Description
This 1990-1995 Yamaha 2-250 hp 2-Stroke Outboard Boat Engine Repair Manual by Clymer provides detailed service information, step-by-step repair instruction and maintenance specifications for 1990-1995 Yamaha 2-250hp two-stroke outboard boat engines including Jet drives, 2-5 HP single-cylinder, 6-55 HP 2-cylinder, 30-90 HP 3-cylinder, 115 and 130 HP V4, 150, 175, 200 and 225 HP 90° V6, and 225 and 250 HP 76° V6 engines. Includes general information on each model, tools and techniques, troubleshooting and testing, lubrication, maintenance and tune-up, timing, synchronization and adjustments, fuel system, electrical and ignition systems, power head, gearcase, drive shaft housing, Jet drives, rewind starter, power trim and tilt systems, oil injection system, Yamaha 703 remote control box and complete wiring diagrams. Features 720 illustrated pages.
1990, 1991, 1992, 1993, 1994, 1995
QUICK REFERENCE DATA
CHAPTER ONE, GENERAL INFORMATION
Manual organization, Notes, cautions and warnings, Torque specifications, Engine operation, Fasteners, Lubricants, Gasket sealant, Galvanic corrosion, Protection from galvanic corrosion, Propellers
CHAPTER TWO, TOOLS AND TECHNIQUES
Safety first, Basic hand tools, Test equipment, Service hints, Special tips, Mechanic’s techniques
CHAPTER THREE, TROUBLESHOOTING
Operating requirements, Starting system, Charging system, Ignition system, Breaker point ignition testing (1990-1994 2 hp engine) , CDI ignition testing, Fuel enrichment system, Fuel system, Engine temperature and overheating, Power head
CHAPTER FOUR, LUBRICATION, MAINTENANCE AND TUNE-UP
Lubrication, Storage, Anti-corrosion maintenance, Complete submersion, Engine flushing, Tune-up
CHAPTER FIVE, TIMING, SYNCHRONIZATION AND ADJUSTMENT
Engine timing and synchronization, 1990-1994 2 hp models, 1995 2 hp models, 3 hp models, 4 hp and 5 hp models, 6 hp and 8 hp models, 9.9 hp and 15 hp models, C25 models, 25 hp models, C30 (2-cylinder) models, 30 hp (3-cylinder) models, C40 (2-cylinder) models, 40 hp, 50 hp and Pro 50 (3-cylinder) models, C55 models, Pro 60, 70 hp and 90 hp models, C75 hp and C85 models, C115 models, 115 hp, Pro V 115, 130 hp V4, 150 hp, Pro V 150, 175 hp Pro V 175, 200 hp, Pro V 200 and 225 hp 90º V6 models, 225 hp, 250 hp 76º V6 models
CHAPTER SIX, FUEL SYSTEM
Fuel system connections, Fuel pump, Prime start system, Carburetors, Throttle plunger carburetor (2 hp) , Integral fuel pump carburetor, Center bowl carburetor (C25) , Center bowl carburetor (C30, C40, C75 and C85) , Center bowl carburetor (C55) , Center bowl carburetor (40, 50, 70 and 90 hp and Pro 50 and Pro 60) , Center bowl carburetor (225, 250 hp 76º V6) , Twin barrel carburetor (115-130 hp V4 and 150-225 hp 90º V6) , Carburetor cleaning and inspection (all models) , Float adjustment, Primer assembly (225 hp 90º V6) , Fuel filter, Reed valve assembly, Integral fuel tank (2-5 hp) , Portable fuel tank (7-250 hp) , Fuel line and primer bulb, Anti-siphon devices
CHAPTER SEVEN, IGNITION AND ELECTRICAL SYSTEMS
Electrical connector adapters, Battery, Battery charging system, Electric starting system, Ignition systems, Magneto breaker point ignition (1990-1994 2 hp) , Capacitor discharge ignition (2-55 hp and Pro 50 models) , Capacitor discharge ignition (75-200 hp [except 1992-on 90 hp]) , Yamaha microcomputer ignition system (YMIS) (1992-on Pro 60, 70 hp, 90 hp 3-cylinder and all 225-250 hp V6 models)
CHAPTER EIGHT, POWER HEAD
Fasteners and torque, Engine serial number, Gaskets and sealants, Flywheel, Power head removal/installation, Power head disassembly, Crankshaft assembly and cylinder block, Power head assembly
CHAPTER NINE, GEARCASE AND DRIVE SHAFT HOUSING
Service precautions and notes, Propeller, Water pump, Gearcase, Gearcase disassembly/inspection/reassembly, Pinion gear and driveshaft, Shift shaft, Forward gear or reverse gear (“L” models) and bearing assembly, Gearcase housing, Pinion gear depth and gear backlash, Trim tab and anode, Pressure and vacuum test
CHAPTER TEN, JET DRIVES
Maintenance, Water pump, Jet drive, Bearing housing, Intake housing liner
CHAPTER ELEVEN, REWIND STARTERS
CHAPTER TWELVE, POWER TRIM AND TILT SYSTEMS
Power tilt system, Power trim/tilt system
CHAPTER THIRTEEN, OIL INJECTION SYSTEM
System components, Operation, Oil level warning system, Oil injection system service, Component replacement
CHAPTER FOURTEEN, YAMAHA 703 REMOTE CONTROL BOX
INDEX
WIRING DIAGRAMS
