Yamaha 250GETO User manual

L250G
SERVICE MANUAL
6S3-28197-5H-116
250G
YAMAHA MOTOR CO., LTD.
Printed in Japan
Aug. 2005 – 1.4 ×1 !
(E_2) Printed on recycled paper
250G, L250G
A3Cover 06.6.9 19:09 Page 1

NOTICE
This manual has been prepared by Yamaha primarily for use by Yamaha dealers and their trained
mechanics when performing maintenance procedures and repairs to Yamaha equipment. It has
been written to suit the needs of persons who have a basic understanding of the mechanical and
electrical concepts and procedures inherent in the work, for without such knowledge attempted
repairs or service to the equipment could render it unsafe or unfit for use.
Because Yamaha has a policy of continuously improving its products, models may differ in detail
from the descriptions and illustrations given in this publication. Use only the latest edition of this
manual. Authorized Yamaha dealers are notified periodically of modifications and significant
changes in specifications and procedures, and these are incorporated in successive editions of this
manual.
Important information
Particularly important information is distinguished in this manual by the following notations:
QThe Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS
INVOLVED!
w
Failure to follow WARNING instructions could result in severe injury or death to the machine
operator, a bystander, or a person inspecting or repairing the outboard motor.
cC
A CAUTION indicates special precautions that must be taken to avoid damage to the out-
board motor.
NOTE:
A NOTE provides key information to make procedures easier or clearer.
250G, L250G
SERVICE MANUAL
©2005 by Yamaha Motor Co., Ltd.
1st Edition, August 2005
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
Printed in Japan
A3Cover 05.10.4 20:14 Page 2

Specification
General information
Periodic check and adjustment
Fuel system
Power unit
Bracket unit
Electrical system
Troubleshooting
Index
Contents
Lower unit
9
8
7
6
2
1
GEN
INFO
SPEC
CHK
ADJ
FUEL
POWR
LOWR
BRKT
ELEC
TRBL
SHTG
3
4
5
6S35H11_01 9/2/05 6:41 PM Page 1

6S35H11_01 9/2/05 6:41 PM Page 2

6S35H11 1-
9
8
7
6
5
4
3
2
1
General information
How to use this manual ............................................................................... 1-1
Manual format .......................................................................................... 1-1
Symbol ..................................................................................................... 1-2
Safety while working ................................................................................... 1-3
Fire prevention ......................................................................................... 1-3
Ventilation ................................................................................................ 1-3
Self-protection ......................................................................................... 1-3
Parts, lubricant, and sealant .................................................................... 1-3
Good working practice ............................................................................. 1-4
Disassembly and assembly ..................................................................... 1-4
Identification ................................................................................................. 1-5
Applicable model ..................................................................................... 1-5
Serial number .......................................................................................... 1-5
Special service tool ..................................................................................... 1-6
Feature and benefit..................................................................................... 1-12
Bracket/upper case................................................................................. 1-15
Lower unit ............................................................................................... 1-16
Fuel system ............................................................................................ 1-19
Propeller selection ..................................................................................... 1-24
Propeller size ......................................................................................... 1-24
Selection ................................................................................................ 1-24
Predelivery check ...................................................................................... 1-25
Checking the fuel system ...................................................................... 1-25
Checking the gear oil ............................................................................. 1-25
Checking the outboard motor mounting height ..................................... 1-26
Checking the remote control cable..........................................................1-26
Checking the steering system ............................................................... 1-27
Checking the gear shift and throttle operation ........................................1-27
Checking the PTT system .......................................................................1-27
Checking the engine start switch and engine stop lanyard switch ........ 1-27
Checking the cooling water pilot hole .................................................... 1-28
Test run .................................................................................................. 1-28
Break-in ................................................................................................. 1-28
After test run .......................................................................................... 1-29
GEN
INFO
6S35H11_01 05.9.10 16:36 Page 3

GEN
INFO
1- 6S35H11
General information
1-1
How to use this manual
Manual format
The format of this manual has been designed to make service procedures clear and easy to under-
stand. Use the information below as a guide for effective and quality service.
9Parts are shown and detailed in an exploded diagram and are listed in the components list (see 1
in the figure below for an example page).
9The component list consists of part names and quantities, as well as bolt and screw dimensions
(see 2in the figure below).
9Symbols are used to indicate important aspects of a procedure, such as the grade of lubricant and
lubrication point (see 3in the figure below).
9Tightening torque specifications are provided in the exploded diagrams (see 4in the figure below
for an example), and in the related detailed instructions. Some torque specifications are listed in
stages as torque figures or angles in degrees.
9Separate procedures and illustrations are used to explain the details of removal, checking, and
installation where necessary (see 5in the figure below for an example page).
NOTE:
For troubleshooting procedures, see Chapter 9, “Troubleshooting.”
LOWR Lower unit
6-5 62Y5A11
Lower unit
No. Part name Q ty Remarks
1 Lower unit 1
2 Plastic tie 1 Not reusable
3Hose 1
4 Check screw 1
5 Gasket 2 Not reusable
6 Dowel pin 2
7 Bolt 4 M10 40 mm
8 Drain screw 1
9Grommet 1
10 Bolt 1 M10 45 mm
11 Bolt 1 M8 60 mm
12 Thrust washer 1
13 Propeller 1
14 Washer 1
15 Washer 1
16 Cotter pin 1 Not reusable
17 Propeller nut 1
18 Trim tab 1
LOWR Lower unit
6-19 62Y5A11
Removing the drive shaft
1. Remove the drive shaft assembly and
pinion, and then pull out the forward
gear.
Disassembling the drive shaft
1. Install the pinion nut , tighten it finger
tight, and then remove the drive shaft
bearing using a press.
CAUTION:
• Do not press the drive shaft threads
directly.
Do not reuse the bearing, always
replace it with a new one.
Disassembling the forward gear
1. Remove the taper roller bearing from the
forward gear using a press.
CAUTION:
Do not reuse the bearing, always replace
it with a new one.
2. Remove the needle bearing from the for-
ward gear.
CAUTION:
Do not reuse the bearing, always replace
it with a new one.
Drive shaft holder 4 : 90890-06518
Pinion nut holder : 90890-06505
Socket adapter 2 : 90890-06507
Bearing inner race attachment :
90890-06639
S62Y6850K
Bearing separator : 90890-06534
Stopper guide plate : 90890-06501
Stopper guide stand :
90890-06538
Bearing puller : 90890-06535
Bearing puller claw 1 :
90890-06536
S62Y6740K
341
1
2
3
3
2
3
4
5
1
2
5
a
×
×
×
1
2
6F660190
1
2
3
6S35H11_01 9/2/05 6:41 PM Page 4

How to use this manual
6S35H11
9
8
7
6
5
4
3
2
1
1-2
GEN
INFO
Symbol
The symbols below indicate the content of a chapter.
General information Fuel system Bracket unit
Specification Power unit Electrical system
Periodic check and adjustment Lower unit Troubleshooting
Symbols 1to 6indicate specific data.
1Special tool
2Specified oil or fluid
3Specified engine speed
4Specified tightening torque
5Specified measurement
6Specified electrical value
(resistance, voltage, electric current)
Symbols 7to ein an exploded diagram or illustration indicate the grade of lubricant and the lubri-
cation point.
7Apply Yamaha 2-stroke outboard motor oil
8Apply gear oil
9Apply water resistant grease (Yamaha grease A)
0Apply molybdenum disulfide grease
qApply corrosion resistant grease
(Yamaha grease D)
wApply low temperature resistant grease
(Yamaha grease C)
eApply injector grease
Symbols rto oin an exploded diagram or illustration indicate the type of sealant or locking agent
and the application point.
rApply Gasket Maker
tApply ThreeBond 1104J
yApply LOCTITE 271 (red)
uApply LOCTITE 242 (blue)
iApply LOCTITE 572
oApply silicon sealant
FUEL BRKT
SPEC POWR ELEC
CHK
ADJ LOWR TRBL SHTG
123456
C
78 0qwe
rtyuio
9
6S35H11_01 9/2/05 6:41 PM Page 5

GEN
INFO
1- 6S35H11
General information
1-3
Safety while working
To prevent an accident or injury and to ensure
quality service, follow the safety procedures
provided below.
Fire prevention
Gasoline is highly flammable.
Keep gasoline and all flammable products
away from heat, sparks, and open flames.
Ventilation
Gasoline vapor and exhaust gas are heavier
than air and extremely poisonous. If inhaled
in large quantities they may cause loss of
consciousness and death within a short time.
When test running an engine indoors (e.g., in
a water tank) be sure to do so where ade-
quate ventilation can be maintained.
Self-protection
Protect your eyes by wearing safety glasses
or safety goggles during all operations involv-
ing drilling and grinding, or when using an air
compressor.
Protect your hands and feet by wearing pro-
tective gloves and safety shoes when neces-
sary.
Parts, lubricant, and sealant
Use only genuine Yamaha parts, lubricants,
and sealants or those recommended by
Yamaha, when servicing or repairing the out-
board motor.
Under normal conditions, the lubricants men-
tioned in this manual should not harm or be
hazardous to your skin. However, you should
follow these precautions to minimize any risk
when working with lubricants.
1. Maintain good standards of personal and
industrial hygiene.
2. Change and wash clothing as soon as
possible if soiled with lubricants.
3. Avoid contact with skin. Do not, for exam-
ple, place a soiled rag in your pocket.
4. Wash hands and any other part of the
body thoroughly with soap and hot water
after contact with a lubricant or lubricant
soiled clothing has been made.
5. To protect your skin, apply a protective
cream to your hands before working on
the outboard motor.
6S35H11_01 9/2/05 6:41 PM Page 6

Safety while working
1-4
6S35H11
9
8
7
6
5
4
3
2
1
6. Keep a supply of clean, lint-free cloths for
wiping up spills, etc.
Good working practice
Special service tool
Use the recommended special service tools
to protect parts from damage. Use the right
tool in the right manner–do not improvise.
Tightening torque
Follow the tightening torque specifications
provided throughout the manual. When tight-
ening nuts, bolts, and screws, tighten the
large sizes first, and tighten fasteners starting
in the center and moving outward.
Non-reusable parts
Always use new gaskets, seals, O-rings, cot-
ter pins, circlips, etc., when installing or
assembling parts.
Disassembly and assembly
1. Use compressed air to remove dust and
dirt during disassembly.
2. Apply engine oil to the contact surfaces
of moving parts before assembly.
3. Install bearings with the manufacture
identification mark in the direction indicat-
ed in the installation procedure. In addi-
tion, be sure to lubricate the bearings lib-
erally.
4. Apply a thin coat of water-resistant
grease to the lip and periphery of an oil
seal before installation.
5. Check that moving parts operate normal-
ly after assembly.
6S35H11_01 9/2/05 6:41 PM Page 7

1-5
GEN
INFO
6S35H11
General information
Identification
Applicable model
This manual covers the following model.
Serial number
The outboard motor serial number is
stamped on a label attached to the port
clamp bracket.
1Model name
2Approved model code
3Transom height
4Serial number
YAMAHA MOTOR CO., LTD.
MADE IN JAPAN
PAYS D'ORIGINE JAPON
1
3
2
4
6B410020
Applicable model
250GETO, L250GETO
Model name Approved Starting
model code serial No.
250G 6S3 1000001–
L250G 6S4 1000001–
6S35H11_01 9/2/05 6:41 PM Page 8

6S35H11 1-6
9
8
7
6
5
4
3
2
1
Identification/Special service tool
Special service tool
Digital tachometer
90890-06760
Leakage tester
90890-06840
Vacuum/pressure pump gauge set
90890-06756
Digital caliper
90890-06704
Timing light
90890-03141
Compression gauge
90890-03160
Flywheel holder
90890-06522
Flywheel puller
90890-06521
Piston slider ø85
90890-06530
Needle bearing attachment
90890-06608, 90890-06610, 90890-06653
90890-06654, 90890-06611
6S35H11_01 9/2/05 6:41 PM Page 9

GEN
INFO
1- 6S35H11
General information
1-7
Support
90890-02394
Pressure pin B
90890-02390
B
Driver rod L3
90890-06652
Driver rod LS
90890-06606
Gear puller
90890-06540
Dial gauge set
90890-01252
Cylinder gauge
90890-06759
Bearing separator
90890-06534
Pinion nut holder
90890-06715
Ring nut wrench extension
90890-06513
6S35H11_01 9/2/05 6:41 PM Page 10

Special service tool
1-8
6S35H11
9
8
7
6
5
4
3
2
1
Puller head
90890-06514
Stopper guide plate
90890-06501
Bearing housing puller claw L
90890-06502
Center bolt
90890-06504
Stopper guide stand
90890-06538
Drive shaft holder 6
90890-06520
Bearing depth plate
90890-06603
Bearing puller assembly
90890-06535
Driver rod LL
90890-06605
Driver rod SS
90890-06604
6S35H11_01 9/2/05 6:41 PM Page 11

6S35H11
1-9
GEN
INFO General information
Magnet base B
90890-06844
Bearing outer race puller assembly
90890-06523
Outer race puller claw B
90890-06533
Slide hammer handle
90890-06531
Bearing outer race attachment
90890-06622, 90890-06624, 90890-06626
90890-06628, 90890-06658
Ball bearing attachment
90890-06635, 90890-06655, 90890-06656
90890-06657
Shimming plate
90890-06701
Shift rod push arm
90890-06052
Pinion height gauge
90890-06710
Bearing inner race attachment
90890-06640, 90890-06659
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6S35H11 1-10
9
8
7
6
5
4
3
2
1
Special service tool
Magnet base plate
90890-07003
Cylinder-end screw wrench
90890-06568
PTT piston vice attachment
90890-06572
Ring nut wrench 4
90890-06510
Ignition tester
90890-06754
Digital circuit tester
90890-03174
Backlash indicator
90890-06706
Ring nut wrench
90890-06578
Peak voltage adaptor B
90890-03172
Diagnostic flash indicator B
90890-06865
6S35H11_01 9/2/05 6:41 PM Page 13

Test harness (3 pins)
90890-06870
GEN
INFO
1-11 6S35H11
General information
PTT oil pressure gauge assembly
90890-06580
Test harness (2 pins)
90890-06867
Tilt rod wrench
90890-06569
Test harness (3 pins)
90890-06857
Test harness (4 pins)
90890-06871
Test harness (6 pins)
90890-06872
6S35H11_01 9/2/05 6:41 PM Page 14

6S35H11 1-12
9
8
7
6
5
4
3
2
1
Special service tool/Feature and benefit
Feature and benefit
Power unit
Piston
An aluminum piston with heat treatment is used to obtain durability and reliability.
Molybdenum coating is given to the skirt of piston to obtain more lubrication and reduce friction.
1st or 2nd oversized piston in available for overhaul service.
NOTE:
This piston is the same as the electronic fuel injected V6 3.1L models.
Connecting rod
The following treatment has been given to the connecting rod to enhance the stiffness.
•Silver plating is given to the side of big end.
•A carbonizing is given to the big end portion.
•Larger size big-end is adopted.
Molybdenum coating
Location mark
UP mark
Recognition mark
18mm
21mm
Recognition mark
60mm
62mm
Piston
Connecting rod
250A
250G
6S35H11_01 9/2/05 6:41 PM Page 15

GEN
INFO
1-13 6S35H11
General information
Cylinder sleeve
The slit of exhaust port is removed and smoother curved exhaust port is used on, which can pre-
vent the piston rings from scuffing with lesser fuel.
Exhaust slit
Sleeve
250A 250G
Cylinder body
The shallow water jacket is designed to increase the rigidity of cylinder body.
Wider rib is used to obtain rigid cylinder body.
Smoother curve structure is given to the #1 and #2 exhaust passages to reduce resistance of
exhaust gases.
Rib 5mm Wider rib 6mm
Deep water
jacket
44 — 96mm
Average 72mm
Shallow water
jacket
44 — 60mm
Average 57mm
Cylinder body
250A 250G
6S35H11_01 9/2/05 6:41 PM Page 16

6S35H11 1-14
9
8
7
6
5
4
3
2
1
Feature and benefit
Engine mount bolt
A fully thread bolt coated with a sealing agent has been used for mounting the engine.
This gives a sealing function to the bolt, which will prevent the bolt from sticking by saltwater enter-
ing into the bolt hole for crystallizing and corroding.
Therefore, the bolts can be removed easily, which obtained better servicing.
NOTE:
If the bolt is reused, apply LOCTITE 572 to the bolt threads.
Bolt Sealing material
No corroded particles
Sealing agent coated
Engine mount bolt
6S35H11_01 9/2/05 6:41 PM Page 17

GEN
INFO
1-15 6S35H11
General information
Bracket/upper case
Ptt unit
The components of clamp bracket and PTT unit are the same as 250A.
Manual valve 20.6 MPa,
210 kgf/cm ,
2
2,988 psi
Main valve
Gear
pump
UP relief valve
12.3 MPa,
125 kgf/cm ,
1,784 psi
2
DOWN relief valve
5.7 MPa,
58 kgf/cm ,
827 psi
2
Trim down valve
0.5 MPa, 5 kgf/cm ,
2
73 psi
Tilt cylinder
Impact relief valve
20.6 MPa, 210 kgf/cm , 2,988 psi
2
Trim
cylinder
PTT fluid flow diagram
PTT specifications
PTT ID mark 61A-25
Tilt stroke 147 mm, 5.8 in
Trim stroke 99 mm, 3.9 in
Fluid ATF Dexron-2
6S35H11_01 9/2/05 6:41 PM Page 18