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FL225F
Yamaha FL225F Manuals
Manuals and User Guides for Yamaha FL225F. We have
2
Yamaha FL225F manuals available for free PDF download: Service Manual, Owner's Manual
Yamaha FL225F Service Manual (576 pages)
Brand:
Yamaha
| Category:
Engine
| Size: 58.58 MB
Table of Contents
Table of Contents
3
General Information
5
Safety While Working
6
Electric Shock
6
Handling of Gasoline
6
Hot Part
6
Propeller
6
Rotating Part
6
Ventilation
6
Handling of Gas Torch
7
Part, Lubricant, and Sealant
7
Self-Protection
7
Working with Crane
7
Disassembly and Assembly
8
Handling of Sealant
8
Non-Reusable Part
8
Special Service Tool
8
Tightening Torque
8
How to Use this Manual
9
Manual Format
9
Abbreviation
10
Lubricant, Sealant, and Thread Locking Agent
12
Symbol
12
Special Service Tool
14
Spec Specification 1
22
Fuel System
22
Specification
22
Model Feature
24
General Feature
24
Model Designation
25
Serial Number
25
Model Data
26
Dimension and Weight
26
Performance
26
Power Unit
27
Bracket Unit
28
Fuel and Oil Requirement
29
Battery Requirement
30
PTT Fluid Requirement
30
Electrical System Technical Data
31
Lower Unit
28
Ignition Timing Control System
31
Fuel Injection Control System
33
Engine Speed Control System
34
VCT System
35
PTT System
36
Shift Actuator
36
Charging System
37
Starting System
37
Gauge/Sensor
38
Fuel System Technical Data
40
Power Unit Technical Data
41
Power Unit
41
Cylinder Head Assembly
42
Crankcase Assembly
44
Lower Unit Technical Data
47
Lower Unit Assembly (Regular Rotation Model)
47
Lower Unit Assembly (Counter Rotation Model)
47
Bracket Unit Technical Data
48
PTT System
48
Specified Tightening Torque
49
Rigging Information
49
Fuel System
49
Power Unit
49
Lower Unit (Regular Rotation Model)
50
Lower Unit (Counter Rotation Model)
51
Bracket Unit
51
PTT Unit
52
General Tightening Torque
53
Tech Fea Technical Features and Description 2
55
Tech Fea
55
Technical Features and Description
56
Electronic Control System
56
Engine ECM Component
57
Sensor, Switch, and Actuator
58
Electronic Fuel Injection Control
60
Ignition Timing Control
63
VCT Control
65
Knock Control
66
Engine Speed Control
67
ETV Control
69
Electronic Shift Control System
70
Fail-Safe Control
71
Charging System
73
Digital Network Control
74
Sensor, Switch
76
Y-Cop
77
Power Unit System
78
Shimless Valve Lifter
79
Sleeveless Cylinder
79
Oil Cooler
80
Fuel System
81
Fuel Diagram
81
Lubrication System
83
Lubrication Diagram
83
Cooling System
84
Cooling Diagram
84
Intake and Exhaust System
86
Intake and Exhaust Diagram
86
Lower Unit
87
Double Taper Roller Bearing
87
Propeller Shaft Bearing (Regular Rotation Model)
87
Propeller
88
Rig Ging Rigging Information 3
90
Rig Ging
90
Rigging Information
92
Outboard Motor Installation
92
Dimension
93
Exterior: F(L)225F, F(L)250D, F(L)300B
93
Clamp Bracket
94
Crate Top Cover Pictograph Description
95
Uncrating Procedure
96
Outboard Motor Mounting
97
Rigging Grommet Mounting
99
Rigging Grommet Description
99
Installing the Main Harness
99
Installing the Battery Cable
100
Installing the Rigging Grommet
100
Optional Equipment
101
Installing the Isolator Lead
101
Installing the Water Pressure Sensor
101
Installing the Speed Sensor
102
Installing Y-COP (Optional in Non-European Markets)
103
Registering the Receiver ID to the ECM
103
Installing the Digital Electronic Control Box and Switch Panel
103
Battery Installation
106
Battery Wiring Without House (Accessory) Battery
106
Battery Wiring with House (Accessory) Battery
108
Digital Network System Diagram
112
Single Outboard Motor Application
112
Twin Outboard Motor Application
114
Triple Outboard Motor Application
117
Digital Electronic Control System Reset
120
Trbl Shtg Troubleshooting 4
125
Trbl Shtg
125
Troubleshooting
126
Ydis
126
Feature
126
Hardware Requirement
126
Function
127
Connecting the Communication Cable to the Outboard Motor
129
Troubleshooting the Power Unit
130
Troubleshooting Procedure
130
Troubleshooting the Power Unit Using the YDIS
130
Troubleshooting the Power Unit (Trouble Code Not Detected)
154
Troubleshooting the PTT Unit
160
Troubleshooting the Lower Unit
161
Elec Electrical System 5
162
Electrical Component
164
Port
164
Starboard
165
Fuse Holder
166
Rear
168
Front
169
Top
170
Bottom Cowling
171
Electrical System
164
Wiring Harness Routing
172
Port
172
Starboard
173
Rear
176
Front
177
Top
178
Bottom Cowling
179
Circuit Diagram
180
ECM Coupler Layout
182
Checking the Electrical Component
184
Using the YDIS
184
Measuring the Peak Voltage
184
Using the Digital Tester
185
Engine Control Unit and Component
185
Checking the Main Relay
185
Checking the Engine ECM Circuit
186
Checking the ETV and TPS
187
Checking the ETV Motor Relay
188
Checking the ETV (TPS) Circuit
188
Checking the SPS
189
Checking the Shift Actuator Relay
190
Checking the Shift Actuator
190
Checking the SPS and Shift Actuator Circuit
191
Checking the Cam Position Sensor
192
Checking the OCV
195
Checking the Oil Pressure Sensor
196
Fuel Control Unit and Component
197
Checking the Water Detection Switch
197
Checking the Fuel Injector
198
Checking the Low-Pressure Fuel Pump and High-Pressure Fuel Pump
200
Checking the High-Pressure Fuel Pump Relay
201
Checking the Vapor Shut-Off Valve
202
Charging Unit and Component
203
Checking the Lighting Coil (Stator Assembly)
203
Checking the Rectifier Regulator
205
Ignition Unit and Component
208
Checking the Ignition Spark
208
Checking the Ignition Coil
209
Checking the Pulser Coil
210
Checking the Air Temperature Sensor
211
Checking the Air Pressure Sensor
212
Checking the Engine Temperature Sensor
213
Checking the Thermoswitch
214
Checking the Knock Sensor
215
Checking the Engine Shut-Off Switch
215
Starting Unit and Component
216
Checking the Starter Relay
216
Checking the Engine Start Switch and Main Switch
216
Checking the Engine Start/Stop Button
217
Checking Y-COP
217
Starter Motor
219
Removing the Starter Motor
221
Checking the Starter Motor Operation
221
Checking the Magnet Switch
221
Checking the Starter Motor Pinion
221
Disassembling the Starter Motor
222
Checking the Armature (Starter Motor)
223
Checking the Brush Holder
224
Assembling the Starter Motor
224
Installing the Starter Motor
226
6Y9 Multifunction Color Gauge Sensor
226
Checking the Water Pressure Sensor (Optional)
226
Checking the Speed Sensor (Optional)
227
Outboard Motor and Digital Electronic Control Connection
228
Checking the Extension Wiring Harness
228
Checking the Main Wiring Harness
228
PTT Electrical System
229
Checking the PTT Relay
229
Checking the PTT Switch (Bottom Cowling)
231
Checking the Trim Sensor
232
Fuel Fuel System 6
234
Hose Routing
236
Fuel Hose and Blowby Hose
236
Vapor Gas Hose
237
Cooling Water Hose
239
Fuel System
236
Fuel System
240
Reducing the Fuel Pressure
241
Disconnecting the Quick Connector
241
Measuring the Fuel Pressure
242
Checking the Pressure Regulator
243
Fuel Filter Assembly
245
Removing the Fuel Filter Assembly
246
Checking the Fuel Filter Assembly
246
Disassembling the Fuel Filter Assembly
247
Checking the Fuel Filter Element
247
Checking the Fuel Cup Assembly
247
Assembling the Fuel Filter Assembly
247
Installing the Fuel Filter Assembly
247
Intake Manifold
249
Removing the Intake Silencer
250
Removing the Intake Manifold
250
Checking the Intake Manifold
251
Installing the Intake Manifold
251
Installing the Intake Silencer
253
Throttle Body
257
Removing the Throttle Body and Surge Tank
257
Checking the ETV
258
Installing the Throttle Body and Surge Tank
258
Canister
260
Removing the Canister
261
Checking the Canister
261
Checking the Canister Check Valve
261
Installing the Canister
262
Low-Pressure Fuel Pump
264
Removing the Low-Pressure Fuel Pump
265
Checking the Low-Pressure Fuel Pump
265
Checking the Primer Pump
265
Installing the Low-Pressure Fuel Pump
266
Vapor Separator
269
Draining the Fuel
270
Removing the Vapor Separator
270
Checking the Vapor Shut-Off Valve
271
Installing the Vapor Separator
271
Disassembling the Vapor Separator
274
Checking the High-Pressure Fuel Pump
275
Checking the Vapor Separator
275
Checking the Check Valve
275
Assembling the Vapor Separator
275
Fuel Injector
278
Removing the Fuel Injector
279
Checking the Fuel Rail
279
Installing the Fuel Injector
279
Powr Power Unit 7
281
Power Unit (Check and Adjustment)
284
Checking the Compression Pressure
284
Checking the Oil Pressure
284
Checking the Pulser Coil Air Gap
284
Checking the Valve Clearance
285
Adjusting the Valve Clearance
287
Removing the Power Unit
291
Installing the Power Unit
293
Power Unit
284
Flywheel Magnet
298
Removing the Flywheel Magnet
298
Installing the Flywheel Magnet
298
Wiring Harness
301
Removing the Wiring Harness
301
Installing the Wiring Harness
303
Junction Box
308
Removing the Rectifier Regulator
311
Removing the Junction Box
311
Installing the Junction Box
311
Installing the Rectifier Regulator
312
Starter Motor
314
Removing the Starter Motor
314
Installing the Starter Motor
314
Engine ECM
316
Removing the Engine ECM
316
Installing the Engine ECM
316
Shift Actuator
318
Removing the Shift Actuator Assembly
318
Disassembling the Shift Actuator Assembly
318
Assembling the Shift Actuator Assembly
318
Installing the Shift Actuator Assembly
318
Timing Belt
321
Removing the Timing Belt
321
Checking the Timing Belt
322
Installing the Timing Belt
322
Camshaft
327
Removing the Driven Sprocket and Camshaft
328
Checking the Sprocket
330
Checking the Valve Lifter
330
Checking the Camshaft
330
Checking the Spark Plug
331
Installing the Camshaft and Driven Sprocket
331
Cylinder Head
336
Removing the Cylinder Head
338
Disassembling the Cylinder Head
338
Checking the Cylinder Head
338
Checking the Cylinder Head Bolt
339
Checking the Valve Spring
339
Checking the Valve
339
Checking the Valve Guide
340
Replacing the Valve Guide
340
Checking the Valve Seat
341
Refacing the Valve Seat
342
Checking the Cylinder Head Anode
343
Assembling the Cylinder Head
343
Installing the Cylinder Head
345
Oil Cooler and Oil Pump Assembly
349
Removing the Oil Filter Bracket
349
Removing the Oil Cooler
349
Removing the Oil Pump Assembly
349
Disassembling the Oil Pump Assembly
349
Checking the Oil Pump Assembly
350
Checking the Oil Cooler
350
Checking the Oil Cooler Anode
350
Assembling the Oil Pump Assembly
350
Installing the Oil Pump Assembly
351
Installing the Oil Cooler
351
Installing the Oil Filter Bracket
352
Cylinder Block Sensor and Switch
353
Removing the Pulley Bracket
355
Removing the Knock Sensor
355
Removing the Thermostat
355
Checking the Thermostat
355
Installing the Thermostat
356
Installing the Knock Sensor
356
Installing the Pulley Bracket
356
Disassembling the Cylinder Block
360
Checking the Piston Diameter
361
Checking the Cylinder Bore
361
Checking the Piston Ring
361
Checking the Piston Ring End Gap
362
Checking the Piston Ring Groove
362
Checking the Piston Ring Side Clearance
362
Checking the Piston Pin Boss Inside Diameter
362
Checking the Piston Pin Diameter
363
Checking the Connecting Rod Small End Inside Diameter and Big End Inside Diameter
363
Checking the Connecting Rod Big End Side Clearance
363
Checking the Crankshaft
364
Checking the Crankcase Bolt
364
Checking the Crankpin Oil Clearance
365
Selecting the Crankpin Bearing
366
Crankpin Bearing Selection Table
368
Checking the Crankshaft Journal Oil Clearance
369
Selecting the Crankshaft Journal Bearing
370
Crankshaft Journal Bearing Selection Table
372
Checking the Cylinder Block Anode
373
Assembling the Cylinder Block
373
Lowr Lower Unit 8
376
Checking the Propeller
382
Disassembling the Propeller
382
Removing the Lower Unit
382
Assembling the Propeller
383
Checking the Lower Unit Anode
383
Lower Unit
384
(Regular Rotation Model, U-Transom Model)
385
Removing the Lower Unit
387
Disassembling the Propeller
387
Checking the Propeller
387
Checking the Lower Unit Anode
387
Assembling the Propeller
387
Removing the Water Pump and Shift Rod
390
Disassembling the Water Pump Housing
390
Checking the Water Pump and Shift Rod
391
Assembling the Water Pump Housing
391
Removing the Propeller Shaft Housing Assembly
395
Disassembling the Propeller Shaft Assembly
396
Disassembling the Reverse Gear
396
Disassembling the Propeller Shaft Housing Assembly
396
Checking the Propeller Shaft
397
Checking the Dog Clutch
397
Checking the Propeller Shaft Housing
397
Checking the Reverse Gear
397
Assembling the Propeller Shaft Assembly
397
Assembling the Reverse Gear
398
Assembling the Propeller Shaft Housing Assembly
398
Drive Shaft and Lower Case (Regular Rotation Model)
401
Removing the Drive Shaft
402
Removing the Forward Gear
402
Disassembling the Oil Seal Housing
402
Disassembling the Drive Shaft
402
Disassembling the Forward Gear
403
Disassembling the Lower Case
404
Checking the Pinion
404
Checking the Forward Gear
404
Checking the Drive Shaft
404
Checking the Lower Case
404
Assembling the Drive Shaft
404
Assembling the Forward Gear
406
Assembling the Lower Case
406
Assembling the Oil Seal Housing
407
Installing the Forward Gear
407
Installing the Drive Shaft
407
Installing the Propeller Shaft Housing Assembly
408
Installing the Shift Rod
410
Installing the Water Pump
410
Checking the Lower Unit for Air Leakage
411
Installing the Lower Unit (X-Transom Model)
412
Installing the Lower Unit (U-Transom Model)
413
Shimming (Regular Rotation Model)
415
Shimming Workflow
415
Shimming Check Sheet
416
Measuring the Forward Gear Backlash and Reverse Gear Backlash before Disassembly
418
Shimming
421
Shim Location
421
Selecting the Pinion Shim (T3)
422
Calculated Value (B) Table
425
Pinion Shim (T3) Selection Table
426
Measuring the Forward Gear Backlash
433
Adjusting the Forward Gear Shim (T1) Thickness
433
Forward Gear Shim (T1) Selection Table
435
Measuring the Reverse Gear Backlash
436
Adjusting the Reverse Gear Shim (T2) Thickness
436
Selecting the Propeller Shaft Shim (T4)
440
Lower Unit
440
Removing the Lower Unit
443
Disassembling the Propeller
443
Checking the Propeller
443
Checking the Lower Unit Anode
443
Assembling the Propeller
443
Lower Unit
444
Removing the Lower Unit
446
Disassembling the Propeller
446
Checking the Propeller
446
Checking the Lower Unit Anode
446
Assembling the Propeller
446
Water Pump and Shift Rod (Counter Rotation Model)
447
Removing the Water Pump and Shift Rod
449
Disassembling the Water Pump Housing
449
Checking the Water Pump and Shift Rod
449
Assembling the Water Pump Housing
449
Propeller Shaft Housing (Counter Rotation Model)
450
Removing the Propeller Shaft Housing Assembly
452
Disassembling the Propeller Shaft Housing Assembly
452
Disassembling the Forward Gear
452
Checking the Propeller Shaft
453
Checking the Dog Clutch
453
Checking the Propeller Shaft Housing
453
Checking the Forward Gear
453
Assembling the Propeller Shaft Housing Assembly and Forward Gear
453
Drive Shaft and Lower Case (Counter Rotation Model)
455
Removing the Drive Shaft
457
Removing the Reverse Gear
457
Disassembling the Oil Seal Housing
457
Disassembling the Drive Shaft
457
Disassembling the Reverse Gear
457
Disassembling the Lower Case
457
Checking the Pinion
457
Checking the Reverse Gear
457
Checking the Drive Shaft
457
Checking the Lower Case
457
Assembling the Lower Case
458
Assembling the Oil Seal Housing
458
Install the Reverse Gear
458
Installing the Drive Shaft
458
Installing the Propeller Shaft Housing Assembly
458
Installing the Shift Rod
459
Installing the Water Pump
459
Checking the Lower Unit for Air Leakage
459
Installing the Lower Unit (X-Transom Model)
459
Installing the Lower Unit (U-Transom Model)
459
Shimming (Counter Rotation Model)
460
Shimming Workflow
460
Shimming Check Sheet
461
Measuring the Forward Gear Backlash and Reverse Gear Backlash before Disassembly
463
Shimming
466
Shim Location
466
Selecting the Pinion Shim (T3)
467
Calculated Value (B) Table
467
Pinion Shim (T3) Selection Table
467
Selecting the Propeller Shaft Shim (T4)
467
Propeller Shaft Shim (T4) Selection Table
469
Measuring the Forward Gear Backlash
470
Adjusting the Forward Gear Shim (T2) Thickness
470
Measuring the Reverse Gear Backlash
474
Adjusting the Reverse Gear Shim (T1) Thickness
474
Reverse Gear Shim (T1) Selection Table
476
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Yamaha FL225F Owner's Manual (110 pages)
Brand:
Yamaha
| Category:
Outboard Motor
| Size: 5.32 MB
Table of Contents
Important Manual Information
3
Table of Contents
5
Safety Information
8
Outboard Motor Safety
8
Propeller
8
Rotating Parts
8
Hot Parts
8
Electric Shock
8
Power Trim and Tilt
8
Engine Shut-Off Cord (Lanyard)
8
Gasoline
8
Gasoline Exposure and Spills
9
Carbon Monoxide
9
Modifications
9
Boating Safety
9
Alcohol and Drugs
9
Personal Flotation Devices (Pfds)
9
People in the Water
9
Passengers
9
Overloading
9
Avoid Collisions
10
Weather
10
Passenger Training
10
Boating Safety Publications
10
Laws and Regulations
10
General Information
11
Identification Numbers Record
11
Outboard Motor Serial Number
11
Digital Electronic Control Serial Number
11
Key Number
12
EC Declaration of Conformity (Doc)
12
CE Marking
12
Compliance Mark and Manufactured Date Label
13
Read Manuals and Labels
14
Warning Labels
14
Specifications and Requirements
17
Specifications
17
Installation Requirements
19
Boat Horsepower Rating
19
Mounting Outboard Motor
19
Yamaha Security System
19
Digital Electronic Control Requirements
19
Battery Requirements
20
Battery Specifications
20
Mounting Battery
20
Multiple Batteries
20
Propeller Selection
20
Counter Rotation Models
21
Start-In-Gear Protection
21
Engine Oil Requirements
21
Fuel Requirements
22
Gasoline
22
Anti-Fouling Paint
23
Outboard Motor Disposal Requirements
23
Emergency Equipment
23
Emission Control Information
23
Star Labels
24
Components
26
Components Diagram
26
Remote Control Transmitter
29
Receiver
30
Yamaha Security System Lock and Unlock Mode
30
Digital Electronic Control Box
31
Digital Electronic Control-Active Indicator
31
Digital Electronic Control-Alert Indicator
32
Control Lever
32
Free Throttle Switch
32
Throttle Friction Adjuster
33
Engine Shut-Off Cord (Lanyard) and Clip
34
Main Switch
35
Start/Stop Switch Panel
35
All Start/Stop Switch Panel
35
Power Trim and Tilt Switch on Digital Electronic Control
35
Power Trim and Tilt Switch on Bottom Cowling
36
Power Trim and Tilt Switches (Twin Type)
36
Trim Tab with Anode
37
Tilt Support Lever for Power Trim and Tilt Model
37
Cowling Lock Lever
38
Flushing Device
38
Fuel Filter
38
Instruments and Indicators
40
6Y9 Multifunction Color Gauge
40
YAMAHA SECURITY SYSTEM Indicator
40
Engine Warm-Up Indicator
40
Engine Synchronization Indicator
40
Overheat Alert
41
Low Oil Pressure-Alert
41
Water Separator Alert
42
Low Battery Voltage-Alert
42
Engine Trouble Alert
42
6Y8 Multifunction Meters
43
6Y8 Multifunction Tachometers
43
Yamaha Security System Information
44
Low Oil Pressure-Alert
45
Overheat Alert
45
Water Separator Alert
46
Engine Trouble Alert
46
Low Battery Voltage-Alert
47
6Y8 Multifunction Speed & Fuel Meters
47
6Y8 Multifunction Speedometers
48
6Y8 Multifunction Fuel Management Meters
49
Optional Meters
49
Engine Control System
51
Alert System
51
Digital Electronic Control Alert
51
Overheat Alert
51
Low Oil Pressure Alert
52
Water Separator Alert
53
Installation
55
Mounting the Outboard Motor
55
Operation
57
First-Time Operation
57
Filling Engine Oil
57
Breaking in Engine
57
Getting to Know Your Boat
57
Checks before Starting Engine
58
Fuel Level
58
Removing Top Cowling
58
Fuel System
58
Controls
59
Engine Shut-Off Cord (Lanyard)
59
Engine Oil
59
Outboard Motor
60
Flushing Device
60
Installing Top Cowling
60
Checking Power Trim and Tilt System
62
Battery
62
Filling Fuel
63
Operating Engine
63
Sending Fuel
63
Starting Engine
63
Checks after Starting Engine
66
Cooling Water
66
Warming up Engine
66
Electric Start Models
66
Checks after Engine Warm up
66
Shifting
66
Stop Switches
66
Stopping Boat
67
Trolling
67
Adjusting Trolling Speed
67
Stopping Engine
68
Procedure for Stopping Engine
68
Trimming Outboard Motor
69
Adjusting Trim Angle (Power Trim and Tilt)
69
Adjusting Boat Trim
70
Tilting up and down
71
(Power Trim and Tilt Models)
71
(Power Trim and Tilt Models)
72
Shallow Water
73
Cruising in Shallow Water
73
Operating in Other Conditions
74
Maintenance
75
Transporting and Storing Outboard
75
Motor
75
Storing Outboard Motor
75
Procedure
75
Lubrication
76
Flushing Cooling Water Passage
76
Checking Painted Surface of Outboard Motor
77
Periodic Maintenance
77
Replacement Parts
77
Severe Operating Conditions
77
Maintenance Chart 1
79
Maintenance Chart 2
81
Greasing
82
Inspecting Spark Plug
83
Inspecting Engine Idle Speed
84
Changing Engine Oil
85
Inspecting Wiring and Connectors
90
Inspecting Propeller
91
Removing Propeller
91
Installing Propeller
92
Changing Gear Oil
93
Inspecting and Replacing Anode(S)
94
Checking Battery (for Electric Start Models)
95
Connecting the Battery
96
Disconnecting the Battery
97
Storing the Battery
97
Trouble Recovery
98
Troubleshooting
98
Procedure for Tilting up (Twin Engines)
101
Temporary Action in Emergency
101
Impact Damage
101
Replacing Fuse
102
Operate
103
Blinks While Cruising
103
Treatment of Submerged Motor
105
Index
106
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