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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.
For instance, the condition of a faulty component will precede an arrow symbol and the
course of action required will follow the symbol.
• Bearings
Pitting/scratches → Replace.
To assist you in finding your way through this manual, the section title and major heading is
given at the top of every page.
MODEL INDICATION
Multiple models are mentioned in this manual and their model indications are noted as fol-
lows.
Model name
USA and
Canada name
Indication
Model name
D150HETO
USA and
Canada name
Indication
D150HETO
Model name
USA and
Canada name
Indication
ILLUSTRATIONS
The illustrations within this service manual represent all of the designated models.
CROSS REFERENCES
The cross references have been kept to a minimum. Cross references will direct you to the
appropriate section or chapter.
HOW TO USE THIS MANUAL
150AET
L150AET
C150TR
—
150AET
L150AET
175AET
D150TR
—
175AET
200FETO
200TR
S200TR
200FETO
S200FETO
150FETO
—
S150TR
150FETO
S150FETO
175DETO
—
S175TR
175DETO
S175DETO
L200FETO
—
L200TR
L200FETO
LS200FETO
L150FETO
—
L150TR
L150FETO
LS150FETO
175FETO
200AET
P175TR
—
175FETO
200AET
200GETO
225DET
P200TR
—
200GETO
225DET
E
150GETO
P150TR
150GETO
L200AET
—
L200AET
225DETO
—
225DETO
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Summary of Contents for Yamaha 150AET
- Page 1 To assist you in finding your way through this manual, the section title and major heading is given at the top of every page. MODEL INDICATION Multiple models are mentioned in this manual and their model indications are noted as fol- lows. Model name 150AET L150AET 150FETO L150FETO 150GETO USA and C150TR —...
- Page 2 World- number number Canada Canada code code wide wide L: 305521 - 175FETO P175TR L: 500647 - 150AET C150TR — X: 704396 - L: 308781 - 200AET — L150AET — X: 750347 - X: 707018 - — L: 352137 - L200AET —...
- Page 3 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 4 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 5 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 6 FUEL FUEL JOINT AND FUEL FILTER 4020 Order Job/Part Q’ty Remarks Fuel filter Bolt Fuel filter bracket Fuel filter cap Fuel filter element O-ring Fuel filter cup For installation, reverse the removal procedure.
- Page 7 POWR FLYWHEEL MAGNET ASSEMBLY FLYWHEEL MAGNET ASSEMBLY REMOVING/INSTALLING THE FLYWHEEL MAGNET ASSEMBLY 5010 Order Job/Part Q’ty Remarks Flywheel magnet assembly cover Flywheel magnet assembly nut Washer Flywheel magnet assembly Woodruff key For installation, reverse the removal procedure. Å S150F, LS150F, S175D, S200F, LS200F/S150TR, L150TR, S175TR, S200TR, L200TR ı...
- Page 8 POWR CYLINDER HEADS 5250 Order Job/Part Q’ty Remarks Gasket Not reusable Thermo switch Engine cooling water temperature sensor Bolt Ground lead Bolt Cylinder head Gasket Not reusable For installation, reverse the removal procedure. 5-28...
- Page 9 POWR CYLINDER BODY ASSEMBLY INSTALLING THE CRANKSHAFT ASSEMBLY Install: • Cylinder body • Crankshaft assembly NOTE: • Align the crankshaft labyrinth ring end gaps with their respective locating pins. • Install the bearing locating pins into the cylinder body. 5570 INSTALLING THE PISTON AND CONNECTING ROD ASSEMBLIES Install:...
- Page 10 PROPELLER SHAFT HOUSING ASSEMBLY LOWR (COUNTER ROTATION MODELS) INSPECTING THE DOG CLUTCH Inspect: • Dog clutch Damage/wear → Replace. INSPECTING THE PROPELLER SHAFT Inspect: • Propeller shaft Damage/wear → Replace. ASSEMBLING THE PROPELLER Å SHAFT HOUSING 1. Install: • Needle bearing Needle bearing installation position a 24.75 - 25.25 mm...
- Page 11 LOWR WATER PUMP (DUAL PROPELLER MODELS) 6330 Order Job/Part Q’ty Remarks Spacer Washer Wave washer Impeller Woodruff key For installation, reverse the removal procedure. 6-54...
- Page 12 INNER PROPELLER SHAFT ASSEMBLY LOWR (DUAL PROPELLER MODELS) INNER PROPELLER SHAFT ASSEMBLY (DUAL PROPELLER MODELS) DISASSEMBLING/ASSEMBLING THE INNER PROPELLER SHAFT ASSEMBLY 6430 Order Job/Part Q’ty Remarks Spring Front dog clutch Front gear assembly (with oil groove a) Washer Spring Continued on next page. 6-70...
- Page 13 SHIMMING (REGULAR ROTATION MODELS) LOWR (FOR USA AND CANADA) SELECTING THE FORWARD GEAR SHIMS NOTE: Find the shim thickness (T1) by selecting shims until the specified value (M0) is obtained with the special tool. 6525 1. Measure: • Specified measurement (M) Out of specified value (M0) →...
- Page 14 LOWR BACKLASH (REGULAR ROTATION MODELS) Measuring steps (1) Set the shift rod into the neutral posi- tion. Shift rod wrench YB-06052 / 90890-06052 6645 (2) Load the reverse gear by installing the propeller without the spacer 1 and then tighten the propeller nut. Propeller nut 10 Nm (1.0 m •...
- Page 15 LOWR BACKLASH (DUAL PROPELLER MODELS) BACKLASH (DUAL PROPELLER MODELS) NOTE: • Do not install the water pump compo- nents when measuring the backlash. • Measure both the forward and reverse gear backlashes. • If both the forward and reverse gear back- lashes are larger than specification, the pinion may be too high.