job/Part Q'ty Remarks1 Bolt 32 Fitting plate 13 Battery cables 14 Throttle cable 25 Shift link rod 16 PT motor lead 17 PT relay lead 28 Engine stop switch lead 19 Neutral switch lead 110 Fuse lead 111 Trailer switch lead 1 (With trailer switch model only)12 Fuel hose 113 Pilot water hose 1


POWER UNIT

20

Step Job/Part Q'ty Remarks14 Water flushing hose 1


ELECTRICAL UNIT

21

ELECTRICAL UNIT

REMOVING/INSTALLING THE ELECTRICAL UNIT

Step Job/Part Q'ty Remarks1 Bolt 12 Rectifier ground lead 13 Bolt (with washer) 14 Starter relay ground lead 15 CDI unit ground lead 16 Starter relay lead 17 Screw (with washer) 18 Oil pressure switch lead 19 Ignition coil lead 210 Bolt (with washer) 211 Bracket 112 Terminal ass'y 113 Rubber 1


ELECTRICAL UNIT

22

Step Job/Part Q'ty Remarks14 Starter relay 115 Bolt 316 Collar 217 Grommet 218 Bolt (with washer) 219 Rectifier regulator ass'y 120 Bracket 121 Bolt 222 CDI unit ass'y 123 Bolt 124 Bolt 125 Nut 126 Washer 1


ELECTRICAL UNIT

23

Step Job/Part Q'ty Remarks27 Bolt 128 Starter motor 129 Oil pressure switch 130 Bolt (with washer) 231 Ignition coil ass’y 1


CYLINDER HEAD AND OIL PUMP

24

CYLINDER HEAD AND OIL PUMP

REMOVING/INSTALLING THE CYLINDER HEAD AND OIL PUMP

Step Job/Part Q'ty Remarks1 Spark plug 22 Bolt (with washer) 43 Cylinder head cover 14 O-ring 1 Not reusable5 Bolt (with washer) 36 Bolt 67 Cylinder head assembly 18 Dowel pin 29 Gasket 1 Not reusable10 Bolt (with washer) 311 Oil pump 112 Oil pump gasket 1 Not reusable


OIL PUMP

25

OIL PUMP

DISASSEMBLING/ASSEMBLING THE OIL PUMP

Step Job/Part Q'ty Remarks1 Screw 22 Oil pump cover 13 O-ring 1 Not reusable4 Inner rotor 15 Shaft 16 Pin 17 Outer rotor 18 Oil pump housing 1


CAMSHAFT AND VALVE

26

CAMSHAFT AND VALVE

REMOVING/INSTALLING THE CAMSHAFT AND VALVE

Step Job/Part Q'ty Remarks1 Locknut 42 Valve adjusting screw 43 Rocker arm shaft 24 Spring 1 15 Spring 2 36 Collar 1 Length: 15.0 mm (0.59 in)7 Collar 1 Length: 22.5 mm (0.89 in)8 Collar 1 Length: 8.5 mm (0.33 in)9 Rocker arm 410 Camshaft 111 Valve cotter 812 Valve spring seat (upper) 413 Valve spring 4


CAMSHAFT AND VALVE

27

Step Job/Part Q'ty Remarks14 Intake valve 215 Exhaust valve 216 Valve spring seat (lower) 417 Valve seal 4 Not reusable18 Oil seal 1 Not reusable19 Cylinder head 1


CAMSHAFT AND VALVE

28

CHECKING THE CAMSHAFT

Measure: Camshaft lobe diameter a and b

Out of specification Replace the camshaft

Rocker arm inside diameter:

IN a: 27.596 - 27.696 mm

(1.0865 - 1.0904 in)

IN b: 23.95 - 24.05 mm

(0.9429 - 0.9468 in)

EX a: 27.616 - 27.716 mm

(1.0872 - 1.0912 in)

EX b: 23.95 - 24.05 mm

(0.9429 - 0.9468 in)

CAMSHAFT AND VALVE

29

REFACING THE VALVE SEAT

Reface: Valve seat

CAUTION:

When turning the valve seat cutter, keep

an even downward pressure (4 - 5 kg) to

prevent chatter mark.

NOTE:After refacing the valve seat, lap the valve seat and valve face.

Refacing steps:

A Valve seat is centered on valve face butit is too wide.

Valve seat width

(intake valve and exhaust valve):

0.6 - 0.8 mm (0.02 - 0.03 in)

Valve seat cutter set:

90890-06803

Valve seat cutter:

90890-06556

Valve seat lapper:

90890-06805

Cut section and seat cutterSeat Cut section Seat cutter

INa: 180° 180°: 90890-06556b: 90° 90°: 90890-06312c: 60° 60°: 90890-06315

EXa: 180° 170°: 90890-06313b: 90° 90°: 90890-06312c: 0° 60°: 90890-06315

Valve seat cutter Desired result

a 180° cutter (IN)170° cutter (EX)

Lap the face a and face c lightly to reduce the valve seat width.c 60° cutter (IN/EX)

EX

a

c

b

IN

a

c

b

AI N

E X

a

ca

a

c

c

CAMSHAFT AND VALVE

30

B Valve seat is in the middle of the valveface but it is too narrow.

C Valve seat is too narrow and it is nearthe valve margin.

D Valve seat is too narrow and it is nearthe valve stem.

INSTALLING THE CAMSHAFT OIL

SEAL

Install: Cam shaft oil seal 1

NOTE:Press fit the oil seal to the stepped portion of the cylinder head and check that it is not at an angle.


b 90° cutter (IN/EX)Lap the face b to increase the valve seat width.


a 180° cutter (IN)170° cutter (EX)

Lap the face a to center the valve seat and lap the face b to increase the valve seat width.

b 90° cutter (IN/EX)


c 60° cutter (IN/EX)Lap the face c to center the valve seat and lap the face b to increase the valve seat width.

b 90° cutter (IN/EX)

Drive rod:

YM-06071/90890-06652

Attachment:

YB-06196/90890-06196

BI N

E Xb

b

b

CI N

E Xa

b

a

ab

b

DI N

E X

bc

c

b

b

c

OIL FILTER, THERMOSTAT AND EXHAUST COVER

31


DISASSEMBLING/ASSEMBLING THE OIL FILTER, THERMOSTAT AND EXHAUST COVER

Step Job/Part Q'ty Remarks1 Oil filter 12 Oil filter plug 13 Bolt (with washer) 24 Thermostat cover 15 Thermostat gasket 1 Not reusable6 Thermostat 17 Bolt (with washer) 58 Exhaust cover 19 Exhaust cover gasket 1 Not reusable10 Bolt (with washer) 311 Breather cover 112 Breather cover gasket 1 Not reusable13 Bolt (with washer) 1



32

Step Job/Part Q'ty Remarks14 Plate 115 Anode cover 116 Bolt (with washer) 117 Grommet 118 Anode 1


STEERING HANDLE ASSEMBLY (F15AEHP/F15PH)

33

STEERING HANDLE ASSEMBLY (F15AEHP/F15PH)REMOVING/INSTALLING THE STEERING HANDLE ASSEMBLY

Step Job/Part Q'ty Remarks1 Throttle cable 22 Engine stop switch lead 13 PT switch lead 14 Grommet 15 Locknut 16 Nut 17 Plate 18 Bushing 19 Steering handle ass'y 1



34

DISASSEMBLING/ASSEMBLING THE STEERING HANDLE ASSEMBLY

Step Job/Part Q'ty Remarks1 Plate washer 12 Plate washer 13 Wave washer 24 Plate washer 15 Bushing 16 Screw 37 Clamp 18 Stay 19 Screw (with washer) 210 PT switch ass'y 111 Screw 112 Steering grip 113 Washer 1



35

Step Job/Part Q'ty Remarks14 Spring 115 Bushing 116 Bolt 217 Stay 118 Split pin 119 Friction adjusting screw 120 Friction piece 121 Throttle cable 222 Throttle shaft 123 Engine stop switch 124 Steering handle bracket 1



36

INSTALLING THE PT SWITCH

1. Install: PT switch

NOTE:Tighten the PT switch mounting screw in sequence

BOTTOM COWLING ASSEMBLY

37

BOTTOM COWLING ASSEMBLYREMOVING/INSTALLING THE BOTTOM COWLING ASSEMBLY

Step Job/Part Q'ty Remarks1 Bolt 22 Plate washer 23 PT relay 14 Collar 25 Grommet 26 Bolt (with washer) 27 Bracket 18 Gasket 19 Trailer switch 110 Hose 1 (Bottom cowling - joint hose)11 Hose 1 (Oil pan - joint hose)12 Hose 1 (Exhaust cover - joint hose)13 Joint hose 1



38

Step Job/Part Q'ty Remarks14 Clamp 115 Grommet 116 PT motor lead 117 Joint assembly 118 Clamp 119 Water flushing hose 120 Bolt (with washer) 121 Adapter 122 Clip 123 Washer 124 Bolt (with washer) 125 Collar 126 Wave washer 1



39

Step Job/Part Q'ty Remarks27 Shift rod link 128 Gear shift handle 129 Shift rod nut 130 Bolt (with washer) 231 Bolt (with washer) 232 Bottom cowling assembly 133 Collar 434 Grommet 435 Rubber seal 1


SWIVEL AND STEERING BRACKET

40

SWIVEL AND STEERING BRACKETREMOVING/INSTALLING THE SWIVEL AND STEERING BRACKET

Step Job/Part Q'ty Remarks1 Screw 22 Wire lead 13 Friction bolt 14 Rubber seal 15 Steering friction ass'y 1 (F15AEHP/F15PH only)6 Steering bracket 17 Washer 18 Bushing 19 Key 110 Bushing 111 O-ring 1 Not reusable12 Bushing 113 Swivel bracket ass'y 1 For installation, reverse the removal

procedure.


41

POWER TILT (PT) UNITREMOVING/INSTALLING THE POWER TILT (PT) UNIT

Step Job/Part Q'ty Remarks1 PT motor lead 12 Clamp 13 Bolt (with washer) 14 Circlip 15 Pin 16 Bushing 17 Bushing 28 Bolt 29 Washer 210 Pin 111 Bushing 212 Bushing 113 Collar 1



42

Step Job/Part Q'ty Remarks14 Power tilt (PT) unit 1



43

DISASSEMBLING/ASSEMBLING THE POWER TILT (PT) CYLINDER

Step Job/Part Q'ty Remarks1 Tilt ram assembly 12 Free piston 13 O-ring 1 20.8 x 2.4 mm Not reusable4 Backing ring 15 Cylinder case 16 O-ring 1 26.0 x 1.8 mm Not reusable7 Cylinder 18 O-ring 1 29.7 x 1.9 mm Not reusable9 O-ring 1 20.8 x 2.4 mm Not reusable10 Backup ring 111 Tilt piston 112 Ball 113 Pin 1



44

Step Job/Part Q'ty Remarks14 Spring 1 Outside diameter 6.8 x Length 13.5 mm15 Dowel pin 116 End screw 117 O-ring 1 12.3 x 2.4 mm Not reusable18 Backup ring 119 Dust seal 1 Not reusable20 Tilt ram 1



45

DISASSEMBLING THE POWER TILT (PT)

CYLINDER

WARNING

To prevent the hydraulic fluid from

spurting out due to internal pressure, the

outboard should be kept fully tilted up

(the tilt rod at full length).

After removing the tilt motor or oil

reservoir, do not push the tilt rod down.

This may cause hydraulic fluid to spurt

out from the port.

CAUTION:

Do not wipe hydraulic system components

with rags, paper, tissues, or the like, as

fibers from such material will cause

malfunctions if they enter the system.

1. Loosen: End screw

2. Loosen: Tilt ram

NOTE:Hold the protruded portion a of the tilt piston with the aluminium plate 1 and turn to loose the tilt ram.

Power tilt wrench:

YB-06560 / 90890-06560

Power tilt wrench:

YB-06560 / 90890-06560


46

ASSEMBLING THE POWER TILT (PT)

CYLINDER

1. Tighten: Tilt ram

NOTE:Hold the protruded portion a of the tilt piston with the aluminium plate 1 and tighten the tilt ram.

2. Fill: Fluid

Filling steps

(1) Fill the cylinder with the fluid to about 70 %.

NOTE:Put the fluid with the free piston 1 installed at the bottom of the cylinder.

(2) Install the tilt ram assembly.

NOTE:The tilt ram assembly is to be installed with the tilt piston 2 and end screw 3 in close contact.

3. Tighten: End screw

Power tilt wrench:

YB-06560 / 90890-06560

Tilt piston:

45 N•m (4.5 kgf•m, 32ft•lb)

Recommended PT fluid:

ATF Dexron II

Power tilt wrench:

YB-06560 / 90890-06560

End screw:

45 N•m (4.5 kgf•m, 32ft•lb)


47

4. Bleed: Air

Bleeding step:

(1) Open the manual valve 1.

(2) Manually push in the tilt ram to its fully contracted state.

(3) Remove the reservoir cap 2 and supply the fluid to the prescribed level.

(4) Close the manual valve 1.

Reservoir cap:

5 N•m (0.5 kgf•m, 3.6ft•lb)


48

(5) Connect the PT motor lead to the battery and place the tilt ram in it fully extended state.

NOTE: When the tilt ram is unstable or does not

move, supply the fluid to the prescribed level.

Repeat until the tilt ram is placed in its fully extended state.

Close the reservoir cap during operation.

(6) Alternately connect the PT motor leads to the battery and extend and contract the cylinder about 3 times.

NOTE: Operate the tilt ram to the full stroke and

relieve it for about 2 seconds at each stroke end.

Place the tilt ram finally in its fully extended state.

Tilt ram PT motor leadBattery

terminal

UpBlue (+)

Green (-)

Tilt ram PT motor leadBattery

terminal

UpBlue (+)

Green (-)

DownGreen (+)

Blue (-)


49

(7) Open the manual valve, leave it to stand for about 1 second and close it.

NOTE:Check the fluid level and replenish if short.

(8) Leave it to stand for about 3 minutes and then repeat steps (6) and (7).

NOTE: Repeat for about 3 times until the up

relief sound is confirmed without delay when the cylinder extends.

Finally confirm the fluid level.

(9) Install the power tilt (PT) unit to the outboard motor.

NOTE:Carrying and working should be done with the power tilt (PT) unit erected.

(10) Operate the PT switch to move down the tilt, relieve it for about 1 second, and then immediately move up the tilt.

NOTE: For moving up the tilt, stop it at about

half the stroke. If it does not stop, air removal is not

complete. Take the steps (6) and (7) with it installed to the outboard motor.

Immediately after the tilt up, check that the outboard motor does not descend. Finally recheck the operation in this procedure.

(11) Move up the tilt and finally check the fluid level.

NOTE:If short, replenish.


50

DISASSEMBLING/ASSEMBLING THE VALVES AND PUMP 1

Step Job/Part Q'ty Remarks1 Reservoir cap 12 O-ring 1 6.8 x 1.9 mm Not reusable3 Bolt 44 PT motor 15 O-ring 1 21.7 x 3.5 mm Not reusable6 O-ring 1 Not reusable7 Manual release rod 18 Pin 19 O-ring 1 5.8 x 1.9 mm Not reusable10 Sponge 111 Spring 2 Outside diameter 5.0 x Length 17.0 mm12 Manual release pin 213 Spring 2 Outside diameter 5.7 x Length 17.2 mm



51

Step Job/Part Q'ty Remarks14 Absorver valve pin 215 Ball 216 Spring 2 Outside diameter 7.6 x Length 14.5 mm17 Spring 1 Outside diameter 8.8 x Length 18.1 mm18 Valve pin 219 Valve seal 2



52

INSTALLING THE RELIEF VALVE

Install: Valve seal 1 Valve pin 2 Spring 3

NOTE:Be careful to install the valve seal facing in the correct direction.


53

DISASSEMBLING/ASSEMBLING THE PT MOTOR

Step Job/Part Q'ty Remarks1 Screw (with washer) 22 Yoke assembly 1 43.9 x 1.5 mm Not reusable3 O-ring 14 Screw (with washer) 15 Armatuer 16 Screw (with washer) 27 Brush 28 Brush spring 29 Oil seal 1 Not reusable10 End frame 1



54

REMOVING THE ARMATURE

1. Remove: Screw 1 Brush 2 Armature 3

NOTE:Push brush 2 to the inside, then remove armature 3.

CHECKING THE PT MOTOR

1. Check: Commutator

Dirt Clean with 600 grit sandpaper.

2. Check: Commutator undercut

Obstruction Clean.

NOTE:Remove all metal particles with compressed air.

3. Measure: Commutator diameter a

Out of specification Replace.

Commutator diameter limit:

15.5 mm (0.61 in)


55

4. Measure: Armature coil continuity


5. Measure: Brush length a


6. Check: End frame

Cracks/damage Replace.

7. Check: Yoke bushing

Cracks/damage Replace.

8. Check: Oil seal

Damage/wear Replace.

Armature coil continuity

Commutator segments Continuity

Segment - laminations No

continuity

Segment - shaft No

continuity

Brush length limit:

3 mm (0.12 in)


56

CHECKING THE PT MOTOR ASSEMBLY

1. Check: PT motor operation

Incorrect operation Repair.

INSTALLING THE OIL SEAL

1. Install: Oil seal

PT motor operation

Blue (+), Green (-)Motor turns

clockwise

Green (+), Blue (-)Motor turns

counterclockwise

Oil seal attachment:

YB-06112/90890-06614

Driver rod:

YB-06071/90890-06652


57

DISASSEMBLING/ASSEMBLING THE VALVES AND PUMP 2

Step Job/Part Q'ty Remarks1 Bolt 62 Gear housing 13 Gear 24 Dowel pin 45 Top chamber shuttle piston 16 O-ring 1 8.5 x 1.5 mm Not reusable7 Spring 2 Outside diameter 2.5 x Length 10.0 mm8 Bottom chamber shuttle piston 19 Circlip 210 Valve seal 211 Valve seat 212 O-ring 2 11.5 x 1.5 mm Not reusable13 Main valve 2



58

Step Job/Part Q'ty Remarks14 Spring 2 Outside diameter 4.1 x Length 12.0 mm15 Filter 216 O-ring 2 8.5 x 1.5 mm Not reusable17 Ball 218 Spring 2 Outside diameter 3.2 x Length 8.0 mm


CLAMP BRACKET

59

CLAMP BRACKETREMOVING/INSTALLING THE CLAMP BRACKET

Step Job/Part Q'ty Remarks1 Bolt (with washer) 12 Bolt 23 Wire lead 14 Anode 15 Screw 16 Wire lead 17 Cap nut 28 Clamp bracket cap 29 Clamp bracket plate 110 Spring pin 111 Stopper knob 112 Stopper shaft 113 Bushing 1


CLAMP BRACKET

60

Step Job/Part Q'ty Remarks14 Nut 215 Washer 216 Bolt 217 Bolt 118 Clamp bracket bolt 119 Clamp bracket 120 Swivel bracket 121 Clamp bracket 122 Bushing 223 Plug 224 Grease nipple 1


ELECTRICAL COMPONENTS

61


(Top view and port side view)

1 CDI unit2 Rectifier regulator3 Pulser coil4 PT terminal5 Lighting coil6 Charge coil7 Oil pressure switch8 Starter relay9 Starter motor0 PT relayA Ignition coilB Spark plugs

A Pass the lighting coil lead on the side of the flywheel cover, next to the boss as shown.

B Install the Pink lead onto the oil pressure switch. Cover the oil pressure switch after tightening it.

C Cover the oil pressure switch lead, ignition coil lead and charge coil lead with the corrugated plastic tube after connecting the same color leads.

D Install the connector in the proper direction as shown.

E Pass each high tension cord through the grommet.


62

(Front view) (F15AEP/F15PH)

1 Pulser coil2 CDI unit lead3 PT terminal4 Starter relay5 Starter motor6 Fuse7 Battery cable

A To the lighting coil.B To the emergency signal light.C To the starter switch.D Mount the starter relay ground

lead along with the CDI unit ground lead and the engine stop switch ground lead.

E CDI unit leads.F To the PT motor.G To the PT relay.H To the handle PT switch.I Clamp the fuse holder to the

battery cable.J To the neutral switch.

K To the rectifier regulatorL To the battery cable.M To the stop switch.N Mount the rectifier regulator

ground lead.


63

(Front view) (F15AEHP/F15PH)

1 Pulser coil2 CDI unit lead3 PT terminal4 Starter relay5 Starter motor6 Fuse7 Battery cable8 Wire harness9 Choke solenoid

A To the lighting coil.B To the emergency signal light.C Mount the starter relay ground lead along

with the CDI unit ground lead and the wire harness ground lead.

D CDI unit leads.E To the PT motor.F To the PT relay.G Clamp the fuse holder to the battery cable.H To the rectifier regulator.I Mount with the rectifier regulator ground

lead and the choke solenoid ground lead.

STARTER MOTOR

64

STARTER MOTOR

DISASSEMBLING/ASSEMBLING THE STARTER MOTOR

Step Job/Part Q'ty Remarks1 Bolt 22 Stator 13 Cap 14 Pinion nut 15 Washer 16 Spring 17 Pinion stopper 18 Pinion gear 19 Front bracket 110 Washer 111 Armature 112 Bolt 213 Brush 2


STARTER MOTOR

65

Step Job/Part Q'ty Remarks14 Spring 415 Brush holder 116 Nut 117 Nut 118 Washer 119 Rubber plate 120 Brush set 121 Rear bracket 1


STARTER MOTOR

66

REMOVING THE PINION NUT

1. Remove: Pinion nut 1

NOTE:Secure the armature with the padded clamp, then remove the pinion nut.

CHECKING THE PINION GEAR

1. Check: Pinion gear teeth

Damage / wear Replace.

2. Check: Clutch movement Incorrect

Replace.

NOTE:Rotate the pinion gear clockwise to check that it moves freely. Also, rotate the pinion gear counterclockwise to make sure it locks.

CHECKING THE ARMATURE

1. Measure: Commutator undercut a


2. Check: Armature coil continuity


Commutator undercut limit:

0.8 mm (0.03 in)

Armature coil continuity:

Commutator segments a Continuity

Segment - Armature core b No continuity

Segment - Armature Shaft c No continuity

STARTER MOTOR

67

CHECKING THE BRUSH HOLDER

1. Measure: Brush length a


2. Check: Brush unit continuity


Brush length limit:

6.4 mm (0.25 in)

Brush unit continuity:

Brush 1 - Brush 2 Continuity

Brush 3 - Brush 4 Continuity

Brush 1, 2 - Bracket 5 No continuity

Brush 3, 4 - Bracket 5 Continuity

POWER TILT (PT) SYSTEM

68


POWER TILT (PT) SYSTEM (F15AEP/F15PR)

1 Battery2 Fuse3 Trailer switch4 PT relay5 Terminal6 PT motor

B : BlackG : GreenL : BlueLg : Light greenR : RedSb : Sky blue


69


POWER TILT (PT) SYSTEM (F15AEHP/F15PH)

1 Battery2 Terminal3 PT relay4 PT motor5 PT switch6 Trailer switch

A With trailer switch modelB To starter relayC To PT relayD Without trailer switch model

B : BlackG : GreenL : BlueLg : Light greenR : RedSb : Sky blue


70

CHECKING THE PT SWITCH

Check: PT switch continuity


CHECKING THE TRAILER SWITCH

Check: Bottom cowling PT switch

continuity Out of specification Replace.

CHECKING THE PT RELAY

1. Check: PT relay continuity


A To battery

Leads color

Sky blue

(Sb)Red (R)

Light

green

(Lg)Switch

position

Up

Free

Down

Leads color

Sky blue

(Sb)Red (R)

Light

green

(Lg)Switch

position

Up

Free

Down

PT relay continuity

Sky blue (Sb) - Black (B)

Light green (Lg) - Black (B)

Continuity

Blue (L) - Black (B)

Green (G) - Black (B)

Continuity

Blue (L) - Red (R)

Green (G) - Red (R)

No continuity


71

2. Check: PT relay operation

No continuity Replace.

Checking steps:

(1) Connect the digital tester between PT relay Blue (L) lead and Red (R) lead.

(2) Connect a 12-V battery as shown.

(3) Check that there is continuity between the PT relay terminals.

(4) Connect the tester between PT relay Green (G) lead and Red (R) lead.

(5) Connect a 12-V battery as shown.

(6) Check that there is continuity between the PT relay terminals.

Sky blue (Sb) lead Positive terminal

Black (B) lead Negative terminal

Light green (Lg) lead Positive terminal

Black (B) lead Negative terminal

TROUBLE ANALYSIS

72

TROUBLE ANALYSIS

TROUBLE ANALYSIS CHART

NOTE:Following items should be obtained before “trouble analysis”.1. Battery is charged and its specified gravity is in specification.2. There is no incorrect writing connection.3. Writing connections are surely engaged and without any rust.4. Lanyard is installed to the engine stop switch.5. Shift position is in neutral.6. Fuel is coming to the carburetor.7. Correct rigging and engine setting are obtained.8. Engine is free from any “Hull problem”.

Trouble mode Check element

EN

GIN

E W

ILL

NO

T S

TAR

T

RO

UG

H ID

LIN

G

EN

GIN

E S

TALL

S

EN

GIN

E W

ILL

NO

T S

TO

P

PO

OR

PE

RFO

RM

AN

CE

OV

ER

HE

AT

ING

LOO

SE

ST

EE

RIN

G

LOO

SE

TIL

T H

OLD

ING

PT M

OT

OR

WIL

L N

OT

RU

N

HA

RD

SH

IFT

ING

IRR

EG

ULA

R W

AR

NIN

G IN

DIC

AT

ION

PO

OR

BA

TT

ER

Y C

HA

RG

ING

Relative partReference

chapter

FUEL SYSTEM Fuel hose 4 Fuel joint 4 Fuel filter 4 Fuel pump 4 Carburetor 4

Idle speed 4 Pilot jet 3

Throttle cable 4POWER UNIT

Spark plugs 3 Compression 5 Timing belt 5 Valve clearance 5 Intake and exhaust valve 5 Intake and exhaust valve seat 5 Cylinder head gasket 5 Piston rings 5 Pistons 5

Thermostat 5 Water passage 5

TROUBLE ANALYSIS

73

Trouble mode Check element

EN

GIN

E W

ILL

NO

T S

TAR

T

RO

UG

H ID

LIN

G

EN

GIN

E S

TALL

S

EN

GIN

E W

ILL

NO

T S

TO

P

PO

OR

PE

RFO

RM

AN

CE

OV

ER

HE

AT

ING

LOO

SE

ST

EE

RIN

G

LOO

SE

TIL

T H

OLD

ING

PT M

OT

OR

WIL

L N

OT

RU

N

HA

RD

SH

IFT

ING

IRR

EG

ULA

R W

AR

NIN

G IN

DIC

AT

ION

PO

OR

BA

TT

ER

Y C

HA

RG

ING

Relative partReference

chapter

LOWER UNIT Neutral position 6 Clutch 6 Gears 6

Water inlet 6 Water pump 6 Propeller shaft and propeller 6

Shifter/Pin 6 Shift cam 6 Shift rod or Shift cable 6 Lower case 6

Shim adjustment 6BRACKET UNIT

Bracket 7 Mount rubber 7 Steering friction ass’y 7

PT UNIT Fluid level 7 Manual valve 7 Fluid passage 7

PT motor 7ELECTRICAL

Ignition coil 8 Ignition control system 8 Starting system 8 Charging system 8

PT control system 8

Printed on recycled paper

Printed in USAApr. 2000 - x 1 (F15AEP, F15AEHP)

YAMAHA MOTOR CO., LTD.

Sb Lg

R

LgSb

G

Br

B

R

W

Sb

L

Lg W

Br

B

L

R

G

Sb

Lg

BB

W B O P L B B

W B

Br W/GP/WY/R

W/GP/WY/R

Br

Br

L

L

R

R

G

G

L

L

P

P

O

O

B

B

B

BB

Br

Br

R

R Sb Lg

Sb R LgUP

FREEDOWN

B

G/W

G

RR R B

B

R

B

W/G

G/W

G

R R

RB

+-

L

G

LL

G G

Pulsercoil

11

CDI unit1

Battery2

Emergencysignal light

3 Rectifier/regulator

4

Fuse(20A)5Starter relay6

Starting motor7

Oil pressureswitch

10

Ignition coil12

Terminal ass'y13

Charge coil9

BlackBrownGreenBlueLight greenOrangePinkRedSky blueWhite

B:Br:G:L:Lg O: P: R:Sb: W:

P/W:W/G:Y/R:G/W:

Pink/whiteWhite/greenYellow/redGreen/whiteLighting coil8

PT motor14

PT relay15

Sparkplugs

16

Trailer switch17

Fuel enrichsolenoid

18

Lg Lg

Sb

Lg

Sb

Lg

Sb

B

R

B L R G

Sb Lg

LB G R

Y/R

P/W

WIRING DIAGRAM F15AEP/F15PR

Sb Lg

R

LgSb

RB

+-

Br

R

R

R

R B

B

B

R

R

R

LL

G G

R Sb Lg

Sb R LgUP

FREEDOWN

B

G G

B B

G

BW

L

L

P

P

O

O

B

B

Br

Br

W B O P L B B

W B

Br Br

Br

Br

Br

Br

W/G

B

Br

B

Sb

Lg

Sb

Lg

Sb LgR RSb Lg

A

C

Pulser coil11

CDI unit1

Battery2

Starter switch3

Rectifier/regulator

4

Fuse(20A)5

Starter relay6

Starting motor7

Oil pressureswitch

10

Ignition coil12

Terminal ass'y13

Charge coil9

BlackBrownGreenBlueLight greenOrangePinkRedSky blueWhite

B:Br:G:L:Lg O: P: R:Sb: W:

P/W:W/G:Y/R:G/W:

Pink/whiteWhite/greenYellow/redGreen/white

Lighting coil8

PT motor14

PTrelay

15

Sparkplugs

16

PT switch17

Engine stop switch18

With trailer switch model

B To starter relay

Neutral switch19

Emargencysignal light

20

To PT relay

Trailer switch

21

Lg

Sb

Lg

Sb Lg

SbLg

Lg

Sb

Lg

L

G

PT switch17

G/W G/W

W/G

W/G

P/WY/R

P/WY/R

D Without trailer switch model

R

B

Sb Lg

LB G R

Y/RP/W

WIRING DIAGRAM F15AEHP/F15PH

15 hp 2004 4 stroke

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