Yamaha 250GETO Manuals

Manuals and User Guides for Yamaha 250GETO. We have 2 Yamaha 250GETO manuals available for free PDF download: Service Manual, Rigging Manual

Yamaha 250GETO Service Manual (293 pages)

Brand: Yamaha | Category: Outboard Motor | Size: 17.68 MB

Table of Contents

3
- Important Information
  2
- How to Use this Manual
  6
  - Manual Format
    6
- Contents
  7
  - Safety While Working
    8
    
    Fire Prevention
    8
    
    Ventilation
    8
    
    Self-Protection
    8
    
    Parts, Lubricant, and Sealant
    8
    
    Good Working Practice
    9
    
    Disassembly and Assembly
    9
  - Identification
    10
    
    Applicable Model
    10
    
    Serial Number
    10
  - Special Service Tool
    11
  - Feature and Benefit
    17
    
    Bracket/Upper Case
    20
    
    Lower Unit
    21
- Periodic Check and Adjustment
  7
  - Symbol
    7
- Specification
  7
- Fuel System
  24
  - Propeller Selection
    29
    
    Propeller Size
    29
    
    Selection
    29
  - Predelivery Check
    30
    
    Checking the Fuel System
    30
    
    Checking the Gear Oil
    30
    
    Checking the Outboard Motor Mounting Height
    31
    
    Checking the Remote Control Cable
    31
    
    Checking the Steering System
    32
    
    Checking the Gear Shift and Throttle Operation
    32
    
    Checking the PTT System
    32
    
    Checking the Engine Start Switch and Engine Stop Lanyard Switch
    32
    
    Checking the Cooling Water Pilot Hole
    33
    
    Test Run
    33
    
    Break-In
    33
    
    After Test Run
    34
Spec Specification

35
- General Specification
  
  36
- Specification
  
  36
  - Fuel
    36
- Maintenance Specification
  
  38
  - Power Unit
    38
  - Electrical
    40
  - Lower Unit
    40
  - Dimension
    44
- Tightening Torque
  
  46
  - Specified Torque
    46
  - General Torque
    48
Chk Adj Periodic Check and Adjustment

49
- Periodic Check and Adjustment
  
  50
- Maintenance Interval Chart
  
  50
- Top Cowling
  
  51
  - Checking the Top Cowling
    51
- Fuel System
  
  51
  - Checking the Fuel Joint and Fuel Hose (Fuel Joint-To-Carburetor)
    51
  - Checking the Fuel Filter
    51
- Power Unit
  
  52
  - Checking the Engine Oil Level
    52
    
    Checking the Spark Plug
    52
    
    Checking the Thermostat
    52
    
    Checking the Cooling Water Passage
    53
- Control System
  
  54
- Bracket
  
  59
  - Checking the PTT Operation
    59
- Lower Unit
  
  60
  - Checking the PTT Fluid Level
    60
    
    Checking the Gear Oil Level
    60
    
    Changing the Gear Oil
    61
    
    Checking the Lower Unit for Air Leakage
    62
    
    Checking the Propeller
    62
- General
  
  62
  - Checking the Anode
    62
  - Checking the Battery
    63
  - Lubricating the Outboard Motor
    63
Fuel Fuel System

65
- Hose Routing
  
  66
  - Fuel Hose and Breather Hose
    66
- Fuel System
  
  66
- Fuel Line
  
  68
- Carburetor
  
  73
- Fuel Pump
  
  78
  - Checking the Fuel Pump
    79
  - Disassembling the Fuel Pump
    79
  - Assembling the Fuel Pump
    80
- Oil Injection System
  
  81
  - Checking the Check Valve
    83
  - Checking the Oil Filter
    83
  - Checking the Oil Tank
    83
  - Assembling the Oil Tank
    83
  - Installing the Oil Pump
    83
  - Bleeding the Oil Pump
    84
Powr Power Unit

86
- Powr
  86
- Power Unit
  
  88
- Intake Manifold
  
  102
  - Removing the Intake Manifold
    104
  - Checking the Reed Valve
    104
- Exhaust Cover
  
  107
  - Removing the Exhaust Cover
    107
  - Checking the Exhaust Cover
    107
  - Checking the PCV
    107
  - Installing the PCV
    107
- Cylinder Head
  
  108
  - Removing the Cylinder Head
    109
  - Checking the Cylinder Head
    109
- Crankcase
  
  110
Lowr Lower Unit

136
- Lowr
  136
- Lower Unit
  
  138
- Lower Unit (Regular Rotation Model)
  
  138
- Propeller Shaft Housing (Regular Rotation Model)
  
  145
- Drive Shaft and Lower Case (Regular Rotation Model)
  
  151
  - Removing the Drive Shaft
    151
  - Disassembling the Drive Shaft Housing
    151
  - Disassembling the Forward Gear
    151
  - Disassembling the Lower Case
    152
  - Checking the Pinion and Forward Gear
    152
  - Checking the Bearing
    152
  - Checking the Drive Shaft
    152
  - Checking the Lower Case
    153
  - Assembling the Lower Case
    153
  - Assembling the Forward Gear
    153
  - Assembling the Drive Shaft Housing
    154
  - Installing the Drive Shaft
    154
  - Installing the Propeller Shaft Housing
    155
  - Installing the Water Pump and Shift Rod
    156
  - Installing the Lower Unit
    157
- Shimming (Regular Rotation Model)
  
  160
  - Shimming
    161
  - Selecting the Pinion Shim
    161
  - Selecting the Forward Gear Shim
    162
  - Selecting the Reverse Gear Shim
    163
- Backlash (Regular Rotation Model)
  
  164
  - Measuring the Forward and Reverse Gear Backlash
    164
- Lower Unit (Counter Rotation Model)
  
  164
- Propeller Shaft Housing (Counter Rotation Model)
  
  172
- Drive Shaft and Lower Case (Counter Rotation Model)
  
  180
  - Removing the Drive Shaft
    182
  - Disassembling the Drive Shaft Housing
    182
  - Disassembling the Reverse Gear
    182
  - Disassembling the Lower Case
    183
  - Checking the Pinion and Reverse Gear
    183
  - Checking the Bearing
    183
  - Checking the Drive Shaft
    183
  - Checking the Lower Case
    184
  - Assembling the Lower Case
    184
  - Assembling the Reverse Gear
    184
  - Assembling the Drive Shaft Housing
    185
  - Installing the Drive Shaft
    185
  - Installing the Propeller Shaft Housing
    186
  - Installing the Water Pump and Shift Rod
    187
  - Installing the Lower Unit
    188
- Shimming (Counter Rotation Model)
  
  191
  - Shimming
    192
  - Selecting the Pinion Shim
    192
  - Selecting the Reverse Gear Shim
    193
  - Selecting the Forward Gear Shim
    195
  - Selecting the Propeller Shaft Shim
    196
- Backlash (Counter Rotation Model)
  
  198
Brkt Bracket Unit

202
- Bracket Unit
  202
- Brkt
  202
- Bottom Cowling
  
  204
- Upper Case, Steering Arm
  
  208
  - Disassembling the Upper Case
    212
  - Checking the Upper Case
    213
  - Assembling the Upper Case
    213
  - Removing the Steering Arm
    217
  - Installing the Steering Arm
    217
  - Installing the Upper Case
    218
- Clamp Bracket and Swivel Bracket
  
  221
  - Removing the PTT Unit
    221
  - Removing the Clamp Bracket
    221
  - Installing the Clamp Bracket
    222
  - Installing the PTT Unit
    222
  - Adjusting the Trim Sensor
    223
- PTT Unit
  
  225
  - Checking the Hydraulic Pressure
    227
- PTT Motor
  
  230
  - Disassembling the PTT Motor
    231
  - Checking the PTT Motor
    232
  - Assembling the PTT Motor
    233
- Gear Pump
  
  234
  - Disassembling the Gear Pump
    236
  - Disassembling the Relief Valve
    236
  - Checking the Main Valve
    237
  - Checking the Gear Pump Housing
    237
  - Checking the Reservoir
    237
  - Checking the Filter
    237
  - Checking Relief Valve
    237
  - Assembling the Relief Valve
    238
  - Assembling the Gear Pump
    239
- Tilt Cylinder and Trim Cylinder
  
  243
  - Disassembling the Tilt Cylinder and Trim Cylinder
    243
  - Checking the Tilt Cylinder and Trim Cylinder
    244
  - Checking the Valve
    245
  - Assembling the Tilt Ram
    245
  - Assembling the Trim Ram
    246
  - Installing the Tilt Cylinder
    246
  - Installing the Trim Ram
    246
  - Installing the PTT Motor
    247
  - Installing the Reservoir
    248
  - Installing the Tilt Ram
    248
  - Bleeding the PTT Unit
    249
  - Bleeding the PTT Unit (Built-In)
    250
- PTT Electrical System
  
  251
  - Checking the Fuse
    251
  - Checking the PTT Relay
    251
  - Checking the PTT Switch
    252
  - Checking the Trim Sensor
    252
Elec Electrical System

253
- Elec
  253
- Checking the Electrical Component
  
  254
  - Measuring the Peak Voltage
    254
- Electrical System
  
  254
- Electrical Component
  
  255
  - Port View
    255
  - Starboard View
    256
  - Junction Box
    257
  - Aft View
    259
  - Top View
    260
- Ignition and Ignition Control System
  
  261
  - Checking the Ignition Spark Gap
    261
  - Checking the Spark Plug Cap
    261
  - Checking the Ignition Coil
    262
  - Checking the CDI Unit
    262
  - Checking the Pulser Coil
    263
  - Checking the Crank Position Sensor
    264
  - Checking the Crank Position Sensor Air Gap
    265
  - Checking the Engine Temperature Sensor
    265
  - Checking the Charge Coil
    266
  - Checking the Thermoswitch
    267
  - Checking the Shift Cut Switch
    267
- Starting System
  
  268
  - Checking the Fuse
    268
  - Checking the Engine Start Switch
    268
  - Checking the Engine Stop Lanyard Switch
    269
  - Checking the Starter Relay
    269
- Starter Motor
  
  270
  - Removing the Starter Motor Pinion
    271
  - Checking the Starter Motor Pinion
    271
  - Checking the Armature
    271
  - Checking the Brush
    272
  - Checking the Starter Motor Operation
    272
  - Checking the Choke Solenoid
    272
- Charging System
  
  273
  - Checking the Lighting Coil
    273
  - Checking the Rectifier Regulator
    273
  - Checking the Hour Meter
    275
- Oil Feed Pump Control System
  
  275
  - Checking the Oil Level Sensor
    275
  - Checking the Emergency Switch
    276
  - Checking the Oil Pump (Remote Oil Tank)
    276
  - Shtg
    277
  - Trbl Shtg
    278
    
    Troubleshooting the Power Unit
    278

Yamaha 250GETO Rigging Manual (226 pages)

Brand: Yamaha | Category: Outboard Motor | Size: 7.75 MB

Table of Contents

5
Propellers

59
- Propeller Specifications
  
  60
  - Propeller Types
    60
  - Propeller Identification
    62
- 2009 Propeller Applications
  
  63
- Propeller Selection
  
  63
- Wot Operation Range Table
  
  69
- Remote Controls
  
  71
  - Remote Control Applications
    72
  - Remote Switch Applications
    85
  - Remote Control Cables
    94
  - Remote Control Attachment Kit
    96
  - Steering Hook
    98
  - Steering Guide Attachment Kit
    101
  - Conventional Wire Harness
    103
  - Digital Electronic Control Wire Harness
    105
Tiller Handles

107
- 6X4 Multi-Function Tiller Handle
  
  108
- Steering Friction Contents
  
  117
Conventional Gauge (6Y5 & 6Y7)

119
- Mounting the Meters
  
  122
  - Meter Mounting Procedure
    122
  - Analog Gauge Illumination (6Y7 Type)
    122
- Analog Tachometer
  
  123
  - Analog Tachometer Applications
    123
  - Analog Tachometer Dimensions
    124
  - Pole Number Set up
    124
- Digital Tachometer
  
  125
  - Digital Tachometer Applications
    125
  - Digital Tachometer Dimensions
    125
  - Pole Number Set up
    126
- Speedometer
  
  127
  - Speedometer Applications
    127
  - Speedometer Dimensions
    128
  - Water Pressure Damper (Op)
    128
  - Speedometer Tube Routing
    129
  - Digital Speedometer Set up
    129
- Fuel Management Gauge
  
  130
  - Fuel Management Gauge Applications
    130
  - Fuel Management Gauge Dimensions
    131
  - Fuel Sender Installation
    132
  - Wiring Description
    133
  - Fuel Management Gauge Set up
    135
  - Fuel Mgt Gauge with Speedometer Set up
    135
- Analog Trim Meter
  
  136
  - Analog Trim Meter Applications
    136
  - Analog Trim Meter Dimensions
    136
  - Trim Sender Adjustment
    136
- Coolant Pressure Meter
  
  137
  - Coolant Pressure Meter Applications
    137
  - Coolant Pressure Meter Dimensions
    137
- Coolant Temp. Meter
  
  138
- Hour Meter
  
  144
  - Hour Meter Applications
    144
  - Wiring the Mechanical Hour Meter
    145
  - Wiring the Digital Hour Meter
    145
- Voltage Meter
  
  146
  - Voltage Meter Applications
    146
  - Voltage Meter Dimensions
    146
  - Wiring the Voltage Meter
    146
- Fuel Meter
  
  147
  - Fuel Meter Applications
    147
  - Fuel Meter Dimensions
    147
- Charge Warning Unit
  
  148
  - Charge Warning Unit Applications
    148
- Wire Harnesses
  
  149
  - Remote-Oil Tank Harness
    149
  - Additional Accessory Lead
    149
  - Meter Harness
    150
  - Lamp Switch
    151
  - Combination Trim and Oil Lead 1
    151
  - Combination Trim and Oil Lead 2
    151
  - Trim Meter Lead
    151
  - Pt/T Switch Lead Extension
    152
  - Trim and Oil Lead
    152
  - Fuel Management Gauge Harness
    152
  - Lighting Coil Extension Harness
    152
  - Rectifier Kit
    152
- Wiring Diagrams
  
  153
  - Wire Color Code
    153
  - Digital Meter
    154
  - Analog Meter (6Y7)
    159
  - Interchangeability between Tachometer and Engine
    161
  - Grommet Description
    164
Digital Network Gauge (6Y8)

167
- Digital Network Gauge Compatible Model
  
  168
- Digital Network Gauge Application
  
  168
  - Square Style Gauge Application
    168
- Digital Network Gauge Dimensions
  
  169
  - Round Style Gauge Application
    169
  - Square Style Gauge Dimensions
    169
  - Round Style Gauge Dimensions
    170
- Optional Equipments
  
  171
  - Multi-Sensor Application
    171
  - Fitting Plate
    171
  - Speed Sensor Kit
    172
  - Coolant Pressure Sensor Kit
    172
- Wire Harness
  
  173
  - Main Bus Wire
    173
  - Pigtail Bus Wire
    173
  - Fuel Tank / Gps Wire
    174
  - Hub
    174
- Wiring Diagrams
  
  175
  - FUEL INJECTED F50-F250 [Mechanical RC] & HPDI ENGINES
    175
  - F350/F300/F250 [Digital Electronic Control]
    178
- Initial Gauge Setup
  
  183
- Troubleshooting
  
  184
- Basic Requirements
  
  185
- Nmea0183 Compatible Equipments Connection
  
  185
Battery

187
- Recommended Battery
  
  188
- Battery Cable Length
  
  189
- Battery Wiring
  
  190
Appendix

195
- Model Name Designation
  
  196
  - Us & Canada Model Identification
    197
  - New Us & Canada Model Identification Code
    197
- Fuel System Vacuum Pressure Standard
  
  198
  - Fuel Hose Routing Resistance Measuring Method
    198
  - Lowest Vacuum Pressure Standard
    199
- Portable Fuel Tanks (Typical)
  
  200
- Fuel Pipes (Typical)
  
  200
- Pre-Delivery Inspection (Pdi) Checks
  
  201
- Conventional Rigging Kit Contents
  
  202
  - Digital Tachometer Kit
    202
  - Digital Tachometer and Speedometer Kit
    202
  - Twin-Motor Kit
    203
  - Remote Oil Tank Kit (for 2-Stroke Engine)
    204
- Digital Network Gauge Rigging Kit Contents
  
  205
- 2009 Manufacturing Start Serial Number
  
  219

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Yamaha 250GETO Manuals

Yamaha 250GETO Service Manual (293 pages)

Table of Contents

Table of Contents

Spec Specification

General Specification

Specification

Maintenance Specification

Tightening Torque

Chk Adj Periodic Check and Adjustment

Periodic Check and Adjustment

Maintenance Interval Chart

Top Cowling

Fuel System

Power Unit

Control System

Bracket

Lower Unit

General

Fuel Fuel System

Hose Routing

Fuel System

Fuel Line

Carburetor

Fuel Pump

Oil Injection System

Powr Power Unit

Power Unit

Intake Manifold

Exhaust Cover

Cylinder Head

Crankcase

Lowr Lower Unit

Lower Unit

Lower Unit (Regular Rotation Model)

Propeller Shaft Housing (Regular Rotation Model)

Drive Shaft and Lower Case (Regular Rotation Model)

Shimming (Regular Rotation Model)

Backlash (Regular Rotation Model)

Lower Unit (Counter Rotation Model)

Propeller Shaft Housing (Counter Rotation Model)

Drive Shaft and Lower Case (Counter Rotation Model)

Shimming (Counter Rotation Model)

Backlash (Counter Rotation Model)

Brkt Bracket Unit

Bottom Cowling

Upper Case, Steering Arm

Clamp Bracket and Swivel Bracket

PTT Unit

PTT Motor

Gear Pump

Tilt Cylinder and Trim Cylinder

PTT Electrical System

Elec Electrical System

Checking the Electrical Component

Electrical System

Electrical Component

Ignition and Ignition Control System

Starting System

Starter Motor

Charging System

Oil Feed Pump Control System

Yamaha 250GETO Rigging Manual (226 pages)

Table of Contents

Table of Contents

Top Cover Pictograph Description

Uncrating Procedure (for Typical Steel Frame)

Mounting the Outboard Motor

Mounting the Remote Oil Tank

Outboard Motor Dimensions

Propellers

Propeller Specifications

2009 Propeller Applications

Propeller Selection

Wot Operation Range Table

Remote Controls

Tiller Handles

6X4 Multi-Function Tiller Handle

Steering Friction Contents

Conventional Gauge (6Y5 & 6Y7)