Service Manual & Repair Guide Yamaha F6Z, F8Z 2004 (MT028738)

Service Manual & Repair Guide Yamaha F6Z, F8Z 2004 (MT028738)

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  This manual covers the following model(s):

  F6Z 2004
  
  F8Z 2004

  We only sell original manuals; the quality of the files is exceptionally good. When you print the file, the pictures are of good quality and very bright. WE DO NOT SELL ANY COPIED MANUALS, ONLY THE ORIGINAL!!!!

  In this manual you have the following chapters:

  GENERAL INFORMATION
  
  IDENTIFICATION
  
  SERIAL NUMBER
  
  STARTING SERIAL NUMBERS
  
  SAFETY WHILE WORKING
  
  FIRE PREVENTION
  
  VENTILATION
  
  SELF-PROTECTION
  
  OILS, GREASES AND SEALING FLUIDS
  
  GOOD WORKING PRACTICES
  
  DISASSEMBLY AND ASSEMBLY
  
  SPECIAL TOOLS
  
  MEASURING
  
  REMOVING AND INSTALLING

  SPECIFICATIONS
  
  GENERAL SPECIFICATIONS (F6AMH/F6MH)
  
  GENERAL SPECIFICATIONS (F8CMH/F8MH)
  
  MAINTENANCE SPECIFICATIONS
  
  POWER UNIT
  
  LOWER UNIT
  
  ELECTRICAL
  
  OUTBOARD DIMENSIONS
  
  BRACKET DIMENSIONS
  
  TIGHTENING TORQUES
  
  SPECIFIED TORQUES
  
  GENERAL TORQUES

  PERIODIC CHECK AND ADJUSTMENT
  
  MAINTENANCE INTERVAL CHART
  
  TOP COWLING
  
  CHECKING THE WATER DRAIN HOLE
  
  CHECKING THE TOP COWLING FIT
  
  FUEL SYSTEM
  
  CHECKING THE FUEL LINE
  
  CONTROL SYSTEM
  
  ADJUSTING THE SHIFT CONTROL CABLE
  
  ADJUSTING THE THROTTLE CONTROL CABLES
  
  ADJUSTING THE THROTTLE AXLE LINK
  
  ADJUSTING THE ENGINE IDLING SPEED
  
  ADJUSTING THE START-IN-GEAR PROTECTION DEVICE
  
  POWER UNIT
  
  CHECKING THE ENGINE OIL LEVEL
  
  REPLACING THE ENGINE OIL
  
  ADJUSTING THE VALVE CLEARANCE
  
  MEASURING THE COMPRESSION PRESSURE
  
  CHECKING THE IGNITION TIMING
  
  CHECKING THE TIMING BELT
  
  COOLING SYSTEM
  
  CHECKING THE COOLING WATER DISCHARGE
  
  LOWER UNIT
  
  CHECKING THE GEAR OIL LEVEL
  
  CHANGING AND CHECKING THE GEAR OIL LEVEL
  
  CHECKING THE LOWER UNIT (FOR AIR LEAKS)
  
  GENERAL
  
  CHECKING THE ANODE
  
  CHECKING THE BATTERY
  
  CHECKING THE SPARK PLUGS
  
  LUBRICATION POINTS

  FUEL SYSTEM
  
  FUEL JOINT, FUEL FILTER AND FUEL PUMP
  
  REMOVING/INSTALLING THE FUEL JOINT, FUEL FILTER AND
  
  FUEL PUMP
  
  CHECKING THE FUEL JOINT
  
  CHECKING THE FUEL FILTER
  
  INSTALLING THE FUEL FILTER
  
  FUEL PUMP
  
  DISASSEMBLING/ASSEMBLING THE FUEL PUMP
  
  CHECKING THE FUEL PUMP
  
  ASSEMBLING THE FUEL PUMP
  
  INTAKE SYSTEM
  
  REMOVING/INSTALLING THE INTAKE SYSTEM
  
  INSTALLING THE INTAKE MANIFOLD
  
  CARBURETOR
  
  DISASSEMBLING/ASSEMBLING THE CARBURETOR
  
  DISASSEMBLING THE CARBURETOR
  
  CHECKING THE CARBURETOR
  
  ASSEMBLING THE CARBURETOR

  POWER UNIT
  
  MANUAL STARTER
  
  REMOVING/INSTALLING THE MANUAL STARTER 1
  
  INSTALLING THE DUST COVER GROMMET
  
  ADJUSTING THE START-IN-GEAR PROTECTION DEVICE
  
  DISASSEMBLING/ASSEMBLING THE MANUAL STARTER
  
  DISASSEMBLING THE MANUAL STARTER
  
  CHECKING THE MANUAL STARTER
  
  ASSEMBLING THE MANUAL STARTER
  
  FLYWHEEL ROTOR
  
  REMOVING/INSTALLING THE FLYWHEEL ROTOR
  
  REMOVING THE FLYWHEEL ROTOR
  
  INSTALLING THE FLYWHEEL ROTOR
  
  POWER UNIT
  
  DISCONNECTING/CONNECTING THE ELECTRICAL LEADS
  
  DISCONNECTING/CONNECTING THE CABLES AND HOSE
  
  ADJUSTING THE THROTTLE CONTROL CABLE(S)
  
  REMOVING/INSTALLING THE POWER UNIT
  
  INSTALLING THE POWER UNIT
  
  REMOVING/INSTALLING THE THROTTLE LINK AND RIGHT SIDE
  
  ELECTRICAL COMPONENTS
  
  REMOVING/INSTALLING THE LEFT SIDE ELECTRICAL
  
  COMPONENTS 1 (ONE LIGHTING COIL MODEL)
  
  REMOVING/INSTALLING THE LEFT SIDE ELECTRICAL
  
  COMPONENTS 2 (ONE LIGHTING COIL MODEL)
  
  REMOVING/INSTALLING THE LEFT SIDE ELECTRICAL
  
  COMPONENTS 1(TWO LIGHTING COILS MODEL)
  
  REMOVING/INSTALLING THE LEFT SIDE ELECTRICAL
  
  COMPONENTS 2(TWO LIGHTING COILS MODEL)
  
  THERMOSTAT, TIMING BELT AND GEARS
  
  REMOVING/INSTALLING THE THERMOSTAT, TIMING
  
  BELT AND GEARS
  
  REMOVING THE TIMING BELT
  
  REMOVING THE DRIVE GEAR
  
  REMOVING THE DRIVEN GEAR
  
  CHECKING THE THERMOSTAT
  
  CHECKING THE TIMING BELT
  
  INSTALLING THE DRIVEN GEAR
  
  INSTALLING THE DRIVE GEAR
  
  INSTALLING THE TIMING BELT
  
  ADJUSTING THE VALVE CLEARANCE
  
  ANODE AND EXHAUST COVER
  
  REMOVING/INSTALLING THE ANODE AND EXHAUST COVER
  
  CHECKING THE ANODE
  
  INSTALLING THE EXHAUST COVER
  
  CYLINDER HEAD AND OIL PUMP
  
  REMOVING/INSTALLING THE CYLINDER HEAD AND OIL PUMP
  
  CHECKING THE SPARK PLUG
  
  INSTALLING THE OIL PUMP
  
  INSTALLING THE CYLINDER HEAD
  
  INSTALLING THE CYLINDER HEAD COVER
  
  OIL PUMP
  
  DISASSEMBLING/ASSEMBLING THE OIL PUMP
  
  CHECKING THE OIL PUMP
  
  ASSEMBLING THE OIL PUMP
  
  CAMSHAFT AND VALVES
  
  REMOVING/INSTALLING THE CAMSHAFT AND VALVES
  
  REMOVING THE VALVE
  
  CHECKING THE VALVE AND VALVE GUIDE
  
  CHECKING THE VALVE SPRING
  
  CHECKING THE ROCKER ARM ROCKER ARM SHAFT
  
  CHECKING THE CAMSHAFT
  
  CHECKING THE CYLINDER HEAD
  
  REPLACING THE VALVE GUIDE
  
  REFACING THE VALVE SEAT
  
  INSTALLING THE VALVE
  
  INSTALLING THE CAMSHAFT OIL SEAL
  
  CRANKSHAFT, PISTON AND CYLINDER BODY
  
  REMOVING/INSTALLING THE CRANKSHAFT, PISTON AND
  
  CYLINDER BODY
  
  DISASSEMBLING/ASSEMBLING THE PISTON AND CONNECTING
  
  ROD
  
  CHECKING THE CYLINDER BODY
  
  CHECKING THE PISTON
  
  CALCULATING THE PISTON-TO-CYLINDER CLEARANCE
  
  CHECKING THE PISTON PIN
  
  CHECKING THE PISTON RING
  
  CHECKING THE CRANKSHAFT
  
  CHECKING THE CRANKSHAFT-PLAIN BEARING OIL CLEARANCE
  
  CHECKING THE CRANKSHAFT-CONNECTING ROD OIL
  
  CLEARANCE
  
  INSTALLING THE PISTON RING
  
  INSTALLING THE CONNECTING ROD
  
  INSTALLING THE PISTON AND CONNECTING ROD
  
  INSTALLING THE OIL SEAL
  
  INSTALLING THE CRANKCASE

  LOWER UNIT
  
  LOWER UNIT
  
  REMOVING/INSTALLING THE LOWER UNIT
  
  REMOVING THE PROPELLER
  
  CHECKING THE PROPELLER
  
  CHECKING THE ANODE
  
  INSTALLING THE LOWER UNIT
  
  INSTALLING THE PROPELLER
  
  WATER PUMP
  
  REMOVING/INSTALLING THE WATER PUMP
  
  CHECKING THE WATER PUMP HOUSING, CARTRIDGE
  
  INSERT AND IMPELLER
  
  PROPELLER SHAFT HOUSING AND PROPELLER SHAFT
  
  REMOVING/INSTALLING THE PROPELLER SHAFT HOUSING
  
  ASSEMBLY AND PROPELLER SHAFT ASSEMBLY
  
  INSTALLING THE PROPELLER SHAFT HOUSING ASSEMBLY
  
  DISASSEMBLING/ASSEMBLING THE PROPELLER SHAFT
  
  ASSEMBLY
  
  CHECKING THE DOG CLUTCH
  
  CHECKING THE PROPELLER SHAFT
  
  ASSEMBLING THE PROPELLER SHAFT ASSEMBLY
  
  DISASSEMBLING/ASSEMBLING THE PROPELLER SHAFT
  
  HOUSING ASSEMBLY
  
  DISASSEMBLING THE PROPELLER SHAFT HOUSING ASSEMBLY
  
  CHECKING THE REVERSE GEAR
  
  CHECKING THE BALL BEARING
  
  CHECKING THE PROPELLER SHAFT HOUSING
  
  ASSEMBLING THE PROPELLER SHAFT HOUSING ASSEMBLY
  
  DRIVE SHAFT AND FORWARD GEAR
  
  REMOVING/INSTALLING THE DRIVE SHAFT AND FORWARD
  
  GEAR
  
  REMOVING THE BALL BEARING
  
  CHECKING THE PINION
  
  CHECKING THE DRIVE SHAFT
  
  CHECKING THE FORWARD GEAR
  
  CHECKING THE BALL BEARING
  
  INSTALLING THE BALL BEARING
  
  BEARING HOUSING, SHIFT CAM AND LOWER CASE
  
  REMOVING/INSTALLING THE BEARING HOUSING, SHIFT
  
  CAM AND LOWER CASE
  
  REMOVING THE SOLID BUSHING
  
  DISASSEMBLING THE BEARING HOUSING
  
  CHECKING THE COLLER
  
  CHECKING THE SHIFT CAM
  
  CHECKING THE LOWER CASE
  
  ASSEMBLING THE BEARING HOUSING
  
  INSTALLING THE SOLID BUSHING
  
  BACKLASH
  
  MEASURING THE FORWARD GEAR BACKLASH
  
  MEASURING THE REVERSE GEAR BACKLASH

  BRACKET UNIT
  
  STEERING HANDLE
  
  REMOVING/INSTALLING THE STEERING HANDLE
  
  INSTALLING THE STEERING HANDLE
  
  ADJUSTING THE THROTTLE CONTROL CABLES
  
  ADJUSTING THE SHIFT CABLE
  
  DISASSEMBLING/ASSEMBLING THE STEERING HANDLE
  
  ASSEMBLING THE STEERING HANDLE
  
  SHIFT LEVER
  
  REMOVING/INSTALLING THE SHIFT LEVER
  
  BOTTOM COWLING
  
  REMOVING/INSTALLING THE BOTTOM COWLING
  
  UPPER CASE
  
  REMOVING/INSTALLING THE UPPER CASE
  
  INSTALLING THE LOWER MOUNT
  
  DISASSEMBLING/ASSEMBLING THE UPPER CASE
  
  INSTALLING THE OIL SEAL
  
  INSTALLING THE MUFFLER
  
  SWIVEL AND STEERING BRACKET
  
  REMOVING/INSTALLING THE SWIVEL AND STEERING BRACKET
  
  STEERING FRICTION
  
  DISASSEMBLING/ASSEMBLING THE STEERING FRICTION
  
  ASSEMBLING THE STEERING FRICTION
  
  CLAMP BRACKET
  
  REMOVING/INSTALLING THE CLAMP BRACKET
  
  INSTALLING THE CLAMP BRACKET PLATE
  
  SWIVEL BRACKET
  
  DISASSEMBLING/ASSEMBLING THE SWIVEL BRACKET

  ELECTRICAL SYSTEM
  
  ELECTRICAL COMPONENTS
  
  (ONE LIGHTING COIL MODEL)
  
  Top view and left side view
  
  Details of the wiring harness connection
  
  (TWO LIGHTING COILS MODEL)
  
  Top view, front view and left side view
  
  Details of the wiring harness connection
  
  ELECTRICAL COMPONENTS ANALYSIS
  
  DIGITAL CIRCUIT TESTER
  
  MEASURING THE PEAK VOLTAGE
  
  PEAK VOLTAGE ADAPTOR
  
  MEASURING A LOW RESISTANCE
  
  IGNITION SYSTEM
  
  CHECKING THE SPARK PLUGS
  
  CHECKING THE IGNITION SPARK GAP
  
  CHECKING THE SPARK PLUG CAPS AND IGNITION COIL
  
  CHECKING THE CHARGE COIL
  
  CHECKING THE PULSER COIL
  
  CHECKING THE CDI UNIT
  
  IGNITION CONTROL SYSTEM
  
  CHECKING THE ENGINE STOP SWITCH
  
  CHECKING THE PULSER COIL
  
  CHECKING THE OIL PRESSURE SWITCH
  
  CHECKING EMERGENCY SIGNAL LIGHT
  
  CHARGING SYSTEM
  
  (ONE LIGHTING COIL MODEL)
  
  (TWO LIGHTING COILS MODEL)
  
  CHECKING THE BATTERY
  
  CHECKING THE LIGHTING COIL
  
  CHECKING THE RECTIFIER AND RECTIFIER/REGULATOR

  TROUBLE ANALYSIS
  
  TROUBLE ANALYSIS
  
  TROUBLE ANALYSIS CHART
  
  TROUBLE SHOOTING FOR PEAK VOLTAGE

  Wiring diagram

  Language: english
  
  Format: PDF
  
  Pages: 208

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