Yamaha Outboard Service and Repair Manual
This Clymer shop manual covers Yamaha 75 HP, 80 HP, 90 HP, 100 HP, 115 HP Inline 4 and 200 HP, 225 HP, and 250 HP 3.3L V6 outboard motors from 2000 to 2013.
Models Included are:Yamaha 75 HP
Yamaha 80 HP
Yamaha 90 HP
Yamaha 100 HP
Yamaha 115 HP
Yamaha 200 HP
Yamaha 225 HP
Yamaha 250 HP
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 / Service hints / Outboard engine identification / Engine operation / Fasteners / Lubricants / RTV gasket sealant / Anaerobic sealant / Threadlocking compound / Galvanic corrosion / Propellers / Basic hand tools / Special tools / Precision measuring tools / electrical system fundamentals / Basic mechanical skills / Specifications
CHAPTER TWO / TROUBLESHOOTING
Electrical component replacement / Preliminary inspection / Starting difficulty / Electric starting system troubleshooting / Fuel system troubleshooting / Ignition system troubleshooting / Warning system troubleshooting / Charging system troubleshooting / Power head / Cooling system troubleshooting / Gearcase troubleshooting / Trim/tilt system troubleshooting / Electronic fuel injection system / Specifications
CHAPTER THREE / LUBRICATION, MAINTENANCE AND TUNE-UP
Before each use / After each use / Routine maintenance / Tune-up / Storage preparation and re-commissioning / Submersion / Corrosion prevention / Specifications
CHAPTER FOUR / TIMING, SYNCHRONIZATION AND ADJUSTMENT
Pilot screw adjustment (75-100 hp models) / Linkage, throttle position sensor, synchronization and idle speed adjustments / Ignition timing check / Throttle cable adjustment / Shift cable adjustment / Valve adjustment / Trim tab adjustment / Trim position sender adjustment / Specifications
CHAPTER FIVE / FUEL SYSTEM
Fuel system service / Fuel tanks / Fuel hoses / Fuel filter / Primer bulb replacement / Mechanical fuel pump / Silencer cover removal and installation / Intake manifold removal and installation / Dashpot replacement / Electrothermal valve replacement / Carburetor / Throttle body removal and installation / Vapor separator tank / Low-pressure electric fuel pump replacement / Fuel pump relay replacement / Fuel pump driver replacement / Fuel cooler replacement / Fuel pressure regulator replacement / Fuel rail and injectors / Idle air control motor replacement / Air temperature sensor replacement / Air pressure sensor replacement / Throttle position sensor replacement / Specifications
CHAPTER SIX / ELECTRICAL AND IGNITION SYSTEMS
Electrical component replacement / Battery / Charging system / Starting system / Ignition system / Specifications
CHAPTER SEVEN / POWER HEAD
Flywheel/cover removal and installation / Timing belt and tensioner removal/installation / Valve cover removal and installation / Camshaft, timing chain and camshaft pulley removal and installation / Cylinder head removal and installation / Water pressure relief valve removal and installation / Thermostat removal and installation / Exhaust/water jacket cover removal and installation / Cylinder head disassembly/inspection/assembly / Power head removal and installation / Oil pump / Oil pump inspection / Crankshaft pulley removal and installation / Power head external component removal and installation / Cylinder block disassembly and assembly / Cylinder block component inspection and measurement / Bearing selection / Engine break-in procedures / Specifications
CHAPTER EIGHT / GEARCASE
Gearcase operation / Gearcase service precautions / Propeller removal and installation / Gearcase removal and installation / Water pump disassembly/assembly / Gearcase disassembly and assembly / Gearcase component inspection / Gearcase shimming / Gearcase pressure test / Specifications
CHAPTER NINE / POWER TRIM AND TILT
Trim/tilt relay replacement / Trim position sender replacement / Trim switch replacement / Manual relief valve replacement / Power trim and tilt system removal and installation / Electric trim/tilt motor removal/installation / Electric trim and tilt motor disassembly, component inspection, testing and assembly / Fluid filling / Specifications
CHAPTER TEN / MIDSECTION
Lower motor mount replacement / Tilt tube replacement / Clamp bracket replacement / Tilt lock lever replacement / Oil pump replacement / Upper motor mount replacement / Swivel tube replacement / Swivel housing replacement / Power head adapter replacement / Exhaust silencer replacement / Exhaust tube replacement / Oil pressure relief valve / Oil pan and oil pickup tube replacement / Drive shaft housing replacement / Specifications
CHAPTER ELEVEN / REMOTE CONTROL
Remote control operation / Cable removal and installation / Remote control disassembly and assembly / Specifications
INDEX
COLOR WIRING DIAGRAMS
Publisher: Clymer Manuals
Binding: Paperback — 8¼ x 10¾ inches
Pages: 560 — Hundreds of b&w photos and illustrations
ISBN: 0892878959
The Yamaha outboard service and repair manual applies to the following years:
2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010, 2011, 2012, 2013
International Shipping
