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20ESHT2
Yamaha 20ESHT2 User Manual
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1995 - 2009
OUTBOARD / MOTEUR HORS-BORD
SERVICE MANUAL / MANUEL D’ATELIER
Model : 20ESHT2, 20ESHU2, 20ESHV2,
20ESHW2, 20ESHX2, 20ESHY2, 20MLH,
20MLHA, 20MLHB, 20MLHC, 20MLHD,
20MLHKZ, 20MLHT2, 20MLHU2, 20MLHV2,
20MLHW, 20MLHW2, 20MLHX, 20MLHX2,
20MLHY, 20MLHY2, 20MLHZ, 20MSH,
20MSHA, 20MSHB, 20MSHC, 20MSHD,
20MSHKZ, 20MSHT2, 20MSHU2,
6L3281977100
*6L3281977100*
2
Table of Contents
1995-2009 YAMAHA 20 25HP 2-STROKE OUTBOARDS
1
PREFACE
58
TABLE OF CONTENTS
76
GENERAL INFORMATION
78
IDENTIFICATION
80
SERIAL NUMBER
80
STARTING SERIAL NUMBERS
80
SAFETY WHILE WORKING
82
FIRE PREVENTION
82
VENTILATION
82
SELF-PROTECTION
82
OILS, GREASES, AND SEALING FLUIDS
82
GOOD WORKING PRACTICES
84
DISASSEMBLY AND ASSEMBLY
86
SPECIAL TOOLS
88
MEASURING
88
REMOVAL AND INSTALLATION
92
SPECIFICATIONS
96
GENERAL SPECIFICATIONS
98
MAINTENANCE SPECIFICATIONS
101
ENGINE
101
LOWER
103
ELECTRICAL
103
DIMENSION
105
TIGHTENING TORQUE
106
GENERAL TORQUE SPECIFICATIONS
106
PERIODIC INSPECTION AND ADJUSTMENT
134
MAINTENANCE INTERVAL CHART
136
PERIODIC SERVICE
140
FUEL SYSTEM
140
Fuel line
140
CONTROL SYSTEM
140
Throttle cable adjustment
140
Start-in-gear protection adjustment
140
Idle speed adjustment
142
Ignition timing adjustment
144
Carburetor link adjustment
146
Neutral opening adjustment
146
OIL INJECTION SYSTEM
146
Oil pump link adjustment
146
LOWER UNIT
148
Gear oil
148
Lower unit leakage check
148
GENERAL
150
Anode
150
Battery
134
Spark plug
152
Grease points
154
FUEL SYSTEM
156
FUEL AND LUBRICATION SYSTEM
158
COMPONENTS
158
FUEL FILTER
160
EXPLODED DIAGRAM
160
REMOVAL AND INSTALLATION CHART
161
SERVICEPOINTS
161
Fuel joint inspection
161
CARBURETOR REMOVAL
168
EXPLODED DIAGRAM
168
REMOVAL AND INSTALLATION CHART
169
CARBURETOR DISASSEMBLY
172
EXPLODED DIAGRAM
172
REMOVAL AND INSTALLATION CHART
173
SERVICE POINTS
180
Carburetor inspection
180
Carburetor assembly
180
FUEL PUMP
182
EXPLODED DIAGRAM
182
REMOVAL AND INSTALLATION CHART
183
OIL TANK
186
EXPLODED DIAGRAM
186
REMOVAL AND INSTALLATION CHART
187
Check valve inspection
187
OIL PUMP
194
EXPLODED DIAGRAM
194
REMOVAL AND INSTALLATION CHART
195
POWER UNIT
198
CONTROL CABLE, LINK AND HOSE.
202
EXPLODED DIAGRAM
202
REMOVAL AND INSTALLATION CHART
203
LEAD WIRE
206
EXPLODED DIAGRAM
206
REMOVAL AND INSTALLATION CHART
206
POWER UNIT
208
EXPLODED DIAGRAM
208
REMOVAL AND INSTALLATION CHART
208
RECOIL STARTER
210
EXPLODED DIAGRAM
210
REMOVAL AND INSTALLATION CHART
211
SERVICE POINTS
218
Sheave drum removal
218
Spiral spring removal
218
Starter rope installation
220
Sheave drum installation
220
Spiral spring setting
220
Recoil starter checking
220
STATOR
222
EXPLODED DIAGRAM
222
REMOVAL AND INSTALLATION CHART
223
SERVICE POINTS
226
Flywheel magneto removal
226
ELECTRICAL UNIT
228
EXPLODED DIAGRAM
228
REMOVAL AND INSTALLATION CHART
228
ELECTRICAL UNIT DISASSEMBLY
230
EXPLODED DIAGRAM
230
REMOVAL AND INSTALLATION CHART
231
CONTROL UNIT
234
EXPLODED DIAGRAM
234
REMOVAL AND INSTALLATION CHART
235
REED VALVE
238
EXPLODED DIAGRAM
238
REMOVAL AND INSTALLATION CHART
239
SERVICE POINTS
239
Reed valve inspection
239
CYLINDER HEAD, THERMOSTAT AND EXHAUST COVER
246
EXPLODED DIAGRAM
246
REMOVAL AND INSTALLATION CHART
247
SERVICE POINTS
254
Cylinder head inspection
254
Thermostat inspection
256
CYLINDER BODY
258
EXPLODED DIAGRAM
258
REMOVAL AND INSTALLATION CHART
259
SERVICE POINTS
266
Piston to cylinder clearance
266
Cylinder body and crankcase installation
268
CRANK SHAFT
270
EXPLODED DIAGRAM
270
REMOVAL AND INSTALLATION CHART
271
SERVICE POINTS
278
Bearing removal
278
Piston inspection
278
Piston pin inspection
278
Piston ring inspection
280
Crankshaft inspection
282
Piston and piston ring installation
282
Crankshaft and piston installation
284
LOWER UNIT
286
LOWER UNIT
288
EXPLODED DIAGRAM
288
REMOVAL AND INSTALLATION CHART
288
WATER PUMP
290
EXPLODED DIAGRAM
290
REMOVAL AND INSTALLATION CHART
291
Propeller shaft housing assembly
298
REVERSE GEAR
300
EXPLODED DIAGRAM
300
REMOVAL AND INSTALLATION CHART
301
SERVICE POINTS
308
Propeller shaft housing removal
308
Propeller shaft housing disassembly
308
Propeller shaft housing assembly
310
FORWARD GEAR
312
EXPLODED DIAGRAM
312
REMOVAL AND INSTALLATION CHART
313
SERVICE POINTS
320
Pinion nut removal
320
Forward gear disassembly
320
Lower case disassembly
320
Lower case assembly
322
Forward gear assembly
324
Pinion nut installation
324
SHIMMING
326
SHIM SELECTION (FOR USA AND CANADA)
326
Pinion gear shim
326
Forward gear shim
328
Reverse gear shim
330
SHIM SELECTION (EXCEPT FOR USA AND CANADA)
330
Pinion gear shim
330
Forward gear shim
332
Reverse gear shim
334
BACKLASH MEASUREMENT
334
Forward gear
336
Reverse gear
338
BRACKET UNIT
342
STEERING BRACKET, SHIFT LEVER AND TILLER HANDLE
344
EXPLODED DIAGRAM
344
REMOVAL AND INSTALLATION CHART
345
BOTTOM COWLING
352
EXPLODED DIAGRAM
352
REMOVAL AND INSTALLATION CHART
352
UPPERCASE
354
EXPLODED DIAGRAM
354
REMOVAL AND INSTALLATION CHART
355
CLAMP BRACKET
362
EXPLODED DIAGRAM
362
REMOVAL AND INSTALLATION CHART
363
SWIVEL BRACKET
366
EXPLODED DIAGRAM
366
REMOVAL AND INSTALLATION
366
STEERING BRACKET DISASSEMBLY
368
EXPLODED DIAGRAM
368
REMOVAL AND INSTALLATION CHART
369
ELECTRICAL SYSTEM
376
ELECTRICAL COMPONENTS
378
ELECTRICAL ANALYSIS
380
INSPECTION
380
Peak voltage measurement
380
IGNITION SYSTEM
382
IGNITION SPARK GAP
384
CDI SYSTEM PEAK VOLTAGE
384
SPARK PLUG
388
SPARK PLUG CAP
388
MAIN SWITCH
390
ENGINE STOP SWITCH
390
STARTING SYSTEM
392
BATTERY
394
FUSE
394
WIRING HARNESS
394
WIRING CONNECTIONS
394
ENGINE STOP SWITCH
394
MAIN SWITCH
394
STARTER SWITCH
394
NEUTRAL SWITCH
394
STARTER RELAY
396
STARTING MOTOR
398
EXPLODED DIAGRAM
398
REMOVAL AND INSTALLATION CHART
399
Pinion inspection
406
Armature inspection
406
Brush holder inspection
406
CHARGING SYSTEM
410
CHARGING SYSTEM PEAK VOLTAGE
410
FUSE
410
BATTERY
410
WARNING SYSTEM
412
THERMO SWITCH
414
OIL LEVEL SENSOR
414
WARNING LAMP
414
TROUBLE-SHOOTING
416
TROUBLE ANALYSIS
418
TROUBLE ANALYSIS CHART
418
SUPPLEMENTARY SERVICE MANUAL
2
PREFACE
2
TABLE OF CONTENTS
4
LOWER UNIT
6
EXPLODED DIAGRAM
6
REMOVAL AND INSTALLATION CHART
6
WATER PUMP AND BEARING HOUSING
8
EXPLODED DIAGRAM
8
REMOVAL AND INSTALLATION CHART
9
Bearing housing assembly
16
REVERSE GEAR
18
EXPLODED DIAGRAM
18
REMOVAL AND INSTALLATION CHART
19
SERVICE POINTS
26
Propeller shaft housing removal
26
Propeller shaft housing disassembly
26
Propeller shaft housing assembly
28
FORWARD GEAR
30
EXPLODED DIAGRAM
30
REMOVAL AND INSTALLATION CHART
31
SERVICE POINTS
38
Pinion nut removal
38
Forward gear disassembly
38
Lower case disassembly
38
Lower case assembly
40
Forward gear assembly
40
Pinion nut installation
40
SHIMMING
42
SHIM SELECTION(FOR USA AND CANADA)
42
Pinion gear shim
42
Forward gear shim
44
Reverse gear shim
46
SHIM SELECTION (EXCEPT FOR USA AND CANADA)
46
Pinion gear shim
46
Forward gear shim
48
Reverse gear shim
50
BACKLASH MEASUREMENT
50
Forward gear
52
Reverse gear
54
5
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Yamaha 20ESHT2 Specifications
General
Brand
Yamaha
Model
20ESHT2
Category
Outboard Motor
Language
English
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