Service Manual & Repair guide Yamaha Z250C LZ250C 2004

Do you want to service & repair your Yamaha Z250C, LZ250C 2004 yourself? We can help you with the official certified Service & Repair manual; just push the button INSTANT DOWNLOAD on the left side, download the file and you can start right away. This manual covers the following model(s): Z250C 2004 LZ250C 2004 We only sell original manuals; the quality of the files is exceptionally good. When you print the file, the pictures are of good quality and very bright. WE DO NOT SELL ANY COPIED MANUALS, ONLY THE ORIGINAL!!!! In this manual you have the following chapters: How to use this manual Manual format Symbols Safety while working Fire prevention Ventilation Self-protection Parts, lubricants, and sealants Good working practices Disassembly and assembly Identification Applicable models Serial number Propeller selection Propeller size Selection Predelivery checks Checking the fuel system Checking the gear oil level Checking the engine oil level Checking the battery Checking the outboard motor mounting height Checking the remote control cables Checking the steering system Checking the gear shift and throttle operation Checking the power trim and tilt system Checking the engine start switch and engine stop lanyard switch Checking the cooling water pilot hole Test run Break-in After test run Specifications General specifications Maintenance specifications Power unit Lower unit Electrical Dimensions Tightening torques Specified torques General torques Periodic checks and adjustments Special service tools Maintenance interval chart Top cowling Checking the top cowling Fuel system Checking the fuel joint and fuel hoses (fuel joint-to-fuel injector) Checking the fuel filter Checking the high-pressure fuel pump gear oil level Changing the high-pressure fuel pump gear oil Power unit Checking the engine oil level Checking the drive belt Replacing the drive belt Checking the spark plugs Checking the thermostats Checking the cooling water passage Control system Checking the engine idle speed Adjusting the throttle cable Checking the gear shift operation Checking the ignition timing Oil injection system Adjusting the oil pump link rod Power trim and tilt unit Checking the power trim and tilt operation Checking the power trim and tilt fluid level Lower unit Checking the gear oil level Changing the gear oil Checking the lower unit for air leakage Checking the propeller General Checking the anodes Checking the battery Lubricating the outboard motor Fuel system Special service tools Hose routing Fuel hoses and fuel pipes Fuel filter Fuel pump Checking the fuel pumps Disassembling the fuel pumps Assembling the fuel pumps Oil injection system Checking the check valve Checking the oil filter Checking the oil tank Assembling the oil tank Installing the oil pump Bleeding the oil injection system Throttle body assembly and vapor separator Measuring the fuel pressure (medium-pressure fuel line) Checking the pressure regulator Reducing the fuel pressure (medium-pressure fuel line Disconnecting the medium-pressure fuel hose joint Removing the throttle body assembly Removing the medium-pressure fuel hose clamps Installing the medium-pressure fuel hose clamps Removing the electric fuel pump filter Checking the vapor separator Installing the electric fuel pump filter Installing the throttle body assembly Synchronizing the throttle valves Adjusting the throttle position sensor High-pressure fuel line High-pressure fuel pump Installing the joints Installing the fuel pipes Installing the fuel injectors Power unit Special service tools Power unit Checking the compression pressure Removing the drive belt and sprockets Checking the drive belt and sprockets Installing the sprockets and drive belt Removing the power unit Removing the flywheel magnet Removing the stator coil and pulser coil Removing the starter motor Intake manifold Removing the intake manifold Checking the reed valve Cylinder head Removing the cylinder head Checking the cylinder head Exhaust and cylinder cover Removing the exhaust cover Checking the pressure control valve Installing the pressure control valve Crankcase Lower unit Special service tools Lower unit (regular rotation model) Removing the lower unit Removing the water pump and shift rod Checking the water pump and shift rod Propeller shaft housing (regular rotation model) Removing the propeller shaft housing assembly Disassembling the propeller shaft assembly Disassembling the propeller shaft housing Checking the propeller shaft housing Checking the propeller shaft Assembling the propeller shaft assembly Assembling the propeller shaft housing Drive shaft and lower case (regular rotation model) Removing the drive shaft Disassembling the drive shaft housing Disassembling the forward gear Disassembling the lower case Checking the pinion and forward gear Checking the bearings Checking the drive shaft Checking the lower case Assembling the lower case Assembling the forward gear Assembling the drive shaft housing Installing the drive shaft Installing the propeller shaft housing Installing the water pump and shift rod Installing the lower unit Shimming (regular rotation model) Shimming Selecting the pinion shims Selecting the forward gear shims Selecting the reverse gear shims Backlash (regular rotation model Measuring the forward and reverse gear backlash Lower unit (counter rotation model) Removing the lower unit Removing the water pump and shift rod Checking the water pump and shift rod Propeller shaft housing (counter rotation model) Removing the propeller shaft housing assembly Disassembling the propeller shaft housing Checking the propeller shaft housing Checking the propeller shaft Assembling the propeller shaft housing Drive shaft and lower case (counter rotation model) Removing the drive shaft Disassembling the drive shaft housing Disassembling the reverse gear Disassembling the lower case Checking the pinion and reverse gear Checking the bearings Checking the drive shaft Checking the lower case Assembling the lower case Assembling the drive shaft housing Installing the drive shaft Installing the propeller shaft housing Installing the water pump and shift rod Installing the lower unit Shimming (counter rotation model) Shimming Selecting the pinion shims Selecting the reverse gear shims Selecting the forward gear shims Selecting the propeller shaft shims Backlash (counter rotation model Measuring the forward and reverse gear backlash Bracket unit Special service tools Bottom cowling Upper case, steering arm, swivel bracket, and clamp brackets Disassembling the upper case Checking the upper case Assembling the upper case Removing the steering arm Installing the steering arm Installing the upper case Removing the power trim and tilt unit Removing the clamp brackets Installing the clamp brackets Installing the power trim and tilt unit Adjusting the trim sensor Power trim and tilt unit Disassembling the power trim and tilt motor Checking the power trim and tilt motor Assembling the power trim and tilt motor Checking the hydraulic pressure Disassembling the gear pump Disassembling the relief valve Disassembling the tilt cylinder and trim cylinders Checking the reservoir Checking the tilt cylinder and trim cylinders Checking the valves Checking the filters Checking the gear pump Assembling the relief valve Assembling the gear pump Assembling the tilt ram Assembling the trim rams Installing the tilt cylinder Installing the trim rams Installing the power trim and tilt motor Installing the reservoir Installing the tilt ram Bleeding the power trim and tilt unit Not installed Built-in Power trim and tilt electrical system Checking the fuse Checking the power trim and tilt relay Checking the power trim and tilt switch Checking the trim sensor Electrical systems Special service tools Checking the electrical components Measuring the peak voltage Measuring the lower resistance Electrical components Port view Starboard view Junction box assembly Aft view Top view Wiring harness Ignition and ignition control system Checking the ignition spark gap Checking the spark plug caps Checking the ignition coils Checking the ECM Checking the pulser coil Checking the crank position sensor Checking the crank position sensor air gap Checking the throttle position sensor Checking the intake air temperature sensor Checking the engine temperature sensor Checking the thermoswitches Checking the shift cut switch Checking the shift position switch Checking the ECM main relay Fuel control system Checking the injector drivers Checking the fuel pressure sensor Checking the water detection switch Checking the electric fuel pump Checking the electric fuel pump relay Checking the injector driver relay Starting system Checking the fuses Checking the starter relay Starter motor Removing the starter motor pinion Checking the starter motor pinion Checking the armature Checking the brushes Checking the magnet switch Checking the starter motor operation Charging system Checking the stator coil Checking the Rectifier Regulator Oil feed pump control system Checking the electric oil pump Checking the oil level sensor Checking the emergency switch Checking the oil pump (remote oil tank) Troubleshooting Special service tools Yamaha Diagnostic System Introduction Power unit Self-diagnosis Diagnosing the electronic control system Language: English Format: PDF Pages: 310 If you have a request, dont hesitate to ask us