DOWNLOAD Yamaha Outboard Repair Manual 1982-2014

Yamaha Outboard Repair Manual

A Yamaha outboard repair manual is a book of instructions detailing the process of how to fix or mend a boat motor back to factory specifications. A Yamaha repair manual, also termed a service manual or workshop manual, covers every aspect of repair—from basic outboard maintenance procedures to complete engine overhaul.

A Yamaha outboard repair manual is divided into several chapters; e.g general information, specifications, periodic checks and adjustments, fuel system, powerhead, lower unit, bracket unit, electrical system, and troubleshooting analysis. Each repair manual also contains a table of contents and an index page.

Download Online Factory Service Repair manual PDF

Most importantly, a Yamaha outboard repair manual contains pictures, illustrations and exploded part diagrams to help make the repair or maintenance procedure go smoothly.

Yamaha outboard manuals available here: http://www.autopartsrepairs.com/yamaha-outboard-repair-manual/

Within each chapter are subchapters. These subchapters detail repair procedures in a step-by-step fashion. This includes removal, disassembly, inspection, cleaning, testing and installation of parts and components. Here is a small sample of subjects found in a Yamaha outboard repair manual:

GENERAL INFORMATION

  • Serial numbers
  • Starting serial numbers
  • Safety while working
  • Special tools
  • And much more

SPECIFICATIONS

  • General specifications
  • Maintenance specifications
    • Powerhead
    • Lower unit
    • Electrical
    • Dimensions
  • Tightening torque specifications
  • And much more

PERIODIC INSPECTION AND ADJUSTMENT

  • Maintenance internal chart
  • Top cowling
  • Checking fuel line and filter
  • Adjusting shift cable
  • Adjust throttle cable
  • Engine idle speed adjustment
  • Synchronizing carburetor (if equipped)
  • Adjust EFI system (if equipped)
  • Start-in-gear protection device adjustment
  • Checking engine oil and level
  • Engine oil and filter replacement
  • Measuring oil pressure
  • Valve clearance adjustment
  • Cylinder compression testing
  • Timing belt check
  • Checking the cooling water discharge
  • Checking power trim and tilt fluid
  • Checking gear oil
  • Changing gear oil
  • Inspecting lower unit for air leaks
  • Anodes check
  • Batter and spark plugs check
  • Checking lubrication points
  • And much more

FUEL SYSTEM

  • Removal and disassembly
  • Inspection and cleaning
  • Testing and installation
    • Hose routing
    • Fuel joint
    • fuel filter
    • Fuel pump
    • Carburetor unit (if equipped)
    • Electronic fuel injection (if equipped)
  • And much more

POWERHEAD

  • Removal and disassembly
  • Inspection and cleaning
  • Testing and installation
    • Flywheel magnet assembly
    • Recoil starter
    • Power unit
    • Stator assembly
    • Electrical unit
    • Shift bracket
    • Throttle control lever
    • Cylinder head
    • Oil pump
    • valve and valve spring
    • Rocker arm and rocker shaft
    • Cam shaft
    • Valve guide and valve seats
    • Exhaust cover
    • Crankshaft and piston
    • Piston-to-cylinder clearance
    • Piston pin
    • Piston ring
  • And much more

BRACKET UNIT

  • Removal and disassembly
  • Inspection and cleaning
  • Testing and installation
  • Tiller handle (if equipped)
  • Steering friction
  • Bottom cowling
  • Upper case assembly
  • Steering arm
  • Clamp brackets
  • Power trim and tilt unit
  • Tilt cylinder assembly
  • Gear pump assembly
  • Pump housing
  • Gear pump unit

LOWER UNIT

  • Removal and disassembly
  • Inspection and cleaning
  • Testing and installation
    • Lower unit
    • Propeller
    • Trim tab
    • Water pump
    • Water pump housing
    • Impeller and insert cartridge
    • Woodruff key
    • Impeller and water pump housing
    • Shift rod assembly
    • Propeller shaft housing assembly
    • Reverse gear
    • Bearings
    • Dog clutch
    • Propeller shaft
    • Drive shaft
    • Forward gear
    • Drive shat bearings
    • Lower case assembly
    • Drive shaft sleeve
    • Needle bearing
    • Shimming
    • Pinion shims
    • Forward gear shims
    • Reverse gear shims
    • Forward, reverse gear backlash
  • And much more

ELECTRICAL SYSTEM

  • Wire harnesses
  • Electrical component analysis
  • Digital circuit tester
  • Measuring peak voltage
  • Measuring low resistance
  • Ignition system
  • Checking spark plugs
  • Ignition spark gap
  • Spark plug caps
  • Charger coil
  • Checking CDI unit
  • Ignition control system
  • Main switch
  • Engine stop switch
  • Pulser coil output peak voltage
  • Sensor resistance
  • Oil pressure switch continuity
  • Starting system
  • Battery and fuses
  • Wire harness continuity
  • Wire connections
  • Main switch
  • Starter relay
  • Starter motor
  • Starter motor pinion
  • Starter amateur
  • Starter brushes
  • Charging system
  • Thermo heater plunger
  • Power trim and tilt
  • Power trim and tilt motor
  • And much more

TROUBLESHOOTING

  • Engine will not start or crank
  • Engine will crank but won’t start
  • Poor battery charging
  • Engine idles rough
  • Shifting difficulty
  • Engine stalls
  • Tilt motor will not run
  • Poor deceleration
  • Loose tilt holding
  • Engine will not stop
  • Loose steering
  • Poor outboard performance
  • Overheating
  • Irregular warning indication
  • Unstable engine speed
  • Difficult to start
  • And much more

Examples of a Repair Manual

Yamaha outboard service manual
Example of a Service Manual

Yamaha outboard repair manual
Example of a Repair Manual

Yamaha outboard workshop manual
Example of a Repair Manual

Yamaha outboard online repair guide
Example of a Repair Manual

2 Comments

    • Horsepower models are listed below (2HP thru 250HP). For years 1984 1985 1987 1986 1989 1988 1991 1990 1993 1992 1995 1994 1996.

      2 hp 1 cyl. (43cc) 2-stroke 1984-1996
      2 hp 1 cyl. (50cc) 2-stroke 1995-1996
      3 hp 1 cyl. (70cc) 2-stroke 1989-1996
      4 hp 1 cyl. (83cc) 2-stroke 1984-1996
      4 hp 1 cyl. (103cc) 2-stroke 1996
      5 hp 1 cyl. (103cc) 2-stroke 1984-1996
      6 hp 2 cyl. (165cc) 2-stroke 1986-1996
      8 hp 2 cyl. (165cc) 2-stroke 1984-1996
      9.9 hp 2 cyl. (246cc) 2-stroke 1984-1996
      9.9 hp 2 cyl. (232cc) 4-stroke 1984-1996
      15 hp 2 cyl. (246cc) 2-stroke 1984-1996
      20 hp 2-cyl. (395cc) 2-stroke 1996
      20 hp 2 cyl. (430cc) 2-stroke 1996
      25 hp 2 cyl. (395cc) 2-stroke 1988-1996
      25 hp 2 cyl. (430cc) 2-stroke 1990-1996
      25 hp 2 cyl. (496cc) 2-stroke 1984-1996
      25 hp 3 cyl. (496cc) 2-stroke 1996
      28 Jet 3 cyl. (698cc) 2-stroke 1990-1996
      30 hp 2 cyl. (496cc) 2-stroke 1984-1996
      30 hp 3 cyl. (496cc) 2-stroke 1987-1996
      35 Jet 3 cyl. (698cc) 2-stroke 1987-1996
      40 hp 2 cyl. (592cc) 2-stroke 1989-1996
      40 hp 3 cyl. (698cc) 2-stroke 1984-1996
      45 hp 4 cyl. (935cc) 4-stroke 1996
      48 hp 2 cyl. (760cc) 2-stroke 1996
      50 hp 3 cyl. (698cc) 2-stroke 1984-1996
      50 hp 3 cyl. (849cc) 2-stroke 1994-1996
      50 hp 4 cyl. (935cc) 4-stroke 1995-1996
      55 hp 2 cyl. (760cc) 2-stroke 1989-1995
      60 hp 3 cyl. (849cc) 2-stroke 1991-1996
      65 Jet 3 cyl. (1140cc) 2-stroke 1987-1996
      70 hp 3 cyl. (849cc) 2-stroke 1984-1996
      75 hp 3 cyl. (1140cc) 2-stroke 1994-1996
      80 hp 3 cyl. (1140cc) 2-stroke 1994-1996
      80 Jet V4 (1730cc) 2-stroke 1987-1996
      85 hp 3 cyl. (1140cc) 2-stroke 1989-1996
      90 hp 3 cyl. (1140cc) 2-stroke 1984-1996
      105 Jet V6 (2596cc) 2-stroke 1996
      115 hp V4 (1730cc) 2-stroke 1984-1996
      130 hp V4 (1730cc) 2-stroke 1988-1996
      140 hp V4 (1730cc) 2-stroke 1984-1996
      140 Jet V6 (2596cc) 2-stroke 1987-1995
      150 hp V6 (2596cc) 2-stroke 1984-1996
      175 hp V6 (2596cc) 2-stroke 1984-1996
      200 hp V6 (2596cc) 2-stroke 1984-1996
      220 hp V6 (2596cc) 2-stroke 1984-1987
      225 hp 76 deg. V6 (3130cc) 2-stroke 1994-1996
      225 hp 90 deg. V6 (2596cc) 2-stroke 1987-1996
      250 hp V6 (3130cc) 2-stroke 1990-1996

      Repair Manuals for 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 models include:

      1996-2002 Yamaha 2HP Manual 2-Stroke/4-Stroke
      2003-2006 Yamaha 2.5HP Manual 2-Stroke/4-Stroke
      1996-2002 Yamaha 3HP Manual 2-Stroke/4-Stroke
      1996-2006 Yamaha 4HP Manual 2-Stroke/4-Stroke
      1996-2002 Yamaha 4HP Manual 2-Stroke/4-Stroke
      1996-2006 Yamaha 6HP Manual 2-Stroke/4-Stroke
      1996-2006 Yamaha 8HP Manual 2-Stroke/4-Stroke
      1996-2006 Yamaha 9.9HP Manual 2-Stroke/4-Stroke
      1996-2006 Yamaha 15HP Manual 2-Stroke/4-Stroke
      1996-1997 Yamaha 20HP Manual 2-Stroke/4-Stroke
      1996-2006 Yamaha 25HP Manual 2-STROKE
      1998-2006 Yamaha 25HP Manual 4-STROKE
      1996-2006 Yamaha 30HP Manual 2-Stroke/4-Stroke
      1996-1997 Yamaha 40HP Manual 2-STROKE
      1998-2006 Yamaha 40HP Manual 4-STROKE
      1996-2006 Yamaha 50HP Manual 2-Stroke/4-Stroke
      1996-2006 Yamaha 60HP Manual 2-Stroke/4-Stroke
      1996-2006 Yamaha 90HP Manual 2-Stroke/4-Stroke
      1996-2006 Yamaha 115HP Manual 2-Stroke/4-Stroke
      1996-2006 Yamaha 130HP Manual 2-Stroke/4-Stroke
      1996-2006 Yamaha 150HP Manual 2-Stroke/4-Stroke

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