This repair and service manual covers 1995-2004 Yamaha, Mercury, Mariner 4-stroke outboard motors, 2.5 to 225 HP, 1- and 4-cylinder and V6 4-stroke models (including Jet Drives).
Published by Seloc Marine with copious photos and illustrations populating its 768 pages, the Yamaha outboard service manual covers every aspect of boat engine repair. In addition to instruction on engine tuneup, disassembly and reassembly, the fuel system, electrical system, ignition system and cooling system, you'll get expert guidance on tilt and trim, the hand rewind starter, engine and torque specs, wiring diagrams, advice on maintenance and off-season boat storage and information on the powerhead. The manual even includes a section on boating safety.
Service and repair DIY manuals like this one are available at The Motor Bookstore with free shipping to the 48 continental United States. Your order will usually ship the same business day.
Book Excerpt: 1995-2004 Yamaha, Mercury, Mariner 4-Stroke Outboard Repair Manual
IGNITION AND ELECTRICAL SYSTEMS
LIGHTING COIL - See Figures 30 and 31
The lighting coil windings really aren't usually part of the ignition system (at least they aren't when separate charge coil winders are provided to power the ignition), however it operates in the same fashion as the charge and pulser coils, and it is replaced in the same fashion, so it makes sense to cover it here.
On many newer Yamaha and Mercury/Mariner motors the charge coil winding are incorporated into the stator (along with the lighting coil), and on some there are no distinct charge coil windings. On these late-model motors, the entire stator assembly must be replaced if a problem is isolated to the ignition charge circuit.
The lighting coil checks are the same as those for the pulser and charge coils. There are normally 2 methods used in testing lighting coils, a static resistance check and a dynamic cranking or running output voltage check. Specifications vary by year and model so significantly that it precludes trying to list them in this procedure.
In addition, the method of conducting the static check will vary with the specifications that are provided. Generally speaking cranking or running tests are more accurate and more likely to show intermittent problems.
Dynamic checks are done under different circumstances, with load (circuit complete) and without load (circuit incomplete), again, depending upon the specifications provided by the manufacturer.
Never, never use automotive type head gasket sealer. The chemicals in the sealer will cause electrolytic action and eat the aluminum faster than you can get to the bank for money to buy a new cylinder block.
Some head gaskets are supplied with a tacky coating on both surfaces applied at the time of manufacture. This tacky substance will provide an even coating all around. Therefore, no further sealing agent is required.
However, If a slight water leak should be noticed following completed assembly work and powerhead start up, do not attempt to stop the leak by tightening the head bolts beyond the recommended torque valve. Such action will only aggravate the problem and most likely distort the head.
Furthermore, tightening the bolts, which are case hardened aluminum, may force the bolt beyond its elastic limit and cause the bolt to fracture.
This would be Bad news, very bad news indeed. A fractured bolt must usually be drilled out and the hole retapped to accommodate an oversize bolt, etc. Avoid such a situation.
Subject: 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004 Yamaha, Mercury and Mariner 4-Stroke Outboard service, maintenance, repair. ISBN-10: 0893300667 | ISBN-13: 9780893300661 | Seloc 1705