Yamaha F9.9 Outboard Service Repair Manual Pid Range 66nk-1000001-1005460 Mfg April 2005 And Newer

F15Z

SUPPLEMENTARY SERVICE MANUAL LIT-18616-02-12

66M-28197-ZA-1X

NOTICE This 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.

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

F15Z SUPPLEMENTARY SERVICE MANUAL Š2000 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

HOW TO USE THIS MANUAL MANUAL FORMAT All of the procedures in this manual are organised in a sequential, step-by-step format. The information has been compiled to provide the mechanic with an easy to read, handy reference that contains comprehensive explanations of all disassembly, repair, assembly, and inspection operations.

In this revised format, the condition of a faulty component will precede an arrow symbol and the course of action required will follow the symbol, e.g., •Bearings Pitting/scratches ➔ Replace.

MODEL INDICATION Multiple models are referred to in this manual and their model indications are noted as follows.

Model name

F15AEP

F15AEHP

USA and Canada name

F15PR

F15PH

Indication

F15AEP

F15AEHP

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 the appropriate section or chapter.

IMPORTANT INFORMATION In this Service Manual particularly important information is distinguished in the following ways.

The safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

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 10 x 25 mm : 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.

SYMBOLS 1

2

3

4

5

6

7

8

9

:

A

B

C

D

E

F

G

H

I

J

K

L

M

N

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

1 2 3 4 5 6 7 8 9

General information Specifications Periodic check and adjustment Fuel system Power unit Lower unit Bracket unit Electrical system Trouble analysis

Symbols : to E indicate specific data. : Special tool A Specified liquid B Specified engine speed C Specified torque D Specified measurement E Specified electrical value [Resistance (Ω), Voltage (V), Electrical current (A)] Symbols F to H in an exploded diagram indicate the grade of lubricant and the location of the lubricant point.

F Apply Yamaha 4-stroke motor oil G Apply water resistant grease (Yamaha grease A, Yamaha marine grease) H Apply molybdenum disufied oil Symbols I to N in an exploded diagram indicate the grade of the sealing or locking agent and the location of the application point.

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.572 N Apply silicon sealant

GENERAL INFORMATION IDENTIFICATION................................................................................................. 1 SERIAL NUMBER ......................................................................................... 1 STARTING SERIAL NUMBERS ................................................................... 1 SPECIAL TOOLS ................................................................................................. 2 REMOVAL AND INSTALLATION ................................................................ 2

SPECIFICATIONS GENERAL SPECIFICATIONS.............................................................................. 3 MAINTENANCE SPECIFICATIONS.................................................................... 5 POWER UNIT................................................................................................ 5 LOWER.......................................................................................................... 8 ELECTRICAL ................................................................................................. 8 DIMENSIONS ............................................................................................. 11 TIGHTENING TORQUES .................................................................................. 13 SPECIFIED TORQUES ................................................................................ 13 GENERAL 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) ........... 17 REMOVING/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 .................................................................................

REMOVING/INSTALLING THE CAMSHAFT AND VALVE .......................

CHECKING THE ROCKER ARM AND ROCKER ARM SHAFT ..................

CHECKING THE CAMSHAFT .....................................................................

REFACING THE VALVE SEAT ...................................................................

INSTALLING THE CAMSHAFT OIL SEAL .................................................

26 26 28 28 29 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) .....................................

REMOVING/INSTALLING THE STEERING HANDLE ASSEMBLY...........

DISASSEMBLING/ASSEMBLING THE STEERING HANDLE ASSEMBLY .................................................................................................

INSTALLING THE PT SWITCH ..................................................................

33 33 34 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 .......................... 41 DISASSEMBLING/ASSEMBLING THE POWER TILT (PT) CYLINDER .... 43 DISASSEMBLING THE POWER TILT (PT) CYLINDER ............................. 45 ASSEMBLING THE POWER TILT (PT) CYLINDER ................................... 46 DISASSEMBLING/ASSEMBLING THE VALVES AND PUMP 1 ............... 50 INSTALLING THE RELIEF VALVE.............................................................. 52 DISASSEMBLING/ASSEMBLING THE PT MOTOR.................................. 53 REMOVING THE ARMATURE ................................................................... 54 CHECKING THE PT MOTOR ...................................................................... 54 CHECKING THE PT MOTOR ASSEMBLY ................................................. 56 INSTALLING THE OIL SEAL ...................................................................... 56 DISASSEMBLING/ASSEMBLING THE VALVES AND PUMP 2 ............... 57 CLAMP BRACKET ............................................................................................. 59 REMOVING/INSTALLING THE CLAMP BRACKET ................................... 59

ELECTRICAL SYSTEM ELECTRICAL COMPONENTS...........................................................................

TOP VIEW AND PORT SIDE VIEW ............................................................

FRONT VIEW (F15AEP/F15PH) ..................................................................

FRONT VIEW (F15AEHP/F15PH) ...............................................................

61 61 62 63

STARTER MOTOR ............................................................................................

DISASSEMBLING/ASSEMBLING THE STARTER MOTOR......................

REMOVING THE PINION NUT ..................................................................

CHECKING THE PINION GEAR .................................................................

CHECKING THE ARMATURE ....................................................................

CHECKING THE BRUSH HOLDER .............................................................

64 64 66 66 66 67

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

POWER TILT (PT) SYSTEM (F15AEP/F15PR) ...........................................

POWER TILT (PT) SYSTEM (F15AEHP/F15PH) ........................................

CHECKING THE PT SWITCH .....................................................................

CHECKING THE TRAILER SWITCH ...........................................................

CHECKING THE PT RELAY ........................................................................

68 68 69 70 70 70

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

IDENTIFICATION 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 name 2 Approval model code 3 Transom height 4 Serial number

STARTING SERIAL NUMBERS The starting serial number blocks are as follows: Model name World USA/ wide Canada F15AEP F15PR F15AEHP F15PH

1

Applicable model code

Starting serial number

66M 66M

L:800141L:900111-

SPECIAL TOOLS SPECIAL TOOLS Using 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:

REMOVAL AND INSTALLATION

1

2a

3a

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-”.

1 Power tilt wrench: P/N. YB-06560 90890-06560 2 Oil seal attachment: P/N. YB-06112, YB-06196 .............. a 90890-06614, 90890-06196.... b

b

3 Driver rod: P/N. YB-06071 ................................ a 90890-06652........................... b

b

4 Valve seat cutter set: P/N. 90890-06803 4

5 Valve seat cutter: P/N. 90890-06556

5

2

GENERAL SPECIFICATIONS GENERAL SPECIFICATIONS Model Item

World wide USA Canada

DIMENSION Overall length Overall width Overall height WEIGHT (with aluminum propeller) PERFORMANCE Maximum output

F15AEHP F15PH F15PH

mm (in) mm (in) mm (in)

643 (25.3) 369 (14.5) 1,207 (47.5)

1,001 (39.4) 427 (16.8) 1,207 (47.5)

kg (lb)

54 (119.0)

55 (121.3)

kW (hp) @ 5,000 r/min r/min L (US gal, lmp gal)/h @ 5,000 r/min

Full throttle operating range Maximum fuel consumption

POWER UNIT Type Number of cylinders Displacement Bore x stroke Compression ratio Compression pressure Number of carburetors Control system Starting system Ignition control system Lighting coil Lighting coil output Starting enrichment Spark plug Exhaust system Lubrication system Ignition timing FUEL AND OIL Fuel type Fuel rating

F15AEP F15PR F15PR

Unit

cm3 (cu. in) mm (in) kPa (kg/cm2, psi)

V-A

Degree (BTDC)

11 (15) 4,500 - 5,500 5.3 (1.39, 1.16)

4 stroke, OHC, in-line 2 323 (19.7) 59.0 x 59.0 (2.32 x 2.32) 9.19 961 (9.8, 139.4) 1 Remote control Tiller control Electric motor C.D.I Single phase DC12-10 with rectifier/regulator Choke valve DPR6EA-9 Propeller hub Wet sump 5 – 30 Unleaded regular gasoline 86 91

PON (*1) PON (*2)

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

3

GENERAL SPECIFICATIONS

Item

World wide USA Canada

Model F15AEP F15AEHP F15PR F15PH F15PR F15PH 4-stroke engine oil API SE, SF, SE-SF, SE-SF-CC SAE 10W-30, 10W-40

Unit

Engine oil type Engine oil grade Engine oil quantity With oil filter Without oil filter Gear oil type Gear oil grade Gear oil quantity BRACKET Trim angle Tilt-up angle Steering angle DRIVE UNIT Gear positions Gear ratio Gear type Propeller direction (rear view) Propeller drive system Propeller series mark ELECTRICAL Battery capacity Cold cranking

cm3 (US oz, Imp oz) cm3 (US oz, Imp oz)

cm3 (US oz, Imp oz)

1,200 (40.6, 42.2) 1,000 (33.8, 35.2) Hypoid gear oil SAE #90 250 (8.45, 8.80)

Degrees Degrees Degrees

8, 12, 16, 20 63 40 + 40 F-N-R 2.08 (27:13) Spiral bevel gear Clockwise Spline J

Ah (kC) A

40 (144) 380

4

MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS POWER UNIT Model Item

World wide USA Canada

CYLINDER HEAD Warpage limit CYLINDER Bore Taper limit Out-of-round limit Cylinder block inside diameter

CAMSHAFT Intake (A) Intake (B) Exhaust (A) Exhaust (B) Cylinder head journal diameter (driven gear end) Cylinder head journal diameter (center) Oil pump housing journal diameter (oil pump end) Camshaft round limit TIMING BELT Slack ROCKER ARM SHAFT Outside diameter ROCKER ARM Inside diameter VALVES Face angle Valve clearance (cold) Intake Exhaust

Head diameter (A) Intake Exhaust Face width (B) Intake Exhaust

F15AEP F15PR F15PR

Unit

mm (in)

F15AEHP F15PH F15PH 0.1 (0.004)

mm (in) mm (in) mm (in) mm (in)

59.000 - 59.015 (2.3228 - 2.3234) 0.08 (0.003) 0.05 (0.002) 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)

mm (in) mm (in) mm (in) mm (in) mm (in)

27.596 - 27.696 (1.0865 - 1.0904) 23.95 - 24.05 (0.9429 - 0.9468) 27.616 - 27.716 (1.0872 - 1.0912) 23.95 - 24.05 (0.9429 - 0.9468) 17.973 - 17.984 (0.7076 - 0.7080)

mm (in)

34.935 - 34.955 (1.3754 - 1.3762)

mm (in)

15.973 - 15.984 (0.6289 - 0.6293)

mm (in)

0.03 (0.001)

mm (in)

0 - 10 (0 - 0.4)

mm (in)

12.941 - 12.951 (0.5095 - 0.5099)

mm (in)

13.000 - 13.018 (0.5118 - 0.5125)

Degree

90.5 - 91.5

mm (in) mm (in)

0.15 - 0.25 (0.006 - 0.010) 0.20 - 0.30 (0.008 - 0.012)

mm (in) mm (in)

27.9 - 28.1 (1.10 - 1.11) 21.9 - 22.1 (0.86 - 0.87)

mm (in) mm (in)

2.0 - 3.1 (0.079 - 0.122) 2.0 - 3.1 (0.079 - 0.122)

5

MAINTENANCE SPECIFICATIONS

Item

World wide USA Canada

Seat width (C) Margin thickness (D) Intake Exhaust Stem outside diameter Intake Exhaust Guide inside diameter Stem-to-guide clearance Intake Exhaust Stem runout limit VALVE SPRING Free length Free length limit Set length Tilt limit PISTON Piston-to-cylinder clearance Piston diameter (D) Standard Measuring point (H) Pin boss inside diameter Oversize piston diameter 1st (except for USA) 2nd PISTON PIN Outside diameter PISTON RINGS Top ring Type Dimensions (B x T) End gap (installed) Wear limit Side clearance (installed) 2nd ring Type Dimensions (B x T) End gap (installed) Wear limit Side clearance (installed)

mm (in)

Model F15AEP F15AEHP F15PR F15PH F15PR F15PH 0.6 - 0.8 (0.02 - 0.03)

mm (in) mm (in)

0.50 - 0.90 (0.020 - 0.035) 0.50 - 0.90 (0.020 - 0.035)

mm (in) mm (in) mm (in)

5.475 - 5.490 (0.2155 - 0.2161) 5.460 - 5.475 (0.2150 - 0.2156) 5.500 - 5.512 (0.2165 - 0.2170)

mm (in) mm (in) mm (in)

0.010 - 0.037 (0.0004 - 0.0015) 0.025 - 0.052 (0.0010 - 0.0020) 0.016 (0.0006)

mm (in) mm (in) mm/kg (in/lb) mm (in)

34.4 (1.35) 32.7 (1.29) 25.4 / 11.0 (1.00 / 24.2) 1.5 (0.06)

mm (in)

0.035 - 0.065 (0.0014 - 0.0026)

mm (in) mm (in) mm (in)

58.950 - 58.965 (2.3206 - 2.3215) 5 (0.20) 14.004 - 14.015 (0.5513 - 0.5518)

mm (in) mm (in)

59.25 (2.333) 59.50 (2.343)

mm (in)

13.996 - 14.000 (0.5510 - 0.5512)

mm (in) mm (in) mm (in) mm (in)

Barrel 1.2 x 2.25 (0.05 x 0.09) 0.15 - 0.30 (0.006 - 0.012) 0.50 (0.020) 0.013 - 0.035 (0.0005 - 0.0013)

mm (in) mm (in) mm (in) mm (in)

Plain 1.5 x 2.6 (0.06 x 0.10) 0.30 - 0.50 (0.012 - 0.020) 0.70 (0.028) 0.02 - 0.04 (0.001 - 0.002)

Unit

6

MAINTENANCE SPECIFICATIONS Model Item

World wide USA Canada

Oil ring Dimensions (B x T) End gap (installed) Wear limit CONNECTING ROD Small end inside diameter Big end oil clearance CRANKSHAFT Crankshaft width Crankshaft big end side clearance Crankcase mark-bearing color Crankshaft journal clearance Runout limit THERMOSTAT ID mark Valve opening temperature Full-open temperature Valve lift FUEL PUMP Discharge

Pressure Diaphragm stroke Plunger stroke OIL PUMP Type

F15AEP F15PR F15PR

Unit

F15AEHP F15PH F15PH

mm (in) mm (in) mm (in)

2.4 x 2.45 (0.09 x 0.10) 0.2 - 0.7 (0.008 - 0.028) 0.9 (0.04)

mm (in) mm (in)

14.015 - 14.029 (0.5518 - 0.5523) 0.021 - 0.045 (0.0008 - 0.0018)

mm (in) mm (in) mm (in) mm (in)

126.70 - 126.90 (4.99 - 5.00) 0.05 - 0.22 (0.002 - 0.009) A:Blue B:Black C:Brown 0.012 - 0.045 (0.0005 - 0.0018) 0.03 (0.0012)

°C (°F) °C (°F) mm (in)

S60°C 58 - 62 (136.4 - 143.6) 70 (158) 3 (0.12)

L (US gal, lmp gal)/h @ 3,000 r/min kPa (kg/cm2, psi) mm (in) mm (in)

25 (6.60, 5.50)

117.6 (1.2, 17.07) 2.4 - 4.8 (0.094 - 0.189) 3.52 - 6.57 (0.139 - 0.259) Trochoid

Outer rotor-to-housing clearance a mm (in) Outer rotor-to-inner rotor clearance b mm (in) mm (in) Rotor-to-cover clearance c Relief valve operating pressure kPa (kg/cm2, psi) CARBURETOR ID mark Main jet # Pilot jet # Float height a mm (in) Idle speed r/min Trolling speed r/min

7

0.10 - 0.15 (0.004 - 0.006) 0.04 - 0.14 (0.002 - 0.006) 0.03 - 0.09 (0.001 - 0.004) 388 - 450 (3.88 - 4.50, 55.2 - 64.0) 66M10 104 45 9.5 - 10.5 (0.37 - 0.41) 900 - 1,000 800 - 900

MAINTENANCE SPECIFICATIONS LOWER Model World wide Item USA Canada GEAR BACKLASH (SST indicator) Pinion-forward Minimum Mid-point Maximum Pinion-reverse Minimum Mid-point Maximum Pinion shim Forward shim Reverse shim TEST PROPELLER Test propeller Specific revolution

F15AEP F15PR F15PR

Unit

F15AEHP F15PH F15PH

mm (in) mm (in) mm (in)

0.19 (0.007) 0.53 (0.02) 0.86 (0.034)

mm (in) mm (in) mm (in) mm mm mm

0.95 (0.037) 1.30 (0.051) 1.65 (0.064) 1.13 / 1.2 0.10 / 0.12 / 0.15 / 0.18 / 0.30 / 0.40 / 0.50 0.1 / 0.2 / 0.3 / 0.4 / 0.5

Part no. r/min

YB - 1619 / 90890-01619 5,200 - 5,400

ELECTRICAL Model Item

World wide USA Canada

IGNITION SYSTEM Ignition timing Charge coil output peak voltage (Br-L) @ cranking 1 (500 r/min) open @ cranking 2 (500 r/min) loaded @ 1,500 r/min @ 3,500 r/min Pulser coil output peak voltage (W/G-B) @ cranking 1 (500 r/min) open @ cranking 2 (500 r/min) loaded @ 1,500 r/min @ 3,500 r/min CDI unit output peak voltage (O-B) @ cranking 1 (500 r/min) open @ cranking 2 (500 r/min) loaded @ 1,500 r/min @ 3,500 r/min Spark plug gap

F15AEP F15PR F15PR

Unit

F15AEHP F15PH F15PH

Degree (BTDC)

5 - 30

V V V V

130 130 180 180

V V V V

4.0 3.5 11.0 23.0

V V V V mm (in)

120 120 165 165 0.9 (0.04)

8

MAINTENANCE SPECIFICATIONS Model World wide Item Unit USA Canada Charge coil resistance (Br-L) Ω Pulser coil resistance (W/G-B) Ω Ignition coil resistance (O-B) Ω Primary Secondary kΩ IGNITION CONTROL SYSTEM Oil pressure switch kPa (kg/cm2, psi) Engine speed limiter Rated timing r/min Ignition off r/min Reset r/min STARTING SYSTEM Fuse A STARTER MOTOR Type Rating Second Output kW Brush length mm (in) Limit mm (in) Commutator undercut mm (in) Limit mm (in) CHARGING SYSTEM Lighting coil output peak voltage V1 (G-G/W) @ cranking 1 (500 r/min) open V @ cranking 2 (500 r/min) loaded V @ 1,500 r/min V @ 3,500 r/min V Rectifier output peak voltage V2 (R-B) @ cranking (500 r/min) open V @ 1,500 r/min V @ 3,500 r/min V Charging current A@ r/min Ω@20°C (68°F) Lighting coil resistance (G-G/W)

9

F15AEP F15PR F15PR

F15AEHP F15PH F15PH 272 - 408 234 - 348 0.16 - 0.24 3.92 - 5.88 14.7 (0.15, 2.13) 6,200 6,800 6,000 20 Bendix 30 1.1 12.6 (0.5) 6.4 (0.25) 2 (0.08) 0.8 (0.03)

6.5 6.0 21 46

6.0 20 45 10 @ 5,000 0.24 - 0.36

MAINTENANCE SPECIFICATIONS Model World wide Item USA Canada POWER TILT (PT) UNIT Fluid type Brush length Limit Commutator diameter Limit

F15AEP F15PR F15PR

Unit

F15AEHP F15PH F15PH ATF Dexroin ll 6 (0.25) 3 (0.12) 16.5 (0.65) 15.5 (0.61)

mm (in) mm (in) mm (in) mm (in)

10

MAINTENANCE SPECIFICATIONS DIMENSIONS

Symbol World wide USA Canada L1 L2 L3 L4 L6 L7 H1 H2 H3 H4 H6 H7 H8 H9 W1 W5 W6 A1 A2 A3

Model Unit mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) Degree Degree Degree

F15AEP F15PR F15PR 483 (19.0) 152 (6.0) – 363 (14.3) 840 (33.1) 308 (12.1) 835 (32.9) 372 (14.7) 135 (5.3) 570 (22.4) 641 (25.2) 261 (10.3) – 587 (23.1) 182 (7.2) 329 (13.0) – 40 63 12

11

F15AEHP F15PH F15PH 483 (19.0) 160 (6.3) 517 (20.4) 363 (14.3) 840 (33.1) 308 (12.1) 835 (32.9) 372 (14.7) 135 (5.3) 570 (22.4) 641 (25.2) 261 (10.3) 12 (0.5) 587 (23.1) 182 (7.2) 329 (13.0) 575 (22.6) 40 63 12

MAINTENANCE SPECIFICATIONS

Symbol World wide USA Canada B1 B2 B3 B4 B5 B6 B9 D1 D2 C1 C2

Model Unit

F15AEP F15PR F15PR

mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in)

F15AEHP F15PH F15PH 95.3 (3.8) 92.4 (3.6) 95.3 (3.8) 94.5 (3.7) 111 (4.4) 326.7 (12.9) 18 (0.7) 8.3 (0.3) 10 (0.4) 40 (1.6) 66 (2.6)

12

TIGHTENING TORQUES TIGHTENING TORQUES SPECIFIED TORQUES Part to be tightened POWER UNIT Power unit mounting Flywheel Carburetor Oil filter Oil filter plug (cylinder block) Spark plug Drive sprocket Driven sprocket Cylinder head cover Cylinder head

1st 2nd 1st 2nd

Valve adjusting screw Oil pump Oil pump cover Exhaust cover

Crankcase

Connecting rod Anode cover Starter motor mounting LOWER UNIT Propeller Lower unit mounting Pinion gear nut BRACKET Tiller handle mounting (pivot) Tiller handle mounting locknut (pivot) Water flushing adapter Bottom cowling Steering friction piece Tilt stop lever Upper rubber mounting Lower rubber mounting Clamp bracket Clamp bracket - upper (PT) Clamp bracket - lower (PT) Upper casing Oil drain plug Exhaust manifold Water inlet cover

1st 2nd 1st 2nd 1st 2nd 1st 2nd

Part name

Thread size

Q’ty

Bolt Nut Bolt – – – Nut Bolt Bolt

M8 M16 M6 – M20 M12 M28 M6 M6

6 1 2 1 1 2 1 1 4

Bolt

M8

6

Bolt

M6

3

– Bolt Screw

M6 M6 M6

4 3 2

Bolt

M6

7

Bolt

M8

4

Bolt

M6

6

Bolt

M7

4

Bolt Bolt

M5 M8

Nut Bolt Nut Nut Nut Bolt Bolt Bolt Bolt Nut Bolt/ Nut Nut Bolt Bolt Bolt Bolt Bolt Screw

13

Tightening torque N•m kgf m ft lb

1 3

21 110 10 18 40 18 55 13 8 15 30 6 12 14 8 4 6 12 15 30 6 12 10 22 5 29

2.1 11.0 1.0 1.8 4.0 1.8 5.5 1.3 0.8 1.5 3.0 0.6 1.2 1.4 0.8 0.4 0.6 1.2 1.5 3.0 0.6 1.2 1.0 2.2 0.5 2.9

15.2 80 7.2 13 29 13 39.8 9.4 5.8 10.8 22 4.5 8.7 10.0 5.8 2.9 4.5 8.7 10.8 22 4.5 8.7 7.2 16 3.6 21

M10 M8 M8

1 4 1

17 18 25

1.7 1.8 2.5

12.3 13 18

M10 M10 M6 M6 M6 M6 M8

1 1 1 4 1 4 2

10 23 10 8 4 8 21

1.0 2.3 1.0 0.8 0.4 0.8 2.1

7.2 16.6 7.2 5.8 2.9 5.8 15

M8

4

32

3.2

23

M22 M8 M8 M8 M14 M6 M5

2 2 2 6 1 2 1

12 24 18 18 27 11 5

1.2 2.4 1.8 1.8 2.7 1.1 0.5

8.7 17.7 13 13 19.5 8.0 3.6

TIGHTENING TORQUES Part to be tightened PT UNIT Reservoir cap PT motor Cylinder end screw Gear pump housing Tilt piston ELECTRICAL Starter motor Solenoid Solenoid mount bracket Lighting coil Oil pressure switch Rectifier/regulator Rectifier/regulator bracket Rectifier/regulator bracket ground

Nut (A)

Bolt (B)

8 mm 10 mm 12 mm 14 mm 17 mm

M5 M6 M8 M10 M12

Tightening torque N•m kgf m ft lb

Part name

Thread size

Q’ty

Bolt Bolt Screw Bolt –

M10 M5 M33 M5 M12

1 4 1 6 1

5 5 45 5 45

0.5 0.5 4.5 0.5 4.5

3.6 3.6 32 3.6 32

Bolt Screw Bolt Bolt Bolt Bolt Bolt Bolt

M8 M5 M6 M6 – M6 M6 M6

3 2 2 4 1 2 3 1

29 3 8 8 8 8 8 8

2.9 0.3 0.8 0.8 0.8 0.8 0.8 0.8

21 2.2 5.8 5.8 5.8 5.8 5.8 5.8

GENERAL TORQUES

General torque specifications N•m kgf•m ft lb 5 0.5 3.6 8 0.8 5.8 18 1.8 13 36 3.6 25 43 4.3 31

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.

14

MAINTENANCE INTERVAL CHART MAINTENANCE INTERVAL CHART Use the following chart as a guide to general maintenance intervals.

Dependant on operating conditions, adjust the maintenance intervals accordingly.

Item TOP COWLING: Water separator drain hole FUEL SYSTEM: Fuel line Fuel filter CONTROL SYSTEM: Throttle cables Remote control throttle cable Throttle link lever Remote control shift cable Shift cable Engine idling speed Start-in-gear protection device POWER UNIT: Engine oil Oil filter Timing belt Valve clearance Ignition timing Thermostat Water leakage Motor exterior Exhaust leakage Cooling water passage POWER TILT SYSTEM: Power tilt fluid LOWER UNIT: Gear oil Impeller Lower unit leakage Propeller GENERAL: Anode Battery Spark plug

Wiring and connector Bolts and nuts Lubrication points

Remarks

Initial Every 10 hours 50 hours 100 hours 200 hours (Brake-in) (3 months) (6 months) (1 year)

Check

Check Check/replace

Check/adjust Check/adjust Check/adjust Check/adjust Check/adjust Check/adjust Check/adjust Check/change Replace Check/replace Check/adjust Check Check/replace Check Check Check Check/clean Check/change

Change Check Check Check Check Check Cleaning/ adjust/ replace Adjust/ reconnect Tighten Lubricate

15

EVERY MONTH

POWER TILT SYSTEM/ GENERAL 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: Recommended hydraulic fluid: ATF Dexron ll Reservoir cap: 5 N•m (0.5 kgf•m, 3.6ft•lb)

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.

16

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

Step 1 2 3 4 5 6 7 8 9 10 11 12 13

Job/Part Bolt Fitting plate Battery cables Throttle cable Shift cable Shift link rod PT motor lead PT relay lead Remote control lead Fuse lead Trailer switch lead Fuel hose Pilot water hose

Q'ty 3 1 1 1 1 1 1 2 1 1 1 1 1

Remarks

Continued on next page.

17

POWER UNIT

Step Job/Part 14 Water flushing hose

Q'ty 1

Remarks

For installation, reverse the removal procedure.

18

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

Step 1 2 3 4 5 6 7 8 9 10 11 12 13

Job/Part Bolt Fitting plate Battery cables Throttle cable Shift link rod PT motor lead PT relay lead Engine stop switch lead Neutral switch lead Fuse lead Trailer switch lead Fuel hose Pilot water hose

Q'ty Remarks 3 1 1 2 1 1 2 1 1 1 1 (With trailer switch model only) 1 1 Continued on next page.

19

POWER UNIT

Step Job/Part 14 Water flushing hose

Q'ty 1

Remarks

For installation, reverse the removal procedure.

20

ELECTRICAL UNIT ELECTRICAL UNIT REMOVING/INSTALLING THE ELECTRICAL UNIT

Step 1 2 3 4 5 6 7 8 9 10 11 12 13

Job/Part Bolt Rectifier ground lead Bolt (with washer) Starter relay ground lead CDI unit ground lead Starter relay lead Screw (with washer) Oil pressure switch lead Ignition coil lead Bolt (with washer) Bracket Terminal ass'y Rubber

Q'ty 1 1 1 1 1 1 1 1 2 2 1 1 1

Remarks

Continued on next page.

21

ELECTRICAL UNIT

Step 14 15 16 17 18 19 20 21 22 23 24 25 26

Job/Part Starter relay Bolt Collar Grommet Bolt (with washer) Rectifier regulator ass'y Bracket Bolt CDI unit ass'y Bolt Bolt Nut Washer

Q'ty 1 3 2 2 2 1 1 2 1 1 1 1 1

Remarks

Continued on next page.

22

ELECTRICAL UNIT

Step 27 28 29 30 31

Job/Part Bolt Starter motor Oil pressure switch Bolt (with washer) Ignition coil ass’y

Q'ty 1 1 1 2 1

Remarks

For installation, reverse the removal procedure.

23

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

Step 1 2 3 4 5 6 7 8 9 10 11 12

Job/Part Spark plug Bolt (with washer) Cylinder head cover O-ring Bolt (with washer) Bolt Cylinder head assembly Dowel pin Gasket Bolt (with washer) Oil pump Oil pump gasket

Q'ty 2 4 1 1 3 6 1 2 1 3 1 1

24

Remarks

Not reusable

Not reusable

Not reusable For installation, reverse the removal procedure.

OIL PUMP OIL PUMP DISASSEMBLING/ASSEMBLING THE OIL PUMP

Step 1 2 3 4 5 6 7 8

Job/Part Screw Oil pump cover O-ring Inner rotor Shaft Pin Outer rotor Oil pump housing

Q'ty 2 1 1 1 1 1 1 1

Remarks

Not reusable

For installation, reverse the removal procedure.

25

CAMSHAFT AND VALVE CAMSHAFT AND VALVE REMOVING/INSTALLING THE CAMSHAFT AND VALVE

Step 1 2 3 4 5 6 7 8 9 10 11 12 13

Job/Part Locknut Valve adjusting screw Rocker arm shaft Spring 1 Spring 2 Collar Collar Collar Rocker arm Camshaft Valve cotter Valve spring seat (upper) Valve spring

Q'ty Remarks 4 4 2 1 3 1 Length: 15.0 mm (0.59 in) 1 Length: 22.5 mm (0.89 in) 1 Length: 8.5 mm (0.33 in) 4 1 8 4 4 Continued on next page.

26

CAMSHAFT AND VALVE

Step 14 15 16 17 18 19

Job/Part Intake valve Exhaust valve Valve spring seat (lower) Valve seal Oil seal Cylinder head

Q'ty 2 2 4 4 1 1

Remarks

Not reusable Not reusable

For installation, reverse the removal procedure.

27

CAMSHAFT AND VALVE 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)

28

CAMSHAFT AND VALVE REFACING THE VALVE SEAT IN

Reface: Valve seat

CAUTION:

c b

When turning the valve seat cutter, keep an even downward pressure (4 - 5 kg) to prevent chatter mark.

a

Valve seat width (intake valve and exhaust valve): 0.6 - 0.8 mm (0.02 - 0.03 in)

EX

Valve seat cutter set: 90890-06803 Valve seat cutter: 90890-06556 Valve seat lapper: 90890-06805 Cut section and seat cutter Seat Cut section Seat cutter a: 180° 180°: 90890-06556 IN b: 90° 90°: 90890-06312 c: 60° 60°: 90890-06315 a: 180° 170°: 90890-06313 b: 90° 90°: 90890-06312 EX c: 0° 60°: 90890-06315

c b

a

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

Refacing steps: A Valve seat is centered on valve face but it is too wide.

A

IN c

Valve seat cutter cutter (IN) a 180° 170° cutter (EX)

c a

EX a

c 60° cutter (IN/EX)

c a

29

Desired result Lap the face a and face c lightly to reduce the valve seat width.

CAMSHAFT AND VALVE B Valve seat is in the middle of the valve face but it is too narrow.

B

IN

Valve seat cutter

b 90° cutter (IN/EX)

b

b EX

Desired result Lap the face b to increase the valve seat width.

b

C Valve seat is too narrow and it is near the valve margin.

C

IN

Valve seat cutter b a

180° cutter (IN)

b

a 170° cutter (EX)

a

EX

b 90° cutter (IN/EX) b

a

D Valve seat is too narrow and it is near the valve stem.

D

IN

c

Valve seat cutter

c

b

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

c 60° cutter (IN/EX)

b EX

b 90° cutter (IN/EX)

c b

Desired result Lap the face c to center the valve seat and lap the face b to increase the valve seat width.

INSTALLING THE CAMSHAFT OIL SEAL Install: Cam shaft oil seal 1 Drive rod: YM-06071/90890-06652 Attachment: YB-06196/90890-06196

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

30

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

Step 1 2 3 4 5 6 7 8 9 10 11 12 13

Job/Part Oil filter Oil filter plug Bolt (with washer) Thermostat cover Thermostat gasket Thermostat Bolt (with washer) Exhaust cover Exhaust cover gasket Bolt (with washer) Breather cover Breather cover gasket Bolt (with washer)

Q'ty 1 1 2 1 1 1 5 1 1 3 1 1 1

Remarks

Not reusable

Not reusable

Not reusable Continued on next page.

31

OIL FILTER, THERMOSTAT AND EXHAUST COVER

Step 14 15 16 17 18

Job/Part Plate Anode cover Bolt (with washer) Grommet Anode

Q'ty 1 1 1 1 1

Remarks

For installation, reverse the removal procedure.

32

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

Step 1 2 3 4 5 6 7 8 9

Job/Part Throttle cable Engine stop switch lead PT switch lead Grommet Locknut Nut Plate Bushing Steering handle ass'y

Q'ty 2 1 1 1 1 1 1 1 1

Remarks

For installation, reverse the removal procedure.

33

STEERING HANDLE ASSEMBLY (F15AEHP/F15PH) DISASSEMBLING/ASSEMBLING THE STEERING HANDLE ASSEMBLY

Step 1 2 3 4 5 6 7 8 9 10 11 12 13

Job/Part Plate washer Plate washer Wave washer Plate washer Bushing Screw Clamp Stay Screw (with washer) PT switch ass'y Screw Steering grip Washer

Q'ty 1 1 2 1 1 3 1 1 2 1 1 1 1

Remarks

Continued on next page.

34

STEERING HANDLE ASSEMBLY (F15AEHP/F15PH)

Step 14 15 16 17 18 19 20 21 22 23 24

Job/Part Spring Bushing Bolt Stay Split pin Friction adjusting screw Friction piece Throttle cable Throttle shaft Engine stop switch Steering handle bracket

Q'ty 1 1 2 1 1 1 1 2 1 1 1

Remarks

For installation, reverse the removal procedure.

35

STEERING HANDLE ASSEMBLY (F15AEHP/F15PH) INSTALLING THE PT SWITCH 1. Install: PT switch

NOTE: Tighten the PT switch mounting screw in sequence

36

BOTTOM COWLING ASSEMBLY BOTTOM COWLING ASSEMBLY REMOVING/INSTALLING THE BOTTOM COWLING ASSEMBLY

Step 1 2 3 4 5 6 7 8 9 10 11 12 13

Job/Part Bolt Plate washer PT relay Collar Grommet Bolt (with washer) Bracket Gasket Trailer switch Hose Hose Hose Joint hose

Q'ty Remarks 2 2 1 2 2 2 1 1 1 1 (Bottom cowling - joint hose) 1 (Oil pan - joint hose) 1 (Exhaust cover - joint hose) 1 Continued on next page.

37

BOTTOM COWLING ASSEMBLY

Step 14 15 16 17 18 19 20 21 22 23 24 25 26

Job/Part Clamp Grommet PT motor lead Joint assembly Clamp Water flushing hose Bolt (with washer) Adapter Clip Washer Bolt (with washer) Collar Wave washer

Q'ty 1 1 1 1 1 1 1 1 1 1 1 1 1

Remarks

Continued on next page.

38

BOTTOM COWLING ASSEMBLY

Step 27 28 29 30 31 32 33 34 35

Job/Part Shift rod link Gear shift handle Shift rod nut Bolt (with washer) Bolt (with washer) Bottom cowling assembly Collar Grommet Rubber seal

Q'ty 1 1 1 2 2 1 4 4 1

Remarks

For installation, reverse the removal procedure.

39

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

Step 1 2 3 4 5 6 7 8 9 10 11 12 13

Job/Part Screw Wire lead Friction bolt Rubber seal Steering friction ass'y Steering bracket Washer Bushing Key Bushing O-ring Bushing Swivel bracket ass'y

Q'ty Remarks 2 1 1 1 1 (F15AEHP/F15PH only) 1 1 1 1 1 1 Not reusable 1 1 For installation, reverse the removal procedure.

40

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

Step 1 2 3 4 5 6 7 8 9 10 11 12 13

Job/Part PT motor lead Clamp Bolt (with washer) Circlip Pin Bushing Bushing Bolt Washer Pin Bushing Bushing Collar

Q'ty 1 1 1 1 1 1 2 2 2 1 2 1 1

Remarks

Continued on next page.

41

POWER TILT (PT) UNIT

Step Job/Part 14 Power tilt (PT) unit

Q'ty 1

Remarks

For installation, reverse the removal procedure.

42

POWER TILT (PT) UNIT DISASSEMBLING/ASSEMBLING THE POWER TILT (PT) CYLINDER

Step 1 2 3 4 5 6 7 8 9 10 11 12 13

Job/Part Tilt ram assembly Free piston O-ring Backing ring Cylinder case O-ring Cylinder O-ring O-ring Backup ring Tilt piston Ball Pin

Q'ty 1 1 1 1 1 1 1 1 1 1 1 1 1

Remarks

20.8 x 2.4 mm Not reusable

26.0 x 1.8 mm Not reusable 29.7 x 1.9 mm Not reusable 20.8 x 2.4 mm Not reusable

Continued on next page.

43

POWER TILT (PT) UNIT

Step 14 15 16 17 18 19 20

Job/Part Spring Dowel pin End screw O-ring Backup ring Dust seal Tilt ram

Q'ty Remarks 1 Outside diameter 6.8 x Length 13.5 mm 1 1 1 12.3 x 2.4 mm Not reusable 1 1 Not reusable 1

For installation, reverse the removal procedure.

44

POWER TILT (PT) UNIT 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 Power tilt wrench: YB-06560 / 90890-06560

2. Loosen: Tilt ram Power tilt wrench: YB-06560 / 90890-06560

NOTE:

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

45

POWER TILT (PT) UNIT ASSEMBLING THE POWER TILT (PT) CYLINDER 1. Tighten: Tilt ram Power tilt wrench: YB-06560 / 90890-06560

Tilt piston: 45 N•m (4.5 kgf•m, 32ft•lb)

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 %.

Recommended PT fluid: ATF Dexron II

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 End screw: 45 N•m (4.5 kgf•m, 32ft•lb)

46

POWER TILT (PT) UNIT 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.

Reservoir cap: 5 N•m (0.5 kgf•m, 3.6ft•lb)

(4) Close the manual valve 1.

47

POWER TILT (PT) UNIT (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.

Tilt ram

PT motor lead

Up

Blue Green

Battery terminal (+) (-)

(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 Up Down

48

PT motor lead Blue Green Green Blue

Battery terminal (+) (-) (+) (-)

POWER TILT (PT) UNIT (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.

49

POWER TILT (PT) UNIT DISASSEMBLING/ASSEMBLING THE VALVES AND PUMP 1

Step 1 2 3 4 5 6 7 8 9 10 11 12 13

Job/Part Reservoir cap O-ring Bolt PT motor O-ring O-ring Manual release rod Pin O-ring Sponge Spring Manual release pin Spring

Q'ty 1 1 4 1 1 1 1 1 1 1 2 2 2

50

Remarks 6.8 x 1.9 mm

Not reusable

21.7 x 3.5 mm Not reusable Not reusable

5.8 x 1.9 mm

Not reusable

Outside diameter 5.0 x Length 17.0 mm Outside diameter 5.7 x Length 17.2 mm Continued on next page.

POWER TILT (PT) UNIT

Step 14 15 16 17 18 19

Job/Part Absorver valve pin Ball Spring Spring Valve pin Valve seal

Q'ty Remarks 2 2 2 Outside diameter 7.6 x Length 14.5 mm 1 Outside diameter 8.8 x Length 18.1 mm 2 2

For installation, reverse the removal procedure.

51

POWER TILT (PT) UNIT 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.

52

POWER TILT (PT) UNIT DISASSEMBLING/ASSEMBLING THE PT MOTOR

Step 1 2 3 4 5 6 7 8 9 10

Job/Part Screw (with washer) Yoke assembly O-ring Screw (with washer) Armatuer Screw (with washer) Brush Brush spring Oil seal End frame

Q'ty Remarks 2 1 43.9 x 1.5 mm Not reusable 1 1 1 2 2 2 1 Not reusable 1

For installation, reverse the removal procedure.

53

POWER TILT (PT) UNIT 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)

54

POWER TILT (PT) UNIT 4. Measure: Armature coil continuity Out of specification Replace.

Armature coil continuity Commutator segments

Continuity

Segment - laminations

No continuity

Segment - shaft

No continuity

5. Measure: Brush length a Out of specification Replace.

Brush length limit: 3 mm (0.12 in)

6. Check: End frame Cracks/damage Replace.

7. Check: Yoke bushing Cracks/damage Replace.

8. Check: Oil seal Damage/wear Replace.

55

POWER TILT (PT) UNIT CHECKING THE PT MOTOR ASSEMBLY 1. Check: PT motor operation Incorrect operation Repair.

PT motor operation Blue (+), Green (-)

Motor turns clockwise

Green (+), Blue (-)

Motor turns counterclockwise

INSTALLING THE OIL SEAL 1. Install: Oil seal Oil seal attachment: YB-06112/90890-06614 Driver rod: YB-06071/90890-06652

56

POWER TILT (PT) UNIT DISASSEMBLING/ASSEMBLING THE VALVES AND PUMP 2

Step 1 2 3 4 5 6 7 8 9 10 11 12 13

Job/Part Bolt Gear housing Gear Dowel pin Top chamber shuttle piston O-ring Spring Bottom chamber shuttle piston Circlip Valve seal Valve seat O-ring Main valve

Q'ty Remarks 6 1 2 4 1 1 8.5 x 1.5 mm Not reusable 2 Outside diameter 2.5 x Length 10.0 mm 1 2 2 2 2 11.5 x 1.5 mm Not reusable 2 Continued on next page.

57

POWER TILT (PT) UNIT

Step 14 15 16 17 18

Job/Part Spring Filter O-ring Ball Spring

Q'ty Remarks 2 Outside diameter 4.1 x Length 12.0 mm 2 2 8.5 x 1.5 mm Not reusable 2 2 Outside diameter 3.2 x Length 8.0 mm

For installation, reverse the removal procedure.

58

CLAMP BRACKET CLAMP BRACKET REMOVING/INSTALLING THE CLAMP BRACKET

Step 1 2 3 4 5 6 7 8 9 10 11 12 13

Job/Part Bolt (with washer) Bolt Wire lead Anode Screw Wire lead Cap nut Clamp bracket cap Clamp bracket plate Spring pin Stopper knob Stopper shaft Bushing

Q'ty 1 2 1 1 1 1 2 2 1 1 1 1 1

Remarks

Continued on next page.

59

CLAMP BRACKET

Step 14 15 16 17 18 19 20 21 22 23 24

Job/Part Nut Washer Bolt Bolt Clamp bracket bolt Clamp bracket Swivel bracket Clamp bracket Bushing Plug Grease nipple

Q'ty 2 2 2 1 1 1 1 1 2 2 1

Remarks

For installation, reverse the removal procedure.

60

ELECTRICAL COMPONENTS ELECTRICAL COMPONENTS (Top view and port side view)

1 2 3 4 5 6 7 8 9 0 A B

CDI unit Rectifier regulator Pulser coil PT terminal Lighting coil Charge coil Oil pressure switch Starter relay Starter motor PT relay Ignition coil Spark plugs

A B

C

D E

61

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

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

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

Install the connector in the proper direction as shown.

Pass each high tension cord through the grommet.

ELECTRICAL COMPONENTS (Front view) (F15AEP/F15PH)

1 2 3 4 5 6 7

Pulser coil CDI unit lead PT terminal Starter relay Starter motor Fuse Battery cable

A B C D

E F G H I J

To the lighting coil.

To the emergency signal light.

To the starter switch.

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

CDI unit leads.

To the PT motor.

To the PT relay.

To the handle PT switch.

Clamp the fuse holder to the battery cable.

To the neutral switch.

62

K L M N

To the rectifier regulator To the battery cable.

To the stop switch.

Mount the rectifier regulator ground lead.

ELECTRICAL COMPONENTS (Front view) (F15AEHP/F15PH)

1 2 3 4 5 6 7 8 9

Pulser coil CDI unit lead PT terminal Starter relay Starter motor Fuse Battery cable Wire harness Choke solenoid

A B C

D E F G H I

63

To the lighting coil.

To the emergency signal light.

Mount the starter relay ground lead along with the CDI unit ground lead and the wire harness ground lead.

CDI unit leads.

To the PT motor.

To the PT relay.

Clamp the fuse holder to the battery cable.

To the rectifier regulator.

Mount with the rectifier regulator ground lead and the choke solenoid ground lead.

STARTER MOTOR STARTER MOTOR DISASSEMBLING/ASSEMBLING THE STARTER MOTOR

Step 1 2 3 4 5 6 7 8 9 10 11 12 13

Job/Part Bolt Stator Cap Pinion nut Washer Spring Pinion stopper Pinion gear Front bracket Washer Armature Bolt Brush

Q'ty 2 1 1 1 1 1 1 1 1 1 1 2 2

Remarks

Continued on next page.

64

STARTER MOTOR

Step 14 15 16 17 18 19 20 21

Job/Part Spring Brush holder Nut Nut Washer Rubber plate Brush set Rear bracket

Q'ty 4 1 1 1 1 1 1 1

Remarks

For installation, reverse the removal procedure.

65

STARTER MOTOR 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 Out of specification Replace.

Commutator undercut limit: 0.8 mm (0.03 in)

2. Check: Armature coil continuity Out of specification Replace.

Armature coil continuity: Commutator segments

a

Segment - Armature core b

Continuity No continuity

Segment - Armature Shaft c No continuity

66

STARTER MOTOR CHECKING THE BRUSH HOLDER 1. Measure: Brush length a Out of specification Replace.

Brush length limit: 6.4 mm (0.25 in)

2. Check: Brush unit continuity Out of specification Replace.

Brush unit continuity:

67

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 POWER TILT (PT) SYSTEM POWER TILT (PT) SYSTEM (F15AEP/F15PR)

1 2 3 4 5 6

Battery Fuse Trailer switch PT relay Terminal PT motor

B G L Lg R Sb

68

: Black : Green : Blue : Light green : Red : Sky blue

POWER TILT (PT) SYSTEM POWER TILT (PT) SYSTEM POWER TILT (PT) SYSTEM (F15AEHP/F15PH)

1 2 3 4 5 6

Battery Terminal PT relay PT motor PT switch Trailer switch

A

With trailer switch model To starter relay To PT relay Without trailer switch model

B C D

B G L Lg R Sb

69

: Black : Green : Blue : Light green : Red : Sky blue

POWER TILT (PT) SYSTEM CHECKING THE PT SWITCH Check: PT switch continuity Out of specification Replace.

Leads color Switch position Up Free Down

Sky blue (Sb)

Red (R)

Light green (Lg)

CHECKING THE TRAILER SWITCH Check: Bottom cowling PT switch continuity Out of specification Replace.

Leads color Switch position Up Free Down

Sky blue (Sb)

Red (R)

Light green (Lg)

CHECKING THE PT RELAY 1. Check: PT relay continuity Out of specification Replace.

PT relay continuity Sky blue (Sb) - Black (B) Light green (Lg) - Black (B) Blue (L) - Black (B) Green (G) - Black (B) Blue (L) - Red (R) Green (G) - Red (R) A

70

To battery

Continuity Continuity No continuity

POWER TILT (PT) SYSTEM 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.

Sky blue (Sb) lead Positive terminal Black (B) lead Negative terminal (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.

Light green (Lg) lead Positive terminal Black (B) lead Negative terminal (6) Check that there is continuity between the PT relay terminals.

71

TROUBLE ANALYSIS TROUBLE ANALYSIS 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 ANALYSIS CHART

POOR BATTERY CHARGING

IRREGULAR WARNING INDICATION

HARD SHIFTING

Check element

PT MOTOR WILL NOT RUN

LOOSE TILT HOLDING

LOOSE STEERING

OVERHEATING

POOR PERFORMANCE

ENGINE WILL NOT STOP

ENGINE STALLS

ROUGH IDLING

ENGINE WILL NOT START

Trouble mode

Relative part

FUEL SYSTEM Fuel hose Fuel joint Fuel filter Fuel pump Carburetor Idle speed Pilot jet Throttle cable POWER UNIT Spark plugs Compression Timing belt Valve clearance Intake and exhaust valve Intake and exhaust valve seat Cylinder head gasket Piston rings Pistons Thermostat Water passage

72

Reference chapter

4 4 4 4 4 4 3 4 3 5 5 5 5 5 5 5 5 5 5

TROUBLE ANALYSIS

POOR BATTERY CHARGING

IRREGULAR WARNING INDICATION

HARD SHIFTING

Check element

PT MOTOR WILL NOT RUN

LOOSE TILT HOLDING

LOOSE STEERING

OVERHEATING

POOR PERFORMANCE

ENGINE WILL NOT STOP

ENGINE STALLS

ROUGH IDLING

ENGINE WILL NOT START

Trouble mode

Relative part

LOWER UNIT Neutral position Clutch Gears Water inlet Water pump Propeller shaft and propeller Shifter/Pin Shift cam Shift rod or Shift cable Lower case Shim adjustment BRACKET UNIT Bracket Mount rubber Steering friction ass’y PT UNIT Fluid level Manual valve Fluid passage PT motor ELECTRICAL Ignition coil Ignition control system Starting system Charging system PT control system

73

Reference chapter

6 6 6 6 6 6 6 6 6 6 6 7 7 7 7 7 7 7 8 8 8 8 8

YAMAHA MOTOR CO., LTD. Printed in USA Apr. 2000 - x 1 (F15AEP, F15AEHP)

Printed on recycled paper

WIRING DIAGRAM

F15AEP/F15PR B: Br: G: L: Lg O: P: R: Sb: W: P/W: W/G: Y/R: G/W:

B R R

R

R

B

5 Fuse(20A)

7 Starting motor

6 Starter relay R B

-

R B

R

3 Emergency signal light

+

4 Rectifier/ regulator

R

Y/R G

2 Battery

G G/W

G/W

P/W

8 Lighting coil

B

B

9 Charge coil 10 Oil pressure switch

11 Pulser

coil

12 Ignition coil

W/G B

18 Fuel enrich

solenoid

Black Brown Green Blue Light green Orange Pink Red Sky blue White Pink/white White/green Yellow/red Green/white

1 CDI unit 13 Terminal ass'y Y/R P/W

W B

O P

L Br B W/G B

Br

B B L

R R G Br L

P

16 Spark

O B

L

L

G

G

plugs B

B

Y/R P/W Br

W

B W/G

L

R

G Br L

P

O B

R G

W

B

Br

L

R

G

B L

G

R

W

Lg

15 PT relay

B

L

L R Sb L

Br

Lg

G Sb

Sb

Lg

Lg

B

Sb

Lg

R

Lg

Sb Sb

17 Trailer switch

UP FREE DOWN

R

Lg

Sb

Lg

Sb Lg Sb

R Sb Lg

G

Lg

14 PT motor

WIRING DIAGRAM

F15AEHP/F15PH

B R R

5 Fuse(20A) B

R

R

3 Starter switch

7 Starting motor

R R

Br B

R

-

+

6 Starter relay B

R G

4 Rectifier/ regulator

G

G

G/W

G/W

13 Terminal ass'y

8 Lighting coil

2 Battery B

D Without trailer switch model 9 Charge coil 10 Oil pressure R switch Lg Lg

11 Pulser coil W/G

20 Emargency

L

G

G

B

B

signal light

L

12 Ignition coil

1 CDI unit

Sb P/W

Y/R Y/R P/W

W B

O P

L Br B W/G B

B

B

Br Br Lg Sb

16 Spark Br L

P

O B

Br L

P

O B

plugs

Br Br Y/R P/W

W

B W/G R Sb Lg

B

B Sb

R

L

G

Lg

L

UP FREE DOWN

G

15 PT

17 PT switch

A With trailer switch model

R

Sb

Lg

relay

B To starter relay Lg

R

Sb

Sb

Lg

R

Sb

17 PT switch

Lg

Lg

21 Trailer

switch

19 Neutral switch

Sb

Sb

Lg

Lg Sb

R Sb Lg

Sb Lg

Lg

C To PT relay

Br

W Br

14 PT motor

18 Engine stop switch B

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

Black Brown Green Blue Light green Orange Pink Red Sky blue White

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

Pink/white White/green Yellow/red Green/white