Yamaha 150A Service Manual Download

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64C-28197-Z8-11

SERVICE

MANUAL

150A, 150F,

L150F, D150H,

175D, 200F,

L200F, 200G,

225D

Summary of Contents for 150A

Page 1: ...64C 28197 Z8 11 SERVICE MANUAL 150A 150F L150F D150H 175D 200F L200F 200G 225D ...

Page 2: ...models may differ in detail from the descriptions and illustrations given in this publica tion Use only the latest edition of this manual Authorized Yamaha dealers are notified periodically of modifications and significant changes in specifications and procedures and these are incorporated in successive editions of this manual 150A 150F L150F D150H 175D 200F L200F 200G 225D SERVICE MANUAL 1998 Yam...

Page 3: ...N Multiple models are mentioned in this manual and their model indications are noted as fol lows 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 Model name 150AET L150AET 150FETO L150FETO 150GETO USA and Canada na...

Page 4: ...leave the section deal ing with the procedure in order to look up the specifications It is important to note the differences in specifications of models When a procedure relates to more than one model the main differences in specifications will be shown in a table similar to the following Model name 150AET L150AET 150FETO L150FETO 150GETO USA and Canada name C150TR S150TR L150TR P150TR Lubrication...

Page 5: ...on charts at the same time as the exploded views These charts list the sequence that the procedures should be carried out in as well as pro viding explanations on part names quantities dimensions and important points relating to each relevant task Example O ring size 39 5 2 5 mm inside diameter D ring diameter d 5 In addition to tightening torques the dimensions of the bolts and screws are also me...

Page 6: ...ploded 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 H Apply molybdenum disulfide oil Symbols I to N in an exploded diagram indicate the grade of the sealing or locking agent and the location of the application point I Apply Gasket Maker J Apply ...

Page 7: ...NFORMATION 1 SPECIFICATIONS 2 SPEC PERIODIC INSPECTIONS AND ADJUSTMENTS 3 FUEL SYSTEM 4 FUEL POWER UNIT 5 POWR LOWER UNIT 6 LOWR BRACKET UNIT 7 BRKT ELECTRICAL SYSTEMS 8 ELEC TROUBLE ANALYSIS 9 GEN INFO INSP ADJ TRBL ANLS ...

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Page 9: ... 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 1 4 SPECIAL TOOLS 1 5 MEASURING 1 5 REMOVING AND INSTALLING 1 7 ...

Page 10: ...ERS The starting serial number blocks are as fol lows Model name Approval model code Starting serial number Model name Approval model code Starting serial number World wide USA Canada World wide USA Canada 150AET C150TR 6G4 L 305521 175FETO P175TR 62H L 500647 X 704396 200AET 6G6 L 308781 L150AET 6K0 X 750347 X 707018 150FETO 6G4 L 352137 L200AET 6K1 X 752202 S150TR X 504118 200FETO 200TR 6G6 L 35...

Page 11: ...leum vapor is heavier than air and is deadly if inhaled in large quantities Engine exhaust gases are harmful to breathe When test running an engine indoors maintain good ventilation 1040 SELF PROTECTION Protect your eyes with suitable safety glasses or safety goggles when grinding or when doing any operation which may cause particles to fly off Protect hands and feet by wearing safety gloves or pr...

Page 12: ...iled wiping rag in your pocket 4 Hands and any other part of the body which have been in contact with lubri cants or lubricant contaminated cloth ing should be thoroughly washed with hot water and soap as soon as practica ble 5 To protect the skin the application of a suitable barrier cream to the hands before working is recommended 6 A supply of clean lint free cloths should be available for wipi...

Page 13: ...ts with compressed air when disassembling 2 Oil the contact surfaces of moving parts before assembly 1090 3 After assembly check that moving parts operate normally 1100 4 Install bearings with the manufacturer s markings on the side exposed to view and liberally oil the bearings 5 When installing oil seals apply a light coating of water resistant grease to the outside diameter ...

Page 14: ...achometer P N YU 08036 A a 90890 06760 b 2 Pressure tester P N YB 35956 90890 06762 3 Mity vac P N YB 35956 90890 06756 4 Pinion height gauge P N YB 34432 7 YB 34432 11 YB 34432 97 90890 06702 5 Dial gauge set P N YU 03097 90890 01252 6 Magnetic base P N YU 34481 90890 06705 7 Digital caliper P N 90890 06704 8 Backlash indicator P N YB 06265 90890 06706 9 Magnetic base attaching plate P N YB 07003...

Page 15: ...54 b E Diagnostic indicator P N YB 06765 90890 06765 F Shimming gauge P N YB 34446 1 YB 34446 3 YB 34446 4 YB 34446 7 YB 34446 8 G Shimming gauge P N YB 34468 1 YB 34468 2 YB 34468 6 H Shimming plate P N 90890 06701 I Shift rod wrench P N YB 06052 90890 06052 J Test harness P N YB 06770 YB 38831 YB 38832 90890 06770 90890 06771 90890 06772 C b B a D b a E F I J G H ...

Page 16: ...02 90890 06604 90890 06605 90890 06606 90890 06652 5 Bearing oil seal attachment P N YB 06205 90890 06663 6 Bearing oil seal attachment P N YB 06194 YB 06195 YB 06200 YB 06246 YB 06258 YB 06276 YB 06336 90890 06619 90890 06622 90890 06623 90890 06624 90890 06629 7 Piston ring compressor P N YU 33294 a 90890 06530 b 8 Bearing separator P N YB 06219 a 90890 06534 b 9 Guide plate stand P N 90890 0653...

Page 17: ... N 90890 06504 G Slide hammer P N YB 06096 90890 06531 H Small universal claws P N 90890 06536 I Bearing oil seal depth plate P N YB 06213 YB 34474 a 90890 06603 b J Drive shaft holder P N YB 06201 90890 06520 K Pinion nut holder P N 90890 06505 L Pinion nut holder attachment P N 90890 06508 M Bearing oil seal attachment P N 90890 06609 90890 06612 90890 06631 90890 06633 90890 06636 90890 06653 N...

Page 18: ... 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 YB 06548 90890 06548 W End screw wrench P N YB 06175 1A X Universal puller P N YB 06540 90890 06540 P Q R S T U V W X ...

Page 19: ... 7 8 9 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: ... 405 6 186 410 1 184 405 6 186 410 1 PERFORMANCE Maximum output kW hp 5 000 r min 110 3 150 128 7 175 147 1 200 Full throttle operating range r min 4 500 5 500 Maximum fuel consumption L US gal lmp gal hr 5 500 r min 72 19 0 15 8 75 19 8 16 5 81 21 4 17 8 POWER UNIT Type 2 stroke V Number of cylinders 6 Displacement cm3 cu in 2 596 158 4 Bore stroke mm in 90 0 68 0 3 54 2 68 Compression ratio 6 2 ...

Page 21: ...US qt lmp qt Gear oil type Hypoid gear oil SAE 90 Gear oil total quantity cm3 US oz lmp oz 980 33 1 34 5 870 29 4 30 6 980 33 1 34 5 870 29 4 30 6 BRACKET Trim angle at 12 boat transom Degree 4 16 Tilt up angle Degree 70 Steering angle Degree 35 35 DRIVE UNIT Gear shift positions F N R Gear ratio 1 86 26 14 Reduction gear type Spiral bevel gear Clutch type Dog clutch Propeller shaft type Spline Pr...

Page 22: ...g lb 194 427 7 196 432 1 194 427 7 198 5 437 6 194 427 7 X kg lb 198 436 5 200 440 9 198 436 5 PERFORMANCE Maximum output kW hp 5 000 r min 110 3 150 128 7 175 Full throttle operating range r min 4 500 5 500 Maximum fuel consumption L US gal lmp gal hr 5 500 r min 72 19 0 15 8 69 18 2 15 2 72 19 0 15 8 69 18 2 15 2 75 19 8 16 5 74 19 6 16 3 POWER UNIT Type 2 stroke V Number of cylinders 6 Displace...

Page 23: ...l type Hypoid gear oil SAE 90 Gear oil total quantity cm3 US oz lmp oz 980 33 1 34 5 870 29 4 30 6 980 33 1 34 5 900 30 4 31 7 980 33 1 34 5 BRACKET Trim angle at 12 boat transom Degree 4 16 Tilt up angle Degree 70 Steering angle Degree 35 35 DRIVE UNIT Gear shift positions F N R Gear ratio 1 86 26 14 2 00 28 14 2 00 26 13 1 86 26 14 Reduction gear type Spiral bevel gear Clutch type Dog clutch Pro...

Page 24: ...ainless steel propeller L kg lb 194 427 7 196 432 1 194 427 7 193 425 5 194 427 7 X kg lb 198 436 5 200 440 9 197 434 3 198 436 5 PERFORMANCE Maximum output kW hp 5 000 r min 128 7 175 147 1 200 165 5 225 Full throttle operating range r min 4 500 5 500 5 000 6 000 Maximum fuel consumption L US gal lmp gal hr 5 500 r min 78 20 6 17 2 81 21 4 17 8 82 21 7 18 0 81 21 4 17 8 82 21 7 18 0 88 23 2 19 4 ...

Page 25: ... US qt lmp qt 0 9 0 95 0 79 0 9 0 95 0 79 sub oil tank L US qt lmp qt 10 5 11 1 9 2 10 5 11 1 9 2 Gear oil type Hypoid gear oil SAE 90 Gear oil total quantity cm3 US oz lmp oz 980 33 1 34 5 870 29 4 30 6 980 33 1 34 5 BRACKET Trim angle at 12 boat transom Degree 4 16 Tilt up angle Degree 70 Steering angle Degree 35 35 DRIVE UNIT Gear shift positions F N R Gear ratio 1 86 26 14 Reduction gear type ...

Page 26: ...ston diameter D mm in 89 895 89 915 3 5392 3 5400 Measuring point H mm in 10 0 4 Piston to cylinder clearance mm in 0 100 0 106 0 0039 0 0042 Limit mm in 0 156 0 0061 Oversize piston diameter 1st mm in 90 15 3 549 2nd mm in 90 40 3 559 PISTON RINGS Type Keystone B mm in 2 0 0 079 T mm in 2 8 0 110 End gap installed mm in 0 30 0 40 0 012 0 016 Limit mm in 0 60 0 024 Side clearance mm in 0 02 0 06 0...

Page 27: ...w Turn out 1 1 4 1 1 16 1 4 1 1 8 1 4 Float height mm in 16 0 0 5 0 63 0 02 Valve seat diameter mm in 1 2 0 05 Idling speed r min 700 25 Trolling speed r min 575 25 OIL INJECTION PUMP ID mark Oil discharge for 3 minutes cm3 US oz Imp oz 1 500 r min Bleeding REED VALVES Reed valve stopper height a mm in 6 5 0 3 0 26 0 01 Warpage limit b mm in 0 2 0 008 THERMOSTATS Opening temperature C F 48 52 118 ...

Page 28: ... Turn out 1 1 4 1 1 4 1 4 1 1 4 1 1 4 1 4 1 9 16 1 4 S 1 1 16 1 4 P Float height mm in 16 0 0 5 0 63 0 02 Valve seat diameter mm in 1 2 0 05 Idling speed r min 700 25 Trolling speed r min 575 25 OIL INJECTION PUMP ID mark 6R400 Oil discharge for 3 minutes cm3 US oz Imp oz 1 500 r min 3 4 0 7 0 115 0 024 0 120 0 025 Bleeding Screw type REED VALVES Reed valve stopper height a mm in 6 5 0 3 0 26 0 01...

Page 29: ... 5 8 1 4 S 1 1 8 1 4 P 1 1 8 1 4 1 1 8 1 4 S 5 8 1 4 P Float height mm in 16 0 0 5 0 63 0 02 Valve seat diameter mm in 1 2 0 05 Idling speed r min 700 25 Trolling speed r min 575 25 570 25 575 25 OIL INJECTION PUMP ID mark 6R400 6R510 Oil discharge for 3 minutes cm3 US oz Imp oz 1 500 r min 3 4 0 7 0 115 0 024 0 120 0 025 4 8 1 1 0 162 0 037 0 169 0 039 Bleeding Screw type REED VALVES Reed valve s...

Page 30: ...P Float height mm in 16 0 0 5 0 63 0 02 Valve seat diameter mm in 1 2 0 05 Idling speed r min 700 25 Trolling speed r min 575 25 600 25 OIL INJECTION PUMP ID mark 6R510 6R510 Oil discharge for 3 minutes cm3 US oz Imp oz 1 500 r min 4 8 1 1 0 162 0 037 0 169 0 039 4 8 1 1 0 162 0 037 0 169 0 039 Bleeding Screw type Screw type REED VALVES Reed valve stopper height a mm in 6 5 0 3 0 26 0 01 Warpage l...

Page 31: ... Pinion forward gear mm in 0 25 0 46 0 010 0 018 0 71 1 01 0 028 0 040 0 19 0 59 0 007 0 023 0 25 0 46 0 010 0 018 Pinion reverse gear mm in 0 74 1 29 0 029 0 051 0 79 1 38 0 031 0 054 0 39 0 70 0 015 0 028 0 74 1 29 0 029 0 051 Pinion shims mm 0 10 0 12 0 15 0 18 0 30 0 40 0 50 Forward gear shims mm 0 10 0 12 0 15 0 18 0 30 0 40 0 50 Reverse gear shims mm 0 10 0 12 0 15 0 18 0 30 0 40 0 50 Item U...

Page 32: ... 28 0 09 150A L150A 175A C150TR 2 05 0 08 200A L200A 3 05 0 12 150F L150F D150H 175D S175D D150TR S175TR 3 33 0 13 S150F LS150F 175F 200G S150TR L150TR P175TR P200TR 2 53 0 10 150G 200F L200F P150TR 200TR 2 78 0 11 S200F LS200F 225D S200TR L200TR CDI unit Output peak voltage lower limit B W B cranking 1 V cranking 2 V 130 65 1 500 r min V 145 140 3 500 r min V 145 135 Charge coil Output peak volta...

Page 33: ... B Y 5 C 41 F kΩ 128 20 C 68 F kΩ 54 69 100 C 212 F kΩ 3 02 3 48 Thermo switch P B OFF ON C F 84 90 183 194 ON OFF C F 60 74 140 165 Oil level sensor engine oil tank Float position a OFF mm in 3 6 0 12 0 24 Float position b ON mm in 33 36 1 30 1 42 Float position c ON mm in 53 56 2 09 2 20 Oil level gauge sub oil tank Float position d ON mm in 150 153 5 91 6 02 STARTING SYSTEM Fuse 1 V A 12 30 12 ...

Page 34: ...r limit G G cranking 1 V cranking 2 V 1 500 r min V 35 20 3 500 r min V 85 50 POWER TRIM AND TILT SYSTEM Trim sensor Resistance P B Ω 582 873 Resistance O B Ω 800 1 200 POWER TRIM AND TILT MOTOR Fluid type ATF Dexron II Brushes Standard length mm in 9 8 0 39 Wear limit mm in 4 8 0 19 Commutator Standard diameter mm in 22 0 0 87 Wear limit mm in 21 0 0 83 Mica Standard undercut mm in 1 35 0 05 Wear...

Page 35: ...in 179 7 0 L4 mm in 647 25 5 717 28 2 631 24 8 634 25 0 L5 L mm in 61 2 4 44 1 7 X mm in 80 3 1 L6 L mm in 1 036 40 8 1 033 40 7 1 0 32 40 6 X mm in 1 152 45 4 1 148 45 2 1 144 45 0 L7 mm in 587 23 1 568 22 4 577 22 7 H1 L mm in 946 37 2 882 34 7 943 37 1 X mm in 1 072 42 2 1 070 42 1 1 072 42 2 H2 mm in 670 25 3 635 25 0 657 25 9 H3 mm in 210 8 3 H4 L mm in 516 20 3 452 17 8 513 20 2 X mm in 642 ...

Page 36: ...5DETO 150GETO 175FETO 200GETO D150HETO 150AET 175AET 200AET L150AET L200AET USA S150TR L150TR S175TR 200TR S200TR L200TR P150TR P175TR P200TR D150TR C150TR Canada S200TR P150TR P175TR P200TR B1 mm in 125 4 4 9 B2 mm in 254 10 0 B3 mm in 163 5 6 4 B4 mm in 50 8 2 0 B5 mm in 180 7 1 B6 mm in 367 14 4 B9 mm in 18 5 0 7 C3 mm in 82 3 2 D1 mm in 13 0 5 D2 mm in 55 5 2 2 ...

Page 37: ...t mount M8 21 2 1 15 Ignition coil M6 8 0 8 5 8 Emergency switch 4 0 4 2 9 Starter motor lead M6 9 0 9 6 5 Relay assembly lead M6 4 0 4 2 9 Starter motor M8 30 3 0 22 Intake manifold 1st M6 4 0 4 2 9 2nd 8 0 8 5 8 Reed valve M5 3 0 3 2 2 Reed valve stopper M3 1 0 1 0 7 Spark plug M14 25 2 5 18 Thermostat cover 1st M6 4 0 4 2 9 2nd 8 0 8 5 8 Cylinder head cover 1st M6 4 0 4 2 9 2nd 8 0 8 5 8 Cylind...

Page 38: ...mechanism screw 24 2 4 17 Upper mount M12 53 5 3 38 Lower mount M14 73 7 3 53 Exhaust manifold assembly M8 21 2 1 15 Muffler M8 18 1 8 13 Exhaust manifold M8 18 1 8 13 Lower exhaust manifold guide M8 18 1 8 13 Clamp bracket M22 15 1 5 11 Trim sensor stopper M6 2 0 2 1 4 Trim stopper 37 3 7 27 POWER TRIM AND TILT UNIT Power trim and tilt reservoir cap 8 0 8 5 8 Power trim and tilt reservoir 1 4 5 0...

Page 39: ... of this manual To avoid warpage tighten multi fastener assemblies in a crisscross fashion and progressive stages until the specified tightening torque is reached Unless other wise specified tightening torque specifica tions require clean dry threads Components should be at room tempera ture Nut A Bolt B General torque specifications Nm m kgf ft lb 8 mm M5 5 0 5 3 6 10 mm M6 8 0 8 5 8 12 mm M8 18 ...

Page 40: ......

Page 41: ... CONTROL SHIFT CABLE 3 11 ADJUSTING THE REMOTE CONTROL THROTTLE CABLE 3 11 COOLING SYSTEM 3 12 INSPECTING THE COOLING WATER DISCHARGE 3 12 OIL INJECTION SYSTEM 3 12 SYNCHRONIZING THE OIL PUMP 3 12 AIR BLEEDING THE OIL INJECTION SYSTEM 3 13 MEASURING THE OIL PUMP DISCHARGE 3 14 POWER TRIM AND TILT SYSTEM 3 16 INSPECTING THE POWER TRIM AND TILT FLUID LEVEL 3 16 LOWER UNIT 3 17 INSPECTING THE GEAR OI...

Page 42: ...ect Exhaust leakage Inspect Cooling water passage Clean flush CONTROL SYSTEM Carburetor synchroni zation Inspect adjust 3 6 Engine idling speed Inspect adjust 3 7 Remote control shift cable Inspect adjust 3 11 Remote control throttle cable Inspect adjust 3 11 OIL INJECTION SYSTEM Oil tank water drain Clean Oil pump lever Inspect adjust 3 12 POWER TRIM AND TILT UNIT Power trim and tilt fluid Inspec...

Page 43: ...hook either up or down slightly 3 Secure the bolts 4 Check the top cowling fitting and repeat the adjustment if necessary NOTE Moving the latch towards the seal will loosen the top cowling Moving the latch away from the seal will tighten the top cowling 3020 FUEL SYSTEM 3 INSPECTING THE FUEL LINE 3 1 Inspect Plastic locking tie Loosen Retighten or replace 2 Inspect Fuel line Cracks damage leaks Re...

Page 44: ...ver 2 Turn the flywheel magnet assembly 1 clockwise and align the timing plate 2 with the specified mark 3 Turn the magneto control lever 3 so that it contacts the full advance adjust ing screw 4 4 Check that the mark a on the flywheel magnet assembly aligns with the mark b on the pulser coil assembly Flywheel magnet assembly position 150A L150A 175A C150TR BTDC 19 200A L200A BTDC 18 150F L150F D1...

Page 45: ... wise to locate BTDC 7 Align the timing plate 2 with the spec ified mark on the flywheel magnet assembly 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 S150F LS150F 175F 200G S150TR L150TR P175TR P200TR 3 33 mm 0 13 in 150G 200F L200F P150TR 200TR 2 53 mm 0 10 in S200F LS200F 225D S200TR L200TR 2 78 mm 0 1...

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