This Clymer 2000-2013 Yamaha Outboard Shop Manual 75-115 HP Inline 4 and 200-250 HP 3.3L V6 provides detailed service information, step-by-step repair instruction and maintenance specifications for Yamaha 75 HP, 80 HP, 90 HP, 100 HP, 115 HP Inline 4 and 200 HP, 225 HP and 250HP 3.6 V6 boat engines.
2000 2001 2002 2003 2004 2005 2006 2007 2008 2009
2010 2011 2012 2013
Yamaha 75 HP (2000-20013)
Yamaha 80 HP (2000-2013)
Yamaha 90 HP (2000-2013)
Yamaha 100 HP (2000-2013)
Yamaha 115 HP (2000-2013)
Yamaha 200 HP (2000-2013)
Yamaha 225 HP (2000-2013)
Yamaha 250 HP (2000-2013)
This repair manual contains 546 pages. Clymer repair manuals are your number one source for repair and service information. They are specifically written for the do-it-yourselfer as well as the experienced mechanic. Using a Clymer repair manual is an inexpensive way to keep you boat working properly. Each manual provides step-by-step instructions based on the complete disassembly of the machine. It is this level of detail, along with hundreds of photos and illustrations, that guide the reader through each service and repair procedure.
Written and edited by industry experts, every manual provides reliable step-by-step technical information in a wide variety of industries. If you are involved in the repair and service of marine engines this repair manual should be an essential tool.
Clymer manuals are the most user-friendly repair manuals available today. This manual includes…
# Handy thumb-tabs put the chapter you need right at your fingertips.
# Detailed substeps expand on repair procedure information
# Notes, cautions and warnings throughout each chapter pinpoint critical information.
# Numbered instructions guide you through every repair procedure step by step.
# Bold figure number help you quickly match illustrations with instructions.
# Detailed illustrations, drawings and photos guide you through every procedure.
# Enlarged inset helps you identify and examine parts in detail.
# Numbered table of contents…easy to use so that you can find the information you need fast.
Clymer also makes it easy to diagnose and repair problems with your machine’s electrical system. Troubleshooting and electrical service procedures are combined with detailed wiring diagrams (color on select titles) for ease of use. What are you waiting for? Fix it yourself and save!
QUICK REFERENCE DATA
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
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
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
CHAPTER FOUR, TIMING, SYNCHRONIZATION AND ADJUSTMENTS
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
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
CHAPTER SIX, ELECTRICAL AND IGNITION SYSTEMS
Electrical component replacement, Battery, Charging system, Starting system, Ignition system
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/installation, Cylinder block disassembly and assembly, Cylinder block component inspection and measurement, Bearing selection, Engine break-in procedure
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
CHAPTER NINE, POWER TRIM AND TILT
Trim/tilt relay replacement, Trim position sender replacement, Trim switch replacement, Manual relief valve replacement, Power trim/tilt system removal/installation, Electric trim/tilt motor removal/installation, Electric trim/tilt motor disassembly, component inspection, testing and assembly, Fluid filling
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
CHAPTER ELEVEN, REMOTE CONTROL
Remote control operation, Cable removal and installation, Remote control disassembly and assembly