2004 Yamaha Marine 160 outboard motor 6V, 8V service manual

Table of Contents

General Information

• Specifications
• Model Identification
• Serial Number Location

Maintenance

• Maintenance Schedule
• Pre-Operation Check
• Periodic Maintenance
• Lubrication Points
• Maintenance Procedures

Fuel System

• Fuel System Components
• Fuel Pump
• Carburetor
• Fuel Line and Filter
• Fuel System Inspection and Repair

Power Unit

• Power Unit Components
• Power Unit Removal and Installation
• Cylinder Head
• Pistons and Rings
• Crankshaft and Bearings

Lower Unit

• Lower Unit Components
• Gear Case
• Propeller Shaft
• Water Pump
• Lower Unit Inspection and Repair

Electrical System

• Electrical System Components
• Ignition System
• Charging System
• Battery
• Electrical System Inspection and Repair

Steering System

• Steering System Components
• Steering Control
• Tiller Handle
• Steering System Inspection and Repair

Cooling System

• Cooling System Components
• Thermostat
• Water Pump
• Cooling System Inspection and Repair

Control System

• Throttle and Shift Control
• Control Cables
• Control System Inspection and Repair

Trim and Tilt System

• Trim and Tilt Components
• Manual Tilt Mechanism
• Power Tilt and Trim
• Trim and Tilt System Inspection and Repair

Engine Overhaul

• Disassembly Procedures
• Inspection and Measurement
• Reassembly Procedures
• Engine Specifications

Troubleshooting

• Troubleshooting Procedures
• Common Engine Issues
• Electrical System Issues
• Fuel System Issues
• Cooling System Issues

Wiring Diagrams

• Wiring Diagram for 6V
• Wiring Diagram for 8V

Appendix

• Special Tools
• Torque Specifications
• Conversion Tables
• Service Data

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