Yamaha Z200Y Service Manual
  1. Manuals
  2. Brands
  3. Yamaha Manuals
  4. Outboard Motor
  5. Z200Y
  6. Service manual
Yamaha Z200Y Service Manual

Yamaha Z200Y Service Manual

Hide thumbs Also See for Z200Y:
Table of Contents

Advertisement

Quick Links

See also: Owner's Manual
SERVICE MANUAL
LIT186160203
LIT-18616-02-10
Z200Y
LZ200Y
68F-28197-Z9-11

Advertisement

Table of Contents
loading

Related Manuals for Yamaha Z200Y

Summary of Contents for Yamaha Z200Y

  • Page 1 Z200Y LZ200Y SERVICE MANUAL LIT186160203 LIT-18616-02-10 68F-28197-Z9-11...
  • Page 2 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.

  • Page 3: How To Use This Manual

    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 refer- ence that contains comprehensive explanations of all disassembly, repair, assembly, and check operations.
  • Page 4 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.
  • Page 5 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.

  • Page 6: General Information

    Symbol F to H in an exploded diagram indicate the grade of lubricant and the loca- tion of the lubrication point. F Apply Yamaha 2-stroke outboard motor oil (TC-W3) G Apply water resistant grease (Yamaha grease A, Yamaha marine grease)

  • Page 7: Table Of Contents

    CONTENTS GENERAL INFORMATION INFO SPECIFICATIONS SPEC PERIODIC INSPECTIONS AND ADJUSTMENTS INSP FUEL SYSTEM FUEL POWER UNIT POWR LOWER UNIT LOWR BRACKET UNIT BRKT – ELECTRICAL SYSTEMS ELEC TROUBLE ANALYSIS TRBL ANLS...
  • Page 8 INFO CHAPTER 1 GENERAL INFORMATION IDENTIFICATION .................... 1-1 SERIAL NUMBER ..................1-1 STARTING SERIAL NUMBERS ............... 1-1 SAFETY WHILE WORKING ................1-2 FIRE PREVENTION ................... 1-2 VENTILATION................... 1-2 SELF-PROTECTION.................. 1-2 OILS, GREASES AND SEALING FLUIDS..........1-2 GOOD WORKING PRACTICES ..............1-3 DISASSEMBLY AND ASSEMBLY ............

  • Page 9: Identification

    IDENTIFICATION INFO IDENTIFICATION 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. 1 Model name 2 Approved model code 3 Transom height...

  • Page 10: Safety While Working

    SAFETY WHILE WORKING INFO SAFETY WHILE WORKING The procedures given in this manual are those recommended by Yamaha to be fol- lowed Yamaha dealers 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.

  • Page 11: Good Working Practices

    SAFETY WHILE WORKING INFO 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 precau- tions is as follows: 1.

  • Page 12: Disassembly And Assembly

    SAFETY WHILE WORKING INFO 3. Non-reusable items Always use new gaskets, packings, O- rings, split-pins, circlips, etc., on reas- sembly. DISASSEMBLY AND ASSEMBLY 1. Clean parts with compressed air when disassembling. 2. Oil the contact surfaces of moving parts before assembly. 3.

  • Page 13: Special Tools

    SPECIAL TOOLS INFO SPECIAL TOOLS Using the correct special tools recom- mended by Yamaha, will aid the work and enable accurate assembly and tune-up. Improvising and using improper tools can damage the equipment. NOTE: • For USA and Canada, use part numbers that start with “J-”, “YB-”, “YM-”, “YS-”,...
  • Page 14 SPECIAL TOOLS INFO 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.
  • Page 15 SPECIAL TOOLS INFO 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 diag- nosis is detected, along with the engine running total hours.

  • Page 16: Removing And Installing

    SPECIAL TOOLS INFO REMOVING AND INSTALLING 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.
  • Page 17 SPECIAL TOOLS INFO 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.
  • Page 18 SPECIAL TOOLS INFO 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.
  • Page 19 SPEC CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS................2-1 MAINTENANCE SPECIFICATIONS..............2-3 POWER UNIT.................... 2-3 LOWER UNIT.................... 2-5 ELECTRICAL ..................... 2-5 DIMENSIONS ................... 2-9 TIGHTENING TORQUES ................2-11 SPECIFIED TORQUES ................2-11 GENERAL TORQUES ................2-13...

  • Page 20: Fuel System

    SPEC GENERAL SPECIFICATIONS GENERAL SPECIFICATIONS Model Worldwide Z200NETO LZ200NETO Item Unit Z200TR LZ200TR Canada Z200TR — DIMENSION Overall length mm (in) 792 (31.2) Overall width mm (in) 554 (21.8) Overall height mm (in) 1,782 (70.2) Boat transom height mm (in) 635 (25.0) WEIGHT (with aluminum propeller)
  • Page 21 SPEC GENERAL SPECIFICATIONS Model Worldwide Z200NETO LZ200NETO Item Unit Z200TR LZ200TR Canada Z200TR — FUEL AND OIL Fuel type Unleaded regular gasoline Fuel rating *PON Engine oil type 2-stroke outboard engine oil Engine oil grade TC-W3 Engine oil capacity (engine oil tank) L (US qt, lmp qt) 0.9 (0.95, 0.79) (sub-oil tank)

  • Page 22: Power Unit

    SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS POWER UNIT Model Worldwide Z200NETO LZ200NETO Item Unit Z200TR LZ200TR Canada Z200TR — CYLINDER HEADS Warpage limit mm (in) 0.1 (0.004) (lines indicate straightedge position) CYLINDERS Bore size mm (in) 90.00 - 90.02 (3.543 - 3.544) Wear limit mm (in) 90.1 (3.55)
  • Page 23 SPEC MAINTENANCE SPECIFICATIONS Model Worldwide Z200NETO LZ200NETO Item Unit Z200TR LZ200TR Canada Z200TR — CONNECTING RODS Small-end axial play mm (in) 2.0 (0.08) limit (F) Big-end side mm (in) 0.12 - 0.26 (0.005 - 0.010) clearance (E) OIL INJECTION PUMP ID mark 68F00 Bleeding...

  • Page 24: Lower Unit

    SPEC MAINTENANCE SPECIFICATIONS LOWER UNIT Model Worldwide Z200NETO LZ200NETO Item Unit Z200TR LZ200TR Canada Z200TR — GEAR BACKLASH Pinion - forward gear mm (in) 0.25 - 0.46 0.21 - 0.43 (0.010 - 0.018) (0.008 - 0.017) Pinion - reverse gear mm (in) 0.74 - 1.29 0.97 - 1.29...
  • Page 25 SPEC MAINTENANCE SPECIFICATIONS Model Worldwide Z200NETO LZ200NETO Item Unit Z200TR LZ200TR Canada Z200TR — IGNITION CONTROL SYSTEM Crank position sensor (G/L) 1.0 ± 0.5 (0.04 ± 0.02) Crank-position-sensor-to- mm (in) flywheel gap Output peak voltage lower limit @ cranking 1 @ cranking 2 @ 1,500 r/min @ 3,500 r/min...
  • Page 26 SPEC MAINTENANCE SPECIFICATIONS Model Worldwide Z200NETO LZ200NETO Item Unit Z200TR LZ200TR Canada Z200TR — Fuel pressure sensor Output voltage (P – B) 2.8 - 3.2 Water detection switch Float position a “ON” mm (in) STARTER MOTOR Type Sliding gear Output Cranking time limit Second Brushes...
  • Page 27 SPEC MAINTENANCE SPECIFICATIONS Model Worldwide Z200NETO LZ200NETO Item Unit Z200TR LZ200TR Canada Z200TR — OIL FEED PUMP CONTROL SYSTEM Oil level sensor (engine oil tank) Float position a mm (in) 3 - 6 (0.12 - 0.24) “OFF” Float position b mm (in) 33 - 36 (1.30 - 1.42) “ON”...
  • Page 28 SPEC MAINTENANCE SPECIFICATIONS DIMENSIONS Symbol Models Worldwide Z200NETO LZ200NETO Unit Z200TR LZ200TR Canada Z200TR — mm (in) 613 (24.1) mm (in) 180 (7.1) mm (in) 646 (25.4) mm (in) 69 (2.7) mm (in) 1,150 (45.3) mm (in) 574 (22.6) mm (in) 1,074 (42.3) mm (in) 708 (27.9)
  • Page 29 SPEC MAINTENANCE SPECIFICATIONS Symbol Models Worldwide Z200NETO LZ200NETO Unit Z200TR LZ200TR Canada Z200TR — mm (in) 125.4 (4.9) mm (in) 254 (10.0) mm (in) 163.5 (6.4) mm (in) 50.8 (2.0) mm (in) 180 (7.1) mm (in) 367 (14.4) mm (in) 18.5 (0.7) mm (in) 82 (3.2)

  • Page 30: Tightening Torques

    SPEC TIGHTENING TORQUES TIGHTENING TORQUES SPECIFIED TORQUES Tightening torques Part to be tightened Thread size m•kgf ft•lb 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...
  • Page 31 SPEC TIGHTENING TORQUES Tightening torques Part to be tightened Thread size m•kgf ft•lb Crankcase Connecting rod LOWER UNIT Propeller Lower unit Ring nut — 14.5 Pinion nut Gear oil drain screw — Gear oil level check screw — BRACKET UNIT Flushing hose Shift rod detent mechanism screw —...

  • Page 32: General Torques

    SPEC TIGHTENING TORQUES GENERAL TORQUES General torque This chart specifies tightening torques for specifications Nut (A) Bolt (B) standard fasteners with a standard ISO m•kgf ft•lb thread pitch. Tightening torque specifica- 8 mm tions for special components or assemblies 10 mm are provided in applicable sections of this 12 mm manual.

  • Page 33: Insp Adj

    INSP 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 ..............3-3 CHECKING THE FUEL FILTER ..............3-4 MEASURING THE FUEL PRESSURE (MEDIUM-PRESSURE FUEL LINE)............
  • Page 34 INSP GENERAL ...................... 3-18 CHECKING THE ANODES..............3-18 CHECKING THE BATTERY..............3-19 CHECKING THE SPARK PLUGS............3-20 LUBRICATION POINTS................3-22...

  • Page 35: Maintenance Interval Chart

    INSP MAINTENANCE INTERVAL CHART MAINTENANCE INTERVAL CHART Use the following chart as a guide to general maintenance intervals. Dependant on operating conditions, adjust the maintenance intervals accordingly. Initial Every Refer to Item Remarks 10 hours 50 hours 100 hours 200 hours page (Break-in) (3 months)

This manual is also suitable for:

Lz200y

Table of Contents