How to Rebuild a Yamaha F255 Outboard Part 1: Electrical & Fuel System Removal

After removing the motor from a Yamaha F225TXRC outboard, the next step is to strip it down before rebuilding it. 

This guide is a companion to our Yamaha F225TXRC Outboard Rebuild Part 1 video above. The video shows you how to remove the following components:

  • Wiring harness
  • Fuel system
  • Vapor separator tank
  • Starter motor
  • Throttle bodies
  • Ignition coils
  • Flywheel

Watch the Yamaha F225TXRC Outboard Rebuild: Part 1 video above to get familiar with what you'll be doing, and use this guide as a checklist as you work through each step. View our Yamaha F225TXRC exploded parts diagrams to see how all the components come apart and fit back together again.

Yamaha F225TXRC outboard rebuild

Tools Needed -  Yamaha F225 Electrical and Fuel System Removal 

  • Ratchet and extensions
  • Socket set
  • Pliers
  • Flywheel puller
  • Impact driver
  • Impact wrench
  • Zip-lock bags

 

PRO TIP: Collect the nuts, bolts, screws, washers, etc. from each component as you remove them, then put them in a zip-lock bag and label it. It'll be much easier to find the correct part for the correct component when the time comes to reassemble the motor.

Removing the Electrical & Fuel Systems From a Yamaha F225TXRC

NOTE: Although an impact wrench is fine for disassembling an outboard, it should never be used to reassemble one, as it is too powerful and will easily strip threads or shear bolts. 

Step 1: Take pictures of the motor from all angles to document all the different connections and couplings, so you can reference the pictures when reassembling the outboard. 

PRO TIP: Continue taking photos of the motor as you disassemble the various components, because some connectors and fastenings are only visible once other parts are removed.

 Yamaha F225 outboard rebuild

Step 2: Remove the wiring harness. Work around the motor and disconnect the electrical connectors, trying to keep the wiring harness in one piece as much as possible. 

NOTE: Be careful with the harness' connectors because if you break one, you may have to replace a large part or all of the wiring harness.

Yamaha F225 outboard wiring harness removal

Watch the clip below to see the wiring harness removal segment of our Yamaha F225TXRC electrical & fuel systems strip-down video.

Step 3: Remove the vapor separator tank. The VST can be removed with the various hoses still attached to it. Don't forget to disconnect the water line that attaches to the fuel cooler.

Yamaha F225TXRC electrical system

Watch the clip below to see the VST removal segment of our Yamaha F225TXRC electrical & fuel systems strip-down video.

Step 4: Remove the starter motor.

Yamaha outboard starter motor removal

Watch the clip below to see the starter motor removal segment of our Yamaha F225TXRC electrical & fuel systems strip-down video.

Step 5: Remove the throttle bodies. Disconnect the throttle linkage that connects the two throttle bodies and unbolt the bodies from the crankcase.

Yamaha F225 outboard throttle bodies

Watch the clip below to see the throttle body removal segment of our Yamaha F225TXRC electrical & fuel systems strip-down video.

Step 6: Remove the ignition coils. Remove the entire ignition coil bracket complete with the three ignition coil assemblies.

Yamaha F225 outboard motor ignition coils

Watch the clip below for the ignition coils removal segment of our Yamaha F225TXRC electrical & fuel systems strip-down video.

Step 7: Remove the flywheel. Make sure the three bolts in the flywheel puller are set at the same distance down, so the flywheel is pulled up evenly and doesn't twist or warp.

Yamaha outboard engine flywheel

Watch the clip below to see the flywheel removal segment of our Yamaha F225TXRC electrical & fuel systems strip-down video.

Step 8: Remove the stator assembly. Use an impact driver to loosen the screws without rounding off the heads.

Yamaha F225 outboard stator removal

Watch the clip below to see the stator assembly removal segment of our Yamaha F225TXRC electrical & fuel systems video.

The first stage of disassembling your Yamaha F225 outboard is complete.

Next is the powerhead teardown. Watch the video below to see how to tear down the top end of the powerhead.

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