Yamaha F400A 2022

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Special service tool

0-14

Needle bearing attach-

ment

90890-06609

Ring nut wrench

90890-06932

Ring nut wrench ex-

tention 2

90890-06784

Stopper guide plate

90890-06501

Bearing housing puller

claw L

90890-06502

Center bolt

90890-06504

Ball bearing attach-

ment

90890-06657

Driver rod LL

90890-06605

Needle bearing attach-

ment

90890-06933

Bearing inner race at-

tachment

90890-06658

Bearing outer race at-

tachment

90890-06621

Driver rod LS

90890-06606

Bearing outer race at-

tachment

90890-06623

Ring nut wrench

90890-06934

Drive shaft holder

90890-06935

Pinion nut holder

90890-06451

Socket adapter

90890-06936

Holder guide

90890-06937

Needle bearing attach-

ment

90890-06967

Needle bearing attach-

ment

90890-06938

Bearing outer race

puller assembly

90890-06523

Stopper guide plate

90890-06939

Bearing inner race at-

tachment

90890-06639

Bearing outer race at-

tachment

90890-06628

Main Page

Table of Contents3
General Information4
Model Information5
Applicable Model5
Model Name Designation5
Important Safety and Service Information7
Rotating Parts7
Hot Parts7
Electric Shock7
Propeller7
Handling of Gasoline7
Ventilation7
Self-Protection7
Lifting Outboard Motors8
Handling of Gas Torch8
Parts, Lubricants, and Sealants8
Handling of Lubricants and Sealants8
Special Service Tools9
Tightening Torque9
Non-Reusable Parts9
Disassembly and Assembly9
Disposal of Used Components and Chemicals9
How to Use this Manual11
Conditions When Testing and Adjusting11
Abbreviation11
Color Code12
Specified Tightening Torque13
General Tightening Torque13
Symbol14
Specification Symbol14
Lubricant, Sealant, and Thread Locking Agent Symbol14
Special Service Tool16
Specification23
Specification Data24
External Dimensions25
Technical Feature and Description28
Model Feature29
General Feature29
Model Comparison Table30
Power Unit31
Intake Silencer32
Shift-Shock Reduction32
Sleeveless Cylinder33
Heat Exhaust Fan and Heat Vent33
Direct Fuel Injection34
Crankshaft35
Camshaft36
Cowlings37
Bracket Unit38
Upper Mount39
SBW (Steer by Wire) System40
System Diagram41
Structure43
Operation44
Outboard Motor Manual Steering Method45
PTT Unit46
PTT Sensor47
PTT Lead48
PTT Totaltilt48
Lower Unit51
Lower Case52
Gear Oil Changing Method53
Reverse Thrust55
Propeller (XTO-EC Series)56
Engine ECM56
Electrical System57
Charging System (F400A/FL400A/XF400)57
Charging System (F450A/FL450A/XF450)58
Knocking Detection61
Overheat Detection61
Electronic Control System62
Electrical Components64
Fail-Safe66
Fuel System70
Fuel Diagram70
High-Pressure Fuel Pump Control73
Low-Pressure Fuel Pump Control73
Vapor Separator74
Fuel Strainer75
Direct Injection Pump76
Lubrication System77
Lubrication Diagram77
Dual Rotor Oil Pump79
Oil Drain Plug80
Cooling System81
Cooling Diagram81
Dual Water Pump84
Engine Anode85
Thermostat86
Intake and Exhaust System87
Intake and Exhaust Diagram87
Hose Routing88
Fuel Hose and Blowby Hose88
Cooling Water Hose89
Rigging Information91
Important Reminder on Rigging92
Outboard Motor Mounting Instructions92
Crate Handling93
Crate Top Cover Symbol Description93
Uncrating94
Uncrating Procedure (Outboard Motor Without Lower Unit)94
Uncrating Procedure (Outboard Motor with Lower Unit)95
Outboard Motor Mounting99
Installing the Outboard Motor99
Outboard Motor Mounting Height103
Rigging Grommet Mounting104
Rigging Grommet Description104
Installing the Battery Cable104
Installing the Main Wire Harness104
Installing the Rigging Grommet104
Connecting the Fuel Hose105
Optional Equipment106
Installing the Isolator Lead106
Installing the SCU Communication Lead106
Installing Y-COP107
Battery Installation108
Battery Wiring110
System Diagram116
Single Outboard Motor Application (Single Station)116
Twin Outboard Motor Application (Single Station)119
Triple Outboard Motor Application (Single Station)122
Quad Outboard Motor Application (Single Station)126
Quint Outboard Motor Application (Single Station)130
Single Outboard Motor Application (Dual Station)134
Twin Outboard Motor Application (Dual Station)137
Triple Outboard Motor Application (Dual Station)141
Quad Outboard Motor Application (Dual Station)145
Quint Outboard Motor Application (Dual Station)149
Digital Electronic Control153
Digital Electronic Control System Reset153
Tilt Limiter154
Setting the Tilt Limiter154
Clearing the Tilt Limiter155
Deactivating the Tilt Limiter155
Calibration (6X9 Digital Electronic Control)157
CL5 Display Calibration158
Configuring the Number of Outboard Motors158
Accessing the Calibration Menu158
Steering Sensor159
Toe Adjust161
Lock to Lock163
Friction Set165
Rigging Recommendation167
Battery Cable Length167
Extension Length Recommendation for Battery Cable167
Propeller Selection169
Propeller Size169
Selection170
Fuel Line Air Purging172
Air Purging During Initial Priming172
Troubleshooting173
Ydis174
Connecting the Communication Cable174
ECM Reprogramming176
Outboard Motor Troubleshooting177
Troubleshooting Procedure177
Troubleshooting the Power Unit Using the YDIS177
Trouble Code and Checking Step181
Troubleshooting Procedure (Trouble Code Not Detected)198
Troubleshooting the Power Unit198
Troubleshooting the PTT Unit206
Troubleshooting the Lower Unit208
Electrical System210
Electrical Component and Wire Harness Routing212
Port212
Starboard214
Rear216
Front218
Top219
Fuse Holder (Electrical Management Box)221
Bottom Cowling222
ECM Circuit Diagram223
ECM Coupler Layout226
Checking the Electrical Component229
Using the YDIS229
Using the Digital Tester229
Engine Control Unit and Component230
Checking the Main Relay230
Checking the Engine ECM Circuit230
Checking the Electrical Management Box231
Checking the ETV and TPS232
Checking the ETV Motor Relay233
Checking the SPS233
Checking the Shift Actuator Relay234
Checking the Shift Actuator234
Checking the Cam Position Sensor234
Checking the OCV236
Checking the Oil Pressure Sensor237
Checking the Water Pressure Sensor237
Fuel Control Unit and Component239
Checking the Injector Driver Circuit239
Checking the Water Detection Switch239
Checking the Fuel Injector240
Checking the Low-Pressure Fuel Pump and High-Pressure Fuel Pump240
Checking the Direct Injection Pump241
Checking the Low-Pressure Fuel Pump Relay242
Checking the High-Pressure Fuel Pump Relay242
Checking the Fuel Pressure Sensor243
Charging Unit and Component245
Checking the Lighting Coil (Stator Assembly)245
Checking the Rectifier/Regulator245
Ignition Unit and Component246
Checking the Ignition Spark246
Checking the Ignition Coil246
Checking the Crankshaft Position Sensor246
Checking the Intake Air Pressure/Temperature Sensor247
Checking the Engine Temperature Sensor248
Checking the Thermo Sensor249
Checking the Knock Sensor250
Checking the Engine Shut-Off Switch (6X6)250
Checking the Engine Shut-Off Switch (EKS)250
Starting Unit and Component252
Checking the Starter Relay252
Checking the Engine Start Switch and Main Switch (6X6)252
Checking the Engine Start/Stop Button (6X6)252
Checking the Power Switch (EKS)253
Checking the Start/Stop Button (EKS)254
Checking Y-COP255
Starter Motor256
Removing the Starter Motor257
Checking the Starter Motor Pinion257
Disassembling the Starter Motor257
Checking the Armature (Starter Motor)258
Checking the Brush Holder258
Assembling the Starter Motor259
Installing the Starter Motor260
Outboard Motor and Digital Electronic Control Connection261
Checking the Extension Wire Harness261
Checking the Main Harness261
Steering Unit263
Checking the Steering Actuator263
PTT System264
Fuel System267
Fuel System Basic Procedure268
Starting the Engine after Running out of Fuel268
Reducing the Fuel Pressure268
Disconnecting the Quick Connector268
Measuring the Fuel Pressure269
Fuel Filter Assembly270
Checking the Fuel Filter Assembly271
Checking the Fuel Filter Element271
Checking the Fuel Cup Assembly271
Checking the Primer Pump271
Assembling the Fuel Filter272
Installing the Fuel Filter272
Low-Pressure Fuel Pump273
Checking the Low-Pressure Fuel Pump274
Checking the Feed Valve (Low-Pressure Fuel Pump)274
Checking the Relief Valve (Low-Pressure Fuel Pump)274
Installing the Low-Pressure Fuel Pump275
Vapor Separator and High-Pressure Fuel Pump276
Draining the Fuel277
Removing the Vapor Separator277
Checking the High-Pressure Fuel Pump277
Assembling the Vapor Separator277
Installing the Vapor Separator278
Fuel Hose Assembly279
Fuel Hose, Feed Valve, Relief Valve, and Fuel Strainer280
Disassembling the Fuel Hose Assembly281
Checking the Fuel Strainer281
Checking the Relief Valve (High-Pressure Fuel Pump)281
Checking the Feed Valve (High-Pressure Fuel Pump)282
Checking the Fuel Pressure Sensor (High-Pressure Fuel Pump)283
Assembling the Fuel Hose Assembly283
Installing the Fuel Hose Assembly284
Direct Injection Pump and Fuel Injector285
Removing the Fuel Rail286
Removing the Fuel Injector286
Checking the Fuel Pressure Sensor (Direct Injection Pump)286
Checking the Direct Injection Pump286
Checking the Fuel Rail and Fuel Injector286
Installing the Fuel Injector and Fuel Rail287
Intake Manifold291
Checking the Intake Manifold293
Installing the Intake Manifold293
Etv295
Checking the ETV296
Checking the Intake Air Pressure/Temperature Sensor296
Installing the ETV and Surge Tank296
Power Unit298
Power Unit (Check and Adjustment)301
Checking the Compression Pressure301
Checking the Oil Pressure301
Checking the Valve Clearance301
Adjusting the Valve Clearance303
Shroud Cover and Terminal Cover305
Installing the Shroud Cover and Terminal Cover306
Exhaust Joint (Outside)307
Removing the Exhaust Joint Assembly308
Disassembling the Exhaust Joint Assembly308
Checking the Exhaust Joint308
Checking the Exhaust Joint Anode308
Checking the Water Pressure Sensor308
Installing the Exhaust Joint Assembly308
Exhaust Joint (Inside)311
Removing the Exhaust Joint312
Checking the Exhaust Joint312
Checking the Exhaust Joint Anode312
Installing the Exhaust Joint312
Power Unit Assembly313
Removing the Power Unit315
Installing the Power Unit317
Electrical Management Box322
Installing the Electrical Management Box323
Flywheel Magneto324
Removing the Flywheel Magneto325
Installing the Flywheel Magneto325
Starter Motor and Extension Wire Harness329
Installing the Starter Motor329
Installing the Extension Wire Harness329
Wire Harness331
Removing the Wire Harness331
Installing the Wire Harness333
ECM, Injector Driver, and Rectifier/Regulator338
Removing the Rectifier/Regulator338
Checking the Rectifier/Regulator Anode338
Installing the ECM and Injector Driver338
Installing the Rectifier/Regulator338
Ignition Coil and Spark Plug340
Checking the Spark Plug341
Installing the Ignition Coil and Spark Plug341
Timing Belt342
Removing the Timing Belt343
Checking the Timing Belt343
Installing the Timing Belt343
Camshaft346
Removing the Camshaft, VCT Assembly, and Driven Sprocket348
Checking the Sprocket349
Checking the Cam Chain349
Checking the Cam Chain Tensioner349
Checking the Valve Lifter350
Checking the Camshaft350
Checking the Camshaft Journal Oil Clearance351
Checking the Camshaft Journal Outside Diameter and Camshaft Journal Inside Diameter352
Installing the Camshaft, VCT Assembly, and Driven Sprocket353
Cylinder Head358
Removing the Cylinder Head359
Disassembling the Cylinder Head359
Checking the Cylinder Head359
Checking the Cylinder Head Bolt360
Checking the Valve Spring360
Checking the Valve361
Checking the Valve Guide361
Replacing the Valve Guide362
Checking the Valve Seat363
Refacing the Valve Seat363
Checking the Cylinder Head Anode366
Checking the Cam Position Sensor366
Checking the OCV366
Assembling the Cylinder Head366
Installing the Cylinder Head368
Oil Pump Assembly370
Removing the Oil Pump Assembly371
Removing the Oil Filter371
Installing the Oil Filler Neck and Relief Valve371
Installing the Oil Pump Assembly371
Installing the Oil Filter371
Oil Cooler and Water Jacket372
Checking the Thermostat373
Checking the Oil Cooler Cover Anode and Water Jacket Anode373
Installing the Cylinder Block Thermostat373
Installing the Water Jacket Cover373
Installing the Oil Cooler Cover374
Cylinder Block Sensor375
Checking the Cylinder Block Anode376
Installing the Cylinder Block Anode376
Installing the Cylinder Block Sensor376
Cylinder Block377
Disassembling the Cylinder Block378
Checking the Piston Diameter378
Checking the Cylinder Bore379
Checking the Piston Clearance379
Checking the Piston Ring379
Checking the Piston Ring End Gap380
Checking the Piston Ring Groove380
Checking the Piston Ring Side Clearance381
Checking the Piston Pin Boss Inside Diameter381
Checking the Piston Pin Diameter381
Checking the Connecting Rod Small End Inside Diameter and Big End Inside Diameter382
Checking the Connecting Rod Big End Side Clearance382
Checking the Crankshaft382
Checking the Crankcase Bolt383
Checking the Big End Oil Clearance383
Selecting the Crankshaft Pin Bearing385
Crankshaft Pin Bearing Selection Table387
Checking the Journal Oil Clearance388
Selecting the Crankshaft Journal Bearing389
Crankshaft Journal Bearing Selection Table391
Assembling the Cylinder Block392
Lower Unit398
Propeller and Water Inlet Cover400
Removing the Propeller401
Disassembling the Propeller (Shift Dampener System [SDS] Propeller)401
Checking the Propeller401
Assembling the Propeller (Shift Dampener System [SDS] Propeller)401
Installing the Water Inlet402
Installing the Propeller402
Lower Unit405
Removing the Lower Unit405
Checking the Lower Unit Anode405
Checking the Gear Oil Passage Check Valve405
Checking the Lower Unit for Leakage405
Installing the Lower Unit406
Extension (Except for X-Transom Model)408
Checking the Extension409
Assembling the Extension409
Installing the Extension409
Water Pump and Shift Rod410
Removing the Shift Rod (Regular Rotation Model)411
Removing the Shift Rod (Counter Rotation Model)411
Removing the Gear Oil Passage Check Valve411
Checking the Water Pump412
Checking the Shift Rod412
Installing the Gear Oil Passage Check Valve412
Assembling the Shift Rod Guide Plate412
Assembling the Water Pump Housing413
Installing the Water Pump and Shift Rod (Regular Rotation Model)414
Installing the Water Pump and Shift Rod (Counter Rotation Model)415
Propeller Shaft Housing (Regular Rotation Model)417
Removing the Propeller Shaft Housing Assembly418
Disassembling the Propeller Shaft Assembly419
Disassembling the Reverse Gear419
Disassembling the Propeller Shaft Housing Assembly419
Checking the Propeller Shaft420
Checking the Dog Clutch420
Checking the Propeller Shaft Housing420
Checking the Reverse Gear421
Assembling the Propeller Shaft Assembly421
Assembling the Reverse Gear421
Assembling the Propeller Shaft Housing Assembly422
Installing the Propeller Shaft Housing Assembly424
Drive Shaft and Lower Case (Regular Rotation Model)426
Removing the Drive Shaft427
Disassembling the Drive Shaft427
Disassembling the Forward Gear428
Disassembling the Lower Case428
Checking the Pinion429
Checking the Forward Gear429
Checking the Drive Shaft429
Checking the Lower Case429
Assembling the Lower Case429
Assembling the Forward Gear430
Assembling the Drive Shaft430
Assembling the Oil Seal Housing432
Installing the Forward Gear433
Installing the Drive Shaft433
Shimming (Regular Rotation Model)435
Shimming Workflow435
Shimming Check Sheet436
Shimming Procedure437
Shim Location437
Selecting the Forward Gear Shim (T1) and Reverse Gear Shim (T2)438
Selecting the Pinion Shim (T3)438
Measuring the Forward Gear Backlash and Reverse Gear Backlash440
Selecting the Propeller Shaft Shim (T4)444
Propeller Shaft Housing (Counter Rotation Model)447
Removing the Propeller Shaft Housing Assembly448
Disassembling the Propeller Shaft Housing Assembly448
Disassembling the Forward Gear449
Checking the Propeller Shaft449
Checking the Dog Clutch450
Checking the Propeller Shaft Housing450
Checking the Forward Gear450
Assembling the Propeller Shaft Housing and Forward Gear450
Installing the Propeller Shaft Housing Assembly451
Drive Shaft and Lower Case (Counter Rotation Model)453
Removing the Drive Shaft454
Disassembling the Drive Shaft454
Disassembling the Reverse Gear454
Disassembling the Lower Case454
Checking the Pinion454
Checking the Reverse Gear454
Checking the Drive Shaft454
Checking the Lower Case454
Assembling the Lower Case454
Assembling the Reverse Gear454
Assembling the Drive Shaft455
Assembling the Oil Seal Housing455
Installing the Reverse Gear455
Installing the Drive Shaft455
Shimming (Counter Rotation Model)456
Shimming Workflow456
Shimming Check Sheet457
Shimming Procedure458
Shim Location458
Selecting the Reverse Gear Shim (T1) and Forward Gear Shim (T2)459
Selecting the Pinion Shim (T3)459
Selecting the Propeller Shaft Shim (T4)459
Measuring the Forward Gear Backlash and Reverse Gear Backlash461
Bracket Unit467
Bottom Cowling Cover and Apron Cover469
Installing the Bottom Cowling Cover470
Bottom Cowling (PORT and STBD)471
Removing the Bottom Cowling473
Assembling the Bottom Cowling473
Installing the Propeller Light Bracket474
Installing the Bottom Cowling475
Apron476
Cooling Water Hose and Gear Oil Changing Hose477
Removing the Cooling Water Hose (Oil Pan Side)478
Installing the Gear Oil Changing Hose478
Installing the Cooling Water Hose480
Shift Actuator and Shift Rod481
Installing the Shift Actuator and Shift Rod482
Bottom Cowling (Front) and Flushing Hose484
Assembling the Bottom Cowling (Front)485
Installing the Bottom Cowling (Front)485
Installing the Flushing Hose and PTT Switch485
Upper Case Assembly and Mount488
Removing the Upper Case Assembly489
Installing the Upper Case Assembly489
Exhaust Guide493
Checking the Exhaust Guide494
Installing the Exhaust Guide494
Upper Case, Muffler, and Oil Pan496
Disassembling the Upper Case497
Checking the Upper Case497
Checking the Muffler497
Checking the PCV497
Checking the Oil Pan and Oil Strainer497
Assembling the Oil Pan497
Assembling the Upper Case498
Installing the Muffler and Upper Case498
Steering Actuator and Steering Arm500
Removing the Steering Actuator (with the Power Unit Installed)501
Removing the Power Steering Unit (with the Power Unit Removed)502
Removing the Steering Arm503
Checking the Steering Arm and Steering Arm Joint504
Installing the Steering Arm504
Installing the Steering Actuator (with the Power Unit Removed)505
Installing the Steering Actuator (with the Power Unit Installed)507
Clamp Bracket and Swivel Bracket510
Removing the Clamp Bracket511
Checking the Clamp Bracket Anode511
Assembling the Swivel Bracket511
Installing the Clamp Bracket511
PTT Unit513
Removing the PTT Unit514
Checking the PTT Motor Electric Current When the Relief Valve Operates514
Bleeding the PTT Unit516
Installing the PTT Unit517
PTT Motor520
Removing the Reservoir521
Disassembling the PTT Motor521
Checking the PTT Motor521
Checking the Brush522
Checking the Reservoir522
Checking the Filter522
Assembling the PTT Motor522
Installing the Reservoir523
Installing the PTT Motor523
PTT Gear Pump525
Disassembling the Gear Pump Assembly527
Checking the Gear Pump527
Checking the Gear Pump Housing527
Checking the Filter527
Assembling the Gear Pump Assembly527
Installing the Gear Pump Assembly529
PTT Cylinder530
Removing the Tilt Ram532
Removing the Trim Ram532
Checking the Tilt Cylinder and Trim Cylinder533
Checking the Absorber Valve533
Assembling the Trim Ram533
Assembling the Tilt Ram533
Installing the Tilt Cylinder534
Installing the Trim Ram534
Installing the Tilt Ram535
Maintenance537
Maintenance Interval Chart538
Checking the Battery546
Checking the Cooling Water Pilot Hole546
Checking the Engine Idle Speed546
Checking the Engine Oil Level547
Replacing the Oil Filter550
Checking the Gear Oil Level551
Greasing Points556
Checking the PTT Fluid Level557
Predelivery Check559
Checking the Outboard Motor Mounting Height562
Wiring Diagram572

Yamaha F400A 2022 - Page 18

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