Yamaha FL250N Manuals

Manuals and User Guides for Yamaha FL250N. We have 1 Yamaha FL250N manual available for free PDF download: Service Manual

Yamaha FL250N Service Manual

Yamaha FL250N Service Manual (490 pages)

Brand: Yamaha | Category: Outboard Motor | Size: 55 MB

Table of Contents

Table of Contents

3
- General Information
  4
- Model Information
  5
- Model Name Designation
  5
- Applicable Model
  5
- General Feature
  7
- Important Safety and Service Information
  8
- Rotating Parts
  8
- Hot Parts
  8
- Electric Shock
  8
- Propeller
  8
- Handling of Gasoline
  8
- Ventilation
  8
- Parts, Lubricants, and Sealants
  9
- Self-Protection
  9
- Handling of Gas Torch
  9
- Lifting Outboard Motors
  9
- Handling of Lubricants and Sealants
  10
- Special Service Tools
  10
- Tightening Torque
  10
- Non-Reusable Parts
  10
- Disassembly and Assembly
  10
- Disposal of Used Components and Chemicals
  11
- How to Use this Manual
  12
- Manual Format
  12
- Abbreviation
  13
- Conditions When Testing and Adjusting
  13
- Color Code
  14
- Specified Tightening Torque
  14
- General Tightening Torque
  14
- Symbol
  15
- Specification Symbol
  15
- Lubricant, Sealant, and Thread Locking Agent Symbol
  15
- Special Service Tool
  17
- Specification
  24
  - Specification Data
    25
  - External Dimensions
    25
  - Clamp Bracket Dimensions
    27
Technical Feature and Description

28
- Technical Feature and Description
  29
- Electronic Control System
  30
- Electrical Components
  33
- Fail-Safe
  35
- Crate Top Cover
  37
- Rigging Information
  37
- Bracket Unit
  38
- SBW (Steer by Wire) System
  38
- System Diagram
  39
- Structure
  41
- Operation
  42
- Outboard Motor Manual Steering Method
  43
- PTT Sensor
  44
- PTT Totaltilt
  45
- Bushing of the Drive Shaft
  47
- Upper Case
  47
- Lower Unit
  48
- Split-Type Drive Shaft
  48
- Reverse Thrust
  49
- Engine ECM
  50
- Fuel System
  50
- High-Pressure Fuel Pump Control
  50
- Low-Pressure Fuel Pump Control
  50
- PTT Protection Control
  50
- Fuel Diagram
  51
- Lubrication Diagram
  53
- Lubrication System
  53
- Cooling Diagram
  55
- Cooling System
  55
- Intake and Exhaust Diagram
  57
- Intake and Exhaust System
  57
- Fuel Hose and Blowby Hose
  58
- Hose Routing
  58
- Pressure Regulator Hose, Vapor Gas Hose, and Intake Air Pressure Sensor Hose
  59
- Cooling Water Hose
  60
Rigging Information 0

61
- Rigging Information
  62
- Important Reminder on Rigging
  63
- Outboard Motor Mounting Instructions
  63
- Crate Handling
  64
- Crate Top Cover Symbol Description
  64
- Uncrating
  65
- Uncrating Procedure
  65
- Installing the Outboard Motor
  66
- Outboard Motor Mounting
  66
- Installing the Battery Cable
  70
- Installing the Main Wire Harness
  70
- Installing the Rigging Grommet
  70
- Rigging Grommet Description
  70
- Rigging Grommet Mounting
  70
- Installing the Isolator Lead
  71
- Installing the SCU Communication Lead
  71
- Optional Equipment
  71
- Battery Installation
  72
- Single Outboard Motor Application (Single Station)
  73
- System Diagram
  73
- Twin Outboard Motor Application (Single Station)
  76
- Triple Outboard Motor Application (Single Station)
  79
- Quad Outboard Motor Application (Single Station)
  82
- Single Outboard Motor Application (Dual Station)
  85
- Twin Outboard Motor Application (Dual Station)
  88
- Triple Outboard Motor Application (Dual Station)
  91
- Quad Outboard Motor Application (Dual Station)
  95
- Digital Electronic Control
  99
- Digital Electronic Control System Reset
  99
- Setting the Tilt Limiter
  100
- Tilt Limiter
  100
- Clearing the Tilt Limiter
  101
- Calibration (6X9 Digital Electronic Control)
  102
- CL5 Display Calibration
  102
- Configuring the Number of Outboard Motors
  102
- Deactivating the Tilt Limiter
  102
- Accessing the Calibration Menu
  103
- Steering Sensor
  104
- Toe Adjust
  106
  - Adjustment Settings
    107
- Lock to Lock
  108
- Friction Set
  110
- Battery Cable Length
  111
- Rigging Recommendation
  111
- Propeller Selection
  112
Troubleshooting 0

115
- Connecting the Communication Cable
  116
- Ydis
  116
- ECM Reprogramming
  118
- Outboard Motor Troubleshooting
  119
- Troubleshooting Procedure
  119
- Troubleshooting the Power Unit Using the YDIS
  119
- Trouble Code and Checking Step
  122
- Troubleshooting Procedure (Trouble Code Not Detected)
  136
- Troubleshooting the Power Unit
  136
- Troubleshooting the PTT Unit
  142
- Troubleshooting the Lower Unit
  143
- Electrical System
  145
  - Fuse Holder
    150
  - Bottom Cowling
    156
  - ECM Coupler Layout
    163
  - Checking the Electrical Component
    165
  - Measuring the Peak Voltage
    165
  - Checking the Engine ECM Circuit
    167
  - Checking the ETV and TPS
    168
  - Checking the OCV
    173
  - Checking the Fuel Injector
    175
  - Checking the Low-Pressure Fuel Pump and High-Pressure Fuel Pump
    176
  - Checking the High-Pressure Fuel Pump Relay
    177
  - Checking the Ignition Coil
    181
  - Checking the Engine Shut-Off Switch
    186
  - Checking the Power Switch
    187
  - Starter Motor
    189
  - Removing the Starter Motor
    190
  - Disassembling the Starter Motor
    190
  - Checking the Starter Motor Pinion
    190
  - Checking the Armature (Starter Motor)
    190
  - Assembling the Starter Motor
    192
  - PTT System
    194
Fuel System 0

198
- Fuel System
  199
- Disconnecting the Quick Connector
  200
- Reducing the Fuel Pressure
  200
- Measuring the Fuel Pressure
  201
- Checking the Pressure Regulator
  202
- Fuel Filter Assembly
  205
- Checking the Fuel Cup Assembly
  206
- Checking the Fuel Filter Assembly
  206
- Checking the Fuel Filter Element
  206
- Removing the Fuel Filter Assembly
  206
- Assembling the Fuel Filter
  207
- Checking the Primer Pump
  207
- Installing the Fuel Filter
  207
- Intake Manifold
  209
- Checking the Intake Manifold
  210
- Installing the Intake Manifold
  210
- Installing the Intake Silencer
  211
- Etv
  212
- Checking the ETV
  213
- Checking the Intake Air Pressure Sensor
  213
- Installing the ETV and Surge Tank
  213
- Canister
  215
- Checking the Canister
  216
- Checking the Canister Check Valve
  216
- Installing the Canister
  216
- Low-Pressure Fuel Pump
  218
- Installing the Low-Pressure Fuel Pump
  219
- Vapor Separator and Vapor Shut-Off Valve
  220
- Checking the Vapor Shut-Off Valve
  221
- Draining the Fuel
  221
- Installing the Vapor Separator
  221
- Vapor Separator and High-Pressure Fuel Pump
  223
- Checking the Check Valve
  225
- Checking the High-Pressure Fuel Pump
  225
- Checking the Vapor Separator
  225
- Assembling the Vapor Separator
  226
- Fuel Injector
  228
- Checking the Fuel Rail
  229
- Installing the Fuel Injector
  229
Power Unit

230
- Power Unit
  231
- Checking the Compression Pressure
  233
- Checking the Oil Pressure
  233
- Checking the Pulser Coil Air Gap
  234
- Checking the Valve Clearance
  234
- Adjusting the Valve Clearance
  236
- Power Unit Assembly
  239
- Removing the Power Unit
  240
- Installing the Power Unit
  242
- Flywheel Magneto
  246
- Installing the Flywheel Magneto
  247
- Removing the Flywheel Magneto
  247
- Wire Harness
  249
- Installing the Wire Harness
  250
- Fuse Box
  253
- Junction Box
  254
- Installing the Junction Box
  256
- Installing the Rectifier/Regulator/Isolator
  256
- Starter Motor
  258
- Installing the Starter Motor
  259
- Engine ECM
  260
- Ignition Coil and Spark Plug
  261
- Checking the Spark Plug
  262
- Shift Actuator
  263
- Assembling the Shift Actuator Assembly
  264
- Installing the Shift Actuator Assembly
  264
- Timing Belt
  265
- Removing the Timing Belt
  266
- Checking the Timing Belt
  267
- Installing the Timing Belt
  267
- Camshaft
  270
- Removing the Camshaft, VCT Assembly, and Driven Sprocket
  271
- Checking the Camshaft
  273
- Checking the Sprocket
  273
- Checking the Valve Lifter
  273
- Checking the Camshaft Journal Oil Clearance
  274
- Checking the Camshaft Journal Outside Diameter and Camshaft Journal Inside Diameter
  275
- Installing the Camshaft, VCT Assembly, and Driven Sprocket
  275
- Cylinder Head
  281
- Disassembling the Cylinder Head
  282
- Removing the Cylinder Head
  282
- Checking the Cylinder Head
  283
- Checking the Cylinder Head Bolt
  283
- Checking the Valve Spring
  283
- Checking the Valve
  284
- Checking the Valve Guide
  285
- Replacing the Valve Guide
  285
- Checking the Valve Seat
  286
- Refacing the Valve Seat
  287
- Assembling the Cylinder Head
  289
- Checking the Cylinder Head Anode
  289
- Installing the Cylinder Head
  291
- Oil Cooler and Oil Pump Assembly
  293
- Checking the Oil Cooler
  294
- Checking the Oil Cooler Anode
  294
- Checking the Oil Pump
  294
- Removing the Oil Filter
  294
- Assembling the Oil Pump
  295
- Installing the Oil Cooler
  296
- Installing the Oil Pump Assembly
  296
- Installing the Oil Filter
  297
- Cylinder Block Sensor and Switch
  299
- Checking the Cooling Water Cover Anode
  301
- Checking the Thermostat
  301
- Installing the Thermostat
  301
- Installing the Cooling Water Cover
  302
- Installing the Knock Sensor
  303
- Installing the Pulley Bracket
  303
- Cylinder Block
  304
- Disassembling the Cylinder Block
  305
- Checking the Cylinder Bore
  306
- Checking the Piston Diameter
  306
- Checking the Piston Clearance
  307
- Checking the Piston Ring
  307
- Checking the Piston Ring End Gap
  307
- Checking the Piston Pin Boss Inside Diameter
  308
- Checking the Piston Ring Groove
  308
- Checking the Piston Ring Side Clearance
  308
- Checking the Connecting Rod Small End Inside Diameter and Big End Inside Diameter
  309
- Checking the Piston Pin Diameter
  309
- Checking the Connecting Rod Big End Side Clearance
  310
- Checking the Crankshaft
  310
- Checking the Big End Oil Clearance
  311
- Checking the Crankcase Bolt
  311
- Selecting the Crankshaft Pin Bearing
  312
- Crankshaft Pin Bearing Selection Table
  314
- Checking the Journal Oil Clearance
  315
- Selecting the Crankshaft Journal Bearing
  316
- Crankshaft Journal Bearing Selection Table
  318
- Assembling the Cylinder Block
  319
- Checking the Cylinder Block Anode
  319
Lower Unit 0

323
- Lower Unit
  324
- Assembling the Propeller (Shift Dampener System [SDS] Propeller)
  327
- Checking the Propeller
  327
- Disassembling the Propeller (Shift Dampener System [SDS] Propeller)
  327
- Propeller
  327
- Removing the Propeller
  327
- Installing the Propeller
  328
- Lower Unit
  329
- Checking the Lower Unit Anode
  330
- Removing the Lower Unit
  330
- Checking the Lower Unit for Leakage
  331
- Installing the Lower Unit
  331
- Extension (Except for X-Transom Model)
  333
- Assembling the Extension
  334
- Checking the Extension
  334
- Installing the Extension
  334
- Water Pump and Shift Rod
  335
- Checking the Intermediate Drive Shaft
  336
- Checking the Shift Rod
  336
- Checking the Water Pump
  336
- Removing the Water Pump and Shift Rod
  336
- Assembling the Water Pump Housing
  337
- Installing the Shift Rod
  338
- Installing the Water Pump
  338
- Propeller Shaft Housing (Regular Rotation Model)
  340
- Removing the Propeller Shaft Housing Assembly
  342
- Disassembling the Propeller Shaft Assembly
  343
- Disassembling the Propeller Shaft Housing Assembly
  343
- Disassembling the Reverse Gear
  343
- Assembling the Propeller Shaft Assembly
  344
- Checking the Dog Clutch
  344
- Checking the Propeller Shaft
  344
- Checking the Propeller Shaft Housing
  344
- Checking the Reverse Gear
  344
- Assembling the Propeller Shaft Housing Assembly
  345
- Assembling the Reverse Gear
  345
- Installing the Propeller Shaft Housing Assembly
  348
- Drive Shaft and Lower Case (Regular Rotation Model)
  350
- Disassembling the Drive Shaft
  351
- Disassembling the Oil Seal Housing
  351
- Removing the Drive Shaft
  351
- Removing the Forward Gear
  351
- Disassembling the Forward Gear
  352
- Checking the Drive Shaft
  353
- Checking the Forward Gear
  353
- Checking the Pinion
  353
- Disassembling the Lower Case
  353
- Assembling the Drive Shaft
  354
- Checking the Lower Case
  354
- Assembling the Forward Gear
  356
- Assembling the Lower Case
  356
- Assembling the Oil Seal Housing
  357
- Installing the Forward Gear
  358
- Shimming (Regular Rotation Model)
  360
- Shimming Workflow
  360
- Shimming Check Sheet
  361
- Shimming Procedure
  362
- Shim Location
  363
- Selecting the Forward Gear Shim (T1) and Reverse Gear Shim (T2)
  364
- Selecting the Pinion Shim (T3)
  364
- Measuring the Forward Gear Backlash and Reverse Gear Backlash
  366
- Selecting the Propeller Shaft Shim (T4)
  370
- Propeller Shaft Housing (Counter Rotation Model)
  372
- Disassembling the Forward Gear
  374
- Disassembling the Propeller Shaft Housing Assembly
  374
- Removing the Propeller Shaft Housing Assembly
  374
- Assembling the Propeller Shaft Housing and Forward Gear
  375
- Checking the Dog Clutch
  375
- Checking the Forward Gear
  375
- Checking the Propeller Shaft
  375
- Checking the Propeller Shaft Housing
  375
- Installing the Propeller Shaft Housing Assembly
  377
- Drive Shaft and Lower Case (Counter Rotation Model)
  378
- Removing the Drive Shaft
  379
- Removing the Reverse Gear
  379
  - Shimming (Counter Rotation Model)
    380
Bracket Unit

391
- Bracket Unit
  392
- Shift Rod and SPS
  393
- Installing the Shift Rod and SPS
  394
- PTT Switch and Cowling Lock Lever
  395
- Bottom Cowling
  397
- Upper Case and Mounts
  398
- Installing the Upper Case
  399
- Removing the Upper Case
  399
- Upper Case
  402
- Disassembling the Upper Case
  403
- Assembling the Upper Case
  404
- Checking the Drive Shaft Bushing
  404
- Checking the Exhaust Guide Anode
  404
- Oil Pan and Exhaust Manifold
  406
- Assembling the Oil Pan and Exhaust Manifold
  407
- Checking the Oil Pan and Exhaust Manifold
  407
- Checking the Oil Strainer
  407
- Steering Actuator and Steering Arm
  409
- Removing the Power Steering Unit
  411
- Checking the Steering Arm and Steering Arm Joint
  412
- Installing the Steering Arm
  412
- Removing the Steering Arm
  412
- Installing the Steering Actuator
  413
- Clamp Bracket and Swivel Bracket
  416
- Assembling the Swivel Bracket
  417
- Checking the Clamp Bracket Anode
  417
- Installing the Clamp Bracket
  417
- Removing the Clamp Bracket
  417
- PTT Unit
  419
- Removing the PTT Unit
  420
- Checking the Hydraulic Pressure
  421
- Bleeding the PTT Unit
  423
- Installing the PTT Unit
  425
- PTT Motor
  428
- Checking the PTT Motor
  429
- Disassembling the PTT Motor
  429
- Removing the Reservoir
  429
- Assembling the PTT Motor
  430
- Checking the Brush
  430
- Checking the Filter
  430
- Checking the Reservoir
  430
- Installing the PTT Motor
  431
- Installing the Reservoir
  431
- PTT Gear Pump
  433
- Assembling the Gear Pump Assembly
  435
- Checking the Filter
  435
- Checking the Gear Pump
  435
- Checking the Gear Pump Housing
  435
- Disassembling the Gear Pump Assembly
  435
- Installing the Gear Pump Assembly
  437
- PTT Cylinder
  438
- Removing the Tilt Ram
  439
- Removing the Trim Ram
  439
- Checking the Absorber Valve
  440
- Checking the Tilt Cylinder and Trim Cylinder
  440
- Disassembling the Tilt Ram
  440
- Assembling the Tilt Ram
  441
- Assembling the Trim Ram
  442
- Installing the Tilt Cylinder
  442
- Installing the Trim Ram
  442
- Installing the Tilt Ram
  443
Maintenance 0

445
- Maintenance Interval Chart 1
  446
- Outline
  446
- Maintenance Interval Chart 2
  448
- Predelivery Check
  449
- Checking the Battery
  452
- Checking the Engine Oil Level
  452
- Checking the Cooling Water Pilot Hole
  453
- Checking the Gear Oil Level
  453
- Checking the Outboard Motor Mounting Height
  454
- Checking the Power Trim and Tilt Unit
  454
- General Periodic Maintenance
  455
- Changing the Engine Oil Using an Oil Changer
  458
- Checking the Cooling Water Inlet
  458
- Checking the Engine Idle Speed
  458
- Changing the Engine Oil by Removing the Drain Bolt
  459
- Replacing the Oil Filter
  461
- Changing the Gear Oil
  462
- Greasing Points
  464
- Checking the Cowling Lock Lever
  465
- Checking the PTT Fluid Level
  465
- Appendix
  467
  - Wiring Diagram
    477

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