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F25A
Yamaha F25A Service Manual
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7-9
E
BRKT
OIL PAN
OIL PAN
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
Step
Procedure/Part name
Q’ty
Service points
OIL PAN DISASSEMBLY
Follow the left “Step” for removal.
1
Oil pan
1
2
Upper case gasket
1
3
Dowel pin
2
4
Water pipe
1
5
Oil strainer
1
6
Relief valve
1
7
Relief valve gasket
1
8
Oil seal
1
9
Exhaust guide
1
Reverse the disassembly steps for instal-
lation.
Not reusable
Not reusable
299
301
Table of Contents
Default Chapter
4
How to Use this Manual
4
Important Information
6
Symbols
10
Systeme D'alimentation
11
Index
12
Table of Contents
13
General Information
14
Identification Serial Number
16
Starting Serial Numbers
16
Safety While Working
18
Fire Prevention
18
Ventilation
18
Self-Protection
18
Oils, Greases and Sealing Fluids
18
Good Working Practices
20
Safe Disassembly and Assembly
22
Measuring
24
Special Tools
24
Outillage Special
25
Removal and Installation
28
Driver Rod (M10)
30
P/N. 90890-06602
31
P/N. 90890-06604
31
P/N. 90890-06605
31
P/N. 90890-06606
31
P/N. Yb-06071
31
(Oil Seal Installer)
32
32. Ball Bearing Attachment
32
90890-06615
32
90890-06637
32
Bearing Inner Race Installer
32
P/N. N.a
32
P/N. Yb-06078
32
P/N. Yb-06082
32
P/N. Yb-06168
32
P/N. Yb-06219
32
Specifications
34
General Specifications
36
Maintenance Specifications
40
Chapitre 2 Caracteristiques D'entretien
41
Moteur
41
Boitier D'helice
47
Partie Electricite
47
Wartungsdaten
51
Motor
51
Dimensions
52
Abmessungen
53
Abmessungen der
53
Abmessungen des Außenborders
53
Motorhalterung
53
Tightening Torques
54
Inferior
55
Schraubenanzugsmomente
55
General Tightening Torques
58
Torsion de Apriete
59
Torsiones de Apriete
59
Periodic Inspection and Adjustment
60
Protection
60
Chapter 1 Chapter 3
62
Maintenance Interval Chart
62
Control System Periodic Service
66
Fuel Filter Replacement
66
Cowling
66
Fuel Line
66
Fuel System Periodic Service
66
Throttle Link Rod Check
66
Water Separator Drain Hole
66
Idle Speed Adjustment
68
Start-In-Gear Protection Device Adjustment
68
Messen
69
Engine Oil Level
70
Engine Oil Replacement
70
Power Unit
70
Moteur Motor
71
Valve Clearance Adjustment
72
Power Trim and Tilt (PTT) System Inspection
74
PTT Fluid Check
74
Gear Oil Check
76
Hydraulic System Air Bleeding
76
Lower Unit Inspection
76
Lower Unit Leakage Check
78
Bloc de Propulsion
79
Anode
80
Battery
80
General
80
Spark Plugs
82
General
82
Lubrication Points
84
Fuel System
86
Combustible
87
Fuel Joint, Fuel Filter, Fuel Pump Exploded Diagram
88
Fuel Pump Exploded Diagram
92
Carburetor Unit Exploded Diagram
96
Carburetor Unit Disassembly
98
Carburetor Exploded Diagram
100
Carburetor Disassembly
100
Carburetor Inspection
106
Motor
111
Ausbau und Einbau
111
Power Unit Exploded Diagram
114
Power Unit Removal
114
Removal and Installation Chart
114
Flywheel Magneto Exploded Diagram
120
Removal and Installation Chart
120
Flywheel Magneto Removal
122
Service Points
122
Starter Hub Removal
122
Flywheel Magneto Installation
124
Starter Hub Installation
124
Recoil Starter Exploded Diagram
126
Removal and Installation Chart
126
Cartridge Spring Installation
132
Sheave Drum Installation
132
Recoil Starter Checking
134
Starter Rope Installation
134
Removal and Installation Chart
136
Stator and Timing Belt Exploded Diagram
136
Driven Sprocket Removal and Installation
138
Service Points
138
Timing Belt Installation
138
Electrical Unit Exploded Diagram
140
Removal and Installation Chart
140
Control Unit Exploded Diagram
146
Cylinder Head and Oil Pump Exploded Diagram
150
Oil Pump Exploded Diagram
154
Cylinder Head Inspection
156
Oil Pump Inspection
156
Service Points
156
Camshaft and Valves Exploded Diagram
158
Service Points
162
Valve Inspection
162
Valve Spring Inspection
164
Camshaft Inspection
166
Rocker Arm and Rocker Arm Shaft Inspection
166
Valve Guide Replacement
168
Valve Installation
168
Valve Seat Cutting Guidelines
170
Valve Seat Refacing
170
Oil Filter Cartridge, Thermostat, and Exhaust Cover Exploded Diagram
174
Service Points
178
Thermostat Inspection
178
Crankcase, Crankshaft Assy, and Cylinder Body Exploded Diagram
180
Cylinder Inspection
188
Piston Inspection
188
Service Points
188
Piston Pin Inspection
190
Piston Ring Inspection
190
Piston-To-Cylinder Clearance
190
Crankshaft Inspection
192
Main-Bearing Oil Clearance
192
Crankcase Main Journal Color Code Indicator
194
Big-End Oil Clearance
196
Connecting Rod Color Code Indicator
198
Piston Ring Installation
198
Oil Seal Installation
200
Lower Unit
202
Lower Unit Exploded Diagram
206
Antriebseinheit Unidad Inferior
207
Water Pump Exploded Diagram
210
Propeller Shaft Assy Exploded Diagram
214
Propeller Shaft Assy. Removal
218
Oil Seal Housing Assembly
218
Propeller Shaft Housing Assy Exploded Diagram
222
Propeller Shaft Housing Assy. Disassembly
224
Propeller Shaft Housing Assy. Assembly
224
Forward Gear and Drive Shaft Exploded Diagram
228
Forward and Reverse Gear Disassembly
232
Forward Gear Disassembly
232
Drive Shaft Disassembly
234
Lower Case Disassembly
234
Forward Gear Assembly
236
Drive Shaft Assembly
236
Lower Case Assembly
238
Forward Gear and Drive Shaft Installation
238
Shimming
242
Shim Selection
242
Pinion Gear Shim
242
Forward Gear Shim
246
Available Shim Thickness
246
Reverse Gear Shim
250
Shimming (Except for USA and Canada)
254
Shim Selection (Except for USA and Canada)
254
Backlash Measurement
264
Forward Gear
264
Backlash Measuring Steps
266
Reverse Gear
268
Bracket Unit
272
Motorhalterung
273
Steering Handle Exploded Diagram
276
Steering Friction (MH, EH-Option) Exploded Diagram
284
Steering Friction Installation
288
Bottom Cowling Exploded Diagram
290
Upper Case Assy Exploded Diagram
294
Oil Pan Exploded Diagram
300
Steering Bracket Exploded Diagram
302
Power Trim and Tilt (PTT) Unit Exploded Diagram
306
Clamp Bracket (MH, EH, E) Exploded Diagram
310
Clamp Bracket Exploded Diagram
312
Clamp Bracket (EHT, ET) Exploded Diagram
314
Swivel Bracket Exploded Diagram
318
Tilt Rod Exploded Diagram
322
Tilt Rod Service Points
326
Tilt Rod Removal
326
Tilt Piston Removal
326
Tilt Piston Installation
328
Tilt Rod Installation
328
Air Bleeding
330
PTT Motor, Pump Housing and Tilt Cylinder Exploded Diagram
334
Pump Housing Exploded Diagram
338
Gear Pump Exploded Diagram
344
PTT Motor Exploded Diagram
346
Motor Inspection
350
PTT Motor Assembly
352
Electrical System
354
Sistemas Eléctricos
355
Extraccion E Instalacion
357
Electrical Components Front and Rear Views
358
Electrical Components Port Side View
360
Starboard Side View
362
Wire Harness (MH) Wiring Diagram
364
Wire Harness (EH) Wiring Diagram
366
Wire Harness (EHT) Wiring Diagram
368
Wire Harness (E) Wiring Diagram
370
Wire Harness (ET) Wiring Diagram
372
Electrical Analysis
374
Digital Circuit Tester
374
Peak Voltage Measurement
374
Peak Voltage Adaptor
374
Test Harness (for the Pulser Coil and Stator Coil)
376
Ignition System
378
Ignition Spark Gap
380
Gen
381
Ignition System Peak Voltage
382
Spark Plug Cap
384
Engine Stop Switch (MH, EH, EHT)
384
Ignition Control System
386
Oil Pressure Switch
388
Engine Temperature Sensor
388
Low-Oil-Pressure Warning Lamp
390
Starting System Diagram
392
Fuse Check
394
Wire Harness Check
394
Wire Connections Check
394
Starter Relay Check
394
Starter Switch (EH, EHT) Check
396
Neutral Switch (EH, EHT) Check
396
Starter Motor Exploded Diagram
398
Starter Motor Service Points
402
Pinion Gear Assy. Inspection
402
Armature Inspection
402
Brush Holder Inspection
404
Charging System Diagram
406
Charging System Peak Voltage
408
Enrichment Control System Diagram
410
Power Bobbin Inspection
412
Electrothermal Ram Inspection
412
Power Trim and Tilt (PTT) Control System (EHT)
414
Power Trim and Tilt (PTT) Control System (ET)
416
Trailer Switch Check
418
PTT Relay Check
418
Trouble-Analysis
422
Trbl Anls
422
Trouble-Analysis Chart
424
Wiring Diagram - Model MH
432
Wiring Diagram - Model EH
434
Wiring Diagram - Model EHT
436
Wiring Diagram - Model E
438
Wiring Diagram - Model ET
440
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Owner's Manual
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Yamaha F25A Specifications
General
Brand
Yamaha
Model
F25A
Category
Outboard Motor
Language
English
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