Yamaha F150A FL150A F150B FL150B 150HP Outboard Service Manual PDF
The Yamaha F150A FL150A F150B FL150B 150HP Outboard Service Manual PDF is a detailed 493-page service reference for the F150A, FL150A, F150B and FL150B outboard motor families. Yamaha states that this manual was prepared primarily for Yamaha dealers and trained mechanics performing maintenance procedures and repairs, and its coverage reflects that technical focus: specifications, system descriptions, diagnostics, adjustment data, electrical testing, mechanical disassembly and assembly, rigging, troubleshooting and periodic maintenance are all developed in depth.
The manual distinguishes regular-rotation and counter-rotation applications where procedures or specifications differ. It also identifies applicable model codes and starting serial numbers, provides extensive component illustrations and exploded views, and gives service measurements, clearances, pressures, electrical values and tightening torques throughout the repair procedures.
File Details
- Manual type: Service Manual
- Brand: Yamaha
- Models: F150A, FL150A, F150B, FL150B
- Document number: 63P-28197-3P-12
- Edition: 1st Edition, October 2011
- Language: English
- Pages: 493
- File format: PDF
Model and Serial Number Coverage
The Yamaha F150A FL150A F150B FL150B service manual identifies four model designations with their approved model codes and starting serial numbers. This information is useful when confirming that the service data applies to the outboard being repaired or inspected.
- F150AET: approved model code 63P, starting serial number 1106291-
- FL150AET: approved model code 64P, starting serial number 1013389-
- F150BET: approved model code 6BM, starting serial number 1001267-
- FL150BET: approved model code 6BN, starting serial number 1000213-
Engine and Service Data
The specification section establishes the mechanical baseline used throughout the manual. The covered power unit is a 4-stroke, inline 4-cylinder DOHC design with 16 valves and 2670.0 cm3 (162.9 cu. in) displacement. Bore and stroke are listed as 94.0 × 96.2 mm (3.70 × 3.79 in), compression ratio as 9.00 : 1, and the fuel system as electronic fuel injection. The manual specifies TCI ignition, water cooling, wet-sump lubrication, electric starting and a maximum generator output of 36 A.
Performance and service data are separated where the A and B model generations differ. F150AET and FL150AET are specified at 110.3 kW at 5500 r/min (150 HP at 5500 r/min) with a full-throttle operating range of 5000-6000 r/min. F150BET and FL150BET are specified at 110.3 kW at 5000 r/min (1150 HP at 5000 r/min) with a 4500-5500 r/min full-throttle range. Engine idle speed is specified at 650-750 r/min.
The lower unit uses F-N-R gear positions, a 2.00 (28/14) gear ratio, spiral bevel gears and a dog clutch. The manual distinguishes clockwise F150 models from counter-clockwise FL150 models and supplies separate lower-unit data and overhaul procedures where required.
Diagnostics, Measurements and Repair Procedures
A major part of this Yamaha F150A FL150A F150B FL150B 150HP Outboard Service Manual PDF is devoted to systematic diagnosis rather than component replacement by guesswork. YDIS version 2.00 coverage includes diagnosis codes, diagnosis records, engine operating hours by RPM, real-time engine monitoring, digital and graph displays, stationary and active tests, data logging, CAN information, communication lists and bus statistics. The troubleshooting chapter links detected trouble codes to specific checking steps and also covers symptoms where no trouble code is detected.
Electrical procedures provide test points and reference values for the ECM circuit, TPS, ISC valve, oil-pressure sensor, water-detection switch, fuel injectors, high-pressure fuel pump, vapor shut-off valve, lighting coil, Rectifier Regulator, ignition coils, pulser coils, temperature and pressure sensors, shift switches, starter circuits, Y-COP components and PTT electrical components. Wiring-harness routing illustrations, ECM terminal assignments and system diagrams support the measurement procedures.
Mechanical service sections extend through compression and oil-pressure checks, valve-clearance measurement and adjustment, timing-belt work, camshaft and cylinder-head service, valve and valve-seat inspection, oil-pump work, piston and cylinder inspection, connecting rods, crankshaft measurements and bearing selection. Numerous exploded diagrams identify component order, reusable and non-reusable parts, fastener dimensions, lubrication points and tightening values.
Chapters Covered
- General information
- Safety while working
- How to use this manual
- Lubricant, sealant and thread locking agent
- Special service tools
- Specification
- Model features and model-name designation
- Serial numbers, dimensions, weight and performance
- Power unit, lower unit and bracket-unit data
- Fuel, oil, battery and PTT fluid requirements
- Electrical, fuel-system and power-unit technical data
- Specified tightening torques
- Technical feature and description
- Electronic control system and engine ECM components
- Engine-speed and fail-safe control
- Y-COP, tilt limiter and YDIS
- Fuel, vapor-gas, lubrication and cooling systems
- Intake and exhaust system
- SDS propeller and PTT operating functions
- Rigging information
- Outboard mounting, external dimensions and clamp bracket
- Shift and throttle cable installation
- 6Y8 Multifunction Meter and conventional-gauge harnesses
- Water-pressure sensor, speed sensor and tilt limiter
- Y-COP installation and receiver registration
- Battery wiring and single/twin-engine system diagrams
- Battery-cable extension and propeller selection
- Troubleshooting
- YDIS functions and communication connection
- Trouble-code diagnosis and checking steps
- Diagnostic flash indicator
- Power-unit troubleshooting without detected trouble codes
- PTT-unit and lower-unit troubleshooting
- Electrical system
- Electrical components and wiring-harness routing
- ECM circuit and coupler layout
- Engine, fuel, charging, ignition and starting components
- Y-COP checks and starter-motor overhaul
- 6Y8 sensors and PTT-system checks
- Fuel system
- Fuel, air, pressure-regulator, vapor-gas and cooling-water hose routing
- Fuel pressure, fuel filter and fuel pump
- Canister and vapor shut-off valve
- Throttle link, throttle body and synchronization
- Fuel injectors, fuel rail and fuel cooler
- Intake manifold, vapor separator and high-pressure fuel pump
- Power unit
- Compression, oil pressure and valve-clearance checks
- Power-unit removal and installation
- Flywheel magnet, stator, timing belt and starter motor
- Camshaft and cylinder-head overhaul
- Valve, guide and valve-seat inspection
- Oil pump, balancer and crankcase service
- Pistons, cylinders, connecting rods, crankshaft and bearing selection
Complete PDF Bookmark Tree
Complete Bookmarks
The complete bookmarks in the “Yamaha F150A FL150A F150B FL150B 150HP Outboard Service Manual PDF” are as follows:
+Contentsp. 3
+General informationp. 5
+!Safety while workingp. 6
Rotating partp. 6
Hot partp. 6
Electric shockp. 6
Propellerp. 6
Handling of gasolinep. 6
Ventilationp. 6
Self-protectionp. 7
Working with cranep. 7
Handling of gas torchp. 7
Part, lubricant, and sealantp. 7
Handling of sealantp. 8
Special service toolp. 8
Tightening torquep. 8
Non-reusable partp. 8
Disassembly and assemblyp. 8
+How to use this manualp. 9
Manual formatp. 9
Abbreviationp. 10
+Lubricant, sealant, and thread locking agentp. 11
Special service toolp. 13
+Specificationp. 22
+Model featurep. 24
General featurep. 24
Model name designationp. 25
Serial numberp. 26
+Model datap. 27
Dimension and weightp. 27
Performancep. 27
Power unitp. 28
Lower unitp. 28
Bracket unitp. 28
Fuel and oil requirementp. 29
Battery requirementp. 29
PTT fluid requirementp. 29
+Electrical technical datap. 30
Ignition timing control systemp. 30
Fuel injection control systemp. 31
Engine speed control systemp. 31
PTT systemp. 31
Charging systemp. 32
Starting systemp. 32
Y-COP (standard for European market and optional for Oceanian market)p. 32
Gauge/sensorp. 33
+Fuel system technical datap. 34
+Power unit technical datap. 35
Power unitp. 35
Cylinder head assemblyp. 35
Crankcase assemblyp. 36
+Lower unit technical datap. 38
Lower unit assembly (regular rotation model)p. 38
Lower unit assembly (counter rotation model)p. 38
+Bracket unit technical datap. 39
+Specified tightening torquep. 40
Rigging informationp. 40
Electrical systemp. 40
Fuel systemp. 40
Power unitp. 41
Lower unit (regular rotation model)p. 42
Lower unit (counter rotation model)p. 42
Bracket unitp. 42
PTT unitp. 43
General tightening torquep. 43
+Technical feature and descriptionp. 44
+Electronic control systemp. 46
Engine ECM componentp. 48
Engine speed controlp. 50
Fail-safe controlp. 51
+Additional featuresp. 52
Y-COP (standard for European market and optional for Oceanian market)p. 52
Tilt limiter (F150A, FL150A [optional for European and Oceanian markets])p. 53
+YDISp. 54
Overviewp. 54
New functionsp. 55
Loggingp. 56
+Power unit systemp. 57
Shimless valve lifterp. 57
+Fuel systemp. 58
Fuel diagramp. 58
Vapor gas diagramp. 59
+Lubrication systemp. 60
+Cooling systemp. 61
+Intake and exhaust systemp. 62
Intake and exhaust diagramp. 62
+Lower unitp. 63
+PTT unitp. 64
Trim-up and tilt-up functionp. 64
Trim-down and tilt-down functionp. 65
Trim ram retraction when tilting the outboard motor upp. 66
Trim ram retraction when there is no load on the tilt ram and trim ramp. 66
Stationary conditionp. 67
Shock-absorbing functionp. 67
+Rigging informationp. 68
+Important reminder on riggingp. 70
Outboard motor mounting instructionsp. 70
+Crate handlingp. 71
Crate top cover pictograph descriptionp. 71
+Uncratingp. 72
+External dimensionsp. 74
F150A, FL150A, F150B, FL150Bp. 74
Clamp bracketp. 75
+Outboard motor mountingp. 76
Installing the outboard motorp. 76
+Rigging grommet mountingp. 78
Rigging grommet descriptionp. 78
Installing the shift cablep. 78
Installing the throttle cablep. 80
Installing the 6Y8 Multifunction Meter harnessp. 81
Installing the conventional gauge harnessp. 81
Installing the main wiring harnessp. 82
Installing the rigging grommetp. 82
+Optional equipmentp. 83
Installing the isolator leadp. 83
Installing the water pressure sensorp. 83
Installing the speed sensorp. 84
Installing the tilt limiterp. 85
Setting the tilt limiterp. 87
Deactivating the tilt limiterp. 89
+Y-COP (standard for European market and optional for Oceanian market)p. 89
Installing Y-COPp. 89
Registering the receiver ID to the ECMp. 89
+Battery installationp. 91
Battery wiring without house (accessory) batteryp. 91
Battery wiring with house (accessory) batteryp. 94
+System diagramp. 98
Single outboard motor application (6Y8 Multifunction Meter)p. 98
Single outboard motor application (conventional gauge)p. 100
Twin outboard motor application (6Y8 Multifunction Meter)p. 102
Twin outboard motor application (conventional gauge)p. 104
+Rigging recommendationp. 106
Extension length recommendation for battery cablep. 106
+Propeller selectionp. 107
Propeller sizep. 107
Selectionp. 107
+Troubleshootingp. 111
+YDISp. 112
Basic componentsp. 112
Functionp. 113
Connecting the communication cablep. 116
+Outboard motor troubleshootingp. 117
Troubleshooting procedurep. 117
Troubleshooting the power unit using the YDISp. 117
Trouble code and checking stepp. 119
Troubleshooting the power unit using the diagnostic flash indicatorp. 121
Troubleshooting the power unit (trouble code not detected)p. 122
Troubleshooting the PTT unitp. 127
Troubleshooting the lower unitp. 128
+Electrical systemp. 130
+Electrical component and wiring harness routingp. 132
Portp. 132
Junction box assemblyp. 134
Rearp. 136
Topp. 137
Bottom cowlingp. 138
+ECM circuitp. 140
Circuit diagramp. 140
ECM coupler layoutp. 142
+Checking the electrical componentp. 143
Using the YDISp. 143
Measuring the peak voltagep. 143
Using the digital testerp. 144
+Engine control unit and componentp. 144
Checking the main relayp. 144
Checking the engine ECM circuitp. 145
Checking the TPSp. 146
Checking the ISC valvep. 146
Checking the oil pressure sensorp. 147
+Fuel control unit and componentp. 147
Checking the water detection switchp. 147
Checking the fuel injectorp. 148
Checking the high-pressure fuel pumpp. 149
Checking the vapor shut-off valvep. 149
+Charging unit and componentp. 150
Checking the lighting coil (stator assembly)p. 150
Checking the Rectifier Regulatorp. 150
+Ignition unit and componentp. 152
Checking the ignition sparkp. 152
Checking the spark plug wirep. 152
Checking the ignition coilp. 152
Checking the pulser coilp. 153
Checking the air temperature sensorp. 154
Checking the air pressure sensorp. 155
Checking the engine temperature sensorp. 155
Checking the thermoswitchp. 156
Checking the shift cut-off switchp. 157
Checking the shift position switchp. 157
Checking the engine shut-off switchp. 158
+Starting unit and componentp. 158
Checking the starter relayp. 158
Checking the engine start switchp. 159
+Y-COP (standard for European market and optional for Oceanian market)p. 160
Checking Y-COPp. 161
Checking the buzzerp. 161
Checking the Y-COP main wiring harnessp. 161
Checking the button cell batteryp. 162
+Starter motorp. 164
Removing the starter motorp. 166
Checking the starter motor pinionp. 166
Disassembling the starter motorp. 166
Checking the armature (starter motor)p. 168
Checking the brush holderp. 168
Assembling the starter motorp. 169
Installing the starter motorp. 170
+6Y8 Multifunction Meter sensorp. 171
Checking the water pressure sensor (optional)p. 171
Checking the speed sensor (optional)p. 171
+PTT systemp. 172
Checking the PTT relayp. 172
Checking the PTT switch (on bottom cowling)p. 173
Checking the trim sensorp. 173
Checking the tilt limiter (optional)p. 174
+Fuel systemp. 176
+Hose routingp. 178
Fuel hosep. 178
Air hose, pressure regulator hose, and vapor gas hosep. 179
Blowby hose and cooling water hosep. 181
+Fuel linep. 182
Reducing the fuel pressurep. 182
Measuring the fuel pressurep. 182
Checking the pressure regulatorp. 182
+Fuel filterp. 184
Removing the fuel filter assemblyp. 185
Checking the fuel filter assemblyp. 185
Disassembling the fuel filter assemblyp. 186
Checking the fuel filter elementp. 186
Checking the fuel cup assemblyp. 186
Checking the primer pumpp. 186
Assembling the fuel filter assemblyp. 186
Installing the fuel filter assemblyp. 187
+Fuel pumpp. 188
Removing the fuel pump assemblyp. 190
Checking the fuel pump assemblyp. 190
Disassembling the fuel pump assemblyp. 191
Checking the diaphragm and valvep. 191
Assembling the fuel pump assemblyp. 191
Installing the fuel pump assemblyp. 192
+Canister and vapor shut-off valvep. 194
Removing the canisterp. 195
Removing the vapor shut-off valvep. 195
Checking the canisterp. 195
Checking the vapor shut-off valvep. 196
Installing the vapor shut-off valvep. 196
Installing the canisterp. 196
Intake silencerp. 198
+Throttle linkp. 199
Removing the throttle linkp. 200
Checking the throttle linkp. 200
Installing the throttle linkp. 200
+Throttle bodyp. 202
Removing the throttle body assemblyp. 203
Checking the TPSp. 203
Installing the throttle body assemblyp. 203
+Throttle body and throttle link adjustmentp. 204
Adjusting the throttle linkp. 204
Adjusting the throttle valve reference opening anglep. 204
Checking the synchronization of the throttle valvep. 206
+Fuel injectorp. 207
Removing the fuel injectorp. 208
Removing the fuel coolerp. 208
Checking the fuel rail and fuel injectorp. 209
Installing the fuel coolerp. 209
Installing the fuel injectorp. 210
+Intake manifold and vapor separatorp. 211
Draining the fuelp. 214
Removing the intake manifoldp. 214
Removing the vapor separatorp. 214
Checking the fuel filterp. 215
Checking the intake manifoldp. 215
Checking the air pressure sensorp. 215
Checking the ISC valvep. 215
Installing the vapor separatorp. 216
Installing the intake manifoldp. 217
+Vapor separator and high-pressure fuel pumpp. 219
Disassembling the vapor separatorp. 220
Checking the high-pressure fuel pumpp. 220
Checking the vapor separatorp. 220
Assembling the vapor separatorp. 221
+Power unitp. 223
+Power unit (check and adjustment)p. 226
Checking the compression pressurep. 226
Checking the oil pressurep. 226
Checking the valve clearancep. 226
Adjusting the valve clearancep. 228
+Power unit assemblyp. 230
Removing the power unitp. 232
Installing the power unitp. 234
+Flywheel magnetp. 237
Removing the flywheel magnetp. 238
Removing the stator assemblyp. 238
Installing the stator assemblyp. 239
Installing the flywheel magnetp. 240
+Timing beltp. 241
Removing the timing beltp. 242
Removing the drive sprocketp. 242
Checking the timing beltp. 242
Installing the drive sprocketp. 242
Installing the timing beltp. 243
+Starter motorp. 245
Removing the starter motorp. 246
Installing the starter motorp. 246
+Rectifier Regulator and ignition coilp. 248
Removing the Rectifier Regulatorp. 250
Removing the ignition coilp. 250
Checking the spark plugp. 250
Installing the ignition coilp. 251
Installing the Rectifier Regulatorp. 251
Fuse boxp. 252
+Wiring harnessp. 253
Removing the wiring harnessp. 255
Installing the wiring harnessp. 256
+Camshaftp. 258
Removing the driven sprocket and camshaftp. 260
Checking the driven sprocketp. 260
Checking the camshaftp. 260
Installing the driven sprocket and camshaftp. 261
+Cylinder headp. 263
Removing the cylinder headp. 265
Disassembling the cylinder headp. 265
Checking the valve lifterp. 265
Checking the cylinder headp. 266
Checking the valve springp. 266
Checking the valvep. 266
Checking the valve guidep. 267
Replacing the valve guidep. 267
Checking the valve seatp. 268
Refacing the valve seatp. 268
Checking the cylinder head and cylinder block anodep. 270
Assembling the cylinder headp. 270
Installing the cylinder headp. 271
+Exhaust coverp. 273
Removing the exhaust coverp. 275
Checking the PCVp. 275
Checking the thermostatp. 275
Checking the exhaust cover anodep. 275
Installing the exhaust coverp. 276
+Cylinder block (F150A, FL150A)p. 277
Removing the oil pump assemblyp. 279
Removing the oil filter bracketp. 279
Removing the balancer assemblyp. 279
Disassembling the oil pumpp. 279
Checking the oil pumpp. 279
Assembling the oil pumpp. 279
Installing the oil pump assemblyp. 280
Installing the balancer assemblyp. 280
Installing the oil filter bracketp. 281
+Cylinder block (F150B, FL150B)p. 283
Removing the oil pump assemblyp. 285
Removing the oil filter bracketp. 285
Removing the crankcase coverp. 285
Disassembling the oil pumpp. 285
Checking the oil pumpp. 285
Assembling the oil pumpp. 285
Installing the oil pump assemblyp. 285
Installing the crankcase coverp. 285
Installing the oil filter bracketp. 285
+Crankcasep. 286
Disassembling the cylinder blockp. 288
Checking the piston diameterp. 289
Checking the cylinder borep. 289
Checking the piston ringp. 289
Checking the piston ring end gapp. 290
Checking the piston ring groovep. 290
Checking the piston ring side clearancep. 290
Checking the piston pin boss inside diameterp. 290
Checking the piston pin diameterp. 291
Checking the connecting rod small end inside diameter and big end inside diameterp. 291
Checking the connecting rod big end side clearancep. 291
Checking the crankshaftp. 291
Checking the big end oil clearancep. 292
Selecting the crankpin bearingp. 293
Crankpin bearing selection tablep. 295
Checking the journal oil clearancep. 296
Selecting the crankshaft journal bearingp. 297
Crankshaft journal bearing selection tablep. 299
Assembling the cylinder blockp. 300
+Lower unitp. 304
+Lower unit (regular rotation model, L-transom model)p. 308
Removing the lower unitp. 310
Disassembling the propeller (SDS propeller)p. 310
Checking the propellerp. 310
Checking the lower unit anodep. 310
Assembling the propeller (SDS propeller)p. 311
+Lower unit (regular rotation model, X-transom model)p. 313
Removing the lower unitp. 315
Disassembling the propeller (SDS propeller)p. 315
Checking the propellerp. 315
Checking the lower unit anodep. 315
Assembling the propeller (SDS propeller)p. 315
+Water pump and shift rod (regular rotation model)p. 316
Removing the water pump and shift rodp. 318
Disassembling the water pump housingp. 318
Checking the water pump and shift rodp. 318
Assembling the water pump housingp. 319
+Propeller shaft housing (regular rotation model)p. 320
Removing the propeller shaft housing assemblyp. 322
Disassembling the propeller shaft assemblyp. 322
Disassembling the propeller shaft housing assemblyp. 323
Checking the propeller shaftp. 323
Checking the dog clutchp. 323
Checking the propeller shaft housingp. 323
Checking the reverse gearp. 323
Assembling the propeller shaft assemblyp. 324
Assembling the propeller shaft housing assemblyp. 324
+Drive shaft and lower case (regular rotation model)p. 326
Removing the drive shaftp. 328
Disassembling the drive shaft housingp. 328
Disassembling the forward gearp. 328
Disassembling the lower casep. 329
Checking the pinionp. 329
Checking the forward gearp. 329
Checking the drive shaftp. 329
Checking the lower casep. 330
Assembling the forward gearp. 330
Assembling the drive shaft housingp. 330
Assembling the lower casep. 331
Installing the drive shaftp. 332
Installing the propeller shaft housing assemblyp. 333
Installing the shift rodp. 334
Installing the water pumpp. 334
Checking the lower unit for air leakagep. 335
Installing the lower unit (L-transom model)p. 336
Installing the lower unit (X-transom model)p. 337
+Shimming (regular rotation model)p. 339
Shimming workflowp. 339
Shimming check sheetp. 340
Measuring the forward gear backlash and reverse gear backlash before disassemblyp. 342
Shimming procedurep. 345
Shim locationp. 345
Selecting the pinion shim (T3)p. 346
Measuring the forward gear backlashp. 348
Adjusting the forward gear shim thickness (T1)p. 348
Measuring the reverse gear backlashp. 350
Adjusting the reverse gear shim thickness (T2)p. 350
+Lower unit (counter rotation model, L-transom model)p. 352
Removing the lower unitp. 354
Disassembling the propeller (SDS propeller)p. 354
Checking the propellerp. 354
Checking the lower unit anodep. 354
Assembling the propeller (SDS propeller)p. 354
+Lower unit (counter rotation model, X-transom model)p. 355
Removing the lower unitp. 357
Disassembling the propeller (SDS propeller)p. 357
Checking the propellerp. 357
Checking the lower unit anodep. 357
Assembling the propeller (SDS propeller)p. 357
+Water pump and shift rod (counter rotation model)p. 358
Removing the water pump and shift rodp. 360
Disassembling the water pump housingp. 360
Checking the water pump and shift rodp. 360
Assembling the water pump housingp. 360
+Propeller shaft housing (counter rotation model)p. 361
Removing the propeller shaft housing assemblyp. 363
Disassembling the propeller shaft housing assemblyp. 363
Disassembling the forward gearp. 363
Checking the propeller shaftp. 364
Checking the dog clutchp. 364
Checking the propeller shaft housingp. 364
Checking the forward gearp. 364
Assembling the propeller shaft housing assembly and forward gearp. 364
+Drive shaft and lower case (counter rotation model)p. 367
Removing the drive shaftp. 369
Removing the reverse gearp. 369
Disassembling the drive shaft housingp. 369
Disassembling the reverse gearp. 369
Disassembling the lower casep. 369
Checking the pinionp. 370
Checking the reverse gearp. 370
Checking the drive shaftp. 370
Checking the lower casep. 370
Assembling the reverse gearp. 370
Assembling the lower casep. 370
Assembling the drive shaft housingp. 371
Installing the reverse gearp. 371
Installing the drive shaftp. 371
Installing the propeller shaft housing assemblyp. 371
Installing the shift rodp. 371
Installing the water pumpp. 371
Checking the lower unit for air leakagep. 371
Installing the lower unit (L-transom model)p. 371
Installing the lower unit (X-transom model)p. 372
+Shimming (counter rotation model)p. 373
Shimming workflowp. 373
Shimming check sheetp. 374
Measuring the forward gear backlash and reverse gear backlash before disassemblyp. 376
Shimming procedurep. 379
Shim locationp. 379
Selecting the pinion shim (T3)p. 380
Selecting the propeller shaft shim (T4)p. 380
Measuring the forward gear backlashp. 381
Adjusting the forward gear shim thickness (T2)p. 381
Measuring the reverse gear backlashp. 383
Adjusting the reverse gear shim thickness (T1)p. 383
+Bracket unitp. 386
+Shift rod and shift bracketp. 388
Removing the shift rod and shift bracketp. 390
Disassembling the shift bracketp. 390
Assembling the shift bracketp. 390
Installing the shift rod and shift bracketp. 391
+PTT switch and cowling lock leverp. 393
Removing the PTT switchp. 395
Removing the cowling lock leverp. 395
Removing the flushing hosep. 395
Installing the flushing hosep. 395
Installing the cowling lock leverp. 396
Installing the PTT switchp. 396
Bottom cowlingp. 398
+Upper case and mountsp. 400
Removing the upper casep. 402
Installing the upper casep. 402
+Upper casep. 404
Disassembling the upper casep. 405
Checking the drive shaft bushingp. 405
Assembling the upper casep. 405
+Oil pan and exhaust manifoldp. 407
Disassembling the oil pan and exhaust manifoldp. 409
Checking the oil pan and exhaust manifoldp. 409
Checking the oil strainerp. 409
Assembling the oil pan and exhaust manifoldp. 409
+Steering armp. 411
Removing the steering armp. 412
Installing the steering armp. 412
+Clamp bracket and swivel bracketp. 414
Removing the clamp bracketp. 417
Checking the clamp bracket anodep. 417
Installing the clamp bracketp. 417
Adjusting the trim sensor camp. 419
+PTT unitp. 420
Removing the PTT unitp. 421
Checking the hydraulic pressurep. 422
Bleeding the PTT unitp. 424
Installing the PTT unitp. 426
+PTT cylinderp. 428
Removing the tilt ram and trim ramp. 430
Disassembling the tilt ramp. 431
Disassembling the trim ramp. 431
Checking the tilt cylinder and trim cylinderp. 431
Checking the absorber valvep. 431
Assembling the tilt ramp. 431
Assembling the trim ramp. 432
Installing the trim ramp. 433
Installing the tilt ramp. 433
+PTT motorp. 435
Removing the reservoirp. 437
Removing the PTT motorp. 437
Disassembling the PTT motorp. 437
Checking the armature (PTT motor)p. 438
Checking the brushp. 438
Checking the reservoirp. 439
Assembling the PTT motorp. 439
Installing the PTT motorp. 440
Installing the reservoirp. 440
+PTT gear pumpp. 441
Removing the gear pump assemblyp. 444
Disassembling the gear pump housingp. 444
Disassembling the gear pumpp. 444
Checking the gear pumpp. 445
Checking the gear pump housingp. 445
Checking the valve sealp. 445
Checking the filterp. 445
Assembling the gear pumpp. 446
Assembling the gear pump housingp. 447
Installing the gear pump assemblyp. 448
+Maintenancep. 450
+Outlinep. 452
Maintenance interval chart 1p. 452
Maintenance interval chart 2p. 454
+Predelivery checkp. 455
Checking the batteryp. 455
Checking the cooling water pilot holep. 456
Checking the engine oil levelp. 456
Checking the main switch/stop switch/choke switchp. 456
Checking the fuel linep. 457
Checking the gear oil levelp. 457
Checking the shift link/shift cable and throttle link/throttle cable/ throttle pick-up timingp. 457
Checking the outboard motor mounting heightp. 457
Checking the power trim and tilt unitp. 458
Checking the steering systemp. 458
Checking the throttle cable and shift cablep. 458
Test runp. 458
Break-inp. 459
After test runp. 459
+General periodic maintenancep. 459
Checking the anodep. 459
Checking the batteryp. 459
Checking the cooling water inletp. 459
Checking the cooling water pilot holep. 460
Checking the engine idle speed/ noisep. 460
Changing the engine oilp. 460
Checking the engine oil levelp. 461
Replacing the oil filterp. 461
Checking the exhaust guide/exhaust manifoldp. 462
Checking the main switch/stop switch/choke switchp. 462
Checking the fuel filterp. 462
Checking the fuel pumpp. 462
Checking for fuel leakage/oil leakagep. 462
Changing the gear oilp. 462
Checking the gear oil levelp. 463
Greasing pointsp. 463
Checking the PCVp. 465
Checking the propeller/propeller nut/ cotter pinp. 465
Checking the PTT fluid levelp. 465
Checking the power trim and tilt unit operationp. 465
Adjusting the shift link/shift cablep. 466
Checking the spark plugp. 466
Checking the timing beltp. 466
Replacing the timing beltp. 466
Checking the thermostatp. 466
Adjusting the throttle link/throttle cable/throttle pick-up timingp. 466
Checking the cowling lock leverp. 466
Checking the valve clearancep. 466
Checking the impeller/water pump housingp. 466
Indexp. 467
+Appendixp. 477
+Wiring diagramp. 477
How to use the wiring diagramp. 477
Engine control unit and fuel unitp. 478
Ignition unitp. 480
Charging unit and starting unit (F150A, FL150A for European and Oceanian markets)p. 482
Charging unit and starting unit (F150A, FL150A [except for European and Oceanian markets] and F150B, FL150B)p. 484
Control unitp. 486
+Shim selection table and chart (regular rotation model)p. 488
Pinion shim (T3) selection tablep. 488
Forward gear shim (T1) selection chart (F150A)p. 489
Reverse gear shim (T2) selection chart (F150A)p. 489
Forward gear shim (T1) selection chart (F150B)p. 490
Reverse gear shim (T2) selection chart (F150B)p. 490
+Shim selection table and chart (counter rotation model)p. 491
Pinion shim (T3) selection tablep. 491
Propeller shaft shim (T4) selection tablep. 491
Forward gear shim (T2) selection chart (FL150A)p. 492
Reverse gear shim (T1) selection chart (FL150A)p. 492
Forward gear shim (T2) selection chart (FL150B)p. 493
Reverse gear shim (T1) selection chart (FL150B)p. 493
- Lower unit
- Regular-rotation and counter-rotation lower units
- Water pump and shift rod
- Propeller-shaft housing, dog clutch and gears
- Drive shaft and lower case
- Gear backlash, shimming and lower-unit leakage checks
- Bracket unit
- Shift rod, shift bracket, PTT switch and cowling lock lever
- Upper case, mounts, oil pan and exhaust manifold
- Steering arm, clamp bracket and swivel bracket
- PTT hydraulic-pressure checks and bleeding
- PTT cylinder, motor, reservoir and gear pump
- Maintenance
- Maintenance interval charts
- Predelivery checks and test run
- Break-in procedures
- Engine oil, oil filter and gear-oil service
- Fuel, ignition, cooling, propeller and PTT inspections
- Timing-belt, thermostat, valve-clearance and water-pump maintenance
Taken together, these chapters give technicians a connected service path from identifying the correct model and specifications through fault diagnosis, electrical testing, component removal, inspection, adjustment, overhaul, reassembly and scheduled maintenance. The document is particularly detailed in areas where exact measurements matter, including valve clearances, sensor values, fuel and hydraulic pressures, gear backlash, bearing and piston measurements, service limits and fastener torque specifications.
Fuel, Cooling, Lubrication and PTT System Detail
The fuel-system material traces the circuit from the primer pump and fuel filter through low-pressure pumps, vapor separator, high-pressure fuel pump, fuel rail and injectors. Service procedures include fuel-pressure measurement, pressure-regulator checks, pump and diaphragm inspection, throttle-body adjustment, TPS adjustment, throttle synchronization, injector work and vapor-separator service.
Separate diagrams explain engine-oil flow, cooling-water flow, intake and exhaust routing and the PTT hydraulic circuit. The PTT section describes trim-up, tilt-up, trim-down and tilt-down operation, relief-valve action, trim-ram retraction, stationary hydraulic conditions and the shock-absorbing function. Later repair chapters cover hydraulic-pressure testing, bleeding, cylinder service, PTT motor inspection and gear-pump disassembly and checking.
Maintenance and Setup Reference
This service manual is also useful beyond major repairs. Maintenance interval charts support routine inspection planning, while the predelivery and rigging sections cover mounting, control-cable setup, electrical harnesses, battery arrangements, sensor installation and propeller selection. Periodic procedures address anodes, battery condition, cooling-water flow, engine oil and filter service, fuel components, gear oil, lubrication points, spark plugs, timing belt, thermostat, valve clearance, propeller hardware and the water pump.
Service and Repair with the Correct Procedures at Hand
The Yamaha F150A FL150A F150B FL150B 150HP Outboard Service Manual PDF supports everything from routine inspection and rigging work to fault-code diagnosis, electrical testing, fuel-system repair, power-unit disassembly, cylinder-head and crankcase work, lower-unit overhaul and PTT repair. Having the specified measurements, tightening torques, adjustment values, wiring information and illustrated assembly sequences available during the job helps technicians follow the procedures and specifications intended for these particular Yamaha outboards rather than relying on generic repair information.
Your manual is supplied as an instant PDF download after purchase. There is no physical book and no shipping delay. Open the PDF on a computer, tablet or compatible mobile device and print the pages you need for workshop use.
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