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1998-2006 Yamaha 25hp outboard motor service manual Preview image 1

1998-2006 Yamaha 25hp outboard motor service manual Preview image 2

1998-2006 Yamaha 25hp outboard motor service manual Preview image 3

1998-2006 Yamaha 25hp outboard motor service manual Preview image 4

1998-2006 Yamaha 25hp outboard motor service manual

Models covered in this manual:

T25Y

ENGINE: 2 Cylinder engines
STROKE: 4-Stroke MODELS ONLY
FUEL SYSTEM: Carburetor
F25ELHW, F25ELRW, F25ESHW, F25TLRW, F25ELHX, F25ELRX, F25ESHX, F25MLHX, F25MSHX, F25TLRX, F25ELHZ, F25ELRZ, F25ESHZ, F25ESRZ, F25MLHZ, F25MSHZ, F25TLRZ, F25ELHA, F25ELRA, F25ESHA, F25ESRA, F25MLHA, F25MSHA, F25TLRA, T25TLRA, T25TLRZ, F25ELHB, F25ELRB, F25ESHB, F25ESRB, F25MLHB, F25MSHB, F25TLRB, T25TLRB, F25ELHC, F25ELRC, F25ESHC, F25ESRC, F25MLHC, F25MSHC, F25TLRC, T25TLRC, F25ELHD, F25ELRD, F25ESHD, F25MLHD, F25MSHD, F25TLRD, F25ELH, F25ELR, F25ESH, F25ESR, F25MLH, F25MSH, F25TLR.

Serial numbers:

1998: 6L2K L 100101 to 6L2K L 109999
1999: 6L2K L 110001 to 6L2K L 119999
2000: 6L2K L 120001 to 6L2K L 129999
2001: 6L2K L 130001 to 6L2K L 139999
2002: 6L2K L 140001 to 6L2K L 149999
2003: 6L2K L 150001 to 6L2K L 159999
2004: 6L2K L 160001 to 6L2K L 169999
2005: 6L2K L 170001 to 6L2K L 179999
2006: 6L2K L 180001 to 6L2K L 189999

File specifications

File size: 31.44 MB
File type: PDF
Language: English
Pages: 795
Printable: Yes
Estimated download time: 0.64 Minutes

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Product Information

General Information

Identification
- Serial Number
- Starting Serial Numbers
Special Tools
- Measuring Tools
- Removing and Installing Tools

Specifications

General Specifications
Maintenance Specifications
- Power Unit
- Lower Unit
- Electrical
- Dimensions
Tightening Torques
- Specified Torques
- General Torques

Periodic Inspection and Adjustment

Maintenance Interval Chart
General
- Checking the Anodes
- Lubrication Points

Power Unit

Camshaft and Valves
- Removing/Installing the Camshaft and Valves
- Replacing the Valve Guides
- Installing the Valves

Lower Unit

Lower Unit
- Removing/Installing the Lower Unit
- Removing the Propeller
- Checking the Propeller
- Installing the Trim Tab
- Installing the Lower Unit
- Installing the Propeller
Water Pump
- Removing/Installing the Water Pump
- Checking the Impeller Housing
- Checking the Impeller and Impeller Housing Cup
- Checking the Woodruff Key
- Installing the Impeller and Impeller Housing
Shift Rod Assembly
- Removing/Installing the Shift Rod Assembly
Propeller Shaft Housing Assembly
- Removing/Installing the Propeller Shaft Housing Assembly
- Disassembling/Assembling the Propeller Shaft Housing
- Checking the Reverse Gear
- Checking the Bearing
- Checking the Propeller Shaft Housing
- Checking the Dog Clutch
- Checking the Propeller Shaft
Drive Shaft
- Removing/Installing the Drive Shaft
- Removing the Pinion
- Removing the Drive Shaft Bearing
- Disassembling the Forward Gear Assembly
- Checking the Pinion and Forward Gear
- Checking the Drive Shaft
- Checking the Bearings
- Assembling the Forward Gear Assembly
- Installing the Drive Shaft Bearing
- Installing the Pinion
Lower Case Assembly
- Disassembling/Assembling the Lower Case Assembly
- Checking the Drive Shaft Sleeve
- Checking the Needle Bearing
Shimming (For USA and Canada)
- Selecting the Pinion Shims
- Selecting the Forward Gear Shims
- Selecting the Reverse Gear Shims
Shimming (For Worldwide)
- Selecting the Pinion Shims
- Selecting the Forward Gear Shims
- Selecting the Reverse Gear Shims
Backlash
- Measuring the Forward Gear Backlash
- Measuring the Reverse Gear Backlash

Bracket Unit

Upper Case Assembly
- Removing/Installing the Upper Case Assembly
- Disassembling/Assembling the Upper Case Assembly
- Disassembling/Assembling the Oil Pan Assembly
Shock Absorber (ED/ER)
- Removing/Installing the Shock Absorber
- Checking the Shock Absorber
Power Trim and Tilt Unit (ET/TR)
- Removing/Installing the Power Trim and Tilt Unit
Clamp Bracket
- Removing/Installing the Clamp Bracket
Steering Arm
- Removing/Installing the Steering Arm

Electrical System

Electrical Components
- Fore and Aft Views
- Port and Starboard Views
Electrical Components Analysis
- Measuring the Peak Voltage
Ignition System
- Checking the Charge Coil
- Checking the Pulser Coil
- Checking the CDI Unit
Charging System
- Checking the Lighting Coil
- Checking the Rectifier/Regulator
Enrichment Control System
- Checking the Power Coil
- Checking the Electrothermal Ram

Wiring Diagram

FT25BED/T25ER
FT25BET/T25TR

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