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The Yamaha outboard motor service manual downloads for the above listed models describes the service procedures for the complete engine. Follow the Maintenance Schedule recommendations to ensure that the motor is in peak operating condition and the emission levels are within the standards set by the your states/county Resources Board. Performing the scheduled maintenance is very important. It compensates for the initial wear that occurs during the life of the outboard motor.
 
All chapters in the Yamaha service manuals apply to the whole engine and illustrates procedures for removal & installation of components that are in detailed step-by-step fashion.
 
Most all service manual chapters start with an assembly or system illustration, diagrams, exploded parts view, quality pictures, service information and troubleshooting for the section. The subsequent pages give detailed procedures. If you don’t know the source of the trouble, go to the troubleshooting page for a list of causes and effects to determine the problem at the end of the manual.


1984-1994 Yamaha Outboard Service Manual/WorkShop Manual Application: 2 hp 1 cyl. (43cc) 2-stroke 1984 1994, 3 hp 1 cyl. (70cc) 2-stroke 1989, 3 hp 1 cyl. (70cc) 2-stroke 1990 1994, 4 hp 1 cyl. (83cc) 2-stroke 1984 1994, 5 hp 1 cyl. (103cc) 2-stroke 1984 1994, 6 hp 2 cyl. (165cc) 2-stroke 1986 1994, 8 hp 2 cyl. (165cc) 2-stroke 1984 1994, 9.9 hp 2 cyl. (246cc) 2-stroke 1984 1994, 9.9 hp 2 cyl. (232cc) 4-stroke 1984 1994, 15 hp 2 cyl. (246cc) 2-stroke 1984 1994, 25 hp 2 cyl. (395cc) 2-stroke 1988 1994, 25 hp 2 cyl. (430cc) 2-stroke 1990 1994, 25 hp 2 cyl. (496cc) 2-stroke 1984 1994, 28 Jet 3 cyl. (698cc) 2-stroke 1990 1994, 30 hp 2 cyl. (496cc) 2-stroke 1984 1994, 30 hp 3 cyl. (496cc) 2-stroke 1987 1994, 35 Jet 3 cyl. (698cc) 2-stroke 1987 1994, 40 hp 2 cyl. (592cc) 2-stroke 1989 1994, 40 hp 3 cyl. (698cc) 2-stroke 1984 1994, 50 hp 3 cyl. (698cc) 2-stroke 1984 1994, 50 hp 3 cyl. (849cc) 2-stroke 1994 1994, 55 hp 2 cyl. (760cc) 2-stroke 1989 1994, 60 hp 3 cyl. (849cc) 2-stroke 1991 1992 1993 1994, 65 Jet 3 cyl. (1140cc) 2-stroke 1987 1994, 70 hp 3 cyl. (849cc) 2-stroke 1984 1985 1986 1987 1988 1989 1990 1991 1992 1993 1994, 75 hp 3 cyl. (1140cc) 2-stroke 1994, 80 hp 3 cyl. (1140cc) 2-stroke 1994, 80 Jet V4 (1730cc) 2-stroke 1987 1994, 85 hp 3 cyl. (1140cc) 2-stroke 1989 1994, 90 hp 3 cyl. (1140cc) 2-stroke 1984 1994, 115 hp V4 (1730cc) 2-stroke 1984 1994, 130 hp V4 (1730cc) 2-stroke 1988 1994, 140 hp V4 (1730cc) 2-stroke 1984 1994, 140 Jet V6 (2596cc) 2-stroke 1987 1994, 150 hp V6 (2596cc) 2-stroke 1984 1994, 175 hp V6 (2596cc) 2-stroke 1984 1994, 200 hp V6 (2596cc) 2-stroke 1984 1994, 220 hp V6 (2596cc) 2-stroke 1984 1985 1986 1987, 225 hp 76 deg. V6 (3130cc) 2-stroke 1994, 225 hp 90 deg. V6 (2596cc) 2-stroke 1987 1988 1989 1990 1991 1992 1993 1994, 250 hp V6 (3130cc) 2-stroke 1990 1994

LIT-18616-01-24 Service Manual Application: Yamaha Ouboard 9.9HP (9.9-HP) 4-stroke engines. Model Names: T9.9T (T9.9-T), F9.9T (F9.9T), T9.9MH (T9.9-MH), F9.9AM (F9.9-AM), F9.9AEM (FT9.9-AEM), T9.9ER (T9.9-ER), F9.9AE (F9.9-AE), F9.9MH (F9.9-MH), F9.9BM (F9.9-BM), T9.9EH (T9.9-EH), F9.9BEM (F9.9-BEM), F9.9BE (F9.9-BE).

LIT-18616-01-28 Service Repair Manual Application: 1995, 1996, 1997 (95, 96, 97) Yamaha Marine Outboard E48T (E48-T) C55T (C55-T) 48HP & 55HP 2-Stroke. Item Model Names: E48T, C55T, E48C, E48MH, E55C, 55BM, C55ER, 55BE, 55BEM, C55TR, 55BET.

LIT-18616-01-35 Service Manual Application: 1996-1997 Yamaha F8, T9.9, F9.9 8HP (8-hp) & 9.9Hp (9.9-hp) 4-stroke engines. Exact Models Covered (Covers All 1996-1997 Models World Wide): F8B (F8-B), F9.9A (F9.9-A), F9.9B (F9.9-B), T9.9U (T9.9-U), F9.9U (F9.9-U), F8BM (F8-BM), F8BEM (F8-BEM), F8BE (F8-BE), T9.9MH (T9.9-MH), T9.9AM (T9.9-AM), FT9.9AMH (FT-9.9-AMH), T9.9EH (T9.9-EH), F9.9AEM (FT9.9-AEM), T9.9ER (T9.9-ER), FT9.9AE (FT9.9-AE), F9.9MH (F9.9-MH), F9.9BM (F9.9-BM), F9.9EH (F9.9-EH), F9.9BEM (F9.9-BEM), F9.9BE (F9.9-BE).

LIT-18616-01-29 Service Repair Manual Application: 1996, 1997 (96, 97) E60, E60H 60HP (60-HP) Yamaha Marine Outboard 2-Stroke. Item Model Names: E60, E60H, E60HM, E60HE, E60HEM, E60MH, E60EH. Covers USA, Canada and wold wide models.

LIT-18616-01-73 Service Repair Manual Application: 1997 97' Yamaha Marine Outboard 75HP (75HP) 2-Stroke. Item Model Names: E75V, E-75-V, E75-V, E-75V 75AM, 75AEM, 75AE, 75AET, 85AEM, 85AE, 85AET, E75B, E60J, E75MH. Covers USA, Canada and wold wide models.

LIT-18616-01-66 Service Repair Manual Application: 1997-1998 Yamaha Marine Outboard 20HP (20-HP) & 25HP 25-HP) 10V, 25V, 25V2 2-Stroke Engines. Model Names 20DM (20-DM), 20DMO (20-DMO), 20DEM (20-DEM), 20DEMO (20-DEMO), 20DERO (20-DERO), 20MH (20-MH), 20MH2 (20-MH2), 20EH (20-EH), 20EH2 (20-EH2), 25DM (25-DM), 25NMO (25-NMO), 25NEMO (25-NEMO), 25NE (25-NE), 25NEO (25-NEO), 25NERO (25-NERO), 25MH (25-MH), 25MH2 (25-MH2), 25EH (25-EH), 25ER (25-ER).

LIT-18616-01-81 Service Repair Manual Application: 1998-1999 98-99 40HP (40-HP) & 50HP (50-HP) 40W 50W Yamaha Marine Outboard 2-Stroke Item Model Names: 40-W, 50-W, 40VMH, 40VMHD, 40VMHO, 40VMO, 40VWH, 40VE, 40VEO, 40VEHTO, 40VET, C40MH, 40MH, C40ER, 40ER, P40TH, C40TR, 40VETO, 50HMHO, 50HMHD, 50HMO, 50HMDO, 50HWHD, 50HEDO, 50HET, 50HETO, 40TR, 50ER, C50TR, 50TR Covers USA, Canada and wold wide models.

LIT-18616-F1-50 & LIT-18616-02-12 Service Repair Manual Application: 1998-2005 Yamaha Marine Outboard 15HP (15-HP) 4-Stroke Engines F15W (F15-W), F15Z (F15-Z) 1998, 1999, 2000, 2001, 2002, 2003, 2004 & 2005. This manual covers all 15HP 4-Stroke models world wide including USA CANADA. USA & CANADA MODELS: F15MHW (F15-MHW), F15EHW (F15-EHW), F15AMH (F15-AMH), F15AEH (F15-AEH), F15AEP (F15-AEP), F15AEHP (F15-AEHP), F15PR (F15-PR), F15PH (F15-PH), F15AEP (F15-AEP), F15AEHP (F15-AEHP). WOLD WIDE MODELS: F15AMH (F15-AMH), F15AEH (F15-AEH), F15AE (F15-AE).

LIT-18616-01-83 Service Manual Application: 1998-2006 Yamaha F8, T9.9, F9.9 8HP (8-hp) & 9.9Hp (9.9-hp) 4-stroke engines for 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005 & 2006. Model Name: T9.9W (T9.9-W), F9.9W (F9.9-W), F8BMH (F8-BMH), F8BEH (F8-BEH), F8BE (F8-BE), T9.9MH (T9.9-MH) FT9.9AMH (FT-9.9-AMH), T9.9EH (T9.9-EH), FT9.9AEH (FT9.9-AEH), T9.9ER (T9.9-ER), FT9.9AE (FT9.9-AE), F9.9MH (F9.9-MH), F9.9BMH (F9.9-BMH), F9.9EH (F9.9-EH), F9.9BEH (F9.9-BEH), F9.9BE (F9.9-BE).

LIT-18616-01-79 Service Repair Manual Application: 1998-2005 Yamaha Marine Outboard 4HP (4-HP) 4-Stroke Engines F4X (F4-X, F-4X) 1999, 2000, 2001, 2002, 2003, 2004 & 2005. This manual covers all 4HP 4-Stroke models world wide including F4MSHX, F4MLHX, F4AMH, USA CANADA.

LIT-18616-01-94 Service Repair Manual Application: 1999-2000 99-00 25HP (25-HP) & 30HP (30-HP) 25X, 25-X, 30X, 30-X, 25J, 25-J, 30D, 30-D Yamaha Marine Outboard 2-Stroke. Model Names: 25JMH, 25MH3, 30DMH, 25JMHO, 30DMHO, 30MH, 25JEHO, 25EH3, 30DWH, 25JEO, 25JETO, 25TR3, 30DEHO, 30EH, 30DMO, 30DE, 30DEO, 30ER, 30DET, 30DETO, 30TR Covers USA, Canada and wold wide models.

LIT-18616-01-96 Service Repair Manual Application: 1999, 2000, 2001, 2002 99, 00, 01, 02 100HP (100-HP) F100X, F100-X, F-100X Yamaha Marine Outboard 4-Stroke. Model Names: F100TR, F100-TR, F-100TR, F100AET, F-100AET, F100-AET Covers USA, Canada and woldwide models.

LIT-18616-02-16 Service Repair Manual Application: 2000, 2001, 2002, 2003 Yamaha Marine Outboard 40HP (40-HP) F40B (F-40B-F40-B) 4-Stroke Engines. Model name F40BMHD, F40BWHD, F40BED, F40BET, USA and Canada name F40MH, F40ER, F40TR.

LIT-18616-02-19 Service Repair Manual Application: 2001, 2002, 2003, 01, 02, 03, Yamaha Marine Outboard 6HP & 8HP (F6Z F8Z) 4-Stroke Engines. Model Name: F6AMH, F8CMH, F6MH, F8MH (F6-AMH, F6-MH, F8-AMH, F8-MH).

ALL 250HP 2003-2006 MODELS Service Repair Manual Application: 2003, 2004, 2005, 2006 Yamaha Marine Outboard 250HP (250-HP) 2-Stroke & 4-Stroke Engines. LIT-18616-02-78 -  2004-2005 Z250C & LZ250C LZ250TR 2-STROKE ENGINE. LIT-18616-02-43 - 2003-2005 Z250B & LZ250B MODEL NAME Z250TR/LZ250TR 2-STROKE ENGINE. LIT-18616-02-97 - 2005-2006 F250 & LF250 F250TR/LF250TR 4-STROKE ENGINE. 

LIT-18616-02-54 Service Repair Manual Application: 2004-2005 Yamaha Marine Outboard 2.5HP (2.5-HP) F2.5C (F2.5-C, F 2.5C) F2.5MH 4-Stroke Engines.

LIT-1816-02-59 Service Repair Manual Application: 2004-2005 Yamaha Marine Outboard 9.9HP & 15HP (9.9-HP 15-HP) 2-Stroke Engines. Model name 9.9CMH & 15CMH ( 9.9 & 15 CMH).

LIT-18616-02-61 Service Repair Manual Application: 2004-2005 Yamaha Marine Outboard 25HP (25-HP) 4-Stroke Engines F25C, T25C (F-25C F25-C T25-C T-25C) F25MH, F25EH, F25ER, F25TR, T25TR.

LIT-18616-02-65 Service Repair Manual Application: 2004 04' & 2005 05' Yamaha Marine Outboard 40HP (40-HP) & 50HP (50-HP) 4-Stroke Engines. Exact model name 40VETO 50HETO, Both USA and CANADA models covered 40TR 50TR / 40C-50C.

LIT-18616-02-66 Service Repair Manual Application: 2004 04' & 2005 Yamaha Marine Outboard 70HP (70-HP) 2-Stroke Engines. Model name 70BETO, USA and Canada name 70TR 70C (70-C).

LIT-18616-02-66 Service Repair Manual Application: 2004 04' & 2005 Yamaha Marine Outboard 90HP (90-HP) 2-Stroke Engines. Model name 90AETO, USA and Canada name 90TR 90C (90-C).

LIT-18616-02-72 Service Repair Manual Application: 2004-2005 Yamaha Marine Outboard 130HP & 115HP (115C 130C) 2-Stroke Engines. Model Name: 115CETO (115-CETO), 130BETO (130-BETO) 115TR, 130TR.

LIT-18616-02-51 Service Repair Manual Application: 2004-2005 Yamaha Marine Outboard 150HP (150-HP) F150C & LF150C (LF-F-150C-F150-C) 4-Stroke Engines. Model name F150TR, LF150TR (F-LF-150-TR)

LIT-18616-02-71 Service Repair Manual Application: 2004-2005 Yamaha Marine Outboard 115HP (115-HP) 4-Stroke Engines. Model name F115AET LF115AET, USA and Canada name F115TR LF115TR.

LIT-18616-02-73 Service Repair Manual Application: 2004-2005 Yamaha Marine Outboard 150 HP (150HP) 150C & V150C 2-Stroke Engines. Model Name: 150FETO, 150GETO.

LIT-18616-02-66 Service Repair Manual Application: 2004 04' & 2005 Yamaha Marine Outboard 60HP (60-HP) 2-Stroke Engines. Model name 60FETO USA and Canada name 60TR, 60C (60-C).

LIT-18616-02-76 Service Repair Manual Application: 2004-2005 Yamaha Marine Outboard F200C, LF200C, F225C, LF225C 200HP (200-HP) & 225HP (225-HP) V6 4-Stroke Engines.

LIT-18616-02-85 Service Repair Manual Application: 2005 Yamaha Marine Outboard 50HP & 60HP (50-HP, 60-HP) 4-Stroke Engines F50D T50D F60D T60D (F-50-D, T-50-D, F60-D, T60-D).

LIT-18616-02-86 Service Repair Manual Application: 2005-2006 05-06' Yamaha Marine Outboard F90D 90HP 4-Stroke Engines. Model Name F90TR


Disassembly

Water Pump - Impeller

NOTE: If water tube seal stayed on water tube (inside of drive shaft housing) when gear housing was removed, pull water tube seal from water tube.
NOTE: Newer models will not have the isolators installed on the water pump.

1. Replace water tube seal, if damaged.
2. Remove 4 screws (2 on each side of water pump housing), washers, and isolators).
3. Remove cover.

a - Water Tube Seal
b - Screw, Washer, Isolator (4 each)
c - Cover

IMPORTANT: The circular groove formed by the impeller sealing bead should be disregarded when inspecting cover (Step 4) and plate (Step 8), as the depth of the groove will not affect water pump output.

4. Replace cover if thickness of steel at the discharge slots is 0.060 in. or less, or if groove(s) (other than impeller sealing bead groove) in cover roof are more than 0.030 in. (0.762 mm) deep.
5. Lift impeller, drive key, and gasket from drive shaft.

a - Impeller
b - Drive Key
c - Gasket

6. Inspect impeller. Replace impeller if any of the following conditions exist:

• Impeller blade(s) are cracked, torn, or worn.
• Impeller is glazed or melted (caused by operation without sufficient water supply).
• Rubber portion of impeller is not bonded to impeller hub.

7. Remove plate and gasket.
8. Replace plate if groove(s) (other than impeller sealing bead groove) in plate are more than 0.030 in. (0.762 mm) deep.

a - Plate
b - Gasket
c - Impeller Sealing Groove

9. Remove screws and washers.

a - Screws and Washers (6 each)

10. Remove water pump base using flat screwdrivers to lightly pry up on base.

a - Water Pump Base

11. Remove (and discard) seals (IT MAY BE BENEFICIAL TO CLAMP THE WATER PUMP BASE IN A VISE WHILE REMOVING SEALS).

a - Seals

12. Remove gasket.

Bearing Carrier and Propeller Shaft

1. Remove fasteners.

a - Fasteners

2. With propeller shaft horizontal, pull carrier (using tool shown) to break seal with gear housing.
3. Remove bearing carrier/propeller shaft components as an assembly by pulling back on the propshaft. Take care not to lose cam follower or 3 metal balls in end of propeller shaft.
4. Remove propeller shaft from bearing carrier.

a - Bearing Carrier
b - Puller Jaws (91-46086A1)
c - Puller Bolt (91-85716)
d - Thrust Hub
e - Propeller Shaft

5. Lift reverse gear, thrust bearing and thrust washer from bearing carrier. Replace thrust bearing and thrust washer if rusted or damaged.
6. Replace reverse gear if gear teeth or clutch teeth on reverse gear are rounded or chipped. If reverse gear must be replaced, pinion gear and sliding clutch should be inspected or damage.

a - Reverse Gear
b - Thrust Bearing
c - Thrust Washer

7. If reverse gear radial bearing is rusted or does not roll freely, replace bearing. If the bearing needs to be replaced remove it using Slide Hammer (91-34569A1).

a - Radial Bearing

8. If bearing is rusted or does not roll freely, replace bearing. If replacement is necessary, remove bearing and oil seals using Mandrel* (91-36569) and Driver Rod* (91-37323). Discard oil seals.

NOTE: *From Bearing Removal and Installation Kit (91-31229A7).

a - Bearing
b - Mandrel (91-36569)
c - Driver Rod (91-37323)

9. Remove propeller shaft seals (if not removed with bearing in Step 9) and bearing carrier O-ring.

a - O-ring

10. Remove spring.

a - Spring

11. Apply constant pressure to cam follower in order to prevent it and internal components from ejecting out of the propeller shaft during removal of the cross pin from the clutch.

a - Cross Pin
b - Cam Follower

12. Remove components from propeller shaft.
13. Replace cam follower if worn or pitted.
14. Replace sliding clutch if jaws are rounded or chipped. Rounded jaws indicate one or more of the following:

• Improper shift cable adjustment.
• Engine idle speed too high while shifting.
• Shifting from neutral to reverse (or forward) too slowly.

a - Cam Follower
b - Metal Balls (3)
c - Guide Block
d - Spring
e - Sliding Clutch
f - Jaws

15. Replace propeller shaft if any of the following exist:

• Splines are twisted or worn.
• Bearing surfaces of propeller shaft are pitted or worn.
• Oil seal surface is grooved.
• Shaft has a noticeable “wobble” or is bent more than 0.009 in. (0.228 mm). Prop shaft trueness should be measured with a dial indicator with prop shaft on V-blocks.

a - V-Blocks
b - Bearing Surfaces
c - Measure with Dial Indicator at This Point

1. Hold drive shaft using Drive Shaft Holding Tool; remove (and discard) pinion nut.
2. Remove drive shaft, pinion gear, pinion bearing and forward gear.
3. Replace pinion gear if it is chipped or worn.
4. Replace pinion bearing and race if either are rusted, pitted or damaged; or if bearing does not roll freely. To remove race, refer to “Lower Drive Shaft Bearing Race,” following.
5. Replace forward gear if gear teeth or clutch teeth are chipped or worn.

a - Drive Shaft Holding Tool
b - Pinion Nut
c - Drive Shaft
d - Pinion Gear
e - Pinion Bearing
f - Forward Gear

6. Replace forward gear needle bearing if it is rusted or does not roll freely.
7. Use suitable tools (screwdriver and awl) to remove retaining ring. Use a punch and hammer to remove bearing.

a - Retaining RIng
b - Forward Gear Needle Bearing

8. Replace forward gear bearing and race if either are rusted, pitted or damaged, or if bearing does not roll freely. Remove bearing from gear using Universal Puller Plate (91-37241) and mandrel. To remove race, refer to “Forward Gear Bearing Race,” following.

a - Forward Gear Bearing
b - Universal Puller Plate (91-37241)
c - Mandrel

9. Replace drive shaft if splines are worn or twisted.
10. If bearing surface is damaged, replace drive shaft and corresponding bearing.

MPORTANT: Do not tighten vise against drive shaft.

11. If wear sleeve is deeply grooved allowing water to enter gear case, remove (and discard) sleeve using Universal Puller Plate (91-37241) and mallet.

a - Crankshaft/Driveshaft Splines
b - Oil Pump Drive Splines 75/90 4-Stroke Only
c - Bearing Surface
d - Wear Sleeve
e - Universal Puller Plate (91-37241)
f - Mallet

12. Remove (and discard) rubber ring.

a - Rubber Ring

Upper Drive Shaft Bearing

1. Replace upper drive shaft bearing and sleeve if either are rust stained, or if bearing will not roll freely. Remove bearing and then sleeve using Puller Assembly (91-83165M) with suitable jaws.

a - Upper Drive Shaft Bearing
b - Sleeve
c - Puller Assembly (91-83165M)

IMPORTANT: Upper drive shaft bearing/sleeve must be removed prior to oil sleeve removal. Refer to “Upper Drive Shaft Bearing,” preceding.


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Yamaha Service Manual, Service Maintenance Manual, Servicing Your Outboard Engine, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, Repair Manual, Engine Repair Manual, Shop Manual, Workshop Manual, Engine Repair Guide, Handbook, Parts Diagram, Exploded View, 95, 96, 97, 98, 99, 00, 01, 02, 03, 04, 05, 06, Engine Problems, Engine Won't Start, Engine Starts And Shuts Off, Engine Stalls, Motor Idels Rough, How To Change Impeller, Impeller Install Directions, Four Stroke, FourStroke, 4Stroke