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Z200 LZ200 OWNER’S MANUAL U.S.A.Edition q Read this manual carefully before operating this LIT-18626-08-75 outboard motor. 68F-28199-1E...
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EMU25073 ZMU01690 Read this manual carefully before operating this outboard motor. Keep this manual onboard in a waterproof bag when boating. This manual should stay with the outboard motor if it is sold.
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Therefore some items may not apply to ev- Yamaha. If you have any question about the ery model. operation or maintenance of your outboard EMU25112 motor, please consult a Yamaha dealer.
Table of contents Safety information......1 Remote control requirements..14 Battery requirements..... 14 Outboard motor safety ....1 Specifications of Battery....14 Propeller..........1 Mounting battery ......15 Rotating parts........1 Multiple batteries ......15 Hot parts ........... 1 Propeller selection ......15 Electric shock ........
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Table of contents Trim meter........29 First-time operation ....... 47 Hour meter ........29 Breaking in engine ......47 Oil level indicator (digital type) ..30 Getting to know your boat ....47 Overheat-alert indicator ....30 Checks before starting engine ..47 Digital speedometer ......
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Flushing power unit ......69 IMPORTANT WARRANTY Cleaning the outboard motor ..70 INFORMATION IF YOU USE Checking painted surface of YOUR YAMAHA OUTSIDE motor..........70 THE USA OR CANADA ....97 Periodic maintenance....70 Replacement parts ......70 Maintenance interval guidelines..71 Maintenance chart 1 .......
Safety information EMU33622 tor and the clamp bracket when the motor is Outboard motor safety trimmed or tilted. Keep body parts out of this Observe these precautions at all times. area at all times. Be sure no one is in this EMU36501 area before operating the power trim and tilt Propeller...
Personal flotation devices cording to the boat manufacturers instruc- Have an approved personal flotation device tions. Overloading or incorrect weight (PFD) on board for every occupant. Yamaha distribution can compromise the boats han-...
Safety information dling and lead to an accident, capsizing or boating in hazardous weather. swamping. EMU33800 Accident reporting EMU33772 Avoid collisions Boat operators are required by law to file a Scan constantly for people, objects, and oth- Boating Accident Report with their state er boats.
Safety information go to boatus.org. http://www.usps.org/ EMU33880 Passenger training Boat Owners Association of The United Make sure at least one other passenger is States trained to operate the boat in the event of an 1-800-336-BOAT (1-800-336-2628) emergency. http://www.boatus.com/ EMU33890 Boating safety publications National Association of State Boating Be informed about boating safety.
Safety information one another, one vessel has the right-of- EMU25521 Rules when encountering vessels way; it is called the “stand-on” vessel. The There are three main situations that you may vessel that does not have the right-of-way is encounter with other vessels which could called the “give-way”...
Safety information EMU25531 Other special situations There are three other rules you should be aware of when driving your boat around oth- er vessels. Narrow channels and bends When navigating in narrow channels, you should keep to the right when it is safe and practical to do so.
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Safety information 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 navigat- ing in a particular direction.
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 sto- len. 1. Key number ZMU04426 1.
Read any manuals supplied with the boat. Read all labels on the outboard motor and the boat. If you need any additional information, contact your Yamaha dealer. EMU33831 Warning labels If these labels are damaged or missing, contact your Yamaha dealer for replacements. Z200, LZ200 ZMU06295...
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General information ZMU05741 EMU33850 Other labels ZMU05710...
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General information EMU35132 Electrical hazard Symbols The following symbols mean as follows. Notice/Warning ZMU05666 ZMU05696 Read Owner’s Manual ZMU05664 Hazard caused by continuous rotation ZMU05665...
Specifications and requirements EMU31480 Spark plug gap: Specifications 1.5–1.6 mm (0.059–0.063 in) TIP: Control system: “(AL)” stated in the specification data below Remote control Starting system: represents the numerical value for the alumi- Electric starter num propeller installed. Likewise, “(SUS)” represents the value for Starting carburetion system: Electronic fuel injection stainless steel propeller installed and “(PL)”...
55.0 Nm (5.61 kgf-m, 40.6 ft-lb) continue using the outboard. Contact EMU33554 Installation requirements your Yamaha dealer. EMU33563 The remote control unit must be equipped Boat horsepower rating with a start-in-gear protection device(s). This...
“L” after the size indication on the pro- appropriate. peller. WARNING! Never use a standard Your Yamaha dealer can help you select the propeller with a counter rotation motor, right propeller for your boating needs. Select or a counter rotation propeller with a a propeller that will allow the engine to reach standard motor.
10% ethanol use only Yamalube 2-M or, if necessary, can cause fuel system damage or cause en- another outboard motor manufacturer’s gine starting and running problems. Yamaha factory-brand TC-W3 oil. does not recommend gasohol containing EMU36360...
Yamaha recommends the use of EMU36351 Emergency equipment Ring Free Fuel Additive, available from your Yamaha dealer. Ring Free Fuel Addi- Keep the following items onboard in case tive has repeatedly proven its ability to clean there is trouble with the motor.
Specifications and requirements engine for details. EMU31471 Approval label of emission control certif- icate This label is attached to the bottom cowling. New Technology ; (HPDI) DFI/HO2S ZMU04726 1. Manufactured date label location ZMU06296 1. Approval label location Manufactured: ZMU04346 EMU25273 Star labels Your outboard motor is labeled with a Cali-...
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Specifications and requirements EMU25280 these standards have 65% lower emissions One Star—Low Emission than One Star-Low-Emission engines. The one-star label identifies engines that meet the Air Resources Board’s 2001 ex- haust emission standards. Engines meeting these standards have 75% lower emissions than conventional carbureted two-stroke en- gines.
Components EMU2579S Components diagram TIP: * May not be exactly as shown; also may not be included as standard equipment on all mod- els. Z200, LZ200 ZMU04850 1. Top cowling 16. Digital speedometer* 2. Cowling lock lever(s) 17. Tachometer* 3. Trim tab (anode) 18.
Components 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)* EMU26181 Remote control box The remote control lever actuates both the shifter and the throttle.
Components used when the remote control lever is in the neutral position. After the button is pushed, the throttle be- gins 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.
Components ZMU04646 When constant speed is desired, tighten the 1. Cord 2. Clip adjuster to maintain the desired throttle set- 3. Engine shut-off switch ting. EMU25994 Engine shut-off cord (lanyard) and START START clip The clip must be attached to the engine shut- off switch for the engine to run.
Components sition, the starter motor turns to start the en- gine. When the key is released, it returns automatically to the “ ” (on) position. EMU26153 Power trim and tilt switch on bottom engine cowling The power trim and tilt switch is located on the side of the bottom engine cowling.
Components EMU26244 Trim tab with anode EWM00840 WARNING An improperly adjusted trim tab could cause difficult steering. Always test run after the trim tab has been installed or re- placed to be sure steering is correct. Be sure you have tightened the bolt after ad- ZMU03985 justing the trim tab.
ZMU01863 The air intake grille on the top cowling is Bolt tightening torque: not designed as a handle and could break Z200 40.0 Nm (4.0 kgf-m, 29.5 ft-lb) if used as such. LZ200 42.0 Nm (4.2 kgf-m, 31 ft-lb) EMU26341...
1. Air intake grille when the gear shift is in neutral. 2. Cowling lock lever(s) If the alert system has activated, stop the engine and consult a Yamaha dealer im- EMU26461 Flushing device mediately. This device is used to clean the cooling wa-...
Instruments and indicators EMU26493 the power trim and tilt switch. Digital tachometer If the trim angle of your motor exceeds the The tachometer shows the engine speed trim operating range, the top segment on and has the following functions. the trim meter display will blink. All segments of the display will light momen- tarily after the main switch is turned on and will return to normal thereafter.
Instruments and indicators EMU26551 Oil level indicator (digital type) This indicator shows the engine oil level. If the oil level falls below the lower limit, the alert indicator will start to blink. For further in- formation, see page 43. ECM00030 NOTICE Do not operate the engine without oil.
Press the “ ” (set) button; the hour dis- the gauge will give false readings. Consult play will begin blinking. your Yamaha dealer on how to correctly set Press the “ ” (mode) button until the the selector switch. NOTICE: Running out desired hour is displayed.
Get back to the port soon if an alert device has activated. For charging the battery, con- sult your Yamaha dealer. The clock operates on battery power. Dis- connecting the battery will stop the clock. Reset the clock after connecting the battery.
Instruments and indicators will return to normal thereafter. EMU26752 Fuel flow meter The fuel flow meter displays the amount of fuel flow over a one-hour period, at the cur- rent rate of engine operation. The fuel flow meter displays gallons/hour or liters/hour according to operator prefer- ence.
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(winter or summer fuel and amount of additives). The Yamaha digital speedometer and fuel ZMU01754 management meter calculates speed, miles traveled, and fuel economy by water 1. Port engine speed is higher...
If large differences in trim angle or throttle ZMU04580 are needed to synchronize the engines, con- 1. Oil level indicators sult your Yamaha dealer for adjustments to the throttle cables. EMU26611 EMU26471 Analog trim meter Analog tachometer...
(fuel filter) while cruising. In such an event, stop the engine immediately and see page 87 of this manual to drain the water from the fuel filter. Get back to the port soon and consult a Yamaha...
& fuel meters In such an event, the engine will not oper- The speed & fuel meter unit shows the boat ate properly. Consult a Yamaha dealer speed and has the functions of fuel meter, to- immediately. tal fuel consumption display, fuel economy...
Instruments and indicators fuel meter unit type for operation information. After the main switch is first turned on, all the displays come on as a test. After a few sec- onds, the gauge will change to normal oper- ation. For more information, see the operation manual originally supplied with the meter.
The fuel management meter has the func- available. For the optional sensors, consult tions of fuel flow meter, total consumption your Yamaha dealer. display, fuel economy display, and remain- After the main switch is first turned on, all the ing fuel display. The chosen display is select- displays come on as a test.
Alert system ECM00091 NOTICE Do not continue to operate the engine if a alert device has activated. Consult your Yamaha dealer if the problem cannot be located and corrected. EMU26827 Overheat alert This engine has the overheat alert device. If the engine temperature rises too high, the alert device will activate.
Engine control system switch of the engine overheating. If the alert system has activated, stop the engine and tilt the outboard motor up to check the cooling water inlet for clogging. If the alert system has still activated, tilt the overheated out- board motor up and return to the port.
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Engine control system ZMU01952 1. Oil filter...
Consult your engine overheating. If the engine is mounted Yamaha dealer or boat manufacturer for fur- too low, water resistance (drag) will in- ther information on determining the proper crease, thereby reducing engine efficiency mounting location.
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Test runs at differ- ent heights can help determine the optimum mounting height. Consult your Yamaha deal- er or boat manufacturer for further informa- tion on determining the proper mounting height.
Operation EMU36381 throttle or less to let the engine cool. First-time operation Remaining 7 hours: EMU27042 Run the engine at any speed. However, Breaking in engine avoid operating at full throttle for more Your new engine requires a period of break- than 5 minutes at a time.
If enough water to raise the float ring is found in the fuel, or if a significant amount of debris is found, the fuel tank should be ZMU06106 checked and cleaned by a Yamaha dealer. ZMU06102 ZMU05499 EMU36442 EMU36461...
2. Clip should supply oil normally. If no oil is 3. Engine shut-off switch flowing after 10 minutes of idling, consult your Yamaha dealer. NOTICE: Be sure START START to take the above steps when operat- ing the engine after a long period of storage.
[ECM01800] ZMU06127 After installing, check the fitting of the top cowling by pushing it with both hands. If the ZMU06050 top cowling is loose, have it repaired by your Yamaha dealer. 1. Fitting 2. Flushing device...
Operation ZMU03458 ZMU04679 1. Tilt rod EMU29158 Checking power trim and tilt system 2. Trim rods EWM01930 WARNING Use the tilt support lever to lock the mo- tor in the up position. Operate the tilt Never get under the lower unit while it down switch briefly so the motor is sup- is tilted, even when the tilt support lever ported by the tilt support lever.
Operation EMU27234 Filling fuel and engine oil EMU30321 Filling fuel for models without a fuel joint EWM01830 WARNING Gasoline and its vapors are highly flam- mable and explosive. Always refuel ac- ZMU04156 cording to this procedure to reduce the risk of fire and explosion. Activate the trim-up switch until the tilt Gasoline is poisonous and can cause rod is fully extended.
5 liters (5.3 US qt, 4.4 Imp qt) of This engine uses the Yamaha oil injection oil should be kept in the remote oil tank. system, which provides superior lubrication...
Operation EMU27321 Oil level indicator operation The various functions of the oil level system are as follows: EMU27383 Oil level indicator Electric start models Oil level-alert Oil level-alert indicator Engine oil Remote oil indicator (analog Remarks (digital tank tank tachometer) tachometer) more than 300 more than...
Operation EMU27452 Operating engine EWM00420 WARNING 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.
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Operation Place the remote control lever in “ ” (neutral). START START ZMU04589 Turn the main switch to “ ” (on). ZMU01880 ZMU04588 TIP: The start-in-gear protection device prevents the engine from starting except when in neu- tral. Attach the engine shut-off cord to a se- cure place on your clothing, or your arm or leg.
Stop the engine and check wheth- er the cooling water inlet on the lower START case or the cooling water pilot hole is blocked. Consult your Yamaha dealer if the problem cannot be located and cor- rected. ZMU04590 Immediately after the engine starts, re- lease the main switch to return it to “...
Operation to neutral. Move the remote control lever firmly for- ward (for forward gear) or rearward (for EMU31721 Stop switches reverse gear) about 35° (a detent can be Confirm that turning the main switch to the felt). “ ” (off) position stops the engine. Confirm that removing the clip from the en- gine shut-off switch stops the engine.
Operation the boat. This could increase the risk of serious injury. It could also damage the shift mechanism. Do not shift into reverse while traveling at planing speeds. Loss of control, boat swamping, or damage to the boat could occur. The boat is not equipped with a separate braking system.
Operation boat, engine, and propeller. Correct trim is also affected by variables such as the load in the boat, sea conditions, and running speed. ZMU04600 After stopping the engine, disconnect the fuel line or close the fuel cock if there is a fuel joint or a fuel cock on the boat.
Operation angle can cause loss of control. If equipped with a power trim and tilt switch located on the bottom cowling, use the switch only when the boat is at a complete stop with the engine off. Do not adjust the trim angle with this switch while the boat is moving.
Operation Bow Up motor trim angle may have little effect on the Too much trim-out puts the bow of the boat trim of the boat when operating. too high in the water. Performance and econ- EMU27935 Tilting up and down omy are decreased because the hull of the boat is pushing the water and there is more If the engine will be stopped for some time or...
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Operation ZMU03196 ZMU04602 ZMU04588 ZMU03995 Press the power trim and tilt switch “ ” Pull the tilt support lever toward you to (up) until the outboard motor has tilted support the engine. WARNING! After up completely. tilting the outboard motor, be sure to support it with the tilt support knob or tilt support lever.
Operation ZMU03998 ZMU03996 Push the power trim and tilt switch “ ” Models equipped with trim rods: Once (down) to lower the outboard motor to the outboard motor is supported with the the desired position. tilt support lever, press the power trim and tilt switch “...
Operation ZMU03999 ZMU04588 Slightly tilt the outboard motor up to the EMU28061 Shallow water desired position using the power trim EMU32851 and tilt switch. WARNING! Using the Power trim and tilt models power trim and tilt switch on the bot- The outboard motor can be tilted up partially tom cowling while the boat is moving to allow operation in shallow water.
Cruising in muddy, turbid, or acidic water Yamaha strongly recommends that you use the optional chromium-plated water pump kit (see page 17) if you use the outboard motor in acidic water or water with a lot of sediment in it, such as muddy or turbid (cloudy) water.
Keep hands, hair, and seal. Seal replacement should be per- clothes away from the flywheel and formed by an authorized Yamaha dealer other rotating parts while the engine prior to use. is running.
Also, do not spray near the si- lencer or into the engine. Otherwise the engine could be damaged. [ECM01402] Wax the cowling with a non-abrasive wax such as “Yamaha Silicone Wax”. EMU28443 Flushing power unit Perform this procedure right after operation for the most thorough flushing.
Maintenance of cooling the engine, which can to perform a maintenance procedure, cause serious overheating. Be sure have a Yamaha dealer or other qualified the connector is tightened securely mechanic do the work. on the fitting after flushing the en- The procedures involve disassembling gine.
Maintenance design and quality. Any part of inferior quality may malfunction, and the resulting loss of control could endanger the operator and passengers. Yamaha genuine parts and ac- cessories are available from your Yamaha dealer. EMU35521 Maintenance interval guidelines The service intervals provided in the Mainte- nance Chart were developed based upon “typical”...
The “ ” symbol indicates the check-ups which you may carry out yourself. The “ ” symbol indicates work to be carried out by your Yamaha dealer. Initial Every 20 hours Item...
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Maintenance Initial Every 20 hours Item Actions hours (1 hours (3 hours (5 months) year) years) years) Fuel line(High pres- Inspection or replace- sure) ment as necessary Fuel line(Low pres- Inspection sure) Fuel line(Low pres- Inspection or replace- sure) ment as necessary Inspection or replace- Fuel pump ment as necessary...
Maintenance EMU28932 Greasing Yamaha marine grease (Water resistant grease) Z200, LZ200 ZMU04724 white, this could indicate an intake air leak or EMU28956 Cleaning and adjusting spark plug carburetion problem in that cylinder. Do not The spark plug is an important engine com- attempt to diagnose any problems yourself.
Maintenance to slowly break down and erode. the correct torque. Remove the spark plug caps from the Spark plug torque: spark plugs. 25.0 Nm (2.55 kgf-m, 18.4 ft-lb) Remove the spark plug. If electrode ero- sion becomes excessive, or if carbon TIP: and other deposits are excessive, you If a torque-wrench is not available when you...
If water or foreign matter is vis- off switch. Turn off the battery cut-off ible in this trap, consult your Yamaha dealer. switch if your boat has one. Do not use your hand to hold the propeller when loosening or tightening the propeller nut.
Remove the propeller nut, washer, and tion and be lost. spacer (if equipped). WARNING! Do Apply Yamaha marine grease or a cor- not use your hand to hold the propel- rosion resistant grease to the propeller ler when loosening the propeller nut.
Never get under the lower unit while it ticles, the gear case may be dam- is tilted, even when the tilt support lever aged. Have a Yamaha dealer check or knob is locked. Severe injury could and repair the outboard motor.
9 Nm (0.9 kgf-m, 6.6 ft-lb) Inspect ground leads attached to external anodes on equipped models. Consult a EMU29313 Yamaha dealer for inspection and replace- Inspecting and replacing anode(s) ment of internal anodes attached to the pow- Yamaha outboard motors are protected from er unit.
Connecting an accessory battery (optional) connections can produce shorting or If connecting an accessory battery, con- arcing and cause an explosion. sult your Yamaha dealer about correct [EWM01910] wiring. For the fuse size, see ABYC (E- EMU35493 Connecting the battery 11).
Maintenance Single engine Twin engines ZMU05939 ZMU05941 1. Isolator lead with circuit protection 1. Starboard side engine 2. Red cable 2. Port side engine 3. Black cable 3. Red cable 4. Fuse 4. Black cable 5. Battery for accessories 5. Isolator lead with circuit protection 6.
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Maintenance Disconnect the positive cable(s) and re- move the battery from the boat. Clean, maintain, and store the battery according to the manufacturer’s instruc- tions.
Q. Has fuel pump malfunctioned? If your outboard motor requires repair, bring A. Have serviced by a Yamaha dealer. it to your Yamaha dealer. If the engine trouble-alert indicator is flash- Q. Are spark plug(s) fouled or of incorrect ing, consult your Yamaha dealer.
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Q. Is fuel contaminated or stale? A. Fill tank with clean, fresh fuel. Q. Is carburetor clogged? A. Have serviced by a Yamaha dealer. Q. Is fuel filter clogged? A. Clean or replace filter. Q. Is fuel joint connection incorrect? A.
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Q. Is fuel system obstructed? Q. Is water pump or thermostat faulty? A. Check for pinched or kinked fuel line or A. Have serviced by a Yamaha dealer. other obstructions in fuel system. Q. Is there excess water in fuel filter cup? Q.
ECM00370 Q. Is steering pivot loose or damaged? NOTICE A. Tighten or have serviced by a Yamaha If the boat is operated with one engine in dealer. the water but not running, water may run...
2. Fuse (20 A × 3, 30 A, 60 A × 2) NOTICE If a main fuse has blown, be sure to also Consult your Yamaha dealer if the new fuse check the other main fuse. immediately blows again. If the outboard motor is operated after a...
Trouble Recovery ZMU05018 1. Water separator-alert indicator 1. Manual valve screw Stop the engine. Put the engine in the desired position, Remove the top cowling. then tighten the manual valve screw by Disconnect the water detection switch turning it clockwise. coupler.
Start the engine and make sure that the Make sure no one is standing behind water separator-alert indicator remains you when pulling the starter rope. It off. Have a Yamaha dealer inspect the could whip behind you and injure outboard motor after returning to port. someone.
Trouble Recovery dangerous. Keep loose clothing and other objects away when starting the START START engine. Use the emergency starter rope only as instructed. Do not touch the fly- wheel 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 EMU29671 Engine fails to operate EMU29742 Low oil level alert activates If the oil level is allowed to drop too low, the red segment will appear on the oil level indi- cator, the buzzer will sound, and engine speed will be limited to about 2000 r/min.
EMU33501 Treatment of submerged motor If the outboard motor is submerged, immedi- ately take it to a Yamaha dealer. Otherwise some corrosion may begin almost immedi- ately. NOTICE: Do not attempt to run the outboard motor until it has been com- pletely inspected.
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