Yamaha 75-115 & 200-225 HP Four-Stroke Outboards 2000 - 2004

Clymer Owners Marine Service & Repair Manual

2000, 2001, 2002, 2003, 2004

by Mark Rolling

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Yamaha 75-115 & 200-225 HP Four-Stroke Outboards 2000 - 2004 - Front Cover

Front Cover

Front Cover


Yamaha 75-115 & 200-225 HP Four-Stroke Outboards 2000 - 2004 Clymer Owners Marine Service & Repair Manual covers the following models:
● Yamaha 75 HP (2000-2004)
● Yamaha 80 HP (2000-2004)
● Yamaha 90 HP (2000-2004)
● Yamaha 100 HP (2000-2004)
● Yamaha 115 HP (2000-2004)
● Yamaha 200 HP (2000-2004)
● Yamaha 225 HP (2000-2004)


Manual organization / Warnings, cautions and notes / Safety / Service hints / Outboard engine identification / Engine operation / Fasteners / Lubricants / RTV gasket sealant / Anaerobic sealant / Threadlocking compound / Galvanic corrosion / Propellers / Basic hand tools / Special tools / Precision measuring tools / electrical system fundamentals / Basic mechanical skills / Specifications

Electrical component replacement / Preliminary inspection / Starting difficulty / Electric starting system troubleshooting / Fuel system troubleshooting / Ignition system troubleshooting / Warning system troubleshooting / Charging system troubleshooting / Power head / Cooling system troubleshooting / Gearcase troubleshooting / Trim/tilt system troubleshooting / Electronic fuel injection system / Specifications

Before each use / After each use / Routine maintenance / Tune-up / Storage preparation and re-commissioning / Submersion / Corrosion prevention / Specifications

Pilot screw adjustment (75-100 hp models) / Linkage, throttle position sensor, synchronization and idle speed adjustments / Ignition timing check / Throttle cable adjustment / Shift cable adjustment / Valve adjustment / Trim tab adjustment / Trim position sender adjustment / Specifications

Fuel system service / Fuel tanks / Fuel hoses / Fuel filter / Primer bulb replacement / Mechanical fuel pump / Silencer cover removal and installation / Intake manifold removal and installation / Dashpot replacement / Electrothermal valve replacement / Carburetor / Throttle body removal and installation / Vapor separator tank / Low-pressure electric fuel pump replacement / Fuel pump relay replacement / Fuel pump driver replacement / Fuel cooler replacement / Fuel pressure regulator replacement / Fuel rail and injectors / Idle air control motor replacement / Air temperature sensor replacement / Air pressure sensor replacement / Throttle position sensor replacement / Specifications

Electrical component replacement / Battery / Charging system / Starting system / Ignition system / Specifications

Flywheel/cover removal and installation / Timing belt and tensioner removal/installation / Valve cover removal and installation / Camshaft, timing chain and camshaft pulley removal and installation / Cylinder head removal and installation / Water pressure relief valve removal and installation / Thermostat removal and installation / Exhaust/water jacket cover removal and installation / Cylinder head disassembly/inspection/assembly / Power head removal and installation / Oil pump / Oil pump inspection / Crankshaft pulley removal and installation / Power head external component removal and installation / Cylinder block disassembly and assembly / Cylinder block component inspection and measurement / Bearing selection / Engine break-in procedures / Specifications

Gearcase operation / Gearcase service precautions / Propeller removal and installation / Gearcase removal and installation / Water pump disassembly/assembly / Gearcase disassembly and assembly / Gearcase component inspection / Gearcase shimming / Gearcase pressure test / Specifications

Trim/tilt relay replacement / Trim position sender replacement / Trim switch replacement / Manual relief valve replacement / Power trim and tilt system removal and installation / Electric trim/tilt motor removal/installation / Electric trim and tilt motor disassembly, component inspection, testing and assembly / Fluid filling / Specifications

Lower motor mount replacement / Tilt tube replacement / Clamp bracket replacement / Tilt lock lever replacement / Oil pump replacement / Upper motor mount replacement / Swivel tube replacement / Swivel housing replacement / Power head adapter replacement / Exhaust silencer replacement / Exhaust tube replacement / Oil pressure relief valve / Oil pan and oil pickup tube replacement / Drive shaft housing replacement / Specifications

Remote control operation / Cable removal and installation / Remote control disassembly and assembly / Specifications


Clymer marine manuals can save you money on maintenance and repair. Step-by-step procedures and detailed illustrations guide you through every job, from routine maintenance and troubleshooting, all the way to complete teardown & rebuild.

General information on Repair Manuals

Please note that workshop manuals are usually written for models sold in a specific country. Differences in specification can exist between models sold in different countries and items such as engines can vary. Please check that the manual will cover your model before purchase and if you are unsure please contact us first.

product details

  • Publisher: Clymer Publications
  • ISBN: 1620921324 (1-620-92132-4)
  • ISBN-13: 9781620921326 (978-1-620-92132-6)
  • Format: Softcover, 492 pages
  • Date Published: 12-2004


Shipping: Due to weight, a surcharge applies only to International shipments (3) read more

Within Australia there is a flat delivery charge of A$9.95 per order (any number of items).


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