Yamaha F100C User manual

SERVICE MANUAL
60C-28197-5D-11
290429
F100B
F100C

NOTICE
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 a 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.
Important information 1
Particularly important information is distinguished in this manual by the following notations:
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 out-
board motor.
NOTE:
A NOTE provides key information to make procedures easier or clearer.
F100B, F100C
SERVICE MANUAL
©2001 by Yamaha Motor Co., Ltd.
1st Edition, June 2001
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
Printed in the Netherlands

Contents
General information 1
GEN
INFO
Specifications 2
SPEC
Periodic checks and adjustments 3
CHK
ADJ
Fuel system 4
FUEL
Power unit 5
POWR
Lower unit 6
LOWR
Bracket unit 7
BRKT
Electrical systems 8
ELEC
Troubleshooting 9
TRBL
SHTG
Index
–+

GEN
INFO
60C5D11
General information
How to use this manual.................................................................................1-1
Manual format............................................................................................1-1
Symbols.....................................................................................................1-2
Safety while working......................................................................................1-3
Fire prevention...........................................................................................1-3
Ventilation..................................................................................................1-3
Self-protection ...........................................................................................1-3
Parts, lubricants, and sealants ..................................................................1-3
Good working practices .............................................................................1-4
Disassembly and assembly .......................................................................1-4
Identification...................................................................................................1-5
Applicable models .....................................................................................1-5
Serial number ............................................................................................1-5
Features and benefits....................................................................................1-6
Power unit..................................................................................................1-6
Ignition system.........................................................................................1-11
Bracket unit and the PTT unit ..................................................................1-13
Cooling system ........................................................................................1-14
Lower unit ................................................................................................1-15
Technical tips ...............................................................................................1-16
Carburetor ...............................................................................................1-16
Acceleration pump...................................................................................1-17
Ignition system.........................................................................................1-18
Ignition timing control...............................................................................1-18
Lubrication system...................................................................................1-20
Cooling system ........................................................................................1-21
PTT (power trim and tilt) unit (F100B) .....................................................1-22
PTT (power trim and tilt) unit (F100C) .....................................................1-24
Propeller selection.......................................................................................1-25
Propeller size...........................................................................................1-25
Selection..................................................................................................1-25

60C5D11
1
2
3
4
5
6
7
8
9
Predelivery checks ......................................................................................1-25
Checking the fuel system ........................................................................1-25
Checking the gear oil...............................................................................1-26
Checking the engine oil ...........................................................................1-26
Checking the battery................................................................................1-26
Checking the outboard motor mounting position .....................................1-26
Checking the remote control cables ........................................................1-27
Checking the steering system .................................................................1-27
Checking the gearshift and throttle operation..........................................1-27
Checking the tilt system...........................................................................1-28
Checking the engine start switch and engine stop switch/
engine shut-off switch ............................................................................1-28
Checking the pilot water outlet ................................................................1-28
Test run ...................................................................................................1-28
Break-in ...................................................................................................1-29
After test run ............................................................................................1-29

GEN
INFO General information
1-1 60C5D11
How to use this manual 1
Manual format
The format of this manual has been designed to make service procedures clear and easy to under-
stand. Use the information below as a guide for effective and quality service.
1Parts are shown and detailed in an exploded diagram and are listed in the components list.
2Tightening torque specifications are provided in the exploded diagrams and after a numbered
step with tightening instructions.
3Symbols are used to indicate important aspects of a procedure, such as the grade of lubricant
and lubrication point.
4The components list consist of parts and part quantities, as well as bolt, screw, O-ring, and hose
dimensions.
5Service points regarding removal, checking, and installation are shown in individual illustrations
to explain the relevant procedure.
NOTE:
For troubleshooting procedures, see Chapter 9, “Troubleshooting.”

60C5D11 1-2
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5
6
7
8
9
Symbols
The symbols below are designed to indicate the content of a chapter.
General information
Specifications
Periodic checks and adjustments
Fuel system
Power unit
Lower unit
Bracket unit
Electrical systems
Troubleshooting
GEN
INFO
SPEC
CHK
ADJ
FUEL
POWR
LOWR
BRKT
ELEC
TRBL
SHTG
–+
Symbols 1to 6indicate specific data.
1Special tool
2Specified oil or fluid
3Specified engine speed
4Specified tightening torque
5Specified measurement
6Specified electrical value
(Resistance, Voltage, Electric current)
Symbols 7to Ain an exploded diagram indicate the grade of lubricant and the lubrication point.
7Apply Yamaha 4-stroke motor oil
8Apply water resistant grease (Yamaha grease A)
9Apply molybdenum disulfide grease
0Apply corrosion resistant grease
(Yamaha grease D)
AApply low temperature resistant grease
(Yamaha grease C)
Symbols Bto Gin an exploded diagram indicate the type of sealant or locking agent and the appli-
cation point.
BApply Gasket Maker®
CApply Yamabond No. 4
DApply LOCTITE®No. 271 (Red)
EApply LOCTITE®No. 242 (Blue)
FApply LOCTITE®No. 572
GApply silicon sealant
123456
T
R
.
.
7890A
E
A M D C
BCDEFG
GM
4
271
LT
242
LT
572
LT SS
How to use this manual

GEN
INFO General information
1-3 60C5D11
Safety while working 1
To prevent an accident or injury and to
ensure quality service, follow the safety pro-
cedures provided below.
Fire prevention
Gasoline is highly flammable.
Keep gasoline and all flammable products
away from heat, sparks, and open flames.
Ventilation
Gasoline vapor and exhaust gas are heavier
than air and extremely poisonous. If inhaled
in large quantities they may cause loss of
consciousness and death within a short time.
When test running an engine indoors (e.g., in
a water tank) be sure to do so where ade-
quate ventilation can be maintained.
Self-protection
Protect your eyes by wearing safety glasses
or safety goggles during all operations involv-
ing drilling and grinding, or when using an air
compressor.
Protect your hands and feet by wearing pro-
tective gloves and safety shoes when neces-
sary.
Parts, lubricants, and sealants
Use only genuine Yamaha parts, lubricants,
and sealants or those recommended by
Yamaha, when servicing or repairing the out-
board motor.
Under normal conditions, the lubricants men-
tioned in this manual should not harm or be
hazardous to your skin. However, you should
follow these precautions to minimize any risk
when working with lubricants.
1. Maintain good standards of personal and
industrial hygiene.
2. Change and wash clothing as soon as
possible if soiled with lubricants.
3. Avoid contact with skin. Do not, for
example, place a soiled rag in your
pocket.
4. Wash hands and any other part of the
body thoroughly with soap and hot water
after contact with a lubricant or lubricant
soiled clothing has been made.
5. To protect your skin, apply a protective
cream to your hands before working on
the outboard motor.

60C5D11 1-4
1
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7
8
9
6. Keep a supply of clean, lint-free cloths for
wiping up spills, etc.
Good working practices
Special tools
Use the recommended special tools to pro-
tect parts from damage. Use the right tool in
the right manner—do not improvise.
Tightening torques
Follow the tightening torque specifications
provided throughout the manual. When tight-
ening nuts, bolts, and screws, tighten the
large sizes first, and tighten fasteners starting
in the center and moving outward.
Non-reusable parts
Always use new gaskets, seals, O-rings, cot-
ter pins, circlips, etc., when installing or
assembling parts.
Disassembly and assembly
1. Use compressed air to remove dust and
dirt during disassembly.
2. Apply engine oil to the contact surfaces
of moving parts before assembly.
3. Install bearings with the manufacture
identification mark in the direction indi-
cated in the installation procedure. In
addition, be sure to lubricate the bearings
liberally.
4. Apply a thin coat of water-resistant
grease to the lip and periphery of an oil
seal before installation.
5. Check that moving parts operate nor-
mally after assembly.
Safety while working

GEN
INFO General information
1-5 60C5D11
Identification 1
Applicable models
This manual covers the following models.
Serial number
The outboard motor serial number is
stamped on a label attached to the port
clamp bracket.
ÈF100B
ÉF100C
1Model name
2Approved model code
3Transom height
4Serial number
NOTE:
If the serial number label is removed, VOID
marks will appear on the label.
Applicable models
F100BET, F100CET
S60C1090
Model name Approved
model code
Starting
serial No.
F100BET 60C L: 000101–
X: 200101–
F100CET 60D L: 000101–
X: 200101–

60C5D11 1-6
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8
9
Features and benefits 1
Power unit
The F100B and F100C have been developed on the bases of the F100A, which has been recog-
nized as being environmentally friendly, with established emission control, and which has received
high marks as an efficiently superior model with a high fuel economy.
Blowby gas, which is discharged from the engine, is returned to the intake silencer and reburned to
purify the exhaust gas.
The intake passage and exhaust passage have been arranged around the engine to make the
entire engine compact. When compared to a small, 2-stroke, V4 engine it is compact like an in-line,
three cylinder engine.
1Silencer
2Carburetor
ÈIntake
ÉExhaust gas
ÊBlowby gas
:
:
: S60C1250
Identification / Features and benefits

GEN
INFO General information
1-7 60C5D11
Piston and connecting rod
The piston pin has been installed by shrink fitting it to the small end of the connecting rod, as a
result, a circlip is not used to install the piston pin.
The top ring has been nitrided and the second ring has been chrome plated for use with leaded gas-
oline.
The connecting rod and end cap are processed as a single unit. After being heat treated, the single
unit is struck and the connecting rod and end cap are split apart as shown in the illustration. To
increase accuracy during installation, the connecting rod and end cap that were processed together
are always installed as a set.
The hollow volume at the top of the pistons has been made larger and the compression ration has
been lowered to increase reliability and durability.
1Top ring
2Second ring
3Oil ring
4Connecting rod
5Connecting rod end cap
6Large hollow volume
7Compression ratio (8.9)
8Small hollow volume
9Compression ratio (9.6)
F100B, F100C
F100A
S60C1270

60C5D11 1-8
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8
9
New plastic-region tightening bolts
To tighten the plastic-region tightening bolts, tighten them to the specified torque, and then tighten
them to the specified angle. By tightening the bolts to the specified angle, they are contracted to a
more accurate torque, making periodic maintenance checks and adjustments to, as well as addi-
tional tightening of the bolt unnecessary.
The cylinder head bolts, connecting rod bolts, and crankcase bolts have adopted this method to
help better control torque accuracy.
1Specified torque
2Specified angle
3Connecting rod bolt
4Cylinder head bolt
5Crankcase journal bolt
Features and benefits

GEN
INFO General information
1-9 60C5D11
Fuel pump and fuel filter
The fuel pump found in the F115A has been adopted. Although the quantity of parts has been
reduced and the necessary servicing time has been decreased as well, the ability of the fuel pump
to supply sufficient fuel has been retained.
A water separation fuel filter has been adopted. When water is mixed with fuel, it is separated and
precipitated at the bottom of the filter to prevent it from flowing to the carburetors. As water gathers
in the fuel cup, the red float inside the cup begins to rise, indicating that the accumulation of water is
taking place. After water has gathered in the fuel cup, the fuel filter can be disassembled to dispose
of the water.
1Fuel pump
2Fuel filter
3Red float
S60C1290

60C5D11 1-10
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9
Hour meter
A newly developed hour meter is incorporated on the F100B and F100C. The hour meter makes it
possible to check the hours of operation of the outboard motor, which can be used to keep track of
periodic checks and adjustments.
When the engine switch is turned to ON, all LED on the display will illuminate for two seconds, and
then the hours of operation will be displayed.
A signal from the Rectifier Regulator, via the green and white (G/W) lead, is sent to the hour meter
as the hours of operation accumulation.
The hours of operation cannot be deleted.
1Hour meter
2Grand (B)
3Battery (Y)
4Engine start switch
5Starter motor
6Fuse
7Rectifier Regulator
8Flywheel magnet
9Signal (G/W)
S60C1300
Features and benefits

GEN
INFO General information
1-11 60C5D11
Ignition system
A CDI system has been incorporated. The CDI unit uses three signals (i.e., crankshaft position,
engine revolution, and throttle position) to determine the optimum ignition timing.
Engine speed is controlled by the CDI unit to prevent damage to the engine when the engine tem-
perature sensor detects that the engine temperature (i.e., water temperature) is too high, or when
the oil pressure switch detects that the oil pressure is too low, or when the engine idle speed is too
high.
In addition, when the engine overheats or when there is low oil pressure, the warning lamp flashes
and the buzzer sounds.
If the throttle position sensor and engine temperature sensor malfunction, the engine ignition timing
is set by the CDI unit to prevent damage to the engine.
1Oil pressure switch
2Puler coil
3Lighting coil
4CDI unit
5Throttle position sensor
6Engine temperature sensor
7Ignition coils
8Fuel pump

60C5D11 1-12
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9
At low speeds, the exhaust gas flows into the water wall through a hole on the side of the exhaust
guide.
ÈExhaust gas flow at low speeds
ÉExhaust gas flow at high speeds
An identification mark has been stamped on the exhaust manifold and exhaust chamber.
1Identification mark “C”
2Exhaust manifold
3Exhaust chamber
4Identification mark “D”
:
:
S60C1330
Features and benefits

GEN
INFO General information
1-13 60C5D11
Bracket unit and the PTT unit
F100B uses the bracket unit of 2-stroke, V4 outboard motor and F100C uses that of F100A.
In addition, the PTT unit has been adopted from the F100A as well.
The F100B uses the one found on the proven 2-stroke, V4, and V6 outboard motors. This PTT unit
has been constructed to feature a single tilt cylinder and two trim cylinders.
The PTT unit of the F100C has been adopted from the proven F100A. This PTT unit consists of a
single cylinder for both tilt and trim functions, making the unit compact and lightweight.
Oil pump
The oil pump has been installed directly above the oil pan and to the exhaust guide.
In addition, the oil pump is operated directly by the drive shaft, therefore proper oil delivery can be
achieved.
1Oil pump
2OUT
3IN
4Oil pan

60C5D11 1-14
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7
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9
Cooling system
A high capacity water pump and a large cylinder head water jacket have been incorporated to
enable better cooling.
A pressure control valve (PCV) has also been incorporated to control the cooling water pressure,
which in turn helps prevent water leakage from the power unit. When the cooling water pressure
becomes too high, the PCV opens and the cooling water flows through a bypass passage to the
upper case.
An additional water inlet, located in front of the trim tab, allows cooling water to flow into the exhaust
passage in the lower unit during high-speed operation. This extra cooling water properly cools the
high-temperature exhaust gas before it exits through the propeller boss, helping to prevent the rub-
ber parts in the propeller boss from being damaged by high gas temperatures.
1Water pump
2Pressure control valve (PCV)
3Trim tab
ÈCooling water
ÉExhaust gas
ÊExhaust gas/Cooling water mixture
Features and benefits

GEN
INFO General information
1-15 60C5D11
Water pump
The water pump has been hard chrome plated to prevent wear from muddy water. By hard chrome
plating the water pump, wear resistance has been enhanced, and as a result, the time necessary
between part changes or maintenance has been extended.
1Blue identification paint
Lower unit
The lower unit of the F100C does not contain a reverse gear shim. Therefore, it is not necessary to
set the position of a shim for the reverse gear.
Gear ratio
1No reverse gear shim
2Reverse gear shim
F100B F100C
58ø
89ø
S60C1390
F100A 2.31 (30/13)
F100B 2.15 (28/13)
F100C 2.31 (30/13)
F100C F100B
S60C1410