1. Massey 9250 Service Manual 05-13

1984-1994 Yamaha Outboard Service Manual/WorkShop Manual Application: 2 hp 1 cyl. (43cc) 2-stroke 1984 1994, 3 hp 1 cyl. (70cc) 2-stroke 1989, 3 hp 1 cyl. (70cc) 2-stroke 1990 1994, 4 hp 1 cyl.

(83cc) 2-stroke 1984 1994, 5 hp 1 cyl. (103cc) 2-stroke 1984 1994, 6 hp 2 cyl.

(165cc) 2-stroke 1986 1994, 8 hp 2 cyl. (165cc) 2-stroke 1984 1994, 9.9 hp 2 cyl. (246cc) 2-stroke 1984 1994, 9.9 hp 2 cyl. (232cc) 4-stroke 1984 1994, 15 hp 2 cyl. (246cc) 2-stroke 1984 1994, 25 hp 2 cyl.

(395cc) 2-stroke 1988 1994, 25 hp 2 cyl. (430cc) 2-stroke 1990 1994, 25 hp 2 cyl. (496cc) 2-stroke 1984 1994, 28 Jet 3 cyl. (698cc) 2-stroke 1990 1994, 30 hp 2 cyl. (496cc) 2-stroke 1984 1994, 30 hp 3 cyl. (496cc) 2-stroke 1987 1994, 35 Jet 3 cyl.

(698cc) 2-stroke 1987 1994, 40 hp 2 cyl. (592cc) 2-stroke 1989 1994, 40 hp 3 cyl. (698cc) 2-stroke 1984 1994, 50 hp 3 cyl. (698cc) 2-stroke 1984 1994, 50 hp 3 cyl.

(849cc) 2-stroke 1994 1994, 55 hp 2 cyl. (760cc) 2-stroke 1989 1994, 60 hp 3 cyl. (849cc) 2-stroke 1991 1992 1993 1994, 65 Jet 3 cyl. (1140cc) 2-stroke 1987 1994, 70 hp 3 cyl. (849cc) 2-stroke 1984 1985 1986 1987 1988 1989 1990 1991 1992 1993 1994, 75 hp 3 cyl. (1140cc) 2-stroke 1994, 80 hp 3 cyl.

(1140cc) 2-stroke 1994, 80 Jet V4 (1730cc) 2-stroke 1987 1994, 85 hp 3 cyl. (1140cc) 2-stroke 1989 1994, 90 hp 3 cyl. (1140cc) 2-stroke 1984 1994, 115 hp V4 (1730cc) 2-stroke 1984 1994, 130 hp V4 (1730cc) 2-stroke 1988 1994, 140 hp V4 (1730cc) 2-stroke 1984 1994, 140 Jet V6 (2596cc) 2-stroke 1987 1994, 150 hp V6 (2596cc) 2-stroke 1984 1994, 175 hp V6 (2596cc) 2-stroke 1984 1994, 200 hp V6 (2596cc) 2-stroke 1984 1994, 220 hp V6 (2596cc) 2-stroke 1984 1985 1986 1987, 225 hp 76 deg. V6 (3130cc) 2-stroke 1994, 225 hp 90 deg. V6 (2596cc) 2-stroke 1987 1988 1989 1990 1991 1992 1993 1994, 250 hp V6 (3130cc) 2-stroke 1990 1994 LIT-18616-01-24 Service Manual Application: Yamaha Ouboard 9.9HP (9.9-HP) 4-stroke engines. Model Names: T9.9T (T9.9-T), F9.9T (F9.9T), T9.9MH (T9.9-MH), F9.9AM (F9.9-AM), F9.9AEM (FT9.9-AEM), T9.9ER (T9.9-ER), F9.9AE (F9.9-AE), F9.9MH (F9.9-MH), F9.9BM (F9.9-BM), T9.9EH (T9.9-EH), F9.9BEM (F9.9-BEM), F9.9BE (F9.9-BE).

Massey 9250 Service Manual 05-13

LIT-18616-01-28 Service Repair Manual Application: 1995, 1996, 1997 (95, 96, 97) Yamaha Marine Outboard E48T (E48-T) C55T (C55-T) 48HP & 55HP 2-Stroke. Item Model Names: E48T, C55T, E48C, E48MH, E55C, 55BM, C55ER, 55BE, 55BEM, C55TR, 55BET. LIT-18616-01-73 Service Repair Manual Application: 1997 97' Yamaha Marine Outboard 75HP (75HP) 2-Stroke. Item Model Names: E75V, E-75-V, E75-V, E-75V 75AM, 75AEM, 75AE, 75AET, 85AEM, 85AE, 85AET, E75B, E60J, E75MH. Covers USA, Canada and wold wide models. LIT-18616-01-66 Service Repair Manual Application: 1997-1998 Yamaha Marine Outboard 20HP (20-HP) & 25HP 25-HP) 10V, 25V, 25V2 2-Stroke Engines. Model Names 20DM (20-DM), 20DMO (20-DMO), 20DEM (20-DEM), 20DEMO (20-DEMO), 20DERO (20-DERO), 20MH (20-MH), 20MH2 (20-MH2), 20EH (20-EH), 20EH2 (20-EH2), 25DM (25-DM), 25NMO (25-NMO), 25NEMO (25-NEMO), 25NE (25-NE), 25NEO (25-NEO), 25NERO (25-NERO), 25MH (25-MH), 25MH2 (25-MH2), 25EH (25-EH), 25ER (25-ER.

LIT-18616-01-81 Service Repair Manual Application: 1998-1999 98-99 40HP (40-HP) & 50HP (50-HP) 40W 50W Yamaha Marine Outboard 2-Stroke Item Model Names: 40-W, 50-W, 40VMH, 40VMHD, 40VMHO, 40VMO, 40VWH, 40VE, 40VEO, 40VEHTO, 40VET, C40MH, 40MH, C40ER, 40ER, P40TH, C40TR, 40VETO, 50HMHO, 50HMHD, 50HMO, 50HMDO, 50HWHD, 50HEDO, 50HET, 50HETO, 40TR, 50ER, C50TR, 50TR Covers USA, Canada and wold wide models. LIT-18616-F1-50 & LIT-18616-02-12 Service Repair Manual Application: 1998-2005 Yamaha Marine Outboard 15HP (15-HP) 4-Stroke Engines F15W (F15-W), F15Z (F15-Z) 1998, 1999, 2000, 2001, 2002, 2003, 2004 & 2005.

This manual covers all 15HP 4-Stroke models world wide including USA CANADA. USA & CANADA MODELS: F15MHW (F15-MHW), F15EHW (F15-EHW), F15AMH (F15-AMH), F15AEH (F15-AEH), F15AEP (F15-AEP), F15AEHP (F15-AEHP), F15PR (F15-PR), F15PH (F15-PH), F15AEP (F15-AEP), F15AEHP (F15-AEHP).

WOLD WIDE MODELS: F15AMH (F15-AMH), F15AEH (F15-AEH), F15AE (F15-AE). LIT-18616-01-83 Service Manual Application: 1998-2006 Yamaha F8, T9.9, F9.9 8HP (8-hp) & 9.9Hp (9.9-hp) 4-stroke engines for 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005 & 2006. Model Name: T9.9W (T9.9-W), F9.9W (F9.9-W), F8BMH (F8-BMH), F8BEH (F8-BEH), F8BE (F8-BE), T9.9MH (T9.9-MH) FT9.9AMH (FT-9.9-AMH), T9.9EH (T9.9-EH), FT9.9AEH (FT9.9-AEH), T9.9ER (T9.9-ER), FT9.9AE (FT9.9-AE), F9.9MH (F9.9-MH), F9.9BMH (F9.9-BMH), F9.9EH (F9.9-EH), F9.9BEH (F9.9-BEH), F9.9BE (F9.9-BE). LIT-18616-01-35 Service Manual Application: 1996-1997 Yamaha F8, T9.9, F9.9 8HP (8-hp) & 9.9Hp (9.9-hp) 4-stroke engines. Exact Models Covered (Covers All 1996-1997 Models World Wide): F8B (F8-B), F9.9A (F9.9-A), F9.9B (F9.9-B), T9.9U (T9.9-U), F9.9U (F9.9-U), F8BM (F8-BM), F8BEM (F8-BEM), F8BE (F8-BE), T9.9MH (T9.9-MH), T9.9AM (T9.9-AM), FT9.9AMH (FT-9.9-AMH), T9.9EH (T9.9-EH), F9.9AEM (FT9.9-AEM), T9.9ER (T9.9-ER), FT9.9AE (FT9.9-AE), F9.9MH (F9.9-MH), F9.9BM (F9.9-BM), F9.9EH (F9.9-EH), F9.9BEM (F9.9-BEM), F9.9BE (F9.9-BE). LIT-18616-01-29 Service Repair Manual Application: 1996, 1997 (96, 97) E60, E60H 60HP (60-HP) Yamaha Marine Outboard 2-Stroke. Item Model Names: E60, E60H, E60HM, E60HE, E60HEM, E60MH, E60EH.

Covers USA, Canada and wold wide models. LIT-18616-01-79 Service Repair Manual Application: 1998-2005 Yamaha Marine Outboard 4HP (4-HP) 4-Stroke Engines F4X (F4-X, F-4X) 1999, 2000, 2001, 2002, 2003, 2004 & 2005.

This manual covers all 4HP 4-Stroke models world wide including F4MSHX, F4MLHX, F4AMH, USA CANADA. LIT-18616-01-94 Service Repair Manual Application: 1999-2000 99-00 25HP (25-HP) & 30HP (30-HP) 25X, 25-X, 30X, 30-X, 25J, 25-J, 30D, 30-D Yamaha Marine Outboard 2-Stroke. Model Names: 25JMH, 25MH3, 30DMH, 25JMHO, 30DMHO, 30MH, 25JEHO, 25EH3, 30DWH, 25JEO, 25JETO, 25TR3, 30DEHO, 30EH, 30DMO, 30DE, 30DEO, 30ER, 30DET, 30DETO, 30TR Covers USA, Canada and wold wide models.

LIT-18616-01-96 Service Repair Manual Application: 1999, 2000, 2001, 2002 99, 00, 01, 02 100HP (100-HP) F100X, F100-X, F-100X Yamaha Marine Outboard 4-Stroke. Model Names: F100TR, F100-TR, F-100TR, F100AET, F-100AET, F100-AET Covers USA, Canada and woldwide models. LIT-18616-02-16 Service Repair Manual Application: 2000, 2001, 2002, 2003 Yamaha Marine Outboard 40HP (40-HP) F40B (F-40B-F40-B) 4-Stroke Engines. Model name F40BMHD, F40BWHD, F40BED, F40BET, USA and Canada name F40MH, F40ER, F40TR. LIT-18616-02-54 Service Repair Manual Application: 2004-2005 Yamaha Marine Outboard 2.5HP (2.5-HP) F2.5C (F2.5-C, F 2.5C) F2.5MH 4-Stroke Engines. LIT-1816-02-59 Service Repair Manual Application: 2004-2005 Yamaha Marine Outboard 9.9HP & 15HP (9.9-HP 15-HP) 2-Stroke Engines. Model name 9.9CMH & 15CMH ( 9.9 & 15 CMH).

LIT-18616-02-61 Service Repair Manual Application: 2004-2005 Yamaha Marine Outboard 25HP (25-HP) 4-Stroke Engines F25C, T25C (F-25C F25-C T25-C T-25C) F25MH, F25EH, F25ER, F25TR, T25TR. LIT-18616-02-65 Service Repair Manual Application: 2004 04' & 2005 05' Yamaha Marine Outboard 40HP (40-HP) & 50HP (50-HP) 4-Stroke Engines. Exact model name 40VETO 50HETO, Both USA and CANADA models covered 40TR 50TR / 40C-50C. LIT-18616-02-66 Service Repair Manual Application: 2004 04' & 2005 Yamaha Marine Outboard 70HP (70-HP) 2-Stroke Engines. Model name 70BETO, USA and Canada name 70TR 70C (70-C). LIT-18616-02-66 Service Repair Manual Application: 2004 04' & 2005 Yamaha Marine Outboard 90HP (90-HP) 2-Stroke Engines.

Model name 90AETO, USA and Canada name 90TR 90C (90-C). LIT-18616-02-72 Service Repair Manual Application: 2004-2005 Yamaha Marine Outboard 130HP & 115HP (115C 130C) 2-Stroke Engines. Model Name: 115CETO (115-CETO), 130BETO (130-BETO) 115TR, 130TR. LIT-18616-02-51 Service Repair Manual Application: 2004-2005 Yamaha Marine Outboard 150HP (150-HP) F150C & LF150C (LF-F-150C-F150-C) 4-Stroke Engines.

Model name F150TR, LF150TR (F-LF-150-TR) LIT-18616-02-66 Service Repair Manual Application: 2004 04' & 2005 Yamaha Marine Outboard 60HP (60-HP) 2-Stroke Engines. Model name 60FETO USA and Canada name 60TR, 60C (60-C). LIT-18616-02-76 Service Repair Manual Application: 2004-2005 Yamaha Marine Outboard F200C, LF200C, F225C, LF225C 200HP (200-HP) & 225HP (225-HP) V6 4-Stroke Engines.

LIT-18616-02-85 Service Repair Manual Application: 2005 Yamaha Marine Outboard 50HP & 60HP (50-HP, 60-HP) 4-Stroke Engines F50D T50D F60D T60D (F-50-D, T-50-D, F60-D, T60-D). LIT-18616-02-86 Service Repair Manual Application: 2005-2006 05-06' Yamaha Marine Outboard F90D 90HP 4-Stroke Engines.

Model Name F90TR LIT-18616-02-19 Service Repair Manual Application: 2001, 2002, 2003, 01, 02, 03, Yamaha Marine Outboard 6HP & 8HP (F6Z F8Z) 4-Stroke Engines. Model Name: F6AMH, F8CMH, F6MH, F8MH (F6-AMH, F6-MH, F8-AMH, F8-MH).

ALL 250HP 2003-2006 MODELS Service Repair Manual Application: 2003, 2004, 2005, 2006 Yamaha Marine Outboard 250HP (250-HP) 2-Stroke & 4-Stroke Engines. LIT-18616-02-78 - 2004-2005 Z250C & LZ250C LZ250TR 2-STROKE ENGINE. LIT-18616-02-43 - 2003-2005 Z250B & LZ250B MODEL NAME Z250TR/LZ250TR 2-STROKE ENGINE. LIT-18616-02-97 - 2005-2006 F250 & LF250 F250TR/LF250TR 4-STROKE ENGINE. LIT-18616-02-71 Service Repair Manual Application: 2004-2005 Yamaha Marine Outboard 115HP (115-HP) 4-Stroke Engines.

Model name F115AET LF115AET, USA and Canada name F115TR LF115TR. LIT-18616-02-73 Service Repair Manual Application: 2004-2005 Yamaha Marine Outboard 150 HP (150HP) 150C & V150C 2-Stroke Engines. Model Name: 150FETO, 150GETO.

PERIODIC MAINTENANCE PERIODIC MAINTENANCE SCHEDULE The chart below lists the recommended intervals for all the required periodic service work necessary to keep the motor operating at peak performance and economy. Maintenance intervals should be judged by number of hours or months, whichever comes first. NOTE: More frequent servicing should be performed on outboard motors that are used under severe conditions. MAINTENANCE AND TUNE-UP PROCEDURES 1.

Place outboard motor upright on a level surface. Remove motor cover. Remove oil level dipstick and wipe it clean. Insert it fully into dipstick hole, then remove it to check oil level.

Oil level should be between full level hole (Max.) and low level hole (Min.). If level is low, add recommended oil to full level hole (Max.). Recommended oil:. 4 stroke motor oil.

API classification SE, SF, SG, SH, SJ. Viscosity rating SAE 10 W-40. This section describes servicing procedures for each of periodic maintenance requirements. ENGINE OIL / ENGINE OIL FILTER ENGINE OIL LEVEL CHECK Inspect oil level before every use.

ENGINE OIL CHANGE / ENGINE OIL FILTER REPLACEMENT ENGINE OIL Change initially after 20 hours (1 month) and every 100 hours (6 months). ENGINE OIL FILTER Replace initially after 20 hours (1 month) and every 200 hours (12 months). NOTE:.

Engine oil should be changed while engine is warm. When replacing engine oil filter, change engine oil at the same time. Place outboard motor upright on a level surface.

Remove oil filler cap. Place a container under engine oil drain plug. Remove engine oil drain plug and gasket to drain engine oil. ENGINE OIL FILTER REPLACEMENT NOTE: For engine oil change only, go to step 6.

To replace engine oil filter: NOTE: Before fitting new oil filter, be sure to oil O-ring. (1) Remove STBD side cover. (2) Using oil filter wrench to loosen the oil filter, then remove filter and O-ring. (3) Screw new filter on by hand until filter O-ring contacts the mounting surface. (4) Tighten filter 3/4 turn from point of contact with mounting surface using an oil filter wrench.

(5) Install STBD side cover. Install gasket and oil drain plug.

Tighten engine oil drain plug to specified torque. Pour recommended engine oil into oil filler opening, then install oil filler cap. Engine oil amounts: Oil change only: 5.5 L (5.8 / 4.8 US / Imp.

Qt) Oil filter change: 5.7 L (6.0 / 5.0 US / Imp. To reset oil change reminder system’s operation time to zero (cancellation); (1) Turn ignition key to “ON” position. (2) Pull out emergency stop switch plate 1. (3) Pull up emergency stop switch knob 2 three times in seven seconds. A short beep will be heard if cancellation is successfully finished.

(4) Turn ignition key to “OFF” position, then set emergency stop switch plate 1 in original position. Start engine and allow it to run for several minutes at idle speed. Refer to the as procedures can differ depending on model and year. To Check oil filter for oil leakage. Turn off engine and wait for approx.

Two minutes, then recheck engine oil level. GEAR OIL Change initially after 20 hours (1 month) and every 100 hours (6 months). Place outboard motor upright on a level surface. Place a container under lower unit. Remove lower gear oil drain plug before gear oil level plug and drain gear oil. Fill with recommended gear oil through oil drain hole until oil just starts to flow out from oil level hole. Gear oil amounts: 1050 ml (35.5 / 37.0 US / Imp.

Oz) Recommended oil: Outboard Motor Gear Oil or SAE #90 Hypoid gear oil. Install oil level plug before removing oil filler tube from drain hole.

Install oil drain plug. Do not re-use gaskets once removed. Always use a new gasket. NOTE: To avoid insufficient injection of gear oil, check gear oil level 10 minutes after doing procedure in step 6.

If oil level is low, slowly inject gear oil up to the correct level. LUBRICATION Inspect every 50 hours (3 months). Apply Water Resistant Grease to the following points. Throttle / shift linkage Propeller shaft Swivel bracket Swivel bracket SPARK PLUG. Inspect every 100 hours (6 months).

Replace every 200 hours (12 months). Standard spark plug: NGK BKR6E CARBON DEPOSIT Inspect for a carbon deposit on spark plug bases. If carbon is present, remove it with a spark plug cleaning machine or by carefully using a pointed tool. SPARK PLUG GAP Using thickness gauge, measure for spark plug gap.

Adjust to within specified range if gap is out of specification. Spark plug gap: 0.7 – 0.8 mm (0.028 – 0.031 in.) CONDITION OF ELECTRODE Inspect electrode for a worn or burnt condition.

If it is extremely worn or burnt, replace spark plug. Also, be sure to replace spark plug if it has a broken insulator, damaged thread, etc. Confirm the thread size and reach when replacing the plug. If the reach is too short, carbon will be deposited on the threaded portion of the plug hole resulting in possible engine damage. TAPPET CLEARANCE Inspect initially after 20 hours (1 month) and every 200 hours (12 months). The tappet clearance specification is the same for both intake and exhaust valves.

Too small a tappet clearance may reduce engine power, too large a tappet clearance increases valve noise and hastens valve and seat wear. When the tappets are set to the specified clearance, the engine will run without excessive noise from the valve mechanism and will deliver full power. In this engine, the tappet clearance is increased or decreased by replacing the shim disc, made of a special wear resistant material, fitted to the top of the tappet. The shim discs are easy to remove and refit. Tappet clearance adjustment should be checked and adjusted:.

at time of periodic inspection. when valve mechanism is serviced. when camshafts are disturbed by removing them for inspection CHECKING AND ADJUSTING TAPPET CLEARANCE 1.

Remove following parts:. Engine side covers. Flywheel cover. Spark plugs 2. Remove breather hose 1 and evaporation hose 2 from cylinder head cover. Remove fuel hose 3 and 4 from low pressure fuel pump. Remove fifteen (15) bolts securing cylinder head cover 5 to cylinder head and remove cylinder head cover.

Rotate crankshaft counterclockwise to bring cam nose vertical to shim surface. Measure tappet clearances by inserting thickness gauge between cam and shim surface. Tappet clearance (cold engine condition): IN.: 0.23 – 0.27 mm (0.009 – 0.011 in.) EX.: 0.23 – 0.27 mm (0.009 – 0.011 in.) This is a left hand (LH) rotation powerhead.

Rotate crankshaft counterclockwise to prevent water pump impeller damage. NOTE:.

Rotate crankshaft and measure clearance for each tappet respectively by bringing cam nose vertical to shim surface. All tappet clearances can be measured during two turns of crankshaft. If out of specification, adjust tappet clearance by changing shim. ADJUSTMENT Tappet clearances are adjusted by replacing tappet shim.

Close valve and turn tappet cut-away toward inside as shown in figure. Rotate crankshaft to open (lift up) valve and then remove camshaft housing bolts where shim is to be replaced. Install special tool with camshaft housing bolts as shown in figure. Rotate top of cam 90 degree clockwise and remove shim from cut-away at tappet. (Two tappets can be adjusted at the same time) 5. After removing shim, measure thickness of original shim and determine correct thickness of shim for proper tappet clearance as calculated by following formula. A = B + (C – 0.25 mm) A: Correct thickness of shim for proper tappet clearance (mm) B: Thickness of original shim (mm) C: Original tappet clearance (mm) 6.

Install shim. Identification number should face towards tappet. Rotate crankshaft to be open (lift up) valve.

Remove tappet holder 1 and tighten camshaft housing bolts to specified torque. Camshaft housing bolt: 11 N.m (1.1 kg-m, 8.0 lb.-ft.) 9. Recheck tappet clearance. NOTE: After completing tappet clearance adjustment and securing camshaft housing bolts, inspect tappet clearance again. INSTALLATION After checking and adjusting all tappet clearances, install cylinder head cover.

Installation is reverse order of removal. IDLE SPEED Inspect initially after 20 hours (1 month) and every 200 hours (12 months). NOTE:. Before checking idle speed, engine should be allowed to warm up.

Check and/or adjust idle speed after engine speed has stabilized. Before checking idle speed, check throttle link mechanism and throttle valve for smooth operation.

Start engine and allow to warm up. Attach engine tachometer to the ignition high-tension cord. Check engine speed.

Idle speed (in neutral gear): 600 – 650 r/min. ADJUSTMENT: If idle speed is out of specification, perform following adjustment procedure. Check that CTP switch is in ON position.

To set the IAC valve duty to constant 15%, raise engine speed to 1000 r/min. Or higher by turning the by-pass air screw and hold that speed for 10 seconds. At this time, caution buzzer will sound to notify that IAC duty is in fixed mode. Turning air screw counterclockwise: Engine speed will increase. Turning air screw clockwise: Engine speed will decrease. NOTE:.

While IAC valve duty is at fixed 15%, caution buzzer will sound for repeated 0.5 second with an interval of 3 seconds. The 15% fixed mode of IAC valve duty will continue for 5 minutes and then it will be automatically cancelled. During fixed mode of IAC valve duty, adjust engine speed to 625 ± 25 r/min. By turning by-pass air screw. Open warm-up lever to turn CTP switch off. NOTE: The fixed mode of IAC valve duty can be manually cancelled by turning CTP switch off. Close warm-up lever and then recheck engine speed.

It should now be stable at 600 – 650 r/min. NOTE: Idling / trolling speed of 600 – 650 r/min. Is controlled by IAC (idle air control) system. If engine speed does not return to specification, IAC passage (including the IAC hose) may be clogged or IAC system may not be operating correctly. NOTE: Trolling speed (in-gear idle speed) is same as idle speed.

IGNITION TIMING Inspect every 200 hours (12 months). NOTE: Before checking ignition timing, make sure idle speed is adjusted within specification.

Start engine and allow to warm up. Attach timing light cord to No.1 ignition high-tension cord. Check ignition timing while operating engine in neutral gear at 1000 r/min.

Ignition timing: Approx. BTDC 8° at 1000 r/min.

BREATHER AND FUEL LINE. Inspect initially after 20 hours (1 month) and every 50 hours (3 months). Replace every 2 years. If leakage, cracks, swelling or other damage is found, replace breather line and/or fuel line.

LOW PRESSURE FUEL FILTER. Inspect every 50 hours (3 months). Replace every 400 hours or 2 years. If water accumulation, sediment, leakage, cracks, or other damage is found, replace fuel filter.

WATER PUMP / WATER PUMP IMPELLER WATER PUMP Inspect every 200 hours (12 months). Inspect case and under panel. Replace If wear, cracks, distortion or corrosion is found. WATER PUMP IMPELLER Replace every 200 hours (12 months). Inspect water pump impeller.

Replace if vanes are cut, torn or worn. PROPELLER / NUT / COTTER PIN Inspect initially after 20 hours (1 month) and every 100 hours (6 months). Inspect propeller for bent, chipped or broken blades. Replace propeller if damage noticeably affects operation.

Inspect propeller splines. Replace propeller if splines are worn, damaged or twisted.

Inspect propeller bush for slippage. Replace if necessary. Make sure that propeller nut is torqued to specification and cotter pin is installed securely. ANODES AND BONDING WIRES Inspect every 50 hours (3 months). ANODES If 2/3 of zinc anode has corroded away, replace anode.

The anode should be periodically cleaned with a wire brush to ensure maximum effectiveness. NOTE: The anode securing bolt should be covered with Suzuki Silicone Seal. BONDING WIRES. If breakage or other damage is found on bonding wire, replace wire.

If rust, corrosion or other damage is found on terminal, clean with cleaning solvent or replace wire. BATTERY Inspect every 50 hours (3 months) CONNECTING BATTERY Upon completion of connection, lightly apply grease to battery terminals. How to connect: 1. Connect positive (+) terminal first. Connect negative (–) terminal second.

How to disconnect: 1. Disconnect negative (–) terminal first. Disconnect positive (+) terminal second. BATTERY SOLUTION LEVEL CHECK Battery solution level should be between UPPER level and LOWER level. If level is low, add distilled water only. BATTERY SOLUTION GRAVITY CHECK Measure gravity of battery solution using hydrometer. Battery solution gravity: 1.28 at 20°C BOLT AND NUTS Check that all bolts and nuts listed below are tightened to their specified torque.

ITEM TIGHTENING TORQUE Cylinder head cover bolt Flywheel bolt Power unit mounting bolt Clamp bracket shaft nut Gearcase bolt Propeller nut FUEL MIXTURE CHECK (O2 FEEDBACK) Perform every 2 years. To perform fuel mixture check (O2 feedback) operation, use personal computer and Diagnostic System software. For fuel mixture check (O2 feedback) operation, refer to Diagnostic System Operation Manual”. OIL PRESSURE Oil pressure (at normal operating temp.): 550 – 600 kPa (5.5 – 6.0 kg/cm2, 78 – 85 psi.) at 3000 r/min. NOTE: The figure shown above is a guideline only, not an absolute service limit. If oil pressure is lower or higher than specification, following causes may be considered.

Low oil pressure:. Clogged oil filter. Leakage from oil passages. Defective oil pump. Defective oil pressure regulator. Damage O-ring. Combination of above items High oil pressure:.

Using an engine oil of too high viscosity. Clogged oil passage. Clogged oil pressure regulator. Combination of above items TEST PROCEDURE 1. Check engine oil level.

Remove bolts and air duct 3. Loosen screw and disconnect blue lead wire from oil pressure switch. Remove oil pressure switch. Install oil pressure gauge in place of pressure switch hole. Attach engine tachometer to ignition coil high tension cord.

Start engine and allow to warm up as follows: Summer: 5 min. At 2000 r/min.

Winter: 10 min. At 2000 r/min. After warming up, shift into forward gear and increase engine speed to 3000 r/min. Then compare pressure indicate on gauge to specifications. After testing, reinstall oil pressure switch. Reinstall air duct.

CYLINDER COMPRESSION Cylinder compression: Standard: 1300 – 1700 kPa (13 – 17 kg/cm2, 185 – 242 psi.) Max. Difference between any other cylinders: 100kPa (1.0 kg/cm2, 14 psi.) NOTE: Figures shown are guidelines only, not absolute service limits. Low compression pressure can indicate one or more of following:. Excessively worn cylinder wall.

Worn piston or piston rings. Stuck piston rings. Poor seating of valves. Ruptured or otherwise damaged cylinder head gasket TEST PROCEDURE 1.

Start engine and allow to warm up, then shut engine off. Remove STBD / PORT side covers.(See page 7-2) 3. Remove all spark plugs. Install compression gauge hose attachment into plug hole, then connect compression gauge hose to gauge hose attachment and compression gauge. Compression gauge Compression gauge hose Compression gauge hose attachment 5.

Disconnect safety lanyard (switch plate) from emergency stop switch. Disconnect the safety lanyard from the emergency stop switch prior to cranking the engine.

This will prevent any residual fuel discharged from the cylinders being ignited by a spark discharge from the spark plug caps. Disconnect remote control throttle cable from throttle lever. Move and hold throttle lever in full-open position. While cranking engine with starter motor, note maximum compression pressure reading on gauge for each cylinder.

Reinstall parts removed earlier. (spark plugs, side covers, etc.).

1999-2008 Service Manual Application: Suzuki DF40QH, DF50QH, DF40 (DF-40HP, DF-40 HP) & DF50 (DF-50HP, DF-50 HP) 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007 & 2008 Outboard boat 4-stroke (four stroke) engine (motor). 2001-2009 Suzuki DF90 DF100 DF115 DF140 Service Manual Outboard 1988 2003 Suzuki DT Outboard Service Manual 2 thru 225 2001-2009 Models Covered: Suzuki DF90 (DF-90) DF100 (DF-100), DF115 (DF-115), DF140 (DF-140) 4-Stroke Outboard boat engine. 1988-2003 Models Covered: DT2 (DT-2) DT2.2 (DT-2.2) / DT4 (DT-4) / DT5Y (DT-5-Y) / DT6 ( DT-6) / DT8 (DT-8) / DT9.9 ( DT-9.9) / DT15 (DT-15) / DT20 (DT-20) / DT25 (DT-25) / DT30 (DT-30) / DT35 (DT-35) / DT40 (DT-40) / DT55 (DT-55) / DT65 (DT-65) / DT75 (DT-75) / DT85 (DT-85) / DT90 (DT-90) / DT100 (DT-100) 1989-1996 & 1996-2001 EFI / DT140 (DT-140) EFI / DT150 (150) EFI / DT175 (175) / DT200 (200) EFI / DT225 (225) / DT4/DT5Y / DT5 DT6 & DT8 / DT25C DT30C (DT25-C, DT30-C) / DT75 & DT85 / DT100TC / DT115STC & DT140TC EFI (DT115-STC, DT140-TC) / DT150 / 175 / 200 / DT225 'M'. LIT- 18616-01-24 Service Manual Application: Yamaha Ouboard 9.9HP (9.9-HP) 4-stroke engines.

Model Names: T9.9T (T9.9-T), F9.9T (F9.9T), T9.9MH (T9.9-MH), F9.9AM (F9.9-AM), F9.9AEM (FT9.9-AEM), T9.9ER (T9.9-ER), F9.9AE (F9.9-AE), F9.9MH (F9.9-MH), F9.9BM (F9.9-BM), T9.9EH (T9.9-EH), F9.9BEM (F9.9-BEM), F9.9BE (F9.9-BE). LIT-18616-01-28 Service Repair Manual Application: 1995, 1996, 1997 (95, 96, 97) Yamaha Marine Outboard E48T (E48-T) C55T (C55-T) 48HP & 55HP 2-Stroke.

Item Model Names: E48T, C55T, E48C, E48MH, E55C, 55BM, C55ER, 55BE, 55BEM, C55TR, 55BET. LIT-18616-01-35 Service Manual Application: 1996-1997 Yamaha F8, T9.9, F9.9 8HP (8-hp) & 9.9Hp (9.9-hp) 4-stroke engines. Exact Models Covered (Covers All 1996-1997 Models World Wide): F8B (F8-B), F9.9A (F9.9-A), F9.9B (F9.9-B), T9.9U (T9.9-U), F9.9U (F9.9-U), F8BM (F8-BM), F8BEM (F8-BEM), F8BE (F8-BE), T9.9MH (T9.9-MH), T9.9AM (T9.9-AM), FT9.9AMH (FT-9.9-AMH), T9.9EH (T9.9-EH), F9.9AEM (FT9.9-AEM), T9.9ER (T9.9-ER), FT9.9AE (FT9.9-AE), F9.9MH (F9.9-MH), F9.9BM (F9.9-BM), F9.9EH (F9.9-EH), F9.9BEM (F9.9-BEM), F9.9BE (F9.9-BE). LIT-18616-01-29 Service Repair Manual Application: 1996, 1997 (96, 97) E60, E60H 60HP (60-HP) Yamaha Marine Outboard 2-Stroke. Item Model Names: E60, E60H, E60HM, E60HE, E60HEM, E60MH, E60EH. Covers USA, Canada and wold wide models.

LIT-18616-01-73 Service Repair Manual Application: 1997 97' Yamaha Marine Outboard 75HP (75HP) 2-Stroke. Item Model Names: E75V, E-75-V, E75-V, E-75V 75AM, 75AEM, 75AE, 75AET, 85AEM, 85AE, 85AET, E75B, E60J, E75MH. Covers USA, Canada and wold wide models.

LIT-18616-01-66 Service Repair Manual Application: 1997-1998 Yamaha Marine Outboard 20HP (20-HP) & 25HP 25-HP) 10V, 25V, 25V2 2-Stroke Engines. Model Names 20DM (20-DM), 20DMO (20-DMO), 20DEM (20-DEM), 20DEMO (20-DEMO), 20DERO (20-DERO), 20MH (20-MH), 20MH2 (20-MH2), 20EH (20-EH), 20EH2 (20-EH2), 25DM (25-DM), 25NMO (25-NMO), 25NEMO (25-NEMO), 25NE (25-NE), 25NEO (25-NEO), 25NERO (25-NERO), 25MH (25-MH), 25MH2 (25-MH2), 25EH (25-EH), 25ER (25-ER). LIT-18616-01-81 Service Repair Manual Application: 1998-1999 98-99 40HP (40-HP) & 50HP (50-HP) 40W 50W Yamaha Marine Outboard 2-Stroke Item Model Names: 40-W, 50-W, 40VMH, 40VMHD, 40VMHO, 40VMO, 40VWH, 40VE, 40VEO, 40VEHTO, 40VET, C40MH, 40MH, C40ER, 40ER, P40TH, C40TR, 40VETO, 50HMHO, 50HMHD, 50HMO, 50HMDO, 50HWHD, 50HEDO, 50HET, 50HETO, 40TR, 50ER, C50TR, 50TR Covers USA, Canada and wold wide models. LIT-18616-F1-50 & LIT-18616-02-12 Service Repair Manual Application: 1998-2005 Yamaha Marine Outboard 15HP (15-HP) 4-Stroke Engines F15W (F15-W), F15Z (F15-Z) 1998, 1999, 2000, 2001, 2002, 2003, 2004 & 2005. This manual covers all 15HP 4-Stroke models world wide including USA CANADA. USA & CANADA MODELS: F15MHW (F15-MHW), F15EHW (F15-EHW), F15AMH (F15-AMH), F15AEH (F15-AEH), F15AEP (F15-AEP), F15AEHP (F15-AEHP), F15PR (F15-PR), F15PH (F15-PH), F15AEP (F15-AEP), F15AEHP (F15-AEHP). WOLD WIDE MODELS: F15AMH (F15-AMH), F15AEH (F15-AEH), F15AE (F15-AE).

LIT-18616-01-83 Service Manual Application: 1998-2006 Yamaha F8, T9.9, F9.9 8HP (8-hp) & 9.9Hp (9.9-hp) 4-stroke engines for 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005 & 2006. Model Name: T9.9W (T9.9-W), F9.9W (F9.9-W), F8BMH (F8-BMH), F8BEH (F8-BEH), F8BE (F8-BE), T9.9MH (T9.9-MH) FT9.9AMH (FT-9.9-AMH), T9.9EH (T9.9-EH), FT9.9AEH (FT9.9-AEH), T9.9ER (T9.9-ER), FT9.9AE (FT9.9-AE), F9.9MH (F9.9-MH), F9.9BMH (F9.9-BMH), F9.9EH (F9.9-EH), F9.9BEH (F9.9-BEH), F9.9BE (F9.9-BE).

LIT-18616-01-79 Service Repair Manual Application: 1998-2005 Yamaha Marine Outboard 4HP (4-HP) 4-Stroke Engines F4X (F4-X, F-4X) 1999, 2000, 2001, 2002, 2003, 2004 & 2005. This manual covers all 4HP 4-Stroke models world wide including F4MSHX, F4MLHX, F4AMH, USA CANADA. LIT-18616-01-94 Service Repair Manual Application: 1999-2000 99-00 25HP (25-HP) & 30HP (30-HP) 25X, 25-X, 30X, 30-X, 25J, 25-J, 30D, 30-D Yamaha Marine Outboard 2-Stroke. Model Names: 25JMH, 25MH3, 30DMH, 25JMHO, 30DMHO, 30MH, 25JEHO, 25EH3, 30DWH, 25JEO, 25JETO, 25TR3, 30DEHO, 30EH, 30DMO, 30DE, 30DEO, 30ER, 30DET, 30DETO, 30TR Covers USA, Canada and wold wide models.

LIT-18616-01-96 Service Repair Manual Application: 1999, 2000, 2001, 2002 99, 00, 01, 02 100HP (100-HP) F100X, F100-X, F-100X Yamaha Marine Outboard 4-Stroke. Model Names: F100TR, F100-TR, F-100TR, F100AET, F-100AET, F100-AET Covers USA, Canada and woldwide models. LIT-18616-02-16 Service Repair Manual Application: 2000, 2001, 2002, 2003 Yamaha Marine Outboard 40HP (40-HP) F40B (F-40B-F40-B) 4-Stroke Engines. Model name F40BMHD, F40BWHD, F40BED, F40BET, USA and Canada name F40MH, F40ER, F40TR. LIT-18616-02-19 Service Repair Manual Application: 2001, 2002, 2003, 01, 02, 03, Yamaha Marine Outboard 6HP & 8HP (F6Z F8Z) 4-Stroke Engines. Model Name: F6AMH, F8CMH, F6MH, F8MH (F6-AMH, F6-MH, F8-AMH, F8-MH). ALL 250HP 2003-2006 MODELS ervice Repair Manual Application: 2003, 2004, 2005, 2006 Yamaha Marine Outboard 250HP (250-HP) 2-Stroke & 4-Stroke Engines.

LIT-18616-02-78 - 2004-2005 Z250C & LZ250C LZ250TR 2-STROKE ENGINE. LIT-18616-02-43 - 2003-2005 Z250B & LZ250B MODEL NAME Z250TR/LZ250TR 2-STROKE ENGINE.

LIT-18616-02-97 - 2005-2006 F250 & LF250 F250TR/LF250TR 4-STROKE ENGINE. LIT-18616-02-54 Service Repair Manual Application: 2004-2005 Yamaha Marine Outboard 2.5HP (2.5-HP) F2.5C (F2.5-C, F 2.5C) F2.5MH 4-Stroke Engines. LIT-1816-02-59 Service Repair Manual Application: 2004-2005 Yamaha Marine Outboard 9.9HP & 15HP (9.9-HP 15-HP) 2-Stroke Engines. Model name 9.9CMH & 15CMH ( 9.9 & 15 CMH).

LIT-18616-02-61 Service Repair Manual Application: 2004-2005 Yamaha Marine Outboard 25HP (25-HP) 4-Stroke Engines F25C, T25C (F-25C F25-C T25-C T-25C) F25MH, F25EH, F25ER, F25TR, T25TR. LIT-18616-02-65 Service Repair Manual Application: 2004 04' & 2005 05' Yamaha Marine Outboard 40HP (40-HP) & 50HP (50-HP) 4-Stroke Engines. Exact model name 40VETO 50HETO, Both USA and CANADA models covered 40TR 50TR / 40C-50C.

LIT-18616-02-66 Service Repair Manual Application: 2004 04' & 2005 Yamaha Marine Outboard 70HP (70-HP) 2-Stroke Engines. Model name 70BETO, USA and Canada name 70TR 70C (70-C). LIT-18616-02-66 Service Repair Manual Application: 2004 04' & 2005 Yamaha Marine Outboard 90HP (90-HP) 2-Stroke Engines. Model name 90AETO, USA and Canada name 90TR 90C (90-C).

LIT-18616-02-72 Service Repair Manual Application: 2004-2005 Yamaha Marine Outboard 130HP & 115HP (115C 130C) 2-Stroke Engines. Model Name: 115CETO (115-CETO), 130BETO (130-BETO) 115TR, 130TR. LIT-18616-02-51 Service Repair Manual Application: 2004-2005 Yamaha Marine Outboard 150HP (150-HP) F150C & LF150C (LF-F-150C-F150-C) 4-Stroke Engines. Model name F150TR, LF150TR (F-LF-150-TR) LIT-18616-02-71 Service Repair Manual Application: 2004-2005 Yamaha Marine Outboard 115HP (115-HP) 4-Stroke Engines.

Model name F115AET LF115AET, USA and Canada name F115TR LF115TR. LIT-18616-02-73 Service Repair Manual Application: 2004-2005 Yamaha Marine Outboard 150 HP (150HP) 150C & V150C 2-Stroke Engines. Model Name: 150FETO, 150GETO. LIT-18616-02-66 Service Repair Manual Application: 2004 04' & 2005 Yamaha Marine Outboard 60HP (60-HP) 2-Stroke Engines. Model name 60FETO USA and Canada name 60TR, 60C (60-C).

LIT-18616-02-76 Service Repair Manual Application: 2004-2005 Yamaha Marine Outboard F200C, LF200C, F225C, LF225C 200HP (200-HP) & 225HP (225-HP) V6 4-Stroke Engines. LIT-18616-02-85 Service Repair Manual Application: 2005 Yamaha Marine Outboard 50HP & 60HP (50-HP, 60-HP) 4-Stroke Engines F50D T50D F60D T60D (F-50-D, T-50-D, F60-D, T60-D). LIT-18616-02-86 Service Repair Manual Application: 2005-2006 05-06' Yamaha Marine Outboard F90D 90HP 4-Stroke Engines. Model Name F90TR.