YAMAHA F4B F5A F6C OUTBOARD Workshop Service Repair Manual

SERVICE MANUAL 6BV-28197-3M-11 F4B F5A F6C

Preface This manual has been prepared by Yamaha primarily for use by Yamaha dealers and their trained mechanics when performing maintenance procedures and repairs to Yamaha equipment. It has been written to suit the needs of persons who have the Bronze Technical Certificate of the YTA (Yamaha Technical Academy) marine or the equivalent basic understanding of the mechanical and electrical concepts and procedures inherent in the work, for without such knowledge attempted repairs or service to the equipment could render it unsafe or unfit for use. Because Yamaha has a policy of continuously improving its products, models may differ in detail from the descriptions and illustrations given in this publication. Use only the latest edition of this manual. Authorized Yamaha dealers are notified periodically of modifications and significant changes in specifications and procedures, and these are incorporated in successive editions of this manual. Also, up-to-date parts information is available on YPEC-web. Additional information and up- to-date information on Yamaha products and services are available on Yamaha Service Portal. Important information Particularly important information is distinguished in this manual by the following notations: The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! A WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury. A NOTICE indicates special precautions that must be taken to avoid damages to the outboard motor or other property. TIP: A TIP provides key information to make procedures easier or clearer. F4B, F5A, F6C SERVICE MANUAL ©2009 by Yamaha Motor Co., Ltd. 1st Edition, August 2009 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited.

Contents General information GEN INFO 0 Specification SPEC 1 Technical features and description TECH FEA 2 Rigging information RIG GING 3 Troubleshooting TRBL SHTG 4 Electrical system ELEC 5 Fuel system FUEL 6 Power unit POWR 7 Lower unit LOWR 8 Bracket unit BRKT 9 Maintenance MNT 10 Index Appendix A

GEN INFO 0 1 2 3 4 5 6 7 8 9 10 A General information 0 Safety while working .................................................... 0-1 Rotating part .............................................................................. 0-1 Hot part ...................................................................................... 0-1 Electric shock ............................................................................ 0-1 Propeller .................................................................................... 0-1 Handling of gasoline .................................................................. 0-1 Ventilation .................................................................................. 0-1 Self-protection ........................................................................... 0-2 Working with crane .................................................................... 0-2 Part, lubricant, and sealant ........................................................ 0-2 Handling of sealant .................................................................... 0-2 Special service tool ................................................................... 0-2 Tightening torque ...................................................................... 0-3 Non-reusable part ...................................................................... 0-3 Disassembly and assembly ....................................................... 0-3 How to use this manual .................................................... 0-4 Manual format ........................................................................... 0-4 Abbreviation .............................................................................. 0-5 Lubricant, sealant, and thread locking agent ................. 0-6 Symbol ...................................................................................... 0-6 Special service tool ........................................................... 0-7

0-1 GEN INFO General information Safety while working To prevent an accident or injury and to pro- vide quality service, observe the following safety procedures. Rotating part • Hands, feet, hair, jewelry, clothing, personal flotation device straps, and so on, can become entangled with internal rotating parts of the engine, resulting in serious injury or death. • Keep the top cowling installed whenever possible. Do not remove or install the top cowling when the engine is running. • Only operate the engine with the top cowling removed according to the specific instructions in the manual. Keep hands, feet, hair, jewelry, clothing, personal flotation device straps, and so on, away from any exposed moving parts. Hot part During and after operation, engine parts are hot enough to cause burns. Do not touch any parts under the top cowling until the engine has cooled. Electric shock Do not touch any electrical parts while starting or operating the engine. Otherwise, shock or electrocution could result. Propeller Do not hold the propeller with your hands when loosening or tightening the propeller nut. Handling of gasoline • Gasoline is highly flammable. Keep gasoline and all flammable products away from heat, sparks, and open flames. • Gasoline is poisonous and can cause injury or death. Handle gasoline with care. Never siphon gasoline by mouth. If you swallow some gasoline, inhale a lot of gasoline vapor, or get some gasoline in your eyes, see your doctor immediately. If gasoline spills on your skin, wash with soap and water. If gasoline spills on your clothing, change your clothes. Ventilation • Gasoline vapor and exhaust gas are heavier than air and extremely poisonous. If gasoline vapor or exhaust gas is inhaled in large quantities, it may cause loss of con- sciousness and death within a short time. • When test running an engine indoors (for example, in a water tank) make sure to do so where adequate ventilation can be maintained.

0-2 Safety while working 0 1 2 3 4 5 6 7 8 9 10 A Self-protection • Protect your eyes by wearing safety glasses or safety goggles during all opera- tions involving drilling and grinding, or when using an air compressor. • Protect your hands and feet by wearing protective gloves and safety shoes when necessary. Working with crane • Outboard motors weighing 18.0 kg (39.7 lb) and over must be carried by a crane. • Use the wire ropes of adequate strength, and lift up the outboard motor using the three point suspension. • If the outboard motor does not have three or more points to be suspended, support it using additional ropes or the like so that the outboard motor can be lifted and carried in a stable manner. Part, lubricant, and sealant Use only genuine Yamaha parts, lubricants, and sealants, or those recommended by Yamaha, when servicing or repairing the outboard motor. Handling of sealant • Wear protective gloves to protect your skin, when using the sealants. • See the material safety data sheet issued by the manufacturer. Some of the sealants may be harmful to human health. Special service tool Use the recommended special service tools to work safely, and to protect parts from damage.

0-3 GEN INFO General information Tightening torque Follow the tightening torque specifications provided throughout the manual. When tightening nuts, bolts, and screws, tighten the large sizes first, and tighten fasteners starting in the center and moving outward. Non-reusable part Always use new gaskets, seals, O-rings, cot- ter pins, and so on, when installing or assembling parts. Disassembly and assembly • Use compressed air to remove dust and dirt during disassembly. • Apply engine oil to the contact surfaces of moving parts before assembly. • Install bearings so that the bearing identifi- cation mark is facing in the direction indi- cated in the installation procedure. In addition, make sure to lubricate the bearings liberally. • Apply a thin coat of water resistant grease to the lip and periphery of an oil seal before installation. • Check that moving parts operate normally after assembly.

0-4 0 1 2 3 4 5 6 7 8 9 10 A How to use this manual Manual format The format of this manual has been designed to make service procedures clear and easy to under- stand. Use the following information as a guide for effective and quality service. • Parts are shown and detailed in an exploded diagram and are listed in the component list (see a in the following figure for an example page). • The component list consists of part names and quantities, as well as bolt and screw dimensions (see b in the following figure). • Symbols are used to indicate important aspects of a procedure, such as the grade of lubricant and the lubrication points (see c in the following figure). • Tightening torque specifications are provided in the exploded diagrams (see d in the following figure), and in the related detailed instructions. Some torque specifications are listed in stages as torque figures or angles in degrees. • Separate procedures and illustrations are used to explain the details of removal, checking, and installation where necessary (see e in the following figure for an example page). TIP: For troubleshooting procedures, see Chapter 4, “Troubleshooting.” 8-1 LOWR Lower unit Lower unit s k r a m e R y t ’ Q e m a n t r a P . o N 2 r e v o C 1 6 M 1 t l o b t n i o j t f i h S 2 20 mm 1 t n i o J 3 1 t n i o J 4 1 w e r c s k c e h C 5 3 t e k s a G 6 1 w e r c s g n i h s u l F 7 2 l e w o D 8 1 n i p r e t t o C 9 1 t u n r e l l e p o r P 0 1 1 r e h s a W 1 1 1 r e l l e p o r P 2 1 1 r e c a p S 3 1 14 Lower case mounting bolt 2 M6 40 mm 1 r e h s a w k c o L 5 1 6 M 1 t l o B 6 1 20 mm 1 e d o n A 7 1 A 1 1 2 3 4 23 8 8 23 22 21 19 19 5 6 11 14 14 18 6 17 15 16 13 12 11 10 9 16 N·m (1.6 kgf·m, 11.8 ft·lb) 15N·m (1.5 kgf·m, 11.1 ft·lb) 11N·m (1.1 kgf·m, 8.1 ft·lb) 9 N·m (0.9 kgf·m, 6.6 ft·lb) 9 N·m (0.9 kgf·m, 6.6 ft·lb) 9 N·m (0.9 kgf·m, 6.6 ft·lb) 7 6 20 11N·m (1.1 kgf·m, 8.1 ft·lb) A L-transom model 8-15 LOWR Lower unit TIP: While turning the drive shaft clockwise, push down on the water pump housing and install water pump housing. 8. Install the plates m and rubber seal n. Checking the lower unit for air leakage 1. Install new gaskets a, the drain screw b and the flushing screw c. 2. Tighten the drain screw b and flushing screw c to the specified torque. 3. Install the special service tool d. 4. Apply the specified pressure to check that the pressure is maintained in the lower unit for at least 10 seconds. NOTICE: Do not over pressurize the lower unit. Otherwise, the oil seals could be damaged. 5. If the specified pressure cannot be maintained, check the drive shaft, propeller shaft, and rubber seal for bends or damage, and check the shift rod rubber seal for damage or wear. Assembling the extension (L- transom model) 1. Install the bushing a and circlip b. Drain screw b: 9 N·m (0.9 kgf·m, 6.6 ft·lb) Flushing screw c: 9 N·m (0.9 kgf·m, 6.6 ft·lb) n m m c a b a Leakage tester d: 90890-06840 Holding pressure: 98.0 kPa (0.98 kgf/cm 2 , 14.2 psi) Driver rod L3 c: 90890-06652 Needle bearing attachment d: 90890-06615 d c d a a c d b e b c d a Safety while working / How to use this manual

0-5 GEN INFO General information Abbreviation The following abbreviations are used in this service manual. Abbreviation Description API American Petroleum Institute BTDC Before Top Dead Center CCA Cold Cranking Ampere CDI Capacitor Discharge Ignition EN European Norm (European standard) F Forward IEC International Electrotechnical Commission N Neutral OHV Overhead Valve PORT Port side R Reverse RON Research Octane Number STBD Starboard side TDC Top Dead Center

YAMAHA F4B F5A F6C OUTBOARD Workshop Service Repair Manual

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