Yamaha 25J Manuals

Yamaha 25J Manuals

Manuals and User Guides for Yamaha 25J. We have 1 Yamaha 25J manual available for free PDF download: Service Manual

Yamaha 25J Service Manual

Yamaha 25J Service Manual (385 pages)

Brand: Yamaha | Category: Outboard Motor | Size: 7.74 MB

Table of Contents

How to Use this Manual
4
Important Information
6
Symbols
10
Index
12
Table of Contents
14
General Information
14
Identification

16
- Serial Number
  16
- Starting Serial Numbers
  16
Chapter 1

16
Safety While Working

18
- Fire Prevention
  18
- Ventilation
  18
- Self-Protection
  18
- Oils, Greases and Sealing Fluids
  18
- Good Working Practices
  20
- Disassembly and Assembly
  22
- Measuring
  24
Special Tools

24
- Outillage Special
  25
- 90890-03169
  27
- 90890-06752
  27
- 90890-06754
  27
- P/N. J-39299
  27
- P/N. Ym-34487
  27
- P/N. Yu-39991
  27
  - Removal and Installation
    28
  - Specifications
    32
Chapter 2

34
General Specifications

34
Maintenance Specifications

42
Caracteristiques D'entretien

43
- Moteur
  43
- Bloc de Propulsion
  47
  - Electrical
    48
  - Partie Electricite
    49
  - Bracket Dimensions
    52
  - Outboard Dimensions
    52
  - Dimensions du Moteur Hors-Bord
    53
  - Dimensions du Support
    53
Daten

53
- Dimensiones de la Ménsula
  53
- Dimensiones del Fuera de Borda
  53
Wartungdaten

53
Especificaciones de Mantenimiento

53
Tightening Torque

54
Torsión de Apriete

55
General Tightening Torque

56
Torsiones de Apriete

57
- Periodic Inspection and Adjustment
  58
Predelivery Service

62
- Contents
  62
- Electric Wiring
  64
Chapter 3

64
- 25Jmh, 25Jmho, 30Dmh, 30Dmho
  64
- 30Dwh, 30Dwho
  66
- 25Jeo, 30Dmo, 30De, 30Deo
  68
- 25Jeto, 30Det, 30Deto
  70
- Fuel Line
  72
- Gear Oil Level
  74
- Operation of Controls and Moving Parts
  74
- Ignition Timing
  76
- Motor Exterior
  76
- Instructing the New Owner
  76
- Fuel Leakage
  76
- Water Leakage
  76
- Exhaust Leakage
  76
- Engine and Lower Unit Noise
  76
- Idle-Speed
  76
Periodic Service

78
- Maintenance Schedule
  78
- Anode
  78
- Battery
  82
- Cylinder Head Bolts, Engine Mounting Bolts, and Flywheel Nut
  84
- Gear Oil
  84
- Oil-Injection Pump
  84
- Operational Test
  84
- Fuel Filter
  84
- Fuel Line
  84
  - Carburetor
    86
  - Carburetor Link Adjustment
    88
  - Fuel Enrichment Valve Adjustment
    88
  - Ignition Timing Adjustment
    88
  - Idle-Speed
    92
  - Oil Pump Link Adjustment
    94
  - Pick-Up Timing
    94
  - 25Jeo, 25Jeto, 30Deo, 30Deto
    96
  - 25Jmho, 30Dmo, 30Dmho, 30Dwho
    96
  - Oil-Level Warning System
    96
  - Propeller
    96
  - Spark Plug
    98
  - Manual Handle Model
    100
  - Start-In-Gear Protection Adjustment
    100
  - Start-In-Gear Protection Model
    100
  - Throttle Cable Adjustment
    100
  - Neutral Opening Limit Adjustment
    102
  - Power Trim and Tilt Fluid Check
    102
  - Hydraulic System Air Bleeding
    104
    
    Fuel System
    106
    
    Fuel System Exploded Diagram
    108
    
    Fuel Filter Cleaning and Inspection
    110
  - Removal
    110
  - Fuel Joints
    112
  - Installation
    112
    
    Carburetor Exploded Diagram
    114
    
    Carburetor Removal and Disassembly
    116
  - Carburetor Body
    118
  - Collar
    118
  - Float
    118
  - Inspection
    118
  - Needle Valve
    118
  - Pilot Screw
    118
  - Fuel Pump
    120
  - Assembly
    122
  - Installation
    124
  - Oil Injection Exploded Diagram
    126
  - Installation
    128
  - Oil Injection Cleaning and Inspection
    128
  - Oil-Hoses
    128
  - Oil-Level Gauge
    128
  - Oil-Tank
    128
  - Oil Injection Removal
    128
  - Power Unit
    130
Exploded Diagram

134
CHAPTER 5 Preparation for Overhaul

136
Removal

136
Disassembly

138
- Cylinder Head
  140
Inspection

140
- Cleaning
  140
- Cylinder Block
  142
- Cleaning
  142
- Inspection
  142
  - Piston Cleaning
    144
  - Piston Inspection
    144
  - Inspection
    146
  - Piston Ring
    146
  - Cleaning
    148
  - Crankshaft
    148
  - Inspection
    148
  - Piston Pin and Small End Bearing
    148
  - Inspection
    150
  - Reed Valve
    150
  - Thermostat
    150
  - (Oil Injection Pump Drive)
    152
  - Cleaning
    152
  - Crank Main Bearing
    152
  - Drive Gear
    152
  - Driven Gear (Oil Injection Pump Drive)
    152
  - Inspection
    152
- Bearing, Oil Seal, O-Ring and Oil Pump Drive Gear
  154
Assembly and Adjustment

154
- Piston
  154
- Crank Cylinder Assembly
  156
- Small End Bearings and Piston Assembly
  156
- Cylinder Head and Exhaust Cover
  158
- Fuel System and Electrical System
  160
Installation

160
- Intake Manifold
  160
- Reed Valve
  160
  - Recoil Starter Exploded Diagram
    162
  - Drive Pawl and Spring
    164
  - Inspection
    164
  - Removal and Disassembly
    164
  - Collar and Roller
    166
  - Sheave Drum
    166
  - Starter Rope
    166
  - Start-In-Gear Protection
    168
  - Starter Spring
    168
  - Lower Unit
    174
  - Lower Unit Exploded Diagram
    178
Preparation for Removal

180
Disassembly

180
- Bearing Housing
  190
- Claw-Washer
  190
- Gear Case
  190
Inspection

190
- Ring-Nut
  190
- Water Pump Housing
  190
  - Bearing
    192
  - Clutch Dog and Components
    192
  - Gear
    192
  - OIL-SEAL HOUSING (Located under the Impeller)
    192
  - Drive Shaft and Propeller Shaft
    194
  - Drive Shaft Sleeve
    194
  - Propeller/Trim Tab/Anode
    194
  - Shift-Plunger, Shift-Shaft, and Boot
    194
  - Forward Gear Shim Selection
    196
  - Pinion Gear Shim Selection
    196
  - Propeller-Shaft Housing
    196
Assembly and Adjustment

196
- Impeller and Cartridge Insert
  192
- Assembly
  196
- Gear Case
  198
- Reverse Gear Shim Selection
  198
- SHIM SELECTION (for USA and CANADA)
  202
  - Pinion Gear Shim
    204
  - Forward Gear Shim
    206
  - Reverse Gear Shim
    210
  - SHIM SELECTION (Except for USA and CANADA)
    212
  - Forward Gear Shim
    216
  - Reverse Gear Shim
    218
  - Forward Gear
    220
  - Measuring the Backlash
    220
  - Reverse Gear
    222
  - Water Pump Installation
    224
  - Lower Unit Leakage Check
    226
  - Bracket Unit
    230
  - Steering Handle Exploded Diagram
    234
  - Steering Handle Removal and Installation Chart
    234
  - Bottom Cowling Exploded Diagram
    236
  - Bottom Cowling Removal and Installation Chart
    236
  - Upper Case Exploded Diagram
    240
  - Upper Case Removal and Installation Chart
    240
  - Steering Bracket Exploded Diagram
    246
  - Steering Bracket Removal and Installation Chart
    246
  - Power Trim and Tilt (Ptt) Unit Exploded Diagram
    250
  - Power Trim and Tilt (Ptt) Unit Removal and Installation Chart
    250
  - Clamp Bracket Exploded Diagram
    254
  - Clamp Bracket Removal and Installation Chart
    254
Clamp Bracket (Except Ptt Model)

254
Clamp Bracket (Ptt Model)

260
- Swivel Bracket Exploded Diagram
  264
- Swivel Bracket Removal and Installation Chart
  264
- Tilt Rod Exploded Diagram
  268
- Tilt Rod Removal and Installation Chart
  268
- Service Points
  272
  - Tilt Rod Removal
    272
  - Tilt Piston Installation
    274
  - Tilt Rod Installation
    274
  - Air Bleeding
    276
  - Ptt Motor, Pump Housing, and Tilt Cylinder Exploded Diagram
    280
  - Pump Housing Exploded Diagram
    284
  - Pump Housing Removal and Installation Chart
    284
  - Gear Pump Exploded Diagram
    290
  - Gear Pump Removal and Installation Chart
    290
  - Motor Inspection
    296
  - PTT Motor Assembly
    298
  - Electrical Systems
    300
Chapter 8

304
Electrical Components

304
- Jeho, 30Dwh, 30Deho
  306
Wire Harness

312
- Flywheel Magneto Removal
  316
- Flywheel Magneto Installation
  320
Electrical Analysis

322
- Digital Circuit Tester
  322
- Peak Voltage Adaptor
  322
Ignition System

326
- Peak Voltage Measurement
  322
- Ignition Spark Gap
  328
  - Ignition System Peak Voltage
    330
  - Engine Stop Switch
    332
Ignition Control System

334
- Spark Plug Cap
  332
- Oil Level Gauge
  336
- Pulser Coil
  336
- Thermo Switch
  336
- Oil Level/Engine Temp. Warning Lamp
  338
  - Starting System
    340
  - Fuse
    342
  - Starter Relay
    342
  - Wire Connections
    342
  - Neutral Switch
    344
  - Starter Switch
    344
  - Fuel Enrichment Valve
    346
  - Starter Motor Exploded Diagram
    348
  - Starter Motor Removal and Installation Chart
    348
  - Armature Inspection
    352
  - Pinion Inspection
    352
  - Brush Holder Inspection
    354
  - Rear Bracket Bushing Inspection
    354
  - Charging System
    356
  - Charging System Peak Voltage
    358
  - Power Trim and Tilt (Ptt) Control System
    360
  - Ptt Relay
    362
  - Trim Sensor
    364
  - Trouble Analysis
    366
  - Trouble Analysis Chart
    368

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