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.

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

3 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

Leave a Reply

Your email address will not be published.


*