This manual covers Yamaha outboard motors from 9.9 HP to 100 HP, manufactured between 1985 and 1999. These engines are renowned for their robust engineering, reliability, and performance, making them suitable for a wide range of boating applications. Whether for recreational use or professional tasks, these Yamaha outboards offer dependable power and efficiency.
This comprehensive guide provides essential information for owners, mechanics, and technicians. It details routine maintenance, tune-up procedures, troubleshooting common issues, and in-depth repair instructions for all major systems, including the fuel, electrical, ignition, power head, and gearcase. With clear explanations and technical specifications, this manual is an indispensable resource for ensuring the longevity and optimal performance of your Yamaha outboard motor.
Models Covered:
Yamaha 9.9 HP (1985-1999)
Yamaha 15 HP (1985-1999)
Yamaha 25 HP (1985-1999)
Yamaha 40 HP (1985-1999)
Yamaha 50 HP (1985-1999)
Yamaha 80 HP (1985-1999)
Yamaha 100 HP (1985-1999)
This manual can be used by anyone from a first time owner/amateur to a professional technician.Easy to read type,And give you all the information needed to do the procedure correctly.Keep this shop manual handy and use it often. Performing routine,preventive maintenance will save you time & money by helping to prevent premature failure and unnecessary repairs.
Manual Contents:
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 / Specifications
CHAPTER TWO / TOOLS AND TECHNIQUES
Safety first / Basic hand tools / Test equipment / Service hints / Special tips / Mechanic's techniques / Specifications
CHAPTER THREE / TROUBLESHOOTING AND TESTING
Test equipment / Troubleshooting preparation / Operating requirements / Starting difficulty / Fuel system component testing / Ignition system testing / Warning system / Starting system / Charging system / Fuses and wire harness / Trim system / Electrical testing / Power head / Cooling system / Gearcase / Specifications
CHAPTER FOUR / LUBRICATION, MAINTENANCE AND TUNE-UP
Lubrication and maintenance / Pre-operational checklist / Post-operational checklist / Routine maintenance / Fuel requirements / Fuel filter service / Engine oil requirements / Oil drain and fill locations / Pumping oil from the engine / Draining oil / Filling the engine with oil / Oil filter / Engine oil and filter change / Oil screen service / Removing carbon deposits from the combustion chambers / Power head anodes / Timing belt and sprocket inspection / Hoses and clamps inspection / Thermostat inspection / Gearcase lubricant / Changing the gearcase lubricant / Gearcase anode inspection / Water pump and impeller inspection / Propeller shaft inspection and lubrication / Swivel tube and tilt tube lubrication / Steering cable lubrication / Trim system fluid level check and change / Starter motor maintenance / Battery maintenance / Throttle and shift linkage lubrication / Tune-up / Compression test / Spark plugs / Valve adjustment / Carburetor adjustment / Ignition timing / Run test / Special maintenance requirements / Submersion / Storage / Corrosion prevention / Specifications
CHAPTER FIVE / SYNCHRONIZATION AND ADJUSTMENT
Fuel system adjustment / Carburetor synchronization / Valve adjustment / Cable and linkage adjustment / Specifications
CHAPTER SIX / FUEL SYSTEM
Servicing the fuel system / Fuel tank / Gloat level (9.9, 25 and 80-100 hp models) / Specifications
CHAPTER SEVEN / ELECTRICAL AND IGNITION SYSTEM
Starting system / Starter motor / Charging system / Ignition system / Warning system / Specifications
CHAPTER EIGHT / POWER HEAD
Flywheel removal and installation / Cylinder head / Cylinder head / Oil pump / Inspection / Power head installation / Bearing selection / Specifications
CHAPTER NINE / GEARCASE AND DRIVE SHAFT HOUSING
Gearcase operation / Gearcase identification / Propeller removal and installation / Gearcase removal and installation / Water pump / Gearcase disassembly and assembly / Inspection / Drive shaft housing removal and installation / Specifications
CHAPTER TEN / REWIND STARTER
CHAPTER ELEVEN / POWER TRIM AND MIDSECTION
Power trim system / Fluid filling and air bleeding / Midsection / Specifications
CHAPTER TWELVE / REMOTE CONTROL
INDEX
WIRING DIAGRAMS
Models Covered:
Yamaha 9.9 HP (1985-1999)
Yamaha 15 HP (1985-1999)
Yamaha 25 HP (1985-1999)
Yamaha 40 HP (1985-1999)
Yamaha 50 HP (1985-1999)
Yamaha 80 HP (1985-1999)
Yamaha 100 HP (1985-1999)
This manual can be used by anyone from a first time owner/amateur to a professional technician.Easy to read type,And give you all the information needed to do the procedure correctly.Keep this shop manual handy and use it often. Performing routine,preventive maintenance will save you time & money by helping to prevent premature failure and unnecessary repairs.
Manual Contents:
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 / Specifications
CHAPTER TWO / TOOLS AND TECHNIQUES
Safety first / Basic hand tools / Test equipment / Service hints / Special tips / Mechanic's techniques / Specifications
CHAPTER THREE / TROUBLESHOOTING AND TESTING
Test equipment / Troubleshooting preparation / Operating requirements / Starting difficulty / Fuel system component testing / Ignition system testing / Warning system / Starting system / Charging system / Fuses and wire harness / Trim system / Electrical testing / Power head / Cooling system / Gearcase / Specifications
CHAPTER FOUR / LUBRICATION, MAINTENANCE AND TUNE-UP
Lubrication and maintenance / Pre-operational checklist / Post-operational checklist / Routine maintenance / Fuel requirements / Fuel filter service / Engine oil requirements / Oil drain and fill locations / Pumping oil from the engine / Draining oil / Filling the engine with oil / Oil filter / Engine oil and filter change / Oil screen service / Removing carbon deposits from the combustion chambers / Power head anodes / Timing belt and sprocket inspection / Hoses and clamps inspection / Thermostat inspection / Gearcase lubricant / Changing the gearcase lubricant / Gearcase anode inspection / Water pump and impeller inspection / Propeller shaft inspection and lubrication / Swivel tube and tilt tube lubrication / Steering cable lubrication / Trim system fluid level check and change / Starter motor maintenance / Battery maintenance / Throttle and shift linkage lubrication / Tune-up / Compression test / Spark plugs / Valve adjustment / Carburetor adjustment / Ignition timing / Run test / Special maintenance requirements / Submersion / Storage / Corrosion prevention / Specifications
CHAPTER FIVE / SYNCHRONIZATION AND ADJUSTMENT
Fuel system adjustment / Carburetor synchronization / Valve adjustment / Cable and linkage adjustment / Specifications
CHAPTER SIX / FUEL SYSTEM
Servicing the fuel system / Fuel tank / Gloat level (9.9, 25 and 80-100 hp models) / Specifications
CHAPTER SEVEN / ELECTRICAL AND IGNITION SYSTEM
Starting system / Starter motor / Charging system / Ignition system / Warning system / Specifications
CHAPTER EIGHT / POWER HEAD
Flywheel removal and installation / Cylinder head / Cylinder head / Oil pump / Inspection / Power head installation / Bearing selection / Specifications
CHAPTER NINE / GEARCASE AND DRIVE SHAFT HOUSING
Gearcase operation / Gearcase identification / Propeller removal and installation / Gearcase removal and installation / Water pump / Gearcase disassembly and assembly / Inspection / Drive shaft housing removal and installation / Specifications
CHAPTER TEN / REWIND STARTER
CHAPTER ELEVEN / POWER TRIM AND MIDSECTION
Power trim system / Fluid filling and air bleeding / Midsection / Specifications
CHAPTER TWELVE / REMOTE CONTROL
INDEX
WIRING DIAGRAMS
