Yamaha Outboard Service and Repair Manual
This Clymer outboard shop manual covers Yamaha 2-90 horsepower two-stroke engines for the years 1999-2009 and includes Jet Drives.
Models Included are:
Yamaha 2 HP (1999-2002)
Yamaha 3 HP (1999-2002)
Yamaha 4 HP (1999)
Yamaha 5 HP (1999-2002)
Yamaha 6 HP (1999-2002)
Yamaha 8 HP (1999-07/2009)
Yamaha 9.9 HP (1999-04/2009)
Yamaha 15 HP (1999-04/2009)
Yamaha 25 HP (Two-Cylinder) (04/2009)
Yamaha 25 HP (Three-Cylinder) (2002)
Yamaha 28 JET (1999-2005)
Yamaha 30 HP (1999-2002)
Yamaha 35 JET (1999-2005)
Yamaha 40 HP (1999-04/2009)
Yamaha 50 HP (1999-04/2009)
Yamaha 60 HP (1999-04/2005)
Yamaha E60 (1999-2000)
Yamaha 67 JET (1999-2005)
Yamaha 70 HP (1999-04/2007)
Yamaha 75 HP (1999)
Yamaha E75 (1999)
Yamaha 90 HP (1999-05/2009)
The Yamaha outboard manual by Clymer is a great reference for repair and service information. This service manual is written for the do-it-yourselfer as well as the experienced mechanic. The repair manual contains hundreds of original photographs and illustrations obtained from the complete disassembly and assembly of the engine. This, in addition to extensive research, is how Clymer repair manuals achieve an unmatched level of detail. The shop manual will guide mechanics and owners through each service, troubleshooting and repair procedure possible.
The Yamaha outboard manual includes the following chapter information:
CHAPTER ONE | GENERAL INFORMATION
Manual organization | Warnings, cautions and notes | Safety | Serial number and model identification | Engine operation | Fasteners | Shop supplies | Galvanic corrosion | Propellers | Basic tools | Special tools | Precision measuring tools | Electrical system fundamentals | Basic mechanical skills | Engine identification codes | Technical abbreviations | Metric tap and drill sizes | Conversion formulas | Specifications
CHAPTER TWO | TROUBLESHOOTING
Preliminary inspection | Operating requirements | Starting difficulty | Fuel system | Starting system | Charging system | Fuse and wire harness | Warning system | Oil injection system | Ignition system | Tilt and trim system | Power head | Cooling system | Gearcase | Starting system troubleshooting | Fuel system troubleshooting | Ignition system troubleshooting | Specifications
CHAPTER THREE | LUBRICATION, MAINTENANCE AND TUNE-UP
Lubrication | Maintenance | Tune-up | Engine break-in | Specifications | Maintenance schedule | Fluid capacities | Oil and fuel mixing rates | Spark plug specifications
CHAPTER FOUR | TIMING, SYNCHRONIZATION AND ADJUSTMENT
Timing, synchronization and adjustments | Test propellers | Wide open throttle speed | Specification
CHAPTER FIVE | FUEL SYSTEM
Fuel system safety | Fuel system component service | Carburetor | Reed housing|intake manifold | Recirculation system | Specifications
CHAPTER SIX | IGNITION AND ELECTRICAL SYSTEMS
Battery | Starting system components | Starter motor | Charging system components | Ignition system components | Warning system components | Specifications
CHAPTER SEVEN | POWER HEAD
Service considerations | Power head break-in | Service recommendations | Lubricants, sealants and adhesives | Fasteners and torque | Power head removal|installation | Flywheel removal|installation | Power head disassembly | Power head components cleaning and inspection | Power head assembly | Specifications
CHAPTER EIGHT | GEARCASE
Gearcase operation | Propeller | Gearcase removal|installation | Water pump | Gearcase disassembly|assembly | Sacrificial anodes | Component inspection | Gearcase pressure test | Specifications
CHAPTER NINE | JET DRIVE
Jet drive operation | Jet drive repair | Specifications
CHAPTER TEN | MANUAL STARTER
Repair | Specifications | Starter rope length
CHAPTER ELEVEN | TILT | TRIM AND MIDSECTION
Manual tilt system removal and installation | Power tilt|trim system removal|installation | Tilt|trim relay replacement | Tilt|trim sender replacement | Electric trim motor removal|installation | Tilt|trim system electric motor repair | Manual release valve removal and installation | Hydraulic system filling and bleeding | Midsection | Specifications
CHAPTER TWELVE | OIL INJECTION SYSTEM
System operation | Oil level sensor removal|installation | Oil reservoir removal|installation | Oil hoses and check valves | Oil pump | Driven gear | Bleeding air from the system | Specifications | Oil reservoir capacity | Oil pump identification
CHAPTER THIRTEEN | REMOTE CONTROL
Neutral throttle operation | Throttle|shift cable removal|installation | Remote control | Specifications
INDEX
WIRING DIAGRAMS
Publisher: Clymer Manuals
Binding: Paperback — 8¼ x 10¾ inches
Pages: 554 — Hundreds of b&w photos and illustrations
ISBN: 0892878274
The Yamaha outboard service and repair manual applies to the following years:
1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009