Z200Y LZ200Y SERVICE MANUAL LIT186160203 LIT-18616-02-10 68F-28197-Z9-11
E PREFACE This manual has been prepared by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers and their trained mechanics when performing maintenance procedures and repairs to Yamaha equipment. It has been written to suit the needs of persons who have a basic understanding of the mechanical and electrical concepts and procedures inherent in the work, for without such knowledge attempted repairs or service to the equipment could render it unsafe or unfit for use.
E HOW TO USE THIS MANUAL MANUAL FORMAT All of the procedures in this manual are organized in a sequential, step-by-step format. The information has been compiled to provide the mechanic with an easy to read, handy reference that contains comprehensive explanations of all disassembly, repair, assembly, and check operations. In this revised format, the condition of a faulty component will precede an arrow symbol and the course of action required will follow the symbol, e.g.
E IMPORTANT INFORMATION In this Service Manual particularly important information is distinguished in the following ways. The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! WARNING Failure to follow WARNING instructions could result in severe injury or death to the machine operator, a bystander, or a person inspecting or repairing the outboard motor. CAUTION: A CAUTION indicates special precautions that must be taken to avoid damage to the outboard motor.
E HOW TO USE THIS MANUAL 1 The main points regarding removing/installing and disassembling/assembling procedures are shown in the exploded views. 2 The numbers in the exploded views indicate the required sequence of the procedure and should be observed accordingly. 3 Symbols are used in the exploded views to indicate important aspects of the procedure. A list of meanings for these symbols is provided on the following page.
E 1 SYMBOLS 2 GEN INFO Symbols 1 to 9 are designed as thumbtabs to indicate the content of a chapter. SPEC 3 1 2 3 4 5 6 7 8 9 4 INSP ADJ FUEL 5 6 LOWR POWR 7 General information Specifications Periodic inspections and adjustments Fuel system Power unit Lower unit Bracket unit Electrical systems Trouble analysis 8 BRKT – ELEC 9 Symbols 0 to E indicate specific data.
E CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC INSPECTIONS AND ADJUSTMENTS FUEL SYSTEM POWER UNIT LOWER UNIT BRACKET UNIT GEN INFO SPEC INSP ADJ FUEL POWR LOWR BRKT – ELECTRICAL SYSTEMS TROUBLE ANALYSIS + ELEC TRBL ANLS 1 2 3 4 5 6 7 8 9
GEN INFO E CHAPTER 1 GENERAL INFORMATION IDENTIFICATION ............................................................................................ 1-1 SERIAL NUMBER ..................................................................................... 1-1 STARTING SERIAL NUMBERS ............................................................... 1-1 SAFETY WHILE WORKING ............................................................................ 1-2 FIRE PREVENTION ...........................................
GEN INFO IDENTIFICATION E IDENTIFICATION 1 SERIAL NUMBER The outboard motor’s serial number is stamped on a label which is attached to the port side of the clamp bracket. NOTE: If the serial number label is removed, “VOID” marks will be appear on the label.
GEN INFO SAFETY WHILE WORKING SAFETY WHILE WORKING E 1 The procedures given in this manual are those recommended by Yamaha to be followed by Yamaha dealers and their mechanics. FIRE PREVENTION Gasoline (petrol) is highly flammable. Petroleum vapor is explosive if ignited. Do not smoke while handling gasoline and keep it away from heat, sparks and open flames. VENTILATION Petroleum vapor is heavier than air and is deadly if inhaled in large quantities. Engine exhaust gases are harmful to breathe.
GEN INFO SAFETY WHILE WORKING E Under normal conditions of use, there should be no hazards from the use of the lubricants mentioned in this manual, but safety is all-important, and by adopting good safety practices, any risk is minimized. A summary of the most important precautions is as follows: 1. While working, maintain good standards of personal and industrial hygiene. 2. Clothing which has become contaminated with lubricants should be changed as soon as practicable, and laundered before further use.
GEN INFO SAFETY WHILE WORKING E 3. Non-reusable items Always use new gaskets, packings, Orings, split-pins, circlips, etc., on reassembly. DISASSEMBLY AND ASSEMBLY 1. Clean parts with compressed air when disassembling. 2. Oil the contact surfaces of moving parts before assembly. 3. After assembly, check that moving parts operate normally. 4. Install bearings with the manufacturer’s markings on the side exposed to view, and liberally oil the bearings. 5.
GEN INFO SPECIAL TOOLS E SPECIAL TOOLS 1 Using the correct special tools recommended by Yamaha, will aid the work and enable accurate assembly and tune-up. Improvising and using improper tools can damage the equipment. 1 a NOTE: • For USA and Canada, use part numbers that start with “J-”, “YB-”, “YM-”, “YS-”, “YU-” or “YW-”. • For worldwide, use part numbers that start with “90890-”. b MEASURING 2 3 4 5 6 a 7 1 Tachometer P/N. YU-08036-A ............................ 90890-06760 ............
GEN INFO SPECIAL TOOLS A B C D E F G H I a a a E A Magnetic base P/N. YU-34481 90890-06705 B Magnetic base attaching plate P/N. YB-07003 90890-07003 C Backlash indicator P/N. YB-06265 90890-06706 D Dial gauge set P/N. YU-03097 90890-01252 E Hydraulic pressure gauge P/N. 90890-06776 F Up-relief valve attachment P/N. 90890-06773 Down-relief valve attachment P/N. 90890-06774 G Digital tester P/N. J-39299 ................................... 90890-06752 ...........................
GEN INFO SPECIAL TOOLS E L Diagnostic unit Check the engine condition by using a personal computer when it is connected to the Electronic Control Unit (ECU). Diagnosis: Indicates the name of a failed part. Diagnosis record: Displays the name of the part whose diagnosis is detected, along with the engine running total hours. Static test: Checks operation sound and ignition sparks by activating the electric fuel pump, electric oil pump, injector and spark plug while the engine is stopped.
GEN INFO SPECIAL TOOLS E REMOVING AND INSTALLING 1 2 a b a b a b a b a b 1 Flywheel magnet assembly holder P/N. YB-06139 ................................ a 90890-06522 ........................... b 2 Universal puller P/N. YB-06117 ................................ a 90890-06521 ........................... b 3 Bearing/oil seal attachment P/N. YB-06205 ................................ a 90890-06663 ........................... b 4 Piston ring compressor P/N. YU-33294 .............................
GEN INFO B a SPECIAL TOOLS E B Propeller shaft housing puller P/N. YB-06207 ................................ a 90890-06502 ........................... b C Center bolt P/N. 90890-06504 D Slide hammer P/N. YB-06096 90890-06531 E Drive shaft holder P/N. YB-06201 90890-06520 F Pinion nut holder P/N. 90890-06505 G Pinion nut holder attachment P/N. 90890-06508 H Bearing puller P/N. YB-06029, YB-06247 90890-06523 I Large universal claws P/N. 90890-06532 J Driver rod P/N.
GEN INFO SPECIAL TOOLS S T U V W X Y Z E S Bearing/oil seal attachment P/N. 90890-06637 T Bearing/oil seal attachment P/N. 90890-06659, 90890-06660, 90890-06661, 90890-06662 U Slide hammer attachment P/N. YB-06335 90890-06514 V End screw wrench P/N. YB-06548 90890-06548 W End screw wrench P/N. YB-06175-1A X Universal holder P/N. YU-01235 90890-01235 Y Sheave holder P/N. YS-1880-A 90890-01701 Z Universal puller P/N.
SPEC E CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS.......................................................................... 2-1 MAINTENANCE SPECIFICATIONS................................................................ 2-3 POWER UNIT............................................................................................ 2-3 LOWER UNIT............................................................................................ 2-5 ELECTRICAL .........................................................
SPEC GENERAL SPECIFICATIONS E GENERAL SPECIFICATIONS 2 Model Item Worldwide USA Canada DIMENSION Overall length Overall width Overall height (X) Boat transom height (X) WEIGHT (with aluminum propeller) (X) (with stainless steel propeller) (X) PERFORMANCE Maximum output (ISO) Full throttle operating range Maximum fuel consumption POWER UNIT Type Number of cylinders Displacement Bore × stroke Compression ratio Fuel system Fuel injection system Intake system Induction system Starting system Ignition co
SPEC GENERAL SPECIFICATIONS E Model Item Worldwide USA Canada FUEL AND OIL Fuel type Fuel rating Engine oil type Engine oil grade Engine oil capacity (engine oil tank) (sub-oil tank) Gear oil type Gear oil total quantity BRACKET Trim angle (at 12˚ boat transom) Tilt-up angle Steering angle DRIVE UNIT Gear shift positions Gear ratio Reduction gear type Clutch type Propeller shaft type Propeller direction (rear view) Propeller mark ELECTRICAL Battery capacity Minimum cold cranking performance Z200NETO Z
SPEC MAINTENANCE SPECIFICATIONS E MAINTENANCE SPECIFICATIONS 2 POWER UNIT Model Item Worldwide USA Canada CYLINDER HEADS Warpage limit (lines indicate straightedge position) CYLINDERS Bore size Wear limit Taper limit Out-of-round limit PISTONS Piston diameter (D) Measuring point (H) Piston-to-cylinder clearance Oversize piston diameter 1st 2nd PISTON RINGS Type (B) (T) End gap (installed) Side clearance CRANKSHAFT Runout limit Z200NETO Z200TR Z200TR Unit LZ200NETO LZ200TR — mm (i
SPEC MAINTENANCE SPECIFICATIONS E Model Worldwide USA Canada CONNECTING RODS Small-end axial play limit (F) Big-end side clearance (E) OIL INJECTION PUMP ID mark Bleeding REED VALVES Reed valve stopper height a Item Z200NETO Z200TR Z200TR Unit LZ200NETO LZ200TR — mm (in) 2.0 (0.08) mm (in) 0.12 - 0.26 (0.005 - 0.010) 68F00 Screw type mm (in) 9.0 ± 0.35 (0.35 ± 0.01) Warpage limit b THERMOSTATS Opening temperature Full-open temperature mm (in) 0.2 (0.
SPEC MAINTENANCE SPECIFICATIONS E LOWER UNIT Model Item Worldwide USA Canada Z200NETO Z200TR Z200TR Unit GEAR BACKLASH Pinion - forward gear mm (in) Pinion - reverse gear mm (in) Pinion shims Forward gear shims Reverse gear shims mm mm mm LZ200NETO LZ200TR — 0.25 - 0.46 0.21 - 0.43 (0.010 - 0.018) (0.008 - 0.017) 0.74 - 1.29 0.97 - 1.29 (0.029 - 0.051) (0.038 - 0.051) 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.
SPEC MAINTENANCE SPECIFICATIONS E Model Worldwide USA Canada IGNITION CONTROL SYSTEM Crank position sensor (G/L) Crank-position-sensor-toflywheel gap Output peak voltage lower limit @ cranking 1 @ cranking 2 @ 1,500 r/min @ 3,500 r/min Engine cooling water temperature sensor Resistance (B/Y – B/Y) @ 5˚C (41˚F) @ 20˚C (68˚F) @ 100˚C (212˚F) Throttle position sensor Input voltage (O – R) Output voltage (P – O) Thermo switch (P – B) OFF → ON ON → OFF FUEL CONTROL SYSTEM Oxygen density sensor Heater resistan
SPEC MAINTENANCE SPECIFICATIONS E Model Worldwide USA Canada Fuel pressure sensor Output voltage (P – B) Water detection switch Float position a “ON” Item Z200NETO Z200TR Z200TR Unit LZ200NETO LZ200TR — V 2.8 - 3.2 mm (in) 47 kW Second Sliding gear 1.4 30 mm (in) mm (in) 15.5 (0.61) 9.5 (0.37) mm (in) mm (in) 29.0 (1.14) 28.0 (1.10) mm (in) mm (in) 0.5 - 0.8 (0.02 - 0.03) 0.2 (0.01) V V V V — 7.5 12.7 12.7 V V V V 7.5 8.
SPEC MAINTENANCE SPECIFICATIONS E Model Worldwide USA Canada OIL FEED PUMP CONTROL SYSTEM Oil level sensor (engine oil tank) Float position a “OFF” Float position b “ON” Float position c “ON” Oil level switch (sub-oil tank) Float position d “ON” POWER TRIM AND TILT SYSTEM Trim sensor Setting resistance Resistance (P – B) Resistance (O – B) POWER TRIM AND TILT MOTOR Fluid type Brushes Standard length Wear limit Commutator Standard diameter Wear limit Mica Standard undercut Wear limit Item Z200NETO Z200TR
SPEC MAINTENANCE SPECIFICATIONS E DIMENSIONS L7 L6 L2 H9 L1 W5 H2 W1 H7 H4 H1 H6 H3 L5 L4 Symbol Worldwide USA Canada L1 L2 L4 L5 L6 L7 H1 H2 H3 H4 H6 H7 H9 W1 W5 Models Unit mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) 2-9 Z200NETO Z200TR Z200TR LZ200NETO LZ200TR — 613 (24.1) 180 (7.1) 646 (25.4) 69 (2.7) 1,150 (45.3) 574 (22.6) 1,074 (42.3) 708 (27.9) 211 (8.3) 643 (25.3) 850 (33.4) 308 (12.1) 835 (32.
SPEC MAINTENANCE SPECIFICATIONS Symbol Worldwide USA Canada B1 B2 B3 B4 B5 B6 B9 C3 D1 D2 Unit mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) 2-10 E Models Z200NETO LZ200NETO Z200TR LZ200TR Z200TR — 125.4 (4.9) 254 (10.0) 163.5 (6.4) 50.8 (2.0) 180 (7.1) 367 (14.4) 18.5 (0.7) 82 (3.2) 13 (0.5) 55.5 (2.
SPEC TIGHTENING TORQUES E TIGHTENING TORQUES 2 SPECIFIED TORQUES Part to be tightened POWER UNIT Intake silencer Electric oil pump Fuel injection unit Atmospheric pressure sensor Electric oil pump bracket Throttle position sensor Intake air temperature sensor Drive belt tensioner Mechanical fuel pump Fuel rail Fuel injector cap Fuel filter nut holder Oil pump Emergency switch Flywheel magnet assembly Negative battery lead Positive battery lead Apron Power unit mount Starter relay holder Oxygen density
SPEC TIGHTENING TORQUES Part to be tightened Crankcase Connecting rod 19 37 Tightening torques m•kgf 1.0 1.8 2.0 4.0 1.9 3.7 * 1.9 3.7 M18 M10 — M22 — — 55 40 145 95 7 7 5.5 4.0 14.5 9.5 0.7 0.7 40 29 105 68 5.1 5.1 M5 — M12 M14 M8 M8 M8 M8 M22 M6 — 5 24 53 73 21 18 18 18 15 2 37 0.5 2.4 5.3 7.3 2.1 1.8 1.8 1.8 1.5 0.2 3.7 3.6 17 38 53 15 13 13 13 11 1.4 27 — 1/4” 1/4” — — 5/16” — — 8 5 5 4 130 9 6 80 0.8 0.5 0.5 0.4 13 0.9 0.6 8.0 5.8 3.6 3.6 2.9 94 6.5 4.
SPEC TIGHTENING TORQUES Nut (A) Bolt (B) 8 mm 10 mm 12 mm 14 mm 17 mm M5 M6 M8 M10 M12 E GENERAL TORQUES General torque specifications Nm m•kgf ft•lb 5 0.5 3.6 8 0.8 5.8 18 1.8 13 36 3.6 25 43 4.3 31 This chart specifies tightening torques for standard fasteners with a standard ISO thread pitch. Tightening torque specifications for special components or assemblies are provided in applicable sections of this manual.
INSP ADJ E CHAPTER 3 PERIODIC INSPECTIONS AND ADJUSTMENTS MAINTENANCE INTERVAL CHART .............................................................. 3-1 TOP COWLING ............................................................................................... 3-3 CHECKING THE TOP COWLING FIT ....................................................... 3-3 FUEL SYSTEM ................................................................................................ 3-3 CHECKING THE FUEL LINE .....................
INSP ADJ GENERAL ...................................................................................................... 3-18 CHECKING THE ANODES...................................................................... 3-18 CHECKING THE BATTERY..................................................................... 3-19 CHECKING THE SPARK PLUGS............................................................ 3-20 LUBRICATION POINTS..........................................................................
INSP ADJ MAINTENANCE INTERVAL CHART E MAINTENANCE INTERVAL CHART 3 Use the following chart as a guide to general maintenance intervals. Dependant on operating conditions, adjust the maintenance intervals accordingly.
