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150A, 150F,
L150F, D150H,
175D, 200F,
L200F, 200G,
225D
SERVICE
MANUAL
64C-28197-Z8-11

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Summary of Contents for Yamaha 150A

  • Page 1 150A, 150F, L150F, D150H, 175D, 200F, L200F, 200G, 225D SERVICE MANUAL 64C-28197-Z8-11...
  • 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 inspection operations.
  • Page 4: Important Information

    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 9 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 10: Identification

    IDENTIFICATION INFO IDENTIFICATION SERIAL NUMBER The outboard motor’s serial number is stamped on a label which is attached to the port clamp bracket. NOTE: As an antitheft measure, a special label on which the outboard motor’s serial number S67H1010 is stamped is bonded to the port clamp bracket.
  • Page 11: 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 12: 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 13: 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. 1080 DISASSEMBLY AND ASSEMBLY 1. Clean parts with compressed air when disassembling. 2. Oil the contact surfaces of moving parts before assembly.
  • Page 14: 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 U.S.A. and Canada, use part numbers that start with “J-”, “YB-”, “YM-”, “YU-”...
  • Page 15 SPECIAL TOOLS INFO B Digital tester P/N. J-39299 90890-06752 C Peak voltage adapter P/N. YU-39991 ........ a 90890-03169 ......b D Spark gap tester P/N. YM-34487 ....... a 90890-06754 ......b E Diagnostic indicator P/N. YB-06765 90890-06765 F Shimming gauge P/N.
  • 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-06196 ........ a 90890-06610, 90890-06637 ..b 4 Driver rod P/N.
  • Page 17 SPECIAL TOOLS INFO A Bearing puller P/N. 90890-06535 B Bearing/oil seal attachment P/N. 90890-06659, 90890-06660, 90890-06661, 90890-06662 C Ring nut wrench P/N. YB-34447 90890-06512 D Ring nut wrench extension P/N. YB-06513 90890-06513 E Propeller shaft housing puller P/N. YB-06207 ........ a YB-06502 ........
  • Page 18 SPECIAL TOOLS INFO P Slide hammer attachment P/N. YB-06335 90890-06514 Q Ring nut wrench P/N. YB-42223 R Bearing/oil seal attachment P/N. YB-42225 S Bearing/oil seal attachment P/N. YB-42227 T Bearing/oil seal attachment P/N. YB-42229 90890-06607 U Pinion nut holder P/N. YB-42224 V End screw wrench P/N.
  • Page 19 SPEC CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS................2-1 MAINTENANCE SPECIFICATIONS..............2-7 POWER UNIT.................... 2-7 LOWER UNIT..................2-12 ELECTRICAL ................... 2-13 DIMENSIONS ..................2-16 TIGHTENING TORQUES ................2-18 SPECIFIED TORQUES ................2-18 GENERAL TORQUES ................2-20...
  • Page 20: Power Unit

    SPEC GENERAL SPECIFICATIONS GENERAL SPECIFICATIONS Model Worldwide 150AET L150AET 175AET 200AET L200AET Item Unit C150TR — — — — Canada — — — — — DIMENSION Overall length mm (in) 828 (32.6) Overall width mm (in) 600 (23.6) Overall height mm (in) 1,577 (62.1) —...
  • Page 21 SPEC GENERAL SPECIFICATIONS Model Worldwide 150AET L150AET 175AET 200AET L200AET Item Unit C150TR — — — — Canada — — — — — Ignition system Starting system Electric Advance type Mechanical FUEL AND OIL Fuel type Unleaded regular gasoline Fuel rating *PON Engine oil type 2-stroke outboard engine oil...
  • Page 22 SPEC GENERAL SPECIFICATIONS Model Worldwide 150FETO L150FETO 150GETO 175DETO D150HETO Item Unit — S150TR — L150TR P150TR D150TR — S175TR Canada — — — — P150TR — — — DIMENSION Overall length mm (in) 823 (32.4) 823 (32.4) (35.3) Overall width mm (in) 577 (22.7) Overall height...
  • Page 23 SPEC GENERAL SPECIFICATIONS Model Worldwide 150FETO L150FETO 150GETO 175DETO D150HETO Item Unit — S150TR — L150TR P150TR D150TR — S175TR Canada — — — — P150TR — — — Cooling system Water Ignition system Microcomputer (CDI) Starting system Electric Advance type Mechanical and microcomputer FUEL AND OIL Fuel type...
  • Page 24 SPEC GENERAL SPECIFICATIONS Model Worldwide 175FETO 200FETO L200FETO 200GETO 225DET 225DETO Item Unit P175TR 200TR S200TR — L200TR P200TR — — Canada P175TR — S200TR — — P200TR — — DIMENSION Overall length mm (in) 823 (32.4) Overall width mm (in) 577 (22.7) Overall height mm (in)
  • Page 25 SPEC GENERAL SPECIFICATIONS Model Worldwide 175FETO 200FETO L200FETO 200GETO 225DET 225DETO Item Unit P175TR 200TR S200TR — L200TR P200TR — — Canada P175TR — S200TR — — P200TR — — Exhaust system Through prop boss Lubrication system Oil injection Pre-mix injection Cooling system Water...
  • Page 26: Maintenance Specifications

    SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS POWER UNIT Model Item Unit 150 hp 175 hp 200 hp 225 hp CYLINDER HEADS Warpage limit mm (in) 0.10 (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 27 SPEC MAINTENANCE SPECIFICATIONS Model Worldwide 150AET L150AET 175AET 200AET L200AET Item Unit C150TR — — — — Canada — — — — — CARBURETORS ID mark 64C00 64D00 64E00 Main jet 150, 154 (PU, PM)*, 150,152 (SL)*, 158 (PL)* 154 (PU, PM)*, 158 (PL)* Main air jet Main nozzle (inside diameter)
  • Page 28 SPEC MAINTENANCE SPECIFICATIONS Model Worldwide 150FETO L150FETO 150GETO D150HETO Item Unit — S150TR — L150TR P150TR D150TR Canada — — — — P150TR — CARBURETORS ID mark 64C00 64CS0 64C00 64CS0 64K00 Main jet 150, 154 150, 154 152, 154 (PU, PM)*, (PU, PM)*, (PU, PM)*,...
  • Page 29 SPEC MAINTENANCE SPECIFICATIONS Model Worldwide 175DETO 175FETO 200FETO Item Unit — S175TR P175TR 200TR S200TR Canada — — P175TR — S200TR CARBURETORS ID mark 64D00 64DS0 64L00 64E00 64ES0 Main jet 150, 154 152, 154 150, 152 (SL)*, (PU, PM)*, (PU, PM)*, 154 (PU, PM)*, 158 (PL)*...
  • Page 30 SPEC MAINTENANCE SPECIFICATIONS Model Worldwide L200FETO 200GETO 225DET 225DETO Item Unit — L200TR P200TR — — Canada — — P200TR — — CARBURETORS ID mark 64E00 64ES0 64F00 Main jet 150,152 (SL)*, 150, 154 (PU, PM)*, 154 (PU, PM)*, 158 (PL)* 158 (PL)* Main air jet Main nozzle (inside diameter)
  • Page 31: Lower Unit

    SPEC MAINTENANCE SPECIFICATIONS LOWER UNIT Model Worldwide L150AET L150FETO L200AET L200FETO Item Unit — L150TR — L200TR Canada — — — — GEAR BACKLASH Pinion - forward gear mm (in) 0.21 - 0.43 (0.008 - 0.017) Pinion - reverse gear mm (in) 0.97 - 1.29 (0.038 - 0.051) Pinion shims...
  • Page 32: Electrical

    Ignition timing Full retard Degrees ATDC 7 Full advance Degrees BTDC 19 (150A, L150A, 175A/C150TR) BTDC 18 (200A, L200A) BTDC 22 (150F, L150F, D150H, 175D, S175D/ D150TR, S175TR) BTDC 23 (S150F, LS150F, 175F, 200G/ S150TR, L150TR, P175TR, P200TR) BTDC 20 (150G, 200F, L200F/P150TR, 200TR)
  • Page 33 SPEC MAINTENANCE SPECIFICATIONS Model Item Unit Oil injection Pre-mix (and 225DET) (except for 225DET) Pulser coil Output peak voltage lower limit (W/R – W/G, W/Y – W/Br, W/B – W/L) @ cranking 1 @ cranking 2 @ 1,500 r/min @ 3,500 r/min IGNITION CONTROL SYSTEM Crank position sensor Output peak voltage lower...
  • Page 34 SPEC MAINTENANCE SPECIFICATIONS Model Item Unit Oil injection Pre-mix (and 225DET) (except for 225DET) STARTER MOTOR Type Bendix Output Rating Second Brushes Standard length mm (in) 16.0 (0.63) Wear limit mm (in) 12.0 (0.47) Commutator Standard diameter mm (in) 33.0 (1.30) Wear limit mm (in) 31.0 (1.22)
  • Page 35: Dimensions

    SPEC MAINTENANCE SPECIFICATIONS DIMENSIONS Symbol Models 150FETO, S150FETO, L150FETO, 150GETO, LS150FETO, 175DETO, S175DETO, 150AET, 175AET, L150AET, Worldwide 175FETO, D150HETO 200FETO, S200FETO, L200FETO, 200AET L200AET 200GETO LS200FETO, 225DET, 225DETO Unit S150TR, L150TR, S175TR, P150TR, P175TR, D150TR C150TR — 200TR, S200TR, L200TR P200TR P150TR, P175TR, Canada...
  • Page 36 SPEC MAINTENANCE SPECIFICATIONS Symbol Models 150FETO, S150FETO, L150FETO, 150GETO, LS150FETO, 175DETO, S175DETO, 150AET, 175AET, L150AET, Worldwide 175FETO, D150HETO 200FETO, S200FETO, L200FETO, 200AET L200AET 200GETO LS200FETO, 225DET, 225DETO Unit S150TR, L150TR, S175TR, P150TR, P175TR, D150TR C150TR — 200TR, S200TR, L200TR P200TR P150TR, P175TR, Canada S200TR...
  • Page 37: Tightening Torques

    SPEC TIGHTENING TORQUES TIGHTENING TORQUES SPECIFIED TORQUES Tightening torques Part to be tightened Thread size m•kgf ft•lb POWER UNIT Fuel pump Intake silencer Carburetor drain plug — Pilot jet plug — Oil pump Flywheel magnet assembly (oil injection and 225DET) Flywheel magnet assembly 16.5 (pre-mix except for 225DET)
  • Page 38 SPEC TIGHTENING TORQUES Tightening torques Part to be tightened Thread size m•kgf ft•lb Connecting rod LOWER UNIT Propeller Rear propeller (for D150H/D150TR) Forward propeller (for D150H/D150TR) Lower unit Ring nut — 14.5 Pinion nut Gear oil drain screw — Gear oil level check screw —...
  • Page 39: 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 41 INSP CHAPTER 3 PERIODIC INSPECTIONS AND ADJUSTMENTS MAINTENANCE INTERVAL CHART.............. 3-1 TOP COWLING ....................3-2 INSPECTING THE TOP COWLING FIT ............ 3-2 FUEL SYSTEM ....................3-2 INSPECTING THE FUEL LINE..............3-2 INSPECTING THE FUEL FILTER .............. 3-3 CONTROL SYSTEM..................3-3 ADJUSTING THE IGNITION TIMING............
  • Page 42: Insp Adj

    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 Item Remarks 10 hours 50 hours 100 hours 200 hours to page (Break-in) (3 months)
  • Page 43: Top Cowling

    INSP TOP COWLING/FUEL SYSTEM TOP COWLING INSPECTING THE TOP COWLING FIT 1. Inspect: • Top cowling fitting Loose/unlatched → Adjust the top cowling hook. 3010 2. Adjust: • Top cowling hook position Adjustment steps (1) Loosen the bolts 1 approximately 1/4 of a turn.
  • Page 44: Control System

    3050 (2) Turn the flywheel magnet assembly 1 clockwise and align the timing plate 2 with the specified mark. Flywheel magnet assembly position 150A, L150A, 175A/ C150TR: BTDC 19˚ 200A, L200A: BTDC 18˚ 150F, L150F, D150H, 175D, S175D/D150TR, S175TR: BTDC 22˚...
  • Page 45 NOTE: Turn the flywheel magnet assembly clock- wise to locate BTDC. Piston position 150A, L150A, 175A/ C150TR: 2.28 mm (0.09 in) 200A, L200A: 2.05 mm (0.08 in) 150F, L150F, D150H, 175D, S175D/D150TR, S175TR: 3.05 mm (0.12 in)
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