68F-9-19 Hyoshi 06.3.17 1:23 PM ページ 1 Z200 LZ200 OWNER’S MANUAL U.S.A.
68F-9-19 Hyoshi 06.3.17 1:23 PM ページ 2 EMU25071 ZMU01690 Read this owner’s manual carefully before operating your outboard motor.
Important manual information EMU31280 To the owner Thank you for choosing a Yamaha outboard motor. This Owner’s Manual contains information needed for proper operation, maintenance and care. A thorough understanding of these simple instructions will help you obtain maximum enjoyment from your new Yamaha. If you have any question about the operation or maintenance of your outboard motor, please consult a Yamaha dealer.
Table of contents General information .......................... 1 Identification numbers record.......... 1 Outboard motor serial number .......... 1 Key number....................................... 1 Emission control information ........... 1 North American models..................... 1 Star labels ......................................... 2 Safety information ........................... 3 Important labels............................... 4 Warning labels ..................................
Table of contents Filling fuel and engine oil............... 40 Filling fuel for models without a fuel joint ........................................ 40 Ring Free Fuel Additive .................. 40 Filling oil for oil injection models...... 40 Oil level indicator operation............. 42 Operating engine........................... 43 Feeding fuel .................................... 43 Starting engine ................................ 43 Warming up engine .......................
Table of contents Consumer information.................... 83 Important warranty information for U.S.A. and Canada ..................... 83 YAMAHA MOTOR CORPORATION, U.S.A. OUTBOARD MOTOR TWO YEAR LIMITED WARRANTY ...... 85 IMPORTANT WARRANTY INFORMATION IF YOU USE YOUR YAMAHA OUTSIDE THE USA OR CANADA ..............
General information EMU25170 Identification numbers record EMU25183 Outboard motor serial number The outboard motor serial number is stamped on the label attached to the port side of the clamp bracket. Record your outboard motor serial number in the spaces provided to assist you in ordering spare parts from your Yamaha dealer or for reference in case your outboard motor is stolen. 1. Key number EMU25221 Emission control information EMU25230 North American models 1 ZMU04426 1.
General information particular label. 1 ZMU05380 ZMU04745 EMU25262 Manufactured date label This label is attached to the clamp bracket or the swivel bracket. 1. Star labels location EMU25280 One Star—Low Emission The one-star label identifies engines that meet the Air Resources Board’s 2001 exhaust emission standards. Engines meeting these standards have 75% lower emissions than conventional carbureted two-stroke engines. These engines are equivalent to the U.S. EPA’s 2006 standards for marine engines.
General information ● ZMU01703 ● EMU25300 Three Stars—Ultra Low Emission The three-star label identifies engines that meet the Air Resources Board’s 2008 exhaust emission standards. Engines meeting these standards have 65% lower emissions than One Star-Low-Emission engines. ● ● ● ZMU01704 EMU25362 ● Safety information ● ● ● Before mounting or operating the outboard motor, read this entire manual. Reading it should give you an understanding of the motor and its operation.
General information the switch, stopping the engine. Know the marine laws and regulations where you will be boating—and obey them. For basic boating rules, see “Rules of the road” on page 5. ● Stay informed about the weather. Check weather forecasts before boating. Avoid boating in hazardous weather. ● Tell someone where you are going: leave a Float Plan with a responsible person. Be sure to cancel the Float Plan when you return. ● Use common sense and good judgment when boating.
General information EMU25401 EMU25465 Label Caution labels EWM01260 WARNING ● ● ● Be sure shift control is in neutral before starting engine. (except 2HP) Do not touch or remove electrical parts when starting or during operation. Keep hands, hair, and clothes away from flywheel and other rotating parts while engine is running. ZMU04435 EMU25413 Label (counter rotation models) EWM01281 WARNING Use only a counterclockwise rotation propeller with this engine.
General information The rules presented here in your Owner’s Manual are condensed, and have been provided for your convenience only. Consult your local U.S. Coast Guard Auxiliary or Department of Motor Vehicles for a complete set of rules governing the waters in which you will be using your boat. EMU25510 Steering and sailing rules and sound signals Whenever two vessels on the water meet one another, one vessel has the right-ofway; it is called the “stand-on” vessel.
General information way! Both of you should alter course to avoid an accident. You should keep the other vessel on your port (left) side. This rule doesn’t apply if both of you will clear one another if you continue on your set course and speed. course and speed. You must stay out of its way until you are clear of it. Likewise, if another vessel is passing you, you should maintain your speed and direction so that the other vessel can steer itself around you.
General information 3. In a narrow channel, a sailing vessel should not hamper the safe passage of a power-driven vessel which can navigate only in such a channel. Reading buoys and other markers The waters of the United states are marked for safe navigation by the lateral system of buoyage. Simply put, buoys and markers have an arrangement of shapes, colors, numbers and lights to show which side of the buoy a boater should pass on when navigating in a particular direction.
General information ZMU01708 EMU25540 Fueling instructions EWM00010 WARNING GASOLINE AND ITS VAPORS ARE HIGHLY FLAMMABLE AND EXPLOSIVE! ● Do not smoke when refueling, and keep ● ● ● away from sparks, flames, or other sources of ignition. Stop engine before refueling. Refuel in a well-ventilated area. Refuel portable fuel tanks off the boat. Take care not to spill gasoline.
General information ● ● ● ● ● dry rags. Do not overfill the fuel tank. Tighten the filler cap securely after refueling. If you should swallow some gasoline, inhale a lot of gasoline vapor, or get gasoline in your eyes, get immediate medical attention. If any gasoline spills onto your skin, immediately wash with soap and water. Change clothing if gasoline spills on it. Touch the fuel nozzle to the filler opening or funnel to help prevent electrostatic sparks.
General information EMU25711 Battery specifications x Minimum cold cranking amps (CCA/ SAE): 512.0 A Minimum marine cranking amps (MCA/ ABYC): 675.0 A Minimum reserve capacity (RC/SAE): 182 minutes NOTE: The engine cannot be started if battery voltage is too low. 1 2 3 ZMU04608 1. Propeller diameter in inches 2. Propeller pitch in inches 3.
Basic components EMU25799 Main components NOTE: * May not be exactly as shown; also may not be included as standard equipment on all models. Z200, LZ200 11 1 10 9 2 2 12 13 14 8 7 15 6 5 16 17 18 3 4 19 20 ZMU04850 1. Top cowling 2. Top cowling lock lever(s) 3. Trim tab (anode) 4. Propeller* 5. Cooling water inlet 6. Anti-cavitation plate 7. Anode 8. Tilt support lever 9. Flushing device 10. Power trim and tilt switch 11. Water separator 12. Remote control box (side mount type)* 13.
Basic components 1 2 3 4 5 6 ZMU05429 1. Tachometer unit (Square type)* 2. Tachometer unit (Round type)* 3. Speedometer unit (Square type)* 4. Speed & fuel meter unit (Square type)* 5. Speed & fuel meter unit (Round type)* 6. Fuel management meter (Square type)* EMU26180 Remote control The remote control lever actuates both the shifter and the throttle. The electrical switches are mounted on the remote control box. 1. Power trim and tilt switch 2. Remote control lever 3.
Basic components 1 F 2 2 4 6 4 N 1 5 7 3 7 ZMU04569 EMU26190 Remote control lever Moving the lever forward from the neutral position engages forward gear. Pulling the lever back from neutral engages reverse. The engine will continue to run at idle until the lever is moved about 35° (a detent can be felt). Moving the lever farther opens the throttle, and the engine will begin to accelerate. 6 5 2 1. Remote control lever 2. Power trim and tilt switch 3. Free accelerator 4.
Basic components NOTE: The neutral throttle lever will operate only when the remote control lever is in neutral. The remote control lever will operate only when the neutral throttle lever is in the closed position. ● ● used when the remote control lever is in the neutral position. After the button is pushed, the throttle begins to open after the remote control lever is moved at least 35°. After using the free accelerator, return the remote control lever to the neutral position.
Basic components NOTE: The engine cannot be started with the lock plate removed. ZMU04646 When constant speed is desired, tighten the adjuster to maintain the desired throttle setting. EMU25990 Engine stop lanyard switch The lock plate must be attached to the engine stop switch for the engine to run. The lanyard should be attached to a secure place on the operator’s clothing, or arm or leg.
Basic components “ ” (start) With the main switch in the “ ” (start) position, the starter motor turns to start the engine. When the key is released, it returns automatically to the “ ” (on) position. ● EMU26151 Power trim and tilt switch on bottom engine cowling OFF ON START OFF The power trim and tilt switch is located on the side of the bottom engine cowling. Pressing the switch “ ” (up) trims the outboard motor up, then tilts it up.
Basic components ● For instructions on using the power trim and tilt switches, see pages 47 and 49. EMU26241 UP Trim tab with anode The trim tab should be adjusted so that the steering control can be turned to either the right or left by applying the same amount of force. DN EWM00840 ZMU03985 NOTE: For instructions on using the power trim and tilt switch, see page 49.
Basic components 1 ZMU03979 1. Tilt support lever EMU26391 Top cowling lock levers To remove the outboard motor top cowling, pull up the front and rear lock levers. Then lift off the cowling. When the cowling, check to be sure it fits properly in the rubber seal. Then lock the cowling again by moving the levers downward. 1. Trim tab 2. Bolt 3. Cap ECM00550 CAUTION: The air intake grille on the top cowling is not designed as a handle and could break if used as such.
Basic components 1 1 2 2 ZMU04437 1. Air intake grille 2. Top cowling lock lever(s) EMU26460 Flushing device This device is used to clean the cooling water passages of the motor using a garden hose and tap water. NOTE: ZMU05499 Activation of warning device ● The water separator warning indicator will blink. ● The buzzer will sound intermittently only when the gear shift is in neutral. ● If the warning system has activated, stop the engine and consult a Yamaha dealer immediately.
Basic components tarily after the main switch is turned on and will return to normal thereafter. 6 7 1 1 2 3 ZMU04580 4 5 8 9 1. Oil level indicators ZMU01958 EMU26550 1. Tachometer 2. Trim meter 3. Hour meter 4. Oil level indicator 5. Overheat warning indicator 6. Water separator warning indicator 7. Engine trouble warning indicator 8. Set button 9. Mode button Oil level indicator (digital type) This indicator shows the engine oil level.
Basic components turning on the main switch to make sure all segments come on. page 33. ECM00050 CAUTION: Do not continue to run the engine if the overheat warning indicator is on. Serious engine damage will occur. NOTE: The speedometer displays km/h, mph, or knots, according to operator preference. Select the desired unit of measurement by setting the selector switch on the back of the gauge. See the illustration for settings. 1 ZMU01868 1.
Basic components power trim and tilt switch. ● ● EMU26620 Trim meter (digital type) This meter shows the trim angle of your outboard motor. NOTE: ● ● ● ● Memorize the trim angles that work best for your boat under different conditions. Adjust the trim angle to the desired using the power trim and tilt switch. If the trim angle of your motor exceeds the trim operating range, the top segment on the trim meter display will blink.
Basic components EMU26700 Clock Press the “ ” (mode) button repeatedly until the indicator on the face of the gauge points to “ ” (time). To set the clock, be sure the gauge is in the “ ” (time) mode. Press the “ ” (set) button; the hour display will begin blinking. Press the “ ” (mode) button until the desired hour is displayed. Press the “ ” (set) button again, the minute display will begin blinking. Press the “ ” (mode) button until the desired minute is displayed.
Basic components EMU26730 3. Water separator warning indicator (operates only if the sensor has been installed) Low battery voltage warning indicator If battery voltage drops, the display will automatically turn on and begin to blink. ECM00870 CAUTION: Get back to the port soon if a warning device has activated. For charging the battery, consult your Yamaha dealer. NOTE: After the main switch is first turned on, all segments of the display come on as a test.
Basic components port and starboard engines. NOTE: ● The fuel flow meter displays gallons/hour or liters/hour according to operator preference. Select the desired unit of measurement by setting the selector switch on the back of the gauge during installation. ZMU01751 EMU26770 Fuel economy 1. Selector switch ● This gauge displays the distance per liter or gallon when cruising, and is only for reference use by the operator.
Basic components ● ● bottom, engine mounting height, skill of the operator, and individual gasoline formulation (winter or summer fuel and amount of additives). The Yamaha digital speedometer and fuel management meter calculates speed, miles traveled, and fuel economy by water movement at the stern of the boat. This distance can vary greatly from the actual distance traveled because of water currents, sea swells, and the condition of the water speed sensor (partially plugged or damaged).
Basic components age display, total hour/trip hour display, oil level display, water detection warning, engine trouble warning, and periodic maintenance notification. If optional sensors are connected to the unit, cooling water pressure display will be available. For the optional sensor, consult your Yamaha dealer. The tachometer unit is available in round or square types. Check your tachometer unit type. 1 2 ZMU05417 1. Set button 2. Mode button 1 4 5 2 2 1 ZMU05415 3 1. Set button 2.
Basic components Preoperation checks Place the gear shift lever in neutral and turn the main switch to “ ” (on). After all the displays come on and the total hour display comes on, the gauge will change to normal operation. If the buzzer sounds and the water separator warning indicator blinks, consult your Yamaha dealer immediately. NOTE: To stop the buzzer, press the “ “ ” (mode) button.
Basic components ● ous engine damage will occur. Do not continue to operate the engine if a warning device has activated. Consult your Yamaha dealer if the problem cannot be located and corrected. soon and consult a Yamaha dealer immediately. Water separator warning This indicator will blink when water has accumulated in the water separator (fuel filter) while cruising. In such an event, stop the engine immediately and see page 76 of this manual to drain the water from the fuel filter.
Basic components 1 ZMU05427 2 ZMU05432 1. Set button 2. Mode button 1 ZMU05428 3 2 EMU31610 Speed & fuel meter unit This unit shows the boat speed and has the functions of fuel meter, total fuel consumption display, fuel economy display, fuel flow display, and system voltage display. If optional sensors are connected to the unit, trip display, water surface temperature display, depth display, and clock will be available. For the optional sensor, consult your Yamaha dealer.
Basic components 1 2 1 3 ZMU05435 1. Speedometer 2. Fuel meter 3. Multifunction display NOTE: After the main switch is first turned on, all the displays come on as a test. After a few seconds, the gauge will change to normal operation. ZMU05436 1. Set button 2. Mode button 1 3 NOTE: The speed & fuel meter unit shows various kinds of information according to the setting made with the “ ” (set) and “ ” (mode) buttons. For details, see the attached operation manual. 2 2 ZMU05437 1. Speedometer 2.
Basic components ual. EMU31630 Fuel management meter This meter has functions of fuel flow meter, total consumption display, fuel economy display, and remaining fuel display. EMU26801 Warning system ECM00090 CAUTION: Do not continue to operate the engine if a warning device has activated. Consult your Yamaha dealer if the problem cannot be located and corrected. EMU26824 2 1 ZMU05438 1. Set button 2. Mode button 1 Overheat warning (twin engines) This engine has an overheat warning device.
Basic components on the engine not affected by overheating, turn off the main switch of the engine overheating. EMU26846 Oil level warning and oil filter clogging warning ON OFF START Oil injection models This engine has an oil level warning system. If the oil level falls below the lower limit, the warning system will activate. Activation of warning device ● Engine speed will automatically decrease to about 2000 r/min. ● The oil level warning indicator will light or blink.
Basic components ZMU03025 1 ZMU01952 1. Oil filter ON OFF START ON OFF START ZMU04584 If the warning system has been activated, stop the engine and check for the cause. NOTE: The warning for oil filter clogging is similar to the warnings for low oil level and overheating. To make troubleshooting easier, check for engine overheating first, then oil level, and finally oil filter clogging. 1 ZMU03987 1.
Operation EMU26901 Installation ECM00110 CAUTION: Incorrect engine height or obstructions to smooth water flow (such as the design or condition of the boat, or accessories such as transom ladders or depth finder transducers) can create airborne water spray while the boat is cruising. Severe engine damage may result if the motor is operated continuously in the presence of airborne water spray. NOTE: During water testing check the buoyancy of the boat, at rest, with its maximum load.
Operation ● board motor is affected by the boat/motor combination and the desired use. Test runs at different heights can help determine the optimum mounting height. Consult your Yamaha dealer or boat manufacturer for further information on determining the proper mounting height. For instructions on setting the trim angle of the outboard motor, see page 47. EMU27041 Breaking in engine 1.
Operation 4. 5. quarter throttle or less to let the engine cool. Remaining seven hours: Run the engine at any speed. However, avoid operating at full throttle for more than 5 minutes at a time. After the first 10 hours: Operate the engine normally. EMU27103 Preoperation checks EWM00080 WARNING If any item in the preoperation check is not working properly, have it inspected and repaired before operating the outboard motor. Otherwise an accident could occur.
Operation blinks, consult your Yamaha dealer immediately. EMU27120 Oil ● your Yamaha dealer. ECM00560 CAUTION: ● Check to be sure you have plenty of oil for your trip. EMU27130 Controls ● ● ● ● Check throttle, shift, and steering for proper operation before starting the engine. The controls should work smoothly, without binding or unusual free play. Look for loose or damaged connections. Check operation of the starter and stop switches when the outboard motor is in the water.
Operation ZMU03989 EMU27233 Filling fuel and engine oil EMU30320 Filling fuel for models without a fuel joint EWM00060 WARNING Gasoline and its vapors are highly flammable and explosive. Keep away from sparks, cigarettes, flames, or other sources of ignition. 1. 2. 3. Remove the fuel tank cap. Carefully fill the fuel tank. Securely close the cap after filling the tank. Wipe up any spilled fuel.
Operation ZMU01877 NOTE: The oil level lines on the remote oil tank indicate the amount of additional oil that can be added to the tank. The top oil level line indicates approximately 1.9 L (0.5 US gal, 0.4 Imp gal) can be added, and the bottom oil level line indicates approximately 3.8 L (1 US gal, 0.8 Imp gal) can be added. 2. 3. Turn on the main switch. The Yamaha oil injection system will automatically feed oil from the remote oil tank to the engine oil tank. Operate the engine normally.
Operation EMU27321 Oil level indicator operation The various functions of the oil level system are as follows: EMU27381 Oil level indicator Electric start models Oil level warning indicator (digital tachometer) Oil level warning indicator (analog tachometer) Green Engine oil tank more than 300 more than cm3 (0.32 US qt, 0.26 Imp qt) 1500 cm3 (1.6 US qt, 1.31 Imp qt) more than 300 Yellow Red–Yellow– Green Remote oil tank cm3 (0.32 US qt, 0.26 Imp qt) 300 cm3 (0.32 US qt, 0.
Operation EMU27450 Operating engine EMU27482 Feeding fuel EWM00420 WARNING ● ● ● 1. 2. 3. Before starting the engine, make sure that the boat is tightly moored and that you can steer clear of any obstructions. Be sure there are no swimmers in the water near you. When the air vent screw is loosened, gasoline vapor will be released. Gasoline is highly flammable, and its vapors are flammable and explosive.
Operation N OFF ZMU04588 2. Attach the engine stop switch lanyard to a secure place on your clothing, or your arm or leg. Then install the lock plate on the other end of the lanyard into the engine stop switch. EWM00120 WARNING ● ● ● ON START OFF ON START ZMU04589 3. Turn the main switch to “ ” (on). NOTE: Dual engine users: When the main switch is turned on, the buzzer operates for a few seconds then stops automatically. The buzzer also operates if one of the engines stalls.
Operation EMU27670 Warming up engine OFF ON EMU27702 START Electric start and prime start models 1. 2. ZMU01881 After starting the engine, allow it to idle for 3 minutes to warm up. Failure to do so will shorten engine life. Check for a steady flow of water from the cooling water pilot hole. ECM00511 CAUTION: ON START ZMU04590 5. Immediately after the engine starts, release the main switch to return it to “ ” (on).
Operation you. EMU27785 Reverse (automatic reverse lock and power trim and tilt models) ECM00220 CAUTION: EWM00190 To change the boat direction or shifting position from forward to reverse or viceversa, first close the throttle so that the engine idles (or runs at low speeds). EMU27764 Forward (tiller handle and remote control models) Tiller handle models 1. Place the throttle grip in the fully closed position. 2. Move the gear shift lever quickly and firmly from neutral to forward.
Operation switch to “ EMU27820 Stopping engine Before stopping the engine, first let it cool off for a few minutes at idle or low speed. Stopping the engine immediately after operating at high speed is not recommended. EMU27852 Procedure 1. Turn the main switch to “ ” (off). ” (off). EMU27861 Trimming outboard motor The trim angle of the outboard motor helps determine the position of the bow of the boat in the water.
Operation not adjust the trim angle with this switch while the boat is moving. Adjust the outboard motor trim angle using the power trim and tilt switch. 1. Power trim and tilt switch 1 1 ZMU04718 DN UP 1. Trim operating angle EMU27882 Adjusting trim angle Power trim and tilt models ZMU04601 EWM00751 WARNING ● ● ● Be sure all people are clear of the outboard motor when adjusting the tilt angle, also be careful not to pinch any body parts between the drive unit and clamp bracket.
Operation To raise the bow (trim-out), press the switch “ ” (up). To lower the bow (trim-in), press the switch “ ” (down). Make test runs with the trim set to different angles to find the position that works best for your boat and operating conditions. EMU27911 Adjusting boat trim When the boat is on plane, a bow-up attitude results in less drag, greater stability and efficiency. This is generally when the keel line of the boat is up about 3 to 5 degrees.
Operation salt corrosion. N EWM00220 WARNING Be sure all people are clear of the outboard motor when tilting up and down, also be careful not to pinch any body parts between the drive unit and engine bracket. EWM00250 ZMU04588 WARNING Leaking fuel is a fire hazard. If there is a fuel joint on the outboard motor, disconnect the fuel line or close the fuel cock if the engine will be tilted for more than a few minutes. Otherwise fuel may leak. 2. 3.
Operation from marine growth and corrosion which could damage the power trim and tilt mechanism. UP ZMU03995 4. Push the tilt support knob into the clamp bracket or pull the tilt support lever toward you to support the engine. ZMU03997 EMU28055 Procedure for tilting down (power trim and tilt models / power tilt models) 1. ZMU03996 2.
Operation to allow operation in shallow water. EWM00660 WARNING DN UP DN ● ● ZMU01936 Place the gear shift in neutral before setting up for shallow water cruising. Return the outboard motor to its normal position as soon as the boat is back in deeper water. ECM00260 CAUTION: Do not tilt the outboard motor up so that the cooling water inlet on the lower unit is above the surface of the water when setting up for and cruising in shallow water. Otherwise severe damage from overheating can result.
Operation 2. Slightly tilt the outboard motor up to the desired position using the power trim and tilt switch / power tilt switch. water passages with fresh water to prevent them from becoming clogged with salt deposits. NOTE: UP For cooling system flushing instructions, see page 55.
Maintenance EMU31480 Specifications NOTE: “(AL)” stated in the specification data below represents the numerical value for the aluminum propeller installed. Likewise, “(SUS)” represents the value for stainless steel propeller installed and “(PL)” for plastic propeller installed. EMU28218 Dimension: Overall length: 792 mm (31.2 in) Overall width: 554 mm (21.8 in) Overall height X: 1782 mm (70.2 in) Transom height X: 643 mm (25.3 in) Weight (without propeller) X: 216.
Maintenance Hypoid gear oil SAE#90 Gear oil quantity: LZ200TR 870.0 cm3 (29.41 US oz) (30.68 Imp.oz) Z200TR 980.0 cm3 (33.13 US oz) (34.56 Imp.oz) Tightening torque for engine: Spark plug: 25.0 Nm (18.4 ft-lb) (2.55 kgf-m) Propeller nut: 55.0 Nm (40.6 ft-lb) (5.61 kgf-m) ered in the normal running position, use an additional support device to secure it in the tilt position. The outboard motor should be trailered and stored in the normal running position.
Maintenance on the use of chemical goods for storage. EMU28303 Procedure EMU30001 Flushing with the flushing attachment 1. Wash the outboard motor body using fresh water. For further information, see page 59. 2. Fill the fuel tank with fresh fuel and add one ounce of “Yamaha Fuel Conditioner and Stabilizer” (Part No. LUB-FUELC12-00) to each gallon of fuel. NOTE: 1. Flushing attachment 5. The use of “Yamaha Fuel Conditioner and Stabilizer” eliminates the need to drain the fuel system.
Maintenance the fogging hole of the silencer cover, if equipped. When properly done, the engine will smoke excessively and almost stall. 8. Remove the flushing attachment and wipe off any excess water. 9. Install the top cowling and propeller. 10. Drain the cooling water completely out of the motor. Clean the body thoroughly. NOTE: A flushing attachment is available from your Yamaha dealer. LUB-SILCNE-13-00). ECM01401 CAUTION: Do not spray when the engine is running.
Maintenance on.) DO NOT SMOKE when charging or handling batteries. KEEP BATTERIES AND ELECTROLYTIC FLUID OUT OF REACH OF CHILDREN. ● Batteries vary among manufacturers. Therefore the following procedures may not always apply. Consult your battery manufacturer’s instructions. Procedure 1. Disconnect and remove the battery from the boat. Always disconnect the black negative cable first to prevent the risk of shorting. 2. Clean the battery casing and terminals.
Maintenance tion. Water will leak out of the connector instead of cooling the engine, which can cause serious overheating. Be sure the connector is tightened securely on the fitting after flushing the engine. NOTE: ● ● When flushing the engine with the boat in the water, tilting up the outboard motor until it is completely out of the water will achieve better results. For cooling system flushing instructions, see page 55.
Maintenance EMU28522 Maintenance chart Frequency of maintenance operations may be adjusted according to the operating conditions, but the following table gives general guidelines. Refer to the sections in this chapter for explanations of each owner-specific action. NOTE: When operating in salt water, turbid or muddy water, the engine should be flushed with clean water after each use. The “ The “ ” symbol indicates the check-ups which you may carry out yourself.
Maintenance Initial Item Water pump High pressure fuel pump drive belt High pressure fuel pump oil level Actions 10 hours (1 month) Every 50 hours (3 months) 100 hours (6 months) 200 hours (1 year) Inspection / replacement Inspection / replacement Inspection / filling Oil pump Inspection / adjustment Oil tank water drain Inspection / cleaning Spark plug(s) Cleaning / adjustment / replacement EMU28874 Maintenance chart (additional) Every Item Actions 500 hours (2.
Maintenance EMU28931 Greasing Yamaha marine grease (Water resistant grease) Z200, LZ200 ZMU04724 EMU28952 Cleaning and adjusting spark plug sparks, which could lead to explosion or fire. EWM00560 WARNING When removing or installing a spark plug, be careful not to damage the insulator. A damaged insulator could allow external 62 The spark plug is an important engine component and is easy to inspect. The condition of the spark plug can indicate something about the condition of the engine.
Maintenance ple, if the center electrode porcelain is very white, this could indicate an intake air leak or carburetion problem in that cylinder. Do not attempt to diagnose any problems yourself. Instead, take the outboard motor to a Yamaha dealer. You should periodically remove and inspect the spark plug because heat and deposits will cause the spark plug to slowly break down and erode.
Maintenance this procedure. Results may vary depending on whether testing is conducted with the flushing attachment, in a test tank, or with the outboard motor in the water. 1. Start the engine and allow it to warm up fully in neutral until it is running smoothly. NOTE: Correct idling speed inspection is only possible if the engine is fully warmed up. If not warmed up fully, the idle speed will measure higher than normal.
Maintenance ● Check that each connector is engaged securely. 1 2 ZMU03458 ZMU04007 1. Tilt rod 2. Trim rods EMU29120 Exhaust leakage 4. Start the engine and check that no exhaust leaks from the joints between the exhaust cover, cylinder head, and body cylinder. Use the tilt support lever to lock the motor in the up position. Operate the tilt down switch briefly so the motor is supported by the tilt support lever.
Maintenance ● ZMU04156 7. Activate the trim-up switch until the tilt rod is fully extended. Unlock the tilt support lever. the main switch to “ ” (off) and remove the key, and remove the lanyard from the engine stop switch. Turn off the battery cut-off switch if your boat has one. Do not use your hand to hold the propeller when loosening or tightening the propeller nut. Put a wood block between the anti-cavitation plate and the propeller to prevent the propeller from turning. ZMU01896 ZMU03460 8.
Maintenance 5. Propeller 6. Thrust washer 3. Remove the propeller and thrust washer. EMU30670 Installing the Propeller EMU29242 Spline models EWM00770 WARNING ● Check the propeller shaft oil seal for damage. NOTE: If the shear pin equipped: it is designed to break if the propeller hits a hard underwater obstacle to help protect the propeller and drive mechanism. The propeller will then spin freely on the shaft. If this happens, the shear pin must be replaced.
Maintenance 2 1 ZMU01899 NOTE: If the propeller nut does not align with the propeller shaft hole after tightening to the specified torque, tighten the nut further to align it with the hole. 1. Gear oil drain screw 2. Oil level plug NOTE: ● EMU29282 Changing gear oil EWM00800 ● WARNING ● ● Be sure the outboard motor is securely fastened to the transom or a stable stand. You could be severely injured if the outboard motor falls on you.
Maintenance the gear oil drain screw hole. Recommended gear oil: Hypoid gear oil SAE#90 Gear oil quantity: LZ200TR 870.0 cm3 (29.41 US oz) (30.68 Imp.oz) Z200TR 980.0 cm3 (33.13 US oz) (34.56 Imp.oz) anodes on equipped models. Consult a Yamaha dealer for inspection and replacement of internal anodes attached to the power unit. ZMU01901 ZMU01900 6. 7. Put a new gasket on the oil level plug. When the oil begins to flow out of the oil level plug hole, insert and tighten the oil level plug.
Maintenance dling or working near batteries. Antidote (EXTERNAL): ● SKIN - Flush with water. ● EYES - Flush with water for 15 minutes and get immediate medical attention. Antidote (INTERNAL): ● Drink large quantities of water or milk followed by milk of magnesia, beaten egg, or vegetable oil. Get immediate medical attention. Batteries also generate explosive hydrogen gas; therefore, you should always follow these preventive measures: ● Charge batteries in a well-ventilated area.
Maintenance ● when installing the battery and disconnect the black battery cable first when removing it. Otherwise, the electrical parts can be damaged. The electrical contacts of the battery and cables must be clean and properly connected, or the battery will not start the engine. Connect the RED lead to the POSITIVE (+) terminal first. Then connect the BLACK lead to the NEGATIVE (-) terminal. 7 3 4 5 2 1 6 ZMU01942 1. Battery for accessories 2. Battery for starting 3. Large black lead 4.
Maintenance ZMU04679 EMU29400 Coating the boat bottom A clean hull improves boat performance. The boat bottom should be kept as clean of marine growth as possible. If necessary, the boat bottom can be coated with an anti-fouling paint approved for your area to inhibit marine growth. Do not use anti-fouling paint which includes copper or graphite. These paints can cause more rapid engine corrosion.
Trouble Recovery EMU29424 Troubleshooting A problem in the fuel, compression, or ignition systems can cause poor starting, loss of power, or other problems. This section describes basic checks and possible remedies, and covers all Yamaha outboard motors. Therefore some items may not apply to your model. If your outboard motor requires repair, bring it to your Yamaha dealer. If the engine trouble warning indicator is flashing, consult your Yamaha dealer. Starter will not operate. Q.
Trouble Recovery Q. Is fuel system obstructed? A. Check for pinched or kinked fuel line or other obstructions in fuel system. Q. Is fuel contaminated or stale? A. Fill tank with clean, fresh fuel. Q. Is fuel filter clogged? A. Clean or replace filter. Q. Have ignition parts failed? A. Have serviced by a Yamaha dealer. Q. Has warning system activated? A. Find and correct cause of warning. Q. Is spark plug gap incorrect? A. Inspect and adjust as specified. Q. Is ignition wiring damaged or poorly connected? A.
Trouble Recovery A. Have serviced by a Yamaha dealer. Q. Is load on boat improperly distributed? A. Distribute load to place boat on an even plane. Q. Are weeds or other foreign matter tangled on gear housing? A. Remove foreign matter and clean lower unit. Q. Is water pump or thermostat faulty? A. Have serviced by a Yamaha dealer. Q. Is fuel system obstructed? A. Check for pinched or kinked fuel line or other obstructions in fuel system. Q. Is there excess water in fuel filter cup? A. Drain filter cup.
Trouble Recovery Q. Is fuel joint connection incorrect? A. Connect correctly. Q. Is heat range of spark plug incorrect? A. Inspect spark plug and replace it with recommended type. damaged by a collision while operating or trailering. Damage could make the outboard motor unsafe to operate. If the outboard motor hits an object in the water, follow the procedure below. Q. Is high pressure fuel pump drive belt broken? A. Have serviced by a Yamaha dealer. Q.
Trouble Recovery 4 3 3 2 5 1 EMU29492 Replacing fuse If the fuse has blown on an electric start model, open the fuse box and use a fuse puller to replace the fuse with a spare one of the proper amperage. 4 ZMU04009 1. Electrical cover 2. Fuse holder 3. Fuse (20 A × 3, 30 A, 80 A × 2) 4. Spare fuse (20 A, 30 A, 80 A) 5. Fuse puller EWM00630 WARNING 1 Be sure to use the specified fuse. An incorrect fuse or a piece of wire could allow excessive current flow.
Trouble Recovery 1 ZMU05018 1. Manual valve screw 2. Put the engine in the desired position, then tighten the manual valve screw by turning it clockwise. 1. Water separator warning indicator 1. 2. 3. EMU31780 Water separator warning indicator blinks while cruising EWM01500 WARNING Gasoline is highly flammable, and its vapors are flammable and explosive. ● Do not perform this procedure on a hot or running engine. Allow the engine to cool. ● There will be fuel in the fuel filter.
Trouble Recovery mains off. NOTE: Have a Yamaha dealer inspect the outboard motor after returning to port. EMU29541 1 Starter will not operate 2 ZMU05501 1. Filter cup 2. Water detection switch lead 5. Drain the water in the filter cup by soaking it up with a rag. If the starter mechanism does not operate (the engine cannot be cranked with the starter), the engine can be started manually with an emergency starter rope. However, the engine cannot be started manually if the battery voltage is low.
Trouble Recovery ● ● ● boat to be thrown forward. Make sure no one is standing behind you when pulling the starter rope. It could whip behind you and injure someone. An unguarded, rotating flywheel is very dangerous. Keep loose clothing and other objects away when starting the engine. Use the emergency starter rope only as instructed. Do not touch the flywheel or other moving parts when the engine is running. Do not install the starter mechanism or top cowling after the engine is running.
Trouble Recovery gine is running. OFF ON START ZMU01906 ZMU04444 3. EMU29670 Engine fails to operate Lift the emergency switch to pump reserve oil into the engine oil tank from the remote oil tank. EMU29741 Low oil level warning activates If the oil level is allowed to drop too low, the red segment will appear on the oil level indicator, the buzzer will sound, and engine speed will be limited to about 2000 r/min.
Trouble Recovery mal operation. The yellow segment will continue to be displayed on the oil level indicator. Start the engine and return to the nearest port for more oil. 5. NOTE: ● ● The maximum reserve oil capacity is 1500 cm3 (1.6 US qt, 1.31 Imp qt). The oil-feed pump will not operate if the engine is tilted up more than 35°. Put the engine in the upright position (not tilted) before using the emergency switch. ZMU01910 3. 4.
Consumer information EMU29811 Important warranty information for U.S.A.
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Consumer information EMU29820 YAMAHA MOTOR CORPORATION, U.S.A.
Consumer information 86
Consumer information 87
Consumer information EMU29841 IMPORTANT WARRANTY INFORMATION IF YOU USE YOUR YAMAHA OUTSIDE THE USA OR CANADA 88
68F-9-19 Hyoshi 06.3.
68F-9-19 Hyoshi 06.3.17 1:23 PM ページ 4 Printed in Japan May 2006–0.
Warranty card-04 2/17/03 2:41 PM Page 1 OUTBOARD MOTOR WARRANTY REGISTRATION ENREGISTREMENT DE LA GARANTIE DU MOTEUR HORS-BORD Please complete and mail this card. This information is necessary to accurately register your unit for warranty. Veuillez signer ci-dessous pour attester que le montage et l’inspection ont été faits dans le respect des directives d’inspection et que la marche à suivre pour la garantie et l’entretien a été expliquée à l’acheteur au détail.
Warranty card-04 2/17/03 2:41 PM Page 2 PLACE POSTAGE HERE ATTN: WARRANTY DEPARTMENT
