Yamaha F100C Bedienungsanleitung

SERVICE MANUAL

60C-28197-5D-11

290429

F100B

F100C

NOTICE

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.

Important information 1

Particularly important information is distinguished in this manual by the following notations:

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS

INVOLVED!

WARNING

Failure to follow WARNING instructions could result in severe injury or death to the machine

operator, a bystander, or a person inspecting or repairing the outboard motor.

CAUTION:

A CAUTION indicates special precautions that must be taken to avoid damage to the out-

board motor.

NOTE:

A NOTE provides key information to make procedures easier or clearer.

F100B, F100C

SERVICE MANUAL

1st Edition, June 2001

Any reprinting or unauthorized use

without the written permission of

Yamaha Motor Co., Ltd.

is expressly prohibited.

Printed in the Netherlands

Contents

General information 1

GEN

INFO

Specifications 2

SPEC

Periodic checks and adjustments 3

CHK

ADJ

Fuel system 4

FUEL

Power unit 5

POWR

Lower unit 6

LOWR

Bracket unit 7

BRKT

Electrical systems 8

ELEC

Troubleshooting 9

TRBL

SHTG

Index

–+

GEN

INFO

60C5D11

General information

How to use this manual.................................................................................1-1

Manual format............................................................................................1-1

Symbols.....................................................................................................1-2

Safety while working......................................................................................1-3

Fire prevention...........................................................................................1-3

Ventilation..................................................................................................1-3

Self-protection ...........................................................................................1-3

Parts, lubricants, and sealants ..................................................................1-3

Good working practices .............................................................................1-4

Disassembly and assembly .......................................................................1-4

Identification...................................................................................................1-5

Applicable models .....................................................................................1-5

Serial number ............................................................................................1-5

Features and benefits....................................................................................1-6

Power unit..................................................................................................1-6

Ignition system.........................................................................................1-11

Bracket unit and the PTT unit ..................................................................1-13

Cooling system ........................................................................................1-14

Lower unit ................................................................................................1-15

Technical tips ...............................................................................................1-16

Carburetor ...............................................................................................1-16

Acceleration pump...................................................................................1-17

Ignition system.........................................................................................1-18

Ignition timing control...............................................................................1-18

Lubrication system...................................................................................1-20

Cooling system ........................................................................................1-21

PTT (power trim and tilt) unit (F100B) .....................................................1-22

PTT (power trim and tilt) unit (F100C) .....................................................1-24

Propeller selection.......................................................................................1-25

Propeller size...........................................................................................1-25

Selection..................................................................................................1-25

60C5D11

Predelivery checks ......................................................................................1-25

Checking the fuel system ........................................................................1-25

Checking the gear oil...............................................................................1-26

Checking the engine oil ...........................................................................1-26

Checking the battery................................................................................1-26

Checking the outboard motor mounting position .....................................1-26

Checking the remote control cables ........................................................1-27

Checking the steering system .................................................................1-27

Checking the gearshift and throttle operation..........................................1-27

Checking the tilt system...........................................................................1-28

Checking the engine start switch and engine stop switch/

engine shut-off switch ............................................................................1-28

Checking the pilot water outlet ................................................................1-28

Test run ...................................................................................................1-28

Break-in ...................................................................................................1-29

After test run ............................................................................................1-29

GEN

INFO General information

1-1 60C5D11

How to use this manual 1

Manual format

The format of this manual has been designed to make service procedures clear and easy to under-

stand. Use the information below as a guide for effective and quality service.

1Parts are shown and detailed in an exploded diagram and are listed in the components list.

2Tightening torque specifications are provided in the exploded diagrams and after a numbered

step with tightening instructions.

3Symbols are used to indicate important aspects of a procedure, such as the grade of lubricant

and lubrication point.

4The components list consist of parts and part quantities, as well as bolt, screw, O-ring, and hose

dimensions.

5Service points regarding removal, checking, and installation are shown in individual illustrations

to explain the relevant procedure.

NOTE:

For troubleshooting procedures, see Chapter 9, “Troubleshooting.”

60C5D11 1-2

Symbols

The symbols below are designed to indicate the content of a chapter.

General information

Specifications

Periodic checks and adjustments

Fuel system

Power unit

Lower unit

Bracket unit

Electrical systems

Troubleshooting

GEN

INFO

SPEC

CHK

ADJ

FUEL

POWR

LOWR

BRKT

ELEC

TRBL

SHTG

–+

Symbols 1to 6indicate specific data.

1Special tool

2Specified oil or fluid

3Specified engine speed

4Specified tightening torque

5Specified measurement

6Specified electrical value

(Resistance, Voltage, Electric current)

Symbols 7to Ain an exploded diagram indicate the grade of lubricant and the lubrication point.

7Apply Yamaha 4-stroke motor oil

8Apply water resistant grease (Yamaha grease A)

9Apply molybdenum disulfide grease

0Apply corrosion resistant grease

(Yamaha grease D)

AApply low temperature resistant grease

(Yamaha grease C)

Symbols Bto Gin an exploded diagram indicate the type of sealant or locking agent and the appli-

cation point.

BApply Gasket Maker®

CApply Yamabond No. 4

DApply LOCTITE®No. 271 (Red)

EApply LOCTITE®No. 242 (Blue)

FApply LOCTITE®No. 572

GApply silicon sealant

123456

7890A

A M D C

BCDEFG

271

242

572

LT SS

How to use this manual

GEN

INFO General information

1-3 60C5D11

Safety while working 1

To prevent an accident or injury and to

ensure quality service, follow the safety pro-

cedures provided below.

Fire prevention

Gasoline is highly flammable.

Keep gasoline and all flammable products

away from heat, sparks, and open flames.

Ventilation

Gasoline vapor and exhaust gas are heavier

than air and extremely poisonous. If inhaled

in large quantities they may cause loss of

consciousness and death within a short time.

When test running an engine indoors (e.g., in

a water tank) be sure to do so where ade-

quate ventilation can be maintained.

Self-protection

Protect your eyes by wearing safety glasses

or safety goggles during all operations involv-

ing drilling and grinding, or when using an air

compressor.

Protect your hands and feet by wearing pro-

tective gloves and safety shoes when neces-

sary.

Parts, lubricants, and sealants

Use only genuine Yamaha parts, lubricants,

and sealants or those recommended by

Yamaha, when servicing or repairing the out-

board motor.

Under normal conditions, the lubricants men-

tioned in this manual should not harm or be

hazardous to your skin. However, you should

follow these precautions to minimize any risk

when working with lubricants.

1. Maintain good standards of personal and

industrial hygiene.

2. Change and wash clothing as soon as

possible if soiled with lubricants.

3. Avoid contact with skin. Do not, for

example, place a soiled rag in your

pocket.

4. Wash hands and any other part of the

body thoroughly with soap and hot water

after contact with a lubricant or lubricant

soiled clothing has been made.

5. To protect your skin, apply a protective

cream to your hands before working on

the outboard motor.

60C5D11 1-4

6. Keep a supply of clean, lint-free cloths for

wiping up spills, etc.

Good working practices

Special tools

Use the recommended special tools to pro-

tect parts from damage. Use the right tool in

the right manner—do not improvise.

Tightening torques

Follow the tightening torque specifications

provided throughout the manual. When tight-

ening nuts, bolts, and screws, tighten the

large sizes first, and tighten fasteners starting

in the center and moving outward.

Non-reusable parts

Always use new gaskets, seals, O-rings, cot-

ter pins, circlips, etc., when installing or

assembling parts.

Disassembly and assembly

1. Use compressed air to remove dust and

dirt during disassembly.

2. Apply engine oil to the contact surfaces

of moving parts before assembly.

3. Install bearings with the manufacture

identification mark in the direction indi-

cated in the installation procedure. In

addition, be sure to lubricate the bearings

liberally.

4. Apply a thin coat of water-resistant

grease to the lip and periphery of an oil

seal before installation.

5. Check that moving parts operate nor-

mally after assembly.

Safety while working

GEN

INFO General information

1-5 60C5D11

Identification 1

Applicable models

This manual covers the following models.

Serial number

The outboard motor serial number is

stamped on a label attached to the port

clamp bracket.

ÈF100B

ÉF100C

1Model name

2Approved model code

3Transom height

4Serial number

NOTE:

If the serial number label is removed, VOID

marks will appear on the label.

Applicable models

F100BET, F100CET

S60C1090

Model name Approved

model code

Starting

serial No.

F100BET 60C L: 000101–

X: 200101–

F100CET 60D L: 000101–

X: 200101–

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