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2007 – 2010 Yamaha F115 4 stroke Lf115 Left 4 stroke 115hp Outboard Models Service Manual – PDF Download
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2007 – 2010 Yamaha F115 4 stroke Lf115 Left 4 stroke 115hp Outboard Models Service Manual
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Description
2007 – 2010 Yamaha F115 4 stroke Lf115 Left 4 stroke 115hp Outboard Models Service Manual
FILE DETAILS:
2007 – 2010 Yamaha F115 4 stroke Lf115 Left 4 stroke 115hp Outboard Models Service Manual
LANGUAGE:ENGLISH
PAGES:345
DOWNLOADABLE:YES
FILE TYPE:PDF
2007 – 2010 YAMAHA F115 4 STROKE LF115 LEFT 4 STROKE 115HP OUTBOARD MODELS SERVICE MANUAL – PDF DOWNLOAD:
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DESCRIPTION:
2007 – 2010 Yamaha F115 4 stroke Lf115 Left 4 stroke 115hp Outboard Models Service Manual
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.
TABLE OF CONTENTS:
2007 – 2010 Yamaha F115 4 stroke Lf115 Left 4 stroke 115hp Outboard Models Service Manual
Back to Index........................................................................ 0 F115 / LF115 SERVICE MANUAL.......................................................... 1 Important information............................................................ 2 Contents......................................................................... 3 General information.............................................................. 5 How to use this manual....................................................... 6 Manual format............................................................ 6 Symbol................................................................... 7 Abbreviation............................................................. 8 Sealant and locking agent table.......................................... 8 Safety while working......................................................... 9 Fire prevention.......................................................... 9 Ventilation.............................................................. 9 Self-protection.......................................................... 9 Part, lubricant, and sealant............................................. 9 Good working practice.................................................... 10 Disassembly and assembly................................................. 10 Identification............................................................... 11 Model.................................................................... 11 Serial number............................................................ 11 Special service tool......................................................... 12 Propeller selection.......................................................... 19 Propeller size........................................................... 19 Selection................................................................ 19 Predelivery check............................................................ 20 Checking the fuel system................................................. 20 Checking the engine oil level............................................ 20 Checking the gear oil level.............................................. 20 Checking the battery..................................................... 20 Checking the outboard motor mounting height.............................. 21 Checking the remote control cable........................................ 21 Checking the steering system............................................. 22 Checking the gear shift and throttle operation........................... 22 Checking the PTT system.................................................. 22 Checking the engine start switch and engine stop lanyard switch.......... 22 Checking the cooling water pilot hole.................................... 23 Test run................................................................. 23 Break-in................................................................. 23 After test run........................................................... 23 Specification.................................................................... 25 General specification........................................................ 26 Maintenance specification.................................................... 28 Power unit............................................................... 28 PTT unit................................................................. 32 Lower unit............................................................... 32 Electrical............................................................... 32 Dimension................................................................ 35 Exterior F115TR, LF115TR............................................. 35 Clamp bracket F115TR, LF115TR........................................ 36 Tightening torque............................................................ 37 Specified torque......................................................... 37 General torque........................................................... 39 Periodic check and adjustment.................................................... 41 Maintenance interval chart................................................... 42 Top cowling.................................................................. 43 Checking the top cowling................................................. 43 Fuel system.................................................................. 43 Checking the fuel joint and fuel hose (fuel joint-to-fuel injector)...... 43 Checking the fuel filter................................................. 44 Draining the fuel........................................................ 44 Power unit................................................................... 45 Checking the engine oil.................................................. 45 Changing the engine oil.................................................. 45 Replacing the oil filter................................................. 46 Checking the timing belt................................................. 46 Checking the spark plug.................................................. 47 Checking the thermostat.................................................. 48 Control system............................................................... 49 Checking the engine idle speed........................................... 49 Adjusting the throttle link and throttle cable........................... 49 Checking the gear shift operation........................................ 50 Bracket unit................................................................. 51 Checking the PTT operation............................................... 51 Checking the PTT fluid level............................................. 52 Lower unit................................................................... 52 Checking the gear oil level.............................................. 52 Changing the gear oil.................................................... 53 Checking the lower unit for air leakage.................................. 54 Checking the propeller................................................... 54 General...................................................................... 54 Checking the anode and trim tab.......................................... 54 Checking the battery..................................................... 55 Lubricating the outboard motor........................................... 56 Fuel system...................................................................... 59 Hose routing................................................................. 60 Fuel and blowby hose..................................................... 60 Vapor gas hose, vacuum hose, and ISC hose................................ 61 Cooling water hose....................................................... 62 Fuel system.................................................................. 63 Reducing the fuel pressure............................................... 63 Measuring the fuel pressure.............................................. 63 Checking the pressure regulator.......................................... 64 Fuel filter and fuel pump.................................................... 65 Checking the fuel filter assembly........................................ 67 Checking the fuel pump................................................... 67 Disassembling the fuel pump.............................................. 68 Checking the diaphragm and valve......................................... 69 Assembling the fuel pump................................................. 69 Intake silencer.............................................................. 71 Throttle link................................................................ 72 Checking the intake silencer............................................. 73 Checking the throttle link............................................... 73 Installing the throttle link............................................. 73 Intake manifold.............................................................. 75 Throttle body and ISC........................................................ 76 Checking the intake manifold............................................. 78 Checking the ISC......................................................... 78 Adjusting the TPS........................................................ 78 Adjusting the TPS (when disassembling or replacing the throttle body).... 79 Fuel rail, fuel cooler, pressure regulator, and fuel injector................ 83 Vapor separator.............................................................. 85 Removing the fuel hose clamp............................................. 88 Installing the fuel hose clamp........................................... 88 Disassembling the vapor separator........................................ 88 Checking the high-pressure fuel pump..................................... 88 Checking the vapor separator............................................. 88 Assembling the vapor separator........................................... 89 Power unit....................................................................... 90 Power unit (check and adjustment)............................................ 92 Checking the compression pressure........................................ 92 Checking the oil pressure................................................ 92 Base assembly................................................................ 94 Timing belt and sprocket..................................................... 95 Ignition coil and starter motor.............................................. 96 Camshaft..................................................................... 98 Measuring the valve clearance............................................ 99 Adjusting the valve clearance............................................101 Replacing the timing belt................................................103 ECM..........................................................................108 Junction box.................................................................109 Power unit assembly..........................................................111 Removing the power unit..................................................113 Removing the timing belt, sprocket, and camshaft.........................114 Checking the timing belt and sprocket....................................116 Checking the camshaft....................................................116 Installing the camshaft, sprocket, and timing belt.......................117 Cylinder head................................................................122 Removing the cylinder head...............................................124 Checking the valve spring................................................124 Checking the valve.......................................................125 Checking the valve guide.................................................125 Replacing the valve guide................................................126 Checking the valve seat..................................................127 Refacing the valve seat..................................................127 Checking the cylinder head...............................................130 Checking the fuel pump drive arm.........................................130 Assembling the fuel pump drive arm assembly..............................130 Installing the valve.....................................................130 Installing the cylinder head.............................................131 Exhaust cover................................................................133 Removing the exhaust cover...............................................135 Checking the PCV.........................................................135 Checking the exhaust cover anode.........................................135 Installing the PCV.......................................................135 Installing the exhaust cover.............................................136 Cylinder block...............................................................137 Disassembling the cylinder block.........................................139 Checking the piston diameter.............................................139 Checking the cylinder bore...............................................140 Checking the piston clearance (reference)................................140 Checking the piston ring.................................................140 Checking the piston ring end gap (reference).............................140 Checking the piston ring groove..........................................141 Checking the piston ring side clearance..................................141 Checking the connecting rod big end side clearance.......................141 Checking the crankshaft..................................................142 Checking the crankpin oil clearance......................................142 Selecting the connecting rod bearing.....................................143 Checking the crankshaft journal oil clearance............................145 Selecting the main bearing...............................................146 Assembling the power unit................................................148 Installing the power unit................................................150 Lower unit.......................................................................154 Lower unit (regular rotation model)..........................................156 Removing the lower unit..................................................159 Removing the water pump and shift rod....................................160 Checking the water pump and shift rod....................................160 Propeller shaft housing (regular rotation model).............................161 Removing the propeller shaft housing assembly............................163 Disassembling the propeller shaft assembly...............................163 Disassembling the propeller shaft housing................................163 Checking the propeller shaft housing.....................................164 Checking the propeller shaft assembly....................................164 Assembling the propeller shaft assembly..................................164 Assembling the propeller shaft housing...................................165 Drive shaft and lower case (regular rotation model)..........................167 Removing the drive shaft.................................................168 Disassembling the drive shaft housing....................................168 Disassembling the forward gear...........................................168 Disassembling the lower case.............................................168 Checking the pinion and forward gear.....................................169 Checking the bearing.....................................................169 Checking the drive shaft.................................................169 Checking the lower case..................................................169 Assembling the lower case................................................170 Assembling the forward gear..............................................170 Assembling the drive shaft housing.......................................171 Installing the drive shaft...............................................171 Installing the propeller shaft housing...................................172 Installing the water pump and shift rod..................................173 Installing the lower unit................................................175 Shimming (regular rotation model)............................................177 Shimming.................................................................178 Selecting the pinion shim................................................178 Selecting the forward gear shim..........................................179 Selecting the reverse gear shim..........................................180 Backlash (regular rotation model)............................................181 Measuring the forward and reverse gear backlash..........................181 Lower unit (counter rotation model)..........................................184 Removing the lower unit..................................................187 Removing the water pump and shift rod....................................188 Checking the water pump and shift rod....................................188 Propeller shaft housing (counter rotation model).............................189 Removing the propeller shaft housing assembly............................191 Disassembling the propeller shaft assembly...............................191 Disassembling the forward gear...........................................191 Disassembling the propeller shaft housing................................192 Checking the propeller shaft housing.....................................192 Checking the propeller shaft assembly....................................192 Assembling the propeller shaft housing...................................192 Drive shaft and lower case (counter rotation model)..........................195 Removing the drive shaft.................................................197 Disassembling the drive shaft housing....................................197 Disassembling the reverse gear...........................................197 Disassembling the lower case.............................................197 Checking the pinion and reverse gear.....................................198 Checking the bearing.....................................................198 Checking the drive shaft.................................................198 Checking the lower case..................................................198 Assembling the lower case................................................198 Assembling the reverse gear..............................................199 Assembling the drive shaft housing.......................................199 Installing the drive shaft...............................................200 Installing the propeller shaft housing...................................201 Installing the water pump and shift rod..................................202 Installing the lower unit................................................203 Shimming (counter rotation model)............................................206 Shimming.................................................................207 Selecting the pinion shim................................................207 Selecting the reverse gear shim..........................................208 Selecting the forward gear shim..........................................209 Selecting the propeller shaft shim.......................................210 Backlash (counter rotation model)............................................210 Measuring the forward and reverse gear backlash..........................210 Bracket unit.....................................................................214 Shift rod....................................................................216 Bottom cowling...............................................................217 Upper case, steering arm, and oil pump.......................................220 Removing the upper case..................................................226 Disassembling the oil pump...............................................226 Checking the oil pump....................................................226 Assembling the oil pump..................................................226 Disassembling the upper case.............................................227 Checking the drive shaft bushing.........................................228 Disassembling the oil pan and exhaust manifold...........................228 Checking the oil pan and exhaust manifold................................228 Checking the oil strainer................................................228 Assembling the oil pan and exhaust manifold..............................229 Assembling the upper case................................................230 Installing the upper case................................................231 Removing the steering arm................................................232 Installing the steering arm..............................................232 Clamp bracket and swivel bracket.............................................234 Removing the PTT unit....................................................237 Removing the clamp bracket...............................................238 Installing the clamp bracket.............................................238 Installing the PTT unit..................................................240 Adjusting the trim sensor cam............................................241 PTT unit.....................................................................243 Checking the hydraulic pressure..........................................244 PTT motor....................................................................247 Disassembling the PTT motor..............................................248 Checking the PTT motor...................................................248 Checking the brush.......................................................249 Checking the filter......................................................250 Assembling the PTT motor.................................................250 Gear pump....................................................................252 Disassembling the gear pump assembly.....................................254 Checking the gear pump...................................................255 Checking the gear pump housing...........................................255 Checking the reservoir...................................................255 Checking the filter......................................................255 Assembling the gear pump assembly........................................255 Tilt cylinder and trim cylinder..............................................257 Disassembling the tilt cylinder and trim cylinder........................258 Checking the tilt cylinder and trim cylinder.............................259 Checking the valve.......................................................259 Assembling the tilt ram..................................................260 Assembling the trim ram..................................................260 Installing the trim ram..................................................261 Installing the gear pump assembly........................................262 Installing the reservoir.................................................262 Installing the tilt ram..................................................263 Installing the PTT motor.................................................263 Bleeding the PTT unit....................................................264 Bleeding the PTT unit (built-in).........................................265 PTT electrical system........................................................266 Checking the fuse........................................................266 Checking the PTT relay...................................................266 Checking the PTT switch..................................................267 Checking the trim sensor.................................................268 Electrical system................................................................270 Checking the electrical component............................................272 Checking using the YDIS..................................................272 Measuring the peak voltage...............................................272 Electrical component and wiring harness routing..............................273 Port view................................................................273 Starboard view...........................................................276 Bow view.................................................................279 Junction box.............................................................282 AFT view.................................................................284 Top view.................................................................285 Bottom cowling...........................................................287 Ignition and ignition control system.........................................290 Checking the ignition spark..............................................290 Checking the ignition coil...............................................290 Checking the pulser coil.................................................291 Checking the ECM.........................................................292 Checking the engine start switch.........................................293 Checking the engine stop lanyard switch..................................294 Engine electric control system...............................................294 Checking the main relay..................................................294 Checking the TPS.........................................................295 Checking the ISC.........................................................296 Checking the intake air temperature sensor...............................298 Checking the intake air pressure sensor..................................299 Checking the cooling water temperature sensor............................299 Checking the shift position switch.......................................300 Checking the oil pressure switch.........................................301 Fuel control system..........................................................302 Checking the water detection switch......................................302 Checking the fuel injector...............................................303 Checking the high-pressure fuel pump.....................................304 Starting system..............................................................305 Checking the fuse........................................................305 Checking the starter relay...............................................305 Starter motor................................................................306 Removing the starter motor...............................................308 Checking the starter motor operation.....................................308 Checking the magnet switch...............................................308 Checking the starter motor pinion........................................309 Disassembling the starter motor..........................................309 Checking the starter motor...............................................311 Checking the brush.......................................................312 Assembling the starter motor.............................................312 Installing the starter motor.............................................314 Charging system..............................................................315 Checking the stator assembly.............................................315 Checking the Rectifier Regulator.........................................316 Troubleshooting..................................................................319 YDIS.........................................................................320 Introduction.............................................................320 Feature..............................................................320 Function.............................................................320 Contents.............................................................321 Connecting the communication cable to the outboard motor.................322 Troubleshooting the power unit...............................................323 Troubleshooting the power unit using the YDIS............................323 Trouble code table...................................................324 Symptoms table.......................................................324 Trouble code and checking step...........................................325 Troubleshooting the power unit using the diagnostic flash indicator......328 Troubleshooting the power unit (trouble code not available)..............329 Troubleshooting the PTT unit.............................................335 Troubleshooting the lower unit...........................................336 Index............................................................................337 Wiring diagram (F115TR, LF115TR).................................................345 F115TR, LF115TR..............................................................345
PLEASE NOTE:
⦁ This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
⦁ Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.
