The active development of the market for motorcycles, jet skis, snowmobiles, ATVs and other power equipment is forcing many manufacturers to improve various production technologies and improve product quality. One of the first "Yamaha Motor Co.
More sophisticated technologies on 2-stroke engines began to be used in the 90s of the last century and made it possible to keep powerful models in the production program that meet the environmental standards of many countries and even surpass them. HPDI technology, which is equipped with high-power injected 2-stroke engines, implies the presence of a fuel injection system in the combustion chamber under high pressure, due to which the fuel-air mixture burns almost completely.
This allows not only to reduce harmful emissions into the atmosphere, but also to increase the efficiency of the motors themselves, as well as to reduce the specific fuel consumption. By , Yamaha Motor Co. If today we ask the owners of boats and boats in various parts of the world, whatever motor they wanted to buy for their boat, then the Yamaha engines will be the first in the rating, so firmly established in their minds is the image of Yamaha Motor Co.
Marian Monday, 13 December Hi, looking for a workshop manual for my yamaha 8Hp 2 stroke outboard, model Thanks marianisacof yahoo. Hi, looking for a workshop manual for my 20Hp 2 stroke outboard.
Many thanks Kev. Ari Bossley Monday, 29 November Tom Sunday, 28 November My factory extended warranty expires August At your earliest convenience; please advise if you can provide me a. Thanks in advance; Tom Email: tomvincent56 gmail. Mark R Wise Tuesday, 12 October Hi, I'm looking for the service manual for my 86' 70ETLJ the service manual is LIT I wasn't sure where to search for that download on your page, any help would be greatly appreciated!
Tim Wednesday, 06 October Hello, I need a service manual for a Yamaha 28A outboad engine. Could you please help me? That would be great. Many thanks. Tim inseln web. Randal Rdnprops hotmail. Patrick G Yarbro Saturday, 18 September I need a hard copy or. I have found a new Bennington boat with the above mentioned Yamaha motor.
Will you please let me if this this information us available online? Just need to know proper operation, maintenance, winterization schedule. Sorry for long, rambling simple question. Where can i get a service manual and owners manual for a ETLG? Joe Loxterkamp Thursday, 09 September We just took delivery of 2 on a Regal 33xo. Thank You. Bruce Michaels Thursday, 26 August I need both service manual and owners manual for a hp saltwater series 2 stroke motor.
Are these available in paper or PDF? Thank you. David Mendoza Monday, 23 August Roberto Thursday, 19 August Thomas Villanova Thursday, 05 August What is the correct owners Manuel for a Yamaha 2 stroke outboard hp saltwater series model sxtxrz. Darren Radcliffe Monday, 02 August Anthony Fedele Friday, 23 July Marty Taylor-Harper Friday, 23 July I have owned this P50P Yamaha motor since November of Now that we are on a fixed income we can no longer afford the service prices. I am having some trouble and want to replace the water pump, thermostat and oil filter myself.
I need a manual showing how to do that. Can you help? Little old lady in Louisiana. George Hedgecock Tuesday, 29 June Saturday, 26 June Hi, there I am looking for a manual for Yamaha 15hp 2 stroke enduro year model. See all posts by John Tyson. Your email address will not be published. Save my name, email, and website in this browser for the next time I comment. Skip to content. Manuals Marine. The handbook outlines every aspect of service and repair. Yamaha Service Manual What is a service manual?
What is in a service manual? The main contents covered in this downloadable manual include the following: General Information Specification Technical Feature and Description Rigging Information Troubleshooting Electrical System Fuel System Power Unit Lower Unit Bracket Unit Maintenance Appendix Each chapter is broken down into sub-chapters that detail each specific component, for example, the Power Unit section covers everything related to the cylinder head, cylinder block, crankcase, timing belt, camshaft, etc.
John Tyson Hi. Share This Post:. You May Also Like. Bolt: 1st: 15 Nm 1. LT LT 11 12 Be sure to remove the battery leads from the batteries and the engine stop lanyard from the engine stop lanyard switch. Put a block of wood between the cavitation plate and pro- peller to keep the propeller from turning. NOTE: If the groove in the propeller nut is not aligned with the cotter pin hole, tighten the nut further until they are aligned. NOTE: Remove the shift rod assembly when the shift rod is in the neutral position.
Propeller shaft housing puller. Slide hammer Needle bearing installation position a Ring nut wrench NOTE: To secure the ring nut, bend one tab into the slot in the ring nut and the other tabs toward the propeller shaft housing assem- bly.
Drive shaft holder Needle bearing installation position a 2. Position a 5. Oil seal installation position a 0. Pinion nut 93 Nm 9. Oil seal installation position a 4. Needle bearing installation position a 0. T1 B1 Measuring steps 1 Calculate the specified value M0. It is stamped on the trim tab mounting surface of the lower case in 0. Pinion height gauge YB, NOTE: If the original shim s is unavailable, start with a 0.
Available shim thickness 0. Shimming gauge YB, -3, -5, M Shimming gauge YB NOTE: Select the shim thickness T3 by using the specified measurement s and the calcula- tion formula. Selecting steps 1 Measure M3. Digital caliper NOTE: Install the bearing housing 1, thrust bear- ing 2, and washer 3. Pinion height gauge NOTE: Select the shim thickness T1 by using the specified measurement s and the calcula- tion formula.
Selecting steps 1 Measure M1. Shimming plate Then, mea- sure the height of the bearing, as shown. NOTE: Select the shim thickness T2 by using the specified measurement s and the calcula- tion formula. Selecting steps 1 Measure M2. Forward gear backlash 0. Measuring steps 1 Set the shift rod into the neutral posi- tion.
Center bolt 10 Nm 1. Backlash indicator Magnetic base attaching plate When the drive shaft stops in each direction, measure the backlash. Forward gear Shim thickness backlash Less than To be decreased by 0. Reverse gear backlash 0. Propeller nut 10 Nm 1. Magnetic-base plate Reverse gear Shim thickness backlash Less than To be increased by 0. NOTE: Find the shim thickness T3 by selecting shims until the specified measurement M is obtained with the special tool.
Measuring steps 6A30 1 Calculate the specified value M0. It is stamped on. NOTE: Find the shim thickness T4 by selecting 6A80 shims until the specified measurement is obtained with the special tool.
Propeller shaft free play 0. Magnetic base NOTE: Find the shim thickness T4 by selecting shims until the specified measurement is obtained with the special tool. Forward gear Shim thickness backlash Less than To be increased by 0. NOTE: When measuring the reverse gear backlash, 6B90 turn the shift rod wrench towards the reverse position with force. Reverse gear Shim thickness backlash Less than To be decreased by 0.
Bearing installer: YB Bearing cup installer: YB NOTE: 1 When installing the oil pump assembly onto the upper case assembly, pour a small 2 amount of engine oil into the oil inlet or oil outlet of the oil pump assembly.
NOTE: Tilt up the outboard and then turn the tilt stop levers 1 to support it. Bleeding steps 1 Connect the battery leads to the bat- tery. Then, let the power trim and tilt fluid settle for about 5 minutes. Add fluid if the level is below the brim. This may cause hydraulic fluid to spurt out from the port. CAUTION: Do not wipe hydraulic system components with rags, paper, tissues, or the like, as fibers from such material will cause mal- functions if they enter the system.
NOTE: Add power trim and tilt fluid until it reaches the top of the gear pump housing. NOTE: Align the armature shaft with the recess in the drive pin. Bleeding steps 1 Set the power trim and tilt unit upright. Connect the leads of the power trim and tilt on the battery terminals until the trim and tilt ram assemblies are fully extended.
Then, reverse the leads on the battery terminals until the trim and tilt ram assemblies are fully compressed. If step A was unsuccessful, connect the leads on the battery terminals and fully compress the tilt ram assembly by hand. If step B was unsuccessful, loosen the manual valve, compress the trim and tilt ram assemblies fully by hand, and then tighten the manual valve. Then, com- press and extend the trim and tilt ram assemblies by connecting the leads on the battery terminals in the up and down positions.
If step C was unsuccessful, disassemble, check, and correct any problems with the power trim and tilt unit. Add power trim and tilt fluid if the level is below the brim. Hydraulic pressure with the power trim and tilt ram assemblies fully extended 9. NOTE: Before measuring the hydraulic pressure, bleed the power trim and tilt unit. Measuring steps 1 Fully tilt up the power trim and tilt ram assemblies.
Hydraulic pressure gauge 9 Nm 0. Up-relief valve attachment 4 Nm 0. NOTE: Remove the manual valve and then quickly attach the special tools before any fluid comes out. Then, measure the hydraulic pressure. Hydraulic pressure gauge Down-relief valve attachment 4 Nm 0. Hydraulic pressure with the power trim and tilt ram assemblies fully compressed 5.
NOTE: After measuring the hydraulic pressure, bleed the power trim and tilt unit. NOTE: Place a container under the power trim and tilt unit.
NOTE: When removing the pump gears, note their original direction and position for proper assembly. NOTE: To remove the check valves, cover the gear pump housing with a clean cloth and then blow compressed air through holes a and b. NOTE: Apply grease to the balls to prevent them from falling out of the gear pump.
NOTE: Tighten the bolts evenly and make sure the pump gears turn smoothly. NOTE: Hold the power trim and tilt unit in a vise using aluminum plates on both sides. NOTE: Add power trim and tilt fluid through the hole a until the fluid level is to the top of the gear pump unit. NOTE: Place the tilt ram end screw at the bottom of the tilt ram and install the tilt ram assem- bly into the tilt ram cylinder.
NOTE: After removing the trim ram assemblies, drain the fluid from the power trim and tilt unit. NOTE: Finger-tighten the trim ram assemblies and then cover the tilt cylinder openings with a clean cloth.
NOTE: Remove the free piston by blowing com- pressed air through the hole a. NOTE: Push the free piston into the tilt ram cylin- der until it bottoms out. Otherwise, the hydraulic fluid may spurt out from the unit. NOTE: Add power trim and tilt fluid through holes a, b and c until all of the passages are filled. NOTE: Place each trim ram end screw at the bot- tom of each trim ram and install them into the trim ram cylinders.
Trim ram end screw 80 Nm 8. If one of these is defective, the peak voltage will be lower than speci- fication. NOTE: The peak voltage adaptor should be used with the digital circuit tester. Measuring steps 1 Disconnect the coupler connections. To obtain the correct value, subtract the internal resistance from the displayed mea- surement. Correct value Displayed measurement — internal resistance.
NOTE: The internal resistance of the digital tester can be obtained by connecting both of its probes. Ignition coil assembly resistance Checking steps 1 Remove the spark plugs from the engine.
Test harness 2-pin Test harness 3-pin Measuring steps 1 Place the engine cooling water tem- perature sensor in a container filled with water. Measuring steps 1 Connect the test harness 3-pin as shown.
NOTE: Make sure the throttle position sensor out- put voltage is within specification when the throttle is fully closed and fully opened. NOTE: Slide the pinion gear down as shown and then remove the clips 1 with a thin screw driver.
NOTE: Rotate the starter motor pinion counter- clockwise and make sure it moves smoothly. Also, rotate the starter motor pin- ion clockwise and make sure it locks. Commutator diameter limit Commutator undercut limit 0. Brush length limit a 9. Brush 1 — Brush 2 No continuity Checking steps 1 Remove the terminal 1 from the mag- netic switch relay. NOTE: Remove the terminal to prevent the pinion gear from turning.
Otherwise, the magnetic switch relay may be damaged. NOTE: The starter motor pinion should be pushed out while the magnetic switch is on. Test harness 6-pin Sb Sb Lg Sb. B Trim sensor resistance Pink P — Black B NOTE: Turn the lever 1 and measure the resis- tance as it gradually changes.
NOTE: Hold the brush with a screwdriver as shown. Then, disconnect the sky blue lead. Brush length 4. NOTE: Push the brushes into the holder and then install the armature. NOTE: Place a clean cloth over the end of the armature shaft and carefully push the arma- ture into the stator with a pair of pliers as shown. The battery is charged and its specified gravity is within specification. There are no incorrect wiring connections. Wiring connections are properly secured and are not rusty.
The engine stop lanyard is installed onto the engine stop lanyard switch. The shift position is in neutral. Fuel is reaching the vapor separator. The rigging and engine setting are correct.
Trouble mode Check elements. Normal condition no defective part or irregular process- ing is found Single flash is given every 4. Trouble code indication Example: The illustration indicates code number Diagnostic test lead YB Checking steps 1 Remove the diagnosis connector 3- pins cap. After that problem is corrected, the light flashes in the pattern of the next lowest numbered problem.
This continues until all of the problems are detected and corrected. Code Symptoms 1 Normal Incorrect pick-up coil input 13 signal Incorrect engine cooling water 15 temperature sensor input signal Incorrect throttle position 18 sensor input signal Incorrect battery positive 19 voltage Incorrect intake air temperature 23 sensor input signal 28 Incorrect shift position switch Incorrect intake air pressure 29 sensor input signal out of normal operating range Microcomputer processing 37 - 59 information 37 Intake passage air leakage Engine stop lanyard switch 44 control operating Ignition timing is being slightly 49 corrected when starting a cold engine Memory data over written 59 abnormally.
Items Symptoms 1. No firing. The starter motor cranks the engine, but no firing is Engine will generated in the cylinder. The firing is generated in the cylinder, but the engine soon stops. Start-up time is too long. The engine will not start-up easily. Check the high-pressure fuel lines. Items Symptoms 2. Erratic idling 1. The engine speed is not constant when idling. The engine stalls when the throttle lever is pulled back. The engine stalls when the throttle lever is opened or during outboard operation.
Check the ignition timing. Items Symptoms 3. Erratic engine 1. The engine is started, but will not run smoothly. The engine speed speed drops during acceleration. Printed in USA Oct. September All rights reserved. Any reprinting or unauthorized use without written permission of Yamaha Motor Corporation, U.
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