Yamaha Outboard Service and Repair Manual

This Clymer outboard shop manual covers Yamaha 115-250 horsepower two-stroke engines for the years 1999-2002 and includes Jet Drives.

Models Included are:
YAMAHA 105 JET
YAMAHA 115 HP
YAMAHA 130 HP
YAMAHA 150 HP
YAMAHA 175 HP
YAMAHA 200 HP (2.6L and 3.1L)
YAMAHA 225 HP (3.1L and 3.3L)
YAMAHA 250 HP (3.1L and 3.3L)
YAMAHA 80 JET

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.

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The Yamaha outboard manual includes the following chapter information:

CHAPTER ONE | GENERAL INFORMATION
Manual organization | Warnings, cautions and notes | Safety | Model identification | Engine operation | Fasteners | Shop supplies | Galvanic corrosion | Propellers | Basic tools | Special tools | Precision measuring tools | Electrical system fundamentals | Basic mechanical skills

CHAPTER TWO | TROUBLESHOOTING
Preliminary inspection | Operating requirements | Starting difficulty | Starting system | Charging system | Fuse and wire harness | Warning system | Ignition system | Fuel system (carburetor equipped models) | Fuel system (EFI and HPDI models) | Electronic control system (EFI and HPDI) | Oil injection system | Tilt and trim system | Power head | Cooling system | Gearcase

CHAPTER THREE | LUBRICATION, MAINTENANCE AND TUNE-UP
Lubrication | Maintenance | Tune-up | Engine break-in

CHAPTER FOUR | TIMING, SYNCHRONIZATION AND ADJUSTMENT
Timing, synchronization and adjustment | Synch and link (80 jet, 105 jet and 115-200 hp [except EFI and HPDI models]) | Synch and link (150-250 hp [EFI and HPDI models]) | Miscellaneous adjustments

CHAPTER FIVE | FUEL SYSTEM
Fuel system safety and general information | Fuel tanks | Primer bulb | Fuel hoses | Fuel hose connector | Fuel pumps | Fuel filters | Vapor separator tank | Silencer cover, fuel rail and injectors (EFI and HPDI models) | Throttle body | High pressure mechanical fuel pump | Carburetor and silencer cover | Reed housing|intake manifold

CHAPTER SIX | ELECTRICAL AND IGNITION SYSTEMS
Battery | Starting system components | Charging system | Ignition system | Sensors, switches and relays | Warning system components

CHAPTER SEVEN | POWER HEAD
Power head preliminary information | Service consideration | Power head break-in | Service recommendations | Lubricants, sealants and adhesives | Sealing surfaces | Fasteners and torque | Power head removal|installation | Flywheel | Power head disassembly | Power head components cleaning and inspection | Power head assembly

CHAPTER EIGHT | GEARCASE
Gearcase operation | Propeller removal|installation | Gearcase removal|installation | Water pump | Gearcase repair | Gearcase disassembly (standard RH rotation gearcase)¿ | Component inspection | Gearcase assembly (standard RH rotation gearcase)¿ | Shim selection (all models) | Counter rotation (LH) gearcases | Gearcase pressure test

CHAPTER NINE | JET DRIVE
Jet drive operation | Jet drive mounting height | Jet drive repair

CHAPTER TEN | POWER TILT | TRIM
Hydraulic tilt|trim system removal and installation | Tilt|trim relay replacement | Tilt|trim sender replacement | Electric tilt|trim motor removal and installation | Tilt|trim system electric motor repair | Manual release valve removal and installation | Hydraulic system filling and bleeding

CHAPTER ELEVEN | MIDSECTION
Midsection

CHAPTER TWELVE | OIL INJECTION SYSTEM
Oil injection system operation | Oil injection system

CHAPTER THIRTEEN | REMOTE CONTROL
Remote control

INDEX

COLOR WIRING DIAGRAMS

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Publisher: Clymer Manuals
Binding: Paperback — 8¼ x 10¾ inches
Pages: 486 — Hundreds of b&w photos and illustrations
ISBN: 0892878460

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The Yamaha outboard service and repair manual applies to the following years:
1999, 2000, 2001, 2002

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