15 HP 2004 4 Stroke

F15Z
SUPPLEMENTARY
SERVICE MANUAL
LIT-18616-02-12 66M-28197-ZA-1X
NOTICE
This Supplementary Service Manual has been prepared to introduce new service and data
for the F15Z. For complete service information procedures, it is necessary to use this
Supplementary Service Manual together with the following manual.
F15A (F15) SERVICE MANUAL: 66M-28197-Z7-11
F15Z
SUPPLEMENTARY SERVICE MANUAL
©2000 by Yamaha Motor Corporation, U.S.A.
1st Edition, April 2000
All rights reserved. Any reprinting or
unauthorized use without the written
permission of Yamaha Motor Corporation, U.S.A.
is expressly prohibited.
Printed in USA
P/N LIT-18616-02-12
HOW TO USE THIS MANUAL
MANUAL FORMAT
All of the procedures in this manual are organised in a sequential, step-by-step format. The
information has been compiled to provide the mechanic with an easy to read, handy
reference that contains comprehensive explanations of all disassembly, repair, assembly, and
inspection operations.
In this revised format, the condition of a faulty component will precede an arrow symbol and
the course of action required will follow the symbol, e.g.,
•Bearings
Pitting/scratches ➔ Replace.
MODEL INDICATION
Multiple models are referred to in this manual and their model indications are noted as
follows.
Model name F15AEP F15AEHP
USA and Canada name F15PR F15PH
Indication F15AEP F15AEHP
ILLUSTRATIONS
The illustrations within this service manual represent all of the designated models.
CROSS REFERENCES
The cross references have been kept to a minimum. Cross references will direct you to the
appropriate section or chapter.
IMPORTANT INFORMATION
In this Service Manual particularly important information is distinguished in the following
ways.
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
outboard motor.
NOTE:
A NOTE provides key information to make procedures easier or clearer.
HOW TO USE THIS MANUAL
1 The main points regarding removing/installing and disassembly/assembly procedure are
shown in the exploded views.
2 The numbers in the exploded views indicate the required sequence of the procedure and
should be observed accordingly.
3 Symbols are used in the exploded views to indicate important aspects of the procedure.
A list of meanings for these symbols is provided on the following page.
4 It is important to refer to the job instruction charts at the same time as the exploded
views.
These charts list the sequence that the procedures should be carried out in, as well as
providing exploded on part names, quantities, dimensions and important points relating
to each relevant task.
Example:
O-ring 39.5 x 2.5 mm: inside diameter (D) x ring diameter (d)
5 In addition to tightening torques, the dimensions of the bolts and screws are also
mentioned.
Example:
Bolt and screw size 10 x 25 mm : bolt and screw diameter (D) x length (d)
6 In addition to the exploded views and job instruction charts, this manual provides
individual illustrations when further explanations are required to explain the relevant
procedure.
SYMBOLS
Symbols 1 to 9 are designed as thumb-tabs
1 2 to indicate the content of a chapter.
1 General information
2 Specifications
3 Periodic check and adjustment
3 4
4 Fuel system
5 Power unit
6 Lower unit
7 Bracket unit
5 6 8 Electrical system
9 Trouble analysis
Symbols : to E indicate specific data.

7 8
: Special tool
A Specified liquid
B Specified engine speed
C Specified torque
9 : D Specified measurement
E Specified electrical value
[Resistance (Ω), Voltage (V), Electrical
current (A)]
A B
Symbols F to H in an exploded diagram
indicate the grade of lubricant and the
location of the lubricant point.
C D F Apply Yamaha 4-stroke motor oil

G Apply water resistant grease
(Yamaha grease A, Yamaha marine
grease)
E F H Apply molybdenum disufied oil
Symbols I to N in an exploded diagram

indicate the grade of the sealing or locking
G H agent and the location of the application
point.
I Apply Gasket Maker®
I J J Apply Yamabond #4
(Yamaha bond number 4)
K Apply LOCTITE® No.271 (Red LOCTITE)
L Apply LOCTITE® No.242 (Blue LOCTITE)
K L
M Apply LOCTITE® No.572
N Apply silicon sealant
M N
GENERAL INFORMATION
IDENTIFICATION................................................................................................. 1
SERIAL NUMBER ......................................................................................... 1
STARTING SERIAL NUMBERS ................................................................... 1
SPECIAL TOOLS ................................................................................................. 2
REMOVAL AND INSTALLATION ................................................................ 2
SPECIFICATIONS
GENERAL SPECIFICATIONS.............................................................................. 3
MAINTENANCE SPECIFICATIONS.................................................................... 5
POWER UNIT................................................................................................ 5
LOWER.......................................................................................................... 8
ELECTRICAL ................................................................................................. 8
DIMENSIONS ............................................................................................. 11
TIGHTENING TORQUES .................................................................................. 13
SPECIFIED TORQUES ................................................................................ 13
GENERAL TORQUES ................................................................................. 14
PERIODIC INSPECTIONS AND ADJUSTMENT

MAINTENANCE INTERVAL CHART ................................................................ 15
POWER TILT SYSTEM...................................................................................... 16
CHECKING THE POWER TILT (PT) FLUID LEVEL .................................... 16
GENERAL .......................................................................................................... 16
CHECKING THE ANODE ............................................................................ 16
POWER UNIT
POWER UNIT .................................................................................................... 17
REMOVING/INSTALLING THE POWER UNIT 1 (F15AEP/F15PR) ........... 17
REMOVING/INSTALLING THE POWER UNIT 1 (F15AEHP/F15PH) ........ 19
ELECTRICAL UNIT ............................................................................................ 21
REMOVING/INSTALLING THE ELECTRICAL UNIT .................................. 21
CYLINDER HEAD AND OIL PUMP ................................................................... 24
REMOVING/INSTALLING THE CYLINDER HEAD AND OIL PUMP ......... 24
OIL PUMP.......................................................................................................... 25
DISASSEMBLING/ASSEMBLING THE OIL PUMP ................................... 25
CAMSHAFT AND VALVE ................................................................................. 26
REMOVING/INSTALLING THE CAMSHAFT AND VALVE ....................... 26
CHECKING THE ROCKER ARM AND ROCKER ARM SHAFT .................. 28
CHECKING THE CAMSHAFT ..................................................................... 28
REFACING THE VALVE SEAT ................................................................... 29
INSTALLING THE CAMSHAFT OIL SEAL ................................................. 30
OIL FILTER, THERMOSTAT AND EXHAUST COVER..................................... 31
DISASSEMBLING/ASSEMBLING THE OIL FILTER, THERMOSTAT
AND EXHAUST COVER ............................................................................. 31
BRACKET UNIT
STEERING HANDLE ASSEMBLY (F15AEHP/F15PH) ..................................... 33
REMOVING/INSTALLING THE STEERING HANDLE ASSEMBLY........... 33
DISASSEMBLING/ASSEMBLING THE STEERING HANDLE
ASSEMBLY ................................................................................................. 34
INSTALLING THE PT SWITCH .................................................................. 36
BOTTOM COWLING ASSEMBLY .................................................................... 37
REMOVING/INSTALLING THE BOTTOM COWLING ASSEMBLY .......... 37
SWIVEL AND STEERING BRACKET................................................................ 40
REMOVING/INSTALLING THE SWIVEL AND STEERING BRACKET ...... 40
POWER TILT (PT) UNIT .................................................................................... 41
REMOVING/INSTALLING THE POWER TILT (PT) UNIT .......................... 41
DISASSEMBLING/ASSEMBLING THE POWER TILT (PT) CYLINDER .... 43
DISASSEMBLING THE POWER TILT (PT) CYLINDER ............................. 45
ASSEMBLING THE POWER TILT (PT) CYLINDER ................................... 46
DISASSEMBLING/ASSEMBLING THE VALVES AND PUMP 1 ............... 50
INSTALLING THE RELIEF VALVE.............................................................. 52
DISASSEMBLING/ASSEMBLING THE PT MOTOR.................................. 53
REMOVING THE ARMATURE ................................................................... 54
CHECKING THE PT MOTOR ...................................................................... 54
CHECKING THE PT MOTOR ASSEMBLY ................................................. 56
INSTALLING THE OIL SEAL ...................................................................... 56
DISASSEMBLING/ASSEMBLING THE VALVES AND PUMP 2 ............... 57
CLAMP BRACKET ............................................................................................. 59
REMOVING/INSTALLING THE CLAMP BRACKET ................................... 59
ELECTRICAL SYSTEM
ELECTRICAL COMPONENTS........................................................................... 61
TOP VIEW AND PORT SIDE VIEW ............................................................ 61
FRONT VIEW (F15AEP/F15PH) .................................................................. 62
FRONT VIEW (F15AEHP/F15PH) ............................................................... 63
STARTER MOTOR ............................................................................................ 64
DISASSEMBLING/ASSEMBLING THE STARTER MOTOR...................... 64
REMOVING THE PINION NUT .................................................................. 66
CHECKING THE PINION GEAR ................................................................. 66
CHECKING THE ARMATURE .................................................................... 66
CHECKING THE BRUSH HOLDER ............................................................. 67
POWER TILT (PT) SYSTEM.............................................................................. 68
POWER TILT (PT) SYSTEM (F15AEP/F15PR) ........................................... 68
POWER TILT (PT) SYSTEM (F15AEHP/F15PH) ........................................ 69
CHECKING THE PT SWITCH ..................................................................... 70
CHECKING THE TRAILER SWITCH ........................................................... 70
CHECKING THE PT RELAY ........................................................................ 70
TROUBLE ANALYSIS
TROUBLE ANALYSIS ....................................................................................... 72
TROUBLE ANALYSIS CHART ................................................................... 72
IDENTIFICATION
IDENTIFICATION
SERIAL NUMBER
The outboard motor’s serial number is
stamped on a label which is attached to the
port clamp bracket.
NOTE:
As an antitheft measure, a special label on
which the outboard motor’s serial number
is stamped is bonded to the port clamp
bracket. The label is specially treated so
that peeling it off causes cracks across the
serial number.
1 Model name
2 Approval model code
3 Transom height
4 Serial number
STARTING SERIAL NUMBERS

The starting serial number blocks are as
follows:
Model name Applicable Starting

World USA/ model serial
wide Canada code number
F15AEP F15PR 66M L:800141-
F15AEHP F15PH 66M L:900111-
1
SPECIAL TOOLS
SPECIAL TOOLS
Using the correct special tools
recommended by Yamaha, will aid the
work and enable accurate assembly and
tune-up.
Improvising and using improper tools can
damage the equipment.
NOTE:
For U.S.A. and Canada, use part numbers
that start with “J-”, “YB-” “YM-”, “YU-”
or “YW-”.
For other countries, use part numbers
that start with “90890-”.
1 REMOVAL AND INSTALLATION

1 Power tilt wrench:
P/N. YB-06560
90890-06560
2 Oil seal attachment:

2a b P/N. YB-06112, YB-06196 .............. a
90890-06614, 90890-06196.... b
3 Driver rod:
P/N. YB-06071 ................................ a
3a b 90890-06652........................... b
4 Valve seat cutter set:

P/N. 90890-06803
5 Valve seat cutter:

4 5
P/N. 90890-06556
2
GENERAL SPECIFICATIONS
Model
World wide F15AEP F15AEHP
Item Unit
USA F15PR F15PH
Canada F15PR F15PH
DIMENSION
Overall length mm (in) 643 (25.3) 1,001 (39.4)
Overall width mm (in) 369 (14.5) 427 (16.8)
Overall height mm (in) 1,207 (47.5) 1,207 (47.5)
WEIGHT
(with aluminum propeller) kg (lb) 54 (119.0) 55 (121.3)
PERFORMANCE
Maximum output kW (hp) 11 (15)
@ 5,000 r/min
Full throttle operating range r/min 4,500 - 5,500
Maximum fuel consumption L (US gal, lmp 5.3 (1.39, 1.16)
gal)/h
@ 5,000 r/min
POWER UNIT
Type 4 stroke, OHC, in-line
Number of cylinders 2
Displacement cm3 (cu. in) 323 (19.7)
Bore x stroke mm (in) 59.0 x 59.0 (2.32 x 2.32)
Compression ratio 9.19
Compression pressure kPa (kg/cm2, psi) 961 (9.8, 139.4)
Number of carburetors 1
Control system Remote control Tiller control
Starting system Electric motor
Ignition control system C.D.I
Lighting coil Single phase
Lighting coil output V-A DC12-10 with rectifier/regulator
Starting enrichment Choke valve
Spark plug DPR6EA-9
Exhaust system Propeller hub
Lubrication system Wet sump
Ignition timing Degree (BTDC) 5 – 30
FUEL AND OIL
Fuel type Unleaded regular gasoline
Fuel rating PON (*1) 86
PON (*2) 91
(*1) PON : Pump Octane Number
(*2) RON : Research Octane Number
3
Model
Item Unit
USA F15PR F15PH
Canada F15PR F15PH
Engine oil type 4-stroke engine oil
Engine oil grade API SE, SF, SE-SF, SE-SF-CC
SAE 10W-30, 10W-40
Engine oil quantity
With oil filter cm3 (US oz, Imp oz) 1,200 (40.6, 42.2)
Without oil filter cm3 (US oz, Imp oz) 1,000 (33.8, 35.2)
Gear oil type Hypoid gear oil
Gear oil grade SAE #90
Gear oil quantity cm3 (US oz, Imp oz) 250 (8.45, 8.80)
BRACKET
Trim angle Degrees 8, 12, 16, 20
Tilt-up angle Degrees 63
Steering angle Degrees 40 + 40
DRIVE UNIT
Gear positions F-N-R
Gear ratio 2.08 (27:13)
Gear type Spiral bevel gear
Propeller direction (rear view) Clockwise
Propeller drive system Spline
Propeller series mark J
ELECTRICAL
Battery capacity Ah (kC) 40 (144)
Cold cranking A 380
4
MAINTENANCE SPECIFICATIONS
POWER UNIT
Model
Item Unit
USA F15PR F15PH
Canada F15PR F15PH
CYLINDER HEAD
Warpage limit mm (in) 0.1 (0.004)
CYLINDER
Bore mm (in) 59.000 - 59.015 (2.3228 - 2.3234)
Taper limit mm (in) 0.08 (0.003)
Out-of-round limit mm (in) 0.05 (0.002)
Cylinder block inside diameter mm (in) A : Blue 38.033 - 38.040 (1.4974 - 1.4976)
B : Black 38.025 - 38.032 (1.4970 - 1.4973)
C : Brown 38.016 - 38.024 (1.4967 - 1.4970)
CAMSHAFT
Intake (A) mm (in) 27.596 - 27.696 (1.0865 - 1.0904)
Intake (B) mm (in) 23.95 - 24.05 (0.9429 - 0.9468)
Exhaust (A) mm (in) 27.616 - 27.716 (1.0872 - 1.0912)
Exhaust (B) mm (in) 23.95 - 24.05 (0.9429 - 0.9468)
Cylinder head journal diameter mm (in) 17.973 - 17.984 (0.7076 - 0.7080)
(driven gear end)
Cylinder head journal diameter mm (in) 34.935 - 34.955 (1.3754 - 1.3762)
(center)
Oil pump housing journal diameter mm (in) 15.973 - 15.984 (0.6289 - 0.6293)
(oil pump end)
Camshaft round limit mm (in) 0.03 (0.001)
TIMING BELT
Slack mm (in) 0 - 10 (0 - 0.4)
ROCKER ARM SHAFT
Outside diameter mm (in) 12.941 - 12.951 (0.5095 - 0.5099)
ROCKER ARM
Inside diameter mm (in) 13.000 - 13.018 (0.5118 - 0.5125)
VALVES
Face angle Degree 90.5 - 91.5
Valve clearance (cold)
Intake mm (in) 0.15 - 0.25 (0.006 - 0.010)
Exhaust mm (in) 0.20 - 0.30 (0.008 - 0.012)
Head diameter (A)

Intake mm (in) 27.9 - 28.1 (1.10 - 1.11)
Exhaust mm (in) 21.9 - 22.1 (0.86 - 0.87)
Face width (B)
Intake mm (in) 2.0 - 3.1 (0.079 - 0.122)
Exhaust mm (in) 2.0 - 3.1 (0.079 - 0.122)
5
Model
Item Unit
USA F15PR F15PH
Canada F15PR F15PH
Seat width (C) mm (in) 0.6 - 0.8 (0.02 - 0.03)
Margin thickness (D)
Intake mm (in) 0.50 - 0.90 (0.020 - 0.035)
Exhaust mm (in) 0.50 - 0.90 (0.020 - 0.035)
Stem outside diameter
Intake mm (in) 5.475 - 5.490 (0.2155 - 0.2161)
Exhaust mm (in) 5.460 - 5.475 (0.2150 - 0.2156)
Guide inside diameter mm (in) 5.500 - 5.512 (0.2165 - 0.2170)
Stem-to-guide clearance
Intake mm (in) 0.010 - 0.037 (0.0004 - 0.0015)
Exhaust mm (in) 0.025 - 0.052 (0.0010 - 0.0020)
Stem runout limit mm (in) 0.016 (0.0006)
VALVE SPRING
Free length mm (in) 34.4 (1.35)
Free length limit mm (in) 32.7 (1.29)
Set length mm/kg (in/lb) 25.4 / 11.0 (1.00 / 24.2)
Tilt limit mm (in) 1.5 (0.06)
PISTON
Piston-to-cylinder clearance mm (in) 0.035 - 0.065 (0.0014 - 0.0026)
Piston diameter (D)
Standard mm (in) 58.950 - 58.965 (2.3206 - 2.3215)
Measuring point (H) mm (in) 5 (0.20)
Pin boss inside diameter mm (in) 14.004 - 14.015 (0.5513 - 0.5518)
Oversize piston diameter
1st (except for USA) mm (in) 59.25 (2.333)
2nd mm (in) 59.50 (2.343)
PISTON PIN
Outside diameter mm (in) 13.996 - 14.000 (0.5510 - 0.5512)
PISTON RINGS
Top ring
Type Barrel
Dimensions (B x T) mm (in) 1.2 x 2.25 (0.05 x 0.09)
End gap (installed) mm (in) 0.15 - 0.30 (0.006 - 0.012)
Wear limit mm (in) 0.50 (0.020)
Side clearance (installed) mm (in) 0.013 - 0.035 (0.0005 - 0.0013)
2nd ring
Type Plain
Side clearance (installed) mm (in) 0.02 - 0.04 (0.001 - 0.002)
6
Model
Item Unit
USA F15PR F15PH
Canada F15PR F15PH
Oil ring
CONNECTING ROD
Small end inside diameter mm (in) 14.015 - 14.029 (0.5518 - 0.5523)
Big end oil clearance mm (in) 0.021 - 0.045 (0.0008 - 0.0018)
CRANKSHAFT
Crankshaft width mm (in) 126.70 - 126.90 (4.99 - 5.00)
Crankshaft big end side clearance mm (in) 0.05 - 0.22 (0.002 - 0.009)
Crankcase mark-bearing color A:Blue B:Black C:Brown
Crankshaft journal clearance mm (in) 0.012 - 0.045 (0.0005 - 0.0018)
Runout limit mm (in) 0.03 (0.0012)
THERMOSTAT
ID mark S60°C
Valve opening temperature °C (°F) 58 - 62 (136.4 - 143.6)
Full-open temperature °C (°F) 70 (158)
Valve lift mm (in) 3 (0.12)
FUEL PUMP
Discharge L (US gal, lmp 25 (6.60, 5.50)
gal)/h
@ 3,000 r/min
Pressure kPa (kg/cm2, psi) 117.6 (1.2, 17.07)
Diaphragm stroke mm (in) 2.4 - 4.8 (0.094 - 0.189)
Plunger stroke mm (in) 3.52 - 6.57 (0.139 - 0.259)
OIL PUMP
Type Trochoid
Outer rotor-to-housing clearance a mm (in) 0.10 - 0.15 (0.004 - 0.006)

Outer rotor-to-inner rotor clearance b mm (in) 0.04 - 0.14 (0.002 - 0.006)
Rotor-to-cover clearance c mm (in) 0.03 - 0.09 (0.001 - 0.004)
Relief valve operating pressure kPa (kg/cm2, psi) 388 - 450 (3.88 - 4.50, 55.2 - 64.0)
CARBURETOR
ID mark 66M10
Main jet # 104
Pilot jet # 45
Float height a mm (in) 9.5 - 10.5 (0.37 - 0.41)
Idle speed r/min 900 - 1,000
Trolling speed r/min 800 - 900
7
LOWER
Model
Item Unit
USA F15PR F15PH
Canada F15PR F15PH
GEAR BACKLASH (SST indicator)
Pinion-forward
Minimum mm (in) 0.19 (0.007)
Mid-point mm (in) 0.53 (0.02)
Maximum mm (in) 0.86 (0.034)
Pinion-reverse
Minimum mm (in) 0.95 (0.037)
Mid-point mm (in) 1.30 (0.051)
Maximum mm (in) 1.65 (0.064)
Pinion shim mm 1.13 / 1.2
Forward shim mm 0.10 / 0.12 / 0.15 / 0.18 / 0.30 / 0.40 / 0.50
Reverse shim mm 0.1 / 0.2 / 0.3 / 0.4 / 0.5
TEST PROPELLER
Test propeller Part no. YB - 1619 / 90890-01619
Specific revolution r/min 5,200 - 5,400
ELECTRICAL
Model
Item Unit
USA F15PR F15PH
Canada F15PR F15PH
IGNITION SYSTEM
Ignition timing Degree 5 - 30
Charge coil output peak voltage (BTDC)
(Br-L)
@ cranking 1 (500 r/min) open V 130
@ cranking 2 (500 r/min) loaded V 130
@ 1,500 r/min V 180
@ 3,500 r/min V 180
Pulser coil output peak voltage
(W/G-B)
@ cranking 1 (500 r/min) open V 4.0
@ cranking 2 (500 r/min) loaded V 3.5
@ 1,500 r/min V 11.0
@ 3,500 r/min V 23.0
CDI unit output peak voltage
(O-B)
@ cranking 1 (500 r/min) open V 120
@ cranking 2 (500 r/min) loaded V 120
@ 1,500 r/min V 165
@ 3,500 r/min V 165
Spark plug gap mm (in) 0.9 (0.04)
8
Model
Item Unit
USA F15PR F15PH
Canada F15PR F15PH
Charge coil resistance (Br-L) Ω 272 - 408
Pulser coil resistance (W/G-B) Ω 234 - 348
Ignition coil resistance (O-B)
Primary Ω 0.16 - 0.24
Secondary kΩ 3.92 - 5.88
IGNITION CONTROL SYSTEM
Oil pressure switch kPa (kg/cm2, psi) 14.7 (0.15, 2.13)
Engine speed limiter
Rated timing r/min 6,200
Ignition off r/min 6,800
Reset r/min 6,000
STARTING SYSTEM
Fuse A 20
STARTER MOTOR
Type Bendix
Rating Second 30
Output kW 1.1
Brush length mm (in) 12.6 (0.5)
Limit mm (in) 6.4 (0.25)
Commutator undercut mm (in) 2 (0.08)
Limit mm (in) 0.8 (0.03)
CHARGING SYSTEM
Lighting coil output peak voltage
V1 (G-G/W)
@ cranking 1 (500 r/min) open V 6.5
@ cranking 2 (500 r/min) loaded V 6.0
@ 1,500 r/min V 21
@ 3,500 r/min V 46
Rectifier output peak voltage
V2 (R-B)
@ cranking (500 r/min) open V 6.0
@ 1,500 r/min V 20
@ 3,500 r/min V 45
Charging current A@ r/min 10 @ 5,000
Lighting coil resistance (G-G/W) Ω@20°C (68°F) 0.24 - 0.36
9
Model
Item Unit
USA F15PR F15PH
Canada F15PR F15PH
POWER TILT (PT) UNIT
Fluid type ATF Dexroin ll
Brush length mm (in) 6 (0.25)
Limit mm (in) 3 (0.12)
Commutator diameter mm (in) 16.5 (0.65)
Limit mm (in) 15.5 (0.61)
10
DIMENSIONS
Symbol Model
Unit
USA F15PR F15PH
Canada F15PR F15PH
L1 mm (in) 483 (19.0) 483 (19.0)
L2 mm (in) 152 (6.0) 160 (6.3)
L3 mm (in) – 517 (20.4)
L4 mm (in) 363 (14.3) 363 (14.3)
L6 mm (in) 840 (33.1) 840 (33.1)
L7 mm (in) 308 (12.1) 308 (12.1)
H1 mm (in) 835 (32.9) 835 (32.9)
H2 mm (in) 372 (14.7) 372 (14.7)
H3 mm (in) 135 (5.3) 135 (5.3)
H4 mm (in) 570 (22.4) 570 (22.4)
H6 mm (in) 641 (25.2) 641 (25.2)
H7 mm (in) 261 (10.3) 261 (10.3)
H8 mm (in) – 12 (0.5)
H9 mm (in) 587 (23.1) 587 (23.1)
W1 mm (in) 182 (7.2) 182 (7.2)
W5 mm (in) 329 (13.0) 329 (13.0)
W6 mm (in) – 575 (22.6)
A1 Degree 40 40
A2 Degree 63 63
A3 Degree 12 12
11
Symbol Model
Unit
USA F15PR F15PH
Canada F15PR F15PH
B1 mm (in) 95.3 (3.8)
B2 mm (in) 92.4 (3.6)
B3 mm (in) 95.3 (3.8)
B4 mm (in) 94.5 (3.7)
B5 mm (in) 111 (4.4)
B6 mm (in) 326.7 (12.9)
B9 mm (in) 18 (0.7)
D1 mm (in) 8.3 (0.3)
D2 mm (in) 10 (0.4)
C1 mm (in) 40 (1.6)
C2 mm (in) 66 (2.6)
12
TIGHTENING TORQUES
TIGHTENING TORQUES
SPECIFIED TORQUES
Part Thread Tightening torque
Part to be tightened Q’ty
name size N•m kgfm ftlb
POWER UNIT
Power unit mounting Bolt M8 6 21 2.1 15.2
Flywheel Nut M16 1 110 11.0 80
Carburetor Bolt M6 2 10 1.0 7.2
Oil filter – – 1 18 1.8 13
Oil filter plug (cylinder block) – M20 1 40 4.0 29
Spark plug – M12 2 18 1.8 13
Drive sprocket Nut M28 1 55 5.5 39.8
Driven sprocket Bolt M6 1 13 1.3 9.4
Cylinder head cover Bolt M6 4 8 0.8 5.8
1st 15 1.5 10.8
Bolt M8 6
2nd 30 3.0 22
Cylinder head
1st 6 0.6 4.5
Bolt M6 3
2nd 12 1.2 8.7
Valve adjusting screw – M6 4 14 1.4 10.0
Oil pump Bolt M6 3 8 0.8 5.8
Oil pump cover Screw M6 2 4 0.4 2.9
1st 6 0.6 4.5
Exhaust cover Bolt M6 7
2nd 12 1.2 8.7
1st 15 1.5 10.8
Bolt M8 4
2nd 30 3.0 22
Crankcase
1st 6 0.6 4.5
Bolt M6 6
2nd 12 1.2 8.7
1st 10 1.0 7.2
Connecting rod Bolt M7 4
2nd 22 2.2 16
Anode cover Bolt M5 1 5 0.5 3.6
Starter motor mounting Bolt M8 3 29 2.9 21
LOWER UNIT
Propeller Nut M10 1 17 1.7 12.3
Lower unit mounting Bolt M8 4 18 1.8 13
Pinion gear nut Nut M8 1 25 2.5 18
BRACKET
Tiller handle mounting (pivot) Nut M10 1 10 1.0 7.2
Tiller handle mounting locknut (pivot) Nut M10 1 23 2.3 16.6
Water flushing adapter Bolt M6 1 10 1.0 7.2
Bottom cowling Bolt M6 4 8 0.8 5.8
Steering friction piece Bolt M6 1 4 0.4 2.9
Tilt stop lever Bolt M6 4 8 0.8 5.8
Upper rubber mounting Nut M8 2 21 2.1 15
Bolt/
Lower rubber mounting M8 4 32 3.2 23
Nut
Clamp bracket Nut M22 2 12 1.2 8.7
Clamp bracket - upper (PT) Bolt M8 2 24 2.4 17.7
Clamp bracket - lower (PT) Bolt M8 2 18 1.8 13
Upper casing Bolt M8 6 18 1.8 13
Oil drain plug Bolt M14 1 27 2.7 19.5
Exhaust manifold Bolt M6 2 11 1.1 8.0
Water inlet cover Screw M5 1 5 0.5 3.6
13
TIGHTENING TORQUES
Part Thread Tightening torque

Part to be tightened Q’ty
name size N•m kgfm ftlb
PT UNIT
Reservoir cap Bolt M10 1 5 0.5 3.6
PT motor Bolt M5 4 5 0.5 3.6
Cylinder end screw Screw M33 1 45 4.5 32
Gear pump housing Bolt M5 6 5 0.5 3.6
Tilt piston – M12 1 45 4.5 32
ELECTRICAL
Starter motor Bolt M8 3 29 2.9 21
Solenoid Screw M5 2 3 0.3 2.2
Solenoid mount bracket Bolt M6 2 8 0.8 5.8
Lighting coil Bolt M6 4 8 0.8 5.8
Oil pressure switch Bolt – 1 8 0.8 5.8
Rectifier/regulator Bolt M6 2 8 0.8 5.8
Rectifier/regulator bracket Bolt M6 3 8 0.8 5.8
Rectifier/regulator bracket ground Bolt M6 1 8 0.8 5.8
General torque GENERAL TORQUES

Nut (A) Bolt (B) specifications This chart specifies tightening torques for
N•m kgf•m ftlb standard fasteners with a standard ISO
8 mm M5 5 0.5 3.6 thread pitch. Tightening torque
10 mm M6 8 0.8 5.8 specifications for special components or
12 mm M8 18 1.8 13 assemblies are provided in applicable
sections of this manual. To avoid warpage,
14 mm M10 36 3.6 25
tighten multifastener assemblies in a
17 mm M12 43 4.3 31
crisscross fashion and progressive stages
until the specified tightening torque is
reached. Unless otherwise specified,
tightening torque specifications require
clean, dry threads.
Components should be at room
temperature.
14
MAINTENANCE INTERVAL CHART
MAINTENANCE INTERVAL CHART
Use the following chart as a guide to general maintenance intervals.
Dependant on operating conditions, adjust the maintenance intervals accordingly.
Initial Every
Item Remarks 10 hours 50 hours 100 hours 200 hours
(Brake-in) (3 months) (6 months) (1 year)
TOP COWLING:
Water separator drain hole Check
FUEL SYSTEM:
Fuel line Check
Fuel filter Check/replace
CONTROL SYSTEM:
Throttle cables Check/adjust
Remote control throttle cable Check/adjust
Throttle link lever Check/adjust
Remote control shift cable Check/adjust
Shift cable Check/adjust
Engine idling speed Check/adjust
Start-in-gear protection device Check/adjust
POWER UNIT:
Engine oil Check/change
Oil filter Replace
Timing belt Check/replace
Valve clearance Check/adjust
Ignition timing Check
Thermostat Check/replace
Water leakage Check
Motor exterior Check
Exhaust leakage Check
Cooling water passage Check/clean
POWER TILT SYSTEM:
Power tilt fluid Check/change
LOWER UNIT:
Gear oil Change
Impeller Check
Lower unit leakage Check
Propeller Check
GENERAL:
Anode Check
Battery Check EVERY MONTH
Spark plug Cleaning/
adjust/
replace
Wiring and connector Adjust/
reconnect
Bolts and nuts Tighten
Lubrication points Lubricate
15
POWER TILT SYSTEM/ GENERAL
POWER TILT SYSTEM / GENERAL
CHECKING THE POWER TILT (PT)

FLUID LEVEL
WARNING
To prevent the hydraulic fluid from
spurting out due to internal pressure, the
outboard should be kept fully tilted up (the
tilt ram at full length) while slowly
removing the screw.
1. Check:
Power tilt fluid level
Level is low Add fluid to the
proper level.
Checking steps:
(1) Tilt up the outboard and lock it with
tilt lock knob 1.
(2) Remove the reservoir cap 2.
(3) Check that the fluid level is directly
below the fluid level checking hole a.
2. Add:
Recommended hydraulic fluid:
ATF Dexron ll
Reservoir cap:
5 N•m (0.5 kgf•m, 3.6ft•lb)
GENERAL
CHECKING THE ANODE
1. Check:
Anode (engine)
Anode (clamp bracket)
Anode (lower unit)
Scales Clean.
Oil/grease Clean.
Excessive wear (half worn) damage
Replace.
CAUTION:
Do not oil, grease, or paint the anode, or it
will not operate properly.
16
POWER UNIT
POWER UNIT
REMOVING/INSTALLING THE POWER UNIT 1 (F15AEP/F15PR)
Step Job/Part Q'ty Remarks

1 Bolt 3
2 Fitting plate 1
3 Battery cables 1
4 Throttle cable 1
5 Shift cable 1
6 Shift link rod 1
7 PT motor lead 1
8 PT relay lead 2
9 Remote control lead 1
10 Fuse lead 1
11 Trailer switch lead 1
12 Fuel hose 1
13 Pilot water hose 1
Continued on next page.
17
POWER UNIT

14 Water flushing hose 1
For installation, reverse the removal

procedure.
18
POWER UNIT
REMOVING/INSTALLING THE POWER UNIT 1 (F15AEHP/F15PH)

1 Bolt 3
2 Fitting plate 1
3 Battery cables 1
4 Throttle cable 2
5 Shift link rod 1
6 PT motor lead 1
7 PT relay lead 2
8 Engine stop switch lead 1
9 Neutral switch lead 1
10 Fuse lead 1
11 Trailer switch lead 1 (With trailer switch model only)
12 Fuel hose 1
13 Pilot water hose 1
19
POWER UNIT


procedure.
20
ELECTRICAL UNIT
ELECTRICAL UNIT
REMOVING/INSTALLING THE ELECTRICAL UNIT

1 Bolt 1
2 Rectifier ground lead 1
3 Bolt (with washer) 1
4 Starter relay ground lead 1
5 CDI unit ground lead 1
6 Starter relay lead 1
7 Screw (with washer) 1
8 Oil pressure switch lead 1
9 Ignition coil lead 2
11 Bracket 1
12 Terminal ass'y 1
13 Rubber 1
21
ELECTRICAL UNIT

14 Starter relay 1
15 Bolt 3
16 Collar 2
17 Grommet 2
19 Rectifier regulator ass'y 1
20 Bracket 1
21 Bolt 2
22 CDI unit ass'y 1
23 Bolt 1
24 Bolt 1
25 Nut 1
26 Washer 1
22
ELECTRICAL UNIT

27 Bolt 1
28 Starter motor 1
29 Oil pressure switch 1
31 Ignition coil ass’y 1

procedure.
23
CYLINDER HEAD AND OIL PUMP
CYLINDER HEAD AND OIL PUMP
REMOVING/INSTALLING THE CYLINDER HEAD AND OIL PUMP

1 Spark plug 2
3 Cylinder head cover 1
4 O-ring 1 Not reusable
6 Bolt 6
7 Cylinder head assembly 1
8 Dowel pin 2
9 Gasket 1 Not reusable
11 Oil pump 1
12 Oil pump gasket 1 Not reusable
procedure.
24
OIL PUMP
OIL PUMP
DISASSEMBLING/ASSEMBLING THE OIL PUMP

1 Screw 2
2 Oil pump cover 1
4 Inner rotor 1
5 Shaft 1
6 Pin 1
7 Outer rotor 1
8 Oil pump housing 1

procedure.
25
CAMSHAFT AND VALVE
CAMSHAFT AND VALVE
REMOVING/INSTALLING THE CAMSHAFT AND VALVE

1 Locknut 4
2 Valve adjusting screw 4
3 Rocker arm shaft 2
4 Spring 1 1
5 Spring 2 3
6 Collar 1 Length: 15.0 mm (0.59 in)
9 Rocker arm 4
10 Camshaft 1
11 Valve cotter 8
12 Valve spring seat (upper) 4
13 Valve spring 4
26
CAMSHAFT AND VALVE

14 Intake valve 2
15 Exhaust valve 2
16 Valve spring seat (lower) 4
17 Valve seal 4 Not reusable
18 Oil seal 1 Not reusable
19 Cylinder head 1

procedure.
27
CAMSHAFT AND VALVE
CHECKING THE CAMSHAFT
Measure:
Camshaft lobe diameter a and b
Out of specification Replace the
camshaft
Rocker arm inside diameter:
IN a: 27.596 - 27.696 mm
(1.0865 - 1.0904 in)
IN b: 23.95 - 24.05 mm
(0.9429 - 0.9468 in)
EX a: 27.616 - 27.716 mm
(1.0872 - 1.0912 in)
EX b: 23.95 - 24.05 mm
(0.9429 - 0.9468 in)
28
CAMSHAFT AND VALVE
REFACING THE VALVE SEAT
IN Reface:
Valve seat
c CAUTION:
When turning the valve seat cutter, keep
b
a an even downward pressure (4 - 5 kg) to
prevent chatter mark.
Valve seat width

(intake valve and exhaust valve):
0.6 - 0.8 mm (0.02 - 0.03 in)
EX
Valve seat cutter set:
c 90890-06803
Valve seat cutter:
b a 90890-06556
Valve seat lapper:
90890-06805
Cut section and seat cutter
Seat Cut section Seat cutter
a: 180° 180°: 90890-06556
IN b: 90° 90°: 90890-06312
c: 60° 60°: 90890-06315
a: 180° 170°: 90890-06313
EX b: 90° 90°: 90890-06312
c: 0° 60°: 90890-06315
NOTE:
After refacing the valve seat, lap the valve
seat and valve face.
A Refacing steps:
IN A Valve seat is centered on valve face but
it is too wide.
c Valve seat cutter Desired result
c Lap the face a
EX a a 180° cutter (IN)
170° cutter (EX) and face c lightly
a to reduce the
c c 60° cutter (IN/EX) valve seat width.
a
29
CAMSHAFT AND VALVE
B B Valve seat is in the middle of the valve
IN face but it is too narrow.
Valve seat cutter Desired result
Lap the face b to
b
b b 90° cutter (IN/EX) increase the valve
EX seat width.
C C Valve seat is too narrow and it is near

IN the valve margin.
b Lap the face a to
b 180° cutter (IN)
a 170° cutter (EX) center the valve
EX a seat and lap the
a
face b to increase
b 90° cutter (IN/EX) the valve seat
b a width.
D D Valve seat is too narrow and it is near

IN the valve stem.
c
b Lap the face c to
c b c 60° cutter (IN/EX) center the valve
EX seat and lap the
face b to increase
c b 90° cutter (IN/EX) the valve seat
b width.
INSTALLING THE CAMSHAFT OIL

SEAL
Install:
Cam shaft oil seal 1
Drive rod:
YM-06071/90890-06652
Attachment:
YB-06196/90890-06196
NOTE:
Press fit the oil seal to the stepped portion
of the cylinder head and check that it is not
at an angle.
30
OIL FILTER, THERMOSTAT AND EXHAUST COVER
DISASSEMBLING/ASSEMBLING THE OIL FILTER, THERMOSTAT AND EXHAUST COVER

1 Oil filter 1
2 Oil filter plug 1
4 Thermostat cover 1
5 Thermostat gasket 1 Not reusable
6 Thermostat 1
8 Exhaust cover 1
9 Exhaust cover gasket 1 Not reusable
11 Breather cover 1
12 Breather cover gasket 1 Not reusable
31

14 Plate 1
15 Anode cover 1
17 Grommet 1
18 Anode 1

procedure.
32
STEERING HANDLE ASSEMBLY (F15AEHP/F15PH)
REMOVING/INSTALLING THE STEERING HANDLE ASSEMBLY

1 Throttle cable 2
2 Engine stop switch lead 1
3 PT switch lead 1
4 Grommet 1
5 Locknut 1
6 Nut 1
7 Plate 1
8 Bushing 1
9 Steering handle ass'y 1

procedure.
33
DISASSEMBLING/ASSEMBLING THE STEERING HANDLE ASSEMBLY

1 Plate washer 1
2 Plate washer 1
3 Wave washer 2
4 Plate washer 1
5 Bushing 1
6 Screw 3
7 Clamp 1
8 Stay 1
10 PT switch ass'y 1
11 Screw 1
12 Steering grip 1
13 Washer 1
34

14 Spring 1
15 Bushing 1
16 Bolt 2
17 Stay 1
18 Split pin 1
19 Friction adjusting screw 1
20 Friction piece 1
21 Throttle cable 2
22 Throttle shaft 1
23 Engine stop switch 1
24 Steering handle bracket 1

procedure.
35
INSTALLING THE PT SWITCH
1. Install:
PT switch
NOTE:
Tighten the PT switch mounting screw in
sequence
36
BOTTOM COWLING ASSEMBLY
REMOVING/INSTALLING THE BOTTOM COWLING ASSEMBLY

1 Bolt 2
2 Plate washer 2
3 PT relay 1
4 Collar 2
5 Grommet 2
7 Bracket 1
8 Gasket 1
9 Trailer switch 1
10 Hose 1 (Bottom cowling - joint hose)
11 Hose 1 (Oil pan - joint hose)
12 Hose 1 (Exhaust cover - joint hose)
13 Joint hose 1
37

14 Clamp 1
15 Grommet 1
16 PT motor lead 1
17 Joint assembly 1
18 Clamp 1
21 Adapter 1
22 Clip 1
23 Washer 1
25 Collar 1
26 Wave washer 1
38

27 Shift rod link 1
28 Gear shift handle 1
29 Shift rod nut 1
32 Bottom cowling assembly 1
33 Collar 4
34 Grommet 4
35 Rubber seal 1

procedure.
39
SWIVEL AND STEERING BRACKET
SWIVEL AND STEERING BRACKET
REMOVING/INSTALLING THE SWIVEL AND STEERING BRACKET

1 Screw 2
2 Wire lead 1
3 Friction bolt 1
4 Rubber seal 1
5 Steering friction ass'y 1 (F15AEHP/F15PH only)
6 Steering bracket 1
7 Washer 1
8 Bushing 1
9 Key 1
10 Bushing 1
12 Bushing 1
13 Swivel bracket ass'y 1 For installation, reverse the removal
procedure.
40
REMOVING/INSTALLING THE POWER TILT (PT) UNIT

1 PT motor lead 1
2 Clamp 1
4 Circlip 1
5 Pin 1
6 Bushing 1
7 Bushing 2
8 Bolt 2
9 Washer 2
10 Pin 1
11 Bushing 2
12 Bushing 1
13 Collar 1
41

14 Power tilt (PT) unit 1

procedure.
42
DISASSEMBLING/ASSEMBLING THE POWER TILT (PT) CYLINDER

1 Tilt ram assembly 1
2 Free piston 1
3 O-ring 1 20.8 x 2.4 mm Not reusable
4 Backing ring 1
5 Cylinder case 1
7 Cylinder 1
10 Backup ring 1
11 Tilt piston 1
12 Ball 1
13 Pin 1
43

14 Spring 1 Outside diameter 6.8 x Length 13.5 mm
15 Dowel pin 1
16 End screw 1
18 Backup ring 1
19 Dust seal 1 Not reusable
20 Tilt ram 1

procedure.
44
DISASSEMBLING THE POWER TILT (PT)
CYLINDER
WARNING
To prevent the hydraulic fluid from
spurting out due to internal pressure, the
outboard should be kept fully tilted up
(the tilt rod at full length).
After removing the tilt motor or oil
reservoir, do not push the tilt rod down.
This may cause hydraulic fluid to spurt
out from the port.
CAUTION:
Do not wipe hydraulic system components
with rags, paper, tissues, or the like, as
fibers from such material will cause
malfunctions if they enter the system.
1. Loosen:
End screw
Power tilt wrench:

YB-06560 / 90890-06560
2. Loosen:
Tilt ram
Power tilt wrench:

YB-06560 / 90890-06560
NOTE:
Hold the protruded portion a of the tilt
piston with the aluminium plate 1 and turn
to loose the tilt ram.
45
ASSEMBLING THE POWER TILT (PT)
CYLINDER
1. Tighten:
Tilt ram
Power tilt wrench:

YB-06560 / 90890-06560
Tilt piston:
45 N•m (4.5 kgf•m, 32ft•lb)
NOTE:
Hold the protruded portion a of the tilt
piston with the aluminium plate 1 and
tighten the tilt ram.
2. Fill:
Fluid
Filling steps
(1) Fill the cylinder with the fluid to about
70 %.
Recommended PT fluid:
ATF Dexron II
NOTE:
Put the fluid with the free piston 1
installed at the bottom of the cylinder.
(2) Install the tilt ram assembly.

NOTE:
The tilt ram assembly is to be installed with
the tilt piston 2 and end screw 3 in close
contact.
3. Tighten:
End screw
Power tilt wrench:

YB-06560 / 90890-06560
End screw:
45 N•m (4.5 kgf•m, 32ft•lb)
46
4. Bleed:
Air
Bleeding step:
(1) Open the manual valve 1.
(2) Manually push in the tilt ram to its

fully contracted state.
(3) Remove the reservoir cap 2 and

supply the fluid to the prescribed
level.
Reservoir cap:
5 N•m (0.5 kgf•m, 3.6ft•lb)
(4) Close the manual valve 1.
47
(5) Connect the PT motor lead to the
battery and place the tilt ram in it fully
extended state.
NOTE:
When the tilt ram is unstable or does not
move, supply the fluid to the prescribed
level.
Repeat until the tilt ram is placed in its
fully extended state.
Close the reservoir cap during operation.
Battery
Tilt ram PT motor lead
terminal
Blue (+)
Up
Green (-)
(6) Alternately connect the PT motor

leads to the battery and extend and
contract the cylinder about 3 times.
NOTE:
Operate the tilt ram to the full stroke and
relieve it for about 2 seconds at each
stroke end.
Place the tilt ram finally in its fully
extended state.
Battery
Tilt ram PT motor lead
terminal
Blue (+)
Up
Green (-)
Green (+)
Down
Blue (-)
48
(7) Open the manual valve, leave it to
stand for about 1 second and close it.
NOTE:
Check the fluid level and replenish if short.
(8) Leave it to stand for about 3 minutes

and then repeat steps (6) and (7).
NOTE:
Repeat for about 3 times until the up
relief sound is confirmed without delay
when the cylinder extends.
Finally confirm the fluid level.
(9) Install the power tilt (PT) unit to the

outboard motor.
NOTE:
Carrying and working should be done with
the power tilt (PT) unit erected.
(10) Operate the PT switch to move down

the tilt, relieve it for about 1 second,
and then immediately move up the
tilt.
NOTE:
For moving up the tilt, stop it at about
half the stroke.
If it does not stop, air removal is not
complete. Take the steps (6) and (7) with
it installed to the outboard motor.
Immediately after the tilt up, check that
the outboard motor does not descend.
Finally recheck the operation in this
procedure.
(11) Move up the tilt and finally check the

fluid level.
NOTE:
If short, replenish.
49
DISASSEMBLING/ASSEMBLING THE VALVES AND PUMP 1

1 Reservoir cap 1
3 Bolt 4
4 PT motor 1
7 Manual release rod 1
8 Pin 1
10 Sponge 1
12 Manual release pin 2
50

14 Absorver valve pin 2
15 Ball 2
18 Valve pin 2
19 Valve seal 2

procedure.
51
INSTALLING THE RELIEF VALVE
Install:
Valve seal 1
Valve pin 2
Spring 3
NOTE:
Be careful to install the valve seal facing in
the correct direction.
52
DISASSEMBLING/ASSEMBLING THE PT MOTOR

2 Yoke assembly 1 43.9 x 1.5 mm Not reusable
3 O-ring 1
5 Armatuer 1
7 Brush 2
8 Brush spring 2
9 Oil seal 1 Not reusable
10 End frame 1

procedure.
53
REMOVING THE ARMATURE
1. Remove:
Screw 1
Brush 2
Armature 3
NOTE:
Push brush 2 to the inside, then remove
armature 3.
CHECKING THE PT MOTOR

1. Check:
Commutator
Dirt Clean with 600 grit
sandpaper.
2. Check:
Commutator undercut
Obstruction Clean.
NOTE:
Remove all metal particles with
compressed air.
3. Measure:
Commutator diameter a
Out of specification Replace.
Commutator diameter limit:
15.5 mm (0.61 in)
54
4. Measure:
Armature coil continuity
Commutator segments Continuity

Segment - laminations No
continuity
Segment - shaft No
continuity
5. Measure:
Brush length a
Brush length limit:
3 mm (0.12 in)
6. Check:
End frame
Cracks/damage Replace.
7. Check:
Yoke bushing
Cracks/damage Replace.
8. Check:
Oil seal
Damage/wear Replace.
55
CHECKING THE PT MOTOR ASSEMBLY
1. Check:
PT motor operation
Incorrect operation Repair.
PT motor operation
Motor turns
Blue (+), Green (-)
clockwise
Motor turns
Green (+), Blue (-)
counterclockwise
INSTALLING THE OIL SEAL

1. Install:
Oil seal
Oil seal attachment:

YB-06112/90890-06614
Driver rod:
YB-06071/90890-06652
56
DISASSEMBLING/ASSEMBLING THE VALVES AND PUMP 2

1 Bolt 6
2 Gear housing 1
3 Gear 2
4 Dowel pin 4
5 Top chamber shuttle piston 1
8 Bottom chamber shuttle piston 1
9 Circlip 2
10 Valve seal 2
11 Valve seat 2
13 Main valve 2
57

15 Filter 2
17 Ball 2

procedure.
58
CLAMP BRACKET
CLAMP BRACKET
REMOVING/INSTALLING THE CLAMP BRACKET

2 Bolt 2
3 Wire lead 1
4 Anode 1
5 Screw 1
6 Wire lead 1
7 Cap nut 2
8 Clamp bracket cap 2
9 Clamp bracket plate 1
10 Spring pin 1
11 Stopper knob 1
12 Stopper shaft 1
13 Bushing 1
59
CLAMP BRACKET

14 Nut 2
15 Washer 2
16 Bolt 2
17 Bolt 1
18 Clamp bracket bolt 1
19 Clamp bracket 1
20 Swivel bracket 1
21 Clamp bracket 1
22 Bushing 2
23 Plug 2
24 Grease nipple 1

procedure.
60
ELECTRICAL COMPONENTS
(Top view and port side view)
1 CDI unit A Pass the lighting coil lead on the side of the
2 Rectifier regulator flywheel cover, next to the boss as shown.
3 Pulser coil B Install the Pink lead onto the oil pressure
4 PT terminal switch. Cover the oil pressure switch after
tightening it.
5 Lighting coil
C Cover the oil pressure switch lead, ignition
6 Charge coil
coil lead and charge coil lead with the
7 Oil pressure switch corrugated plastic tube after connecting the
8 Starter relay same color leads.
9 Starter motor D Install the connector in the proper direction
0 PT relay as shown.
A Ignition coil E Pass each high tension cord through the
B Spark plugs grommet.
61
(Front view) (F15AEP/F15PH)
1 Pulser coil A To the lighting coil. K To the rectifier regulator

2 CDI unit lead B To the emergency signal light. L To the battery cable.
3 PT terminal C To the starter switch. M To the stop switch.
4 Starter relay D Mount the starter relay ground N Mount the rectifier regulator
5 Starter motor lead along with the CDI unit ground lead.
6 Fuse ground lead and the engine
stop switch ground lead.
7 Battery cable
E CDI unit leads.
F To the PT motor.
G To the PT relay.
H To the handle PT switch.
I Clamp the fuse holder to the
battery cable.
J To the neutral switch.
62
(Front view) (F15AEHP/F15PH)
1 Pulser coil A To the lighting coil.

2 CDI unit lead B To the emergency signal light.
3 PT terminal C Mount the starter relay ground lead along
4 Starter relay with the CDI unit ground lead and the wire
5 Starter motor harness ground lead.
D CDI unit leads.
6 Fuse
E To the PT motor.
7 Battery cable
F To the PT relay.
8 Wire harness
G Clamp the fuse holder to the battery cable.
9 Choke solenoid
H To the rectifier regulator.
I Mount with the rectifier regulator ground
lead and the choke solenoid ground lead.
63
STARTER MOTOR
STARTER MOTOR
DISASSEMBLING/ASSEMBLING THE STARTER MOTOR

1 Bolt 2
2 Stator 1
3 Cap 1
4 Pinion nut 1
5 Washer 1
6 Spring 1
7 Pinion stopper 1
8 Pinion gear 1
9 Front bracket 1
10 Washer 1
11 Armature 1
12 Bolt 2
13 Brush 2
64
STARTER MOTOR

14 Spring 4
15 Brush holder 1
16 Nut 1
17 Nut 1
18 Washer 1
19 Rubber plate 1
20 Brush set 1
21 Rear bracket 1

procedure.
65
STARTER MOTOR
REMOVING THE PINION NUT
1. Remove:
Pinion nut 1
NOTE:
Secure the armature with the padded
clamp, then remove the pinion nut.
CHECKING THE PINION GEAR

1. Check:
Pinion gear teeth
Damage / wear Replace.
2. Check:
Clutch movement Incorrect
Replace.
NOTE:
Rotate the pinion gear clockwise to check
that it moves freely. Also, rotate the pinion
gear counterclockwise to make sure it
locks.
CHECKING THE ARMATURE

1. Measure:
Commutator undercut a
Commutator undercut limit:

0.8 mm (0.03 in)
2. Check:
Armature coil continuity:
Commutator segments a Continuity

Segment - Armature core b No continuity
Segment - Armature Shaft c No continuity
66
STARTER MOTOR
CHECKING THE BRUSH HOLDER
1. Measure:
Brush length a
Brush length limit:

6.4 mm (0.25 in)
2. Check:
Brush unit continuity
Brush unit continuity:
Brush 1 - Brush 2 Continuity

Brush 3 - Brush 4 Continuity
Brush 1, 2 - Bracket 5 No continuity
Brush 3, 4 - Bracket 5 Continuity
67
POWER TILT (PT) SYSTEM
POWER TILT (PT) SYSTEM (F15AEP/F15PR)
1 Battery B : Black
2 Fuse G : Green
3 Trailer switch L : Blue
4 PT relay Lg : Light green
5 Terminal R : Red
6 PT motor Sb : Sky blue
68
POWER TILT (PT) SYSTEM (F15AEHP/F15PH)
1 Battery B : Black
2 Terminal G : Green
3 PT relay L : Blue
4 PT motor Lg : Light green
5 PT switch R : Red
6 Trailer switch Sb : Sky blue
A With trailer switch model

B To starter relay
C To PT relay
D Without trailer switch model
69
CHECKING THE PT SWITCH
Check:
PT switch continuity
Leads color
Light
Sky blue
Switch Red (R) green
(Sb)
position (Lg)
Up
Free
Down
CHECKING THE TRAILER SWITCH

Check:
Bottom cowling PT switch
continuity
Leads color
Light
Sky blue
Switch Red (R) green
(Sb)
position (Lg)
Up
Free
Down
CHECKING THE PT RELAY

1. Check:
PT relay continuity
PT relay continuity
Sky blue (Sb) - Black (B) Continuity

Light green (Lg) - Black (B)
Blue (L) - Black (B) Continuity
Green (G) - Black (B)
Blue (L) - Red (R) No continuity
Green (G) - Red (R)
A To battery
70
2. Check:
PT relay operation
No continuity Replace.
Checking steps:
(1) Connect the digital tester between PT
relay Blue (L) lead and Red (R) lead.
(2) Connect a 12-V battery as shown.
Sky blue (Sb) lead Positive terminal

Black (B) lead Negative terminal
(3) Check that there is continuity between

the PT relay terminals.
(4) Connect the tester between PT relay
Green (G) lead and Red (R) lead.
(5) Connect a 12-V battery as shown.
Light green (Lg) lead Positive terminal

Black (B) lead Negative terminal
(6) Check that there is continuity between

the PT relay terminals.
71
TROUBLE ANALYSIS
TROUBLE ANALYSIS
NOTE:
Following items should be obtained before “trouble analysis”.
1. Battery is charged and its specified gravity is in specification.
2. There is no incorrect writing connection.
3. Writing connections are surely engaged and without any rust.
4. Lanyard is installed to the engine stop switch.
5. Shift position is in neutral.
6. Fuel is coming to the carburetor.
7. Correct rigging and engine setting are obtained.
8. Engine is free from any “Hull problem”.
TROUBLE ANALYSIS CHART

Trouble mode Check element
IRREGULAR WARNING INDICATION
POOR BATTERY CHARGING
PT MOTOR WILL NOT RUN
ENGINE WILL NOT START
ENGINE WILL NOT STOP

POOR PERFORMANCE
LOOSE TILT HOLDING
Reference
Relative part
LOOSE STEERING
chapter
ENGINE STALLS
HARD SHIFTING
ROUGH IDLING
OVERHEATING
FUEL SYSTEM
Fuel hose 4
Fuel joint 4
Fuel filter 4
Fuel pump 4
Carburetor 4
Idle speed 4
Pilot jet 3
Throttle cable 4
POWER UNIT
Spark plugs 3
Compression 5
Timing belt 5
Valve clearance 5
Intake and exhaust valve 5
Intake and exhaust valve seat 5
Cylinder head gasket 5
Piston rings 5
Pistons 5
Thermostat 5
Water passage 5
72
TROUBLE ANALYSIS
Trouble mode Check element
IRREGULAR WARNING INDICATION

POOR BATTERY CHARGING
PT MOTOR WILL NOT RUN
ENGINE WILL NOT START
ENGINE WILL NOT STOP

POOR PERFORMANCE
LOOSE TILT HOLDING

Reference
Relative part
LOOSE STEERING
chapter
ENGINE STALLS
HARD SHIFTING
ROUGH IDLING
OVERHEATING
LOWER UNIT
Neutral position 6
Clutch 6
Gears 6
Water inlet 6
Water pump 6
Propeller shaft and propeller 6
Shifter/Pin 6
Shift cam 6
Shift rod or Shift cable 6
Lower case 6
Shim adjustment 6
BRACKET UNIT
Bracket 7
Mount rubber 7
Steering friction ass’y 7
PT UNIT
Fluid level 7
Manual valve 7
Fluid passage 7
PT motor 7
ELECTRICAL
Ignition coil 8
Ignition control system 8
Starting system 8
Charging system 8
PT control system 8
73
YAMAHA MOTOR CO., LTD.
Printed in USA
Apr. 2000 - x 1
(F15AEP, F15AEHP)
Printed on recycled paper

WIRING DIAGRAM F15AEP/F15PR
B
B: Black
R
Br: Brown
G: Green
R R R B L: Blue
Lg Light green
5 Fuse(20A) O: Orange
7 Starting motor
6 Starter relay P: Pink
R R
R: Red
B Sb:
B R Sky blue
3 Emergency 4 Rectifier/ W: White
signal light regulator R P/W: Pink/white
- + Y/R W/G: White/green
G G
Y/R: Yellow/red
P/W G/W G/W 8 Lighting coil
2 Battery G/W: Green/white
B
B
11 Pulser 9 Charge coil

coil 10 Oil pressure
switch
18 Fuel enrich W/G B 12 Ignition coil

solenoid
1 CDI unit
13 Terminal ass'y
Y/R P/W W B O P L Br B W/G B B B L R R G
Br L L
Br L P O B 16 Spark
plugs
B B
G G
Y/R P/W W B W/G L R G

Br
Br L P O B
G W B L R G
Br B L G R
Lg W
B 15 PT relay
L L
R G
Lg Lg Sb Lg
Sb G
Br L Sb Sb Sb
Lg Lg Lg
B Sb 14 PT motor
R Sb Lg
Sb Lg
Sb Lg
Sb R Lg
UP
17 Trailer switch FREE
DOWN
WIRING DIAGRAM F15AEHP/F15PH
B
R
R
5 Fuse(20A)
R R B
3 Starter switch
7 Starting motor
R
Br R 6 Starter relay
B R B
R
- + G
4 Rectifier/ G G
regulator G/W G/W 13 Terminal ass'y
2 Battery 8 Lighting coil
B
L L
9 Charge coil D Without trailer switch model

11 Pulser coil
10 Oil pressure
R G G
W/G switch Lg Lg
20 Emargency B
B
signal light 12 Ignition coil
1 CDI unit
Sb
P/W Y/R
Y/R P/W W B O P L Br B W/G B B B Br Br
Lg Sb
16 Spark
Br L P O B plugs
Br Br
Y/R P/W W B W/G
Br L P O B R Sb Lg
B B L G R
Sb R Lg
UP L
FREE
DOWN 15 PT G
17 PT switch relay
Sb Lg
A With trailer switch model
B To starter relay
14 PT motor
Lg Lg 19 Neutral switch 18 Engine stop switch
Sb Sb Br W B
C To PT relay
Lg Lg Br
Sb B: Black P/W: Pink/white
R Sb Lg R Sb Lg
Br: Brown W/G: White/green
Sb Lg
G: Green Y/R: Yellow/red
L: Blue G/W: Green/white
Sb Lg R
Lg Light green
O: Orange
P: Pink
Sb Lg
R: Red
Sb: Sky blue
W: White
21 Trailer
17 PT switch
switch

15 HP 2004 4 Stroke

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

15 HP 2004 4 Stroke

Uploaded by

Copyright:

Available Formats

F15Z

F15A (F15) SERVICE MANUAL: 66M-28197-Z7-11

Model name F15AEP F15AEHP

USA and Canada name F15PR F15PH

Indication F15AEP F15AEHP

Symbols : to E indicate specific data.

C D F Apply Yamaha 4-stroke motor oil

Symbols I to N in an exploded diagram

PERIODIC INSPECTIONS AND ADJUSTMENT

STARTING SERIAL NUMBERS

Model name Applicable Starting

1 REMOVAL AND INSTALLATION

2 Oil seal attachment:

4 Valve seat cutter set:

5 Valve seat cutter:

Head diameter (A)

Outer rotor-to-housing clearance a mm (in) 0.10 - 0.15 (0.004 - 0.006)

Part Thread Tightening torque

General torque GENERAL TORQUES

CHECKING THE POWER TILT (PT)

Step Job/Part Q'ty Remarks

Step Job/Part Q'ty Remarks

For installation, reverse the removal

REMOVING/INSTALLING THE POWER UNIT 1 (F15AEHP/F15PH)

Step Job/Part Q'ty Remarks

Step Job/Part Q'ty Remarks

For installation, reverse the removal

Step Job/Part Q'ty Remarks

Step Job/Part Q'ty Remarks

Step Job/Part Q'ty Remarks

For installation, reverse the removal

Step Job/Part Q'ty Remarks

Step Job/Part Q'ty Remarks

For installation, reverse the removal

Step Job/Part Q'ty Remarks

Step Job/Part Q'ty Remarks

For installation, reverse the removal

Valve seat width

C C Valve seat is too narrow and it is near

D D Valve seat is too narrow and it is near

INSTALLING THE CAMSHAFT OIL

Step Job/Part Q'ty Remarks

Step Job/Part Q'ty Remarks

For installation, reverse the removal

Step Job/Part Q'ty Remarks

For installation, reverse the removal

DISASSEMBLING/ASSEMBLING THE STEERING HANDLE ASSEMBLY

Step Job/Part Q'ty Remarks

Step Job/Part Q'ty Remarks

For installation, reverse the removal

Step Job/Part Q'ty Remarks

Step Job/Part Q'ty Remarks

Step Job/Part Q'ty Remarks

For installation, reverse the removal

Step Job/Part Q'ty Remarks

Step Job/Part Q'ty Remarks

Step Job/Part Q'ty Remarks

For installation, reverse the removal

DISASSEMBLING/ASSEMBLING THE POWER TILT (PT) CYLINDER

Step Job/Part Q'ty Remarks

Step Job/Part Q'ty Remarks

For installation, reverse the removal