1996-2006 Yamaha Marine Outboard Motor 20V, 25V, 25V2 Service Manual

Addresses 20V, 25V, 25V2 systems including diagnostics, removal sequences, and maintenance for engine control, fuel system, power unit, and electrical components.

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Document Details

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Document Number / Seller:
30066 / Charles Jones
File Size:
34.01 MB
File Type:
PDF
Language:
English
Printable:
Yes
Category:
Outboard Motor
Last updated / verified
Mar 11, 2025

Models Covered & Key Technical Specifications

Yamaha 20V, 25V, 25V2 (LIT-18616-01-66) - 1996-2006 Service Manual | Archive Binder.

  • Authorized Size Parameters: 67 mm is the standard bore diameter for optimal engine operation.
  • Specific Installation Footprint: For optimal operation, 2.6 mm defines the piston ring end gap for the 2nd ring.
  • Critical Coupling Torques: 35 N•m -- signifies the propeller shaft housing torque specification.
  • Operational System Fill: The gear case requires 370 cm³ for proper lubrication.
  • Measured Power Framework: Maximum output reaches 18.7 kW at 5,000 rpm.
  • Established Mass Specs: The weight of the outboard motor is 51 kg for the CV25ED model.

Professional Workshop Service Manual & Technical Specifications

Systematic Training Factory Manual: Yamaha 20V, 25V, 25V2 - Comprehensive Outboard Service & Repair Manual, 996-2006 Edition OEM-Documentation

Equipment-Series: Outboard Motor // Procedure-Type: Service Manual / Repair Manual Logic // Equipment-Series: 1996-2006

TOP

Integrated-Framework Value Calibration-Standards
General Information 1-1 Serial Number Information
Specifications 2-1 General Specifications
Maintenance Schedule 3-1 Periodic Service Intervals
Fuel System 4-1 Fuel and Lubrication Components
Power Unit Overhaul 5-1 Preparation for Overhaul

Diagnostic procedures address common issues and provide systematic troubleshooting steps. Parts identification is covered for all major assemblies, ensuring accurate part ordering and replacement.

Proper maintenance and repair are crucial for the longevity and performance of your Yamaha outboard motor. This manual details the necessary procedures, including component removal and installation, with clear diagrams and instructions.

This manual documents torque specifications for critical engine components to ensure proper oscillation integrity.

Parts identification is covered for all assemblies, including the fuel system, power unit, and electrical components. Removal and installation procedures are clearly outlined with diagrams to guide the technician.

FAQ

Specify the **applicable** lubrication requirements for the gear oil. keyboard_arrow_down

370 cm³ (US oz, Imp oz) is the recommended capacity for Hypoid gear oil SAE #90 in the lower unit.

What is the **exact** testing parameters for the CDI unit output? keyboard_arrow_down

105 V at 1,500 r/min is the specified output for the CDI unit, which should be checked during a diagnostic procedure.

Calculate the **specific** diagnostic procedures for spark plug gap. keyboard_arrow_down

0.6 - 0.7 mm (0.024 - 0.028 in) is the required spark plug gap. To check, use the spark plug gap tester YM-34487/90890-06754. Readings on pages 85+ detail the correct procedure.

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Reviews (4)

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This manual is incredibly detailed and helpful for anyone with a Yamaha outboard. The troubleshooting section is particularly useful!
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Rated 5 out of 5 stars
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I had a smooth download experience, and the support team was quick to respond to my questions. Great resource!
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The email with the download link came right away, and the manual itself is well-organized. Definitely worth the investment!