2002 Yamaha Marine 2B, 2C, 2U outboard motor service manual

Table of Contents

1. Introduction

2. Specifications

• 2.1 Engine
• 2.2 Fuel System
• 2.3 Ignition System
• 2.4 Gearbox
• 2.5 Cutting Attachment
• 2.6 Special Accessories
  • 2.6.1 For the User
  • 2.6.2 For Service
• 2.7 Tightening Torques

3. Clutch

• 3.1 Disassembly
• 3.2 Installation

4. Engine

• 4.1 Muffler/Spark Arrester Screen
• 4.2 Leakage Testing
  • 4.2.1 Preparations
  • 4.2.2 Pressure Test
  • 4.2.3 Vacuum Test
• 4.3 Oil Seals
• 4.4 Exposing the Cylinder/Spacer Flange
• 4.5 Cylinder and Piston
  • 4.5.1 Removal
  • 4.5.2 Installation
• 4.6 Piston Rings
• 4.7 Crankcase
  • 4.7.1 Removing the Crankshaft
  • 4.7.2 Installing the Crankshaft

5. Ignition System

• 5.1 Spark Plug Terminal
• 5.2 Ignition Module
  • 5.2.1 Ignition Timing
  • 5.2.2 Removal and Installation
• 5.3 Flywheel

6. Rewind Starter

• 6.1 General
• 6.2 Starter Cover
• 6.3 Rewind Spring
  • 6.3.1 Replacement
  • 6.3.2 Tensioning
• 6.4 Starter Rope (ElastoStart)
• 6.5 Starter Grip (ElastoStart)
• 6.6 Starter Carrier/Pawl

7. Throttle Control

• 7.1 Throttle Trigger/Interlock Lever (Throttle Cable with One Short-Circuit Wire)
• 7.2 Throttle Cable with One Short-Circuit Wire
• 7.3 Contact Spring/Detent Spring in Control Handle (Throttle Cable with One Short-Circuit Wire)
• 7.4 Throttle Trigger/Interlock Lever (Throttle Cable with Two Short-Circuit Wires)
• 7.5 Throttle Cable with Two Short-Circuit Wires
• 7.6 Adjusting the Throttle Cable

8. Fuel System

• 8.1 Air Filter
• 8.2 Carburetor
  • 8.2.1 Leakage Testing
  • 8.2.2 Removal and Installation
  • 8.2.3 Adjustment (Two Adjusting Screws)
  • 8.2.4 Adjustment (One Adjusting Screw)
• 8.3 Tank Vent
• 8.4 Pickup Body
• 8.5 Fuel Tank/Hoses

9. AV System

• 9.1 Repair

10. Shaft

• 10.1 Cowhorn Handle
• 10.2 Looped Handle
• 10.3 Drive Shaft/Insulating Tube
• 10.4 Protective Tube

11. Cutting Tool Drive

• 11.1 Bearing Housing (FS 75)
• 11.2 Gearbox (FS 80, 85)
• 11.3 Gearbox (FC 75)
• 11.4 Clutch Drum

12. Cutting Device (HL 75)

• 12.1 Gearbox
• 12.2 Cutting Blade
• 12.3 Gearwheel

13. Special Service Tools and Aids

• 13.1 Special Tools
• 13.2 Servicing Aids

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