Yamaha F150B User manual

SERVICE MANUAL
6BM-28197-5L-11
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 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 ser-
vice 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 product and services are available on 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.
F150B, FL150B
SERVICE MANUAL
©2008 by Yamaha Motor Co., Ltd.
1st Edition, June 2008
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
Printed in China

Contents
General information 0
Specification 1
Technical features 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
GEN
INFO
SPEC
TECH
FEA
RIG
GING
TRBL
SHTG
ELEC
FUEL
POWR
LOWR
BRKT
MNT

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
Handling of burner ..................................................................... 0-2
Part, lubricant, and sealant ........................................................ 0-2
Handling of sealant .................................................................... 0-2
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
Sealant and locking agent ...................................................... 0-6
Symbol ...................................................................................... 0-6
Special service tool .................................................................. 0-8

0-1
GEN
INFO General information
Safety while working
To prevent an accident or injury and to
ensure quality service, follow the safety pro-
cedures provided below.
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 in place whenever
possible. Do not remove or replace the
cowling with the engine running.
• Only operate the engine with the cowling
removed according to the specific instruc-
tions 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. Avoid touching
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. They can cause
shock or electrocution.
Propeller
Do not hold the propeller with your hands
when loosening or tightening it.
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 should
swallow some gasoline or 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 cloth-
ing, change your clothes.
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
(example: in a water tank), be 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 a wire rope of adequate strength, and
lift up the outboard motor with the three
point suspension.
• If the outboard motor does not have three
or more points to be suspended, support it
with additional ropes or the like so that the
outboard motor can be lifted and carried in
a stable manner.
Handling of burner
• Incorrect handling of burner may result in
burns. Refer to the operation manual
issued by the manufacturer to assure the
correct handling.
• When using a burner, keep it away from the
gasoline and oil, to prevent a fire.
• Components become very hot enough to
cause burns. Do not touch 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.
Handling of sealant
• Wear protective gloves to protect your skin,
when using the sealants.
• Refer to the material data sheet issued by
the manufacturer. Some of the sealants
may be harmful for human health.

0-3
GEN
INFO General information
Special service tool
Use the recommended special service tools
to work safety, and to protect parts from dam-
age.
Tightening torque
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 part
Always use new gaskets, seals, O-rings, cot-
ter pins, circlips, 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 with the manufacture identi-
fication mark in the direction indicated in
the installation procedure. In addition, be
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
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 information below 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 figure below for an example page).
• The component list consists of part names and quantities, as well as bolt and screw dimensions
(see bin the figure below).
• Symbols are used to indicate important aspects of a procedure, such as the grade of lubricant and
lubrication point (see cin the figure below).
• Tightening torque specifications are provided in the exploded diagrams (see din the figure below
for an example), 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 ein the figure below for an example page).
TIP:
For troubleshooting procedures, see Chapter 4, “Troubleshooting.”
8-1
LOWR Lower unit
Lower unit (regular rotation model)
No. Part name Q’ty Remarks
1 Extension 1
2Dowel 4
3 Hose nipple 2
4O-ring 2 Not reusable
5Cover 2
6Seal 2
7 Water pipe 1
8 Grommet 1
9 Bolt 1 M10 ×45 mm
10 Bolt 12 M10 ×45 mm
11 Check screw 1
12 Gasket 2 Not reusable
13 Water pipe 1
14 Lower unit 1
15 Spacer 1
16 Propeller 1
17 Washer 1
21
15
14
17
18
19
20
16
2
2
11
12
10
10
9
8
2
7
13
5
66
5
10
10
2
23
12
47 N m (4.7 kgf m, 34.7 ft lb)
47 N m (4.7 kgf m, 34.7 ft lb)
42 N m (4.2 kgf m, 31.0 ft lb)
54 N m (5.4 kgf m, 39.8 ft lb)
9 N m (0.9 kgf m, 6.6 ft lb)
9 N m (0.9 kgf m, 6.6 ft lb)
22
47 N m (4.7 kgf m, 34.7 ft lb)
1
3
4
4
3
8-16
Drive shaft and lower case (regular rotation model)
0
1
2
3
4
5
6
7
8
9
10
A
Removing the drive shaft
1. Remove the pinion nut.
2. Remove the drive shaft housing, shim(s)
(T3), thrust bearing, drive shaft, and
pinion.
3. Pull out the forward gear assembly.
Disassembling the drive shaft
housing
1. Remove the oil seals a.
2. Remove the needle bearing b.
Disassembling the forward gear
1. Remove the taper roller bearing a.
2. Remove the needle bearings from the
forward gear.
Disassembling the lower case
Use heat-resistant gloves, otherwise
burns could result.
Remove any flammable substances,
such as gasoline and oil, around the
working area to avoid the risk of fire.
Heat the lower case in a well-ventilated
area.
1. Remove the water inlet covers.
Drive shaft holder 6 a: 90890-06520
Pinion nut holder b: 90890-06715
a
b
b
a
b
cd
c
d
Needle bearing attachment c:
90890-06610
Driver rod L3 d: 90890-06652
Bearing separator b: 90890-06534
Needle bearing attachment c:
90890-06608
cb
a
bc
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
ABYC American Boat and Yacht Council
AFT Aft end
API American Petroleum Institute
AWG American Wire Gauge
BL Backlash
BOW Bow end
BTDC Before Top Dead Center
CA Crank Angle
CCA Cold Cranking Ampere
C/E Check Engine
C/L Centerline
D.E.S. Dual Engine System
DN Down side
ECM Electronic Control Module
EN European Norm (European standard)
EX Exhaust
FForward
IEC International Electro-technical Commission
IN Intake
ISC Idle Speed Control
M Measurement
N Neutral
PCV Pressure Control Valve
PORT Port side
PTT Power Trim and Tilt
RReverse
RON Research Octane Number
SAE Society of Automotive Engineers
STBD Starboard side
SW Switch
TDC Top Dead Center
TPS Throttle Position Sensor
UP Upside
W/F Water in Fuel
YDIS Yamaha Diagnostic System

0-6
Sealant and locking agent
0
1
2
3
4
5
6
7
8
9
10
A
Sealant and locking agent
Symbol
Symbols in an exploded diagram or illustration indicate the grade of lubricant and the lubrication
point.
Symbols in an exploded diagram or illustration indicate the grade of sealant and the seal point.
Symbol Name Application
Yamaha 4-stroke motor oil Lubricant
Gear oil Lubricant
Water resistant grease
(Yamaha grease A)
Lubricant
Molybdenum disulfide grease Lubricant
Corrosion resistant grease
(Yamaha grease D)
Lubricant
Low temperature resistant grease
(Yamaha grease C)
Lubricant
WR-No.2 grease Lubricant
Symbol Name Application
Gasket Maker Sealant
ThreeBond 1104J Sealant
ThreeBond 1280B Sealant
ThreeBond 1322 Sealant
ThreeBond 1386B Sealant
LOCTITE 271 (red) Sealant
How to use this manual / Sealant and locking agent

0-7
GEN
INFO General information
Symbol Name Application
LOCTITE 242 (blue) Sealant
LOCTITE 572 (white) Sealant

0-8
Special service tool
0
1
2
3
4
5
6
7
8
9
10
A
Special service tool
For all markets except for U.S.A. and Canada
Special tools with Yamaha parts number (90890-*****) are distributed by Parts Division.
Drilling plate
90890-06783
YDIS (CD-ROM, Ver. 1.30)
60V-WS853-04
YDIS (KIT)
60V-85300-04
Diagnostic flash indicator B
90890-06865
Digital circuit tester
90890-03174
Peak voltage adapter B
90890-03172
Test harness (3 pins)
90890-06869
Test harness (3 pins)
90890-06847
Test harness (3 pins)
90890-06846
Ignition tester
90890-06754
SOFTWARE
Ver
OUTBOARDS
WATERCRAFT
Sealant and locking agent / Special service tool

0-9
GEN
INFO General information
Test harness (2 pins)
90890-06792
Test harness (3 pins)
90890-06791
Vacuum/pressure pump gauge set
90890-06756
Test harness (2 pins)
90890-06867
Fuel pressure gauge
90890-06786
Leakage tester
90890-06840
Test harness (3-pins)
90890-06793
Vacuum gauge
90890-03159
Digital tachometer
90890-06760
Compression gauge
90890-03160

0-10
Special service tool
0
1
2
3
4
5
6
7
8
9
10
A
Compression gauge extension
90890-06563
Flywheel holder
90890-06522
Flywheel puller
90890-06521
Valve spring compressor
90890-04019
Valve spring compressor attachment
90890-06320
Valve guide remover/installer
90890-06801
Valve guide installer
90890-06810
Valve guide reamer
90890-06804
Valve lapper
90890-04101
Valve seat cutter holder
90890-06316

0-11
GEN
INFO General information
Valve seat cutter
90890-06817, 90890-06326, 90890-06816,
90890-06325, 90890-06324
Oil filter wrench
90890-06830
Needle bearing attachment
90890-06654, 90890-06611, 90890-06653,
90890-06610, 90890-06612
Driver rod L3
90890-06652
Bearing separator
90890-06534
Gear puller
90890-06540
Piston ring compressor
90890-05158
Shift rod push arm
90890-06052
Ring nut wrench 4
90890-06512
Ring nut wrench extension
90890-06513

0-12
Special service tool
0
1
2
3
4
5
6
7
8
9
10
A
Bearing housing puller claw L
90890-06502
Stopper guide plate
90890-06501
Center bolt
90890-06504
Stopper guide stand
90890-06538
Bearing puller assembly
90890-06535
Driver rod SS
90890-06604
Bearing depth plate
90890-06603
Bearing inner race attachment
90890-06640
Drive shaft holder 6
90890-06520
Pinion nut holder
90890-06715

0-13
GEN
INFO General information
Needle bearing attachment
90890-06608, 90890-06607
Ball bearing attachment
90890-06636, 90890-06633
Driver rod LL
90890-06605
Bearing outer race attachment
90890-06619
Bearing outer race puller assembly
90890-06523
Driver rod LS
90890-06606
Backlash indicator
90890-06706
Magnet base plate
90890-07003
Dial gauge set
90890-01252
Magnet base B
90890-06844

0-14
Special service tool
0
1
2
3
4
5
6
7
8
9
10
A
Pinion height gauge
90890-06671
Slide hammer handle
90890-06531
Puller head
90890-06514
Ring nut wrench
90890-06578
Ball bearing attachment
90890-06629
Bearing inner race attachment
90890-06660
Up relief fitting
90890-06773/06838
Hydraulic pressure gauge
90890-06776/06800
Down relief fitting
90890-06774
Trim & tilt wrench
90890-06587

SPEC
Specification 1
Model features ............................................................................ 1-1
General feature ......................................................................... 1-1
Model designation ..................................................................... 1-2
Serial number ............................................................................ 1-2
Model data ................................................................................... 1-3
Dimension and Weight .............................................................. 1-3
Performance .............................................................................. 1-3
Power unit ................................................................................. 1-3
Lower unit .................................................................................. 1-4
Bracket unit ............................................................................... 1-4
Fuel and oil requirement ............................................................ 1-4
Battery requirement ................................................................... 1-5
PTT requirement ....................................................................... 1-5
Electrical technical data .......................................................... 1-6
Ignition timing control system .................................................... 1-6
Fuel injection control system ..................................................... 1-7
Engine speed control system .................................................... 1-8
PTT system ............................................................................... 1-8
Charging system ....................................................................... 1-9
Starting system .......................................................................... 1-9
Gauge / sensor ........................................................................ 1-10
Fuel system technical data ................................................... 1-11
Fuel system ............................................................................. 1-11
Power unit technical data ..................................................... 1-12
Power unit ............................................................................... 1-12
Cylinder head assembly .......................................................... 1-12
Crankcase assembly ............................................................... 1-14
Lower unit technical data ...................................................... 1-16
Lower unit assembly (regular rotation model) ......................... 1-16
Lower unit assembly (counter rotation model) ........................ 1-16
Bracket unit technical data ................................................... 1-17
PTT system ............................................................................. 1-17