Yamaha F150 Wartungshandbuch

F150AFL150ASERVICE MANUAL63P-28197-3F-11290503

GEN INFOGeneral information1-563P3F11Identification1Applicable modelsThis manual covers the following models.Serial numberThe outboard motor serial nu

POWRPower unit5-1563P3F1119. Install the camshaft caps, and thentighten them to the specified torques intwo stages and in the sequence shown inthe ill

63P3F115-16123456789NOTE:Do not turn the flywheel magnet counter-clockwise.24. Check the valve clearances. Adjust ifnecessary.25. Install the spark pl

POWRPower unit5-1763P3F114. Remove the flywheel magnet.CAUTION:To prevent damage to the engine or tools,screw in the puller set bolts evenly andcomple

63P3F115-181234567899. Install a new timing belt 7 from the drivesprocket side with its part number in theupright position, turn the belt a half turnc

POWRPower unit5-1963P3F112. Disconnect the battery leads 1.3. Disconnect the throttle cable 2 and shiftcable 3.4. Remove the junction box cover, and t

63P3F115-20123456789CAUTION:To prevent damage to the engine or tools,screw in the puller set bolts evenly andcompletely so that the puller plate is pa

POWRPower unit5-2163P3F112. Using a hexagon wrench, turn the timingbelt tensioner 1 clockwise to push thetiming belt, increase strength gradually,and

63P3F115-221234567894. Install the drive sprocket 3 and timingbelt tensioner 4, and then tighten thebolts to the specified torques.5. Check that the “

POWRPower unit5-2363P3F11Cylinder head5No. Part name Q’ty Remarks1Bolt 10 M8 × 55 mm2 Valve shim 163 Valve lifter 164 Valve cotter 325 Valve spring re

63P3F115-241234567895No. Part name Q’ty Remarks18 Intake valve 819 Gasket 1Not reusable20 Collar 221 Anode 122 Screw 3 ø6 × 16 mm23 Anode 2Cylinder he

63P3F111-6123456789Features and benefits1Crankshaft and cylinderThe center of the crankshaft is offset 10 mm (0.39 in) from the center of the cylinder

POWRPower unit5-2563P3F115No. Part name Q’ty Remarks1 Engine temperature sensor 12 Washer 13Bolt 14Plug 1 M14 × 12 mm5 Washer 16 Engine hanger 17Bolt

63P3F115-261234567895No. Part name Q’ty Remarks18 Gasket 1Not reusable19 Thermostat 120 Cover 121 Thermoswitch 122 Holder 123 Bolt 3 M6 × 30 mm24 Gask

POWRPower unit5-2763P3F115No. Part name Q’ty Remarks35 Pressure control valve 136 Spring 137 Gasket 1Not reusable38 Cover 139 Bolt 3 M6 × 20 mm40 Wash

63P3F115-28123456789Removing the cylinder head1. Remove the camshaft caps in thesequence shown.2. Remove the camshafts and cylinderhead bolts in the s

POWRPower unit5-2963P3F112. Measure the valve spring tilt b. Replaceif out of specification.Checking the valves1. Check the valve face for pitting or

63P3F115-301234567892. Calculate the valve stem-to-valve guideclearance as follows. Replace the valveguide if out of specification.Replacing the valve

POWRPower unit5-3163P3F11Checking the valve seat1. Eliminate carbon deposits from the valvewith a scraper.2. Apply a thin, even layer of Mechanic’sblu

63P3F115-32123456789aSlag or rough surfaceCAUTION:Do not over cut the valve seat. Be sure toturn the cutter evenly downward at a pres-sure of 40–50 N

POWRPower unit5-3363P3F117. If the valve seat contact area is too nar-row and situated near the top edge of thevalve face, use a 30° cutter to cut the

63P3F115-341234567893. Measure the camshaft journal diameterc and cylinder head journal inside diam-eter d. Replace the camshaft and cylin-der head if

GEN INFOGeneral information1-763P3F11BalancerA two-piece balancer is used in the crankcase to reduce the secondary forces of inertia produced byrecipr

POWRPower unit5-3563P3F112. Install the valve 2, valve spring 3, andvalve spring retainer 4 in the sequenceshown, and then attach the special ser-vice

63P3F115-36123456789NOTE:• Apply engine oil to the cylinder head boltsbefore installation.• Tighten the M10 bolts to the specifiedtorques in two stage

POWRPower unit5-3763P3F11Removing the exhaust cover1. Remove the cover 1 and thermostat 2.2. Remove the exhaust cover bolts in thesequence shown.Check

63P3F115-38123456789Cylinder block5No. Part name Q’ty Remarks1 Engine hanger 12Bolt 3 M6 × 20 mm3 Oil filler cap 14O-ring 15 Oil filler neck 16Gasket

POWRPower unit5-3963P3F115No. Part name Q’ty Remarks18 Oil seal 1Not reusable19 Oil seal 2Not reusable20 Bolt 4 M6 × 40 mm

63P3F115-401234567895No. Part name Q’ty Remarks1Bolt 10 M10 × 85 mm2Bolt 10 M8 × 55 mm3 Crankcase 14 Main bearing cap 15 Collar 106 Cylinder block 17

POWRPower unit5-4163P3F11Disassembling the cylinder block1. Remove the oil pump.2. Remove the balancer bolts in thesequence shown.3. Remove the crankc

63P3F115-42123456789Checking the cylinder bore1. Measure the cylinder bore (D1–D6) atmeasuring points a, b, and c, and indirection d (D1, D3, D5), whi

POWRPower unit5-4363P3F112. Level the piston ring 1 in the cylinderwith a piston crown.3. Check the piston ring end gap d at thespecified measuring po

63P3F115-44123456789Checking the crankshaft1. Check the teeth of the crankshaft gearfor cracks or wear. Replace the crank-shaft if necessary.2. Measur

63P3F111-8123456789Connecting rodA direction mark for installing the connecting rod to the crankshaft in the proper direction is on theconnecting rod

POWRPower unit5-4563P3F11Checking the crankpin oil clearance1. Clean the bearings and the connectingrod.2. Install the upper bearing into the con-nect

63P3F115-461234567896. Remove the connecting rod cap andmeasure the width of the compressedPlastigauge (PG-1) on each crankpin.Replace the connecting

POWRPower unit5-4763P3F114. Select the suitable color c for the con-necting rod bearing from the table.NOTE:• Example: If the connecting rod big endin

63P3F115-48123456789NOTE:Do not put the Plastigauge (PG-1) over theoil hole in the main journals of the crankshaft.5. Install the remaining half of th

POWRPower unit5-4963P3F113. Select the suitable color c for the mainbearing from the table.NOTE:• Example: If the crankshaft journal mark ais “89” an

63P3F115-501234567893. Install a new oil seal into the oil pumphousing.4. Install a new oil seal 6 and the gasket7, and then tighten the screws 8 to t

POWRPower unit5-5163P3F113. Install the upper bearing into the con-necting rod 4 and the lower bearing intothe connecting rod cap 5.NOTE:Install the c

63P3F115-52123456789NOTE:• Main bearing cap bolts 1–6 can bereused three times.• Apply engine oil to the main bearing capbolts before installation.• M

POWRPower unit5-5363P3F1110. Install half of the main bearings A intothe crankcase.11. Apply sealant to the mating surface ofthe crankcase.NOTE:• Inst

63P3F115-5412345678916. Apply sealant to the mating surface ofthe balancer assembly.NOTE:Do not get any sealant inside the balancerassembly.17. Instal

GEN INFOGeneral information1-963P3F11Intake systemMulti-point, group fuel injection with four separate throttle valves is adopted for the intake syste

POWRPower unit5-5563P3F1120. Before installing the oil filter, be sure tofill it with engine oil through the oil pas-sage j of the oil filter bracket.

63P3F115-561234567894. Connect the PTT switch coupler, shift cutswitch coupler, neutral switch coupler,cooling water pilot hose, and flushinghose.5. I

POWRPower unit5-5763P3F119. Connect the battery leads B.10. Install the stator coil assembly.11. Install the Woodruff key.12. Install the flywheel mag

63P3F115-58123456789— MEMO —Cylinder block

LOWR63P3F11Lower unitSpecial service tools ...6-1Lower unit (regular

63P3F11123456789Lower unit (counter rotation model) ...6-32Removing the lower unit ...

LOWRLower unit6-163P3F11Special service tools6Ring nut wrench 490890-06512Ring nut wrench extension90890-06513Bearing housing puller claw L90890-06502

63P3F116-2123456789Driver rod SS90890-06604Bearing depth plate90890-06603Bearing inner race attachment90890-06640, 90890-06660Drive shaft holder 69089

LOWRLower unit6-363P3F11Shift rod push arm 90890-06052Pinion height gauge90890-06710Digital caliper90890-06704Shimming plate90890-06701Backlash indica

63P3F116-4123456789Lower unit (regular rotation model)6No. Part name Q’ty Remarks1 Lower unit 12 Check screw 13Gasket 2Not reusable4 Bolt 6 M10 × 45 m

63P3F111-10123456789The shape of the fuel injectors is the same for the F115, F150, F200 and F225.Therefore, each fuel injector is identified by color

LOWRLower unit6-563P3F116No. Part name Q’ty Remarks18 Extension 1 X-transom model19 Bolt 6 M10 × 45 mm / X-transom model20 Bolt 1 M10 × 200 mm / X-tra

63P3F116-61234567896No. Part name Q’ty Remarks1 Shift rod 12 Oil seal 1Not reusable3 Oil seal housing 14O-ring 1Not reusable5Spring 16 Circlip 17Bolt

LOWRLower unit6-763P3F116No. Part name Q’ty Remarks18 Collar 119 Spacer 120 Washer 221 Wave washer 122 Impeller 123 Outer plate cartridge 124 Gasket 1

63P3F116-8123456789Removing the lower unit1. Drain the gear oil. For draining proce-dures, see Chapter 3, “Changing thegear oil.”2. Set the gear shift

LOWRLower unit6-963P3F11Checking the water pump and shift rod1. Check the water pump housing for defor-mation. Replace if necessary.2. Check the impel

63P3F116-10123456789Propeller shaft housing (regular rotation model)6No. Part name Q’ty Remarks1 Shift rod joint 12Ball 23 Shift slider 14Ball 25Ball

LOWRLower unit6-1163P3F116No. Part name Q’ty Remarks18 Straight key 119 Needle bearing 120 Oil seal 2Not reusable21 Claw washer 122 Ring nut 123 Cooli

63P3F116-12123456789Removing the propeller shaft housing assembly1. Straighten the claw washer tabs a, andthen remove the ring nut and clawwasher.2. P

LOWRLower unit6-1363P3F112. Remove the ball bearing.3. Remove the oil seals and needle bear-ing.Checking the propeller shaft housing1. Clean the prope

63P3F116-14123456789Assembling the propeller shaft assembly1. Install the dog clutch as shown.NOTE:Install the dog clutch 1 with the “F” mark afacing

GEN INFOGeneral information1-1163P3F1164E type power trim and tilt unitThe 64E type clamp bracket and power trim and tilt unit used for current V4 and

LOWRLower unit6-1563P3F113. Install the thrust washer 5 and new ballbearing 6 onto the reverse gear 7 usinga press.NOTE:Install the ball bearing with

63P3F116-16123456789Drive shaft and lower case (regular rotation model)6No. Part name Q’ty Remarks1 Drive shaft 12Sleeve 13 Cover 14 Oil seal 2Not reu

LOWRLower unit6-1763P3F11Removing the drive shaft1. Remove the drive shaft, drive shaft hous-ing, and pinion, and then pull out the for-ward gear.Disa

63P3F116-18123456789NOTE:Install the claws as shown.2. Remove the needle bearing.Checking the pinion and forward gear1. Check the teeth of the pinion,

LOWRLower unit6-1963P3F11Assembling the lower case1. Install the original shim(s) and taper rollerbearing outer race.CAUTION:Add or remove shim(s), if

63P3F116-201234567892. Apply grease to a new oil seals, and theninstall them into the drive shaft housingto the specified depth.NOTE:Install an oil se

LOWRLower unit6-2163P3F11Installing the propeller shaft housing1. Install the washer 1 and propeller shaftassembly 2 into the propeller shafthousing a

63P3F116-221234567893. Install the Woodruff key into the driveshaft.4. Align the groove in the impeller 5 withthe Woodruff key 6, and then install the

LOWRLower unit6-2363P3F117. Install the new O-ring D and pump hous-ing assembly E into the lower case,tighten the bolts F, and then install theseal G

63P3F116-241234567896. Install the propeller and propeller nut,and then tighten the nut finger tight.Place a block of wood between the anti-cavitation

63P3F111-12123456789Cooling systemThe cooling water flow diagram is as follows.To cool the propeller damper, the cooling system is designed so that fr

LOWRLower unit6-2563P3F11Shimming (regular rotation model)6S63P6390FRPB4T3B361.0A3T1B137.016.3T2B2A1A2

63P3F116-26123456789ShimmingNOTE:• Shimming is not required when assemblingthe original lower case and inner parts.• Shimming is required when assembl

LOWRLower unit6-2763P3F115. Calculate the pinion shim thickness (T3)as shown in the examples below.NOTE:“P” is the deviation of the lower case dimen-s

63P3F116-28123456789NOTE:“F” is the deviation of the lower case dimen-sion from standard. The “F” mark a isstamped on the trim tab mounting surface of

LOWRLower unit6-2963P3F113. Calculate the reverse gear shim thick-ness (T2) as shown in the examplesbelow.NOTE:“R” is the deviation of the lower case

63P3F116-301234567894. Install the backlash indicator onto thedrive shaft (22.4 mm [0.88 in] in diame-ter), then the dial gauge onto the lowerunit.5.

LOWRLower unit6-3163P3F1110. Slowly turn the drive shaft clockwise andcounterclockwise and measure the back-lash when the drive shaft stops in eachdir

63P3F116-32123456789Lower unit (counter rotation model)6No. Part name Q’ty Remarks1 Lower unit 12 Check screw 13Gasket 2Not reusable4 Bolt 6 M10 × 45

LOWRLower unit6-3363P3F116No. Part name Q’ty Remarks18 Extension 1 X-transom model19 Bolt 6 M10 × 45 mm / X-transom model20 Bolt 1 M10 × 200 mm / X-tr

63P3F116-341234567896No. Part name Q’ty Remarks1 Shift rod 12 Oil seal 1Not reusable3 Oil seal housing 14O-ring 1Not reusable5Spring 16 Circlip 17Bolt

GEN INFOGeneral information1-1363P3F11Lubrication systemThe lubrication oil flow diagram is as follows.There is a small hole in the relief valve to al

LOWRLower unit6-3563P3F116No. Part name Q’ty Remarks18 Collar 119 Spacer 120 Washer 221 Wave washer 122 Impeller 123 Outer plate cartridge 124 Gasket

63P3F116-36123456789Removing the lower unit1. Drain the gear oil. For draining proce-dures, see Chapter 3, “Changing thegear oil.”2. Set the gear shif

LOWRLower unit6-3763P3F11Checking the water pump and shift rod1. Check the water pump housing for defor-mation. Replace if necessary.2. Check the impe

63P3F116-38123456789Propeller shaft housing (counter rotation model)6No. Part name Q’ty Remarks1 Shift rod joint 12Ball 23 Shift slider 14Ball 25Ball

LOWRLower unit6-3963P3F116No. Part name Q’ty Remarks18 Propeller shaft housing 119 Straight key 120 Needle bearing 121 Oil seal 2Not reusable22 Claw w

63P3F116-40123456789Removing the propeller shaft housing assembly1. Straighten the claw washer tabs a, andthen remove the ring nut and clawwasher.2. P

LOWRLower unit6-4163P3F11Disassembling the propeller shaft housing1. Remove the oil seals and needle bear-ing.Checking the propeller shaft housing1. C

63P3F116-42123456789NOTE:• Install the needle bearing with the manufac-ture identification mark a facing toward theoil seal (propeller side).• When us

LOWRLower unit6-4363P3F115. Install the thrust washer 0, forward gearA, and dog clutch B using a press.NOTE:Install the dog clutch B with the “F” mark

63P3F116-44123456789Drive shaft and lower case (counter rotation model)6No. Part name Q’ty Remarks1 Drive shaft 12Sleeve 13 Cover 14 Oil seal 2Not reu

63P3F111-14123456789A dual oil drain system is adopted.An oil drain bolt is located on the bottom of the oil pan.A long dipstick guide, which reaches

LOWRLower unit6-4563P3F116No. Part name Q’ty Remarks18 Needle bearing 2Not reusable19 Reverse gear 1

63P3F116-46123456789Removing the drive shaft1. Remove the drive shaft assembly andpinion, and then pull out the reverse gearand thrust bearing.Disasse

LOWRLower unit6-4763P3F112. Remove the needle bearing from thelower case.Checking the pinion and reverse gear1. Check the teeth of the pinion, and the

63P3F116-481234567892. Install the needle bearing outer case intothe lower case.NOTE:Apply gear oil to the needle bearing outercase before installatio

LOWRLower unit6-4963P3F112. Apply grease to new oil seals, and theninstall them into the drive shaft housingto the specified depth.NOTE:Install an oil

63P3F116-50123456789CAUTION:Add or remove shim(s), if necessary, ifreplacing the forward gear, taper rollerbearing, propeller shaft housing, thrustwas

LOWRLower unit6-5163P3F113. Install the Woodruff key into the driveshaft.4. Align the groove in the impeller 5 withthe Woodruff key 6, and then instal

63P3F116-52123456789Installing the lower unit1. Set the gear shift to the neutral positionat the lower unit.2. Align the center of the set pin a with

LOWRLower unit6-5363P3F116. Install the propeller and propeller nut,and then tighten the nut finger tight.Place a block of wood between the anti-cavit

63P3F116-54123456789Shimming (counter rotation model)6S63P6740FRPB4T3B361.0A3T1B136.5A1T2B5A5A4A2T4B7B616.7B2Drive shaft and lower case (counter rotat

NOTICEThis manual has been prepared by Yamaha primarily for use by Yamaha dealers and their trainedmechanics when performing maintenance procedures an

GEN INFOGeneral information1-1563P3F11Fuel systemA fuel pressure regulator is incorporated onto the outlet of the electric fuel pump to obtain a compa

LOWRLower unit6-5563P3F11ShimmingNOTE:• Shimming is not required when assemblingthe original lower case and inner parts.• Shimming is required when as

63P3F116-56123456789NOTE:“P” is the deviation of the lower case dimen-sion from standard. The “P” mark a isstamped on the trim tab mounting surface of

LOWRLower unit6-5763P3F112. Calculate the reverse gear shim thick-ness (T1) as shown in the examplesbelow.NOTE:“F” is the deviation of the lower case

63P3F116-581234567893. Calculate the forward gear shim thick-ness (T2) as shown in the examplesbelow.NOTE:“R” is the deviation of the lower case dimen

LOWRLower unit6-5963P3F112. Install the thrust bearing 4 onto the pro-peller shaft 5, and then measure thepropeller shaft flange and thrust bearingthi

63P3F116-601234567898. Measure the propeller shaft free play.Repeat steps 1–7 if out of specification.Backlash (counter rotation model)6Measuring the

LOWRLower unit6-6163P3F115. Set the lower unit upside down.NOTE:Install the dial gauge so that the plunger acontacts the mark b on the backlash indica

63P3F116-6212345678914. Turn the shift rod to the reverse positionc with the shift rod push arm.15. Slowly turn the drive shaft clockwise andcountercl

LOWRLower unit6-6363P3F11— MEMO —

63P3F11BRKT123456789Bracket unitSpecial service tools ...7-1Bottom c

63P3F111-16123456789Rectifier RegulatorA water-cooled Rectifier Regulator is incorporated onto the exhaust outer cover.This allows for a compact engin

BRKTBracket unit7-163P3F11Special service tools7Up relief fitting90890-06773Down relief fitting90890-06774Hydraulic pressure gauge90890-06776Trim and

63P3F117-2123456789Bottom cowling7No. Part name Q’ty Remarks1Bracket 12 Shift cut switch 13Bracket 14 Neutral switch 15Screw 2 ø4 × 16 mm6Plate 17 Bus

BRKTBracket unit7-363P3F117No. Part name Q’ty Remarks18 Spacer 119 Bushing 120 Bolt 1 M6 × 35 mm21 Bracket 122 Ball 123 Bolt 124 Grease nipple 125 Spa

63P3F117-41234567897No. Part name Q’ty Remarks1 Bottom cowling 12 Rubber seal 13Grommet 24Bolt 4 M8 × 35 mm5Grommet 46Grommet 47 Collar 48 Cowling loc

BRKTBracket unit7-563P3F117No. Part name Q’ty Remarks18 Grommet 119 Holder 120 Bolt 1 M6 × 20 mm21 Retaining plate 122 Bolt 2 M6 × 30 mm23 Cable holde

63P3F117-6123456789Upper case, steering arm, swivel bracket and clamp brackets7No. Part name Q’ty Remarks1 Upper case assembly 12 Cover 23 Ground lead

BRKTBracket unit7-763P3F117No. Part name Q’ty Remarks18 Steering arm 119 Washer 220 Washer 221 Trim stopper 222 Nut 223 Bolt 4

63P3F117-81234567897No. Part name Q’ty Remarks1 Upper case 12 Dowel 23Grommet 14Damper 15Screw 2 ø5 × 15 mm6 Baffle plate 17 Drive shaft bushing 18 Ci

BRKTBracket unit7-963P3F117No. Part name Q’ty Remarks18 Washer 219 Washer 220 Upper mount 221 Washer 222 Collar 223 Bolt 2 M8 × 30 mm24 Bolt 4 M10 × 4

63P3F117-101234567897No. Part name Q’ty Remarks1Bolt 8 M8 × 35 mm2 Muffler 13 Dowel 24Pipe 15 Rubber seal 16Gasket 2Not reusable7Plate 18Gasket 1Not r

GEN INFOGeneral information1-1763P3F11Technical tips1Electronic control systemThe electronic control system consists of the sensors and the ECM (elect

BRKTBracket unit7-1163P3F117No. Part name Q’ty Remarks18 Gasket 1Not reusable19 Gasket 1Not reusable20 Exhaust guide 1S63P7110201918171615121413111089

63P3F117-12123456789Draining the engine oil1. Place a drain pan under the drain hole,and then remove the drain bolt 1 and letthe oil drain completely.

BRKTBracket unit7-1363P3F113. Install the oil pan 4, and then tighten thebolts finger tight.4. Install the exhaust manifold 5 and bolts,and then tight

63P3F117-1412345678911. Install the upper mounts E and bolts intothe upper case.12. Install the bracket F and bolts, and thentighten the bolts to the

BRKTBracket unit7-1563P3F114. Install the steering yoke 9 to the steer-ing arm 3 by aligning the center a ofthe yoke with the center b of the steer-in

63P3F117-16123456789Clamp brackets7No. Part name Q’ty Remarks1 Swivel bracket 12 Clamp bracket 13 Clamp bracket 14 Self-locking nut 15 Grease nipple 6

BRKTBracket unit7-1763P3F117No. Part name Q’ty Remarks18 Anode 119 Through tube 120 Bolt 1 M8 × 20 mm21 Tilt stop lever 122 Bush 423 Collar 124 Distan

63P3F117-18123456789Removing the clamp brackets1. Remove the power trim and tilt unit. Forremoval procedures, see “Removing thepower trim and tilt uni

BRKTBracket unit7-1963P3F114. Fully tilt the outboard motor up, and thensupport it with the tilt stop lever 3. WARNINGAfter tilting up the outboard mo

63P3F117-20123456789Power trim and tilt unit7No. Part name Q’ty Remarks1 Power trim and tilt unit 12 PTT motor lead 23Shaft 14 Plastic tie 3Not reusab

63P3F111-18123456789Fail-safe controlIf the electrical components malfunction, the ECM controls the ignition and fuel injection as shown inthe table.D

BRKTBracket unit7-2163P3F117No. Part name Q’ty Remarks1 Power trim and tilt motor 12 Reservoir 13 Reservoir cap 14O-ring 15O-ring 1Not reusable6Bolt 3

63P3F117-221234567897No. Part name Q’ty Remarks1Screw 1 ø4 × 15 mm2Stator 13 Armature 14O-ring 1Not reusable5Screw 2 ø4 × 12 mm6Brush holder 17Brush 2

BRKTBracket unit7-2363P3F117No. Part name Q’ty Remarks1Bolt 4 M5 × 16 mm2 Gear pump assembly 13Ball 24 Shuttle piston 25O-ring 2Not reusable6 Main val

63P3F117-241234567897No. Part name Q’ty Remarks18 Up-relief valve seat 119 O-ring 1Not reusable20 Filter 221 O-ring 1Not reusable22 Down-relief valve

BRKTBracket unit7-2563P3F117No. Part name Q’ty Remarks1 Tilt ram 12Trim ram 23 Cylinder body 14 Free piston 15 Backup ring 16O-ring 1Not reusable7 Dus

63P3F117-261234567897No. Part name Q’ty Remarks18 O-ring 1Not reusable19 O-ring 1Not reusable20 Washer 121 Nut 122 Ball 423 Valve 424 Spring 4S63P7350

BRKTBracket unit7-2763P3F11Removing the power trim and tilt unit1. Fully tilt the outboard motor up, and thensupport it with the tilt stop lever 1. WA

63P3F117-28123456789NOTE:Hold the power trim and tilt unit with onehand, and pull the upper mount shaft out at adownward angle with the other.6. Remov

BRKTBracket unit7-2963P3F117. Connect the PTT motor leads to the bat-tery terminals to fully retract the trim andtilt rams.8. Reverse the PTT motor le

63P3F117-3012345678913. Connect the PTT motor leads to the bat-tery terminals to fully retract the trim andtilt rams, and then measure the hydraulicpr

GEN INFOGeneral information1-1963P3F11Warning controlThis outboard motor is equipped with warning control functions to avoid serious engine damage.The

BRKTBracket unit7-3163P3F113. Remove the lead holder 1 and rubberspacers 2 from the stator, and then slidethem away from the stator.4. Remove the stat

63P3F117-321234567892. Check the brush and circuit breaker forcontinuity. Replace if there is no continu-ity.CAUTION:Do not touch the bimetal b, other

BRKTBracket unit7-3363P3F11Assembling the power trim and tilt motor1. Connect the PTT motor leads 1, andthen tighten the screws 2.2. Push the brushes

63P3F117-341234567893. Drain the fluid from the reservoir andcheck it for damage. Replace if neces-sary.4. Check the reservoir cap and O-ring fordamag

BRKTBracket unit7-3563P3F115. Remove the main valves. WARNINGNever look into the pump housing open-ing while removing the main valvesbecause the main

63P3F117-361234567892. Install new O-rings 6 onto the mainvalves 7, and then install the mainvalves into the gear pump housing.3. Install the drive ge

BRKTBracket unit7-3763P3F11Disassembling the tilt cylinder and trim cylinder1. Loosen the tilt cylinder end screw, andthen remove the tilt piston asse

63P3F117-38123456789Checking the tilt cylinder and trim cylinder1. Disassemble the tilt piston assembly.2. Check the tilt piston and free piston forsc

BRKTBracket unit7-3963P3F11Assembling the tilt piston and trim pistons1. Install the new dust seal 1 and new O-rings 2 and 3 onto the tilt cylinder en

63P3F117-40123456789Assembling the power trim and tilt unit1. Fill the tilt cylinder with the specifiedamount of the recommended fluidthrough the hole

63P3F111-20123456789Shift cut controlThis outboard motor is equipped with a shift cut control system for easier shifting.This device misfires and reta

BRKTBracket unit7-4163P3F114. Install the trim piston assemblies into thetrim cylinders, and then tighten the trimcylinder end screws to the specified

63P3F117-4212345678910. Install the tilt piston assembly into the tiltcylinder, and then tighten the tilt cylinderend screw to the specified torque.CA

BRKTBracket unit7-4363P3F1115. Remove the reservoir cap, and thencheck the fluid level in the reservoir.NOTE:If the fluid is at the correct level, the

63P3F117-44123456789NOTE:• Repeat this procedure so that the rams goup and down four or five times (be sure towait a few seconds before switching thel

BRKTBracket unit7-4563P3F11Bleeding the power trim and tilt unit (built-in)1. Fully turn the manual valve counterclock-wise.2. Fully tilt the outboard

63P3F117-46123456789Power trim and tilt electrical system71Fuse holder2Fuse (20 A)3Fuse (50 A)4Battery5Power trim and tilt relay6Power trim and tilt m

BRKTBracket unit7-4763P3F11Checking the fuse1. Check the fuse for continuity. Replace ifthere is no continuity.Checking the power trim and tilt relay1

63P3F117-48123456789Checking the trim sensor1. Measure the trim sensor resistance.Replace if out of specification.NOTE:Turn the lever 1 and measure th

BRKTBracket unit7-4963P3F11— MEMO —

63P3F11ELEC– +123456789Electrical systemsSpecial service tools ...8-

GEN INFOGeneral information1-2163P3F11Propeller selection1The performance of a boat and outboardmotor will be critically affected by the sizeand type

ELECElectrical systems– +8-163P3F11Special service tools8Ignition tester90890-06754Digital circuit tester90890-03174Peak voltage adapter B90890-03172T

63P3F118-2123456789Checking the electrical components8Measuring the peak voltageNOTE:Before troubleshooting the peak voltage,check that all electrical

ELECElectrical systems– +8-363P3F11Electrical components8Port view1ECM2Starter motor3Rectifier Regulator4Thermoswitch5Ignition coil6Oil pressure senso

63P3F118-4123456789Junction box assembly1ECM2Power trim and tilt relay3Starter relay4Diode5Fuse (30 A)6Main relay7Fuse (20 A)8Fuse (50 A)9Intake air t

ELECElectrical systems– +8-563P3F11Aft view1Intake air pressure sensor2Throttle position sensor3Fuel injector4Shift cut switch5Neutral switch6Ignition

63P3F118-6123456789Top view1Fuel injector2Ignition coil3Starter motor4Stator coil5Engine temperature sensor6Throttle position sensor7Idle speed contro

ELECElectrical systems– +8-763P3F11Wiring harnessConnect to:1Fuse holder2Fuse holder3Diagnostic flash indicator4Starter relay5Ground6Power trim and ti

63P3F118-8123456789B: BlackBr : BrownG: GreenGy : GrayL: BlueLg : Light greenO : OrangeP: PinkR: RedSb : Sky blueW: WhiteY : YellowB/O : Black/orangeB

ELECElectrical systems– +8-963P3F11Ignition and ignition control system81Spark plug2Ignition coil3Thermoswitch4Oil pressure sensor5Pulser coil6Stator

63P3F118-101234567898B: BlackG: GreenO : OrangeP: PinkR: RedY : YellowB/O : Black/orangeB/W : Black/whiteB/Y : Black/yellowG/B : Green/blackG/R : Gree

63P3F111-22123456789Predelivery checks1To make the delivery process smooth andefficient, the predelivery checks should becompleted as explained below.

ELECElectrical systems– +8-1163P3F11Checking the ignition spark gap1. Remove the spark plug wire cover.2. Disconnect the spark plug caps from thespark

63P3F118-12123456789Checking the ECM1. Disconnect a ignition coil coupler.2. Connect the test harness (2 pins) to theignition coil.3. Measure the ECM

ELECElectrical systems– +8-1363P3F11Checking the throttle position sensor1. Remove the flywheel magnet cover.2. Connect the test harness (3 pins) to t

63P3F118-14123456789Checking the thermoswitch1. Place the thermoswitches in a containerof water and slowly heat the water.2. Check the switch for cont

ELECElectrical systems– +8-1563P3F11Fuel control system81Pulser coil2ECM3Intake air temperature sensor4Fuse holder5Main relay6Fuse (20 A)7Fuse (50 A)8

63P3F118-161234567898B: BlackG: GreenL: BlueO : OrangeP: PinkR: RedY : YellowB/Y : Black/yellowG/B : Green/blackG/R : Green/redG/Y : Green/yellowP/G :

ELECElectrical systems– +8-1763P3F11Checking the injectors1. Measure the resistance of the fuel injec-tors. Replace if out of specification.NOTE:Check

63P3F118-18123456789Starting system81Fuse holder2Fuse (30 A)3Fuse (20 A)4Fuse (50 A)5Starter relay6Starter motor7BatteryÈTo remote control box/switch

ELECElectrical systems– +8-1963P3F11Checking the fuses1. Check the fuses for continuity. Replace ifthere is no continuity.Checking the starter relay1.

63P3F118-20123456789Starter motor8No. Part name Q’ty Remarks1 Clip 12 Pinion stopper 13 Starter motor pinion 14Spring 15Bolt 2 M6 × 35 mm6 Housing 17

GEN INFOGeneral information1-2363P3F11Checking the outboard motor mounting height1. Check that the anti-cavitation plate isaligned with the bottom of

ELECElectrical systems– +8-2163P3F118No. Part name Q’ty Remarks18 Brush assembly 119 Brush spring 420 Brush holder 121 Plate 122 Washer 123 Bracket 12

63P3F118-22123456789Removing the starter motor pinion1. Slide the pinion stopper 1 down asshown, and then remove the clip 2.NOTE:Remove the clip with

ELECElectrical systems– +8-2363P3F114. Check the armature for continuity.Replace if out of specifications.Checking the brushes1. Measure the brush len

63P3F118-24123456789Charging system81Stator coil2Rectifier Regulator3Fuse holder4Fuse (50 A)5Accessory battery6BatteryB: BlackG: GreenR: RedS63P8230#1

ELECElectrical systems– +8-2563P3F11Checking the stator coil1. Disconnect the stator coil coupler.2. Connect the test harness (3 pins) to thestator co

63P3F11TRBLSHTG123456789TroubleshootingSpecial service tools ...9-1Y

TRBLSHTGTroubleshooting9-163P3F11Special service tools9Yamaha Diagnostic System60V-85300-02Yamaha Diagnostic System60V-WS853-02Diagnostic flash indica

63P3F119-2123456789Yamaha Diagnostic System9IntroductionFeaturesThe newly developed Yamaha Diagnostic System provides quicker detection and analysis o

TRBLSHTGTroubleshooting9-363P3F11Hardware requirementsMake sure that your computer meets the following requirements before using this software.Compute

63P3F119-4123456789Connecting the communication cable to the outboard motorModels: F(L)150ABow viewS63P90303-pin communication couplerYamaha Diagnosti

63P3F111-24123456789Checking the steering system1. Check the steering friction for properadjustment.2. Check that the steering operatessmoothly.3. Che

TRBLSHTGTroubleshooting9-563P3F11NOTE:• Before troubleshooting the outboard motor, check the compression pressure, the mounting andrigging of the outb

63P3F119-6123456789YesNoCheck the wiring harness for continuity.YesRepair or replace the wiring har-ness.NoDisassemble and check the starter motor.Rep

TRBLSHTGTroubleshooting9-763P3F11Ignition systemCheck the condition of the spark plugs.Clean, adjust, or replace the spark plugs.NoCheck the ignition

63P3F119-8123456789Fuel systemYesRepair or replace the spark plug wires.NoGood condition?Check the ECM output peak voltage.Check the main relay for co

TRBLSHTGTroubleshooting9-963P3F11YesNoCheck the starting system or the ignition system.Replace the injectors.Good condition?NoYesReplace the diaphragm

63P3F119-10123456789Symptom 2: Engine speed at wide open throttle is low, engine speed decreases, or enginestalls (poor acceleration or poor decelerat

TRBLSHTGTroubleshooting9-1163P3F11Ignition systemCheck the condition of the spark plugs.Clean, adjust, or replace the spark plugs.NoCheck the ignition

63P3F119-12123456789Fuel systemYesRepair or replace the spark plug wires.NoGood condition?Check the ECM output peak voltage.Check the electric fuel pu

TRBLSHTGTroubleshooting9-1363P3F11YesNoYesNoCheck the injector resistance and check the injectors for clogs.Replace the pressure regulator.Replace the

63P3F119-14123456789Lubrication systemAdd engine oil to the correct level.NoCheck the oil pump for debris or oil leaks.YesNoCheck the oil passage.Repl

ContentsGeneral information1GEN INFOSpecifications2SPECPeriodic checks and adjustments3CHK ADJFuel system4FUELPower unit5POWRLower unit6LOWRBracket un

GEN INFOGeneral information1-2563P3F11Checking the cooling water pilot hole1. Check that cooling water is dischargedfrom the cooling water pilot hole.

TRBLSHTGTroubleshooting9-1563P3F11Symptom 3: Engine speed not stable at low speeds.YesRepair or replace the defective part.NoCheck the neutral switch

63P3F119-16123456789Ignition systemCheck the condition of the spark plugs.Clean, adjust, or replace the spark plugs.NoCheck the ignition spark using t

TRBLSHTGTroubleshooting9-1763P3F11Fuel systemCheck the fuel pump dia-phragm.Check the vapor separator nee-dle valve.YesNoReplace the diaphragm.Replace

63P3F119-18123456789Symptom 4: Hunting occurs.Symptom 5: Engine speed rises even when the throttle position is fixed.Check the throttle valve opening

TRBLSHTGTroubleshooting9-1963P3F11Self-diagnosis9Diagnosing the electronic control system1. Connect the special service tool to theoutboard motor as s

63P3F119-20123456789Code Symptom1Normal13 Incorrect pulser coil signal15Incorrect engine temperature sensor signal18Incorrect throttle position sensor

Indexi-163P3F11Numerics64E type power trim and tilt unit...1-11A.Adjusting the throttle link and throttle cable ...

63P3F11i-2123456789IndexChecking the injectors...8-17Checking the intake air temperature sensor ...

Indexi-363P3F11E.ECM ...1-17Electrical ...2-7

63P3F11i-4123456789IndexRemoving the steering arm...7-14Removing the timing belt and sprockets ...5-20Removing the water pump and

63P3F11SPEC123456789SpecificationsGeneral specifications...2-1Maintena

Wiring diagramF150AET, FL150AET1 Spark plug2 Ignition coil3 Thermoswitch4 Oil pressure sensor5 Diode6 Starter relay7 Starter motor8 Starting battery9

YAMAHA MOTOR CO., LTD.Printed in the NetherlandsJul. 2003 – 1.2 × 1 CR(E)

15 16 17 18 191234 7891042322212 14351543 4437 38 39 4031 33 3426 27 2817 18 19 2029 3021 23 241234 891056711 12 13 14B/OW/BL/WP/WYP/WP/BR/YG/YBPPu/BP

SPECSpecifications2-163P3F11General specifications2Item UnitModelF150AET FL150AETDimensionOverall length mm (in) 822 (32.4)Overall width mm (in) 511 (

63P3F112-2123456789(*1)RON: Research Octane NumberPON: Pump Octane Number = (RON + Motor Octane Number)/2(*2)CCA: Cold Cranking AmpereEN: European Nor

SPECSpecifications2-363P3F11Maintenance specification2Power unitItem UnitModelF150AET FL150AETPower unitMinimum compression pressure(*1) kPa (kgf/cm2,

63P3F112-4123456789Oil ringDimension B mm (in) 2.40–2.47 (0.0945–0.0972)Dimension T mm (in) 2.30–2.70 (0.0906–0.1063)End gap mm (in) 0.15–0.60 (0.0059

SPECSpecifications2-563P3F11Valve liftersValve lifter outside diameter mm (in) 32.982–32.997 (1.2985–1.2990)Valve lifter-to-cylinder head clearancemm

63P3F112-6123456789Lower unitOil pumpDischargeat 97–103 °C (207–217 °F) with 10W-30 engine oilL (US gal, lmp gal)/min8.0 (2.113, 1.760) at 700 r/minPr

SPECSpecifications2-763P3F11ElectricalItem UnitModelF150AET FL150AETIgnition and ignition control systemIgnition timing (cylinder #1) Degree TDC at en

63P3F112-8123456789Starter motorType Sliding gearOutput kW 1.40Cranking time limit Second 30BrushesStandard length mm (in) 15.5 (0.61)Wear limit mm (i

GEN INFO63P3F11General informationHow to use this manual...1-1Manual for

SPECSpecifications2-963P3F11DimensionsExteriorS63P2010mm (in)12˚4˚256 (10.1)433 (17.0)629 (24.8)L: 1,032 (40.7)X: 1,148 (45.2)164 (6.5) 698 (27.5)75 (

63P3F112-10123456789Clamp bracketS63P2020mm (in)82 (3.2)13 (0.5)180 (7.1)163.5 (6.4)254 (10.0)55.5 (2.2)367 (14.4)163.5 (6.4)125.4 (4.9)125.4 (4.9)180

SPECSpecifications2-1163P3F11Tightening torques2Specified torquesPart to be tightened Thread sizeTightening torquesN·mkgf·mft·lbFuel systemFuel filter

63P3F112-12123456789Exhaust cover bolt1stM660.64.42nd 12 1.2 8.9Thermostat cover bolt1stM660.64.42nd 12 1.2 8.9Exhaust cover plugM14 23 2.3 17.0M18 55

SPECSpecifications2-1363P3F11General torquesThis chart specifies tightening torques forstandard fasteners with a standard ISOthread pitch. Tightening

63P3F11CHK ADJ123456789Periodic checks and adjustmentsSpecial service tools ...

CHK ADJPeriodic checks and adjustments3-163P3F11Special service tools3Oil filter wrench90890-06830Digital tachometer90890-06760Timing light90890-03141

63P3F113-2123456789Maintenance interval chart3Use the following chart as a guideline for general maintenance.Adjust the maintenance intervals accordin

CHK ADJPeriodic checks and adjustments3-363P3F11Top cowling3Checking the top cowling1. Check the fitting by pushing the cowlingwith both hands. Adjust

63P3F113-4123456789NOTE:Be sure not to spill any fuel when removingthe fuel filter cup.Power unit3Checking the engine oil1. Place the outboard motor i

63P3F11123456789Predelivery checks ...1-22Checking the fuel system

CHK ADJPeriodic checks and adjustments3-563P3F116. Install the oil filler cap and dipstick, andthen start the engine and warm it up for 5minutes.7. Tu

63P3F113-61234567895. Pour the specified amount of the recom-mended engine oil into the oil filler hole.6. Install the oil filler cap and dipstick, an

CHK ADJPeriodic checks and adjustments3-763P3F114. Check the spark plug gap a. Adjust if outof specification.5. Install the spark plugs, tighten them

63P3F113-8123456789Checking the cooling water passage1. Check the cooling water inlet cover 1and cooling water inlet for clogs. Clean ifnecessary.2. P

CHK ADJPeriodic checks and adjustments3-963P3F114. Turn throttle lever 1 7 and the throttlecam 8 counterclockwise so that they arein the positions sho

63P3F113-1012345678910. Contact the stopper 0 on the throttlelever 2 to the fully closed stopper A onthe cylinder block and check that throttlecam rol

CHK ADJPeriodic checks and adjustments3-1163P3F115. Operate throttle lever 2 to check that thethrottle valves fully close and fully open.NOTE:The thro

63P3F113-121234567896. Adjust the position of the shift cable jointuntil its hole is aligned with the set pin.CAUTION:The shift cable joint must be sc

CHK ADJPeriodic checks and adjustments3-1363P3F11Power trim and tilt unit3Checking the power trim and tilt operation1. Fully tilt the outboard motor u

63P3F113-14123456789NOTE:If the oil is at the correct level, the oil shouldoverflow out of the check hole when thecheck screw is removed.3. If necessa

GEN INFOGeneral information1-163P3F11How to use this manual1Manual formatThe format of this manual has been designed to make service procedures clear

CHK ADJPeriodic checks and adjustments3-1563P3F11Checking the lower unit for air leakage1. Remove the check screw 1, and theninstall the special servi

63P3F113-16123456789CAUTION:Do not oil, grease, or paint the anodes orthe trim tab, otherwise they will be ineffec-tive.2. Replace the anodes or trim

CHK ADJPeriodic checks and adjustments3-1763P3F11NOTE:Apply grease to the grease nipple until itflows from the bushings a.2. Apply low temperature res

63P3F11FUEL123456789Fuel systemSpecial service tools ...4-1Hose rout

FUELFuel system4-163P3F11Special service tools4Vacuum/pressure pump gauge set90890-06756Fuel pressure gauge90890-06786Digital circuit tester90890-0317

63P3F114-2123456789Hose routing4Fuel and blowby hoses1Blowby hoses2Fuel hose (fuel tank-to-fuel filter)3Fuel hoses (fuel filter-to-fuel pumps)4Fuel ho

FUELFuel system4-363P3F11Fuel filter, fuel pump, and intake silencer4No. Part name Q’ty Remarks1 Intake assembly 12Bolt 5 M8 × 40 mm3Bolt 2 M8 × 20 mm

63P3F114-41234567894No. Part name Q’ty Remarks1 Throttle lever 1 12 Throttle cam 13 Throttle lever 2 14 Throttle link rod 15Bolt 1 M6 × 35 mm6Bolt 2 M

FUELFuel system4-563P3F114No. Part name Q’ty Remarks1Bolt 1 M6 × 14 mm2Bracket 13Bolt 1 M6 × 16 mm4 Washer 15 Holder 16Cap 17O-ring 1Not reusable8 Fue

63P3F114-61234567894No. Part name Q’ty Remarks1Screw 3 ø6 × 35 mm2 Cover 13 Fuel pump body 2 14 Fuel pump body 1 15 Plunger 16Spring 17Nut 38Spring 19

63P3F111-2123456789SymbolsThe symbols below are designed to indicate the content of a chapter.General informationSpecificationsPeriodic checks and adj

FUELFuel system4-763P3F11Checking the fuel pumps1. Place a drain pan under the fuel hoseconnections, and then disconnect thefuel hoses from the fuel p

63P3F114-81234567892. Push down on the plunger and the dia-phragm, turn fuel pump body 1 1approximately 90° to a position where thepin 2 can be remove

FUELFuel system4-963P3F11Intake assembly and vapor separator4No. Part name Q’ty Remarks1Bolt 2 M6 × 25 mm2 Fuel cooler 13 Vapor separator 14 Fuel hose

63P3F114-101234567894No. Part name Q’ty Remarks1O-ring 1Not reusable2 Float chamber 13Drain screw 14 Pressure regulator 15Screw 2 M6 × 12 mm6O-ring 1N

FUELFuel system4-1163P3F114No. Part name Q’ty Remarks1 Fuel rail 12Bolt 2 M8 × 25 mm3O-ring 4Not reusable4 Rubber damper 4Not reusable5 Fuel injector

63P3F114-121234567894No. Part name Q’ty Remarks18 Collar 619 Grommet 320 Bracket 121 Screw 4 ø6 × 16 mm22 Screw 2 ø4 × 12 mm23 Throttle position senso

FUELFuel system4-1363P3F11Measuring the fuel pressure1. Remove the cap 1.2. Connect the fuel pressure gauge to thepressure check valve. WARNING• When

63P3F114-14123456789 WARNING• When connecting the fuel pressuregauge, first cover the connectionbetween the gauge and the pressurecheck valve with a c

FUELFuel system4-1563P3F11Reducing the fuel pressure1. Remove the cap 1.2. Cover the pressure check valve a of thefuel rail with a rag, and then press

63P3F114-16123456789Synchronizing the throttle valvesCAUTION:Do not adjust the throttle valve when it isoperating properly. Excess adjustmentmay cause

GEN INFOGeneral information1-363P3F11Safety while working1To prevent an accident or injury and toensure quality service, follow the safety pro-cedures

FUELFuel system4-1763P3F115. Turn the synchronizing screw 5 so thatthe vacuum pressure of cylinder #3 or #4is within 4 kPa (30 mmHg) based on thevacuu

63P3F114-18123456789NOTE:To measure the output voltage, connect thepositive tester probe to the pink wire of thetest harness and the negative tester p

FUELFuel system4-1963P3F1112. Install the throttle joint link rod 3 so thethrottle cam roller 4 is aligned with thealignment mark a as shown.NOTE:Make

63P3F114-20123456789— MEMO —Intake assembly and vapor separator

POWR63P3F11Power unitSpecial service tools ...5-1Power unit...

63P3F11123456789Cylinder block ...5-38Disassembling the cyl

POWRPower unit5-163P3F11Special service tools5Compression gauge90890-03160Compression gauge extension90890-06563Test harness (3 pins)New: 90890-06869C

63P3F115-2123456789Valve guide reamer90890-06804Valve seat cutter holder90890-06316Valve seat cutter90890-06324, 90890-06325, 90890-06326, 90890-06327

POWRPower unit5-363P3F11Power unit5No. Part name Q’ty Remarks1 Dipstick 12Bolt 1 M6 × 20 mm3 Dipstick guide 14O-ring 1Not reusable5 Flywheel magnet co

63P3F115-41234567895No. Part name Q’ty Remarks1Nut 12 Washer 13 Flywheel magnet 14Bolt 4 M6 × 35 mm5 Holder 16Bracket 27 Collar 28 Holder 19 Stator co

63P3F111-41234567896. Keep a supply of clean, lint-free cloths forwiping up spills, etc.Good working practicesSpecial service toolsUse the recommended

POWRPower unit5-563P3F115No. Part name Q’ty Remarks1 Starter motor 12Bolt 3 M8 × 45 mm3Terminal 14Nut 15Cap 16Bolt 1 M6 × 10 mm7 Starter motor lead 18

63P3F115-61234567895No. Part name Q’ty Remarks1Grommet 12 Fuse holder 13 Terminal plate 44Terminal 85Terminal 86 Fuse holder 17Fuse 2 50 A8Screw 4 ø5

POWRPower unit5-763P3F115No. Part name Q’ty Remarks1 Junction box 12ECM 13Bolt 4 M6 × 16 mm4 Wiring harness 15Bolt 1 M6 × 20 mm6 Washer 27Nut 28Cap 29

63P3F115-81234567895No. Part name Q’ty Remarks18 Holder 119 Bolt 1 M6 × 12 mm20 Intake air temperature sensor 121 Grommet 122 Screw 1 ø6 × 19 mm23 Bra

POWRPower unit5-963P3F115No. Part name Q’ty Remarks1 Timing belt 12 Timing belt tensioner 13Bolt 4 M5 × 40 mm4 Drive sprocket 15Plate 16 Woodruff key

63P3F115-101234567895No. Part name Q’ty Remarks18 Screw 8 ø4 × 8 mm19 Plate 120 Grommet 621 Cylinder head cover 122 Bolt 15 M6 × 30 mm23 Holder 224 Bo

POWRPower unit5-1163P3F11Checking the compression pressure1. Start the engine, warm it up for 5 min-utes, and then turn it off.2. Remove the engine st

63P3F115-12123456789Checking the oil pressure sensor1. Connect the test harness (3 pins) to theoil pressure sensor.2. Start the engine and warm it up

POWRPower unit5-1363P3F115. Check the intake valve clearance for cyl-inders #1 and #2, and exhaust valveclearance for cylinders #1 and #3. Adjustif ou

63P3F115-1412345678913. Remove the camshafts.14. Remove the valve shim 7 from the valvelifter 8 using compressed air.NOTE:Do not mix the valve train p