Yamaha LZ200Y Service Manual Download | Manualshive

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2-10

SPEC

E

MAINTENANCE SPECIFICATIONS

Symbol

Unit

Models

Worldwide

Z200NETO

LZ200NETO

USA

Z200TR

LZ200TR

Canada

Z200TR

—

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)

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Summary of Contents for LZ200Y

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

Page 2: ...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 CAUTION USE UNLEADED STRAIGHT GASOLINE ONLY Gasoline containing lead can cause performance lose and engine damage Do not use gasoline mixed with oil premix Use YAMALUBE 2 stroke outboard oil or ano...

Page 3: ...equired will follow the symbol e g 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 ILLUSTRATIONS The illustrations within this service manual represent all of the designated mod...

Page 4: ...UR SAFETY IS INVOLVED WARNING Failure to follow WARNING instructions could result in severe injury or deathto the machine operator a bystander or a person inspecting or repairing the outboard motor CAUTION A CAUTION indicates special precautions that must be taken to avoid damage to the out board motor NOTE A NOTE provides key information to make procedures easier or clearer ...

Page 5: ...instruction 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 or screws are...

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 ...

Page 8: ... 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 8 ...

Page 9: ...cket 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 4 Serial number STARTING SERIAL NUMBERS The starting serial number blocks are as fol lows Model name Approved model code Starting serial number Worldwide USA Canada Z200NETO Z200TR Z200TR 6G6 X 100101 LZ200NETO LZ200TR 6K1 X 100101 ...

Page 10: ...Petroleum 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 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 11: ...soiled 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 wi...

Page 12: ...arts with compressed air when disassembling 2 Oil the contact surfaces of moving parts before assembly 3 After assembly check that moving parts operate normally 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 13: ...hat start with 90890 MEASURING 1 Tachometer P N YU 08036 A a 90890 06760 b 2 Fuel pressure gauge P N YB 06766 90890 06786 3 Mity vac P N YB 35956 90890 06756 4 Pressure tester P N YB 35956 90890 06762 5 Digital caliper P N 90890 06704 6 Pinion height gauge P N YB 34432 7 YB 34432 11 a 90890 06702 b 7 Shimming gauge P N YB 34446 1 YB 34446 3 YB 34446 4 YB 34446 7 YB 34446 8 8 Shimming gauge P N YB ...

Page 14: ... valve attachment P N 90890 06773 Down relief valve attachment P N 90890 06774 G Digital tester P N J 39299 a 90890 06752 b H Peak voltage adapter P N YU 39991 a 90890 03169 b I Spark gap tester P N YM 34487 a 90890 06754 b J Test harness P N YB 06443 YB 06767 YB 06768 YB 06769 YB 06779 YB 06787 YB 06788 90890 06757 90890 06767 90890 06768 90890 06769 90890 06779 90890 06787 90890 06788 K Diagnost...

Page 15: ...change in its speed by stopping the operation of the spark plug on each cylinder while the engine is in the neutral position Engine monitor Indicates information on the sensors and switches by converting it to each value while the engine is running Data logger Indicates in numeric values the engine speed throttle opening voltage oxygen density sensor voltage water temperature sensor voltage and fu...

Page 16: ... 06205 a 90890 06663 b 4 Piston ring compressor P N YU 33294 a 90890 06530 b 5 Bearing separator P N YB 06219 a 90890 06534 b 6 Guide plate stand P N 90890 06538 7 Guide plate P N 90890 06501 8 Bearing puller P N 90890 06535 9 Small universal claws P N 90890 06536 0 Ring nut wrench P N YB 34447 a 90890 06512 b A Ring nut wrench extension P N 90890 06513 1 b a 3 b a 6 7 4 b a 5 b a 2 b a 8 9 A 0 b ...

Page 17: ...2 J Driver rod P N YB 06071 90890 06604 90890 06605 90890 06606 90890 06652 K Bearing oil seal depth plate P N 90890 06603 L Bearing oil seal attachment P N YB 06194 YB 06196 YB 06246 M Bearing oil seal attachment P N YB 06195 YB 06258 N Bearing oil seal attachment P N YB 06200 O Bearing oil seal attachment P N YB 06336 P Bearing oil seal attachment P N 90890 06610 90890 06612 90890 06631 90890 06...

Page 18: ...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 YU 01235 90890 01235 Y Sheave holder P N YS 1880 A 90890 01701 Z Universal puller P N YB 06540 90890 06540 S T U V W Y Z X ...

Page 19: ... 9 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: ...ull throttle operating range r min 4 500 5 500 Maximum fuel consumption L US gal lmp gal hr 5 500 r min 68 18 0 15 0 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 Cylinders 1 4 6 4 Cylinders 5 6 6 1 Fuel system Electronic fuel injection Fuel injection system Sequential injection Intake system Reed valve I...

Page 21: ... Hypoid gear oil SAE 90 Gear oil total quantity cm3 US oz lmp oz 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 32 32 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 Propeller direction rear view Clockwise Counterclockwise...

Page 22: ... limit mm in 0 08 0 003 Out of round limit mm in 0 05 0 002 PISTONS Piston diameter D mm in 89 845 89 869 3 5372 3 5381 Measuring point H mm in 10 0 4 Piston to cylinder clearance mm in 0 150 0 156 0 0059 0 0061 Limit mm in 0 206 0 0081 Oversize piston diameter 1st mm in 90 11 3 548 2nd mm in 90 36 3 557 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 ...

Page 23: ...MP ID mark 68F00 Bleeding Screw type REED VALVES Reed valve stopper height a mm in 9 0 0 35 0 35 0 01 Warpage limit b mm in 0 2 0 008 THERMOSTATS Opening temperature C F 48 52 118 126 Full open temperature C F 60 140 Valve open lower limit mm in 3 0 12 ENGINE SPEED Idling speed r min 700 30 Item Unit Model Worldwide Z200NETO LZ200NETO USA Z200TR LZ200TR Canada Z200TR ...

Page 24: ...40 0 50 Reverse gear shims mm 0 10 0 12 0 15 0 18 0 30 0 40 0 50 Item Unit Model Worldwide Z200NETO LZ200NETO USA Z200TR LZ200TR Canada Z200TR IGNITION SYSTEM Ignition timing 1 Degree ATDC 3 BTDC 17 Fuse 1 V A 12 80 Fuse 2 V A 12 30 Fuse 3 V A 12 20 Control unit B O B Y B L B Br B G B W R Y Output peak voltage lower limit cranking 1 V cranking 2 V 140 1 500 r min V 205 3 500 r min V 220 Pulser coi...

Page 25: ...age P O V 0 50 0 02 Thermo switch P B OFF ON C F 84 90 183 194 ON OFF C F 60 74 140 165 FUEL CONTROL SYSTEM Oxygen density sensor Heater resistance R W B Ω 2 100 Output voltage Gy B W V 0 0 1 0 Atmospheric pressure sensor Output voltage at 101 32 kPa P B V 3 2 4 6 Intake air temperature sensor Resistance B Y B Y kΩ 1 5 4 0 Injector driver O R Pu R O B Pu B O Y Pu Y O G Pu G O L Pu L O W Pu W Outpu...

Page 26: ...in 29 0 1 14 Wear limit mm in 28 0 1 10 Mica Standard undercut mm in 0 5 0 8 0 02 0 03 Wear limit mm in 0 2 0 01 CHARGING SYSTEM Rectifier regulator R B Output peak voltage lower limit cranking 1 V cranking 2 V 7 5 1 500 r min V 12 7 3 500 r min V 12 7 Lighting coil G G Output peak voltage lower limit cranking 1 V 7 5 cranking 2 V 8 0 1 500 r min V 12 3 500 r min V 12 Cranking 1 Open circuit volta...

Page 27: ...N mm in 150 153 5 91 6 02 POWER TRIM AND TILT SYSTEM Trim sensor Setting resistance Ω 80 12 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 limit mm in 0 85 0 03 It...

Page 28: ...e Z200NETO LZ200NETO USA Z200TR LZ200TR Canada Z200TR L1 mm in 613 24 1 L2 mm in 180 7 1 L4 mm in 646 25 4 L5 mm in 69 2 7 L6 mm in 1 150 45 3 L7 mm in 574 22 6 H1 mm in 1 074 42 3 H2 mm in 708 27 9 H3 mm in 211 8 3 H4 mm in 643 25 3 H6 mm in 850 33 4 H7 mm in 308 12 1 H9 mm in 835 32 9 W1 mm in 277 10 9 W5 mm in 396 15 6 ...

Page 29: ...nit Models Worldwide Z200NETO LZ200NETO USA Z200TR LZ200TR Canada Z200TR 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 30: ...ch 4 0 4 2 9 Flywheel magnet assembly M20 190 19 137 Negative battery lead M8 9 0 9 6 5 Positive battery lead M8 9 0 9 6 5 Apron M6 8 0 8 5 8 Power unit mount M8 21 2 1 15 Starter relay holder M5 3 0 3 2 2 Oxygen density sensor cover M6 9 0 9 6 5 Oxygen density sensor bracket M6 14 1 4 10 Oxygen density sensor M18 49 4 9 35 Reed valve assembly M6 10 1 0 7 2 Reed valve M5 3 0 3 2 2 Reed valve stopp...

Page 31: ...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 5 3 6 Pow...

Page 32: ...ns 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 1...

Page 33: ...ION SENSOR 3 8 ADJUSTING THE ENGINE IDLING SPEED 3 9 ADJUSTING THE REMOTE CONTROL SHIFT CABLE 3 10 ADJUSTING THE REMOTE CONTROL THROTTLE CABLE 3 10 CHECKING THE DRIVE BELT 3 11 ADJUSTING THE CRANK POSITION SENSOR 3 12 COOLING SYSTEM 3 12 CHECKING THE COOLING WATER DISCHARGE 3 12 OIL INJECTION SYSTEM 3 12 CHECKING THE OIL STRAINER 3 12 SYNCHRONIZING THE OIL PUMP 3 13 AIR BLEEDING THE OIL INJECTION ...

Page 34: ...E 1 2 3 4 5 6 7 8 9 INSP ADJ 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: ...Check Cooling water passage 1 Clean CONTROL SYSTEM Throttle valve synchronization Check adjust 3 7 Engine idling speed Check adjust 3 9 Throttle position sensor Check adjust 3 8 Remote control shift cable Check adjust 3 10 Remote control throttle cable Check adjust 3 10 Drive belt 2 Check adjust 3 11 OIL INJECTION SYSTEM Oil tank water drain Clean Oil pump lever Check adjust 3 13 POWER TRIM AND TI...

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