Yamaha F150A User manual

SERVICE MANUAL
63P-28197-3P-12
F150A
FL150A
F150B
FL150B

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 out-
board motor or other property.
TIP:
A TIP provides key information to make procedures easier or clearer.
F150A, FL150A, F150B, FL150B
SERVICE MANUAL
©2011 by Yamaha Motor Co., Ltd.
1st Edition, October 2011
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.

Contents
General information 0
Specification 1
Technical feature and description 2
Rigging information 3
Troubleshooting 4
Electrical system 5
Fuel system 6
Power unit 7
Lower unit 8
Bracket unit 9
Maintenance 10
Index
Appendix A

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
Handling of gas torch ................................................................ 0-2
Part, lubricant, and sealant ........................................................ 0-2
Handling of sealant .................................................................... 0-3
Special service tool ................................................................... 0-3
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 ........................................................... 0-8

0-1
Safety while working
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 cowl-
ing removed according to the specific
instructions in the manual. Keep hands,
feet, hair, jewelry, clothing, personal flota-
tion 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 start-
ing 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 gaso-
line 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 main-
tained.

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 pro-
tective gloves and safety shoes when nec-
essary.
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.
Handling of gas torch
• Improper handling of a gas torch may result
in burns. For information on the proper han-
dling of the gas torch, see the operation
manual issued by the manufacturer.
• When using a gas torch, keep it away from
the gasoline and oil, to prevent a fire.
• Components become hot enough to cause
burns. Do not touch any hot components
directly.
Part, lubricant, and sealant
Use only genuine Yamaha parts, lubricants,
and sealants, or those recommended by
Yamaha, when servicing or repairing the out-
board motor.

0-3
Safety while working
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 dam-
age.
Tightening torque
When tightening nuts, bolts, and screws, fol-
low the tightening instructions provided
throughout the manual. If the tightening order
is not specified, tighten the large sizes first,
and then tighten the small sizes, starting from
the center and moving outward.
Non-reusable part
Always use new gaskets, seals, O-rings, cot-
ter pins, and so on, when installing or assem-
bling 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 bear-
ings 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
How to use this manual
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 “1”
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 “2” 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 “3” in the following figure).
• Tightening torque specifications are provided in the exploded diagrams (see “4” 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 “5” in the following figure for an example page).
TIP:
For troubleshooting procedures, See Chapter 4, “Troubleshooting”.
8-6
Lower unit (regular rotation model, X-transom model)
0
1
2
3
4
5
6
7
8
9
10
A
Lower unit (regular rotation model, X-transom model)
skrameRyt’QemantraP.oN
2elppinesoH1
elbasuertoN2gnir-O2
1wercskcehC3
elbasuertoN2teksaG4
01M21tloB5 ×45 mm
1noisnetxE6
4lewoD7
2revoC8
2laeS9
1epipretaW01
1epipretaW11
1temmorG21
01M1tloB31 ×45 mm
1tinurewoL41
1recapS51
1relleporP61
relleporpSDStpecxE1recapS71
23
15
14
18
17
19
20
16
7
7
3
4
5
5
13
12
7
10
11
8
99
8
5
5
7
25
424
6
1
2
2
121
22
43 N·m (4.3 kgf·m, 31.7 ft·lb)
48 N·m (4.8 kgf·m, 35.4 ft·lb)
48 N·m (4.8 kgf·m, 35.4 ft·lb)
48 N·m (4.8 kgf·m, 35.4 ft·lb)
55 N·m (5.5 kgf·m, 40.6 ft·lb)
9 N·m (0.9 kgf·m, 6.6 ft·lb)
9 N·m (0.9 kgf·m, 6.6 ft·lb)
8-24
Drive shaft and lower case (regular rotation model)
0
1
2
3
4
5
6
7
8
9
10
A
3. Install a new O-ring “1”.
Assembling the lower case
•Use heat-resistant gloves. Otherwise,
burns could result.
•To prevent fires, remove any flammable
substances, such as gasoline and oil,
around the working area.
•Keep good ventilation while working.
1. Install the original forward gear shims “1”.
2. Heat the area of the lower case where
the taper roller bearing outer race is to be
installed using a gas torch, and then
install a new taper roller bearing outer
race “2”.
When heating the lower case, heat the
entire installation area evenly. Otherwise,
the paint on the lower case could be
burned.
TIP:
Do not reuse a shim if deformed or
scratched.
3. While holding the special service tool “1”,
strike the tool to check that the taper
roller bearing outer race is installed prop-
erly.
TIP:
If a high-pitched metallic sound is produced
when the special service tool is struck, the
outer race is installed properly.
Bearing outer race attachment “2”:
90890-06628
Driver rod LS “3”: 90890-06606
Installation depth “a”:
0.25–0.75 mm (0.010–0.030 in)
1
2
3
a
1
1
2
2
1
1
2
1
2
34
5

0-5
How to use this manual
Abbreviation
The following abbreviations are used in this service manual.
Abbreviation Description
ABYC American Boat and Yacht Council
API American Petroleum Institute
ATF Automatic Transmission Fluid
AWG American Wire Gauge
CCA Cold Cranking Ampere
DN Down side
DOHC Double Overhead Camshaft
ECM Electronic Control Module
EN European Norm (European standard)
EX Exhaust
FForward
ID Identification
IEC International Electrotechnical Commission
IN Intake
ISO International Organization for Standardization
ISC Idle Speed Control
N Neutral
PCV Pressure Control Valve
PORT Port side
PTT Power Trim and Tilt
RReverse
RON Research Octane Number
SAE Society of Automotive Engineers
SDS Shift Dampener System
STBD Starboard side
TCI Transistor-Controlled Ignition
TDC Top Dead Center
TPS Throttle Position Sensor
UP Up side
Y-COP Yamaha Customer Outboard Protection
YDIS Yamaha Diagnostic System

0-6
Lubricant, sealant, and thread locking agent
0
1
2
3
4
5
6
7
8
9
10
A
Lubricant, sealant, and thread locking agent
Symbol
Symbols in an exploded diagram or illustration indicate the grade of lubricant and the lubrication
points.
Symbols in an exploded diagram or illustration indicate the type of sealant or thread locking agent
and the application points.
Symbol Name Application
Yamaha 4-stroke motor oil Lubricant
Hypoid gear oil Lubricant
Water resistant grease
(Yamaha grease A) Lubricant
Low temperature resistant grease
(Yamaha grease C) Lubricant
Corrosion resistant grease
(Yamaha grease D) Lubricant
Molybdenum disulfide grease Lubricant
WR-No.2 grease Lubricant
Symbol Name Application
Gasket Maker Sealant
ThreeBond 1280B Sealant
ThreeBond 1303N Thread locking agent
ThreeBond 1322 Thread locking agent
ThreeBond 1377B Thread locking agent
ThreeBond 1386B Sealant

0-7
Lubricant, sealant, and thread locking agent
ThreeBond 1401 Thread locking agent
ThreeBond 1530D Sealant
LOCTITE 271 (red) Thread locking agent
LOCTITE 242 (blue) Thread locking agent
LOCTITE 572 (white) Sealant
Silicone sealant Sealant
Symbol Name Application

0-8
Special service tool
0
1
2
3
4
5
6
7
8
9
10
A
Special service tool
For all markets except U.S.A. and Canada.
Special service tools with part numbers 90890-06883 and FIM20000ME are distributed by the
Marine Service Division.
Special service tools with part numbers other than 90890-06883 and FIM20000ME are distributed
by the Parts Division.
Drilling plate
90890-06783
YDIS 2 starter kit
90890-06883
Diagnostic flash
90890-06873
Digital circuit tester
90890-03189
Peak voltage adapter B
90890-03172
Test harness (3 pins)
90890-06869
Vacuum/pressure pump gauge set
90890-06945
Test harness (3 pins)
90890-06847
******
******
***

0-9
Special service tool
Test harness (3 pins)
90890-06846
Ignition tester (spark gap tester)
90890-06754
Test harness (2 pins)
90890-06792
Test harness (3 pins)
90890-06791
Test harness (2 pins)
90890-06867
Fuel pressure gauge
90890-06753
Leakage tester
90890-06840
Small end bearing installer
90890-06528
Vacuum gauge
90890-03159
Fuel injection meter
FIM20000ME

0-10
Special service tool
0
1
2
3
4
5
6
7
8
9
10
A
Compression gauge
90890-03160
Compression gauge extension
90890-06563
Flywheel holder
90890-06522
Flywheel stopper
90890-06598
Flywheel puller
90890-06521
Hydro puller kit
90890-06593
Valve spring compressor
90890-04019
Valve spring compressor attachment
90890-06320
Valve guide remover/installer
90890-06801
Valve guide installer
90890-06810

0-11
Special service tool
Valve guide reamer
90890-06804
Valve lapper
90890-04101
Valve seat cutter holder
90890-06316
Valve seat cutter 30°
90890-06327
Valve seat cutter 45°
90890-06325
Valve seat cutter 60°
90890-06324
Valve seat cutter 30°
90890-06326
Oil filter wrench
90890-06830
Driver rod L3
90890-06652
Needle bearing attachment
90890-06611

0-12
Special service tool
0
1
2
3
4
5
6
7
8
9
10
A
Bearing separator
90890-06534
Gear puller
90890-06540
Piston ring compressor
90890-05158
Needle bearing attachment
90890-06653
Shift rod socket
90890-06681
Ring nut wrench extension
90890-06513
Ring nut wrench 4
90890-06512
Bearing housing puller claw L
90890-06502
Stopper guide plate
90890-06501
Center bolt
90890-06504

0-13
Special service tool
Stopper guide stand
90890-06538
Bearing puller assembly
90890-06535
Driver rod SS
90890-06604
Needle bearing attachment
90890-06610
Bearing depth plate
90890-06603
Bearing inner race attachment
90890-06640
Needle bearing attachment
90890-06654
Drive shaft holder 6
90890-06520
Pinion nut holder
90890-06715
Needle bearing attachment
90890-06608

0-14
Special service tool
0
1
2
3
4
5
6
7
8
9
10
A
Ball bearing attachment
90890-06636
Driver rod LL
90890-06605
Needle bearing attachment
90890-06612
Bearing outer race attachment
90890-06628
Driver rod LS
90890-06606
Bearing outer race attachment
90890-06619
Ball bearing attachment
90890-06633
Bearing outer race puller assembly
90890-06523
Backlash indicator
90890-06706
Magnet base plate
90890-07003

0-15
Special service tool
Dial gauge set
90890-01252
Magnet base B
90890-06844
Pinion height gauge
90890-06671
Slide hammer handle
90890-06531
Puller head
90890-06514
Needle bearing attachment
90890-06607
Ring nut wrench
90890-06578
Bearing inner race attachment
90890-06660
Ball bearing attachment
90890-06629
PTT hydraulic gauge adapter
90890-06863