1997 Yamaha 225HP 250HP 2-Stroke Saltwater Series Outboard Repair Manual

1997 OUTBOARD SERVICE MANUAL Model : L225TXRV, L250TXRV, S225TXRV, S250TXRV 65L281972100 *65L281972100*

PREFACE This manual has been prepared by the Yamaha Motor Company Ltd. primarily for use by Yamaha dealers and their trained mechanics when performing maintenance procedures and repairs to Yamaha equipment. It has been written to suit the needs of persons who have a basic understanding of the mechanical and electrical concepts and procedures inherent in the work, for without such knowledge attempted repairs or service to the equipment could render it unsafe or unfit for use. Because the Yamaha Motor Company Ltd. has a policy of continuously improving its prod- ucts, models may differ in detail from the descriptions and illustrations given in this publication. Use only the latest edition of this manual. Authorized Yamaha dealers are notified periodically of modifications and significant changes in specifications and procedures, and these are incorporated in successive editions of this manual. J A10001-0" (L)225, (L)250 SERVICE MANUAL ©1996 Yamaha Motor Co., Ltd. 1st Edition, August 1996 All rights reserved. No part of this publication may be reproduced or transmitted in any form or by any means including photocopying and recording without the written permission of the copyright holder. Such written permission must also be obtained before any part of this pyblication is stored in a retrieval system of any nature. Printed in Japan P/N 65L-28197-Z6-11

HOW TO USE THIS MANUAL MANUAL FORMAT All of the procedures in this manual are organized in a sequential, step-by-step format. The information has been compiled to provide the mechanic with an easy to read, handy refer- ence that contains comprehensive explanations of all disassembly, repair, assembly, and inspection operations. In this revised format, the condition of a faulty component will precede an arrow symbol and the course of action required will follow the symbol, e.g., • Bearings Pitting/scratches _ Replace. To assist you in finding your way through this manual, the section title and major heading is given at the top of every page. ILLUSTRATIONS The illustrations within this service manual represent all of the designated models. CROSS REFERENCES The cross references have been kept to a minimum. Cross references will direct you to the appropriate section or chapter.

WARNINGS, CAUTIONSAND NOTES In this Service Manual particularly important information is distinguished in the following ways. The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! F!_lvAv/±1 ;] k._ II_[¢tl Failure to follow WARNING instructions could result in severe injury or death to the machine operator, a bystander, or a person inspecting or repairing the outboard motor. _:_._..i!i_ i_.=_•__i:_::: i•:ii:::_ ................. _i:i!i!;ii_:.:_ ......... A CAUTION indicates special precautions that must be taken to avoid damage to the outboard motor. NOTE: A NOTE provides key information to make procedures easier or clearer.

HOW TO READ DESCRIPTIONS 1. To help identify parts and clarify procedure steps, exploded diagrams (_ are provided at the start of each section. 2. Numbers Q indicate the order of the job steps. 3. Symbols (_) indicate the contents and notes of the job. For the meanings of the symbols, refer to the next page(s). 4. The "Removal and Installation Chart" Q accompanies the exploded diagram and explains the job steps, part names, notes for the jobs, etc. 5. The "Service points" (_) give informative notes and discuss the appropriate sections to refer to. PROPELLER SHAP"TAND REVERSEGEAR .,_ I I "REMOVAL AND 'NiTALI"A'rION CHART I {tm / I I t ( G..,o,, ,.,........ "_.OWERU_,'-, .......... I ' I chopl,, I I/_ , I III , ........ +1 .......... ................ I I • p,._.+, i_p,1 1 ll} °''': ...... :' }

CZ_ A50001-I-4 @ ® SYMBOLS i,,,,,=o ,,,,,=cl,,-i m' o's o re0e • tabs to indicate the content of a chapter. (_) Q Q General information I Q Specifications Q Periodic inspection and adjustment FUEL ,_ Fuel system ® Power unit (_) (_) ® Lower unit I 11 O Bracket unit ® Electrical system OWR LOWR ® Trouble-analysis ® ® ® ® Symbols @to (_ indicate specific data: [TRBL] _ ] _ (_ Special tool @ Specified liquid [ANLSJ @ Specified engine speed @ Specified torque @ @ (_ Specified measurement [_ _ _ Specifiedelectricalvalue [Resistance (D), Voltage (V), Electric current (A)] @ ® @) Symbol (_ to @)in an exploded diagram | indicate the grade of lubricant and the Ioca- tion of the lubrication point: @ Apply Yamaha 2-stroke outboard motor oil @ @ @ Applywaterresistantgrease (Yamaha grease A, Yamaha marine grease) _ @ Apply molybdenumdisulfidegrease @ @ Symbols (_ to @ in an exploded diagram indicate the grade of the sealing or locking ._ ._ agent and the location of the application point: @ Apply Gasket maker ® (_ _ _ Apply Yamabond #4 (Yamaha bond No.4) t_ (_ Apply LOCTITE® N°" 271 (Red LOCTITE) Apply LOCTITE ® No. 242 (Blue LOCTITE) 271 242 _ Apply LOCTITE ® No. 572 @ @Applysiliconsealant 572

oooo.o INDEX r_ GENERAL INFORMATION GEN INFO SPECIFICATIONS SPEC PERIODIC INSPECTION AND ('_ ADJUSTMENT INSP ADJ FUEL SYSTEM FUEL POWER UNIT POWR LOWER UNIT LOWR BRACKET UNIT _'_ BRKT TROUBLEANALYSIS TRBL ANLS

I GEN ,FOlI CHAPTER 1 GENERAL INFORMATION IDENTIFICATION ............................................................................................ 1-1 SERIAL NUMBER .................................................................................... 1-1 STARTING SERIAL NUMBERS .............................................................. 1-1 SAFETY WHILE WORKING ........................................................................... 1-2 FIRE PREVENTION .................................................................................. 1-2 VENTILATION .......................................................................................... 1-2 SELF-PROTECTION ................................................................................. 1-2 OILS, GREASES AND SEALING FLUIDS ............................................... 1-2 GOOD WORKING PRACTICES ............................................................... 1-3 DISASSEMBLY AND ASSEMBLY .......................................................... 1-4 SPECIAL TOOLS ............................................................................................ 1-5 MEASURING ........................................................................................... 1-5 REMOVAL AND INSTALLATION ............................................................ 1-7 COUNTER ROTATION MODEL MEASURING ....................................... 1-9 REMOVAL AND INSTALLATION ............................................................ 1-9

I GEN INFO I '_r I IDENTIFICATION <_ IDENTIFICATION -_i_ SERIAL NUMBER The outboard motor's serial number is stamped on the label attached to the port side of the clamp bracket. NOTE: For USA model: As an antitheft measure, a special label on which the outboard motor's serial number is stamped is bonded to the port side of the clamp bracket. The label is specially treated so that peeling it off causes cracks across the serial number. O Model name Q Approved model No. O Transom height Q Serial number STARTING SERIAL NUMBERS The starting serial number blocks are as fol- lows: Approval Starting Model name model serial code number S225TXRV UL: 100101 ~ 225FETO 62J S225TURV SUL: 200101 ~ L225TXRV UL: 100101 ~ L225FETO 62K L225TURV SUL: 200101 ~ S250TXRV UL: 100101 ~ 250BETO 61A S250TURV SUL: 200101 ~ L250TXRV UL: 100101 ~ L250FETO 61B L250TURV SUL: 200101 ~ 1-1

I GEN INFOI '_r [ SAFETY WHILE WORKING SAFETY WHILE WORKING The procedures given in this manual are those recommended by Yamaha to be fol- lowed by Yamaha dealers and their mechanics. FIRE PREVENTION Gasoline (petrol) is highly flammable. Petroleum vapor is explosive if ignited. Do not smoke while handling gasoline (petrol), and keep it away from heat, sparks, and open flames. VENTILATION Petroleum vapors are heavier than air and if " _ inhaled in large quantities can be deadly. Engine exhaust gases are harmful to _._j breathe. When test-running an engine indoors, maintain good ventilation. SELF-PROTECTION Protect your eyes with suitable safety spec- tacles or safety goggles when using com- _:-_ - pressed air, when grinding or when doing any operation which may cause particles to fly off. Protect hands and feet by wearing safety gloves or protective shoes if appropriate to the work you are doing. OILS, GREASESAND SEALING _! FLUIDS Use only genuine Yamaha oils, greases and '_ sealing fluids or those recommended by Yamaha. 1-2

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1997 Yamaha 225HP 250HP 2-Stroke Saltwater Series Outboard Repair Manual

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